SIMOTION SCOUT to TIA Portal Migration: D4x5-2 and CX32-2 Guide

SIMOTION SCOUT to TIA Portal Migration: Hardware Replacement and Firmware Update Reference

Migrating an existing SIMOTION project into the TIA Portal (Totally Integrated Automation) with SCOUT TIA is one of the most common engineering tasks when modernizing a machine that was originally commissioned in the classic SIMOTION SCOUT environment. The migration path is not transparent because SCOUT TIA does not support every legacy SIMOTION Control Unit, every SINAMICS firmware version, or every PROFINET/PROFIBUS function block that classic SCOUT supported. Engineers typically encounter two immediate errors when opening an older project: the message that CX32_2 cannot be configured and the message that D435_1 is not supported. Both are symptoms of the same root cause: the project contains first-generation SIMOTION D hardware that SCOUT TIA does not catalog.

This reference consolidates the official Siemens Product Notification for SCOUT TIA V4.4 HF2, the TIA Portal V20 SCOUT TIA migration documentation, and field-proven migration steps into a single decision tree that covers hardware replacement, firmware alignment, unsupported feature workarounds, HMI migration, and final verification.

1. Supported SIMOTION Hardware Matrix in SCOUT TIA

SCOUT TIA is a subset of the classic SIMOTION SCOUT engineering environment that is hosted inside the TIA Portal framework. Its device catalog is deliberately narrower to match the devices that Siemens actively maintains with security patches and firmware updates. The current SCOUT TIA V4.4 HF2 catalog supports the following SIMOTION platforms:

Hardware that is not in this catalog will fail to import. The most commonly encountered exclusions during migration are:

• SIMOTION D410, D410 PN (non-'-2' variants)
• SIMOTION D425, D435, D445 (first generation, non-'-2')
• SIMOTION CX32 (first generation)
• CBE30 (first generation, only CBE30-2 supported)

2. SINAMICS S120 Drive Firmware Requirements

SIMOTION D control units integrate a SINAMICS S120 CU320-2 drive controller. SCOUT TIA V4.4 HF2 accepts only the following SINAMICS firmware versions on drives interconnected with a SIMOTION CPU via PROFINET or PROFIBUS:

Firmware files are stored on the SCOUT TIA installation media under S7DATA/SIMOTION/SINAMICS_FW and on the support portal as SIEMENS SIMOTION/SINAMICS firmware packages. If the legacy project references SINAMICS firmware V2.5 or V4.3, those files must be upgraded to V4.7 prior to commissioning in TIA Portal. A firmware mismatch will surface as a topology error during Go Online or during the consistency check.

3. Unsupported Features in SCOUT TIA V4.4 HF2

Even after hardware replacement, several classic SCOUT functions are still unavailable in SCOUT TIA. Plan migration workarounds before starting the conversion so that functional regressions are caught early:

4. Pre-Migration Checklist

1. Document the existing topology. Export the classic SCOUT project as XML (program data only) and as ZIP archive.
2. Identify every Control Unit. List each SIMOTION D, each CX32, each SINAMICS S120 CU, and each firmware version.
3. Identify every PROFINET/PROFIBUS safety device. Any F-Proxy, PROFIsafe slave-to-slave, or MRPD topology must be redesigned before migration.
4. Inventory HMI panels. Classic MP377, MP277, or TP177 panels are not configured in SCOUT TIA directly; they migrate through WinCC TIA.
5. Inventory DCC blocks. Run a global search for _DCC_ symbols; flag for ST port.
6. Check the TIA Portal version. The receiving TIA Portal must be V13 SP1 Update 9 or later, with the SIMOTION SCOUT TIA add-on installed at V4.4 HF2 or newer.
7. Back up the project. Store at least one offline backup on a separate drive before any modification.

5. Hardware Replacement Procedure (D4x5-1 → D4x5-2, CX32-1 → CX32-2)

The replacement is performed inside the TIA Portal hardware catalog after the project has been opened in SCOUT TIA. The classic SCOUT device objects remain visible in the project tree, but their associated hardware must be re-pointed to the -2 variant.

5.1 Replace the SIMOTION D Control Unit

1. Open the migrated project in TIA Portal with the SCOUT TIA add-on.
2. Open the Devices & Networks editor.
3. Select the SIMOTION D4x5-1 in the device view. Note the PROFINET device name, IP address, and topology slot.
4. Drag a SIMOTION D4x5-2 from the hardware catalog (folder SIMOTION > Controller > D4x5-2) onto the same PROFINET subnet. Use the same PROFINET name and IP.
5. Delete the original D4x5-1 device. The deletion triggers a topology check; confirm the new device remains bound to the same PROFINET subnet.
6. Right-click the new D4x5-2 → Device properties → Firmware version and select V4.4 (or V4.3 if matching the old kernel).
7. Open the SIMOTION SCOUT view (Project navigation, SIMOTION D4x5-2 > SCOUT TIA). The tool starts the automatic hardware reconciliation: the CX32-1 is automatically upgraded to CX32-2, and the SINAMICS Integrated version is bumped to the firmware level of the SIMOTION D (typically V4.7).

5.2 Verify CX32-2 Reconciliation

The automatic upgrade of the CX32 from -1 to -2 only succeeds if the underlying SIMOTION D firmware version matches. If the CX32 stays at V2.5 after step 7 above, the SIMOTION D firmware selection did not propagate. Manually correct the CX32:

1. Open Devices & Networks and select the CX32 submodule.
2. Open Properties > General > Device Identification.
3. Change Firmware version from V2.5 to V4.7 (matching the SINAMICS firmware installed with the -2 platform).
4. Compile the project. The HWCN must compile without errors before continuing.

