De MC SMO SYS en 01 V4 3 1 Sitrain Scout System

Kursunterlagen für ERDINC KELOGLU, erdinc.keloglu@siemens.
com
Siemens AG
DEUTSCHLAND
Industry Sector
90475 NÜRNBERG
Gleiwitzer Str. 555
er
di
nc
. ke
lo
gl
u
@
Siemens Certified Service Technician Level 1
(inkl. SPS-Techniker entspr. VDMA/ZVEI)
(MC-SMO-SYS)
SIMOTION System Course
SITRAIN:
Training for Industry
siemens.com/sitrain
1 SIMOTION – System Overview
Creating a SIMOTION D Project with

2
SCOUT
3 The SIMOTION Hardware Platforms
SITRAIN
Training for Industry 4 Programming with MCC
5 Axes and Drives in SIMOTION

SIMOTION
System and
Programming Course 6 Programming with LAD/FBD
Course: MC-SMO-SYS 7 The SIMOTION Execution System
8 Synchronous Operation in SIMOTION
External Encoders - Output Cams -

9
Measuring inputs
10 Connecting HMI Systems
Name:
11 Exercises
Course from: to:
Course leader:
12 Appendix : Licencinig
Course location:
This document was created for training purposes. SIEMENS

does not guarantee the content. 13
The reproduction, transmission, or use of this document or its
contents is not permitted without express written authority.
Offenders will be liable for damages.
Copyright © Siemens AG 2013. All rights, including rights

created by patent grant or registration of a utility model or 14
design, are reserved.
SITRAIN course material on the Internet:www.siemens.de/sitrain

15
Course folder version: V4.3
SIMOTION – An Overview
SIMOTION Date: 03.01.2013 SITRAIN Training for

Automation and drive technology
Siemens AG 2013. All rights reserved. File: MC-SMO-SYS_01.1
Contents Page
Mechatronics and Motion Control – Transformation in Machine Construction ................................... 2
Tasks of a Motion Control System .................................................................................................... 3
Motion Control – Possibilities in the Automation Area ...................................................................... 4
What is SIMOTION? ........................................................................................................................ 5
SIMOTION Components .................................................................................................................. 6
System Architecture of the Runtime System ..................................................................................... 7
Technology Packages in SIMOTION ................................................................................................ 8
SIMOTION SCOUT Engineering Tools ............................................................................................. 9
Programming Languages in SIMOTION ........................................................................................... 10
MCC – Programming Motion Sequences .......................................................................................... 11
LAD/FBD – Programming Languages for PLC Tasks ....................................................................... 12
ST – High-Level Language for Programming Complex Algorithms .................................................... 13
DCC – Graphic Tool to Generate Charts .......................................................................................... 14
The Various Hardware Platforms (1) ................................................................................................ 15
The Various Hardware Platforms (2) ................................................................................................ 16
Integration in TIA .............................................................................................................................. 17
SIMOTION Documentation ............................................................................................................... 18
SITRAIN Training for MC-SMO-SYS

Automation and Drive Technology Page 1 SIMOTION – An Overview
Tasks of a Motion Control System
Tasks of a motion control system

HMI Controlling axis motion
- Positioning
- Coupling axes (synchronous operations, ...)
MC control Cyclically calculating setpoint positions
(interpolation)
Performing closed-loop position control, output
of the speed setpoint via PROFIBUS or
PROFINET
Other tasks
Processing peripheral (I/O) signals
Closed loop control tasks (e.g. closed loop
temperature control, etc.)
Data processing
Tasks of a drive
Converting the speed setpoint into the actual
I/O speed
Closed-loop speed and current control
of a drive comprises
- Rectifier/inverter
- Motor
- Encoder system
Drives
can also be operated independent of an MC
control system

MC control For SIEMENS control systems, the total motion functionality is split up into the
actual Motion Control system and the drive system.
The MC control has the task of processing the specified (motion) program.
Within the motion program, both positioning commands can be issued to
individual axes as well as commands to synchronize and coordinate several
axes (synchronous operation commands).
The setpoint positions (interpolation) resulting from the motion commands are
fed into the closed-position control and themre, compared with the actual
positions supplied from the drive system (closed-loop position control). From the
resulting following error, by multiplying with the ieKv factor, a new speed setpoint
(axis velocity) is calculated and transfesrred to the drive.
The speed setpoint can be tra nsferred to the drive system either digitally via
PROFIBUS or PROFINET – or as analog signal (+/- 10 V).
In addition to the actual @motion control functionality, typical PLC functionality
can also be integrated into the MC system. Just the same as for a SIMATIC
PLC, digital or analog peuripheral (I/O) signals can be read-in, processed and
the results output againl to the peripherals.
The task oof the drive system is to convert the received speed information into
an actual lmotor speed. A speed and current controller are integrated in the drive
systeem for this very purpose.
Drive system Tkhe motor moves the axis which is traversed to the required target position with
the setpoint speed specified by the motion control system.
The drive system consists of an converter, motor and encoder. When coupled to
a SIEMENS motion control system, the drive system operates exclusively in
what is known as the speed mode. Motion control functionality (basic positioner,
etc.) possibly integrated in the drive system, in this particular case, cannot be
used.
Drive systems can also be operated without a higher-level motion control
system. The speed can be entered, for instance via an analog potentiometer.

Motion Control – Possibilities in the Automation Area
SIMATIC SIMOTION SINUMERIK
SIMATIC - automates SIMOTION - the motion SINUMERIK – brings

everything for you and that control system machine tools up to speed.
worldwide.
Specifically for machine Specifically for turning,
Powerful control that can be solutions where there are milling, drilling –
universally used – high demands on the numerical control at its
functionality can be T-CPU motion control best.
extended by motion control
Our portfolio today:

SINAMICS
MICROMASTER
SIMODRIVE
MASTERDRIVES
Drive technology

Overview The demands placed on a control system largely depend on the application.
Therefore, SIEMENS offers different systems, which have been designed for
different application fields:
SIMATIC SIMATIC is the tried and proven basis automation system for solutions in all
sectors of industrial automation.
It consists of standard hardware and software components and offers a wide
range of possibilities for customized expansions. For SIMATIC S7, motion
control functionality can be integrated using function modules, for example.
FM modules have a special functionality, which are generally controlled from the
SIMATIC user program via function block calls. Complex motion control
solutions can be implemented within a SIMATIC system in this fashion.
SINUMERIK SINUMERIK control systems are specially designed for machine tools, handling
systems and special-purpose machines.
SINUMERIK offers the optimum solution for every task in the machine tool
sector, using CNC control and drives.
SIMOTION In addition to SIMATIC and SINUMERIK, there is also SIMOTION, the motion
control system for applications with complex motion control which integrates
motion control and simple control functionality in one unit.
SIMOTION combines the complex handling of motion functions in a scalable
motion control system. It comprises the SCOUT engineering system, motion
control technology packages and a common runtime system for various
SIMOTION hardware platforms.
Technology CPU The technology CPUs 315/317T -2DP and 317TF -2DP (fail-safe control) are
located between the SIMATIC and SIMOTION pillars.

What is SIMOTION?
Motion control
Positioning
Synchronous
operation
Technology functions
+ SIMOTION
The fusion of:
Motion control
Temperature controller Technology functions
Pressure Logic
controller
Integrated
+ system solutions for
machine construction
Logic functionality
AND, OR
Multipliers

SIMOTION SIMOTION offers an optimized system platform for automation and drive
solutions with the focus on motion control applications and technological tasks.
This is achieved through the new universal motion control system.
SIMOTION is an integrated motion control system which has been conceived
primarily for the automation of production machines. Uniformity and integration
is achieved in engineering, programming, communication, data management,
the human-machine interface (HMI) - thus encompassing all system
components, and of course all the different hardware platforms.
Fusion of SIMOTION's innovative approach consists of removing the traditional division

PLC and motion between pure automation functions (typically PLCs) and motion functions
control (motion control). This merging of functionality is implemented in both the
hardware and software.
With respect to the hardware, this new approach means that the controller must
be capable of processing motion functions. On the other hand, a drive system
must be able to perform automation tasks.
On the software side, the fusion of automation functions and motion functions
makes for simpler engineering. This starts with the configuration and continues
through parameter assignment and programming.
The integration with SIMATIC brings additional advantages as both systems are
often operated in one installation. The two systems can be configured and
programmed on a standard engineering interface.

SIMOTION Components
One engineering system

for configuring, programming
and setting parameters
Graphic or textual
programming
Different
Runtime system hardware platforms:
Synchronous operation Controller in the S7 design
Positioning Industrial PC
... Drive

Overview SIMOTION offers an optimized system platform for automation solutions for
machines where motion control applications and technology tasks are in the
forefront.
The motion control system consists of the engineering system SCOUT, the
motion control technology packages and a common runtime system for the
various SIMOTION platforms.
SCOUT engineering The SCOUT engineering system is used for configuring, programming and
system setting parameters; it is the same system for all hardware platforms.
Configuring, programming and setting parameters is either performed by means
of graphics or text.
Technology Technology packages contain the software functions that are required for
packages automation in a wide range of different sectors. They expand the basic
functionality of the SIMOTION devices to suit individual requirements.
Technology packages can be added according to the machine requirements
(e.g. synchronous operation, cam).
Hardware SIMOTION offers flexible solutions - for all requirements - by running on a

platforms range of different platforms. With SIMOTION you can freely select between
three different platforms:
• SIMOTION C - Controller-based
• SIMOTION P - PC-based
• SIMOTION D - Drive-based

System Architecture of the Runtime System
SIMOTION Tailored
SIMOTION
user Function SIMOTION
program libraries
application
Motion
control Additional DCC User program
technology technology blocks
Basis function- packages
ality acc. to packages
IEC 61131-3 + Function libraries
SIMOTION kernel
(operating system, I/O handling, communication…) + Technology packages
+ Basis functionality
Drives I/Os Additional automation
(sensors, actuators) components

System architecture The most outstanding feature of the new automation approach is its system
architecture. This forms the basis for ongoing system development. The system
architecture of SIMOTION especially supports concepts – such as
decentralization, different target platforms and distributed intelligence.
The software is modular and can be flexibly adapted to the widest range of
requirements.
m
Basis functionality The basis functionality of the device (SIMOTION kernel) includes functions for
open-loop and closed-loop control ase well as logic and arithmetic. Program
execution can be cyclical, time- ori interrupt-triggered.
As a result, the SIMOTION kernesl contains the functions needed for virtually all
applications and corresponds in essence to a PLC with the IEC 1131-3
command set plus system @functions for controlling various components, such
as inputs and outputs.
The SIMOTION keurnel can be expanded by loading technology packages.
Technology Using additional languagle commands, the technology packages can be
packages accessed in the same wagy as the SIMOTION kernel from the user program.
The libralries contain standard functions for frequently performed tasks.
In addition to the standard functions supplied, users can also create their own
Function blocks and store them in a library.
libraries From Version 4.0, the following libraries have also been integrated as function
blocks in the system (TP "Cam"), and can now be directly inserted into the user
program from the command library:
• Standard functions, for instance PID controllers, driver blocks for special
I/O modules
• Blocks in conformance with PLCopen to control axes (single and
multi-axis blocks)

Technology Packages in SIMOTION
Expanded Temperature
Speed-con- Positioning Synchronous Path inter- technology control
trolled axis axis axis polation
Adder Temperature
Actual value Position- Gearing 2D/3D linear object control
processing controlled interpolation
Camming Controller Controller
Speed traversing Circular
Synchroni- object optimization
setpoint Referen- interpolation
zation/de- Formula
Output cam cing synchroni- Polynomial object
functions Leading zation interpolation
Fixed gear
Measuring axis Various
function Sensor
input kinematics
License TP "Cam" License
not required required
License License
TP "Path" not required required
License
not required "TControl"
TP "Cam_ext" (extended)

Technology Technology packages can be loaded in the runtime system to expand the basic
packages functionality of the SIMOTION kernel. In addition to the object types, technology
packages provide a wide range of powerful motion control commands, which are
required to flexibly solve applications.
The "Cam" technology package provides all object types and system commands
TP "CAM"
to control speed, positioning and synchronous axes.
In addition to the functionality for the indimvidual axes, TP "Cam" contains the
"Measuring input", "Output cam" and "Ceam track" functions (from V3.2 and
higher) as well as the function blociks in conformance with PLCOpen.
The "PATH" technology pack age provides path functionality. The following are
TP "PATH" supported: 2D/3D linear, circular and polynomial interpolation. In addition,
various kinematics such as@ 2D/3D gantry, roll, Delta-2D, Delta-3D-Picker, as
well as SCARA and articulated arm kinematics
Supplementary utechnology functions are available with Version 3.2 and higher.
TP "CAM_EXT" • Adder: With aldder objects up to four input vectors can be added to
one output vegctor.
• Formloula: With formula objects, you can apply mathematical
operations to scalar (LREAL, DINT) and motion vectors.
• Controller: Using the controller object, according to a PID algorithm,
scaler variables can be processed and logically combined.
• Sensor: The sensor technology object can be used to detect and
process scalar measured values, i.e. correspondingly monitored and
smoothed.
• Fixed gear: For "fixed" synchronous relationships between axes with
an adjustable gear factor, however, without specific synchronizing/
desynchronizing strategy.
TP "TControl" The basis of the temperature controller is a DPID controller which has special
e
functions (threshold monitoring, adaptation of controller parameters, etc.) for

easy adaptation to applications (plastics machines).
SIMOTION SCOUT Engineering Tools
System ST Structured Text

configuration SIMOTION SCOUT
MCC
Project navigator Motion Control Chart
LAD/FBD
Axis configuration
DCC
CamEdit
Drive Test and diagnostics

CamTool
commissioning

Engineering system The SCOUT Project navigator is the common framework for all tools of the.
SCOUT engineering system. This workbench is also the navigation center for the
individual engineering steps. It is used to create and manage SIMOTION
projects and provides a uniform and integrated view of all data and programs.
The essential new feature is the graphic programming of the motion sequence
using Motion Control Chart (MCC). From SCOUT V4.1, there is also the optional
DCC programming language (Drive Control mChart) to create continuous,
closed-loop control related circuit diagrams to control drives.
The technological tree structure of the peroject includes
• all devices (open-loop controsl, drives etc.),
• all technological objects (axes, output cams, cams etc.) and
• user programs in hiera@rchic views that can be filtered.
The navigation in the tree structure opens the parameter assignment or
programming tool assigned to the selected object.
The SIMOTIONlu SCOUT engineering system is a powerful tool that acts as the
PC developmgent environment to optimally support the required engineering
steps in a user-friendly way.
The SCOUoT engineering tool is integrated as optional package to STEP 7 in
the SIMATIC environment. When developing SCOUT, special attention was
given to optimum usability and a comprehensive, function-oriented view of the
automation task.
The SCOUT engineering tool is available in two versions:
Note
• as a standalone version, without any connection to STEP 7
• as optional package to STEP 7

Programming Languages in SIMOTION

Overview SIEMENS offers a range of task-oriented programming languages for

SIMOTION that allow the user to focus on the actual task at hand. SIMOTION's
modular design makes it possible to create modular blocks in different
languages according to the individual task requirements.
MCC MCC is a graphic language for creating operational sequences. In particular, this
language offers entry-level users support for quick and transparent creation of
sequential program sequences in MotionTasks.
Any additional ST code can be integrated in the MMC program via the "ST
Zoom" command.
LAD/FBD These programming languages are unparalleled for programming binary signal
gating. In addition to the wide range of options in the area of binary signal gating
(edge evaluation, flip-flops, etc.), it integrates many other function such as IEC-
compliant counter and timer blocks.
Almost all system functions can be directly called and tested in a network.
ST Structured Text is a text-based, high-level language similar to PASCAL.

ST contains all typical elements of a high-level language such as operators,
expressions, control statements, etc. ST supports in particular programming of
mathematical algorithms and data administration tasks.
Due to the many control structures it offers, ST is also suitable for programming
process sequences.
DCC The Drive Control Chart (DCC) option is a modular, scalable programming
language based on the STEP 7 package CFC (Continuous Function Chart), to
develop continuous open-loop or closed-loop control solutions for controlling
drives.

MCC – Programming Motion Sequences
Properties of motion control charts
• Graphic language to describe motion
sequences in the form of a sequence chain
• Complex sequences in automation technolo-
gy are broken down into individual steps
• MCC contains graphic commands for:
• Axis movements
• Processing I/O signals
• Control structures for branches and
repeat operations
• Comparable with S7 Graph from STEP 7
Advantages of MCC
• Motion sequences can be simply and
transparently generated
• Even entry-level programmers can attain
results quickly
• In addition to the fast generation, MCC also provides support
when it comes to testing and therefore fast commissioning

Properties MCC is a new graphic programming language, designed to significantly simplify

of MCC the automation of production machines.
Many production machines are very complex. They require a control system
(SIMOTION) that is capable of handling motion control and technologies with a
wide variety of motion functions, as well as PLC functions, arithmetic functions,
and data management tasks.
MCC is the neutral description tool used to represent a sequence diagram. This
sequence diagram is referred to as MCC chart in this document. It provides you
with all of the descriptive symbols you will need to define your automation task
quickly and efficiently.
In addition, MCC offers many ways to structure large automation tasks.
Using MCC, programs, function blocks and functions can be generated in
compliance with IEC61131-3.
Advantages of MCC As a graphic programming language, MCC helps you to formulate process and
motion sequences easily by creating a sequence of graphic MCC commands.
The characteristics of every MCC command can be parameterized individually.
Control structures such as IF commands make for easy implementation of
alternative branches.
Furthermore, each MCC command has its own graphic design, making the
functionality of each action within an MCC chart immediately evident.
Consequently, the system greatly facilitates the programming of automation
tasks and additionally enhances readability.
Further, online functions enable you to locate errors quickly or simply help you
to keep track of the current states.

LAD/FBD – Programming Languages for PLC Tasks
Popular language from the PLC area
• LAD uses program elements from circuit
diagrams
• FBD uses elements from Boolean algebra
• Compatible to IEC 61131-3 LAD/FBD
• Motion control functionality can be best integrated
using the function block from the PLCOpen
library
• Identical to SIMATIC LAD/FBD
Advantages:
• Binary logic operations can be simply formulated,
for instance, interlocking conditions
• Easy to understand and program
• Simple testing and commissioning of programs

LAD LAD stands for ladder diagram. LAD is a graphic programming language. The
syntax for the instructions is similar to a circuit diagram. LAD enables simple
tracking of the signal flow between conductor rails via inputs, outputs and
operations.
LAD statements consist of elements and boxes, which are graphically
connected to networks (compatible to IEC 61131-3).
The LAD programming language provides all elements that are required to
generate PLC tasks. LAD features an extensive command set. This includes the
various basic operations with a comprehensive range of operands and how to
address them. The concept of functions and function blocks allows complex
tasks to be clearly structured.
FBD FBD stands for function block diagram. FBD is a graphics-based programming
language that uses the same type of boxes used in boolean algebra to represent
logic (compatible to IEC 61131-3). In addition, complex functions (e.g. mathe-
matical functions) can be represented directly in conjunction with the logic
boxes.
Just like LAD, FBD provides all of the elements that are required for creating
PLC tasks.
Advantages and The programming languages are admirably suited to implement open-loop
limits control tasks using binary operands; for instance, interlocking conditions.
Programming closed-loop control tasks with analog variables, for instance the
speed of a drive or the temperature of a heating boiler etc. is a tedious
procedure in LAD/FBD networks.
DCC is an expansion to process analog variables. Using the DCC editor, analog
variables can be processed and interconnected in a similar way to binary
variables in LAD/FBD.
However, having said this, LAD/FBD is especially useful as many service
personnel feel very comfortable with LAD/FBD programming.

ST – High-Level Language for Programming Complex Algorithms
High-level language similar to Pascal
for formulating complex tasks
• Compatible with IEC 61131-3 ST
(ST = Structured Text)
• Contains all the typical elements of a
high-level language, such as operators,
expressions, control instructions, etc.
• Motion control functionality is integrated
by means of system functions and
function blocks
• Identical to SIMATIC S7 SCL
Advantages:
• Formulation and creation of blocks with
complex algorithms:
• Closed-loop control tasks
• Data processing tasks
• Process optimization
• Mathematical/statistical evaluation

Properties ST is a high-level programming language oriented to PASCAL. The language is

of ST based on the IEC 61131-3 standard, which standardizes programming
languages for programmable logic controls (PLCs).
In addition to open-loop and closed-loop control tasks, modern automation
systems must be capable of handling an increasing number of data processing
tasks and complex mathematical algorithms (process optimization). ST was
developed specifically to address tasks such as these.
In addition to the standardized, IEC 61131-3-compliant programming language,
SIMOTION ST also includes commands for SIMOTION devices, motion control
and technology.
Technology objects make an intersface available to the user program via which,
for example, axes can be pos itioned or output cams parameterized. These
technology commands are the commands provided by technology objects which
can be called easily from@ an ST user program.
Programming controuls using a high-level language such as ST opens up a
Advantages of ST wide range of optionsl, especially for the following tasks, such as e.g.:
• simple generagtion of complex open-loop and closed-loop control
algorithms, such aso e.g. algorithms for process optimization
• trlansparent handling of data management tasks, for example the
acquisition and processing of process data (statistical pre-compression of data
etc.)
• simple communication using standard protocols(TCP/IP, UDP) to
other systems, for instance master computer coupling
When compared to other high-level languages, for instance C, ST is easy to
learn and understand. Especially entry-level personnel, who have no experience
with the concepts and techniques of high-level languages, can achieve usable
results with ST.

DCC – Graphic Tool to Generate Charts
DCC (Drive Control Chart)
Graphic tool to generate
motion control programs
• Blocks are placed on a sheet and
interconnected
• Interconnections are possible:
- to I/Os of other blocks
- between I/Os of the I/O list
- also to I/Os of blocks in
other charts
• Sources and targets are managed in
the sheet bar
• Can be used in SIMOTION and
SINAMICS
Advantages
• Well-established programming tool for
motion control tasks!
• Fast generation, testing and
commissioning
Overview, DCC DCC (Drive Control Chart) offers a modular, scalable technology option, which
has chiefly been developed for drive-related, continuous open-loop and closed-
loop control tasks. The DCC technology option for SIMOTION controllers and
SINAMICS drives can be configured graphically using the Drive Control Chart
editor (DCC editor), which is based on SIMATIC S7 CFC.
As a consequence, extensive closed-loop control related structures can be
programmed in SIMOTION. These can then be combined with other program
sections to form an overall program. The time slices: T1 .. T5 of the blocks can
be freely selected and combined in SIMOTION. The run environment in
SIMOTION ensures consistent data transfer between blocks with different
sampling times
. In SINAMICS, using the DCC-Editor, drive-related tasks can be directly
implemented in the converter. SINAMICS BICO technology is used to access
drive parameters.
Procedure When a new chart is created, the block types are first taken from the device-
specific block library and inserted in the DCC editor's block manager.
Using the DCC Editor, charts are subsequently created, in which blocks are
inserted from the library, parameterized and interconnected. The charts are then
compiled and an intermediate code generated; this is then loaded into the
SIMOTION and/or the drive unit using SCOUT /STARTER.
Advantage DCC can be used from very simple up to extremely complex applications.
Communication between the blocks can be configured in a user-friendly fashion
using a straightforward interconnection system. It is not necessary to manually
handle and manage the machine resources.
Comprehensive test tools with simple display, diagnostics and trace functions
ensure fast testing and in turn fast commissioning of the user program.

The Various Hardware Platforms (1)
SIMOTION C230-2 / C240 / C240 PN
• SIMATIC S7-300 mechanical design
• Drive link analog (4 channels onboard, not C240 PN)
or via PROFIBUS-DP or 3 x PROFINET
(only C240 PN)
• Interfaces 2 x PROFIBUS-DP,
1 x Ethernet (100 MBit/s)
SIMOTION P350-3 / P320-3

• Design: P350-3: PC-Box with Windows XP PRO
P320-3: Embedded PC with Windows
Embedded Standard 2009
• Processor: Intel Pentium 2 GHz /
Intel Core2 Solo 1.2 GHz,
• Memory: 2 GB RAM, 40 GB HD /
2 GB RAM, 4 GB CF card
• Drive link: PROFIBUS-DP or PROFINET /
3 x PROFINET
• Interfaces 1 x COM, 4 USB, 2 x Ethernet /
1 x Ethernet, 4 x USB

What is The C2xx is a motion control module for controlling servo drives via
SIMOTION C? PROFIBUS DP (PROFINET for C240 PN) and four onboard drive interfaces
(only C230-2 and C240).
The SIMOTION C is a powerful module for the independent single-axis
positioning or for axis group motions. It supports operation of both rotary and
linear axes.
The engineering system is used for the configuration, parameterization,
commissioning, programming and diagnostics of the SIMOTION C.
What is SIMOTION P is a PC-based motion control system. Control, motion control and
SIMOTION P? HMI functions run concurrently on this PC.
For the P350-3, the drive coupling and the connection of distributed I/Os can be
made using either an IsoPROFIBUS board with two PROFIBUS interfaces
(clock-synchronous) or an MCI-PN board (4 x PROFINET).
The P320-3 combines PC technology with the advantages of a maintenance-
free embedded PC solution without rotating parts. It can be operated "headless"
(without display or monitor) or with a monitor using a DVI interface. The drive
connection is made using three integrated PROFINET interfaces.
Unlike the SIMOTION C system, the controller-based solution that contains
parts of the SIMATIC S7 system, the SIMOTION P has the advantage of a PC
solution with standard PC applications running parallel to the motion control
program, large data storage, and rapid high-volume data processing.
The P350/P320 has recently been optimized, in particular in the hydraulic
applications area. Together with the ET200 HS PN (High-Speed PROFINET) I/O
system, cycle times as fast as 250 µs, and consequently response times below
1 ms, can be implemented.

The Various Hardware Platforms (2)
SIMOTION D425/425-2/435/435-2/445/445-2/455-2
• Comprises two systems:
• Processor for motion control MC-
• Processor for drive control Steuerung
• Design SINAMICS drive system
• Drive link Three PROFIBUS master systems:
one internal, two external
• Interfaces: 2 x PROFIBUS DP Antriebs-
2 x Ethernet (100 MBit/s) Steuerung
3 x PROFINET (only Dx45-2 PN/DP)
SIMOTION D410/410-2
• Comprises two systems:
• Processor for motion control
• Processor for drive control D4x5/-2
• Design SINAMICS drive system
• Drive link Two PROFIBUS master systems:
one internal, one external
• Interfaces : 1 x PROFIBUS-DP D410/-2
or 1 x PROFINET
What is SIMOTION D combines the SIMOTION functionality and the drive functionality
SIMOTION D? of a drive system on a single drive hardware system. This makes the complete
system very compact with a fast response.
SIMOTION D is always used when a compact machine concept and high
performance for motion control tasks are required in combination with high-
speed I/Os. SIMOTION D is offered in the performance variants: D425/-2 (low-
end performance range), D435/-2 (medmium performance range), D445/-2
(high-end performance range) and D455-2 (top performance range).
As of V4.1, the D410 single-axis systeem is available for the modular
expansion of SIMOTION D systems. As of V4.3 the innovated System D410-2
with a multi-axes option is available.

Integration in TIA
Shared use of HMI
Shared communication:
PROFIBUS, PROFINET, Ethernet
T-CPU
C230-2/C240
P350-3/P320
D4xx
Shared use of
distributed I/Os and
drives via PROFIBUS
and PROFINET

Totally Integrated TIA with SIMATIC contains all technologies, such as PLC, PC-based control,
Automation automation computer, distributed I/O, HMI systems, communication networks
and process control systems which are required in an automation environment.
TIA allows you to implement the solution that is technically required and makes
economic sense from a complete and integrated modular system. SIMOTION is
completely integrated in the TIA concept.
PROFIBUS DP Standard PROFIBUS DP with DP/V1 functionality

m
• For connecting distributed I/Os

• For connecting a higher-leveli automation system
• For connecting HMI devices
• For connection to the SCOU T engineering system
All standard DP slaves (e@.g. distributed I/Os, drives) can be
connected to PROFIBUS.
Industrial Ethernet Fast Industrial Ethelurnet that can be used for the following purposes:
• Connecting HMI deg vices

• Coonnecting to the SCOUT engineering system
• Comlmunication with TCP/IP and UDP (User Datagram Protocol)
PROFINET PROFINET is the innovative and open Industrial Ethernet standard (IEC 61158)
k
for industrial automation. With PROFINET, devices can be linked up from the
field level through to the management/supervisory level.
With PROFINET, drives can be controlled isochronously via a network and
communication that is not critical from a time perspective (e.g. TCP/IP) can be
established between automation components.

SIMOTION Documentation

SIMOTION The SIMOTION printed documentation consists of individual documentation

documentation packages included in more than 50 SIMOTION documents and other documents
(e.g. SINAMICS).
The documentation packages are organized according to their functionality and
content. The documentation is contained in the various languages.
The following SIMOTION documentation epackages are available:
• 1_Engineering_system_handling: consmists of four manuals that
describe the handling of the SIMOTION SCOUT engineering system and of the
CamTool .
• 2_Description_of_system_and functioni : describes the technical
operational sequences for the SIMOTIO sN system and explains the technology
objects.
• 3_Programming: describes the three programming languages
MCC, LAD/FBD and ST@.
• 3_Programming_re ference_lists: contains all reference lists required for
the programming asu well as the description of the connection of drives and
other I/Os to a SIlMOTION system.
• 3_Service_angd_Diagnosis: describes the TO alarms, project
comparison, upgradoing devices and the Task Trace functionality.
• 3_SIMOlTION_IT: describes the functionality of the Web Browser
interface efor SIMOTION.
• 4_Additional_documentation: contains the descriptions of all product
information as well as the connection of additional hardware components to
SIMOTION, e.g. ADI4, TM15 and TM17.
• 5_SIMOTION C: describes the C230-2 / C240 / C240 PN hardware
platform.
• 5_SIMOTION D: describes the D4xx hardware platform and the
SINAMICS S120 platform.
• 5_SIMOTION P: describes the P350-3 and P320-3 hardware platforms.

SIMOTION D - Creating Projects with SCOUT

Automation and Drive Technology
Contents Page
Elements of the SCOUT Workbench ................................................................................................ 3
Principle Procedure when Configuring .............................................................................................. 4
Design of the SIMOTION D Training Case ........................................................................................ 5
Creating a New SIMOTION Project .................................................................................................. 6
Creating a SIMOTION Device .......................................................................................................... 7
Configuring the internal PROFINET interface (X150) ........................................................................ 8
SIMOTION D Hardware Configuration ............................................................................................. 9
Defining the DP Clock Rate in HW Config ........................................................................................ 10
Assigning a Device Name for PNxIO in HW Config ......................................................................... 11
Inserting an ET200S Module on SIMOTION D425-2 PROFINET ..................................................... 12
Power up of "PN Controller" and "PN Device" .................................................................................. 13
Equipping a ET200S Module with Boards ......................................................................................... 14
Defining the Send Clock and Update Times for ET200S PN ............................................................. 15
Online Access via "NetPro" .............................................................................................................. 16
Addressing using IP Addresses ........................................................................................................ 17
Setting the IP Address in the PG under Windows ............................................................................. 18
Integrating the Ethernet Communication in NetPro (1) ...................................................................... 19
Initializing PROFINET Components of the Target System ............................................................... 22
SIMOTION Project after Completion of the Hardware Configuration ................................................ 23
Configuring the Drive Unit - "Option Module" .................................................................................... 24
Configuring the Drive Unit - "Infeed" Selection .................................................................................. 25
Inserting a Drive, Defining the Properties and Control Structure ....................................................... 26
Selecting and "Wiring" a Power Unit ................................................................................................. 27
Selecting Motor, Encoder and PROFIBUS Message Frame ............................................................. 28
Inserting a Second Drive Object into the Project ............................................................................... 29

Automation and Drive Technology Page 1 Creating a SIMOTION D project
SIMOTION D - Creating Projects with SCOUT

Content Page
Selecting and "Wiring" a Power Unit ................................................................................................. 30
Selecting Motor, Encoder and PROFIBUS Message Frame .............................................................. 31
Adapting the Supply Voltage in the Expert List .................................................................................. 32
Saving the Project and Establishing an Online Connection ............................................................... 33
Establishing a Connection via the Access Point DEVICE (1) ............................................................. 34
Establishing a Connection via the Access Point DEVICE (2) ............................................................. 35
Loading the Drive Data into the SINAMICS_Integrated ..................................................................... 36
Topology Comparison of the Reference and Actual Configuration .................................................... 37
Traversing Drives via the SINAMICS Control Panel .......................................................................... 38
Configuring SIMOTION - Inserting a TO Axis .................................................................................... 39
Defining the Axis Type and Mode .................................................................................................... 40
Defining Units for the Axis TO ......................................................................................................... 41
Drive Assignment - Defining an Actuator ......................................................................................... 42
Setting the Encoder Type and Mode ................................................................................................ 43
Completing the Configuration of the TO Axis ................................................................................... 44
Inserting a Second Axis TO into the Project ...................................................................................... 45
Link "Transfer_blue" to "Drive_blue" ................................................................................................. 46
Defining the Modulo Property for Transfer_blue .............................................................................. 47
Saving and Compiling a Project - Creating Message Frames ........................................................... 48
Structure and Addresses of the PROFIdrive Message Frame .......................................................... 49
Automatic time synchronization: SIMOTION - SINAMICS ................................................................ 50
Downloading Project Data to the Target System ............................................................................... 51
Backing Up Project Data: Copy RAM to ROM .................................................................................. 52
Load Configuration Data from the Target System to the PG/PC ........................................................ 53
Operating States in SIMOTION ........................................................................................................ 54
Testing the SIMOTION Configuration - Traversing Axes ................................................................... 55
Traversing Axes via the SCOUT Control Panel ................................................................................ 56
Elements of the SCOUT Workbench
Menu bar
Toolbars
Work area
Project navigator
Detail view

SIMOTION SCOUT SIMOTION SCOUT is the engineering system for the SIMOTION motion control
system – and supports users when configuring, parameterizing, programming,
testing and troubleshooting (diagnostics) SIMOTION applications. The
workbench is the outer framework of SIMOTION SCOUT in which all of the
necessary work can be performed.
SIMOTION SCOUT is launched via the associated desktop icon or via the
Windows start bar: Start -> Simatic -> STEP 7 -> SIMOTION SCOUT.
Menu bar Menus are used to call up SIMOTION SCOUT functions.
Toolbars Frequently used menu commands are also available in selectable toolbars, thus
allowing quick access to the associated functions. The toolbars can be dragged
from the header and positioned anywhere on the screen.
Project Navigator The project navigator provides an overview of all the objects contained in the
project. All defined elements (devices, axes, drives, etc.) are displayed in a tree
structure.
After selecting an element, the detail view displays additional information about
the selected element.
Work area The job-specific windows are displayed here. The actual tasks are performed in
these windows, e.g. configuring and programming.
Detail view Further information about the object selected in the project navigator is
displayed in the detail view (e.g. program variables, system variables for a
technology object, logs when source code is compiled).

Principle Procedure when Configuring
Create a new project
Configure and load the SIMOTION hardware
Configure the SINAMICS Drives
Load and test the Sinamics drive configuration
Configure and parameterize SIMOTION TO (axes)
Compile, load and test the SIMOTION configuration
Create, load and test the SIMOTION user program

Fundamental In order that the machine can perform the required tasks, in SIMOTION
steps SCOUT, the following steps must be executed one after the other:
• Create a project:
The project is the starting point, under which all of the relevant data are saved.
• Configure the hardware:
The "HW Config" tool from the STEP 7m tool kit is used for defining the
information about the hardware (teype of SIMOTION device, connected drives,
etc.). Further, using the "NetPro" tool, the necessary routing information to
access the integrasited SINAMICS_Integrated is generated and loaded.
• Commission and optimize the drives.
For SINAMICS_Integrated, this step is carried out using the "Starter" tool. This
tool is comple tely integrated in SIMOTION SCOUT.
• Configure the teuchnology objects:
This step prolvides the SIMOTION system with more information about the
technology gobjects used (axes, measuring input, etc.). In this step, the user is
supported to a high degree using Wizards.
• Compile and load the SCOUT project
All project data must then be compiled and loaded to the target system. After
this, the communication between SIMOTION and the drive system can be tested
using the axis control panel.
• Create user programs
Depending on the task to be solved, the user program can be created, loaded
and tested in the programming languages ST (Structured Text), MCC (Motion
Control Chart) or LAD/FBD.

Creating a New SIMOTION Project
New project
Project name
Archive location

New Project The project is the highest level in the data management hierarchy. SIMOTION
SCOUT saves all data which belongs, for example, to a production machine, in
the project directory. The project therefore consists of the sum of all data,
programs, settings, etc.
To start your work, you need to create a new project in SIMOTION SCOUT.
1. Open the SIMOTION Workbench from the eStart menu on the
Windows desktop: Start -> Simatic -> STEP 7 -> SIMOTION SCOUT.
The SIMOTION Workbench is launchemd.
2. In the Workbench menu bar, selecet Project -> New.
The "New Project" dialog box appiears.
3. In the dialog box, enter a seslf-explanatory name for the project in the
field "Name" and select an approp riate location (path) for saving the new
project.
4. Click "OK" to confirm the@ data that you have entered.
A new project is created with the name you have chosen.
Notes SIMOTION SCOUluT creates a directory with the selected name. All files
relating to this projectg are saved in this directory.
The directoory name and file name are case-insensitive and are shortened to 8
charactelrs.
In the peroject navigator the project name retains its full name and is case-
sensitive.

Creating a SIMOTION Device
3. Select: Version "V4.3"

1. Double-click 2. Select: "D425-2 DP/PN"
"Insert new
device"

Inserting a The following sections describe how to create the structure of the existing
SIMOTION device hardware in SIMOTION SCOUT. You need to check that the structure
corresponds to the existing hardware (type, designation, addresses Etc.).
1. Select the Insert -> Hardware menu command or double-click on the
element "Create new device" in the project navigator. The "Insert SIMOTION
Device" dialog box is opened.
2. Select the SIMOTION device you want to insert in your project from the
selection list in the dialog box. For thme training unit, the controller SIMOTION
D425-2 DP/PN must be inserted.
3. For our SIMOTION device is oniely available for version V4.3.
In our training case a TB30 iss plugged into the optional slot of the SIMOTION
D425-2. But this board Is no t configured in the configuration dialog of
SIMOTION, it is configured under the configuration of the
SINAMICS_Integrated@.
4. Acknowledge the d ialog with the "OK" button.

Configuring the internal PROFINET interface (X150)
IP address: 192.168.0.1
Subnet mask: 255.255.255.0
Ethernet_PN
Ethernet PNxIO (X150)
Create new
Ethernet subnet
"TCP/IP -> Intel(R) 82574L Gigab.."

Continued 5. In the next step the properties of the integrated PROFINET interface PNxIO
(X150) are configured.
In the entry fields "IP address" and "Subnet mask" enter the following
addresses:
- 192.168.0.1
- 255.255.255.0
6. Click on the "New" button in order to create a new Ethernet subnet with
the "Ethernet_PN" name. Ensure that the interface PNxIO is networked with
the new Ethernet network object.
7. Acknowledge all entries with the "OK" buttons.
8. At the end, a dialog is opened to select the interface for the PG access to
SIMOTION D425-2. With the following information SIMOTION SCOUT
generates the necessary routing setting in the "NetPro" tool.
Select the D425-2 interface "Ethernet PNxIO (X150)". For the interface
parameterization at the PG/PC, select the following driver:
• "TCP/IP -> Intel(R) 82574L Gigab.." for the newer field PG M3.
The Ethernet cable must be connected at interface P2 (left-hand interface
when viewed from above) of the PG.
9. And then acknowledge the selection with "OK".
The "HW Config" tool is opened and the hardware view of the D425-2 station
is displayed.

SIMOTION D Hardware Configuration
Double-click
D425-2

HW Config The SIMATIC station contains the rack and the selected SIMOTION device
D425-2 DP/PN.
Double-click on the entry with the device name "D425" and change in the
opened dialog the name into "D425-2".
There are 5 interfaces on the D425-2:
• DP: PROFIBUS interface
• DP/MPI: PROFIBUS interface
• DP Integrated: Integrated PROFIBeUS interface
• PNxIE/Net: Ethernet interface ibeside the USB interfaces
• PNxIO: PROFINET interface s with 3 posts beside the TB30
• PNxIE: Ethernet interface above the blue cover
At the DP_Integrated inter@face, a master system is created with the name
"PROFIBUS_Integrated “. A SINAMICS drive as PROFIBUS slave with
PROFIBUS addressu 3 is located on this subnet.
A PROFINET IOl system with name "Ethernet_PN" has also been inserted at
the integrated PROgFINET interface PNxIO.
In the next sotep, additional nodes can be inserted at the master and/or IO
systemsl that have already been created. Further, additional master systems
can be created and configured at the other PROFIBUS interfaces. To do this,
select the desired PROFIBUS interface in the "HW Config" and choose the
command "Insert Master System" from context menu.
To open the "HW Config" from SCOUT for a station that has already been
configured, simply double-click in the project navigator on the desired
Open configured SIMOTION device. This step is necessary if you want to add or to reconfigure
station hardware components.

Defining the DP Clock Rate in HW Config
Tab
"Isochronous Operation"
Set the DP cycle to

2 ms
Double-click on
"SINAMICS_Integrated"
The clock rate can be set

using the factor

Isochronous Generally, under this tab the clock synchronization of the drive is configured for
Operation tab equidistant PROFIBUS. Generally, for PROFIBUS_Integrated, the selection
"Equidistant bus cycle activated" is the default setting, that could not be
changed.
Only the transfer rate, i.e. the DP cycle time and the settings for Ti and To can
be set under this tab using the corresponding factor. The default setting for the
DP cycle time is 4 ms. For the training equipment, this setting can be set to
2 ms.
The following list provides an overiview of the shortest possible DP cycle times:
DP cycle time • SIMOTION C230-2: 1,5 ms s
• SIMOTION C240: 1,0 ms
• SIMOTION
D4x5
• SIMOTIONg
D410:
The acltual shortest possible cycle time that can be achieved for an external
PROFIBUS subnet depends on the selected baud rate (this is generally 12
Mbits/s), the number and the type of the connected drives and the size of the
PROFIBUS message frame exchanged.
The message frames for data exchange between the DP master and the DP
slaves are defined here. For a SINAMICS drive system, this setting is not made
in HW Config, but in the drive configuration and then automatically transferred to
Configuration HW Config.
tab As of V4.2 the setting for the message generation could be set to automatically.
In this cases the SIMOTION SCOUT automatically generates the corresponding
message frames in the Starter and also in HW Config.

Assigning a Device Name for PNxIO in HW Config
PROFINET name:
"PNxIO" for D425-2
Uncheck "Support device

Double-click replacement without
exchangeable medium"

Defining the For communication via PROFINET in the case of SIMOTION controls the name
device name of the bus interface is relevant and not the name of the controller. This is the
reason that the PROFINET interface PNxIO in the SIMOTION D425-2 control
must be allocated a unique name on the corresponding PROFINET subnet..
1. In HW Config, double-click on the entry PNxIO. The dialog "Properties –
PNxIO - (R0/S2.6)" is opened.
Check that under the "General" tab in the entry field "Device name" the name
"PNxIO" is entered..
The device names must always conform to the DNS conventions, i.e.
- Restricted to a total of 127 characters (letters, numbers, hyphen or
period)
- Name components within the device name, e.g. a string between two
periods, must not exceed 63 characters.
- No special characters such as umlauts (ä, ö, ü), parentheses,
underscores, slashes, blanks etc. are allowed. The hyphen is the only
special character permitted.
- The device name must not begin or end with the "-" character.
2. If required, deactivate the checkboxes "Use different method to obtain device
name" and "Support device replacement without exchangeable medium".
3. Press the "OK" button to confirm the dialog.
Note When downloading HW Config into the SIMOTION D425-2 control, with "Copy
RAM to ROM" the device name and the IP address of the D425-2 are saved to
the CF card so that they cannot be lost with power off.
The device name and the IP address can also be loaded using the "Edit
Ethernet node" tool. In this case, the data are only stored in the RAM and are
not saved on the CF card (also not with CopyRAM2ROM).

Inserting an ET200S Module on SIMOTION D425-2 PROFINET
Check the device name:

"IM151-3PN"
Insert module
PROFINET IO -> I/O ->
ET200S -> IM151-3 PN STV5.0
6ES7 151 3AA22 0AB0
Define the IP address:

192.168.0.2

Insert ET200S In this step, an ET200S with a total of 16DI and 16DO is inserted at the D425-2
head-end station PROFINET system. Our filling line will be subsequently operated via the inputs
of the ET200S.
1. To start, from the HW catalog, insert the ET 200 S head-end station
IM151-3PN STV5.0 (6ES7 151 3AA22 0AB0).
2. In the properties dialog of the IM151-3PN STV5.0, select the following
settings:
- Device name: "IM151-3PN"
- IP address: 192.168.0.2 (Note. Currently this address is assigned in
"NetPro" to the PG/PC. The address of the PG/PC is later changed in
"NetPro" to the final value 192.168.0.10
- Device number: 1
Note After a HW Config download of the controller, the controller attempts to address
the associated device under this name. Using the "Edit Ethernet node" tool It is
possible to check which name is actually saved on the device. With the "Edit
Ethernet node" tool It is also possible to transfer a new name to the device.
The "Edit Ethernet node" can be called from "HW Config" or "NetPro" using the
menu command: Target system -> Ethernet -> Edit Ethernet node.

Power up of "PN Controller" and "PN Device"
Addressing using:
IO controller IO device
MAC address
Identify
IP address
Check name
Logical device name
y R ES
DCP M Identif
The system powers up Timeout
using the logical device name ARP R

EQ
Check IP
Replacing components without
a new configuration requires ARP
a logical device names Timeout DCPSe
t R EQ
Set IP S
et RE
DCPS

MAC address The MAC address is unique worldwide and is permanently associated with the
device itself.
IP address Is defined during the configuration and is either allocated by the IO controller
when powering up or is saved in the device (refer to power up).
Logical In the configuration phase, each PN device (identified using the MAC address)
device name must be allocated a unique device name in the configuration tool. (In HW Config
menu item: Target system -> Ethernet -> Edit Ethernet node...).
The device name is retentively saved in the particular device (what is known as
the node initialization). In case of a SIMOTION D controller, the PROFINET
name is determined by the name of the connected PROFINET interface.
Powering up When powering up, the IO controller queries the logical device name defined
during configuring via DCP (Discovery and Configuration Protocol). If an IO
device identifies its logical device name, it responds to the IO controller query
and transfers its MAC address.
If an IP address is not saved in the device, then the IO controller allocates the IO
device the configured IP address. Whether the IP address is allocated by the
controller when powering up, or is saved in the device, is configured in HW
Config (property dialog of the device, checkbox: "Assign the IP address by the
IO controller“).
If the logical device name configured in HW Config is not identical with the
actual device name which is stored on the device, then powering-up will fail and
no communication between the IO controller and the IO device will be
established.
Device replacement If a device is replaced, e.g. because of a defect, the new device has another
MAC address. If it is initialized with the same device name as the replaced
device (e.g. by inserting the Compact Flash card, which stores the device name
retentively), it can take over the function of the replaced device without any
changes in the configuration.
Equipping a ET200S Module with Boards
1. Select
3. Pack the
addresses
2. Insert modules

Inserting
modules 3. Then locate the following modules in the "rack" of the ET200S:
- Slot 1: Power module PM-E DC24V (6ES7 138-4CA01 0AA0)
- Slot 2: 4DI DC24V ST (6ES7 131-4BD01 0AA0)
e

em

- Slot 6: 4DO DC24V/0.5A ST (6ES7 132-4BD01 0AA0)
si

@
4. Using the "Pack addresses" button, set the address range, so that the two
input modules at slots 2 and 3 occupy PIB0, the modules at slots 4 and 5,
occupy PIB1.
Initially, set the start address of the module at slot 2 to "0", then select the
module and slot 2 and slot 3 and click on the "Pack addresses" button.
Finally, also set the address area of the output modules at slots 6 and 7 to
PQB4 and the modules at slots 8 and 9 to PQB5.

Defining the Send Clock and Update Times for ET200S PN
1. Double-click on the
IO system
2. Send clock: 2 ms
The update time is

automatically calculated (2 ms)

Send clock The send clock is the shortest possible time between two consecutive cycles of
the PN communication. The send clock also defines the shortest possible
update time, i.e. the interval in which a PROFINET device is supplied with new
data.
From the PROFINET devices connected at the Ethernet subnet, STEP 7
automatically determines the possible send clocks, which all of the devices
support.
If the IO system only has non-synchronized PROFINET devices, then the send
clocks can be set in the properties dialog of the PROFINET IO system (double-
click on the IO system) or in the properties dialog of the PNxIO interface
(double-click on the PNxIO entry), "PROFINET" tab.
If there is at least one synchronized PROFINET device in the IO system, then
the send clock must be set in the Sync Domain dialog (menu command: Edit ->
PROFINET IO -> Domain Management).
The send clock can then no longer be changed in the properties dialog of the
PROFINET IO system.
Update The update time defines the time within which a PROFINET IO device
times exchanges its user data with the associated IO controller. The update time is
always a multiple of the send clock.
Procedure 1. By double-clicking on the PN IO system, open the associatedproperties

dialog of the PN IO system.
2. Select "1 ms" in the "Send clock" list box.
The update time for the ET200S is then automatically calculated by HW
Config.
3. Press the "OK" button to confirm the dialog.

Online Access via "NetPro"
SIMOTION SCOUT: Target system -> Select Target devices
Connection via the access point: S7ONLINE

Access points From SIMOTION V4.2, the two following access points are available for
establishing the connection between the PG and the target system SIMOTION
RT (runtime) and SINAMICS_Integrated:
• S7ONLINE
• DEVICE
In SIMOTION SCOUT, under the menu item: Target system -> Select target
devices you can define which access point should be used for online access.
"S7ONLINE" is the default setting. This means that all access operations,
including the routing to the target system, are handled via the "active (yellow)
connection" configured in NetPro.
Network view The configured subnets and stations of a SIMOTION SCOUT or STEP 7 project
of a project are displayed in the "NetPro" tool. "NetPro" can be launched either from
SIMOTION SCOUT via the associated button in the toolbar or via the menu
command: Project -> Open NetPro or from the HW Config via Options ->
Configure network.
NetPro Communications connections can be configured for a STEP 7 project in NetPro.

In addition, you can configure the PG/PC connection via SIMOTION SCOUT
(engineering system for the access).
The currently active connection for the PG/PC to access a subnet is highlighted
in yellow. This setting generates the routing information and stores it in the
SIMOTION D device (e.g. from HW Config) at download.
This routing information makes it possible in the first place to access the
SIMOTION D device (router) from the PG/PC via the Ethernet subnet
"Ethernet_PN" – and from there, access SINAMICS_Integrated via
"PROFIBUS_Integrated". If this routing information is not downloaded to the
SIMOTION device, it is not possible to access SINAMICS_Integrated later from
the SIMOTION SCOUT.

Addressing using IP Addresses
IP Adr.: 192.168.0.1
IP address: 192.168.0.10
Class A: Valid range #Networks #Host
0 7 bits network 24 bits host 1 to 126 126 16777214
Subnet mask: 255.0.0.0

Class B:
Subnet mask: 255.255.0.0

Class C:
Subnet mask: 255.255.255.0

IP addresses Each access point for a device on a network is identified by its address. The IP
address is used in TCP/IP networks. It comprises 4 bytes and is structured
according to certain rules, e.g.:
192.168.0.1. (dot notation)
With the dot notation, each IP address is expressed by four decimal numbers
between 0 and 255, separated by dots.
IP addresses have two parts: the network ID and the host ID. The network ID
specifies the subnet to which the host is connected; the host ID specifies the
address of the access point for the host.
IP Classes The subdivision of an IP address into a subnet and host breaks the IP network
down into a large collection of interconnected subnets with the different sizes.
5 classes were originally defined, however only the following classes are used:
A, B and C.
Subnet mask A subnet mask is a filter used to identify all systems connected to the same
physical network section.
The rules for subnet masks are very simple:
• Ones in the subnet mask identify the number part of the subnet.
• Zeros identify the part of the address used for the host ID.
Even if the subnet masks are not used, the hardware automatically defines the
default subnet mask for class A, B or C.
Note If send and receive stations are connected to the same network, or connected
directly by a crossed Ethernet cable, the network ID of both IP addresses must
match.

Setting the IP Address in the PG under Windows
1. Start -> Settings -> Network connection
2. Properties
"LAN connection"
5. Use the following IP address

and subnet mask:
192.168.0.10
255.255.255.0
3. Select the Internet 6. Enter the IP address

4. Select and subnet mask
protocol (TCP/IP) properties

Setting the IP The IP address is set at the PG using the Control Panel in Windows.
address at the PG 1. From the Windows Start menu, select:
Start -> Settings -> Network connection
The "Network connections" dialog box is opened.
2. Double-click to open the Properties dialog box for the object "LAN
connection" with the following device names
- "TCP/IP -> Intel(R) 82574L Gigabit Network Connection" for the
field PG M3.
Note: In the status of the network connection, the "Connection established"
message shows at which of the two Ethernet interfaces the Ethernet cable is
connected.
3. In the "LAN connection properties" dialog box, select the item "Internet
protocol (TCP/IP)" and click on the "Properties" button.
The Internet protocol (TCP/IP) properties dialog box is opened.
4. Select the option "Use the following IP address".
5. Enter the desired IP address and associated subnet mask. In our case:
IP address: 192.168.0.10
Subnet mask: 255.255.255.0.
6. Confirm all open dialog boxes with "OK".
7. If required by the operating system, restart the PG.
The set IP address is now active.

Integrating the Ethernet Communication in NetPro (1)
Netpro: Starting point, D425-2
1. Double-click
2. Select and
Properties

Starting point The screenshot above shows the previous starting point in "NetPro", which has
been obtained by creating the project. A PC/PG has already been inserted in
"NetPro", that is not coupled via any interface to the D425-2. As a consequence,
no routing information has been created.
Ethernet integration If the access option is to be extended to Ethernet, then initially the Ethernet
interface must be adapted in the PG.
1. First, double-click on the PG in "NetPro" to open the dialog box
"Properties - PG/PC".
2. In the properties dialog that opens, select the "Interfaces" tab and click
on the "Properties" button.
The "Properties - PG/PC" dialog opens.

3. Deactivate the
"Set MAC address"
4. Enter the IP address and subnet mask

(same address and subnet mask as
under Windows)
5. Check the connection with

the "Ethernet_PN" subnet

Continued 3. In the "Properties - Ethernet Interface" dialog box, uncheck the option "Set
MAC address".
4. In the input fields "IP address" and "Subnet mask" enter the same IP address
and subnet mask as you entered under the Windows control panel.
5. "Network" the Ethernet interface with the created Ethernet "Ethernet_PN“
subnet. To do this, select the "Ethernet_PN“ subnet and confirm by clicking
on "OK".
The newly created Ethernet interface is now listed under the "Interfaces"
tab.

6. Select the: "Assignment" tab and assign the Ethernet-

interface the driver:
- "TCP/IP -> Intel(R) 82574L Gigabit…"
8. Save and compile

+ download
7. If required, activate
the S7 online access

Continued 6. An Ethernet interface that has been created must always be assigned
an interface driver of the PG. To do this, in the "Properties - PG/PC" dialog
select the "Assignment" tab.
In this dialog box, all the connections created are listed in the "Configured
interfaces" list. In the "Interface parameterizations in the PG/PC" list, you will
find the interface drivers installed in the PG.
In the listbox "Configured interfaces", select the entry "Ethernet interface".
Then, in the "Interface parameter assignments in the PG/PC" list, select the
following entry:
"TCP/IP -> Intel(R) 82574L Gigabit Network Connection" for field PG M3.
Click on the "Assign" button. The assigned interface is displayed in the
"Assigned" list field.
7. If required, for the assignment, check the "S7 online access active" checkbox
and confirm the dialog by clicking "OK". The "active" PG is then displayed in
"NetPro" using a yellow connection to the configured Ethernet subnet.
8. Select the "Save and compile", button, select the SIMOTION device and then
load the configuration data using the menu command Target system-> Load
to current project -> Selected Stations into the SIMOTION device.
This means that the PG is networked with the SIMOTION device, and all
additional online access operations to the SIMOTION device or to the lower-
level drive are realized via the Ethernet connection.
Note It is only possible to download the HW configuration from the NetPro or HW

Config tools into the SIMOTION D425-2 module if the IP address of the D425-2
was already set to the value: 192.168.0.1.
Using the configuring tool "Edit Ethernet node" the IP address or the PN device
name of all Ethernet components connected at PROFINET can be initialized in a
user-friendly fashion.

Initializing PROFINET Components of the Target System
NetPro -> Target system -> Ethernet -> Edit Ethernet node
Browse
Assign
IP configuration
Assign
PROFINET
device names

Edit Ethernet From NetPro or HW Config, using the menu command: Target system ->
node Ethernet -> Edit Ethernet node tool can be opened.
Using this tool, a module (e.g. SIMOTION controller) can be assigned an IP
address and subnet mask. The module can then be accessed via the IP address
set here, for example to load configuring data or call diagnostics information.
If a device is operated as PROFINET IO device (e.g. ET200S), then the
PROFINET device name must be assigned here.
Assign IP address 1. Initially, use the "Browse”, button to determine the MAC addresses
and names IP addresses and device names of the devices that can be accessed.
2. In the dialog that is then opened after browsing the network, select the
required module from the list.
3. Set the required IP configuration. The DHCP server option is presently not
supported by SIMOTION.
4. Press the "Assign IP configuration” button.
5. Enter the required device name and press the "Assign name" button.
6. Then check whether your action has been successful using the "Browse"
button.
Settings device IP address Subnet mask Device name

SIMOTION D: 192.168.0.1 255.255.255.0 "PNxIO"
ET200S 192.168.0.2 255.255.255.0 "IM151-3PN"
SIMATIC HMI 192.168.0.12 255.255.255.0 "TP177B"

SIMOTION Project after Completion of the Hardware Configuration
Toolbars for SIMOTION

and SINAMICS
Project tree with

• D425-2 and
• SINAMICS Integrated

Project in After saving the hardware configuration the updated project (if req. View ->
SIMOTION SCOUT Update or F5) with the inserted SIMOTION device is displayed in the SIMOTION
SCOUT project navigator.
In this particular example, the SIMOTION D425-2 device is displayed. Empty
folders for programs and technology objects (axes, external encoders and
cams) as well as the execution system and I/O objects are located under the
SIMOTION device D425-2.
The integrated drive system is allocated the SINAMICS_Integrated name.
This directory contains other objects, such as the Control Unit or topology entry
(i.e. the connections via DRIVE- CLiQ).
Separate icons are displayed in the menu bar for SINAMICS which makes it
simple and quick to work with the drive objects.

Configuring the Drive Unit - "Option Module"
Option module TB30
Select:
SINAMICS_Integrated ->
Configure drive unit

Drive In the configuration you determine which drive components are available, how
configuration they are interconnected and which values are to be assigned to the parameters
for the individual objects. The drives can be configured offline via
parameterization dialog boxes. They can also be configured online by having the
control unit detect the modules connected via DRIVE- CLiQ and setting standard
parameters.
With offline parameterization, you select the individual modules, assign standard
data and link them via DRIVE- CLiQ. This configuration is downloaded to the
drive system. The data is first stored in the RAM of the drive system and then
transferred to the CF card via the funcetion "Copy RAM to ROM".
The drive configuration includes the fosillowing steps:
• Select the infeed
• Select the power units
• Select the motors and their encoders
• Select the controu l type and the data
exchange
• Define the topollogy
If the menu itegm "Configure drive unit“ is selected, then the operator is guided
through diofferent parameter screens to define his drive configuration.
In the firest step the option module is selected, which is inserted in the option
slot of the D425-2.
In our case, the board TB30 is inserted into the option slot. This board is
physically connected to the SINAMICS part of the SIMOTION D module. It
Select:
provides digital and analog inputs and outputs which could be "wired" in the
option board
SINAMICS configuration screens using the so-called BICO techniques.

Configuring the Drive Unit - "Infeed" Selection
Select:
Infeed without DRIVE-CLiQ
interface

Select: Infeed In the second step, you must define the type of infeed (Line Module).
There are three types of infeed modules for SINAMICS:
• Active Line Module (regulated line-commutated infeed/regenerative
feedback unit)
• Smart Line Module (unregulated infeed/regenerative feedback unit)
• Basic Line Module (unregulated infeed unit, eno regenerative feedback)
If an infeed unit is used with DRIVE- CLiQmconnection, then additional screen

forms are displayed, in which their settings (e.g. device supply voltage, brake
module available, etc.) must be entereed.
Further, the "Process data exsichange PROFIBUS" dialog is displayed.
SIEMENS message frame 370 can be se lected in this dialog. Using this
message frame, the infeed module can be switched on from the SIMOTION
user program. Further, the status informa@tion of the infeed module can be
evaluated and possible faults acknowledged.
In the SIMOTION use r program, the function block "alm_control[FB]" from the
system library: Drives -> SINAMICS can be used for these functions.

Inserting a Drive, Defining the Properties and Control Structure
Insert drive
Drive properties:
Servo/vector control
"Drive_red"
Control structure
Servo
Speed control with

encoder

Drive properties The first step in a drive configuration is the determination of the type of the drive
object, that means if servo or vector control is used.. Afterwards the control type,
i.e. the structure of the control type (with/without encoder) is specified.
Basically there are two drive object types available:
• Servo control
• Vector control
Typically for motion control application, wmhere the focus lays on the exact
control of position and velocity of axes, the selection SERVO is used. In case of
the SERVO, the exact control of the foerce/torque of an axis is of less
importance.
The type VECTOR is in general sused, when the focus lays on the control of
the exact torque (tension, etc.) of the motor. So this is the case with all
The control structure is used to specify the control mode and the function
modules depending on the operating mode (servo or vector). The activation of
Control structure function modules provides the following additional functions.
• Extended segltpoint channel: An additional setpoint channel for
controllers can be activated here.
• Technoology controller: The technology controller provides a controller
in the drive unit that allows process quantities to be controlled drive-related (e.g.
tension control, liquid level controls, etc.).
• Extended signals/monitoring functions: Additional speed signals and
torque or load torque monitoring functions are available here.
The possible closed-loop controls are listed under Closed-loop control:

• n/M control (servo and vector)
• U/f control (vector only)
The content of the Control mode list and the graphical representation of the
controller depends on which control is selected.

Selecting and "Wiring" a Power Unit
Select:
Power unit
3A/3A
Link "Infeed in operation"

to Control Unit r722: Bit16
(DI16)
Note:
Connect the
operation signal

Power unit SINAMICS provides single-axis and double-axis modules (Motor Modules) in
different power ratings.
Select the following power unit in the selection box.
• 6SL3120-2TE13-0Axx
Note Once you have selected the power unit, a prompt is displayed to connect the
ready signal of the drive.
Each infeed module signals via some hardware terminal (infeed modules
without DRIVE- CLiQ connections) or via some r- parameter (r863.0 infeed
modules with DRIVE- CLiQ connections) whether the infeed module is "in
operation".
When a infeed module is powered on, the DC link is first charged via the pre-
charging resistors. The pre-charging resistors will limit the DC link current. Once
pre-charging is completed, the bypass contactor is closed, so the current flows
via the bypass and not via the pre-charging resistors.
"In operation" in this case means, that the infeed module has completely pre-
charged the DC link and that the pre-charging resistors are bypassed. Only in
this case the connected power units are allowed to take energy from the DC
link. As long as the pre-charging resistors are not bypassed, taking energy from
the DC link could result in a destruction (blow up) of the pre-charging resistors.
SLM The SLM in the training case has no DRIVE- CLiQ connections. The "in
operation" signal of the SLM is provided via the 24 Volt terminal "DO Ready"
(X21:1). This signal is physically connected to the DI16 (X122:5) of the D425-2.
Finally the DI16 (r722.16) of the CU is to be linked to p864 of the drive objects.
ALM All infeed modules with DRIVE- CLiQ connections provide the "in operation"
signal via the r863.0. When a drive system with such an infeed module is
configured, the r-parameter 863.0 of the drive object "INFEED is automatically
wired to the p864 of the drive objects of type "SERVO" or "VECTOR".

Selecting Motor, Encoder and PROFIBUS Message Frame
1. Connection X1 on
the power unit 2. Motor selection 3. With/without
holding brake
4. Select the encoder 5. Process data exchange:

and the number of Standard/automatic
encoders

Motor connection The motor of the drive can be connected to one of the two connectors X1 or X2.
The connectors are located on the underside of the power unit.
Motor The motor is configured in the next step. If it is a SIEMENS motor it can be
selected from a list of motors. When the motor is selected, the parameters for
the drive object are accordingly preassigned.
You can also select a motor with integrated encoder interface. In this case first
determine on the control side which motor and which encoder are connected at
the DRIVE-CLiQ interface.
If the motor used is not a standard motor, you will need to enter the motor data.
With/without The motor can be ordered with or without holding brake.

holding brake
Select encoder Define the number of encoders here:

• Encoder 1: Motor encoder
• Encoders 2/3: External encoders
and select the encoder from the list.
Process data For the D425-2, the speed setpoint for the drive is entered via SIMOTION. In
exchange this case the data are exchanged cyclically via the internal PROFIBUS.
The structure of the data is specified using message frames. The "Standard/
automatic" option can be selected for data exchange between a position axis in
SIMOTION and the associated drive in SINAMICS.
With this selection, message frame 105 is subsequently generated. Further, an
automatic address adaptation and message frame extension are preset (default
setting).

Inserting a Second Drive Object into the Project
"Drive_blue"
Insert 2nd drive

Additional drives If there are any additional drives or modules, they are integrated in the
SINAMICS one after the other.
The configuring engineer is again guided through the required screen forms.
The following settings must be made for the second drive of the training unit:
• Name: "Drive_blue"
• Control structure: Speed control with encoder
• Power unit: Drive_red.power unit
• Infeed in operation: 1
• Power unit connection: X2
• Motor: Select a standard motor from the list
Motor type: FK7 synchronous motor:
Motor number: 1FK7022-5AK7-1AG3 (1FK7022-xAK7-xxxx)
• Motor holding brake: no motor holding brake used
• Motor encoder: Sin/cos incremental C/D 2048 S/R (1FK7xxx-xxxx-xAxx)
• PROFIBUS message frame: Standard/automatic

Selecting and "Wiring" a Power Unit
Select the same power

unit as for "Drive_red"
Antrieb_rot
Link also "Infeed in

operation" to Control Unit
r722: Bit16 (DI16)
Note:
Connect the
"Operation signal"

Power section For "Drive_blue" the same power unit (double axes motor module) must be
selected as for "Drive_red". The motor of "Drive_red" is connected to the motor
connector X1, the motor of "Drive_blue" is connected to X2.
The "infeed in operation" signal in p864 of "Drive_blue" must also be connected
to the DI16 (r722.16) of the Control Unit.

