Configuring SINAMICS G120 PROFINET Connection to STARTER Software

1. System Overview and Connectivity Options

The SINAMICS G120 is a modular low-voltage drive family consisting of a Control Unit (CU) and a Power Module (PM). PROFINET communication is implemented in the Control Unit — not in the Power Module — so the selection of CU determines the available fieldbus, safety, and I/O features. Common PROFINET-capable Control Units include the CU230P-2 PN (pump/fan/HVAC), CU240B-2 PN and CU240E-2 PN (general purpose), CU250S-2 PN (servo-class motion), and CU320-2 PN (multi-axis). F-variant CUs add PROFIsafe on top of standard PROFINET.

Three commissioning paths exist for connecting a G120 to a PC running STARTER (Siemens' classic commissioning tool, V5.x) or its successor Startdrive integrated in TIA Portal:

All three paths require the G120 GSDML file installed in the engineering tool, and an accessible PROFINET node with a unique IP address on the engineering subnet.

2. Prerequisites: Hardware, Firmware, and Software

Before attempting any of the connection methods, verify the following prerequisites.

2.1 Hardware

• SINAMICS G120 with PROFINET-capable Control Unit (CU2xx-x PN or CU230P-2 PN).
• 24 V DC power on the CU (separate from the power module's main supply).
• PROFINET cable (Cat 5e or higher, RJ45) or standard Ethernet patch cable for direct peer-to-peer.
• PC with Ethernet port; Auto-MDI/MDIX (auto-crossover) is required for direct connection without a switch.
• Optional: managed PROFINET switch if the PC port does not support crossover detection.

2.2 Firmware

The CU firmware version dictates which STARTER/Startdrive version is supported and which PROFINET features are available. Common firmware families on G120 CUs include V4.4, V4.5, V4.7, V5.1, and V5.2. Newer CU firmware (V5.x) typically requires STARTER V5.4 SP3 or higher, or Startdrive V15 and later in TIA Portal. Mismatched firmware is a leading cause of "device not found" errors during PROFINET discovery.

2.3 Software

• STARTER V5.x — classic commissioning tool, still widely used for installed-base drives.
• Startdrive — successor integrated in TIA Portal (V13 SP1 onward; V20 referenced for current shared-device functionality).
• GSDML file for the specific G120 CU variant — downloaded from Siemens Product Support and installed into the engineering tool.
• Drive ES (engineering software) for SIMATIC Manager integration, if routing through an S7 PLC.

3. Method 1 — Direct Ethernet Peer-to-Peer to STARTER

This is the simplest commissioning path and is recommended for bench setup or single-drive startup without a PLC.

3.1 Physical Connection

1. Power the CU with 24 V DC.
2. Connect the PC's Ethernet port directly to the PROFINET port (port 1 or 2) of the G120 CU using a standard RJ45 patch cable.
3. If the PC's NIC does not support Auto-MDI/MDIX (auto-crossover), insert a small Ethernet switch or crossover adapter between PC and CU.

3.2 IP Address Assignment

The CU ships with no IP address or a default IP such as 169.254.11.22 (link-local) depending on firmware. If the CU has a default IP in the same subnet as the PC's link-local address, STARTER can discover it immediately. Otherwise assign an IP using one of these approaches:

• Starter → Accessible nodes: STARTER scans the subnet and lists all reachable PROFINET devices, including ones without an IP, displaying their MAC addresses.
• PRONETA (Siemens free tool): scan the network, right-click the CU, and assign IP, subnet mask, and PROFINET device name.
• Web server of the CU: browse to the CU's default IP, log in, and configure network parameters.
• TIA Portal / SIMATIC Manager online functions: assign IP via the online accessible nodes view.

3.3 STARTER Project Setup

1. Open STARTER and create a new project. Insert a SINAMICS G120 drive object.
2. Right-click the drive and select Accessible nodes. STARTER will scan the subnet and list the CU by its IP or MAC address.
3. Select the CU and click Accept. The drive is inserted into the project tree with its online configuration.
4. Click Connect to target system (the lightning-bolt icon). The online/offline comparison screen appears.
5. Download the project to the drive (or upload from drive to project). After the download, STARTER shows the online configuration.

3.4 Verification

• The status LED on the CU PROFINET port should show steady green (link established) and may flash amber during cyclic data exchange if a controller is present.
• In STARTER, the Online indicator in the drive object tree turns green when the connection is active.
• The Diagnostics buffer of the drive can be opened to confirm no PROFINET stack faults are present.

4. Method 2 — Routing Through SIMATIC S7 PLC

When the G120 resides on a plant PROFINET network behind an S7-300, S7-400, S7-1200, or S7-1500 PLC, STARTER can route through the PLC's PROFINET interface to reach the drive. This uses the S7 routing protocol.

4.1 Architecture

[PC / STARTER] -- Ethernet -- [S7 PLC] -- PROFINET -- [G120 CU]
                    S7 routing gateway          PROFINET subnet

4.2 Configuration Steps

1. In SIMATIC Manager, open the S7 project containing the PLC.
2. From the Drives ES library, drag the G120 Power Module and PROFINET Control Unit into the PROFINET subnet.
3. Assign the G120's PROFINET device name and IP address. The device name must match what is configured on the CU itself (use PRONETA or the CU's web server).
4. Save and compile the project. Ensure no PROFINET name or IP conflicts exist.
5. In STARTER, select Open project via S7 connection. Provide the PG/PC interface (TCP/IP to the S7 PLC) and the routing target.
6. STARTER traverses the S7 routing chain and opens an online connection to the G120.

