Overview of service and diagnostics. options SIMOTION. SIMOTION SCOUT Overview of service and diagnostics options. Preface 1.

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1 Overview of service and diagnostics options SIMOTION SIMOTION SCOUT Overview of service and diagnostics options Product Information Preface 1 Introduction 2 Part I: Service on the device 3 Part II: Service without SCOUT Engineering System (PC-based, IT DIAG) 4 Part III: Service with SCOUT Engineering System 5 Appendix 6 11/2010

2 Legal information Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed. Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Industry Sector Postfach NÜRNBERG GERMANY Copyright Siemens AG Technical data subject to change

3 Table of contents 1 Preface Preface Introduction Part I: Service on the device Overview LEDs Overview SIMOTION C SIMOTION P320-3/P SIMOTION D4x5/D4x SIMOTION D Communication Board CBE Controller Extension CX32/CX Control Unit CU320/CU Communication Board CBE segment display Interfaces HMI Backing up diagnostic data and non-volatile data Updating devices using the Device Update tool Licensing/License key Overview Checking and amending licensing information Remedial measures in the event of loss Part II: Service without SCOUT Engineering System (PC-based, IT DIAG) Overview Establishing a connection to the device Device diagnostics Overview I&M (identification & maintenance) data Diagnostics buffer System utilization Analyzing user data Diagnostic data and non-volatile data (retain data) Overview Backing up diagnostic data and non-volatile data Storing diagnostic data and non-volatile data Displaying diagnostic data via websites Restoring non-volatile data...60 Product Information, 11/2010 3

4 Table of contents 4.5 Backing up, updating, and restoring device data User-defined service and diagnostics information Part III: Service with SCOUT Engineering System Overview Going online Overview PROFIBUS Ethernet/PROFINET Going online without a user project Going online with a user project Factory settings for SIMOTION devices Device diagnostics Overview Diagnostics buffer System utilization Userlog/Syslog content.txt Service overview Ethernet/PROFINET topology Comparing projects Error handling in technology objects Advanced functions in the address list Testing programs Commissioning functions Appendix Diagnostic data and non-volatile data (retain data) Backing up during operation using a service selector switch Backing up during ramp-up using a service selector switch or INI file Backing up during operation using IT DIAG Restoring non-volatile data Index Product Information, 11/2010

5 Preface Preface Contents This document is part of the SIMOTION Service and Diagnostics documentation package. Area of application This manual is valid for SIMOTION V4.2. Information in this manual The following is a list of chapters included in this manual along with a description of the information presented in each chapter. Part I: Service on the device This chapter outlines the diagnostics options available on the device and contains references to additional descriptions as well as descriptions relating to specific devices. Part II: Service without SCOUT Engineering System (PC-based, IT DIAG) This chapter outlines the diagnostics options available with PC-based systems and with IT DIAG, and contains references to additional descriptions. Part III: Service with SCOUT Engineering System This chapter outlines the diagnostics options available with the SCOUT Engineering System and contains references to additional descriptions. Appendix The appendix contains detailed descriptions and guidelines relating to the individual chapters. Index Keyword index for locating information. An overview of the SIMOTION documentation can be found in a separate list of references. This documentation is included as electronic documentation in the scope of delivery of SIMOTION SCOUT. It comprises 10 documentation packages. The following documentation packages are available for SIMOTION V4.2: SIMOTION Engineering System SIMOTION System and Function Descriptions SIMOTION Service and Diagnostics SIMOTION IT SIMOTION Programming Product Information, 11/2010 5

6 Preface 1.1 Preface SIMOTION Programming - References SIMOTION C SIMOTION P SIMOTION D SIMOTION Supplementary Documentation Additional information Click the following link to find information on the the following topics: Ordering documentation/overview of documentation Additional links to download documents Using documentation online (find and search in manuals/information) Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following address: docu.motioncontrol@siemens.com My Documentation Manager Click the following link for information on how to compile documentation individually on the basis of Siemens content and how to adapt this for the purpose of your own machine documentation: Training Click the following link for information on SITRAIN - Siemens training courses for automation products, systems and solutions: FAQs You can find Frequently Asked Questions on the Service&Support pages under Product Support: Technical support Country-specific telephone numbers for technical support are provided on the Internet under Contact: 6 Product Information, 11/2010

7 Introduction This manual lists the system diagnostics options available for SIMOTION devices. It also contains references to additional manuals and online help texts featuring the detailed information that is applicable in each case. The Manuals and Commissioning Manuals for the individual platforms describe device-specific diagnostics options in detail. Note The full version of this manual is available as an online help containing links. This manual (i.e. the PDF version) provides an overview of how this help text is organized and structured. It does not include links to subjects that are only covered in the online help. The relevant manual is referred to in each case. Note In the event of an error/fault (e.g. CPU STOP), analyze the entries in the diagnostics buffer. You can access this in any of the scenarios covered here (Parts I to III). An overview of the scenarios is provided later. Comprehensive diagnostic data (Page 53) can be generated to enable the machine manufacturer or SIEMENS to carry out a more in-depth analysis. Figure 2-1 Overview of functions associated with diagnostics options Product Information, 11/2010 7