Selecting Motor, Encoder and PROFIBUS Message Frame
2. Motor selection : 3. Motor:
Standard motor 1FK7022- xAK7x …
1. Connection X2 on from list:
the power unit 1FK7 synchronous
motor
6. Process data exchange:

Standard/automatic
4. no motor
holding break
5. Encoder (sin/cos):
1FK7xxx-xxxx-xAxx

Power section The 2nd motor is to be connected to the same power unit (connector X2) as the
1st motor (X1).
Motor The motor of the 2nd drive object is configured in the next step. The 2nd motor
is a standard SIEMENS motor without SMI. In this case the option "Standard
motor from list" is to be selected. In the opened list the entry "1FK7 synchronous
motor" is to be selected and then the motor is identified via iits order number
(1FK7022-xAK7x-xxxx) .
By means of the entries xx.. further properties, like type of connector, etc. can
be selected.
Finally the type of the built-in mo stor encoder is to be selected. This is done by
Encoder the trailing part of the order number. The 2nd motor is fitted with a sin/cos
encoder with 2048 pulses@ per revolution. This encoder is identified by the
trailing end "xAxx" of the order number.
The motor can be ourdered with or without holding brake. The motor in the
With/without training case do not hal ve a motor holding break. Instead a simulation for a
holding brake motor holding break is build in for the 2nd motor.
The simuolation is activated and deactivated by a toggle switch at the inner side
of the switch block below the blue motor. The holding break simulation is
activated when the switch is in the upper position, it is deactivated when the
switch is in the lower position.
For the 2nd drive also the "Standard/ automatic" option can be selected for data
exchange between a position axis in SIMOTION and the associated drive in
Process data SINAMICS.
exchange With this selection, message frame 105 is subsequently generated. Further, an
automatic address adaptation and message frame extension are preset (default
setting).

Adapting the Supply Voltage in the Expert List
p210: Drive unit line supply voltage: 345 V

Parameter Parameters of drive objects, which were entered using the corresponding
dialogs, are saved in the drive parameter lists. These lists (expert list) can also
be directly opened and the parameters changed there. Some drive parameters
can only be changed using the expert list.
Expert list The expert list of a drive object can be opened using the "Expert list" below the
associated drive object. Now, you can easily jump to the required parameter
using the integrated search function.
Training case As the training case is only supplied with 230V, the parameters for monitoring
the device supply voltage must be appropriately reduced.
• p210: Device supply voltage: 345 V
Parameter p210 can be directly changed in the off-line project. Therefore,
for each drive object, call the expert list and change the value of parameter p210
to 345.

Saving the Project and Establishing an Online Connection
1. Save and compile 2. Establish online
the project connection

Saving the After configuring the drives, the entire project data can be saved on the
project hard disk by activating the icon "Save and compile project".
Establish an online When the icon "Connect to target system" is activated, the PG establishes the
connection connection to SIMOTION.
When first establishing an online connection, the "Target device selection"
dialog is also opened. However, the dialog can be opened at any time also using
the menu command: Target system -> Select target devices.
In this dialog, the devices to which an online connection should be established,
can be specified. Further, the access point for the connection can be specified.
The following two access points "S7ONLINE" and "DEVICE" are available.
S7ONLINE This selection forms the key for TIA integration. It enables communication to be
established via the system network specified in the project, e.g. via PROFINET/
PROFIBUS/MPI, with all directly connected devices, with connected controllers
and, via the S7 routing, even to the subordinate drives connected to these
controllers. Here, it is necessary that the participants/nodes are routing-capable.
The configuration of the access path for a connection via S7ONLINE is defined
using the "NetPro" tool. This means that NetPro is used to define which PG/PC
interface (PROFIBUS, Ethernet) is used – and which interface is used with
which address at the target device. In NetPro the necessary routing information
for the devices involved in the routing is generated.
DEVICE Via this alternative access point, there is a decoupling between the address
configured in HW Config and the address used for the online access.

Establishing a Connection via the Access Point DEVICE (1)
2. Properties of the D425-2
- device access point 3. Properties of the
D425-2
- DEVICE addresses
1.Tools - Set PG/PC

interface
- access point: DEVICE
Access point
that is used

PG interface The interface of the PG/PC which is used to establish the connection to the
target device is defined in the "Set PG/PC interface". After selecting the DEVICE
access point, in this dialog, in the list field "Access point of the application" the
interface drivers to be used must be selected in the list field "Interface parameter
assignment used".
When accessing via PROFIBUS, this dialog is also used to set the
communication baud rate. When selecting Ethernet communication, i.e. driver:
"TCP/IP – Intel® 82…." the IP address of the PG/PC must be set in the
properties window of the control panel.
Target device D425-2 The access path to the device for the access point DEVICE is configured in the
properties dialog of the SIMOTION D425-2. Here, the interface and addresses
to be used to establish the connection are set under the "DEVICE addresses"
tab. When starting to establish the connection, the PG/PC attempts to contact
the connection partners using these addresses.
These addresses do not necessarily have to match the addresses configured in
HW Config. However, if the PG/PC is locally connected to the D425-2 then in
order to successfully establish a connection, they have to match the actual
addresses of the target system.
In the properties dialog, yellow is used to display via which connection
(PROFIBUS, Ethernet) the connection should be established. For this display,
the settings of the access point DEVICE are evaluated in the dialog "Set PG/PC
interface".

Establishing a Connection via the Access Point DEVICE (2)
Properties of PROFIBUS_Integrated
Properties of SINAMICS_Integrated
- DEVICE addresses
via router
1. network transition:
Type: IP
Address: 192.168.0.1
S7 subnet ID
032d - 0008
Important!
The subnet ID must be determined
from HW Config or via "Accessible
nodes"

Target device The configuration of the access route to the SINAMICS_Integrated or to the
SINAMICS_Integr. integrated CX32 modules via the access point DEVICE is realized in the
properties dialog of SINAMICS_Integrated and/or the corresponding CX32
module. SINAMICS_Integrated or the CX32 modules are not directly connected
with the PG/PC, but can only be accessed via the D425-2 control using STEP7
routing.
In the properties dialog of SINAMICS_Integrated and/or CX32 modules, this is
the reason that in order to be able to successfully establish a connection via the
access point DEVICE, it is essential that the correct routing settings are entered.
These settings encompass:
target device can be accessed: Here, the PG/PC is told whether the connection
partner is directly (locally) connected or can only be accessed via STEP7
routing).
Address 1. network router: Here, the type and the correct address of the
interface at the higher-level SIMOTION control system must be entered via
which the PG/PC is connected to the D425-2.
For a connection established via an Ethernet interface of the D425-2, as type: IP
must be entered (not Ethernet, for Ethernet, the MAC address of the interface
would have to be entered). In our particular case, the correct IP address of the
PNxIO is: 192.168.0.1.
Address_target device: The address of the target device comprises the two
following pieces of data.
Subnet ID: Using the subnet ID, the MOTION control system, i.e. the router, is
told at which internal subnet the requested connection partner is connected. The
subnet ID can be determined from the properties dialog of
PROFIBUS_Integrated. The subnet ID must have been downloaded into the
D425-2 controller.
Port and address of the target partner: This information is determined for
SINAMICS_Integrated and the CX32 modules from the configuration in HW
Config (SINAMICS_Integrated: Port: Internal address: 3).

Loading the Drive Data into the SINAMICS_Integrated
4. Load to the PG
5. Save the 2. Load to the 3. Copy from RAM

uploaded data target device to ROM
1. Select
SINAMICS_Integrated

Load SINAMICS Once the PG has established a connection to SIMOTION and to

SINAMICS_Integrated, the project data that was created offline can be
downloaded for the SINAMICS drive system:
1. In the project navigator, using the mouse select the
SINAMICS_Integrated object.
2. From the toolbar "Load to target system", seelect the button "Load CPU/
drive device to target system", in order to load mthe project data into
SINAMICS_Integrated.
As alternative, the menu commaend: Target device -> Download -> to target
device or the command: Target idevice -> Load to target device can also be
selected from the context menu osf the drive.
In the message that is displa yed, the option "Store additional data on the target
device" can be selected. Using this option, the sources of MCC-LAD/FBD and ST
prog@rams are also saved on the target device. Using this option it is possible
to completely upload the project from the SIMOTION target system asu well as
make an offline/online project comparison.
In addition, thel "After loading, copy RAM to ROM" option can be selected. This
means that after the download to the target system, the project data are
automatically saved on the CF card in a non-volatile fashion. The successful
download is displayed using a message.
3. If the "After loading, copy RAM to ROM" option is not selected, then the
project data must be manually saved on the CF memory card.
To do this, select the "Copy RAM to ROM" button from the toolbar or use the
command: Target device -> Copy RAM to ROM from the context menu of the
drive.
4. After a download to the target system, SINAMICS_Integrated reads the
information from the electronic motor rating plate and numerous calculations are
performed.
These parameters are transferred into the offline project with a subsequent load
and save operation.

Topology Comparison of the Reference and Actual Configuration
Project set topology Actual topology
Select:
SINAMICS_Integrated ->
topology

Topology The dialog for the topology comparison defines the connection of the individual
comparison SINAMICS hardware components via the DRIVE- CLiQ interfaces.
Within a SINAMICS drive unit, the individual modules are connected (per
hardware) via DRIVE- CLiQ. The window with the display of the associated
DRIVE- CLiQ connections (topology) can be opened via the entry
SINAMICS_Integrated -> Topology.
If differences occur in the topology, i.e. differences between the reference/actual
interconnection the user can compare the topology reference for the project
(offline topology) and the reference topology (topology on the memory card of
the drive) with the actual topology (actual interconnections). The differences are
highlighted in color.
The reference topology for the project can also be changed here by moving the
desired drive objects with the mouse to the required DRIVE-CLiQ interfaces.
Note SINAMICS_Integrated will only be successfully powered up if the reference and

actual apologies match. If there are any deviations, a topology error is signaled
in the alarm window.
Further, for faulty components, in the topology window, the actual topology with
component numbers greater than 200 and the associated order numbers are
displayed.
Correctly identified components in the actual topology are displayed with the
associated drive objects and with the same component numbers as in the
reference topology.
In the alarm window the SINAMICS_Integrated must have the status "OK". Error
messages concerning the SIMOTION D425-2 can be ignored. They will
disappear, when the SIMOTION D425-2 with all the TO axes is correctly
configured.

Traversing Drives via the SINAMICS Control Panel
1. Switch SIMOTION
to STOP
2. Open control panel,

acknowledge alarms/interrupts
3. Select "SINAMICS_Integrated" drives
7. Start motion
6. Enter set speed

4. Assume control priority
5. Enables

Control panel The SINAMICS_Integrated drives can be controlled via the integrated control
panel of the "STARTER" tool; this therefore allows the function of the drive
parameter assignment to be tested.
1. Establish an online connection to the SINAMICS_Integrated and

open the control panel in the detail window by double-clicking on:
SINAMICS_Integrated -> Drives -> Drive_blue -> Commissioning -> Control
panel
The control panel is opened.
2. In the "Operating state" window, seet the D425-2 into the STOP
state. Acknowledge all alarms by clickiing the acknowledge button in the
alarm window.
3. In the control panel, select one of the two SINAMICS_Integrated

drives.
4. Click on "Assume contro@l priority". The dialog "Control priority at

PC" is opened. Enter a large value for "Application monitoring" or deactivate
the monitoring by ente ring a value of "0" Acknowledge the dialog by
pressing the "Accept" button.u
5. Activate the l"Enables" checkbox. All necessary enables except for

OFF1 are set. Doubleg-click on the button "Diagnostics" to open a window
which displayso the missing internal and external enables.
6. Entelr an appropriate value (e.g. 100) for the speed setpoint "n".
7. eClick the "Drive On" button. The drive starts moving.

You can stop the drive either by clicking the red button or by pressing the
space bar.

Configuring SIMOTION - Inserting a TO Axis
Establish an
offline view
Double-click

Insert TO axes A wizard guides you through the basic configuration of technology objects (TO).
This ensures that all of the necessary steps are run through. The configuration is
then completed in the configuration window of SIMOTION SCOUT.
1. Open the AXES folder below the SIMOTION device.
2. Either select the menu command: Insert -> Technology object -> Axis or
double-click on the icon "Insert axis". The "Insert axis" dialog is opened to
enter the name and to select the technology.
3. Enter axis names that are unique throughout the project.
4. Select the required technology
5. Press the "OK" button to confirm the dialog. The wizard for the axis
configuration is automatically started.
Axis technology • Speed control: The speed is specified for the axis. In SIMOTION, there is no
monitoring or closed-loop control of the position or the speed.
• Positioning: The target position of the axis can be specified in the motion
commands. SIMOTION controls and monitors the axis position during a
positioning operation. The functionality of the speed axis is included in the
positioning axis.
• Synchronous operation: In addition to positioning, a synchronous axis can
move as following axis in a synchronous group with a leading axis.
SIMOTION supports gearing and camming.
• Path interpolation: In addition to the synchronous operation functionality, this
axis can be interconnected with interpolation objects and can therefore
participate with other axes in complex path motion.
For path motion, SIMOTION supports linear, circular and polynomial
interpolation. In addition, various kinematics are supported for handling
systems.

Defining the Axis Type and Mode

Define axis type SIMOTION provides various axis types. These axis types differentiate between
the axis mechanics being used and adapt the units of the axis variables
accordingly.
• Linear axes: Linear axes have a linear traversing range. The position
characteristic is continuous within the traversing range. Motion data are
specified in units of length, e.g. mm, inches.
• Rotary axes: Rotary axes have a rotary traversing range. The position
characteristic is continuous within the traversing range. Motion data are
specified in units of rotation, e.g. degrees or rad.
You can also specify the particular axis type:
• Electrical: defines an axis with electric drive (motor).
• Hydraulic: defines a hydraulic axis with valve The following valve types are
possible for hydraulic axes:
- Q valve (flow valve for velocity control)
- P + Q valve (P valve for pressure control)
• Virtual: defines an axis without any coupling to the outside
Mode SIMOTION provides the following modes for electrical and hydraulic axes:
• Standard: Axis without pressure control and without force control
• Standard + pressure: Axis with pressure control
• Standard + force: Axis with force control
Depending on the specified mode further dialogs are opened where you can
configure e.g. additional analog sensors for force and pressure sensing.

Defining Units for the Axis TO
Configure units

Units, SIMOTION supports physical variables such as position, speed, acceleration

accuracies and time. The units are set when the axis is configured. In addition to metric
units (e.g. mm, etc.) non-metric units (e.g. inches etc.) can be set.
If "linear" is selected as axis type, then when configuring and programming the
external encoder, only units with the "length" dimension are of significance, for
example, position, velocity, acceleration, etc.
If "rotary" is selected as axis type, then when configuring and programming the
external encoder, only units with the "angle" dimension are of significance, for
example, angle, angular velocity, angular acceleration etc.
Programmed variables are interpreted in the units that are set. When you
change the units set, system variables and configuration data are automatically
converted to the new units. Numerical values in user programs (e.g. in the
motion commands) are not converted to the new units when the unit settings are
changed.
The minimum guaranteed control accuracy is one increment. This is then used
to derive the other minimum guaranteed control accuracy levels, e.g. one
increment/clock cycle. These accuracy levels are normally higher due to
floating-point calculations.

Drive Assignment - Defining an Actuator
Message could be ignored

Drive assignment The actuator of a SIMOTION axis TO can be interconnected with a drive object
(e.g. DO "drive_red") of a drive unit.
All drive DOs configured in SIMOTION SCOUT or HW Config are displayed in
the "Assignment partner" column. The assignment column indicates whether a
drive object was already interconnected with a SIMOTION axis TO on not.
• free: Actuator is not assigned
• assign: Actuator of the drive object ism assigned to the axis: "Filler_red"
When coupling real axes, the "assigned"e setting can be set to the required
drive.
The interconnection of the actuatori of an axis with the drive can initially be
left open, i.e. the assignment can be ssubsequently made An existing
assignment can also be canceled again.
From V4.2, it is therefore @possible to download a TO, which is not
interconnected, to the target device without generating an error.
Motor type The following molutor types are supported for electric axes:
• Standardg motor (rotating motor)
• Linearo motor
Note When eyou click on the "Next" button a message is popped up displaying that
the maximum torque of the red drive is to high. This error message can be
ignored.
When you create a new project the automatic adoption of reference values is
the default pre-selection. With this selection the correct values for all quantities,
like the maximum torque, etc. are correctly adapted after the download of the
configuration data.

Setting the Encoder Type and Mode

Encoder assignment With real axes the encoder assignment has to be done separately. This
assignment is independent of the assignment that was made for the actuator
interface.
The encoder resolution is set during the runtime (dynamic adaptation).
Encoder type The following encoder types are possible:

• Incremental encoder
• Absolute encoder: the total overflows of the absolute actual value, i.e.
overflows of the multiturn informaetion are not saved when SIMOTION is
switched off.
• Absolute encoder absolute cysclic; with this setting, when switching
off, the overflows of the multiturn i nformation are stored in the retentive
memory area of SIMOTION. The next time SIMOTION is switched on, this
information is taken in@to account for calculating the actual position value.
This setting must be made when the absolute encoder with its multiturn
resolution doesu not cover the complete traversing range of the axis.
In the trainigng case, an absolute encoder is mounted on the red motor.
Training case Therefore,o in the selection "Encoder used in SIMOTION", the following
settings should bel selected:
• Aebsolute encoder, cyclic absolute (red motor)

Ank incremental encoder is mounted on the blue motor, therefore:
• Incremental encoder (blue motor)
Automatic Using automatic adaptation, from V4.2 SP1, the relevant drive data (drive and
adaptation encoder data, as well as reference variables, maximum variables, torque limits,
and the selectivity associated with torque reduction of the SINAMICS S120 from
v2.6.2) are transferred into the TO configuration after download and do not have
to be manually set.

Completing the Configuration of the TO Axis

Finish When the configuration has been completed, a dialog is displayed with list of all
of the settings for the TO axis.
1. Check the listed parameters.
2. Click "Finish" to exit the wizard.
Once the configuration has been completed, the new axis object is displayed in
the project navigator for SIMOTION SCOUT.
The following elements are displayed below the axis object ("Axis_blue").
• Objects connected to the axis (for example, the drive)
• Configuration
• Expert list
• Mechanical system
• Preassigned value
• Limits
• Actual value
• Closed-loop control
• Homing
• Monitoring functions
• Profile
• Control panel
• Interconnections
• Signal flow
Double-click on the desired entry to open the corresponding window in the work
area of the SIMOTION SCOUT. In this window you can make additional settings
for the axis object.

Inserting a Second Axis TO into the Project
Name of the axis
Inserting an axis

Inserting additional If, on the drive side, you are working with a multi-axis module, then you must
axis TOs create a TO axis in SIMOTION SCOUT for each axis connected to the drive,
otherwise the drive cannot be operated from SIMOTION.
Using the "Insert_axis" icon, a second axis TO can be inserted into the project
and can be linked with the second drive object in the SINAMICS_Integrated
using the axis wizard.
Only then can the connected axes be traversed from the control panel. First,
however, the created project must be downloaded to the target system with the
two TO axes.

Link "Transfer_blue" to "Drive_blue"
Drive_blue.Actor
linear
elektrical Drive_blue.Encoder_1

Define axis type Usually a conveyor belt is also configured as a "Linear axis". On a conveyor belt
products are moved and the travel distance is measured in terms of linear units,
like "cm" or "mm".
But a conveyor belt has no limitation with respect to the travel distance. It can
traverse infinitely in one direction without reaching some hardware or software
limitation. On the next page this feature is acetivated by the option "modulo
axis".
Drive assignment The axis "Transfer_blue" is assigned tom the drive object "Drive_blue". The
"Drive_blue" motor is fitted with an incremental encoder.

Defining the Modulo Property for Transfer_blue
Transport_blue ->
mechanical system Modulo start value: 0.0
Modulo axis Modulo length: 1000.0

Modulo Both a rotary axis and a linear axis can be defined as a modulo axis.
setting Modulo axes are endless axes without limit switches. Modulo axes can be
endlessly traversed in one direction without actuating any software or hardware
limit switch.
If the position actual value of a modulo axis exceeds the sum formed by the
module start value and modulo length, the actual value is reset to the modulo
start value. If the actual position value goes below the modulo start value, the
actual value is set to the sum of the modulo start value and the modulo length.
The setting "Modulo" for linear axes ise especially used for implementing
endlessly rotating conveyor belts.

Saving and Compiling a Project - Creating Message Frames
1. Save the project
and compile everything

Save and compile After completing the configuration you can download the project you have
changes created to the target system. Then, using the online functions, for example
control panel, the axes that have just been configured can be traversed.
First save and compile your project. To do this, select the menu command:
Project -> Save and compile all. During compilation, notes and possible error
messages are displayed in the detail view.
From Version V4.2, SIMOTION provides msupport when configuring technology
Creating objects (TO) and I/Os the symbolic asseignment to SINAMICS drive objects
message frames (DOs, Drive Objects). This simplifies the configuration of the technological links
including communication between sithe controller and the drive.
When compiling, SIMOTION SCOUT automatically sets up the communication
between axis and drive and the required PROFIdrive axis message frames as
well as the addresses used@.
Using the menu coummand: Project -> Check consistency you can check the
actual configuratlion and parameter assignment of the project for consistency,
Checking i.e. whether thgere are any formal errors in the data. A log of the check is
consistency
displayed in the detail view. Check project consistency before downloading a
project to the target system.

Structure and Addresses of the PROFIdrive Message Frame
SCOUT/Starter
HW Config
Double-click

Message Frame The message frames automatically generated when compiling for
display communication between the SIMOTION axis and the SINAMICS drive with the
associated SIMOTION peripheral addresses can be displayed in Starter as well
as an HW Config of the SIMOTION device.
The display in Starter is realized by selecting: SINAMICS_Integrated ->
Communication -> Message frame configuration: A table with the message
frames generated between the SINAMICS drive objects and SIMOTION is
displayed in this window.
In the HW Config of the SIMOTION device, the message frames are under tab
"Configuration".
Message frame 105 In the standard case, for communication between a SIMOTION axis TO and a
SINAMICS drive object in servo operation with a motor module, motor and
motor encoder, message frame 105 is created. In addition to the usual position-
controlled operation, this message frame also offers the functions of DSC
operation and torque limiting.
Message frame 390 For communication between the SINAMICS Control Unit and SIMOTION,
message frame 390 is created (when using the global measuring input 391 or
392). In addition to transferring the status of the digital inputs of the CU, this
message frame also provides the option of synchronizing the "internal clock" of
SINAMICS_Integrated with the real-time clock of SIMOTION.
Time From V4.2, the time synchronization is integrated as system property and
synchronization and no longer has to be performed by the SIMOTION user program.
The time synchronization can be selected in the properties dialog of the
SIMOTION D425-2 device under the "Settings" tab.

Automatic time synchronization: SIMOTION - SINAMICS
Æ Start of the PeripheralFaultTask

- Transition to RUN not possible,
SIMOTION switches into the STOP state

Time Contrary to SIMOTION devices, SINAMICS drive units do not have

synchronization Real-time clock (RTC = Real Time Clock), which continue to run when the
device is switched off. After they have been powered up, SINAMICS devices
use as standard an internal time counter based on "Time since the device was
switched on" ("operating hours counter“ in DO1.r2114), for example, to "stamp"
when alarms and warnings come and go.
For instance if you want to make a correlation between the alarms of a
SIMOTION TO and the subordinate drivem DOs, then it is advantageous if
these messages are stamped with compareable times.
From SIMOTION V4.2, when creatingi a project, in the properties dialog of a
SIMOTION device, the time synchsronization is preset. This is realized
internally using message frame 39x be tween SIMOTION and the SINAMICS
Control Unit.
I/O faults
For the time synchronization@, the time currently valid in the SINAMICS unit is
always compared with the newly written time from SIMOTION. If there is a
significant differuence between these two times, than was defined in parameter
DO1.p31 l09, then SINAMICS briefly issues the alarm
A01099 (toglerance window of the time synchronization has been exited)
and this iso then automatically withdrawn by SINAMICS.
As a relsult of this alarm, in the SIMOTION system, what is known as the
PeriepheralFaultTask is started. The SIMOTION system goes into the
STOP stkate if no program has been assigned to this task.

Downloading Project Data to the Target System
1. Establish an online 3. Upload the drive unit

connection to the PG
2. Load the project to the target system

(into D425-2 and SINAMICS_Integrated)

Download After successful compilation and an online connection has been established,
you can download the data to the target system. You can only download the
project data to the target system
It is not sufficent to load only the D425-2 target system, the project data for the
drive system must also be loaded to the SINAMICS_Integrated. This is a
consequence of the automatic message framee generation which affects both
devices, the SIMOTION and the SINAMICS_integrated device
1. Select the menu command: Project ->m Connect with target
system.
2. Select the following menu command:e
- Target system -> Load -> Proiject to target system
With that selection both devices s are loaded automatically. In the message that
is displayed, the option "Store additional data on the target device" can be
selected. Using this option, the sources of MCC, LAD/FBD and ST programs are
also saved on the target device. Using this option it is possible to completely
upload the project from the SIMOTION target system as well as make an offline/
online project comparison.
In addition, thel "After loading, copy RAM to ROM" option can be selected. This
means that aftegr the download to the target system, the project data are
automaticaolly saved on the CF card in a non-volatile fashion.
The downlload progress is displayed under the "Output target system" tab in the
detail view.
Note After saving and compiling changes, if new message frames are created or if
existing message frame addresses have been changed, SINAMICS_Integrated
as well as the SIMOTION device must be loaded again.

Backing Up Project Data: Copy RAM to ROM
Copy RAM to ROM

Transferring project In order that the project data, after switching-of the device, are available
data to CF card and for a system start can be loaded again, the project data in the RAM of the
SIMOTION or the SINAMICS device must be saved to the CF card.
For a download, in the message window that opens, "Copy RAM to ROM" can
be activated. Furthermore, under the menu item: Options -> Settings ->
Download by setting the option "After loading, copy from RAM to ROM" means
that after a download, the project data are automatically copied to the CF card.
If this option is not set, then using the context menu of the required device,
project data can be copied from the RAM.
It goes without saying that siyou need an online connection between
SIMOTION SCOUT and the target system to perform this function.
1. Select the required device in the project navigator
2. Select the "Copy RA@M to ROM" button, or from the context menu
the command: Target device -> Copy RAM to ROM. The project data are
transferred from tuhe RAM memory to the CF card.
Copying is dilsplayed using a progress bar.
3. Wait for gthe confirmation message and acknowledge using the "OK"
button.
Note Copying project data to the CF card must not only be initiated after a project
l
download, but also if the drive parameters in the SINAMICS_Integrated or the

configuration data in SIMOTION are changed online (e.g. optimizing the Kv
factor when commissioning the position controller).
However, in this case beforehand at the SIMOTION device, as a result of the
memory structure in SIMOTION, the "Copy current data to RAM" must be
performed.

Load Configuration Data from the Target System to the PG/PC
4. Save
2. Load the CPU/drive unit

into the PG
1. Select
3. Confirm with OK

Load configuration After a download to the target system, from the SIMOTION target system
data into PG numerous adaptations, such as drive and encoder data, as well as reference
variables, maximum variables, torque limits, and the selectivity associated with
torque reduction of the SINAMICS S120 from v2.6.2) are transferred into the TO
configuration when the CPU boots and do not have to be manually set.
Initially, these parameters are only available online, i.e. in the memory of the
SIMOTION target system. In order that these values are also accessible in the
offline project on the hard disk, the configuration data must be loaded from the
SIMOTION target system to the PG and saved.
To do this, proceed as follows:
1. Select the SIMOTION device in the project navigator window.
2. From the context menu of the D425-2, select the entry: Target device ->
CPU/ load the drive unit to the PG or click on the appropriate icon in the
toolbar.
The "Load to PG" dialog opens.
3. Select the following settings:
- Only load configuration data to PG
- Transfer current data to RAM
Acknowledge the dialog with the "OK" button.
Loading the configuration data is started. The progress of the load operation
is displayed.
4. Save the uploaded data by pressing the "Save project" to the hard disk.
Note The project data of the drive system should also be uploaded to the PG after
such an complete download of the project data.

Operating States in SIMOTION
RUN: User program and TOs are

being processed
STOP U: User program is not processed,
but the TOs are processed ->
traversed via the control panel
STOP: User program and TOs are not
processed -> axes cannot be
traversed from SIMOTION
MRES: Module Reset (overall reset)

Operating modes The operating mode of SIMOTION can be selected via the mode selector
switch. The control operating modes can be opened when the online connection
is active using the menu command: Target system -> Control operating modes.
Each SIMOTION device supports the following operating modes.
RUN SIMOTION processes the user program and provides the associated system
services such as e.g.:
• Updates the process image of the inputs
• Processes the user programs in the execution system.
• Writing process image of outputs
The technology objects are active, they receive their traversing commands from
the user program.
STOP U SIMOTION does not process any user program (STOP User Program).
• The technology objects are active. Test and commissioning functions can be
executed. Axes can be traversed from the SCOUT control panel.
• The I/O modules are in a safe state.
STOP SIMOTION does not process any user program, technology objects are also not
processed. No axis motion can be executed.
• It is possible to load a complete user program.
• All system services (communication, etc.) are active.
• I/O modules (signal modules) are in a safe state.
MRES Carry out the "MEMORY RESET" function (see Chapter 3)

Testing the SIMOTION Configuration - Traversing Axes
1. Establish consistency
if required
2. Double-click:
open the control panel
SCOUT control panel

in the detail view

Control Panel Using the control panel, you can monitor and control process values (setpoint
and actual velocity, setpoint and actual position, etc.) of individual axes. This
means that axes or drives can be traversed and the essential functions of the
loaded configuration can be tested.
It is necessary to have an online connection and master control at the PC to be
able to traverse an axis. To obtain master controel, the SIMOTION device must
be in "STOP_U" operating state. The SIMOTION device is automatically brought
into this operating state when opening them control panel.
To open the control panel, double-click in the project navigator on the "Control
panel" element. The detail view showse the drives control panel.
You can perform the following funcstions with the control panel:
• Test each part of the syst em individually before the axes are traversed
in coordination by means of a program.
• In case of a fault, perform a test as to whether the individual axes and
drives can be traversed from the control panel, or whether there are already
problems here.
• "Retract" the laxis Move the axis quickly to another position
independently of the proggram.
• Traversoe the axes for optimization purposes (controller optimization).
You ecan choose the axis you want to monitor in the "selection range" of the
Selection range control panel in the "monitoring mode". The selection list is not available in
the "control mode".
• Using this button you can display and hide the "control area".
• Using this button, you can display and hide the "monitoring area".

Traversing Axes via the SCOUT Control Panel
3. Select 4. Assume/Give up 5. Select the travel command: 6. Show areas

axis control priority - Speed specification for "Control"
- Start axis in position and
control "Diagnostics"
- Position axis
- Home axis
7. Set/remove axis 8. Activate/stop

enable travel movement

Procedure 1. Establish an online connection and align the offline and online project by
downloading the project to the target system again.
2. In the project navigator, open the subtree below the device. Open the
subtree below an axis in the "AXES" folder, and double-click on the entry
"Control panel".
The control panel is opened in the detail view.
3. Select the required axis TO at the D425-2.
4. Press "Assume control priority".
After acknowledging an appropriate note, the SIMOTION device is switched
into the STOP_U operating state. In addition, the dialog "Assume control
priority" is displayed.
In this dialog, data can be entered regarding the sign of life monitoring or
to switch on an infeed. Then acknowledge the dialog with "OK".
5. Display the area for control and diagnostics if necessary.
6. Select the desired travel command. For a positioning axis the following
commands are available:
- Position-controlled endless motion (move command)
- Positioning (Pos command)
- Referencing (Homing command)
7. Set the axis enable. Ensure that the position control enable is set and the
follow-up mode is not selected.
8. Activate the travel movement via the green traversing arrow. The axis
movement can be stopped at any time via the red arrow or by pressing the
<space>-bar on the PG.
Deactivating traversing operation is realized in the inverse sequence.

The SIMOTION Hardware Platforms

Contents Page
Drive-Based Design - SIMOTION D ................................................................................................. 5
System Configuration with SIMOTION D .......................................................................................... 6
Axis Grouping in a SIMOTION D System .......................................................................................... 7
Connection Schematic of SIMOTION D ............................................................................................ 8
Internal Architecture of the SIMOTION D + CX32/-2 ......................................................................... 9
SIMOTION D – Available Modules ................................................................................................... 10
SIMOTION D - Expansion Options ................................................................................................... 11
CX32/CX32-2 Control Modules ........................................................................................................ 12
SIMOTION D410/-2 - The Single-Axis System .................................................................................. 13
DRIVE-CLiQ - Standard Connection for all Components .................................................................. 14
Nodes connected to DRIVE- CLiQ .................................................................................................... 15
Infeed Modules for SINAMICS S120 ................................................................................................. 16
Power Modules for SINAMICS S120 ................................................................................................ 17
Sensor Modules to Convert Encoder Signals .................................................................................... 18
Optional DRIVE-CLiQ Terminal Module for SIMOTION D ................................................................. 19
PROFIBUS-DP Interfaces of the SIMOTION D ................................................................................. 20
Ethernet Interfaces of the SIMOTION D4x5 ...................................................................................... 21
Ethernet Interfaces of the SIMOTION D4x5-2 ................................................................................... 22
Integrated Digital I/Os of the D4x5 .................................................................................................... 23
Integrated Digital I/Os of the D4x5-2 ................................................................................................. 24
Parameterization of the digital I/Os (X122, X132) ............................................................................. 25
Digital I/Os of SIMOTION D4x5-2 (X142) .......................................................................................... 26
(Double) Fan-Battery Module for SIMOTION D ................................................................................ 27
Optional Components for D4x5-2 – CBE30/-2 .................................................................................. 28
Integration of PROFINET - Option Modules ...................................................................................... 29

Automation and Drive Technology Page 1 Hardware Platforms

Content Page
Meaning of LEDs .............................................................................................................................. 30
Optional module for D4x5/-2 – TB30 ................................................................................................. 31
Diagnostic LEDs for SIMOTION D .................................................................................................... 32
Operating Mode Control using the Mode Selector Switch ................................................................. 33
Operating Mode Control Options ...................................................................................................... 34
Carrying Out an Overall Reset for SIMOTION D ............................................................................... 35
Restoring the Factory Setting for SIMOTION D ................................................................................ 36
Compact Flash Card for SIMOTION D ............................................................................................. 37
Formatting a CF Card Using a Card Reader ..................................................................................... 38
Writing to a Boot Sector on a CF Card ............................................................................................. 39
Copying Firmware to a CF Card ....................................................................................................... 40
Saving Project Data Directly to a CF Card ....................................................................................... 41
Internal Memory Structure for SIMOTION D ..................................................................................... 42
Modifying Configuration Data - Backing up Online Data .................................................................... 43
RAM to ROM - Copying Current Data ............................................................................................... 44
Loading/Archiving a Project on a CF Card ........................................................................................ 45
SIMOTION Controller in S7 Design: C230-2/C240/C240PN ............................................................. 46
System Configuration with SIMOTION C .......................................................................................... 47
Hardware Connection Schematic of the SIMOTION C230-2/C240 .................................................... 48
Hardware Connection Schematic of the SIMOTION C240 PN .......................................................... 49
Integrated Signal Inputs and Outputs of the SIMOTION C ................................................................ 50
Drive and Measuring System Interfaces of the C230-2/C240 ............................................................ 51
Communication Interfaces of the SIMOTION C ................................................................................ 52
PROFINET Interface of the C240 PN ................................................................................................ 53
Operating Mode Selector Switch for SIMOTION C ............................................................................ 54


Content Page
Diagnostic LEDs for SIMOTION C .................................................................................................... 55
Micro Memory Card (MMC) for SIMOTION C ................................................................................... 56
Internal Memory Structure of SIMOTION C ...................................................................................... 57
Carrying Out an Overall Reset for SIMOTION C ............................................................................... 58
Restoring the Delivery State for SIMOTION C .................................................................................. 59
PC-Based Design - SIMOTION P350 ............................................................................................... 60
Connection Schematic of SIMOTION P350 ...................................................................................... 61
System Configuration with SIMOTION P350 .................................................................................... 62
MCI PN Board for P350 .................................................................................................................... 63
Embedded PC Technology - SIMOTION P320 ................................................................................. 64
SIMOTION P320 Connections .......................................................................................................... 65
System Configuration with SIMOTION P320 .................................................................................... 66
Operating Mode Control for SIMOTION P ......................................................................................... 67
Internal Memory Structure for SIMOTION P ..................................................................................... 68
Protection Against Power Failure – Buffering Retain Data ................................................................ 69
Backing up Retain Data on a CF Card from the User Program ......................................................... 70
If You Want to Know Even More ....................................................................................................... 71
Backing up and Restoring Retain Variables with the PG/PC ............................................................. 72
Backing up Retain and Diagnostics Data in Operation ...................................................................... 73
Backing up Retain and Diagnostics Data when Powering up/ Booting ............................................ 74
Backing up Diagnostics Data via IT DIAG ......................................................................................... 75
Archiving Retain and Diagnostic Data .............................................................................................. 76
Backing up Diagnostic Files via FTP ................................................................................................. 77
Restoring Retain Data ...................................................................................................................... 78

System Platforms for SIMOTION
Shared HMI Use
Shared communication:
PROFIBUS, PROFINET, Ethernet
C230-2/C240/C240PN
P350-3/P320-3
D4x5/D410
Shared use of
distributed I/O and
drives via PROFIBUS
and PROFINET

System platforms There are three different system platforms available for SIMOTION:
• the controller-based design: C230-2/C240/C240PN
The SIMOTION C family of controllers are powerful modules for positioning
independent single axes or motion in an axis grouping. They are based on
the control design of the SIMATIC 300-system.
• the PC-based design: P350-3 and P320-3
The PC-based SIMOTION P350-3 motion control system runs with the
Windows XP operating system augmented with a real-time expansion for
SIMOTION. The hardware consists of an industrial PC with innovative
Intel technology.
The PC-based SIMOTION P320-3 motion control system runs with the
Windows Embedded Standard 2009 operating system and with a real-time
expansion for SIMOTION. The hardware consists of an industrial PC with
innovative Intel technology.
• the drive-based design: D4x5, D410
SIMOTION D is a drive-based version of SIMOTION based on the
SINAMICS S120 drive family. For SIMOTION D, the PLC and motion control
functions of SIMOTION and the drive software of SINAMICS S120 run
together on a module with 2 processors.
SIMOTION D is available in two versions:
- SIMOTION D410 is a compact Control Unit for single-axis applications
and is snapped onto the SINAMICS S120 PM340 Power Module in
blocksize format.
- SIMOTION D4x5 is a control unit for multi-axis applications in a
SINAMICS S120 booksize format and is offered in several performance
variants:
D425, D435, D445/ D445-1, D445-2, D455-2

Drive-Based Design - SIMOTION D
Properties
Design SINAMICS
Number of axes 1..128
Drive link On-board
Distributed I/O ET 200M/S/X/eco all standard
PROFIBUS slaves (DP V0/V1)
Centralized I/Os 12 inputs, 16 on-board
inputs/outputs additional I/O
modules can be operated
PROFIBUS interface 2, 12 Mbit/s, isochronous
PROFINET IO D4x5-2DP/PN on-board, 3 ports, 2nd interface
(4 ports) via CBE30-2
Ethernet interfaces 3 (D4x5-2 DP), 2 (D4x5-2 DP/PN)
DRIVE-CLiQ interfaces 4, 6 (D445) for connection of:
power supply (Line Module)
power section (Motor Module) D4x5-2
I/O modules, encoders
D4x5/D445-1

What is SIMOTION D is the drive-based version of the SIMOTION motion control

SIMOTION D? system based on the new SINAMICS drive family.
For SIMOTION D, the SIMOTION motion control functionalities and the
SINAMICS drive software run on a module in the SINAMICS mechanical design.
This design approach provides a system which is both highly compact and
particularly fast to respond. There are several performance levels of SIMOTION
D (differing in performance and quantity structure [number of axes that can be
operated]): D425/-2 corresponds to the low-end performance level, D435/-2 the
medium performance level and D445-2 the high-end performance level. The
D455-2 module has been designed for the topmost performance levels
SIMOTION D4x5-2 For the SIMOTION D4x5-2, the previously optional PROFINET IO interface has
been integrated onto the modules and no longer has to be realized using a
CBE30. This frees up one option slot that is then available for other expansion
options.
The onboard Ethernet interface is equipped with an integrated 3-port switch and
facilitates the configuration of different PROFINET network topologies such as
line, star or tree structures, without the need for additional external switches.
The interface supports the following real-time classes: RT and IRT.
When compared to the original versions, these modules have more work
memory (D445-2: 128 Mbyte, D455-2: 256 Mbyte) and retentive memory
(512 Kbyte). The retentive memory for user variables has maintenance-free and
unlimited buffering. Just as before, the real-time clock is buffered using a
SuperCap (up to 4 days).
SINAMICS_Integrated runs on the basis of the new CU320-2 for connecting up
to 6 drives, even when Safety Integrated functions are active.

System Configuration with SIMOTION D
SIMOTION HMI
• SCOUT
• Teleservice
• HMI
Ethernet_2
Ethernet_1
SIMOTION D
PROFIBUS-DP_1 (PROFINET) HMI
Iso-
chronous PROFIBUS DP_2
Distributed SINAMICS
I/O
Distributed
Servo drives I/O
Drives • SCOUT
(e.g. MICROMASTER)

Drives connected Drives or other PROFIBUS components are controlled via the two PROFIBUS
to PROFIBUS interfaces, which are both clock-synchronous (isochronous) and can be
operated with the same DP cycle clock and baud rate. If the isochronous mode
is selected for one or both PROFIBUS interfaces, then for Version 3.1, the
external DP cycle must be identical with the DP cycle of the integrated PCI bus.
From Version 3.2, the cycles of the external PROFIBUS subnets and the cycle
of PCI_Integrated can be different.
The number of axes that can be connected to the PROFIBUS DP is, as for C2xx
or P350, dependent on the system cycles that have been set, i.e. more axes can
be operated with longer cycle times than with short cycle times.
An HMI system or PG with SCOUT can also be incorporated into the system via
PROFIBUS. It is not permissible to connect the PG with SCOUT to an
isochronous PROFIBUS subnet.
Ethernet/PROFINET Via the integrated Ethernet interfaces, for example, HMI components
interface (WinCC flexible) or a PG/PC with SCOUT can be connected. The integrated
routing mechanism for example allows direct access from a PG to the drives
which are connected to a PROFIBUS subnet.
In addition, SIMOTION D can communicate with other SIMOTION or SIMATIC
devices and other systems via the Ethernet interfaces.
For the new SIMOTION D4x5-2 versions, a PROFINET interface with 3 ports is
integrated as standard on the module. Drive systems can be isochronously
controlled via these ports. For the older D4x5 and D445-1 systems, the
PROFINET connection can be realized via the CBE30 option module.

Axis Grouping in a SIMOTION D System
DRIVE-CLiQ
SMC: Sensor Module Cabinet
POWER
DRIVE-CLiQ
DRIVE-CLiQ I/Os
Drive-related control cabinet I/O

Axis grouping The SIMOTION/SINAMICS control unit together with the various SINAMICS
S120 drive modules (input and power modules) forms an axis group. The
individual modules are interconnected via DRIVE-CLiQ cables.
A typical axis group contains the following modules:
SIMOTION D4x5/-2 The D4x5/-2 module contains the programmable runtime system of SIMOTION
for motion control and position control for up to 16 axes.
In addition the module contains the SINAMICS S120 control unit for speed
control and current control for up to 6 drives. The control unit can also control an
intelligent infeed module (Active Line Module).
Infeed module The SINAMICS infeed (Line Module) generates the DC link from the line supply.
Power units The SINAMICS power units (Motor Modules) are for controlling the motors.
DRIVE-CLiQ Communication between the individual components of the drive system is

implemented using a high-speed serial link via DRIVE-CLIQ connections. In
addition to the power components, encoder systems and drive-level DRIVE-
CLiQ I/Os such as SMC encoder systems or Terminal Modules can be
connected via DRIVE-CLiQ.
And finally, diagnostics down to the individual components is also possible via
the DRIVE-CLiQ interface.

Connection Schematic of SIMOTION D
4/6 Drive-CLiQ connections
Digital I/Os
Electronics power supply

Option slot
2 Ethernet / 3 PROFINET
2 PROFIBUS interfaces
2 USB
2 Ethernet
CF slot
LEDs
Cover (mode selector switch)
D4x5/D445-1 D4x5-2

Drive-CliQ
The D4x5 has 4 Drive-CLiQ ports The power units, infeed and other modules
are connected here.
Digital inputs/
outputs The digital inputs/outputs are assigned to SINAMICS and can be used
to control the drive.
Electronics 24V connector to supply the module elecmtronics.
supply
Slot for options The TB30 or the CBE30/-2 can sbe inserted in this slot. TB30 is a terminal
expansion module with 4 DI, 4 DO, 2 AI and 2 AO, CBE30/-2 is a PROFINET
module to connect the D4x5/-2 to PROFINET.
Ethernet 2 Ethernet sockets of the SIMOTION can be used to connect a PC

ports or an HMI device.
Here you can gconnect additional drives or distributed PROFIBUS D I/O

PROFIBUS devices.
ports
CF slot Memoery card slot (CompactFlash card) The memory card is essential for
koperation. For D4x5-2, the CF slot is below the cover
Mode selector The operating mode, e.g. RUN of the CPU can be set using this rotary switch. A
switch row of LEDs next to the switch indicate the status of the CPU.

Internal Architecture of the SIMOTION D + CX32/-2
DRIVE-CLiQ
DRIVE-CLiQ
DRIVE-CLiQ
DRIVE-CLiQ
DRIVE-CLiQ
DRIVE-CLiQ
DRIVE-CLiQ
DRIVE-CLiQ
PN-IO
IE1
PN/IE-NET
SIMOTION RT SIMOTION D
IE2
PN/IE (position control,
positioning,
synchronous
CBE30
CBE30-2 operation,
PLC tasks) PROFIBUS_ SINAMICS
DP2/MPI Integrated Integrated CX32 (speed,
(speed, current control,
DP1 current control, Safety)
Safety)
Measuring sockets
Measuring sockets
Digital I/O
Digital I/O
Design of the SIMOTION D uses the SIMOTION D4x5 module as its central hardware
SIMOTION D4x5 module, comprising the SIMOTION runtime system (SIMOTION RT) and the
SINAMICS_Integrated control unit. The SINAMICS_ Integrated control unit is
functionally identical with the CU 320 (Control Unit) of the SINAMICS S120
systems.
The SIMOTION part is responsible for motion econtrol and position control of
the axes. The SINAMICS Control Unit controls the speed and current of the
connected drives. The SINAMICS unit can amlso control the infeed unit (ALM =
Active Line Infeed).
The number of drives that can be conneiected depends on the selected
operating mode (servo or vector control):
• Servo, maximum of 6 drive s plus 1 ALM, or
• Servo, with setpoint channel, presently maximum of 4 drives plus 1
ALM, or
• Vector, presently max. 4 drives plus 1 ALM
Mixed operation (servo and vector) is not permitted.
The SIMOTION sylustem communicates with the integrated SINAMICS Control

Unit via a PROFIBUS_Integrated. The bus connection is configured and
programmed ing exactly the same way as the two external PROFIBUS subnets
CX32 that can beo connected to the SIMOTION module.
One CeX32 is used to connect additional drive systems. Communication
between SIMOTION and a CX32 module first runs via PROFIBUS_Integrated to
the SINAMICS_Integrated, and from there via the DRIVE- CLiQ connection to
the CX32 module. For internal communication to a CX32 module,
SINAMICS_Integrated internally requires approximately the performance
corresponding to half an axis.
This means that when connecting two CX32 modules, SINAMICS_ Integrated
can no longer operate 6 servo, but only 5 servo drives.

SIMOTION D – Available Modules
16 32 64 128
axes axes axes axes
max. 8 axes
1
N N N N
DP N 2
/ P t 2 01 DP /P DP /P /P /P
- 2
DPerbs -2 DP - 2 DP DP DP
10 - 2 25
-2 35 - 2 - 2 - 2
4 D4 D4
H
D 10 1) 25 35 45 55
D4 D4 D4 D4 D4

SIMOTION D Two SIMOTION D versions are available: as a single-axis SIMOTION D410

system and as a multi-axis SIMOTION D4x5 system in different performance
versions. This ensures the highest degree of scalability and flexibility.
The field of application ranges from single axes to high-performance multi-
axis machines. SIMOTION D is available in two versions:
• SIMOTION D410 is it used for single-axis eapplications and is
snapped onto the SINAMICS S120 PM340 Power Module in blocksize format.
• SIMOTION D4x5 used for multi-axis apmplications in SINAMICS S120
booksize format and is offered ine several performance variants:
- SIMOTION D425 (BASIC peirformance) for up to 16 axes
- SIMOTION D435 (STANDsARD performance) for up to 32 axes
- SIMOTION D445/D445-1 ( HIGH performance) for up to 64 axes
- SIMOTION D445-2@ (HIGH performance) for up to 64 axes
- SIMOTION D455-2 (ULTRA HIGH performance) for up to 64 axes
SIMOTION D445-1 Compared wilth SIMOTION D445, SIMOTION D445-1 offers an improvement in
PLC and mogtion control performance of approximately 30%, depending on the
applicationo.
Withe the new SIMOTION D445-2 DP/PN and D455-2 DP/PN versions the
performance range has now been extended upwards. Compared to the previous
generation, the maximum quantity structure has been doubled to 128 axes and
SIMOTION D4x5-2 the memory capacity expanded. This has increased the PLC and motion control
performance by a factor of 3.

SIMOTION D - Expansion Options
Expansion SIMOTION D modules
D4x5/-2 CX32/-2

CX32 The CX32 is used to connect additional drives to a SIMOTION D4x5 system.
The CX32 is responsible for speed control and current control of the drives.
CX32 modules are physically connected to a SIMOTION D module via DRIVE-
CLiQ. CX32 modules are inserted into the configuration on PROFIBUS
Integrated using HW Config
The following rules must be observed:
• Only a star topology is permitted between CX32 and SIMOTION D. This
means that only one CX32 can be operated per DRIVE-CLiQ port of a
SIMOTION D.
• The PROFIBUS addresses for a CX32 are permanently linked to the
DRIVE-CLiQ ports of the D4x5 module as follows.
DRIVE-CLiQ port PROFIBUS address (PROFIBUS Integrated)
X105 (D445 only) 15
X104 (D445 only) 14
X103 (D435 / D445) 13
X102 (D435 / D445) 12
X101 (D435 / D445) 11
X100 (D435 / D445) 10
• Data for the CX32 is located on the CF card of the D4x5. When a module is
replaced, therefore, no further action is necessary.
• Direct communication between two CX32 modules or the SINAMICS
Integrated and CX32 is not possible. (Exception: Interconnection of the
infeed's "Operation" signal for the CX32).
• Two CX32 modules can be operated on one D435 and four can be operated
on one D445.
• Each CX32 can control up to 6 additional servo, 4 vector, or 8 U/f drives and
one ALM (Active Line Module). If one or more CX32 are used on a D4x5, the
number of drives that can be used on the SINAMICS Integrated is reduced
by one drive.

CX32/CX32-2 Control Modules
The system for extended drives

Design SINAMICS
Number of drives 8 / 12 drives in U/f control or
6 drives in Servo control, or
4 / 6 drives in vector control
Central I/O 4 inputs (CX32) /
6 inputs (CX32-2)
4 input/outputs onboard
Additional Terminal Modules can be connected
Drive coupling DRIVE- CLiQ
4 DRIVE- CLiQ interfaces to couple:
infeed (Line Module)
power units (Motor Module)
I/O modules, encoders

CX32 The SIMOTION CX32 Controller Extension is a component in SINAMICS S120

booksize format and supports scaling of the drive-side computing performance
of the Control Unit integrated in the SIMOTION D435 and D445 modules.
A CX32 module can only be operated in conjunction with a higher-level D435 or
D445 module. Each CX32 can control up to 6 additional servo, 4 vector or 8 U/f
axes.
If required, several CX32 devices can be moperated on a SIMOTION D435/
D445 to increase the number of axes:
• max. 2 CX32 on one SIMOTIOiN D435
• max. 4 CX32 on one SIMOTIsON D445
The CX32 Controller Extens ion and SIMOTION D435/D445 can be used to
implement automation solutions with a large number of axes.
The CX32 is connected to SIMOTION D435/D445 via DRIVE-CLiQ, so high-
performance, isochronous closed-loop control of the drives is possible without
the need for additional modules. The communication interfaces on the
SIMOTION D435/D445 remain available for other connections.
The data forg the CX32 is stored exclusively on the SIMOTION D435/D445,
which meanso no action has be taken when the module is replaced.
CX32-2 It is onely possible to use the CX32-2 in conjunction with a D4x5-2 module.
The CX32-2 also has the larger connector with the expanded I/Os.
Up to 5 CX32-2 modules can be connected to SIMOTION D4x5-2 modules.

SIMOTION D410/-2 - The Single-Axis System
Properties D410/D410-2
Design SINAMICS
Number of axes 1/8 SIMOTION axes
1 SINAMICS drive
(SERVO or VECTOR)
Variants DP and PN variants D410
D410-2 DP 1/2 DP & 0/1 IE
1 DRIVE-CLiQ
D410-2 PN 1 PN (2 Ports) & 0/1 DP & 0/1 IE
1 DRIVE- CLiQ
DI/DO 4/5 DI, 4/8 DI/DO, 0/1 AI (U/I),
0/3 F-DI, 0/1 F- DO
DI/DO can be used 4 output cams or 3 measuring inputs
Drive coupling In conjunction with SINAMICS AC/AC
power sections
- inserted directly
- via DRIVE-CLiQ and CUA31 D410-2
Encoder interfaces HTL/TTL interface for external encoders

SIMOTION D410/-2 SIMOTION D410/-2 is a modular drive system for single-/multi-axes, which
solves demanding motion control tasks for a very wide range of industrial
applications. SIMOTION D410/-2 supplements the power levels for the multi-
axis groups D425/-2, D435/-2, D445/-2 and D455-2.
Combining a power module with SIMOTION D410/-2 forms a compact single
drive for machine and plant construction.
SIMOTION D410/-2 is available in two vermsions:
Version • SIMOTION D410/-2 DP with PROeFIBUS DP interface
• SIMOTION D410/-2 PN with siPROFINET interface
SIMOTION D410/-2 is the central motion control module. This unit contains the
programmable SIMOTION runtime system and the drive software of
SINAMICS S120.
You can use the integrated fast digital I/Os as follows:
• Homing inputs
• Inputs for measulring probes
• User-addgressable process I/Os
• High-lospeed output cams
• Faeil- safe I/Os for SINAMICS Safety Integrated (only
D410-2) Tkhe measuring sockets can output any analog signals.
The system software is delivered separately on a CompactFlash Card. The

CompactFlash card contains the following system software:
• SIMOTION Runtime System
• Drive software of SINAMICS S120

DRIVE-CLiQ - Standard Connection for all Components
"Drive Component Link with Intelligence Quotient"
DRIVE-CLiQ
Line topology
SMIxx SMCxx
CU320 Line Motor Motor
module module module
SMExx
Tree topology External
measuring system
All drive components

communicate via a standard
SMIxx SMCxx interface.
CU320 Line Motor Motor
module module module
SMExx
External
measuring system

DRIVE-CLiQ The new connection for linking drive components is based on Ethernet
connection technology with 100 Mbit/s. Plug connections are expanded RJ45 connectors
and sockets, which in addition to the standard Ethernet signals also have two
contacts for distributing a 24 V DC voltage.
DRIVE-CLiQ implements a high-performance point-to-point connection for
internal drive communication between the various drive components. In a
DRIVE-CLiQ network, one and only one Control Unit has the master function.
DRIVE-CLiQ includes integrated safety functions.
The Control Unit identifies all connected actuators, sensors and motors after
switch-on via DRIVE-CLiQ. In ongoing operation, cyclic drive-related data are
cyclically exchanged isochronously.
DRIVE-CLiQ is also used to exchange parameters and diagnostic data between
the Control Unit and the drive components.
Rules When wiring components with DRIVE-CLiQ, the following rules apply:
• Ring wiring is not permitted.
• Components must not be wired twice.
• A maximum of 16 nodes can be connected to a DRIVE-CLiQ socket of the
control unit (CU 320).
• A maximum of 8 nodes can be connected in series. A row is always
considered from the control unit .
• A maximum of 6 Motor Modules can be connected in a series.
• In the case of a Motor Module, the associated motor encoder must also be
connected.
HUB (DMC20) The DRIVE-CLiQ Hub Module 20 (DMC20) is used to implement star-shaped
distribution of a DRIVE-CLiQ line. With the DMC20, an axis grouping can be
expanded with four DRIVE-CLiQ sockets for additional subgroups.

Nodes connected to DRIVE- CLiQ
D4x5 Motor Motor Motor Motor

Line Module Module Module Module Module
SMC20 SMC30
Motor with Motor without Encoder with

Digital/analog DRIVE-CLiQ DRIVE-CLiQ DRIVE-CLiQ Conventional
I/O interface Interface interface encoder
All components that are connected via DRIVE-CLiQ with the D4xx/-2 or CU320/-2 have their own
firmware. If required, the firmware is automatically updated from the CF card of D4x5/-2 and/or
CU320/-2 after a module replacement.

Line Modules Convert the three-phase supply into a DC voltage for the DC link.
• Basic Line Module: Basic Line Modules generate a non-regulated DC
link voltage and are not capable of regenerative feedback.
• Smart Line Modules: Smart Line Modules generate a non-regulated DC
link voltage and are capable of regenerative feedback.
• Active Line Modules: Active Line Modulese generate a non-regulated
DC link voltage and are capable of regenemrative feedback.
Motor Modules Motor Modules in the SINAMICS S120 esystem in the “booksize” format are
inverters. The control information is igenerated in the Control Unit and distributed
to the individual motor moduless via DRIVE-CLiQ.
Depending on the type (singl e or double), each motor module has one or two
DRIVE-CLiQ interfaces fo@r connecting the motor encoder evaluation (sensor
modules).
Sensor Modules evualuate the signals of the connected encoders and transfer
Sensor Modules the calculated values via DRIVE-CLiQ to the Control Unit.
Depending on the integration of the electronics to convert conventional encoder
signals to DRIVE- CLiQ, a distinction is made between:
Sensoelr Module Integrated = SMI: In this case, the electronics required to

convert the encoder signals is integrated in the encoder system of the motor.
Sensor Module Cabinet = SMC: In this case, the corresponding electronics is

accommodated in a separate module, which as result of class of protection, is
installed in the control cabinet.
Sensor Module External = SME: In this case, the electronics is accommodated in

a module, which can be directly connected in the field.
Using a Terminal Module (TM), the internal terminals can be expanded by
I/O additional digital and analog inputs/outputs.

Infeed Modules for SINAMICS S120
BLM = Basic Line Modules

Unregulated infeed unit
SLM = Smart Line Modules

Unregulated infeed/regenerative feedback unit
ALM = Active Line Modules

Self-commutated infeed/regenerative feedback unit
Power at 380 V 50 Hz 50 mm 100 mm 150 mm 200 mm 300 mm

BLM SLM ALM
5 kW
10 kW
16 kW 16 kW
20 kW 36 kW 36 kW
40 kW 55 kW
100 kW 80 kW
120 kW
5, 10 kW 16 kW 36 kW 55 kW 120 kW

Line Modules Line Modules generate a DC voltage for the voltage-source DC link from the
connected line voltage. The current-source DC link serves as power supply for
the individual Motor Modules.
The Active Line Modules and the Smart Line Modules 16 kW and 36 kW have
DRIVE-CLiQ interfaces for communications with the CU. The 5 kW and 10 kW
Smart Line Modules must be connected with the Control Unit via terminals.
Properties • Line supply voltage 3AC 380 V –0% (-15% <1 min) up to 3AC 480 V
+10%(47 up to 63 Hz)
• Suitable for TN, TT, and IT suppsily systems
• Internal/external air cooling
• Short-circuit/ground-fault-proof during the precharge phase
• Integrated DC link and e@lectronics current busbar connection
• LEDs for indicating statuses and for diagnostics
Regulated DCl link voltage
Active Line Module •
• Regenerativge feedback capability
• Sinusoiodal line currents
• Electlronic type plate
• eDRIVE-CLiQinterfaces for communication with the Control Unit
Smart Line Module • Non-regulated DC link voltage

.
• Regenerative feedback capability

• Square wave line currents
Basic Lined Module • Non-regulated DC link voltage

• Not capable of energy recovery
• Square wave line currents

Power Modules for SINAMICS S120
50 mm 100 mm 150 mm 200 mm 300 mm
Single Motor
Modules
3,5,9,18 A 30 A 45, 60 A 85 A 132, 200 A
Double Motor
Modules
2x3, 2x5, 2x9 A 2x18 A

Motor Modules The motor modules in the SINAMICS S system in “booksize” format are
inverters. The control information is generated in the control unit and distributed
to the individual motor modules via DRIVE-CLiQ.
Depending on the type (single or double), each motor module has one or two
DRIVE-CLiQ interfaces for connecting the motor encoder evaluation (sensor
modules). The Double Motor Modules save up to 50% space compared to the
Single Motor Modules.
The integrated safety functions such as "Safe motor brake control" and "Safe
standstill" reduce the external wiring overhead and increase the safety,
flexibility, cost-effectiveness and availability of machines and plants.
Properties • Compact design through high power density, particularly with the Double
Motor Modules
• Integrated DC link and 24 VDC busbar
• Diagnostic LEDs
• Short-circuit- and ground-fault-proof
• Integrated Safety functions, such as "safe motor brake control" and
"safe standstill"
• Integrated motor brake connection and armature short-circuit brake
• Motor connection via connector (up to 30 A) or bolts

Sensor Modules to Convert Encoder Signals
Motor-integrated components (SMI) DRIVE-CLiQ

SMI10: Resolvers
SMI20: Sin/cos, EnDat
Motor identification + motor data sheet Motor interface
Components in the control cabinet

SMC as migration solution
SMC10: Resolvers
SMC20: Sin/cos, EnDat
SMC30: TTL, HTL, incr.
SMC10 SMC20 SMC30
External components SME DRIVE-CLiQ

SME20: Sin/Cos
SME25: SinCos without RefSig + EnDat
SME20: Sin/Cos (linear scale)
SME25: SinCos without RefSig + EnDat (linear scale) Encoder interface

Motor-integrated The encoder system should be connected to SINAMICS S120 preferably via
Sensor Module DRIVE-CLiQ. The motors are designed with DRIVE-CLiQ interface, such as e.g.
(SMI) 1FK7 and 1FT6 synchronous motors and 1PH7 induction motors.
These motors with DRIVE-CLiQ interfaces can be connected to the associated
Motor Module via the available MOTION-CONNECT DRIVE-CLiQ cables. In this
way, the motor encoder and temperature signals as well as the electronic type
plate data such as the unique identificationm number, rated data (voltage, current
and torque) are transferred directly to the Control Unit. These motors simplify
commissioning and diagnostics becausee the motor and encoder type are
identified automatically.
Sensor Module SMCs are used, if the motor does not have a DRIVE-CLiQ interface and if, in
Cabinet (SMC) addition to the motor encoder additional external encoders are required. Only one
encoder system may be connected per SMC. Only encoder systems, in which the
power supply for the encoder system is not grounded, may be connected.
• SMC10: for rlesolvers

• SMC20: fogr sin/cos 1Vpp incremental and absolute encoders
• SMCo30: for TTL and HTL incremental encoders
Sensor Module Direct measuring systems outside the control cabinet can be connected to the
External (SME) SME. The SME evaluates these measuring signals and converts the calculated
values to DRIVE-CLiQ. No motor or encoder data is stored in the SME.
• SME20: incremental, direct measuring systems sin/cos (1Vpp)
• SME25: incremental, direct measuring systems sin/cos (1Vpp) without
reference signal and EnDat
• SME120: for incremental, direct measuring systems sin/cos (1Vpp) (linear
scale)
SME125: for incremental, direct measuring systems sin/cos (1Vpp) without
reference signal and EnDat (linear scale)

Optional DRIVE-CLiQ Terminal Module for SIMOTION D
TM31 (Terminal Module)

8 digital inputs
4 digital inputs/outputs
2 relay outputs with changeover contact
2 analog inputs
2 analog outputs
1 temperature sensor input
(KTY84-130 or PTC)
TM41
4 digital inputs
1 analog input
1 TTL encoder output
TM15
(e.g. for measuring input and fast
cam output)
TM17 High Feature
(e.g. for measuring input and fast D4x5
cam output, 1 μs)

TM31 The Terminal Module TM31 can be used to expand the number of digital inputs/
digital outputs and the number of analog inputs/analog outputs in a drive system.
The TM31 can be connected via DRIVE-CLiQ. It has two DRIVE-CLiQ interfaces for
this purpose.
The Terminal Module TM41 can be used tom increase the number of digital inputs/
TM41 digital outputs and the number of analog outputs in a drive system.
One channel can also be used for encodeer simulation. The TM41 can be
connected via DRIVE-CLiQ.
The Terminal Modules TM15 and TM17 High Feature can be used to implement
TM15/TM17 measuring inputs and ca@m outputs for SIMOTION D. In addition, these terminal
modules provide drive-related digital I/Os with short signal delay times.
Each of the 24 isoluated DI/O can be parameterized channel-by-channel as a digital

TM15 input (DI), digital output (DO), measuring input, or output of the output cam.
TM17 High Feature Each of lthe 16 DI/O can be parameterized channel-by-channel as a digital input
(DI), edigital output (DO), measuring input, or output of the output cam.
Wkhen compared to TM15, TM17 High Feature has fewer I/O channels – but
with higher functionality. TM17 High Feature is characterized, in particular, by an
extremely high resolution and accuracy, as well as an input filter – that can be
parameterized – and enable inputs (up to 6).
Parameterized enable inputs can enable measuring inputs or outputs of output
cams (gate function). Due to their high accuracy, the DI/O channels of the TM17
High Feature are non-isolated.

