SIMOTION C230-2 CPU Backup: Selecting SIMOTION Scout Version

Problem Snapshot: SIMOTION C230-2 Backup Returns an Empty Project

An engineer attempts to back up a deployed SIMOTION C230-2 controller (order number 6AU1230-2AA00-0AA0, Version B, MLFB edition A5E00128707) using SIMATIC Manager V5.7 after the project archive on the engineering station was lost. The online view either returns no recognizable project or fails to write a usable archive. The supplier then suggests OPC Scout, and web searches point at SIMOTION Scout V3.2 / V4.2. Because the wrong tool was selected, the controller is left without a maintainable source. This reference consolidates the correct procedure, the version constraints of SIMOTION Scout, and the role of MEMORY.XML on the micro memory card (MMC).

Hardware Identification: SIMOTION C230-2 AXIS-CONTROL

The C230-2 is a compact, embedded SIMOTION controller in the C2xx family designed for axis-control applications. The version discussed here is the 8 DO / 18 DI DC 24 V variant integrated with a SINAMICS / SIMODRIVE 611 drive section.

For full ordering options and variant definitions, refer to the SIMOTION C2xx operating manual (see SIMOTION C Operating Instructions, C2xx_Operating_en-US.pdf). The C230-2 is documented in the SIMOTION C - Support entry attached to that manual.

Root Cause: Wrong Engineering Tool Selected

The failure is procedural, not electrical. Three separate mistakes are common in field service:

1. SIMATIC Manager V5.7 used as a generic upload tool. SIMATIC Manager can browse the S7 portion of a SIMOTION C station (S7-300 compatible backplane) but cannot read, decode, or re-serialize a SIMOTION project. Any resulting archive will only contain the S7 program, not the SIMOTION MCC, technology objects, drive configuration, or trace data.
2. OPC Scout recommended as a backup tool. OPC Scout is a diagnostics client for browsing OPC DA/UA tag space; it is not a project archive tool. It cannot generate a SIMOTION project, technology objects (TO), or axis configuration.
3. SIMOTION Scout TIA assumed to be the same as SIMOTION Scout. SIMOTION Scout TIA (the variant integrated into TIA Portal) does not support the C230-2. The C2xx family is excluded from the TIA Scout runtime, including TIA Portal V17. Even if a TIA installation is already licensed, an additional classic SIMOTION Scout license is required.

Correct Tool: SIMOTION Scout (Classic)

SIMOTION Scout is the dedicated engineering environment for the SIMOTION C, D, and P platforms. For the C230-2 it performs three roles relevant to backup:

1. Reads the project (MCC chart, programs, technology objects, axis configuration) from the controller's MMC.
2. Reads the SIMOTION kernel and runtime version stored on the same MMC.
3. Reads the connected SIMODRIVE 611 parameter set through the integrated drive interface.

The C230-2 can be used to save the SIMOTION Kernel in order to run a firmware update; the kernel must always be stored on the micro memory card alongside the user project. Without the original SIMOTION Scout project file on the PG, the only source of truth for that controller is the MMC, and the only tool that can read it is SIMOTION Scout.

Version Selection Matrix for the C230-2

Two mainstream Scout versions are deployed in the field and both are candidates for the C230-2 backup. The table below summarizes the practical differences for this specific use case.

Choose Scout V4.2 if the engineering PC is 64-bit Windows 7 or 10. Choose Scout V3.2 only if the existing engineering station is locked to a 32-bit OS and the STEP 7 version cannot be upgraded. Both versions read the same MMC layout, so a project backed up on V3.2 can be opened by V4.2 for migration, but not vice-versa for projects created on V4.2 with newer MCC libraries.

Prerequisites Before the Backup

• Engineering PC with administrator rights.
• SIMOTION Scout V3.2 or V4.2 installed and licensed. License key on USB dongle or hardlock.
• STEP 7 V5.5 or V5.6 installed (Scout V4.2) or V5.4 SP3 / V5.5 (Scout V3.2).
• Ethernet / PROFIBUS connection from the PG to the C230-2 X120 / X130 interface.
• Know the controller's IP address, subnet mask, and PG/PC interface assignment in Set PG/PC Interface.
• Verify the MMC is present, recognized, and writable.

Step-by-Step Backup Procedure

1. Open SIMOTION Scout. From Options > Set PG/PC Interface, select the TCP/IP or PROFIBUS adapter that reaches the C230-2.
2. From the menu bar select Project > Open / New Project to create a new empty project shell named, e.g., C2302_BACKUP_<date>.
3. Right-click the project in the project tree and choose Insert SIMOTION Device. In the device catalog select SIMOTION C230-2 (MLFB 6AU1230-2AA00-0AA0).
4. Confirm the device version. Scout will only let you create a project whose Scout version matches or is newer than the runtime version on the target. If the target reports a newer kernel, you must upgrade the local Scout installation first.
5. Right-click the C230-2 device and select Target System > Online > Connect to Target System. Wait for the connection status to turn green.
6. Right-click the device again and choose Target System > Copy from Target to PG (or Read from Target Device in V3.2). This uploads the entire user project, technology objects, axis configuration, and the drive parameter set.
7. When prompted, choose Read all data. Do not uncheck the SIMODRIVE 611 parameter set unless you have a documented reason.
8. After the upload completes, the project tree in the local PG is populated. Right-click the project and select Archive.... Choose User project (without HW configuration) for a small archive, or Complete project for a full restoration source.
9. Save the archive (.zip) to two separate physical media, e.g., network share and offline USB drive.
10. Power-cycle the C230-2 once after the backup to confirm the MMC still boots cleanly.