8 Introduction 2.1 Note If you contact the hotline for support, you should provide a description of the error/fault scenario that is as precise and detailed as possible. Depending on the nature of the error/fault, the following information may be useful: Diagnostics buffer backup data (see also the descriptions of scenarios without the SCOUT Engineering System (Page 54) and with the SCOUT Engineering System (Page 79)) Full alarm messages with numbers and all additional information State of LEDs/7-segment displays Installed software versions (SIMOTION SCOUT > Help > Information > System info...) Screenshots of error/fault messages and/or dialogs 8 Product Information, 11/2010

9 Introduction 2.1 Part I Service on the device (Page 13) Part I describes the diagnostics and service options that can be implemented directly on the device. Figure 2-2 Example: D4x5 module Figure 2-3 Example - SIMOTION P350 - P state Product Information, 11/2010 9

10 Introduction 2.1 Part II Service without SCOUT Engineering System (PC-based, IT DIAG) (Page 45) Part II describes the service options that can be implemented without the SCOUT Engineering System, via the Ethernet interface of SIMOTION devices. Diagnostic functions can be viewed using an Internet browser. Figure 2-4 Example: IT DIAG - diagnostics in browser Figure 2-5 Example: Simplified websites, e.g. for PDA or MP Product Information, 11/2010

11 Introduction 2.1 Part III Service with SCOUT Engineering System (Page 63) Part III presents the comprehensive range of SIMOTION SCOUT Engineering System functions that are available for error/fault diagnostics. Figure 2-6 Example: SIMOTION SCOUT, Device diagnostics Product Information, 11/

12 Introduction Product Information, 11/2010

13 Part I: Service on the device Overview The device hardware offers various displays and interfaces that may be used for diagnostics purposes. Diagnostic information can be displayed either directly on the device (e.g. by means of LEDs) or indirectly (e.g. HMI via Ethernet interface). In the case of SIMOTION D, a service selector switch can be used to initiate a backup of diagnostic data on the device and write this to the memory card. Figure 3-1 Interfaces and front panel elements - example of SIMOTION D425 and SIMOTION D435 Product Information, 11/

14 Part I: Service on the device 3.1 Overview Service selector switch/button The service selector switch enables diagnostic data backed up in a SIMOTION device in the event of an error/fault to be stored offline without SIMOTION SCOUT. For details, please refer to Backing up diagnostic data and non-volatile data (Page 40). SIMOTION D modules have a service selector switch that is important for service and diagnostic functions. In "normal" operation, this switch must remain in the 0 position. See also Backing up during operation using a service selector switch (Page 95) and Backing up during ramp-up using a service selector switch or INI file (Page 97). With SIMOTION P320-3/P350-3, virtual versions of the service selector and mode switches and the LEDs appear in the SIMOTION P state application. See also Backing up during operation using a service selector switch (Page 95) and Backing up during ramp-up using a service selector switch or INI file (Page 97). SIMOTION C does not provide any switches on the device for diagnostic functions. Errors/faults and states are displayed by means of LEDs. Part II (Page 53) contains a detailed description of how diagnostic data and non-volatile data should be handled. Mode switch You can use the mode switch to set the operating mode on the device. With SIMOTION P, the function of this switch is implemented by means of the SIMOTION P state application. It is also possible to change the operating mode via SIMOTION SCOUT. Operating modes, based on the example of SIMOTION D4x5: RUN SIMOTION D4x5 is processing the user program. The technology packages are active in this state. They can execute commands from the user program. STOPU SIMOTION D4x5 is not processing a user program. The technology packages are active. Test and commissioning functions can be executed. The I/O modules are in a safe state. This means, for example, that digital outputs are "LOW" and analog outputs are de-energized or at zero current. STOP SIMOTION D4x5 is not processing a user program. It is possible to load an entire user program. All system services (communication, etc.) are active. The I/O modules are in a safe state. This means, for example, that digital outputs are "LOW" and analog outputs are de-energized or at zero current. The technology packages are not active. MRES Switch position for overall reset of the module. Note Please take note of the information in the Manuals for the switches. 14 Product Information, 11/2010

15 Part I: Service on the device 3.2 LEDs Additional information Links in the Guides menu of the online help SIMOTION C Operating Instructions SIMOTION D4x5 Manual SIMOTION D4x5 Commissioning and Hardware Installation Manual SIMOTION D4x5-2 Manual SIMOTION D4x5-2 Commissioning and Hardware Installation Manual SIMOTION D410 Manual SIMOTION D410 Commissioning Manual SIMOTION P320-3 and Panels Manual SIMOTION P350-3 and Panels Manual 3.2 LEDs Overview Every SIMOTION device features LEDs that are used for device diagnostics. The LED displays indicate the different operating modes and any errors/faults that occur. They do so by lighting up, flashing, or flickering in different colors. With SIMOTION P320-3/P350, representations of the LEDs appear in the SIMOTION P state application. Note A STOPU LED may also light up if an axis control panel is activated. The STOPU LED flickers when a CF/MMC card is being formatted. This does not indicate an error/fault. See also Overview (Page 53) Backing up diagnostic data and non-volatile data (Page 40) Backing up during operation using a service selector switch (Page 95) Backing up during ramp-up using a service selector switch or INI file (Page 97) Part II: Service without SCOUT Engineering System (PC-based, IT DIAG) (Page 45) Product Information, 11/