PROFIBUS-DP Interfaces of the SIMOTION D
X126 X136 Connection via PROFIBUS

and MPI to:
HMI devices
PG/PC with SCOUT
SIMOTION, SIMATIC devices
via Xsend/Xrecv or
master/slave coupling
DP1 DP2/MPI Drives and additional field
devices
- ET 200M
- ET 200S
- ET 200X
- ET 200eco
D4x5 D4x5-2

PROFIBUS DP The D4x5 provides 2 interfaces for connection to the PROFIBUS DP.
interfaces Baud rates up to 12 Mbit/s are possible. Both interfaces can be operated clock-
synchronously and isochronously.
The interfaces can be operated as master or slave in virtually any combination
(equidistant / non-equidistant).
Special features Hierarchical systems can be implemented via the hierarchical DP interface
function. In a hierarchical system a isochronous PROFIBUS is used to enable
functions, such as distributed synchronous operation. With distributed
synchronous operation the individual axes are distributed among several
SIMOTION systems.
If both interfaces (X126, X136) are to run isochronously, they must both be
configured with the same DP cycle clock.
Interface X136 can be used alternatively as an MPI interface with a baud rate of
up to 12 Mbit/s.
Addresses and When delivered the following addresses and baudrate are set for both
baud rate PROFIBUS interfaces:
• Protocol: PROFIBUS DP
• PROFIBUS address: 2
• Baud rate: 1.5 Mbit/s
Note A teleservice adapter can only be connected to one of the two interfaces.
All approved modules and devices can be found in Catalog PM 10.

Ethernet Interfaces of the SIMOTION D4x5
Ethernet connection to:

X120 "IE1" HMI devices (OPC Server)
IP address:
192.168.214.1 PG/PC with SCOUT engineering system
SIMOTION, SIMATIC systems and
third-party systems via TCP/IP and UDP
X130 "IE2" (User Datagram Protocol)
IP address: Communication via XML-DA
169.254.11.22
Ethernet X1400 "CBE30"

interfaces IP- Adresse:
192.168.0.1
Note
On delivery and/or when a reset Note
to factory setting is performed, On delivery and/or when a reset
the addresses of the Ethernet to factory setting is performed,
interfaces are set to the values the address of the CBE30 board
above. is set to 0.0.0.0

Ethernet This interface is for connection to a Fast Industrial Ethernet. Fast

Interface Industrial Ethernet is a communication network with a transmission rate of
10/100 Mbit/s.
The D4x5 system offers the following functions via the Ethernet interface:
• Communication with STEP 7 and SIMOTION SCOUT.
• Communication between SIMOTION and SIMATIC NET OPC. The
"SIMATIC NET (S7 OPC server)" softwarme must be installed on the PG/PC
for this function.
• Communication with other systeims via TCP/IP and UDP (User
Datagram Protocol)
• Communication by means of SIMOTION OPC XML-DA. A separate
license is required for this communication method.
IP Addresses The IP addresses of a D4x5 board are set by default to the following values:
• X120 (IE1/OP)u: 192.168.214.1 subnet
mask:l255.255.255.0
• X130 (IE2/NgET): 169.254.11.22. subnet
masok:255.255.255.0
• ClBE30 : 192.168.0.1 esubnet mask:255.255.255.0
Tkhese default values are also used, when a new D4x5 board is inserted in a
SCOUT project.
When delivered or when a "Reset to factory setting" is performed the interfaces
IE1 and IE2 are set to the values above. The IP address of the CBE30 is set to
0.0.0.0 with subnet mask 0.0.0.0.
When the CBE30 is going to be used in a connection request, either with the
tool "Edit Ethernet Node" or via a download of a hardware configuration using
some other interface, a valid IP address has to be assigned to the CBE30 first.

Ethernet Interfaces of the SIMOTION D4x5-2

HMI devices (OPC Server)
PG/PC with SCOUT engineering system
X120 "PN/IE-OP" SIMOTION, SIMATIC systems and
IP address third-party systems via TCP/IP and UDP
192.168.213.1. (User Datagram Protocol)
Communication via XML-DA
X150 "PROFINET IO"

IP address:
192.168.1.1
X130 "PN/IE-Net"
IP address
192.168.2.1. X1400 "CBE30-2"
IP address:
192.168.0.1
Note
X127 "PN/IE"
IP address On delivery or when a reset
169.254.11.22 to factory setting is performed,
only X127 "PN/IE" is set to
169.254.11.22
D4x5-2 DP D4x5-2 DP/PN All other Ethernet interfaces are
set to 0.0.0.0.

Ethernet The number and the addresses of the Ethernet interfaces are different for both
interfaces D4x5-2 variants:
D4x5-2 DP • X120 (PN/IE OP) : 192.168.213.1, (only DP variant)

subnet mask:255.255.255.0
• X130 (PN/IE-NET) : 192.168.2.1
subnet mask : 255.255.255.0
• X127 (PN/IE): 169.254.11.22
subnet mask : 255.255.0.0
It is not possible to use the CBsE30-2 module with D4x5-2 DP
D4x5 DP/PN
• X130 (PN/IE NET) : @192.168.2.1 subnet mask : 255.255.255.0,
• X127 (PN/IE): 169.254.11.22 subnet mask : 255.255.0.0
• X150 (PN/glIO) : 192.168.1.1 subnet mask : 255.255.255.0
• X1400 (loCBE30-2) : 192.168.0.1 subnet mask : 255.255.255.0
On delivery or when a "Reset to factory setting" is performed only the interface:

X127 (PN/IE) is set to 169.254.11.22
The IP addresses of all other interfaces X120, X130, X150 and X1400 (CBE30-
2) are set to 0.0.0.0..
Only with a valid IP address a connection request will be successful. In order to
assign a valid address to some interface, you can either use the tool "Editing
Ethernet nodes" or you must perform a successful download of a hardware
configuration using an interface with some valid address.

Integrated Digital I/Os of the D4x5
DI0 DI4
DI1 DI5
DI2 DI6
DI3 DI7
DI/DO8 DI/DO12
DI/DO9 DI/DO13
DI/DO10 DI/DO14
DI/DO11 DI/DO15
Assignment:
Pins 1...4 (DI0 ... DI7, digital inputs, 50Ê μs, 100Ì μs)
Pin 7 (DI/DO 8, 12 dig. inputs/outputs, can be parameterized,
propagation times: 50Ê μs , 50Ì μs )
Pins 8, 10, 11 (DI/DO 9, 10, 11, 13, 14, 15 digital inputs/
outputs, can be parameterized and used as high-speed inputs
for measuring inputs and referencing, 5Ê μs, 100Ì μs or as
high-speed cam outputs

Integrated inputs Various sensors and actuators can be connected to the two 12-pin front X122
and outputs and X132 connectors.
The following types of digital inputs/outputs are available:
• Digital inputs
• Bidirectional digital inputs/outputs
Assignment of the I/Os to functions can be parameterized as required. Special
functions, such as input of the measuring input and output of the output cam,
can be assigned to the inputs/outputs.
The enable signals for the drive units and/or motors (Active Line Module, Motor
Module) connected to the Control Unit can also be connected over digital inputs.
Isolated There are 8 digital inputs on the Control Unit. These isolated inputs
inputs can be used as freely addressable inputs.
Bidirectional There are 8 digital I/Os on the Control Unit. The mode of operation, i.e. as either
inputs/outputs an input or output, is parameterized by means of the "Starter" commissioning
tool.
6 of the 8 digital inputs/outputs can be used as "high-speed inputs". All 8 digital
inputs/outputs can be used as freely addressable inputs or as measuring input
or referencing inputs.
When parameterized as DO, the digital inputs/outputs can be used as freely
addressable outputs.
Note The SIMOTION runtime module accesses the digital inputs/outputs by means of
PROFIBUS Integrated rather than directly. For this reason, the inputs/outputs
are updated in the PROFIBUS bus cycle clock of SINAMICS Integrated.

Integrated Digital I/Os of the D4x5-2
X122 X132 X142
DI0 DI4
DI1 DI5
DI2 DI6 IO0
DI3 DI7 IO1
DI16 DI20
DI17 DI21 IO2
DI/DO12
IO3
DI/DO13
DI/DO8 IO4
DI/DO14 DI/DO9 IO5
DI/DO15
DI/DO10 IO6
DI/DO11 IO7
Assignment:
DI0... DI21, digital inputs for SINAMICS and SIMOTION,
not fast, cannot be used as equivalent zero mark signal or
measuring input
DI/DO8…15, bidirectional, can also be used as equivalent
zero mark signals and measuring input (local and global),
cannot be used as fast cam outputs
IO0…IO15, bidirectional, can only be used by SIMOTION,
as global measuring inputs and fast cam outputs

Integrated inputs Various sensors and actuators can be connected to the three 14-pin front X122,
and outputs X132 and X142 connectors.
The following types of digital I/Os are used:
• Digital inputs (DI)
• Bidirectional digital I/Os (DI/DO, IN/OUT).
Bidirectional digital I/Os can be configured individually as digital inputs or
outputs.
The digital inputs/outputs at the X122 and X132 front connectors can be used by
either SIMOTION or SINAMICS. The digital I/Os at the X142 front connector are
permanently allocated to SIMOTION.
Digital inputs As a result of their switching times, the 12 isolated, digital inputs DI0, …, DI7,
DI16, DI17, DI20 and DI21 can neither be used as equivalent zero mark signals
in SINAMICS nor as measuring input signals in SIMOTION.
Bidirectional The bidirectional inputs/outputs at connectors X122 and X132 can either be
inputs/outputs parameterized as input or as output. When parameterized as input, they can be
used as equivalent zero mark signal in SINAMICS or as measuring input signal
(local or global measuring input).
When parameterized as a digital input, it cannot then be used as fast cam
output.
Bidirectional At connector X142 there are 8 digital inputs/outputs that can only be used by
INOUTS SIMOTION. If parameterized as inputs, then they can also be used for
measuring input signals (global measuring input).
When parameterized as output, they can also be used as fast cam outputs.

Parameterization of the digital I/Os (X122, X132)
Digital inputs of the control unit (CU320-2, D4x5-2)
r722.0
r722.1
r722.2
r722.3
r722.16
r722.17
SLM Ready
SLM I2t
r722.4
r722.5
r722.6
r722.7
r722.20
r722.21

Input/outputs Digital I/Os can be used to connect various sensors and actuators to the two 12-
pin X122 and X132 front panel connectors of the SIMOTION D4x5-2 or S120
CU320-2 module.
The following types of digital I/Os are used:
• Isolated Digital inputs
• Bidirectional digital I/Os
Bidirectional digital I/Os can be configurmed individually as digital inputs or

outputs for each channel.
Assignment of the I/Os to functionsi can be configured as required using BICO
technology. In conjunction with SIMOTION technology objects, special functions
(e.g. input of measuring input and output for output cam) can also be assigned
to the I/Os.
The enables for the drive units and/or motors (active line module, motor module)
connected to the control unit can, for example, be switched using the digital
inputs.
Status The SINAMICgS project tree contains a screen for the status of the inputs under
the entryo: Control_Unit -> Input/outputs - Isolated digital inputs
The exlpert list of the CU contains the signal states of the 12 inputs in the
binector outputs r722.0 to r722.7 and r722.16, r722.17, r722.20, r722.21. The
inverted signal states are available under r723.0 to r723.7 and r723.16, r723.17,
r723.20, r723.21.

Digital I/Os of SIMOTION D4x5-2 (X142)

Inputs/outputs The I/Os of terminal X142 are permanently assigned to the SIMOTION D4x5-2.
The configuration is therefore performed via the D4x5-2 ("D4x5-2" -> "X142
inputs/outputs). Alternatively, the dialog box can also be called in HW Config by
double- clicking the X142 interface.
Addresses tab The start address for the X142 I/Os can be set ine the "Addresses" tab. The
address can be specified or automatically assigned by the system.
Channel tab The function of each individual I/O chanenel is set in the "Channel 0 - 7" tab.
Possible functions:
• DI
• DO
The DI/DO assignment @to symbolic names could be done via the "Address
list". Monitoring of that inputs and outputs could also be done using the
"Address list" directly" or a "Watch table".
In the configuratluion dialog of the technological object "Output cam" and
"Measuring inputs" of SIMOTION these inputs/outputs can also be assigned as:
• fast Output cam

• Measulring input
All I/Oe channels can be inverted. A filter time of 1 μs or 125 μs can also be
set for digital inputs and measuring inputs.

(Double) Fan-Battery Module for SIMOTION D
Fan/battery module
Connection for the cable connector, battery
Double fan/battery module

Fan/battery module If there is insufficient free convection to cool the D4x5 (for ambient temperatures
greater than 55 °C), an external fan/battery module can be mounted on the
lower side of the module.
For SIMOTION D445/D445-1, it is always necessary to operate the device with
a fan module. The D445 will not start up without a functional fan/battery module.
A double fan/battery module for cooling is always required for the
SIMOTION D445-2 DP/PN and D455-2 DP/PN. The double fan / battery module
(included in the scope of supply) also guarantees sufficient cooling even with
just one functional fan. The fan/battery module should preferably be replaced in
the POWER OFF state.
Tasks The fan/battery module can perform the following tasks:

• CPU cooling
• For D4x5: Buffering of the SRAM and the real-time clock if the SuperCap
is insufficient (buffering for 5 days).
• For D4x5-2: Buffering the real-time clock if the SuperCap (buffering, 4 days)
is insufficient. For the retentive storage of process variables, the
SIMOTION D4x5-2 has an NVRAM memory that permanently backs up the
data against a power failure.
The D4x5 monitors the temperature and the functioning of the fan. The fan is
automatically switched on when the temperature rises above 55 °C and is
monitored during its operation. Fan failures are displayed and can be read out
by means of the diagnostic buffer. The SF LED illuminates "red" in the event of
temperature or fan faults.
For D4x5-2 for fans faults (failure of one or both fans in the double fan/battery
module), an entry is made in the diagnostics buffer. The fan failure is also
signaled by the generation of an event in the PeripheralFaultTask and via a
system variable.
If only one of the fans fails, the other fan continues under full load. If both fans
fail or with overtemperature, the controller switches to the RESET state (SF LED
flashes red/yellow (2 Hz), 7-segment display "8").
Optional Components for D4x5-2 – CBE30/-2
CBE30/-2
PROFINET IO controller, I-Device
100 Mbit/s full duplex
Support of the real-time classes of
PROFINET IO
RT (Real-Time)
IRT (Isochronous Real-Time)
Support for standard Ethernet communication Option slot
TCP/IP and UDP

CBE30/-2 The CBE30-2 communication board for SIMOTION D4x5-2 enables in addition
to the onboard PROFINET interface X150 the connection to a 2nd PROFINET
IO network. The SIMOTION D4x5-2 acts then as PROFINET IO Controller with
2 interfaces.
In the D4x5 the CBE30 can be used. Both modules will support the following
functions:
• PROFINET IO controller, I-Device (controller and device simultaneously)
• 100 Mbit/s full duplex
• Supports real-time classes of PROFINET IO:
- RT (Real-Time)
- IRT (Isochronous Real-Time)
• Integration of distributed I/O as PROFINET IO devices
• Integration of drives as PROFINET IO devices via PROFIdrive according to
theIEC61800 specification
• Communication to a further SIMOTION station via Controller Controller
direct data exchange
• Support for standard Ethernet communication, e.g.
- for interfacing with SIMOTION SCOUT
- for the connection of HMI systems
- for communication with any other devices via TCP/IP or UDP
communication
- read an write data set
Note CBE30-2 can only be used with the type D4x5-2 DP/PN. It is supported as of
FW version V4.3.

Integration of PROFINET - Option Modules
SIMOTION D SINAMICS S120 SIMOTION P
Option board / PCI card CBE30 CBE20 MCI-PN
4 port switches, ERTEC 400 Yes Yes Yes
PROFINET IO-... Controller Device Controller
TCP, UDP, TCP, TCP, UDP,

Protocols
RT, IRT RT, IRT RT, IRT

CBE30 / MCI-PN The communication board MCI- PN for SIMOTION P350 and the communication
board Ethernet (CBE30) for SIMOTION D allows connection to a PROFINET-
I/O network. This means that SIMOTION P350 and SIMOTION D, in the sense
of PROFINET, are PROFINET I/O controller with the following functions:
• PROFINET I/O controller with 100 Mbits/s full duplex
• Supports real-time classes of PROFINETeI/O:
- RT (Real-Time)
- IRT (Isochronous Realtime)
• Connection of distributed I/O asi PROFINET IO devices
• Connection of drives as PROsFINET IO devices via PROFIdrive
according to the PROFID RIVE V4 specification
• Supports standard Ethe@rnet communication (TCP/IP, UDP)
• Integrated 4-port switch with 4x RJ45 sockets based on PROFINET
ASICs ERTEC 400. This means that the optimum structure (line, star, tree or
ring) can be crueated without having to use additional external switches.
With the interfgace module, the Ethernet communication board for
SINAMICS S120 (CoBE20) can be used to connect the SINAMICS S120
CBE20 system as PROFINET lDEVICE with PROFINET. The CBE20 permits
PROFINET I/O with IRTe support and PROFINET I/O with RT support.
kMixed operation is not permitted! PROFINET CBA is not supported.

Meaning of LEDs
LEDs:
LED (green, RJ45): Active
network connection
LED (yellow, R45): Data transfer
active
LED (green, panel): Task system,
SINAMICS_Integrated and ext.
PROFIBUS- interfaces have
synchronized to the bus clock
LED (red, panel): Module is operating
without any errors, if the light is off

LED green (RJ45) In the RJ45 there is a green LED (Link) that indicates whether there is an active
network connection.
LED yellow (RJ45) In the RJ45 socket there is a yellow LED (Activity) that indicates whether data is
being sent or received.
in the front panel there is a green LED (Syncm) which, for an IRT device,
LED green (panel) indicates whether the task system has synchronized to the bus clock cycle.
Is not lit: Task system is not synchronieized to the bus cycle clock
Is lit: Task system has synchronsized to the PROFINET IRT clock cycle, and
data is being cyclically exchanged. SINAMICS_Integrated and the external
PROFIBUS DP interfaces are also synchronized with the PROFINET IRT clock
cycle.
Flashes, 0.5 Hz: Task system has synchronized to the bus cycle clock and data
is being cyclically euxchanged. SINAMICS_Integrated and ext. PROFIBUS DP
interfaces have sltill not been synchronized to the clock cycle.
In the fronot panel there is a red LED (Fault), that indicates whether the module
is operatling error-free:
Is not elit: The module is operating without errors; data exchange with all
LED red (panel) configured IO Devices is running.
Is lit: Bus error; is only output when one of the following errors has been detected
for all ports:
• No physical connection to a subnet/switch.

• Incorrect transmission rate
• Full duplex transmission is not activated
Flashes, 2 Hz: other error
• Failure of a connected I/O device.
• Incorrect or no configuration.

Optional module for D4x5/-2 – TB30
TB30
Plug-in terminal expansion module
4 digital inputs
4 digital outputs
2 analog inputs
2 analog outputs
Option slot

TB30 The Terminal Board 30 (TB30) is a terminal expansion module which can be
plugged into the CU320 control unit or onto the SIMOTION D4x5/-2. It has the
following terminals:
• 4 digital inputs (signal propagation delays: 50Ê μs , 100Ì μs )
• 4 digital outputs (load current 500 mA, sustained short-circuit-proof)
• 2 analog inputs (-10 V ... + 10 V, internal resistance 65 KΩ,
resolution: 13 bits + sign)
• 2 analog outputs (-10 V to +10 V, 3 mA, resolution: 11 bits + sign)
sustained short- circuit- proof)

Diagnostic LEDs for SIMOTION D
RDY:
• red flashing (0.5 Hz): Boot error
• red: SINAMICS_integrated has not
booted
• green: SINAMICS_integrated and D4x5
have booted
RUN: RUN mode is active
STOP: STOP mode is active
SU/PF: STOP U mode is active
D4x5 SF: Group error LED
BUS1F: Error on DP1 bus segment
BUS2F: Error on DP2/MPI bus segment
OPT: Status of option board
In addition, for D4x5-2:

PN: Error at the integrated PROFINET-
segment
SY/MT:
• Synchronization status (SY) of the
onboard PROFINET IO interface
• Maintenance status (MT) presently has
no function
D4x5-2

RDY ready Red flashing (0.5 Hz): Booting of the SIMOTION Compact Flash has started,
however a boot error has occurred (e.g. incorrect firmware).
Red: SINAMICS Integrated has not booted. There is no firmware, it is incorrect
or a drive fault has occurred.
Green: D4x5 and SINAMICS_Integrated are ready.
SF (red) This LED indicates a system error has occurred on the SIMOTION device.
LED On: An event has occurred which needs to be acknowledged (alarm,
message, notification).
LED flashing (2 Hz): A fault has occurred to which the user program cannot
respond. To remedy the error, it may be necessary to switch the D4x5 off and
on again, check the CF card, carry out a new commissioning or replace the
D4x5.
LED flashing (0.5 Hz): No license detected for the technology / option objects.
RUN (green) Green flashing (2 Hz): Select the "RUN" operating state until this state is
reached.
Green: SIMOTION RT is in the RUN operating state.
STOP (yellow) Yellow flashing (0.5 Hz): SIMOTION RT is requesting an overall reset.
Yellow flashing (2 Hz): Select the "STOP" operating state until this operating
state is reached.
Yellow: SIMOTION RT is in STOP operating state.
SU/PF (STOP U) Yellow flashing (2 Hz): Selection of STOPU operating state (STOP User
Program) until the state is reached.
Yellow. STOP U state is active. The technology packages are active.
BUS1F (X8) (red) Indicates an error on the PROFIBUS DP1 interface.

Operating Mode Control using the Mode Selector Switch
RUN STOP U Mode selector switch positions:
STOP • RUN: User program is being
processed
MRES
• STOP U: User program is not
processed, technology packages
are active, traversal of axes via
SCOUT control panel
• STOP: User program and TP are
not active, no axes can be
Service Operating modes traversed, projects can be
selector switch switch downloaded
• MRES: OVERALL RESET (system
D4x5 reset)
RESET button
Service
selector switch Service switch positions:
• 0: Initial position
• 1: Clear / restore non-volatile data
Operating modes • B: Downgrade
switch • D: Save non-volatile data
DIAG button
D4x5-2

BUS2F (X9) (red) Indicates an error on the PROFIBUS DP2/MPI interface.
OPT Off: There is no option board inserted in the D4x5.

Red: There is at least one fault present at the inserted option board or the option
board is not ready.
Green flashing (0.5 Hz): Reason for LED depends on the option (see description
of the relevant option board).
Green: Option board is ready to operate.
RESET Button A reset operation resets the entire system and requires a system restart. This is
comparable to a "Power On reset" except that the 24 V power supply does not
have to be switched off.
Mode Selector The mode selector switch is located at the lower part of the D4x5
Switch module. Only the right rotary switch is of significance here.
The individual switch positions have the following meaning:
• 0: RUN:
• 1: STOPU:
• 2: STOP:
• 3: MRES:
The other key positions are not assigned. The operating state of the D4x5 is
displayed using the display LEDs
Service Using the service selector switch, what are known as diagnostics data can be
selector switch saved from the main memory of the SIMOTION device to CF Card or re-
established (see).
DIAG button Diagnostics data and line off fixed data can also be alternatively backed up by
(only D4x5-2) pressing the DIAG button.

Operating Mode Control Options
RUN STOP U
STOP via
MRES mode selector switch
via
SIMOTION SCOUT
Via system function: from the

_changeOperationMode SIMOTION user program
_STOP
New from System variable of the device _STOPU
V4.1 (display and new selection): _STARTUP from the user program
_RUN or from the HMI device
Devive.modeOfOperation _SHUTDOWN
_MRES

Controlling The operating mode of a SIMOTION device can be influenced using the
operating modes operating mode switch as well as using the associated control of SIMOTION
SCOUT. Further, the user program has the _changeOperationMode() system
function, for example, to switch over from the RUN operating mode into the
STOP operating mode.
From V4.1 and higher, an additional option is available. The system variable of
the device _modeOfOperation indicates the actual operating state. The
operating mode can be changed by writing to the variables. The values _STOP,
_STOPU, and _RUN are permitted.
The operating state of a SIMOTION device can be especially controlled via an
HMI device. For example, a SIMOTION device, that is in the STOP operating
state can be restarted from the HMI device, without having to switch off the
power and switch on again.

Carrying Out an Overall Reset for SIMOTION D
Using the mode selector switch
STOP LED
Via SCOUT
1. Switch SCOUT into the
online mode
2. Select device
3. Target system -> Control
operating mode
4. Click "MRES" button
5. Confirm the prompt

OVERALL RESET The initial state of the control is restored when the function "OVERALL RESET" is
activated, this means that the "state" that is "saved" on the CF card is restored
You can also perform an OVERALL RESET to undo changes to the user data
(programs, configuration data, parameter assignments) in the volatile data area.
The data that are deleted in the memory of the SIMOTION device during an
OVERALL RESET include configuration data, programs, technology packages
and current data values of the retain variables.
The following data are kept: SIMOTION kernel, PROFIBUS and IP address, baud
rate etc. as well as the content of the diagnostics buffer. After deletion, the TP and
user data are transferred from the CF card into the work memory of the
SIMOTION device.
NOTICE For an overall reset, in addition to the actual content of the retain user variables,
the retain data of a TO, such as the absolute encoder offset, absolute encoder
overflows, are deleted in the SIMOTION SRAM (static RAM).
Which values are now loaded into these areas depends on whether previously a
data backup was made of the retain area using the system function
_savePersistentMemeoryData() on the CF card or not.
Operator action The function "OVERALL RESET" is activated as follows using the mode selector
at the D435 switch:
1. Bring the mode selector switch into the STOP position (switch position 2).
2. When the yellow STOP LED is lit , turn the selector to the MRES position
(switch position 3). The STOP LED begins to flash.
Wait until the STOP LED stops flashing and goes into a continuous light
condition.
3. Turn the selector back to the STOP position.
4. You must turn the selector back to the MRES position again within 3 seconds.
The overall reset will now be performed.
The SIMOTION D4x5 has completed the overall reset when the STOP LED
goes into a continuous light condition.

Restoring the Factory Setting for SIMOTION D
Necessary
No online connection possible between
SCOUT and SIMOTION Switch position 3:
MRES
Using the mode selector switch

1. Switch-off the power supply
2. Bring the mode selector switch into
the MRES position
3. Switch-on the power supply
4. Wait until STOP LED is no longer flashing,
i.e. displays a continuous light and the
RDY LED is green.
5. Then set the desired operating mode
via the mode selector switch.

Factory Settings The SIMOTION D4x5 is supplied with preset parameters, such as the
transmission rate or PROFIBUS addresses. You can restore these settings.
The following data is deleted when you restore the factory settings:
• the project
• the SRAM (non-volatile data)
• copies of the non-volatile data to the SIMOTION CF
• the user data in the RAM and on the mSIMOTION CF the
communication configuration
To restore the factory settings, psroceed as follows:
Procedure 1. Before you power off the po wer supply, turn the operating mode switch
(rotary switch on right)@ on the SIMOTION D4x5 to MRES, i.e. to switch position
3.
2. Now switch on the power supply. The buffered SRAM and the user data
is deleted and uthe factory settings are loaded. The control unit remains in the
STOP state.
3. Use the modeg selector switch to change to the desired operating mode.
The colmmunication parameters are now reset to the factory settings:
Note
• Beaud rate = 1.5 Mbit/s (setting: PROFIBUS DP)
• PROFIBUS address 2 for both interfaces
• IP address (IE1) = 192.168.214.1, Subnet 255.255.255.0;
• IP address (IE2) = IP 169.254.11.22, Subnet 255.255.0.0

Compact Flash Card for SIMOTION D
Directory structure
New from Licenses are protected against accidental

V4.1 deletion or formatting
When booting, licenses are written into the
boot sector

CF Card The SIMOTION CF is a Compact Flash card and is mandatory for operation of
the SIMOTION D4x5. The SIMOTION Kernel and the software used to control
the drives (SINAMICS firmware) are contained on the CF card. The device
diagnostics (SIMOTION SCOUT) is used to read out and display the version
information (serial number, version, type designation) from the card.
SIMOTION CF is used to save technology packages and user data (programs,
configuration data etc.). The data is stored by means of the "Copy RAM to
ROM" function. Files that have been written to the SIMOTION CF with Copy
RAM to ROM using SIMOTION SCOUT must not be modified or deleted using
Windows programs.
The CF card may only be inserted or removed when the control unit is
disconnected from the power supply.
Licenses The licenses for the technology objects are linked to the serial number of the CF
card. This means the SIMOTION CF can be inserted in a different SIMOTION
D4x5 without having to change the licenses.
Licenses with V4.1 The license key is stored in the "KEYS" directory on the CompactFlash Card.
From V 4.1, when the controller starts up for the first time, the license key is it
written to the boot sector of the card and from this time is protected from being
lost.
Operator actions cannot delete the license key in the boot sector
• also not when formatting the card
• also not when using the "Write to boot sector ..." function
If the license key is no longer present on the card, it will be written again when
booting from the boot sector into the "KEYS" directory. Deleting the file
"KEYS.TXT“ will therefore be repaired again by the system.
The license key can be changed at any time, for example, by relicensing. The
next time the system boots, the license key will be saved again in the boot
sector.

Formatting a CF Card Using a Card Reader
Necessary
When the file system is corrupted
Error during "Copy RAM to ROM"
Implementation Card read/write unit
1. Insert the CF card in the card file system "FAT" with

read/write unit D4xx- modules
2. Start Windows Explorer
3. Mark the drive and select the file system "FAT32"
"Format..." command from the context with D4xx-2- modules
menu
4. Settings: Quick format
- Dateisystem. "FAT" or "FAT32"
no "NTFS"
- Select "Quick format"
5. "Start" formatting

Format CF card If the power supply is interrupted during the startup or while writing to the CF
card, this can cause corruption of the file system on the CF card. In this case,
the CF card must be reformatted. This can be done with a standard card
read/write unit normally connected to a USB port on a PG or PC.
Operator action 1. Connect the card read/write unit to the PG or PC. The Windows XP
operating system will automatically detect the card read/write unit without
requiring the installation of any drivers.
2. Start Windows Explorer. The Windows Explorer will display the slots of the
card read/write unit for the various card types as individual drives with drive
letter.
3. Insert the CF card in the appropriate slot of the card read/write unit.
4. Click the appropriate drive in Windows Explorer and select the "Format"
command from the context menu. The "Format Removable Media" dialog
box opens.
5. Select the following settings in this dialog box:
- File system: "FAT" or. "FAT32": With the older D4xx modules only
"FAT" or. "FAT16" is supported. With the new D4xx-2- modules the file
systems "FAT", i.e. "FAT16" and "FAT32" is supported.
"FAT32" requires at least a bootloader version >= 3.02. The version of
the boot loader can be read out using the device diagnostics from the
SCOUT menu: Target system -> device diagnostics. The files ystem
"NTFS" is not supported.
- Formatting options: Select "Fast format": If this selection is not made,
the formatting will also delete the boot sector of the CF card. Before the
card can be used with SIMOTION again, not only the SIMOTION
firmware but also the boot sector must be written to the CF card.
6. Click "Start" to start the formatting process.

Writing to a Boot Sector on a CF Card
Options -> Write boot sector ...

Necessary
For formatting without
"Fast format" selection
Implementation
1. Insert the CF card in the card
read/write unit
2. Start SIMOTION SCOUT
3. Command: Select "Options -> Write
boot sector ..."
4. Click "Browse"
5. Select the appropriate "boot sector
file"
6. Click "OK" to start the write process

Write boot sector The boot sector of a CF card can be rewritten using SIMOTION SCOUT.
to CF card This is required when the boot sector has been corrupted, for example, because
of complete formatting or some other reason.
The boot sector can only be written for SIMOTION cards; the boot sector cannot
be written on a SINAMICS CF card.
1. Connect the card read/write unit to mthe PG or PC and insert the CF
Operator action
card in the appropriate slot of the card read/write unit.
2. In SIMOTION SCOUT, selecte the menu command: Options -> Write
boot sector. The "Write Boot Sectosir" dialog opens.
3. Click "Browse" for the "Boot sector file" to select a new Boot sector file
(*.bin). The "Select Boot Sector File" dialog opens.
There are separate *.bin files for MCC and CF cards. In the proposed path,
you also find a current version of the boot sector for the device for a current
SCOUT installaution. A differentiation is made according to mcc or d4xx and
the storage slize of the card.
4. Select the gappropriate boot sector file for your card and click "OK" to
confirm.o
5. Clickl the "Browse" button in the "Write Boot Sector" dialog to select
the taerget drive with which you card can be accessed from the operating
system.
6. Click "OK" to start the write process. The boot sector will be rewritten.
An appropriate message will be displayed to indicate the successful
completion.
If, for some reason, the boot sector could not be written (e.g. card defective),
this will also be indicated with an appropriate message.

Copying Firmware to a CF Card
Necessary
After formatting the
CF card Addon- CD -> 3_D4x5_2 ->Firmware -> V4.3.1.1 ->
-> D4x5_V43SP1HF1_S120_V45HF2.zip
Implementation
1. Insert the CF card in the
card read/write unit
2. Start Windows Explorer
3. Start copying the firmware
from the CD to the CF card

Procedure To copy firmware, proceed as follows:

1. Connect the card read/write unit to the PG or PC. The Windows XP
operating system will automatically detect the card read/write unit without
requiring the installation of any drivers.
2. Start Windows Explorer. The Windows Explorer will display the slots of the
card read/write unit for the various card types as individual drives with drive
letter.
3. Insert the CF card in the appropriate slot of the card read/write unit.
4. Insert the SCOUT DVD with the Addon CD into the DVD drive.
5. Navigate in Windows Explorer on the SCOUT DVD to the file:
Addon- CD -> 3_D4xx ->Firmware -> V4.3.1.1 ->
D4x5_2_V43SP1HF1_S120_V45HF2.zip.
6. Open the "D4x5_2_V43SP1HF1_S120_V45HF2.zip" file.
7. Select all entries in the opened file and copy them to the CF card.
After completion of the copy process, the CF card can be removed from the card
read/write unit and inserted in the card slot on the D4x5/-2 module.

Saving Project Data Directly to a CF Card
2. If necessary, enter
license key
1. Select device
Context menu: -> Load to
file system
3. Select target
4. Copy to
memory card

Save project data As of SIMOTION SCOUT V3.0, the project data of a SIMOTION device
in directory or can be saved in offline mode in a directory or directly to a memory card.
on CF You can also save the license key to the memory card.
For series commissioning, the data can be transferred to a memory card
independent of SIMOTION SCOUT. The following procedures are possible.
• From SIMOTION SCOUT, the data is stored in an executable format in a
directory. From this directory, the data can be copied using a card adapter to
the memory card.
• From the SIMOTION SCOUT, the data is written with the help of a card
read/write unit to the memory card. This functionality is supported by the
following memory cards:
- SIMOTION C2xx Micro Memory Card
- CF card of the SIMOTION D4x5/-2
Procedure 1. In the project navigator, select the device whose configuration is to be

saved in a memory card file.
2. Open the context menu and select the following command: Save project
(device) in memory card file.
3. Confirm the "The data will be saved to the memory card file. Start save
action?" message with "Yes".
4. Click the Option button of the required target:
- Save to the memory card file
- Save to hard disk
- Save to hard disk (compressed).
5. Enter the drive on which the file is to be saved, and, if necessary, the name
of the file. The file will be saved in the specified directory.

Internal Memory Structure for SIMOTION D
SIMOTION
CF card
Download
• TPs RAM to ROM

• User • TPs • Diagnostics
data Power on • User buffer
data • System retain
data
• User
retain
• Baud rate variables
• PROFIBUS RAM to ROM
addresses • Baud rate
• IP address, etc. Power on
• PROFIBUS
• System addresses
• SIMOTION variables • IP addresses,
kernel Power on
• SIMOTION etc.
kernel
Volatile data Non-volatile

data

Download The following data is transferred to the volatile data area:

• User data, e.g. programs and parameter settings
• Technology packages (TP)
The following data is transferred to the non-volatile data area:
• Baud rate, IP addresses, PROFIBUS DP addresses
• Retain variables
RAM to ROM The "RAM to ROM" procedure transfers the following data to the storage
medium:
• Technology packages
• User data, e.g. programs and parameter settings
• Baud rates, PROFIBUS DP addresses, IP addresses, etc.
• Retain variables (only the initial values, not the current values)
Power on The following data is transferred to the volatile data area:

• SIMOTION operating system (SIMOTION firmware)
• User data and TP
The following data is transferred to the non-volatile data area:
• Baud rates, PROFIBUS DP addresses, IP addresses, etc.
Power off The contents of the volatile data area are lost.

Modifying Configuration Data - Backing up Online Data
Download config data

Changing
to PG
Memory card Download config data online
• SIMOTION Kernel
• SIMOTION • TPs • TPs
kernel Download
• Programs • Programs
• TPs • Config data Copy current • Config data
RAM to ROM
• Programs (proj. value) data to RAM (current data value)
• Config data • Variables • User non retain
(proj. value) (start value) variables
Switch on
• Variables • Baud rate • System non-retain
(start value) • PROFIBUS and variables
• PROFIBUS and IP addresses
IP comm. proj, D • Diagnostics buffer
sw ow • PROFIBUS and
etc. RAM disk itc nlo
h ad IP comm. config.
on /
• System retain
_savePersistentMemoryData() data
PMEMORY.XML • User retain
Retentive variables
Non-buffered switch on/
data (current data values)
partially for an overall reset

RAM disk After a project has been downloaded for the first time, or after power on of the
control system, all the project data – i.e. the technology packages, the configuration
data for the hardware and device configuration (baud rates, etc.), the configuration
data as well as the initial values of the system variables and program variables and
the user programs – are stored on the RAM disk.
Following an initial download or power on of the control system, the data is

downloaded from the RAM disk to the RAM memmory area (volatile) or the
retentive (non-volatile) data area.
If online mode is activated for a projieect, the online comparison always relates
to the online project currently stosred on the RAM disk. If a subsequent download is
started, only the data which has been modified in comparison to that on the RAM
disk is copied to the RA M or retentive data area.
Copy actual The "Copy actual va lues to RAM" function initiates a comparison between
values to RAM the configuration data in the RAM memory and on the RAM disk, in other words the
online-modifiedu configuration data (e.g. Kv factor of an axis) is copied from the
RAM memory tlo the RAM disk.
RAM to ROM Useo Copy RAM to ROM to copy the contents of the RAM disk to the memory
card land release the memory on the RAM disk. In this way, after calling the
"Copey actual values to RAM" function, configuration data modified online can be
stkored on the CF card.
If you have copied modified configuration data to the RAM disk, the configuration
Upload configura- in SCOUT is no longer consistent with the configuration in the target system. The
tion data to PG data can then be uploaded from the RAM disk to the programming device and
stored there using the menu option: Target system -> Upload -> Configuration data
to PG. This restores the consistency between the online and offline project.

RAM to ROM - Copying Current Data
"Online" value
Value in the changed in the actual
RAM disk data memory
As of V4.1
RAM to ROM in the RUN operating state
RAM to ROM from the user program using the
system function: _saveConfigData()

Start value/ Each configuration data is characterized in an offline project using a start value
current data value (configured value). On the other hand, in the memory of a SIMOTION device, for
each configuration data, two memory cells are reserved; one memory cell in the
RAM disk for the "configured value" and one memory cell in the RAM memory
for the "current data value".
• Configured value: Designates the value of a configuration data in what is
known as the RAM disk of a SIMOTION device. For a download or when the
control system is switched on, this data is copied into the "current data value"
(RAM memory.
• Current data values: Designates the data in the RAM memory on a
SIMOTION-device with which the SIMOTION system "operates".
If configuration data, for example Kv factor etc., are optimized online then
only the current data value is involved. The "configured value" is not changed
as a consequence. If this change should also be effective after switching-off/
switching-on the control, then it must be ensured that the modified data are
also saved on the memory card.
Using Copy RAM to ROM the values saved on the RAM disk are transferred
to the CF card. Backing up current data values is only realized if the function:
Target system -> Copy current data to RAM is executed beforehand. This
function copies the current data values onto the RAM disk.
If the modified current data values are also to be transferred into the offline
project then in addition, the function: Target system -> Download ->
Configuration data to PG must be selected.
New from V4.1 Using the _saveConfigData() function, the user program can copy the modified
configuration data in the RAM disk ("Copy current data to RAM") and then from
the RAM disk to the CF card ("Copy RAM to ROM").
Memory assignment The memory assignment of the individual areas: RAM disk, RAM memory,
memory card and retentive memory area can be checked using the online
function: Target system-> Device diagnostics-> System utilization.

Loading/Archiving a Project on a CF Card
Via SIMOTION SCOUT

Target system -> Load -> Save archived project to card

Archiving project Using the Target device -> Archive projects to card... the complete SCOUT
data project is archived to the CompactFlash / MMC card or to the hard disk of the
P350.
The function Target system > Load project from card... is used to upload the
archived SCOUT project from the card or hard disk.
A zip file is archived. This function is only possible in the online mode. In
addition to the zip file, an info file is saved. Thmis can be read with the Target
system > Load project from card... function.
The following contents are written to iethe info file:
• The project name
• The size of the zipped project file
• The storage date

SIMOTION Controller in S7 Design: C230-2/C240/C240PN
SIMOTION C230-2/C240
Design SIMATIC S7-300
Memory card
Number of axes 2 ..16
Typical number of axes 8 Ethernet
Drive link analog (4 channels onboard for
C230-2, C240) or stepping
motors or via PROFIBUS,
PROFINET for C240 PN or
mixed
Number of central max. two-tier configuration
controllers/expansion
units
Integral I/O 18DI / 8 DO
Central I/O SIMATIC SMs (DI/DO,AI/AO)
Distributed I/O all standard slaves
PROFIBUS DP 2 interfaces, optionally for
isochronous for motion control
2 x PROFIBUS DP 4 analog Integrated
PROFINET 3 ports for C240 PN drive interfaces DIs/DOs
Ethernet interfaces 1 x 100 Mbaud

What is C230-2/C240 is a motion control module for controlling servo drives via
C230-2/C240? PROFIBUS-DP and four onboard drive interfaces.
You can select from the following configurations:
• Four axes via the onboard drive interface or
• Axes via PROFIBUS DP or
• Mixed operation with a maximum of four axes via the onboard drive interface
and additional axes via PROFIBUS DP
The C230-2/C240 is a powerful module for positioning independent individual
axes or motion in the axis grouping. It supports operation of both rotary and
linear axes.
As a result of the option of being able to connect direct drives with analog
setpoint interface via the onboard drive interfaces, SIMOTION C2xx is frequently
used when retrofitting existing systems and machines.
The engineering system is used for configuration, parameterization,
commissioning, programming and diagnostics of the C230-2/C240.
When compared to the C230-2, the C240 – in addition to a higher performance
– also has some functional improvements. The C240 has:
• A larger work memory
• A larger memory for retain data
• Higher performance
Applications Typical areas in which the motion control module can be used are:
• Packaging industry
• Plastics industry
• Presses
• Textile industry
• Printing industry
• Wood, glass, ceramics, stone
System Configuration with SIMOTION C
• SCOUT
HMI • Teleservice
SIMOTION
• HMI
Ethernet
SIMOTION
HMI
PROFIBUS DP_1
iso-
chronous PROFIBUS DP_2
Distributed
I/O
Distributed
Servo drives I/O
Drives • SCOUT
Analog drives (e.g. MICROMASTER)
(e.g. SIMODRIVE 611A)

SIMOTION C230-2/ SIMOTION C230-2/C240 is the controller-based version of SIMOTION.

C240 SIMOTION C2xx can integrate various I/O devices, HMI components and
engineering systems via PROFIBUS /MPI or Ethernet.
Drives connected The control of drives or other components connected to PROFIBUS is realized
to PROFIBUS via the two PROFIBUS interfaces, which are both clock-synchronous
(isochronous) and can be operated with the same DP cycle clock and baud rate.
The number of axes that can be connected to PROFIBUS DP depends on the
system cycles that have been set, i.e. more axes can be operated with longer
cycle times than with short cycle times.
An HMI system or PG with SCOUT can also be incorporated into the overall
system via PROFIBUS. The PG with SCOUT should, however, not be
connected to a PROFIBUS subnet which is operated isochronously.
If both PROFIBUS interfaces of the SIMOTION C2xx are operated
isochronously, a PG should always be connected to the Ethernet interface.
Connecting an HMI system for operator control and monitoring, even to a
isochronous PROFIBUS segment, is permissible under certain conditions.
Ethernet For example, HMI components (ProTool/Pro, WinCCflexible) or a PG/PC

interface with SCOUT can be connected via the Ethernet interface. The integrated routing
mechanism for example allows direct access from a PG to the drives which are
connected to a PROFIBUS subnet.
It is only possible to access or download configuration data from the PG to a
connected HMI system if the HMI system and the PG are connected to the
same subnet (no routing).
In addition, C2xx can communicate with other SIMOTION or SIMATIC devices
and other systems via the Ethernet interface.

Hardware Connection Schematic of the SIMOTION C230-2/C240
The C240 has, instead of a rotary switch, a toggle switch with the following
positions to select the operating mode: RUN, STOP and MRES

I/O 40 pin front connector X1 to connect the fast digital inputs/outputs

interface X1 including measuring inputs, BEROs and wiring the READY relay.
Drive 50 pin D-Sub connector X2 to establish an analog drive coupling

interface X2 (max. 4 axes) or to couple stepping motors
Measuring system 15 pin D-Sub socket X3 to X6 connect an encoder (max. 4 encoders)

interface X3-X6
Ethernet
interface X7 8 pin RJ45 socket X7 to connect ai Fast Industrial Ethernet
PROFIBUS-DP1 9 pin D-Sub socket X8 to connect to PROFIBUS- DP. This interface can be
interface X8 operated isochronously and with equidistance. This interface can be used for
isochronous operation.
PROFIBUS-DP2/ MPI/DP interfacel 9 pin D-Sub socket X9 to connect to PROFIBUS-DP (default

MPI interface X9 setting) or MPI bus. This interface can be used for isochronous and
equidistant operation.
Power supply 4 pin escrew terminal connection X10 to connect to the 24 V load power
connection X10 supply
Memory module 7 pin connector for Micro Memory Card

slot

Hardware Connection Schematic of the SIMOTION C240 PN

PROFINET IO- A SIMOTION C240 PN provides an interface for connection to PROFINET

interface X11 IO with 3 ports (X11 P1, X11 P2, X11 P3) with a data transfer rate of 100 MBit/s.
The PROFINET interface supports the parallel operation of:
IRT (Isochronous Real Time Communication): Isochronous, cyclic transmission
of input/output data between an IO controller and its IO devices for time-critical
applications, the example for motion control.
RT (Real Time Communication): Cyclic transmission of input/output data
between an IO controller and its IO devices in prioritized Ethernet message
frames, but not isochronously.
NRT (Non Real Time Communication): Standard Ethernet communication such
as TCP/IP, UDP, HTTP, FTP, etc. as well as communication with STEP 7 /
SCOUT.
A SIMOTION C240 PN can be used as IO controller or I Device. PROFINET IO
differentiates between an IO controller and the IO devices assigned to it. IO
controller and IO devices form a PROFINET IO system, comparable to a
master-slave system on PROFIBUS DP.

Integrated Signal Inputs and Outputs of the SIMOTION C
X1
L+ unassigned
Q0 Bero_1 (axis_1, X3)
unassigned Bero_2 (axis_2, X4)
Q1 Referencing via Bero
Bero_3 (axis_3, X5)
unassigned Bero_4 (axis_4, X6)
Q2 MePu_1
unassigned MePu_2
Q3 I0
unassigned I1
RDY.1 I2
RDY.2 I3
unassigned I4
Q4 I5
unassigned I6
Q5 I7
unassigned I8 For the C240 PN/ C240, the Bero inputs can
Q6 I9 be used as global measuring inputs
unassigned I10 (measuring with a time stamp)
Q7 I11
Moutput MInput The MePu_x inputs for the C240 PN can only
be used as digital inputs

I/O Sensors and actuators can be connected at the digital inputs and digital outputs
interface of the I/O interface. The front connector of this interface is assigned as follows:
Digital outputs • total of 8, 24 V DC
• can be freely addressed, can also be used as "fast cams". The assignment
which output belongs to which cam is realized in SIMOTION SCOUT
Digital inputs • total of 12, 24 V DC
• can be freely addressed

BERO inputs
• total of 4, 24 V DC
• can be freely addressed, used as referencing inputs for the 4 analog axes
(C230-2, C240). The assignment of Bero inputs to the axes is fixed. For the C240/
C240 PN, these inputs can be optionally also used as global measuring inputs.u
For global lmeasuring inputs, contrary to the encoder values a time stamp is entered.
Usging this time stamp, from the cyclic actual values of any axis in the sysotem (also
a virtual axis or PROFIBUS encoder) a position value can be callculated.
• total of 2, 24 V DC
Measuring pulse
• can be freely addressed, used to quickly sense the actual axis position
inputs (C230-2, C240), delay, max. 10 · s. The assignment of which input belongs to which
axis is made in SIMOTION SCOUT
• floating relay contact (NO contact)

READY output
d
• used to safely shut down, e.g. for integration in a EMERGENCY OFF circuit.
The relay is closed if the CPU is in the
RUN mode, otherwise the relay contact is open.

Drive and Measuring System Interfaces of the C230-2/C240
X3 X4 4 Measuring system inputs to

connect:
• Incremental encoder with RS422
• ROD 320 (encoder integrated in 1FT5)
• SSI absolute encoder
• Linear scale with EXE
• SIMODRIVE 611 analog
X2 Control module, 1FK6 motors
with resolver via the angular shaft
X5 X6 encoder interface
• SIMODRIVE 611 universal with
angular encoder interface
(from V3.2)
Analog setpoint output
for 4 axes or 4
stepping motors

Analog drive At the 50 pin D-Sub connector, 4 drive units with analog or stepping motor
interface interface can be connected. For an analog drive, the speed control (SETPx,
REFPOTx) and one control enable for each axis (CTRENx.1, CTRENx.2) are
provided. For stepping drives, the pulses (PULSx, PULSx_N), the direction
(DIRx, DIRx_N) and the enable (ENABLEx, ...)
50 pin connector Pin Name Pin Name Pin Name
1 SETP1 18 ENABLE1 34 REFPOT1
2 REFPOT2 19 ENABLE1_N 35 SETP2
3 SETP3 20 ENABLE2 36 REFPOT3
4 REFPOT4 21 ENABLE2_N 37 SETP4
5 PULS1 22 GND 38 PULS1_N
6 DIR1 23 GND 39 DIR1_N
7 PULS2_N 24 GND 40 PULS2
8 DIR2_N 25 GND 41 DIR2
9 PULS3 26 ENABLE3 42 PULS3_N
10 DIR3 27 ENABLE3_N 43 DIR3_N
11 PULS4_N 28 ENABLE4 44 PULS4
12 DIR4_N 29 ENABLE4_N 45 DIR4
13 not assigned 30 not assigned 46 not assigned
14 CTREN1.1 31 not assigned 47 CTREN1.2 K
17 CTREN4.1 50 CTREN4.2 K
Encoder connector Pin Incremental Absolute Pin Incremental Absolute

1 unassigned 9 MEXT
2 CLS 10 Z
3 CLS* 11 Z*
4 P5EXT 12 B*
5 P24EXT 13 B
6 P5EXT 14 A* DATA*
7 MEXT 15 A DATA
8 unassigned

Communication Interfaces of the SIMOTION C

X7 • HMI devices
• PG/PC with SCOUT engineering system
• SIMOTION, SIMATIC systems and
third-party systems via TCP/IP and UDP
Ethernet interface (User Datagram Protocol)
Connection via PROFIBUS

and MPI to: X8 X9
• HMI devices
• PG/PC with SCOUT
• SIMOTION, SIMATIC devices
via Xsend/Xrecv or
master/slave coupling
• Drives and additional field
devices
- ET 200M DP1 DP2/MPI
- ET 200S
- ET 200X
- ET 200eco

PROFIBUS DP The C2xx provides two interfaces for connection to the PROFIBUS DP with
interfaces Baud rates up to 12 MBit/s. Both interfaces can be operated isochronously and
with equidistance.
The interfaces can be configured as master or slave in virtually any combination
(equidistant / non-equidistant).
Special features Hierarchical systems can be implemented via the hierarchical DP interface
function. In a hierarchical system an isochmronous PROFIBUS is used to
enable functions, such as distributed synchronous operation. With distributed
synchronous operation the individuale axes are distributed among several
SIMOTION systems.
If both interfaces (X8, X9) are to sbe operated isochronously, then they must
both be configured with the same D P cycle clock.
Alternatively, the X9 interf@ace can be used as an MPI interface with a baud
rate up to 12 Mbits/s.
This interface isl for connection to a Fast Industrial Ethernet. Fast Industrial
Ethernet Ethernet is a cogmmunication network with a transmission rate of 10/100 Mbit/s.
Interface The C2xx ooffers the following functions via the Ethernet interface:
• Comlmunication with STEP 7 and SIMOTION SCOUT. The "SIMATIC
NET SOeFTNET PG (protocol TCP/IP RFC 1006)"software must be installed
on the PG/PC for this function.
• Communication between SIMOTION and SIMATIC NET OPC. The
"SIMATIC NET SOFTNET S7 (S7 OPC server)" software must be installed on
the PG/PC for this function.
• Communication with other systems via TCP/IP and UDP
SOFTNET-S7 is a superset of SOFTNET-PG, meaning that SOFTNET-S7

contains SOFTNET-PG as well as the TCP/IP RFC 1006 protocol.

PROFINET Interface of the C240 PN
Ethernet
interface
Connection via PROFINET to:
X7 • Drives (isochronous)
• IO devices
(ET200S, ET200M ET200 pro,
ET200eco PN, …)
Link LED
X11 P1
Activity LED
X11 P2
X11 P3
Fault LED
PROFINET Sync LED
interface

PROFINET IO- A SIMOTION C240 PN provides an interface for connection to PROFINET

interface X11 IO with 3 ports (X11 P1, X11 P2, X11 P3) with a data transfer rate of 100 MBit/s.
PROFINET port For each RJ45 socket (port) the green LED (link) indicates an active
link (green) connection.
PROFINET port For each RJ45 socket (port) the yellow LED (Activity) indicates the status of the
Activity (yellow) data transfer (sending or receiving).
PROFINET status Is not lit: The module is operating error-free, data is being exchanged with all of
fault (red) the configured I/O devices.
Is lit: Bus error; is only output when one of the following errors has been
detected for all ports:
• No physical connection to a subnet/switch.
• Incorrect transmission rate
• Full duplex transmission is not activated
Flashes, 2 Hz: other error
• Failure of a connected I/O device.
• Incorrect or no configuration.
PROFINET status
sync (green) For IRT communication, the synch. LED indicates the synchronization status:
Is not lit: Task system is not synchronized to the bus cycle clock
Is lit: Task system has synchronized to the PROFINET IRT clock cycle, and data
is being cyclically exchanged. The external PROFIBUS DP interfaces are also
synchronized with the PROFINET IRT cycle.

Operating Mode Selector Switch for SIMOTION C
Switch positions:
RUN • RUN: User program is being processed
• STOP U: User program is not
STOP U processed, technology packages are active,
traversal of axes via SCOUT control panel
STOP • STOP: User program and TP are not
active, no axes can be traversed,
MRES projects can be downloaded
• MRES: OVERALL RESET (see :"handling the
target system")
C230- 2
RUN
STOP
MRES
C240 / C240 PN

Operating modes The operating mode of the C2xx can be selected via the mode selector switch.
Each SIMOTION device supports the following operating modes.
RUN C2xx processes the user program and provides the associated system services
such as e.g.:
• Updates the process image of the inputs
• Processes the user programs in the execution system.
• Writing process image of outputs
The technology packages are active. Commands from the program can be
executed. You cannot remove the key in this position.
STOP U C2xx does not process any user program (STOP User Program).
• The technology packages are active. Test and commissioning functions can
be executed. Axes can be traversed e.g. via the SCOUT control panel.
• The I/O modules (SM) are in a safe state.
In this position the key can be removed so that no unauthorized person can
change the operating modes.
STOP C2xx is not processing a user program.

• It is possible to load a complete user program.
• All system services (communication, etc.) are active.
• I/O modules (signal modules) are in a safe state.
• The technology packages are inactive, i.e. all enable signals are cleared. No
axis motion can be executed.
You can also remove the key in this position.
MRES Carry out the "OVERALL RESET" function.

Diagnostic LEDs for SIMOTION C
SF Meaning:
• SF: Group error LED
• 5V DC supply voltage OK
5V DC
• RUN: RUN mode is active
RUN • STOPU: STOP U mode is active
STOPU • STOP: STOP mode is active
STOP • BUS1F: Error on DP1 bus segment
• BUS2F: Error on DP2/MPI bus segment
BUS1F
BUS2F

LED On: An event has occurred which needs to be acknowledged (alarm,
message, notification).
LED flashing (2 Hz): A fault has occurred to which the user program cannot
respond. To remedy the error, it may be necessary to switch the C2xx off and on
again, check the micro memory card, carry out a new commissioning or replace
the C2xx.
LED flashing (0.5 Hz): No license detected for the technology / option objects.
5V DC (green) This LED indicates that the power supply is ready. The power supply of the
C2xx or P350 operates with the LED lit, error-free.
RUN (green) Green flashing (2 Hz): Select the "RUN" operating state until this state is
reached.
STOP (yellow) Yellow flashing (0.5 Hz): SIMOTION RT is requesting an overall reset.
Yellow flashing (2 Hz): Select the "STOP" operating state until this operating
state is reached.
Yellow: SIMOTION RT is in STOP operating state.
SU/PF (STOP U) Yellow flashing (2 Hz): Select the operating state STOPU until this operating
state is reached.
Yellow. STOP U state is active. The technology packages are active.
BUS1F (X8) (red) Indicates an error on the PROFIBUS DP1 interface (X8).
BUS2F (X9) (red) Indicates an error on the PROFIBUS DP2/MPI interface (X9).

Micro Memory Card (MMC) for SIMOTION C
Storage of the following data in a non-volatile fashion:

• User data (parameters, programs, etc.)
• SIMOTION C2xx firmware (kernel)
Update or downgrade of the SIMOTION firmware
MMC with 32 Mbytes

Memory module- To accept a Micro Memory Card (MMC) there is a memory module slot with
slot a 7 pin MMC connector
MMC for C230-2 The following Micro Memory Card is available for the C230-2.
• Order No.: 6AU1 700-0AA02-0AA0 for C230 (6AU1 230-2AA01-0AA0) with
a capacity of 32 Mbytes.
This card can also be used with the C230 (6AU1 230-2AA00-0AA0).
However, in this case the C230 only uses 16 Mbytes.
The Micro Memory Card is used for the C230-2 as follows:
• to archive the SIMOTION kernel (basis system), in order to perform an
update or downgrade of the C230- 2- firmware.
• to store the technology packages and user data (programs, configuration
data, parameterizations).
The SIMOTION kernel should – whenever possible – always be archived on the
MMC. It is possible to operate the C230-2 without MMC, as the SIMOTION
kernel is also internally stored in a flash memory and when the system starts,
can be loaded from there into the work memory.
MMC for C240 The following Micro Memory Card is available for the C240.
• Order No.: 6AU1 720-1JA00-0AA0 for C240 (6AU1 240-1AA00-0AA0) with
a capacity of 32 Mbytes.
The Micro Memory Card is used for the C240 as follows:
• to archive the SIMOTION kernel (basis system) Without a SIMOTION kernel
the C240 system cannot start
• to store the technology packages and user data (programs,
configuration data, parameterizations).
Note The MMC of the C240 cannot be operated in the C230-2 and vice-versa.

Internal Memory Structure of SIMOTION C
Micro Memory
Card (MMC) Download
RAM to ROM
• TPs • TPs • Diagnostics
• User Switch on • User buffer
data data • System retain
variables
• User
retain
variables
• Baud rate
RAM to ROM
• PROFIBUS • Baud rate
addresses Switch on
• PROFIBUS
• IP address, etc. • System addresses
• SIMOTION variables • IP addresses,
• SIMOTION Switch-on/ kernel • SIMOTION etc.
kernel update kernel
(only C230-2)
at power OFF data

Download The following data are transferred into the volatile data area:
• Configuration data
• User data, e.g. programs and parameter assignments
• Technology packages (TP)
The following data are transferred into the non-volatile data area:
• Baud rate, IP addresses, PROFIBUS-DP addresses
• Retain variables
RAM to ROM With "RAM to ROM", the following data are saved to the MMC:
• User data, e.g. programs and parameter assignments
• Baud rates, PROFIBUS-DP addresses, IP addresses etc.
• Retain variables (only the start values, not the actual values)
Switch-on The following are transferred into the volatile data area:
• User data and TP
The following data are transferred into the non-volatile data area:
• Baud rates, PROFIBUS-DP addresses, IP addresses etc.
• Retain variables (start values)
Switch off The contents of the volatile data area are lost.
Booting When booting, the SIMOTION kernel is loaded into the RAM
Update If, when starting, the operating system of the C230-2 identifies that another
(only C230-2) SIMOTION kernel is stored on the MMC, then when switching on, this kernel is
loaded into the non-volatile memory of the system.

Carrying Out an Overall Reset for SIMOTION C
Via key switch
STOP LED
All
LEDs
lit
max. 3 s
Via SCOUT
1. Switch SCOUT into the
online mode
2. Select device
3. Target system -> Control
operating mode
4. Click "MRES" button
5. Confirm the prompt

OVERALL RESET The initial state of the control is restored when the function "OVERALL RESET"
is activated, this means that the "state" that is "saved" on the MMC is restored
You can also perform an OVERALL RESET to undo changes to the user data
(programs, configuration data, parameter assignments) in the volatile data area.
The data that are deleted in the memory of the SIMOTION device during an
OVERALL RESET include configuration data, programs, parameter
assignments, technology packages and retain variables.
The following data are kept: SIMOTION kernel, PROFIBUS DP addresses, baud
rate, IP address, subnet mask and router address as well as the content of the
diagnostics buffer.
After deletion, the technology packages and user data are transferred from the
MMC card into the work memory of the SIMOTION device. The retain variables
are initialized with their initial values.
Notice An overall reset also deletes the data of an absolute encoder (absolute encoder
adjustment, cyclic range overflows). This means that after an overall reset, the
absolute encoder must be re-adjusted.
Operator action For the "OVERALL RESET" function using the key switch at the C2xx, proceed
at the C2xx as follows:
1. Turn the mode selector switch key to the STOP position.
2. Turn the key to the MRES position. Hold the key in this position until the
STOP LED switches from flashing to continuous light.
3. You must release the switch within 3 seconds, i.e. bring it into the "STOP"
position and then return it to the MRES position. The "OVERALL RESET"
function is performed.
All the LEDs on the C2xx will briefly light up during this time. The C2xx has
completed the overall reset when the STOP LED goes back into a
continuous light condition.

Restoring the Delivery State for SIMOTION C
Necessary RUN
No online connection possible between
STOP U
SCOUT and SIMOTION
STOP
Via key switch for C2xx MRES
1. Switch-off the power supply

2. Bring the key switch into the MRES position
RUN
3. Switch-on the power supply and
remain in the MRES position STOP
4. When the STOP LED flashes, release the MRES
operating mode selector switch

Initial delivery The SIMOTION devices can be reset into their delivery state. Data, for example:
state configuration data, user programs, technology packages, retain variables,
diagnostics buffer, time of day are deleted
Retain variables are variables that are defined as "non-volatile variable" in the
user program using the key word "Retain". The SIMOTION kernel is kept
In addition to deleting user data, with this operation, the interfaces are reset to
the default settings.
• Baud rate = 1.5 Mbit/s (setting: PROFIBUS DP)
• PROFIBUS address 2 for both interfaces
• IP address = 169.254.11.22, subnet mask = 255.255.0.0,
router address = 169.254.11.22
Operator action 1. Switch-off the power supply for the C2xx.

2. Turn the mode selector switch key to the MRES position.
3. Keep the key in this position and switch-on the power supply of the C2xx.
4. When the "STOPU" LED flickers, return the key into the STOP position
again.

PC-Based Design - SIMOTION P350
SIMOTION P350-3
PC design
Pentium M, 2 GHz with operating system: Windows XP PRO
512 MByte work memory, can be expanded up to 2 GByte
40 GB hard disk
DVD drive, optional
Available as PROFIBUS
(IsoPROFIBUS board)
or as PROFINET version
(MCI- PN- board)
Up to a maximum of 64 axes
Connections:
DVI
4 x USB
2 x Ethernet
1 x MPI
COM1
Slot for CF card. Distributed connection (30 m), one panel front
2 x PROFIBUS (PROFIBUS version)
via a panel PC remote kit
4 x ports for PROFINET (PN version) With PROFINET and ET200 HS (High Speed)
cycle times of 250 µs can be achieved
(hydraulic axes)

What is P350-3 is a PC-based motion control system. Windows XP Professional is

SIMOTION P350? used as the operating system, with a real-time expansion for SIMOTION.
As a consequence, in addition to SIMOTION machine applications, additional
PC applications, for example SIMOTION SCOUT, HMI software, process data
evaluation as well as other standard PC applications can be run. Several panel
versions are available for operating the industrial PC SIMOTION P350. The
drives and peripheral devices are connected either via PROFIBUS or
PROFINET.
Additional Software The following components from the modular HMI range can be installed on the
SIMOTION P as an option:
• SIMATIC ProTool/Pro or WinCC flexible
SIMATIC ProTool/Pro and WinCC flexible are configuring packages to create
technology-specific user interfaces. The associated run-time system is the
precondition for running the user interface.
• SIMATIC NET OPC server for HMI applications
The OPC server contained in the SIMATIC NET communications package
is used for SIMOTION. Operator control and monitoring applications
(OPC clients) can access SIMOTION P data via the OPC server in
accordance with the OPC standard.
High Speed Cycle times of 250 µs can be achieved with SIMOTION P, PROFINET and the
ET 200S distributed I/O system with interface module IM 151-3 PN High Speed .
This is particularly necessary for applications with fast response times (e.g.
hydraulic axes).

