Siemens SIMOTION D4 5-2 Series User manual

SIMOTION D4x5- 
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SIMOTION
SIMOTION D4x5-2
Commissioning and Hardware Installation Manual
Valid for SIMOTION D4x5-2, CX32-2, CBE30-2 and
TB30
02/2012
Preface
Description
1
Installing
2
Connecting
3
Commissioning (hardware)
4
Parameter assignment /
addressing
5
Commissioning (software)
6
Service and maintenance
7
Diagnostics
8
Configuration of drive-related
I/Os (without symbolic
assignment)
A
Standards and approvals
B
ESD guidelines
C

Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
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 48 48
90026 NÜRNBERG
GERMANY
Copyright © Siemens AG 2012.
All rights reserved

SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 3
Preface
Contents of this commissioning and hardware installation Manual
This document is part of the SIMOTION D documentation package.
Scope
The SIMOTION D4x5-2 Commissioning and Hardware Installation Manual is valid for the
SIMOTION D4x5-2 control units as well as for the CX32-2, CBE30-2 and TB30
supplementary system components.
A separate SIMOTION D4x5 Commissioning and Hardware Installation Manual is available
for the SIMOTION D425, SIMOTION D435 and SIMOTION D445/D445-1 devices including
the CX32, CBE30 and TB30 system components.
Standards
The SIMOTION system was developed in accordance with ISO 9001 quality guidelines.
Information in this manual
The following is a description of the purpose and use of this Commissioning and Hardware
Installation Manual:
● Description
Provides information about the SIMOTION system and its integration in the automation
environment.
● Installing
Provides information on the various installation options for the device.
● Connecting
Provides information about connecting and cabling the various devices, and about
communications interfaces.
● Commissioning (hardware)
Provides information on commissioning the device.
● Parameter assignment / addressing
Provides information on configuring and parameterizing the various bus systems.
● Commissioning (software)
Provides information on configuring and commissioning the system.
● Service and maintenance
Provides information about service and maintenance procedures that must be performed
on the device.

Preface
SIMOTION D4x5-2
4 Commissioning and Hardware Installation Manual, 02/2012
● Diagnostics
Provides information about the available diagnostic information, how to interpret it, and its
meaning.
● Appendices with factual information for reference (e.g. standards, approvals, and ESD
guidelines).
SIMOTION Documentation
An overview of the SIMOTION documentation can be found in a separate list of references.
This documentation is included as electronic documentation in the scope of delivery of
SIMOTION SCOUT. It comprises 10 documentation packages.
The following documentation packages are available for SIMOTION V4.3:
● SIMOTION Engineering System
● SIMOTION System and Function Descriptions
● SIMOTION Service and Diagnostics
● SIMOTION IT
● SIMOTION Programming
● SIMOTION Programming - References
● SIMOTION C
● SIMOTION P
● SIMOTION D
● SIMOTION Supplementary Documentation

Preface
SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 5
Hotline and Internet addresses
Additional information
Click the following link to find information on the the following topics:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
[e-mail]
My Documentation Manager
Click the following link for information on how to compile documentation individually on the
basis of Siemens content and how to adapt this for the purpose of your own machine
documentation:
http://www.siemens.com/mdm
Training
Click the following link for information on SITRAIN - Siemens training courses for automation
products, systems and solutions:
http://www.siemens.com/sitrain
FAQs
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:
http://support.automation.siemens.com
Technical support
Country-specific telephone numbers for technical support are provided on the Internet under
Contact:
http://www.siemens.com/automation/service&support

Preface
SIMOTION D4x5-2
6 Commissioning and Hardware Installation Manual, 02/2012
Disposal and recycling of the device
SIMOTION D is an environmentally friendly product. It includes the following features:
● In spite of its excellent resistance to fire, the flame-resistant agent in the plastic used for
the housing does not contain halogens.
● Identification of plastic materials in accordance with ISO 11469.
● Less material used because the unit is smaller and with fewer components thanks to
integration in ASICs.
The disposal of the products described in this manual should be performed in compliance
with the valid national regulations.
The products can be largely recycled owing to their low pollutant content. To recycle and
dispose of your old device in an environmentally friendly way, please contact a recycling
company certified for electronic waste.
If you have any further questions about disposal and recycling, please contact your local
Siemens representative. Contact details can be found in our contacts database on the
Internet at:
http://www.automation.siemens.com/partner/index.asp
Further information / FAQs
You can find further information on this manual under the following FAQ:
http://support.automation.siemens.com/WW/view/de/27585482
The following information sources are also available:
● SIMOTION Utilities & Applications: SIMOTION Utilities & Applications will be included in
the SIMOTION SCOUT scope of delivery and, along with FAQs, also contain free utilities
(e.g. calculation tools, optimization tools, etc.) as well as application examples (ready-to-
apply solutions such as winders, cross cutters or handling)
● The latest SIMOTION FAQs at
http://support.automation.siemens.com/WW/view/en/10805436/133000
● SIMOTION SCOUT online help
● Refer to the list of references (separate document) for additional documentation

SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 7
Table of contents
Preface ...................................................................................................................................................... 3
1 Description............................................................................................................................................... 13
1.1 System overview..........................................................................................................................13
1.2 System components ....................................................................................................................18
1.3 I/O integration...............................................................................................................................23
1.4 Commissioning software..............................................................................................................24
1.5 Safety information ........................................................................................................................26
2 Installing .................................................................................................................................................. 27
2.1 Installation notes ..........................................................................................................................27
2.2 Installing the SIMOTION D4x5-2 .................................................................................................27
2.2.1 Installing the SIMOTION D4x5-2 .................................................................................................27
2.2.2 Mounting the SIMOTION D4x5-2 with spacers............................................................................29
2.2.3 Mounting the SIMOTION D425-2 and D435-2 without spacers ..................................................30
2.2.4 Mounting the SIMOTION D445-2 and D455-2 without spacers (external air cooling).................31
2.3 Installing supplementary system components.............................................................................33
2.3.1 Installing the TB30 .......................................................................................................................33
2.3.2 Installing the CBE30-2 .................................................................................................................34
2.3.3 Installing the CX32-2....................................................................................................................35
2.3.4 Removing the cover of the CX32-2..............................................................................................40
3 Connecting .............................................................................................................................................. 41
3.1 General Overview ........................................................................................................................41
3.2 Safety information for wiring ........................................................................................................43
3.3 Opening the front cover ...............................................................................................................47
3.4 Power supply................................................................................................................................49
3.4.1 Safety rules ..................................................................................................................................49
3.4.2 Standards and regulations...........................................................................................................50
3.4.3 Mains voltage...............................................................................................................................50
3.4.4 Connecting the power supply.......................................................................................................51
3.5 Connecting DRIVE-CLiQ components.........................................................................................52
3.5.1 DRIVE-CLiQ wiring ......................................................................................................................52
3.5.2 Connectable DRIVE-CLiQ components.......................................................................................54
3.5.3 Connecting the CX32-2................................................................................................................56
3.6 Connecting I/Os ...........................................................................................................................58
3.6.1 Creating a shield connection........................................................................................................59
3.6.2 Connecting I/Os of the TB30........................................................................................................61
3.7 Connecting PROFIBUS/MPI........................................................................................................63
3.7.1 PROFIBUS connection components ...........................................................................................63

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SIMOTION D4x5-2
8 Commissioning and Hardware Installation Manual, 02/2012
3.7.2 PROFIBUS cables and connectors............................................................................................. 64
3.7.3 Length of PROFIBUS cables ......................................................................................................65
3.7.4 Rules for the laying of PROFIBUS cables .................................................................................. 65
3.7.5 Connecting PROFIBUS DP (interfaces X126 and X136) ........................................................... 66
3.7.6 Connection rules in the PROFIBUS subnet................................................................................ 67
3.7.7 Operating the X136 interface as MPI.......................................................................................... 69
3.8 Connecting Ethernet ................................................................................................................... 72
3.8.1 Wiring Ethernet ........................................................................................................................... 72
3.8.2 Ethernet cables and connectors .................................................................................................73
3.9 Connecting PROFINET IO components ..................................................................................... 74
3.9.1 Wiring PROFINET....................................................................................................................... 74
3.9.2 PROFINET cables and connectors............................................................................................. 75
3.10 Routing........................................................................................................................................ 77
3.10.1 Routing on SIMOTION D ............................................................................................................ 77
3.10.2 Routing on SIMOTION D (SINAMICS integrated) ...................................................................... 81
4 Commissioning (hardware)...................................................................................................................... 83
4.1 Requirements for commissioning................................................................................................ 83
4.1.1 Inserting the CompactFlash card ................................................................................................84
4.1.2 Checking the system................................................................................................................... 86
4.1.3 Switching on the power supply ................................................................................................... 86
4.2 RESET button ............................................................................................................................. 89
4.3 User memory concept ................................................................................................................. 89
4.3.1 SIMOTION D4x5-2 memory model............................................................................................. 89
4.3.2 Properties of the user memory.................................................................................................... 90
4.3.3 Operations and their effect on the user memory......................................................................... 94
4.3.4 Module replacement.................................................................................................................. 103
4.4 Fan ............................................................................................................................................ 106
4.4.1 Cooling the SIMOTION D4x5-2 ................................................................................................ 106
4.4.2 Fan/battery module ................................................................................................................... 107
4.4.3 Overview of states, fan/battery module..................................................................................... 108
4.4.4 Response to overtemperature .................................................................................................. 111
5 Parameter assignment / addressing ...................................................................................................... 113
5.1 Software requirements.............................................................................................................. 113
5.2 Creating a project and configuring the communication............................................................. 114
5.2.1 Creating a SIMOTION project and inserting a D4x5-2 ............................................................. 114
5.2.2 Configuring the PROFIBUS PG/PC interface ........................................................................... 116
5.2.3 Configuring the Ethernet PG/PC interface................................................................................ 117
5.2.4 Representation of SIMOTION D4x5-2 in HW Config................................................................ 120
5.3 Configuring PROFIBUS DP ...................................................................................................... 121
5.3.1 General information about communication via PROFIBUS DP ................................................ 121
5.3.2 Operating the SIMOTION D4x5-2 on PROFIBUS DP .............................................................. 122
5.3.3 Assignment of the PROFIBUS addresses in HW Config.......................................................... 124
5.3.4 Setting the DP cycle and system cycle clocks.......................................................................... 125
5.3.5 Cycle clock scaling of external PROFIBUS interface to internal PROFIBUS interface ............ 126
5.3.6 Creating a new PROFIBUS subnet........................................................................................... 128
5.3.7 Modifying the data transmission rate ........................................................................................ 129