16 Part I: Service on the device 3.2 LEDs SIMOTION C Figure 3-2 LED displays on the device - example of SIMOTION C240 PN Note The SIMOTION C Operating Instructions contain a detailed description of the LED displays, including all the possible combinations and flashing frequencies. 16 Product Information, 11/2010

17 Part I: Service on the device 3.2 LEDs Typical errors Table 3-1 Typical errors Error Frequent causes Remedy SF LED lights up red (error/fault state on the SIMOTION C) An event which can be acknowledged is pending (alarm, message, note) Acknowledge the event. A fault has occurred that does not allow a response from the user program SF LED flashes red (error/fault state on the SIMOTION C) License missing for licensed technology/optional objects Check the licenses. 5 VDC does not light up (supply voltage for electronics) No line supply connected or switched on No specified load current supply connected Module not connected correctly Defective module Switch the SIMOTION device off and then on again. Check the line supply connection and the module STOP LED lights up yellow (control is in STOP mode - diagnostics with Engineering System or IT DIAG) I/O access error Correct I/O access Program error (e.g. floating point exception) Technological alarms with CPU STOP response STOP LED flashes yellow (overall reset request) Memory card has been removed The non-volatile data does not match up with the project on the memory card Localize error: Check entries in the device diagnostics Example: Entry "Operating mode transition blocked" -> check error before this -> entry "I/O access error" Overall reset STOPU LED lights up or flashes yellow (control in STOP mode of user program) The technology packages are active The user program is not active or is faulty Device stuck at startup task Check the entries in the diagnostics buffer and the user program. Switch the control to RUN mode. Product Information, 11/

18 Part I: Service on the device 3.2 LEDs Error Frequent causes Remedy BUS1F, BUS2F LED lights up red (fault on PROFIBUS DP interface) Terminating resistor missing or in the wrong place Not all of the connected devices are switched on Cabling fault Incorrect baud rate configured or incorrect baud rate set on a bus node Configuration error Parameter assignment error Check terminating resistor, bus nodes, cabling, baud rate, configuration settings, and configuration in HW Config Table 3-2 Typical C240 PN errors Error Frequent causes Remedy PROFINET Link LED does not light up There is no physical connection Check the cabling, connectors, and device. The connected device is not switched on PROFINET Activity LED does not light up continuously There is no message frame traffic If the Link LED is green, use a ping command to check that the system is ready for communication PROFINET Fault LED lights up (bus fault) No physical connection to a subnet/switch Incorrect transmission rate Full duplex transmission is not activated PROFINET Fault LED flashes red (bus fault) Failure of a connected I/O device At least one of the assigned I/O devices cannot be addressed Incorrect or no configuration settings PROFINET Sync LED does not light up or flashes SIMOTION C task system is not synchronized with the send cycle of PROFINET IO IRT Check configuration settings, check IO device, check connection Check configuration settings, check IO device Check configuration settings, check error message in SINAMICS diagnostics buffer Additional information Links in the Guides menu of the online help SIMOTION C Operating Instructions 18 Product Information, 11/2010

19 Part I: Service on the device 3.2 LEDs SIMOTION P320-3/P350-3 The LEDs and mode switch, which are implemented as hardware on other SIMOTION platforms, are displayed in virtual form on the SIMOTION P system screen. This is achieved via the SIMOTION P state application. Figure 3-3 SIMOTION P state Note The relevant Manual/Commissioning Manual contains a detailed description of the LED displays, including all the possible combinations and flashing frequencies. Typical errors Table 3-3 Typical errors Error Frequent causes Remedy SF LED lights up red (error/fault state on the SIMOTION P) An event which can be acknowledged is pending (alarm, message, note) Acknowledge the event. A fault has occurred that does not allow a response from the user program SF LED flashes red (error/fault state on the SIMOTION P) License missing for licensed technology/optional objects Check the licenses. Switch the SIMOTION device off and then on again. Product Information, 11/

20 Part I: Service on the device 3.2 LEDs Error Frequent causes Remedy STOP LED lights up yellow (SIMOTION P in STOP mode) I/O access error Correct I/O access Program error (e.g. floating point exception) Technological alarms with CPU STOP response STOP LED flashes yellow (overall reset request) Memory card has been removed The non-volatile data does not match up with the project on the memory card Localize error: Check entries in the device diagnostics Example: Entry "Operating mode transition blocked" -> check error before this -> entry "I/O access error" Overall reset STOPU LED lights up or flashes yellow (SIMOTION P in STOP user program mode) The technology packages are active The user program is not active or is faulty Device stuck at startup task Check the entries in the diagnostics buffer and the user program. Switch the control to RUN mode. BUS1F, BUS2F LED (error/fault state on PROFIBUS DP interface, P350-3 only) Terminating resistor missing or in the wrong place Not all of the connected devices are switched on Cabling fault Incorrect baud rate configured or incorrect baud rate set on a bus node Configuration error Parameter assignment error Check terminating resistor, bus nodes, cabling, baud rate, configuration settings, and configuration in HW Config Additional information Links in the Guides menu of the online help SIMOTION P320-3 and Panels Manual SIMOTION P320-3 and Panels Commissioning and Hardware Installation Manual SIMOTION P350-3 and Panels Manual SIMOTION P350-3 and Panels Commissioning and Hardware Installation Manual 20 Product Information, 11/2010

