SIMOTION. SIMOTION SCOUT Updating SIMOTION Devices. Preface. Fundamental safety instructions 1. Overview 2. Updating 3. Restoring 4.

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1 Preface Fundamental safety instructions 1 SIMOTION SIMOTION SCOUT Overview 2 Updating 3 Restoring 4 Operating Instructions Appendix A A Valid as of Version /2014

2 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 indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: Trademarks 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 complied with. The information in the relevant documentation must be observed. All names identified by are registered trademarks of 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 All rights reserved

3 Preface Content This document is part of the documentation package Service and Diagnostics. Scope of validity This manual is valid for SIMOTION SCOUT product level V4.4: SIMOTION SCOUT V4.4 (engineering system of the SIMOTION product family) SIMOTION Kernel V4.4 SIMOTION Cam, Cam_ext and TControl technology packages Sections in this manual This manual describes a simple way of exchanging the configuration or firmware of one or more SIMOTION devices. This procedure is called updating. Overview General overview of update data and media, of update scenarios, and of the people involved Updating Description of the individual stages of updating Restoring Information about restoring SIMOTION Documentation An overview of the SIMOTION documentation can be found in the SIMOTION Documentation Overview document. This documentation is included as electronic documentation in the scope of delivery of SIMOTION SCOUT. It comprises ten documentation packages. The following documentation packages are available for SIMOTION V4.4: SIMOTION Engineering System Handling SIMOTION System and Function Descriptions SIMOTION Service and Diagnostics SIMOTION IT SIMOTION Programming SIMOTION Programming - References Operating Instructions, 04/2014 3

4 Preface SIMOTION C SIMOTION P SIMOTION D SIMOTION Supplementary Documentation Hotline and Internet addresses Additional information Click the following link to find information on the the following topics: Ordering documentation / overview of documentation Additional links to download documents Using documentation online (find and search manuals/information) Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following address: docu.motioncontrol@siemens.com My Documentation Manager Click the following link for information on how to compile documentation individually on the basis of Siemens content and how to adapt it for the purpose of your own machine documentation: Training Click the following link for information on SITRAIN - Siemens training courses for automation products, systems and solutions: FAQs Frequently Asked Questions can be found in SIMOTION Utilities & Applications, which are included in the scope of delivery of SIMOTION SCOUT, and in the Service&Support pages in Product Support: Technical support Country-specific telephone numbers for technical support are provided on the Internet under Contact: 4 Operating Instructions, 04/2014

5 Table of contents Preface Fundamental safety instructions General safety instructions Safety instructions for electromagnetic fields (EMF) Handling electrostatic sensitive devices (ESD) Industrial security Residual risks of power drive systems Overview Data flow and handling update data Update data, update archive, and update media Update data behavior within a SIMOTION device Assigning update data to devices Single and multiple updates Device-specific update media Transferring device-specific user data to the update data Updating Overview Creating update data using SIMOTION SCOUT Creating update data with the Device Update tool Creating update data, including copying to a USB memory stick Creating update data, including copying to a CF/MMC card Creating update data including generating a SIMOTION IT file Creating update data as an update archive Copying to the update media on the basis of an update archive Copying to an update medium without SIMOTION SCOUT Transferring the update data Copying data to a USB memory stick Copying data to a CF/MMC card Creating a SIMOTION IT file and copying the update data Transferring update data to the SIMOTION device Behavior of the retain data on updating (and restoration) Receiving unit data SIMOTION device status during updating Transferring update data from the update medium to SIMOTION devices Updating a module with a USB memory stick Updating a module with a CF/MMC card Updating a module with a SIMOTION IT file...73 Operating Instructions, 04/2014 5

6 Table of contents 3.5 Possible error messages for the Device Update tool Restoring Restoring a SIMOTION device SIMOTION device status during restoring Particular aspects of restoring SIMOTION devices...84 A Appendix A...89 A.1 Restoring the original status of a USB memory stick...89 Index Operating Instructions, 04/2014

7 Fundamental safety instructions General safety instructions DANGER Danger to life due to live parts and other energy sources Death or serious injury can result when live parts are touched. Only work on electrical devices when you are qualified for this job. Always observe the country-specific safety rules. Generally, six steps apply when establishing safety: 1. Prepare for shutdown and notify all those who will be affected by the procedure. 2. Disconnect the machine from the supply. Switch off the machine. Wait until the discharge time specified on the warning labels has elapsed. Check that it really is in a no-voltage condition, from phase conductor to phase conductor and phase conductor to protective conductor. Check whether the existing auxiliary supply circuits are de-energized. Ensure that the motors cannot move. 3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or water. 4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or shortcircuiting or closing valves, for example. 5. Secure the energy sources against switching on again. 6. Ensure that the correct machine is completely interlocked. After you have completed the work, restore the operational readiness in the inverse sequence. WARNING Danger to life from hazardous voltage when connecting an unsuitable power supply Touching live components can result in death or severe injury. Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV (Protective Extra Low Voltage) output voltages for all connections and terminals of the electronics modules. Operating Instructions, 04/2014 7

8 Fundamental safety instructions 1.1 General safety instructions WARNING Danger to life from touching live parts on damaged devices Improper handling of devices can result in damage. For damaged devices, hazardous voltages can be present at the enclosure or at exposed components; if touched, this can result in death or severe injury. Observe the limit values specified in the technical specifications during transport, storage, and operation. Do not use damaged devices. WARNING Danger to life through electric shock due to unconnected cable shields Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected cable shields. As a minimum, connect cable shields and the cores of power cables that are not used (e.g. brake cores) at one end at the grounded housing potential. WARNING Danger to life due to electric shock when not grounded For missing or incorrectly implemented protective conductor connection for devices with protection class I, high voltages can be present at open, exposed parts, which when touched, can result in death or severe injury. Ground the device in compliance with the applicable regulations. WARNING Danger to life due to fire spreading if housing is inadequate Fire and smoke development can cause severe personal injury or material damage. Install devices without a protective housing in a metal control cabinet (or protect the device by another equivalent measure) in such a way that contact with fire inside and outside the device is prevented. Ensure that smoke can only escape via controlled and monitored paths. 8 Operating Instructions, 04/2014

9 Fundamental safety instructions 1.1 General safety instructions WARNING Danger to life from unexpected movement of machines when using mobile wireless devices or mobile phones Using mobile radios or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or causing material damage. Switch off wireless devices or mobile phones in the immediate vicinity of the components. WARNING Danger to life due to fire if overheating occurs because of insufficient ventilation clearances Inadequate ventilation clearances can cause overheating of components followed by fire and smoke development. This can cause death or serious injury. This can also result in increased downtime and reduced service life for devices/systems. Ensure compliance with the specified minimum clearance as ventilation clearance for the respective component. WARNING Danger of an accident occurring due to missing or illegible warning labels Missing or illegible warning labels can result in accidents involving death or serious injury. Check that the warning labels are complete based on the documentation. Attach any missing warning labels to the components, in the national language if necessary. Replace illegible warning labels. Operating Instructions, 04/2014 9

10 Fundamental safety instructions 1.1 General safety instructions WARNING Danger to life when safety functions are inactive Safety functions that are inactive or that have not been adjusted accordingly can cause operational faults on machines that could lead to serious injury or death. Observe the information in the appropriate product documentation before commissioning. Carry out a safety inspection for functions relevant to safety on the entire system, including all safety-related components. Ensure that the safety functions used in your drives and automation tasks are adjusted and activated through appropriate parameterizing. Perform a function test. Only put your plant into live operation once you have guaranteed that the functions relevant to safety are running correctly. Note Important safety notices for safety functions If you want to use safety functions, you must observe the safety notices in the safety manuals. WARNING Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death. Protect the parameterization (parameter assignments) against unauthorized access. Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY STOP or EMERGENCY OFF). 10 Operating Instructions, 04/2014

11 Fundamental safety instructions 1.3 Handling electrostatic sensitive devices (ESD) 1.2 Safety instructions for electromagnetic fields (EMF) WARNING Danger to life from electromagnetic fields Electromagnetic fields (EMF) are generated by the operation of electrical power equipment such as transformers, converters or motors. People with pacemakers or implants are at a special risk in the immediate vicinity of these devices/systems. Ensure that the persons involved are the necessary distance away (minimum 2 m). 1.3 Handling electrostatic sensitive devices (ESD) Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or devices that may be damaged by either electric fields or electrostatic discharge. NOTICE Damage through electric fields or electrostatic discharge Electric fields or electrostatic discharge can cause malfunctions through damaged individual components, integrated circuits, modules or devices. Only pack, store, transport and send electronic components, modules or devices in their original packaging or in other suitable materials, e.g conductive foam rubber of aluminum foil. Only touch components, modules and devices when you are grounded by one of the following methods: Wearing an ESD wrist strap Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring Only place electronic components, modules or devices on conductive surfaces (table with ESD surface, conductive ESD foam, ESD packaging, ESD transport container). Operating Instructions, 04/

12 Fundamental safety instructions 1.5 Residual risks of power drive systems 1.4 Industrial security Note Industrial security Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for a product-specific newsletter. For more information, visit WARNING Danger as a result of unsafe operating states resulting from software manipulation Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe operating states to develop in your installation which can lead to death, severe injuries and/ or material damage. Keep the software up to date. Information and newsletters can be found at: Incorporate the automation and drive components into a state-of-the-art, integrated industrial security concept for the installation or machine. For more detailed information, go to: Make sure that you include all installed products into the integrated industrial security concept. 1.5 Residual risks of power drive systems The control and drive components of a drive system are approved for industrial and commercial use in industrial line supplies. Their use in public line supplies requires a different configuration and/or additional measures. These components may only be operated in closed housings or in higher-level control cabinets with protective covers that are closed, and when all of the protective devices are enabled. These components may only be handled by qualified and trained technical personnel who are knowledgeable and observe all of the safety instructions on the components and in the associated technical user documentation. 12 Operating Instructions, 04/2014

13 Fundamental safety instructions 1.5 Residual risks of power drive systems When assessing the machine's risk in accordance with the respective local regulations (e.g. EC Machinery Directive), the machine manufacturer must take into account the following residual risks emanating from the controller and drive components of a drive system: 1. Unintentional movements of driven machine components during commissioning, operation, maintenance, and repairs caused by, for example: Hardware faults and/or software errors in sensors, controllers, actuators, and connection systems Response times of the controller and drive Operating and/or ambient conditions outside of the specification Condensation / conductive contamination Parameterization, programming, cabling, and installation errors Use of radio devices/cellular phones in the immediate vicinity of the controller External influences / damage 2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter, for example: Component malfunctions Software errors Operating and/or ambient conditions outside of the specification External influences / damage Inverters of the Open Type / IP20 degree of protection must be installed in a metal control cabinet (or protected by another equivalent measure) such that the contact with fire inside and outside the inverter is not possible. 3. Hazardous touch voltages caused by, for example: Component malfunctions Influence of electrostatic charging Induction of voltages in moving motors Operating and/or ambient conditions outside of the specification Condensation / conductive contamination External influences / damage 4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too close. 5. Release of environmental pollutants or emissions as a result of improper operation of the system and/or failure to dispose of components safely and correctly. Operating Instructions, 04/

