Running Siemens MICROMASTER 440 Standalone: Profibus Bypass Guide

1. Overview: Operating the MICROMASTER 440 Independent of Profibus

The Siemens MICROMASTER 440 (MM440) is a general-purpose vector drive rated from 0.12 kW up to 250 kW. Although the drive is frequently deployed in Profibus-DP networks via the PROFIBUS Module 6SE6400-1PB00-0AA0 (and the later PN-flavor variants), the converter is fundamentally a standalone device. The Profibus module is a plug-in option that provides the cyclical PZD (process data) and acyclical PKW (parameter channel) interface; with the module removed, or with the command source re-pointed to the terminal strip or keypad, the drive will run in complete isolation from the fieldbus.

Two scenarios drive the question of standalone operation most often in the field:

1. Spare-drive replacement: an MM440 has failed in a Profibus cluster and a replacement unit is installed with factory defaults. Profibus masters and HMI screens depend on pre-loaded parameter sets; a fresh out-of-box unit will not respond.
2. Temporary isolation: one node of a multi-drive Profibus segment is being commissioned, rewired, or replaced, but the master PLC must continue running the other nodes.

This reference covers the complete procedure: how to upload parameters from a healthy unit, how to download them to a replacement, how to wire the drive for local control, how to set the Profibus address when the module is reinstalled, and the diagnostic fault codes you will encounter if anything is misconfigured.

2. Prerequisites: Hardware, Software, and Tooling

Before starting the swap-out, confirm the following tools and parts are on hand. Most are inexpensive and stocked by any Siemens distributor or industrial spares supplier.

3. Parameter Upload from a Healthy MM440 via DriveMonitor

The fastest way to put a replacement drive into service is to clone the parameter set from one of the working 22 kW units. The four 22 kW units in the cluster are typically identical, which makes a single upload reusable for all.

3.1 Connection Procedure

1. Power down the healthy MM440. Wait for the DC-link discharge LED to extinguish.
2. Plug the optical RS485 adapter from the PC Connection Kit 6SE6400-1PC00-0AA0 into the dual optical port on the front of the drive. The connector is keyed; do not force.
3. Connect the USB end to the engineering laptop. Windows installs the adapter as a virtual COM port (e.g., COM7).
4. Launch DriveMonitor, choose File → Online → Connect, and select the COM port. Default USS address is 0, baudrate 9600.
5. Once connected, choose Drive → Read Parameters from Drive (or Ctrl+R). DriveMonitor reads the entire parameter image to the project tree.
6. Save the project to disk: File → Save As → MM440_22kW_baseline.dg4.

3.2 Save to AOP MMC (Alternative Method)

If a laptop is unavailable, the Advanced Operator Panel can clone a drive:

1. Insert a blank MMC into the AOP.
2. On the AOP, navigate to Extras → Up/Download → Up to MMC.
3. Power down the AOP, move it to the replacement drive, and select Extras → Up/Download → Down from MMC.

This method copies the entire parameter image, including command data sets (CDS) and drive data sets (DDS), and re-establishes the Profibus address automatically if the module is present.

4. Parameter Download to the Replacement MM440

4.1 Push the Saved Project to the Spare Unit

1. Connect DriveMonitor to the spare MM440 the same way as in §3.1.
2. Open the saved MM440_22kW_baseline.dg4 project.
3. Confirm the new drive's firmware is identical (read parameter r0018 for FW version). Mismatched firmware between source and target can cause ramped parameters to revert to defaults silently. A typical MM440 22 kW is shipped with firmware 3.2 or 3.3.
4. Select Drive → Write Parameters to Drive (Ctrl+W). DriveMonitor writes every parameter, then performs a factory reset + re-load automatically.
5. Power-cycle the drive. The display will show rdy after a few seconds if the parameter load succeeded.

4.2 Verify the Load

Critical parameters to spot-check after the download:

5. Switching the Drive to Standalone (Local) Control

For temporary isolation of a single MM440 from the Profibus cluster, the command source and setpoint source must be redirected away from the bus. The MM440 has three Command Data Sets (CDS) and three Drive Data Sets (DDS), so it is possible to mix bus and local control on a single drive — useful when one Profibus node must be hand-controlled during a maintenance window.

5.1 Command Source (P0700)

To run the drive offline from the bus:

1. Set P0700[0] = 2 for digital-input start/stop, or P0700[0] = 1 for BOP control.
2. Set P1000[0] = 1 for motor potentiometer (BOP up/down arrows) or P1000[0] = 2 for analog input 1.

5.2 Setpoint Source (P1000)

5.3 Local / Remote Toggle (P0810 / P0811)

For installations that need both Profibus and local control, the Local/Remote toggle is implemented via parameters P0810 and P0811. These select which CDS is active:

• P0810 = 0 (default): CDS0 is active (Profibus).
• P0810 = 722.x: CDS is selected by digital input 722.x (e.g., a panel selector switch).

A common wiring pattern is to wire a key-switch on DIN5 (terminal 9) to switch between Profibus control (CDS0, P0700=6) and Local control (CDS1, P0700=2) without re-programming the drive. This is a very clean method to comply with the user's stated requirement of isolating the 3rd MM440 from the system while still leaving the other three in Profibus.

