Siemens SINAMICS RAILCTRL Parts list manual

Function Manual
Rail Control
RAILCTRL
Edition
SINAMICS
09/2019 www.siemens.com/drives

SINAMICS
Rail Control
RAILCTRL
Function Manual
Valid for
RAILCTRL Technology Extension
with firmware version 2.2
for SINAMICS S120 and SINAMICS Integrated from
firmware version 5.2
for SIMOTION from firmware version 5.3 SP1
09/2019
A5E38120767B
Introduction 1
Safety instructions 2
Applications and
characteristics 3
Installation and activation 4
Function description 5
Commissioning 6
Parameter 7
Function diagrams 8
Faults and alarms 9
List of abbreviations A

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:
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
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E38120767B
Ⓟ 10/2019 Subject to change
Copyright © Siemens AG 2018 - 2019.
All rights reserved

Table of contents
1 Introduction...................................................................................................................................................5
1.1 The SINAMICS converter family ..............................................................................................5
1.2 General information about SINAMICS documentation.............................................................6
2 Safety instructions ........................................................................................................................................9
2.1 General safety instructions.......................................................................................................9
2.2 Warranty and liability for application examples ......................................................................10
2.3 Industrial Security...................................................................................................................11
3 Applications and characteristics .................................................................................................................13
3.1 Applications............................................................................................................................13
3.2 Features .................................................................................................................................15
4 Installation and activation ...........................................................................................................................17
4.1 Installation via the TIA Portal .................................................................................................17
4.2 Installing using STARTER or SIMOTION SCOUT .................................................................18
4.2.1 Preconditions for installing using STARTER or SIMOTION SCOUT .....................................18
4.2.2 Installing the OA Support Package in STARTER...................................................................20
4.2.3 Downloading the technology package ...................................................................................21
4.2.4 Activating the Technology Extension in the drive object ........................................................22
4.2.5 Commissioning the RAILCTRL Technology Extension..........................................................23
4.3 Upgrading using STARTER or SIMOTION SCOUT...............................................................24
4.3.1 Preconditions for upgrading using STARTER or SIMOTION SCOUT ...................................24
4.3.2 Installing the OA Support Package in STARTER...................................................................25
4.3.3 Download the technology package for the new version.........................................................26
4.3.4 Additional information about upgrading..................................................................................27
4.4 Uninstalling using STARTER or SIMOTION SCOUT.............................................................28
4.5 Scripting with STARTER or SIMOTION SCOUT ...................................................................30
4.5.1 Information about scripting.....................................................................................................30
4.5.2 Scripting for Technology Extensions......................................................................................31
5 Function description ...................................................................................................................................33
5.1 Function of components.........................................................................................................33
5.2 Closed-loop controlled operation ...........................................................................................35
5.3 Open-loop controlled operation..............................................................................................36
5.4 Geometry data .......................................................................................................................37
5.5 Communication ......................................................................................................................38
5.6 SINAMICS Safety Integrated .................................................................................................41
5.7 Sampling times and number of controllable drives ................................................................42
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6 Commissioning ...........................................................................................................................................43
6.1 Commissioning overview .......................................................................................................43
6.2 Basic commissioning..............................................................................................................45
6.3 Setting the geometry data ......................................................................................................47
6.4 Parameterizing BICO interconnections ..................................................................................49
6.5 Setting communication across CUs .......................................................................................50
6.6 Examples for configuring RAILCTRL .....................................................................................52
6.6.1 Example 1 ..............................................................................................................................52
6.6.2 Example 2 ..............................................................................................................................55
7 Parameter...................................................................................................................................................57
8 Function diagrams ......................................................................................................................................71
9 Faults and alarms .......................................................................................................................................79
A List of abbreviations....................................................................................................................................87
Index...........................................................................................................................................................99
Table of contents
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Introduction 1
1.1 The SINAMICS converter family
With the SINAMICS converter family, you can solve any individual drive task in the low-voltage,
medium-voltage and DC voltage range. From converters to motors and controllers, all Siemens