14 Fundamental safety instructions 1.5 Residual risks of power drive systems Note The components must be protected against conductive contamination (e.g. by installing them in a control cabinet with degree of protection IP54 according to IEC or NEMA 12). Assuming that conductive contamination at the installation site can definitely be excluded, a lower degree of cabinet protection may be permitted. For more information about residual risks of the components in a drive system, see the relevant sections in the technical user documentation. 14 Operating Instructions, 04/2014

15 Overview 2 SIMOTION offers a convenient solution for updating SIMOTION devices or SIMOTION projects for machine manufacturers and machine operators. Updating does not simply refer to an update to a higher version of firmware; rather, in general terms it refers to switching to a defined configuration, e.g. a project update. It is also possible to return (restore) to a previous configuration. Update or restore procedures can easily be performed on SIMOTION devices locally or remotely. The data can be imported to a SIMOTION device via a portable, handy storage medium or a communication connection. Options and advantages There is an extensive range of options available for updating SIMOTION devices. These include, for example: The user-friendly creation of update data is via SIMOTION SCOUT with the aid of the Device Update Tool (at the machine manufacturer's site). SIMOTION device updates independent of time and place (without SIMOTION SCOUT, at the machine operator's site) The update data can be sent from the machine manufacturer to the machine operator via or post No need for license key handling, i.e. the licenses are retained or are updated at the same time. Retain data is retained. An update which has been imported can be discarded again, and the previous configuration restored. You can update either a single SIMOTION device or multiple devices from one or more SIMOTION projects. You can limit the update to configuration subsets, e.g. only project data. Single or multiple updates Various update scenarios are possible: When performing a single update, only one SIMOTION device is updated, while one or more SIMOTION devices from one or more projects can be updated when performing a multiple update. Operating Instructions, 04/

16 Overview 2.1 Data flow and handling update data Update data Update data is data that is created via SIMOTION SCOUT on the basis of one or more SIMOTION projects. The update data contains all the information required for updating or restoring the data on a SIMOTION device. This includes: SIMOTION project Technology packages User data (unit data, SIMOTION IT data) Firmware Handling update data The update data is created by the machine manufacturer's application developer using SIMOTION SCOUT. The update data can then be handled flexibly depending on both the SIMOTION device (SIMOTION C, D, or P) and the customer requirements: Creating update data and then copying them to a storage or update medium: CF/MMC card USB memory stick SIMOTION IT file or Creating an update archive Alternatively, the update data can be created and stored in an archive on the computer, so that it can be imported to an update medium that is compatible with the SIMOTION device at a later point in time. The data can be transferred to an update medium at either the machine manufacturer's site or the machine operator's site. For this purpose, the machine manufacturer transfers their update archive to the users at the machine operator's site. The user imports the update data into the SIMOTION device(s) on an operator-guided basis, without any involvement by the application developer, thereby updating the SIMOTION device(s) (SIMOTION SCOUT does not need to be available on-site). 2.1 Data flow and handling update data The machine manufacturer's application developer creates the update data using the SIMOTION SCOUT engineering system. He or she writes the SIMOTION applications and puts them into operation. The user at the machine operator's site carries out service work on the machine. The user receives the update data from the application developer and transfers them to the machine. There is no need for SIMOTION SCOUT to be available on-site in order to transfer the update data to the SIMOTION device or to update a SIMOTION project. The user at the machine operator's site can import the previously created update data, which are located on an update medium, to the SIMOTION device. The figure below provides an overview of how the update data are handled. Update media include CF/MMC card, USB memory stick and SIMOTION IT file. 16 Operating Instructions, 04/2014

17 Overview 2.2 Update data, update archive, and update media Alternatively, the user has the option of creating and storing update data in an update archive, and then creating the update medium at a later point. This can be carried out by either the application developer at the machine manufacturer's site or by the user at the machine operator's site. The update data can be imported to an update medium immediately after they have been created by the application developer. The update media CF/MMC card or USB memory stick can be sent by post, or electronically by SIMOTION IT file and update archive to the machine operator. The update data are generally transferred to the SIMOTION devices by the user at the machine operator's site. Figure 2-1 Data flow and handling of the update data at the machine manufacturer's and machine operator's sites 2.2 Update data, update archive, and update media Update data is required to update a SIMOTION device or SIMOTION project. The newly created update data can be stored in an update archive or saved onto an update medium immediately. The advantage of the update archive or the update media is that the update data created at the machine manufacturer's site can be used by the machine operator anywhere and at any time. SIMOTION SCOUT is not required in order to transfer the update data on-site. Operating Instructions, 04/

18 Overview 2.2 Update data, update archive, and update media Update data The configuration is determined on the basis of the composition of the update data. Update data is all the data required for an update procedure. The update data is created using SIMOTION SCOUT. The update data contains the following data: Firmware (FW): The firmware comprises all the firmware components that are required to operate the respective SIMOTION device (e.g. drive FW, CBE FW, TM FW, BIOS, etc.) Project data: The project data contains all the data required to operate the respective SIMOTION device. SIMOTION D also contains the drive configuration for the SINAMICS Integrated and the CX32/CX32-2. Technology packages (TP) User data (e.g. HTML pages, SSL key, SIMOTION project for storing data on memory cards, SIMOTION IT data, JAVA programs and unit data sets) SCOUT project archive (for data storage on the memory card) It is assumed, in principle, that all of the update data components referred to above are to be updated. However, only individual update data components can be updated, e.g. only the technology packages. This is at the discretion of the user and is defined when the update data is created. Note For SIMOTION P, there are currently only plans to update the project data, technology packages and user data. The firmware cannot be updated because of its dependence on other Windows components. Update archive The update data created using SIMOTION SCOUT is stored in an update archive if it is not imported to an update medium. The update archive is a directory tree in which all of the update data is saved. Update media The term "update media" is used to refer to storage media on which the update data is saved before being imported to the SIMOTION devices to be updated. Update media used by SIMOTION are USB memory sticks, CF/MMC cards and SIMOTION IT files. The choice of update media depends on the SIMOTION devices to be updated. For updating an individual device in the case of SIMOTION C or SIMOTION D, a CF/MMC card can be loaded or a SIMOTION IT file can be generated (also for several devices). SIMOTION D4x5/D4x5-2 also supports the option of using a USB memory stick as the update medium. The USB memory stick can be used to update one or more SIMOTION devices. 18 Operating Instructions, 04/2014

19 Overview 2.3 Update data behavior within a SIMOTION device In the case of SIMOTION P, you can select either a USB memory stick or a SIMOTION IT file as an update medium for either an individual device or for several devices. To find an overview of which update medium is suitable for which SIMOTION device, go to: Device-specific update media (Page 25) 2.3 Update data behavior within a SIMOTION device Each SIMOTION device has a memory card containing the most important data for the device, such as firmware, technology packages, project data, and saved retain data. In the case of SIMOTION D this is the CF card (Compact Flash Card), and in SIMOTION C the MMC (Micro Memory Card), while for SIMOTION P the memory card takes the form of a virtual memory card on the hard disk. If a SIMOTION device is updated, the data on the memory card in the SIMOTION device behave as follows: Operating Instructions, 04/

20 Overview 2.3 Update data behavior within a SIMOTION device Figure 2-2 Update data behavior within a SIMOTION device 1. The update data are transferred from the update medium to the memory card in the SIMOTION device. (USB memory stick, SIMOTION IT) In the case of a CF/MMC card, this mechanism takes place using the CF/MMC adapter. 2. The existing data are then saved on the memory card. 3. The update data takes effect when the device is restarted. 20 Operating Instructions, 04/2014

21 Overview 2.4 Assigning update data to devices 4. The memory card now contains both the update data and, concurrently, the saved data from the previous configuration. 5. In the event of an error, or if the new application does not meet your requirements, you can revert back to the saved data. These are activated when you perform a restore function, overwriting the update data. Note The current configuration data are saved as restore data when updating. The SIMOTION device has only one backup. If the same update data are imported twice by mistake, the backed up restore data will also be overwritten. In order to back up data over a longer period of time, the update archive can be backed up separately (onto a DVD, for example). 2.4 Assigning update data to devices The device name which was saved in the project is contained in the update data. This name is used for assigning the update data to the relevant device. The name is saved persistently Operating Instructions, 04/

22 Overview 2.5 Single and multiple updates on the device. Since the name is saved persistently within the SIMOTION device, a corresponding device assignment takes place during the update. 2.5 Single and multiple updates Update data can be created for both a single SIMOTION device or multiple SIMOTION devices relating to one or more SIMOTION projects. During multiple updates, i.e. when updating at least two SIMOTION devices, it is imperative that device names are assigned. If the device names in the update data do not match the persistently saved names of the devices to be updated, the update cannot take place. An exception to this is the single update of a device that has not yet been assigned a persistently saved name. In this case, the device receives its name from the update data. In a single update scenario, it is also possible to force an update if the device names do not match. 22 Operating Instructions, 04/2014

23 Overview 2.5 Single and multiple updates Single update Update data for a single SIMOTION device are created during a single update. This scenario is recommended in the case of large projects, for example, in which only one SIMOTION device from a project is to be updated. The following scenarios are depicted in the figure: The SIMOTION device to be updated does not have a name. The update is carried out and the SIMOTION device to be updated is assigned the SIMOTION device name D435_1 from the update data. The SIMOTION device to be updated and the SIMOTION device from which the update data have been created have the same name. The data are updated without any query. The SIMOTION device to be updated and the SIMOTION device from which the update data originate do not share the same name. It is assumed, in principle, that they are two different SIMOTION devices, and that the data are not updated. If there is an explicit request for the data from SIMOTION device D435_1 to be applied by SIMOTION device D435_4, the Force update option can be selected. This means that the SIMOTION device is assigned the complete set of new data, including the device name. The Force update option only exists when updating a single SIMOTION device. See also Assigning update data to devices (Page 21) Operating Instructions, 04/

24 Overview 2.5 Single and multiple updates Multiple update Where multiple updates are concerned, the update data are created for at least two, if not all, of the SIMOTION devices from one or more SIMOTION projects. Either update data components of a project or the entire project can be updated. This is at the discretion of the user. However, it is imperative that the devices from the update data and the devices to be updated have the same names. Update data from two different SIMOTION devices with the same name (e.g. from different projects) may not be created at the same time because the data cannot be assigned. See also: Assigning update data to devices (Page 21) The graphic below shows the pool of update data which has been created for the SIMOTION D435_1, D435_2, and D435_3 devices, and which is still located on an update medium. Where multiple updates are concerned, the device names from the update data must match the persistently saved device names from the SIMOTION devices to be updated, in order to guarantee that the update data are assigned correctly. If this is not the case, the update cannot be performed. 24 Operating Instructions, 04/2014

