Cam Generation Error - D445-1 V4.3 Controller

The error 40008 during cam generation, specifically with offset issues on the D445-1 V4.3 controller (while working on D425-2 V5.1), coupled with LCamHdl error 400C/21, strongly suggests a configuration mismatch related to interpolation and offset handling.

Possible Causes & Solutions:

• Technology Object Version: Verify the Technology Objects used for cam generation are compatible with the D445-1 V4.3. Older versions may not handle offsets correctly.
• Interpolation Method: Different controllers/versions may default to different interpolation methods. Explicitly set the interpolation method in your cam profile to ensure consistency.
• Offset Configuration: Double-check all offset parameters (radial, axial, etc.) in your cam profile. Ensure they are within valid ranges for the D445-1.
• Firmware/Software Patch Level: Confirm you are running the latest available firmware and software patches for the D445-1 V4.3.

SiePortal Resources:

• Siemens Industry Online Support - For general troubleshooting and documentation.
• Search SiePortal using keywords "40008 cam generation", "LCamHdl 400C", and "D445-1 offset" to find specific knowledge base articles.

If these steps don't resolve the issue, please provide the cam profile configuration and a sample program for detailed analysis.

Force Limitation with Differential Force Measurement for Hydromotors

You've correctly identified the limitation with using a positive-only force limit when employing differential force measurement for bidirectional hydromotor control. The _enableforcelimitingvalue function inherently works with positive values, causing issues when the differential force becomes negative during reverse operation.

Here's how to address this:

1. Use Two Force Limits: Implement two separate force limits. One for positive differential force (current setup) and another for negative differential force.
2. Scaling and Mapping: Scale your negative differential force measurement to a positive value before applying the force limit. You can achieve this using a mathematical transformation within your control logic (e.g., abs(differential_force) and applying the limit to the absolute value). However, ensure this doesn't negatively impact control responsiveness.
3. Sign Consideration in Controller: Within your force controller logic, consider the sign of the differential force when determining the control action. This ensures the controller responds appropriately to forces in both directions.

Important Resources:

• Refer to the Siemens documentation for the _enableforcelimitingvalue function and related force control parameters within your specific controller (e.g., SINUMERIK, SIMATIC). SiePortal is a good resource: SiePortal
• Check for application examples related to hydraulic cylinder or hydromotor control with force limitation in the Siemens Industry Online Support.

If you can provide the specific controller you are using (e.g., SINUMERIK 840D sl, SIMATIC S7-1500), I can provide more tailored guidance.

Scout V5.5 Installation Error: SetupMode.ini

The error message "With Silent Installations, the SetupMode.ini file must be copied into another directory and changed" indicates an issue with your installation method. This typically occurs when attempting a silent installation without proper configuration.

Resolution:

1. Copy the SetupMode.ini file from the Scout V5.5 installation source to a different directory.
2. Edit the copied SetupMode.ini file to configure your silent installation parameters.
3. Run the installation from this new directory using the modified SetupMode.ini.

For detailed instructions and available parameters, please refer to the Siemens documentation on silent installations for Scout:

If the problem persists, consult the Scout V5.5 documentation or open a support request via SiePortal.

Scout Project Download Issues via VPN - Siemens Self Support

You're encountering difficulties downloading Scout projects and WinCC screens through a VPN due to NAT and IP address conflicts. Here's a breakdown of the issue and potential solutions:

Understanding the Problem

The core problem is that Scout and WinCC are configured with the VPN's IP address (10.9.50.100/10.9.50.101) after you reconfigured the Simotion IP within NetPro. This causes hardware configuration download failures because the hardware configuration itself now references the VPN IP, which is unreachable once the VPN connection shifts or terminates.

Recommended Solutions

1. Maintain Original Simotion IP: The ideal approach is to avoid changing the Simotion's IP address (100.100.100.100) in NetPro. Keep it as the original IP.
2. VPN Routing & NAT: Ensure your VPN setup correctly routes traffic to the Simotion's actual IP (100.100.100.100) through the NAT. Your routing on your PC (route 10.9.50.0 mask 255.255.255.0 100.100.100.111) is a good start, but verify the customer site's VPN device is properly translating 10.9.50.x to 100.100.100.x.
3. Scout/WinCC Configuration: Configure Scout and WinCC to connect to 100.100.100.100 (the Simotion’s actual IP), not the VPN IP (10.9.50.100/10.9.50.101).
4. Hardware Configuration Download: When downloading hardware configurations, verify that all IP addresses within the hardware configuration itself (e.g., for I/O modules) are also correct and reflect the 100.100.100.x addressing scheme.

