Preliminary Man Sinamics-Simotion v1 7 Eng

Preliminary
SINAMICS
SIMOTION
(Version 1.7)
Preliminary_man_sinamics-simotion_v1_7_eng.doc RELIMINARY ROTOMEC S.p.A.
SOMMARIO
1 Electrical drawings ...........................................................................................................5

1.1 Electrical drawings: SIMOTION D4x5 .........................................................................6
1.2 Electrical drawings: SINAMICS CU320 .......................................................................7
1.3 Electrical drawings: SINAMICS CU320-2 ....................................................................8
1.4 Electrical drawings: Double Motor Module...................................................................9
1.5 Electrical drawings: TM41 .........................................................................................10
1.6 Electrical drawings: Power Supply ............................................................................11
2 Control Unit .....................................................................................................................12
2.1 PLC Hardware Configuration ....................................................................................12
2.2 Sinamics S120 Drives System ..................................................................................14
2.2.1 CONTROL UNIT ..................................................................................................16
2.2.1.1 CompactFlash Card .....................................................................................18
2.2.2 Power Module ......................................................................................................19
2.2.2.1 Basic Line Modules ......................................................................................19
2.2.2.2 Smart Line Modules .....................................................................................20
2.2.2.3 Active Line Modules .....................................................................................20
2.2.2.4 Active Line Modules in booksize format ........................................................21
2.2.2.5 Active Interface Modules ..............................................................................23
2.2.3 Drives...................................................................................................................24
2.2.3.1 Motor Modules .............................................................................................24
2.2.3.2 Single Motor Modules in booksize format .....................................................24
2.2.3.3 Double Motor Modules in booksize format ....................................................26
2.2.3.4 Motors with DRIVE-CLiQ interface ...............................................................27
2.2.3.5 Motors without DRIVE-CLiQ interface...........................................................28
2.3 Sinamics Configuration .............................................................................................29
2.3.1 I/O Configuration ..................................................................................................41
2.3.2 Safety Integrated ..................................................................................................42
2.3.2.1 The operating principle of Safety Integrated..................................................43
2.3.2.2 Setting Safety Integrated ..............................................................................45
2.3.3 Script....................................................................................................................46
2.3.3.1 Sample script for a drive Sinamics:...............................................................48
2.3.3.2 Script: execution ..........................................................................................49
2.3.4 Topology ..............................................................................................................49
2.4 Mapping Profibus communication .............................................................................51
2.4.1 PLC -> SINAMICS................................................................................................51
2.4.2 SINAMICS -> PLC................................................................................................52
2
3 Typical Values.................................................................................................................54
4 Application Description ..................................................................................................55
4.1 System Requirements ..............................................................................................55
4.2 Automation for Printing Machines .............................................................................56
5 Structure of the program and interface .........................................................................58
5.1 Structure of the program ...........................................................................................58
5.2 Operating modes ......................................................................................................59
5.3 Interface Description.................................................................................................59
5.3.1 CPU S7 Simotion............................................................................................60
5.3.2 Simotion CPU S7.............................................................................................61
5.3.3 Structure INPUT DATA in SIMOTION ...................................................................62
5.3.4 Structure OUTPUT DATA in SIMOTION ...............................................................64
6 D445 Simotion.................................................................................................................66
6.1 SIMOTION D Control Units .......................................................................................67
6.1.1 Insert new Device (D445) .....................................................................................69
7 Insert additional Sinamics ..............................................................................................71
8 Hardware configuration Profibus Network ....................................................................78
8.1 Profibus Network Properties .....................................................................................83
9 Simotion - Axis configuration.........................................................................................84
9.1 Axis with gear ratio NOT 1 - 1 ...................................................................................88
10 Sinamics TM41 ................................................................................................................89
10.1 Sinamics TM41 Configuration ...................................................................................91
11 TM41 Simotion configuration .........................................................................................92
12 External Encoder ............................................................................................................96
13 Technological Objects synchronization ...................................................................... 100
14 Execution System ......................................................................................................... 101
15 Programs & Libraries.................................................................................................... 102
16 Trace – Function Generator.......................................................................................... 104
16.1 Trace...................................................................................................................... 104
16.2 Function Generator................................................................................................. 105
17 Measuring Function ...................................................................................................... 106
18 Automatic Controller Setting........................................................................................ 107
19 Stationary/Turning Measurement................................................................................. 110
20 Control Panel ................................................................................................................ 113
21 Appendix A.................................................................................................................... 114
22 Appendix B – StartUp ................................................................................................... 115
23 Appendix C – MDI position ........................................................................................... 123
24 Appendix D – Bode-Nyquist ......................................................................................... 124
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25 Appendix E - Script ....................................................................................................... 133

26 Comunication PLC S7 – Simotion D445 - ROUTING.................................................... 144
26.1.1 Profibus connection........................................................................................ 144
26.1.2 Ethernet connection ....................................................................................... 147
27 Appendix F – Typical Values ........................................................................................ 149
28 Appendix G – Var_Glob ................................................................................................ 151
29 Appendix H – Notes ...................................................................................................... 152
4
1 Electrical drawings
Drive Cliq connection
Sinamics
Rew CU
Simotion
D4x5
Sinamics
Unw CU
5
1.1 Electrical drawings: SIMOTION D4x5
6
1.2 Electrical drawings: SINAMICS CU320
7
1.3 Electrical drawings: SINAMICS CU320-2
8
1.4 Electrical drawings: Double Motor Module
9
1.5 Electrical drawings: TM41
10
1.6 Electrical drawings: Power Supply
11
2 Control Unit
2.1 PLC Hardware Configuration
- Fill in the hardware configuration of the S7 drive Sinamics 120 selecting from the
library:
Profibus-DP\Sinamics\Sinamics S120
- Select the profibus address, the network which must be connected and the version
of the drive (2.5x, 2.6.2 or 4.3.2)
- Setting up a number of word and the communication addresses, for example, as
follows:
Infeed - Telegram 370 1/1 - 256
Drive 1 - Telegram Bico 5/5 - 258
Drive 2 - Telegram Bico 5/5 – 268
- To do this, select the first item in the telegram "Telegram 370, PZD-1 / 1".
- Insert two new items with "Standard telegram 1, PZD-2 / 2," which will then later
modified in automatic mode in "User" (Bico) not listed.
12
- Go to the window and set it up as details in the picture:
- Save, fill and load in the PLC.
13
2.2 Sinamics S120 Drives System
SINAMICS S120 is designed to allow free combination of power and control

performance. Multi-axis drives with higher-level motion control can be implemented
with the SINAMICS S120 modular system as easily as single-drive solutions.
On the SINAMICS S120, the drive intelligence is combined with closed-loop control
functions in Control Units.
These units are capable of controlling drives in Vector, Servo and V/f modes. They
also perform the speed and torque control functions plus other intelligent drive
functions.
The use of a SINAMICS S120 in Vector control mode is recommended for drive
solutions with continuous material webs, for example, wire-drawing machines, film
and paper machines, as well as for hoisting gear, centrifuges and marine drives.
Servo control with SINAMICS S120 is employed for cyclic processes with precise,
highly dynamic position control and servo motors, e.g. in textile, packaging, printing
machines and machine tools.
All SINAMICS S120 components, including the motors and encoders, are
interconnected by a shared serial interface called DRIVE-CLiQ.
DRIVE-CLiQ forms the backplane for the complete drive system. The standardized
cables and connectors reduce the variety of different parts and cut storage costs.
Converter boards (Sensor Modules) for converting standard encoder signals to
DRIVE-CLiQ are available for third-party motors and retrofit applications.
An important digital linkage element of the SINAMICS S120 drive system is the
electronic rating plates integrated in every component.
They allow all drive components to be detected automatically via a DRIVE-CLiQ link.
As a result, data does not need to be entered manually during commissioning or
component replacement - helping to ensure that drives are commissioned quickly
and successfully!
The electronic rating plates of the motors contain, for example, the parameters of
the electrical equivalent circuit diagram and the characteristic data of the built-in
motor encoder, information such as order and identification numbers.
14
The multi-axis design, also, referred to as common DC bus, is very modular with a
power offering of Line Modules and Motor Modules – both available in booksize and
chassis formats. Line Modules function as the central energy supply to the voltage
source DC link. Line Modules are optionally available with regulated
infeed/regenerative feedback to provide a constant DC link voltage. Motor Modules
(DC/AC units) supply the motors with energy from the DC link. All the drive
intelligence is organized into Control Units. The control units perform all the closed-
loop control functions for the drive grouping. They also handle all other drive
functions such as the interconnection of drive related I/O’s, positioning functions,
etc. and feature PROFIBUS DP or PROFINET as the central interface for linking to
higher level automation systems.
On single axis units, also referred to as AC drives, the rectifier and inverter power
section are contained in one device, the Power Module – available in blocksize and
chassis formats. For single axis applications, drive control functions are performed by
a single axis Control Unit (e.g. CU310) mounted on to the Power Module. This
separation of power and intelligence allows for maximum flexibility and scalability.
Integration into multi-axis applications is easily accomplished by connecting al DRIVE
CLiQ link to a multi-axis Control Unit (e.g. CU320). This is accomplished by mounting
a CU adapter (CUA31) on a block size Power Module in place of the single axis
Control Unit.
15
Together this integrated line offers the most optimal drive solution for any
application servo or vector.
2.2.1 CONTROL UNIT
With its separate power unit and Control Unit, the SINAMICS S120 drive system can
be perfectly adapted to a wide variety of different drive tasks.
The Control Unit is selected according to the number of drives to be controlled and
the required performance level, while the power unit must be rated to meet the
energy requirements of the system. The connection between the Control Unit and
power unit is made very simply using the digital system interface
DRIVE-CLiQ.
The CU320 Control Unit has been designed to control multiple drives. A CU320 is
capable of operating up to
• 8 drives in V/f control mode or
• 6 drives in Servo control mode or
• 4 drives in Vector control mode.
The CU320 Control Unit can be used to create links between individual drives and
implement simple technology functions.
CU320 Control Unit features the following interfaces as standard:

• 4 x DRIVE-CLiQ sockets for communication with other DRIVE-CLiQ devices, e.g.,
Motor Modules, Active Line Modules, Sensor Modules, Terminal Modules
• 1 PROFIBUS interface with PROFIdrive V4 profile
• 8 parameterizable digital inputs (floating)
• 8 parameterizable bidirectional digital inputs/digital outputs (non-floating), of
which 6 are high-speed digital inputs
• 1 serial RS232 interface
• 1 interface for the BOP20 Basic Operator Panel
• 1 slot for the CompactFlash Card on which firmware and parameters are stored
• 1 slot for mounting an option module (e.g. TB30 Terminal Board)
• 3 test sockets and one reference ground for commissioning support
• 1 connection for the electronics power supply via the 24 V DC power supply
connector
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• 1 PE (protective earth) connection

• 1 ground connection
A shield connection for the signal cable shield on the option module is located on the
CU320 Control Unit.
The available option slot is used to expand the interfaces, for example, to include
additional terminals or for communication purposes.
The status of the CU320 Control Unit is indicated via multi-color LEDs.
As the firmware and parameter settings are stored on a plug-in CompactFlash card,
the Control Unit can be changed without the need for software tools.
The CU320 Control Unit can be mounted on the side of the Line Module in booksize
format via brackets integrated in a Line Module.
The CU320 Control Unit can also be fixed to the wall of the control cabinet using the
integrated fixing lugs. As the CU320 Control Unit is not as deep as the Line Modules,
suitable spacers are available to increase the depth of the CU320 Control Unit to 270
mm (10.63 in).
DRIVE-CLiQ components, for example, Motor Modules and Active Line Modules, can
be connected to a CU320 Control Unit.
The number of modules depends on the performance required, including duty type
and additional functions.
The BOP20 panel can also be snapped onto the CU320 Control Unit during operation
to perform troubleshooting procedures.
The CU320 Control Unit and other connected components are commissioned and
diagnosed with the STARTER commissioning tool.
Communication between a CU320 Control Unit and the connected components takes
place via DRIVE-CLiQ.
If an application requires more than one Control Unit, the number can be increased
accordingly. The Control Units are then interconnected on a higher-level controller
via PROFIBUS with the PROFIdrive V4 profile.
The integrated safety functions such as e.g. "Safe brake control" ("Safe standstill")
must be selected in two channels. Two digital inputs are required for this purpose.
17
2.2.1.1 CompactFlash Card
The CompactFlash card contains the firmware and parameter settings. It is inserted
into the appropriate slot on the CU310 or CU320 or CU320-2 Control Unit.
18
2.2.2 Power Module
The stand alone version of a SINAMICS S120 drive system consists of a CU310
Control Unit and a Power Module. A mains rectifier, a voltage-source DC link and an
inverter for supplying a motor are integrated in the Power Module.
Power Modules are designed for single drives which are not capable of regenerating
energy to the supply. Generated energy produced during braking is converted to
heat via braking resistors.
Power Modules can also be operated by a CU320 or a SIMOTION D Control Unit, e.g.
in configurations where a single drive has been added to a multi-axis drive grouping.
In this case, the Power Modules in blocksize format must be equipped with the
CUA31 Control Unit Adapter. This is connected with the CU320 or SIMOTION D
Control Unit using DRIVE-CLiQ. Power Modules in chassis format can be directly
connected to the multi-axis Control Unit using a DRIVE-CLiQ cable.
A voltage-source DC link and an inverter for supplying a motor are integrated in the
Motor Module.
Motor Modules are designed for multi-axis drive systems and are controlled by either
a CU320 or a SIMOTION D Control Unit. Motor Modules are interconnected by means
of a shared DC busbar.
Since the Motor Modules share the same DC link, they can exchange energy with one
another, i.e. if one Motor Module operating in generator mode produces energy, the
energy can be used by another Motor Module operating in motor mode. The voltage-
source DC link is suppied with mains voltage by a Line Module.
Line Modules generate a DC voltage from the line voltage and supply Motor Modules
with energy via the voltage-source DC link.
2.2.2.1 Basic Line Modules
Basic Line Modules are designed only for infeed operation, i.e. they are not capable
of recovering regenerative energy to the supply system. If regenerative energy is
produced, e.g. when drives brake, it must be converted to heat by means of a
Braking Module and a braking resistor. When a Basic Line Module is used as the
infeed, the matching line reactor must be installed.
A line filter can be installed optionally to restrict conducted interference to Class C2
limits (EN 61800-3).
19
2.2.2.2 Smart Line Modules
Smart Line Modules can supply energy and return regenerative energy to the supply
system. A Braking Module and braking resistor are required only if the drives need to
be decelerated in a controlled manner after a power failure (i.e. when energy cannot
be recovered to the supply). When a Smart Line Module is used as the infeed, the
matching line reactor must be installed. A line filter can be installed optionally to
restrict conducted interference to Class C2 limits (EN 61800-3).
2.2.2.3 Active Line Modules
Active Line Modules can supply energy and return regenerative energy to the supply
system. A Braking Module and braking resistor are required only if the drives need to
be decelerated in a controlled manner after a power failure (i.e. when energy cannot
be recovered to the supply). In contrast to Basic Line Modules and Smart Line
Modules, however, Active Line Modules generate a regulated DC voltage which
remains constant despite fluctuations in the line voltage. In this case, the line
voltage must remain within the permissible tolerance range. Active Line Modules
draw a virtually sinusoidal current from the supply which limits any harmful
harmonics.
• Active Line Modules in booksize format
When an Active Line Module is used as the infeed, the matching line reactor must be
installed. To minimize interference emission, the Active Line Module should always
be operated with a combination of line filter and line reactor.
All the components required to operate an Active Line Module are integrated in the
Active Interface Module. An external bypass contactor is required in addition for sizes
HX and JX.
Power Modules, Motor Modules and Line Modules are available in formats "booksize",
"blocksize" and "chassis"
• Power Modules in blocksize and chassis formats for single axis,