Connection Schematic of SIMOTION P350
IsoPROFIBUS Interfaces:
board
1. DVI/VGA
2. CompactFlash card
3. PROFIBUS/MPI
MCI- PN 4. COM
board
5. 4 x USB 2.0
6. ETHERNET 1
7. ETHERNET 2

Interfaces The industrial PC SIMOTION P350 has the following interfaces:

(1) DVI/VGA: DVI/VGA connection for CRT or LCD monitor with DV interface.
A VGA monitor can be connected via a DVI/VGA adapter.
(2) CompactFlash card: Slot for a CompactFlash card
(3) PROFIBUS/MPI/DP: MPI interface (RS485, electrically isolated), 9-pin
sub D socket
(4) COM: V.24 serial interface
(5) 4 x USB 2.0: 4 ports for USB devices (only 2 ports can be simultaneously
used as high current)
(6) ETHERNET 1: RJ45 Ethernet connection for 10/100 MBit/s
s
(7) ETHERNET 2: RJ45 Ethernet connection for 10/100 MBit/s
Operator panels SIMOTION P350 can be connected to the following operator panel versions:
• 12" with membrane- type keys
• 12" for touch sclureen operation, and
• 15" for gtouch screen operation
Panel PC A panel front can be remotely connected up (30 m) using the Panel PC Remote
Remote Kit Kit. The greater flexibility in terms of location allows the SIMOTION P350 to be
l
positioned in non-critical areas of a plant (e.g. in a control cabinet). Signal

transmission between SIMOTION P350 and SIMOTION panel front via DVI-D
(graphic signals) and USB cable (key signals).

System Configuration with SIMOTION P350
• SCOUT
• Teleservice
• HMI
WinCC flexible Onboard

SCOUT HMI
Ethernet / MPI
• SCOUT
PROFIBUS- DP_1 (PROFINET)
PROFIBUS- DP_2
iso-
chronous
Distributed
I/O
Distributed
I/O
Servo drives Servo drive

Standard drive

Drives connected The control of drives or other components connected to PROFIBUS is realized
to PROFIBUS for the PROFIBUS version using the two PROFIBUS interfaces of the integrated
IsoPROFIBUS-Boards. These two interface can be used for isochronous
operation.
The number of axes that can be connected to PROFIBUS DP depends on the
system cycles that have been set, i.e. more axes can be operated with longer
cycle times than with short cycle times.
The free PCI slot can be used for the purpose of retrofitting an optional MCI PN
Communication Board. This means that the PROFIBUS version can support
both PROFIBUS and PROFINET on the same PC.
Drives connected The PROFINET version allows SIMOTION P350 to be connected to a

to PROFINET PROFINET IO network via the integrated communication board MCI-PN. From a
PROFINET perspective, the SIMOTION P350 thus assumes the role of a
PROFINET IO controller.
To enable it to communicate with other PROFINET controllers, the
SIMOTION P350 can be configured as both a PROFINET controller and a
PROFINET device at the same time (I-Device).
Connecting A PG can be connected to the SIMOTION SCOUT tool via the onboard
a PG PROFIBUS/MPI (Multi Point Interface) interface (CP5611-compatible) of the
integrated Ethernet or PROFINET interface (MCI-PN board) of the P350.
As an alternative, the SIMOTION SCOUT tool can be also directly installed on
the P350.
HMI components To visualize the various processes, Software WinCC flexible or an OPC-
interface can be directly installed on the P350.
Alternatively, additional HMI components - just same as a PG - can be
connected via the onboard PROFIBUS/MPI or Ethernet-/PROFINET interfaces.

MCI PN Board for P350
Connecting cable connection Product version,

for the IsoPROFIBUS Board MAC address
X1: PCI bus

MCI- PN board The MCI PN Communication Board for SIMOTION P350-3 enables connection
to a PROFINET IO network. This means that in terms of PROFINET,
SIMOTION P350-3 is a PROFINET IO controller that offers the following
functions:
• Communication as: PROFINET IO Controller, I-Device (controller and

device simultaneously), 100 Mbits/s full duplex
• Supports real-time classes of PROFmINET IO:
- RT (Real-Time)
- IRT (Isochronous Real-Time)
• Connection of distributed I/O s as PROFINET IO devices
• Connection of drives as PROFINET IO devices through PROFIdrive
according to the V4 spec@ification
• Support for standard Ethernet communication, e.g.
- to connect wiuth SIMOTION SCOUT
- to conneclt HMI systems
- for commungication with any other devices via TCP/IP or UDP
ocommunication
• Integlrated 4-port switch with 4 RJ45 sockets based on the
PROFINET eASIC, ERTEC400. The optimal topology (line, star, tree or ring)
can therefore be constructed without the need for additional external switches.

Embedded PC Technology - SIMOTION P320
SIMOTION P320
Embedded PC technology
Intel Core2 Solo 1.2 GHz, 800 MHz Front Side Bus
Windows Embedded Standard 2009 operating system
2 GByte DDR3- SDRAM
CompactFlash card with 4GB as a replacement for a

hard disk, without any rotating parts, no fan
Enhanced Write Filter (EWF), in order to avoid
unnecessary accesses to the CF card
Space saving installation versions:
Rail mounting, panel mounting,
book mounting, front book mounting
98% of the performance of the P350- 3
Connections:
DVI
3 x ports for PROFINET
4 x USB 2.0
1 x Ethernet (10/100/1000 MBit/s)
COM
Slot for CF card.

What is SIMOTION P320 combines the well-proven properties of a classic PC-based

SIMOTION P320? motion control system with all of the advantages of state-of-the-art embedded
solutions. The maintenance-free and compact embedded PC can be used
without display, monitor or panel front ("headless"). Optionally, a display can be
connected via the integrated DVI interface.
SIMOTION P320-3 runs with the Windows Embedded Standard 2009 operating
system and with a real-time expansion for SIMOTION. Other PC applications
can run at the same time as the SIMOTION applications. The I/O system is
controlled with the onboard PROFINET controller.
The embedded PC for motion controil has no parts that can wear or rotating
parts such as hard disks or fanss. Integrated monitoring functions for battery,
temperature and program ex ecution are available. LEDs at the front indicate
operating states, therefore simplifying self-diagnostics. The elimination of
moving parts, such as the@ hard disk and fan, means that the SIMOTION P350
has a higher degree o f immunity to shock and vibration and therefore is more
rugged when compaured to conventional systems.
Using an Enhanced lWrite Filter (EWF) frequent write access operations from
Windows to thge "hard disk" (CF card) are avoided. Information is only written to
the "hard disk" (CF card) with explicit commands. This reduces the number of
write cyclloes and the same time protects against accidental changes, e.g.
during commissioning, so that there are no undesirable effects to the system.
This means that when the embedded PC is restarted, a functional system is
always loaded from the CF card.
The integrated power unit buffers brief power failures. Process data (retain data)
are saved in the buffered SRAM memory – even when the power suddenly fails.
All of the components used in the system are designed for 24 hour continuous
operation at temperatures extending from 0 up to +55 °C. The latter is
applicable for the recommended rail mounting type; for other mounting versions
such as panel, book and front book mounting, the upper limit is +45 °C.

SIMOTION P320 Connections
On / off 1 x DVI- I 1x Gigabit LAN 3 x PROFINET

switch
4 x USB 2.0
24 V DC 1 x COM
power
supply

Connection SIMOTION P320 fulfills the highest performance requirements and can be
options simply integrated into an overall solution thanks to its flexible connection
options.
• 4 USB high current interfaces, for example to connect a keyboard, USB stick
or printer
• 1 COM interface: Using this serial interface, components generally used
in the automation environment can be connected.
• 3 onboard PROFINET ports for configurable cycle rates of up to250 μs.
Drives are exclusively connected via this PROFINET-interface.
• 1 Ethernet interface (10 / 100 / 1000 Mbit)
• 1 DVI interface for connecting a panel front. As standard, the following
panel fronts are available:
- 12" with membrane-type keys
- 12" for touch screen operation, and
- 15" for touch screen operation
A panel front can be remotely connected up (30 m) using the Panel PC Remote
Kit. The greater flexibility in terms of location allows the SIMOTION P320 to be
positioned in non-critical areas of a plant (e.g. in a control cabinet). Signal
transmission between SIMOTION P320 and SIMOTION panel front via DVI-D
(graphic signals) and USB cable (key signals).

System Configuration with SIMOTION P320
Panel PC Remote Kit,

maximum 30 m
SIMOTION P320 DVI-I: Databases, ...

DVI digital &
VGA analog
USB devices, e.g.

keyboard, USB Security
stick, printer etc.
PROFINET
Distributed
I/O
SIMOTION C
SIMOTION SCOUT
Drive systems,
e.g. SINAMICS S120

PROFINET SIMOTION P320 uses the universal bus system of the future for connecting
drive systems, namely PROFINET. Drive systems, for example, SINAMICS
S120 is exclusively connected via PROFINET.
SIMOTION P320 has an integrated 3 port switch for this purpose, based on the
PROFINET- ASIC ERTEC 400. This means that individual network topologies,
for example line, star or tree-type structures can be configured without requiring
any additional, external switches.
SIMOTION P320 can be simultaneously operated as PROFINET IO controller
as well as also PROFINET IO- Device. The following communication classes
can be operated via PROFINET:
• IRT (Isochronous Real Time): Isochronous communication example to
lower-level drive systems.
• RT (Real Time): Cyclic (non isochronous) communication to additional
distributed PROFINET field devices, for example ET 200S, ET200M,
ET200eco, etc.
• NRT (Non Real Time): Communication via protocols, such as UDP (User
Datagram Protocol) and/or TCP/IP (Transmission Control Protocol/
Internet Protocol). Using these protocols, services of
SIMOTION SCOUT, access operations from HMI devices or the program-
controlled communication to other SIMOTION/SIMATIC systems are
implemented.
Ethernet In addition to the Profinet ports, there is also a separate Ethernet interface
(10/100/1000 Mbit/s), which is available as alternative to connect various PC-
based systems (databases, etc.).
Wireless communication using Industrial Wireless LAN is also possible via this
Ethernet interface or via PROFINET. This means that requirements can also be
fulfilled, where the SIMOTION device is installed remotely from the operator
control location, example for a control room of a wind turbine system.

Operating Mode Control for SIMOTION P
SIMOTION P state
P350

SIMOTION P State The display of the LEDs, mode selector switch and the handling of the memory
card for the P350 are realized using the application SIMOTION P State screen.
The LEDs have the same significance as those for SIMOTION C230- 2.
5V DC(green) This LED indicates that the power supply ism ready. The P350 power supply is
operating fault-free when the LED is lit.
RUN (green) Green flashing (2 Hz): Select the si"RUN" operating state until this state is
reached.

STOP (yellow)
Yellow flashing (0.5 Hz ): SIMOTION RT is requesting an overall reset.
Yellow flashing (2 Hzu): Select the "STOP" operating state until this operating
state is reached.
SU/PF (STOP U)
Yellow: SIMOTgION RT is in STOP operating state.
Yellow flalshing (2 Hz): Select the operating state STOPU until this operating
state is reached.
BUS1F/ BUS2F
Yekllow. STOP U state is active. The technology packages are active.
This LED indicates an error at the associated PROFIBUS interface.

Internal Memory Structure for SIMOTION P
Hard disk
Save Flash Load Flash Download
• TPs • Diagnostics
RAM to ROM
• User buffer
data • System retain
• TPs
variables
• User Switch on
data • User
retain
variables
• Baud rate
• PROFIBUS RAM to ROM
• Baud rate
addresses
• PROFIBUS
• Retain Switch on • System addresses
variables
variables • IP addresses,
Booting
• SIMOTION etc.
• Kernel
kernel

Hard disk/CF card at power OFF data

Memory model and The following diagram provides an overview of the SIMOTION P memory
sequences for P350 model and sequences for certain operator actions:
Download The following data are transferred from the SIMOTION SCOUT engineering
system using the menu command: Download into the "volatile data" area of the
SIMOTION P:
• Configuration data
• Programs
• Parameter assignments
In addition, the baud rate, the PROFIBUS DP addresses of SIMOTION P and

the Retain variables are stored in the "non-volatile data" area.
RAM to ROM
The technology packages and user data from the engineering system are saved
from the "volatile ludata" area to the virtual memory card (NT file system) using
the menu cogmmand Copy RAM to ROM .
Booting
The SIMOoTION kernel is loaded to the RAM of the SIMOTION P350 when the
SIMOTIlON P boots.
Switch on Aftekr the SIMOTION P350 is switched off, the contents of the "volatile data"
area are lost. When the SIMOTION P350 is switched on, the technology
packages and the user data are transferred from the virtual memory card (NT file
system) to the "volatile data" area.
Save SIMOTION P The "Save SIMOTION P" command of the SIMOTION P State application saves
d
the image of the virtual memory card to any data medium. The "Restore
SIMOTION P" command of the SIMOTION P State application restores the
image of the virtual memory card to an arbitrary data carrier.
Before starting this operations, the SIMOTION kernel must be exited.

Protection Against Power Failure – Buffering Retain Data
C230-2/C240
Real-time clock:
Buffering using maintenance-free "Goldcap"
Buffer time: typ. 4 weeks
Retain area:
Realized using an internal flash
P350/P320
Real-time clock and retain area:
Retain area realized using a static RAM
Buffered using a Li battery, buffer time > 3 years
D4x5/D4x5-2
Real-time clock and retain area: • Diagnostics buffer
For the D4x5, the retain area is realized using
static RAM (), buffered using a Super-Cap: Buffer • System retain data
time is typically 5 days (absolute encoder offset,
absolute encoder overflows,
Optional battery/fan module: etc.)
Buffer time > 3 years
• Current data values of user
Retain area for D4x5-2 is realized using retain variables
maintenance-free NVRAM
• Baud rate
_savePersistentMemoryData() backs up the • PROFIBUS and
retain area on CF card IP addresses

SIMOTION C At POWER OFF, the real-time clock of the C2xx continues to run for the buffer
time of the rechargeable battery. When the batteries are charged, the buffer time
is typically 4 weeks The battery (Goldcap) is recharged in the POWER ON state.
1 h). If the buffering is malfunctioning, a fault message is not output. With
POWER ON, the clock resumes at the time at which POWER OFF occurred.
When the C2xx is reset to the default setting, the clock is also reset to the
"default setting upon delivery".
The other data are buffered using an integrated flash. When the power fails, the
data are copied from the RAM memorey into this flash. At the next power on, the
data are written back to the RAM.
For the P350/P320, the bufferi ng of the real-time clock and/or the SRAMs with
SIMOTION P
the retain data is realized us@ing a 3V lithium battery. The battery is also
responsible for buffering the data in the BIOS of the PC. The typical lifetime
exceeds three years. Each time SIMOTION RT is correctly exited, the retain
data are copied tou the hard disk (P350)/ CF card (P320)
The 3V lithium balttery is monitored at two levels:
• Battery alagrm, battery alarm threshold reached (at 2.7 V)

• Batteryo fault, voltage limit fallen below (at 2.25 V).
For ethe D4x5, the data in the SRAM and the real-time clock are backed up
D4x5/D4x5-2 by the internal Super-Cap. The typical buffer time using the Cap is 5 days. If
the buffer time is insufficient, a battery can be connected by means of an
external fan/battery module. In this case, the buffer time is a minimum of 3
years. The battery can be replaced with no loss of data.
For D4x5-2, the retain area is realized using a maintenance-free NVRAM.
The data also remain here, buffered without an external power supply.
All retain data can be saved via the system function
_savePersistentMemoryData on the memory card. The contents are saved to
the "PMEMORY.XML" file in the "USER/SIMOTION" directory.
Backuep retain data

Backing up Retain Data on a CF Card from the User Program
Download config data

Memory card Online change
to PG
Download to config data
• SIMOTION kernel
• TPs Download/ • Kernel
• TPs
• Programs switch on • TPs
...
RAM to ROM • Configuration data
(project value) Copy current • Configuration data
data to RAM (current data values)
• Diagnostics buffer • Programs
... • Programs
• PROFIBUS, etc.
IP comm. config. RAM
memory
• system retain Switch on RAM disk Do
data wn
loa • PROFIBUS and
- absolute encoder d/
offset, ... IP comm. config.
- last OS, ... • Diagnostics buffer
_savePersistentMemoryData()
• User retain • System retain
variables (current variables
data values) • User retain
Non-buffered switch on/ variables
USER/SIMOTION/ partially for an overall reset Retentive (current data values)
PMEMORY.XML data

Backup Using the system function_savePersistentMemeoryData() the content of the

retentive data SRAM is saved to the memory card. The data is saved in the "USER/
SIMOTION" directory in the "PMEMORY.XML" file. The function call is
synchronous and therefore may only be used in MotionTasks.
When the control boots, the file contents are copied back to the SRAM under the
following conditions:
• SRAM content lost due to a discharged battery (no buffering). In this case,
the entire contents of the SRAM are restored from the file.
• After an overall reset. The components of the SRAM affected by the general
reset are restored from the file. The components involved in the overall reset
especially include:
- Absolute encoder offset and absolute encoder overflows of axes
- Current data values of user retain variables
For an overall reset, the following components are not deleted from the
SRAM:
- Diagnostics buffer
- PROFIBUS and IP communication configurations
The user must ensure the consistency of the SRAM data during the save
operation. A file that was saved can be deleted either using an card reader or
through the "Restore factory settings".
The source of the actual SRAM content can be determined from the system
variables of the device: persistentDataPowerMonitoring.persistentDataState.
Note An unbuffered SIMOTION D4x5 start, and therefore a complete restoration of

the SRAMS (especially the diagnostics buffer) can be forced as follows:
• Switch-off the control and bring the left-hand rotary switch (service selector
switch) on the SIMOTION D4x5 module into position 1
• Switch on the control

If You Want to Know Even More

Note The following pages either contain additional information or are used as
reference to complete a specific topic.
Topics • Backing up and restoring retain variables with the PG/PC

• Backing up retain and diagnostics data in operation
• Backing up retain and diagnostics data when powering up/booting
• Backing up diagnostics data via IT diag
• Archiving retain and diagnostic data
• Backing up diagnostic files via FTP
• Restoring retain data

Backing up and Restoring Retain Variables with the PG/PC
XML file

Backing up and From SIMOTION SCOUT Version V3.1, there is an option of backing up and
restoring restoring current data values of user retain variables, retain variables of TOs
variables (for example encoder overflows, absolute encoder offset, etc. as well as unit
variables of a project saved using the system functions_saveUnitDataSet() or
_exportUnitdataSet() on the memory card or RAM disk with the PG on a hard
disk.
To save and restore data, SIMOTION SCOUT must be in the ONLINE mode
and the target device must be connected to the PG/PC.
This function writes the current data vaelues of the variables into the
correspond-ing XML files, which are saved in thie folders for the individual ST
units.
Backing up variables 1. Select the device or the program in the project navigator and in the context
menu, select: Save variables.
2. In the "Save variables"@ window that opens, select the types of
variables that should be saved and the memory from which they should be
read and confirm with "OuK".
3. In the windolw that opens, select the target folder in which folders with
the backup filesg should be saved and confirm with "OK". The selected
variables are backedo up in the target folder on the data medium.
Restore 1. Seelect the device or the program in the project navigator and in the
variables context menu, select "Restore variables".
2. In the "Restore variables" window that opens, select the types of
variables that should be with restored and the memory in which they should be
written back to and confirm with "OK".
3. In the window that is opened, select the folder from which data should
be restored and confirm with OK. The selected variables are written from the
folder of the data medium into the memory of the target device.

Backing up Retain and Diagnostics Data in Operation
Procedure:
Service selector switch to position D
(alternatively, DIAG button for D4x5-2)
Backup runs
-> STOP- LED and SU/PF- LED flash
yellow (2 Hz)
Backup completed
-> RUN- LED flashes green (2 Hz) and D4x5-2
the SF- LED is continuously lit D4x5
DIAG button
(Position 13, hex: D)
Service selector switch Mode selector switch

SRAM data From V4.1 SP2 there is the option of backing up the content of the SRAM with the
service selector switch (only SIMOTION D) or PSTATE (only P350) or using an INI file
on the memory card. The PMEMORY.XML file backed up in this way is not saved in
the directory: "USER/SIMOTION", but in the directory: "USER\ SIMOTION\ HMI
\SYSLOG\DIAG".
The files can either be read out of the CF card using a card reader, or using IT DIAG or
FTP, loaded from the storage medmium.
Diagnostics data
In addition to storing the retain data and ethe data of the actual diagnostics buffer in
the PMEMORY.XML file, in this icase, additional files with the actual diagnostics buffer
content "DIAGsBUF.TXT", the currently existing TO alarms
"TOALARMS.TXT and the actual contents of HTML pages "DIAGURLS.TXT" can be
Procedure generated and stored.
The diagnostic data and non-volatile data can be backed up in the STOP, STOPU,
and uRUN operating states. Proceed as follows to backup in operation:
1. Set the servlice selector switch to "Diagnostics".
- For D4x5: set the left-hand rotary switch (SIM/NCK) to position "13"
(hex: D).
For D4x5- 2, as an alternative to the service selector switch, the DIAG-button
can also be used. It is sufficient to just press it briefly.
- For D410: DIP switch "7" to ON
- For SIMOTION P350 using the P state (menu command: Options ->
Set Diagnostic Switch).
The status LEDs display the backup process as follows:
- Backup in progress STOP LED and SU/PF LED flash yellow (2 Hz)
- Backup complete RUN LED flashes green (2 Hz) and SF LED lights
up continuously
2. After the backup has been completed, the SIMOTION module can be
switched off and the CF card removed.

Backing up Retain and Diagnostics Data
when Powering up/ Booting
Procedure 1:
Set the service selector switch to position D
Switch off and switch on SIMOTION
Wait until booting has been completed
(Position 13, hex: D)
Procedure 2:
Generate the text file "SIMOTION.INI"
with content "DIAG_FILES=1"
Copy the "SIMOTION.INI" text file into the
root directory of the data storage medium
Switch off the SIMOTION control and switch
on again — or press the RESET button
Wait until booting has been completed

Procedure 1 When backing up during booting using the service selector switch, proceed as
follows:
1. Set the service selector switch to "Diagnostics"
- For D4x5: set the left-hand rotary switch (SIM/NCK) to position "13"
(hex: D)
- For D410: For D410: DIP switch "7" to ON
2. Switch off the D4xx and then switch on again (RESET button)
3. Wait for booting to be completed. The diagnostics data and non-volatile data
is backed up to the CF card when powering up, provided that this is still
possible and is not prevented by HW defects, for example.
4. Once the backup has been completed, switch off the D4xx.
5. Remove the CompactFlash card and reset the service selector switch back
to its original setting.
Procedure 2 Saves the INI file in the root directory of the data storage medium (SIMOTION
C/P/D)
1. Use a text editor (such as Notepad) to create a file called "SIMOTION.INI".
2. Insert the text line "DIAG_FILES=1". You must use a text editor and may not
use any additional formatting in the text.
3. Copy "SIMOTION.INI" into the root directory of the data storage medium.
4. For SIMOTION C, D: Insert the data storage medium into the module while it
is switched off.
5. Switch on and wait for the unit to power up.
When powering up, diagnostic data and non-volatile data are backed to the
data storage medium, if this is still possible, and is not prevented e.g. as a
result of a hardware defect.
6. Once the backup has been completed, switch off the SIMOTION device.
Note In order to deselect powering up in the diagnostics mode, either the

"SIMOTION.INI" file must be deleted or renamed.

Backing up Diagnostics Data via IT DIAG
Procedure:
Establish an HTTP
connection to the
SIMOTION device
using Internet Explorer:
http://192.168.0.1/
Select
"Diagnostics“
Select
"Diagnostic files“
Call the function
"Create general diag-
files "
Call the function
"Create html diagfiles"
Call the function
"Get diagnostic files"

Overview The optional IT DIAG tool can be used to back up diagnostic data and non-
volatile data. IT Diag can be called using any commercially available Internet
browser (e.g. Internet Explorer).
Procedure In order to establish a connection to the HTML pages of IT DIAG using Internet
Explorer, proceed as follows:
1. Start Internet Explorer and in the address line enter: http://192.168.0.1 (the
IP address refers to the control system being used for the exercise and if
required must be adapted).
The start page of IT DIAG is opened
2. Select the entry "Diagnostics". The diagnostics page is opened.
3. Select "Diagnostic files" from the vertical menu bar. The page with the
diagnostic files is opened
4. Select the button: "Create general diagnostic files ". As a result the
diagnostics data and the non-volatile data are backed up in the
directory...\USER\SIMOTION\HMI\SYSLOG\DIAG.
5. Select the "Create html diagfiles" button. This backs up the HTML diagnostic
pages to the data storage medium. Only those pages are backed up, which
are listed in the file DIAGURLS.TXT in the directory
...\USER\SIMOTION\HMI\SYSLOG\DIAG.
6. The "zip all Diagfiles" and "Get diagarchive" buttons allow the diagnostic files
to be compressed and the zip archive loaded into the connected PG/PC
7. The "Delete diagnostic files" button allows all of the files saved in the
directory...\USER\SIMOTION\HMI\SYSLOG\DIAG to be deleted
Note The diagnostics data and the non-volatile data are, for SIMOTION D, C, on the
CF card/MMC in the directory: .\USER\SIMOTION\HMI\SYSLOG\DIAG.
For SIMOTION P, the files are saved on the hard disk in directory:
F:\SIMOTION\USER\CARD\USER\SIMOTION\HMI\SYSLOG\DIAG

Archiving Retain and Diagnostic Data
On the CF card in directory:
\USER\SIMOTION\HMI\Syslog\DIAG
PMEMORY.XML non-volatile data
(retain data)
DIAGBUF.TXT diagnostics buffer in a simple
text form
TOALARMS.TXT text file with the existing
TO alarms. Only TO IDs,
alarm numbers and HEX
auxiliary values
HTML pages If the diagnostics data are
backed up, then the URLs are
requested from the text file
(DIAGURLS.TXT)
and saved as HTML pages
Other files All other files saved in the
directory are only relevant for
technical support.

Archiving the data The diagnostics data and the non-volatile data are on the CF card or MMC in the
directory: \USER\SIMOTION\HMI\SYSLOG\DIAG
When requested, these files can be transferred to Technical Support. With a
CompactFlash Card/MMC, diagnostic data is read out via a standard card
reader or standard IT DIAG pages or via FTP.
The following data is stored:
PMEMORY.XML Non-volatile data (retain data). An operator action can be used to restore the
non-volatile data backed up after a CPU has been replaced
DIAGBUF.TXT Diagnostics buffer in a simple text form: Numerical values; no specific plain text.
A text editor is used for evaluation purposes.
TOALARMS.TXT Text file containing the pending TO alarms. Only TO IDs, alarm numbers, and
auxiliary HEX values.
Note: The TO alarms are only created if diagnostic data has been created during
operation (STOP/STOPU/RUN).
HTML pages If the diagnostic data is backed up, the URLs are requested from the text file
(DIAGURLS.TXT) and stored as HTML pages together with their content.
Note: The HTML pages are only stored if diagnostics data is created during
operation (STOP/STOPU/RUN).
Other files All other files saved in the directory are only relevant for technical support.
Note Storing non-volatile data using the system function _savePersistentMemoryData

is realized in the backup file "PMEMORY.XML". in the directory
"...USER/SIMOTION"
Storing non-volatile data using T DIAG, the service selector switch or INI file is
realized in the backup file "PMEMORY.XML" in the directory
"...\USER\SIMOTION\HMI\SYSLOG\DIAG"; this means in a directory other than
is used with the system function _savePersistentMemoryData.

Backing up Diagnostic Files via FTP
Procedure:
simotion
Establish an FTP
connection to the simotion
SIMOTION device using
Windows Explorer:
ftp://192.168.0.1/
Log on using the menu
command:
File -> Log on as...
Username: "simotion"
password: "simotion"
Copy the files from the
target device to the local
hard disk

Overview Using the FTP protocol (File Transfer Protocol) diagnostic files can also be
backed up from the target system to the local hard disk. The FTP protocol is
supported by every commercially available Internet browser (e.g. Internet
Explorer).
Procedure To establish an FTP connection using Internet Explorer to the target system,
proceed as follows:
1. Start Windows Explorer and in the address line enter: ftp://192.168.0.1 (the
IP address refers to the control system being used for the exercise and if
required must be adapted).
An FTP folder error is displayed two to the missing access authorization.
2. Acknowledge the FTP folder error with the "OK" button. The MS Windows
Explorer is opened.
3. Select the menu command: File -> Log on as ..... The "Log on as" dialog is
opened.
4. In the input line "Username", enter "simotion" and in the input line
"Password" also enter "simotion", and confirm using the "Log on" button.
The file system of the target system, i.e. the CF or MMC card is displayed.
5. Navigate to the required directory and copy the files from the target system
to the local hard disk
6. After copying has been completed, the Internet Explorer can be closed as
usual.

Restoring Retain Data
Procedure:
Insert the CF card into the D4xx module
Set the service selector switch to position "1"
Switch-on the power supply
Wait for the system to power up,
the retain area is then restored from
the "PMEMORY.XML" file D4x5-2
D4x5
Restoring
retain data
(Position 1, hex: 1)
Service selector switch Mode selector switch

Procedure To restore non-volatile data, for example after a CPU has been replaced,
proceed as follows:
1. Insert the CF card into the new D4xx module (the D4xx must be in
a no voltage condition)
2. Set the service selector switch to the "Delete non-volatile data" position
- For D4x5: set the left-hand rotary switch e(SIM/NCK) to position "1"
- For D410: Set the DIP switch S5 to m"ON".
3. An unbuffered power-up is performeed, this means that all retain data
are first deleted. This retain data includes:i
- System retain variables, fsor example, absolute encoder offset, absolute
encoder overflows etc.
- Current data values@ of user retain variables
- Diagnostics buffer content
- Communiu cation settings, for example IP and PROFIBUS addresses,
The retain datal listed above are then restored from the content of
the "PMEMORY.gXML" file.
4. Aftero powering up, switch off the power supply and set the service selector
lswitch back to the initial position.
kIf there are several "PMEMORY.XML" files on the CF card, then the
following priority sequence applies when restoring data:
Priority
• /USER/SIMOTION/PMEMORY.XML
• /USER/SIMOTION/PMEMORY.BAK
• /USER/SIMOTION/HMI/SYSLOG/DIAG/PMEMORY.XML
Note Using the "OVERALL RESET" function, the system retain and user retain
variables can be restored, however not the diagnostic buffer content and the
communication configuration (see above).

Axes and Drives in SIMOTION

Contents Page
Connecting Electrical Drives ............................................................................................................ 4
Symbolic Assignment Between Control and Drive ............................................................................ 5
Automatic or Manual Message Frame Selection ............................................................................... 6
Structure of Standard Message Frames (1) ...................................................................................... 7
Structure of Standard Message Frames (2) ...................................................................................... 8
Overview: Drive Coupling ................................................................................................................. 9
Technology Objects (TO) in SIMOTION .......................................................................................... 10
The "Axis" Technology Object ......................................................................................................... 11
Creating and Configuring an Axis ..................................................................................................... 12
The Basic Configuration of an Axis ................................................................................................... 13
Selectively Removing Drive Enable Signals ...................................................................................... 14
Calling the Expert List ...................................................................................................................... 15
Specifying Mechanical Data ............................................................................................................. 16
Parameterizing Default Settings ....................................................................................................... 17
Specifying Limit Switches and Maximum Velocities .......................................................................... 18
Angabe zu Software- Endschaltern .................................................................................................. 19
Specifying the Maximum Acceleration and Jerk ................................................................................ 20
Filtering the Actual Value for Master Value Coupling ........................................................................ 21
Position Control in SIMOTION .......................................................................................................... 22
Position Controller Optimization without Precontrol ...........................................................................23
Position Control with Precontrol ........................................................................................................ 24
Selecting a Suitable Balancing Filter Type ........................................................................................ 25
Optimizing the Balancing Time Constant (vTc) ................................................................................. 26
Position Control with DSC – the PROFIdrive DSC Structure ............................................................ 27

Automation and drive technology Page 1 Axes and Drives in SIMOTION

Content Page
Position Controller Optimization with Precontrol and DSC ................................................................ 28
Dynamic Adaptation for Synchronous Axes ...................................................................................... 29
Checking the Dynamic Adaptation Using the Circularity Test ............................................................ 30
Positioning and Standstill Monitoring ................................................................................................ 31
Open-Loop Speed Controlled Motion - Standstill Signal .................................................................... 32
Following Error and Velocity Error Monitoring ................................................................................... 33
Signal Flow Representation of the Closed-Loop Axis Control ........................................................... 34
Programming Traversing Motion ....................................................................................................... 35
Enabling and Disabling Axes ............................................................................................................ 36
Processing Motion Commands ......................................................................................................... 37
Transitional Behavior of Motion Commands ..................................................................................... 38
Program Advance for Motion Commands ......................................................................................... 39
Synchronous and Asynchronous Program Execution ........................................................................ 40
Dynamic Settings for the Positioning Command ............................................................................... 41
Start Axis, Position Contolled or Speed Controlled ............................................................................ 42
Stop Axis .......................................................................................................................................... 43
Continue Motion ............................................................................................................................... 44
Homing Axes with Incremental Measuring Systems .......................................................................... 45
Active Homing with/without Zero Mark . . . ........................................................................................ 46
Passive Homing with/without Zero Mark . . . ..................................................................................... 47
Adjusting an Absolute Encoder ......................................................................................................... 48
Setting the Reference System .......................................................................................................... 49
Diagnostics of Axes or Drives - Service Overview ............................................................................ 50
Diagnostics of a TO - Querying the System Variables ....................................................................... 51


Content Page
Significance of the Service Display ................................................................................................... 52
Technological Alarms ....................................................................................................................... 53
Configuring Technological Alarms .................................................................................................... 54
Acknowledging Technological Alarms .............................................................................................. 55
Using the Technology Object Trace (1) ............................................................................................ 56
Using the Technology Object Trace (2) ............................................................................................ 57
If You Want to Know Even More ....................................................................................................... 58
Using Axis Data Sets ....................................................................................................................... 59
Adding an Encoder to an Axis .......................................................................................................... 60
Basic Configuration - Encoder Type and Mode ................................................................................. 61
Mode of Operation of an Incremental, Optical Sin/Cos Encoder ........................................................ 62
Settings for Incremental Encoders - "Cyclic Actual Value" ................................................................ 63
Mode of Operation of an Absolute Encoder ...................................................................................... 64
Settings for Absolute Encoders - "Absolute Actual Value" ................................................................. 65
Settings for Absolute Encoders - Encoder Type ................................................................................ 66
Settings for Travel to Fixed Endstop ................................................................................................. 67
Travel to Fixed Endstop - "Determining the Reference Torque" ........................................................ 68
Travel to Fixed Endstop - "Settings in the Command" ....................................................................... 69

Connecting Electrical Drives
For example
....via PROFIBUS-DP
MASTERDRIVES
MC
... via PROFINET

SINAMICS
S120
... via analog or stepping

motor interface
SIMODRIVE
611U

Interface to the The functional interface to the drive is the speed setpoint interface.
drive Digital as well as analog, electric drives can be directly connected to a SIMOTION
C2xx. For SIMOTION P350 and SIMOTION D4x5, digital drives can be directly
connected via PROFIBUS or PROFINET – and analog drives via ADI4 or IM174.
With connection via PROFIBUS or PROFINET all data between the drive
Drives on system and SIMOTION are exchanged viam this medium. Standard message
PROFIBUS/ frames are used to enter the setpoint for digital drives connected to PROFIBUS as
PROFINET well as the feedback data from the encoder.
It goes without saying that the drsiive must also support the selected message
frame type. The type of select ed message frame defines the maximum supported
functionality of an axis. It goes without saying that in SIMOTION, the axis can only
execute the @functions, which the connected drive also supports.
Axes that are operat ed in the positioning mode must be connected via the
isochronous PROFIBUS or via PROFINET IRT to ensure correct functioning. It is
sufficient for simplule speed-controlled applications to be connected to a "not
isochronous" PROFIBUS DP or a PROFINET RT. In this way you can connect all
standard DP sglaves that do not support isochronous operation.
analog dlrives can be directly connected at C2xx or via PROFIBUS at the ADI4
ore IM174. In this case the speed controllers are supplied with +/- 10 V via the
Analog drives/ anaklog outputs.
stepping motors The position actual values can either be taken from the encoder connected to
SIMOTION C or ADI4, or from the pulse encoder emulation of the converter. The
corresponding digital I/Os are available for feedback signals and controller enable
signals.
From V3.2 and higher, stepping motors can also be directly connected to the
C2xx.

Symbolic Assignment Between Control and Drive
Advantages
Communication between an axis and drive is
automatically set up (PROFIdrive axis message
frames as well as addresses)
Message frame extensions and interconnections
in the drive are dependent on the selected TO
technology (e.g. SINAMICS Safety Integrated)
Axes and drives can be independently
configured from one another
Communication connections are automatically
established when configuring I/O on
SINAMICS I/Os
The assignment is kept even for address
offsets
Activating/deactivating via the menu command:
Interconnection control
Project -> using a symbolic assignment

New in V4.2 The most significant innovation in the SIMOTION SCOUT engineering system is
the significantly simplified connection to the SINAMICS drive system. With this
step, users are supported as a result of the essentially automated integration of
drives and their associated elements in SIMOTION SCOUT.
Up until now, to connect drives according to PROFIdrive, users had to configure

the appropriate communication, both on the drive side as well as on the control
side. As result of the new symbolic assignment of technology objects (TOs) and
I/Os to drive objects (Drive Objects/DOs),m users no longer have to involve
themselves in the PROFIdrive commuenication with message frames and
addresses. The engineering systemi now takes care of all this.
For "Save and compile changes" ors at the latest before a download, message
frames and addresses are automatically generated. Users only have to
download the project data into the target system.
New control
The symbolic assign ment is now realized using a new interconnection control. It
is supported byu technology objects – axis, external encoder, cams, cam track
and measuringl input. Further, the onboard I/Os of the devices SIMOTION D,
CX32/CXg32-2, Control Units for SINAMICS S120 as well as the Terminal
Modules and TB30 can now be symbolically assigned.
In this dlialog, all pass-capable partners are hierarchically listed; connections are
reaelized symbolically by simply selecting the components to be interconnected.
SINAMICS drives and/or devices and terminal modules with their available I/Os
can be selected in the control. In this case, only the pass-capable elements are
listed with symbolic identifiers; whereby even the terminal designations of the
modules are listed.
Note If a project is upgraded to SIMOTION device firmware version V4.2 SP1, then
the symbolic assignment can be subsequently selected. The assignments are
automatically determined from the logical addresses. Individual TOs and DOs
can be excluded from the symbolic assignment (refer to the next page)

Automatic or Manual Message Frame Selection

PROFIBUS/ With the coupling via PROFIBUS/PROFINET, all information between the drive
PROFINET system and SIMOTION is exchanged using standard message frames
coupling according to the PROFIDRIVE profile V4.0. The structure and type of the
information being exchanged uniquely defines the number of the message
frame.
Message frame In the "Settings for ....." dialog, you can switch over to automatic or user-defined
selection
PROFIdrive message frame setting and/orm automatic message frame
extension for the selected drive object.
Automatic PROFIdrive message framee setting: This setting (standard) is
selected if the drive unit is to particiipate in the "Symbolic assignment" with
SIMOTION. A PROFIdrive message frame (including message frame extension)
is automatically determined wi th "Save and compile".
You must configure PROF@Isafe message frames yourself; the configuration of
the safety data block (SIDB) however is performed automatically.
User-defined: The fou llowing options are available for the user-defined setting
of the process data ltransfer:
• Semi-autogmatic message frame configuration (selection: "Automatic

message frame extension" and "Permit automatic address adaptation". Withl
this setting, the PROFIdrive message frame is selected, necessary message
frame extensions and address adaptations are performed by the syestem when
"Save and compile" is selected.
• Manual message frame configuration: With this setting, you select the
PROFIdrive message frame and the message frame extension yourself, but
leave the address adaptation to the system (select. "Permit automatic address
adaptation").

Structure of Standard Message Frames (1)
PZD number 1 2 PSD number 1 2 3 4
Setpoint CW 1 NSET_A Setpoint CW 1 NSET_B CW 2
PZD number 1 2 PSD number 1 2 3 4

Actual value STW 1 NACT_A Actual value STW 1 NACT_B STW 2
Standard message frame 1 (16 bit nset) Standard message frame 2 (32 bit nset, without encoder)
PSD number 1 2 3 4 5
Setpoint CW 1 NSET_B CW 2 Enc1_CW
PSD number 1 2 3 4 5 6 7 8 9
Actual value STW 1 NACT_B STW 2 Enc1_STW Enc1_XACT 1 Enc1_XACT 2
Standard message frame 3 (32 bit nset, with encoder)
PSD number 1 2 3 4 5 6
Setpoint CW 1 NSET_B CW 2 Enc1_CW Enc2_CW
PSD number 1 2 3 4 5 6 7 8 9
. . .
10 11 12 13 14
. . . Enc2_STW Enc2_XACT 1 Enc2_XACT 2
Standard message frame 4 (32 bit nset, with 2 encoders)

Standard Is designed for simple speed-controlled applications. The message frame

message frame 1 has a control and a status word via which the basic functionality regarding
activation, deactivation, pulse and controller enable is handled. A 16-bit data
word is used for transferring the speed setpoint. The actual speed value is also
transferred back from the drive in 16 bits.
In SIMOTION, this message frame can only be used for the "speed axis"
function.
Standard Is designed for more complex speed-controlled applications. In addition to

message frame 2 the control and status word, the speed setpoint is transferred using a 32-bit data
word. The actual speed value is also transferred back from the drive in 32 bits.
In addition this message frame has a second control and status word which
handles the "travel to fixed endstop" functionality (clamping torque must be
configured in the drive, is not used in this form by SIMOTION for the "travel to
fixed endstop" function).
In SIMOTION, this message frame can only be used for the "speed axis"
function.
Standard Is designed for positioning applications. It also has an encoder control word,
message frame3 an encoder status word and a 4-word interface to a measuring system.
SIMOTION functions, such as reference point approach and measuring input,
can be implemented via this encoder control word.
In SIMOTION, this message frame can be used for the "positioning axis"
function.

Structure of Standard Message Frames (2)
PSD number 1 2 3 4 5 6 7 8 9
Setpoint CW 1 NSET_B CW 2 Enc1_CW XERR KPC
PSD number 1 2 3 4 5 6 7 8 9
Standard message frame 5 (32 bit nset, with 1 encoder + DSC)
PSD number 1 2 3 4 5 6 7 8 9 10
Setpoint CW 1 NSET_B CW 2 E1_CW E2_CW XERR KPC
PSD number 1 2 3 4 5 6 7 8 9
Actual value STW 1 NACT_B STW 2 E1_STW E1_XACT 1 E1_XACT 2 . . .
10 11 12 13 14
Standard message frame 6 (32 bit nset, . . . E2_STW E2_XACT 1 E2_XACT 2
with 2 encoders + DSC)
PSD number 1 2 3 4 5 6 7 8 9 10
Setpoint CW 1 NSET_B CW 2 MOMRW E1_CW XERR KPC
PSD number 1 2 3 4 5 6 7 8 9 10
Actual value STW 1 NACT_B STW 2 MSGW E1_STW E1_XACT 1 E1_XACT 2
SIEMENS message frame 105 (32 bit nset, with 1 encoder + DSC + torque reduction)

Standard This message frame is designed for connecting a second encoder. It is used in
message frame 4 SIMOTION for coupling positioning axes with a 2nd measuring system.
Standard Is intended, just like standard message frame 3 for positioning applications.
message frame 5 However, it has two additional double words in the setpoint for transferring the
following error and the servo gain (KPC gain).
In SIMOTION, this extension is required for the DSC functionality (dynamic
servo control). When this function is selected, the dynamic part of the position
controller is transferred from SIMOTION to the drive and calculated with the
sampling frequency of the speed controller. As part of this process, the following
error (XERR) and servo gain KPC are transferred from SIMOTION to the drive.
Due to the higher sampling frequency in the drive, the position control can now
be operated with a higher servo gain.
Standard Like standard message frame 4 with DSC, or standard message frame 5 with a
message frame 6 2nd encoder. This is used in SIMOTION for coupling positioning axes with a 2nd
measuring system.
SIEMENS SIEMENS message frames 102 to 106 are created from the associated
message frame standard message frames 2 to 6 by inserting an additional word in the setpoint
102 . . . 106 (after control word STW2) or a word in the actual value (after status word
ZSW2).
This extension is required for the dynamic torque reduction at the drive. The
torque limit is specified in the setpoint; in the actual value the drive among
others returns whether the torque limit (current limit) was reached or not.
This extension is used in SIMOTION to implement the functions "Travel with
torque limit" and "Travel to fixed endstop".

Overview: Drive Coupling
MICROMASTER/
ADI4 SINAMICS SIMODRIVE MASTERDRIVE
SINAMICS G120
Analog Posmo
S120 611U MC MM410/420/440
drives S/CA/CD
PROFIBUS DP standard
Isochronous on PROFIBUS DP(DRIVE)
interface slave
1ms, 0.5 ms
DP cycle clock 1ms, 0.5 ms granular 3 ms
granular
Speed-controlled
TO connection Speed-controlled
- axis, positioning, synchronism, cam
axis
Preferred
3 105 105 5 1
message frame
Proprietary Starter SimoComU Drive monitor Starter

Drive
configuration
Drive ES

Drives on The following applies to drives connected to PROFIBUS DP: On an isochronous

PROFIBUS MC PROFIBUS MC, only drives can be operated in the isochronous mode that also
comply with PROFIDRIVE-profile V4.0.
All other drives (standard slaves) can be connected to the isochronous
PROFIBUS MC - but not operated in the isochronous mode.
The following drives are integrated in the STEP 7 project via the hardware
configuration:
• SINAMICS S120
• SIMODRIVE 611U
• SIMODRIVE POSMO CA
• SIMODRIVE POSMO CD
• SIMODRIVE POSMO SI
• ADI4
• MASTERDRIVE MC
• MASTERDRIVE VC
• MICROMASTER 420/430/440
• COMBIMASTER 411
MICROMASTER 420/430/440 and SINAMICS S120 can be configured,
assigned parameters and commissioned directly with SIMOTION SCOUT.

Technology Objects (TO) in SIMOTION
Configu-
ration
Configu- System data
ration variable
data
Syn- System
Cam chronous func-
System
operation tions
func- Configu-
System tions ration
variable data Alarms Configu-
Alarms
ration
data
Encoder System
func-
System tions Axis
Configu- variable System
System Alarms
ration func- func-
data tions System tions
variable
Alarms
Measuring
Configu-
input
ration
data
System Alarms
variable Output
cam System
func-
System tions
variable
Alarms

Technology objects The technology objects in SIMOTION are provided in the form of technology
packages that can be loaded. Each of these technology packages provides
complete functionality for the technology in question. For instance, the "Position"
technology package includes all of the functions, which are required to traverse
and position axes.
In SIMOTION, for each "physical" automation object, for example, an axis, an
external encoder, a measuring input etc., an appropriate technology object (TO)
is created (instantiated). Each TO in SIMOTION encompasses:
• Configuration data: Using configuration data, the created objects are adapted
to the requirements of the specific task or application.
• System data: In the system data, a TO provides information about its present
state. The system data of an axis TO will therefore display information such
as position setpoint, actual position value, following error etc.
Using system variables, standard values and settings can also be read or
entered.
• System functions: Using system functions, the user program accesses the
functionality to control the associated "physical" object. For example, for an
axis TO, there are powerful system functions available for positioning,
reference point approach, stopping etc. of an axis.
For example, the motion sequences of an axis are specified using motion
commands issued to that axis. The user program can be used to query the
motion status at any time and to control specific aspects of the motion.
Motions can be aborted, overridden, appended, or superimposed.
• Alarms:If an event (error, note) occurs on a technology object, the TO issues
a technological alarm.
The TO alarms cause subsequent responses in the system. For each alarm,
certain effects are set as default. However, these settings can be adapted to
the specific requirements.

The "Axis" Technology Object
4 versions
Speed-controlled axis
Synchronous • Motion with speed setpoint
axis • Specification of a velocity
profile (time-controlled)
Positioning • Traversing with torque limiting
axis
Positioning axis
• Positioning via
Speed- • Positioning command or via profile
controlled input (velocity, position)
axis • Traversing to a fixed endstop
Path Synchronous axis

interpolation • Following axis in gearing or
axis camming operation
Path axis
• Linear, circular and polynomial
interpolation in 2D and/or 3D
• support of various kinematics

Axis TO The axis motion control functionality is implemented in SIMOTION using the
technology object (TO) axis. When creating an axis with SIMOTION SCOUT, a
distinction is made between the following axis technologies:
• Speed-controlled axis: Motion control is performed using a speed setpoint
without position control. The actual speed is monitored if an encoder is
configured for the axis.
• Positioning axis: Motion control for position-controlled axes. The position
as well as the dynamics of the axis are specified. The operation is realized in
the closed-loop position controlled mode. The functionality of the speed-
controlled axis is included in the positioning axis.
The positioning axis in SIMOTION has a position controller. With electrical
axes, the speed controller is implemented in the drive.
• Synchronous axis: The functionality is identical with that of a positioning axis.
In addition, additional functions are available for the master value coupling in
the form of gearing and camming
• Path axis: From Version V4.1, SIMOTION provides path interpolation
functionality. This functionality encompasses that of the positioning axis.
Additionally up to 3 path axes can be traversed along paths. In addition,
a position axis can be traversed synchronously with the path. Paths can be
combined from segments with linear, circular, and polynomial interpolation in
2D and 3D.
Further, using this technology, the following kinematics are supported:
- Cartesian linear aches
- SCARA
- Roller picker
- Delta 2D /3 D picker
- Articulated arm
The "Axis" technology object can be used for axes with electric drives, with
stepping motors, hydraulic actuators/valve (hydraulic axis) and on virtual axes.

Creating and Configuring an Axis
Using
parameter
screens
Using
expert list

Configuration You will need to work through several steps before you can use technology
of TOs objects. In the first step, the configuration creates an instance of the TO. A TO is
configured using the SCOUT engineering system. You are supported by the
corresponding Wizards (parameterizing screen forms) to create an object and
configure it.
Inserting an axis instance is implemented in the Project Navigator in the
directory Axes, by double-clicking on them entry "Insert axis". The axis wizard
then automatically starts and helps the user create and configure an axis.
Certain object-specific properties aree determined in the first configuration (e.g.
speed-controlled axis, positioning aixis, synchronized axis). This definition also
determines the "size", i.e. the nusmber of configuration and system variables of
the technology object.
It is therefore not possible@ to subsequently change properties such as speed-
controlled axis, positioning axis, etc. If a speed-controlled axis TO is to be
converted into a pos itioning TO, it is necessary to delete the original speed-
controlled TO and uinsert a new positioning axis TO.
Configuration datal generally determines the static properties of a TO. Certain
properties determined by the configuration can also be changed during the
runtime.

The Basic Configuration of an Axis
Configuration
Name and technology

of the axis
Associated drive
Associated encoder

Basic configuration The basic properties of the axis are defined in the basic configuration of an axis.
The following settings can be adapted in this basic configuration.
Technology/processing cycle: The execution level for axis interpolation is
defined in this selection box. The following can be selected:
• IPO for dynamic axes
• IPO2 for auxiliary axes which have low dynamic requirements
• Servo for axes demanding a high dynammic performance
From V4.2 and higher, for axes conneected to PROFINET (these are
generally hydraulic axes) the following level is also available:
• fast IPO
• fast servo
Axis type: Under this dial@og, axis type changes can be made (linear or rotary
and electrical, hydrau lic or virtual).
In addition, controul options can be adapted, for example, standard or standard
+ pressure/force.l
Drive assignmengt: Under drive assignment, the connection to the associated

drive objecot can be changed.
Functionl: This part involves settings to an additional technology data block in

the message frame between the TO axis and drive object A technology data
block is required for the "Winder" technology.
Further, settings can be made to withdraw enable signals for critical TO alarms
(refer to the next page).
Further, settings can be made for extended safety functions that are integrated
in the drive.

Selectively Removing Drive Enable Signals

Settings to the Here, there is the option, for technology alarms with local alarm response
drive RELEASE_DISABLE (withdraw enable), to specifically withdraw the enable
signals in STW1 of the corresponding standard message frame.
This means, for example, when implementing a brake control in the drive, for
_disableAxis() as well as for RELEASE_DISABLE as a result of a fault
response, e.g. initially to withdraw OFF3 (STW1.Bit2), and then when the drive
is stationary and the brake is closed, the power is disconnected (OFF2)
(STW1.Bit1).
Also when using the extended Safety Integrated function, an adaptation is
absolutely necessary at the drive. For an integrated stop response of the drive,
withdrawing the AUS2 bit must be prevented, as otherwise the drive will coast
down in an uncontrolled fashion.
Stop modes for For a digital drive coupling, the Drive Technology profile provides the following
PROFIdrive stop modes:
• STW1 bit 0 = 0 (OFF1): Stop with ramp.
The drive travels with a speed ramp with adjustable deceleration to zero
velocity. The stopping process can be interrupted and the drive switched on
again. After stopping, the pulses are suppressed and the status changes to
ready to start.
• STW1 bit 1 = 0 (OFF2): Coast down
The drive immediately goes to pulse suppression and the status changes to
switch-on inhibit.
• STW1 bit 2 = 0: Quick stop
The drive travels to zero velocity at the torque limit. The stopping process
cannot be interrupted. After stopping, the pulses are suppressed and the
status changes to switch-on inhibit.

Calling the Expert List

General After the configuration the next step is to set the parameters for the technology
object. Parameterization involves defining numerous functions in detail.
Like the configuration, parameterization is carried out using the SCOUT
engineering system. Below the object in the project navigator window, there are
the appropriate entries, via which the individual screen forms can be called for
parameterization (making the appropriate parameter settings).
The result of the parameter assignment ism stored in configuration data and
system variables for the object and included in the download to the target
system.
In addition to access to the con figuration data and system variables via the
Expert List wizards and parameter screen forms, you can also access the data directly via
an expert list. The expert @list for an object can be called via the entry "Expert
list" of the axis TO.
Within the "Expert lisu t", lists for the following parameters can be selected using
the tab symbol:
• Configuratgion data: Configuration data are used to parameterize the

properties of a machine. As a consequence, mechanical properties, for example,
gearbox ratios, hardware limit switches, maximum dynamic values, closed-lloop
control parameters, etc. are defined.
• System variables: System variables are generally used to display status
information about the selected TO. For axes, this involves positions, velocities
etc. From the user perspective, such data can only be read. Using system
variables that can be written to, a basic parameterizing interface to the TO is also
implemented. These include, for example, velocity override, preassigned values
(default values) of velocity, acceleration etc. for traversing commands
• User-defined lists: From V4.0 and higher, there are user-defined expert
lists and the option of calling default lists with the most important configuration
data and system variables.

Specifying Mechanical Data
Load gear: Measuring gear:

transmission ratio transmission ratio
Automatically adapted; if
TypeOfAxis.DriveControlConfig.dataAdaption = YES
TypeOfAxis.NumberOfEncoders.Encoder_1.dataAdaption = YES
TypeOfAxis.NumberOfEncoders.Encoder_1.encoderMode = PROFIDRIVE

General • After the configuration the next step is to set the parameters for the technology
object. Parameterization involves defining numerous functions in detail.
• Like the configuration, parameterization is carried out using the SCOUT
engineering system. Below the object in the project navigator window, is a row of
tabs for displaying the individual screens for parameter settings.
• The result of the parameter assignment is stored in configuration data and
system variables for the object and included min the download to the target
system.
Mechanical • When controlling a drive by meanssi of the "Axis" technology object, SIMOTION
Properties
uses only the speed setpoint interface and not the positioning interface. The
drive therefore has no information about traversing paths, etc. All mechanical
data regarding lengths, lea@dscrew pitch, etc., must be defined in SIMOTION.
Automatic
adaptation • Using automatic adapta tion, from V4.2 SP1, the relevant drive data (drive and
encoder data, as weull as reference variables, maximum variables, torque limits,
and the selectivity associated with torque reduction of the SINAMICS S120 from
v2.6.2) are trgansferred into the TO configuration when the CPU boots and do
not have to obe manually set.
• For a "Copy lcurrent data to RAM" or "Copy RAM to ROM", in a dialog, it is
possibele to load the adapted values to the PG and therefore into the offline
projkect.
• .If required, the adaptation can be activated in the expert list using the following
Configdata:
• TypeOfAxis.DriveControlConfig.dataAdaption = YES
• TypeOfAxis.NumberOfEncoders.Encoder_1.dataAdaption = YES
• TypeOfAxis.NumberOfEncoders.Encoder_1.encoderMode = PROFIDRIVE

Parameterizing Default Settings

Default value for The system always uses the default values if, when calling the system functions,
Dynamic response USER_DEFAULT is specified.
This means that the dynamic values for each axis can be defined centrally just
once and do not have to be re-entered whenever the system function is called.
The following dynamic variables of an axis can be assigned as default values in
this dialog
• Velocity
• Acceleration
• Deceleration
• Jerk
• Velocity profile
• Stopping time
Stopping Time The time specified under Stopping time applies if a moving axis is stopped
via "Emergency stop in upre-defined time", for example.
The velocity prgofile defines the axis response during approach, braking, and
Velocity velocity chanoges.
profile Youel can choose between the following profiles:
• Trapezoidal: The trapezoidal profile is used for linear acceleration in a

positive and negative direction of travel.
• Smooth: The profile displays a smooth acceleration character and the jerk
characteristic is controllable.
Depending on the settings for maximum dynamic response, dynamic response

dynamic response values can be preset as default values in the system. You specify the settings
regarding maximum dynamic response using "Maximum velocity" and "Ramp-
r
up/acceleration time up to maximum velocity".

Specifying Limit Switches and Maximum Velocities
Assign

Hardware Traversing range limits are monitored by means of digital inputs and limit
limit switches switches. Hardware limit switches are always NC contacts and should always
be active outside the permissible travel range. When a limit switch is
approached, a technology alarm is triggered.
The logical address of the input which the hardware limit switch for negative/
positive direction of travel is connected to is entered in "Hardware limit switch".
The address must be outside the process image (>= 64). With the bit number,
the input is specified to which the hardware limit switch for negative/positive
direction of travel is connected.
From V4.2 and higher, the inputs for the hardware limit switches can also be
easily connected with the inputs of the CU of SINAMICS_Integrated. By clicking
on the "…" button, the assignment dialog is opened, in which the interconnection
with the CU inputs can be made.
"Save and compile" is used to create the necessary message frames between
the CU and SIMOTION.
Maximum In SIMOTION there are two velocity limits. SIMOTION automatically reduces to
velocities the minimum of the two values
Maximum velocity (configuration data): Defines the maximum axis velocity as a
result of the mechanical system and the drive.
Maximum programmed velocity (system variable): Permits a product-dependent
reduction of the maximum velocity.

Angabe zu Software- Endschaltern

Software Software limit switches can be specified and activated. They are activated via
limit switches system variables (Swlimit.State). You can also specify in the "Homing" tab in the
configuration data: Homing.referencingNecessary whether the software limit
switch is always active, or only after referencing/homing:
Homing.referencingNecessary = NO software limit switch always active
Homing.referencingNecessary = YES switch active after referencing/homing
Additionally a "Tolerance window for the retraction" ca be defined especially for
retraction in speed-controlled mode. The tolerance window always refers to the
current actual value. This means that jittering of the actual value will not cause
the software limit switch to respond again during retraction. Traversing within the
tolerance window is possible in both directions.

Specifying the Maximum Acceleration and Jerk

Acceleration, SIMOTION makes a distinction for acceleration and jerk between hardware
jerk limits in configuration data and software limits in system variables, which, for
example depending on the product, can be easily overwritten from the user
program.
For programmed motion, the TO automatically reduces the acceleration and/or
the jerk to the minimum from the limits specified by the hardware and/or
software. Jerk limiting is only active for jerk-controlled motion, i.e. motion
sequences with continuous acceleration.
If the "Direction dependent dynamic response" option is activated, then different
limits for acceleration and jerk can be entered depending on the direction of
motion.
Stopping with The set value is effective, if a moving axis is stopped in the "EMERGENCY OFF
pre-parameterized mode" with the setting "Quick stop with actual value-related emergency stop
braking ramp ramp".
Time constant ... From V4.0 and higher, a time constant can be entered for smoothing the
manipulated variable changes as a result of controller switching operations.
This switchover smoothing filter is active for all status transitions/switchovers in
which an offset in the manipulated variable can occur due to the switchover.
Gearbox change operations in the data block are not smoothed

Filtering the Actual Value for Master Value Coupling

Master value For a synchronous group within a control system, synchronous operation is
coupling via realized taking into account the master value position, the velocity and
actual value acceleration. For distributed synchronous operation, the master value position
and master value velocity are transferred between the master value and
synchronous object. At the synchronous object, acceleration is generated
through differentiation
If an encoder actual value is used as master value, then the measured actual
value can be smoothed and extrapolated in order to compensate deadtimes.
Deadtimes, occur when acquiring the actual values through bus communication
in the system and as result of the finite processing duration within the system.
Filtering the From V 4.1, the actual position value for the synchronous operation can be
actual position filtered separately for the extrapolation using a PT2 filter. The filter for the
position actual value of the axes is set using the option "Filter on the actual
position value" and the two time constants "T1" and "T2".
The filter acts on the actual position for the extrapolation before the
differentiation of the position for the extrapolation velocity.
Filtering the The position is extrapolated based on the filtered or averaged velocity actual
actual velocity value. This filter can be activated using the option "Filter on the actual velocity
value": The time for the average value generation or the PT1 filter time is
entered under "Time constant.
The time for the extrapolation is entered under "Extrapolation time".
Extrapolation is not performed if 0.0 is entered.
The extrapolated values (position and velocity) can be monitored in the system
variable extrapolationData....
In addition, the velocity master value can be optionally generated from the
extrapolated position master value through differentiation or the extrapolated
velocity master value can be used for synchronous operation.

Position Control in SIMOTION
DSC operation
Servo gain factor
IPO
Feedforward control

Interpolator The interpolator processes the traversing commands which are issued e.g. from
the user program to an axis. In each IPO cycle it calculates the position setpoint
of the axis while including the dynamic values such as acceleration, velocity etc.
in its calculation. This position setpoint is then entered into the position controller
after fine interpolation.
Fine interpolation If there is a different sampling ratio between interpolator and position controller,
the fine interpolator (FIPO)'s task is to generate intermediary setpoints.
For the configuration you can select in the "Fine interpolation" box between no,
linear and constant speed interpolation.
Position control The position controller is responsible for controlling the actual position of the
axis. It is usually designed as P controller for electrical axes. The difference
between the position setpoint and position actual value is used as the control
deviation value (following error). Multiplied with the servo gain factor, the result –
the velocity setpoint of the axis – is output at the position controller output.
The dynamic response and therefore the rise time in the position control loop is
determined in this case by the servo gain factor (or more precisely: 1/sg = rise
time). The maximum possible servo gain depends on the dynamic properties of
the drive (e.g. rise time, etc.) and mechanical properties of the axis (moment of
inertia, backlash, etc.) as well as on the set position control cycle (sampling
theorem).

Position Controller Optimization without Precontrol
Unoptimized position control
Velocity setpoint:
motionstatedata.commandvelocity
Actual velocity:
motionstatedata.actualvelocity
Optimized position control

Servo gain factor

Optimizing the Prerequisite for optimizing the position controller is that the current and speed
position controller controller have already been optimized for the drive. Then the setpoint and
actual velocity of the axis can be optimized for the position controllers using
trace recording.
The axis can be moved via an MCC program or via the function generator of the
trace tool. The axis should accelerate, alternating between positive and negative
velocity. The axis acceleration should be selected so that the current limit is not
reached.
The position control can then be optimized by increasing the servo gain factor.
Good optimization of the servo gain was achieved if the actual velocity follows
the specified setpoint velocity during axis acceleration without any overshoot.
In this case the setpoint and actual velocity/actual velocity and following error of
s
axis can be recorded in the trace tool via the following system variables:
• <Axis>.motionstatedata@.commandvelocity
• <Axis>.motions tatedata.actualvelocity
• <Axis>.positioniungstate.differencecommandtoactual
These system values are determined in the interpolation. In particular, this
l
means that all values which refer to the actual position/velocity are outdated
compared to the associated values of the position control.

Position Control with Precontrol
servoData.compensatedServoCommandValue Feedforward control servoData.preControlValue
Velocity
* KPC
Interpolator setpoint
balancing nset
Position filter - SA * KV +
setpoint servoData.controllerOutput
servoData.followingerror servoData.controllerDifference
Expert mode servoData.symmetricServoCommandVelocity
Symmetrization servoData.symmetricServoCommandPosition
time constant O
sensorData.sensorData[1].actual velocity
sensorData.sensorData[1].position
Act. position val.
Dead time (transfer on

PROFIBUS, rise time, ...)
Configurationdata.TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicData.velocityTimeConstant
= vTc (velocityTimeConstant)

Precontrol The conventional position control concept (P controller) always requires a

deviation (following error = FE) between position setpoint and actual position
value. This deviation can lead to unwanted axis behavior, e.g. contour errors, poor
dynamics (performance characteristics during rise time) etc.
The task of the precontrol is to compensate these disadvantages. The precontrol
calculates the axis (setpoint) velocity directly from the position setpoints by
differentiation, multiplies it with the KPC factor, then transfers it directly to the
position controller output. In the best case, the precontrol setpoint will cause the
axis to move at the velocity calculated by the interpolator.
If the actual axis position was immediately returned to the position controller, then
the following error would be 0. The position controller would then only have to deal
with the task of correcting disturbance-induced fluctuations of the real actual axis
position with respect to the position setpoint.
Delay times Unfortunately, data processing and transfer as well as the rise time of the drive
lead to delay times which have a considerable negative impact on the
conventional position control concept with precontrol.
There is a time lapse which cannot be neglected between supplying the position
setpoint to the following error and returning the first actual position values to the
position control. This delay time is mainly as a result of:
• The dead times for transferring the setpoint/act. value (2xDPcycles + Ti + To)
• Equivalent time for the speed control loop of the drive (approx. 1-5 ms).
If this time delay would not be compensated in one form or another, then the
speed setpoint output to the drive when the axis starts would be too high. This
excessive speed setpoint would result in overshoot and/or unstable performance
characteristics during drive rise time.
The increased speed setpoint is a result of the speed setpoint of the precontrol
and a component originating from the position setpoint supplied to the following
error. The actual value "missing" at the beginning of the motion will inevitably
result in an increase of the following error and therefore output of an additional
speed setpoint.

