SIMOTION Winder V3.0.0: Sample Project, Manual, and Commissioning Reference

The SIMOTION Winder application package is Siemens' standardized function library for closed-loop web winding on SIMOTION motion controllers driving SINAMICS S120 converters. Version V3.0.0 (released 06.08.2015) reorganized internal structures and introduced the function extensions that form the basis of every current (V3.2.x) installation. Because the package ships only as a controlled download, engineers must know how to retrieve the manual, the sample project, and the supporting Print Standard reel-stand AddOn from official Siemens channels rather than the open Internet.

This reference consolidates the official entry ID 35818687, the V3.2.7 manual revision, the relationship to the SIMOTION Print Standard reel-stand AddOn, and the workflow for requesting the sample project through a Siemens sales partner.

1. Product Overview and Use Cases

SIMOTION Winder delivers a complete technological building block for:

• Center-driven winders and unwinders (single drives)
• Differential winder pairs (turret, multi-motor)
• Center winder with dancer or load-cell tension feedback
• Closed-loop dancer position with PID overlay to line speed
• Closed-loop tension control with indirect and direct tension measurement
• Automatic diameter calculation from line speed, web length, and material thickness
• Taper tension profiles (linear, hyperbolic, table-based)
• Torque / speed / current limitation cascading with SINAMICS S120
• Winding axis mode 40 integration with the SIMOTION Print Standard reel-stand AddOn

The package targets machine builders in the converting, packaging, printing, paper, foil, textile, and wire industries. It is implemented as a technology object set bound to the SIMOTION runtime and exposes its functionality through function blocks (FBs) and function calls callable from Structured Text (ST), Motion Control Chart (MCC), or Ladder Diagram (LAD/FBD).

2. Version History and Compatibility Matrix

The following table reflects the public revision history recorded in the Siemens support entry Manual_SIMOTION_Winder_V3.2.7.pdf and prior changelog releases.

Engineers using SCOUT V4.4 SP2 can load V2.3.0 directly from the original Applications DVD, but must request V3.0.0 or later through Siemens partner channels because the higher revisions were not republished on the free DVD image.

3. Locating the Official Manual and Entry ID

The canonical reference is Siemens Industry Online Support entry 35818687:

SIMOTION Winder - Support entry 35818687

The entry page lists all public attachments. The authoritative PDF is:

Manual_SIMOTION_Winder_V3.2.7.pdf

The manual contains:

• Block diagram of the winder technology package (technology object winder, FB interface, SINAMICS interface)
• Interface definition tables (input, output, in/out variables for every FB)
• State machine descriptions for Run-up, Jog, Centering, Eject, Thread, Splice, Stop, and Emergency-Stop
• Wiring examples for SINAMICS S120 with DRIVE-CLiQ and PROFIBUS/PROFINET
• Commissioning checklist and parameter acceptance log
• Diagnostic and fault-reaction tables mapped to SINAMICS F codes and SIMOTION technology alarms

4. Workflow for Obtaining the V3.0.0 Sample Project

Unlike V2.3.0 (which shipped on the SCOUT Applications DVD), V3.0.0 and later revisions are released only on request through a Siemens sales channel. The validated procedure used by machine builders is:

1. Verify your SCOUT version. V3.0.0 is compatible with SCOUT V4.4 (with HF ≥ 4 required for some FB instances) and SINAMICS S120 firmware ≥ V4.7. The free DVD bundled with SCOUT V4.4 SP2 contains only the older V2.3.0; do not attempt to load V3.0.0 archives into SCOUT versions older than V4.4.
2. Open Siemens entry 35818687 in a browser and confirm your target version exists in the revision table before requesting.
3. Identify your local Siemens DI MC sales partner (sales contact for Motion Control). Siemens publishes a worldwide contact finder inside the entry 35818687 page footer.
4. Submit a written request to the partner with: company name, sales order or budget code (some partners ship the project on a paid maintenance contract), target SCOUT version, target SIMOTION hardware (D445, D455, C240, etc.), and intended application (center winder, differential winder, dancer, load cell).
5. Receive the archive by encrypted download link, or on DVD when bundled with a maintenance order. The archive is a .zip containing the SCOUT project tree, a PDF print of the documentation, an export of the SINAMICS drive parameter set, and a README.txt describing changes from prior revisions.
6. Check the integrity of the archive with the SHA-256 checksum that the partner provides. Do not deploy a project with a missing or unreadable README; the file documents the SCOUT hotfix level and required TIA Portal add-ins.

5. Sample Project Structure

Once delivered, the V3.0.0 sample project is a standard SCOUT archive with the following top-level structure:

SIMOTION_Winder_V3.0.0.zip
├── SIMOTION_Winder_V3.0.0\SIMOTION D445-1 DP\Project.pcs
├── SIMOTION_Winder_V3.0.0\SINAMICS_S120\S120_Parameter_Backup.dmp
├── SIMOTION_Winder_V3.0.0\Library\SIMOTION_Winder_V3.0.0_lib.lml
├── SIMOTION_Winder_V3.0.0\HMI\WinCC_Flexible_V2008_SP3\Panel_OP270.op6
├── SIMOTION_Winder_V3.0.0\Documentation\Manual_SIMOTION_Winder_V3.0.0.pdf
├── SIMOTION_Winder_V3.0.0\README.txt
└── SIMOTION_Winder_V3.0.0\Changelog_V2.3_to_V3.0.0.txt

The library file SIMOTION_Winder_V3.0.0_lib.lml contains the following FBs (the names follow the V3.0.0 namespace and are mandatory references when integrating into a custom project):

6. FB Interface Conventions

All FBs use the same interface convention for state, command, and feedback variables. The enable, execute, and busy/done/error flags follow the IEC 61131-3 standard. The winder-specific signals are documented in the manual chapter "FB Interfaces" and listed in the table below for quick reference.