21 Part I: Service on the device 3.2 LEDs SIMOTION D4x5/D4x5-2 RDY RUN STOP SU/PF SF DP DP/MPI PN SY/MT OPT Figure 3-4 LED displays on the device - example of SIMOTION D4x5-2 In addition to the SIMOTION devices themselves, optional modules and interfaces such as PROFINET interface CBE30 for D4x5 also feature LEDs for displaying states and error/fault diagnostics. Note The relevant Commissioning Manuals contain a detailed description of the LED displays, including all the possible combinations and flashing frequencies. Product Information, 11/

22 Part I: Service on the device 3.2 LEDs Typical errors Table 3-4 Typical errors Error Frequent causes Remedy RDY LED lights up red (SIMOTION D or SINAMICS Integrated error/fault) SINAMICS Integrated has not ramped up or is faulty Correct and acknowledge fault Acknowledgment carried out with e.g. operator panel, engineering tool, etc. connected STOP LED lights up yellow (control is in STOP mode - diagnostics with Engineering System or IT DIAG) I/O access error Correct I/O access Program error (e.g. floating point exception) Technological alarms with CPU STOP response STOP LED flashes yellow, slow flashing (0.5 Hz) (overall reset request) Memory card has been removed Overall reset The non-volatile data does not match up with the project on the memory card Localize error: Check entries in the device diagnostics Example: Entry "Operating mode transition blocked" -> check error before this -> entry "I/O access error" SU/PF LED lights up or flashes yellow, fast flashing (2 Hz) (control in STOP mode of user program) The technology packages are active Check the entries in the diagnostics buffer and The user program is not active or is faulty the user program. Switch the control to RUN mode. Device stuck at startup task SF LED lights up red (error/fault state on the SIMOTION D) An event which can be acknowledged is pending (alarm, message, note) Acknowledge the event. SF LED flashes red, slow flashing (0.5 Hz) (error/fault state on the SIMOTION D) License missing for licensed technology/optional objects Check the licenses. DP, DP/MPI LED lights up red (bus fault) Terminating resistor missing or in the wrong place Not all of the connected devices are switched on Cabling fault Incorrect baud rate configured or incorrect baud rate set on a bus node PN LED flashes red (bus fault) Failure of a connected I/O device At least one of the assigned I/O devices cannot be addressed Incorrect or no configuration settings Check terminating resistor, bus node, cabling, and configuration settings Check configuration settings, check IO device 22 Product Information, 11/2010

23 Part I: Service on the device 3.2 LEDs Error Frequent causes Remedy SY/MT LED does not light up or flashes SIMOTION D4xx task system is not synchronized with the send cycle of PROFINET IO IRT SINAMICS Integrated and ext. DP interfaces are not yet synchronized with the PROFINET IO IRT cycle OPT LED lights up/flashes red, slow flashing (0.5 Hz) Bus fault (CBE30 in the case of D4x5): Failure of a connected I/O device At least one of the assigned I/O devices cannot be addressed Incorrect or no configuration settings Firmware download faulty Link LED does not light up There is no physical connection The connected device is not switched on Check configuration settings, check error message in SINAMICS diagnostics buffer Check devices (still set to factory settings?), check connection, check cycle Check the cabling, connectors, and device. Activity LED does not light up There is no message frame traffic If the Link LED is green, use a ping command to check that the system is ready for communication Additional information Links in the Guides menu of the online help SIMOTION D4x5 Commissioning and Hardware Installation Manual SIMOTION D4x5-2 Commissioning and Hardware Installation Manual S120 Control Units and Supplementary System Components Manual See also Communication Board CBE30 (Page 27) Product Information, 11/

24 Part I: Service on the device 3.2 LEDs SIMOTION D410 Figure 3-5 LED displays on the D410 device Note The Commissioning Manual contains a detailed description of the LED displays, including all the possible combinations and flashing frequencies. Typical errors Table 3-5 Typical errors Error Frequent causes Remedy RDY LED lights up red (SIMOTION D or SINAMICS Integrated error/fault) SINAMICS Integrated has not ramped up or is faulty Correct and acknowledge fault Acknowledgment carried out with e.g. operator panel, engineering tool, etc. connected SF/BF LED lights up red (error/fault state on the SIMOTION D) An event which can be acknowledged is pending (alarm, message, note) Acknowledge the event. SF/BF LED flashes red, slow flashing (0.5 Hz) (error/fault state on the SIMOTION D) License missing for licensed technology/optional objects Check the licenses. 24 Product Information, 11/2010