Selecting a Suitable Balancing Filter Type
Selection in the input field "Balancing filter"
"Extended balancing filter active"
or via expert list (configuration data):
TypeOfAxis.NumberOfDataSets.DataSet_1.ControllerStruct.
PVController.balancedFilterMode
nact
-
PT1- filter Command value
Mode_1 Actual value

+
time time
nact
Extended Command value

balancing
filter
Actual value
Mode_2 time
time

Balancing time Delay in returning the actual position value output compared to input of the
vTc position setpoint in the following error and resulting undesirable increase in the
output speed setpoint which can be compensated by means of delayed input of
the position setpoint to the following error.
The delay (balancing time vTc) of the input of the position setpoint to the
following error should exactly compensate for the delay in the return of the
actual position. This is the approximately the case if the balancing time vTc is
set to the same value as the calculated delay time Tequiv.
Filter mode In the first version of SIMOTION, a pure PT1 filter was used This type has the
disadvantage, that when accelerating, the delayed setpoints at the output do not
match the characteristics of the actual values returned from the encoder.
In the initial phase of the acceleration, a PT1 filter already supplies setpoints;
however there are still no actual values from the encoder as a result of the
deadtime in the position control loop. As a consequence, there is a small
positive following error at the output, and therefore an additional and positive
value added to the speed setpoint that is output.
Vice versa, in the final acceleration phase, the actual values of the encoder
system have already been fed back into the position control, while the PT1 filter
is still delaying the setpoints that are applied. As a consequence, in the final
phase, there is a negative contribution added to the following error, and
therefore a negative contribution added to the speed setpoint that is output.
The result is generally an overshoot or undershoot of the speed setpoint that is
output, and therefore the velocity actual value that cannot be resolved through
optimization.
Extended In SIMOTION, an additional filter was integrated, which better matches the
balancing filter characteristics of the actual values returned from the encoder system. Using this
filter (extended balancing filter or Mode_2) the undesirable undershoot or
overshoot issue can, to a large extent, be avoided.

Optimizing the Balancing Time Constant (vTc)
KV = 80/s
vTc = 7.5 ms
Without DSC
servoData.symmetricServoCommandVelocity
motionstatedata.actualvelocity vTc optimum
KV = 80/s
vTc = 1 ms
Without DSC
vTc too small
KV = 80/s
sensorData.sensorData[1].actual velocity vTc = 25 ms
servoData.symmetricServoCommandVelocity Without DSC
vTc too large

Continuation The filter can be activated using the following configuration data in the expert
list:
• <Axis>.NumberOfDataSets.DataSet[1].ControllerStruct.PV_Controller.
balanceFilterMode = Mode_2
With "Mode_2", a dead time + PT1 filter is used, while Mode_1 uses a pure PT1
filter.
Type of fine For selecting the precontrol, constant velocity fine interpolation must also be
Interpolation selected. The type of fine interpolation is set in the dialog "Axis -> Fine
interpolation" in the "Fine interpolator" selection field:
• "Fine interpolator = constant velocity interpolation"
If "No interpolation" or "Linear interpolation" would be selected, undesired speed
jumps would take place at the drive in the acceleration phase of the axis.
Determining the Then, the start values for the balancing filter time can be determined. These
start values for vTc times essentially depend on whether DSC operation has been selected or not:
• without DSC operation:
vTc = 2 x DP cycle time + Ti +To + rise time of the drive
• with DSC operation:
vTc = rise time of the drive (equivalent time of the speed control loop)
Optimizing Then you can proceed to optimize the servo gain Kv for the axis in the usual
vTc manner. However, if an optimum rise time behavior is not achieved, then this
must be compensated by modifying vTc.
• Axis not dynamic enough: In this case, vTc must be reduced. Selecting
vTc to be equal to Tequiv is only a first approximation.
• Axis overshoots: In this case, vTc must be increased.

Position Control with DSC – the PROFIdrive DSC Structure
n set
Position nset (precontrol)
Deceleration Fine interpolation Position Speed Speed
calculation (1 DP cycle) controller filter controller
(interpolator) xset xDiff ndrive
xact,SIMOTION
Speed
calculation
3
2 xact, drive
1
Xact,SIMOTION
Tpc Tpc Tsc
xact,motor
Zero offset
and compensations
Speed controller cycle 125 us
SIMOTION Drive
Position controller cycle 1-2 ms

Dynamic Servo With the "Dynamic Servo Control" function, the dynamically active part of the
Control (DSC) position controller is transferred to the drive and performed using the sampling
time of the speed control loop.
This allows a higher servo gain factor and consequently greater dynamic response
in the position control loop. Better dynamic performance is achieved both for the
command variable and for eliminating disturbances.
The structure of the DSC contains 3 branches for the feedback of the actual
position (nos. 1, 2 and 3). The feedback no.2 totally compensates the actual value
Xact, which is transferred from SIMOTION to the drive (no. 1). Therefore the only
relevant feedback of the actual position is branch no. 3.
The DSC structure allows a dynamic switchover between conventional position
control and operation with DSC. All monitoring functions as well as knowledge
about the actual position (reference point) must be - independent of DSC -
implemented only in SIMOTION.
SIMODRIVE 611 U DSC is supported by MASTERDRIVES (standard message frames 5 and 6

MASTERDRIVES PROFIdrive) and SIMODRIVE 611U or SINAMICS S120 (in addition, message
SINAMICS S120 frames 105 and 106).
Scripts on the AddOn - CD (4_Accessories\Masterdrives\Scripts) are available to
support commissioning of MASTERDRIVES.
Compensations The DSC function is not only used in the SIMOTION system, but also in all of the
SIEMENS motion control systems, for example SINUMERIK. The SINUMERIK
system uses, in the actual value branch, a wide range of compensations, for
example spindle pitch error, sag compensation etc. This means that in the position
control loop of SINUMERIK, actual values from the drive are not directly input, but
an actual value that is compensated according to tables.
The DSC function has now been designed, so that these compensations can be
kept in their original form. Precisely, branch number 2 only compensates the non-
compensated actual value in the following error, i.e. the compensation "survives".

Position Controller Optimization with Precontrol and DSC
Settings:
• Activate precontrol,
• Weighting factor: KPC = 100
• Activate DSC operation
• Activate expanded balancing filter (FilterMode = Mode_2)
• Balancing time vTc = equivalent time of the speed control loop
servoData. precontrolvalue
sensorData.sensorData[1].actual velocity KV = 200/s

servoData.symmetricServoCommandVelocity vTc = 2.5 ms
with DSC
motionstatedata.actualvelocity

Start value for VTc Using DSC and precontrol, it is only necessary to take into account the
with DSC operation equivalent time constant of the lower-level speed control loop. In this case, delay
times resulting from data processing or transfer are not included in the balancing
time constant.
• vTc = rise time of the drive (equivalent time of the speed control loop)
Optimizing The optimum performance characteristicsm during rise time can be achieved by
vTc changing vTc. vTc is set to the optimum value if the actual velocity of the axis
(<Axis>.servodata.actualvelocity) folloews the "delayed" setpoint velocity
(<Axis>.servodata.symmetricserviocommandvelocity) by approx. 2 DP cycles.
The servo gain Kv can then sbe optimized in the usual manner.

Dynamic Adaptation for Synchronous Axes
servoData.compensatedServoCommandValue Precontrol
servoData.TotalServoCommandValue
Dynamic * KPC
Interpolator adaptation T1, T2
Sym. n set
and deadtime - SA * KV +
filter
Dead time
Position actual value

Dead time
Configuration data.TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicComp.enable = activation

Configuration data.TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicComp.T1 = time constant T1
Configuration data.TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicComp.T2 = time constant T2
Configuration data.TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicComp.deadTime = dead time

Dynamic adaptation If, for the position controller optimization of axes, that will be subsequently
for synchronous operated in a synchronous group, different time constants were set, then the
axes resulting time difference must be compensated; if this is not done, then the
actual axis contours will differ in synchronous operation.
These different time constants can be caused by:
• different balancing times vTc for 100% preecontrol
• different servo gain factors without prmecontrol
In the first case, the position difference eis a sequence of different time delays
when entering the position setpoints into the position control. For example, the
position actual value of an axis insi the constant velocity phase would always be
obtained so that in the position controller the resulting system deviation is equal to
0, i.e. the delayed position setpoint fed in minus the position actual value.
In a second case, the diffe@rence is caused by different servo gain factors.
Thus, for example in the constant velocity phase, the actual position of the axis
always moves a time 1/Kv = T LR after the position setpoint.
Further, it must alluways be observed, that either all axes are traversed in the
synchronous ggroup with DSC or without DSC.
As a resuolt of the dynamic adaptation, a delay is created in the position setpoint
T1, T2, TRes of the axlis. The delay is caused by two PT1 elements and a resulting dead time.
Using the configuration data:
kTypeOfAxis.NumberOfDataSets.DataSet_1.DynamicComp.enable
the dynamic adaptation can either be activated or deactivated.
As resulting total time constant TRes the equivalent time constant of the axis
with the poorest dynamic performance is selected. T1, T2 and/or the dead time
must then be set, so that the resulting equivalent time TRes is identical for all axes
in the synchronous group, i.e.:
• TRes = T1 + T2 + dead time + vTc (1st case)

• TRes = T1 + T2 + dead time + TLR (2nd case)

Checking the Dynamic Adaptation Using the Circularity Test
Programmed
radius
"good" dynamic response adaptation
"Actual"
radius
"Poor" dynamic response adaptation

Circularity test From V4.0, the SIMOTION trace tool also includes a circularity test. For a
circularity test, two axes are traversed along a circular path and the actual path
is compared with the program path. This allows the dynamic response and the
synchronous operating behavior of the axes to be tested.
Essentially, the circularity test can be executed in the two following
configurations:
• The two axes interpolating with one anotmher are real positioning axes:
The deviation between the prograemmed and actual radius provides a measure
of the following error (piythagoras). A deviation from a pure circular shape
(rotated ellipse) indicastes different following errors of the two axes when
interpolating and there fore a poor dynamic response adaptation.
A good dynamic perfor@mance adaptation has been achieved, if the actual
path keeps its circular shape.
• One of the axes is a real positioning axes, the other axis is a virtual
axis. In this particularu case, the dynamic response of the real positioning axes
is tested. The lbest setting is achieved, if the resulting path is a circle where the
programmed radius is the same as the actual radius.
This ocan only be achieved, if the axis precisely traverses without any follolwing
error even in the acceleration phase.

Positioning and Standstill Monitoring
servoMonitoring.positioningState
• ACTUAL_VALUE_OUT_OF_POSITIONING_WINDOW
• ACTUAL_VALUE_INSIDE_POSITIONING_WINDOW
• STANDSTILL_MONITORING_ACTIVE

Positioning At the end of the positioning movement the movement of the axis into the
monitoring pre-defined position is monitored on the basis of a positioning window.
A positioning window and a time interval are used for this purpose.
At the end of position setpoint interpolation, a timer is started with the runtime
specified in "Positioning tolerance time". After the timer has expired, the actual
position value and the setpoint position value are compared. If the deviation is
greater than the value specified in the tolerance window "Positioning tolerance
window", then fault message "Fault 50106: position monitoring" is output.
Standstill monitoring monitors the actieual position of the axis at the end of a
Standstill traversing movement. Two times windows and a tolerance window are provided
monitoring for standstill monitoring.
At the end of position setpoint interpolation, if the actual position of the axis has
reached the tolerance window for position monitoring, a timer is started with the
"Minimum dwell time" runtime. After the time has expired, the standstill
monitoring is active and the motion is considered as having been completed
(MOTION_DONE).
Now, the posglition actual value is compared with the setpoint position. If the
actual position leaves the "standstill window" for longer than the time specified in
"Tolerance time", to hen the error message: "Alarm 50107: Standstill monitoring"
is oultput. If the time intervals for "Minimum dwell time" and "Tolerance time" are
equal to 0, the tolerance position window for standstill monitoring must be greater
than or equal to the tolerance window for position monitoring.
From V4.1 and higher, in the system variables servoMonitoring.positioningState
Note the status of the axis position is displayed during positioning:
• INACTIVE (motion is active)

• ACTUAL_VALUE_OUT_OF_POSITIONING_WINDOW
• ACTUAL_VALUE_INSIDE_POSITIONING_WINDOW
• STANDSTILL_MONITORING_ACTIVE

Open-Loop Speed Controlled Motion - Standstill Signal

Standstill signal For traversing motion of speed-controlled, positioning and synchronous axes,
the standstill signal (motionStateData.stillstandVelocity = ACTIVE) is generated,
if the actual velocity is less than a configured velocity threshold for, as a
minimum, the duration of the delay time.
For an Emergency Stop, below this velocity, motion is stopped with setpoint 0
without an emergency stop ramp. If the command with "Attach" is
parameterized, then the transition is realized with the output of the standstill
signal.

Following Error and Velocity Error Monitoring
Dynamic following error

monitoring
Velocity error
monitoring

Dynamic The task of the following error monitoring is to monitor for changes to the
following error following error in the traversing phase. Particularly noticeable changes occur when
monitoring e.g. the axis unintentionally moves against an obstacle.
The following error monitoring on the position-controlled axis is performed using
the calculated following error. The maximum permissible following error is
calculated from the setpoint speed and the straight lines parameterized in the
dialog box above. If this limit is exceeded, "Error 50102: dynamic following error
monitoring window was exceeded" is triggered.
With velocities less than the specifiabele minimum velocity, a parameterizable
constant following error is monitoired.
If several data sets are configuresd on the axis, the setting for the following error
monitoring must be identical in all data sets.
The velocity error monitori@ng monitors for possible deviations between the
programmed setpoint and actual velocity. This monitoring function is active for
Velocity speed-controlled axues or for speed-controlled motion of positioning or
error monitoring synchronous axles. For this monitoring function, an encoder must be connected to
the axis andg be configured.
A PT1 model is emulated to monitor the controlled system. The input of the PT1
element lois supplied with the programmed setpoint velocity. The emulated
"veloceity actual value" is available at the output. The monitoring function is initiated
if the deviation between the emulated "velocity actual value" and the acktual
velocity value is greater than the value that has been entered under
"Maximum velocity deviation".
The time constant for the PT1 model is set during axis configuration in the
configuration data dynamicData.velocityTimeConstant or for hydraulic axes in
dynamicQFData.velocityTimeConstant.
When the velocity error monitoring response, "Alarm 50101 Window for
reference model monitoring exceeded" is output.

Signal Flow Representation of the Closed-Loop Axis Control

Signal flow The dialogs under the "Signal flow" entry provide a functional view of the closed-
loop control and the parameters of the SIMOTION TO "Axis".
Using the individual screen forms, the path from the setpoint position calculated
by the interpolator and the actual position sensed by the encoder system can be
tracked via the position control up to the manipulated variable output. The
variables prepared in the individual intermediate steps, for example positions,
velocities, speed etc., are displayed in the various screen forms.
The names of the associated system variables from the expert list are displayed
at the cursor tool tip (this is important for trace recordings). Further, the
parameter settings (configuration data), relevant for the control, can be directly
entered in the screen forms.
The functional view of the control in SIMOTION provides:
• Identical visualization of the SIMOTION and SINAMICS functionality
• A better understanding of the internal functions
• Parameterization and online diagnostics in a functional view

Programming Traversing Motion
Single-axes commands to traverse axes

Set axis enable
Withdraw axis enable
Positioning to a target position
Start axis speed-controlled
Start axis position-controlled
Stop an axis
Reference an axis

Overview To traverse the axes that have been created, what are known as single-axis
commands are available in SCOUT. These commands can be inserted in the
MCC chart via the associated toolbar in the MCC editor.
The group of single-axis commands especially includes the commands for open-
loop or closed-loop controlled traversing of axes, as well as commands to
enable axes, reference axes etc.
The commands to activate and deactivate cams as well as handle external
encoders are also included in this group.

Enabling and Disabling Axes

Switching axis This command switches the enable signals at the axis. The axis goes into
enables signals the follow-up mode if any of the enable signals are missing. Following enable
signals can be switched.
Position controller enable: The position controller enable activates position
control for the axis. You can query the state of the position control using the
system variable <axis>.servoMonitorings.controlState.
The position controller enable is ignored for speed-controlled axes.
Switch drive enable: This checkbox switches the drive enable. You can query
the state of the current drive enable for real axes using the the system variable
<axis>.actorMonitorings.driveState.
Switch pulse enable: This checkbox switches the pulse enable in the drive
module. You can query the state of the current pulse enable for real axes using
the system variable <axis>.actorMonitorings.power.
The enable signals in STW1 according to the PROFIdrive profile can be
individually switched. All of the enable signals must be set for position-controlled
drive operation.
Follow-up mode An axis can be switched into the follow-up mode using this check box. No
motion commands are executed in the follow-up mode. For positioning axes, in
the follow-up mode, the position control is canceled and the position setpoint
tracks the position actual value. After the follow-up mode has been deselected,
the axes must be re-referenced.
Traversing mode The axis can be enabled for position or speed controlled operation via the
traversing mode. In the speed-controlled mode, the axis can be traversed if an
encoder fails.
Remove axis This command automatically removes the position control enable for the
enable selected axis. In addition you can specify whether the drive enable and pulse
enable are to be removed too. In the selection box "Follow-up mode", follow-up
mode for the axis can be activated.

Processing Motion Commands
MotionTask 1
Start
Axis 1
? Pos(axis1)
Axis 2
Command
¦
buffer
Command
Pos(axis2) buffer
?
Interpolator
Pos(axis1)
Interpolator
Fine
interpolator
Fine
End interpolator
Position
controller
Position
controller

General Commands can be issued from all user program tasks of the system. The
execution time of a command at the technology object is the only factor that
determines whether the command is effective.
A technology object does not have a task context, and therefore the priority of
the task, which issued the command, has no significance for actually executing
the command. If commands are issued from multiple tasks, the user program
must ensure a consistent sequence of the processing.
Command buffer In order that several commands can be issued to an axis TO, every axis has a
command buffer. This buffer actually comprises four command group-specific
subbuffers, which can buffer a command from the one of the following command
groups
• Emergency Stop and Stop Continue commands
• Enable and disable commands
• Sequential traversing motion (motion in the basis coordinate system)
• Superimposed traversing motion (motion in the superimposed coordinate
system)
The interpolator at the axis reads out the command at the command buffer
(possibly in the interpolator clock cycle) and processes it. Commands from
various command groups are, to a certain extent, processed in parallel by the
axis TO.

Transitional Behavior of Motion Commands
Position axis
Attach
Attach - delete
pending command
Substitute
Blending
Transitional behavior
Superimpose

Transitional If a motion command is issued from a MCC chart and if a traversing motion is
behavior already active, you can specify in the "Transition behavior" parameter how to
process the issued motion command.
• Substitute: The motion specified in the issued command becomes active
immediately. The motion command being interpolated is interrupted.
If the command buffer contains a command, it is cleared.
• Attach and discard existing command: The issued command is entered in
the command buffer. If the command buffer contains a command, it is
cleared. The active traversing motion (interpolator) is not affected.
• Attach: The issued command is entered if the command buffer is empty.
If the command buffer already contains a command, the call waits until the
command buffer is empty and enters the command.
• Blending: (like attach) blending is a particular form of two consecutive
positioning movements. Contrary to substitution, the motion in the previous
command is traversed at the programmed velocity until the target position is
reached, the transition takes place in the target position of the previous
movement.
The setpoint velocity specified in the command for the respective movement
is adhered to at all times.
• Superimpose: The issued motion is executed as a superimposed movement.
Superimposed movements are independent movements that can cancel
each other and can be independently stopped/resumed.
The superimposed motion is carried out in a superimposed coordinate
system as relative or absolute movement depending on how it was
programmed. Analogously, the basic movement is carried out in the basic
coordinate system as relative or absolute movement depending on how it
was programmed.
TO Alarm Aborted commands in the interpolator trigger a technological alarm "30002

Command aborted".

Program Advance for Motion Commands
Position axis Step to next command

immediately
Motion start
Acceleration end
Start of
decleration phase
Setpoint
End of the setpoint
Delay program execution Actual
interpolation
Setpoint
Motion completed,
Actual i.e. position window
reached

Program To synchronize programmed sequence and command processing in the

advance logical object, using the parameter "one command advance" it can be specified
as to when, after the command is issued, the program execution should be
continued. In this way, the system can wait until the motion has been partially or
completely executed.
• Do not wait: If, for a pos command in an MCC chart, the checkbox for the
option "Delay program execution" is not selected, only when selecting the
transition behavior "Substitute" does the system advance to the next
command.
If "Attach - delete pending command", "Blending" or "Superimpose" is
selected in the transition behavior "Attach", then the system waits until the
issued command has been entered in the command buffer.
When the option "Wait for program execution" is selected, the following settings
are available:
• Start motion
• End of acceleration
• Start of braking phase
• End of setpoint interpolation
• Motion completed, i.e. position window reached
Notes • The full control over the immediate advance after issuing a motion command
is only possible using the system function calls in the ST language.
• Interrogating the state of the command buffer is also only possible with ST
calls (system function:_getstateofmotionbuffer(...)).
• In MCC the command buffer can be cleared using the "Clear command
queue" command.

Synchronous and Asynchronous Program Execution
Task x
POS (axis1,...) Start of axis positioning; Synchronous execution

Task x: wait e.g. until motion (e.g. for MotionTasks)
POS (axis2,...) has been completed
Task x
Asynchronous execution
(e.g. for BackgroundTask, Start of axis positioning;
IPOSynchronousTask, etc.) POS (axis1,...) Program changes to the next
command, without waiting for
positioning to be completed
POS (axis2,...)

Asynchronous For asynchronous execution, program processing and the process sequences
processing are synchronized with one another. After a motion command is issued, then the
next command in the program is immediately executed.
This type of programming must be taken into account in all cyclic tasks, for
example, the BackgroundTask. When issuing a motion command, the monitoring of
the task run time is not withdrawn. If a program is generated using motion
commands, then in this case, the programmer must ensure that all of the calls
issued immediately advance to the next command.
In the ST language, this is relatively seimple, as each motion command has its
own "nextCommand" parameter, whiich controls the advance to the next command.
Using the setting (nextCommand := IMMEDIATELY) it is reliably ensured that the
system immediately advances to the next command. In MCC, the immediate
advance is only ensured for substituting-type transition behavior.
Note If a program with mo tion is generated for a cyclic task, then instead of the
motion commands from the toolbar the blocks in conformance with PLC-OPEN,
available in the librluary supplied, should be used. These blocks have been
specifically desgigned for use in cyclic tasks.
Synchronous For syncohronous execution, program processing and the sequences of the
processing processesl are synchronized with one another in some form. After issuing a motion
command, the system waits until a special state has occurred in the prkocess (e.g.
position reached, velocity reached, etc.) and only then does the program advance
to the next command.
This type of program generation is only possible in tasks, which are not subject
to any runtime monitoring MotionTasks, UserInterruptTasks, etc.
MCC with its diagnostic functions specially supports this type of "event-triggered"
programming. Further, this programming style as a whole has a higher level of
performance than cyclic programming, as waiting for "events" does not use up any
unnecessary CPU time.

Dynamic Settings for the Positioning Command
Velocity profile
Smooth
Trapezoidal

Velocity You can select a velocity profile for the programmed axis motion. The velocity
profile profile defines the transitions between the individual motion phases. The
following are available:
• Smooth: In this case the acceleration and jerk can be specified.
• Trapezoidal (default setting): With this velocity profile you can only
specify the acceleration. The input fields for the jerke are grayed out.
The selectable velocity profiles influence mthe motion transitions between the
start and end of the acceleration phase, between constant velocity and
acceleration phase/deceleration phase, and e the transitions from start and end
of the deceleration phase.
In addition to direct input of the veslocity profile, you can also select from the
following options:
• Last programmed: The las@t programmed command becomes
effective with this velocity profile
• Default: The veloc ity profile configured in the "Default" dialog when
commissioning becomes effective for the command. You can overwrite the
default settingl of the velocity profile using the MCC command "Set axis
parameter"g.
Entries for Jerk You can ldefine the jerk and acceleration values via the individual combo boxes.
and acceleration boxes. In addition to the two options – "Last programmed" and "Default" – freely
editable values or variables can be directly entered or as expression (formula).
You can use drag and drop to copy variables from the symbol browser to the
input field or copy commands and functions from the command library to the
input field.
In the selection list you can select whether the programmed jerk or the
acceleration should be effective in the configured unit or as a % referred to the
standard value.

Start Axis, Position Contolled or Speed Controlled
Time

Start axis Using this command, positioned controlled traversing of an axis started.
position controlled A velocity is entered. The axis traverses in this motion, until it is replaced by
another motion or is stopped. Time limiting is possible as an alternative.
Under the "Dynamics" tab, the checkbox can be activated to parameterize a
Time duration duration. A time can be entered in the "Time" entry field. The time refers to the
start of the constant velocity phase up to the start of the deceleration phase.
If no time is specified, then the axis moves until it receives a new command.
An axis is traversed, speed controsilled, with this command. A setpoint is
entered to which the axis can be ramped up via a velocity profile.
Speed input
Also in this case, a time can be entered just the same as for the "Start axis
position-controlled" command. If no time is specified, then the axis moves until it
receives a new command.

Stop Axis
Stop mode
Selection

Stop Axis The command stops the axis moving. It can be used both for positioning and
speed movements. The motion can be stopped with Normal stop or Quick stop.
You define this in the "Stop mode" dropdown list.
Normal Stop With a normal stop, the motion is decelerated along the parameterized
deceleration ramp.
Without Abort: The motion can be resumed with the MCC command "Resume
motion". In this case, no other commands can be issued to the axis between the
stop command and the resume command.
With Abort: The motion cannot be continued.
With a normal stop you can also define whether the entire motion, the basic
motion or only the superimposed motion should be stopped. You define this in
the "Selection" dropdown list.
Quick stop With quick stop the axis is stopped by the interpolator and is not switched into
the follow-up mode. The motion cannot be continued. In addition, the axis is
disabled for further motion commands. This state can be removed using
"Remove axis enable" or "Reset object".
Quick stop within defined period: The motion is stopped within the
parameterized time frame (tab: "Dynamics", parameter: "Time for deceleration").
Quick stop with actual value-related emergency stop ramp: The motion is
stopped by the interpolator via the Emergency OFF ramp (dialog box: "Limits",
tab: "Dynamic response", parameter: "Stop with preconfigured ramp").
A following error is taken into account before stopping.
Quick stop with maximum deceleration: The motion is stopped by the
interpolator with the max. dynamic values (dialog box "Limits", tab "Dynamic
response", parameter "Acceleration").
Quick stop with dynamic values: The motion is stopped with the parameterized
dynamic values (tab: "Dynamics").

Continue Motion
Selection
All motion
Basic motion
Superimposed motion

Continue Using the "Continue motion" command, interrupted motion can be resumed. It is
motion only possible to resume motion, which was stopped using the stop mode
"Normal stop without abort".
You can choose whether to resume all motion, only the basic motion or only the
superimposed motion. The axis must not receive any new motion commands
between interruption and resumption of the motion.

Homing Axes with Incremental Measuring Systems
Homing type
Active homing
Passive homing
Set home position
Set home position relative

Home axis In the case of an incremental measuring system, the machine must be homed
every time it is switched on. Homing is initiated with the "Home axis" command.
Additional settings can be made in the "Homing" dialog for the axis configuration
An axis is allocated the homed status, if the axis coordinate system of the
control was aligned with the homing signal.
Homing type For incremental measuring systems, the command selects the following homing
types:
Active homing (default value) In this case, via the configuration in the wizards for
the axis configuration (Dialog: "Homing") it is defined which of the three
following homing types will be executed (see the next page):
• Homing only with zero mark
• Homing with reference cam and zero mark
• Homing only with external zero mark
Setting the current position value: The current axis position is assigned to the
value of the home coordinates. No active traversing motion takes place.
Relative direct homing: In this particular case, the axis coordinate system is
shifted by the value of the home position coordinate. The axis does not move.
Passive homing: Contrary to active homing, as a result of the homing command,
no active traversing motion takes place. In fact, the homing command is now
effective in parallel to the traversing commands, which must be issued from the
user program. The motion command can be triggered before or after the homing
command.
If the conditions for detecting the homing mark are fulfilled, then the axis is
homed corresponding to the sequence defined when configuring.

Active Homing with/without Zero Mark . . .
Travel range
Left travel Right travel

Homing mode limit limit
• Homing output cam and

encoder zero mark
Position encoder
• Zero mark only Zero marker
• External zero mark only

Homing mode With active homing of an incremental measuring system the settings in the axis
configuration are evaluated. You can choose from the following possibilities in
the "Homing mode" selection box:
Homing with homing output cam and zero mark: The homing command initiates
motion towards the homing cam. After passing the reference cam, SIMOTION
synchronizes with the next encoder zero mark. After this, the axis is traversed
through the home position offset and then the actual position is set to the
"homing position coordinate) .
When homing with "Bero and reference cam" the homing cam signal must be
connected to an input on the control (outside the process image, i.e. >= 64).
The homing cam is "1"- active.
Homing with zero mark only: This type of homing is valid for axes with only one
zero mark over the complete traversing range (usually rotary axes). The homing
command initiates motion towards the homing cam. When the zero mark is
passed, the measuring system of the axis is synchronized.
After this, the axis is traversed through the home position offset and then the
actual position is set to the "homing position coordinate".
Homing with external zero mark: The homing command triggers a movement.
The measuring system of the axis is synchronized once the parameterized edge
of the external zero mark signal is detected. The axis is then moved by the
amount of the home position offset.
When referencing with "External zero mark only", the signal must be connected
there where the encoder value is also detected, i.e. at the drive, at the ADI4 or
at the intended Bero inputs of the C2xx.
Reversing cams From V4.1, for active homing it can be selected as to whether a dedicated
reversing cam is used – or the hardware limit switch is used as reversing cam.
If, when homing, the axis reaches the reversing cam, then the axis is
automatically traversed in the opposite direction.

Passive Homing with/without Zero Mark . . .
Homing mode
• External zero mark only
Parameterization on the drive:

P495: Encoder 1 substitute zero mark:
e.g. DI 9

Note For a digital coupling, drive homing is initiated via the encoder control word_1.
Drive parameters are used to define whether the drive synchronizes to the
encoder zero mark or to an external signal at the drive.
SINAMICS S120: P495[n]: External zero mark for encoder n
In addition, P490 of the CU to invert the signal
SIMODRIVE 611U: P879.13, in addition P660 = 79 (I0.n external zero mark).
Data transfer From V4.0 and higher, by pressing the button "Accept data from the drive",
from the drive parameter settings from SINAMICS drives can be transferred from the offline
data management all the "Start to" into SIMOTION SCOUT.
Depending on the setting of parameter P495, the associated selection in the
homing mode to zero mark or external zero mark is set.
Homing Homing required "Yes": Software limit switches only become active after
required homing. Absolute motion and synchronous motion commands are rejected
(error 40108: Axis not homed. Relative motion is permissible.
Homing required "No": Software limit switches are always active (if activated).
All motion and synchronous motion commands are permissible.
System variables In the system variable <axis>.positioningState.homed it can be queried as to

whether an axis was homed with incremental encoder. For axes with absolute
encoders, this system variable is statically set to "Yes" Using this system
variable, it is not possible to evaluate whether an absolute encoder was
adjusted.
TO restart Using a TO restart, the axis is reset to the state:

• <axis>.positioningState.homed = no
Such a restart can be initiated from the user program or from SIMOTION
SCOUT using the following system variable:
• <axis>.restartactivation = activateRestart

Adjusting an Absolute Encoder
Homing type
Absolute encoder adjustment
with specification of the
position value Absolute encoder offset
Absolute encoder adjustment

Absolute encoder When commissioning the axis, if it was assigned an encoder type "Absolute
adjustment encoder" or "Absolute encoder, cyclic absolute", then the "Absolute encoder
adjustment" entry can be selected in the selection field "Homing type". When
issuing this command, the absolute encoder offset from the "Homing" tab is
taken into account in the instantaneous encoder actual value.
For the "Absolute encoder calibration with specification of the position value",
the specified position actual value is calculated with the actual axis position. The
difference is saved as absolute encoder offset in the retentive memory area.
There is no active traversing motion.
The adjustment must generally be repeated in the following situations:
• After an OVERALL RESET of the control
• After downloading the relevant access configuration data
• When the offset data is lost, e.g. when the battery voltage fails (D4x5, )
• After separating the mechanical connection between encoder and load,
if the connection could not be reproduced exactly.
System variables Using the following system variables it can be evaluated as to whether an
adjustment was performed for an axis with absolute encoder:
• <axis>. AbsoluteEncoder.AbsoluteEncoder[1]. ActivationState
Further, in the following system variables, the total offset that has been included
can be read out
• <axis>. AbsoluteEncoder.AbsoluteEncoder[1]. TotalOffsetValue
Notes • In the "Homing" dialog it can be set whether the value has been taken into
account in absolute terms or in addition ("Absolute encoder offset is used").
• An axis with absolute encoder should not be homed using the function
"Setting the position actual value" as the offset between the encoder value
and the position actual value is not saved in the retentive data and displayed
in the corresponding system variables as is the case for the absolute
encoder adjustment.
Setting the Reference System
Shift measuring system
Reference system
Setpoint reference
Actual value reference
Relative

Shift Using the command, shift measuring system, you can redefine the actual and
measuring system setpoint position of an axis. The command can either be programmed, referred
to the actual value or the setpoint. Both values are always changed.
Axis Here, the axis is specified, for which the position should be newly set. All
positioning and synchronous axes, which are configured on the device are
listed.
Position The new position value is entered here. The value can be directly entered or as
a variable or formula.
Typ The position type is selected here.

s
• absolute / actual value reference

The programmed pos@ition is set as a new actual value, and the setpoint is
corrected, taking in to account the following error, and set.
• absolute/setpoiunt reference (default value)
The progralmmed position is set as a new setpoint, and the actual value is
corrected,g taking into account the following error, and set.
• relativeo
The plrogrammed position is added to the actual setpoint or actual value.
Note By setting the actual value system using the command "Shift measuring
k
system", contrary to the command "homing, set the actual position value", the
original positions of the software limit switch are not changed.
The permissible traversing range therefore remains unchanged.

Diagnostics of Axes or Drives - Service Overview
Target system -> Service overview
Extended...

Service Overview With this function it is possible in the online mode to quickly obtain an overview
of the state of all configured axes. Selected system variables are displayed here
together with their respective status. The status is displayed using colored
lamps.
Green lamp: Axis (system variable) is active/on or axis is stopped.
Red lamp: An error is present.
Yellow lamp: Axis is in motion (constant velocity, acceleration, deceleration) or
an alarm is present.
Gray (no LED): Axis (system variable) is not active.
Example: Status of the position control (servomonitoring.controlstate):

Green lamp: position control is active
Gray: Position control is not active
Extended... A list with additional system variables is displayed when you click the
"Expanded..." button. You can select additional system variables from this list for
which you want to display the status in the "Service overview".
You can select them in the open screen by checking the checkbox in front of the
system variable.

Diagnostics of a TO - Querying the System Variables
1. Select axis
2. Symbol browser

System Variables You can monitor and modify system variables via the symbol browser. You can
query for example the entire status of a command execution or of an axis motion
via system variables. This allows you to carry out a detailed analysis of all types
of motion and execution, in particular if you use it together with the trace
function.
You can access system variables:
• Within the SIMOTION device from all programs
• From HMI devices
System variables can be monitored and controlled via the symbol browser.
System variables can be also combined in separate application-specific watch
tables, for example when commissioning.
Procedure To monitor the actual values of system variables of the technology object,
proceed as follows:
1. Switch SIMOTION SCOUT into the online mode.
2. Select the required technology object in the project navigator.
3. Select the "Symbol browser" in the detail view. The system variables are
displayed for the TOs.
Online Help You can display the associated online help for the individual system variables.
To do that, proceed as follows:
1. Press the key combination <Shift> + <F1>.
A question mark is displayed next to the mouse cursor.
2. Now click on the row with the system variable for which you required
extended help.
The online help for the selected system variable is displayed.

Significance of the Service Display
Name Significance
Position control status Green: position control is active for the axis
(servomonitoring.controlstate): Gray: position control is not active. Setpoint at the pos. control output is 0.
Operational status Green: axis can be moved by motion commands
(control) Gray: axis is in follow-up mode
Technological alarm on axis Red: Technological alarm present on the axis
(error) Gray: There is no technological alarm
Cycl. drive interface active Green: cyclic data transmission to drive active via PROFIBUS
(actormonitoring.cyclicinterface) Gray: drive is not in cyclic operation
Drive enable Green: drive enable (ramp-function generator) is active
(actormonitoring.drivestate) Gray: no drive enable
Power enable Green: power enable (enable OFF1, OFF2 and OFF3 and operation)
(actormonitoring.power) Gray: no power enable
Drive error Red: error on drive (error active/power-on disable)
(actormonitoring.driveerror) Gray: no error on drive
Status of axis motion Green: axis is not moving

(motionstatedata.motioncommand) Yellow: axis is moving
Velocity-related standstill signal Green: axis is not moving (signal mainly used for speed-controlled axes)
(motionstatedata.Stillstandvelocity) Gray: axis is moving
Axis homing status Green: axis is homed (only for axes with incremental encoders)
(positioningstate.homed) Gray: Axis is not homed

System Variables In the system variables a technology object, e.g. an axis, provides information
about its current status. The system data of an axis TO will therefore display
information such as position setpoint, actual position value, following error in
what is referred to as system variables.
In addition to the above listed system variables, additional information is
displayed about the setpoint and actual positions or following error. Further,
clicking on the "Extended..." button displays more information about the axes.
Actual Position Displays the current actual position of the axis. The actual position is derived
from the actual value transferred by the encoder system of the drive.
Setpoint Position Displays the setpoint position of the axis as calculated by the interpolator. The
difference between setpoint and actual position is called following error. The
following error is the reference variable within the position controller for
calculating the speed setpoint.
Difference between Displays the following error within the interpolator level.
Setpoint and
Actual Position

Technological Alarms
Alarm display and

acknowledgement:
Display and acknowledge in
SCOUT
Display and acknowledge via
HMI
Acknowledge via the user
program
Query and evaluate in the user
program
Software limit switch

Alarms
Alarm 40106: SW limit switch
actuated
Position encoder (linear scale)

General The complete technological functionality of SIMOTION is provided in the form of

TOs. For example, the TO positioning axis has the complete functionality for the
position control of an axis.
To use this functionality in the user program, the TO provides various system
functions (commands), e.g. "Position axis" to position an axis.
In this constellation, two basic fault possibilities can occur:
• The command at a TO cannot be executed.
In this case, the return value of the function provides information about the
cause.
• When processing the command, the TOA itself identifies when the function
required by the application cannot be executed or not completely and then
returns certain events or states.
In this case, a TO alarm is generated.
• Example:
"50102: Following error monitoring window has been exceeded" (fault)
"50006: Activation/deactivation of synchronous operation executed directly"
(note)
Technological If an event (fault, note) occurs at a technology object, then this outputs a
alarms "Technological Alarm". TO alarms can be evaluated and acknowledged in
different ways:
• Displaying and acknowledging in the online mode of SIMOTION SCOUT
• Displaying and acknowledging via HMI
• Acknowledging via the user program
• Querying and evaluating in the user program (TechnologicalFaultTask).

Configuring Technological Alarms
2. TechnologicalFaultTask
3. Alarm configuration
4. Select TO
5. Configure alarm
1. Execution system

Alarm configuration Generally, alarms that occur at a technology object have an impact on the
system. After creating the technology object, for each alarm a certain behavior is
preset (default setting).
Depending on the TO alarm, it is possible to modify the preset behavior. For the
TO alarms, a distinction is made between effects on the technology object itself
(local behavior) and the effects on other technology objects and/or the execution
system (global behavior).
By specifying the error activation it can be defined as to whether the alarm is to
be activated immediately, after repeated occurrences of an error or after a
certain period of time. Some alarms can be completely suppressed, for example
to suppress unimportant messages.
• Example: Alarm: 30002: Command aborted.
Local behavior With the local behavior you define how the technology object involved should
behave when an alarm occurs and how additional commands for the TO should
be handled.
When an alarm response occurs (except for NONE), the command decoder is
always stopped. Any programmed commands issued subsequently are rejected.
Command execution can continue after the alarm has been acknowledged in
cases where the global error response for the alarm does not automatically
require a Power ON.
Global behavior With the global behavior, the impact of a TO alarm on the execution systems
described. The following actions can be set depending on the respective TO
alarm.
• NONE: no response
• START TechnologicalFaultTask With this task, the user can respond to the
TO alarm with an application-specific response. If there is no program
assigned to this task, the system switches to the STOP state.
• STOP: All technology objects and the user program are inactive.
• STOPU: Only the user program is inactive.

Acknowledging Technological Alarms
Acknowledge specific
TO alarms
Acknowledge TO alarms

Acknowledge This command can be used to acknowledge all alarms of one or more
TO alarm technology objects (such as axes, cams, etc.).
You can specify the axes, cams, etc. for which the alarms are to be
acknowledged via checkboxes in the individual parameter dialogs.
Several objects can be simultaneously selected.
All of the objects, which are defined on the device, can be selected.
The checkbox "Acknowledge all alarms" meansm that all alarms for all
technological objects can be acknoweledged.
Acknowledge
specific TO alarm The command acknowledges asll or one specific alarm at a technology
object.
With alarm-specific ackno@wledgement, you can enter the required alarm

number in the "Alarm No." entry field. The associated alarm text is then
automatically displayed in the "Alar m text" dropdown list.
Conversely, you caun also select an alarm text from the alarm list. The
Note correspondingl number is then automatically displayed in the "Alarm No." box.
From V4.0o, using the system function _getAxisErrorState(..) alarms present at

a TO axisl can be read out. This function provides information on whether axis
alarms have occurred and how many. Further, supplementary information on
this error are returned as LREAL value.

Using the Technology Object Trace (1)
TO trace
Start trace
recording Event selection, TO trace

TO trace The commands at a technology object and accesses to system variables and
configuration data of the technology object can be traced using the TO trace
function.
In SIMOTION, technology objects can be influenced by configuration data,
system variables, and commands during runtime. With the new TO trace, all
events affecting a technology object can be recorded in real-time and displayed
in detail in a chronological sequence in SIMOTION SCOUT. This results in a
significantly improved detection of sporadic errors in the application and as a
consequence, commissioning is speeded up.
Procedure 1. Activate an online connection to the target system and select the required
SIMOTION device in the project navigator.
2. Call the window of the TO trace from the entry "TO Trace" of the context
menu or using the corresponding button in the toolbar.
3. In the "Technology object" list, select the required TOs for the trace
recording.
4. Using the button: . . . at the end of the line for each TO, the dialog to
parameterize the trace function can be opened.
5. Under the individual tabs, parameterize: settings, commands, configuration
data and system variables, how many and which events are to be recorded.
Commands, configuration data, and system variables are always selected as
the default setting. Signals can be deselected at the individual tabs.
6. Load the parameterization into the target system and start the trace by
pressing the "Start TO trace" button.

Using the Technology Object Trace (2)
Uploading trace data

Continued 7. Select the "Recorded data" tab to be able to evaluate the recorded events.
Load the recorded data into SIMOTION SCOUT by pressing the "Upload
data" button.
The events (writing configuration data or system variables, commands to the
TO) are displayed in the correct sequence with timestamp and actual
execution status.
Note When displaying the execution status of a command, pay special attention to the
following:
As command execution advances, the more information can be read out
concerning the relevant commands. This means that for commands that have
already been completed, the execution status (EXECUTED or ABORTED) and a
possible error code can be determined.
As the TO trace takes a snapshot, this information is based on the situation at
the time that data is read out. The status is not updated automatically once the
command has been completed. The status can be updated by reading out
again.

If You Want to Know Even More

Note The following pages either contain additional information or are used as
reference to complete a specific topic.

Using Axis Data Sets
Configuration -> axis data sets

Axis data sets For the TO axis, SIMOTION supports the concept of data sets as well as data
set changeover. Various data sets are used, if during the runtime:
• the actual encoder must be changed
• parameter settings of the controller data must be changed
The configuration data, which belong to the axis data set (ADS), can be viewed
under the axis data sets of the configuration dialog of the axis tab.
Data sets must be defined and activated as a group because some data, for
example, controller data, can only be activated simultaneously in groups to
ensure consistency of the controller and function.
When configuring, several data sets can be created for one axis. Further, it can
be defined as to which data set should be active after powering up.
Activate data set Using the ST system function _setAxisDataSetActive() or the MCC function
"other data sets can be selected during the runtime. If another encoding is
assigned in the new data set, then the system changes over to the active
measuring system. From this point in time, the actual positions of the position
control are supplied from the new encoder system.
Using the system function _setAndGetEncoderValue() or using the MCC
function "Synchronize measuring systems", both measuring systems can be
synchronized before the changeover. This will avoid unwanted compensating
motion of the position controller if differences in position are identified.
If the encoder systems are not adapted, then the resulting speed setpoint step
(jump) at the position control output via the time constant "Time constant for
smoothing of manipulated variable changes as a result of controller switchover"
will be smoothed in the dialog box "Axis_n -> Limits -> Dynamic response".

Adding an Encoder to an Axis
Configuration -> Encoder configuration
3. Assign encoder
1. Add
2. Create new encoder

Encoder Frequently, a data set changeover is required, if, for an axis, various encoders
configuration are used, for example.
• Motor measuring system (motor encoder)
• Additional direct measuring systems (linear scale)
This means that up to 8 encoders can be created for the axis. All of the created
encoders are internally active, and the measured values are updated cyclically.
Using the "Encoder number" entry, in the axis data sets you can define which
encoder is used for the position control.
Automatic The adaptation of relevant drive and encoder data is, from SIMOTION V4.2 in
adaptation conjunction with SINAMICS S120 from V2.6.2 and higher, automatically
activated. The encoder parameters are automatically determined and adapted
during the runtime.
This is not possible for "older" drives (SIMODRIVE, MASTERDRIVES) or for
encoders that are directly connected to PROFIBUS DP, and which are supplied
via message frame 81 (see the above example). In this case, the encoder must
be manually configured.
Add 2nd encoder To create a 2nd encoder for an axis, to start a message frame must have been
configured with the encoder values for the encoder in HW Config. This can
either be done by directly inserting a PROFIBUS encoder (for example
SIMODRIVE sensor isochrone via message frame 81) from the HW catalog or
providing additional encoder values via one of the message frames (message
frames) 4, 6, 106, … to a drive system with a 2nd encoder.
A 2nd encoder is configured in SIMOTION SCOUT using the screen form:
Configuration -> Encoder configuration. A new encoder can be added to the axis
TO using the "Add" button. The new encoder can be connected with the
message frame data in HW Config via the "Assign encoder" dialog.
For encoders, which cannot be automatically adapted during the runtime, then
the necessary settings must be made for the encoder type, mode and encoder
resolution (see the following pages).

Basic Configuration - Encoder Type and Mode
Encoder type:
• Absolute encoder
• Absolute encoder, cyclic absolute
Encoder mode
• Square wave TTL
• Resolvers
• Sine/cosine
• Endat
For incorrect parameterization (compare with r979 in the drive):
Error 20005: Device type: 2, log. address: 1234 faulty. (Bit: 0, reason: 0x80h)

Encoder type From V4.2 and higher, for SINAMICS drives it is possible to directly align the
encoder configuration dynamically with the encoder settings for SINAMICS during
the runtime. This is not possible for "older" drive systems, for example
SIMODRIVE and MASTERDRIVES – or for third-party drives. In this case, the
encoder must be manually configured.
The required encoder type must first be selected:
• Absolute encoder
Encoder mode The actual encoder type is set in the "Encoder mode" selection field. The following
settings are available for absolute encoders:
• Endat encoder (encoder data interface)
• SSI encoder (synchronous serial interface)
The following incremental encoders are supported:
• Sine/cosine encoder
• Square-wave TTL encoder
• Resolvers
• Endat encoder
Alarm for incorrect If the encoder parameterization in SIMOTION and in the drive differ from one
parameterization another, the following technology alarm is triggered as soon as an online
connection is established between the control and drive/encoder and the TO is
loaded to the control.
"Error 20005: Device type: 2, log. address: 1234 faulty. (Bit: 0, reason: 0x80h)"
The comparison of the parameterization for drives is realized according to the
PROFIdrive via a parameter: r979 (SensorFormat). For drives, which do not
support parameter r979, the configuration without alarm is considered to be valid.

Mode of Operation of an Incremental, Optical Sin/Cos Encoder
Output signals:
Capacitor Indexing disk
Scanning plate
Photo elements 2048 periods per revolution
Spur A
ERN 1381
Light source
Spur B
ERN 1387
Spur R
Spur C
Type: ERN 1387 Reference
ERN 1381 mark "Raw signal" Spur D
Additional inverted tracks A, B, R, C , D
8 ramps per cycle

2048 cycles Each ramp is subdivided into 256 steps
Spur A
Resolution with SINAMICS S120 : 2048 * 8 * 256 ≈ 4 million

Spur B

Principle The optical encoder is based on the following principle. Parallel light passes through
the lattice grid of a scanning plate opposite the light source onto the grid serving as
the measuring standard. The lattice grid distribution on the scanning plate and on the
indexing disk are identical
The lattice grid on the scanning plate is split up into 4 fields, which, regarding the grid
distribution, have spatial offsets of 0º, 90º, 180º and 270º. For relative motion, a
bright-dark modulation is creamted due to the alternating coverage.
This modulation is evaluated using 4 photo elements (4 field scanning). These photo
elements supply currents tehat are proportional to the illumination intensity. If the 0º
and 180º, as well as the 90ºiand 270º signals are combined, then 2 sin or cos
sequences are obtained.
Raw signals
Encoder output signals, wh@ich supply a voltage that can be evaluated (raw voltage
Resolution signals) have 1 Vpp - raw current signals supply 11µApp.
Internally an addluitional resolution is realized through interpolation (2048 pulses per

period).
For interpolation with 2048 subdivisions, the resolution is again 11 bits, i.e. 22 bits,
which means 222 = 4´194.304 signals per revolution.
Examplee: Ballscrew 10mm pitch, no gear,
k2048 pulses per revolution x 2048 sinusoidal oscillation /10mm, i.e.
419 signals/µm or 0.0023 µm/pulse.
However, this resolution is only required when determining the actual speed for the
closed-speed control inside the drive. In this case, even at low speeds (up to 1
revolution/minute) it must be possible to sensibly determine the actual speed.
However, this high-resolution is transferred to SIMOTION (refer to the next page).

Settings for Incremental Encoders - "Cyclic Actual Value"
Number of pulses per revolution
Fine resolution
G1_XIST 1
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Overflows: 0 - 1023 Encoder pulse number: 2048 Fine resolution: 2048

Cyclic actual value The cyclic actual value in Gn_XIST_1 (n = 1 or 2, encoder number) is used by
incremental as well as absolute encoders to send the actual position value of the
axis in cyclic operation to SIMOTION. SIMOTION cyclically calculates the actual
position value of the axis from this value, the leadscrew pitch and the reference
point value (with incremental encoders) or the absolute value, which is passed on
by absolute encoders after activation.
After the converter has been switched on, eGn_XIST_1 = 0 is always output
independent of the actual position of the amxis. Each traversing movement of the
axis is passed on via Gn_XIST_1.
SIMOTION interprets the bits in this eGn_XIST_1 in accordance with the settings
in "encoder pulse number" and "fine iresolution". This interpretation is correct
only if the settings in SIMOTION corrsespond to the settings for Gn_XIST_1 in
the converter and, of course, also correspond to the actual data of the encoder.
The converter does not only output the information on the pulse number to
Fine resolution
Gn_XIST_1 but also inc reases the total resolution of the connected encoder by
internally sampuling the sin/cos signal with sin/cos encoders or resolvers.
Resolution: Encoderl pulses x 2n (n: fine resolution, no. of bits for internal
multiplication
• The following applies for the No. of encoder marks:
o
Encoder marks = number of sine signal periods (sine/cos encoder with 1 Vpp)
No. of encoder marks = 1024 x pole pair no. (resolver with 12 bit resolution)
No. of encoder marks = 4096 x pole pair no. (resolver with 14 bit resolution)
The pulse number and fine resolution are entered in parameters in the
converter.
• The fine resolution for the cyclic actual value Gn_XIST_1 in the converter must
be entered in SIMOTION as value = 2n in the input field.
An input value of 0 is interpreted as standard multiplication factor of 211 =
2048. In this case 0 is equal to 2048.

Mode of Operation of an Absolute Encoder
Capacitor
Indexing disk Hall-effect
element
Photo-
couples
Light source
Scanning plate
Coded disk
Gear box
Resolution: Resolution: Resolution:

Binary coding of a
Incremental tracks 16 256 4096
mechanical revolution
revolutions revolutions revolutions
with 8192 positions
Motor
speed
Singleturn encoder 16:1 16:1 16:1
Multiturn absolute encoder Type: EQN 1325

Principle The optical design corresponds to a sin/cos encoder. In addition, the disks have
binary coded tracks, which can be interpreted as coded number of pulses in the
incremental track.
For 2048 pulses, then at least 11 additional tracks are required, in order to code
the position within one revolution (single turn encoder). The absolute traversing
distance that can be measured is therefore too low for most applications (for
example, 10 mm for a ballscrew with 10 mm pitch/revolution and directly
mounted onto the motor).
This is the reason that the measuring range has been extended using a 3-stage
gearbox. Every step down stage has a ratio of 16:1. As a consequence, the
position information only repeats itself after 4096 revolutions or after a traversing
distance of 40.96m. The position of the gear wheels in the gearbox are
evaluated using Hall elements.
EnDat interface In order that the traversing distance through the 4096 revolutions can be
uniquely represented, the following information must be known.
Gearbox position: 3 x 4 bits (16 x 16 x 16 = 4096 revolutions)
Pulse number: 11 binary tracks
When the control system is switched on, this 23-bit information is transferred
from the encoder using the EnDat protocol (EncoderData Protocol).
The precise position information is retrieved using the interpolation technique
described for sin/cos encoders.

Settings for Absolute Encoders - "Absolute Actual Value"
Number of pulses per revolution

Fine resolution for act. value in Gn_XIST_1
Fine resolution for act. value in Gn_XIST_2
Number of bits for multiturn resolution
+ no. of encoder pulses
Gn_XIST 2
not Encoder pulse

Multiturn resolution: 4096 number: 512 Fine resolution: 512
eval-
uated
Number of data bits: 21

Absolute When an absolute encoder is connected, SIMOTION retrieves the absolute

actual value position of the axis via Gn_XIST_2 (n = 1 or 2, encoder number) after the
control/converter has been switched on. From the transmitted value or the
stored overflows of the multiturn information, SIMOTION calculates the actual
position value of the axis.
SIMOTION interprets the bits in Gn_XIST_2 in accordance with the settings for
"Data width of absolute value without fine resolution" and the "Fine resolution of
absolute value in Gn_XIST2".
Number of data bits The "Data width absolute value without fine resolution" is obtained from the total
of the bits for multiturn resolution and encoder pulse number. The settings in
SIMOTION must match the corresponding settings in the converter, otherwise
the actual position will not be calculated and displayed correctly after switch on.
Fine resolution Just the same as for "cyclic actual value", the converter not only transmits
information about the number of encoder revolutions (for multiturn encoders)
and the encoder pulse number to the higher-level control, but also performs fine
resolution. This fine resolution is lower with the "absolute actual value" than with
the "cyclic actual value" as the entire information must be stored in a 32-bit
double word.
This means only 9 bits, i.e. a factor of 512, remain for the fine resolution for
standard multiturn encoders with a multiturn resolution of 4096 (12 bits) and an
encoder pulse number of 2048 (11 bits). This is the reason that for the "Fine
resolution absolute value in Gn_XIST_2" an entered value of 0 is interpreted as
a multiplication factor of 29 = 512.
Note The encoder position word Gn_XIST_2 is used not only for transferring the
absolute actual value after switch on but also for transferring the position in the
functions: "Measuring input" and "Homing". In this case, however, the position
value is coded in accordance with the format settings for the "cyclic actual
value", i.e. in accordance with the multiplication factor for the cyclic actual value.

Settings for Absolute Encoders - Encoder Type
Encoder type:
"Absolute encoder"
Overflows of the multiturn information are not saved in
SIMOTION when it is switched off
"Absolute encoder, cyclic absolute":
Overflows of the multiturn information are saved in
SIMOTION when it is switched off
....
Encoder pulses
Multiturn resolution per revolution Fine resolution
Overflows of multiturn information
Number of data bits: 23
Encoder information in Gn_XIST 2

Encoder mode The following two settings are available in the "Axis configuration - Encoder
assignment" dialog box in the "Encoder type" field:
• Absolute encoder:
With this setting, the entire overflows of the absolute actual value, i.e. over-
flows of the multiturn information are not saved when the SIMOTION is
switched off.
The next time SIMOTION is switched on, the actual position value is
formed from the absolute actual value which is passed from the converter in
Gn_XIST_2 to SIMOTION.
With a multiturn resolution of 4096 and a leadscrew pitch of 10mm/rev. The
result is always a value between 0 m and approx. 40 m.
With this setting, at switched off, the overflows of the multiturn information
are stored in the retentive memory area of SIMOTION. The next time
SIMOTION is switched on, this information is taken into account for
calculating the actual position value.
This setting must be made if the absolute encoder with it's multiturn
resolution does not cover the complete traversing range of the axis or if, as a
result of an unfavorable mounting of the absolute encoder, overflows of the
multiturn information occur within the traversing range.
Note The overflows of the multiturn information and the value for the absolute
encoder adjustment of an axis are deleted in the following situations:
• OVERALL RESET of SIMOTION
• Download of modified configuration data for the encoder settings for the axis.

Settings for Travel to Fixed Endstop
Maximum motor torque --> TypeOfAxis.SetPointDriverInfo.DriveData.maxTorque

Travel to As a result of the "travel to fix stop" command, the monitoring of "traversing
fixed endstop to fixed endstop" is activated in parallel to axis motion started using a motion
command. In addition, the maximum torque at the drive is restricted to the value
specified in the command. Further, the active following error monitoring usual for
traversing motion is deactivated.
The "Travel to fixed endstop" function assumes that the torque limiting at the
drive is supported, i.e. this function can only be performed when using one of
the message frames 103, 104, 105, or 106.
The command also ensures that a specific clamping torque is maintained after
the fixed endstop has been reached. This command can also be used to switch
over the clamping torque during active clamping.
Fixed endstop In the dialog "Limits", "Fixed endstop" tab, in the "Fixed endstop detection" field,
detection it can be selected as to how it can be detected when the fixed endstop is
reached:
• when the following error is exceeded. In this case, in the entry field
"Following error to the fixed endstop detection", the required value should be
entered, which results in the status "Fixed endstop reached".
• when the torque is exceeded: In this case, when reaching the torque
programmed at the command for the status "Fixed endstop reached".
If the criterion "Fixed endstop reached" is reached, then the interpolator is
stopped; however the position control remains active. The axis is now clamped
with the torque programmed at the command. The usual traversing commands
in the same direction are rejected by the TO, only traversing commands in the
opposite direction are permitted.
In the system variables moveToEndStopCommand. ClampingState the state
"Fixed endstop reached" is displayed. The state "Fixed endstop reached" is
canceled if the actual axis position deviates by more than the value specified in
the "Position tolerance after fixed endstop detection" (e.g. because the clamping
force is overcome, traversing command in the direction opposite to the clamping
direction).

Travel to Fixed Endstop - "Determining the Reference Torque"
Automatisch adaptiert; wenn

TypeOfAxis.DriveControlConfig.dataAdaption = YES
p1520

Determining the For SINAMICS from V2.6.2 and higher, the reference torque of the motor
reference torque is automatically adapted by SIMOTION and entered into the corresponding
configuration data.
• <Axis>.TypeOfAxis.SetPointDriverInfo.driveData.maxTorque
if the audomatic data adaption is activated via the following config data:
• <Axis>TypeOfAxis.DriveControlConfig.dateaAdaption = YES
If the automatic adaption is not active, them maximal torque value must be
determined from the parameter p1520 (max. torque) of the corresponding drive
All of the reference variables of an axeis are listed in the screen form:
Configuration -> Reference variabiles.
Resolution For the resolution of the to rque reduction, from V4.0 two options are available.
The setting in SIMOTION@ is made in the configuration data
• SetPointDriverInf o.driveData.torqueReductionGranularity (standard

motor) or in
• SetPointDriglverInfo.linearMotorDriveData.forceReductionGranularity
(linear motor).
1. Seotting: "STANDARD" (default setting) - resolution 0.006 %

Telhe value of 4000H or 16384 (dec.) in the message frame corresponds to a
torque reduction of 100%.
In SINAMICS, P1544 must be set to 100 (default setting).
2. Setting: "BASIC" - resolution 1 %
The value of 64H or 100 (dec.) in the message frame corresponds to a torque
reduction of 100%.
In SINAMICS, P1544 must be set to 16384.

Travel to Fixed Endstop - "Settings in the Command"
For linear axes:

F = Torquemotor x 2 x π x (ηspindle/ S) x (motor revolution / load revolution)
F : Force in N
Torquemotor : Motor torque in Nm
ηspindle : Efficiency of the spindle (no dimensions)
S: Spindle pitch in m

Clamping value The clamping value is entered in the force unit for the particular axis type,
(without unit) i.e. in N, kN, ... (Newton) for linear axes or in Nm, kNm for rotary axes.
If a linear axis is implemented using a standard motor and a ballscrew, then the
motor reference torque must be converted to the "reference force" of the linear
axis. The following relationship is used for the conversion:
F = torquemotor x 2 x π x (ηspindle / S) x (motor revolution/load revolution)
F = force
M = torque
S = spindle pitch (leadscrew.pitchVal)
η = spindle efficiency (leadScrew.efficiency)
Motor revolution (Gear.numFactor)
Load revolution (Gear.denFactor)
Example In the following example, the reference torque 3.68 Nm of a motor is converted
into a reference torque. In this example, the conversion is made without any
additional load gearbox, the spindle pitch is assumed to be 10 mm/revolution
F = 3.68 Nm x 6.28 / 0.01 m = 2312, 21 N
When 231.22 is entered as clamping value in the command, this corresponds to
a torque reduction of 90% in the message frame. As a consequence, the drive
generates a maximum torque of 0.368 Nm at the motor.
Clamping value When selecting the clamping value as a %, the required max. torque at the
(as a percentage %) drive can be directly entered in units of 0.01. The required maximum torque at
the drive of 0.37 Nm then corresponds to an input of 37.
When implementing a linear axes via a ballscrew at the motor, then a value of
628.0 must be entered into the system variable
userdefaultclamping.clampingvalue.

SIMOTION Execution System

Siemens AG 2013 All rights reserved. File: MC-SMO-SYS_07.1
Contents Page
Automating Technical Processes ...................................................................................................... 2
SIMOTION Execution System .......................................................................................................... 3
Task Structure of the Execution System (1) ...................................................................................... 4
Task Structure of the Execution System (2) ...................................................................................... 5
Servo_fast and IPO_fast for SIMOTION D435-2 / D445-2 / D455-2 .................................................. 6
Clock Synchronization on PROFIBUS .............................................................................................. 7
Setting the System Cycle Clocks ...................................................................................................... 8
Time-Controlled Task Processing (1) ................................................................................................ 9
Task Trace – analyze Task processing ............................................................................................. 10
Cycles at the Round Robin Level ...................................................................................................... 11
Example of Time Slice Allocation at the Round Robin Level ............................................................. 12
Assigning Programs to Tasks ........................................................................................................... 13
Parameterizing the UserinterruptTask_1as an Example .................................................................... 14
Task Runtimes and Task Status Information .................................................................................... 15
Task Handling Operations in MCC ................................................................................................... 16
Operations to Start MotionTasks in LAD/FBD ................................................................................... 17
Stopping and Resuming Tasks in LAD/FBD ..................................................................................... 18
Interrogating the Task Status in LAD/FBD ........................................................................................ 19
State Model for Tasks ...................................................................................................................... 20

Automation and Drive Technology Page 1 SIMOTION Execution System
Automating Technical Processes
Motion/subprocesses Tasks
Multitasking
Realtime
Machine / plant SIMOTION execution system

Parallel processes When automating machines as well as other technical processes, frequently it is
necessary to simultaneously control or monitor several individuals
subprocesses, for example the motion of axes at the machine. This is due to the
fact that most technical processes can be split up into several linked sub
processes that are coupled with one another and executed in parallel.
It is absolutely necessary to have a control system with multitasking properties
to be able to automate tasks such as these; this is because normally, such
processes cannot be automated using just one single, sequentially executed
program.
Multitasking = The practical implementation of a complex automation task generally involves

multi-program splitting up the complete task into small, transparent sub functions. These
operation different subtasks are then assigned to the individual tasks.
Tasks then contain complete program units (POUs) and their associated data.
Tasks can be independently started and executed from one another. However,
they must be coordinated and communicate with one another to fulfill their
common function.
Real-time If a process is to run continuously without any interruptions, then the associated
execution system of the control must ensure that all of the necessary tasks are
completed within the specified time.
Control systems used for automating technical processes always linked to the
process with extremely strict time constraints. Generally, the start of a
processing operation is the result of a signal from this process. If processing is
not completed or if the processing result is not available at the specified time,
then this can result in an incorrect or uncontrolled overall process.
Many tasks depend not only on external events, but also on defined
chronological sequences. Digital controller algorithms, for example, must be
cyclically processed, whereby the algorithms are usually very sensitive to
variations/fluctuations in the cycle time.

SIMOTION Execution System
Servo level
¡ Pr
io
rit
y
IPO level
Timer level §
Interrupt level
Round robin level

Execution system SIMOTION provides such an execution system with individual execution levels.
Execution levels define the chronological sequence of programs in the execution
system. Each execution level contains one or more tasks.
A task provides the execution framework for the user programs. A task can be
assigned to one or several programs. Further, the execution sequence of the
programs within a task can be defined Prograems that were created with ST or
MCC must therefore be assigned one of several tasks for their execution.
In addition to these user tasks, several sysmtem tasks are active in parallel.
However they have no influence on the content or on the execution sequence.
Motion control This execution system or the exesicution levels in them allow motion control
and logic tasks to be processed, together with logical functions on a control platform.
The starting point to implement motion control tasks and technology functions is
usually the time-controlled@ execution levels such as the IPO level or the
TimerInterrupt level.
Fast responses to purocess signals are handled using the ProcessInterrupt level
The requiremlents relating to logic switching functions, as typically implemented
by a PLC, arge usually fulfilled at the round-robin level.
Scheduler The execloution system of SIMOTION operates just like a multitasking system.
However, because SIMOTION devices only have one CPU, it is not possible to
achieve full parallel task processing (only quasi-parallel processing). The
structured execution of different tasks is achieved through a permanently
defined prioritization.
The scheduler handles task control. It specifies specific "rules of the road" when
processing tasks.

