Migrating SIMOTION D435 to Drive with S210 PROFINET IRT

Migration Overview: From SIMOTION D435 + S120 to Drive Controller + S210

The legacy machine architecture combines a SIMOTION D435-2 PN/DP motion controller, SINAMICS S120 Booksize power units with a Smart Line Module (SLM) common DC bus, and six 1FT/1KF7 servomotors with absolute encoders. The original topology communicates exclusively over DRIVE-CLiQ, with an external encoder also on DRIVE-CLiQ for cam synchronization. Three to four dynamic cams and high-dynamic position/velocity profiles characterize the load profile. After roughly 17 years of field service (40 machines worldwide), the next migration step is moving to a SIMOTION Drive Controller (e.g., SIMOTION D4x5-2 DP/PN or the newer SIMOTION C/D generation running on a SIMATIC drive controller) and replacing S120 booksize with SINAMICS S210 single-axis servo converters connected over PROFINET IO with IRT (Isochronous Real-Time).

The principal driver for this migration is supply-chain risk on legacy S120 components (Line Modules, Motor Modules, Control Units, DRIVE-CLiQ cables) caused by the post-2020 semiconductor shortage. S210 is supplied as a fully integrated single-axis converter with a fixed PROFINET interface, no DRIVE-CLiQ port, and firmware preloaded with the safety, telegram, and motor parameter set required for the supported motor families.

Hardware Architecture: S120 Booksize vs. S210 Single-Axis

The S120 booksize platform is modular: a Smart Line Module (SLM), Active Line Module (ALM), or Basic Line Module (BLM) feeds a common DC bus, and individual Motor Modules (Single/Double) close the loop with the servomotors over DRIVE-CLiQ. The S210 inverts that architecture. Each S210 is a self-contained single-axis converter with an integrated line filter, line reactor (in higher power classes), and braking resistor. There is no shared DC bus.

If the legacy application consumed a common DC bus for energy sharing between axes (regenerative energy from decelerating axes feeding the accelerating axes), the S210 topology changes that balance. Each S210 must dissipate its own regenerated energy through its internal brake resistor, or the panel design must add a higher-capacity line-side supply. The Smart Line Module that previously conditioned the network must be retained as the line-side feeder only if harmonic limits or controlled DC bus charging were required; otherwise, an S210 can be fed from a standard three-phase industrial supply.

Motor Compatibility and Encoder Migration

The original machine uses 1FT (synchronous servomotors) and 1KF7 (asynchronous servomotors) series. The S210 supports the following Siemens motor families:

• 1FK2 — compact synchronous servomotor (high-dynamic, low-inertia)
• 1FT2 — high-dynamic synchronous servomotor (replacement for 1FT6/1FT7)
• 1FS2 — clean-room / hygienic synchronous servomotor

1KF7 asynchronous motors are not supported on S210. If the application depends on the asynchronous motor characteristics (e.g., wide constant-power range, robust overload behavior, low rotor inertia to mass ratio), it must stay on S120, or the mechanical redesign must accept a 1FK2/1FT2 substitution. Verify torque, speed, and inertia on the SIZER selection tool and re-check acceleration profiles against the new motor's torque-vs-speed envelope.

Encoder migration: 1FT and 1KF7 originally shipped with absolute EnDat 2.2 singleturn or multiturn encoders. 1FK2/1FT2 use EnDat 3 with integrated electronic nameplate. The S210 reads the motor's electronic rating plate automatically during first commissioning (analogous to DRIVE-CLiQ auto-configuration on S120). No manual parameterization of motor type, current, or pole-pair count is required when using approved Siemens motors with their factory-fitted cables.

Safety Functions: S120 Advanced vs. S210 Basic/Extended

Functional safety is the single largest functional gap between S120 and S210. The S120 platform, especially when combined with a CU320-2 and the Safety Integrated firmware option, supports the full Siemens safety portfolio:

• SBT — Safe Brake Test
• SBC — Safe Brake Control
• SS1 / SS2 — Safe Stop 1/2
• SOS — Safe Operating Stop
• STO — Safe Torque Off
• SSM — Safe Speed Monitor
• SLS — Safely-Limited Speed
• SDI — Safe Direction
• SLP — Safely-Limited Position
• SP — Safe Position (absolute or relative)
• SCA — Safe Cam

The S210 supports only Basic and Extended Safety Integrated functions: STO via PROFIsafe, SS1 (time-controlled and speed-controlled), SBC, SS2, SOS, SLS, SDI, SSM, and SBT. The advanced position-domain functions (SLP, SP, SCA) are not available on S210.