25 Part I: Service on the device 3.2 LEDs Error Frequent causes Remedy SF/BF LED flashes red, fast flashing (2 Hz) (bus fault) A bus fault is pending Check PROFIBUS master At least one slave is missing the bus nodes, cabling, configuration settings, PROFIBUS slave No parameter assignment master found and configuration in HW Config. PROFINET Failure of a connected I/O device; at least one of the assigned I/O devices cannot be addressed; incorrect or no configuration settings RUN/STOP LED lights up red (control is in STOP mode - diagnostics with Engineering System or IT DIAG) Ramp-up of the D410 without Check the CompactFlash Card. CompactFlash Card or with CompactFlash Card without valid operating system (the bootloader may be defective) RUN/STOP LED lights up yellow Control is in stop mode - diagnostics with Engineering System or IT DIAG I/O access error Correct I/O access Program error (e.g. floating point exception) Technological alarms with CPU STOP response Control in STOP mode of user program The technology packages are active The user program is not active or is faulty Device stuck at startup task Localize error: Check entries in the device diagnostics Example: Entry "Operating mode transition blocked" -> check error before this -> entry "I/O access error" Check the entries in the diagnostics buffer and the user program. Switch the control to RUN mode. RUN/STOP LED flashes yellow, slow flashing (0.5 Hz) (overall reset request) Memory card has been removed Overall reset The non-volatile data does not match up with the project on the memory card OUT > 5V does not light up (electronic power supply for measuring system) Electronic power supply for measuring system <= 5 V The electronic power supply is configured for 5 V encoders. If you wish to connect a 24 V encoder, please check the parameter settings. Product Information, 11/

26 Part I: Service on the device 3.2 LEDs Additional information Links in the Guides menu of the online help SIMOTION D410 Manual SIMOTION D410 Commissioning Manual S120 Control Units and Supplementary System Components Manual 26 Product Information, 11/2010

27 Part I: Service on the device 3.2 LEDs Communication Board CBE30 The device is connected to PROFINET IO using the Communication Board Ethernet CBE30 interface module for SIMOTION D4x5. The module supports PROFINET IO with isochronous Realtime Ethernet (IRT), PROFINET IO with RT, and standard TCP/IP communication. The Option Board has an X1400 interface with four ports and integrated switch functionality. Note A CBE30 can only be inserted into a SIMOTION D4x5. It cannot be inserted into a SIMOTION D4x5-2. SIMOTION D445-2 DP/PN and D455-2 DP/PN feature an onboard PROFINET IO interface. Figure 3-6 Communication Board Ethernet CBE30 Figure 3-7 D4x5 example: Inserting a CBE30 Product Information, 11/

28 Part I: Service on the device 3.2 LEDs Typical errors Table 3-6 Typical errors Error Frequent causes Remedy Link LED does not light up There is no physical connection The connected device is not switched on Check the cabling, connectors, and device. Activity LED does not light up There is no message frame traffic If the Link LED is green, use a ping command to check that the system is ready for communication Fault LED lights up red (bus fault) No physical connection to a subnet/switch Incorrect transmission rate Full duplex transmission is not activated Fault LED flashes red (bus fault) Failure of a connected I/O device At least one of the assigned I/O devices cannot be addressed Incorrect or no configuration settings Sync LED does not light up or flashes SIMOTION D task system is not synchronized with the send cycle of PROFINET IO IRT SINAMICS Integrated and ext. DP interfaces are not yet synchronized with the PROFINET IO IRT cycle Check configuration settings, check IO device, check connection Check configuration settings, check IO device Check configuration settings, check error message in SINAMICS diagnostics buffer Additional information Links in the Guides menu of the online help SIMOTION D4x5 Commissioning and Hardware Installation Manual SIMOTION D4x5-2 Commissioning and Hardware Installation Manual 28 Product Information, 11/2010

29 Part I: Service on the device 3.2 LEDs Controller Extension CX32/CX32-2 The Controller Extension enables scaling of the drive-side computing power of products within the SIMOTION D range. This allows additional drives to be connected, for example. Figure 3-8 LED displays - example of CX32 Note The SIMOTION D4x5 Commissioning and Hardware Installation Manual and the SIMOTION D4x5-2 Commissioning and Hardware Installation Manual contain detailed descriptions of the LED displays, including all the possible combinations and flashing frequencies. Product Information, 11/

30 Part I: Service on the device 3.2 LEDs Typical errors Table 3-7 Typical errors Error Frequent causes Remedy RDY LED does not light up (power supply) The electronic power supply is missing or outside the permissible tolerance range RDY LED lights up red (fault or ramp-up) At least one fault is pending (e.g. RESET, watchdog monitoring, basic system error) CX32/CX32-2 is ramping up RDY LED flashes red (boot error) Boot error (e.g. firmware cannot be loaded into the RAM) RDY LED flashes yellow (load firmware) Unable to load firmware into RAM Firmware checksum error (CRC error) DP1 LED lights up red Not all of the connected devices are switched on Cabling fault CX32/CX32-2 not ready to run (e.g. after switch-on) Check power supply Check messages in diagnostics buffer Check connection to SIMOTION, check data on CompactFlash Card, reinstall firmware if necessary Check whether CompactFlash Card of D4x5 has been inserted correctly and is firmly in place Replace CompactFlash Card of D4x5 Voltage Off/On Check cabling and configuration settings Check messages in diagnostics buffer Additional information Links in the Guides menu of the online help SIMOTION D4x5 Commissioning and Hardware Installation Manual SIMOTION D4x5-2 Commissioning and Hardware Installation Manual 30 Product Information, 11/2010