• Motor Modules and Line Modules for multi axis in booksize and chassis formats.
20
Booksize format units are optimized for multi-axis applications and are mounted
adjacent to one another. The connection for the shared voltage-source DC link is an
integral feature.
2.2.2.4 Active Line Modules in booksize format
The self-commutated feed/feedback units (with IGBTs in infeed and regenerative

feedback directions) generate a regulated DC link voltage. This means that the
connected Motor Modules are decoupled from the line voltage. Line voltage
fluctuations within the permissible supply tolerances have no effect on the motor
voltage. Active Line Modules are designed for connection to grounded-neutral (TN,
TT) and non-grounded (IT) supply systems.
The DC link is pre-charged via integrated precharging resistors.
The Active Line Modules in booksize format feature the following interfaces as
standard:
• 1 power connection via screw-type terminals
• 1 connection for the 24 V DC electronics power supply
via the 24 V terminal adapter included in the scope of
supply
• 1 DC link connection via integrated DC link busbars
• 3 DRIVE-CLiQ sockets
• 2 PE (protective earth) connections
The status of the Active Line Modules is indicated via two

multicolor LEDs.
On the 100 mm (3.94 in) wide Active Line Module, the
shield for the power supply cable can be connected to the
integrated shield connection plate via a shield connection
terminal or tube clip, e.g., Weidmüller type KLBÜ CO 4.
The shield connection terminal must not be used for strain
relief. Shield connection kits are available for the 150 mm
(5.91 in), 200 mm (7.87 in) and 300 mm (11.81 in) wide modules.
The signal cable shield can be connected to the Line Module by means of a shield
connection terminal, e.g. Weidmüller type KLBÜ 3-8 SC.
The scope of supply of the Active Line Modules includes:
21
• DRIVE-CLiQ cable for connection to the Control Unit for drive control on the
immediate left
• DRIVE-CLiQ cable (length depends on module width) to connect Active Line Module
to adjacent Motor Module
• Jumper for connecting the 24 V DC busbar to the adjacent Motor Module
• 24 V terminal adapter (X24)
• Connector X21 for digital inputs
The Active Line Module communicates with the CU 320 Control Unit via DRIVE-CLiQ
and receives its control information via this route.
22
2.2.2.5 Active Interface Modules
Active Interface Modules are used in combination with Active Line Modules in chassis
format. Active Interface Modules contain a clean power filter with basic RI
suppression, the precharging circuit for the Active Line Module, the line voltage
sensing circuit and monitoring sensors. The bypass contactor is an integral
component in types FI and GI, thereby making the module very compact. The
bypass contactor must be provided separately for types HI and JI.
The vast majority of line harmonics are suppressed by the clean power filter.
The scope of supply of the Active Interface Modules
includes:
• Type FI:
- 0.60 m (1.97 ft) DRIVE-CLiQ cable for
connection between Active Interface Module
and Active Line Module
connection between the CU320 or
SIMOTION D Control Unit and first Motor
Module.
• Type GI:
connection between Active Interface Module
and Active Line Module
connection between the CU320 or SIMOTION D Control Unit and first Motor
Module.
• Types HI and JI:
- 2.40 m (7.88 ft) DRIVE-CLiQ cable for connection between Active Interface
Module and Active Line Module
23
2.2.3 Drives
2.2.3.1 Motor Modules
A wide range of single-axis and two-axis Motor Modules with graded current/power
ratings can be supplied:
• Single Motor Modules: Single-axis variant
- Booksize format with rated output currents of 3 A to 200 A
- Chassis format with rated output currents of 85 A to 1405 A
• Double Motor Modules: Two-axis variant
- Booksize format with rated output currents of 3 A to 18 A
In principle, all Single and Double Motor Modules can be operated on Basic Line
Modules, Smart Line Modules or Active Line Modules for the appropriate voltage
range.
2.2.3.2 Single Motor Modules in booksize format
The Single Motor Modules in booksize format feature the following

interfaces as standard:
24
• 2 DC link connections via integrated DC link busbars

• 1 electronics power supply connection via integrated 24 V DC bars
• 1 motor connection, plug-in (not included in scope of supply) or screw-stud
depending on rated output current
• 1 safe standstill input (enable pulses)
• 1 safe motor brake control
• 1 temperature sensor input (KTY84-130 or PTC)
The status of the Motor Modules is indicated via two multi-color LEDs.
The motor cable shield is inside the connector on 50 mm (1.97 in) and 100 mm
(3.94 in) width modules. A shield connection kit can be supplied for 150 mm (5.91
in), 200 mm (7.87 in) and 300 mm (11.81 in) wide modules. On these modules, the
motor cable shield can be connected using a tube clip.
The signal cable shield can be connected to the Motor Module by means of a shield
connection terminal, e.g. Weidmüller type KLBÜ 3-8 SC.
The scope of supply of the Motor Modules includes:
• DRIVE-CLiQ cable (length depends on module width) to connect Motor Module to
adjacent module
• Connector X21
• Connector X11 for the motor brake connection (for Motor Modules with a rated
output current of 45 A to 200 A)
25
2.2.3.3 Double Motor Modules in booksize format
Double Motor Modules feature the following interfaces as standard:

• 2 DC link connections via integrated DC link busbars
• 2 electronics power supply connections via integrated 24 V DC bars
• 2 plug-in motor connections (not included in scope of supply)
• 2 safe standstill inputs (1 input per axis)
• 2 safe motor brake control
• 2 temperature sensor inputs (KTY84-130 or PTC)
The status of the Motor Modules is indicated via two multi-color LEDs.
On Double Motor Modules, the motor cable shield can be connected in the connector.
The signal cable shield can be connected to the Motor Module by means of a shield
connection terminal, e.g. type KLBÜ 3-8 SC by Weidmüller.
The scope of supply of the Motor Modules includes:
• DRIVE-CLiQ cable (length depends on module width) to connect Motor Module to
adjacent module
26
• Connectors X21 and X22
2.2.3.4 Motors with DRIVE-CLiQ interface
DRIVE-CLiQ is the preferred

method for connecting the
encoder systems to
SINAMICS S120.
Motors with DRIVE-CLiQ
interface can be ordered for
this purpose, for example,
1FK7/1FT6 synchronous
motors, 1FW3 torque motors
27
and 1PH7, 1PL6 and 1PH4 asynchronous motors.
Motors with DRIVE-CLiQ interface can be directly connected to the associated Motor
Module via the available MOTION-CONNECT DRIVE-CLiQ cables. The connection of
the MOTION-CONNECT DRIVE-CLiQ cable at the motor has degree of protection IP67.
The DRIVE-CLiQ interface supplies the motor encoder via the integrated 24 V DC
supply and transfers the motor encoder and temperature signals and the electronic
rating plate data, e.g. a unique identification number, rated data (voltage, current,
torque) to the Control Unit. This means that for the various encoder types – e.g.
resolver or absolute encoder – different encoder cables with varying permissible
lengths are now no longer required; just one cable type, MOTION-CONNECT DRIVE-
CLiQ, can be used for all encoders.
These motors simplify commissioning and diagnostics, as the motor and encoder
type are identified automatically.
Motors with DRIVE-CLiQ interface and resolver (2-

pole/multi-pole), incremental encoder sin/cos 1 Vpp,
absolute encoder EnDat (512 pulses/revolution, 2048
pulses/revolution) or single absolute encoder
Max. current requirement at 24 V DC (via Motor Module and 190 mA
MOTION-CONNECT DRIVE-CLiQ cable)
Max. DRIVE-CLiQ cable length • 100 m (328 ft) when using MOTION-CONNECT 500 DRIVE-
CLiQ cables
• 50 m (164 ft) when using MOTION-CONNECT 800 DRIVE-
CLiQ cables
Motor encoder and temperature signals must be connected to the corresponding

Motor Module or Power Module and external encoders to the Control Unit.
2.2.3.5 Motors without DRIVE-CLiQ interface
The encoder and temperature signals of motors without DRIVE-CLiQ interface, as

well as those of external encoders, must be connected via Sensor Modules. Sensor
Modules Cabinet-Mounted are available in degree of protection IP20 for control
cabinet installation, as well as Sensor Modules External-Mounted (degree of
protection IP67).
Only one encoder system can be connected to each Sensor Module.
28
2.3 Sinamics Configuration
Requirements: check if Drive Cliq network is properly wired and if the Compact Flash
memory with the v2.5, 2.6.2 or 4.3.2 firmware is inserted into the CU320.
- Open the software Scout

To insert a new drive, follow these steps:
click on "Insert Single Drive Unit"
select the type of device (Device Type), the version (Version) and the address
(Address Type, Bus addr.)
29
Double click on Configure drive unit
Click on Next pushbutton
To insert a Power Supply select YES and click on Next pushbutton
30
Select the type of Power Supply:

(For example on the simulator 6SL3130-7TE21-6AA1 16kW 27°)
Press "Next"; on the next page leave the check on “Line / DC-Link identification at
first switch-on". In this way, when you first turn on the power, it will be
automatically identified. In "Device voltage connection" set 401 V.
31
401
WARNING!
If the infeed is continually in the controlled mode with high DC link voltages (p3510
> 660 V), depending on the particular application, this can damage the connected
motors that have not been specified for these high voltages.
Before an active infeed with a line supply voltage p0210 > 415 V goes into pulsed
operation it must be ensured that all of the components connected to the DC link can
be permanently operated with DC link voltages exceeding 660 V.
Controlled operation of booksize power units for p0210 > 415 V is possible if the
maximum steady-state DC link voltage (p0280) is increased as follows: p0280 >=
1.5 * p0210 and p0280 > 660 V.
In this case, the setpoint of the DC link voltage p3510 is not automatically adapted.
We recommend p3510 = 1.5 * p0210. Closed-loop voltage controlled operation is
active with p3400.0 = 0 and p3400.3 = 1.
Notice:
For p0210 > 415 V for booksize power units with a supply voltage of 3-ph. 380 ...
480 V, the smart mode is automatically activated (p3400.0 = 1). In this case, the
smart mode cannot be de-activated. This is because in the voltage controlled mode,
the maximum steady-state DC link voltage (p0280) would be exceeded.
For booksize power units with supply voltage of 3-ph. 380 ... 480 V AC, the following
applies:
380 V <= p0210 <= 400 V --> Pre-assignment, setpoint for the DC link voltage:
p3510 = 600 V
32
401 V <= p0210 <= 415 V --> Pre-assignment, setpoint for the DC link voltage:
p3510 = 625 V
416 V <= p0210 <= 480 V --> Smart Mode with non-regulated DC link voltage:
p3510 = 1.35 * p0210
Note:
When pre-assigning the setpoint for the DC link voltage (p3510), the following is
generally valid:
p3510 = 1.5 * p0210
The voltage range for the supply voltage depends on the type and the voltage class
of the power unit.
Active Line Module, 400 V unit: 380 V <= p0210 <= 480 V
Active Line Module, 690 V unit: 660 V <= p0210 <= 690 V
Active Line Module, 500/690 V unit: 500 V <= p0210 <= 690 V
Smart Line Module, 400 V unit: 380 V <= p0210 <= 480 V
Smart Line Module, 690 V unit: 500 V <= p0210 <= 690 V
Press " Next "; select the type of Profibus telegram used.
For Power Supply you have to select "SIEMENS telegram 370, PZD-1 / 1 (370)"
33
To insert a motor select YES and click Next pushbutton
34
On the following page there is no need to check any option.
Press "Next" to select the Power section.

(For example for the simulator 6SL3120-2TE21-8AA0 9.7kW 18A/18A DC / AC)
Press "Next" to select where the engine is connected (X1 Connection / Connection
X2).
If the Active Line is controlled via another CU the following message will appear.
35
Click “OK”
Set “1” in “Infeed in operation.
Press “Next”
36
Press "Next" to select the type of engine connected.

