Migrating SIMOTION D445-1 to D445-2: Hardware Replacement Guide

1. Overview

The SIMOTION D445-2 motion controller is the second hardware revision of the D445-1 platform and provides higher PLC and motion control performance than the original D445. Replacing a D445-1 with a D445-2 in the field is straightforward from a mechanical standpoint—both controllers share the same form factor, backplane interface, and I/O footprint—but the migration is not a true drop-in replacement. The firmware load on the CompactFlash (CF) card, the SCOUT/SCOUT TIA engineering version, and the project device assignment must all be updated before the new controller will boot the existing application.

This guide walks through the controller family identification, part numbers, prerequisite checks, hardware swap procedure, CF card handling, firmware flashing, SCOUT project re-targeting, and verification steps required to execute a clean D445-1 to D445-2 migration.

2. SIMOTION D445 Family Identification

Siemens has shipped several hardware revisions of the SIMOTION D445 controller over the product lifecycle. Each revision is identified by the suffix on the device label and has a unique MLFB (order number). The D445-1 was a transitional revision, while the D445-2 introduced higher compute density and revised onboard interfaces. Field-replacement situations often require the engineer to confirm which variant is currently installed before ordering spares.

2.1 Part Number Reference Table

Cross-reference for the redesign of the higher-end D455-2 line is published at SIOS Entry 109955164 – Replacement of SIMOTION D445-2/D455-2 devices. The redesigned D455-2 DP/PN (6AU1455-2AD00-0AA2) supersedes both the legacy D445-2 and D455-2 modules and is the strategic spare for new installations.

3. Prerequisites

Before removing the controller from the rack, verify the following prerequisites are in place. Each item is mandatory; skipping any one will produce a non-functional or partially-functional migration.

3.1 Engineering Software

Projects originally created with SCOUT versions below V4.3 cannot load the D445-2 device catalog. If your engineering workstation runs SCOUT V4.0 – V4.2, install the latest SIMOTION SCOUT service pack (or upgrade to SCOUT TIA) before attempting the migration. The upgrade is free of charge but requires a valid license key.

3.2 Hardware Prerequisites

• Replacement D445-2 controller with intact anti-static packaging
• Compatible CF card (Siemens-approved 6AU1400-1PA00-0AA0 or approved third-party card; minimum 1 GB, SLC industrial grade recommended)
• Backup of the current D445-1 CF card image (full image, not just project)
• Latest D445-2 firmware image downloaded from SIOS
• Engineering PC with Ethernet connectivity to the SIMOTION service interface (X127 or X130 port)
• ESD-safe workspace, anti-static wrist strap, and labeled screw container for the controller mounting bolts
• Live project archive (.zip) of the current D445-1 program from SCOUT

3.3 Firmware Image Files

Each SIMOTION controller boots from a CF card that contains three image partitions: the firmware image, the runtime project, and the user data area. For the D445-2 the firmware image must be downloaded separately. Typical filenames follow the convention:

SIMOTION_D4x5_V04_30_00_00.fw
SIMOTION_D4x5_V05_04_00_00.fw

Store the firmware file in the SCOUT working directory:

C:\ProgramData\Siemens\Automation\SIMOTION\FW

4. Pre-Migration Backup Procedure

1. Connect the engineering PC to the SIMOTION service interface (X127) of the D445-1 using a standard Ethernet cable. Set the PC IP to 169.254.11.22 / 255.255.0.0 if the controller is set to DHCP-fallback mode (default).
2. Open SCOUT, select Target System > Online > Connect to target system.
3. Upload the current project to the engineering PC: Target System > Load to PG. Save the resulting archive as ProjectName_D445-1_Backup.zip.
4. Read out the current CF card image: Target System > Read CF card image to PC. Store the .img file on the engineering PC and on a separate network share.
5. Record the currently loaded firmware version from Target System > Device Diagnostics > Firmware. Note the version string for the post-migration verification step.
6. Export the device configuration: Project > Export > Export to SIMOTION archive. The archive contains the device assignment, technology objects, and I/O topology.