31 Part I: Service on the device 3.2 LEDs Control Unit CU320/CU320-2 The Control Unit is a central control module in which closed-loop and open-loop functions are implemented for Line Modules and/or Motor Modules. Figure 3-9 LED displays - example of CU320 Note The SINAMICS S120 Control Units and Supplementary System Components Manual contains a detailed description of the LED displays, including all possible combinations and flashing frequencies. Product Information, 11/

32 Part I: Service on the device 3.2 LEDs Typical errors Table 3-8 Typical errors Error Frequent causes Remedy RDY LED does not light up (power supply) The electronic power supply is missing or outside the permissible tolerance range RDY LED lights up red (fault or ramp-up) At least one fault is pending (e.g. RESET, basic system error) CU320/CU320-2 is ramping up RDY LED flashes red Boot error (e.g. firmware cannot be loaded into the RAM) DP1 LED lights up red Terminating resistor missing or in the wrong place Not all of the connected devices are switched on Cabling fault Incorrect baud rate configured or incorrect baud rate set on a bus node DP1 LED flashes orange (load firmware) Unable to load firmware into RAM Firmware checksum error (CRC error) OPT LED does not light up The electronic power supply is missing or outside the permissible tolerance range Option Board not present No corresponding drive object created OPT LED lights up red At least one fault is pending Option Board not ready to run (e.g. after switch-on) Check power supply Check messages in diagnostics buffer Check data on CompactFlash Card, reinstall firmware if necessary Check terminating resistor, bus node, cabling, and configuration settings Check whether CompactFlash Card has been inserted correctly and is firmly in place Replace CompactFlash Card Voltage Off/On Check power supply Check Option Board Create drive object Check messages in diagnostics buffer Additional information Links in the Guides menu of the online help SINAMICS S120 Control Units and Supplementary System Components Manual 32 Product Information, 11/2010

33 Part I: Service on the device 3.2 LEDs Communication Board CBE20 The device is connected to PROFINET IO using the Communication Board Ethernet CBE20 interface module for SINAMICS S120. The module supports PROFINET IO with isochronous Realtime Ethernet (IRT), PROFINET IO with RT, and standard TCP/IP communication. The Option Board has an X1400 interface with four ports and integrated switch functionality. Figure 3-10 Communication Board Ethernet CBE20 Typical errors Table 3-9 Typical errors Error Frequent causes Remedy Link LED does not light up There is no physical connection The connected device is not switched on Check the cabling, connectors, and device. Activity LED does not light up There is no message frame traffic If the Link LED is green, use a ping command to check that the system is ready for communication Fault LED lights up red (bus fault) No physical connection to a subnet/switch Incorrect transmission rate Full duplex transmission is not activated Fault LED flashes red (bus fault) Failure of a connected I/O device At least one of the assigned I/O devices cannot be addressed Incorrect or no configuration settings Check configuration settings, check IO device, check connection Check configuration settings, check IO device Product Information, 11/

34 Part I: Service on the device segment display Error Frequent causes Remedy Sync LED does not light up If the Link LED is green: Control Unit task system is not synchronized with the IRT cycle clock. An internal substitute cycle clock is generated. Check configuration settings, check error message in diagnostics buffer Additional information SINAMICS S120 Control Units and Supplementary System Components Manual segment display In the case of SIMOTION D4x5/D4x5-2 and P350, a 7-segment display is used to indicate the SIMOTION state. Meanings of the displays 6 - RUNNING SIMOTION has ramped up and the cyclic tasks are activated 0-5, a-f - internal states (displayed during ramp-up) If a state 6 is displayed continuously during ramp-up (i.e. for more than 3 minutes), please analyze the diagnostics buffer. If necessary, contact the hotline to clarify the meaning of the display. Flashing point Communication is taking place between SIMOTION and SINAMICS Integrated Additional information Links in the Guides menu of the online help SIMOTION D4x5 Commissioning and Hardware Installation Manual SIMOTION D4x5-2 Commissioning and Hardware Installation Manual SIMOTION P350-3 and Panels Manual 34 Product Information, 11/2010