drive components are perfectly matched to each other and can be easily integrated into your
existing automation system. With SINAMICS you are prepared for digitization. You benefit from
highly efficient engineering with a variety of tools for the entire product development and
production process. And you also save space in the control cabinet – thanks to the integrated
safety technology.
You can find additional information about SINAMICS at the following address (http://
www.siemens.com/sinamics).
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1.2 General information about SINAMICS documentation
SINAMICS documentation
The SINAMICS documentation is organized in the following categories:
● General documentation/catalogs
● User documentation
● Manufacturer/service documentation
Standard scope
The scope of the functionality described in this document can differ from that of the drive system
that is actually supplied.
● Other functions not described in this documentation might be able to be executed in the
drive system. However, no claim can be made regarding the availability of these functions
when the equipment is first supplied or in the event of service.
● The documentation can also contain descriptions of functions that are not available in a
particular product version of the drive system. Please refer to the ordering documentation
only for the functionality of the supplied drive system.
● Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on all
of the product types, and cannot take into consideration every conceivable type of installation,
operation and service/maintenance.
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS drive system.
Benefits
This manual provides all of the information, procedures and operator actions required for the
particular usage phase.
Siemens MySupport/Documentation
You can find information on how to create your own individual documentation based on
Siemens content and adapt it for your own machine documentation at the following address
(https://support.industry.siemens.com/My/ww/en/documentation).
Introduction
1.2 General information about SINAMICS documentation
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Additional information
You can find information on the topics below at the following address (https://
support.industry.siemens.com/cs/document/108993276):
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
Questions relating to the technical documentation
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following email address (https://
support.industry.siemens.com/cs/de/en/ps/faq).
FAQs
You can find Frequently Asked Questions under Product Support
(mailto:[email protected]).
Training
At the following address (http://www.sitrain-learning.siemens.com), you can find information
about SITRAIN (Siemens training on products, systems and solutions for automation and
drives).
Technical Support
Country-specific telephone numbers for technical support are provided in the Internet at the
following address (http://support.industry.siemens.com/sc/ww/en/sc/2090) in the "Contact"
area.
Compliance with the General Data Protection Regulation
Siemens respects the principles of data protection, in particular the data minimization rules
(privacy by design).
For this product, this means:
The product does not process neither store any person-related data, only technical function
data (e.g. time stamps). If the user links these data with other data (e.g. shift plans) or if he
stores person-related data on the same data medium (e.g. hard disk), thus personalizing these
data, he has to ensure compliance with the applicable data protection stipulations.
Introduction
1.2 General information about SINAMICS documentation
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Introduction
1.2 General information about SINAMICS documentation
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Safety instructions 2
2.1 General safety instructions
WARNING
Danger to life if the safety instructions and residual risks are not observed
If the safety instructions and residual risks in the associated hardware documentation are not
observed, accidents involving severe injuries or death can occur.
● Observe the safety instructions given in the hardware documentation.
● Consider the residual risks for the risk evaluation.
WARNING
Malfunction of the machine as a result of incorrect or changed parameter settings
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.
● Handle possible malfunctions by taking suitable measures, e.g. emergency stop or
emergency off.
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2.2 Warranty and liability for application examples
The application examples are not binding and do not claim to be complete regarding
configuration, equipment or any eventuality which may arise.
Application examples are not customer-specific solutions, but merely provide assistance with
typical tasks. As user you are responsible for ensuring that the products described are operated
correctly. These application examples do not relieve you of your responsibility for safe handling
when using, installing, operating and maintaining the equipment.
Safety instructions
2.2 Warranty and liability for application examples
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2.3 Industrial Security
Note
Industrial Security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens products and solutions represent only one component of such a
concept.
Customers are solely responsible for preventing unauthorized access to their plants, systems,
machines, and networks. Systems, machines and components should only be connected to the
company's network or the Internet if and to the extent necessary and with appropriate security
measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ recommendations regarding appropriate security measures should be
taken into account. For more information about Industrial Security, please visit:
Industrial Security (http://www.siemens.com/industrialsecurity).
Siemens products and solutions undergo continuous development to make them even more
secure. Siemens strongly recommends to apply product updates as soon as available and to
always use the latest product versions. Use of product versions that are no longer supported
and failure to apply the latest updates may increase exposure to cyber threats.
To constantly be informed about product updates, subscribe to the Siemens Industrial Security
RSS Feed at:
Industrial Security (http://www.siemens.com/industrialsecurity).
WARNING
Unsafe operating states resulting from software manipulation
Software manipulation (e.g. viruses, trojans, malware or worms) can cause unsafe operating
states in your plant that may lead to death, serious injury, and property damage.
● Keep the software up to date.
● Incorporate the automation and drive components into a state-of-the-art, integrated
Industrial Security concept for the installation or machine.
● Make sure that you include all installed products into the integrated Industrial Security
concept.
● Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
Safety instructions
2.3 Industrial Security
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Safety instructions
2.3 Industrial Security
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Applications and characteristics 3
3.1 Applications
Introduction
The "Closed-loop control for segmented linear motors" (RAILCTRL, Rail Control)
Technology Extension is an extension for the SINAMICS SERVO drive object.
A Technology Extension (TEC) is also known as "OA application".
Multi-carrier system applications
The RAILCTRL Technology Extension is used in multi-carrier systems (MCS). Multi-carrier
systems are transport systems with linear motors used in packaging machines and assembly
applications, for example.
The following diagram shows a configuration example for a multi-carrier system.