25 Overview 2.6 Device-specific update media 2.6 Device-specific update media The table below provides an overview of which update media can be used for which SIMOTION devices, and in which update scenarios: Table 2-1 Overview of the update scenarios in combination with SIMOTION devices and update media SIMOTION device USB memory stick SIMOTION IT CF/MMC C C240 / C240 PN - Single/multiple update Single update D4x5/D4x5-2 Single/multiple update Single/multiple update Single update D410/D Single/multiple update Single update P320/P350 Single/multiple update Single/multiple update - Note Requirement for updating or restoring: SIMOTION SCOUT V4.1 SP2 or higher Firmware on the SIMOTION device to be updated, V4.1 SP2 or higher Update data must contain firmware V4.1 SP2 or higher (if firmware is selected). Note The SIMOTION device is started from the USB memory stick when updating devices via a USB memory stick. For this reason, a bootable USB memory stick must be used. We recommend SIMATIC memory sticks. Due to the rapid developments within the market for USB memory sticks, it is not possible to make any additional recommendations. For information on this, go to: Note Because of the size of the memory card, the update or restore function is not possible for the SIMOTION C With the SIMOTION C240, a 64 MB MMC must be used for the update or restore function because a 32 MB MMC (supplied V4.0 HF2) does not have sufficient memory space. With the SIMOTION C240 / C240 PN, the function is partly limited due to the memory space available on the MMC (not with large projects). For information on this, go to: Operating Instructions, 04/

26 Overview 2.7 Transferring device-specific user data to the update data 2.7 Transferring device-specific user data to the update data Definition of user data During an update, the following data are not part of the SIMOTION project and therefore must be made available by the user through the following path, for example: E: \ update \ userdata \ all \ IT_DIAG The following structure must be created in the IT_DIAG folder: IT_DIAG IT_CONF Data for configuring the web server (SIMOTION IT) and user rights UserDataBase \ UserDataBase.XML User administration (file UserDataBase.XML in the folder UserDataBase) WebCfg.XML Configuration data The data can be found on the CF card under: \USER\SIMOTION \HMICFG\ For more information, see: Diagnostic manual SIMOTION IT Diagnostics and Configuration SETTINGS Settings for watch tables and traces from SIMOTION IT IT_FILES User websites JAVA_PRG Java programs (*.class, *.jar) JAVA_DAT Java files used Unit data sets (UDS) In the unit data sets, values from unit variables (e.g. machine data from commissioning) can be saved during runtime in data sets on the memory card using _save/_export UnitDataSet. These are uniquely identified by the unit name and data set number (refer also to the Basic Functions Function Manual, section "Backing up data from the user program"). In order to be able to use the data sets in the user data when updating, they must first be transferred via a card reader or FTP from the memory card to the PC. After backing up, the data sets are on the card under \ USER \ SIMOTION \ USER_DIR \ UPP \ UNITDS \. Alternatively, the Save Variables function in SIMOTION SCOUT can be used. Assigning user data to the SIMOTION device Only the user knows that user data has been assigned to the SIMOTION device to be updated. The following points must be clarified in order to enable user update data to be transferred: Which user data is involved here? (Content) Where is the user data located? (Source) Where should the data be imported to? (SIMOTION device) 26 Operating Instructions, 04/2014

27 Overview 2.7 Transferring device-specific user data to the update data To ensure that all information is available, the user data must be provided in a directory structure that has already been defined. Directory structure of the user data The user data is to be stored in the following defined directory structure, as shown in the figure. The directory structure is created using a new folder in Windows Explorer. The structure must be accessible via Windows Explorer. The data can be saved on the hard disk, a USB memory stick, or in a network folder, for example. The ID of the user-specific folder is defined by the user. Operating Instructions, 04/

28 Overview 2.7 Transferring device-specific user data to the update data Figure 2-3 Directory structure for saving user data The entire directory UPP \ UNITDS with its included unit data sets must be stored in the UDS folder. 28 Operating Instructions, 04/2014

29 Overview 2.7 Transferring device-specific user data to the update data The path to a user-specific file must be specified when importing user data via the Device Update Tool. See also: Creating update data with the Device Update Tool (Page 32), Select additional options dialog. The user data for all the devices from the projects are located in the user-specific folder. Data saved in the subdirectory all is imported to all the devices to be updated. Data saved in device-specific folders, e.g. <Device1>, is only imported to the SIMOTION device whose name matches the folder name. In the event of a conflict, if data is available for a device from both the all subdirectory and a device-specific folder (e.g. <Device1>), the user data from the device-specific folder is used. Operating Instructions, 04/

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31 Updating Overview Updating procedure The following section provides an overview of the procedure for updating a SIMOTION device: Creating update data (machine manufacturer) Update data is created on an operator-guided basis via the Device Update Tool at the machine manufacturer's site, using the SIMOTION SCOUT engineering system. This is conducted by the application developer as part of commissioning or service. Copying the update media (machine manufacturer or machine operator) Once the update media has been created, it can either be saved directly to an update medium or stored as an update archive. If data is to be copied to the update medium at a later date, the update data that has been created is saved in an update archive (File system). This can be called up at any time and imported to an update medium. Data are copied to an update medium without SIMOTION SCOUT: This can be performed by either the application developer at the machine manufacturer's site or by the user at the machine operator's site. Transferring data from the update medium to the SIMOTION device (machine operator) Update data can also be imported from the update medium to the SIMOTION device, irrespective of time and place, using the Device Update tool on an operator-guided basis. Note If the parameterization of the SINAMICS Safety Integrated functions is contained in the update data, these functions must be activated after the update. See also SINAMICS S120 Safety Integrated Function Manual. Operating Instructions, 04/

32 Updating 3.2 Creating update data using SIMOTION SCOUT Saving update data to the update media or as an update archive The special features for saving on the update media USB memory stick, CF/MMC card or SIMOTION IT file are described according to the procedure using the Update Tool device. The creation of the update archive is also examined. Creating update data with SIMOTION SCOUT and transferring data to an update medium Creating update data, including copying to a USB memory stick (Page 47) Creating update data, including copying to a CF/MMC card (Page 48) Creating update data including generating a SIMOTION IT file (Page 49) Creating update data as an update archive (Page 49) Copying to the update media on the basis of an update archive Copying data to a USB memory stick (Page 55) Copying data to a CF/MMC card (Page 57) Creating a SIMOTION IT file and copying the update data (Page 58) Transferring update data from the update medium to SIMOTION devices Updating a module with a USB memory stick (Page 68) Updating a module with a CF/MMC card (Page 72) Updating a module with a SIMOTION IT file (Page 73) 3.2 Creating update data using SIMOTION SCOUT The section below describes how update data are created. Update data are created on an operator-guided basis using SIMOTION SCOUT. The individual data items are selected step-by-step using a wizard Creating update data with the Device Update tool Requirement The following data is required in order to create update data: SIMOTION SCOUT V4.1 SP2 or higher installed SIMOTION project(s) One or more SIMOTION devices (firmware V4.1 SP2 or higher) Current SIMOTION FWSP (Firmware Support Package) is installed (applies as of > V4.1 SP2) User data 32 Operating Instructions, 04/2014

33 Updating 3.2 Creating update data using SIMOTION SCOUT Update data creation procedure Update data is essentially created using SIMOTION SCOUT as follows: Call the Device Update Tool via the SIMOTION SCOUT menu Choose whether to create update data or restore data Select a project Select a device Select data Select further options (e.g. user data) Enter the version details Display the summary Copy the update data to an update medium or save it in an archive (to be copied to an update medium at a later date) How to create update data Call up the Device Update Tool via SIMOTION SCOUT. This will give you a step-by-step guide to creating the required update data, which is then either saved in an update archive or imported directly to an update medium. Note If you call up the Device Update Tool via an open project, the project is automatically selected in the dialog. If you also wish to save an archived SIMOTION SCOUT project in the update data, you must close the project before creating the update data. Operating Instructions, 04/

34 Updating 3.2 Creating update data using SIMOTION SCOUT 1. Select Project > Start Device Update Tool directly in SIMOTION SCOUT. Figure 3-1 SIMOTION SCOUT: Start Device Update Tool 2. The Device Update Tool opens at the start screen Welcome to the SIMOTION Device Update tool V (The Device Update Tool is in English.) Here, you can decide whether data is to be created for the purpose of updating or restoring a SIMOTION device or a SIMOTION project. Select Create update data if you wish to create data for updating a device or project. "Updating" means changing to a specific, defined configuration from update data components; this may even be an older version than the current SIMOTION device. Select the Select configuration of data which were formerly stored option if you are already updating a device/devices or a project/projects for a second time and wish to restore the default settings for projects, devices, and data from the last update. This information can be obtained either from an update archive or directly from an update 34 Operating Instructions, 04/2014

35 Updating 3.2 Creating update data using SIMOTION SCOUT medium. Enter the path to the target folder of the update archive or SIMOTION IT file or the drive to the update medium plugged into the PC (USB memory stick, CF/MMC). The Update Tool device will run through each step. The default settings can also be changed if required. If you have selected this option, the Version information dialog is also displayed and write-protected (refer to point 7). Select Create restore trigger if you wish to create data for restoring a device or project. When restoring data, activate the configuration saved on the memory card for the SIMOTION device during the last update. Further information can be found in the section Downgrading (Page 79). Figure 3-2 Start screen for Device Update Tool Always click Next to proceed to the next dialog box. Operating Instructions, 04/

36 Updating 3.2 Creating update data using SIMOTION SCOUT 3. The Select SIMOTION projects dialog then opens. All the projects that have been saved for SIMOTION SCOUT in the standard path or have already been opened on this computer using SIMOTION SCOUT appear here. Figure 3-3 Select SIMOTION Projects dialog Please select one or more SIMOTION projects for which you wish to generate update data. The currently open project is automatically selected. Via button Select all you can select all displayed projects. Via Select none you can undo the project selection. Under Path of selected project the path of the selected project is displayed. 36 Operating Instructions, 04/2014

37 Updating 3.2 Creating update data using SIMOTION SCOUT 4. In the next dialog (Select Devices), all devices assigned to the previously selected projects are displayed. Select the device(s) for which you wish to create update data. Using the Select all button, select all devices shown that were selected in the dialog prior to this. You can deselect the devices by clicking Select none. The path for the project containing the selected device is displayed under Project path of selected device. Figure 3-4 Select Devices dialog Note The selected devices from the selected projects must possess different device names. If there are two devices with the same name, only one of them can be selected. See also: Assigning update data to devices (Page 21) Operating Instructions, 04/

38 Updating 3.2 Creating update data using SIMOTION SCOUT 5. In the Select data dialog, select the data to be stored in the update archive for each selected device. The options of which update data is to be created can be selected separately for each SIMOTION device. Figure 3-5 Select Data dialog The following options can be selected on the left-hand side of the dialog in the device tree: Project (without TPs): Project data without technology packages TPs (technology packages) The technology packages selected in the Select Technology Packages dialog box in SIMOTION SCOUT are added to the update. Archive (compressed scout project file): The archive data contains the entire archived SIMOTION SCOUT project belonging to this device (ZIP file). If the update data is created via an open SIMOTION project, the archive cannot be created. Note If SCOUT projects already archived on the memory card are to be deleted, this can be carried out via a card reader or FTP. 38 Operating Instructions, 04/2014