35 Part I: Service on the device 3.4 Interfaces 3.4 Interfaces SIMOTION devices feature integrated interfaces, to which an HMI device or engineering PC, for example, can be connected for the purpose of reading out diagnostic information. This equipment is connected via either a PROFIBUS or PROFINET/Ethernet interface. Use the following tools or software for reading out the information: SIMOTION SCOUT Engineering System (see Part III: Service with SCOUT Engineering System (Page 63)) IT DIAG Web interface via Web browser (see Part II: Service without SCOUT Engineering System (PC-based, IT DIAG) (Page 45)) HMI devices, e.g. WINCC flexible Bus analyzer for diagnosing bus or device faults: PROFIBUS DP, e.g. SIMATIC ET200 diagnostic repeater SIMATIC diagnostic repeater for PROFIBUS DP BT 200 physical bus test device for PROFIBUS DP ( PROFINET/Ethernet, e.g. BANY PNIO ( for PROFINET Standard network protocol analyzer for Ethernet, e.g. Wireshark ( For information on establishing an online connection via an interface, please refer to Establishing a connection to the device (without SCOUT Engineering System) (Page 46) or the individual sections in Going online (Page 64) (with SCOUT Engineering System). Additional information Links in the Guides menu of the online help SIMOTION C Operating Instructions SIMOTION D4x5 Manual SIMOTION D4x5-2 Manual SIMOTION D4x5 Commissioning and Hardware Installation Manual SIMOTION D4x5-2 Commissioning and Hardware Installation Manual SIMOTION D410 Manual SIMOTION D410 Commissioning Manual SIMOTION P320-3 and Panels Manual SIMOTION P320-3 and Panels Commissioning and Hardware Installation Manual SIMOTION P350-3 and Panels Manual SIMOTION P350-3 and Panels Commissioning and Hardware Installation Manual Product Information, 11/

36 Part I: Service on the device 3.5 HMI 3.5 HMI An HMI can be connected via the interfaces on the SIMOTION device not only for operator process control purposes, but also to enable diagnostics and display states. See also Interfaces (Page 35). In principle, the following message classes are available: User error messages These are usually messages from the process, containing information on how to resolve the error. They are transmitted independently of the HMI system itself, by means of what is known as a discrete message procedure. The user him/herself assigns the texts to the bit numbers. The user can choose to acknowledge the messages via the HMI system or via the application. The message texts and their compilation data are located in the HMI. Technological alarms and drive messages, technical state alarms (info, warning), and fault messages (alarms) for devices/functions These are messages relating to function faults or errors, for example, in components such as CPUs or drives. The user can use the ALARM_S procedure from SIMATIC for these messages. ALARM_S is a message number procedure. The message numbers are automatically assigned during configuration in SIMOTION SCOUT. Message texts are uniquely assigned on the basis of the numbers. The messages are called and acknowledged during runtime by means of appropriate system commands. The message texts and their compilation data are located in the SIMOTION SCOUT project. System messages (e.g. diagnostics buffer) These messages cannot be displayed directly in the WinCC flexible message window. If you wish to display the messages, you need to send them individually via the ALARM_S message procedure or read them out using IT DIAG or the SCOUT engineering tool. Warning and error messages relating to technology objects are usually output on the HMI and can be acknowledged by the operator. Examples of Siemens HMI systems: Operator panels WinCC flexible WinCC Note Diagnostics buffer entries can also be displayed in a Web browser via Ethernet (a PCbased method); see Part II: Service without SCOUT Engineering System (PC-based, IT DIAG) (Page 45). 36 Product Information, 11/2010

37 Part I: Service on the device 3.5 HMI WinCC flexible The discrete message procedure can be used to display messages stored on the device (even if these are in more than one language), e.g. information on machine states. Additionally, S7-compliant message procedures can be used with Alarm_S messages (e.g. information on system errors). Alarm_S messages are also available in SIMOTION. These messages are configured using the "Message configuration" editor in SIMOTION SCOUT. Alarm_S messages from SIMOTION are processed in WinCC flexible, in the same way as Alarm_S messages from STEP 7. Special settings need to be made in WinCC flexible and the SIMOTION project in order to use this procedure. Figure 3-11 Message displays on the operator panel with WinCC flexible Product Information, 11/

38 Part I: Service on the device 3.5 HMI How to activate Alarm_S and SIMOTION messages: 1. In WinCC flexible, open the Message Settings tab under Messages > Settings. Figure 3-12 Message Settings in WinCC flexible 2. In the Message procedures table, activate the Alarm_S messages by assigning them to the message classes (activate the All display classes checkbox). 3. In the Message procedures table, activate the SIMOTION TO messages using the combo box. 38 Product Information, 11/2010

39 Part I: Service on the device 3.5 HMI How to activate the display for the Alarm_S and SIMOTION messages: 1. In WinCC flexible, open the Message View tab under Messages > Settings. Figure 3-13 Message View dialog in WinCC flexible 2. Under General, activate the following message classes: Errors Warnings S7 Message S7 Event Message How to activate CPU messages in SIMATIC Manager: In SIMATIC Manager, open the CPU Messages dialog by selecting Target system > CPU messages... for the SIMOTION device. Select the checkboxes in the W (Warning) and A (Alarm) columns for the SIMOTION module (see the image below). Figure 3-14 CPU Messages dialog in SIMATIC Manager Additional information Links in the Guides menu of the online help See also Manuals for SIMATIC HMI (WinCC flexible) ( Product Information, 11/