If you use the engine without the interface Drive Cliq, you must manually select the
type of engine and the type of encoder like this:
If you use instead of the engine with the interface Drive Cliq tick "Motor with DRIVE-
CLiQ interface" and "Read motor out again."
Press "Next"; if there is a brake on the engine you can select it on the next page.
37
Press "Next"; if you use interface engines without DRIVE-CLiQ you must select the
type of encoder connected.
Click on OK.
38
If you use an engine with the interface Drive Cliq you do not need any check.
Press "Next" to select the type of Profibus telegram used.
39
Select a telegram Siemens standard, for example for an application Sinamics

(Unwinder or Rewinder) "Standard telegram 1, PZD-2 / 2 (1)" or for an application
Simotion (for devices DP5, DP6, DP7) “106/107, PZD-11/15” for Axis 00 and “105, PZD-
10/10” for axis 01 to axis15; you can modify it later in "Free telegram configuration with
BICO (999)" depending on needs, consistence with which is included in the hardware
configuration in S7 .
In this way the command and status words are automatically wired.
Repeat for all drive.
- Change the communication telegrams with the drives by clicking on

"SINAMICS_S120_CU320-> Configuration."
In the window “PROFIBUS message frame” you have to select “Free telegram
configuration with BICO” and change the length which is similar in configuration set
in HW S7.
40
2.3.1 I/O Configuration
- Setting up the I / O on CU320 / CU320-2. To do this you have to expand the object
CU in the project navigator and click on "Inputs / Outputs". Give as follows:
r722.0 (X122.1) -> Drive_01, p849.0 (OFF3)

r722.1 (X122.2) -> Drive_02, p849.0 (OFF3)
r722.1 (X122.2) -> Drive_02, p849.0 (OFF3)
41
- Save and compile.
2.3.2 Safety Integrated
The "Safety Integrated" functions provide highly-effective application-oriented

protection for personnel and machinery.
These functions are integrated in the drive; this means that a higher-level controller
is not required. The current version of SINAMICS S120 offers the following Safety
Integrated functions (terms as defined in draft standard IEC 61800-5-2):
• Safe Torque Off (STO)
• Safe Brake Control (SBC)
• Safe Stop 1 (SS1)
These safety functions are completely integrated in the drive system and use drive-
specific interfaces:
• 2 input terminals for selection of the "Safe Torque Off" (STO) function
• 2 output terminals for the "Safe Brake Control" (SBC) function
They are fail-safe and fully electronic and therefore ensure short response times.
Error detection is supported by integrated selftests.
Safe Torque Off
"Safe Torque Off" (STO) – also known as "Safe Standstill" (SH) – is a function that
helps prevent the drive from restarting unexpectedly in accordance with EN 60204-1,
Section 5.4. "Safe Torque Off" disables the drive pulses and immobilizes the power
42
supply to the motor. The drive is reliably torque-free. This state is monitored
internally in the drive. Feedback to a higher-level control or integration of a main
contactor are no longer required.
Safe Brake Control
The Safe Brake Control (SBC) function is used to operate holding brakes which are
operative at zero current, e.g. motor holding brakes. The brake control circuit is a
fail-safe, twochannel design.
The Safe Brake Control function is activated when "Safe Torque Off" is selected and
when safety monitors with safe pulse disable are tripped.
Note: "Safe Brake Control" does not detect faults in the brake itself (e.g. worn
brake).
Safe Stop 1
The "Safe Stop 1" function can stop the drive in accordance with EN 60204-1, stop
category 1. When "Safe Stop 1" is selected, the drive brakes along the OFF3 ramp
and automatically activates the "Safe Torque Off"/"Safe Brake Control" function
when the parameterized safety delay timer runs down.
2.3.2.1 The operating principle of Safety Integrated
Two independent switch-off signal paths
Two independent switch-off signal paths are available. All switch-off signal paths are
low active, thereby ensuring that the system is always switched to a safe status if a
component fails or in the event of cable breakage. If an error is discovered in the
switch-off signal paths, the "Safe Torque Off" function is activated and a system
restart inhibited.
Two-channel monitoring structure
All the main hardware and software functions for Safety Integrated are implemented
in two independent monitoring channels (e.g. switch-off signal paths, data
management, data comparison).
43
A cyclic crosswise comparison of the safety-relevant data in the two monitoring

channels is carried out.
The monitoring functions in each monitoring channel work on the principle that a
defined status must prevail before each action is carried out and a specific
acknowledgement made after each action. If these expectations of a monitoring
channel are not fulfilled, the drive coasts to a standstill (two channel) and an
appropriate message is output.
Forced dormant error detection or testing of the switch-off signal paths
Forced dormant error detection of the switch-off signal paths is used to detect errors
in the software/hardware of the two monitoring channels as quickly as possible and
is performed automatically when safety functions are activated/deactivated. To fulfill
the requirements of EN 954-1 regarding early error detection, the two switch-off
signal paths must be tested at least once within a defined time to ensure that they
are functioning properly.
For this purpose, forced dormant error detection must be triggered manually by the
user or automatically. A timer monitors the timing of forced dormant error detection
runs.
A forced dormant error detection run must be performed on the switch-off signal
paths at least once during the time set in this parameter. Once this time has
elapsed, an alarm is output and remains active until forced dormant error detection
is carried out.
When the appropriate safety devices are implemented (e.g. protective doors), it can
be assumed that running machinery will not pose any risk to personnel. For this
reason, only an alarm is output to inform the user that a forced dormant error
detection run is due, thereby requesting that this be carried out at the next available
opportunity. This alarm does not affect machine operation.
The user must set the time interval for carrying out forced dormant error detection
runs to between 0 and 9000 hours depending on the application (factory setting: 8
hours).
Examples of when forced dormant error detection runs are
required:
• When the drives are at a standstill after the system has been switched on
• When the protective door is opened
• At defined intervals (e.g. every 8 hours)
44
• In automatic mode, dependent on time and event.
2.3.2.2 Setting Safety Integrated
- Setting (online only) the Integrated Safety. Click on "Integrated Safety" located in
the project navigator expanding the object drive under "Functions". Click on "Change
settings" and in "Control selection" select "STO/SBC/SS1 via terminal" and configure
as shown:
The inputs must be:

Drive_1 -> CU_004,r722.0 (X122.1) (r722: Bit 0)
Drive_2 -> CU_004,r722.1 (X122.2) (r722: Bit 1)
Set "Safe stop 1 Delay time" to 15.00s and 15000.00ms
45
15.00
15000.00
Click on "Safe standstill Extended settings."
168.00
In "Forced dormant error detection of the shutdown" set 168.00h and click Close.
2.3.3 Script
- Click the right button on the first drive in the project navigator and select:
Expert\Insert Script folder
46
Right click on the Scripts folder you have just created and select "ASCII import ...",
open the file "Script.txt" and now you can modify the parameters you need to
change on the drive.
- Repeat this for the other drive.
47
2.3.3.1 Sample script for a drive Sinamics:
' Drive_CH_Par
'rotation motor reversed

parameters (10,0)= 3 To reverse the direction of
rotation of the engine you
parameters (1821,0)= 1 have to enable the lines
parameters (10,0)= 0 highlighted in the circle.
'Profibus connections Set Point

parameters (1511,0)= "2050:2:" & driveid 'Set Torque Forward
parameters (1522,0)= "2050:3:" & driveid 'Set Torque Limit positive
parameters (1523,0)= "2050:3:" & driveid 'Set Torque Limit negative
parameters (1455,0)= "2050:4:" & driveid 'Speed Loop P Gaing
'Profibus connections Actual

parameters (2051,2)= "80:0:" & driveid 'Actual Torque
parameters (2051,3)= "27:0:" & driveid 'Actual Current
parameters (2051,4)= "35:0:" & driveid 'Actual Temperature
Parameters(1457, 0) = 100.00 'Speed controller P gain adaptation upper

starting point
Parameters(1456, 0) = 10.00 'Speed controller P gain adaptation lower
starting point
Parameters(1459, 0) = 100.0 'Adaptation factor, upper
Parameters(1458, 0) = 10.0 'Adaptation factor, lower
Parameters(1460, 0) = 13.000 'Speed controller P gain adaptation speed,

lower
Parameters(1461, 0) = 100
Parameters(1462, 0) = 2000.00 'Speed controller integral time adaptation
speed lower
Parameters(1463, 0) = 100
Parameters(1441, 0) = 3.00 'Actual speed smoothing time [ms]
Parameters(1512, 0) = 1 'Scaling Additional Torque 1=100%
48
'Parameters(1524, 0) = 100.0 'Scaling Upper Torque Limit

Parameters(1525, 0) = -100.0 'Scaling Lower Torque Limit
Parameters(2000, 0)= 5497.13 'Reference speed reference frequency

Parameters(1082, 0)= 5497.13 'Maximum speed
parameters (2175,0)= 0 'Disable motor locked
‘parameters (1121,0)= 10.00 'OFF1
parameters (1135,0)= 10.00 'OFF3
Parameters (1752,0)= 7000.0 'Motor model
Parameters(2003, 0) = Parameters(333, 0) 'Reference Torque
Parameters(2002, 0) = Parameters(305, 0) 'Reference Current
Parameters(1520, 0) = Parameters(333, 0) * 2
Parameters(1521, 0) = - Parameters(333, 0) * 2
2.3.3.2 Script: execution
To run the script file, first you have to connect On-line with the device and then
click on the botton “Accept and Execute”
2.3.4 Topology
- Check, by clicking on "SINAMICS_S120_CU320-> Topology", the consistency of the

connections of the devices included in topology, with amendments if necessary.
49
Set, for each object, the "Comparative quality" to "Low".
50
2.4 Mapping Profibus communication
In communication we have 5 words in writing and 5 in reading.
2.4.1 PLC -> SINAMICS
The communication from S7 to Sinamics is as follows:

Descrizione Tipo
Commands Word Word
Speed Setpoint Word
Torque Forward Setpoint Word
Torque Limit Setpoint Word
Speed Loop PGain Word
Commands Word:
SetPoint words:
51
2.4.2 SINAMICS -> PLC
The communication from the Sinamics S7 is as follows:
Descrizione Tipo
Status Word Word
Actual Speed Word
Actual Torque Word
Actual Current Word
Actual Temperature Word
Status Word:
52
Actual Words:
53
3 Typical Values
Drives
Unwinder Axis_1 and Axis_2 Pgain P1460 13 Nms/rad
Igain P1462 2000 ms
Motor encoder filter P1441 1 ms
Rewinder Axis_1 and Axis_2 Pgain P1460 15 Nms/rad

Igain P1462 30 ms
Motor encoder filter P1441 1 ms
Power Supply Line contactor monitoring time P861 500 ms
54
4 Application Description
4.1 System Requirements
• SIMOTION SCOUT 4.1.5.6

• SIMATIC STEP 7 V5.5 + SP1
SIMOTION SCOUT
The SCOUT engineering software enables the solution of Motion Control, PLC and technology
tasks in the SIMOTION Motion Control system and supplies all tools for this purpose, such as
programming and parameterization, testing and commissioning, as well as diagnostics.
The SIMOTION D Control Units contain as standard a basic functionality (Kernel), which is
programmable in accordance with IEC 61131.
Loadable technology packages provide further functionalities, such as positioning, synchronous
operation, electronic cams and temperature channels.
These technology packages enable the creation of technological objects, which offer an easy and
overall view of associated functions.
There are various technological objects, which are all created, configured and parameterized in
the same way.
Additionally the technological objects comprise of a programming interface, making it possible to
use the functionality out of the user program.
The high-level language Structured Text (ST) provides all language resources in the form of
commands. This permits the generation of well-structured applications.
The basic commands implement all requirements for:
• data management,
• computing functions,
• control structures
• I/O operations
The addition of the technology packages for Motion Control increases the scope of commands by
adding powerful, highly flexible Motion Control commands (e. g.: _pos(...) for position controlled
axis positioning).
An ST source file basically consists of continuous text. This text can be divided and structured in
sections, which represent logical sections of an ST source file.
These sections can consist of the following:
• Program assigned to a runtime task
55
• Function block with a dedicated memory

• Function without a dedicated memory
Functions and function blocks are not assigned to a runtime task. They are called from programs.
Motion Control Chart (MCC) can be used to formulate the processes of a machine graphically
with simple and logical tools.
The result is one or more flowcharts showing the chronological sequence of the individual
actions.
Above all, MCC supports the simple description of the motion sequences of machines with many
axes with the help of powerful Motion Control commands (e. g. reference axis, position axis,
synchronize or desynchronize cam, and many more).
Different commands are available for controlling the machine, e. g. if conditions must be fulfilled,
I/O signals can be read or set, calculations can be formulated and different control structures
such as condition (IF), cases (CASE) and loops (WHILE, REPEAT UNTIL) can be programmed.
Several MCC programs may be created to describe different process situations. For example,
you can create one MCC program to bring the machine to a defined initial state when it is
powered on, a second MCC program for the normal production sequence, and a third MCC
program to specify what the machine is to do in the event of a fault.
All commands are available in tool bars (sorted according to functions) and are automatically
inserted in the flowchart at the selected point with a click. By clicking on different elements,
individual dialogs for further parameterization are opened. Of course, it is also possible to include
individual comments to document the sequence.
4.2 Automation for Printing Machines
The project was designed to generate different axis operation modes that are needed in printing
presses.
The Virtual Master is the main engine (virtual) machine, which other elements will be
synchronized (in relative or absolute).
It 'also possible to synchronize the engines to an external encoder, as Real Master, for specific
applications.
56
Speed ref
Encoder ext
PLC
Bit VM or RM
VM
TM41
Numerator
denominator
Abs Phasing phase

Draw
MDI Homing
Abs sync
Bit sequence homing
MDI
Bit spd ctrl

With pos loop
Speed
Position control
loop
Bit spd ctrl
Torque limit
Speed loop
MOTOR
57
5 Structure of the program and interface
5.1 Structure of the program
The philosophy of this project is to process the logic in the cyclical

background task and to issue motion commands in the acyclic
Motion Tasks. Each axis has assigned exactly one motion task.
Nowhere else but in this motion task motion commands are issued
(The only other place is in the shutdown task of the Simotion
controller).
Different operation modes are defined for each axis. A mode change
is performed by a restart of the motion task. Each operation mode
scans and executes relevant set point changes.
The structure of the project can be seen in Figure. This picture

shows the processing of the signals from he PLC interface to the
axis.
On top the interface between an external PLC and Simotion can be

seen. This data, control bits and set points, are copied from that
PLCc Interface data structure in the S_Axis program into an internal
interface, the so called STDc Interface. Beside that copy process the
set points are normalized. The structure of those two interfaces is
defined in the library SPrint20.
The Interface description can be found on the following pages.
The data in the STDc Interface is processed in the _Axis program again. In that program a mode
change function is executed. In case a new operation mode is requested on the interface, the
axis motion task is restarted. In that motion task an axis FB, that contains all the axis commands,
is called. The automation concept does not make any difference between real or virtual axes.
Regardless of the axis technology or type the same schematic and interface is used.
58
5.2 Operating modes
Inside the MCC function blocks is a case structure with each branch being a different mode of
operation. Each mode is represented by a number. That makes it easier to handle the logic and
to add new operation modes.
Mode Nr Name Description

