Migrating SINAMICS S120 CU320 to CU320-2DP Control Unit

Migration Overview

The Siemens SINAMICS S120 drive platform reached a hardware transition point when the original CU320 control unit (order number 6SL3040-0MA00-0AA1) was declared obsolete. The successor CU320-2DP (6SL3040-0MA00-0AA0) and its CU320-2PN (PROFINET) variant are the only supported control units in current production. Migrating from the legacy CU320 to the CU320-2 family is not a drop-in swap because the CompactFlash card, firmware generation, and several drive modules changed at the same time.

The CU320-2 introduces a higher-performance signal processor, a larger number of digital inputs, and supports the STARTER / SINAMICS Startdrive V14+ engineering workflow. The hardware platform also requires firmware V4.x and a different DRIVE-CLiQ topology map. When the original Booksize Single Motor Module, the Active Line Module, or the CompactFlash card from a CU320 is moved into a CU320-2 line-up, the control unit normally stays in orange RDY state and reports F1360 with value "Topology contains an unsupported component". The fault is the canonical symptom of a half-completed migration and is the focus of this guide.

Affected Components and Part Numbers

The hardware items typically present in a CU320 to CU320-2 migration, with the official Siemens part numbers, are summarised below.

Why Copying the User Folder Is Not Enough

The original CU320 stored its firmware, the parameter backup, the licence key, and the user-generated STARTER project in a fixed directory tree on the CompactFlash card. A CU320-2 cannot boot from a CU320 card because:

1. Firmware generation differs. A 6SL3054-0CD00-1AA0 card holds firmware V2.x or V3.x. The CU320-2 control unit only boots firmware V4.x or V5.x.
2. Boot-block geometry changed. The new card (6SL3054-0EE00-1BA0) is partitioned with an image suitable for the CU320-2 boot ROM.
3. DRIVE-CLiQ component descriptors are versioned. The topology component table the CU320-2 expects contains entries for V4-era modules only.

Three legitimate migration paths exist for the CF card:

• Card delivered pre-loaded with firmware (6SL3054-0EE00-1BA0 factory image): Copy only the USER folder from the old card to the new card root. The firmware, addon images, and boot loaders are already present.
• Empty new card: Copy the USER folder and install the V4.x / V5.x firmware, addon images, and any SCRIPTS folder using the Siemens firmware update tool, then re-insert the card.
• STARTER online migration (recommended for F1360 cases): Use STARTER to upload the project from the legacy CU320, change the target device to CU320-2DP, then download the converted project. The PC writes a complete bootable image to the new card during the download.

Fault F1360: Root Cause Analysis

Fault F13600 / F1360 is raised during the DRIVE-CLiQ topology scan when the CU320-2 detects a connected component whose part number / firmware combination is not present in the V4.x component descriptor list. The fault value field typically shows:

• Fault value 1: Component not in the supported list
• Fault value 2: Component firmware incompatible with current CU firmware
• Fault value 3: Component descriptor CRC mismatch

The standard remediation is documented in the SINAMICS S120 Function Manual (FH1) and the SINAMICS S120/S150 List Manual (LH1) as: replace the unsupported component with a successor module that carries the matching MLFB and firmware generation. For the 30 A Booksize Single Motor Module used in the typical migration case, the directly compatible successor is 6SL3120-1TE23-0AA4 (FW V4-ready, same 30 A rating, same footprint and DRIVE-CLiQ interface).

LED Status Interpretation

The CU320-2 has four diagnostic LEDs on the front bezel. During the migration the most informative combinations are listed below. The states observed on a half-migrated cabinet (RDY orange, DP1 orange, OPT green, downstream modules orange) confirm that the CU is alive but the topology check has not cleared.

Pre-Migration Checklist

Before powering up the new CU320-2, verify the following:

1. Every Booksize module in the cabinet carries an MLFB suffix of AA3 or higher. The 6SL3120-1TE23-0AA1 module must be replaced with the 6SL3120-1TE23-0AA4 successor.
2. The Active Line Module 6SL3130-7TE21-6AA3 is firmware V4.0+ (check the sticker on the side of the module or read parameter r0127[0] via STARTER).
3. The DRIVE-CLiQ cabling matches the wiring diagram. Do not reuse cables that loop through a DMC20 hub without confirming the hub itself is the V4 version (6SL3055-0AA00-6AA1).
4. The new CompactFlash card 6SL3054-0EE00-1BA0 has been ordered with the firmware version matching the target release (V4.8 or V5.x). The packaging label shows the firmware version.
5. A complete parameter backup of the existing CU320 has been stored on a PC using STARTER Upload to PG. This is the safety net for the migration.
6. STARTER V5.x (for FW V4 targets) or SINAMICS Startdrive V14+ (for FW V5 targets) is installed on the engineering PC.