PROFINET IRT Communication and Telegram Selection

Both S120 and S210 communicate with SIMOTION over PROFINET IRT, but the topology and telegram-set differ. The legacy S120 configuration uses telegram 105 (or 111) which is a Siemens-standard PROFIdrive profile telegram that includes a control word, status word, encoder 1/2, and DSC (Dynamic Servo Control) bits. DSC shifts the velocity/position control loop into the SIMOTION motion kernel, leaving only the current loop in the drive — which is the standard high-dynamic configuration.

The S210 supports the same PROFIdrive telegrams including telegram 1, 2, 3, 4, 5, 6, 7, 9, 102, 105, 106. Telegram 105 is the recommended choice for SIMOTION Drive Controller integration with DSC enabled. Telegram 106 extends it with supplementary torque feedforward. Telegram 9 supports speed setpoint with two encoders. The PROFIdrive safety telegram for PROFIsafe is automatically appended: telegram 30 (extended safety), telegram 31, telegram 901 (PROFIsafe on PROFINET), or a vendor-specific safe telegram.

Configuration steps for PROFINET IRT:

1. Assign a PROFINET device name to each S210 (e.g., s210-axis-1) via the S210 webserver, PRONETA, or TIA Portal topology editor.
2. Configure an IRT topology with a sync domain. Define one PROFINET IO controller (the SIMOTION Drive Controller) and one sync master. Set the send clock to 500 µs or 1 ms; S210 supports both. Lower send clocks increase deterministic jitter control at the cost of higher CPU load on the controller.
3. Insert telegram 105 in the S210 device view of TIA Portal / SIMOTION Scout. Enable DSC (Dynamic Servo Control) so that the position controller runs in the SIMOTION motion kernel.
4. Append the PROFIsafe telegram (typically 30) and assign the F-CPU's PROFIsafe destination address.
5. Verify the IRT phase relationship: each S210 must be in the same sync domain and report a known phase offset relative to the sync master (typical values 0–1000 µs).
6. For further guidance on PROFINET IO drive configuration with SIMOTION, refer to the TIA Portal help:
   SIMOTION controller with PROFINET IO drive.

Drive Control Chart (DCC), EPOS, and Closed-Loop Functions

The S120 platform supports DCC (Drive Control Chart), a graphical programming environment inside the drive for adding custom control blocks (PID, ramp, math, logic). DCC is unavailable on S210. If the legacy code relied on DCC for axis-specific functions, those blocks must be moved to the SIMOTION application (Technology Objects, MCC charts, or IEC 61131-3 logic) running on the Drive Controller.

The S120 also includes the basic positioner (EPOS) firmware option, which allows the drive itself to handle point-to-point positioning, traversing blocks, and referencing. S210 does not include EPOS. In SIMOTION architectures, this is rarely an issue because motion control is centralized on the controller — EPOS on S120 was used when a SIMATIC PLC (without SIMOTION) drove the axis directly. For a SIMOTION migration, motion control remains in the controller.

Synchronous Operation and Dynamic Cams

The legacy application uses three to four dynamic cams synchronized to an external DRIVE-CLiQ encoder (mounted on the machine, not on the motor). With DRIVE-CLiQ removed from S210, the external encoder must be re-routed:

1. Mount a PROFINET I-Device gateway or use an encoder with native PROFINET interface (e.g., Siemens SIMODRIVE absolute encoder or third-party PROFINET encoder).
2. Configure the encoder as a PROFINET IO device on the SIMOTION controller. The actual value is consumed by the SIMOTION TO Axis and the camming TO (TO_Cam).
3. Alternatively, use a SIMOTION Sensor Module — but only if it has PROFINET capability, not DRIVE-CLiQ.

Dynamic cams (TO_Cam) on SIMOTION support linear cams, polynomial cams, and multi-dimensional cam profiles. Cam leading-value source can be a real axis (the external encoder), a virtual axis, or another TO. The transition from a DRIVE-CLiQ encoder to a PROFINET encoder does not change the camming algorithm, but the latency profile changes. Re-tune cam acceleration jerk values and verify cam leading-edge timing against the new system cycle time.