Additional Resources

• Siemens Industry Support - For general Siemens support articles.
• SiePortal - Access to Siemens documentation, software downloads, and support requests.

Disclaimer: Incorrect network configuration can disrupt operations. Proceed with caution and ensure you have a backup before making any changes.

Migrating Simotion D410 Program to D425

Dear User,

Migrating a Simotion D410 program to a D425 while preserving the existing program logic generally involves these steps:

1. Hardware Configuration: Create a new hardware configuration in TIA Portal V15.1 specifically for the Simotion D425.
2. Program Transfer: Transfer your existing program blocks from the D410 project to the new D425 project.
3. Hardware Mapping: Carefully remap the I/O addresses and signal connections in your program to align with the D425 hardware configuration. Pay close attention to any differences in module addressing.
4. Technology Objects: Review and potentially adjust any technology objects (e.g., axes, drives) to ensure compatibility with the D425’s capabilities.
5. Firmware Compatibility: Ensure the firmware on the D425 is compatible with your TIA Portal version and the program requirements.
6. Testing: Thoroughly test the migrated program on the D425 hardware to verify functionality and address any issues.

For detailed guidance, please refer to the Siemens Support article and FAQ's on SiePortal: Simotion D425 Migration. Also, review the Simotion documentation for specific hardware differences between D410 and D425.

If you encounter specific errors or have further questions, please provide details about the error messages or issues you are facing.

Sincerely,
Siemens Self Support

Simotion CPU Issue & CF-Card Handling

Based on the symptoms (all LEDs blinking red, no communication, error code F) and troubleshooting steps taken, the Simotion CPU likely experienced a critical failure.

CF-Card Transfer to New CPU

Inserting the old CF-card into the new CPU may work, but it's not guaranteed. It depends on whether the firmware and configuration on the old card are compatible with the new CPU's hardware. Given the complete failure you experienced, it’s risky.

New CPU Hardware Version

Since the customer provided the CPU reference number to Siemens, the replacement should be the correct version. However, it's prudent to confirm with Siemens if the delivered CPU is identical in hardware revision. A hardware revision change could necessitate a firmware update or configuration adjustments. Check the article Simotion CPU - How to determine the hardware and firmware version for more details.

New CF-Card Usage

Copying the old content to the new CF-card is not recommended without verifying compatibility. The new CF-card might require a specific firmware version or configuration for optimal performance and stability. Use the Siemens tools to configure the new card.

Multiaxis License

The multiaxis license is typically tied to the CF-card. Contact Siemens support to transfer the license to the new CF-card or the new CPU. Do not attempt to simply copy the license file; this often results in an invalid license. See How do I transfer a license to another hardware? for guidance.

Recommendation: After receiving the new CPU and CF-card, use Siemens tools (e.g., SCOUT) to properly configure the system and apply the necessary licenses. Contact Siemens support for assistance if needed.

Hardware Emergency Stop Implementation in Siemens Systems

Implementing a hardware emergency stop is critical for safety. It's strongly recommended to utilize dedicated safety inputs on your motor starter/drive and safety PLC (e.g., SIMATIC Safety Integrated) rather than relying solely on pulse enable inputs on the motor module.

Recommended Approach: Safety Circuit

A dedicated safety circuit provides the highest level of reliability. This involves:

• Hardware Emergency Stop Buttons: Wired in series.
• Safety Relays/Modules: Like SIRIUS 3RF23/3RF24 or SIMATIC Safety Integrated. These monitor the emergency stop circuit for faults (wire break, short circuit).
• Direct Disconnection: The safety relay/module directly disconnects power to the motor starter/drive.
• Feedback: The safety module provides feedback to the PLC confirming the safe state.

Using Pulse Enable (Not Recommended as Primary Safety)

While you *can* use a pulse enable input, it's not a safety-rated solution. It relies on the PLC continuously sending a pulse, and a PLC failure could prevent the pulse, leading to uncontrolled motion. It can be used as *additional* safety layer with a safety circuit.