6. Profibus Address Configuration (DIP Switches)

If the Profibus module is reinstalled, the address is not taken from a parameter — it is read from the rotary DIP switches on the 6SE6400-1PB00-0AA0 module itself. The address range is 1..126; 0 is reserved for master class 2 tools.

Sum of weighted bits = 4. The drive shows the active address in r0918 at power-up. If the address displayed in r0918 does not match the DIP switch setting, the module is faulty or the connector between the module and the control board is not seated.

7. Control Terminal Wiring for Standalone Operation

When the drive is removed from the bus and run by hard-wire, the following terminal assignments are used. The MM440 control terminal block is on the underside of the drive, with 1.5 mm² spring-clamp terminations.

7.1 Minimum Local Wiring (2-Wire Control)

For the simplest case — a maintained start switch and a 0–10 V potentiometer for speed — wire as follows:

• Connect a 10 kΩ pot wiper to terminal 2 (AI1+), one end of the pot to terminal 6 (+24 V), the other to terminal 7 (0 V).
• Bridge terminal 8 (DIN1) to terminal 6 (+24 V) to issue ON. To stop, open the bridge. This is OFF1 (ramp-down).
• Set P0700[0] = 2 and P1000[0] = 2.

7.2 3-Wire Control (Momentary Start / Stop)

• DIN1 = Stop button (NC), DIN2 = Start button (NO, P-impulse).
• Requires P0700[0] = 2 and the 3-wire macro by setting P0727 = 3.

8. Fault Codes, Warnings, and Diagnostics

A replacement MM440 that was never connected to Profibus but is still fitted with the Profibus module will trip on F0070 or F0071 at the first run command. Likewise, a drive removed from the bus while running will alarm. Knowing the codes saves hours of bench time.

To clear Profibus faults after switching the drive to local control, set P0700 away from 6 and either:

• Acknowledge with the BOP's FN key, or
• Issue P3981 = 0 (fault code list reset), or
• Cycle power.

9. Verification: Step-by-Step Commissioning Checklist

Use this checklist to bring a standalone MM440 online safely. The checklist assumes a 22 kW 400 V 3-phase unit wired to a star-delta or DOL motor.

1. Visual: confirm the Profibus module is removed (or fully seated if bus is to be used). All control-terminal screws torqued to 0.22 N·m.
2. Insulation: megger the motor to ground at 500 V; insulation should be > 100 MΩ phase-to-ground.
3. Power-on idle: apply mains, observe r0018 firmware, r0021 DC-link voltage (≈ 540 V DC for 400 V supply), r0000 = 0.00 rpm (motor stopped).
4. Quick commission: P0010 = 1, enter nameplate, P3900 = 1 to compute motor model and exit commissioning.
5. Source select: P0700 = 2 (terminals), P1000 = 2 (analog input 1).
6. Ramp check: set P1120 = 10 s, P1121 = 10 s for the first test.
7. Spin test: close the start contact, slowly turn the pot. Motor should ramp to speed without tripping F0001.
8. Thermal check: after 30 min, monitor r0037 (inverter °C) and r0035 (motor °C). Both should be below 80 % of trip threshold.
9. Direction: with the motor uncoupled, verify rotation matches the arrow on the motor. Reverse by swapping any two motor phases (or set P1820 = 1 to swap internally).
10. Hand-off: open the start contact, motor should coast or ramp down to zero on the set ramp.

When re-connecting to Profibus, the additional steps are:

11. Set DIP switches on the Profibus module to the original address.
12. Set P0700 = 6, P1000 = 6.
13. Configure the Profibus master (e.g., S7-300/400 with SIMATIC Manager, or S7-1200/1500 with TIA Portal) with the correct GSD file: SIEM8115.GSD (or SI01815B.GSD for newer master stacks).
14. Verify the slave goes to data exchange state (DX) by checking r0918 matches the address and the master diagnostic buffer no longer flags the slave as station failure.

10. Troubleshooting Matrix

11. Notes on Platform Compatibility and Sizing

The MM440 family covers frames A through F. The 22 kW unit is typically frame C (3-phase 400 V, 380 mm H, 50 kg), and the 22 kW rating is a continuous value at 4 kHz switching frequency. For applications that require lower acoustic noise, the drive can be run at 8 kHz or 16 kHz (P1800), but the continuous output current derates linearly. At 16 kHz, expect roughly 75 % of nameplate current. Always size the drive for the motor's nameplate current, not for its kW rating alone, especially in low-speed / high-torque applications.

For users moving to the successor platform, the SINAMICS V20 is the low-cost modern replacement, and the SINAMICS G120 with a CU240B/E-2 control unit is the functional drop-in replacement that supports Profinet/Profibus natively via PN/DP variants. Parameter migration is not automatic; the V20 has a different parameter number scheme and a connection macro concept rather than P0700/P1000. Always reference the SINAMICS V20 product page and the SINAMICS G120 product page when planning a migration.

For the legacy platform, the official MICROMASTER 440 parameter list and the MICROMASTER 440 operating instructions are the canonical references and supersede any third-party parameter descriptions. The GSD file for Profibus is available from the official Siemens PROFIBUS GSD library.