39 Updating 3.2 Creating update data using SIMOTION SCOUT User data: Your user data Further information on user data can be found at: Transferring device-specific user data to the update data (Page 26) Firmware: In order to be able to add the firmware to the update data, it is necessary to install a corresponding SIMOTION FWSP (Firmware Support Package). Note The compatible SIMOTION FWSP (Firmware Support Package) is automatically supplied as of SIMOTION SCOUT installation V4.1 SP4. Subsequent hotfixes (HFs) are also provided as SIMOTION FWSPs via the SIMOTION Product Support pages on the Internet at: Only one FWSP version can be installed within a main version. Check whether the installed FWSP corresponds to the desired firmware version. If this is not the case, install the correct FWSP. You can define the selection options for all devices using the checkboxes on the righthand side of the dialog: Using Select options, you can select all data for all devices with the Select all option. Selecting Select none deselects all devices. Using Global select options, you can select certain options which are assigned to all devices. For example, in this case Project (project data), TPs (technology packages), and User data have been selected on a global basis for the selected devices as update data to be created. By clicking the Apply button, the selection made on the right-hand side of the dialog is assigned to the left-hand side, thereby validating the selection for the devices. The settings on the right-hand side of the dialog are not saved for the next time the Device Update Tool is run. Note For SIMOTION P, there are currently only plans to update the project data, technology packages and user data. The firmware cannot be updated because of its dependence on other Windows components. Operating Instructions, 04/

40 Updating 3.2 Creating update data using SIMOTION SCOUT 6. In the Select additional options dialog, you can select additional options and specify whether the user data is to be replaced or extended. Figure 3-6 Select Additional Options dialog Using the Force update option, you can carry out an update even if the name of the device from the update data is not identical to the persistently saved device name of the SIMOTION device to be updated. The device to be updated receives the name of the device from the update data if you click Force update. This option is only available if precisely one device has been selected (single update). The option is deactivated in the example shown because two devices have been selected. Enter the path to the user data under User data path. This option can only be selected if the User data is selected as the update data to be created in the Select data dialog box. The data provided from the User data path is displayed on the folder structure on the left-hand side of the dialog box. The option Merge or Replace must be selected separately for each SIMOTION device. The selection of the user data is already defined in the user-specific folder. 40 Operating Instructions, 04/2014

41 Updating 3.2 Creating update data using SIMOTION SCOUT Note The options Replace and Merge refer to the directory level, i.e. file contents are not changed. Further information about the behavior for Replace and Merge is at the end of this section. On the right-hand side of the dialog, under Select options you can specify whether the user data is to be split and replaced according to IT Config, IT Files, IT Settings, Java Program, Java Data and Unit Data Sets (Replace all), or whether the existing data is to be extended to include new information (Merge all). For the significance of user data, refer to Acceptance of device-specific user data into update data (Page 26) For example, if Unit Data Sets and Replace all are selected, and no data is contained within the relevant user-specific folder, the Unit Data Sets (unit data) on the memory card are deleted. By clicking the Apply button, the selection on the right-hand side of the dialog is assigned to the left-hand side, thereby validating the selection for all devices. The settings on the right-hand side of the dialog are not saved for the next time the Device Update Tool is run. The options can also be selected separately for each SIMOTION device on the left-hand side of the device tree. If the button Next is grayed after the selection, this refers to an insufficient selection as the check is executed automatically. Please check if in the directory under User data path no user data has been saved for a device or if the selection on the left-hand side in the device tree or on the right-hand side in the dialog under Select options is incomplete. Operating Instructions, 04/

42 Updating 3.2 Creating update data using SIMOTION SCOUT 7. Enter the version information for the update data in the Add version information dialog: Author Version Date Comment The update information is attached to the update data and can be displayed throughout the entire update procedure. Figure 3-7 Add version information dialog 42 Operating Instructions, 04/2014

43 Updating 3.2 Creating update data using SIMOTION SCOUT 8. You can call up a summary of the projects and devices you have selected, as well as their associated components, in the Summary dialog box. Figure 3-8 Summary dialog Operating Instructions, 04/

44 Updating 3.2 Creating update data using SIMOTION SCOUT 9. In the Select storage location/media dialog, you can specify whether the update data created is to be copied to a specific update medium, or is to be saved in an update archive in order to be written to an update medium at a later date. File system (Update archive) The data is to be exported to a File system in order to be written to an update medium at a later date. An update archive will be created, which can be called up at a later date outside the SIMOTION SCOUT context in order to load an update medium (USB memory stick, CF/MMC card) or to transfer the data through a communication link (SIMOTION IT file). See also Creating update data as an update archive (Page 49) To call up the update archive, refer to Transferring the update data (Page 50) USB memory stick If you select USB memory stick, the update data is written directly to a USB memory stick inserted previously. Check the drive setting. This USB memory stick will have to be formatted before it can be used for updating purposes for the first time. Select the Format as update stick option. See also Creating update data, including copying to a USB memory stick (Page 47) Should you wish to undo the formatting of the USB memory stick, refer to Restoring the original status of a USB memory stick (Page 89) CF/MMC If you select CF/MMC, the update data is written directly to a CF/MMC card. See also Creating update data, including copying to a CF/MMC card (Page 48) SIMOTION IT file If you select SIMOTION IT file, the update data will be written to a SIMOTION IT file. If update data are created for several SIMOTION devices, essentially one SIMOTION IT file will be created per device with the name of the device (<devicename>.zip). See also Creating update data including creating a SIMOTION IT file (Page 49) 44 Operating Instructions, 04/2014

45 Updating 3.2 Creating update data using SIMOTION SCOUT Figure 3-9 Select storage location/media dialog Once you have selected the update medium, click Finish to activate the creation of the update data. 10.After the update data has been created, the Succeeded dialog appears. All successfully created update data is listed here and the storage location recorded. Close the Device Update Tool by clicking the Close button. Operating Instructions, 04/

46 Updating 3.2 Creating update data using SIMOTION SCOUT Figure 3-10 Closing window for the Device Update Tool Canceling the Device Update Tool As a rule, the Device Update Tool can be canceled after every step by clicking the Cancel button. If the data has already begun to be written to the update medium, you cannot cancel this action until the procedure is complete. Behavior after Merge or Replace The following table shows the behavior of original and new files after Merge and Replace. Original files Update files After Merge After Replace Backup files File 1 (original) File 1 (original) File 1 (original) * File 2 (original) File 2 (new) File 2 (new) File 2 (new) File 2 (original) File 3 (original) File 3 (original) File 3 (original) -- * File 4 (new) File 4 (new) File 4 (new) -- * In the example, File 2 is replaced and File 4 is added. 46 Operating Instructions, 04/2014

47 Updating 3.2 Creating update data using SIMOTION SCOUT For the Merge option, the original files are adopted and only replaced by new files with the same name or expanded by new files. For the Replace option, only the new files are adopted. The original files are backed up for Merge and Replace and can be restored Creating update data, including copying to a USB memory stick The USB memory stick can be used both for single and multiple updates with SIMOTION D4x5/ D4x5-2 and SIMOTION P devices, i.e. you can update either a single device or multiple devices. See also Device-specific update media (Page 25) Particular aspects of saving update data on a USB memory stick The USB memory stick, with at least a 512 MB capacity, appears as a logical drive when plugged into the PC. The USB memory stick must be formatted when it is used for the first time (Format as update stick option). You require administrator rights to do this. The following hardware is required in order to update a SIMOTION D4x5/D4x5-2 using a USB memory stick: Table 3-1 Hardware required for USB memory stick updates Module Order no. Minimum hardware release SIMOTION D425 6AU AA00-0AA0 F 2) required 1) SIMOTION D435 6AU AA00-0AA0 Update via USB memory stick is not supported SIMOTION D435 6AU AA00-0AA1 F 2) SIMOTION D445 6AU AA00-0AA0 A SIMOTION D AU AA00-0AA1 A SIMOTION D425-2 DP 6AU AA00-0AA0 from delivery SIMOTION D425-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D435-2 DP 6AU AA00-0AA0 from delivery SIMOTION D435-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D445-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D455-2 DP/PN 6AU AD00-0AA0 from delivery 1) The hardware release can be found on the rating plates on the SIMOTION D 2) Modules with hardware release A to E can be updated (update to BIOS V ) With SIMOTION D425/D435, a BIOS version of at least V is required for USB support. Modules as of hardware release F are supplied with a corresponding BIOS version. A BIOS update can be conducted on SIMOTION D425/D435 modules with a BIOS version < V Operating Instructions, 04/

48 Updating 3.2 Creating update data using SIMOTION SCOUT If you wish to conduct a BIOS update, refer to the Commissioning Manual for the SIMOTION D4x5. Note Note the following information The SIMOTION device is started from the USB memory stick when updating devices via a USB memory stick. For this reason, a bootable USB memory stick must be used. With the exception of SIMATIC USB memory sticks, due to the rapid developments within the market for USB memory sticks it is not possible to give any concrete recommendations. For information on this, go to: If you are using the USB memory stick to update SIMOTION devices for the first time, it is imperative that you format the stick first. Unless it is formatted, the USB memory stick will not work, nor will the update process. Once the USB memory stick has been formatted, the amount of space which can be used in Windows is limited to 450 MB, irrespective of how much memory capacity is actually available. During formatting, all the existing data on the USB memory stick is permanently deleted. The system checks the size of the USB memory stick. If this is less than 512 MB, this option is not available in the Store data dialog box. The USB memory stick has to be restored to its original formatting if you wish to use it for any other purpose. Refer to: Restoring the original status of a USB memory stick (Page 89) Creating update data, including copying to a CF/MMC card The CF/MMC card can be used exclusively for single updates with SIMOTION C and SIMOTION D devices, i.e. only one device can be updated. See also Device-specific update media (Page 25) 48 Operating Instructions, 04/2014

49 Updating 3.2 Creating update data using SIMOTION SCOUT Particular aspects of saving update data on a CF/MMC card The CF/MMC card is inserted into the PC or CF/MMC card adapter and is visible as a logical drive. Note Note the following information You can only perform updates using a CF/MMC card if there already is a bootable SIMOTION system present on the target card, i.e. at the very least, executable firmware V4.1 SP2 must be present. A blank CF/MMC card cannot be updated. If the Device Update Tool has not finished or the copying procedure has been interrupted, updating with the CF/MMC card will not be possible. If an error occurs while data is being written to the CF/MMC card - for example, a power failure - all the data on the card may be lost. In the case of MMC (SIMOTION C), restoring can only take place through a restoration archive or SIMOTION IT Creating update data including generating a SIMOTION IT file With SIMOTION IT, you can carry out single and multiple updates, i.e. both single and multiple SIMOTION devices can be updated. SIMOTION IT is suitable as an update medium for all update scenarios and all SIMOTION devices. If update data are created for several SIMOTION devices, essentially one SIMOTION IT file will be created per device with the name of the device (<devicename>.zip). See also Device-specific update media (Page 25) Specifics for saving update data as a SIMOTION IT file Note Note the following information If there is already a SIMOTION IT file in the selected directory, an error message will appear and the procedure will be aborted. First delete the existing SIMOTION IT file from the directory before storing the new SIMOTION IT file Creating update data as an update archive The update data are created using the Device Update tool in SIMOTION SCOUT on an operator-guided basis, and then saved as an update archive in a directory. Select the File system option in the second-to-last dialog box in the Device Update tool (Select storage location/media ). Enter the path to a blank directory here. As soon as the Operating Instructions, 04/