Resources

• Siematic Safety Integrated: https://new.siemens.com/global/en/products/automation/industrial-communication/safety-technology.html
• SIRIUS Safety Relays: https://new.siemens.com/global/en/products/automation/industrial-controls/safety-relays.html
• Emergency Stop Function in TIA Portal: Check Siemens documentation for specific details based on your PLC and motor control setup within TIA Portal. Search SiePortal for "Emergency Stop TIA Portal".

Disclaimer: Safety implementations are application-specific. Consult safety standards (e.g., ISO 13849, IEC 61508) and qualified safety engineers to ensure a safe and compliant design.

Error Explanation: TIA Portal Proxy Data Update

The error you're encountering after adding a boolean array to your variable structure likely stems from a size limitation or data type conflict within the proxy data handling in TIA Portal.

Possible Causes & Solutions:

• Data Size Limit: Proxy data has size limitations. Adding a large boolean array may exceed this limit. Try reducing the array size if possible.
• Data Type Compatibility: Ensure the boolean array's data type is fully compatible with the proxy data update mechanism.
• TIA Portal Bug: While less common, there have been instances of bugs affecting proxy data updates. Consider updating TIA Portal to the latest version via Siemens Support.
• Recreate the Proxy: Delete the existing proxy configuration and recreate it from scratch.

Further Investigation:

Please review the TIA Portal documentation regarding proxy data limitations and data type compatibility. You can find helpful resources on the Siemens Industry Online Support. If the issue persists, provide the exact error message and details about the array size for more specific assistance.

Data Exchange between Classic Scout and Scout TIA via DP Communication

Establishing distributed synchronization between Classic Scout and Scout TIA projects using DP communication requires careful configuration on both sides. Here's a breakdown of the key steps and troubleshooting points:

Configuration Steps:

1. Project Settings: Ensure both projects are configured for distributed synchronization. In Classic Scout, check the "Distributed Synchronization" settings under Project Properties. In Scout TIA, verify the relevant settings within the project's General configuration.
2. Communication Channels: Define DP communication channels in both projects, specifying the correct partner device (PLC or other Scout/TIA project).
3. Data Point Mapping: Precisely map the data points you want to exchange between the two projects. This mapping is crucial for correct data transfer.
4. Cycle Time: Configure the synchronization cycle time. Start with a conservative value (e.g., 100ms) and adjust as needed.
5. User Rights: Verify that the users accessing the synchronized data have the necessary permissions in both projects.

Troubleshooting Tips:

• Check Communication: Verify basic DP communication between the PLCs involved using diagnostics tools.
• Error Logs: Examine the error logs in both Classic Scout and Scout TIA for synchronization-related errors.
• Data Type Compatibility: Ensure that the data types of the mapped data points are compatible between the two projects.
• Siemens Support Articles: Review these SiePortal resources for detailed guidance:
  • Distributed synchronization with Scout TIA
  • How do you set up distributed synchronization between Scout and TIA Portal projects?

If issues persist, consider opening a support request through the Siemens Industry Online Support portal, providing detailed project information and error logs for faster resolution.

Uploading/Downloading Parameters with SIMOTION Scout & MicroMaster 440

Dear Sandip,

You can upload and download parameters to/from your MicroMaster 440 inverter using SIMOTION Scout. Here's a guide:

1. Connection: Utilize the PC-Inverter connection kit (MicroMaster 4) you have. This typically uses a standard RS-232 cable.
2. Software Setup: In SIMOTION Scout, configure a communication connection. Select the appropriate COM port corresponding to your PC's RS-232 port. Set the communication parameters (baud rate, data bits, parity, stop bits) as per the MicroMaster 440's manual - typically 9600/8/N/1.
3. Upload/Download: Establish the connection within SIMOTION Scout. Then, use the "Parameter Upload" or "Parameter Download" functions in the software.

Important Resources:

• MicroMaster 440 Configuration with SIMOTION Scout
• SiePortal - Micromaster 440

Refer to the MicroMaster 440 hardware and SIMOTION Scout documentation for detailed instructions and troubleshooting.