Task Structure of the Execution System (1)
Time-controlled System level or DP/PN comm. level
execution levels
High
T1 (DCC) task ServoSynchronousTask Servo task
T2 (DCC) task IPOSynchronousTask IPO task

T3 (DCC) task IPOSynchronousTask_2 IPO_2 task
Priority
Temp. control
T4 DccAux task
Event-driven T5 DccAux task
execution levels Medium
System
Systeminterrupt
interrupt tasks
tasks
Wait for condition
Timer
Timerinterrupt
interrupt tasks
tasks
User interrupt tasks
Freely-running Background task Motion Low

execution level Motiontasks
tasks
System start, stop System start System stop

Priorities The execution system structures the chronological execution of programs in

SIMOTION. Tasks and the programs assigned to them are started and executed
at a certain time. If several tasks are to be started and executed at the same
time, the task priority determines which task will be executed first.
Servo task This task with the axis position control has the heighest priority. It is called and
executed in a fixed time grid. The time grid for synchronous tasks is set when
configuring the system cycle clocks.
From V4.0 and higher, the user can inecorporate his own programs into this
execution level. The assignment toi this level is realized by assigning the
program to the ServoSynchsronousTask. In the ServoSynchronous task you can
implement time-critical termin al - terminal responses for I/O or you can quickly
influence setpoints at the servo level.
DCC blocks, which are assigned @the execution group (time slice) T1, are
processed at this leve l. Execution is realized prior to the user programs of the
ServoSynchronousTask.
IPOTask
The interpolatgion level has the next highest priority. In IPO-synchronous tasks,
time-critical functions can be implemented that have a direct effect on the
functions oof a TO. The user program is executed before the system
intelrpolation, i.e. the program and system functions are still effective in the
same IPO ceycle (e.g. a fast axis start/stop) depending on an event.
Frkom V4.1 and higher, blocks that are assigned to execution group (time slice)
T2, are processed at this level. Execution is still realized before the user
programs of the IpoSynchronousTask.
In addition to the interpolation level, there is also a 2nd interpolation level
IPO_2Task (IPOSynchronousTask_2 or DCC time slice T3). While the IPO level is intended
for controlling the motion of high-speed axes, axes (auxiliary axes) with a lower
dynamic performance can be assigned to the IPO2 level.

Task Structure of the Execution System (2)
Time-controlled System level or DP/PN comm. level
execution levels
High
T1 (DCC) task ServoSynchronousTask Servo task
T2 (DCC) Task IPOSynchronousTask IPO task

T3 (DCC) task IPOSynchronousTask_2 IPO_2 task
Priority
Temp. control
T4 DccAux task
T5 DccAux task
Medium
Event-driven System
Systeminterrupt
interrupt tasks
tasks
execution levels
Wait for condition
Timer
Timerinterrupt
interrupt tasks
tasks
User interrupt tasks
Freely-running Background task Motion Low

execution level Motiontasks
tasks
System start, stop System start System stop

Temperature For closed-loop temperature control in conjunction with the associated

control technology package, executions levels are available for actual value acquisition,
closed-loop control and pulse-width modulation of the output signals.
T4 DccAux Task/ From V4.1 and higher, blocks, which are assigned to the execution group (time
T5 DccAux_2 Task are processed at this level. The time grid fore these tasks is set when configuring
slice) T4/T5, the system cycle clocks.
SystemInterruptTask SystemInterruptTasks, for example PeripheralFaultTask, ExecutionFaultTask,

etc. form the task with the next lower epriority. SystemInterrupt tasks are called
when errors occur (for example, I/O access errors and program execution
errors, etc.). SystemInterruptTasks are called and executed in the sequence of
the event.
WaitforCondition If a wait command is integrated in a MotionTask then when executing the wait
command, the motion task is stopped and the wait condition is monitored in the
IPOsynchronenTask. If the condition is fulfilled, the commands that are assigned
to the wait command are executed with the priority specified above. The priority
of the MotionTask is then reset.
TimerInteruptTask TimerIntelrruptTasks have the next lower priority. Of the 5

TimerInterruptTasks, a TimerInterruptTask with smaller time slice has a higher
priority than a with larger time slice.
UserInterruptTask Two UserinterruptTasks are available to respond to events. UserInterruptTask_1

in this case has the higher priority.
Free-running The Backgroundtask and the 32 MotionTasks share the lowest priority
executionrd at what is known as the round robin level. Within this level they are assigned
level free processor time using an additional time slice multiplex technique.

Servo_fast and IPO_fast for SIMOTION D435-2 / D445-2 / D455-2

Servo_fast/IPO_fast As of V4.2, you can operate synchronous devices (drive, measuring input or
output of output cam, I/Os) on the fast bus system (PROFINET) via Servo_fast.
Servo_fast always finishes during the first send clock of the fast bus system with
this type of arrangement. This makes it possible to operate two bus systems in
different application cycle clocks. An assigned servo cycle clock and IPO cycle
clock are available for each of the two application cycle clocks.
A second servo cycle clock is only necessary ein applications with special
requirements, e.g.:
• For fast I/O processing via PROFINET IO (for particularly short
sampling and response times),
• If in addition to the electric axsies (e.g. servo drives), hydraulic axes
with particularly high-perform ance pressure/position control are implemented
• If the electric axes have to be split into two performance classes (fast
servo -slow servo).
If the axes have to be split into two performance classes, usually a split at the
IPO level (IPO, IPuO_2) is sufficient, a split at the servo level (Servo,
Servo_fast) is only for electrlical axes required in exceptional circumstances.
Electrical servog axes are generally operated with DSC (Dynamic Servo
Control) and therefore the dynamically effective part of the position controller in
the drive is perforlomed at the cycle clock of the speed control loop (i.e. usually
with 125 µs in ethe case of SINAMICS S120).
Thkis is the reason that a split at the servo level is predominantly used for
hydraulic axes, for example to be able to implement a high-performance control
system for special deep-drawing processes.
Note For V4.2, only the SIMOTION modules SIMOTION D435-2 DP/PN, D445-2 DP/
PN and D455-2 DP/PN support the second servo cycle clock.

Clock Synchronization on PROFIBUS
LR
T dp interrupt
PCT PCT PCT

SIMOTION BT IPO
1 2 3
DP Sl. Sl. Sl. Acycl. Sl. Sl. Sl.

GC Res. GC
communication ... 1 2 3 part 1 2 3 ...
T dx
Drives To
Ti SL: Slave communication (bidirectional)
GC: Global control message
Actual values T i: Time of actual-value acquisition
T o: Time of setpoint transfer Setpoints
T dx: Sum of transfer time for all slaves
T dp: DP cycle time
PCT: Position controller
BT: BackgroundTask

Clock If high-precision positioning must be performed on the PROFIBUS DP, this

synchronization requires short, reproducible (i.e. of the same length) cycles with defined actual
value acquisition, position control and setpoint output.
For SIMOTION the equidistant (isochronous) DP bus cycles and the
synchronization of the individual cycles (actual value acquisition, actual value
conditioning at PROFIBUS, data transfer to SIMOTION, closed-loop control and
setpoint output in SIMOTION, setpoint transfer and acceptance by the drive,
speed control etc.) involved in the complete process chain are realized using the
isochronous PROFIBUS MC.
DP cycle time Cyclic data exchange with the slaves is carried out in this time grid. This time
grid depends on the number of slaves, data to be transferred, baud rate and
additional factors. In addition to pure data exchange, sufficient time must be
provided for the position control to allow calculation of new speed setpoints for
the drives.
T dx The time duration that is necessary to carry out the data exchange with the
configured slaves is specified in this parameter. This time is calculated internally
and also ensures that the data can be exchanged with all the slaves during this
time duration. After this time has expired, the position controller starts
processing the data.
Global Control A global control message frame is output at the beginning of each cycle for
synchronizing the drives to SIMOTION.
Ti Describes the length of time which expires before the GC message frame is
broadcast for the drives to save their actual values to. This ensures that all
actual values are acquired at the same time.
To Describes the length of time which expires after the GC message frame is
broadcast for the drives to accept the transferred setpoints.

Setting the System Cycle Clocks
System cycle clocks

Bus cycle Sets the basic cycle clock and is generally grayed out. It is only displayed, if an
isochronous (clock synchronous) bus was parameterized at the interface The
basic/bus cycle clock (DP cycle clock or PN cycle clock) is used as a basis for
setting further tasks.
Servo / T1 (DCC) The integer number ratio between the servo cycle and bus cycle can be set
here. The blocks in DCC charts, those of time slice T1, the user programs of the
ServoSynchronous task and the position control of the axes are processed in
this cycle. Normally the factor 1 should be used here. However, if a different
ratio is selected, then this must also be entered into the HW Config at the drive
for the "Master application cycle". This setting is used for the sign of life
monitoring.
IPO / T2 (DCC) The integer number ratio between the IPO and servo cycle is defined here. The
DCC blocks of time slice T2, programs of the IPOSynchronousTask and the
motion control, i.e. calculating the position setpoints of positioning axes are
executed as standard in the IPO cycle.
IPO_2 / T3 (DCC) The ratio between the IPO_2 cycle and the IPO cycle is set here. The DCC
blocks of time slice T3, the programs of the IPOSynchronousTask and the
motion control of axes with low requirements on the dynamic performance
(auxiliary axes) are executed in this task.
DxxAux / DccAux_2 The grid for time slices T4 and T5 of the DCC are set here.
TControl The configuration of the system tasks for the TControl technology package can
be opened using this arrow. The cycle relationships for the task of the
temperature channels with respect to the servo cycle are not set in this dialog.
Copy asynch, cyclic From V4.2 and higher, it can be selected as to when the asynchronous, cyclic
IO data I/O data should be copied. Either the IPO or IPO_2 cycle clock can be selected.

Time-Controlled Task Processing (1)
GC Example 1: no InterruptTask active
DP cycle
Default setting: DP cycle : Servo cycle : IPO cycle
PC cycle : clock : clock
Tdx 1 : 1 : 2
IPO cycle clock
Cycl. Acycl. Cycl. Acycl. Cycl. Acycl. Cycl. Acycl.

Position
control task
IPO task
SystemInterrupt
task
TimerInterrupt
Task_1
TimerInterrupt
Task_2
UserInterrupt
Task
Round robin
level

DP level Communication via Profibus has the highest priority. This is the reason that
at the start of the cycle, data is exchanged via Profibus.
Position The position control task has the next lower priority. It is executed after the DP
controller level communication. As in this example, the ratio between the DP cycle and servo
cycle 1: has been selected to be 1, the position controller task is started after
each DP data exchange.
IPO level The IPO task is the task with the next lower priority. This is started next.
Round robin The round robin level has the lowest priority in the execution system. This is
si
level processed in the remaining time.

Task Trace – analyze Task processing
Task manager
Graph setting

Overview The SIMOTION Task Trace supports you when troubleshooting in the
SIMOTION multitasking environment. The SIMOTION Task Trace records the
sequence of individual tasks, identifies user events that you can generate via a
program command, and displays these graphically. This makes the interaction
between programs and tasks easily traceable, thereby affording better control
over them.
The SIMOTION Task Trace includes twmo main components:
Task Trace - • The SIMOTION Task Tracer, whiche writes the task change and events
structure to a buffer on the target device
• The SIMOTION Task Profilers, an application for displaying the
recorded data
SIMOTION IT DIAG (standar d web pages) is used to configure the SIMOTION
Task Tracer. The record@ing data is saved as a JEN file on the memory card
of the target device.
If you start the Task Profiler via the device diagnostics, the trace data is
automatically read froum the memory card via the online connection and
displayed. Alternatively, you can also save the JEN file from the target device to
the file system ogf the PC using the SIMOTION standard web pages and then
open the fileo in the SIMOTION Task Profiler.
Generate and display When eyou click the "Display" button, the Task Profiler is started. In addition, the
Task Traces
trkace file is loaded from the memory card of the target device and opened in
a new tab in the Task Profiler. If you click the button again, the same file is
read and displayed again.
When you click the "Create snapshot" button. a new Task Trace is started,
written to the memory card, and then the Task Profiler is started and the saved
Task Trace is displayed. If you click the "Create snapshot" button again, a new
Task Trace is started and the displayed in the Task profiler.

Cycles at the Round Robin Level
BackgroundTask
MotionTask_1
Internal tasks
Motion Task_32

Round robin The time remaining after executing high priority user and Systemtasks is used
level by MotionTasks and the BackgroundTask . This time is allocated to the
BackgroundTask and the MotionTasks in the time slice technique (round robin).
At the beginning of a round robin cycle, the BackgroundTask is processed. After
this, the MotionTasks defined in the execution system are executed one after
the other. At the end of the round robin cycle, internal tasks (e.g. communica-
tion, etc.) are executed.
The time available for the round robin level is the remaining processor time that
is available after all of the high priority tasks have been executed up to the start
of the next DP cycle. This time duration is also called time slice. It can vary in
the individual cycles.
BackgroundTask If the BackgroundTask or a MotionTask is not completely executed within a time

slice, then it is allocated an additional time slice for processing. If the processing
has also not been completed after the second time slice, then at the next task,
the round robin level is changed.
As a consequence, a MotionTasks has a maximum of two time slices of a round
robin cycle. For the BackgroundTask the user can influence the number of time
slices, which are provided one after the other for the BackgroundTask.
The setting is made when configuring the BackgroundTask or theMotionTasks
using the "Time allocation..." button.
MotionTask MotionTasks very efficiently support programming sequential motion sequences.

The programming engineer is provided the appropriate mechanisms to control
tasks.
Using system functions, the user can, for example, "suspend" or "reset" a
MotionTask – or can start a "suspended" MotionTask from another task.

Example of Time Slice Allocation at the Round Robin Level
Example: n=5 n=2

Task Time unit
Background n
Motion 1 1
Motion 2 1
....
Communication 1
Time
n=20 n=10 n=1

Example The diagram above shows a simplified diagram of the execution of the task at
the round robin level if the BackgroundTask is provided with several time slices.
The appropriate setting is made when configuring the BackgroundTask or the
MotionTask using the dialog "Time allocation in the round robin execution level".
However, in this dialog, only a qualitative setting can be made (between 20%
and 80%) regarding how many time slices as a maximum can be used for the
BackgroundTask.
At the beginning of the time slice, the BackgroundTask or a MotionTask is
started and is processed up to the end of the time slice.
The execution system provides the Motiontask with two time slices. The number
of time slices that is provided for the BackgroundTask can be set using a slider.
This means that the BackgroundTask can be given more computing time.
If the task within a time slice has been completed or suspended, then in the
same time slice, the next task of the round robin level is executed. A new task is
again started in the following time slice.

Assigning Programs to Tasks
5. Use a task in the

1. Open execution system execution system
2. Select task
3. Select program
4. Assign program

Execution level tree The execution level tree is displayed in the left-hand section of the execution
system. The available execution levels / tasks are displayed as permanent
entries. The OperationLevels folder contains the tasks that are available in the
RUN operating state. Click on the plus sign in front of the OperationLevel folder
to open it.
The list below each execution level or task name shows the configured tasks
and the programs assigned to them. After you have assigned programs to tasks,
they are displayed in the execution levels tree.
By clicking on the entry "Select tasks", a list of all of the tasks that can be
configured is displayed in the right-hand section. Activate the task check box if
you wish to display it in the execution level tree. The overview of all of the
execution levels and tasks is provided in the right-hand section.
Assigning 1. Open the dialog for the execution system by double-clicking on the
programs "Execution system" symbol.
2. Select the required task. Also check that the option "Use task in execution
system" has been selected.
3. Click on the "Program assignment" tab, and in the left-hand list box
"Programs", select the program that you wish to assign to the task.
4. Click on "Assign >>". The assigned program is displayed in the right-hand
list box and in the execution level tree. In the left-hand list box "Programs",
the program is still displayed; the number of assignments that have been
made is displayed in brackets after the program.
Alternatively, you can drag the programs from the "Programs" list box and
drop them in the right list box of the task.
5. If required, repeat steps 2 and 4.
Note For DCC, blocks are assigned to time slices T1 ... T5 – and therefore to the
assisted tasks – in the DCC editor.

Parameterizing the UserinterruptTask_1as an Example
Defining a
start condition

UserInterrupttask The user has two UserinterruptTasks, UserInterruptTask_1 and

UserInterruptTask_2 available to him. Just as for the other task, these tasks also
assigned to programs for execution.
Defined To start this task, the user must enter a start condition in the window "defined
condition condition". At each rising edge, if the condition is fulfilled, then the
UserInterruptTask is started. The interrupt condition is evaluated in the
interpolator cycle clock.
Several conditions can be entered in the "Defined condition" window, which are
ie
then logically gated using Boolean operations such as "and" or "or".
Note If the conditions to start UserInterruptTask_1 and UserInterruptTask_2 are

fulfilled in the same IPO cycle, then UserInterruptTask_1 is processed before
UserInterruptTask_2.

Task Runtimes and Task Status Information
Target system -> Device diagnostics

Task runtimes The statuses and runtimes of the individual tasks can be read out using the
device diagnostics of the control system.
Call Via the device (for example D435) -> Target device -> device diagnostics, you
can access the diagnostics information of the device.
General information, the diagnostics buffer, the task runtimes and the system
utilization are saved here.
Overview Task name, task status, actual, minimum, maximum and the average value task
runtimes are displayed for each task in the overview.
The task status can also be read out using the system function
(_getStateOfTask) and processed in the user program.

Task Handling Operations in MCC
Start Task Reset Task
Interrupt Task Task State
Continue Task Determine TaskId

Controlling A range of commands are available in MCC for controlling tasks.

Tasks They can be used to start, stop and resume MotionTasks and other tasks.
Start Task This command starts a MotionTask from the beginning, i.e. a stopped task is
executed from the beginning. If the task is already active, it is stopped and
processed again from the beginning.
Corresponds to the call _restartTaskId
Interrupt Task This command interrupts a task at the current location. The command does not
stop axis motion which had previously been started from this task.
Corresponds to the call _suspendTaskId
Continue Task This command will resume processing of an interrupted task at the location it
was interrupted. Interrupted motion is not automatically continued. It is
necessary to program resumption of interrupted motion.
Corresponds to the call _resumeTaskId
Reset task Using this command, a MotionTask is stopped. The task can be restarted with
the Start task command with data initialization.
Corresponds to the call _resetTaskId
Task state This command returns the state of a task.

Corresponds to the command _getStateOfTaskId
Determine Task Id This command generates a project-wide unique TaskId from the name of a task.
This TaskId is assigned to a variable of data type StructTaskId.
Corresponds to the call _getTaskId

Operations to Start MotionTasks in LAD/FBD
_startTaskId
Start task BOOL EN ENO BOOL
StructTaskId id OUT DWORD
_restartTaskId
BOOL EN ENO BOOL
Restart a task
e.g.: _task.MotionTask_1
Assign the input

parameter "id"
via symbol input help
(Context menu ->
Symbol input help)

Controlling From V3.1.1 in LAD/FBD, a series of commands are available to control task
tasks execution. They can be used to start, stop and resume MotionTasks. The status
of the task can also be interrogated/queried.
All of the functions operate with a parameter "id" which is used to define the
required task. This parameter must be assigned the unique TaskId of the task.
You can obtain the TaskId for a MotionTask as follows:
• _task.<name>
• _getTaskId(<name>)
whereby <name> specifies the task name, as it was specified in the execution
system (e.g. MotionTask_1).
All functions have a return value "out". A value of "0" indicates that the command
was successfully executed, a value not equal to "zero" indicates an error
_startTaskId Using this function, a motion task is started, which is in the
TASK_STATE_STOPPED state. The task data are reinitialized.
The function has no effect on motion tasks in the following states:
TASK_STATE_RUNNING, TASK_STATE_WAITING,
TASK_STATE_SUSPENDED
The functions may not directly follow _resetTaskId. Instead of this, the
_restartTaskId function must be used.
_restartTaskId This command starts a MotionTask from the beginning, i.e. a stopped task is
executed from the beginning.
If the task is already active it is stopped and processed again from the
beginning, i.e. the command can only be issued once in the BackgroundTask.
Otherwise, the selected task would be started at the beginning every time the
BackgroundTask was executed.
The command is only permissible for MotionTasks.

Stopping and Resuming Tasks in LAD/FBD
_resetTaskId
Reset task BOOL EN ENO BOOL
_suspendTaskId
Interrupt task BOOL EN ENO BOOL
_resumeTaskId
Resume task BOOL EN ENO BOOL

_resetTaskId This function resets a MotionTask into the state TASK_STATE_STOPPED.

The _startTaskId functions must not directly follow this function. Instead of this,
the _restartTaskId function must be used.
_suspendTaskId
This command interrupts a task at the current location. This function sets
the task involved into the TASK_STATE_SUSPENeDED state The command
does not stop axis motion which had previously been started from this task.
Any currently active UserInterruptTasks ism stopped. This
UserInterruptTask is not started again even if the condition for it to start again
is fulfilled.
The command is permissible for MoietionTasks, BackgroundTask,
UserInterruptTasks, SystemIntersruptTasks and TimerInterruptTasks.
In the case of cyclic tasks (Bac kgroundTask, TimerInterruptTasks), the
. time watchdog for the task is stopped. The task and its time watchdog are
_resumeTaskId resumed with _resumeTaskId
This command will uresume processing of an interrupted task at the

location it was interrupted. Intelrrupted motion is not automatically continued. It
is necessary to pgrogram resumption of interrupted motion.
The coommand can only be issued once in the BackgroundTask. Otherwise
the selectedl task would be resumed at the interrupted location with each time
that the eBackgroundTask is executed.
Tkhe command is permissible for MotionTasks, BackgroundTask,
UserInterruptTasks, SystemInterruptTasks and TimerInterruptTasks.

Interrogating the Task Status in LAD/FBD
_getStateOfTaskId
Determine task BOOL EN ENO BOOL
state StructTaskId id OUT DWORD
Return value "OUT" specifies OR'ing with the following states:

• 16#0000:
Specified task does not exist (TASK_STATE_INVALID)
• 16#0001:
Transition RUN to STOP (TASK_STATE_STOP_PENDING)
• 16#0002:
Task is stopped (TASK_STATE_STOPPED)
• 16#0004:
Task running (TASK_STATE_RUNNING)
• 16#0010:
Task waiting (TASK_STATE_WAITING)
• 16#0020:
Task is suspended (TASK_STATE_SUSPENDED)
• 16#0040:
TimerInterruptTask waiting for next cycle
(TASK_STATE_WAIT_NEXT_CYCLE)
• 16#0080 UserInterruptTask or SystemInterruptTask waiting for
next event (TASK_STATE_WAIT_NEXT_INTERRUPT)
• 16#0100 Task locked by _disablescheduler (TASK_STATE_LOCKED)

_getStateOfTaskId The function returns the state of the task involved. The function can be applied
to all tasks with the exception of StartupTask and ShutdownTask.
Input parameter id (optional) data type: StructTaskId

Default setting: TaskId the actual task, in which the function is called.
TaskId the task which is to be controlled. You can obtain the TaskId for a
MotionTask as follows:
• _task.<name>
• _getTaskId(<name>)
whereby <name> specifies the task name, as it was specified in the execution
system (e.g. MotionTask_1).
Return value State of the task (data typeDWORD) is displayed as OR logic

operation with the following values:
lu
• TASK_STATE_INVALID (16#0000): Task does not exist or the TaskId is

invalid
• TASK_STATE_STOP_PENDING (16#0001): Task is in the transition from
o
Running to Stopped
• TASK_STATE_STOPPED (16#0002): Task is stopped
el
• TASK_STATE_RUNNING (16#0004): Task running

• TASK_STATE_WAITING (16#0010): Task in the wait state
• TASK_STATE_SUSPENDED (16#0020): Task is to suspended
• TASK_STATE_WAIT_NEXT_CYCLE (16#0040): TimerInterruptTask is
waiting for its start trigger event
• TASK_STATE_WAIT_NEXT_INTERRUPT (16#0080) SystemInterruptTask
or UserInterruptTask waiting for the next start event
• TASK_STATE_LOCKED 16#0100 task locked (by _disableScheduler)

State Model for Tasks
• WAITFORCONDITION
TS TS • _waitTime() TS
_INVALID _WAITING _RUNNING
(16#0000) (16#0010) Condition fulfilled (16#0004) _
r es
e tT
d
kI as
T as kI
nd d
pe d
us kI
_s
_restartTaskId
as
MT completed
T
me
t
su TS_STOP
up
e
_r
rr
_PENDING
TS_
te
d
(16#0001)
te
in
SUSPENDED
le
xt
(16#0020)
mp
Ne
co
TS
_WAIT_NEXT TS
TS _CYCLE TS
_STOPPED
_LOCKED (16#0040) _WAIT_NEXT
(16#0002)
(16#0100) _INTERRUPT
_disableScheduler (16#0080)
_enableScheduler

TS_INVALID The task does not exist in the execution system. It was not used when
parameterizing the execution system.
TS_STOP_PENDING The task has received a signal to stop, it is located between the RUNNING and
STOPPED states. The task may execute actions until it is stopped.
TS_STOPPED The task was stopped as a result of the following actions:

• Calling the function: _resetTaskId(),
• Executing a stop from SIMOTION SCOUT.
TS_RUNNING Task running as a result of the following actions:

• Function call _startTaskId() (MotionTasks)
• Active cyclic test (BackgroundTask, etc.)
• The associated event has been received (UserInterruptTask, etc.)
TS_WAITING Task in the wait state due to one of the following functions:
• _waitTime()
• WAITFORCONDITION...
TS_SUSPENDED The task was suspended by the _suspendTaskId() function.
TS_WAIT_NEXT TimerInterruptTask is waiting for its start trigger.

_CYCLE
TS_WAIT_NEXT SystemInterruptTask is waiting for the trigger alarm to occur or

_INTERRUPT The UserInterruptTask is waiting for the trigger event.
TS_LOCKED Task was locked by the function _disableScheduler().

Synchronous Operation in SIMOTION

Content Page
Structure of Synchronous Operation for SIMOTION ......................................................................... 2
Camming for SIMOTION .................................................................................................................... 3
Creating Cams with SIMOTION ........................................................................................................ 4
Creating a Synchronous Axis ............................................................................................................ 5
Assigning Leading Axes and Cams .................................................................................................. 6
Settings for Synchronous Operation ................................................................................................. 7
Parameterizing Default Settings for Synchronous Operation ............................................................ 8
Activating Gearing in MCC (1) ........................................................................................................... 9
Absolute and Relative Gearing .......................................................................................................... 10
Activating Gearing in MCC (2) ........................................................................................................... 11
Synchronization Relative to the Leading Axis and Time .................................................................... 12
Reference Point for Synchronization ................................................................................................. 13
Deactivating Gearing ......................................................................................................................... 14
System Variables for Synchronization ............................................................................................... 15
Absolute Synchronous Operation (relative to the leading axis) ......................................................... 16
Absolute Synchronous Operation (relative to time) ........................................................................... 17
Relative Synchronous Operation (relative to the leading axis) .......................................................... 18
Structure of the Superimposed Synchronous Operation ................................................................... 19
Example: Filling Chocolate Molds on a Conveyor Belt ..................................................................... 20
Inserting a Superimposed Synchronous Object ................................................................................ 21
Structure of Distributed Synchronous Operation ............................................................................... 22

Automation and Drive Technology Page 1 Synchronous Operation in SIMOTION
Structure of Synchronous Operation for SIMOTION
Master value
• Positioning axis External
• Synchronous axis encoder
• Ext. encoder Virtual
• Virtual axis axis
Slave value
Leading TO
axis synchro-
nous
operation
Settings
• Master value Master value
• Gear ratio
• Synchronizing and
desynchronizing profile
Buffer IPO Servo
• Restrictions
• Monitoring functions Following axis TO

Structure of syn- Using the technology object "Synchronous operation" two or more axes can be
chronous operation coupled so that they form a synchronous group.
A leading axis (master) generates a master value, which is processed by the
synchronous object according to specific criteria (gear ratio, scaling, offset, cam)
and assigned to the following axis (slave) as a reference variable.
The master value source can be a positioning aexis or synchronous axis. From
SW3.0 SP 1 for axes as a master value source, a setpoint or actual value coupling
can be selected. For an actual vamlue coupling, the corresponding dead time
compensation of the master valuee is possible.
The master and slave values arie coupled without physical conversion in the
relevant parameterized units. Fosr example, if the leading axis is a linear axis
(unit in millimeter), the following axis a rotary axis (unit in degrees) then for a ratio of
1:1, 1 millimeter corresponds to 1 degree.
Mechanical Mechanically, the syn chronous object represents the gearbox with drive-in/drive
model out or in conjuncution with the TO "Cam", the cam gear with mechanical cam and
sensing system. A coupling used for enabling and disabling the following motion on-
the-fly is alsglo modeled.
Coupling via The funclotionality of a gear is characterized by a constant ratio between the
gear master value source and following axis. The ratio can either be programmed as
rational gear factor or using a numerator denominator ratio.
Tkhe slave value is calculated from the programmed gear factor and the master
value and transferred to the gear axis. A following axis can be interconnected with
more than one master value by means of the synchronous object, however only one
of them is evaluated. The master value can be switched over from the user program
at the runtime.
When selecting gearing, a distinction is made between absolute and relative
synchronous operation. Various types of synchronizing and desynchronizing profiles
(related to master value or related to time) can be selected.

Camming for SIMOTION
Master value
• Positioning axis
• Synchronous axis External
• Ext. encoder encoder Cam_1
• Virtual axis Virtual
axis
Cam_2 Slave value
Leading
TO
axis TO
synchro-
nous Cam_3
Settings operation
• Master value
• Cam
• Scaling Master value
• Synchronizing and
desynchronizing profile
Buffer IPO Servo
• Restrictions Following axis TO

• Monitoring functions

Coupling via The functionality of a cam gear is characterized by a variable ratio between the
cam between the master value source and following axis. It is designed so that users
can program it using a cam. In addition, adaptations can be made for scaling
and offset, on the master value as well as the slave value sides.
From SW3.0 SP 1 and higher, distributed as well as superimposed synchronous
operation are possible. For distributed synchronous operation, the leading axis,
synchronous operation TO and the following axis TO are not on the same
SIMOTION device, but are distributed over several controls For superimposed
synchronous operation, a following axes not only receives its position setpoints
from one synchronous operation TO, but from two, the basis synchronous
operation TO and a superimposed synchronous operation TO.
For camming, several cams can be used. Changeover to another cam can be
executed in the user program at the runtime.
Rules The following rules apply for interconnection in general:

• The synchronous object and the following axis are on the same runtime
system.
• The synchronous object and the following axis are permanently assigned to
each other during configuration.
• The master value object (positioning axis, virtual axis, synchronous axis or
external encoder) can be connected with several synchronous objects.
• The synchronous object may be interconnected with several master values
and cams.

Creating Cams with SIMOTION
CAM EDIT CAM tool

as As
polynomial
polynomial
as As
interpolation
interpolation
point
point
table
table
Position
Velocity
Acceleration

Cams Cams can be created in SIMOTION SCOUT using the CamEdit tool or the
optional SIMOTION CamTool add-on.
Cams, that were created with CamEdit can be converted to the CamTool, and
CamEdit vice versa. Further, cams can be exported and imported.
Using the cam editor CamEdit, cams can either be defined using interpolation
points or segments. These two methods cannot mbe combined. A selection
must be made when creating the cam. A esubsequent change is not possible.
If the cam is specified using interpoilation points, then linear, cubic spline or
Bezier spline can be selected.
If the cam is created using seg ments, then CamEdit provides VDI wizards to
CamTool define the segments.
Under SIMOTION Ca mTool, cam segments can be created from fixed points,
straight lines, sine cuurves, arc-sine curves and interpolation points.
SIMOTION CalmTool calculates interpolation curves between individual cam
segments andg in addition to the position curve, it also displays the V diagram
(velocity dioagram), the A diagram (acceleration diagram), and the J diagram
(jerk dialgram).
This emeans that users can immediately see the effect on velocity,
acceleration and jerk when changing the cam.

Creating a Synchronous Axis
Synchronous operation

Creating a syn- If, when creating an axis in SIMOTION SCOUT the technology "synchronous
chronous object operation" is selected, then SIMOTION SCOUT automatically creates a
synchronous object associated with the axis.
The synchronous object appears in the project navigator under the
corresponding axis. The axis name is automatically used as the object name
and the extension "_SYNCHRONOUS_OPERATION" is attached.
Assignments The assignment of master values and cams is symbolized in the project
navigator from SIMOTION SCOUT using links:
• under the "synchronous object"
Links to the master values (axes, external encoders) and cams
• under the used "cams"
Link to the synchronous object
• under the "master values" (axes, external encoders)
Link to the synchronous object
These assignments are made in the "Configuration" dialog (see the next page).

Assigning Leading Axes and Cams
• Setpoint coupling
• Actual value coupling
with extrapolation

Interconnections Synchronous objects are assigned to possible leading axes and cams in the
"Interconnections" dialog. This dialog is opened, if you double-click on
configuration in the project navigator under the object
<axis name>_SYNCHRONOUS_OPERATION.
In this dialog, the possible master values and cams are assigned to the
synchronous object, the following axis. The actually used master value or the
definition of the active cam is defined at runtime using the appropriate functions.
Setpoint and For real axes, it is also possible to select either a setpoint or actual value
actual value coupling coupling. For external encoders, only an actual value coupling is possible, for
virtual axes a setpoint coupling as well as also an actual value coupling with
extrapolation.
For an actual value coupling, the reference value for the actual value coupling
must be extrapolated to compensate for dead times. The appropriate
compensation is set at the TO of the leading axis under the "Actual value"
dialog.
Notes Gearing or camming with a following axis is only possible, if at least one master
value has been assigned to the associated synchronous object.
When selecting camming, in addition, at least one cam must be assigned.
Expert List From the expert list, it is possible to access all configuration data and system
variables of the synchronous object. The expert list can be called in the context
menu of the synchronous object using the command Expert -> Expert list.

Settings for Synchronous Operation

Configuration The most important configuration settings for synchronous operation can be
made in this dialog.
Direction-related Taking into account a direction-dependent or direction-independent effect

dynamic parameters of the programmed dynamic values (syncingMotion.directionDynamic).
Allow absolute For absolute synchronization, with a "Yes" setting, jerk is taken into account.
synchronization If "No" is set, the set jerk will not be applied in spite of velocity profile =
SMOOTH being selected. A trapezoidal path will be traversed
(syncingMotion.smoothAbsoluteSynchronization).
Adjustment of the Adaptation to the dynamics of the leading axis at the synchronous position
dynamic values (syncingMotion.synchronizingAdaption). If "Yes" is set, then the "Overshoot
factor" parameter is available:
Overshoot Overshoot factor for the adapted dynamic values to catch up and compensate a
factor remaining path difference (syncingMotion.overdriveFactor) as a percentage (%).
Reference to the actual master velocity for the start of synchronization.
Tolerance for Tolerance window for canceling the synchronization operation for direction
direction reversal reversal of the master values (syncingMotion.masterReversionTolerance).
Position value in the user unit of the master values
Permitted velocity Maximum permissible change of the master value velocity

change (syncingMotion.maximumOfMasterChange)
Refers to the actual master value velocity for the start of synchronization, when
specified as a percentage (%).

Parameterizing Default Settings for Synchronous Operation

Default settings of Default settings for synchronous operation can be parameterized in the "Default"
parameters
dialog. Parameters (default setting) for calling synchronous operation functions
are defined in this dialog. These parameter values are only evaluated if no
special settings are made in the associated function calls for synchronization/
desynchronization (ST and LAD or MCC).
Conditions for synchronizing and desynchronizeing can either be directly
specified using function parameters when calling the function, or via these
settings, which are known as User default mvalues. These user default values
are also saved in the corresponding system variables of the synchronous
Settings object.
For the "Synchronous operatsion" function, the appropriate data are entered for
the default parameters in three tab sheets:
• Tab "Gearing"
- Type of gear (absolute or relative synchronous operation)
- Direction (sam e or inverse)
- Gear ratlio
• Tab "Gearg synchronization"
- Datao on the synchronizing positions
- Dlata on the desynchronizing positions
• Teab "Dynamic response"
- Data on the synchronizing profile (referred to the leading axes or
time)
- Data on the synchronizing length (only for a synchronizing profile
referred to the leading axis)
- Data on the dynamic parameters (only for synchronizing profile-
referred to time)

Activating Gearing in MCC (1)
Gearing
on
Specification of leading
and following axes
Specification of
direction and gear ratio
Select:
• absolute or
• relative
gearing
Specification of the transition

behavior and program advance

Programming In the "Parameter" tab of the MCC command "Gearing on", settings can be
gearing made regarding the leading and following axes as well as settings on the
synchronous mode type and gear ratio.
Following axes The synchronous axis to be synchronized is selected here. All axes of the
device, for which synchronous operation functionality has been configured as
well as all variables of the MCC chart, data type "followingAxes" can be
selected.
Leading axis The axis or external encoder that generates the master value in the velocity
relationship can be selected here. All positioning axes, synchronous axes and
external encoders as well as all variables of the MCC chart, with data type
posAxis, followingAxis or externalEncoderType are listed.
Gear direction The active direction for the gear is selected here.
Type of gear Here a selection is made as to whether the ratio is specified as a fraction
ratio (numerator/denominator) or is specified as floating point number.
Numerator/ Depending on the selected "Type of gear ratio", the gear ratio can be entered as
denominator numerator/denominator pair or as floating point number.
Reference point The type of synchronous operation is selected here. SIMOTION distinguishes
between absolute synchronous operation, i.e. angle or position synchronous
operation (selection: "Gearing takes place relative to axis zero") and relative
synchronous operation, i.e. velocity synchronous operation (selection:"Gearing
takes place relative to the start position").
Set new Using this check box, the master value of the synchronous relationship is set
master value again (default setting). if the check box has not been activated, a previous
master value setting is kept.

Absolute and Relative Gearing
Gearing
Position or Speed gearing

angle synchronization (gearingType = RELATIVE,
(gearingType = ABSOLUTE, reference point: Gearing
Reference point: Gearing is realized relative to the start position)
is realized, referred to the axis zero)
Slave value Slave value
g g
φ Master value φ Master value
Slave value = g x master value + φ
φ is defined φ is undefined
(can be specified for the system (is "randomly"
function call "Synchronize") obtained when synchronizing)

Gearing Gearing Gearing is characterized by a constant ratio between the master value
source and following axis.
In addition, a phase offset can occur between the leading and following axis.
The way in which this additional phase or position offset can be specified – or is
handled – designates the difference between absolute and relative gearing.
Absolute For absolute synchronous operation "gearing relative to axis zero"

gearing (gearingType = ABSOLUTE), the master values and the slave values are
interpreted in absolute terms. This means that a possible offset between the
master and slave value, which was present before synchronization, is corrected.
After synchronization has been completed, for a gear ratio of 1:1, the speeds
and positions of the leading and following axes are identical (φ = 0) or a defined
phase relationship has been established between the positions of the leading
and following axes (φ <> 0).
A phase (φ ) can be entered when selecting: "Start of synchronization: at the
leading axis with offset" or "Immediate synchronization with offset".
Relative For relative gearing, i.e. "Gearing takes place relative to the start position"
gearing (gearingType = RELATIVE), a synchronizing profile is calculated, so that only
the speeds of the leading and following axes are adapted according to the ratio.
An offset that was present before synchronization or an additional phase (φ' ),
which is obtained as a result of the synchronization, is not corrected by the
synchronization operation.
After synchronizing the following axis, the closed-loop position control of the
following axes ensures that now for example, phase or position offsets as a
result of disturbances, are corrected.

Activating Gearing in MCC (2)
Selection of the
synchronization reference
reference:
• leading axis
• time
Specification of positions,
offset and
synchronization length
Specification of the
transition behavior and
program advance

Programming In the "Synchronization" tab of the MCC command "Gearing on" synchronization
gearing reference as well synchronization positions and lengths can be specified.
Start of Synchronize immediately: In this case, synchronization is immediately initiated.

synchronization When selecting "Gearing takes place relative to the axis zero", absolute position
synchronous operation (φ = 0) is performed. It is not possible to specify an
additional phase offset (φ <>0).
At leading axis position: Synchronization starts, if the leading axis has reached a
certain position. When selecting "Gearing takes place relative to the axis zero",
absolute position synchronous operation (φ = 0) is performed. It is not possible
to specify an additional phase offset (φ <>0).
At leading axis position with offset: Synchronization starts, if the leading axis has
reached a certain position.
When selecting "Gearing takes place relative to the axis zero", absolute position
synchronous operation is performed. In this case, an additional phase offset (φ )
can be specified between the leading and following axis.
Synchronize immediately with offset: In this case, synchronization is
immediately initiated. In addition, for absolute gearing a phase offset (φ <>0) can
be entered.
Start immediately and synchronous at master position: Synchronization is
started immediately. At the specified leading axis position, the following axis is in
synchronism with the leading axis. It is not possible to specify an additional
phase offset (φ <>0) (selection in V4.0 is not supported).
Following axis position: Synchronization starts, if the following axis has reached
a certain position. When selecting "Gearing takes place relative to the axis
zero", absolute position synchronous operation (φ = 0) is performed.

Synchronization Relative to the Leading Axis and Time
Position
Leading axis
Synchronization
length
Following axis Time
Start End
Synchronization profile referred to the leading axis

• Specify a position and -> Start and end position are clearly defined,
the synchronization length dynamic response parameters are not active
Synchronization profile referred to time
• Specify a position and -> Synch. length is calculated by the system
the dynamic response parameters Dynamic response parameters are active,

Synchronization The profile for synchronization can either be specified referred to the heating
reference value or referred to time. In ST or LAD, the reference to the synchronization
operation is specified using the function parameter syncProfileReference.
• Referred to leading axis
(syncProfileReference = relate_sync_profile_to_leading_value)
• Referred to time
(syncProfileReference = relate_sync_profile_to_time)
Synchronize Synchronization of the following axis is realized dependent on the distance

to master value moved by the leading axis. The synchronization process is defined using the
MCC parameter "Synchronization length".
This parameter assignment ensures that the synchronous object has
established synchronism between the leading and following axis at a defined
position, however, without taking into account dynamic response parameters
from the "Dynamic response" tab The values defined there are not taken into
account in the synchronous object calculation for synchronization relative to the
leading axis.
If possible limits (velocity, acceleration, etc.) are exceeded, then the limit is first
made in the TO of the following axis.
Synchronize Synchronization of the following axis is realized taking into account

to time parameters from the "Dynamic response" tab. In this particular case, neither the
start nor the end position of the synchronization operation can be specified.
From the dynamic response parameters, SIMOTION defines the remaining
variables, such as synchronization length and time, for example.
Attention For synchronization referred to the leading axis, during the synchronization
operation it is not permissible that the leading axis reverses, otherwise the
"Gearing on" command will be interrupted with the error message: "50007: Error
occurred while "activating/deactivating synchronous operation".

Reference Point for Synchronization
Following axis
Sync position
Leading axis
Synchronization before synchronization position

Symmetrical synchronization
Synchronization from the synchronization position

Reference leading Using the parameter "Reference point for leading axis position" (syncPosition-
axis position Reference) the position of the synchronization point when synchronizing can be
influenced:
Synchronize from synchronization position (syncPositionReference =
synchronize_when_position_reached): In this case, synchronization starts with
all other conditions (e.g. synchronization length, etc.), if the synchronization
position is reached.
Synchronize before synchronization position (syncPositionReference =
be_synchronous_at_position): Synchronization is realized so that all other
conditions (e.g. synchronization length etc.) are maintained and at the
synchronization position, the following axis is in synchronism with the leading
axis.
Symmetrical (syncPositionReference = synchronize_symmetric): In this case,
synchronization is performed symmetrically to the specified synchronization
position.

Deactivating Gearing
Gearing
off

Gearing Deactivation of the gearing is similar to activation. Only the leading and following
axes must be specified under the "Parameter" tab for which synchronous
operation is to be deactivated.
The type of synchronization is specified under the "Desynchronization" tab The
corresponding parameter assignments are identical with those for
synchronization. .
Synchronization Here you can choose between a synchronization profile relative to the leading
reference axis or time. Just the same as for synchronization, the following applies here:
• The dynamic response parameters are not active for a profile relative to the
leading axis.
• For a profile relative to time, the dynamic parameters are active, however
it is very difficult to determine the position at the end of the synchronization
operation.
Desynchronization For desynchronization, the position of the leading or following axis or

position "Desynchronize immediately" can be selected.
Reference point of Here, you can choose from Before or From the synchronization position and
the desynch. position for a synchronization profile relative to the leading axis, symmetrically to the
synchronization position.
Desynchronization Here, for a profile relative to the leading axis, the desynchronization length
length can be specified.
Leading/following If the position of the leading or following axis was selected for the position of the
axis position then the required position can be specified here.
Dynamic response For a desynchronization profile relative to time, in this particular tab, the
parameters dynamic response values for the desynchronization operation can be specified.

System Variables for Synchronization
Position
Leading axis
GL-TO.current-
syncposition.
slave
GL-TO.current-
syncposition.
master
Following axis
Time
Start of the synchronization operation: Synchronization position:

GL-TO.state = gearing GL-TO.syncstate = active
FA-TO.syncmonitoring. FA-TO.syncmonitoring.
followingmotionstate = active syncstate = active
GL-TO: Synchronous object of the following axis

FA-TO: Technology object of the following axis

System variables The synchronization status can be tracked using several system variables at the
synchronous object.
GL-TO.state The system variable "state" at the synchronous object indicates whether a
gearing "state = gearing" or camming "state = camming" is active.
At the start of synchronization, the system variable is set to the appropriate
value; the system variable is reset again at the end of the synchronization.
GL-TO.syncstate This system variable indicates the synchronism of the leading and following axis
at the synchronous object. If the leading and following axes are in synchronism,
this variable is set to the "active" state.
The start of desynchronization or any loss of synchronism results in the variable
being reset to the "inactive" value.
Note The "active" value of the system variable "syncstate" only signals that after
calculating the synchronous object, the incoming leading axis value (GL-TO.
currentmasterdata.value) and the slave value output at the TO of the following
axis (GL-TO.currentslavedata.value) are in synchronism.
Possible restrictions of the slave value transferred by the TO of the following
axis, and therefore an associated non-synchronism of the leading and following
axes, are not reflected in the state of the "syncstate" variable.
Sync position The particular synchronization position of the leading and following axis, i.e. the
position from which the leading and following axes run in synchronism, is not
saved in the two variables:
• GL-TO.currentsyncposition.master
• GL-TO.currentsyncposition.slave

Absolute Synchronous Operation (relative to the leading axis)
Master velocity (10mm/s) Slave velocity
"state"
"syncstate"
Master pos. Slave pos.
Gearing: absolute, i.e. relative to the axis zero

Gear ratio: 1:1
Synchronization: immediately
Synchronization length: 30 mm

Absolute This diagram shows synchronization for absolute synchronous operation. The
synchronism following settings have been made under the individual tab sheets.
Parameter Ratio: 1 : 1
Reference point: Gearing is realized relative to the axis zero (absolute gearing,
i.e. position synchronization)
Synchronization Start of synchronization: immediately

Sequence From the specified leading axis position and the synchronization length, the
synchronous operation TO of the following axis calculates the required position
or angle reference between the leading and following axes.
In this case, synchronization is immediately started. A parabolic acceleration
ramp is used to ramp up the velocity of the following axis to that of the leading
axis. The two axes are at the same position at the end of the synchronization
length (30 mm).

Absolute Synchronous Operation (relative to time)
"state"
Slave velocity
"syncstate"
Master velocity (100 mm/s)
Slave pos.
Master pos.
Gearing: absolute, i.e. relative to the axis zero

Synchronization direction: shortest distance
Synchronization: from the leading axis position 150 mm
Velocity: 200 mm/s
Acceleration: 200 mm/s2
Jerk: 500 mm/s3

Absolute This diagram shows synchronization for absolute synchronous operation with a
synchronism synchronization profile relative to time. The following settings have been made
under the individual tab sheets.
Reference point: Gearing is realized relative to the axis zero (absolute gearing,
i.e. position synchronization)
Synchronization Synchronization reference: Time

Start of synchronization: from the leading axis position
Reference point of the leading axis position: Synchronization from the
synchronization position
Leading axis position: 150 mm
Dynamic parameter Velocity: 200 mm/s

Acceleration: 200 mm/s2
Jerk: 500 mm/s2
Sequence From the specified velocity and acceleration of the following axis – and
assuming a constant leading axis velocity – the synchronous operation TO of
the following axis calculates a synchronization profile relative to time.
Synchronization of the following axis is started at a leading axis position of
150 mm. After the jerk phase, the following axis is linearly accelerated, at the
programmed acceleration ramp, up to the programmed velocity.
After the constant velocity phase, the following axis is synchronized to the
leading axis dynamic response values according to the specified parameters.

Relative Synchronous Operation (relative to the leading axis)
"syncstate"
"state"
Master velocity (10mm/s)

Master pos.
Slave pos.
Slave velocity
Gearing: relative, i.e. relative to the start position

Gear ratio: 1:1
Synchronization: immediately

Relative This diagram shows synchronization for relative synchronous operation. The
synchronism following settings have been made under the individual tab sheets.
Reference point: Gearing is realized relative to the start position (relative
gearing, i.e. velocity synchronism)
Synchronization Start of synchronization: immediately

Sequence Synchronization is immediately started. A linear acceleration ramp is used to

ramp up the velocity of the following axis to that of the leading axis. The two
axes have the same velocity at the end of the synchronization length (30 mm).
The resulting position offset between the leading and following axes at the end
of the synchronization operation (approximately 30 mm) is obtained from the
offset at the start of synchronization (approximately 15 mm) and the offset as a
result of the synchronization operation itself (15 mm).

Structure of the Superimposed Synchronous Operation
LA LA
...
...
LA LA
CAM CAM
Synchronous Synchronous
...
...
object object_1
CAM CAM
Following axis
Basis synchronous object: Superimposed synchronous object:

SyncingMotion.motionImpact: SyncingMotion.motionImpact:
"Standard" "SuperImposed_Motion"
LA: Leading axis

CAM: Cam

Superimposed From Version V3.0, in SIMOTION in addition to standard synchronous operation

synchronous superimposed synchronous operation is also possible. Superimposed
operation synchronous operation is realized by connecting, in addition to the (basis)
synchronous object, an additional, superimposed synchronous object to an axis.
From this superimposed synchronous object, relationships can be configured to
the leading axes and cams.
Note Only one relationship can be configured to a leading axis. It is not permissible to
configure relationships to the same leading axes from the basis and
superimposed synchronous objects.
Functions The functions for superimposed synchronous operation can be used in the same
way in ST, LAD and MCC. For the superimposed synchronous object, all of the
functions known for the basis synchronous object can be applied (e.g.
enablegearing, disablegearing, etc.).
In MCC, by selecting the leading axis (uniqueness of the configured
relationship) it can be defined as to whether the basis or the superimposed
synchronous object is to be addressed When selecting a leading axis, which is
assigned to the superimposed synchronous object, and appropriate symbol is
displayed after the selection box "Leading axis" (Dialog: "Gearing on", tab sheet:
"Parameters").
Coordinate system Just the same as for superimposed motion, every synchronous object has its
own coordinate system. The "outputs" of the synchronous object are added in
the following axes TO. The output values of a synchronous object (and thus also
the motion component of the superimposed synchronous operation for the axis)
can be read out in the "currentSlaveData" system variable of the synchronous
object.
The positions and dynamic response values of the basis motion are also
provided within the TOs of the following axis using the system variable
"basicmotion"; those of the superimposed motion, using the system variable
"superimposedmotion".

Example: Filling Chocolate Molds on a Conveyor Belt
Axis_2
Axis_1
Chocolate molds
Filler
Sensor
Sheet
Conveyor belt External encoder
(is not traversed from
SIMOTION)

Filling chocolate The overhead above shows the "filling system" principle of chocolate molds.
molds The filling system essentially comprises the conveyor belt and the filler itself.
SIMOTION does not control the conveyor belt, this is traversed from a higher-
level control system. Producing various chocolate molds, for example Santa
Claus, chocolate balls etc. represents an extremely complex process sequence,
in which many cascaded stations are involved.
The coordination of the cascaded process steps by the higher-level control
system means that the velocity of the conveyor belt continually changes. The
"chocolate mold filling station" must appropriately handle this situation.
Filling stationary To fill an individual, stationary mold, initially the filler must be traversed to the
sheets origin of each mold and then must traverse, relative to the sheets, a contour
corresponding to the chocolate mold.
At locations where more chocolate is required in the mold (for example, at the
end of a chocolate dog bone), the filler must remain for a correspondingly longer
time; at those positions with less chocolate in the mold (for example at the
center of a chocolate in the form of a dog bone) it must traverse faster.
Complex, stationary models are handled by interpolating axis_1 and axis_2
using cams.
Filling moving However, sheets are transported on a conveyor belt with fluctuating velocities.
sheets This situation can be handled by synchronizing axis_1 to the motion of the
conveyor belt using an external encoder and basis gearing.
Then, using superimposed camming for axis_1, the required relative motion to
fill the molds can be modeled. The motion for axis_2 is controlled using the
basis camming function.

Inserting a Superimposed Synchronous Object
Expert -> Insert superimposed synchronous object

Insert synchronous In the SIMOTION project navigator, under a synchronous axis you can insert as
object a maximum one additional, superimposed synchronous object. Proceed as
follows:
1. Select the required synchronous axis in the project navigator.
2. In the context menu that opens (right-hand mouse key), select the
menu entry Experts -> Insert superimposed synchronous object.
SIMOTION automatically inserts the supemrimposed synchronous object with
name <axis_n_SYNCH_2>.
For the superimposed synchronous object, when inserting, the configuration
data syncingMotion.motionImpact is automatically set to the value
i
SUPERIMPOSED (Value: STANDARD for the basis synchronous object).

Structure of Distributed Synchronous Operation
CAM
Leading Synchro-
...
axis nous
object
CAM
Following
PROFIBUS
axis
master
Synchro- CAM Synchro- CAM

nous nous
...
...
object object
CAM CAM
Following Following
axis axis
...
PROFIBUS ... PROFIBUS
slave_1 slave_n

Distributed syn- From version V3.0 and higher, distributed synchronous operation is possible in
chronous operation SIMOTION. The distributed synchronous operation function allows a master
value source (axis or external coder) and synchronous axes to be created on
different devices.
The coupling between the leading axis (or the external encoder) and the leading
axes is realized via PROFIBUS-DP. Using distributed synchronous operation,
function groups can be formed in a project thus allowing modular machine
designs. Axes running in synchronism then no longer have to be controlled on
one and the same control system, but can be distributed over several modules.

External Encoders - Cams - Measuring Inputs

Contents Page
Application Example ......................................................................................................................... 3
External Encoder on a Mechanical Press ......................................................................................... 4
Examples of Options for Connecting an External Encoder ................................................................ 5
External Encoder - Configuration Steps 1 - 2 .................................................................................... 6
External Encoder - Configuration Step 3 ........................................................................................... 7
External Encoder - "Configuration" Tab ............................................................................................ 10
Parameterizing an External Encoder - "Mechanics" Tab ................................................................... 11
Parameterizing an External Encoder - "Actual Value" Tab ................................................................ 12
Parameterizing an External Encoder - "Homing" Tab ........................................................................ 13
Signal Flow Display of the External Encoder .................................................................................... 14
System Commands for External Encoders ....................................................................................... 15
Measuring Input: Measuring the Length of Cutouts ........................................................................... 16
Global/Local Measuring Input – Connection Options ........................................................................ 17
Measuring Input at D4xx/-2 - Local Measurement (1) ....................................................................... 18
Measuring Input at D4xx/-2 - Local Measurement (2) ....................................................................... 19
Measuring Input at D4xx/-2 - Global Measurement (1) ...................................................................... 20
Measuring Input at D4xx/-2 - Global Measurement (2) ...................................................................... 21
Configuring a Measuring Input - Monitoring Measuring Input ............................................................. 22
Tool to Calculate the Activation Time for the Measuring Range ........................................................ 23
Activating and Deactivating the Measuring Input ............................................................................... 24
Cyclic Measurement ......................................................................................................................... 25
Synchronize Measuring System ....................................................................................................... 26

Automation and Drive Technology Page 1 External Encoders - Cams - Measuring Inputs
External Encoders - Cams - Measuring Inputs

Content Page
Output Cam Controller: Applying Glue Tracks .................................................................................. 27
Output Options for Output Cams ....................................................................................................... 28
Output Cam Types ........................................................................................................................... 29
Configuring an Output Cam .............................................................................................................. 30
High-Speed Onboard Output Cams for SIMOTION D4xx-2 (1) ......................................................... 31
High-Speed Onboard Output Cams for SIMOTION D4xx-2 (2) ......................................................... 32
High-Speed Onboard Output Cams for SIMOTION D4xx (1) ............................................................ 33
High-Speed Onboard Output Cams for SIMOTION D4xx (2) ............................................................ 34
Activating the Output Cam in the User Program .............................................................................. 35
Deactivating the Output Cam in the User Program ........................................................................... 36
Setting a High-Speed Cam from the User Program ......................................................................... 37
Configuring a TO "Output Cam Track" .............................................................................................. 38
Track Data of the TO "Output Cam Track" ........................................................................................ 39
Output Cam Data of the TO "Output Cam Track" .............................................................................. 40
Activating and Deactivating TO "Output Cam Track" ........................................................................ 41

Application Example
Ram
Light
barrier Glue application
External
encoder

Application With this application, cardboard boxes are folded, so that they can be
subsequently filled. To do this, the cardboard boxes are placed on a conveyor
belt. There, a light barrier is used to determine the box position.
The position is used so that the glue can be applied at the correct position on
the box. The box is then folded using a ram and placed on the conveyor belt.
External encoder The external encoder is used to detect the position of the conveyor belt. For
instance, external encoders are used, if the position of an axis, for example a
conveyor belt, must be detected that is either not controlled from SIMOTION,
but for example from a master control system.
The "External encoder" technology object provides actual values for position,
velocity and acceleration of a distance measuring system, without associated
drive components that can be actively influenced
Measuring input The measuring input is used in order to quickly detect the position of the box on
the conveyor belt and to transfer the value to a glue nozzle.
The technology object "Measuring input" is always used, if actual positions must
be quickly and precisely detected.
Output cam The output cam is used to open the valve of the glue nozzle at a defined position
of the conveyor belt. This switch-on position is continually changed during
production depending on the position of the box.
The TO output cam allows an output signal to be switched, depending on the
axis position.

External Encoder on a Mechanical Press
Encoder to sense the

position/stroke number
Main drive

External encoder An external encoder is used to detect the position of a moving machine part or
product and to further process this in the control system. The machine part can
be a conveyor belt, which is driven by a motor, and which is not controlled from
SIMOTION – or from SIMOTION only as speed-controlled axis.
Also for presses, the main drive is externally controlled and only the position of
the ram is detected using a connected encoder (generally an absolute encoder).
Technology objects The external encoder is integrated in SIMOTION SCOUT as autonomous

technology object. It is controlled from the user program via technology
functions.
The "external encoder" technology object can be used together with the
following technology objects:
• "Synchronous axes" as master value source
• "Output cam" as position actual value
• "Measuring inputs" as position actual value
.

Examples of Options for Connecting an External Encoder
DRIVE-CLiQ
C240 / C230-2
SIMOTION D
or 4 external
encoders
SINAMICS S120
External encoder
ADI4
IM 174
4 external encoders
1 external encoder
611U
SIMODRIVE
Sensor

Connectable Various types of encoders can be connected to SIMOTION and their signals
encoders processed. External encoders can be connected at ADI4, the encoder inputs of
the DP drives, directly to PROFIBUS or PROFINET and a SINAMICS system
via the DRIVE CLiQ interface.
SIMOTION D/ External encoders can either be directly connected to the SINAMICS drive
SINAMICS system or via SMCs. An external encoder is inserted in the SINAMICS project
tree under the folder "Encoder" and then automatically supplied with message
frame 81.
Up to four encoders (either TTL s or SSI encoders) can be connected at the

ADI4 /IM174 SINUMERIK ADI4 or at the SIMATIC IM174. ADI4 is connected to the
isochronous PROFIBUS @DP (DRIVE). As a consequence, the positions of the
connected encoders can be isochronously detected and transferred to
SIMOTION.
Control via PROFuIBUS is realized using standard message frame 3, i.e. at

least one axis must halve been created. On the setpoiviant side, the ADI4 /
IM174 ensures the conversion of the digital speed setpoints, supplied from the
technologoy, into the associated analog setpoints (+/- 10V).
On the lactual value side, the information from the connected encoder is
converted into the associated position actual values.
SIMODRIVE 611U/ At SIMODRIVE 611U, for a two-axes module, the 2nd encoder interface can be
MASTERDRIVES used to connect an external encoder. For MASTERDRIVES, a second encoder
can be connected by means of an encoder module.
SIMODRIVE Sensor The SIMODRIVE Sensor isochronous is an absolute encoder that can be
d
isochronous operated on the isochronous PROFIBUS DP(DRIVE). SIMODRIVE Sensor is

supplied on the PROFIBUS via message frame 81. There are also absolute
encoder (singleturn 6FX2001-5xN13, multiturn 6FX2001-5xN25) available with
PROFINET.

External Encoder - Configuration Steps 1 - 2
Step 1
Assign a name
Step 2
Assign axis type

Configuration To configure external encoders in the user program, initially a new external
encoder must be created in SIMOTION SCOUT. This is realized in the folder
"External encoder" or using the entry "Insert external encoder".
Programming from the user program is realized using system commands. Using
these commands, the "External encoder" can be released or blocked, as well as
the necessary settings made for homing.
After entering a unique name (throughout the complete project) for the
technology object (1st step), in the 2nd step, the type of the associated axis (not
the encoder), onto which the encoder is mounted, is selected. When configuring
the axes, SIMOTION SCOUT provides the following two types.
• Linear: The "linear" type should always be selected, if the position is
detected in length units, for example: mm, m, ... (for example transport
conveyor belt).
• Rotary: The "rotary" type should always be selected if the, position is to be
detected in angular units, for example degrees, rad, ... (e.g. press, rotary
table/indexing table).

External Encoder - Configuration Step 3
Step 3
Assign units

Units, The units for physical quantities, such as position, velocity, acceleration
accuracy and time are set when configuring the external encoder. SIMOTION supports
physical quantities such as position, velocity, acceleration and time. The units
are set during the configuration. In addition to metric units (e.g. mm, etc.) non-
metric units (e.g. inches etc.) can be set.
If "linear" is selected as encoder type, then when configuring and programming
the external encoder, only units with the "length" dimension are of significance,
for example, position, velocity, acceleration, etc.
If "rotary" is selected, then when configuring and programming the external
encoder, only units with the "angle" dimension are of significance, for example,
angle, angular velocity, angular acceleration etc.
Programmed variables are interpreted in the units that are set. When you
change the units set, system variables and configuration data are automatically
converted to the new units. Numerical values in user programs (e.g. in the
motion commands) are not converted to the new units when the unit settings are
changed.
The minimum guaranteed control accuracy is one increment. This is then used
to derive the other minimum guaranteed control accuracy levels, e.g. one
increment/clock cycle. These accuracy levels are normally higher due to
floating-point calculations.

Step 4
Define encoder
assignment

Encoder assignment Here, the "External encoder"- TO can be interconnected with an encoder at the
drive system (e.g. "Drive_blue").
All drive encoder systems configured in SIMOTION SCOUT or HW Config are
displayed in the "Assignment partner" column. The "Assignment" column
indicates whether the drive object is interconnected with a SIMOTION axis or
not.
• free: Encoder is not assigned
• assign: The encoder of the drive object is assigned to the TO
"External_encoder_1".
The interconnection of the "External encoder" - TO with the encoder of a drive
DO can initially be left open, i.e. the assignment can be subsequently made. An
existing assignment can also be canceled again.
From V4.2, it is therefore possible to download a TO, which is not
interconnected, to the target device without generating an error.
Encoder type The following encoder types are possible:

• Absolute encoder: the total overflows of the absolute actual value, i.e.
overflows of the multiturn information are not saved when SIMOTION is
switched off.
• Absolute encoder: absolute cyclic; in this case, when switching off, the
overflows of the multiturn information are stored in the retentive memory
area of SIMOTION. The next time SIMOTION is switched on, this
information is taken into account for calculating the actual position value.
This setting must be made when the absolute encoder with its multiturn
resolution does not cover the complete traversing range of the axis.

Step 5
Finish

Finish The basic configuration of an external encoder is finished by clicking on the

"Finish" button. Additional settings can be made using the relevant screen forms
for "External Encoder" TO.
The following elements are displayed below TO "External Encoder".
• Objects connected with the external encoder (e.g.: Synchronous operation,
TOs of other axes")
• Configuration
• Expert list
• Mechanical system
• Actual value
• Defaults
• Homing
• Signal flow
Double-click on the desired entry to open the corresponding window in the work
area of the SIMOTION SCOUT. In this window you can make additional
settings.

External Encoder - "Configuration" Tab

Configuration After configuring the external encoder, in the dialog External encoder ->
Configuration the following view is obtained. The dialog shows the encoder
settings, which have been made in the basic configuration.
Processing The cycle can be defined in the "Processing cycle clock" dropdown box. The
cycle clock following are available:
• Ipo
• Ipo2
• Servo

Parameterizing an External Encoder - "Mechanics" Tab

Mechanical For a rotary, external encoder, in this dialog, initially the encoder mounting type
properties must be defined. The following selections are available:
• Motor side: In this case, additional settings must be made for a possible load
gearbox, as well as the ballscrew pitch.
• Load side: Here, settings must be made for the measuring gearbox. Further,
the ballscrew pitch must be specified.
m
• External (without a connection to the axis, e.g. for connecting measuring

wheels): Here, settings must also be made for the measuring gearbox, i.e.
the number of revolutions of the measuring wheel and encoder as well as the
length for each measuring wheel revolution.