50 Updating 3.3 Copying to the update media on the basis of an update archive Device Update tool is closed, the update data selected and created previously are written to the directory and stored there for later use. The update archive can be called up independently of SIMOTION SCOUT at a later point in time, so that it can be copied to an update medium. Particular aspects of saving the update data as an update archive Note Note the following information If data are already present in the directory selected, an error message is output and the process is stopped. No data are written. Select another blank directory in the Select storage location/media dialog. The update data are then written to the newly appointed directory. If the CF/MMC card has been selected as an update medium, the update medium may only be one device. 3.3 Copying to the update media on the basis of an update archive Copying to an update medium without SIMOTION SCOUT Requirements The update data has already been created and is located in an update archive. SIMOTION Device Update tool (update archive component) SIMOTION SCOUT is not required to be installed Released for the Windows XP SP3, Windows 7 Ultimate and Windows 7 Professional operating systems Sequence The data is copied to the update media independently of SIMOTION SCOUT; therefore, this can be conducted at either the machine manufacturer's site or the machine operator's site. All that is required is the update archive in which all the update data and the SIMOTION Device Update tool are saved Transferring the update data The SIMOTION Device Update Tool is part of the update archive that is created within the context of SIMOTION SCOUT. 50 Operating Instructions, 04/2014

51 Updating 3.3 Copying to the update media on the basis of an update archive You call up the Device Update Tool for the purpose of transferring update data from an update archive to an update medium. This involves starting the SIMOTION Device Update Tool via a batch file, independently of SIMOTION SCOUT. Proceed as follows: 1. Open the update archive directory. 2. Start the upd_tool.bat batch file from the directory. The SIMOTION Device Update Tool is started. 3. The Welcome to the SIMOTION Device Update tool V dialog appears as the start screen. The Update Tool device is in English. Figure 3-11 Device Update Tool start screen for transferring update data to an update medium 4. Click Load update data/restore trigger to call up either an update archive created using SIMOTION SCOUT or a restore archive. Select the path in which the update archive has been stored. Click Next to proceed to the next dialog box. Operating Instructions, 04/

52 Updating 3.3 Copying to the update media on the basis of an update archive 5. The Version Information dialog box contains the stored identification data that was entered during the creation of the update data. Figure 3-12 Displaying the identification data for the update archive 52 Operating Instructions, 04/2014

53 Updating 3.3 Copying to the update media on the basis of an update archive 6. Select the update medium in the Select storage location/media dialog box. Data will then be written directly to this. You can select from the following: USB memory stick CF/MMC card SIMOTION IT The update medium you can use depends on the SIMOTION device or on whether a single or a multiple update is taking place. You can find an overview under: Device-specific update media (Page 25) Click Finish to activate and execute the copying of data to the update medium. The following data can be created during this procedure: USB memory stick: Update medium for SIMOTION D4x5/D4x5-2 and SIMOTION P. Update data for one or more SIMOTION devices is saved on this update medium. If you are using the USB stick as an update medium for the first time, you must format it. To do this, select Format as update stick. See also Copying data to a USB memory stick (Page 55) CF/MMC: Memory cards are an update medium for single updates on the SIMOTION C and SIMOTION D. Update data for a single SIMOTION device is saved on this update medium. See also Copying data to a CF/MMC card (Page 57) SIMOTION IT file SIMOTION IT is an update medium suitable for all update scenarios (single and multiple updates) and for all SIMOTION hardware platforms (SIMOTION C, D, P). If update data is generated for several SIMOTION devices, essentially one SIMOTION IT file is created per device with the name of the device (<devicename>.zip) is created. See also Creating a SIMOTION IT file and copying the update data (Page 58) Operating Instructions, 04/

54 Updating 3.3 Copying to the update media on the basis of an update archive Figure 3-13 Selecting the update medium 7. The final Succeeded dialog in the Device Update Tool shows which devices the update data from the update archive have been stored for, and at what location. 54 Operating Instructions, 04/2014

55 Updating 3.3 Copying to the update media on the basis of an update archive Figure 3-14 Final Succeeded dialog Canceling the Device Update Tool The Device Update Tool can be canceled after every step by clicking the Cancel button. However, if the data has already begun to be written to the update medium, you cannot cancel this action until the procedure is complete Copying data to a USB memory stick The USB memory stick can be used both for single and multiple updates with SIMOTION D4x5/ D4x5-2 and SIMOTION P devices, i.e. you can update either a single device or multiple Operating Instructions, 04/

56 Updating 3.3 Copying to the update media on the basis of an update archive devices. See also Device-specific update media (Page 25) Note The SIMOTION device is started from the USB memory stick when updating devices via a USB memory stick. For this reason, a bootable USB memory stick must be used. With the exception of SIMATIC USB memory sticks, due to the rapid developments within the market for USB memory sticks it is not possible to make any other concrete recommendations. For information on this, go to: Particular aspects of transferring update data from the update archive to a USB memory stick The USB memory stick, with at least a 512 MB capacity, appears as a logical drive when plugged into the PC. The USB memory stick must be formatted when it is used for the first time (Format as update stick option). You require administrator rights to do this. The following hardware is required in order to update a SIMOTION D4x5/D4x5-2 using a USB memory stick: Table 3-2 Hardware required for USB memory stick updates Module Order no. Minimum hardware release SIMOTION D425 6AU AA00-0AA0 F 2) required 1) SIMOTION D435 6AU AA00-0AA0 Update via USB memory stick is not supported SIMOTION D435 6AU AA00-0AA1 F 2) SIMOTION D445 6AU AA00-0AA0 A SIMOTION D AU AA00-0AA1 A SIMOTION D425-2 DP 6AU AA00-0AA0 from delivery SIMOTION D425-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D435-2 DP 6AU AA00-0AA0 from delivery SIMOTION D435-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D445-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D455-2 DP/PN 6AU AD00-0AA0 from delivery 1) The hardware release can be found on the rating plates on the SIMOTION D 2) Modules with hardware release A to E can be updated (update to BIOS V ) With SIMOTION D425/D435, a BIOS version of at least V is required for USB support. Modules as of hardware release F are supplied with a corresponding BIOS version. A BIOS update can be conducted on SIMOTION D425/D435 modules with a BIOS version < V Operating Instructions, 04/2014

57 Updating 3.3 Copying to the update media on the basis of an update archive If you wish to conduct a BIOS update, refer to the Commissioning Manual for the SIMOTION D4x5. Note Note the following information If you are using the USB memory stick to update SIMOTION devices for the first time, it is imperative that you format the stick first. Unless it is formatted, the USB memory stick will not work, nor will the update process. Once the USB memory stick has been formatted, the amount of space which can be used in Windows is limited to 450 MB, irrespective of how much memory capacity is actually available. During formatting, all the existing data on the USB memory stick is permanently deleted. The system checks the size of the USB memory stick. If this is less than 512 MB, this option is not available in the Store data dialog box. The USB memory stick has to be restored to its original formatting if you wish to use it for any other purpose. Refer to: Restoring the original status of a USB memory stick (Page 89) Copying data to a CF/MMC card The CF/MMC card can be used exclusively for single updates with SIMOTION C and SIMOTION D devices, i.e. only one device can be updated. See also Device-specific update media (Page 25) Operating Instructions, 04/

58 Updating 3.4 Transferring update data to the SIMOTION device Particular aspects of transferring update data from the update archive to a CF/MMC card The CF/MMC card is inserted into the PC or CF/MMC card adapter and is visible as a logical drive. Note Note the following information You can only perform updates using a CF/MMC card if there already is a bootable SIMOTION system present on the target card, i.e. at the very least, there must be executable firmware V4.1 SP2. A blank CF/MMC card cannot be updated. If the Device Update tool has not finished or the copying procedure has been interrupted, updating with the CF/MMC card will not be possible. If an error occurs while data are being written to the CF/MMC card - for example, a power failure - all the data on the card may be lost. If the update fails using MMC (in the case of C2xx) or if the previous configuration has to be accessed for other reasons, the restoration data must be created through SIMOTION SCOUT by the machine manufacturer or restoration can occur using SIMOTION IT Creating a SIMOTION IT file and copying the update data With SIMOTION IT, you can carry out single and multiple updates, i.e. both single and multiple SIMOTION devices can be updated. SIMOTION IT is suitable as an update medium for all update scenarios and all SIMOTION devices. If update data are created for several SIMOTION devices, essentially one SIMOTION IT file will be created per device with the name of the device (<devicename>.zip). See also Device-specific update media (Page 25) Specifics when transferring update data from the update archive to the SIMOTION IT file Note Note the following information If there is already a SIMOTION IT file in the selected directory, an error message will appear and the procedure will be aborted. First delete the existing SIMOTION IT file from the directory before storing the new SIMOTION IT file. 3.4 Transferring update data to the SIMOTION device After update data has been created, it must be transferred to the relevant SIMOTION device. 58 Operating Instructions, 04/2014

59 Updating 3.4 Transferring update data to the SIMOTION device The starting point for this is the update media to which the update data has already been written. An update medium is either plugged into the SIMOTION device being updated (USB memory stick or CF/MMC card) or the update data can be transferred through a communication link to the SIMOTION device involved (SIMOTION IT). The update procedure is triggered by restarting the SIMOTION device to be updated. After first transferring the update data to the memory card in the device (this applies to both the USB memory stick and the SIMOTION IT), the data is backed up. The update data is activated as the current configuration after the SIMOTION device has been restarted. Note If the parameterization of the SINAMICS Safety Integrated functions is contained in the update data, these functions must be activated after the update. See also SINAMICS S120 Safety Integrated Function Manual. Requirements for updating: Firmware on the SIMOTION device to be updated, V4.1 SP2 or higher Update data must contain firmware V4.1 SP2 or higher (if firmware is selected). Updating devices Updating a module with a USB memory stick (Page 68) Updating a module with a CF/MMC card (Page 72) Updating a module with SIMOTION IT (Page 73) Behavior of the retain data on updating (and restoration) Overview After the update data have been transferred to the SIMOTION device, the device is restarted and the update data are applied. During rebooting, the non-volatile data that are saved in the SIMOTION device is checked to determine its compatibility with the current configuration. Compatibility checks are conducted in relation to: Retain kernel data Device-global retain variables Unit retain variables TO retain data Operating Instructions, 04/

60 Updating 3.4 Transferring update data to the SIMOTION device Behavior of the SIMOTION retain data during updating / restoring (from V4.4) During updating, existing retain data are retained under the following conditions: If no changes have been made to the retain data In the case of TO retain data, if the TO name is unchanged In the case of structural changes to unit-global retain data segments of program units, if the name and type of a variable is unchanged If the name of a variable is unchanged but its data type has changed and the value to be restored fits the value range of the new data type Otherwise the retain data will be initialized. If no retain data is contained in the new project, the entire retain memory will be initialized in the control. Behavior of the SINAMICS retain data The SINAMICS retain data are kept during updates. All SINAMICS retain data can be located in the retain memory and interpreted by a new version of the firmware Receiving unit data Behavior of SIMOTION unit data during updating After the update data has been transferred to the SIMOTION device, the device is restarted and the update data is applied. When loading a unit data set, a check is executed for compatibility with the current unit. Data saved with _saveunitdataset is only compatible if the data structure within the unit has not changed. Data backed up using _exportunitdataset() also remains compatible after structure changes of the unit. This means that the data is retained even after a version or project change (when the unit and the data have the same name). Whether existing unit data sets should be kept (Merge) or deleted (Replace) can be specified using the Device Update Tool. New unit data sets can replace existing ones (Replace) or extend them (Merge). Replace means that all existing unit data sets are deleted and the new unit data sets are applied. Merge means that all existing unit data sets are kept and the new unit data sets are added to them. The only exception are the unit data sets with identical names. In this case, the existing unit data sets will be replaced with the new ones. Further information on the Replace and Merge options can be found at: Creating update data with the Device Update tool (Page 32) in the Select additonal options dialog box. 60 Operating Instructions, 04/2014

