6.22 Migration of SIMOTION D4x5 to SIMOTION D4x5-2

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1 Changeover from SIMOTION D4x5 to A /CX32-2 not only has a different structure, but also a different functionality to a SIMOTION D4x5/CX32. This has effects that must be taken into account during a changeover. Change from D4x5 to D4x5-2 (upgrade) The change from D4x5 to D4x5-2 is performed via a module replacement in HW Config. That means the change is similar to that of a D425 to D435. The module replacement is started by dragging the new module to the frame of the module rack with the existing module in HW Config, see Section Device replacement in HW Config (Page 326). The module replacement is performed automatically. During this operation, the technology packages and the device versions are updated. Existing configurations of the D4x5 are mostly taken over by the D4x5-2 during the module replacement. Information on when project adaptations are required or not required when changing from a D4x5 to a D4x5-2 can be found in the following sections (see Table Transfer of existing projects from D4x5 to D4x5-2). For further information on measures generally required for project adaptations, see Section Service and maintenance (Page 309). Change from D4x5-2 to D4x5 (downgrade) As a SINAMICS drive cannot be downgraded, a module replacement of a (SINAMICS Integrated firmware V4.x) with a SIMOTION D4x5 (SINAMICS Integrated firmware V2.x) is not possible. However, project data can be transferred by means of an XML export/import. Transfer of existing projects Existing configurations of the D4x5 are mostly taken over by the D4x5-2 during the module replacement. The following table provides information on where project adaptations are required or not required: Commissioning and Hardware Installation Manual, 02/

2 Table 6-19 Transfer of existing projects from D4x5 to D4x5-2 PROFINET interface D4x5 with CBE30 (4 ports) is mapped on D4x5-2 DP/PN onboard PROFINET interface (3 ports): Only the wiring of ports 1 to 3 are taken over Components on port 4 have to be reconnected Communication relations, I/O data, synchronous operation connections, data exchange broadcast data, module addresses and diagnostics addresses are retained PROFIBUS interfaces Reduction ratio of PROFIBUS cycle clock to position control cycle clock Any existing PG/PC assignment is taken over Mapping of D4x5 on D4x5-2: X1400 (P1, P2, P3, not P4) X150 (P1, P2, P3) The configurations on the PROFIBUS interfaces including any existing PG/PC assignment are retained. Mapping of D4x5 on D4x5-2: X126 DP1 X126 DP X136 DP2/MPI X136 DP/MPI As of SIMOTION V4.3, the supports reduction ratio of PROFIBUS cycle clock to position control cycle clock. The following applies for V4.2: PROFIBUS cycle clock: Position control cycle clock = 1: 1 If SIMOTION D4x5 projects have been transferred in which a reduction ratio factor was set, A SIMOTION version V4.3 must be used, or The cycle clock setting must be adapted for V4.2 projects 302 Commissioning and Hardware Installation Manual, 02/2012

3 Ethernet interfaces The configurations on the Ethernet interfaces including any existing PG/PC assignment are retained. Mapping of D4x5 on D4x5-2: X120 IE1/OP X127 P1 PN/IE (interface on the front of the module) X130 IE2/NET X130 P1 PN/IE-NET (interface under the front flap) The X120 P1 PN/IE-OP interface is only available on the D4x5-2 DP. Mapping is never performed on this interface. The following figure provides an overview of the default addresses as well as the behavior when upgrading a D4x5 to D4x5-2 (assumption: The default addresses have been used for the D4x5). Message frame configurations SINAMICS Integrated / controller extension With SIMOTION D4x5, the Ethernet interfaces of the D4x5 have default addresses in the delivery condition. These addresses are also offered as default addresses in the configuration of SIMOTION SCOUT. With, only interface X127 P1 has a default address in the delivery condition. Interface X127 P1 is preferable for the PG/PC connection because it is easier to access. The default address is an Automatic Private IP Address (APIPA or Auto IP). In this way, a PG/PC can automatically configure the network interface. Interfaces X120 P1 and X130 P1 do not have an address in the delivery condition. When configuring the interfaces, the addresses shown in the figure are offered as default addresses. Message frame configurations on the PROFIBUS and PROFINET interfaces are retained. The same applies for the addresses of the slots/subslots. The SINAMICS Integrated and controller extension are changed to the new type and its corresponding version. The drive configuration and the assignments of the DRIVE-CLiQ interfaces are retained. Commissioning and Hardware Installation Manual, 02/

4 Configuration of the onboard I/Os The configuration of the onboard I/Os is retained. Functionality, quantity structure and terminal designations of the onboard I/Os for the D4x5-2/CX32-2 differ from the previous modules because of innovations. Example: D4x5-2 has additional technology I/Os on terminal block X142 (e.g. for high-precision cam outputs); a cam output on X122/X132 is no longer supported Terminal blocks X122/X132 have additional digital inputs and therefore the pin assignments on the terminal block have been moved. CompactFlash card / firmware Mixture of Control Units of different generations SIMOTION D4x5 and D4x5-2 have different CompactFlash cards and different card mappers (firmware). 1 GB CompactFlash cards of the D4x5 can also be used for the D4x5-2 when a new boot loader is loaded. For details, see Section Boot loader on the CompactFlash card (Page 344). The firmware version of a controller extension (CX) is always identical to the SINAMICS Integrated. Therefore The CX32 can only be operated on the D4x5 Connectable drive components The CX32-2 can only be operated on the D4x5-2 These dependencies do not apply for SINAMICS S120 Control Units. A CU320 can therefore be operated on a D4x5-2. As for the CU320-2, some older drive components are also no longer supported by the D4x5-2/CX32-2. For details, see Section Permissible combinations (Page 306) 304 Commissioning and Hardware Installation Manual, 02/2012