1 E_stop Axis in Emergency Stop condition.
5 Enable Axis If the Axis is inactive it will be enabled.
12 Local referencing Homing function is possible here.
The axis running with the speed Dynamic_data.
homing_speed. The axis stop at the zero
position one round after set the actual position
to zero in the position where is the zero mark of
the encoder.
20 Local positioning Absolute positioning always with positive
direction.
The positions are set with the 4 MDI bits.
30 Local speed ctrl Axis run in local with speed setpoint specify.
The position loop is open and the torque limit of
the drive is set by profibus.
31 Local position ctrl Axis run in local with speed setpoint specify.
The position loop is closed.
60 Global gear Axis running under Virtual Master axis.
Here all the possible correction on register are
implemented:
- absolute register movement
- Draw
- absolute synchronization (without lost
absolute register movement already done)
65 Global gear (Gear numerator:=0) This mode is selected when the numerator of
the gear is set at zero.
5.3 Interface Description
The maximum number of bytes that we can use in communications amounted to 244; the number
of axis to manage is 16 real axis plus a Virtual Master.
The words in communication were divided into groups of 16 being the maximum number of word
of consistency managed by SFC14 and SFC15 equal to 16.
59
5.3.1 CPU S7 Simotion
Service Data format Description S7 Simotion

From To From To
Service Input Chanel 1 Word Index for Sinamix-Simotion alarm 2500 2501 4000 4001
mngt
Service Input Chanel 2 Word Drive number (Low byte)+ Parameter 2502 2503 4002 4003
Index (High byte)+ R/W bit (bit 6,7)
Service Input Chanel 3 Word Parameter number 2504 2505 4004 4005
Service Input Chanel 4 Word Parameter value - High 2506 2507 4006 4007
Service Input Chanel 5 Word Parameter value - Low 2508 2509 4008 4009
Virtual Master CMD format Description S7 Simotion
From To From To
Virtual Master Commands Word 2510 2501 4010 4011
00: OFF1 Bool
01: Reset position to zero Bool
02: Reset Alarm Bool
03: Real Master Selection Bool
04: Alm ON (foreseen) Bool
05: Spare Bool
06: Spare Bool
07: Spare Bool
08: Spare Bool
09: Spare Bool
10: Spare Bool
11: Spare Bool
12: Spare Bool
13: Spare Bool
14: Spare Bool
15: Spare Bool
Virtual Master Speed Word Rpm 2512 2513 4012 4013
Real Axis format Description S7 Simotion

From To From To
Real Axis Commands
OFF1 Word Axis 00_15 2514 2515 4014 4015
Start Homing Word Axis 00_15 2516 2517 4016 4017
Start MDI 1 Word Axis 00_15 2518 2519 4018 4019
Start speed ctrl Word Axis 00_15 2526 2527 4026 4027
Start pos ctrl Word Axis 00_15 2528 2529 4028 4029
Rel sync Word Axis 00_15 2530 2531 4030 4031
Abs sync Word Axis 00_15 2532 2533 4032 4033
Direction Word Axis 00_15 2534 2535 4034 4035
Change_Sync_Spd Word Axis 00_15 2536 2537 4036 4037
60
Spare 13 Word Axis 00_15 2538 2539 4038 4039

Spare 14 Word Axis 00_15 2540 2541 4040 4041
Spare 15 Word Axis 00_15 2542 2543 4042 4043
Spare 16 Word Axis 00_15 2544 2545 4044 4045
Real Axis Setpoint
Set Phase 01 – 08 Word Axis 00_07 [°*10000] 2546 25 77 4046 4077
Set Phase 09 – 16 Word Axis 08_15 [°*10000] 2578 26 09 4078 4109
Local Speed Word Axis 00_15 [°/sec] 2610 2641 4110 4141
Torque Limit Byte Axis 00_15 [%] 2642 2657 4142 4157
Speed Loop Pgain Byte Axis 00_15 [%] 2658 2673 4158 4173
Gear numerator Word Axis 00_15 [-] 2674 2705 4174 4205
Gear denominator Word Axis 00_15 [-] 2706 2737 4206 4237
5.3.2 Simotion CPU S7
Service Data format Description S7 Simotion

From To From To
Service Output Chanel 1 Word Index for Sinamix-Simotion alarm 2500 2501 4000 4001
mngt
Service Output Chanel 2 Word Fault number 2502 2503 4002 4003
Service Output Chanel 3 Word R/W confirmation (bit 0,1) 2504 2505 4004 4005
Service Output Chanel 4 Word Parameter value - High 2506 2507 4006 4007
Service Output Chanel 5 Word Parameter value - Low 2508 2509 4008 4009
Virtual Master format Description S7 Simotion

From To From To
Virtual Master status Word 2510 2501 4010 4011
00: Enable Bool
01: Fault Bool
02: Zero Speed Bool
03: Real Master Selection Bool
04: Alm Fault (foreseen) Bool
05: Spare Bool
06: Spare Bool
07: Spare Bool
08: Used for Program version Bool
Virtual Master Actual Speed Word [°/sec] 2512 2513 4012 4013
61
Real Axis format Description S7 Simotion

From To From To
Real Axis Status
Zero Speed Word Axis 00_15 2514 2515 4014 4015
Dec Active Word Axis 00_15 2516 2517 4016 4017
Homing Active Word Axis 00_15 2518 2519 4018 4019
MDI Active Word Axis 00_15 2520 2521 4020 4021
Speed OK Word Axis 00_15 2522 2523 4022 4023
Rel sync OK Word Axis 00_15 2524 2525 4024 4025
Abs sync OK Word Axis 00_15 2526 2527 4026 4027
Fault Word Axis 00_15 2528 2529 4028 4029
Running Word Axis 00_15 2530 2531 4030 4031
Operation Word Axis 00_15 2532 2533 4032 4033
Homing Done Word Axis 00_15 2534 2535 4034 4035
MDI Done Word Axis 00_15 2536 2537 4036 4037
Spare 13 Word Axis 00_15 2538 2539 4038 4039
Spare 14 Word Axis 00_15 2540 2541 4040 4041
Spare 15 Word Axis 00_15 2542 2543 4042 4043
Spare 16 Word Axis 00_15 2544 2545 4044 4045
Real Axis Actual
Actual position 01 – 08 Word Axis 00_07 [°*10000] 2 546 2577 4046 4077
Actual position 09 – 16 Word Axis 08_15 [°*10000] 2 578 2609 4078 4109
Actual Speed Word Axis 00_15 [°/sec] 2610 2641 4110 4141
Actual Torque Word Axis 00_15 [Nm*100] 2642 2673 4142 4173
5.3.3 Structure INPUT DATA in SIMOTION
PLCIO_RA_IN structure input data for the real axis:
Name Format Description

PLC_RA_CW1 STRUCT Control Word
Bit0_off1_estop BOOL 1:ON; 0=OFF=e stop
Bit1_start_homing BOOL 1=ON Homing CMD
Bit2_start_MDI_1 BOOL 1=ON MDI1 CMD
Bit3_start_MDI2 BOOL 1=ON MDI2 CMD
Bit6_start_spd_ctrl BOOL 1=ON SPEED CONTOL
Bit7_start_pos_ctrl BOOL 1=ON POSITION CONTOL
Bit8_rel_sync BOOL 1=ON RELATIVE SYNCRONIZATION
Bit9_abs_sync BOOL 1=ON ABSOLUTE SYNCRONIZATION
Bit10_direction BOOL 1=POSITIVE DIRECTION; 0=NEGATIVE DIRECTION
Bit11_Change_Sync_Spd BOOL 1=60 °/sec (10 rpm); 0=2 4 °/sec (4 rpm)
62
Bit12_spare BOOL
Bit13_spare BOOL
Bit14_spare BOOL
Bit15_spare BOOL
Set_phase_high WORD Set Cylinder phase – High word [°*10000]
Set_phase_low WORD Set Cylinder phase – Low word [°*10000]
Local_Speed_Setpt WORD Local Speed Setpoint [°/sec]
Torque_limit BYTE Set torque limit [%]
Speed_Loop_PGain BYTE Set gain [%]
Gear_Num_Setpoint WORD Set gear numerator [-]
Gear_Den_Setpoint WORD Set gear denominator [-]
PLCIO_VA_IN structure input data for the Virtual Master

PLC_VA_CW1 STRUCT Control Word
Bit0_off1_estop BOOL 1:ON; 0=OFF=e stop
Bit1_set_pos_to_zero BOOL 1=ON Set to zero VM position
Bit2_reset BOOL 1=ON Alarm Reset
Bit3_RM_selection BOOL 1=ON Real Master Selection
Bit4_Alm_ON (foreseen) BOOL 1=ON Power Supply
Bit5_spare BOOL
Bit6_spare BOOL
Bit7_spare BOOL
Bit8_spare BOOL
Bit9_spare BOOL
Bit10_spare BOOL
Bit11_spare BOOL
Bit12_spare BOOL
Bit13_spare BOOL
Bit14_spare BOOL
Bit15_spare BOOL
Local_Speed_Setpt WORD Set VM speed [°/sec]
The structure for data input is defined in the library SPr20_IT: PLCc_RA for real axes and
PLCc_VA for the Virtual Master.
63
5.3.4 Structure OUTPUT DATA in SIMOTION
PLCIO_RA_OUT structure outgoing data for the real axis:

PLC_RA_SW1 STRUCT Status Word
Bit0_zerospeed BOOL 1:ON; axis zero speed
Bit1_dec_active BOOL 1=ON deceleration active
Bit2_homing_active BOOL 1=ON homing active
Bit3_MDI_active BOOL 1=ON MDI active
Bit4_speed_ok BOOL 1=ON speed reached
Bit5_rel_sync_ok BOOL 1=ON relative synchronization ok
Bit6_abs_sync_ok BOOL 1=ON absolute synchronization ok
Bit7_fault BOOL 1=ON axis fault
Bit8_running BOOL 1=ON axis running
Bit9_operation BOOL 1=ON axis operative
Bit10_homing_done BOOL 1=ON homing DONE
Bit11_MDI_done BOOL 1=ON MDI DONE
Bit12_spare BOOL
Bit13_spare BOOL
Bit14_spare BOOL
Bit15_spare BOOL
Actual_position_high WORD Actual axis position – High word [°*10000]
Actual_position_low WORD Actual axis position – Low word [°*10000]
Actual_Speed WORD Actual Local Speed [°/sec]
Actual_Torque WORD Actual torque [Nm*100]
64
PLCIO_VA_OUT structure outgoing data for the Virtual Master

PLC_VA_SW1 STRUCT Control Word
Bit0_operation BOOL 1:ON; VM operative
Bit1_fault BOOL 1=ON fault
Bit2_zerospeed BOOL 1=ON VM zero speed
Bit3_RM_selected BOOL 1=ON Real Master Selected
Bit4_Alm_Fault (foreseen) BOOL 1=ON Power Supply Fault
Bit5_spare BOOL
Bit6_spare BOOL
Bit7_spare BOOL
Bit8_spare BOOL
Bit9_spare BOOL
Bit10_spare BOOL
Bit11_spare BOOL
Bit12_spare BOOL
Bit13_spare BOOL
Bit14_spare BOOL
Bit15_spare BOOL
Speed_Actual WORD Actual VM speed [°/sec]
The structure for outgoing data is defined in the library SPr20_IT: PLCc_RA for real axes and
PLCc_VA for the Virtual Master.
65
6 D445 Simotion
A SIMOTION D Control Unit is used for applications requiring coordinated motion

control such as synchronous operation, electronic gear, cam disk or complex
technology functions.
SIMOTION D Control Units are available in a range of performance variants:
• A SIMOTION D425 Control Unit can control up to 16 axes,
• A SIMOTION D435 Control Unit can control up to 32 axes,
• A SIMOTION D445 Control Unit can control up to 64 axes.
SIMOTION D is the compact, drives-based version of SIMOTION based on the SINAMICS drives
family. With SIMOTION D, the logic, technology functions, motion control and drive control run on
a single, compact hardware platform.
SIMOTION D is available in different performance variants. This ensures the highest degree of
scalability and flexibility. The IEC 61131-3-compliant PLC integrated in SIMOTION D means that
the system is not just capable of controlling sequences of motions, but the entire machine as well.
HMI devices can be operated directly on the onboard PROFIBUS or Ethernet interface for
operator control and monitoring. Functions such as remote maintenance, diagnostics and
teleservice can also be used via these interfaces.
The SIMOTION D controllers basic functionality is supplied with the CompactFlash card and is
loaded when the system is powered on. The basic scope of functions includes the following
software components:
• SINAMICS S120 drive control
• SIMOTION runtime system
- Programmable with several languages conforming to IEC 61131
- Various runtime levels (cyclic, sequential, event-driven)
- PLC and arithmetic functionality
- Communications and management functions
- Motion control functions (Motion Control Basic)
• Test and diagnostic interfaces
Technology packages (TP)
A special feature of SIMOTION is that the basic functionality can be expanded by loading
technology packages, such as:
• Motion control with technology packages:
66
- Positioning – POS
- Synchronous operation/electronic gear – GEAR
- Cam disk – CAM
• Temperature controller - TControl
Since the technology functions have modular licenses, you only pay for what you really need.
6.1 SIMOTION D Control Units
SIMOTION D Control Units are available in a range of performance variants. This ensures the
highest degree of scalability and flexibility. The individual variants SIMOTION D425, SIMOTION
D435 and SIMOTION D445 differ in terms of performance characteristics (Motion Control + PLC)
and the following features:
SIMOTION D425 SIMOTION D435 SIMOTION D445