61 Updating 3.4 Transferring update data to the SIMOTION device Additional references Additional information on the functions can be found in: SIMOTION Basic Functions Function Manual SIMOTION System Functions/Variables Devices List Manual SIMOTION SCOUT Configuration Manual SIMOTION SCOUT Online Help SIMOTION device status during updating Status of SIMOTION devices The table below provides an overview of the possible statuses, the corresponding LEDs, and their significance for SIMOTION devices during the update procedure. Table 3-3 LED display on SIMOTION D for "Copying update data via USB memory stick to the memory card" LED display Status Meaning Description RDY LED flashes yellow/ green at 0.5 Hz, later longer green and yellow phases (< 10 s) USB in progress Update running, data is being copied from the USB memory stick to the memory card. RDY LED constantly red USB ERROR 1 Error copying from the USB memory stick. RDY LED must be constantly green for > 10 s so that the procedure is completed RDY LED flashes yellow at 0.5 Hz (longer than 10 s) USB done USB BOOT ERROR Data has been successfully copied from the USB memory stick to the memory card. Booting is not possible from the used USB memory stick. Update in progress. Do not switch off the SIMOTION device. Error occurred while copying. SIMOTION device is waiting. No communication possible with the SIMOTION device. Required operator actions: 1. Switch off the device. 2. Remove the USB memory stick. 3. Switch on the device. The device boots up in the starting configuration. SIMOTION device is waiting. No communication possible with the device. Required operator actions: 1. Switch off the device. 2. Remove the USB memory stick. 3. Switch on to start the actual update procedure (see following table: LED display when updating the devices). See Device-specific update media (Page 25) Operating Instructions, 04/

62 Updating 3.4 Transferring update data to the SIMOTION device Table 3-4 LED display when updating the devices LED display Status Meaning Description SIMOTION D/P: SF LED flashes green at 0.5 Hz SIMOTION C: SF LED flashes red at 2 Hz SF LED flickers red (10 Hz) IN PROGRESS Update running Update in progress. Do not switch off the SIMOTION device. ERROR 2 Possible errors are: Error backing up the configuration; update has not been accepted. Defective update; update data has been copied, but is defective. SF LED off 1) DONE 1 Update successfully completed SIMOTION device is booting up in STOP with start inhibit After OFF/ON, the device boots up in the starting configuration. If required, a restore must be activated. SIMOTION device boots up with the updated configuration. 1) The update has been successfully completed when the SF LED goes out; the device then boots up automatically in the updated configuration. (SF LED display then depends on the respective mode of the device.) The update status is shown not only via the LEDs, but also in the device diagnostics on the Syslog tab. Syslog can also be read using SIMOTION IT. 62 Operating Instructions, 04/2014

63 Updating 3.4 Transferring update data to the SIMOTION device Flow diagram: "Copying update data via USB memory stick to the memory card" The figure below illustrates the processes that run during updating within the SIMOTION device, using the USB memory stick as an example of an update medium. The status and corresponding LED are displayed with different colors by way of analogy. Operating Instructions, 04/

64 Updating 3.4 Transferring update data to the SIMOTION device 64 Operating Instructions, 04/2014

65 Updating 3.4 Transferring update data to the SIMOTION device Note In this procedure, only the update data is copied from the USB memory stick to the memory card, e.g. for SIMOTION D from the USB memory stick to the CF card. The actual update procedure must be initiated in a further step (see flow diagram: "Updating the device"). Operating Instructions, 04/

66 Updating 3.4 Transferring update data to the SIMOTION device Flow diagram: "Updating a SIMOTION device" The figure below shows how a SIMOTION device can be updated once the update data has been copied to the device's memory card. The status and corresponding LED are displayed with different colors by way of analogy. 66 Operating Instructions, 04/2014

67 Updating 3.4 Transferring update data to the SIMOTION device Operating Instructions, 04/

68 Updating 3.4 Transferring update data to the SIMOTION device Transferring update data from the update medium to SIMOTION devices Updating a module with a USB memory stick Requirement USB memory stick updates are supported by the SIMOTION D4x5/D4x5-2 and SIMOTION P devices. Requirements for updating with a USB memory stick: USB memory stick, to which the required update data has already been copied SIMOTION device(s) to be updated A CF card with sufficient memory capacity for the data to be copied must be inserted into the SIMOTION device(s) to be updated. The following hardware is required in order to update a SIMOTION D4x5/D4x5-2 using a USB memory stick: Table 3-5 Hardware required for USB memory stick updates Module Order no. Minimum requirement SIMOTION D425 6AU AA00-0AA0 F 2) required 1) SIMOTION D435 6AU AA00-0AA0 Update via USB memory stick is not supported SIMOTION D435 6AU AA00-0AA1 F 2) SIMOTION D445 6AU AA00-0AA0 A SIMOTION D AU AA00-0AA1 A SIMOTION D425-2 DP 6AU AA00-0AA0 from delivery SIMOTION D425-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D435-2 DP 6AU AA00-0AA0 from delivery SIMOTION D435-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D445-2 DP/PN 6AU AD00-0AA0 from delivery SIMOTION D455-2 DP/PN 6AU AD00-0AA0 from delivery 1) The hardware release can be found on the rating plates on the SIMOTION D 2) Modules with hardware release A to E can be updated (update to BIOS V ) With SIMOTION D425/D435, a BIOS version of at least V is required for USB support. Modules as of hardware release F are supplied with a corresponding BIOS version. A BIOS update can be conducted on SIMOTION D425/D435 modules with a BIOS version < V Operating Instructions, 04/2014

69 Updating 3.4 Transferring update data to the SIMOTION device If you wish to conduct a BIOS update, refer to the Commissioning Manual for the SIMOTION D4x5. Note SIMOTION D4x5-2 - Updating using a USB stick When upgrading using a USB stick, the points listed below must be observed. The version details refer to the firmware version on the CF card (i.e. to the original version from which the update should occur). Version V4.2: Upgrading via a USB stick is not supported. Version < V4.3 SP1 HF12: The USB stick may only be inserted when the Control Unit is switched off. Version V4.3 SP1 HF2: The USB stick can be inserted when the Control Unit is switched on or off. Procedure for updating the SIMOTION D4x5/D4x5-2 When using a USB memory stick to perform an update, proceed as follows: 1. Check the position of the Service selector switch (for D4x5: SIM/NCK; for D4x5-2: SVC/NCK). The switch position must be at Insert the USB memory stick in one of the two USB interfaces of the activated SIMOTION D4x5/D4x5-2. (Only one USB memory stick may be inserted.) 3. Switch the device OFF/ON or reset it using the RESET button. 4. The SIMOTION D4x5/D4x5-2 will now begin copying the data from the USB memory stick to the CF card. The copying procedure starts with some LED state changes and is finally displayed by a yellow/green flashing RDY-LED (0.5 Hz). In the end phase of the update, the RDY LED has longer green and yellow phases (< 10 s). After completion of the copying procedure the RDY-LED changes to: Constant green, only when the RDY-LED is constantly green for > 10 s, has the copying procedure been completed successfully Constant red, if copying was not successful Meaning of the 7-segment display 0 No memory card available. 1 Internal error 2 Internal error 3 No or incomplete update data available on the USB memory stick. Operating Instructions, 04/

70 Updating 3.4 Transferring update data to the SIMOTION device Meaning of the 7-segment display 4 No update data can be copied because there is no project available in the SIMOTION device, but update data for several SIMOTION devices is available on the USB memory stick. Because of the missing project on the SIMOTION device, assignment to the data on the USB memory stick is not possible. 5 The update data cannot be copied, for example, because there is not sufficient memory space. 6 Internal error 7 Unknown update data available on the USB memory stick. 1. Switch off the SIMOTION D4x5/D4x5-2 and remove the USB memory stick. 2. Switch the SIMOTION D4x5/D4x5-2 back on. The system now starts the update procedure. The SF LED flashes green (0.5 Hz) during the update. The procedure can take several minutes. 3. Observe the green flashing of the SF LED: As soon as the update procedure has been completed successfully, the SF LED goes out. The device then boots up automatically in the updated configuration. (The SF LED display then depends on the respective operating state of the device.) If the update procedure was not successful, the SF LED flickers red (10 Hz). Note If the update has not been successful in terms of the application (for example, the machine is not behaving as desired), it can be undone using an operator action. Note If the firmware is being updated for SIMOTION D, depending on the firmware version on the SINAMICS components (DRIVE-CLiQ components, TB30, PM340, etc.), the component firmware will also be automatically updated. This procedure can take up to several minutes and is indicated by LED displays. A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing red and green: FW update running: RDY-LED flashes slowly (0.5 Hz) FW update complete: RDY-LED flashes rapidly (2 Hz), POWER ON required These flashing patterns are also displayed on the yellow RDY LED on the SIMOTION D/ CX32/CX32-2, and indicate that the firmware update has been carried out on components connected to the SIMOTION D/CX32/CX32-2 or that all components have completed the firmware update. Components that require a POWER ON according to the firmware update will signal this through a rapidly flashing RDY-LED. Switch on the 24 V supply for initializing Off/On (POWER ON) for the respective components. 70 Operating Instructions, 04/2014

71 Updating 3.4 Transferring update data to the SIMOTION device Procedure for updating the SIMOTION P 1. The USB memory stick, to which the update data has been copied, is inserted into one of the available USB ports on the SIMOTION P. Updating or restoring is started automatically. 2. If the SIMOTION P is running at that point, you will be prompted to switch the SIMOTION P off. Figure 3-15 SIMOTION P: Query after the USB memory stick is inserted 3. After you click y to confirm, the device is switched off, and the update is started automatically. The data is copied from the USB memory stick to the SIMOTION P's hard disk. While this process is running, you will be kept informed of progress via SIMOTION P Update. 4. Once the copying procedure is complete, you will be prompted whether you wish to restart the SIMOTION P. If you click y to confirm, the SIMOTION P is restarted. Figure 3-16 SIMOTION P: Device restart enquiry 5. The update or restore is activated when the SIMOTION P is restarted. Operating Instructions, 04/

72 Updating 3.4 Transferring update data to the SIMOTION device Updating a module with a CF/MMC card Precondition CF/MMC card to which the required update data has already been copied SIMOTION device which is to be updated The memory card must have sufficient free storage space (for the active configuration, update data, and backup) Note Only update data for one specific SIMOTION device can be saved on the CF/MMC card. Procedure 1. Switch off the SIMOTION device to be updated. 2. Insert the CF/MMC card into the SIMOTION device. 72 Operating Instructions, 04/2014