4.3 Verification

• STARTER's online indicator turns green after the routing handshake completes.
• Check the PLC's online diagnostics for active S7 connections; STARTER appears as a routed connection.
• Confirm the drive's PROFINET diagnostics show no station name mismatch or IP conflict.

5. Method 3 — TIA Portal Shared Device (SIMOTION + F-CPU)

For applications where one SINAMICS G120 must be accessed simultaneously by a SIMOTION motion controller and a fail-safe CPU (F-CPU) — for example, a coordinated axis with PROFIsafe stop functions — TIA Portal V20 supports shared device configuration. Each controller owns a defined subset of the drive's PROFINET slots.

5.1 Configuration Outline

1. Open the TIA Portal project containing both the SIMOTION controller and the F-CPU.
2. In the network view, click the SINAMICS G120 drive unit.
3. In the Inspector window, navigate to PROFINET interface → Extended options → Real-time settings → Shared device.
4. Assign slots to the SIMOTION controller (standard telegrams for motion control) and to the F-CPU (PROFIsafe telegram for safety).
5. Configure the PROFIsafe parameters on the F-CPU side and the safety telegrams on the G120 (parameter p9610, p9650, p9700 family on F-variant CUs).
6. Compile and download to both controllers.

5.2 Commissioning Caveats

• The shared-device slot assignment must be non-overlapping. SIMOTION typically owns telegram 1, 2, 3, or 5; the F-CPU owns PROFIsafe telegram 30 or 31.
• Both controllers must assign matching PROFINET device names to their respective access points on the G120.
• Verify shared-device behavior with the manufacturer documentation at SINAMICS G120 shared by SIMOTION and F-CPU prior to commissioning.

6. GSDML Installation and Drive ES Library

GSDML (General Station Description Markup Language) files describe the drive's PROFINET identity, slots, telegrams, and diagnostic data to the engineering tool. Without the correct GSDML, the G120 cannot be inserted into a PROFINET topology.

6.1 Obtaining the GSDML

1. Search Siemens Product Support for the specific G120 CU variant and firmware version. The GSDML filename typically includes the firmware version, e.g., GSDML-V2.31-Siemens-SINAMICS_G120_CU240E-2_PN_FW....
2. Download the ZIP archive and extract to a known folder.

6.2 Installing in TIA Portal

1. Open TIA Portal. From the menu choose Options → Manage general station description files (GSD).
2. Browse to the extracted GSDML folder and select all GSDML files. Click Install.
3. After installation, the G120 appears in the hardware catalog under Other field devices → PROFINET IO → Drives → Siemens AG → SINAMICS.

6.3 Installing in SIMATIC Manager (Classic)

1. Close all SIMATIC Manager instances.
2. Run the GSDML installer executable, or copy the GSDML file into the SIMATIC Manager GSD folder (e.g., C:\Program Files\Siemens\Automation\SIMATIC Manager\S7DATA\GSD).
3. Restart SIMATIC Manager and update the hardware catalog (Options → Update Catalog).

7. PROFINET Telegram Configuration

PROFINET telegrams define the cyclic data exchanged between the controller (PLC/SIMOTION) and the drive. Telegram selection determines which process data words (PZDs) are mapped to setpoints and actuals.

The telegram is selected in the G120 parameter set via p0922 (or via STARTER's telegram dialog) and must match the slot assignment in the PLC project.

8. STARTER Project Setup Detail

Once the online connection is established, complete the following steps to bring the drive into service.

1. Configure the drive object: select control mode (V/Hz, vector without encoder, vector with encoder), enter motor data from the motor nameplate, run the automatic motor identification (rotating measurement at p1900 = 2 or static measurement at p1910).
2. Setpoint / command source: assign PROFINET as the setpoint source (p10750 family and p2051 family in STARTER's configuration masks).
3. Communication fault response: define how the drive reacts to PROFINET failure — typically ramp to stop with OFF3, configurable via p2045 and p2100/p2101.
4. Save parameter set: copy RAM to ROM via Copy RAM to ROM button in STARTER to persist the configuration across power cycles.
5. Back up project: save the STARTER project for documentation and future restore.

9. Verification, Diagnostics, and Commissioning Checklist

Use the following checklist to confirm a successful STARTER-to-G120 PROFINET commissioning.

• [ ] CU PROFINET port LED steady green (link up).
• [ ] CU has a unique PROFINET device name and IP address on the subnet.
• [ ] GSDML matches the installed CU firmware major version.
• [ ] STARTER shows the drive object as online (green indicator).
• [ ] Telegram configured in STARTER (p0922) matches the slot in the PLC project.
• [ ] PROFINET diagnostics buffer is free of station name mismatch, IP conflict, and watchdog faults.
• [ ] Motor identification completed successfully (if motor data was unknown).
• [ ] Setpoint source assigned to PROFINET and verified by toggling a PZD from STARTER's control panel.
• [ ] Save (RAM → ROM) performed.
• [ ] Project backup stored in a known engineering repository.

9.1 Real-Time Diagnostics Tools

10. Troubleshooting Matrix

11. Migration Note: STARTER to Startdrive

Siemens is migrating G120 commissioning from STARTER to Startdrive inside TIA Portal. Newer firmware releases (V5.2 and later on many CUs) are best supported in Startdrive V16+. STARTER remains supported for installed-base drives but receives fewer feature updates. If a mixed fleet is in service, maintain both toolchains and use STARTER project converter utilities to migrate legacy projects to TIA Portal.

12. Frequently Asked Questions