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SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 9
5.3.8 Establishing a PG/PC assignment.............................................................................................130
5.4 Configuring the MPI bus ............................................................................................................131
5.4.1 Operating the X136 interface as MPI.........................................................................................131
5.4.2 MPI parameters .........................................................................................................................131
5.5 Configuring an Ethernet subnet .................................................................................................132
5.5.1 Properties of the Ethernet interfaces .........................................................................................132
5.5.2 Configuring Ethernet addresses in HW Config..........................................................................136
5.5.3 Reading out IP and MAC address .............................................................................................137
5.6 Configuring PROFINET IO.........................................................................................................138
5.6.1 General information about communication via PROFINET IO ..................................................138
5.6.2 Setting a send cycle clock and system cycle clocks..................................................................142
5.6.2.1 Basic principles ..........................................................................................................................142
5.6.2.2 Setting of the cycle clocks (one servo activated = default)........................................................145
5.6.2.3 Setting of the cycle clocks (two servos activated) .....................................................................147
5.6.2.4 Using a second PROFINET interface ........................................................................................149
5.6.3 Properties of PROFINET ...........................................................................................................151
5.6.4 Configuration tasks ....................................................................................................................151
6 Commissioning (software) ..................................................................................................................... 153
6.1 Overview of commissioning .......................................................................................................153
6.1.1 Symbolic assignment / adaptation .............................................................................................153
6.1.2 Procedure when commissioning................................................................................................157
6.1.3 Important functions for the project handling during commissioning...........................................158
6.2 Performing the configuration for the D4x5-2 offline ...................................................................159
6.2.1 Overview ....................................................................................................................................159
6.2.2 Accessing the drive wizard ........................................................................................................160
6.2.3 Configuring components............................................................................................................161
6.2.4 Downloading a project into the target system............................................................................181
6.2.5 Downloading a project to the CompactFlash card.....................................................................182
6.2.6 Loading a project, including sources and additional data..........................................................184
6.2.7 Archiving a project to the CompactFlash card (zip file) .............................................................185
6.3 Performing an online configuration for the D4x5-2 ....................................................................186
6.3.1 Overview ....................................................................................................................................186
6.3.2 Establish an online connection ..................................................................................................187
6.3.3 Starting automatic configuration ................................................................................................188
6.3.4 Editing SINAMICS components.................................................................................................192
6.3.5 Downloading a project to the SIMOTION D4x5-2......................................................................192
6.4 Configuring a CX32-2 ................................................................................................................194
6.4.1 Overview ....................................................................................................................................194
6.4.2 Basic principles of the CX32-2...................................................................................................194
6.4.3 Preparing for configuration.........................................................................................................196
6.4.4 Displaying the topology..............................................................................................................198
6.4.5 CX32-2 offline configuration.......................................................................................................200
6.4.5.1 Loading a project created offline to the target system...............................................................200
6.4.5.2 Loading a project created offline to the CF card........................................................................201
6.4.6 Performing an online configuration for the CX32-2....................................................................202
6.4.7 CX32-2 configuration information ..............................................................................................204
6.4.7.1 CX32-2 power-up.......................................................................................................................204
6.4.7.2 Interconnecting the infeed "Operation" signal on the CX32-2 ...................................................204