Maximum number of axes 16 32 64
DRIVE-CLiQ interfaces 4 4 6
Fan/battery module Option Option Required
Additional drives can be operated by means of PROFIBUS or PROFINET with the CU320 Control
Units. Additional drives can also be directly connected to the SIMOTION D445 Control Unit by
means of DRIVE-CLiQ with the SIMOTION CX32 module.
The drives can operate in Servo, Vector or V/f control mode.
Interfaces
• Displays, diagnostics
- LEDs to display operating states and errors
- 7-segment status/error display during system power-up
- 3 test sockets
• Interfaces
- 4 × DRIVE CLiQ (6 × DRIVE CLiQ for SIMOTION D445)
- 2 x Industrial Ethernet
- 2 × PROFIBUS DP
• Integrated I/Os
- 8 digital inputs
- 8 digital inputs/outputs
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• Various
- Terminals for 24 V electronics power supply
- Slot (Option slot) to receive a terminal expansion or additional communications ports
Data storage/data backup
SIMOTION D425, D435 and D445 Control Units have 320 KB of non-volatile SRAM (battery-
backed for at least 5 days) for process variable storage. There are two options for storing data for
a longer period:
• System commands for storing data on the SIMOTION CompactFlash card (CF)
• Use of a battery module
The CompactFlash card stores the runtime software and the user data and programs.
I/O
PROFIBUS DP
• Certified PROFIBUS standard slaves (DP/V0, DP/V1, DP/V2)
• SIMATIC ET 200S/M/X/eco/pro distributed I/O systems DRIVE-CLiQ
• Modules from the SINAMICS range
• DRIVE-CLiQ cables, which are required to connect Line/Motor Modules to SIMOTION
D, are supplied with the Line/Motor Modules (standard length).
The maximum permissible cable lengths should be taken into account when planning the cable
layout.
Malfunctions may occur if longer lengths are used.
The permissible length of PROFIBUS DP cables depends on the configuration.
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Modern machines must be capable of handling ever more complex motion control tasks and
performing the task with increasing accuracy and speed. In regards to this requirement, the
SIMOTION Motion Control System and high-performance SINAMICS S120 drive system form a
perfect team. The SIMOTION D variant, which is physically integrated in the SINAMICS S120
drive, is the ideal solution for machines with a large number of axes and stringent precision
requirements. This distributed automation structure allows the machine to be segmented into
various axis groupings, with each grouping controlled by a separate SIMOTION Motion Control
System. The SIMOTION systems communicate either via PROFIBUS DP or PROFINET. Another
important aspect: The compact machine design, thanks to the distributed automation structure
and a Control Unit directly in the drive.
6.1.1 Insert new Device (D445)
In project navigator double-click on "Create new device" then select CPU type "D445 V4.1" and
Variant "SINAMICS S120 Integrated v2.5 or 2.6.2 in D445."
Press OK and then select the interface for connecting PG / PC.
Press Ok.
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In the hardware configuration is inserted the new D445 and Sinamics Integrated (DP3) connected
to the Integrated profibus network.
70
7 Insert additional Sinamics
From hardware configuration double-click on the device DP1 Simotion to insert a new network
profibus (PROFIBUS (MC)) which will be connected to other devices Sinamics.
Click on “Properties ...”
Click on “New ...” to enter the new network where new devices Sinamics will be connected
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Enter the name of the new network and press OK
Select the transmission speed of the network (12 Mbps) and press OK
Click on Options…
Select “Activate constant bus cycle time” and set “Constant DP Cycle:” to 6.000ms.
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Press OK
Verify that the network selected is that just provided ((PROFIBUS (MC) 12 Mbps)
Press OK
Now you can include in the hardware configuration the Sinamics devices needed.
73
Open the catalog with key
The GSD searched is under PROFIBUS DP ->

SINAMICS -> SINAMICS S120 CU320
Give the address to the new device profibus
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Check the version (2.5x, 2.6.2 or 4.3.2)
Now you can change the telegram communication (this can be done at a later time, when the
drives or TM41 are added, see " Hardware configuration Profibus Network”)
Turning to page "Isochronous Operation" you have to select “Syncrhronize drive to equidistant
DP cycle” and you can set the timing of the network (even this can be done at a later time, see
"Hardware configuration Profibus Network”)
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N.B. you have to verify these set for all new Sinamics devices and also for Synamics Integrated
(DP3).
When you have finished you can Save and Compile HW configuration
You can close Hardware Configuration and return to Scout project.

Now you can place needed devices into the new Sinamics.
From Scout project Navigator click on the new Sinamics and then on "Configure drive unit."
In the Configuration window, leaving "no option module” and press “Continue>”
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The power supply is connected to the Unwinder Sinamics (see man. Sinamics), so you have to
select ”NO” to the request to use a power supply DRIVE-CLiQ connected
Press Continue>
Now you can configure a new drive directly by selecting “Yes” or terminate the wizard by
choosing “No”.
For the parameter of a new drive you follow the Pressing Finish you will close the wizard. You
instructions described in the Sinamics CU can put the necessary arrangements later (see
configuration Sinamics CU configuration)
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8 Hardware configuration Profibus Network
In a system with 16 axes and 16 boards TM41, in addition to Sinamics integrated in Simotion
(node DP3) attached to the profibus integrated, other 4 Sinamics (DP4, DP5, DP6, DP7)
connected to Profibus Master of the machine are needed.
Node Network Devices

DP3 Profibus Integrated TM41 axis 0-11
DP4 Profibus MC TM41 axis 12-15
DP5 Profibus MC Axis 0-5
Sinamics
Integrated
DP3
DP4
DP91 DP5 DP6 DP101 DP7
N.B.: There is a correspondence between the motors connected under Sinamics CU320 (DP5,
DP6 and DP7) and the TM41 connected under Sinamics Integrated (DP3) and Sinamics CU320
(DP4).
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If a motor is present on the machine we can have the related TM41, NOT the opposite.
The TM41 connected to the motors of the CU320 (DP5) are under the drive click network
connected on D445 port X102.
connected on D445 port X103.
connected to the Sinamics CU320 DP4.
Motor TM41 Device Port
Axis 00 TM41_Axis00 D445 X102
Axis 01 TM41_Axis01 (FORESEEN) D445 X101
Axis 12 TM41_Axis12 CU320 DP4 X102
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To set or change the properties click with right button on the device and choose “Object
Properties ... “
On the General page you can set the "Diagnostic Address" used for disabling the device during
the automatic configuration of the machine and the 'Address for "slot" 2 ".
The addresses used are as follows:
Node DP Diagnostic Address Address for “Slot” 2

DP 3 16301 16300
DP 4 16306 16305
DP 5 16311 16310
DP 6 16316 16315
DP 7 16321 16320
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On the page Configuration - Overview you can set the communication telegrams with the devices:
The telegram used for communicating with the TM41 is "Standard message frame3, PZD-5 / 9"
set in the "DP slave properties” of Sinamics correspondent.
The addresses reserved for TM41 are:
Boards Input (9 words) Output (5 words)

TM41 axis 00 –DP3 9 Words 696 5 Words 696
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The telegram used for communication with the axis is "User-defined" set in the "DP slave
properties of Sinamics correspondent.
The addresses reserved for the axes are:
Board Input (9 words) Output (5 words)

Axis 00 – DP5 17 Words 302 13 Words 302
On the page Configuration - Details you can set addresses hardware and the lengths of
telegrams if should be used telegrams with non-standard lengths:
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In Isochronous Operation page, you can set the time ...
Note: using CU320-2 DP cycle Tdp[ms] will be set to 24 instead of 48.
8.1 Profibus Network Properties
To set or change the properties of the Profibus network click with right button on PROFIBUS
(MC): DP Master System and choose Object Properties ... "
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9 Simotion - Axis configuration
In project navigator double-click on "AXES -> Insert axis".

In the window that appears enter the axis name and then select "Synchronous operation"
Press OK
Select the type of axis: "Rotary" and "Electrical" in case of real axis, or: "Rotary" and "Virtual" in
the case of virtual axis
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Press "Continue>"
Press "Continue>"
Select "Modulo axis"
Press "Continue>"
Select the device Sinamics in window "Which drive unit are you using?"
Press "Align SINAMICS devices ..." and select the device to be aligned.
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Press "Align"
Select Drive
Select message frame “106/107, PZD-11/15” for Axis 00
(External Encoder foreseen)
and “105, PZD-10/10” for axis 01 to axis15
Press "Continue>"
Select where the encoder is connected and the encoder type
Press "Continue>"
86
Enter the number of pulses and the encoder resolution
Press "Continue>"
Press "Finish"
87
9.1 Axis with gear ratio NOT 1 - 1
If you have an axis with a gear ratio different from 1 – 1, for example on our machine the
unwinder draw group (gear ratio 3 -1), you can set it under “AXES -> RA_Axis_00 -> Mechanics”
N.B.: If you change the gear ratio you have to change P1082 (Maximum speed [RPM]), P2000
(Reference speed reference frequency [RPM]) on Sinamics Drive and Max speed
(TypeOfAxis.SetPointDriverInfo.DriveData.maxSpeed), nominal speed
(TypeOfAxis.SetPointDriverInfo.DriveData.nominalSpeed) on Simotion Axis.
These parameters are already included in the Machine Script.
88
10 Sinamics TM41
The TM41 Terminal Module supplies TTL signals which simulate an incremental
encoder, e.g. to a higher-level control. The encoder interface (incremental encoder
simulation) can be linked to an encoder signal from the Control Unit, e.g.
incremental encoder sin/cos, by parameter assignment.
The TM41 Terminal Module increases the number of digital inputs/outputs and
analog inputs that are available in the drive system
The following are located on the TM41 Terminal Module:
• 4 bidirectional digital inputs/outputs
• 4 digital inputs (with electrical isolation)
• 1 analog input
• 1 interface for simulation of TTL incremental encoder (RS422)
• 1 LED for signaling zero mark detection for encoder interface
• 1 connection for the 24 V DC supply to digital outputs
• 1 connection for the electronics power supply via the 24 V DC power supply connector
• 1 PE (protective earth) connection
The TM41 Terminal Module can be snapped onto a TH 35 tophat rail to EN 60715 (IEC 60715).
The signal cable shield can be connected to the TM41 Terminal Module via a shield connection
terminal, e.g., Phoenix Contact type SK8 or Weidmüller type KLBÜ CO 1. The shield connection
terminal must not be used for strain relief.
The status of the TM41 Terminal Module is indicated via a multicolor LED.
An LED next to the interface for TTL pulse encoder simulation is illuminated as soon as a zero
mark is detected.
89
90
10.1 Sinamics TM41 Configuration
Under SINAMICS_Integrated or SINAMICS_DP4 click on "Input / Output component -> Insert

input / output component"
Select the type of device (TM41) and assign the desired name
Press OK
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11 TM41 Simotion configuration
In project navigator double-click on "AXES -> Insert axis"

In the window that appears enter the TM41 axis name and then select "Synchronous operation"
Press OK
Select "Rotary" and "Electrical"
92
Press "Continue>"
Press "Continue>"
Press "Continue>"
Select the device Sinamics in the window "Which drive unit are you using?"
Press "Align SINAMICS devices ..." and select the device to be aligned
93
Press "Align"
Select Drive
If you need to change the message communication
Press "Continue>"
94
Press "Continue>"
Press "Finish"
95
12 External Encoder
In project navigator double-click on "EXTERNAL ENCODERS -> Insert external encoder"

Enter the name and press OK
Select the type of encoder
96
Press "Continue>"
Press "Continue>"
Press "Continue>"
97
Select the device Sinamics which is connected to external encoder in the window "Where is the
encoder connected?"
Select the type of telegram used and the type of encoder (for the type of encoder can acquire
data directly from the drive by pressing "Data transfer from the drive")
Press "Continue>"
98
Press "Continue>"
Press "Finish"
99
13 Technological Objects synchronization
In Project Navigator under AXES, select the device that must be synchronized, e.g.
RA_Axis_00_TM41_Follobj, and choose what subject sync, e.g. RA_Axis_00.
How kind of synchronization choose "Set point coupling."
Repeat the same procedure just done for the purpose TM41 to the object axis.
Under AXES select the desired axis and then, e.g. for Axis 00, RA_Axis_00_FollObj, and choose
what to sync it, is normally chosen the Virtual Master (VA_LM1).
How kind of synchronization choose "Set point coupling."
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14 Execution System
To retrieve a program in the task you want, you have to click in the Project Navigator, on
"EXECUTION SYSTEM"
Select the task (e.g. Startup Task, Task Motion ...)
In the column "Programs (number of applications):" select the program and transfer it to the
column "Programs used”: press
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15 Programs & Libraries
ALM: No longer used for the power supply,

connected with the D445, management;
dData: Used to interface with the tool Castomat;

variables defined in it are called in pMain;
DrivePar: Used to read / write drive parameters

SINAMICS; called in BackgroundTask;
extDP: Manages communication between S7 plc

and Simotion system, the programs contained in it are
referred to in BackgroundTask;
F_config: monitor the implementation of the various

devices when the machine is switched on: it deactivates the
devices not present and actives the devices that are present.
The program machine does not run until this FB is not
finished. It’s called in P_conf;
fCasto: Used to interface with the tool Castomat;

variables defined in it are called in pMain;
P_conf: is used for auto configuration of the

machine, it’s called in MotionTask32;
P_fault: used for reading fault / alarms and for

communication with S7 plc, it’s called in BackgroundTask;
pMain: Used to interface with the tool Castomat. The programs are called in:
pcprotudpstartup() Startup_Task
pcprotudp() BackgroundTask
pcprostream() TimerInterruptTask_1(12.00ms)
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S_Axis: used to interfacing with the axis (real and virtual); it’s called in BackgroundTask;
Shutdwn: administering the emergency stop axis, it’s called in ShutdownTask;
Startup: is the only program to be CHANGED during the machine startup; the
configuration of the machine, the positions of MDI and the speed, acceleration and jerk of the
various operating modes are defined in it. It’s called in StartupTask;
It’s possible to modify:
machine configuration, number of engines and related TM41;
MDI positions:
Axis 00 is the unwinder draw group, so there is no need to change the MDI_Pos; for the other
axes MDI_Pos_1 corresponds to the position of pliers angle of 45 ° (for insertion / extraction), the
MDI_Pos_3 corresponds to the vertical position of pliers (for insertion), the other two locations are
used for reversible stations.
TechF: used for the management of faults. It’s called in TechnologicalFaultTask;
Var_Glob: defining the global variables used in the machine program;
M_Axis: handles the different ways of operating axes; it’s called in MotionTask1-16;
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16 Trace – Function Generator
16.1 Trace
You can use the trace to record and save signal characteristics and variable values.
The data recorded can be used to analyze motion sequences of the machine, and for
troubleshooting in user programs, for example. For better diagnostics, variables can
be assigned defined setpoints (function generator) and other variable values
recorded at the same time. You can visualize and edit your measurements in a
diagram.
You can also save the data uploaded from the device and open the data again later.
You can print the curve display for archiving or for quick viewing by clicking the
mouse. Simple measurements of amplitudes and points in time is possible with the
two moveable measuring cursors. Measurements can be mathematically processed
and the results displayed.
To start the trace:
Select Target system > Trace or
select Drives -> Commissioning -> Trace or
select
The Trace Tool window is displayed in the working

area.
Depending on the device, the operation of the
trace is different and more recording possibilities
are available.
Trace for SIMOTION
One Trace tab for the system and program variable trace
Measuring functions for the controller optimization
Additional trigger conditions
4 trace blocks each with 8 channels
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Trace for SINAMICS
One Trace tab for the parameter trace