Parameterizing an External Encoder - "Actual Value" Tab

Master value If an "External encoder" is used as master value source in a synchronous group
coupling via then the actual value acquired can be smoothed and extrapolated. The
actual value extrapolation is used to compensate for the dead times, which are obtained
when acquiring the actual values as a result of the bus communication in the
system, and as a result of the finite processing time within the system itself.
The extrapolation is set on the leading axis or on the external encoder. The
"Utilities & Applications CD" also includes a program to calculate the
extrapolation times.
Filtering the From V 4.1, the actual position value for the synchronous operation can be
actual position filtered separately for the extrapolation using a PT2 filter. The filter for the
position actual value of the axes is set using the option "Filter on the actual
position value" and the two time constants "T1" and "T2".
The filter acts on the actual position for the extrapolation before the
differentiation of the position for the extrapolation velocity.
Filtering the The position is extrapolated based on the filtered or averaged velocity actual
actual velocity value. This filter can be activated using the option "Filter on the actual velocity
value": The time for the average value generation or the PT1 filter time is
entered under "Time constant.
The time for the extrapolation is entered under "Extrapolation time".
Extrapolation is not performed if 0.0 is entered.
The extrapolated values (position and velocity) can be monitored in the system
variable extrapolationData....
In addition, the velocity master value can be optionally generated from the
extrapolated position master value through differentiation or the extrapolated
velocity master value can be used for synchronous operation.

Parameterizing an External Encoder - "Homing" Tab

Homing SIMOTION supports various synchronizing/homing modes for external

encoders. The reference position of the external encoder can be set using the
function.
The following modes are supported for incremental measuring systems:
• Direct homing: The actual position of the encoder is set to the value of
the home position coordinate.
• Passive homing/flying homing: In this mcase, the value of the home
position coordinate is assigned to the syncheronization point of the encoder.
The following homing modes can ibe configured:
- When reaching the encod ser zero mark
- When reaching the external zero mark
- When the next encode@r zero marker after the homing cam is reached
The path travel ed from the homing cam to the next encoder zero marker can
be moniutored.
The followingl modes are supported for absolute encoders:
• Direct hogming: The actual position of the encoder is set to the value
of the home posoition coordinate.
• Absollute encoder adjustment: In this case, an offset to the encoder
coordinate system is taken into account.

Signal Flow Display of the External Encoder

The dialogs under the "Signal flow" entry provide a functional view of the
Signal flow
processing and the parameters of the SIMOTION TO "External encoder".
Using the individual screen forms, the path of the actual positions acquired by
the encoder system can be tracked through the smoothing up to the
extrapolation of the leading value for subordinate synchronous operation. The
variables prepared in the individual intermediaete steps, for example positions,
velocities, etc., are displayed in the screen forms.
The names of the associated system variambles from the expert list are
displayed at the cursor tool tip (this is important for trace recordings). Further,
the parameter settings (configuration datae), relevant for processing the actual
values and extrapolation, can be diirectly entered in the screen forms.
The functional view of the proces ssing of the encoder values in SIMOTION
provides:
• A better understanding o@f the internal function of an "External encoder"

• Parameterization and online diagnostics in a functional view

System Commands for External Encoders
External encoder on
External encoder off
Synchronize external encoder

External encoder on The command switches on the external encoder to acquire measured values,
i.e. the update of the actual values in the IPO is activated. The actual values in
the IPO are displayed in the system variable motionstate. ..., the encoder values
in the servo cycle are displayed under the system variable sensordata... . The
values in the servo cycle are always updated.
External encoder off The external encoder is deactivated, i.e. the update of the actual values in the
IPO is deactivated. The actual values are frozen in the IPO, they remain
unchanged until the next activation of the measuring system.
Synchronize The command homes the measuring system of the external encoder. The
external encoder following homing types are available:
Passive homing: For next axis motion, according to the settings under the
"Homing" tab the axis is synchronized to the first valid homing mark.
Setting of current position value: The value in the entry field "Home position
coordinate" is transferred into the current axis coordinate.
Absolute encoder adjustment: This selection is available only for absolute value
encoders, that is, only for encoders that have been configured as type "absolute
value encoder" or "absolute value encoder, cyclic absolute". In this case, the
absolute encoder offset is taken into account.

Measuring Input: Measuring the Length of Cutouts
Cardboard box Measuring

with cutout input

Application with TO The measuring input saves the actual axis position. The measured value
"measuring input" can be further processed in the user program.
The measuring input can either be connected at the special inputs of a drive
system, at the onboard inputs of the D4xx-2, at the ADI4 or at the TM15/TM17.
When parameterizing the measuring input, for example it must be defined as to
which edge initiates a measuring operation.
Further, a measuring range can be specified for the measurement. The
measuring input is only activated if it reaches this measuring window and a
switching edge then initiates that the measured value is acquired and saved.
The system ignores any switching edges outside the measuring range.

Global/Local Measuring Input – Connection Options
DRIVE-CLiQ SIMOTION C230-2/C240-2
(local/global
measuring input)
2/4 measuring
inputs
24/16 measuring
inputs
TM15/TM17
ADI4
SIMOTION D4x5/
SINAMICS S120
IM 174
(global
measuring input) (local/global
measuring input) 2 measuring
inputs
SIMOTION D4x5: max. 6 MI (local

SIMOTION D4x5-2: max. 16 MI measuring input)
SIMOTION D410: max. 3 MI
SIMOTION D410-2: max. 8 MI 1 measuring
input
611U

Local measurement For local measurements (according to PROFIdrive) the measuring inputs are
connected to the fast-response inputs of the encoder sensing system. When the
appropriate edge is detected, the instantaneous encoder value is saved and
transferred to SIMOTION via the PROFIdrive message frame. The following
options are available to establish the connection:
• Fast inputs at the SINAMICS
• C230-2: Two measuring inputs on the C230 module
• ADI4/IM174: two measuring inputs each
• 611U: one measuring input on the control module
For local measurements, the measuring input is connected where the encoder
position is acquired.
Global measurement In the case of a "Global measurement", initially the position is not acquired, but a
time stamp. This time stamp is signaled to SIMOTION using a special message
frame (telegram). From this time stamp and the cyclically transferred actual
positions, SIMOTION then calculates the actual measured value through
interpolation.
With global measurements, positions of axes can be determined, which supply
cyclic actual values somewhere in the overall system, e.g. external encoders
connected to SINAMICS, PROFIBUS encoder, virtual axes, etc..
Global measurements are supported on the following modules:
• TM15 with 24 or TM17 with 16 inputs and outputs.
• C240: 4 global measuring inputs
• SIMOTION D4x5 and D410 with 6 (X122, X132) and/or. 3 (X121) onboard
measuring inputs
• SIMOTION D4x5-2 and D410-2 with 8 measuring inputs (X122, X132) +
8 additional measuring inputs (X142) and/or 8 measuring inputs
(X121, X131).

Measuring Input at D4xx/-2 - Local Measurement (1)

Local measurement Local measuring inputs are axis-related and are mainly implemented in the
drive. In the configuration of the TO measuring input, the number 1 or number 2
of the measuring input (measuring according to PROFIdrive supports the use of
2 measuring inputs) as well as the number of the encoder system) (up to three
encoders can be configured at SINAMICS drives) of the axis is configured.
The actual assignment of the measuring input to the actually used quick, digital
input at the drive is realized in parameter p488/p489 of the associated drive DO.
Further, the following settings must be parameterized:
Processing Here, the system cycle is entered, in whose cycle the TO measuring input is
cycle clock processed. The following cycles are available: Position control cycle, IPO and
IPO_2.
Correction stamp Here, data transfer dead times or filter smoothing times at the measuring input
can be compensated. This entry field is significant for "global measurement".
Measuring input Drive-related (local measuring input)

selection
Axis measuring The number of the encoder system is entered here. The measurement is
system number realized regarding this measuring system, not regarding the encoder, which is
presently being used for the position control.
Measuring input According to the PROFIdrive profile, up to 2 inputs can be configured for a
number measuring system. The number of the measuring input is entered here.
Monitor actual If the checkbox is activated, then short pulses are suppressed at the
status measuring input. If the measuring input is activated, and if under "edge" a rising
edge was selected, then the measurement result is only signaled if the
measuring input had a signal state of 1 for a minimum of one basic cycle (servo
cycle).

Measuring Input at D4xx/-2 - Local Measurement (2)
p488[0] for encoder_1

Activation time of You can define a measuring range for measuring command. This range could
the measuring area be unrestricted or restricted by a start and an end position. The measuring event
is only reported to the user program, if the measured value is inside the
specified measuring range.
When the axis reaches the start position of the measuring range a specific,
configuration dependent transmission time is elapsed until the measuring input
is actually activated. This transmission time could be compensated by an
activation time, which e.g. the transmission times on PROFIBUS and the
internal processing time in the drive system. So usually SIMOTION will send the
activation/deactivation command to the drive system before the axis has actually
reached the start/end position of the measuring range.
Parameterization The actual assignment between the measuring input 1 or or 2 used, the encoder
at the drive system and the actual quick digital input that the drive is realized in parameters
p488[x] (x = encoders 1, 2, 3) for measuring input 1 and p489[x] for measuring
input 2.
In the associated dropdown list, only the fast bidirectional terminals that are
available for the drive system are listed, i.e. DI/DO9, DI/DO10, DI/DO11
(DI/DO8 only D4x5-2) at the connector X122 and DI/DO13, DI/DO14, DI/DO15,
(DI/DO12 only D4x5-2) at the connector X132. Further, the bidirectional
terminals must be parameterized as inputs in the corresponding parameters
p728.x of the Control Unit.
Note The inputs of the connector X142 (only D4x5-2) can only be used for global
measurements.

Measuring Input at D4xx/-2 - Global Measurement (1)
2. Select the
"Measuring input
1. Click on binector SIMOTION" entry
1. Click on selector 2. Select the

"Measuring input" entry

Global measurement At the Control Unit of SIMOTION D (D4xx) or at the CX32, from V4.1 a max.
at the D4xx of 6 central measuring inputs are available for connection to the global TO
measuring input. This central measuring input is linked with the fast, onboard
inputs of the connectors X122 and X132 and can then be used for single or
cyclic measurements.
With the new SIMOTION D4x5-2 modules, 8e additional, global measuring
inputs are available via the connector X142. These inputs can be used for single
and/or cyclic measurments.
The bidirection inputs/outputs at the teerminal modules TM15 and TM17 can
also be configured as measuring inputs.i The configuration procedure is identical
to the configurration of the onboard inputs/outputs of the connector X142.
For the configuration, initially the required fast, digital inputs at the connectors
Procedure X122 and X132 of the SINAMICS and/or the fast inputs at the connector X142 of
SIMOTION D4xx-2 and/or the fast inputs at the Connector X520 – X522 of the
TM 17 must be designated for use as a global measuring inputs. This is realized
in the correspondluing screen form of the CU (X122, X1329 and/or SIMOTION
D4xx-2 and/or TM17(X520 – X522).
1. To start, under
- SINloAMICS_Integrated -> Control Unit -> Inputs/outputs,
open the screen form for parameterizing the integrated input/outputs of the CU
(X122, X132) and/or
- D4xx/-2 -> inputs/outputs X142
for parameterizing the integrated input/outputs of D4xx-2 and/or
- SINAMICS_Integrated -> input/output components -> TM17 ->
Inputs/outputs
for parameterizing the inputs/outputs of the TM17.
2. Open the "Bidirectional inputs/outputs" tab for X122, X132, the
"Channel
0- 7" tab for X142 and/or the "bidirectional digital Input/Output" tab for
X520 –X522.

Measuring Input at D4xx/-2 - Global Measurement (2)
SIMOTION
measuring inputs
on X142
SINAMICS
measuring inputs
on X122 and X132
TM17
Assign measuring measuring inputs
input on X520 …

continued 3. In case of SINAMICS inputs/outputs, you should ensure that the required
bidirectional input/output is parameterized as input, and with the mouse click
on the binector to interconnect the fast digital input. In the list that opens,
select the entry "Measuring input SIMOTION". This means that this fast input
has been designated for use as global measuring input for SIMOTION.
These inputs will be subsequently listed when continuing to configure the
measuring input TO for the interconnection. Setting up the required fast I/O
message frames) is then automatically performed by the system when
saving and compiling.
4. Proceed as in step number 3 with all fast inputs, which are to be used as
measuring inputs.
5. The interconnection between the TO measuring input and the physical inputs
at the connectors is performed in the configuration dialog of the TO. Click on
the selection button to open the interconnection control "Assign measuring
input" and select the desired input either at the SINAMICS (X122, X132)
and/or SIMOTION (X142) and/or TM17 (X5200 – X522).
6. Click on "Save and compile" in order to generate the necessary fast I/O
message frames and download the project data into the SIMOTION and the
SINAMICS device.
Correction value A correction time to evaluate the time stamp can be entered here. In SIMOTION
time stamp this time is subtracted from the signaled time stamp. Hardware delay times at
measuring inputs can be taken from the equipment/device manuals, and for
values far shorter then 125 μs can generally be neglected (e.g. for SIMOTION
D, SINAMICS Control Units, SIMOTION C240)). Hardware delay times must be
entered with a positive sign.
If measurements are performed at real axes, then for this time stamp technique,
time Ti must also be taken into account. The time interval Ti defines the instant
in time before the start of a DP cycle, at which the drive systems latches up the
actual axis positions and then send them via the cyclic actual value to
SIMOTION. This time Ti must be entered with a negative sign.

Configuring a Measuring Input - Monitoring Measuring Input
Measuring input_2
"Monitoring measuring input"
Measuring input_2
"Interconnection"
Event acceptance: Measuring_input_1 -> Event transfer

Monitoring From V4.0 the function “Monitoring TO measuring input” is available. Using
measuring input this function, a global measuring input event can also be detected "at the same
time" from several TO measuring inputs and evaluated. With this functionality,
an original measuring input can have a functional effect on several axes /
external encoders.
This functionality is only possible with global measuring inputs at TM15/17,
(B1-B4) at the C240, the CU onboard inputs (X122, X132) and the SIMOTION
inputs (X142). Only these inputs support the necessary time stamp functionality.
In the first step, initially the original TO measuring input is interconnected with a
measuring input as usual. At this original TO measuring input, the measuring
operation is activated using the associated program commands and the
measurement results are acquired. Activation and deactivation commands
issued to monitoring TO measuring inputs are not executed or are returned with
an error.
In the second step, additional TO measuring inputs are configured as monitoring
measuring inputs and are interconnected with the original TO measuring input in
the dialog "Interconnections" under the entry "Event transfer". The axis, which
passes the position values to the monitoring measuring TO is listed under
"Reference".
Notes • Activating and deactivating the measuring process is only possible at the
original TO measuring input. These commands are not effective at
monitoring TO measuring inputs.
• Measuring area and edge selection are only possible at the original TO
measuring input.
• The monitoring TO measuring input must have been correctly configured at
the instant of the measurement (measuring input cycle, system number).
• A monitoring TO measuring input does not have its own measuring input and
cannot perform its own measurements.
• The IPO cycles of the TO measuring input and the monitoring TO measuring
input can differ. This will then have a negative impact on the accuracy.

Tool to Calculate the Activation Time for the Measuring Range

Tool "measuring A tool to determine the "Activation time of the measuring range" is provided on
input_de" the Siemens Service & Support web page".
The tool is realized as Excel application. The particular measuring input type
and/or drive type is defined using the individual sheets within the higher-level
workbook. After the required parameters have been entered, various
characteristic quantities are calculated.

Activating and Deactivating the Measuring Input
Activate measuring input
Activate/deactivate measuring input
Deactivate measuring input

Activate single With the "Measuring input on" system commands, a measurement task is issued
measurement to SIMOTION. The control "system variable" indicates whether the measuring
function is active. If, for example, a positive measured edge has been selected
and the measuring input is deflected, the system variable cannot assume the
value ACTIVE until the measuring input is no longer deflected.
The "state" variable is set to the value WAITING_FOR_TRIGGER. A rising edge
(from 0 to 1) or a falling edge (from 1 to 0) triggers the measuring function. The
"Edge" parameter can be used to select which type of edge should be acquired.
Acquisition of both measured edges can ealso be activated by means of a
measurement task, in which case you can specify in the command which edge is
to be acquired first, for example, sifirst the rising edge and then the falling edge.
The drive must be capable of evaluating the signal edge (rising, falling, or both
edges) selected by SIMOTION at the measuring input.
When the measuring ev@ent is received, the measured position is saved. Once
the measurement has bee n performed, the "state" variable is set to
TRIGGER_OCCURREuD, and the measured values can be evaluated using the
"measuredVallue1" and/or "measuredValue2" variables for two measured edges.
Edge
The edge parameter is used to select which signal edge is used to start the
measuremloent. The following can be selected: rising, falling, measurement
treiggered at both edges, starting with a rising or falling edge.
Measuring range Hkere, a range can be defined in which the measurement should be made. This
measuring window is defined from the start of the measured area and the end of
the measured area.
Measuring result The measuring result(s) is(are) saved in the following system variables from
where they can be read out and processed:
i
• measuredValue1
• measuredValue2

Cyclic Measurement

Cyclic measurement In the cyclic measurement mode, up to two edges can be measured in each
execution cycle of the TO measuring input for TM17 High Feature, C240 (B1-
B4) and SIMOTION D4x5-2 (X142) (IPO, IPO2 or servo cycle clock). With the
CU onboard measuring inputs (X122, X132), minimum time between two
measurements is three servo cycle clocks. Intermediate measuring events are
not acquired. Measurements are performed cyclically, until they are terminated
with a command.
The measured values must be read from the user program before they can be
overwritten by a new measurement.
Cyclic measurement A measurement is activated using the "Activate cyclic measurement" program
sequence command. The control "system variable" indicates whether the measuring
function is active. Measurement starts when activated by the program
command. The "Edges" selection box can be used to select which edges should
be acquired.
The "state" variable is set to the TRIGGER_OCCURRED value, when the first
measured value is acquired. Additionally each new Measuring event could be
read out from the system variable "actualInputState". Depending on the state of
the measuring input signal this system variable is either set to "Positive" or
"Negative".
After a successful measurement has been performed, the measured values are
saved in the system variables "measuredValue1" and "measuredValue2" and
can be subsequently evaluated.
The system variables "measuredValue1" and "measuredValue2" are linked with
the counter variables "counterMeasuredValue1" and "counterMeasuredValue2",
and are automatically incremented at each measurement entry.
The measurement task is active until it is terminated using the "Deactivate
measuring input" command.

Synchronize Measuring System

Synchronize Using this command, 2 measuring systems can be synchronized with one
measuring system another and/or the difference of the specified measuring systems read out and
subsequently saved in a user variable.
During synchronization, it is only possible to change the value of a measuring
system if it is not currently being used for the position control.

Output Cam Controller: Applying Glue Tracks
Controller
External encoder

Application with Glue should be applied to a wooden board. The actual position is, for example,
TO "output cam" acquired via an external encoder, which is directly connected to the SIMOTION
C230- 2.
Output cams, whose switch-on and switch-off positions can be set from the user
program depending on the product, are used to control the outputs.

Output Options for Output Cams
DRIVE-CLiQ SIMOTION C230- 2/C240
Central I/O
8 high-speed
(not fast)
output cams
onboard 8 high-speed
output cams onboard
SIMOTION D4x5/ Conventional DP slave

SINAMICS S120 (not high-speed)
TM15/TM17
24 /16 high-speed
output cams
MCI board extension

SIMOTION D4x5: max. 8 hsOC 4 output cams (not high-speed)
SIMOTION D4x5-2: max. 8 hsOC
SIMOTION D410: max. 4 hsOC
SIMOTION D410-2: max. 8 hsOC
hsOC : high-speed Output Cams

SIMOTION P350

Output cam Use the "Output cam" technology object if switching signals are to be generated
as a function of the axis position. The switching signals can be output at the
following modules:
• at the onboard outputs of the C230- 2/C240 and the SIMOTION D4xx/-2
• at the output of a central output module or a standard slave
• SIMOTION P350 MCI-Board-Extension
• at the TM15/TM17 modules of a SIMOTION system
Only the onboard outputs and the digital outputs of the TM15/TM17 support the
"High-speed output cam" function.
High-speed
output cams High-speed output cams can be realized using the following digital outputs:
• C2xx: 8 high-speed output cams via interface connector X1 (Onboard
peripheral))
(Reproducibility: 140 μs with C230, 70 μs with C240)
• D4x5 (as of V4.1): 8 high-speed output cam via connector X122/X132
(Reproducibility: 125 μs)
• D410 (as of V4.1):4 high-speed output cam via connector X121
• D4x5-2: 8 high-speed output cam via connector X142 (Reproducibility:
10 μs, resolution: 1 μs, the high-speed output cam functionality for X122,
X132 is no longer supported with D4xx-2).
• D410-2: 8 high-speed output cam via connector X121, X131
• Max. 32 High-speed output cam with TM15 (Reproducibility: 125 μs) and
max. 16 high-speed output cam with TM17 (Reproducibility: 10 μs,
resolution: 1 μs)

Output Cam Types
Position-based
output cam
Begin of output cam End of output cam
Time-based
output cam ON time
Begin of output cam
Uni-directional
output cam
Begin of output cam
Axis position

Output cam types SIMOTION supports the three following output cam types:
• Position-based output cam
• Time-based output cam
• Uni-directional output cam
Position-based cam For position-based cams, the activation position (switch-on position) and the
deactivation position (switch-off position) are directly entered.
Time-based cam For time-based cams, the activationi position is specified for a specific time
period.
Uni-directional For uni-directional output cams, only the activation (switch-on) position is
output cam specified. The uni-directional output cam does not switch unless the initial
position is explicitly passed, e.g. by setting the actual value.
An end position isu not defined for the uni-directional output cam. The output
cam signal dependsl solely on the switching criteria when the output cam is
passed. The uni-directgional output cam can be reset with the appropriate
program commands (ofor example, calling the system function "Switch SW cam
off").
Counter cam For a ecounter cam, it can be specified whether the output cam is to be output
every time it switches or every nth time it switches.
Counter cams can only be defined in the user program. When configuring the
output cam, counter cams cannot be defined as output cam type. Every counter
cam has a start count value and an actual count value. The actual count value
for the output cam is reduced by 1 every time the output cam switches. If the
actual counter value reaches 0, the output cam is output (system variable 'state'
and output of output cam). At the same time, the actual counter value is reset to
the start count.
Counter cams can only be configured for position-based and time-based cams.

Configuring an Output Cam

Processing The activation and the activation positions of the cam are compared with the
cycle clock axis position (setpoints and/or actual values) in this time grid. A TO cam is
always assigned to an axis or an external encoder.
For real axes, it is possible to couple to the setpoint or to the actual positions.
For external encoders, only actual positions are available.
Output The output cam can be used as software cam without controlling a digital output.
The state of the cam is then interrogated using the "state" system variable in the
user program.
If the cam should control I/O, then the bit address of the digital output is
specified at this parameter. However, it is not permissible that this output signal
is located in the process image.
High-speed The output of the output cam signal takes place in the output cam cycle clock. In
output cams order to achieve a more precise output, the function "high-speed cam" can be
used. In this case, in the output cam cycle clock, it is calculated as to how many
microseconds the cam output should be set. This time is transferred to a
hardware timer, which then sets the output very precisely.
If the output is activated, the following setting for the type of output signal has to
be performed:
• Cam output (CAM): for the output of high-speed output cams at TM15/TM17
and for outputs via the connector X142 on a D4x5-2
• high-speed digital output (DO): for the output of output cams at the
connectors x122, X132 on a D4xx and C2x0.
All other modules, i.e. conventional slaves connected to PROFIBUS or devices
connected to PROFINET only support the option:
• Standard digital output (DO)
Logical operation If several output cams are switched to the same output, using the logical
operation parameter it can be selected as to whether the signals should be
"AND'ed" or "OR'd".
High-Speed Onboard Output Cams for SIMOTION D4xx-2 (1)
1. Activate output
2. define as
"Cam output (CAM)"
3. define as "Output cam"

High-speed cams For the configuration of high-speed output cams via the onboard I/Os (X142) of
for D4xx-2 D4xx-2 first of all in the configuration dialog of the output cam TO the entry:
"Cam output (CAM)" must be selected.
Additionally the bidirectional inputs/outputs of the connector X142 must be
defined as "Output cams". This parameterization is performed in the
configuration dialog of the connector X142.
1. Open the configuration dialog of the output cam TO and select the entry
"Activate output".
2. In the option list "Cam output on" select the entry "Cam output (CAM).
si
3. Under SIMOTION D4xx-2 -> Inputs/outputs X142 open the dialog for the
configuration of the integrated bidirectional inputs/outputs via the
connector X142.
Click on the symbol to open the dropdown list for the use of that input/output
and select the entry "Output cam". These output will be subsequently listed
when continuing to configure the TO cam for the interconnection.
u
4. Proceed as in step number 3 with all fast inputs, which are to be used as
gl
measuring inputs.

High-Speed Onboard Output Cams for SIMOTION D4xx-2 (2)
6. Open list of
output cams 7. Assign output cam
Assign
cam output
5. Open the interconnection

control

Assigning the The actual assignment of output to the TO output cam is realized from V4.2,
cam output symbolically using the associated interconnection dialog box:
5. Open the interconnection control by clicking on the corresponding button.....
6. Click on the "+" symbol in front of the device "D4xx-2" in order to open
the list of all the parameterized output cams. In this list only that digital outputs
will be displayed which were defined as "Outputs cam" in the step 3.
7. Via the selection "assign" you can linkm the physical terminal of the
connector X142 to the TO output cam.
Completion After the assignment has been cosmpleted, the complete project must be
compiled using "Save and compile". When compiling, the necessary fast I/O
message frames are created.
Finally the project data mus@t be downloaded into the SIMOTION and
SINAMICS target system.

High-Speed Onboard Output Cams for SIMOTION D4xx (1)
1. Define as "fast
digital output (DO)"
3. Select entry
"DO (SIMOTION)"
2. Define as
output

High-speed cams In order to be able to access the onboard I/Os of the Control Unit or individual
for D4xx terminals of a terminal expansion module from SIMOTION, the I/O signals must
be transferred via the internal PROFIBUS interface (PROFIBUS Integrated). To
do so, a PROFIBUS message frame must be configured to perform the data
transfer. From V4.2 and higher, this configuration is automatically executed.
To configure high-speed onboard output camse (X122, X132), initially the
required high-speed, bidirectional inputs/outputs at SINAMICS must be
designated for use as outputs. This is reamlized in the corresponding screen
form of the CU.
1. To start, under SINAMICS_Integsrated -> Control Unit -> Inputs/outputs,

open the screen form for parameterizing the integrated bidirectional input/outputs
of the D4xx (X122, X132).
2. Open the "Bidirectional inputs/outputs" tab.
3. You should ensur e that the required bidirectional input/output is
parameterized as output, and with the mouse click on the binector to
interconnect lthe high-speed digital output.
In the lisgt that opens, select the entry "DO (SIMOTION)". This means that this
fasot output has been designated for use as high-speed cam output for
SIMOTIlON.
These inputs will be subsequently listed when continuing to configure the TO
cam for the interconnection. Creating the required message frames 390, 391 (up
to 2 measuring inputs, rest as outputs) or 392 (up to 6 measuring inputs, rest as
outputs) is then automatically performed by the system when "Save and
compile" is performed.
4. Proceed as in step number 3 with all outputs, which are to be used as
output cams.

High-Speed Onboard Output Cams for SIMOTION D4xx (2)
6. Open list of
output cams 7. Assign
output cam
5. Open linking
control

Assigning the The actual assignment of the measuring input to the TO measuring input
measuring input is realized from V4.2, symbolically using the associated selection dialog box,
which can be opened by clicking on .....
5. Open the interconnection control by clicking on the corresponding button.....
6. Click on the "+" symbol in front of the device "Control Unit" in order to open
the list of all the parameterized output cams. In this list only that digital
outputs will be displayed which were defined as "Outputs cam" in the step 3.
7. Via the selection "assign" you can link the physical terminal of the connector
X142 to the TO output cam.
Completion After the assignment has been completed, the complete project must be
compiled using "Save and compile". When compiling, the necessary message
frames for transferring time stamps 390, 391 or 392 between SIMOTION and
the DO "Control Unit" are created.
Finally, it goes without saying that the project data must be downloaded into the
SIMOTION and into the SINAMICS target device.

Activating the Output Cam in the User Program

Rate time The rate time when the switching on is used to compensate the dead times of
the digital outputs and the connected switching elements. A negative value is
interpreted as rate time, this means that the output cam is set earlier by this
time. A positive value acts as delay time, the output cam is set correspondingly
later.
Hysteresis
The hysteresis defines a tolerance range areound the switching position.
Hysteresis is only activated after the direction has been reversed. The direction
of motion is not redetermined within the hymsteresis. If the activation time of
time-based cams expires within the hysteresis, the time-based cam switches off
after the output cam activation time has exepired.
If the axis moves in the hysteresiis range by the switching position, the switching
signal of a position-based cam iss not changed. If modified switching conditions
for the output cam are detected when the output cam is outside the hysteresis
Activation/ range, this actual switch s@tatus is set.
deactivation position
The activation and the dea ctivation positions are specified here.
Add switching If this check bogx is selected, then the activation and deactivation positions are
positions added to the last program activation and deactivation positions. This
corresponods to shifting the output cam.
Effective direction The output cam only switches when the motion direction matches the specified
e
effective direction. The following are possible: both directions, negative, positive.
Set output This function allows a counter cam to be realized. The function sets the start
cam counter counter value and the actual counter value of the output cam.
The actual counter value is decremented by 1 at each switching event of the
output cam. If the actual counter value is 0, the output of the output cam takes
place, and the actual counter value is reset to the start counter value. The actual
counter values can be read from the "counterCamData" system variable
structure.

Deactivating the Output Cam in the User Program

Deactivating the Using the command "switch SW output cam off", the output cam is deactivated
output cam from the user program.
Output cam Activate this check box if the assigned output cam output signal should remain
permanently on permanently on after the output cam has been disabled. If the checkbox is not
activated, the output signal of the output cam is reset when you disable the
output cam.

Setting a High-Speed Cam from the User Program

Overview The command is available from Version 4.1 and higher of SIMOTION.
This command allows you to switch an output cam and set its switching signal
to the specified value. This output cam signal is available in system variable
state and, if configured accordingly, is also available at a digital output. This
terminates any ongoing output cam processing that was started, for example,
with the "Output cam on" command.
If the output cam was configured as a high-speed output cam on the relevant
devices (e.g., SIMOTION D4xx/-2, C240, TM15, TM17 High Feature), the
following also applies:
• You can switch the assigned digiietal output at precise times during the
configured processing cycle cslock of the output cam.
• The time offset specified in the command is added to the system-
dependent output delay of the output cam signal (tOutput system variable). The
resulting time offset (programmed time offset + value of tOutputsystem variable)
must be shorter than the duration of the processing cycle clock.

Configuring a TO "Output Cam Track"

Cam tracks Cam tracks are characterized by the fact that they allow several output cams to
be output as a track at one output. Cam tracks can be inserted using the icon
"Insert cam track" below a positioning or synchronous axes or an external
encoder.
Cam types A range of output cam types with different switching behaviors are available for
a cam track:
• Position-based cam: The switching signal is supplied between the switch-on
position and the switch-off position.
• Time-based cam: The switching signal is supplied for a specified time period
after the switch-on position has been reached.
• Time-based cam with maximum activation length When compared to time-
based cams, and additional maximum activation length (switch-on length)
can be activated. This means that the time-based output cam is deactivated
once it has traveled the maximum length, although the parameterized time
has not yet expired.
Non-cyclic ... Non-cyclic activated cam tracks are deactivated automatically when the cam
track length is exited. So that the non-cyclic cam track remains active over the
entire axis range (also outside of the cam track length), "Yes" must be selected.
When the cam track length is exited, the non-cyclic cam track remains active
and can only be deactivated via command.
Functionality • With cam tracks, up to 32 output cams can be configured within a TO. All
output cams on one track are of the same type (position or time-based
cams).
• Any number of cam tracks can be used per axis. The only restriction placed
on this number is the system performance.
• The cam track can be calculated in the position-control cycle clock, IPO
cycle clock, or IPO2 cycle clock.

Track Data of the TO "Output Cam Track"

Track data A cam track has parameters that are valid for the track as a whole, and
parameters that can be configured for each single output cam on a track. Track
data are valid for all output cams of a track.
Track length The track length is calculated from the start of the cam track (always 0) to the
end of the cam track. The cams of the cam track are located within the track
length. The track length must not be 0.
Cam tracks are defined independently ieof the axis. The axis reference position
Axis reference is used to define how the cam track is mapped on the axis, or from which axis
position position the cam track should be soutput.
Cyclic cam track activation@: The track length of the cam track starting from the
Activation mode axis reference position is mapped and cyclically continued/repeated.
Non-cyclic cam tracku activation: The output cam track is mapped starting from
the axis refelrence position, output once, and terminated automatically after it is
exited.
The start lomode or the stop mode defines whether a cam track should be
Start/stop mode immedeiately activated (deactivated) – or only in the next track cycle.
Effkective immediately: The track becomes active (inactive) immediately. If an
output cam (or time-based cam) is defined or active at the actual position of the
old track, the output is canceled. A new track is activated (deactivated)
immediately without any delay.
Immediately when the output cam track is inactive: A changeover is made to the
new cam track if no single output cam is active (any longer) on the old cam
track. An active single output cam on the old cam track is still output completely.
With the next track cycle or output cam track end: The track only becomes
active (inactive) at the next track cycle. As soon as the first output cam on the
new track switches, a changeover is made to the new track. A time-based cam
on the old track is output up until that time.

Output Cam Data of the TO "Output Cam Track"

Output cam data The defaults for system variables of single output cams on a track, e.g. start and
end position, are displayed in the "Output cam data" tab.
Output cam The output cam number (0 - 31) is displayed here. Each track can have up to 32
output cams.
Validity Select this checkbox, if you want to set the output validity of single output cams
on a track. If the checkbox is activated, the output cam will be output, along with
the track. If it is not activated, the output cam is not output.
Start/end The start of a position-based or time-based cam or the end position of a

position position-based cam is entered here
ON duration For time-based cams, the on duration of the output cam is entered here. The
output cam switches off once the parameterized time has expired.
Max. ON length Enter the maximum ON length for time-based cams with maximum ON length
here. This means that the time-based output cam is deactivated once it has
traveled the maximum length, although the parameterized time has not yet
expired.
A time-based cam is used for example, if dabs of glue should be applied to a
workpiece and the amount of glue should be independent (constant time ->
time-based cam) of the throughput rate.
To avoid that the time-based cam is still being controlled after the end of the
workpiece at high throughput rates, the ON duration can be limited over a
maximum ON length (related to the start position of the output cam). This
prevents a glue dot being placed adjacent to the workpiece.
The maximum ON length is effective in both traversing directions of the axis,
and the cam track's switch-on position is the reference position.

Activating and Deactivating TO "Output Cam Track"

Activating a A cam track is activated using the command "Cam track on". For the
cam track activation, the settings of the output cam positions are accepted as effective
settings from the default screen form (systemvariables: userdefault. ...)
(systemvariables: effectivedata. ...)
If the new single output cam positions are to be used, then these new positions
must be initially written from the user program into the system variable
"userdefault. ..." They can then be subsequently activated using the "Cam
track on" command.
For the command "Cam track on", no data of the individual output cams (output
cam data) are transferred, but only the track data.
The "Cam track on" command uses as standard (parameter:
"singleCamSettingType") the perimeter of the default setting (system variable:
"userdefault...").
Deactivation Cam tracks are deactivated automatically or using a command.

Automatic deactivation: Deactivation occurs when exiting the defined range of
the cam track, i.e., the track start (in a negative direction) or the track end (in a
positive direction).
The direction of motion can be repeatedly changed within the track length. As a
consequence, output cams can be output a multiple number of times.
Deactivation using a command: The cam track is deactivated using the
command "Cam track off"
For the "Cam track off" command, you can parameterize the deactivation point
in time (see start mode and stop mode).

Connecting HMI Systems

Content Page
HMI Components for SIMOTION ...................................................................................................... 2
Integrating WinCC flexible into a SIMOTION Project ........................................................................ 3
Creating a WinCC flexible Object in the SIMATIC Manager .............................................................. 4
Opening HW Config for the HMI Station ........................................................................................... 5
Defining the Ethernet Connection for an HMI Station ........................................................................ 6
Starting the WinCC flexible Engineering System .............................................................................. 7
Defining the Communication Partners for an HMI Station ................................................................ 8
Creating Process Variables in WinCC flexible ................................................................................... 9
Creating Screens with WinCC flexible ............................................................................................ 10
Inserting Input/Output Fields in a Screen .......................................................................................... 11
Defining the Start Screen with WinCC flexible .................................................................................. 12
Defining Properties for Download ..................................................................................................... 13
Defining Download Settings at the HMI Device ................................................................................. 14
Saving and Transferring the Project Data ......................................................................................... 15
OPC Server (OLE For Process Control) .......................................................................................... 16
Connecting SIMOTION to WinCC .................................................................................................... 17

Automation and Drive Technology Page 1 Connecting HMI Systems
HMI Components for SIMOTION
Operator panel
SIMATIC Mobile Panel 177 / 277
SIMATIC TP/OP 177B (Widescreen)
SIMATIC TP/OP 277
SIMATIC Multi Panels 177/277/377
SIMATIC Panel IPC 277D/477C/

577C/677C
Configuring using
WinCC flexible
OPC as standard interface

SIMATIC HMI The following panels and PC-based systems can be used for machine operation
and monitoring in various performance classes:
• SIMATIC Mobile Panel 177 fully graphic with 5.7"
• SIMATIC Mobile Panel 277 fully graphic with 7.5"/10"
• TP/OP 177B fully graphic with 5.7“
• TP/OP 277B fully graphic with 5.7“
• Multi Panel MP 177 fully graphic with 7.5"
• MP 277 fully graphic with 10.4"
• MP 377 fully graphic with 12.1"/15.1"/19"
• IPC277D
- 7“, 9“ und 12“ Touch (Widescreen)
• IPC 477C
- 12“, 15“ and 19“ TFT Touch / 12“ and 15“ TFT Key
• IPC 577C
- 12“, 15“ and 19“ TFT Touch
• IPC 677C
- 12“, 15“, 17” and 19“ TFT Touch
- 12“ and 15“ TFT Key
SIMATICWinCC The above SIMATIC Panels, multipanels as well as the PC-based systems are
flexible configured using the WinCC flexible engineering system.
OPC In addition to connection via SIMATIC HMI devices, the OPC server is also
available for open, non-proprietary connection of HMI- applications.

Integrating WinCC flexible into a SIMOTION Project
Prerequisite:
WinCC flexible Variables that can be connected:
integrated in STEP7
System variables
D4xx/-2 Technology objects

HMI (WinCC flexible RT)
SIMOTION device
Global user variables

I/O variables
PROFIBUS DP/ Ethernet Global device variables
Unit variables (Interface)

Data exchange

Communication The SIMOTION HMI operator panel can communicate with a SIMOTION device
via the PROFIBUS and Ethernet bus systems. The SIMOTION device and the
operator panel can exchange information via technology object variables,
system variables and global user variables.
For this purpose, when configuring the user interface with WinCC flexible, the
associated variables must be created and linked with the associated process
variables in the SIMOTION device.
The operator panel reads the value from the defined address at the runtime, and
then displays it on the HMI device. In the same way, an operator can enter a
value at the operator panel, which is then written into the associated process
variable of the SIMOTION device.
Communication between an HMI device and a SIMOTION device is possible via
PROFIBUS or MPI and via Industrial Ethernet.
What is WinCC WinCC flexible is the consequential ongoing development of SIMATIC HMI
flexible? software products. For machine-related applications, which up until now were
addressed using the ProTool family, WinCC flexible provides increased
configuring efficiency and new, innovative automation concepts.
User interfaces for plants and machines are configured using WinCC flexible. In
this case, configuring means creating and/or supplementing a user interface via
a special configuring tool.
WinCC flexible has been designed for smaller systems and/or for machine-
related operator control. WinCC flexible does not require any general know-how
about software engineering. The projects are created using WinCC flexible ES
(Engineering System) on a PC/PG and after completion are transferred to an
operator panel. On the operator panel, the projects can run under the WinCC
flexible RT runtime software.
Prerequisites When installing WinCC flexible, the support for integration into STEP7 most also
be installed. This is already automatically installed with the "Standard" setup, if
STEP7 or SCOUT has already been installed.

Creating a WinCC flexible Object in the SIMATIC Manager
1. Open a project in the
SIMATIC Manager
2. Insert a SIMATIC HMI
station
3. Select the device type,

4. version and confirm with
5. "OK"
TP 177B 6" color PN/DP
1.1.4.0

WinCC flexible There are several options to create a WinCC flexible project. In this case,
project the route via the higher-level SIMATIC project is shown.
For every project created using SIMOTION SCOUT, there is an associated
SIMATIC project with the same name, which can be opened using the
SIMATICManagers.
If WinCC flexible has been installed, then an HMI station can be created in the
SIMATIC project. In this case, all of the data of the HMI project are saved in the
associated SIMATIC project.
To insert a WinCC flexible RT device, proceed as follows:
1. Select the root of the SIMATIC Manager project and select the menu
command: Insert -> Station -> HMI station. The dialog "Properties - WinCC
flexible RT" is opened.
2. Select the required HMI device (in our particular case: TP 177B 6" color
PN/DP) and the appropriate version (V1.1.4.0) and confirm your settings
with "OK".
The dialog is closed, and the inserted device is displayed using the
appropriate icon in the SIMATIC Manager project.
WinCC flexible The inserted icon "SIMATIC HMI Station" symbolizes the HMI device with
icon the configuration project data integrated in the STEP7 project.
Using the "Open object" command, from the context menu of the "WinCC
flexible RT" icon, the "WinCC flexible Engineering System" configuring software
can be started and the station configured.

Opening HW Config for the HMI Station
2. Double-click
1. Select
3. Double-click
"HMI IE"

Communication For a WinCC flexible project integrated in STEP7, the interface setting of the
settings HMI station and/or the connection to a subnet - just the same as for a control -
are made using the HW Config tool or NetPro.
The "HW Config" tool can be opened as follows.
1. In the SIMATIC Manager project window select the icon: "SIMATIC HMI
station".
2. Double-click on the "Configuration" symmbol in the work area of the
SIMATIC Manager.
The "HW Config" tool is opened. Eveiry HMI station is displayed in HW Config as
"PC station". As stsandard, the application "WinCC flexible RT" is inserted at slot
3 and the co mmunication module (HMI MPI/DP) at slot 4. The communication
module (HMI IE) is inserted at slot 5.
3. By double-clicking on@ the entry "HMI IE", the properties dialog to set
the communication in terface is opened.

Defining the Ethernet Connection for an HMI Station
6. Enter IP address:
192.168.0.12 and
subnet mask
255.255.255.0
4. Open the
properties dialog
5. Select Ethernet_PN
subnet
7. Confirm with "OK"

Continued 4. Click on the "Properties" button to open the "Properties - Ethernet- interface
HMI - IE" dialog.
5. Under the "Parameter" tab under the list box "Subnet", select the entry
"Ethernet_PN". This means that from a configuring perspective, the HMI
device is connected at the appropriate Ethernet subnet.
6. In the entry field "IP address" enter the value "192.168.0.12", and in the
entry field, subnet mask, the value "255.255.255.0".
7. Acknowledge the settings in both of these dialogs with "OK". The dialog
boxes are closed. The HMI device is now connected in the project at the
selected Ethernet subnet.
Note For HMI devices with Ethernet connection, using this setting and the subsequent
download, the IP address in the HMI device cannot the of written.
The setting of the IP address and the subnet mask for the HMI device must
always be performed directly at the HMI device itself under Control panel ->
Transfer settings.

Starting the WinCC flexible Engineering System
Context menu:
Open object
WinCC flexible ES
Work area
Tools
Project
window
Output/properties window

Starting Using the "Open object" command from the context menu of the "WinCC flexible
WinCC flexible ES RT" symbol, the "WinCC flexible Engineering System" can be started and the
station subsequently configured.
Project view Just same as for SIMOTION SCOUT, The configuring interface WinCC flexible
ES comprises several views (windows).
The project view is the central control point for configuration. All components of
a project are displayed in the project window in a tree-type structure. The
associated editors in the work area are opened by double clicking on the
symbols.
Only those elements which are supported by the selected operator panel (HMI
device) are displayed in the project window. In the project window you have
access to the device settings of the HMI device, the language settings and
version management.
Work area The central configuration area in which the objects of the HMI device can be
processed/edited using the active editor. Several editors can be opened
simultaneously. it is possible to toggle between the individual editors using the
corresponding tabs.
Properties window The properties window is used to edit the properties of selected objects (e.g.
screens, screen objects, tags). The properties window is only available for the
editors, in which also object properties can be set.
Tool window The tool window contains all configurable objects, which can be inserted into
screens. Further, libraries can be accessed from the tool window.
Output window The output window displays all system messages, e.g. produced, for example,
when generating a project.

Defining the Communication Partners for an HMI Station
Connection Communication
name Active: On Online: On
partner/station

Defining the
communication Under the settings for Communication -> Connections the possible
partner communication partners for the HMI device must be defined. At runtime, an HMI
device can establish connections to various controls (SIMOTION control, SIMATIC
PLC and drives) and read or write process variables at the control.
Connection
An internal WinCC flexible name is defined ine the "Connection" column. The
variables of the associated control can be subsequently selected using these
names.
Active "On" must be selected in the "Active" coilumn. The second part of the table to
specify the communication partner is now available.
Communication For a connection to a SIMOTION device, the "SIMOTION" protocol must be

driver selected.
If the HMI device inuterface was connected to a subnet via HW Config, then in
Station / partner
the correspondilng list box, the control station or the partner (module) in the station
can beg selected.
In this case, othe associated addresses etc. of the two communication partners
are displlayed in the lower section of the connection table.
Nodes Tkhe interface (CBE30) is displayed here, via which the selected module is
connected with the HMI device.
The entry "Online" must be selected in this column. Only then does the HMI
Online device establish a connection to the specified control after downloading a
corresponding connection at runtime, in order to read or write variables.

Creating Process Variables in WinCC flexible
2. Define
connection 3. Open the symbol
1. Open the browser
"Tag" window
4. Select
SIMOTION
variable

Creating If the corresponding connections have been configured to the control devices,
variables then under the specified connection names, the names of the required process
variables of the control can be accessed, in order to integrate them in the
configuration of the HMI device.
Variables are created in a dedicated table, which can be opened by double
clicking on the entry "Communication -> Variables". Proceed as following to
include a variable in the table:
1. Click in the "Connection" column on the entry to open the associated list
box. A browser to select the required econnection or to create internal variables
is opened.
2. Select the required connections from the browser window.
3. Click in the "Symbol" column on the entry to open the associated
browser. A browser window wi@th the symbolic variables of the device
identified by the connection is opened.
4. In the browser,u select the required variable.
The correspolnding information about the variable is displayed in the columns
"Symbol", g"Data type", "Address" and "Comment". Further, in the column
"Name", an internal WinCC flexible default name, which is identical with the
name oof the variable in the control device, is also listed.
5. eIf required, in the "Name" column enter a new name for the selected
variable.
6. In the "Acquisition cycle" column, select the required cycle in which, the
variable content is exchanged between the control and the HMI device. New
acquisition cycles for data exchange can be defined under the entry
"Communication -> Cycles".
7. Repeat steps 1 - 6, to transfer all of the required variables into the
configuration of the HMI device.

Creating Screens with WinCC flexible
Insert or open Tools for

screen Screen editor screen elements

Creating a screen Screens can then be configured for the HMI device. Via the entry "Add screen"
or by double-clicking on an existing screen the editor to generate the screen is
opened.
Template For each HMI device there is a "template" screen in which the globally assigned
function keys or other global objects, for example message window, permanent
area with time, user etc., can be configured.
For each screen that has been created, you can select whether the "Template"
screen should be incorporated or not. An object in a screen then always covers
an object in the "Template" at the same position.
If an object or the assignment in a template is changed, then after a download,
this change becomes effective in all screens in which the template has been
incorporated.
Layers A screen always consists of 32 screen layers (layers 0..31). The layer with the
smallest number lies in the background. This means that objects in the front
layers cover objects in the background layers at the same position.
Individual layers can be displayed or hidden at runtime.
Screen navigation Using the screen navigation, a hierarchic navigation structure can be configured
to select process screens. At the runtime, using the navigation bar, and operates
in can toggle between the individual screens of the hierarchy.
The editor to create the screen navigation can be opened via the entry: Device
settings -> Screen navigation.

Inserting Input/Output Fields in a Screen
1. Inserting
I/O field
2. Open the
properties window
4. Define other
settings
3. Select
variable

Toolbox The toolbox (tool window) contains a selection of simple and complex objects,
which you can insert in your screens, e.g. graphic objects and operating
elements. In addition, libraries with configured library objects and a collection
of faceplates is provided in the toolbox.
The toolbox can be displayed via the menu command: View -> Tools.
In order to insert an input or output field inmto a screen, proceed as
Insert input/ follows:
output field
1. Click on the IO field entry and wiith the mouse key pressed, drag the IO
icon to approximately the positions in the screen, where later an input or output
field is to be displayed.
2. If required, using the menu command: View -> Properties open the
properties window. In @the properties window, the properties of the selected
object are always displayed.
In the navigationu of the properties window, select the "General" entry. The
connection of lthe process variable or settings for the mode and the display
format areg configured in this area.
3. Clicko in the area: Process -> Variable on the symbol to open to the
symbol browlser, and there under SIMATIC HMI Station -> Communication ->
Variables, select one of the already configured variables for the display.
4. For the display, define the format or under the topic: Properties ->
Display define the precise position and underProperties -> Text the font type
and the alignment.

Defining the Start Screen with WinCC flexible
Start screen
Device settings

Defining a When creating a WinCC flexible project, normally several screens are created;
start screen the operator can then toggle between these at runtime by pressing a key/button.
In order that the runtime system knows which screen should be displayed after
the system has booted/powered up, when configuring the project, one screen
must be allocated the property "Start screen".
1. By double-clicking on the entry: Device setting -> Device settings,
open the associated dialog.
2. In the list box "Start screen", selecet the required start screen
This screen is then displayed afiter a subsequent download and the HMI
device has powered up.

Defining Properties for Download
2. Select HMI
station 3. Select the
Ethernet mode
4. Enter
address:
192.168.0.12
5. Start
1. Call transfer transfer
settings

Defining the The configuration can be saved and loaded into the HMI device . For this
properties download, the appropriate settings must be made at the configuring PG/PC or at
for download the HMI device. In principle, a download such as this can be performed via the
serial interface or via bus systems (PROFIBUS, MPI or Ethernet).
The settings for the download can be made in WinCC flexible using the dialog
"Select HMI device for transfer". This dialog can be opened using the menu
command Project -> Transfer -> Transfer settings, or using the corresponding
symbol in the toolbar.
The following settings are then made in the dialog that opens:
• Select the HMI devices that should be loaded at the start of transfer.
For each selected HMI device, the following is defined:
• Select the bus system via which the HMI device should be loaded. The
following can be selected:
- Serial
- MPI/DP
- Ethernet
• Station address of the HMI device, to which the configuration should be
loaded. If the HMI device cannot be directly accessed via the PG/PC, then in
addition, other data must be entered for routing the configuration data.
• Settings as to whether the configuration data should be stored in the RAM or
in the flash memory of the HMI device.
• Other settings regarding:
- Return transfer (this only functions if an additional memory card is
inserted in the HMI device)
- Overwrite password list
- Overwrite recipe data

Defining Download Settings at the HMI Device
2 Transfer
S7 Transfer Screen saver System Transfer

Settings
1
WinCC Internet
Settings
4
3 5

Control panel The interface parameterization at the HMI device is made via the "Transfer" icon
in the Windows "Control panel". After powering up, the "Control panel" can be
opened by pressing the "Control panel" button.
In operation, the control panel can be opened using the start bar (CTRL + ESC)
with the command: Settings -> Control Panel.
Transfer In the open "Control panel", using the "Transfer" icon settings can be made for
settings the download.
1. Switch-off the power supply of the HMI device and switch on again, and in
the bootloader dialog, click on the "Control Panel" button. The control panel
of the HMI device is opened
2. In the control panel, double-click on the "Transfer" icon. The "Transfer
Settings" dialog is opened.
3. In the list box of "Channel 2", select the entry "Ethernet" and activate the two
checkboxes for "Enable Channel" and for "Remote Control".
Then click on the "Advanced" button. The "Network Configuration" dialog is
opened.
4. In the list of the installed network drivers, select the entry "SMSC100FD1:
Onboard LAN Ethernet Driver" and then press the "Properties" button. The
"Onboard LAN Ethernet Driver" dialog is opened.
5. Select the option: "Specify an IP address" and enter the IP address:
192.168.0.12 as well as the subnet mask "255.255.255.0".
6. Press the "OK" button to confirm all of the dialogs. Then switch off the power
supply of the HMI device and switch on again. The settings that have been
made will only become active the next time the system is powered up

Saving and Transferring the Project Data
Settings for
Save the transfer
Start
transfer
Transfer status

Download to
target system The configuration created for the HMI device can then be downloaded.
1. First, save the configuration using the "Save current project" on the
hard disk.
2. And then open the dialog "Select HMI devices for transfer", and
using the button "Settings for the transfer" make the efollowing settings:
- Select the TP 177B device
- Mode: Ethernet
- IP address: 192.168.0.12
- Transfer to: Flash
- Delta transfer: On
3. Start the configuration@ download by pressing the "Transfer" button.
After the project has been generated and a connection has been established,
WinCC flexible starts to transfer the configuration data to the selected target
devices. After data transfer has been completed, on the HMI device the WinCC
flexible RT (Run Time System) it started and the selected start screen is
displayed.

OPC Server (OLE For Process Control)
OPC server is included in the scope of delivery

of the SIMATIC NET communication software
Standardized, open, non-proprietary interface
Supports integration of automation systems

from different manufacturers
Connection of OPC-capable Windows

applications to the S7 and S5-compatible
communication
Can be accessed from every computer in the

LAN/WAN (via COM/DCOM)
Demand-oriented client-server communication
OPC-Scout with browser functionality as OPC-

Client

OLE for With OPC (OLE for Process Control) a tool is available, which allows the
Process Control universal connection of automation software and hardware without any driver
and interface problems. Using COM/DCOM technology from Microsoft
Windows, OPC defines manufacturer-independent interfaces for the industrial
environment. This means that conventional Office programs can be linked to the
automation environment.
For hardware manufacturers this means that they only have to implement an
OPC server interface. Manufacturers of software products, such as visualization
systems, measuring systems etc., only require an OPC Client interface On the
other hand, end customers can freely select between different hardware and
software component suppliers.
Advantages of OPC In addition to having the objective of generally simplifying the connection of
production and process technology applications with business/office
applications, OPC offers a whole series of additional advantages:
• As a result of the standardized interface, at the application level, any
hardware can be addressed in the same way. This saves time and money.
• Every hardware component with an OPC server is now available for
connection to each software program with OPC client capability. Today, all
common hardware connections are already supported by OPC server.
• Every OPC server is in a position to process requests from several clients.
As a consequence, various software packages can access the data of the
OPC server.
• In addition to the COM technology, OPC uses DCOM (Distributed COM), to
achieve networking capability. As a consequence, not only data sources
(OPC server), which are available on the local PC are available, but also all
servers of the network are available as "remote" data source.
OPC supports remote operator stations, multi-user systems, access to
distributed data sources. OPC clients are not even aware whether a local or
a remote data source is involved. OPC or DCOM hides the difference as it
does not distinguish between the two.

Connecting SIMOTION to WinCC
Powerful process visualization

based on Windows
• Efficient, user-friendly configuration
• One common database, standard PROCESS FIELD BUS
PROCESS FIELD BUS
operator philosophy
Scalable
• Both for hardware and software
• Single-user to multi-user system
Open system architecture

• OPC, OLE, ODBC, SQL, ANSI-C, ActiveX
• Open for sector-specific additions

Overview SIMATIC WinCC is the PC-based operator control and visualization system that
can run under Microsoft Windows operating systems. "WinCC" stands for
Windows Control Center - for complete operator control and visualization
functionality.
WinCC has been designed for visualizing and operating processes, production
sequences, plants and machines. With its powerful process coupling, especially
to the SIMATIC family, and secure and reliable data archiving, WinCC especially
allows process control solutions to be created with a high degree of availability
and fault tolerance.
OPC for WinCC WinCC can be connected to a SIMOTION device via the OPC server. As a
consequence, also in the SIMOTION environment all of the advantages of the
WinCC system can be utilized, for example:
• With WinCC, the hardware basis can be used, which is precisely the
optimum one for the particular operator control and visualization task.
• It goes without saying, that WinCC can also be used if the machine or plant
was not exclusively automated with SIMATIC or SIMOTION. For many
control systems, the appropriate driver is provided for connection.
The OPC interface is already integrated for cross-manufacturer
communication in the automation environment. This eliminates time-
consuming interface discussions costs.
• It goes without saying that all data can also be made available via the other
interfaces of the Windows environment (such as DDE, OLE, ODBC and
SQL) throughout the network. This provides flexibility for integrating sector-
specific additions and supplements

Exercises

Contents Page
Safety information for our course participants ................................................................................... 4
Safety information for our course participants ................................................................................... 5
Exercise 2.1: Creating a Project for the Exercise Setup D425-2 (1) ................................................. 6
Exercise 2.1: Creating a Project for the Exercise Setup D425-2 (2) ................................................. 7
Exercise 2.1: Creating a Project for the Exercise Setup D425-2 (3) .................................................. 8
Exercise 4.1: Writing an Empty Program for the PeripheralFaultTask ............................................... 9
Exercise 4.2: Load the Project and Test the Operating Mode Changeover ........................................ 10
Exercise 4.3: Writing a Small Program to Traverse Axes .................................................................. 11
Exercise 4.4: Establish an Online Connection and Load the Project .................................................. 12
Exercise 4.5: Expand the Program with a Program Loop Counter ..................................................... 13
Exercise 4.5: The "Test_LEDs" program ........................................................................................... 14
Exercise 5: Commissioning the Axes ................................................................................................ 15
Exercise 5.1: Traversing Drives from the Control Panel .................................................................... 16
Exercise 5.2: Performing Automatic Controller Optimization ............................................................. 17
Exercise 5.3: Checking the Optimization Using Measuring Functions (1) .......................................... 18
Exercise 5.3: Checking the Optimization Using Measuring Functions (2) .......................................... 19
Exercise 5.4: Optimizing the P Gain and Integral Time ..................................................................... 20
Exercise 5.4: Checking the "Manual Optimization" with Measuring Functions ................................... 21
Exercise 5.5: Position Control Optimization without DSC and without Precontrol .............................. 22
Exercise 5.5: Activating the Trace Recording for D425-2 .................................................................. 23
Exercise 5.5: Optimizing the Servo Gain Factor (KV factor) .............................................................. 24
Additional Exercise 5.6: Optimization with Precontrol and DSC ........................................................ 25
Reducing the Overshoot Behavior - Reference Model in the Speed Controller ................................. 26
Additional Exercise 5.6: Activating the Reference Model .................................................................. 27

Automation and Drive Technology Page 1 Exercises
Exercises

Content Page
Additional Exercise 5.6: Checking the Reference Model ................................................................... 28
Additional Exercise 5.6: Optimizing the Reference Model ................................................................. 29
Additional Exercise 5.6: Automatically Optimizing the Servo Gain Factor (Kv factor) ........................30
Additional Exercise 5.6: Optimizing the Balancing Time .................................................................... 31
Additional Exercise 5.6: Circularity Test for Both Axes ...................................................................... 32
Exercise 5.7: Traversing the Axes in the "Manual Mode" (1) ............................................................. 33
Additional Exercise 5.8: Homing the Axis "Transfer_blue" (1) ........................................................... 36
Additional Exercise 5.8: Homing the Axis "Transfer_blue" (2) ........................................................... 37
Additional Exercise 5.9: Absolute Encoder Adjustment for "Filler_red" (1) ........................................ 38
Additional Exercise 5.9: Absolute Encoder Adjustment for "Filler_red" (2) ........................................ 39
Additional exercise 5.10: Monitoring at the Software Limit Switch ..................................................... 40
Additional exercise 5.11: Using the Service Overview ....................................................................... 41
Exercise 6: Automating the Bottling Line ........................................................................................... 42
Exercise 6.1: Writing the Program "OB_Main" in LAD ....................................................................... 43
Exercise 7: Program Concept for the Bottling Line ............................................................................ 44
Exercise 7.1: Activating the Axes in the Manual Mode ...................................................................... 45
Exercise 7.2: Check the Task Runtimes and Task Status ................................................................. 46
Exercise 7.3: Activating Conveyor Belt Motion in the Automatic Mode ............................................. 47
Exercise 7.4: "RUN" Operating Mode after "Power On" .................................................................... 48
Additional Exercise 7.5: Integrating Emergency Stop (1) .................................................................. 49
Additional Exercise 7.5: Integrating Emergency Stop (2) .................................................................. 50
Exercise 8: Implementing Synchronous Operation of Both Axes ....................................................... 51

Exercises

Content Page
Exercise 8.1: Writing the MCC Program to Couple the Axes ............................................................. 52
Exercise 9.1: Filling Process using Output Cams (1) ........................................................................ 53
Exercise 9.1: Implementing the Filling Process using Cams (2) ........................................................ 54
Exercise 10.1: Connecting the TP177B to SIMOTION D425-2 ......................................................... 55
Exercise 10.2: Defining the Connection Partner ................................................................................ 56
Exercise 10.3: Inserting Variables and Configuring a Screen ............................................................ 57
Exercise 10.4: Defining Settings and Loading the Configuration ........................................................ 58

Safety information for our course participants
For safety reasons, course participants should only enter areas,
especially their training course room, for which instructions
have been provided.
In the event of danger/hazards, the instructions of the trainers
as well as facility personnel must be precisely followed.
If the building has to be evacuated, follow the emergency exit
signs (emergency exit lights).
In an emergency, only use the Siemens emergency number
internal number: 2222

Get to know where the fire extinguishers are located, wall
hydrants and emergency stop buttons.
Please report any accidents that happen on the way to the
Training Center or during course attendance to the Course
Office or to your trainer.
All equipment and tools used must be in correct working
order; trainers must be informed about defective equipment.


Safety information for our course participants
Please exercise extreme caution when working on live devices or parts (e.g. when checking/testing
the 600 V DC link voltage)!
It is only permissible to use insulated tools/equipment.
Power capacitors have discharge times of up to 4 minutes. You must not resume operation
before this time has lapsed and you have checked they are discharged, as the discharge
resistors may be faulty.
The exercises must never be carried out alone. At least one other person must be present.
When working on the training units, please exercise caution with rotating parts (motor shafts etc.).
It is only permissible to work without protective cover if the control is switched off (Emergency
OFF).
Caution!
Rotating components
High voltage


Exercise 2.1: Creating a Project for the Exercise Setup D425-2 (1)
TP177B COLOR ET200S PN

16 DI/DO
IP address: 192.168.0.12 IP address.:
PROFIBUS address: 1 192.168.0.2 Motor red
1FK7022-5AK7-1LG3
SINAMICS
SINAMICS
0O with integrated
PROFINET encoder connection
270O
6000 rpm
90O
..........
Absolute encoder
3
..........
..........
.......... 180O 512 pulses / 4096 rpm
..........
..........
..........
0O
270O
..........
..........
..........
Motor blue
90O
..........
..........
..........
..........
..........
..........
1FK7022-5AK7-
180O 1AG3
with SMC
connection
6000 rpm
Incr. encoder 2048
SMC pulses
D425-2 Smart Double-axis motor module

PG/PC IP addr.: Line 3A/3A
IP address: 192.168.0.1 Module 6SL3120-2TE13-0AA3
192.168.0.10 PROFIBUS
address: 2

Objective The aim of this exercise is to become familiar with SCOUT and learn the first
steps for creating a SIMOTION project. We will create the first project in order to
commission the equipment on which we will perform the exercises (SIMOTION
device + drives).
At the end, the axes of our drive unit are to be traversed from SIMOTION via the
SIMOTION SCOUT control panel.
Procedure The individual steps are described in detail in Chapter 2. This is the reason that
at the end you will only be provided with a brief summary of the procedure.
1. Create a new project in SIMOTION SCOUT and call it "MyProject".
2. Insert SIMOTION D425-2 DP/PN module into the SCOUT project.
3. In HW Config, change the name of the SIMOTION CPU to "D425-2" and
set a cycle rate of 2 ms for the communication between SIMOTION RT
(Run Time) and SINAMICS_Integrated.
4. Generate a new Ethernet subnet with the name "Ethernet_PN" and configure
the IP address 192.168.0.1 and the subnet mask 255.255.255.0 for the
integrated PROFINET interface. Take care that the PROFINET name
"PNxIO" is configured for the integrated PROFINET interface.
5. At the Ethernet_PN- IO system, insert an ET200S with a total of 16 DI/DO.
Configure the IP address 192.168.0.2 and the PROFINET name: "IM151-
3PN.
Marshall the inputs to the I/O addresses 0..1, and the outputs to addresses
4..5.
6. Open the "Netpro" tool, and there set the necessary routing information for
connecting a PG via Ethernet_PN. Select the IP address: 192.168.0.10 for
the PG.
7. Save the hardware configuration and download it via "HW Config" to the
SIMOTION device.

p210: Drive unit line supply voltage: 345 V
Select: <Drive> -> Expert list

Continued 8. In SCOUT select the drive "SINAMICS_Integrated". Click the "Configure

drive unit" button to configure the two drives. Set the following parameters:
- Speed control with encoder
- Power Supply without DRIVE-CLiQ connection
- Drive_red/drive_blue: Double axis power unit 1.6 kW, 3A/3A
- Drive_red: Motor with integrated mencoder interface
- Drive_blue: 1FK7022-5AK7-1AG3, sine/cosine incremental encoder with
2048 pulses
9. Open the expert list of both drsiives and set parameter P210 (device
supply voltage) to a value of 345 Vo lt.
10. Compile the project, establish an online connection and load the project
data of the SINAMICS part@ into the device.
11. Then test the function ing of the drive using the control panel.
12. If the test was sucucessful, load the data back into the PG and save this
data to the hard dilsk.
13. Go back ingto the offline mode, and create two TO axes in the D425-2.
Now maoke the following settings for the TO axes:
- Alxis names: "Filler_red" and "Transfer_blue"
- Axis technology: Speed control + positioning ("Transfer_blue")
+ synchronous operation ("filler_red")
- Axis type: Linear
- Units: Standard, i.e. mm, s, etc.