5 User program In principle, a D4x5 user program can run on a D4x5-2, however, adaptations may be required because of innovations in the hardware. Examples: The non-volatile data is backed up permanently and maintenance-free for the D4x5-2 (backed-up SRAM for D4x5); a buffer failure signaled via persistentdatapowermonitoring.powerfailure = "YES" therefore only applies to the realtime clock, not for the non-volatile data. The runtime behavior of the D4x5-2 modules changes because of the increase in performance. As long as the user program does not contain any "runtime-dependent code", adaptations should not be necessary. The D4x5-2 has a double fan module. The user program must be adapted in order to profit from the advantages of a double fan compared with a single fan (identification of required maintenance). See Section Overview of the fan/battery module states (Page 108). The user program will have to be modified with respect to detection of the maintenance case for D425-2/D435-2 if D425/D435 was used without a fan/battery module. See Section Overview of states, fan/battery module (Page 108). The batterynecessary and fannecessary system variables have different states depending on the device. See Section Operations and their effect on the user memory (Page 94) and Section Cooling the (Page 106) As of SIMOTION V4.3, the following additional functions are available for the D4x5-2: System variables rtcfailure and retaindatafailure Backup of the non-volatile SINAMICS data (NVRAM data) via CU parameter p7775 Automatic detection of a module replacement on the basis of the serial number of the Control Unit Hardware The following changes have been made because of the hardware innovations: CompactFlash card under a cover (previously open access) Additional and slightly differently arranged operator control and display elements Modified connectors (larger cable cross-section, screw connection on the 24 V terminal block, etc.) D445-2 DP/PN and D455-2 DP/PN have a heat sink so that the spacers (with the exception of external heat dissipation) cannot be disassembled as for the D See also Section Mounting a (Page 27). A double fan/battery module is always required for D4x5-2 Control Units. See Section Cooling the (Page 106). Controller extensions (CX) for D4x5 can only be used for the D435 and D445/D445-1; with the D4x5-2, all Control Units support the use of CX32-2 controller extensions. Commissioning and Hardware Installation Manual, 02/

6 Permissible combinations DRIVE-CLiQ components Some "older" DRIVE-CLiQ components can no longer be used with the SIMOTION D4x5-2/CX32-2. Table 6-20 DRIVE-CLiQ components that cannot be used with the D4x5-2/CX32-2 DRIVE-CLiQ components Information Ending of the order no. Single motor modules (SMM) Double motor modules (DMM) Line modules (ALM/SLM) Chassis power units (line modules, motor modules, power modules) 6SL31* (all booksize compact motor modules 6SL34* can be used) 6SL313* The following can generally be used: All BLM (6SL313*) SLM (6SL313*) 5 and 10 kw < 3 < 3 < 3 SMC30 sensor modules cabinet < 2 TM31/TM41 terminal modules < 1 SME20/25 sensor modules external < 3 CUA31 Control Unit adapter < 1 Power modules (chassis) < 3 A detailed, regularly updated list of the DRIVE-CLiQ components approved for use with SIMOTION, as well as notes on their use, can be found on the Internet at ( If incorrect components are used, a topology error is signaled F01360 Topology: Actual topology not permitted. CX32-2 The tables below provide an overview of the possible combinations: Table 6-21 Controller extension combinations Controller extension Order number Use in D4x5 Use in D4x5-2 CX32 6SL3040-0NA00-0AA0 Possible Not possible CX32-2 6AU1432-2AA00-0AA0 Not possible Possible Only approved combinations can be configured. If physically an incorrect controller extension is used, a topology error is signaled. F01360 Topology: Actual topology not permitted 306 Commissioning and Hardware Installation Manual, 02/2012

7 CBE30-2 The tables below provide an overview of the possible combinations: Table 6-22 Communication board Ethernet combinations Communication board Ethernet Order number Use in D4x5 Use in D4x5-2 CBE30 6FC5312-0FA00-0AA0 Possible Not possible CBE30-2 6FC5312-0FA00-2AA0 Not possible D4x5-2 DP/PN: As of V4.3 D4x5-2 DP: Not possible Only approved combinations can be configured. If physically an incorrect Ethernet communication board is used, the CBE cannot be fully inserted into the option slot. CompactFlash card A CompactFlash card with D4x5 firmware / drive software cannot run on a D4x5-2. The same applies for the reverse situation. In case of an error, the six LED displays (RUN to DP/MPI) flash yellow at 2 Hz. An entry is also made in the diagnostic buffer. Licenses Licenses purchased for SIMOTION D can be used for both the D4x5 and D4x5-2. Previously used platform-specific "MultiAxes Package for D445/D445-1" licenses can also be used for the D445-2 DP/PN and D455-2 DP/PN. A new license has not been introduced for the D455-2 DP/PN performance class. Commissioning and Hardware Installation Manual, 02/