73 Updating 3.4 Transferring update data to the SIMOTION device 3. Switch the SIMOTION device on again. The system now starts the update procedure. During the update, the SF LED flashes: Green for SIMOTION D (0.5 Hz) Red for SIMOTION C (2 Hz) The update procedure can take several minutes. 4. Observe the flashing of the SF LED: When the update procedure has been completed successfully, the SF LED goes out. The device then boots up automatically in the updated configuration. (The SF LED display then depends on the respective operating state of the device.) If the update procedure was not successful, the SF LED flickers red (10 Hz). Note If the firmware is being updated for SIMOTION D, depending on the firmware version on the SINAMICS components (DRIVE-CLiQ components, TB30, PM340, etc.), the component firmware will also be automatically updated. This procedure can take up to several minutes and is indicated by LED displays. An FW update on DRIVE-CLiQ components is indicated by the RDY LED flashing red/ green: FW update running: RDY LED flashing slowly (0.5 Hz) FW update complete: RDY-LED flashes rapidly (2 Hz), POWER ON required These flashing patterns are also displayed on the yellow RDY LED on the SIMOTION D/ CX32/CX32-2, and indicate that the firmware update has been carried out on components connected to the SIMOTION D/CX32/CX32-2 or that all components have completed the firmware update. Components that require a POWER ON after the firmware update will signal this through the rapidly flashing RDY-LED. Switch on the 24 V supply to initialize the OFF/On (Power ON) for the respective components Updating a module with a SIMOTION IT file Requirement The updating / restoration data have already been created and are available as.zip in a SIMOTION IT file. There is a browser installed on the computer that is in use. The computer is connected via TCP/IP to the SIMOTION device to be updated. A memory card with sufficient memory capacity for the data to be copied must be inserted into the SIMOTION device(s) to be updated. Operating Instructions, 04/

74 Updating 3.4 Transferring update data to the SIMOTION device It is imperative that updating / downgrading a SIMOTION device using SIMOTION IT takes place when the operational status is STOP. Sufficient memory capacity on the CF/MMC card: Memory capacity is required for the current configuration, the backup copy and the ZIP file. Note Switching off the control during data transfer may lead to loss of data on the CF/MMC card. Procedure 1. Establish a connection via the browser to the SIMOTION device to be updated. The system sends the HTML start screen to the browser. 2. Select the Manage Config page and then the Device Update tab. The system sends the authentication page to the browser. 3. Log in on the Manage Config page using the password. 4. In the Device Update tab, under Send new update data, select the stored SIMOTION IT file (the update data) using the button. 5. Click Send update data to copy the update data to the memory card in the SIMOTION device. The data from the existing configuration is renamed and backed up, and can be retrieved again at any time. In the event of a data restore, this data is activated again. 6. The SIMOTION device is restarted. When the device is booted, the data which has recently been imported is applied as the current configuration and activated. Note If the firmware is being updated for SIMOTION D, depending on the firmware version on the SINAMICS components (DRIVE-CLiQ components, TB30, PM340, etc.), the component firmware will also be automatically updated. This procedure can take up to several minutes and is indicated by LED displays. A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing red/ green: FW update running: RDY-LED flashes slowly (0.5 Hz) FW update complete: RDY-LED flashes rapidly (2 Hz), POWER ON required These flashing patterns are also displayed on the yellow RDY LED on the SIMOTION D/ CX32, and indicate that the firmware update has been carried out on components connected to the SIMOTION D/CX32/CX32-2 or that all components have completed the firmware update. Components that require a POWER ON after the firmware update will signal this through the rapidly flashing RDY-LED. Switch on the 24 V supply to initialize the Off/On (POWER ON) for the respective components. 74 Operating Instructions, 04/2014

75 Updating 3.4 Transferring update data to the SIMOTION device Figure 3-17 SIMOTION IT - Manage Config tab Saving and archiving the current configuration Get selected data: Select this button if you wish to save and archive the current configuration of the SIMOTION device externally. The data is saved on the PC as a.zip file. The configuration saved in this way can be reloaded and activated at a later time using Send update data (e.g. in the case of a memory-card defect). You can choose whether you want to archive the entire configuration or just specific subsets, e.g. firmware (FW), technology packages (TP), project and/or user data (Scout Archive, SIMOTION IT and UDS (Unit Data Sets)). You will find additional information about the Restore last update button in the section titled Restoring a SIMOTION device (Page 79). Literature More information on SIMOTION IT can be found in the following documents: SIMOTION IT Diagnostics and Configuration SIMOTION IT Programming and Web Services SIMOTION IT Virtual Machine and Servlets Operating Instructions, 04/

76 Updating 3.5 Possible error messages for the Device Update tool 3.5 Possible error messages for the Device Update tool Error messages and possible solutions The error messages in the following list can occur when the Device Update Tool is being run. The error messages are in English. Possible causes and remedies are described in the table below. Error message Cause Solution To add firmware to the update data, the firmware must be provided by installing a FW Support Package (FWSP). Currently, there is no appropriate FWSP installed. Please refer to the SCOUT documentation to get more information about the FWSP. The following selected projects are not consistent: In order to generate update data out of those projects, you must recompile them first. To add the selected archive data, the corresponding SCOUT project must not be opened by SCOUT. Please close the corresponding project within SCOUT or deselect the project within the SIMOTION Device Update Tool. The selected projects contain devices with identical names. To generate update data, all device names must be unique. Please deselect appropriate projects or rename the corresponding devices names to become unique. This applies to the following devices. The selected directory already contains data. Please select an empty directory, or delete all the data in the chosen directory. The firmware must be updated for at least one device. The corresponding SIMOTION FWSP (Firmware Support Package) is not available. The selected projects are not compiled in SIMOTION SCOUT. Compiled and consistent projects are required for updating. Projects opened in SIMOTION SCOUT cannot be archived. Several projects were selected when creating update data and devices with identical names exist within this project. The target directory for the update data must be empty. Please install the SIMOTION FWSP (Firmware Support Package). FWSP for versions, service packs (SPs) and hotfixes (HFs) are provided on the SIMOTION Product Support pages on the Internet at: view/en/ Projects that you wish to update must first be compiled in SIMOTION SCOUT and checked for consistency. With the project open, select: Project > Save and compile changes Project > Check consistency Before you call up and run the Device Update Tool, close the project in SIMOTION SCOUT. Create the update data individually for each project or assign unique names to the devices. Select an empty directory or delete the data from an existing one. 76 Operating Instructions, 04/2014

77 Updating 3.5 Possible error messages for the Device Update tool Error message Cause Solution No access to SCOUT. <Device name> not found on the card. Error occurred while accessing the project. An attempt has been made to copy update data to a CF/MMC card. A project is already located on the card and the existing device name does not match the device name in the update data. If SIMOTION SCOUT is online, go offline. Contact the hotline in other cases. If the overwriting of the project on the card is required, select the option Force update in the Select additional options dialog. Operating Instructions, 04/

78

79 Restoring 4 In the following cases it is recommended that you perform a restore on a SIMOTION project or device: Restoring to a previous configuration whenever an error occurs during updating Since a SIMOTION device update may fail, this ensures that communication capability is maintained, even after an update failure. If, for instance, the updated firmware is not recognized, the SIMOTION device may be restored to the firmware that was previously valid. Restoring in situations where a SIMOTION device or project has been successful but the new configuration has failed to perform as required; option of returning to the previous configuration. 4.1 Restoring a SIMOTION device Overview During restoring procedures, it makes no difference whether the previous update was successful or unsuccessful. In both cases, the device is restored to the configuration backed up most recently. If the update could not be carried out, the communication capability of the device is restored. Restoring is triggered off by an explicit action by the user. When a restore is carried out, the SIMOTION device reverts to the configuration saved at the last update. As long as the initial state of the SIMOTION device is not restored after an unsuccessful update attempt, the device remains in the state STOP with start inhibit. This means that, at the very least, communication capability will be ensured. A restore procedure is necessary in order to resume work on a SIMOTION project following an unsuccessful update. Following a successful update, the device can be restored specifically to the data that had been backed up previously. This is the case if, for example, the new configuration has failed to perform as required and you wish to return to the previous configuration. A backup is created as the first step in every update procedure. The device can only be restored to this backup. Characteristics of a failed update A project failure may manifest itself as follows: The SIMOTION device will not go into RUN. The SIMOTION device goes into RUN but performs incorrectly. Operating Instructions, 04/

80 Restoring 4.1 Restoring a SIMOTION device The new firmware has not been updated. The previous firmware state is restored, as a result of which the new project or the new technology packages cannot be loaded. The causes of this behavior are displayed in the diagnostics buffer entries. The stated information can be determined using the diagnostic pages in SIMOTION IT, for example. The SIMOTION device displays a request for an overall reset. Requirements for restoring A backup of the previous configuration was created during the update procedure, which ensured that a backup of the data exists. The configuration includes firmware (FW), technology package(s) (TP), project(s), and any user data which may exist. Triggering a restore Restoration is triggered by saving the restoration archive on the memory card, by operator control actions at the SIMOTION device or by using the Restore last update button in the Manage Config (SIMOTION IT) dialog. In the case of SIMOTION D, restoration is possible through switch settings on the device. Alternatively, restoration can be initiated in all SIMOTION devices by transferring the restoration archive. See Specifics in restoring SIMOTION devices (Page 84) Backup data The backed up data from a SIMOTION device is retained as long as the backup exists, i.e. until it is overwritten by another update. Should errors occur during the update procedure, the device can be restored to the backup. SIMOTION data behavior during restoring Current retain data The retain data will be restored only if the firmware is restored or if data structures are not compatible. Behavior is described under: Behavior of the retain data during updating (Page 59). Current diagnostic buffer The content at the time of backup is activated again. You can find additional information in the section Particular aspects of restoring SIMOTION devices (Page 84) Behavior of the SINAMICS retain data during restoring After a firmware restore has been carried out, the SINAMICS retain data is in the same state as when the data was backed up. 80 Operating Instructions, 04/2014

81 Restoring 4.2 SIMOTION device status during restoring 4.2 SIMOTION device status during restoring Status of SIMOTION devices The table below provides an overview of the possible statuses, the corresponding LEDs, and their meanings for SIMOTION devices during the restore process. Table 4-1 Overview of SIMOTION device status during restoring LED display Status Meaning Description SF LED flickers green (from V4.4) SIMOTION D/P: SF LED flashes green at 0.5 Hz SIMOTION C: SF LED flashes red at 2 Hz SF LED flickers red (10 Hz) IN PROGRESS Restoration required. The flickering green SF LED indicates that a restoration is required. The restoration procedure is started by resetting the service selector switch IN PROGRESS Restore running Restore in progress. Note Do not switch off the SIMOTION device. ERROR 4 Restore error SIMOTION device is booting up in STOP with start inhibit After OFF/ON, the device boots up in STOP with start inhibit. SF LED off 1) DONE 2 Restore successfully completed SF LED flickers red (10 Hz) ERROR 6 Error SIMOTION D only: Service selector switch is still set at Restore. SIMOTION device boots up with the restored configuration SIMOTION device boots up in STOP with start inhibit. Switch off the device, reset the Service selector switch and switch the device back on. If the restoration was otherwise successful, the devices boots up with the restored configuration. 1) The restore has been successfully completed when the SF LED goes out; the device then boots up automatically in the restored configuration. (The SF LED display depends on the respective operating state of the device.) The restore status is shown not only via the LEDs, but also in the device diagnostics on the tabs diagnostic buffer and Syslog. Operating Instructions, 04/