This triple-redundancy (live archive, CF image, exported archive) ensures that even a partial failure during migration can be reversed without re-engineering.

5. Hardware Replacement Procedure

1. Bring the machine to a safe stop state and confirm the safety system is locked out (ESTOP active, guard doors interlocked, drive enable cleared).
2. Power down the SIMOTION D445-1 and the SINAMICS drive line-up. Wait a minimum of 5 minutes for the DC bus capacitors to discharge below 50 V (verify with a Cat III multimeter at the DC link test points).
3. Label and remove the PROFIBUS / PROFINET connectors (X126, X127, X130, X136), the DRIVE-CLiQ cables (X100 – X105), and the 24 V power supply connector.
4. Loosen the four M5 mounting bolts and slide the D445-1 out of the rack. Place the removed controller in an ESD bag immediately.
5. Inspect the new D445-2: verify the nameplate shows 6AU1445-2AD00-0AA1 (or the specific MLFB you ordered). Confirm the rotary address switches are set identically to the original (default: 0/0/0).
6. Slide the D445-2 into the rack, torque the four M5 bolts to 3.0 Nm.
7. Reconnect the 24 V supply first, then the DRIVE-CLiQ ring, then the fieldbus connectors. Match every cable to its original port label to avoid crossed links.

6. Firmware and CF Card Migration

The CF card is the most failure-prone element of any SIMOTION migration. The D445-2 requires a firmware image that is not present on the original D445-1 card. There are two acceptable paths; pick the one that matches your site policy.

6.1 Option A – Re-image the existing CF card

1. With the D445-1 powered down and the card unlocked, press the ejector and remove the CF card. Place it in the engineering PC's CF reader.
2. Open SIMOTION Explorer > CF card > Restore firmware image in SCOUT. Select the downloaded D445-2 firmware image.
3. SCOUT writes the firmware partition only, leaving the project partition intact if the partition table is compatible. Verify the write completed without errors.
4. Reinsert the CF card into the D445-2, restore power, and observe the seven-segment display during boot.

6.2 Option B – Use a fresh CF card

1. Use a Siemens-approved blank CF card (recommendation: 6AU1400-1PA00-0AA0, 1 GB SLC industrial).
2. Insert the blank card into the D445-2.
3. Power up. The seven-segment display should show --, indicating the controller is waiting for firmware load.
4. From SCOUT, select Target System > Load firmware to CF card. Choose the D445-2 firmware image.
5. After firmware load completes, power-cycle the controller.

6.3 Seven-Segment Display Codes

After loading the firmware, the D445-2 should transition from -- → 8. → 0. If the display stops at -- or shows F, the firmware image is incompatible with the controller's hardware revision; re-flash with the matching image.

7. SCOUT Project Reconfiguration

Even though the program logic is identical between D445-1 and D445-2, the project file must be re-targeted to the new controller. SCOUT stores the device assignment inside the project tree; changing it without re-downloading will leave the controller in an undefined state.

7.1 Change of Controller in the Project

1. Open the project archive ProjectName_D445-1_Backup.zip in SCOUT.
2. In the project navigator, right-click on the controller node D445-1 and select Change device > SIMOTION D445-2.
3. SCOUT will prompt to migrate technology objects and I/O addresses. Accept the migration with default settings. The wizard preserves all axis configurations, cams, and program POUs.
4. Verify the new device node shows the correct MLFB: 6AU1445-2AD00-0AA1.
5. Open Project > Properties > Target Firmware and confirm the firmware version matches what was flashed to the CF card (e.g., V4.30 or V5.40).
6. Compile the project. Check the output window for warnings. If SCOUT reports Controller catalog not found, the engineering software version is too old—install SCOUT V4.3 SP1 or later.