Migration Procedure via STARTER (Recommended)

This procedure is the lowest-risk path and the one Siemens recommends for converting a working CU320 project to a CU320-2DP target.

1. Connect the engineering PC to the legacy CU320 via PROFIBUS or Ethernet service interface and open STARTER.
2. Perform Upload to PG (target system → upload) so that the full parameter set, drive objects, and topology are on the PC. Save the project as Backup_preMigration.zip.
3. Open the project offline, right-click the control unit in the navigator, and choose Target device → Change device version → CU320-2DP (6SL3040-0MA00-0AA0). STARTER converts the project tree in place and updates the topology descriptors to the V4 component set.
4. Insert the new CompactFlash card 6SL3054-0EE00-1BA0 into the CU320-2. The card must already contain the V4.x firmware (factory image or pre-loaded from the Siemens support portal).
5. Power on the line-up with the CU320-2. The RDY LED will flash green at 0.5 Hz while the control unit waits for the first download.
6. From STARTER, execute Download to target device. STARTER writes the full image (parameters, topology, script files, licence keys) to the new card and runs the initial commissioning pass.
7. After the download, navigate to the Topology view in STARTER and confirm that every module is shown in green (active and matched) and that the alarm buffer is empty.
8. Run the Commissioning → Commissioning wizard for each drive object so that the motor data identification and encoder calibration are refreshed against the new controller.
9. Save the final project to the PG and to the card.

Manual CF Card Migration (Card-Only Path)

If a STARTER online session is not possible, the CF card can be migrated manually, provided every hardware component is already V4-compatible.

1. Remove the legacy card 6SL3054-0CD00-1AA0 from the old CU320 and read it in a card reader on the PC. The relevant data sits in the /USER directory tree (typically USER/SINAMICS/DATA/...).
2. Insert the new card 6SL3054-0EE00-1BA0 into the reader. If the card is empty, run the Siemens firmware update tool (USS_FW_UPD / Siemens Card Installer) and load the V4.x firmware image appropriate for the CU320-2DP. If the card shipped with firmware, skip this step.
3. Copy the entire USER folder from the old card root to the new card root, preserving directory structure and file attributes. Do not overwrite /FIRMWARE, /ADDON, /OEM, or /SCRIPTS directories unless the equivalent files were created on the new card by the firmware installer.
4. Verify that /USER/SINAMICS/DATA/CCX contains a valid *.ACX topology file. If the file is missing or empty, the control unit will boot to orange RDY.
5. Insert the card into the CU320-2DP, power on, and go online with STARTER. Acknowledge the prompt to re-detect the topology. The control unit should run a topology comparison and clear F1360 once every component is recognised.

Motor Module Replacement Procedure

When the Single Motor Module 6SL3120-1TE23-0AA1 cannot be kept, replace it with the V4 successor 6SL3120-1TE23-0AA4. The replacement procedure is:

1. De-energise the drive line-up and wait 5 minutes for the DC bus to discharge below 50 V. Verify with a meter at the line-side terminals.
2. Remove the 24 V supply to the Control Unit and the DRIVE-CLiQ cables from the old module.
3. Unlock the module from the Booksize rail by depressing the locking lever on the underside and lift it clear.
4. Install the new 6SL3120-1TE23-0AA4 in the same slot and lock it onto the rail. The footprint and DC bus bar dimensions are identical, so no mechanical modification is required.
5. Reconnect the DRIVE-CLiQ cables. The new module's DRIVE-CLiQ port 0 must go to the upstream module (Line Module or DMC20) and port 1 to the next downstream device in the topology.
6. Power on and go online with STARTER. Execute Target system → Topology → Compare with offline to confirm that the new module is recognised with the correct MLFB and firmware version.
7. Run the Automatic controller setting and Encoder adjustment for the affected drive object.

Verification and Commissioning

A migration is complete when the following conditions are met:

• CU320-2DP RDY LED = green steady and DP1 LED = green (PROFIBUS cyclic, no diagnostics).
• Active Line Module RDY = green and DC LINK LED = green.
• Single Motor Module RDY = green.
• STARTER alarm buffer shows no F1360, no F08501 (DRIVE-CLiQ COMM), and no F08502 (DRIVE-CLiQ CRC).
• STARTER Topology → Compare offline ↔ online returns a green "identical" status.
• Function test: enable the drive in jog mode from STARTER and verify that the motor accelerates to the configured reference speed without alarm A07980 (rotor position identification) persisting.
• Final backup: Target system → Upload to PG and store the project as the new reference for the site.

Troubleshooting Matrix

Safety and Handling Notes

FAQ