Measuring functions for the controller optimization
Additional trigger conditions
2 trace blocks each with 8 channels
16.2 Function Generator
The function generator is only displayed in ONLINE mode.
In the Function generator tab, you can generate different signal forms for test
purposes. You can freely parameterize the signals with respect to their properties
(e.g. amplitude, period). The output of the function generator is mapped on a BiCo
parameter. This signal can be further interconnected to one or, if required, several
connector sinks via the BiCo mechanism.
If the measuring functions are used, the function generator can be parameterized in
such a way, that its output signal is applied directly to the control structures. For
this, the function generator deactivates parts of the control if required. If, for
example, you want to measure the response to setpoint changes of the current
controller, the function generator signal is applied directly to the current setpoint and
all higher-level controllers, such as the speed and position controllers, are
automatically switched off by the function generator. The function generator is
mainly used for controller optimization. For this, you can select preset operating
modes which switch the signal into predefined positions of the control loop.
Faulty parameters are displayed in red for input check. You must change this
parameter before you can load the settings to the target system (RT).
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17 Measuring Function
The measuring function is only displayed in ONLINE mode.
The measuring function is used for the controller optimization of the drive. With the
measuring function, you can directly inhibit the influence of higher-level control loops
by means of simple parameterization, and analyze the dynamic response of
individual drives. To do this, the function generator and the trace are coupled. The
function generator signal is applied to the control loop at one position (e.g. speed
setpoint) and at another position (e.g. actual speed value), the trace is recorded.
When you parameterize the measuring function, the trace is also automatically
parameterized. The operating modes to be used are already predefined for the trace.
For easier handling of the controller optimization, predefined measuring functions are
available for selection. The operating mode is automatically set depending on the
measuring function. The following can be set for a selected controller optimization:
Signal form (step or noise), amplitude, settling time of the applied signal
Measuring duration for step functions in the time range
Bandwidth and number of averages in the frequency range for the recording
Depending on the configuration, certain parameters are either not displayed or

displayed in gray. Faulty parameters are displayed in red for input check.
To start the trace:

Select Target system > Measuring function or
select
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18 Automatic Controller Setting
You can use the Automatic controller setting screen form to perform an automatic
setting of the speed controller and the DSC position controller (only SCOUT) for
SINAMICS drive devices. The steps required for this calculation can be controlled
using this screen form. The calculated parameter
values of the speed control or the position
controller can be displayed and then transferred
online to the drive or to the axis on the controller.
The automatic control setting is made from the
Target system > Automatic control setting
menu, or under “Drives -> Commissioning ->
Automatic controller setting”, or by pressing
Requirements
Drive is a SINAMICS drive
Drive is operated in the "SERVO" operating type
The control is performed with the motor encoder
An online connection to the associated drive device exists
You can cancel the automatic controller settings by pressing the SPACER BAR.
The step currently being performed will be cancelled.
The drive is disabled.
This combobox offers all SINAMICS drive devices of the opened project that contain
drives that are operated in the "SERVO" control type and use the motor measuring
system as encoder. Selection is possible provided the control priority has not yet
been fetched.
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After you have assumed control priority and switched on the motor,
you can choose if you want automatically perform all steps of the controller setting starting with
the current marking of the step display. This button will be deactivated once the last possible
step has been performed, or, if you want perform the single step of the controller optimization
marked by the step display will be performed and the step display then incremented by one step.
This button will be deactivated once the last possible step has been performed.
Before starting you can select:

Controller: The controller section can be used to preselect which controller is to
be set. The view on the screen form shows the appropriate controller.
Speed controller (SCOUT and Starter)
Position controller (DSC) (SIMOTION SCOUT).
Prior to accepting the setting, several call conditions are tested and
any unsatisfied conditions displayed.
The selection can be changed at any time provided no step is
currently being executed.
Drive: The drive selection can be used to select a drive that corresponds to
the setting of the drive device field.
The field can only be operated provided the control priority has not
yet been fetched. As soon as a change is registered in the drive
selection field, the parameters of the newly set drive will be reported
in the current value column in the result display for a cyclical
updating.
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Expert mode If the checkbox for expert mode is set, the Amplitude, Bandwidth,
Messages and Offset input field will be displayed. The user can make
in these fields special settings to be used for the next optimization
step.
The checkbox is deselected as default setting. If the checkbox is
deactivated, the parameter settings determined by the optimization
tool are used for the measurement.
When the optimization is finished the table displays the parameters whose values
were determined during the controller optimization.
The Current value column displays the current value of the parameter fetched
cyclically from the target device.
The Calculated value column displays the value of the parameter determined from
the controller setting. Provided no new value has been calculated, the "–" character
is displayed instead of the value. This is also the standard display when the screen
form starts.
If you want apply new values you have to click on “Accept”
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19 Stationary/Turning Measurement
To start the Stationary/Turning Measurement:

select Drives -> Commissioning -> Trace
The motor identification (MotID) helps with determining the motor data, for example,
for third-party motors. It can also be used for series motors, however, it cannot be
guaranteed in all cases that the determined data is more accurate than the stored
data or the datasheet details. Like the kT estimator, the MotID can help to improve
the torque accuracy.
Caution
Incorrect details for the rated current or the maximum current can damage the
motor!
Caution
While a turning measurement is selected and running, you cannot perform any
upload, download, RAM2ROM or reset to the factory settings. This means you cannot
load the data into the PG using a second PG or a new project. This is possible again
only after a power ON/OFF.
Perform a measurement
The Measurement type list shows the available measuring types. When the screen
form is opened, a check is made whether a measurement is already active and, if so,
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it will be displayed. If no measurement is selected, a check is made which

measurement has already been performed and then used as recommendation.
After executing the drive wizard and the subsequent download, the selection in
measurement type is set to "stationary measurement", because the "complete
calculation of the motor/control parameters" has already been performed. The
selection list is not active and the measurement is active (button set to Deactivate
measurement). The next step then involves performing the measurement.
To start the measurement
When you open the screen form in ONLINE mode, the drive control panel that you
require for the measurement if you want to enter the ON command from the control
panel will be opened automatically.
1. First obtain the control priority in the drive control panel.
2. If necessary, click Activate measurement, if it is not yet active, to initiate the
motor data identification with the next ON command, for example, from the
drive control panel. The center of the screen form contains the status display
that shows the progress of the measurement (parameter r47). The motor
identification completes independently and a message appears that the drive
has the power-on inhibit state. After the measurement, the new parameter
values are displayed in the results table. You can compare the old and the
new values.
3. Accept the new values with Apply values.
To start the next measurement
1. Click Next measurement.

The next measurement will be suggested by STARTER and the corresponding
entry displayed in the Measurement type list.
2. Perform the measurement as described above.
3. Continue to perform Next measurement until the no entry appears in the
Measurement type list. You have then performed all required measurements.
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Select measurements yourself
If (and only) you are an experienced user, you should manually select the
measurement in the list. This allows you to perform a specific encoder adjustment or
repeat a measurement.
The specified measurement types depend on the motor.
Perform the measurement as described above.
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20 Control Panel
Click "Control Panel" that is under "Commissioning" in one of the drives just insetred.
In the new window select "Assume Control priority" in order to control the switching
on of the power supply from the control panel with key
By selecting Enable is now possible to run motors controlled by the control panel.
To select another engine the priority control should be given up ( "Give up control priority!").
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21 Appendix A
Typical variables that you can trace in Simotion / Sinamics

Simotion
Following error: _to.RA_Axis_00.servodata.followingerror

Actual Position dell’asse00: _to.RA_Axis_00.positioningstate.actualposition
Actual Velocity dell’asse00: _to.RA_Axis_00.motionstatedata.actualvelocity
Actual Torque dell’asse00: _device\Var_Glob.ra_axis_00_stdcio.out.actual_torque
Sinamics
Select the drive and variablile you want to view.
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22 Appendix B – StartUp
Verify the correct profibus, drive click and safety off connections
Drive Click
Safety Off
Profibus
Verify the address for all the CU320 or CU320-2 connected both under Profibus DP both
under Profibus MC networks
CU320
Remouve the
cover and set
the correct
CU320-2
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Downgrade / Upgrade Firmware
Verify the firmware used for CU320/CU320-2 and Simotion D4x5 insede Scout project
- right click on the control unit

- select Target device -> Device version
Firmware used:
Machine Type Device Firmware
Rotogravure D445 4.1.4.1 (Sinamics Integrated: 2.5x)
CU320 2.5x
Rotogravure D445 4.1.5.6 (Sinamics Integrated: 2.6.2)
CU320-2 4.3.2
CL D425 4.1.5.6 (Sinamics Integrated: 2.6.2)
CU320 2.6.2
CL D425 4.1.5.6 (Sinamics Integrated: 2.6.2)
CU320-2 4.3.2
SL CU320 2.6.2
SL CU320-2 4.3.2
DELTA D445 4.1.5.6 (Sinamics Integrated: 2.6.2)
CU320 2.6.2
DELTA D445 4.1.5.6 (Sinamics Integrated: 2.6.2)
CU320-2 4.3.2
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Use a card reader to open the CU320 / CU320-2 or D4x5 CF, select all except the folder KEYS.
Delete all the selected files and folders.

Copy all files and folders from the correct firmware folder.
Paste into the CU320 / CU320-2 or D4x5 CF
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Download project
D4x5:
In Off-Line mode, Open the D4x5 project, modify, if necessary, the Startup program,
run the Machine Script number 3, number 4 and number 5 (for the printing units you
have on the machine) save and compile
CU320 / CU320-2
In Off-line mode, for all the CU320 open the Scout project; open the motor configuration
window and verify if the “Read out motor again” is active
118
Open the CU320 / CU320-2 Topology and verify if the motor comparative quality is set to
LOW
Download Project
In Off-Line mode, Open the Scout project, for all the CU320 / CU320-2 and for
the D4x5
Right click on the CU320 or on the D4x5 and select “Load to file system”
On the new window push on Select target

and select the card reader with the CF
where you need to download the project
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Insert the CF into the D4x5 or into the CU320 / CU320-2 and switch on the machine.
Connect your computer and go in on-line mode.
Save Ram to Rom and Upload the project into your PG
Save and compile the project uploaded
In on-line mode try to recognize the alarms present on the CU320 / CU320-2 and on the
D4x5.
If you have alarms related to the Safety Integrated function, you need to refresh the
safety integrated properties for all the drives where you have the alarms
- Click on “Change Settings”; if a password is requested type 0000.
- Verify that you have 168h on Forced dormant error detection of the shutdown
15.00
15000.0
168.00
- You DO NOT need to CHANGE other parameters.

- If you are using Scout V4.1.5.6 before clicking on Active Settings you have to
click the pushbutton “Copy”.
- Click on "Activate settings" and ignore the change of password by
clicking on "Cancel".
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- The next request click on "Axis parameter."

- Repeat for all the drives.
Copy
Save Ram to Rom and Upload the project into your PG
Now you can run the script to configure the motor parameters (in On-Line mode).
For Unwinder and Rewinder (and other CU320 / CU320-2 not connected under Profibus
MC) (verify the motor speed P2000 and P1082, you can find the correct value on the
motor calculation table) you have a Script folder under each motor.
For the printing units you have only one script the Machine Script (in On-line mode you
can run the Machine_script number 1 and number 2 for the printing units you have on
the machine)
Save and compile the project uploaded
When you have the CU320 / CU320-2 in green status you must verify if the motor
encoder are connected to the right motor module.
Open the Control Panel, select the motor you need to check, set a reference speed (rpm) and
start the motor.
121
If the actual speed is coherent with the set speed all the motor phases are connected
correctly, on the contrary you must change two phases on the motor.
After this check if the motor turn in wrong way (with reference to the web direction) you have
to change parameter P1821.
Now you can execute the Stationary Measurement (see cap.17 man Simotion).
After Start Up
If you have to change some parameters on motors or TM41 you have to change it on-line
and then you have to save RAM in ROM and to upload the project into the PG
If you have to change some parameters on Technological Object or into Simotion

Program you have to change it off-line and then you have go on-line and download D4x5
project
Troubleshooting: - Sometimes during download you may have alarms and the download do
not end in the correct way. To solve this kind of problem you need to reset the D4x5
performing an MRES of the D4x5:
o In On-Line mode right click on the D4x5, Select Target Device and Operating
mode …
o Now select MRES
122
23 Appendix C – MDI position
If can set four MDI position, two for the unit used in normal work and two for the unit selected in
reversible.
Axis 00 is the unwinder draw group, so there is no need to change the MDI_Pos; for the other
axes MDI_Pos_1 corresponds to the position of pliers angle of 45 ° (for insertion / extraction), the
MDI_Pos_3 corresponds to the vertical position of pliers (for insertion), the other two locations are
used for reversible stations (MDI_Pos_2 corresponds to the position of pliers angle of 45 °, the
MDI_Pos_4 corresponds to the vertical position of pliers).
You car read the position into the RA_Axis_xx parameter (servodata.actualposition)
or into the PROGRAMS Var_Glob

ra_axis_xx_stdcio.actual_position
After you have read the value of the angle

(expressed in degree) you must copy it into the
Program Startup, save and compile the project
and download it into the control unit SIMOTION
D445.
MDI position in Program Startup for the

Axis_01:
123
24 Appendix D – Bode-Nyquist
Excel Configuration
Select Tools -> Add-Ins
Select the Analysis ToolPak

Select Tools -> Macro -> Security
Reduce the Security Level to Low
124
Now select Start -> Control Panel and double click on
Verify the Regional Option setting clicking on Customize
If you do not have “;” like List separetor

Modify it in “;”
125
Open Loop analysis
To start the trace:

select
Select the CU320 where the drive is connected; 1

Select the drive; 2
Select Measuring function: “Speed controller system (excitation after current setpoint filter)”; 3
Set the other variables (Amplitude, Offset, Ramp-up…) 4
1 5
3
2
After you have assumed control priority and switched on the 5
126
motor, the Bode trace starts