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SIMOTION D4x5-2
10 Commissioning and Hardware Installation Manual, 02/2012
6.4.7.3 Upgrading the CX32-2 .............................................................................................................. 207
6.4.7.4 Replacing the CX32-2............................................................................................................... 208
6.5 Additional information on configuring the SINAMICS Integrated.............................................. 209
6.5.1 Settings for DP slave properties ...............................................................................................209
6.5.2 Using vector drives.................................................................................................................... 211
6.5.3 Setting the time of day .............................................................................................................. 213
6.5.4 Backing up / restoring / deleting SINAMICS NVRAM data ....................................................... 217
6.5.5 SINAMICS diagnostic buffer .....................................................................................................221
6.5.6 Acyclic communication with the drive ....................................................................................... 221
6.5.7 Control properties and performance features ........................................................................... 223
6.5.8 Current controller cycle clocks <> 125 µs / use of output cams and measuring inputs............ 224
6.6 Testing a drive with the drive control panel............................................................................... 226
6.7 Creating and testing axes ......................................................................................................... 229
6.7.1 Overview of SIMOTION engineering ........................................................................................ 229
6.7.2 Creating an axis with the axis wizard........................................................................................ 229
6.7.3 Testing the axis with the axis control panel .............................................................................. 236
6.8 Activating the infeed (line module)............................................................................................239
6.8.1 Infeed without DRIVE-CLiQ connection.................................................................................... 239
6.8.2 Infeeds with DRIVE-CLiQ connection....................................................................................... 241
6.8.3 Using one infeed for several CUs ............................................................................................. 242
6.9 Setting up addresses and message frames.............................................................................. 243
6.9.1 Setting up communication for symbolic assignment................................................................. 243
6.9.2 Message frame configuration....................................................................................................244
6.10 Linking an additional encoder (optional) ................................................................................... 248
6.10.1 Basic principles ......................................................................................................................... 248
6.10.2 Additional encoders on the drive...............................................................................................249
6.10.3 Additional encoders via PROFIBUS/PROFINET ...................................................................... 250
6.11 Symbolic assignment of I/O variables (PROFIdrive message frame / drive parameters) ........ 251
6.11.1 Symbolic assignment of I/O variables to the PROFIdrive message frame of the TO axis ....... 251
6.11.2 Symbolic assignment of I/O variables to drive parameters....................................................... 252
6.12 Configuring drive-related I/Os (with symbolic assignment)....................................................... 255
6.12.1 Configuration of the I/O terminals .............................................................................................257
6.12.1.1 Configuration of the D4x5-2 I/Os (terminal X122/X132) ........................................................... 258
6.12.1.2 Configuration of the D4x5-2 I/Os (terminal X142)..................................................................... 260
6.12.1.3 Configuration of the CX32-2/CU3xx/TB30/TMxx I/O terminals................................................. 261
6.12.1.4 Configuration of the TMC I/O terminals .................................................................................... 261
6.13 Configuration of the technology objects and I/O variables ....................................................... 262
6.13.1 Configuration of global measuring inputs.................................................................................. 262
6.13.2 Configuration of local measuring inputs.................................................................................... 263
6.13.3 Configuration of output cams / cam tracks................................................................................ 264
6.13.4 Configuration of the I/Os (variables / TO axis).......................................................................... 266
6.14 DMC20/DME20 DRIVE-CLiQ hub ............................................................................................ 268
6.14.1 Hub properties........................................................................................................................... 268
6.14.2 Creating a DMC20/DME20 DRIVE-CLiQ hub........................................................................... 269
6.15 TM41 terminal module .............................................................................................................. 270
6.15.1 Overview ................................................................................................................................... 270
6.15.2 Configuring TM41 at SINAMICS Integrated.............................................................................. 271