7.2 Download to the New D445-2

1. Connect to the D445-2 via service interface (X127) using SCOUT. Accept the new certificate if prompted.
2. Select Target System > Download to target system. Choose Download to CF card rather than Download to RAM; the project must be persisted to the CF card to survive a power cycle.
3. SCOUT will copy the project, the technology objects, and the user data partition. Wait for the Download successful message.
4. Power-cycle the D445-2 to confirm the project boots from CF.

7.3 Drive Topology and DRIVE-CLiQ Assignment

The D445-2 retains the same DRIVE-CLiQ port count (X100 – X105) and the same PROFIBUS / PROFINET interfaces as the D445-1. The topology configured in SCOUT is preserved during the device swap, but verify it after the download:

1. Open Project Navigator > SINAMICS_Integrated > Topology.
2. Confirm each drive node shows the expected component number and serial number.
3. For multi-axis systems, run Target System > Topology > Compare with offline to detect any address drift.

8. Commissioning and Verification

After the controller is running with the re-targeted project, execute a staged commissioning sequence. Do not place the machine into production after only a software-level verification—always run the full safety and motion acceptance test.

8.1 Boot and Online Check

1. Verify the seven-segment display reaches 2 (run state).
2. In SCOUT, open the device diagnostics: Target System > Device Diagnostics. Confirm:
   • Firmware version matches the flash image
   • Project CRC matches the offline archive
   • All technology objects report OK
   • Communication stacks (PROFINET, PROFIBUS, Ethernet) report No error
3. Open Target System > Control Panel and verify the actual axis position matches the setpoint within one encoder increment.

8.2 Safety System Verification

1. Verify the safety PLC (e.g., SIMATIC F-CPU or integrated F-capability of the D445-2) retains its PROFIsafe address and passivation status.
2. Trigger a test stop (category 1 or category 2 stop per ISO 13849-1 / IEC 62061) and confirm the drives shut down within the rated response time.
3. Re-integrate the safety slots and confirm the F-signature has not changed.

8.3 Performance Validation

The D445-2 offers increased PLC and motion control performance versus the D445-1. Verify the existing program benefits without altering timing margins unintentionally:

• Compare the IPO (interpolator) cycle time. D445-1 supports a minimum of 1 ms; D445-2 retains the 1 ms minimum but with a higher saturation headroom.
• Check servo cycle and position controller cycle: both should remain at the values configured in SCOUT.
• Run a profile test (e.g., a cam trace or a positioning move) and compare the lag error trace against the pre-migration baseline.

8.4 Acceptance Checklist

9. Migration from D445 to D445-1 (Historical Context)

For installations still running the original D445 and considering an upgrade path, Siemens published an official migration guide covering the performance and topology differences. The reference document is available as D4x5 Migration Manual (PDF, SIOS Entry 42503430). Key points relevant to the D445 → D445-1 transition are:

• Application programs designed for the D445 run unchanged on the D445-1; the firmware transparently maps the increased compute resources.
• The CF card image is not interchangeable between D445 and D445-1 without re-flashing.
• SCOUT V4.0 SPx or later is required for the D445-1 device catalog.

10. Long-Term Spare Strategy

Siemens has announced the strategic replacement for the D445-2 and D455-2 product lines via the redesigned D455-2 DP/PN module (6AU1455-2AD00-0AA2). When planning a multi-year spare-part inventory, treat the redesigned D455-2 as the preferred spare for both the D445-2 and the legacy D455-2 modules. The reference notice is published at SIOS Entry 109955164. Key implications:

• Pin-compatible with existing D455-2 installations; electrical compatibility with the D445-2 footprint requires verification of the I/O count per channel.
• Firmware baseline is V5.4 or later; older D445-2 firmware projects must be upgraded.
• Existing D445-2 spares remain supported for the full product lifecycle but should not be reordered for new installations.

11. Troubleshooting Matrix

12. Frequently Asked Questions