5.3 Replace Standalone SINAMICS S120 Drives

1. Open each S120 CU310-2 DP/PN or CU320-2 DP/PN in the topology.
2. Set firmware to V4.7 (recommended) or V4.5 SP3 (minimum).
3. Re-assign the PROFIsafe slots if the original project used PROFIsafe; SCOUT TIA enforces stricter slot mapping than classic SCOUT.
4. Re-download the drive parameter set after the next commissioning.

6. SCOUT Program Data Migration

After hardware replacement, the SIMOTION program objects (axes, programs, technology objects, cams, fault tables, watch tables) must be transferred. Three valid paths exist:

For the path that triggered this article (migrating an existing classic SCOUT project), the recommended sequence is:

1. Open classic SCOUT. Right-click the SIMOTION device → Export → XML export of program data. Save the file.
2. Open TIA Portal with SCOUT TIA. Create a new project and insert the SIMOTION D4x5-2 as described in section 5.
3. Open the SCOUT TIA view of the new device. Right-click → Import → select the XML from step 1.
4. Re-compile. Address any cross-references that broke (typically technology object references and TO instance names).
5. Re-run the consistency check (Project > Compile > All) and the consistency check for the SCOUT TIA add-in (SIMOTION > Consistency check).

7. PROFINET Topology Migration

SCOUT TIA enforces the PROFINET specification more strictly than classic SCOUT. After hardware replacement, run through this checklist:

1. Verify that every device on the PROFINET subnet has a unique PROFINET device name. SCOUT TIA will refuse to compile if duplicate names exist.
2. Verify that the IP addresses are inside the configured IP subnet. The TIA Portal validates this during compile.
3. If the original used PROFINET IRT with the Performance Upgrade option, disable it. SCOUT TIA does not support the Performance Upgrade.
4. If the original used MRPD (Media Redundancy with Planned Duplication), switch to MRP. SCOUT TIA supports MRP client role only; the MRP manager role must be assigned to a different controller.
5. If the original used F-Proxy through PROFINET GSDML, reconfigure the F-CPU and the SIMOTION I-Device in the same project. SCOUT TIA blocks GSD-based F-Proxy.
6. If a Shared I-Device was configured, split the I/O assignment. SCOUT TIA does not support Shared I-Device for SIMOTION.

8. HMI Migration (MP377 / MP277 / TP177 → TP1500 Comfort)

SIMOTION HMI panels are not configured inside SCOUT TIA. They live in the parallel WinCC (TIA Portal) engineering tree. The migration is a separate workflow:

1. In the original project, note every HMI tag connection pointing to the SIMOTION CPU.
2. Open the project in WinCC TIA. Run the project migrator (Project > Migrate project). WinCC TIA supports direct migration of MP377, MP277, TP177, and most earlier Multi Panels and Comfort Panels.
3. When the migrator finishes, change the panel type if needed: Devices & Networks > right-click HMI > Change device > TP1500 Comfort.
4. Re-bind HMI tags. WinCC TIA breaks connections to the SIMOTION HMI variables if the connection was based on the OPC DA default; switch to the new SIMOTION HMI connection type (S7-MEC or named connection).
5. If the original used the diagnostic channel for S120 alarms, recreate the diagnostic screens manually. SCOUT TIA does not provide the automatic diagnostic channel for S120.
6. Compile the HMI. Deploy to the new panel only after the SIMOTION CPU has been downloaded with the new firmware.

9. Commissioning and Verification

After the migration has compiled cleanly, follow this verification sequence before powering the machine:

1. Offline consistency check. Run SIMOTION > Consistency check. The tool reports unresolved references and missing technology objects.
2. Hardware compilation. Run Compile > HWCN (all). All PROFINET/PROFIBUS devices must show green status.
3. Download to CF card. Use the SCOUT TIA card reader function. Insert the CF card, write the boot project, and verify the boot signature file BOOTFILE.BIN exists at the root.
4. First power-up. Power the SIMOTION D rack. Watch the 7-segment display: 6 = run, F = firmware error, C = CF card error, H = hardware fault.
5. Go Online. Connect TIA Portal > Online > Accessible nodes. The SIMOTION CPU should appear with the assigned PROFINET name.
6. Compare values. Open every technology object and compare axis parameters with the offline project. Look for defaults that did not migrate (e.g., encoder scaling, torque limits).
7. Drive trace. Trigger a controlled move on each axis and record with the SINAMICS trace. Compare against the legacy commissioning trace files.
8. Safety test. If PROFIsafe is involved, run the safety acceptance test again. F-Proxy through PROFINET has different timing characteristics after migration.

10. Troubleshooting Matrix

11. Document and Standards Reference

The migration rules summarized above are anchored in the following Siemens-published documents:

• Siemens Product Notification 96311883 - SCOUT TIA V4.4 HF2 supported functionality
• TIA Portal V20 - Migrating a SIMOTION SCOUT project
• SIMOTION D4x5-2 Operating Instructions (Siemens manual set on the support portal)
• SINAMICS S120 Function Manual FW V4.7 (firmware release notes)
• PROFINET Installation Guideline (PROFIBUS International, PI) - referenced for PROFINET naming, IP, and topology rules

12. FAQ