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Commissioning and Hardware Installation Manual, 02/2012 11
6.15.3 Configuring the TM41 using the axis wizard..............................................................................272
6.16 Optimizing the drive and controller ............................................................................................273
6.16.1 Overview of automatic controller setting....................................................................................273
6.16.2 Automatic speed controller setting.............................................................................................274
6.16.3 Automatic position controller setting ..........................................................................................275
6.16.4 Measuring functions, trace, and function generator...................................................................277
6.16.5 Manual speed controller optimization ........................................................................................278
6.17 Loading and saving SIMOTION user data.................................................................................283
6.18 Deleting data..............................................................................................................................285
6.18.1 Overview of data deletion ..........................................................................................................285
6.18.2 Memory reset of SIMOTION D4x5-2 .........................................................................................285
6.18.3 Deleting user data on CompactFlash card ................................................................................288
6.18.4 Restoring the default settings of SINAMICS Integrated ............................................................289
6.18.5 Setting SIMOTION D4x5-2 to the factory settings.....................................................................289
6.19 Powering down the system ........................................................................................................291
6.20 Configuring Safety Integrated functions.....................................................................................291
6.21 Quantity structures.....................................................................................................................298
6.22 Migration of SIMOTION D4x5 to SIMOTION D4x5-2 ................................................................301
6.22.1 Changeover from SIMOTION D4x5 to SIMOTION D4x5-2 .......................................................301
6.22.2 Permissible combinations ..........................................................................................................306
7 Service and maintenance ...................................................................................................................... 309
7.1 Overview ....................................................................................................................................309
7.2 Replacing modules (spare part scenario) ..................................................................................313
7.2.1 Parts replacement for SIMOTION D4x5-2 .................................................................................313
7.2.2 Removal and replacement of the SIMOTION D4x5-2 ...............................................................314
7.2.3 Replacing DRIVE-CLiQ components.........................................................................................315
7.2.4 Replacing the CompactFlash Card............................................................................................318
7.3 Adapting a project (Upgrading the project / Replacing the SIMOTION controller)....................319
7.3.1 Creating backup copies (project/CF) .........................................................................................319
7.3.2 Backing up user data (backup variables)...................................................................................320
7.3.3 Upgrading a user project to the new SCOUT version................................................................322
7.3.4 Platform replacement via XML export/import.............................................................................323
7.3.5 Preparing the device replacement .............................................................................................324
7.3.6 Device replacement in HW Config.............................................................................................326
7.3.7 Upgrading technology packages................................................................................................327
7.3.8 Upgrading the device version of SINAMICS S120 control units................................................329
7.3.9 Upgrading a library.....................................................................................................................330
7.3.10 Save project, compile and check consistency ...........................................................................330
7.4 Performing a firmware and project update.................................................................................331
7.4.1 Upgrading the boot loader on the CompactFlash card..............................................................331
7.4.2 Update - preparatory measures.................................................................................................331
7.4.3 Upgrade via IT DIAG..................................................................................................................332
7.4.4 Upgrade via device update tool (upgrading SIMOTION devices)..............................................333
7.4.5 Update via CompactFlash card..................................................................................................337
7.4.5.1 Backup of the CompactFlash card data.....................................................................................337
7.4.5.2 Firmware update via CompactFlash card ..................................................................................339

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SIMOTION D4x5-2
12 Commissioning and Hardware Installation Manual, 02/2012
7.4.5.3 Upgrading SINAMICS ............................................................................................................... 339
7.4.5.4 Download project to target system............................................................................................ 341
7.5 SIMOTION CompactFlash card ................................................................................................ 342
7.5.1 Changing the CompactFlash card ............................................................................................ 342
7.5.2 Writing to the the CompactFlash card....................................................................................... 342
7.5.3 Formatting the CompactFlash card........................................................................................... 343
7.5.4 Bootloader on the CompactFlash card ..................................................................................... 344
7.5.5 Recommended method of handling CompactFlash cards........................................................ 345
7.5.6 Card reader for CF cards .......................................................................................................... 345
8 Diagnostics ............................................................................................................................................ 347
8.1 Diagnostics via LED displays.................................................................................................... 347
8.1.1 SIMOTION D4x5-2 and SINAMICS Integrated displays........................................................... 348
8.1.2 LED displays of the PROFINET interface................................................................................. 354
8.1.3 LED displays of the Ethernet interface...................................................................................... 357
8.1.4 LED displays of the CX32-2 controller extension ..................................................................... 357
8.2 Diagnostic data and non-volatile SIMOTION data.................................................................... 359
8.2.1 Overview ................................................................................................................................... 359
8.2.2 Backup of diagnostic data and non-volatile SIMOTION data ................................................... 359
8.2.2.1 Diagnostic data ......................................................................................................................... 359
8.2.2.2 Non-volatile SIMOTION data (retain data)................................................................................ 360
8.2.2.3 Procedure for backing up during operation............................................................................... 361
8.2.2.4 Procedure for backing up during startup................................................................................... 363
8.2.2.5 Storing data............................................................................................................................... 366
8.2.3 Diagnostics via websites ........................................................................................................... 367
8.2.4 Deleting/restoring non-volatile SIMOTION data ....................................................................... 368
8.2.5 Backing up diagnostics data and non-volatile SIMOTION data using IT DIAG........................ 370
8.3 Additional service and diagnostics options ............................................................................... 372
8.3.1 SIMOTION Task Profiler application......................................................................................... 372
8.3.2 Diagnostics using IT DIAG........................................................................................................ 372
A Configuration of drive-related I/Os (without symbolic assignment)......................................................... 373
A.1 Overview ................................................................................................................................... 373
A.2 Local and global measuring inputs ........................................................................................... 374
A.3 Configuring local measuring inputs........................................................................................... 376
B Standards and approvals....................................................................................................................... 379
B.1 General rules............................................................................................................................. 379
B.2 SIMOTION D4x5 device-specific notes .................................................................................... 381
B.3 Safety of electronic controllers.................................................................................................. 382
C ESD guidelines ...................................................................................................................................... 385
C.1 ESD definition ........................................................................................................................... 385
C.2 Electrostatic charging of individuals..........................................................................................386
C.3 Basic measures for protection against discharge of static electricity ....................................... 387
Index...................................................................................................................................................... 389

SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 13
Description 1
1.1 System overview
Overview
SIMOTION D is a drive-based version of SIMOTION based on the SINAMICS S120 drive
family.
With SIMOTION D, the SIMOTION PLC and motion control functionalities as well as the
SINAMICS S120 drive software run on shared control hardware.
SIMOTION D is available in two versions:
● SIMOTION D410-2 is a compact control unit predestined for single-axis applications. The
control unit is snapped directly on to the SINAMICS S120 PM340 power modules in
blocksize format and has an integrated drive control for either one servo, one vector or
one
V/f axis.
● SIMOTION D4x5-2 is a control unit for multi-axis applications in the SINAMICS S120
booksize format. The following performance versions are offered:
– SIMOTION D425-2 (BASIC performance) control unit for up to 16 axes
– SIMOTION D435-2 (STANDARD performance) control unit for up to 32 axes
– SIMOTION D445-2 (HIGH performance) control unit for up to 64 axes
– SIMOTION D455-2 (ULTRA-HIGH performance) control unit for up to 128 axes or
applications with very short control cycles
The SIMOTION D4x5 2 is described in this manual. Separate manuals are available for the
SIMOTION D410-2 and the D4x5/D410 predecessor modules.
Like SINAMICS S120, SIMOTION D also follows the Totally Integrated Automation (TIA)
concept. TIA is characterized by integrated data management, configuration, and
communication for all products and systems. Thus, an extensive toolbox of automation
modules is also available for SIMOTION D.
Note
In order to cover all versions of SIMOTION D for multi-axis applications, the product will be
referred to as "D4x5-2". Specific product designations will be used for information that
applies only to one product version, e.g. D445-2 DP/PN.
SIMOTION D4x5-2 DP describes all PROFIBUS versions and SIMOTION D4x5-2 DP/PN all
PROFIBUS/PROFINET versions of the SIMOTION D4x5-2 control units.

Description
1.1 System overview
SIMOTION D4x5-2
14 Commissioning and Hardware Installation Manual, 02/2012
Application
The SIMOTION D4x5-2 is ideally suited to applications with many coordinated axes with high
clock-pulse rates.
Typical applications include:
● Compact multiple-axis machines
● High-performance applications with short machine cycles
● Compact machines
– Including the complete machine control in the drive
– With extensive connection possibilities for communication, HMI and I/O
● Distributed drive concepts
– Applications with many axes
– Synchronization of several SIMOTION D control units using distributed synchronous
operation
Versions
The control units are available in the versions SIMOTION D425-2 (BASIC performance),
SIMOTION D435-2 (STANDARD performance), SIMOTION D445-2 DP/PN (HIGH
performance) and SIMOTION D455-2 DP/PN (ULTRA-HIGH performance). The versions
differ in their PLC performance and in their motion control performance. The main
distinguishing features are:
Table 1- 1 Device versions and characteristics
SIMOTION
D425-2
SIMOTION
D435-2
SIMOTION
D445-2
SIMOTION
D455-2
Maximum number of
axes
16 32 64 128
Minimum
servo/interpolator cycle
clock
0.5 ms D435-2 DP: 0.5 ms
D435-2 DP/PN:
0.5/0.25 ms 1)
0.5/0.25 ms 1) 0.5/0.25 ms 1)
DRIVE-CLiQ interfaces 4 6 6 6
1) Explanation:
● 0.5 ms in connection with SINAMICS S120 (incl. SINAMICS Integrated / CX32-2)
● 0.25 ms in connection with Servo_fast and IPO_fast for fast I/O processing or
high-performance hydraulic applications. The sensors and actuators are connected
via high-speed PROFINET IO I/O modules.
The control units feature PLC and motion control performance (open-loop control and motion
control) for up to 16, 32, 64 or 128 axes, as required.
The integrated drive computing performance of the control units allows up to six servo,
six vector or twelve
V / f axes on each D4x5-2 control unit (drive control based on CU320-2,
firmware version ≥ V4.x).