When you have finished you have to export the trace in .csv format.
Select Trace -> Measurement -> Export measurements
Select CSV file (*.CSV)
Save the trace

Open the new file.
Copy the columns (A, B, C) with values into the firs worksheet (Dati_GREZZI) of the file “BODE-
NYQUIST mechanical analysis.xls”, verify the consistency of the settings and data and press
the button “One-Click Processing”
127
On the page Bode, get to the first lower peak and measure the frequency (X-Value).
Set this frequency in ωz
Read the Amplitude for ωz/1.41 and ωz/2 and write these values in G(ωz/1.41) dB and G(ωz/2)
dB.
In G(ωz/1.41) Nms/rad and G(ωz/2) Nms/rad you will have the maximum gain for the load you
have analized.
128
Closed Loop analysis
To start the trace:

select
Select the CU320 where the drive is connected; 1

Select the drive; 2
Select Measuring function: “Speed controller setpoint frequency response (after speed setpoint 3
filter)”; 4
Set the other variables (Amplitude, Offset, Ramp-up…)
1 5
3
2
129
After you have assumed control priority and switched on the 5

motor, the Bode trace starts
When you have finished you have to export the trace in .csv format.
Select Trace -> Measurement -> Export measurements
Select CSV file (*.CSV)
Save the trace

Open the new file.
Copy the columns (A, B, C) with values into the firs worksheet (Dati_GREZZI) of the file “BODE-
NYQUIST closed loop analysis.xls”, verify the consistency of the settings and data and press
the button “One-Click Processing”
130
Automatically it calculates Bode and Nyquist diagrams

Remember to Update data on Nyquist page to see the correct diagram
Nyquist diagram is divided in two part, to see system behavior at low and high frequency.
131
If you need to add/change filters, you have to select on Scout Project the Axis Open-loop/Closed-
loop control and click one of the Setpoint filter…
Now you can modify or add new filters

When you change a parameter you need to click on the Accept push button to apply it and if you
need to add new filters, you have to select Filter effective to activate the filter
132
25 Appendix E - Script
It’s possible to modify the parameters both for axis, both for the TM41 and also to mask certain
types of technological objects warnings, using a script ( "Machine_Script") present in folder
"SCRIPT".
Open the script and run it by clicking the button
In the window that appears you can select the type of parameters to
be changed and the devices you want to act.
1) Drive: changes the parameters into the drives connected to the CU320 / CU320-2
(DP5, DP6, DP7) (Execute in ON-LINE)
2) TM41_Sinamics: changes the parameters into the TM41 connected to the Sinamics
Integrated and CU320 / CU320-2 (DP4) (Execute in ON-LINE)
3) TM41_SIMOTION: changes the parameters into the technological objects TM41.
(Execute in OFF-LINE)
4) Simotion_RA: changes the parameters into the technological objects Axis.
5) Mask Alarm 30002: Warnings are being masked for specified items.
6) V_M: changes the parameters into the Virtual Master
After running the selection and press Ok specify into which devices make the changes:
The following is a listing of the script "Machine_Script."

'-----------------------------------------------------------------------------------------------------------------------
' SIEMENS SpA
' (c)Copyright 2008. All Rights Reserved.
'-----------------------------------------------------------------------------------------------------------------------
' Limitation of liability
' The customer receives for the software the non-exclusive, non transferable, free right to use the software; this includes
' the right to change the software, to copy it changed or unchanged, and to combine it with the customer's own software.
' Siemens SpA has not subjected the software to the normal system test otherwise usual for software.
133
' Any liability – irrespective of the legal reason – in particular because of software errors or the associated
' documentation or damages resulting from consulting is excluded, unless, for example, because of premeditation, gross
' negligence, risk to life, injury or health, acceptance of suitability guarantee, malicious concealment of a fault or
' a violation of significant contractual obligations, would force liability. A reversal of the burden of proof to the
' customer's disadvantage is thus not included.
'-----------------------------------------------------------------------------------------------------------------------
' Functionality provided by this script (short description)
' Setting Up The Rotomec Machine Parameters and Mask Alarm 30002
'-----------------------------------------------------------------------------------------------------------------------
' Status: Released (tested)
'-----------------------------------------------------------------------------------------------------------------------
' File name: Machine Script
' System: SIMOTION
' Version: SIMOTION Scout V4.1
'-----------------------------------------------------------------------------------------------------------------------
' Script to be stored on level ... in project (mark appropriate levels with [x] below)
' [ ] External
' [ ] All levels possible
' [ ] Project level
' [x] Device level
' [ ] Object level (TO/DO)
' [ ] Subobject level
'-----------------------------------------------------------------------------------------------------------------------
' Restrictions, known limitations: None.
'-----------------------------------------------------------------------------------------------------------------------
' Requirements, prerequisites, external resources used: None.
'-----------------------------------------------------------------------------------------------------------------------
' Change log table (latest change is at the bottom of the list):
' version date changes applied
' V1.0 2008-07-30 first release
'-----------------------------------------------------------------------------------------------------------------------
'Global Variable Definition
Dim iMyReturn, sSimoParam, sSinaParam, sDeviceName, iNumberofAxisEnd, iNumberofAxisStart, DriveArray,

AxisArray, AxisArray_TM41_FO, AxisArray_FO, AxisArray_TM41, iCounter, DriveArrayDelta, iNumberOfDrives
APP.LogActive = TRUE
APP.LogMode = 1
'Axis Definition
AxisArray = Array("RA_Axis_00", "RA_Axis_01", "RA_Axis_02", "RA_Axis_03", "RA_Axis_04", "RA_Axis_05",

"RA_Axis_06", "RA_Axis_07", "RA_Axis_08", "RA_Axis_09", "RA_Axis_10", "RA_Axis_11", "RA_Axis_12", "RA_Axis_13",
"RA_Axis_14", "RA_Axis_15")
DriveArray = Array("Axis_00", "Axis_01", "Axis_02", "Axis_03", "Axis_04", "Axis_05", "Axis_06", "Axis_07", "Axis_08",
"Axis_09", "Axis_10", "Axis_11", "Axis_12", "Axis_13", "Axis_14", "Axis_15")
TM41Array = Array("TM41_Axis_00", "TM41_Axis_01", "TM41_Axis_02", "TM41_Axis_03", "TM41_Axis_04",

"TM41_Axis_05", "TM41_Axis_06", "TM41_Axis_07", "TM41_Axis_08", "TM41_Axis_09", "TM41_Axis_10",
"TM41_Axis_11", "TM41_Axis_12", "TM41_Axis_13", "TM41_Axis_14", "TM41_Axis_15")
AxisArray_TM41 = Array("RA_Axis_00_TM41", "RA_Axis_01_TM41", "RA_Axis_02_TM41", "RA_Axis_03_TM41",

"RA_Axis_04_TM41", "RA_Axis_05_TM41", "RA_Axis_06_TM41", "RA_Axis_07_TM41", "RA_Axis_08_TM41",
"RA_Axis_09_TM41", "RA_Axis_10_TM41", "RA_Axis_11_TM41", "RA_Axis_12_TM41", "RA_Axis_13_TM41",
"RA_Axis_14_TM41", "RA_Axis_15_TM41")
AxisArray_FO = Array("RA_Axis_00_FollObj", "RA_Axis_01_FollObj", "RA_Axis_02_FollObj", "RA_Axis_03_FollObj",

"RA_Axis_04_FollObj", "RA_Axis_05_FollObj", "RA_Axis_06_FollObj", "RA_Axis_07_FollObj", "RA_Axis_08_FollObj",
"RA_Axis_09_FollObj", "RA_Axis_10_FollObj", "RA_Axis_11_FollObj", "RA_Axis_12_FollObj", "RA_Axis_13_FollObj",
"RA_Axis_14_FollObj", "RA_Axis_15_FollObj")
AxisArray_TM41_FO = Array("RA_Axis_00_TM41_FollObj", "RA_Axis_01_TM41_FollObj", "RA_Axis_02_TM41_FollObj",

"RA_Axis_03_TM41_FollObj", "RA_Axis_04_TM41_FollObj", "RA_Axis_05_TM41_FollObj",
134

"RA_Axis_15_TM41_FollObj")
APP.PrintToLog "Starting Script"
'Select Script Type
sRetVal = InputBox("Which script do you want to apply 1)Drive 2)TM41_Sinamics 3)TM41_SIMOTION

4)Simotion_RA 5)Mask Alarm 30002 6)V_M", , "Insert a number")
iTypeofScript=CInt(sRetVal)
if iTypeofScript < 6 then
'Select Axes
sRetVal = InputBox("Insert the number of the first axis to modify", , "Insert a number")
iNumberofAxisStart=CInt(sRetVal)
sRetVal = InputBox("Insert the number of the last axis to modify", , "Insert a number")
iNumberofAxisEnd=CInt(sRetVal)
end if
Select Case iTypeofScript

Case 1
Modify_Drive()
Case 2
Modify_TM41_Sinamics()
Case 3
Modify_TM41_SIMOTION()
Case 4
Modify_Simotion_RA()
Case 5
Mask_Alarm()
Case 6
Virtual_Master()
End Select
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Modify_Drive
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom drive Parameters for all printing units selected
'
'-----------------------------------------------------------------------------------------------------------------------
' Parameters: None.
'-----------------------------------------------------------------------------------------------------------------------
Private Sub Modify_Drive()

APP.PrintToLog "Modifying Drives Properties"
For iCounter = (iNumberofAxisStart) To (iNumberofAxisEnd)
If (iCounter<=15) Then sDeviceName = "Sinamics_DP7"
If (iCounter=0) Then Sinamics_Motor_Ext_Enc() Else Sinamics_Motor()
APP.PrintToLog("Parameters for drive n. " & iCounter & " changed ")
Next
135
APP.PrintToLog "Everything has gone fine"

End Sub
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Sinamics_Motor_Ext_Enc
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom drive Parameters for unit with External encoder
'
'-----------------------------------------------------------------------------------------------------------------------
' Parameters: None.
'-----------------------------------------------------------------------------------------------------------------------
Private Sub Sinamics_Motor_Ext_Enc()

' Sinamics_Mot with telegram 106 (AXIS_00)
'inversione rotazione motore

'Parameters (10,0)= 3
'Parameters (1821,0)=1
'torque feedback and torque limit
idriveid = PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).driveid
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (922,0) = 999
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (2051,15)= "80:0:" & idriveid 'torque feedback
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1522,0) = "2050:11:" & idriveid 'pos torque lim
from profibus
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1523,0) = "2050:11:" & idriveid 'neg torque lim
from profibus
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1455,0) = "2050:12:" & idriveid 'Pgain
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1528,0)= "1524:0:" & idriveid 'scaling from fix

parameter
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1524,0)= 100.0 'pos scaling
parameter
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1525,0)= -100.0 'neg scaling
'current power torque limit
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (573, 0) = 1
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (2003, 0) =
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters(333, 0) 'Reference Torque = 100% of motor
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (340, 0) = 0 'automatic mot
parameters calculation OFF
' Parameters (640, 0) = Parameters(305, 0)*2 'current limit = 2 * Inom
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters(333, 0)*2 'torque limit pos
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters(333, 0)*-2 'torque limit neg
'Pgain adaption
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1457,0)= 100

136
' disable motor lock
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (2175,0)= 0.0
' emergency stop

'Reference Speed
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (2000, 0) = 1600 *3
'Maximal Speed
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1082, 0) = 1600 *3
'OFF3 ramp
'speed gain
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1460,0)= 100 'Pgain

PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1462,0)= 20 'Igain
'reference model
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1400,0)= "3A8H"

'Active Filter
' Parameters (1656,0)= 0

' Parameters (1658,0)= 1999
' Parameters (1659,0)= 0.7
' Parameters (1660,0)= 1999
' Parameters (1661,0)= 0.7
'Parameters (1668,0)= 1999
'Parameters (1669,0)= 0.7
'Parameters (1670,0)= 1999
'Parameters (1673,0)= 1999
'Parameters (1675,0)= 1999
End Sub
'msgbox driveid
'msgbox parent.parent.TOs("mot_sp2").driveid 'sintassi per prendere le
'connessioni da un drive diverso.
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Sinamics_Motor
137
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom drive Parameters for unit with External encoder
'
'-----------------------------------------------------------------------------------------------------------------------
' Parameters: None.
'-----------------------------------------------------------------------------------------------------------------------
Private Sub Sinamics_Motor()

' Sinamics_Mot with telegram 105
Dim idriveid
'inversione rotazione motore
'Parameters (1821,0)=1
idriveid = PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).driveid
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (922,0) = 999
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (2051,10)= "80:0:" & idriveid 'torque feedback
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1522,0) = "2050:10:" & idriveid 'pos torque lim
from profibus
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1523,0) = "2050:10:" & idriveid 'neg torque lim
from profibus
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1455,0) = "2050:11:" & idriveid 'Pgain

parameter
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1524,0)= 100.0 'pos scaling
parameter
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1525,0)= -100.0 'neg scaling
'current power torque limit
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters(333, 0) 'Reference Torque = 100% of motor
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (340, 0) = 0 'automatic mot
parameters calculation OFF
' PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (640, 0) = PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters(305, 0)*2 'current limit = 2 * Inom
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters(333, 0)*2 'torque limit pos
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters(333, 0)*-2 'torque limit neg
'Pgain adaption

' disable motor lock
' emergency stop
138

'Reference Speed
'Maximal Speed
'OFF3 ramp
'speed gain
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1460,0)= 250 'Pgain

PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1462,0)= 40 'Igain
'reference model
PROJ.devices(sDeviceName).TOs(DriveArray(iCounter)).Parameters (1400,0)= "3A8H"

'Active Filter

' Parameters (1658,0)= 1999
' Parameters (1659,0)= 0.7
' Parameters (1660,0)= 1999
' Parameters (1661,0)= 0.7
'Parameters (1668,0)= 1999
'Parameters (1670,0)= 1999
'Parameters (1673,0)= 1999
'Parameters (1675,0)= 1999
End Sub
'msgbox driveid
'msgbox parent.parent.TOs("mot_sp2").driveid 'sintassi per prendere le
'connessioni da un drive diverso.
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Modify_TM41_Sinamics
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom TM41 Parameters for all TM41s selected
'
'-----------------------------------------------------------------------------------------------------------------------
139
' Parameters: None.