40 Part I: Service on the device 3.6 Backing up diagnostic data and non-volatile data 3.6 Backing up diagnostic data and non-volatile data Following a fault on a SIMOTION device, diagnostic data (e.g. diagnostics buffer content, upto-date content of websites, etc.) can provide important information on the cause of the fault. With V4.1 SP2 and higher, the user has the option of backing up this data using a simple operation (e.g. a switch position). The data is stored on the CompactFlash Card/MMC in the case of SIMOTION D/C and on the hard disk in the case of SIMOTION P. The process of backing up and restoring diagnostic data differs according to which SIMOTION platform is being used (C/P/D). SIMOTION D is the only SIMOTION device to feature both a service selector switch and a DIAG button. This subject is covered in detail for all platforms in Part II, Diagnostic data and non-volatile data (retain data) (Page 53). 3.7 Updating devices using the Device Update tool In SIMOTION SCOUT, the Device Update tool can be used to create update data on the basis of one or more SIMOTION projects (menu Project > Start Device Update tool). The update data created in this way can be uploaded to the SIMOTION device using the CompactFlash Card/MMC, for example, or even using a USB stick in the case of SIMOTION D4x5/D4x5-2. An Engineering System is not required to do this. You can also update SIMOTION devices via IT DIAG Backing up, updating, and restoring device data (Page 61). License keys are either retained or may need to be relicensed in the case of function extensions. Updating does not only mean updating to a higher firmware version, but also involves a project update (for example). The following update data can be selected and created: SIMOTION project (without technology packages) Technology packages Archive (ZIP file containing SIMOTION SCOUT project) User data Firmware The update data contains all the information required for updating or restoring the data on a SIMOTION device. Note An up-to-date Firmware Support Package (FWSP) needs to be installed in order to update firmware (V4.1 SP2 and higher). The FWSP is provided with the SIMOTION SCOUT DVD2 under Add-ons and can also be obtained via the Internet at SIMOTION Firmware Support Package ( 40 Product Information, 11/2010

41 Part I: Service on the device 3.7 Updating devices using the Device Update tool Restoring refers to the process of reinstating the configuration that was backed up in the SIMOTION device when updating was last performed. If an attempt to update a SIMOTION device fails, for example, the device can be restored to the previous configuration. Restoring can be carried out via IT DIAG and, as an option, via the selector switch in the case of SIMOTION D. Saving update data When creating update data using the Device Update tool, you can select the following: Update medium (selection dependent on SIMOTION device) USB stick CF/MMC card SIMOTION IT DIAG file File system (update archive) If you select the file system option, an update archive containing the upd_tool.bat batch file (amongst other things) will be created. By executing the upd_tool.bat file, you have the option of installing an update medium on a PC at a later point in time or creating a SIMOTION IT DIAG file. A SIMOTION SCOUT installation is not required on the PC for this purpose. Transferring update data to the SIMOTION device The starting point for this is the update media to which the the update data has already been written or a SIMOTION IT DIAG file. An update medium (USB stick or CF/MMC card) is either inserted into the SIMOTION device to be updated, or the update data is transferred to the SIMOTION device via a communication connection (IT DIAG). The update process is triggered by restarting or switching on the SIMOTION device to be updated. Once the update data has been transferred to the memory card in the device for the first time, the data is backed up in the SIMOTION device (this applies to the USB memory stick and IT DIAG). The update data is activated as the current configuration after the SIMOTION device has been restarted. Behavior of the retain data during updating After the update data has been transferred to the SIMOTION device, the device is restarted and the update data is applied. During ramp-up, the non-volatile data that is saved in the SIMOTION device is checked to determine whether it is compatible with the current configuration. For additional information, please refer to the chapter titled Behavior of the retain data during updating in the Updating SIMOTION Devices Operating Instructions. Additional information Links in the Guides menu of the online help Updating SIMOTION Devices Operating Instructions Product Information, 11/

42 Part I: Service on the device 3.8 Licensing/License key 3.8 Licensing/License key Overview Depending on the type and number of RT components used in the project, licenses must be acquired as part of the licensing procedure for SIMOTION. The licenses required for a SIMOTION device are assigned to a hardware component. With SIMOTION C and D they are assigned to the memory cards, and with SIMOTION P to the Communication Board. One or more license keys are generated when the licenses are assigned to the hardware. The license key(s) are saved on the storage medium of the SIMOTION device or in file format during the licensing process. When replacing the memory card or Communication Board (in the case of P350) or modifying the RT components (e.g. a new technology object), the license key(s) must be redetermined and stored on the virtual memory card. Additional information Links in the Guides menu of the online help SIMOTION SCOUT Configuration Manual PM 21 Catalog: Chapter 8, SIMOTION Runtime Software SIMOTION C Operating Instructions SIMOTION D4x5 Commissioning and Hardware Installation Manual SIMOTION D4x5-2 Commissioning and Hardware Installation Manual SIMOTION D410 Commissioning Manual SIMOTION P320-3 and Panels Commissioning and Hardware Installation Manual SIMOTION P350-3 and Panels Commissioning and Hardware Installation Manual Configurator for SIMOTION runtime licenses in the Mall ( See also FAQ: Runtime licensing ( FAQ: Displaying the license key ( 42 Product Information, 11/2010