Description
1.1 System overview
SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 15
The drive control supports servo control (for a highly dynamic response), vector control (for
maximum torque accuracy) and
V / f control.
The SIMOTION D4x5-2 control units and their CX32-2, CBE30-2 and TB30 supplementary
system components are described in the following.
Note
With the SIZER configuration tool, you can easily configure the SINAMICS S110/120 drive
family including SIMOTION.
It provides you with support for selecting and dimensioning the components required for a
motion control task.
You can also determine the possible number of axes and the resulting load with SIZER in
accordance with your performance requirements.
Hardware components
As the central hardware, SIMOTION D uses the SIMOTION D4x5-2 as control unit consisting
of the SIMOTION runtime system and the SINAMICS drive control. The control unit uses the
SINAMICS Integrated drive with various SINAMICS S120 drive modules (line and motor
modules) to perform open-loop and closed-loop control of the axis grouping. A range of
additional SINAMICS S120 components, such as SMx encoder systems or terminal modules
can also be connected via DRIVE-CLiQ. With a few exceptions (e.g. no basic positioner
EPOS, no basic operator panel BOP20, etc.), the drive control integrated in SIMOTION D
has the same control characteristics and performance features as the SINAMICS S120
CU320-2 control unit. The EPOS functionality is provided by the SIMOTION technology
functions. The functionality of SIMOTION D can be expanded with the distributed I/O via
PROFIBUS or PROFINET IO.
The following figure shows a typical SIMOTION D axis grouping.

Description
1.1 System overview
SIMOTION D4x5-2
16 Commissioning and Hardware Installation Manual, 02/2012
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Figure 1-1 Example of an axis grouping with SIMOTION D4x5-2
A SIMOTION D axis grouping generally consists of the following elements:
● SIMOTION D (control unit) (1)
This unit contains the programmable runtime system of SIMOTION and the drive software
of SINAMICS S120. In principle, SIMOTION D is capable of controlling multiple
axes/drives.
● One SINAMICS infeed (line module) (2)
This module generates a DC link from the supply system.
● SINAMICS power units (motor modules) (3)
These modules are used to control motors.
It is also possible to operate SINAMICS PM340 power modules with the SINAMICS
control unit adapter (CUA). A separate infeed is then unnecessary.
● DRIVE-CLiQ components (4)
In SINAMICS S120 / SIMOTION D, the individual components of the drive system
communicate with each other via DRIVE-CLiQ. In addition to power components,
encoder systems and special DRIVE-CLiQ I/O devices can also be linked via
DRIVE-CLiQ.

Description
1.1 System overview
SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 17
Extension of the drive computing performance
The motion control performance of a SIMOTION D4x5-2 can be utilized in full by expanding
the computing performance at the drive in two different ways:
● SINAMICS S110/S120 control units (e.g. CU320-2, CU305, etc.) complete with further
drive components can be connected via PROFIBUS or PROFINET.
● With SIMOTION D4x5-2, the CX32-2 controller extension can be connected via
DRIVE-CLiQ. This module is extremely compact, does not require a separate
CompactFlash card and can control up to six servo, six vector or twelve
V / f axes.
Software components
The basic functionality of SIMOTION D is supplied on a CompactFlash card containing the
following:
The SIMOTION runtime system with the following functions:
● Freely programmable runtime system (IEC 61131)
● Various runtime levels (tasks)
● PLC and arithmetic functionality
● Motion control functions
● Communication functions
The SINAMICS S120 drive control with the following functions:
● Closed-loop current and torque control
● Closed-loop speed control
● Closed-loop infeed

Description
1.2 System components
SIMOTION D4x5-2
18 Commissioning and Hardware Installation Manual, 02/2012
1.2 System components
Central components
SIMOTION D4x5-2 communicates with automation components via the following interfaces:
● PROFIBUS DP
● Ethernet
● PROFINET IO
● DRIVE-CLiQ (DRIVE Component Link with IQ)
SIMOTION D features a SINAMICS Integrated drive element. The communication with the
SINAMICS Integrated is performed via PROFIBUS mechanisms (DP Integrated), i.e. the
communication is handled, for example, via PROFIdrive message frames.
Shorter cycle times and greater numbers of addresses for each node are achieved with the
"DP Integrated" compared to the "external PROFIBUS DP".
The most important components of the system and their functions are shown below.
Table 1- 2 Central components
Component Function
SIMOTION D4x5-2
controller
... is the central motion control module.
This module contains the programmable SIMOTION runtime for the
SIMOTION D4x5-2 and the SINAMICS S120 drive software.
You can use the integrated high-speed digital I/Os as:
•User-addressable process I/Os
•Homing inputs
•Inputs for measuring inputs
•Outputs for fast output cams
The measuring sockets can output any analog signals.
System software The basic functionality of SIMOTION D is supplied on a CompactFlash
card containing the following:
•SIMOTION runtime (kernel)
•Drive software of SINAMICS S120 - implements all drive functions
Power supply ... provides the electronic power supply for SIMOTION D, e.g. via the
SITOP power supply.