Commissioning with the S210 Webserver

The S210 is commissioned either through the integrated webserver (accessed via a browser at the IP address of the converter) or through SINAMICS Startdrive in TIA Portal. The webserver covers the most common commissioning tasks: setting the IP address, PROFINET device name, telegram selection, safety configuration, motor auto-tuning, and basic control panel (JOG, enable, setpoint).

1. Initial power-up: Connect 3AC 400 V to L1/L2/L3 (or 1AC 200–240 V on the lower power class), 24 V to the logic supply, and the PROFINET cable to port X1.
2. IP assignment: Default IP is 192.168.0.1 / 255.255.255.0. Access the webserver at https://192.168.0.1 with default credentials (see S210 manual).
3. Device name: Assign the PROFINET device name to match the TIA Portal hardware configuration. Restart to apply.
4. Telegram selection: Choose telegram 105 + PROFIsafe telegram 30 (or whatever the safety design requires).
5. Motor assignment: The S210 recognizes the connected 1FK2/1FT2/1FS2 motor via the electronic rating plate. Confirm in the webserver's Drive → Motor page.
6. Auto-tuning: Run the auto-tuning routine. S210 supports one-button tuning (1KN) and real-time auto-tuning.
7. Safety commissioning: Configure PROFIsafe address and accept safety parameters via the webserver or Startdrive. Save and download to drive.
8. Verification: Use the webserver's Control panel to enable the drive, run a JOG profile, and observe encoder actual values, currents, and temperatures.

Detailed S210 commissioning steps, parameter descriptions, and safety acceptance procedure are documented in the S210 operating manual available on the Siemens Industry Online Support portal:
SINAMICS S210 (6SL5) Operating Manual.

Step-by-Step Migration Procedure

1. Inventory the existing S120 application: list every Motor Module, the line module type, every DRIVE-CLiQ device (motors, external encoders, SMC/SME, terminal modules), every active safety function, and every DCC chart.
2. Map each axis to an S210 power class: use SIZER to size the replacement based on the existing motor's torque-speed profile. If a 1KF7 is in scope, mark the axis as "retain S120" or "redesign to 1FK2/1FT2."
3. Re-route external encoders from DRIVE-CLiQ to PROFINET or to a SIMOTION sensor input.
4. Re-implement lost safety functions in the F-CPU: SLP, SP, SCA logic, with safe position transmission over PROFINET/PROFIsafe.
5. Migrate DCC blocks into SIMOTION MCC, ST, or Ladder logic.
6. Update the TIA Portal / Scout project: replace S120 Motor Modules with S210 single-axis devices. Re-check IRT topology, sync domain, and send clock.
7. Replace telegrams with telegram 105 + DSC + PROFIsafe as required.
8. Run axis-by-axis commissioning: start with the lead axis, then the follower axes, then the cam group.
9. Verify tracking error at rated speed and rated acceleration. Compare against the legacy machine's commissioning record.
10. Run the full acceptance test including safety acceptance test (PROFIsafe trace), EMC test, and any regulatory re-certification if required.

Verification and Field Test

Key Field Caveats

• DC bus regeneration — without a common bus, the S210's internal brake resistor must absorb all regenerated energy. For high-inertia axes with frequent braking, verify the chopper threshold and resistor rating; add a higher-capacity resistor if needed.
• Motor cable lengths — Siemens-approved S210 motor cables are limited (typically 10–20 m depending on the converter and EMC class). For long cable runs, validate with an EMC test on the actual installation.
• Grounding and shielding — S210 has a defined grounding concept (PE stud, shield clamp on the motor cable). Re-route grounding per the manual; do not reuse S120 grounding topology.
• Cooling clearance — S210 is forced-air-cooled in higher power classes. Maintain the manufacturer's minimum clearance (typically 100 mm above and below).
• Firmware consistency — match the S210 firmware version with the SIMOTION Scout / TIA Portal GSDML import for PROFINET. Mismatch can cause telegram parsing faults at startup.
• Engineering tool version — S210 commissioning requires SINAMICS Startdrive V16 or later, integrated into TIA Portal. SIMOTION Scout standalone (V5.x) does not support S210; use TIA Portal with the SIMOTION option package for new projects.

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