①Motor plate with one motor segment
②Carrier (workpiece holder)
③Optional measuring system for closed-loop-controlled operation
④SINAMICS S120 drive system
⑤SIMOTION P motion control system
Figure 3-1 Configuration example for a multi-carrier system
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Topology
The topology for a multi-carrier system comprises a higher-level control system (e.g.
SIMATIC S7‑1500 T‑CPU) that communicates with one or more SINAMICS S120 Control Units
via PROFINET. To allow linear motors to be arbitrarily scaled, SINAMICS S120 Control Units
can be connected via DRIVE-CLiQ.
The Control Units handle the following closed-loop control functions:
● Closed-loop control of the drives for the machine axes
● Closed-loop control of the motor segments of a linear motor path (multi-carrier system)
This Manual describes the RAILCTRL Technology Extension for:
● The segment transition with communication of the SERVO drive objects within a Control Unit
● The segment transition between several Control Units connected with DRIVE-CLiQ.
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Figure 3-2 Topology for the multi-carrier system application example
Note
If you use the RAILCTRL Technology Extension on a Control Unit, in addition to the SERVO
drive objects and the Technology Extension, it is not permissible that you create a VECTOR
drive object.
Applications and characteristics
3.1 Applications
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3.2 Features
Properties
The RAILCTRL Technology Extension handles the closed-loop control of segment transitions
for carriers across multiple linear motors (linear motor path).
For a jerk-free transition, the RAILCTRL Technology Extension can put the motor segments
into the "Slave preceding", "Master", "Slave following" and "Switched off" states. Whereby, the
controlled variables are copied from the master to the slave. The segment states are switched
depending on the associated application mode.
The RAILCTRL Technology Extension supports two application modes for traversing the path
sections:
● Closed-loop controlled traversing of carriers
This mode controls the traversing of a carrier on a segment. Controlled paths (closed-loop)
offer more power, dynamic response and precision.
Segment states (master/slave) are switched independently based on the encoder values.
● Open-loop-controlled traversing of carriers
This mode permits the traversing of multiple carriers, for example in convoys. In
uncontrolled paths (open loop), the segment and the carrier form a system that is capable
of oscillation. To ensure smooth traversing, this application mode also provides oscillation
dampening, not only when traversing on a single segment, but also at a segment transition.
Master/slave switchover is made by a higher-level control system.
Multi-carrier systems with the RAILCTRL Technology Extension offer the following advantages:
● Machining processes can be flexibly implemented
● Motion profiles with a high dynamic response
● The overall throughput (yield) can be increased by controlling the workpiece holder with an
individual motion profile
● Transport systems can be scaled as required
System integration
The application can be used with servo control in the following systems:
● SINAMICS S120 (CU320-2) in conjunction with SIMATIC S7-1500 T-CPU
● SINAMICS S120 (CU320-2) in conjunction with SIMOTION P and SIMOTION D
● SINAMICS Integrated (SIMOTION D4x5-2) for compact solutions with up to 6 axes
License Key
You require a License Key for the RAILCTRL Technology Extension. Additional information is
provided in Section "Commissioning overview (Page 43)".
Applications and characteristics
3.2 Features
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Applications and characteristics
3.2 Features
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Installation and activation 4
4.1 Installation via the TIA Portal
Commissioning using the TIA Portal library
The TIA Portal library is available when using Technology Extension RAILCTRL running on a
SINAMICS CU320-2 in conjunction with a SIMATIC 1500T controller. The TIA Portal library
supports you when configuring, commissioning and operating the system.
You can find the TIA Portal library in SIOS under the following address (https://
support.industry.siemens.com/cs/ww/en/view/109762340).
Manual configuring using the TIA Portal and STARTER or SIMOTION SCOUT
You can manually configure SINAMICS CU320-2 using the TIA Portal and STARTER or
SIMOTION SCOUT. To do this, proceed as follows:
1. Install Technology Extension RAILCTRL using STARTER or SIMOTION SCOUT, see
Chapter "Installing using STARTER or SIMOTION SCOUT (Page 18)".
2. Commission the Technology Extension RAILCTRL, see Chapter "Commissioning
(Page 43)".
3. For the configured SINAMICS CU320-2, create a GSD or GSDML file. To do this, use the
following script (https://support.industry.siemens.com/cs/ww/en/view/92022677).
4. Import the GSD file that you created into the TIA Portal to establish communications
between the SIMATIC 1500T and the SINAMICS CU320-2.
A description on how to import a GSD file into the TIA Portal is available at the following
address (https://support.industry.siemens.com/cs/ww/en/view/109738401).
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4.2 Installing using STARTER or SIMOTION SCOUT
4.2.1 Preconditions for installing using STARTER or SIMOTION SCOUT
Note
The subsequent description in this chapter refers to the fictitious Technology Extension
"ABC_OA" with version V1.1.
The procedure described in this chapter can be correspondingly applied to any real Technology
Extension.
This description for installing and commissioning a Technology Extension is applicable to the
STARTER commissioning tool and to engineering software with integrated STARTER (e.g.
SIMOTION SCOUT).
Generally, the term STARTER is used hereafter.
Terms
Technology Extension (TEC)
Software component that is installed as an additional technology package and that expands the
functionality of the SINAMICS drive system.
A Technology Extension is also known as an OA application (OA, Open Architecture).
OA Support Package (OASP)
Installing an OA Support Package (OASP) expands the STARTER commissioning tool with the
corresponding Technology Extension.
An OA Support Package is only required if the associated Technology Extension is used.
Generally, it can be sourced through your local Siemens office.
Devices
This description is applicable for SINAMICS S120 (CU320-2) and SIMOTION D4x5-2 with
SINAMICS Integrated.
Installation and activation
4.2 Installing using STARTER or SIMOTION SCOUT
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