Description
1.2 System components
SIMOTION D4x5-2
Commissioning and Hardware Installation Manual, 02/2012 19
PROFIBUS DP
The control unit can communicate with the following components via the PROFIBUS DP
interfaces:
Table 1- 3 Components on PROFIBUS DP
Component Function
Programming device (PG/PC) ... configures, parameterizes, programs, and tests with the
"SIMOTION SCOUT" engineering system (ES)
SIMATIC HMI device ... is used for operating and monitoring functions. This is not an
essential requirement for the operation of a control unit
Other controllers (e.g.
SIMOTION or SIMATIC)
... e.g. higher-level controller (plant controller); modular machine
concepts with multiple controllers, distributed across individual
machine modules.
Distributed I/O systems
SIMATIC ET 200M Modular I/O system for control cabinet installation and high channel
density
SIMATIC ET 200S Finely scalable I/O system for control cabinet configuration and
particularly time-critical applications; including motor starters, safety
technology and individual grouping of load groups.
SIMATIC ET 200pro Modular I/O system with IP65/67 degree of protection for machine-
related applications with no control cabinet; with features such as
compact designs, integrated PROFIsafe safety technology,
PROFINET connection and live module replacement.
SIMATIC ET 200eco I/O system with IP65/67 degree of protection for cabinet-free use
close to the machine with flexible and fast ECOFAST or M12
connection methods.
Other PROFIBUS I/O
Gateways •DP/AS-Interface link 20E and DP/AS-Interface link Advanced for
the PROFIBUS DP gateway to AS-Interface
•DP/DP coupler for connecting two PROFIBUS DP networks
Drive interfaces •ADI4 (Analog Drive Interface for four axes) for connection of
drives with analog ±10 V setpoint interface or for external
encoders
•IM174 (interface module for four axes) for connection of drives
with analog ±10 V setpoint interface, for external encoders, or for
connection of stepper drives with pulse-direction interface
Drive units with
PROFIBUS DP interface (e.g.
SINAMICS S120)
... convert speed setpoints into signals for controlling the motor and
supply the power required to operate the motors.
Also can be operated as an isochronous slave on PROFIBUS DP.
Teleservice adapter Remote diagnostics

Description
1.2 System components
SIMOTION D4x5-2
20 Commissioning and Hardware Installation Manual, 02/2012
Ethernet
The control unit can communicate with the following components via the Ethernet interfaces
or be embedded in an automation environment:
Table 1- 4 Components on the Ethernet
Component Function
Programming device (PG/PC) ... configures, parameterizes, programs, and tests with the
"SIMOTION SCOUT" engineering system (ES)
Master computer ... communicates with other devices via UDP, TCP/IP
SIMATIC HMI device ... is used for operating and monitoring functions. This is not an
essential requirement for the operation of a control unit.
PROFINET IO
The D4x5-2 DP/PN can communicate with the following components via the onboard
PROFINET IO interface or via the Ethernet communication board (CBE30-2).
Table 1- 5 Components on the PROFINET IO
Component Function
Programming device (PG/PC) ... configures, sets parameters, programs, and tests using the
"SIMOTION SCOUT" Engineering System (ES).
SIMATIC HMI device ... is used for operating and monitoring functions. This is not an
essential requirement for the operation of a control unit.
Other controllers (e.g.
SIMOTION or SIMATIC)
... e.g. higher-level controller (plant controller); modular machine
concepts with multiple controllers, distributed across individual
machine modules.
Master computer ... communicates with other devices via UDP, TCP/IP.
Distributed I/O systems
TMC Multi-channel, fast and isochronous I/O for mechanical engineering
with PROFINET IO connection in a rugged SINAMICS S120
booksize compact format; direct connection of the I/O channels on
the module or separately via wiring modules.
SIMATIC ET 200M Modular I/O system for control cabinet installation and high
channel densities.
SIMATIC ET 200S Finely scalable I/O system for control cabinet configuration and
particularly time-critical applications; including motor starters,
safety technology and individual grouping of load groups.
SIMATIC ET 200pro Modular I/O system with IP65/67 degree of protection for machine-
related applications with no control cabinet; with features such as
compact designs, integrated PROFIsafe safety technology,
PROFINET IO connection and live module replacement.
SIMATIC ET 200eco PN Compact block I/O with IP65/66/67 degree of protection for
cabinet-free usage in machines with M12 connection method. Very
rugged and resistant encapsulated metal enclosure.