7. SINAMICS S120 Drive Configuration

The sample project includes a complete SINAMICS S120 parameter set for a 1FK7 / 1FT7 / 1PH8 motor on a single-axis Line Module. The relevant drive parameters and their default values used by FBWinder are:

8. Relationship to the SIMOTION Print Standard AddOn

Machine builders in the printing industry extend SIMOTION Winder with the SIMOTION Print Standard reel-stand AddOn (entry 48947256). The AddOn activates the winder axis in operating mode 40 — winding and exposes its state through the Print Standard STDcIO interface.

The integration points are documented in Manual_Print_Standard_AddOn_Reel_Stand_V300_en.pdf:

• STDcIO.bWinderActive — TRUE when the reel stand is the active winder
• STDcIO.rWinderDiameter_mm — current diameter broadcast from FBDiameter to the print line
• STDcIO.rWinderTaperTension_N — current tension after taper profile, used by the print's own tension control
• STDcIO.qWinderSplice — TRUE while a splice is in process; the print line pauses inking for the splice length

Engineers porting a V2.3.0 reel-stand AddOn project to V3.0.0 must remap the STDcIO tag names; the V3.0.0 release renamed several signals for consistency with the Converting Toolbox variable model.

9. Converting Toolbox Alignment

SIMOTION Winder aligns its function-block names, variable naming, and HMI tag structure with the broader Converting Toolbox — Siemens' free, standardized function set for the SIMATIC, SIMOTION, and SINAMICS platforms. The toolbox webinar archive at Winder Applications with SIMATIC — Siemens Canada webinar documents this cross-platform alignment.

Consequences for migration:

• An application developed on a SIMATIC S7-1500 with Converting Toolbox Winder functions can be re-implemented on a SIMOTION D4x5-2 with SIMOTION Winder using the same application-level engineering drawings, alarm masks, and HMI screens.
• The toolbox's DCC (Drive Control Chart) library can be mixed with SIMOTION Winder for hybrid machines where part of the winder is implemented in SINAMICS DCC and the part in SIMOTION.

10. Commissioning Step-by-Step

1. Hardware commissioning: wire the SINAMICS Line Module, Motor Module, and motor per SIMOTION Winder manual chapter 5. Verify DRIVE-CLiQ topology with STARTER / SCOUT online Topology view.
2. Motor and encoder commissioning: run p0010 = 1 → motor data entry → p0010 = 0 → p1900 = 1 (motor identification) → p1960 = 2 (speed controller optimization). Confirm p1961 > 60 % for an acceptable tuning quality.
3. Load SIMOTION Winder library: in SCOUT, choose Options → Libraries, import SIMOTION_Winder_V3.0.0_lib.lml. Add the library to the project's source container.
4. Instantiate FBs: in the SIMOTION program, instantiate FBWinder, FBDiameter, FBTensionControl (or FBDancerControl), FBTaperTension, and FBWinderDiag as VAR_GLOBAL RETAIN instances.
5. Map SINAMICS telegrams: configure PROFIdrive telegram 103 on the drive axis and 110 on the encoder input. Bind the SIMOTION TO_Axis telegram configuration to the same numbers.
6. Wire the HMI: load the WinCC flexible / TIA Portal screen from the sample project, or re-import the HMI tags from the library's HMI_Tags.csv.
7. Dry run: in SCOUT online mode, set i_EnableWinder = TRUE and verify that q_WinderReady transitions to TRUE after the FBWinder state machine reaches Run. Watch the trace in FBWinderDiag for any alarms during the first 10 s of run-up.
8. Tension loop tuning: with the web threaded but the line stationary, command a small line speed (e.g., 5 m/min) and adjust FBTensionControl P / I / D gains to settle the tension setpoint in 1–2 s without overshoot > 5 %.
9. Production ramp: increase line speed to operating value; verify taper tension profile and diameter calculation against a manual measurement with a tape measure at 10 %, 30 %, 50 %, 70 %, and 90 % of full roll.

11. Diagnostic and Troubleshooting Matrix

12. Version-Upgrade Path from V2.3.0 to V3.0.0

Engineers holding an installed V2.3.0 application (e.g., the version on the SCOUT V4.4 SP2 Applications DVD) can migrate to V3.0.0 by following the procedure documented in the supplied Changelog_V2.3_to_V3.0.0.txt:

1. Open the V2.3.0 project in SCOUT V4.4 (or later).
2. Export the user-specific recipe, HMI tags, and drive parameter set to a backup file.
3. Detach the V2.3.0 library and re-attach the V3.0.0 library from the partner-supplied archive.
4. Re-instantiate FBs that have been renamed (V2.3.0 FB_WindTech → V3.0.0 FBWinder; FB_Diam → FBDiameter).
5. Rebuild and re-load the SIMOTION program.
6. Run an acceptance test against the migration checklist supplied with the partner archive.

The migration cannot be performed by a simple SCOUT "update library references" operation because several FB interfaces were restructured in V3.0.0 to support the new taper-tension and dancer-cascaded-speed FBs. The recompile must be done explicitly.

13. Frequently Asked Questions