'-----------------------------------------------------------------------------------------------------------------------
Private Sub Modify_TM41_Sinamics()

APP.PrintToLog "Modifying TM41 Properties"
If (iCounter<=11) Then sDeviceName = "Sinamics_Integrated"
'Reference Speed
PROJ.devices(sDeviceName).TOs(TM41Array(iCounter)).Parameters (2000, 0) = 5000
APP.PrintToLog("Parameters for drive n. " & iCounter & " changed ")
Next
End Sub
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Modify_TM41_SIMOTION
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom TM41 Parameters for all TM41s selected
'
'-----------------------------------------------------------------------------------------------------------------------
' Parameters: None.
'-----------------------------------------------------------------------------------------------------------------------
Private Sub Modify_TM41_SIMOTION()

APP.PrintToLog "Modifying TM41 Properties"
sDeviceName = "D445"
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).Symbols("CFG:TypeOfAxis.NumberOfDataSets.DataSet_
1.ControllerStruct.PID_Controller.kp") = 16 'Kp position control
1.DynamicData.positionTimeConstant") = 0.00 '
1.DynamicData.velocityTimeConstant") = 0.00 '
1.ControllerStruct.PID_Controller.preCon") = "YES" 'speed precontrol enabled
1.ControllerStruct.PID_Controller.kpc") = 100 '%of speed precontrol
1.DynamicComp.enable") = "YES" 'enable dead time compensation
1.DynamicComp.T1") = 0.012'dead time compensation
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).Symbols("cfg:TypeOfAxis.GearingPosTolerance.enableC
ommandValue") = 0 'Activation status of the setpoint tolerance
IF (iCounter = 0) then
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.m
axSpeed") = 5000 '* 3 'Maximum Motor Speed
140
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.no
minalSpeed") = 5000 '* 3 'Nominal Motor Speed
ELSE
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.m
axSpeed") = 5000 'Maximum Motor Speed
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.no
minalSpeed") = 5000 'Nominal Motor Speed
END IF
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.sp
eedReference") = 1 'Speed Reference = NOMINAL (1)
APP.PrintToLog("Parameters for TM41 n. " & iCounter & " changed ")
Next
End Sub
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Modify_Simotion_RA
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom Simotion_RA Parameters for all RA selected
'
'-----------------------------------------------------------------------------------------------------------------------
' Parameters: None.
'-----------------------------------------------------------------------------------------------------------------------
Private Sub Modify_Simotion_RA()

APP.PrintToLog "Modifying Simotion Axes Properties"
'---------------Write here the max mechanical speed of the cilinder in grad/sec----------------

'
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.MaxVelocity.maximum") = 9600.0
'(00 is max mechanical) 'grad/sec
'-----------------------------------------------------------------------------------------------
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("SYS:pluslimitsofdynamics.velocity")= 9600.0 'speed

limit axis
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("SYS:userdefaultdynamics.velocity") = 9600.0 'scaling
speed for axis
' Position Controller

' ID
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.NumberOfDataSets.DataSet_1.Contr
ollerStruct.PV_Controller.kv") = 16 'Kp position control
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.NumberOfDataSets.DataSet_1.Dyna
micData.velocityTimeConstant") = 0.00 '
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.NumberOfDataSets.DataSet_1.Dyna
micData.positionTimeConstant") = 0.00 '
ollerStruct.PV_Controller.enableDSC")= "YES" 'DSC enabled
141
ollerStruct.PV_Controller.preCon") = "YES" 'speed precontrol enabled
ollerStruct.PV_Controller.kpc") = 100 '%of speed precontrol
' monitoring
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.GearingPosTolerance.enableComma
ndValue") = 0 'axis doesn't stop when in gearing and max mech. spd is reached
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.MaxJerk.maximum") =
1000000000.00
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.MaxAcceleration.maximum") =
1000000000.00
'gear
if (iCounter = 0) then
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.NumberOfDataSets.DataSet_1.Gear.n
umFactor") = 3 'Motor revolutions
else
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.NumberOfDataSets.DataSet_1.Gear.n
umFactor") = 1 'Motor revolutions
end if
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.NumberOfDataSets.DataSet_1.Gear.d
enFactor") = 1 'Load revolutions
'Speed
if (iCounter = 0) then
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.maxSpee
d") = 1600 * 3 'Maximal Speed
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.nominalS
peed") = 1600 * 3 'Nominal Speed
else
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.maxSpee
d") = 1600 'Maximal Speed
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.SetPointDriverInfo.DriveData.nominalS
peed") = 1600 'Nominal Speed
end if
'passive homing mode
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("cfg:TypeOfAxis.NumberOfEncoders.Encoder_1.IncHo
mingEncoder.passiveHomingMode") = 2 'Homing mode 2=only with zero mark
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).Symbols("CFG:TypeOfAxis.MaxVelocity.maximum") = 9600.0
'(00 is max mechanical) 'grad/sec
APP.PrintToLog("Parameters for Axis n. " & iCounter & " changed ")
Next
142
End Sub
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Mask_alarm
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom Simotion_RA Parameters for all RA selected
'
'-----------------------------------------------------------------------------------------------------------------------
' Parameters: None.
'-----------------------------------------------------------------------------------------------------------------------
Private Sub Mask_Alarm()

APP.PrintToLog "Masking Simotion Axes Alarms"
PROJ.devices(sDeviceName).TOs(AxisArray(iCounter)).TechAlarms("30002").Type = "hidden"
PROJ.devices(sDeviceName).TOs(AxisArray_FO(iCounter)).TechAlarms("30002").Type = "hidden"
PROJ.devices(sDeviceName).TOs(AxisArray_TM41(iCounter)).TechAlarms("30002").Type = "hidden"
PROJ.devices(sDeviceName).TOs(AxisArray_TM41_FO(iCounter)).TechAlarms("30002").Type = "hidden"
Next
End Sub
'-----------------------------------------------------------------------------------------------------------------------
' Subroutine name: Virtual Master()
'-----------------------------------------------------------------------------------------------------------------------
' Description: Modify Custom V_M Parameters
'
'-----------------------------------------------------------------------------------------------------------------------
' Parameters: None.
'-----------------------------------------------------------------------------------------------------------------------
Private Sub Virtual_Master()

'PROJ.devices("D4_No01").TOs("RA_red").
' TO
'---------------Write here the max mechanical speed of the machine in grad/sec----------------

'LM with format
PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("CFG:TypeOfAxis.MaxVelocity.maximum") = 11000.0 'grad/sec

10000grad/sec=500 meter/min with cilinder format 300mm
'-----------------------------------------------------------------------------------------------
PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("SYS:pluslimitsofdynamics.velocity")= 10000.0 'speed limit axis

PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("SYS:userdefaultdynamics.velocity") = 10000.0 'scaling speed for
axis
' monitoring
PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("CFG:TypeOfAxis.GearingPosTolerance.enableCommandValue"
) = 0 'axis doesn't stop when in gearing and max mech. spd is reached
PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("CFG:TypeOfAxis.MaxJerk.maximum") = 1000000000.00
PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("CFG:TypeOfAxis.MaxAcceleration.maximum") =
1000000000.00
'gear
'PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("cfg:TypeOfAxis.NumberOfDataSets.DataSet_1.Gear.denFactor") = 1 'Load revolutions
'PROJ.devices(sDeviceName).TOs("VA_LM1").Symbols("cfg:TypeOfAxis.NumberOfDataSets.DataSet_1.Gear.numFactor") = 1 'Motor revolutions

End Sub
143
26 Comunication PLC S7 – Simotion D445 - ROUTING
You can communicate with Simotion D4x5 via Profibus and/or via Ethernet network.
26.1.1 Profibus connection
You can connect your PC to the Profibus Master network setting the PG/PC Interface according
to network properties.
Select the Interface you are using and click on “Properties…”
Select the transmission rate (12 Mbps) and the profile (DP)
144
To communicate via Profibus you have to enable the routing throw profibus network.
Click on to open NetPro; double click on PG/PC(1)
Click on “New…” to insert the profibus network
Select “PROFIBUS”
Press OK and select PROFIBUS(PLC) 12 Mbps
Press OK
145
Select your PG/PC Interface and click on “Assign”
Select the new interface and press OK
In NetPro a connection between Profibus(PLC) and PG/PC will appear
Save and Compile
146
26.1.2 Ethernet connection
To communicate through Ethernet network you have to disable Rotomec Firewall by clicking on
Then you have to click on the green light of traffic lights and press OK.
To modify the IP address you have to select Internet Protocol (TCP/IP) in window Local Area
Connection Properties and then click on Properties
172. 16 . 9 . 1
Set the PC IP address and the subnet mask to the same values of the Simotion Ethernet port and
change only the last number of the IP address. In Simotion we have two Ethernet port with
different IP address:
IE1 IP 172.16.9.1
Subnet mask 255.255.0.0
IE2 IP 192.168.214.1
Subnet mask 255.255.255.0
Make a ping command (with the address 172.16.9.1) of the Simotion equipment trough the
cmd.exe
147
This is only to be shore that the connection between computer and Simotion Ethernet port 2 it´s
good.
Check for the follow answer
172.16.9.1
172.16.9.1
148
27 Appendix F – Typical Values
Drives
Unwinder Draw Group (Axis 00) Pgain P1460 100 Nms/r
ad
Igain P1462 20 ms
Axis 00 -> Axis 15 Pgain P1460 250 Nms/r

ad
Igain P1462 40 ms
Technological Objects
_to_TM41 Axis 00 -> Axis 15 Kp pos.ctrl TypeOfAxis.NumberOfDataS 16 1/s
ets.DataSet_1.ControllerStruc
t.PID_Controller.kp
_to_Axis 00 -> _to_Axis 15 Kp pos.ctrl TypeOfAxis.NumberOfDataS 16 1/s

ets.DataSet_1.ControllerStruc
t.PV_Controller.kv
Program Startup:
Speed °/s rpm
Homing 180 30
MDI 360 60
abs_register_speed 24 / 60 4 / 10
sync_speed 72 12
2
Acceleration °/s Time from 0 to 1600 rpm
Local 960 10 s
Pos 960 10 s
Clutch 192 50 s
abs_register 250 38 s
synch 720 13 s
draw 1920 5 s
Estop 1920 5 s
149
3
Jerk °/s Time from 0 to max acc
Local 9600 0.1 s
Pos 960 1 s
Clutch 19200 0.01 s
abs_register 8333 0.03 s
synch 7200 0.1 s
draw 19200 0.1 s
Estop 19200 0.1 s
Virtual Master
2
Acceleration °/s Time from 0 to 1600 rpm
Local 1920 5 s
Clutch 960 10 s
draw 960 10 s
Estop 1920 5 s
3
Jerk °/s Time from 0 to max acc
Local 19200 0.1 s
Clutch 9600 0.1 s
draw 9600 0.1 s
Estop 19200 0.1 s
150
28 Appendix G – Var_Glob
If you need to command the different mode

of functioning of the motor (Sync, Local,
Homing, MDI…) you can by-pass the plc by
setting to TRUE the variable
“ra_axis_00_test_io_activated” (for example
for the axis_00) using the “Symbol Browser”
of the program “Var_Glob”.
You can find the command under the
variable ra_axis_xx_axis_data -> in ->
control_1.
Here you can set even phase, local speed,
torque limit and gear
numerator/denominator.
You can read the actual values under

ra_axis_xx_stdcio -> out -> status_1 and
you can read the actual position, speed,
torque and functioning mode number.
151
29 Appendix H – Notes
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153

Preliminary Man Sinamics-Simotion v1 7 Eng

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Preliminary Man Sinamics-Simotion v1 7 Eng

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What components are involved in the Sinamics drive system?

What components are involved in the Sinamics drive system?

How is the control unit configured?

How is the control unit configured?

Preliminary

1 Electrical drawings ...........................................................................................................5

25 Appendix E - Script ....................................................................................................... 133

Drive Cliq connection

1.1 Electrical drawings: SIMOTION D4x5

1.2 Electrical drawings: SINAMICS CU320

1.3 Electrical drawings: SINAMICS CU320-2

1.4 Electrical drawings: Double Motor Module

1.5 Electrical drawings: TM41

1.6 Electrical drawings: Power Supply

2.1 PLC Hardware Configuration

- Go to the window and set it up as details in the picture:

- Save, fill and load in the PLC.

2.2 Sinamics S120 Drives System

SINAMICS S120 is designed to allow free combination of power and control

2.2.1 CONTROL UNIT

CU320 Control Unit features the following interfaces as standard:

• 1 PE (protective earth) connection

2.2.1.1 CompactFlash Card

2.2.2 Power Module

2.2.2.1 Basic Line Modules

2.2.2.2 Smart Line Modules

2.2.2.3 Active Line Modules

• Active Line Modules in booksize format

• Power Modules in blocksize and chassis formats for single axis,

2.2.2.4 Active Line Modules in booksize format

The self-commutated feed/feedback units (with IGBTs in infeed and regenerative

The status of the Active Line Modules is indicated via two

2.2.2.5 Active Interface Modules

2.2.3.1 Motor Modules

2.2.3.2 Single Motor Modules in booksize format

The Single Motor Modules in booksize format feature the following

• 2 DC link connections via integrated DC link busbars

2.2.3.3 Double Motor Modules in booksize format

Double Motor Modules feature the following interfaces as standard:

• Connectors X21 and X22

2.2.3.4 Motors with DRIVE-CLiQ interface

DRIVE-CLiQ is the preferred

and 1PH7, 1PL6 and 1PH4 asynchronous motors.

Motors with DRIVE-CLiQ interface and resolver (2-

Motor encoder and temperature signals must be connected to the corresponding

The encoder and temperature signals of motors without DRIVE-CLiQ interface, as

2.3 Sinamics Configuration

- Open the software Scout

Double click on Configure drive unit

Click on Next pushbutton

To insert a Power Supply select YES and click on Next pushbutton

Click on Next pushbutton

Select the type of Power Supply:

Click on Next pushbutton

To insert a motor select YES and click Next pushbutton

Click on Next pushbutton

On the following page there is no need to check any option.

Press "Next" to select the Power section.

Set “1” in “Infeed in operation.