Sincerely,
Siemens Self Support

PM340 Power Module Not Recognized After PCB Replacement

Dear Customer,

It appears the Control Unit (CU305 DP) is not recognizing the new driver PCB (A5E03894525) on your PM340 power module after replacement. This typically requires parameter re-initialization.

Here's a troubleshooting approach:

1. Parameter Reset: Perform a full parameter reset on the PM340. In Simotion Scout, navigate to the drive parameters and initiate the reset.
2. Firmware Check: Ensure the CU305 DP and PM340 firmware are compatible. Refer to the Siemens Support Portal for firmware compatibility information.
3. Hardware Detection: After the reset, force a hardware detection/scan in Simotion Scout. This should re-identify the PM340.
4. Module Address: Verify the module address in Simotion Scout matches the physical address set on the PM340 (if adjustable).

If the issue persists, please provide the following information for further assistance:

• Simotion Scout version
• CU305 DP firmware version
• PM340 firmware version
• Any error messages displayed in Simotion Scout

You can find additional resources and FAQs on the Siemens Industry Online Support.

Sincerely,
Siemens Self Support

Profibus Connection Issue: Simotion D435 (Slave) & Simatic S7-315-2DP (Master)

Hello Szymon,

I understand you're facing issues establishing a Profibus connection between your Simotion D435 and Simatic S7-315-2DP, with the S7 as master and Simotion as slave. The Simotion station appears active in the PG/PC interface, but isn't visible in the Simatic HW configuration.

Here are potential causes and troubleshooting steps:

• Profibus Address: Verify the Profibus address configured on the Simotion D435 is unique and doesn't conflict with other devices on the network.
• GSD File: Ensure the correct GSD file for the Simotion D435 is imported into the Simatic S7 hardware configuration. You can find the appropriate GSD file on the Siemens Support website.
• Network Configuration: Double-check the Profibus network termination resistors are correctly installed at both ends of the network.
• Communication Parameters: Confirm that the baud rate, data bits, parity, and stop bits are identically configured on both the Simatic S7 and Simotion D435.
• Simotion Configuration: In the Simotion Scout, verify the Profibus interface is correctly configured as a slave and enabled for communication.

For a detailed guide and example, refer to this FAQ: Profibus DP communication between SIMOTION and SIMATIC S7.

If the problem persists, please provide the following information for further assistance:

• Simotion Scout Version
• STEP 7 Version
• Detailed error messages
• Network topology diagram

Best regards,
Siemens Self Support

Simotion Backup Upgrade from V13 to V14 - PEData.plf Error

Dear Customer,

The error "PEData.plf' could not be upgraded" during a Simotion backup upgrade from V13 to V14 typically indicates an incompatibility or corruption issue with the PEData file. Simply copying the file isn't always sufficient.

Here's a breakdown of potential causes and solutions:

• TIA Portal Version Compatibility: Ensure your TIA Portal V14 is fully updated to the latest Service Pack.
• PEData File Integrity: The PEData.plf file might be corrupted. Try restoring a previous backup if available.
• Hardware Configuration Changes: Significant hardware configuration changes between V13 and V14 can cause upgrade issues.
• Manual Upgrade Required: In some cases, a manual upgrade of the PEData file within TIA Portal V14 is necessary. Open the V13 project, then attempt to save it as a TIA Portal V14 project.

Further Support:

Please refer to the Siemens Support article PEData.plf Upgrade Issues for detailed troubleshooting steps.

If the issue persists, please create a support request on SiePortal with the error screenshot and project details for expert assistance: SiePortal

Sincerely,
Siemens Self Support

Siemens Self Support - Scout Installation Issue

Dear Sam,

Yes, you can install Scout alongside your existing Siemens software (Step 7, TIA Portal versions 13-15). However, the error message indicates a missing dependency.

1. Compatibility: Scout 4.4.0.11 requires SIMATIC S7 F Configuration Pack V5.5.11.0 or higher to be installed. This is a known prerequisite.

2. Download Location: You can download the SIMATIC S7 F Configuration Pack V5.5.11.0 (or a newer version) from the Siemens Support website via SiePortal:

After installing the Configuration Pack, you should be able to install and run Scout 4.4.0.11 without issues.