82 Restoring 4.2 SIMOTION device status during restoring Flow diagram: "Restoring a SIMOTION device" The figure below shows how a SIMOTION device restore may proceed once the restore archive has been transferred to the memory card of the SIMOTION device. The status displays appear in different colors by way of analogy. 82 Operating Instructions, 04/2014

83 Restoring 4.2 SIMOTION device status during restoring Operating Instructions, 04/

84 Restoring 4.3 Particular aspects of restoring SIMOTION devices Note Restore request from Version V4.4 From Version V4.4 the restore request is indicated by a green flickering SF LED. The restore procedure starts once the service selector switch is reset. In the case of SIMOTION < V4.4, the restoration starts once the module is switched on. Here, the service selector switch must be reset immediately once the flash code is displayed (SF LED flashes green at 0.5 Hz). If the service selector switch is not reset or not reset promptly, this will lead to the error status "Service selector switch is still at restore" (SF LED flickers red). 4.3 Particular aspects of restoring SIMOTION devices Precondition During restoring procedures, it makes no difference whether the previous update was successful or unsuccessful. The procedure is identical for every SIMOTION device. A distinction is made between SIMOTION devices where a restore can be requested via an operator control. In the case of SIMOTION devices with Ethernet / PROFINET interfaces, the user can also request a restoration using SIMOTION IT. For all SIMOTION devices, restore data can be created as a restore archive on an operator-guided basis via the Device Update Tool. These can then be saved to the memory card of the SIMOTION device. Table 4-2 Assignment of restore options to SIMOTION devices SIMOTION device Restore options Method C2xx Creating the restore archive via the Device Update Tool Machine manufacturer D4x5/D4x5-2 D410/D410-2 Preferred solution: Via Service selector switch on the device Alternative: Create the restore archive via the Device Update Tool Preferred solution: Via Service selector switch on the device Alternative: Create the restore archive via the Device Update Tool Machine operator Machine operator P320/P350 Creating the restore archive via the Device Update Tool Machine manufacturer Restoration using SIMOTION IT is essentially possible for all SIMOTION devices with Ethernet interfaces for all restore scenarios and can be carried out by the machine operator. 84 Operating Instructions, 04/2014

85 Restoring 4.3 Particular aspects of restoring SIMOTION devices Restoring SIMOTION D410/D4x5 using the operating element on the device The user can use an operator control to carry out a restore at the machine operator's site without any involvement by the machine manufacturer, since there is no need for SIMOTION SCOUT. 1. Switch off the SIMOTION D410/D4x5 device. 2. Set the service selector switch to restore. (D410: DIP switch 6 to ON and DIP switch 7 to OFF D4x5: SIM/NCK - Service selector switch in position B) 3. Switch the SIMOTION D410/D4x5 back on. The system restores the data saved during the update. The data from the restore procedure is deleted. 4. The restoration is signaled by a green flashing SF LED (0.5 Hz) and may take several minutes. Reset the service selector switch immediately the flash code is displayed (D410: DIP switch 6 to OFF and DIP switch 7 to OFF D4x5: Reset service selector switch to position 0 ). 5. Observe the flashing of the SF LED: When the restore procedure has been completed successfully, the SF LED goes out. The device then boots up automatically in the restored configuration. (The SF LED display depends on the respective operating state of the device.) If the restore procedure was not successful, the SF LED flickers red (10 Hz). Note If the Service selector switch is not reset or not reset in good time, this results in fault state Service selector switch is still set to restore (SF LED flickers red at 10 Hz). In this case, switch the SIMOTION D410/D4x5 off, reset the service selector switch and switch the SIMOTION D410/D4x5 back on again. If the restoration was otherwise successful, the SIMOTION D410/D4x5 will start up with the restored configuration. Restoring SIMOTION D410-2/D4x5-2 using the operating element on the device The user's machine operator can restore using the operating element independent of the machine manufacturer, as no SIMOTION SCOUT is required. 1. Switch off the SIMOTION D410-2/D4x5-2 device. 2. Set the service selector switch to position B (in the case of D410-2: SVC, in the case of D4x5-2: SVC/NCK). Operating Instructions, 04/

86 Restoring 4.3 Particular aspects of restoring SIMOTION devices 3. Switch the SIMOTION D410-2/D4x5-2 device back on again. The flickering green SF LED indicates that a restoration is required. 4. Reset the service selector switch to position 0. The system restores the data saved during the update. The data from the update procedure will be deleted. The restore will be signaled by a green flashing SF LED (0.5 Hz) and this may take several minutes. After a successful restoration, the module will start up automatically. (SF LED display will then depend on the respective operating status of the device). If the restore was not successful, the SF LED will flicker red. Note Start of the restore procedure (SIMOTION < V4.4) In the case of SIMOTION < V4.4, the restore procedure starts when the module is switched on (see Step 3). The service selector switch must be turned to position 0 immediately the flash code is displayed (SF LED flashes green at 0.5 Hz). If the service selector switch is not reset to position 0 or not reset there promptly, this will lead to the error status "Service selector switch is still at restore" (SF LED flickers red). In this case, switch off the SIMOTION D Control Unit, reset the service selector switch and switch the Control Unit back on again. If the restore was otherwise successful, the Control Unit will start up with the restored configuration. Restoring firmware for SIMOTION D Note If the firmware is being restored for SIMOTION D, depending on the firmware version on the SINAMICS components (DRIVE-CLiQ components, TB30, PM340, etc.), the component firmware will also be automatically restored. This procedure can take up to several minutes and is indicated by LED displays. A FW update on DRIVE-CLiQ components is signaled by red-green flashing of the LED RDY: FW update running: LED RDY flashes slowly (0.5 Hz) FW update complete: LED RDY flashes rapidly (2 Hz), POWER ON required This flash pattern is additionally displayed at the yellow LED RDY of the SIMOTION D/CX32/ CX32-2 and signals that components connected to the SIMOTION D/CX32/CX32-2 are carrying out a FW update or that all components have completed the FW update. After the firmware update has been completed on all components, a POWER ON must be carried out for all restored components. 86 Operating Instructions, 04/2014

87 Restoring 4.3 Particular aspects of restoring SIMOTION devices Restoring via the restore archive A restore archive is created at the machine manufacturer's site using the Device Update Tool function in SIMOTION SCOUT. When restoring, you are guided through the Device Update Tool (just as is the case with updating). 1. Select Project > Start Device Update Tool in the open SIMOTION project. 2. The Device Update Tool opens with the start screen Welcome to the SIMOTION Device Update tool V Here, you can decide which data is to be created for updating or restoring a SIMOTION device. Select Create restore trigger, since you wish to create data for restoring a device. 3. The subsequent steps in this procedure are identical to those involved in updating. Refer to: Creating update data with the Device Update Tool (Page 32) Restoring using SIMOTION IT The user's machine operator can perform a restore using the SIMOTION IT web server independent of the machine manufacturer, as no SIMOTION SCOUT is required. To do this, in the Manage Config tab, under CPU update, select the Restore last update button, in order to effectively switch the device backup. The system restores the data saved during the update. The data from the update procedure will be deleted. Once this is complete, the SIMOTION device restarts. After ramping up, the configuration is restored to its pre-update status. See also: Updating a module with SIMOTION IT (Page 73) Operating Instructions, 04/

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89 Appendix A A A.1 Restoring the original status of a USB memory stick Requirement A USB memory stick has to be formatted once before it can be used as an update medium for the first time. A bootable update medium is created during formatting. The USB stick's memory is limited to a fixed value of 450 MB, irrespective of how much memory capacity is actually available. Various partitions, which are required for updating, are created. To restore the USB memory stick to its original status, it is not enough to simply format it as the partitions have to be deleted first. Note A USB memory stick formatted using the Device Update Tool can only be restored under Windows XP and can then be used again. Procedure Before formatting the USB memory stick, the existing partitions must be deleted and a partition encompassing the entire USB memory stick must be created. The procedure is as follows: 1. Insert the USB memory stick that has been formatted as an update medium into a USB port on the computer. 2. Right-click the My Computer icon on your desktop and select Manage from the context menu. Alternatively, you can also open the Windows Explorer. Right-click My Computer in the Start menu window and select Manage from the context menu. The Computer Management window opens. Operating Instructions, 04/

90 Appendix A A.1 Restoring the original status of a USB memory stick 3. Scroll down the Computer Management window until you reach Disk Management. In this example the USB memory stick appears under drive letter (F:). The total memory capacity of the USB memory stick is shown at the top right-hand side of the window under Capacity. The different partitions and the memory capacity that is currently available for use appear in the bottom right of the window under Disk 2. The USB memory stick is divided into three partitions: VOLUME (F:) MB FAT32 - Error-free: The area on the left is the partition which is visible in Windows; this contains the update data. 30 MB - Error-free: The area in the middle is the partition containing the LINUX system GB - Not allocated: The area on the right is the partition containing the part of the USB memory stick which is of no relevance to the update data. The size varies depending on the memory capacity of the USB memory stick. This partition is not allocated and cannot, therefore, be read by Windows either. Figure A-1 Computer Management window 4. In order to create a complete partition again, the LINUX partition which is not visible in Windows must be deleted. Right-click the middle partition (in this case 30 MB) and select Delete Partition... from the context menu. 90 Operating Instructions, 04/2014

91 Appendix A A.1 Restoring the original status of a USB memory stick 5. Click Yes in the dialog box that appears to confirm that you wish to delete the partition. Figure A-2 Disk Management 6. There is now only a single unallocated partition available under Disk 2 in the Computer Management window. Selecting the middle partition also automatically deletes the partition on the left-hand side containing the update data. Figure A-3 Computer Management window In order to create a new partition, right-click the unallocated partition and select Activate new partition in the context menu. Operating Instructions, 04/

92 Appendix A A.1 Restoring the original status of a USB memory stick 7. The New Partition Wizard appears. Run the wizard, as indicated in the steps below. Click Next to proceed to the next window. Figure A-4 "New Partition Wizard" start screen 8. Confirm Primary partition as the partition type. Figure A-5 Wizard: Defining the partition type 92 Operating Instructions, 04/2014

93 Appendix A A.1 Restoring the original status of a USB memory stick 9. Confirm the partition size. Figure A-6 Wizard: Defining the partition size 10.Assign the drive into which the USB memory stick is to be inserted. Figure A-7 Wizard: Assign the drive letter or path. Operating Instructions, 04/

94 Appendix A A.1 Restoring the original status of a USB memory stick 11.Choose the following settings in order to format the partition: File system to be used: FAT Allocation unit size: Standard Volume identifier: Volume Figure A-8 Wizard: Format a partition 94 Operating Instructions, 04/2014

95 Appendix A A.1 Restoring the original status of a USB memory stick 12.The settings selected are displayed in the closing window for the wizard. Click Finish to close the wizard. 13.The changed partition appears in the Computer Management window under Disk 2. The USB memory stick is restored to its original status. The entire memory capacity will now be available again in a partition and displayed in Windows. Figure A-9 Computer Management - View of the newly created partition Operating Instructions, 04/