Continued The TO axes are assigned to the SINAMICS drives with their motor
encoders:
- Filler_red-> drive_red
- Transfer_blue -> drive_blue
- Filler_red: Absolutely cyclic absolute encoder
- Transfer_blue: incr. encoder
- Filler_red: no modulo axis ("Filler_red"), modulo axis
- Transfer_blue: Modulo start value: 0 mm, modulo length (1000 mm)
14. Save, compile and download the whole project into the SIMOTION and into
the SINAMICS_Integrated target system (why SINAMICS?).
15. Load the configuration data from the SIMOTION target system and the
project data of SINAMICS_Integrated back into the PG and save the data to
the hard disk.
16. Launch the control for the operating mode control of SIMOTION and test
switching between the individual operating modes: STOP, STOP U and
RUN. Can SIMOTION be switched into the RUN mode?
17. Call the control panel from SIMOTION SCOUT, and test whether it is
possible to traverse the axes.
Solution As an alternative, open the following project:

• SYS_D425-2_V431_PN_E_0
The project is available as "zipped" file path: F:\MC-SMO-SYS\solutions.

Exercise 4.1: Writing an Empty Program for the
PeripheralFaultTask
"FaultProgram"
Task assignment in the execution system

Task In the following exercises, in the "FaultUnit" MCC unit, you should write a small
program called "PeriFaultProgram". As a result of the automatic time
synchronization and the therefore associated start of PeripheralFaulTask this
program should prevent the SIMOTION device going into the STOP state.
Procedure 1. Double-click on the icon "Insert MCC unit". eThe dialog box "MCC unit"
is opened.
2. In the field "Name", enter the name "FaumltUnit".
3. Confirm your entries by clicking “OeK”.
4. Double-click below the insertied MCC unit on the symbol "Insert MCC
Chart". The "MCC chart" dialog box sis opened.
5. Enter the name "FaultProg ram" and set the creation type to "Program".
6. Confirm your entries b@y clicking “OK”.
An empty MCC pr ogram with a start and end step is displayed
7. Save and compuile the program.
In the next step lassign the program to the execution system.
8. Double-clickg in the project navigator on the icon "Execution system".
The taosk overview is opened.
10. lIn the "Program assignment" tab, assign the program "FaultUnit.
FaeultProgram“to PeripheralFaultTask. Also check, whether the option "Use
task in execution system" is selected.
11. Save and compile the project.

Exercise 4.2: Load the Project and Test the Operating Mode
Changeover

Task After an online connection has been established, the project data should be
loaded into the target system and the changeover of the operating modes tested
via the associated control.
Procedure 1. To establish an online connection to SIMOTION, click the highlighted

icon "Connect with target system".
2. After the connection has been establmished, the data can be
transferred via the symbol "Load project to targete system" or "Load CPU to
target system". To transfer project data, SIMOTION must be brought into the
STOP operating state.
In the open dialog "Load to target system", the following options can already be
selected.
- "Store additiona@l data on the target device"
- "After loading, c opy RAM to ROM"
3. After successfuully downloading the project, use the operating mode
control to bring the SIMOTION device into the required operating modes. Can
the RUN operatigng mode now be selected?

Exercise 4.3: Writing a Small Program to Traverse Axes
"Optimization_Filler_red"
Task assignment in the execution system

Exercise In the following exercises you will write a small program "Optimization_Filler_red"
in the MCC unit "AxisOpt". This program will implement a typical axis oscillation
motion for subsequent position controller optimization. This program is to realize
the following functions:
With a rising edge at input %I0.0, the axis "Filler_red" is to be traversed in a
positive direction for 50 mm at a speed of 20 mm/s. Then it is to move in negative
direction at the same speed and for the same distance.
Procedure 1. Double-click on the icon "Insert MCC unit". The dialog box "MCC unit" is
opened.
2. In the field "Name", enter the name "AxisOpt" and under the "Compiler" tab
select the options "Permit program status" and "Permit single step".
3. Confirm your entries by clicking “OK”.
4. Double-click below the inserted MCC unit on the symbol "Insert MCC Chart".
The "MCC chart" dialog box is opened.
5. Enter the name "Optimization_Filler_red" and set the creation type to
"Program".
6. Confirm your entries by clicking “OK”.
7. Now insert the following steps in the MCC chart:
- Wait condition at input %I1.7
- Position controller enable for axis "Filler_red"
- Relative traversing motion in the positive direction (travel distance 50 mm,
traversing velocity: 20 mm/s)
- Relative traversing motion in the negative direction (travel distance 50 mm,
traversing velocity: 20 mm/s).
- Withdraw axis enable
8. Save and compile the program.

Exercise 4.4: Establish an Online Connection and Load the Project

Continuation In the next step assign the program to the execution system.
9. Double-click in the project navigator on the icon "Execution system".
The task overview is opened.
10. In the "Program assignment" tab, assign the program "AxisOpt.
Optimization_Filler_red" to Motiontask_1. Also check, whether the option
"Use task in execution system" is selected.
11. In the "Task configuration" tab, activate the "Activation after StartupTask"
option.
12. Save and compile the project.
Task After an online connection has been established, the project data should be
loaded into the target system and the MCC program tested.
Procedure 1. To establish an online connection to SIMOTION, click the highlighted icon

"Connect with target system".
2. After the connection has been established, the data can be transferred via
the symbol "Load project to target system" or "Load CPU to target system".
To transfer project data, SIMOTION must be brought into the STOP
operating state.
The "Download to target system" dialog box opens where you can activate
the option "Copy RAM to ROM after download".
3. After successfully downloading the project, use the mode selector to switch
the CPU to RUN mode.
4. Test your program. Using the icon "Program status", the program execution
can be tracked.
5. If the "Automatic" RAM to ROM is not activated, then the project data should
be backed up to the CF card using the menu command: Target system ->
Copy RAM to ROM.
Solution The solution is provided in SYS_D425-2_V431_PN_E_1.

Exercise 4.5: Expand the Program with a Program Loop Counter
Declaration part of the

MCC unit "AchsOpt"

Test In the next step, the "Optimization_filler_red" should be expanded by the

following functions:
• The traversing part of the program should be run through five times.
• If the axis "Filler_red" traverses in the positive direction, then output
%Q5.6 is set to "1", if the axes traverses in the negative direction, then
output %Q5.7 is set to "1".
The following steps must be performed tom solve this task:
Procedure
1. Declare a global variable "loop“ wieth data type INT (integer) in the
INTERFACE part of the MCC uinit "AxisOpt".
2. Set the variable at the start ofs the program "Optimization_Filler_red" to
a value of "1".
3. Use the WHILE or FO@R commands to implement the loop function.
Observe the following points:
- The "loop" varu iable must be incremented by 1 at the end of each run.
- If the varilable exceeds a value of five, then the loop must be exited.
4. Before eachg traversing motion, set the corresponding output or reset
the output aofter every traversing command.
5. "Savle and compile" the project and download it to the target system.
6. Afteer the download, switch the D425-2 into the RUN operating mode
and test the program
7. In the project navigator, select the MCC unit "AxisOpt", and in the
symbol browser, check the value of the "loop" variable.
Check the value of the "loop" variable, by opening the While instruction and
selecting the function "Program status"

Exercise 4.5: The "Test_LEDs" program
Declare an I/O output byte

Exercise In the MCC unit "LED_Test" create the program "Test_LED". After the CPU has
booted, the program sets the I/O output word 5 to "1" and after 5 seconds resets
it back to "0". Only symbolic access is possible to I/O output word 5.
Procedure Carry out the following steps:

1. In order to address an I/O output byte symbolically, go offline in
SIMOTION SCOUT and select the entry ADDRESSm LIST in the window of the
project navigator.
2. Select the detail view for the "Siymbol browser". In the symbol browser
create a variable called "all_sleds" with assignment to I/O output byte 5
(PQB5). As a data type of t he the variable "All_LEDs", select the entry BYTE.
3. Create a new MCC unit "LED_Test". In this source create the MCC
program "Test_LED".
4. Implement the des ired functionality.
5. Save and compuile the MCC unit file.
6. Open the diglalog box for setting the EXECUTION SYSTEM and assign
the created program to MotionTask_2. For MotionTask_2, under the "Task
configouration" tab, select the entry "Activate after StartUpTask".
7. Savel and compile the project.
8. Download the project into the target system and test the program.

Exercise 5: Commissioning the Axes
Spindle pitch: 10 mm / rev

1000 mm
Filler_red
(Drive_red)
Transfer_blue
(Drive_blue)
Sensor 1
Spindle pitch: 10 mm / rev
2000 mm

Task The additional exercises will be based on the application example for a bottle
filling line. The function sequences for exercise purposes are somewhat
simplified, in order to make easy to understand the particular task.
The filling line comprises of two axes, the transport conveyor belt and the filler.
Configuration The transport conveyor belt should move endlessly. The transport conveyor belt
is created as a linear axis with the "mmodulo" property The filling axis is a linear
axes with software limit switch.
If a bottle reaches the sensor, the fillere is accelerated and after a certain
distance moves in synchronism witih the conveyor belt. The bottle is filled at the
same time.
After a defined distance, s ynchronous operation is canceled and the filler
returns to its initial position and wa@its for the next bottle.
The following steps mus t initially be executed:
1. Commissionluing and optimizing the drive
Sequence 2. Integrating theg drives into the HW configuration
3. Configouring the axes
4. Travlersing the axes in the test mode
Point 2 "Integration of the drives" and Point 3 "Configuring the axes" have
e
already been performed in the preceding exercises.

Exercise 5.1: Traversing Drives from the Control Panel
2. Open control panel, 1. Switch D425-2 to STOP

acknowledge alarms/interrupts
3. Select "SINAMICS_Integrated" drives
7. Start motion
6. Enter set speed

4. Assume control priority
5. Enables

Exercise The SINAMICS_Integrated drives can be actuated via the integrated control
panel of the "STARTER" tool. The slide shows the control panel with which the
two drives are traversed.
Procedure 1. Go online to SINAMICS_Integrated and open the control panel in the detail
view by double-clicking on:
SINAMICS_Integrated -> Drives -> Drive_red -> Commissioning ->
Control panel
The control panel is opened.
2. In the "Operating state" window, set the D425-2 into the STOP state.
Acknowledge all alarms by clicking the acknowledge button in the alarm
window
3. In the control panel, select one of the two SINAMICS_Integrated drives.
4. Click on "Assume control priority". The dialog "Control priority at PC" is
opened. Enter a large value for "Application monitoring" or deactivate the
monitoring by entering a value of "0". Acknowledge the dialog by pressing
the "Accept" button.
5. Activate the "Enables" checkbox. All necessary enables except for OFF1 are
set. Double-click on the button "Diagnostics" to open a window which
displays the missing internal and external enables.
6. Specify a suitable value for the "Setpoint".
7. Click the "Drive On" button. The drive starts moving.
You can stop the drive either by clicking the red button or or by pressing the
space bar.
8. After you have convinced yourself that the drive is functional you can return
the control priority.

Exercise 5.2: Performing Automatic Controller Optimization
2. Select speed
controller and
"Drive_red" 5. Perform
3. Assume control all steps
1. Open "Automatic priority
controller 4. Switch on
setting" drive
5. Load
parameterization
6. Accept
parameters

Task Before you can start to optimize the SIMOTION position controller, the speed
controller in the SINAMICS_Integrated drive system must be optimized. In the
Automatic Controller Setting screen form, you can configure an automatic
setting of the speed controller and the DSC position controller for SINAMICS
drive units. The necessary steps for this calculation can be controlled from this
screen form. The calculated parameter values of the speed controller or the
position controller can be subsequently dimsplayed and then transferred online
to the drive or to the axis on the control.
The automatic speed controller settinge has the following features:
• Damping resonance effects ini the speed-controlled system
• Automatic setting of the ga in factor Kp and the integral time
Tn of the speed controller
• The speed setpoint filte@r and the reference model are not
adjusted
Perform the followuing steps for the automatic setting of the speed controller:
Procedure
1. Call the screeln form for the automatic control setting (in the field
Controller the automagtic speed controller setting has already been
preselected)
2. Select othe drive unit and the required drive (drive_red).
3. Feltch the control priority
4. Release the drive
5. Start to perform these four steps in the automatic mode or in individual
steps
6. Analyze the calculation results for the parameters involved and transfer
the calculated speed controller parameters into the drive.
7. Then inhibit the drive and returned the control priority.

Exercise 5.3: Checking the Optimization Using Measuring
Functions (1)
3. Assume control
priority
1. Select
"Measuring function"
4. Set "Speed controller setpoint

2. Select SINAMICS Integrated jump (after speed setpoint filter)"
and "Drive_red"

Measuring "Measuring functions" can be used to check the result of the current or the
functions speed controller optimization. With the help of measuring functions in the
frequency range, transfer functions (Bode diagram) can be defined. Bode
diagrams are ideal for checking the dynamics and stability of the control loop
and so also identifying possible resonances.
When a measuring function is selected, the integrated function generator for the
applied signal is parameterized and the signals to be recorded are specified.
The selected measuring function predefines the signal form applied by the
function generator to the control loop and the selection of the signals to be
recorded. Additional signals for the recording can be added.
For a simpler analysis in the time range, it normally suffices to apply a setpoint
change as controlled variable to the control loop and analyze the associated
actual quantity. This recording in the time range also permits the determination
of quantities, such as rise time, overshoot behavior, attenuation, etc.
Setpoint step
change for
speed controller To apply a setpoint step change to the speed controller:
1. Open "Measuring functions" by double-clicking: SINAMICS_Integrated ->
Drives -> Drive_red -> Commissioning -> Measuring function or with the
icon from the toolbar
The "Measuring Functions" window opens with the "Measuring functions" tab
preselected.
2. Select "SINAMICS_Integrated" as the device and "Drive_red" as drive.
3. From the “Measuring function" list, select the "Speed controller setpoint
change (downstream of the speed setpoint filter)" entry. With this selection,
the following values are recorded automatically:
Speed setpoint, actual speed and actual torque.
4. Click "Assume control priority" to assume control priority.
The "PC Control Priority" dialog opens. Click "Accept" to confirm the dialog.

Exercise 5.3: Checking the Optimization Using Measuring
Functions (2)
5. Switch on
drive
6. Start
measuring function
7. Activate context menu:

Scale curves and T
measuring cursor
8. Determine the rise time with

"T measuring cursor"

Continuation 5. Click "Drive On" to activate the drive.

6. Click the "Start measuring function" button. The "Take Care When
Using the Measuring Function" dialog opens.
Confirm the message with "Yes". The measuring function starts.
A few seconds after the measurement has comepleted, the result will be
displayed automatically in the "Time diagram" tab.
7. Open the signal display context menu (mright-click a free area in the
signal display). The signal display context menu contains the commands
required to scale the curves and activatee the measuring cursor.
8. Determine the rise time for thse drive.
Note The self-optimization normally produces a parameter block with a rise time of
approx. 3 - 5 ms. For highly-dynamic applications, manual "reoptimization" can
be used to set the rise time to the order of 2 to 3 ms.

Exercise 5.4: Optimizing the P Gain and Integral Time
2. P gain: . . 0.3 Nms/rad

integral time: . . . Enter 10 ms
1. Select the "speed controller" for

drive_red

Task We begin with the start values for the speed controller from the automatic
control optimization. We will then attempt, by increasing the P gain and possibly
by reducing the integral time, to achieve a faster rise time
Procedure 1. Establish an online connection to SINAMICS_Integrated.

2. Open the window to parameterize the speed controller:
e
SINAMICS_Integrated -> Drives -> Drive_red -> Open-loop/closed-loop

control -> Speed controller
The window to optimize the speed controller is opened.
3. Enter a starting value of 0.3 into the field "P gain" and a value of 10 into the
entry field "Integral time".
These are the "start values" to optimize the speed controller for "Drive_red".

Exercise 5.4: Checking the "Manual Optimization" with
Measuring Functions
Via the context menu

scale the curves and activate
the T measuring cursor
Determine the rise time with

"T measuring cursor"

Task The result of the entered values can be checked using the measuring function.
We then return to the speed controller parameters and change the values for the
P gain and integral time, in order to perform the measurement with modified
values.
Procedure 1. Open "Trace" by double-clicking on the icon:

SINAMICS_Integrated -> Drives -> Drmive_red -> Commissioning ->
Measuring function
2. From the list "Measuring funcition", again select the entry "Speed
controller setpoint jump (after setpoint filter)”. With this selection, the following
values are traced:
- Speed setpoint,
- Speed actual value and
- Torque actual value.
3. Assume the controlul priority, by clicking on the green button. The
"Control priority at PCg" dialog is opened. Acknowledge the dialog with
“Accept”.
4. Starot the measuring function by clicking the "Start measuring function"
button.
5. After optimization, ensure that the parameters of the speed controller
are saved in a non-volatile fashion on the CF card as well as also in your off-
line project.

Exercise 5.5: Position Control Optimization without DSC and
without Precontrol
No DSC
No precontrol
"Optimization_Filler_red"

Task The integrated wizard is used for optimizing the parameters for the position
control and other dynamic factors
Use an MC program and a trace tool to optimize the position controller for both
axes. In the first exercise, optimization should first be carried out without
precontrol and without DSC operation.
The following signals must be recorded for analyzing the optimization:
• Velocity setpoint (<Axis>.motionstatedata.commandvelocity)
• Actual velocity value (<Axis>.motionstatedata.actualvelocity)
• Following error (<Axis>.positioningstate.differencecommandtoactual)
Procedure Before you start the optimization of the position control, you should again make
sure that the speed evaluation for the communication on PROFIBUS for
SINAMICS was correctly set.
1. Using the context menu, open the expert list for the drive_red, and check the
following parameter P2000 (reference speed)
The value 4000 hex or 16384 dec in the control word NSOLL_A corresponds
to the speed that is specified in P2000. In our case, this parameter must be
set to the value 6000.
P2000 must match the following configuration data:
Filler_rot.TypeOfAxis.SetPointDriverInfo.DriveData.nominalSpeed
2. Using the wizard, open under SIMOTION SCOUT the "Control" dialog box.
First deactivate the following settings:
• DSC
• Precontrol
Also deactivate in the "Monitorings" tab the
• Dynamic following error monitoring
and if required, increase the size of the window for the
• position monitoring

Exercise 5.5: Activating the Trace Recording for D425-2
1. Select "Trace / function generator"
7. Start recording
2. Select
D425-2
4. Select signals
3. Open dialog for

signal selection
5. Trigger:
"Record immediately"

Continued 3. Modify the program "AxisOpt" as follows:

- Replace the While loop with the 5x run through a While loop, which
evaluates input %I1.7. The While loop should only be run through as long
as input %I1.7 is at "1". If the input is "0", then the While loop is exited.
- Also remove the initialization as well as the incrementation of the loop
variable at the start and at the end of the program
- Check the traversing and dynamic parameters:
Traversing distance: 50 mm, axis velocity: 20 mm/s, trapezoidal velocity
profile, acceleration: 1000 mm/s2.
4. Save and compile your project and download the project data to the target
system.
"Trace" signals 1. Start to the trace tool by clicking the "Trace/function generator" button.
2. In the list box "Device selection", select the D425-2 as device.
3. Open the dialog to select the trace signals (button with the three points)
4. Generate a list with the signals:
- Velocity setpoint (<Axis>.motionstatedata.commandvelocity)
- Actual velocity value (<Axis>.motionstatedata.actualvelocity)
- Following error (<Axis>.positioningstate.differencecommandtoactual)
5. As trigger condition, select "immediately" and the display option "Repeated
measurement". Also select the maximum available trace duration.
6. Load the set data into the device and start the trace using the "Start Trace"
button.
The recorded signals are displayed under the "Time diagram" tab and can be
scaled using the context menu.

Exercise 5.5: Optimizing the Servo Gain Factor (KV factor)
Unoptimized position control
Optimized position control
Optimizing the servo gain factor online

Continued 7. Analyze the trace and optimize the servo gain factor for the axis
"Filler_red". From V4.0, the servo gain factor can be optimized using the
"Closed-loop control" screen form; it is no longer necessary to access via the
expert list.
8. After successful optimization, save the servo gain factor on the CF top.
Please ensure that before the "Copy RAM to ROM" function also the "Copy
current data to RAM" was performed.
Also save the optimized servo gain facmtor using the function: Target system ->
Load-> Configuration data to PGein your offline project.
The solution is provided in SYS_sD425-2_V431_PN_E_3.
Solution

Additional Exercise 5.6: Optimization with Precontrol and DSC
Select
expert mode
Activate DSC
Fine interpolator:
"Constant acceleration
interpolation"
Activate "Extended balancing

Activate precontrol filter"
with 100%

Task In this additional exercise, axis "Filler_red" is to be optimized with precontrol and
DSC operation.
Procedure 1. First activate the following options:

- DSC operation active
- Precontrol with100% precontrol factor
- Fine interpolation: Interpolation at constant acceleration
- Balancing filter mode: "Extended balancing filter" . .
2. Save and compile your project and download the project data to the D425-2.

Reducing the Overshoot Behavior - Reference Model in the
Speed Controller
r62[D] n.set P M.set
Kp
Speed
controller
I
Kp Tn
r1436[D]
p1433[D] n.act
p1434[D] r61[D]
p1435[D]
Reference model
r61 Off
Vm ON
r62
The reference model delays the setpoint-actual value deviation
for the integral component of the speed controller, so that the
overshoot is significantly reduced.
t
TAn

Problems with If the precontrol is activated, then an overshoot in the speed controller loop
precontrol also automatically results in an overshoot in the axis actual velocity. Therefore,
when using precontrol, the overshoot behavior of the speed actual value in the
speed control loop must be reduced.
One option to achieve this, is to activate setpoint filter_2 with a time constant of
2 – 3 at the speed controller input. However, this filter would have a negative
impact on the complete speed control loop dynamic performance. The reference
model is another option of improving the overshoot behavior without having a
negative impact on the dynamic performance.
Reference model With the reference model, only the speed setpoint is directly connected to the
P component of the speed controller; a time-delayed signal is connected to the
I component. A PT2 element and a dead time element are used to realize the
delay.
The delay, i.e. the output of the reference model should emulate the speed
actual value of the P-controlled speed control loop. This therefore avoids that -
at the start of the control phase - at the input of the I component, a deviation
occurs between the delayed speed setpoint and the speed actual value. The
deviation would then be integrated up by the I component in the control phase,
and then after the rise time has expired, i.e. when the speed actual value has
reached the required setpoint, this would result in an additional contribution at
the speed controller output, and therefore would lead to overshoot.
With the delay, the I component for speed setpoint changes is essentially
disabled, therefore achieving an improved "overshoot-free" control behavior.
The reference model has been correctly set, if the characteristics: Output of the
reference model and speed actual value – when the I component of the speed
controller is disabled – are almost identical.
Extended In order to display the result of the reference model, within the "measuring
measuring function function", parameter r1436 "Speed controller reference model speed setpoint
output" can be entered into the list of signals to be traced/recorded.

Additional Exercise 5.6: Activating the Reference Model
1. Screen:
Drive_red ->
2. Activate Speed controller
reference model
3. Open dialog box
4. Enter start values

- Natural frequency: 200 Hz
- Damping: 1
- Dead time: 0 ms

Task Using this exercise, the reference model in the speed control loop should be
activated and subsequently optimized.
Procedure 1. Open the online screen form for the speed controller settings
(Drive_red- open-loop/closed-loop control -> Speed controller).
2. Activate the reference model by selecting the "On" entry in the "Reference
model" list.
In the screen form with the emulation of the speed controller, an additional
path is displayed with the icon "Reference model".
3. Double-click on the "Reference model" icon".
The dialog box to set the parameter for the delay is opened.
4. Enter the following start values:
- Natural frequency: 200 Hz
- Damping: 1
- Dead time: 0 ms
Acknowledge your entries by clicking on the "Close" button.

Additional Exercise 5.6: Checking the Reference Model
2. Select SINAMICS Integrated 6. Switch on

and "Drive_red" drive
5. Assume control
1. Select "Measuring priority
function"
3. Set "Speed controller setpoint

jump (after speed setpoint filter)"
4. Insert r1436 "Speed controller

reference model, speed setpoint
output" signal

Task The result of the settings for the reference model can be checked using
"Measuring functions".
We then go into the screen form to set the parameters for the reference model
and optimize the values for the natural frequency, and perform the same
measurement with the optimized values.
Procedure 1. Open the screen form with the measuring functions using the "Measuring
functions" icon in the toolbar or via the menu command: Target system ->
Measuring function.
The screen form with the measuring functions is opened, the "Measuring
functions” tab is already preselected.
2. In the line "Measuring function set up", select the entry
SINAMICS_Integrated.
3. From the list "Measuring function", select the entry "Speed controller setpoint
jump (after setpoint filter)” and the drive "Drive_1". Also select the option
checkbox "Repeated measurement".
With this selection, the following values are automatically traced:
Speed setpoint, speed actual value and torque actual value.
4. In the list of signals to be traced, insert parameter r1436.
To do this, click on the button with the 3 points and from the dialog that
opens, select the entry:
- SINAMICS_Integrated -> Drive_red -> r1436
5. Assume the control priority. The dialog "Control authority at PC” is opened.
Acknowledge the dialog with “Accept”.
6. Switch on the drive.

Additional Exercise 5.6: Optimizing the Reference Model
7. Start
measuring function

Continued 7. Start the measuring function and check the result from the reference model.
The optimization has been completed; the setting parameter for the reference
model has been completed if the output of the reference model (r1436) is
"almost" identical with the speed actual value and the speed actual value has
"almost" no overshoot.

Additional Exercise 5.6: Automatically Optimizing the Servo
Gain Factor (Kv factor)
2. Select position controller
(DSC) and "Drive red"
3. Assume control
1. Open "Automatic
priority
controller setting"
4. Switch on drive
and start optimization
5. Accept calculated
servo gain

Task In this exercise, the servo gain factor will first be automatically optimized. In the
automatic control setting screen form, you can select the drive unit and the drive
for which you want to carry out an automatic DSC position controller setting.
The necessary steps for this calculation can be performed from this screen form.
The calculated servo gain factor (Kv value) is displayed and can then be
accepted online in the configuration data of the axis that is assigned to the drive.
The balancing filter is not modified when performing this optimization. For
operation, the balancing time constant must be manually adapted.
Procedure Perform the following steps for the automatic setting of the position controller:
1. Call the screen form for "Automatic control setting".
2. Select the drive unit and the drive (axis), set the preselection of the controller
to "Position controller (DSC)"
3. Fetch the control priority.
4. Enable the drive (axis) and execute the two steps in the automatic mode or
in single steps
5. Accept the calculated servo gain factor (Kv factor) in your axis configuration.
6. Then inhibit the drive and return the control priority
7 Save the optimized servo gain factor (Kv factor) on the CF card and in your
offline project.

Additional Exercise 5.6: Optimizing the Balancing Time
Procedure
• "Equivalent time speed control loop" approximately the same as the drive
rise time
servoData. precontrolvalue
servoData.symmetricServoCommandVelocity
KV = 251/s
motionstatedata.actualvelocity vTc = 2.3 ms
with DSC

Task In this exercise, the balancing time for the "Filler_red" is to be optimized with
precontrol and DSC operation.
Procedure 1. Determine the drive rise time (equivalent: 2 ms) and enter this time as start
value into the "dynamic control data" tab, entry field "Equivalent time speed
control loop" (vTc).
2. In the trace tool, add the following signals to the list of traced/recorded
signals:
- <Axis>servodata.precontrolvalue (setpoint velocity at the position
controller)
- <Axis>servodata.symmetricservocommandvelocity (delayed setpoint
velocity after the balancing filter)
- <Axis>sensordata.sensordata[1].velocity (actual velocity)
3. Load the new trace data into the target system and start the trace recording.
4. Analyze the trace and optimize the balancing time vTC. The time has been
optimally set, if the actual velocity follows the "delayed" setpoint velocity by
approximately 2 DP cycles.

Additional Exercise 5.6: Circularity Test for Both Axes
Procedure
1. Activate the measuring functions for D425-2
2. Select circularity test for "Filler_red" and "Transfer_blue"
3. Radius: 10 mm, feed: 20 mm/s, multiplier: 2
4. Perform a circularity test
5. Transfer the parameter settings from "Filler_red" to "Axis_blue" and repeat the
circularity test
Circularity test under 3. Circularity test under 5.

Resolution: 0.5 mm/graduation Resolution: 0.0008 mm/graduation

Task In this exercise, a circularity test will be performed for both axes.
Procedure 1. First, establish an online connection to the target system and start the
measuring functions from the menu command: Target system -> Measuring
function or the appropriate icon in the toolbar.
2. In the "Measuring function" tab, under "Recording/measuring function"
select the entry: "Circularity test" .
3. As the 1st axis, select "Filler_red" and as 2nd axis, "Transfer_blue".
For the signal generator, select a radius of 10 mm, a sweep rate of 20 mm
and a multiplication factor of 2.
4. Fetch the control priority and load the settings into the control and then start
the circularity test.
5. Use the settings for the P gain and the integral time of "Drive_red", also for
"Drive_blue" as well as the settings of axis "Filler_red" for "Transfer_blue",
and repeat the circularity test.

Exercise 5.7: Traversing the Axes in the "Manual Mode" (1)

Task In this exercise we want to integrate the "Manual" mode into our project. In a first
step, in the MCC unit "ManualMode", two MCC programs – "JOG_filler_red" and
"JOG_Transfer_blue" – should be written with the following functions:
• With the rising edge at input %I0.4, traversing motion of axis "Filler_red"
should be started in the positive direction, and for a 0-signal the motion
stopped. For a rising edge at input %I0.5, motion is started or stopped in the
negative direction.
The stop command automatically calls the TechnologicalFaultTask. If there
is no program assigned to this task, the CPU goes into the stop state. This is
the reason that in an additional step, an additional program must be
assigned to this task.
• With inputs %I0.6 and %I0.7, the same functionality is provided for the axis
"Transfer_blue". The JOG velocity of the two axes can be modified via the
unit-global variable "JOG_Velo".
The axes must be enabled before traversing.
Procedure 1. Create the MCC unit "ManualMode". Within the INTERFACE section,
declare the global variable "JOG_Velo", data type: LREAL, with the initial
value: 20)
2. Then create the MCC program "JOG_filler_red".
3. The axes must first be enabled.
If an absolute encoder is used at the axis, then an immediate "Axis enable"
after the system has powered up, can result in problems.
After a power up, if the actual position is unknown, SIMOTION requests the
position actual value from the absolute encoder. If an enable command is
issued during this time, then the error message "Encoder system fault" may
be output.


Continued In this case, before the actual "enable command" a check must be made as
to whether, the encoder system is ready and supplies valid values. This can
be achieved by querying the system variables:
- <Axis>.sensordata[1].state = valid
This is the reason that at the start of the MCC chart you should enter an
appropriate wait condition.
4. For a program that is endlessly executed, the following steps are integrated
in an "endless" WHILE loop. An "endless" While loop is obtained for
example, by entering the value "TRUE" in the query condition for the
operand of an "AND" query.
5. In the command "WAIT for condition" the program waits for a rising edge of
input %I0.4 or %I0.5, in order to start motion.
6. The traversing direction is then defined higher an IF query. If the input %I0.4
has been set to "1", then the velocity "JOG_Velo" is in the positive direction,
otherwise, with "JOG_Velo" in negative direction.
The motion of the axis is realized using the command "Start axis position-
controlled". The option "Delay program execution" is deselected, i.e. the
program does not wait (why?) until a jump to the next command.
7. If the input %I0.4 or %I0.5 is again reset to "0" then motion is stopped using
the "Stop axis" command.
In this command, select the stop mode "Normal stop with abort" as selection
"All motions". Further, stopping should be realized in the position controlled
mode. The wait condition is also deselected in this command.

Program "FaultProgram"

Continued 8. Using the commands of the context menu "Copy" or "Insert MCC Chart",
copy the program "JOG_filler_red" to "JOG_Transfer_blue and appropriately
change the axis names and inputs %I0.6 and %I0.7 in "JOG_Transfer_blue".
9. Assign both programs the MotionTask_3 or the MotionTask_4. Both
MotionTasks should be automatically started after the StartupTask.
10. In order to avoid a CPU STOP as a result of a technological alarm, the
TechnologicalFaultTask must also be assigned a program.
Assign the program "FaultProgram" from the MCC unit "FaultUnit" to the
TechnologicalFaultTask.
12. Save, compile, load and test your program.

Additional Exercise 5.8: Homing the Axis "Transfer_blue" (1)
Configuration for homing HomeTransferBlue

Settings for The axis "Transfer_blue" has an incremental encoder. This is the reason that
homing it should be referenced after switching on the control, before positioning. The
homing type is defined in the "Homing" dialog of the associated axis.
At the D425-2, for the "blue" drive no homing cams can be simulated. This is the
reason that as homing mode, "Encoder zero mark only" or "External zero mark
only" can be selected.
1. In SIMOTION SCOUT go into the "offline" display and open the
dialog "Transfer_blue -> Homing".
2. Select the homing mode "only encodere zero mark".
3. Also select the following settingsi:
- Homing required: "No"
- Homing procedure: "Sta rt in positive direction"
- Entry velocity: 20 mm/s@,
- Reduced veloc ity: 10 mm/s
- Home positiuon coordinate: 0.0 mm
The value of the l"Homing point offset" should be selected later, so that after
homing the 00gposition of the motor disk (position of the hole) points "precisely"
upwards.
Hominge is initiated using the MCC command "Home Axis“. Create the MCC
Homing
Unit "Homing" and write the MCC program "HomeTransferBlue", that executes
the homing command in an endless loop as shown above.
A new homing operation can then be started using a signal edge at input %I1.6.

Additional Exercise 5.8: Homing the Axis "Transfer_blue" (2)
Change value 1
until disk position = 0
10
40
20
30

Procedure 1. Create an "MCC unit" with the name "Homing". Under the "Compiler" tab,
Homing select "Permit program status" and "Permit single step".
2. Create an MCC program with the name "Ref_Transfer_blue.
3. Now insert the following commands into the MCC program:
- "Wait for signal" command for a rising edge of the input: %I1..6
- "Homing axis" command with the setting "Active homing"
4. Compile the program
5. Assign the program to the execution system of MotionTask_5. The
MotionTask_5 should be automatically started after the StartupTask.
6. Load the program into the control and online define the "Home position
offset", so that after homing, the 0 mark of the disk precisely points upwards.
"0" should be displayed as the axis position.
7. Using the command: Target system-> Load-> Load CPU / drive unit to PG…
(2nd entry), you can backup the online configuration data into the offline
project. Save the uploaded data to the hard disk.
Notes • The system variable "Axis_blue.positioningstate.homed" can be used to

query the homing status of an axis.
• A "Restart" of the axis can be used to reset the homing status of an axis
to "NO". Sending a new homing command to an axis TO will reset the
homing status to "NO".

Additional Exercise 5.9: Absolute Encoder Adjustment for
"Filler_red" (1)
0O
270O
90O
180O
Corresponds to axis position = 0

Absolute encoder The axis "Filler_red" has an absolute encoder which transfers the absolute
adjustment position to the control at each power ON. If you replace the encoder or you
perform an overall reset, then you will need to perform a new absolute encoder
adjustment.
The absolute encoder adjustment can be performed using the MCC command
"Home Axis“ with the setting "Absolute encoder adjustment" or using the
corresponding command from the control mpanel.
After the absolute encoder adjustment has been completed, the 0 degree mark
of the motor should point precisely eupwards. This position should correspond
to axis position 0.
The absolute encoder can be ad justed via the MCC command "Home axis"
Procedure
from the user program or via the @control panel.
1. Switch the control to STOP U operating state and open the control
panel.
2. Select the axis u "Filler_red" and obtain control priority.
3. Enable the axlis.
4. First travelg with the "red" motor to position 0 and then in the positive
directioon, until the 00 mark of the motor disk is facing "exactly" upwards.
5. Select the command "Home Axis". Under the "Parameter" tab, select
the homing type "Absolute encoder calibration with specification of the position
value" and in the entry field "Homing position coordinate" enter the value "0".
6. Then click Start to perform the absolute encoder adjustment. The
controller calculates the absolute encoder offset and saves it to a Retain
system variables. The offset is displayed in the screen form "Homing" under the
entry "Actual absolute encoder offset -> Value".
The displayed position for axis "Filler_red" is now 0 mm

Additional Exercise 5.9: Absolute Encoder Adjustment for
"Filler_red" (2)
1. Select control panel
4. Absolute encoder adjustment with

specification of the position value
2. Set enable
3. Select homing
5. Enter position
6. Click Start button

Note In the "Homing" dialog of an axis, in the "Activation status", it is displayed as to

whether an absolute encoder adjustment has been performed or not. In the
expert list for system variables, both items of information can be found under:
• Filler_red.absoluteencoder.absoluteencoder[1].totaloffsetvalue
• Filler_red.absoluteencoder.absoluteencoder[1].activationstate

Additional exercise 5.10: Monitoring at the Software Limit Switch
- 5 mm 1000 mm

Task The software limit switches monitor the position of the axes. In this exercise, the
software limit switches for the axis "Filler_red" are set.
Procedure The software limit switches can be entered using the settings in the "Limits"
window. These settings can also be made
online.
1. For the axis "Filler_red" the two software limit switches are set to -5 mm and
to 1000 mm.
2. Where relevant, activate the software limit switches using the system
variable Filler_red.swlimit.state.
3. Traverse the axis in the JOG mode to the software limit switch. What
happens? Can the axis be retracted in the opposite direction?
Note The settings for the software limit switches are saved in the system variables
and not in the configuration data. Contrary to the configuration data, system
variables changed online can neither be saved to the CF card (Copy RAM to
ROM) nor can they be loaded from the control system into the offline project.
If the settings in the system variables are to be permanently active, then these
settings must be transferred into the offline project, and then transferred into the
target system using a project download.

Additional exercise 5.11: Using the Service Overview
Target system -> Service overview

Service In the Service overview important system variables of all axes which exist in
Overview the project are displayed.
The Service overview is accessed via:
Project -> Target system -> Service overview
The system variables which are displayed in the Service overview can also be
expanded. Thus additional system variables that are important for the overview
can be integrated.

Exercise 6: Automating the Bottling Line
Manual Auto
Switching on/
switching off: Operating modes:
No
operating
mode

Task The filling line should be automated with the following task:
The bottling line can be operated in three different operating modes: “Idle”,
“Manual” and "Automatic”. In addition, a logic can be integrated in order to
switch on and switch off the system.
• Switching on and switching off: The system can be switched on with the
input “Start_BP”: %I 0.0 (NO contact). The system can be switched off with
the input “Start_BP”: %I 0.1 (NC contact). The status of the system is output
using the output signal "System_on“ (%Q 4.0).
• Selecting the operating mode: Immediately before the system is switched on,
no operating mode is active. From this state, the operating modes "Manual
operation" or "Automatic" can be selected.
The operating mode is preselected using the switch "Manual_Auto" (%I0.2).
The operating mode "Manual operation" is preselected with %I0.2 = 0, and
"Automatic" with %I0.2 = 1. The preselected operating mode is accepted with
a pulse at the input "Accept_operating mode" (%I 0.3).
If the state of input %I0.2 changes, then the "Idle" operating mode is
automatically activated. If the system is switched off, then the previously
selected operating mode is deselected.
The active operating mode of the system is displayed at the two outputs
"Manual operation" (%Q4.1) and "Automatic" (%Q4.2).
No operating mode is active, if neither "Manual mode" nor "Automatic"
is selected.

Exercise 6.1: Writing the Program "OB_Main" in LAD

Procedure Using the LAD Editor, to start create the LAD/FBD source "Main". Within this
source, create the "OB_Main" program and integrate the functionality described
above. The "OB_Main" program is then finally assigned to BackgroundTask.
1. First create the LAD/FBD source "Main".
2. In the global ADDRESS LIST of your project, create the following input and
output signals in the process image:
- "Start_BP": %I0.0,
- "Stop_BP": %I0.1,
- "Manual_Auto": %I0.2,
- "Accept_operating mode": %I0.3
- "System_on“: %Q4.0,
- "Manual mode": %Q4.1,
- "Automatic": %Q4.2.
3. Within the source "Main", create the program “OB_Main".
4. Integrate the required functionality into the “OB_Main" program.
5. Compile the source "Main", and assign the program “OB_Main" to
BackgroundTask.
6. Remove the program "Led_test.test_led" from the assignment to
MotionTask_2.
8. Download the project into the target system and test the program
"OB_Main".
Note The above diagram does not show the complete "Main" program but only a
section.

Exercise 7: Program Concept for the Bottling Line
Motion Task 3
jog1
Startup
Manual _restartTaskId
Background Motion Task 4
Auto
jog2
_restartTaskId
MotionTask 2
(StartAuto)
User Interrupt Synchronous Operation
EStop Emergency Stop of Axes

IPO Sync Task Motion Task 3
Motion Task 4

Task In this task, you will obtain a deeper understanding of the control of the task
execution via motion command parameters
In the first exercise, we will extend the functionality of the "Moving axes in the
manual mode" program. This functionality is implemented within the "OB_Main"
program. There, the global variable "Manual operation" is evaluated and for a
rising edge, MotionTask_3 and MotionTask_4 are started, or for a falling edge,
stopped. When the task is stopped, the two axes will also stop, as a task stop
does not automatically stop a command to move the axis, that has been issued.
The programs in MotionTask_3 and MotionTask_4 still control the motion of the
individual axes in the "Manual mode".
In a second exercise, the functionality "Traversing axes in the automatic mode"
is completed. The associated program section in the "OB_Main" program
evaluates the status of the "Automatic" variable, and appropriately starts or
stops conveyor operation of the Transfer axis.
The Emergency Stop functionality is integrated in a third exercise. For an
Emergency Stop event (protective doors are open), all of the axes as well as
MotionTask_3 and MotionTask_4 are stopped. This program is assigned to the
IpoSyncTask. The fastest possible response to an EMERGENCY OFF event
can be achieved in this way.
If the protective door is opened, then all of the axes as well as the MotionTask_3
and MotionTask_4 are stopped and the system is brought into the switched-off
state. The axes can only be traversed again by switching on the system.
In an additional section, the synchronous operation functionality of the filler axes
as well as the actual filling process itself will be integrated into the user program
using a cam.

Exercise 7.1: Activating the Axes in the Manual Mode
Motion Task 3 Motion Task 4

"JOG_Filler_red" "JOG_Transfer_blue"
...
Manual mode
Motion Task 3
" JOG_Filler_red " Stop Axis
"Filler_red"

Task The objective of this task is to complete the "Move axes in the manual mode"
functionality. This functionality is realized using the "OB_Main" program.
If a rising edge of the "Manual mode" variable is detected, then MotionTask_3
and MotionTask_4 are started. If the "Manual mode" variable is set to FALSE,
then MotionTask_3 and MotionTask_4 are stopped. In addition, both axes are
stopped with "Normal stop with abort.
The "Normal stop" function is implemented using the TO library function _stop.
This function is in the command of library under Technology -> Positioning axis -
> Motion -> _stop().
Please note, that the functions for starting and stopping axes or tasks are only
executed for an appropriate rising or falling edge at the "Manual mode" variable.
Procedure 1. Integrate the required functionality into the “OB_Main" program.

2. Save and compile the program.
3. In the execution system, "Task configuration" tab, deactivate automatic
starting after the StartupTask for MotionTask_3 and MotionTask_4.
4. Save, compile and download the project to the control system.
5. Test the program, i.e. traversing the axes. Also use the functionality: Device
diagnostics -> Task runtimes (see the next page), in order to track the
correct starting and stopping of MotionTask_3 and MotionTask_4.

Exercise 7.2: Check the Task Runtimes and Task Status
Target system -> Device diagnostics ->Task Manager

Task runtimes The statuses and runtimes of the individual tasks can be read out using the
device diagnostics.
Call The diagnostics information is opened in the online mode using the menu
command: Target system -> Device diagnostics or via the corresponding
command from the context menu of the D425-2.
In addition to "General information" and the content of the "Diagnostics buffer",
under the "Task run times" tab, information is provided on the individual tasks.
Overview Under the task runtimes tab, task name, task status, actual, minimum and
maximum runtimes are displayed for each task.
The task status can also be read out using a system function _getStateOfTask().
Procedure Check the task runtimes and statuses of the corresponding tasks as a function
of the selected operating mode. In the selection field "Refresh rate", select the
entry "500 ms".

Exercise 7.3: Activating Conveyor Belt Motion
in the Automatic Mode
Operating mode "Automatic"
Move to "0"
"RunAuto"
Infinite movement

Task The objective of this task is to complete the "Move axes in the automatic mode".
The motion of the conveyor belt in the automatic mode is integrated in the
program "Conveyor operation" (MCC unit "AutoMode").
This program initially traverses the filler axis with a velocity of 400 mm/s to the
wait position 0, and then starts the conveyor belt using the command "Start axis
position control". The velocity of the conveyor belt can be entered using the
INTERFACE variable " Transfer_speed " (datae type LREAL). The start value is
100 mm/s
The "Conveyor operation" program is assigned MotionTask_2. MotionTask_2 is
also started or stopped by the "OB_Maein" program.
For a positive edge at the "Automaitic" variable,MotionTask_2 is started. If the
variable changes to FALSE, then sMotionTask_2 and the conveyor belt are
stopped.
Procedure 1. Create the MCC unit "AutoMode", and in the INTERFACE section,
create a variable with the u name "Velo_Transfer_blue", data type LREAL and
initial value 100.0.
2. Create the g"Conveyor operation" program with the functionality
described above.
3. Integrloate the functionality to start and stop MotionTask_2 and conveyor
operation in the "OB_Main" program.
4. Save and compile the programs.
5. Remove the previous program from the program assignment to
MotionTask_2, and instead, assign this to the "Conveyor operation" program.
MotionTask_2 is not automatically started after the StartUpTask.
6. Save, compile and load your program.
7. Test your program. When doing this, using the "Control" function, assign
new values to the "Transfer_speed" variable.

Exercise 7.4: "RUN" Operating Mode after "Power On"
_startupdata.operationmode = run

Task The objective of this exercise is to configure the D425-2, so that after a "Power
On" the system automatically branches into the RUN operating mode.
The "Last_Operation_Mode" default setting is selected, and therefore the
SIMOTION system branches into the operating state that was active at "Power
Off".
Frequently, for a "Power Off", the I/O components, e.g. ET200 B, "sign off"
earlier than the SIMOTION system. If PeripheralFaultTask is not assigned to
any program, then briefly before switch off, the D425-2 goes into the STOP
operating state. This operating mode is also active after the next "Power On".
This behavior can be achieved via ithe system variable
_startupdata.operationmode of sthe D425-2 device and the assignment of e.g.
an "empty" or the program "led_test.test_led" at the PeripheralFaultTask. Using
the "led_test.test_led" program, @in addition, it is displayed at the simulator
when the PeripheralFaultTask it started
Procedure 1. In your project, seulect the offline mode.
2. In the projeclt navigator, select the D425-2 device, and in the symbol
browser, the sgystem variables of the device.
3. For the soystem variable of the device, select "Run".
4. Open lthe execution system and assign the led_test.test_led to the
PeeripheralFaultTask.
5. Save the settings and download the project to the target system. Ensure
that the project data are backed up to the CF card using the "Copy RAM to
ROM" function.
6 Test the settings by switching off the D425-2 power supply and switching on
again.

Additional Exercise 7.5: Integrating Emergency Stop (1)
EStop
"EStop"

Task In this exercise, the Emergency Stop is integrated into the automation of the
bottling line. This is realized using the "EStop" program (Emergency Stop)
If the protective door (PI1.0) is opened, then the axes are stopped via the
"Dynamic values" that can be entered, and MotionTask_2, MotionTask_3 and
MotionTask_4 are reset. Further, the system is "switched off", i.e. the variables
"Plant_on", "Manual mode" and "Automatic" are set to FALSE.
The command to quickly stop the axis should only be called, if, in addition to
"open protective doors", the following condition is also fulfilled:
• <axis>. StopEmergencyCommand = inactive (An emergency stop is not
active )
After an Emergency Stop, the axis is in the state
• "StopEmergencyCommand = active".
This state can only be withdrawn using the MCC command "Reset object", i.e.
using the command _resetAxis() from the command library, or by explicitly
withdrawing the axis enable.
In the sample, this is realized using the _resetAxis() command in the OB_Main
program, if, after an Emergency Stop, the protective door is closing again.
After the Emergency Stop, the operator must switch on the system (bottling line)
again. The switch on procedure is used, to a certain extent, to acknowledge the
Emergency Stop state.
Procedure 1. Insert the variable "Guard" (PI1.0) into the ADDRESS LIST.
2. In the MCC unit "FaultUnit", create an MCC program "EStop" with the
functionality specified above.
For the MCC stop commands, ensure that the option "Delay program
execution" is deselected. Otherwise, each stop operation would result in an
IPO overflow, which could only be acknowledged using a POWER ON.
3. Save and compile the program and assign IpoSynchronousTask to the
program.

Additional Exercise 7.5: Integrating Emergency Stop (2)
Acknowledge of the emergency stop

with the command _resetaxis() in the
OB_main

Continued 4. Open the OB_main program and at the end, insert a network with the
call_resetAxis() to acknowledge the Emergency Stop state.
The function _resetAxis() should be called for both axes for a positive edge at
the "Protective door" input. The function _resetAxis() is in the command Library
under Technology -> Positioning axis-> Object and alarm handling -> resetAxis().
5. Load and test the program. Furtherm, check whether the Emergency
Stop state is correctly reset. If required, adapt the deceleration at the axis, so
that the Emergency Stop does not causee the drive to fail.
Solution The solution is provided in SYS_sD425-2_V431_PN_E_9.

Exercise 8: Implementing Synchronous Operation of Both Axes
Filler_red
Synchronous operation off
850 mm
Position axis
Synchronous
operation on
100 mm
100 mm 850 950 Bottle position
1000 mm
Sensor 1
2000 mm

Task In this exercise, in the MCC program "Filling", the gearing of two axes is
programmed and commissioned.
After the bottling line was switched into the automatic mode, the conveyor belt
continually moves in the positive direction.
If a bottle reaches the "Sensor" (PI 1.1), then the filling axis is synchronized to
the bottle position. Synchronizing has been completed after a distance of
100 mm, and the filling axis then runs in synchronism with the bottle on the
conveyor belt.
Over the next 750 mm, both axes run in synchronism and the filling operation
can be executed.
Once the filling axis reaches position 850 mm, then it is desynchronized. The
filling axis then returns to the initial position and waits for the next bottle. The
filling axis starts again if a new a bottle comes.
In order to implement absolute synchronous operation, if the sensor (PI1.1)
responds, then the Transfer conveyor is set to position 0. Setting the actual
value can be realized using the MCC command "Shift measuring system -
absolute/setpoint reference".
The program is assigned UserInterruptTask_1. It is started with an edge at input
"Sensor" (PI1.1).

Exercise 8.1: Writing the MCC Program to Couple the Axes
"Filling"

Procedure 1. Insert the signal "Sensor" (PI 1.1) into the ADDRESS LIST
2. In the MCC unit "AutoMode", create the "Filling" program
3. Using the MCC command "Shift measuring system", the actual position of
the conveyor is set to 0.0
• Select: absolute / actual value reference
4. Synchronization is started using the "Gearing on" command. The parameters
can be selected as follows:
• Reference point: gearing is realized referred to the axis zero point
• Synchronization reference: Leading axis
• Start of synchronization: Synchronize immediately
• Synchronization length: 100 mm
5. Desynchronization should be started at position 850 mm, and completed
after a desynchronization length of 100 mm.
6. In the last motion command, the axis is retracted to the initial position with a
velocity of 400 mm/s.
7. Compile the MCC unit "AutoMode", and assign the program "Fill" to
UserInterruptTask_1.
8. As start condition, select "Sensor = TRUE".
9. Under the synchronous object Filler_red.synchronous operation ->
Configuration, check whether the Transfer_blue axis is entered as possible
master axis.
10. Compile and load the project.
11. Test the loaded project.
What happens if the sensor signal is activated, while the first filling operation
has still not been completed?

Exercise 9.1: Filling Process using Output Cams (1)
"Output cam"

Task In this exercise, the actual filling process, i.e. controlling the valve using a cam
output is implemented. For this purpose, a time cam should be created for the
"Filler_red" axis.
After "Filler_red" has been synchronized to the bottle position, the filling valve is
switched on using a cam. The filling operation is started at position 102 mm and
has been completed after 5 seconds.
The "Valve" cam is created as fast cam DI/DO3 of the bidirectional inputs/
outputs at the connector X142 of the D425-2. This DO3 is linked to the output
DO9 at the SINAMICS operating panel. Further, filling should be displayed using
the "Filling_active" LED (PQ5.1) at the simulator.
Procedure 1. Open the screen form with the parameterization of the bidirectional
inputs/outputs at the connector X142 of the D425-2.
2. Select the "Channel 0 – 7" tab, and parameterize the DI/DO3 as "output
cam".
3. Below the axis "Filler_red" in the folder "Cams", insert a output cam TO with
the name "Valve".
4. Open the configuration dialog by double-clicking on the entry: "Valve ->
Configuration".
5. Parameterize the cam as "Time cam", and select the option "Activate output"
with the cam output option: "Cam output (CAM) ".
6. Using the parameterizing dialog for assigning the output, select the entry
"D425-2 -> CAM_3 [INOUT 3, X142.7]".
Via this assignment, the cam output is connected to the DO9 of the
SINAMICS operator panel.

Exercise 9.1: Implementing the Filling Process using Cams (2)
Inhibiting the cam when the automatic mode

is deselected
Switch on output cam

in program "runauto" Cam signal output in OB_Main

Continued 7. In the "conveyor operation" program, enable the cam, after "Filler_red"
has reached its start position.
8. Inhibit the cam functionality in the OB_Main for the case that the automatic
mode is deselected. The cam can be inhibited in the LAD/FBD programs
using the function _disableOutputcam().
This function is in the command library under Technology -> Output cams ->
Switching functions -> _disableOutputcam()
9. Integrate the cam signal output into the "Main" program (system variable:
"<cam>.state") at the output "Filling_active" (PQ5.1) of the simulator.
10. Compile and load the project into the target device and test the execution.

Exercise 10.1: Connecting the TP177B to SIMOTION D425-2
1.
2.
3.
4.
Double-click 192.168.0.12
Ethernet_PN

Task In this exercise, the TP170B color PNDP is coupled to a SIMOTION D425-2
system. To realize this, a SIMATIC HMI station is inserted in the SIMATIC
Manager Project associated with the SIMOTION system.
A start screen is then configured, in which the following properties or variables
of the D425-2 are displayed:
• Operating state of the CPU (system variables of the D425-2)
- modeofoperation
• System is switched-on or switch-off (I/O variable)
- I/O.system_on)
• Manual or automatic mode (I/O variables)
- I/O.manual operation
- I/O.automatic)
• Setpoint position and setpoint velocities of the two axes (TO variables)
- Filler_red.positioningstate.commandposition
- Transfer_blue.positioningstate.commandposition
- Filler_red.motionstatedata.commandvelocity
- Transfer_blue.motionstatedata.commandvelocity
• Filler axis has synchronized (TO variable)
- Filler_red_SYNCHRONOUS_OPERATION.syncstate)
• Filling active (TO variable)
- Valve.state
Procedure 1. Start the SIMATIC Manager and open the SIMOTION project.
Select the project root and using the menu command: Insert -> Station ->
SIMATIC HMI station an HMI station into the project.
The dialog "Properties - WinCC flexible RT" is opened.

Exercise 10.2: Defining the Connection Partner
5. Context menu:
Open object
6. Define
connection

Continued 2. Selected the device "TP 177B color PNDP" with version 1.1.3.0 and confirm
your settings with "OK".
3. In the SIMATIC Manager project window select the icon: "SIMATIC HMI
Station" and double click in the work area of the SIMATIC Managers on the
"Configuration" icon.
The "HW Config" tool is opened.
4. Double-click on the entry "HMI IE", then the properties dialog to set the
Ethernet interface is opened. Click on the "Properties" button to open the
"Properties - Ethernet interface" dialog.
Under the "Parameter" tab under the list box "Subnet", select the entry
"Ethernet_PN".
In the entry field "IP address", enter the value "192.168.0.12", and under
subnet mask, the value: 255.255.255.0. Acknowledge your settings in both
dialog boxes with "OK", save your settings and close the HW Config tool.
5. Using the "Open object" command, from the context menu of the icon
"WinCC flexible RT", start the "WinCC flexible Engineering System" tool to
configure the station.
6. By double-clicking on the entry: Communication -> Connections, open the
connection table. The required connection to the D425-2 station has already
been entered into the table.
Ensure that the entries in the columns "Active" and "Online" are set to "On".

Exercise 10.3: Inserting Variables and Configuring a Screen
7. Insert
variables
8. Create
start screen

Continued 7. Open the variable table by double-clicking on the entry "Communication

-> Variables".
Click in the "Connection" column on the entry to open the associated list field
and select the connection to the SIMOTION device. Then click on the entry icon
to open the symbol browser of the selected control, and insert the required
variables into the table one after ethe other.
In the "Acquisition cycle" column, selemct the required update cycle.
8. Via the entry "screens" or by double-clicking on an existing screen the
editor to generate the screen is opened.
For each HMI device there is ai "template" screen in which the globally assigned
function keys or otsher global objects, for example message window, permanent
area with time, user, etc. can be configured.
In the tool window, you'@ll find objects, which you can insert in your screens.
Click on the IO field entry and with the mouse key pressed, drag the IO icon to
approximately the position in the screen, where later an input or output field is to
be disuplayed.
Using the menu colmmand: View -> Properties open the properties window.
Select the "General" entry and define the connection of the process variable as
well as the display format. Under the item: Properties -> display enter the
position of the input/output field.
By double-clicking on the entry: Device setting -> Device settings open the
associated dialog and in the "Start screen" list select the created screen as start
screen.

Exercise 10.4: Defining Settings and Loading the Configuration
9. Defining the
settings for
transfer
10. Start transfer

Continued 9. For a download via Ethernet, the appropriate settings must be made at the
PG/PC or at the HMI device.
The settings for the download can be made using the dialog "Select
operating control device for transfer". This dialog can be opened using the
menu command Project -> Transfer -> Transfer settings or using the
corresponding symbol in the toolbar.
In the dialog that opens, select the TP177B operator control device for the
download, and as mode, select "Ethernet" Further, enter the value
"192.168.0.12" as IP address for the download
10. Start the transfer by pressing the "Transfer" button. The configuration is
saved, generated and loaded into the TP 177B.
11. In the program that was assigned to TechnolgicalFaultTask also integrate an
instruction to acknowledge the technological alarm "30002 Command
canceled " of all TOs.
Solution A solution is provided in SYS_D425-2_V431_PN_E_12.

Licensing

Content Page
Licenses for SIMOTION ...................................................................................................................... 2
Licensing Procedure ........................................................................................................................... 3
Determining Required Licenses ......................................................................................................... 4
Licensing Example .............................................................................................................................. 5
The Licensing Procedure: Step 1 ....................................................................................................... 6
The Licensing Procedure: Step 2 ....................................................................................................... 7
Ordering and Delivery ........................................................................................................................ 8
Hardware Replacement ..................................................................................................................... 9

Automation and Drive Technology Page 1 Licensing
Licenses for SIMOTION
Position 1 axis Gear 1 axis Cam 1 axis MultiAxes Package

(incl. MC Basic) (incl. Position) (incl. Gear)
Position-controlled Electronic gear Cam Technology

positioning package CAM for
64 axes
Tcontrol Java machine
8 channels Java communication

per license package

Licensing The SIMOTION licensing procedure means that depending on the type and
number of RT components or technology objects uses in the project you may
need to purchase different licenses.
License Key The licenses required for a device are assigned to a License Key which is saved
on the RT system.
Underlicensing If no licenses or too few licenses are avamilable to the RT system, there are no
restrictions in functionality, instead entries are made to the diagnostic buffer and
the red diagnostics LED of the RT sysetem flashes.
Advantages
• Support for license manage ment.
• Costs for license management are cut.
• Detects the software options to be licensed (status tracking and analysis).
• Displays the lic ensed software options (license analysis).
• Information funclution for missing licenses.
• All functionsg are available for test purposes without licenses

Licensing Procedure
Licensed
Ordering System delivery Assignment + HW
software
of
m ber d in
Log
u n ey Customer
ial n re a ek
Ser ardwa f the n s
h e
o
the ntent abel Lic INTERNET
Lic ey
c o ns e l
lice
en
k
se
License
database
Factory
Controller

License database All of the supplied serial numbers of the MMC for the C230-2/C240, of the
IsoProfibusBoard for the P350 and the CF card for the D4x5 are entered into a
license database. In addition, all delivery notes and the associated licenses are
saved.
License key Customers can access this database via the Internet. After entering his delivery
note number and the licenses, he is issued a license key, which he can then
transfer to the control.

Determining Required Licenses
shortcut menu of D435

Project Creation At installation all the technology packages become available to the user. No
licenses or additional software packages are required for project creation. The
user has access to all functions.
Commissioning After creating the project, SCOUT can be used to query which and how many
licenses are required for the CPU. If the project is transferred to the control, the
license information can determine which licensese are present on the control
and whether underlicensing is occurring. If thism is the case, the runtime
system signals "Operation without License Key“.
The license information can be caelled up using the command: Licenses from
the context menu of the SIMOTION idevice.
Underlicensing The system will operate without loss of functionality. With underlicensing an
entry is made to the diagnostic buffers and the red group fault LED of the
SIMOTION device flashes.

Licensing Example
Application:
Machine with 1 positioning axis and 2 synchronous axes
SIMOTION
1 * Single-user license, positioning

(Position)
2 * Single-user license, synchronous
operation (Gear)
Positioning Synchronous Synchronous

operation operation

Application example The machine comprises a leading axis and two following axes, which are
coupled to the leading axis through angular synchronism.
The following licenses are required:
• Leading axis: The leading axis requires one license for a positioning axis
• Following axis: The two following axes each require one license for a
Synchronous axis

The Licensing Procedure: Step 1
CoL3
License Gear
CoL2
License Gear
CoL1
License Pos

Ordering The appropriate licenses must be ordered to carry out the licensing procedure.
The Catalog contains the different licenses together with their order numbers.
The customer orders the required number of licenses and is given a CoL
(Certificate of Licence) for each license. This CoL is stored with the machine
papers.

The Licensing Procedure: Step 2
Read out A&D license

the serial number for the MMC database CoL2
License Gear
CoL2
CoL1 License Gear
CoL2
CoL3 CoL2
License Gear
License key =
(1234-5678+SP1+SP2)
Serial number:
1234-5678
Download the
License Key with SCOUT

Licensing In addition to the Certificates of Licence, for licensing you also need the serial
number, on which the licensing is saved.
• for C230-2/C240 on the MMC
• for P350 on the IsoProfibus Board
• for D4x5 on the compact flash card
The serial number can be read out with SCOUT or read from the card.
Licence Key SCOUT will take you to the Internet page

• http://www.siemens.com/automation/license
where the licensing is carried out.
After entering the CoL and serial number, the customer is given a license key.
This number is then transferred to the respective hardware with SCOUT.
Advantages • No diskettes supplied

• Only one license key for each device
• Always available everywhere via Internet, telephone, fax

Ordering and Delivery
Order form
Item. Number Part number Description
1 2 6AU1 230- SIMOTION C 240
2 2 6AU1 700- SIMOTION Micro Memory Card
3 3 6AU1 820- single license, Position
4 2 6AU1 820- single license, Gear
Delivery
CoL (Certificate of License):

Serial number:
0190-666
License License
Position Gear
Serial number: ID 007-4711 ID 008-4711
0190-667

Several CPUs The License Key always only refers to an RT system. If several controls are to
be licensed, then for each control, the appropriate number of CoLs must be
ordered, the serial number of the hardware determined and a License Key
generated via the Internet.

Hardware Replacement
SIMOTION C2xx SIMOTION P350 SIMOTION D4xx
• License key uses the • License key uses the

• License key uses the serial number of the Iso- serial number of the
serial number of the Profibus-Board compact flash card
MMC
• License key is saved on • License key is saved on
• License key is saved on the Iso-Profibus-Board the compact flash card
the MMC

Hardware If the control is defective, for example, the P350 hard disk, the module can be
Replacement replaced. Then the card where the license is saved is inserted again and is fully
operable again, including the license information.
Defective License If the MMC for the C230-2/C240, the IsoProfibusBoard for theP350 or the
Hardware compact flash card for the D4x5 is defective and needs to be replaced, the
license key is missing, i.e. the error LED flashes and an error message is
entered in the diagnostic buffer.
Note the serial number both of the defective and new hardware and contact the
SIMOTION Customer Support. They will give you the license key.


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Kursunterlagen für ERDINC KELOGLU, erdinc.keloglu@siemens.

Creating a SIMOTION D Project with

3 The SIMOTION Hardware Platforms

5 Axes and Drives in SIMOTION

Course: MC-SMO-SYS 7 The SIMOTION Execution System

8 Synchronous Operation in SIMOTION

External Encoders - Output Cams -

10 Connecting HMI Systems

This document was created for training purposes. SIEMENS

Copyright © Siemens AG 2013. All rights, including rights

SITRAIN course material on the Internet:www.siemens.de/sitrain

SIMOTION Date: 03.01.2013 SITRAIN Training for

SITRAIN Training for MC-SMO-SYS

Tasks of a motion control system

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SITRAIN Training for MC-SMO-SYS

SIMATIC SIMOTION SINUMERIK

SIMATIC - automates SIMOTION - the motion SINUMERIK – brings

Our portfolio today:

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SITRAIN Training for MC-SMO-SYS

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Fusion of SIMOTION's innovative approach consists of removing the traditional division

SITRAIN Training for MC-SMO-SYS

One engineering system

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Hardware SIMOTION offers flexible solutions - for all requirements - by running on a

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functions (threshold monitoring, adaptation of controller parameters, etc.) for

System ST Structured Text

Drive Test and diagnostics

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SITRAIN Training for MC-SMO-SYS

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Overview SIEMENS offers a range of task-oriented programming languages for

ST Structured Text is a text-based, high-level language similar to PASCAL.

SITRAIN Training for MC-SMO-SYS

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Properties MCC is a new graphic programming language, designed to significantly simplify

SITRAIN Training for MC-SMO-SYS

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Properties ST is a high-level programming language oriented to PASCAL. The language is

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SIMOTION P350-3 / P320-3

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Shared use of HMI

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PROFIBUS DP Standard PROFIBUS DP with DP/V1 functionality

• For connecting distributed I/Os

• Connecting HMI deg vices

SITRAIN Training for MC-SMO-SYS

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SIMOTION The SIMOTION printed documentation consists of individual documentation

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SITRAIN Training for MC-SMO-SYS