If you continue to experience problems, please provide more details about your operating system and specific TIA Portal installation configurations.

Sincerely,
Siemens Self Support

Profibus Setpoint Timeout with SINAMICS Drive & SIMOTION D445

You're encountering a common issue when interfacing SINAMICS drives (CU320) with SIMOTION D445 via PROFIBUS, specifically concerning data type mismatches and resulting timeout errors.

Here's a breakdown and troubleshooting steps:

1. Data Type Correction: The parameter r063 (actual speed) is a floating-point value (FLOAT32). Using WORD initially explains the 8x higher value – a WORD represents an integer, leading to scaling issues.
2. DWORD & Timeout: The PROFIBUS timeout when using DWORD likely indicates a data length mismatch within the telegram (PZD2). PZD2 has defined data lengths for each parameter. A DWORD (4 bytes) might be exceeding the expected length for r063 within that telegram.
3. Solution - Floating Point Transfer: SIMOTION needs to read r063 as a floating-point value. You'll likely need to use a data type that supports this and configure the PROFIBUS communication accordingly. Check SiePortal for the correct data type mapping for FLOAT32 in SIMOTION.
4. Telegram Configuration: Verify PZD2 configuration in both SINAMICS and SIMOTION. Ensure the data length and offsets for r063 are correctly defined. Incorrect offsets or lengths will cause the timeout.
5. Scaling: After establishing floating-point communication, ensure proper scaling in your SIMOTION program to interpret the speed value correctly.

Resources:

• SIMOTION and SINAMICS Communication
• PROFIBUS Parameterization Documentation

If the problem persists, provide your exact SIMOTION and SINAMICS firmware versions, and a screenshot of your PROFIBUS address list configuration. Also confirm the exact PZD2 configuration.

Simotion D435 with Sinamics - Motion Freeze After MDS Changeover

Dear MNA,

Based on your description, the issue appears to be related to communication or data inconsistencies between the S7-400 PLC and the Simotion D435 after switching between MDS units. The discrepancy between the PLC-sent setpoint and the value received by Simotion (r2060[1]) is a key indicator.

Here are potential causes and troubleshooting steps:

• Communication Issues: Investigate the PROFINET communication between the PLC and Simotion. Check for packet loss, cable integrity, and correct IP address configuration.
• Telegram Configuration: Verify the Free Telegram configuration (PZD settings) in both Simotion and the PLC. Ensure the setpoint data is being mapped correctly and that there are no conflicts.
• PLC Logic: Review the PLC program's logic handling the MDS changeover and setpoint transmission. Ensure a smooth and consistent transition of setpoint values. Consider adding a brief delay or synchronization mechanism after the changeover.
• Simotion Firmware: Ensure you are using the latest recommended firmware for your Simotion D435 and Sinamics drives.
• Hardware Interference: While less likely, investigate potential electrical noise or interference that might affect communication during the changeover.

Further Investigation:

Access SiePortal and search for similar issues related to "Simotion setpoint mismatch" or "Simotion MDS changeover". You might find relevant FAQs, knowledge base articles, or forum discussions.

If the problem persists, consider opening a support request through Siemens Support with detailed logs from both Simotion and the PLC.

Sincerely,
Siemens Self Support

Simotion C230-2 MMC Card Compatibility with C240

Dear Customer,

You can reuse your existing MMC card (6UA1700-0AA02-0AA0) from the Simotion C230-2 with the new Simotion C240. However, a few steps are necessary to ensure compatibility and proper functionality:

1. Firmware Update: The MMC card may require a firmware update to be fully compatible with the C240. Use Simotion Scout 3.2.0.2 to check and update the firmware.
2. Configuration Transfer: Transfer the existing Simotion project from your C230-2 configuration to the C240.
3. Hardware Configuration: Within Simotion Scout, verify and adjust the hardware configuration to match the C240. Pay attention to differences in I/O modules and their addresses.
4. Download & Test: Download the configured project to the C240 and thoroughly test all functionalities.

For detailed guidance and specific instructions, please refer to the following resources in SiePortal:

• Simotion C240 - Getting Started
• Simotion Scout - Firmware Updates

If you encounter any issues, please don't hesitate to create a support request in SiePortal with detailed information about the problem.