Reading the MMC Directly: MEMORY.XML

If SIMOTION Scout cannot establish online communication (for example the controller is in a fault state that blocks the service interface), the micro memory card can be removed and read on a PC with a standard MMC card reader. The user project is encoded as MEMORY.XML on the card.

• Mount the MMC in a Windows card reader.
• Copy the entire contents of the card to a working directory, e.g., D:\C2302_MMC\<date>\.
• Locate \USER\SIMOTION\MEMORY.XML. This file is the serialised SIMOTION project.
• To restore: insert the MMC into the C230-2 with the controller powered off, then apply power. The controller boots from the MMC and reloads the project.

Per the SIMOTION C2xx operating manual, the kernel should always be stored on the MMC. Treat MEMORY.XML as the authoritative backup artefact for offline recovery.

Drive ES Requirement Analysis

The discussion thread raises whether Drive ES is required to back up the SIMODRIVE 611 parameter set when the project is read through SIMOTION Scout. The practical answer is:

• For a project-only backup via SIMOTION Scout, Drive ES is not required. Scout handles the drive parameters through its integrated SIMODRIVE 611 view.
• Drive ES is required when you need offline parameterization of the drive, automatic parameter comparison, or commissioning a replacement drive module without SIMOTION in the loop.
• Always check the Drive ES version against the Scout version. A Drive ES version that pre-dates the Scout version may be silently ignored during upload.

Why the Original Project File Matters

If the engineering PC has no SIMOTION Scout project file at all, the backup operation can still succeed by reading the MMC, but the resulting local project will reflect the controller's current state, not its as-commissioned state. This has three consequences:

1. Source comments are lost. The runtime configuration in MCC charts may be readable, but symbol names, network comments, and programmer-defined identifiers may have been optimised away or encrypted at runtime.
2. Reuse for duplication is risky. A second machine cloned from the upload will be functionally equivalent to a snapshot, not to the original commissioning state. Treat the upload as a recovery artefact, not as a version-controlled source.

Verification Steps

1. Compare the online connection status in Scout: it must read Online, run or Online, stop, not Online, error.
2. Open Project > Compare Online/Offline. The report should show no structural differences in technology objects, axes, or programs.
3. Open Target System > Device Diagnostics > Version and confirm the kernel and runtime version match the label on the controller front flap.
4. Check that the archive contains a SIMOTION subfolder with *.xml files, plus a PLC subfolder with the S7-300 station. The presence of both confirms a complete C2xx upload.
5. Re-archive the project on a different physical drive and verify the CRC / file size matches.

Edge Cases and Field-Proven Caveats

• Scout version older than the controller kernel. Scout refuses to open the project. The error is logged as a version mismatch, not a hardware mismatch. Upgrade the local Scout to the same version as the controller before the backup.
• MMC write-protect engaged. SIMOTION can still boot but the backup over the online interface fails. Remove the write-protect sticker or replace the MMC with a clean one of the same type.
• Controller in STOP with a non-recoverable fault. Scout online may succeed for the project read but fail for trace data. Accept the partial upload and proceed; the project read is independent of trace.
• Engineering PC firewall blocks UDP broadcast. Scout cannot auto-discover the device. Disable the firewall rule or enter the IP address manually in the device view.
• Profibus and Profinet in the same station. The C230-2's S7-300 backplane can carry both. Make sure Scout's S7 configuration is loaded for the full station; otherwise the upload only sees the SIMOTION side and not the distributed I/O.

Compatibility Between TIA Portal V17 and SIMOTION C230-2

TIA Portal V17 is unrelated to the C230-2 backup. The TIA integration of SIMOTION (SIMOTION Scout TIA) is limited to newer SIMOTION C, D, and P variants. The C230-2 is not in the device catalogue of SIMOTION Scout TIA, including V17. If TIA Portal V17 is already installed, it can co-exist with classic SIMOTION Scout, but it cannot replace it for the C230-2. Keep both installations on the same PG only if disk and licensing constraints allow; the two install sets are independent and can be activated against the same hardware key.

Documentation References

• SIMOTION C Operating Instructions (C2xx_Operating_en-US.pdf) - canonical reference for C230-2 operation, MMC layout, and kernel storage.
• Backing up an online CPU - TIA Portal reference procedure for an S7 CPU. Useful for understanding the conceptual equivalent in classic Scout; the menu wording differs.

FAQ