Sincerely,

Siemens Self Support

Simotion D425-2 DP/PN Ascending Order Problem

Dear User,

We understand you're facing issues with an ascending order program in Simotion D425-2 DP/PN simulation, while it functions correctly in S7-1500 simulation. This discrepancy often arises from differences in hardware-specific instruction behavior and cycle times.

Possible Causes & Troubleshooting:

• Cycle Time: Simotion's cycle time is typically faster than S7-1500, potentially causing issues with timing-sensitive logic. Adjust the Simotion cycle time to match the S7-1500 environment as closely as possible.
• Hardware Configuration: Verify the hardware configuration in Simotion precisely mirrors the intended target setup.
• Data Type Mismatch: Ensure consistent data types are used throughout the program.
• Instruction Differences: Some instructions may behave slightly differently between Simotion and S7-1500. Review the Siemens documentation for the specific instructions used in your ascending order logic.

Sample Program & Resources:

You can find relevant examples and documentation on the Siemens Industry Online Support: Siemens Industry Online Support. Search for "Simotion ascending order example" or "Simotion sorting example". Also, explore the SiePortal for Simotion specific FAQs and knowledge base articles: SiePortal.

If the problem persists, please share the program code (or a simplified, representative section) and the Simotion hardware configuration for further analysis.

Sincerely,
Siemens Self Support

Simotion D425-2DP Drive System Issue - Ice Cream Linker

The issue you're experiencing with the Simotion D425-2DP system, where the SAM1(2) drive crashes into the fence at higher production rates (2500 trays/hour), suggests a potential problem with the drive's ability to accurately control position during rapid acceleration/deceleration cycles.

Here's a breakdown of potential causes and troubleshooting steps, leveraging Siemens resources:

Possible Causes:

• Insufficient Jerk/Acceleration/Deceleration Settings: Even though you're achieving high speeds, the *rate* of change in speed (jerk) might be too aggressive for the mechanical system (belt drive) and drive configuration.
• Mechanical Issues: While you mention the motors are the same, inspect the belt tension, pulleys, and linear guides for any slippage or play. Even slight mechanical imperfections are magnified at high speeds.
• Voltage Fluctuations: The low voltage message is a critical clue. Investigate the power supply stability. Voltage dips can cause temporary drive errors.
• Parameter Mismatch: Ensure all drive parameters (especially those related to motion control, like following error windows) are correctly configured for the new Simotion system. Directly converting Allen-Bradley parameters isn't always possible.
• Drive Firmware: Outdated firmware can have known bugs.

Troubleshooting Steps:

1. Review Jerk/Acceleration/Deceleration Profiles: Significantly reduce the jerk, acceleration, and deceleration values in your Simotion configuration. Test incrementally increasing these values to find a stable point.
2. Power Supply Analysis: Monitor the DC bus voltage during operation, especially during acceleration. Use a power quality analyzer if possible. Ensure the power supply can handle the increased load from the higher production rate.
3. Mechanical Inspection: Thoroughly inspect the entire mechanical system.
4. Parameter Verification: Compare the Simotion drive parameters to the manufacturer's specifications for the motors and the system requirements.
5. Firmware Update: Update the drive firmware to the latest version.
6. Following Error Window: Check and potentially increase the following error window.

Resources:

• SiePortal: https://support.industry.siemens.com/ (Search for Simotion D425-2DP troubleshooting, motion control parameters)
• Siemens Industry Online Support: https://www.siemens.com/global/en/products/automation/industry-software/support.html

Important: Due to the potential for damage and safety concerns, carefully test any parameter changes in a controlled environment before returning the system to full production.

Simotion Scout Project Compatibility Issue

You're encountering an error because your Simotion Scout V4.1.5.15 (version 47.80.30.00) is attempting to open a project created with a newer version (62.28.00.00) of the S120 drive firmware/Scout software.

Solution: You must update your Simotion Scout software to a version equal to or newer than the version used to create the backup.

Recommended Update: Download and install the latest Simotion Scout V4.1.5.15 Update from the Siemens Support Portal. Ensure you have the correct update for your specific hardware and software configuration. Check the release notes to confirm compatibility with S120.

Important Note: Always back up your current Scout installation before applying any updates. Refer to the SiePortal documentation for detailed upgrade instructions.