SINAMICS G120 Firmware Update in TIA Portal V15 via StartDrive

David Krause11 min read
SiemensTutorial / How-toVFD / Drives
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SINAMICS G120 Firmware Update in TIA Portal V15 via StartDrive

The SINAMICS G120 modular inverter family (CU230P-2, CU240B-2, CU240E-2, CU250S-2 control units paired with PM240, PM240-2, PM250, or PM330 power modules) is engineered for seamless integration inside the TIA Portal engineering framework. When a physical drive ships with a newer firmware version than the one exposed by the TIA Portal V15 hardware catalog, the engineering tool cannot configure, parameterize, or commission the drive until the matching Hardware Support Package (HSP) is installed. This guide walks through the complete procedure to install the SINAMICS G120 V4.7 SP10 HSP, integrate it into the TIA Portal V15 project, and execute an online firmware update using StartDrive V15.

1. Background: Firmware Versions, HSP, and StartDrive

Each SINAMICS G120 control unit ships with a Control Unit firmware (CU FW) and a Power Module firmware (PM FW) stored on a removable card or in the unit's flash memory. Siemens labels the firmware with a four-segment version string, for example 4.7.10 or 4.7.10.11. The trailing segment denotes a Hotfix (HF), and the letter pair that follows an SP indicates the Service Pack level.

Version segment Meaning Example
Major.Minor Firmware generation 4.7
Service Pack (SP) Functional maintenance release SP10
Hotfix (HF) Bug fix patch on a service pack HF11
Build Internal build counter 11 (4.7.10.11)

When TIA Portal V15 is shipped, the bundled G120 device library exposes the firmware version that was current at the time of release. Drives that have been manufactured or serviced later than the TIA Portal release date will not appear in the device catalog. The fix is to install the appropriate Hardware Support Package, which expands the device catalog with newer firmware revisions and adds new drive types if any were added in that release.

Critical compatibility rule: StartDrive version must match the TIA Portal version, including Service Pack and Update. Mixing StartDrive V15 with TIA Portal V15.1, for example, will block the catalog update and online operations.

2. Prerequisites

Before attempting the firmware update, verify the following prerequisites are satisfied.

  1. TIA Portal V15 with matching Service Pack installed (V15, V15.1, or later within the V15 line). Determine the installed build by selecting Help > About in the TIA Portal menu bar.
  2. StartDrive V15 installed, with the same Service Pack and Update level as TIA Portal.
  3. Administrator privileges on the engineering PC. HSP installation writes into the TIA Portal installation directory and the Windows registry.
  4. SINAMICS G120 HSP V4.7 SP10 downloaded from the Siemens Industry Online Support portal. The file is distributed as Startdrive_V15_HSP_FW_V4_7_SP10.zip (approximately 460 MB compressed).
    Source URL: HSP V4.7 SP10 entry on Siemens Support.
  5. PROFINET or PROFIBUS connection between the engineering PC and the SINAMICS G120 control unit. For PROFINET, ensure the drive's IP address is reachable from the PC; for PROFIBUS, the PC adapter must be online.
  6. Compatible firmware file for the Control Unit: SINAMICS_G120_firmware_V4_7_HF11.zip (79 MB). Extract to obtain the .upd firmware loader file used in Section 6.
Common pitfall: The raw firmware ZIP from the firmware download entry is not an installer. It contains a .upd file for online flashing only. To make the new firmware selectable inside the TIA Portal project offline, install the HSP first.

3. Downloading the Correct HSP

Two download paths exist. Pick the one that matches your connectivity and version target.

3.1 Manual Download (offline-capable)

  1. Navigate to the Siemens Industry Online Support entry ID 109754382.
  2. Locate the download block titled Startdrive_V15_HSP_FW_V4_7_SP10.
  3. Save the ZIP archive to a local path, e.g. C:\Siemens\HSP\G120_V47_SP10\.
  4. Extract the archive. The resulting folder contains an .isp15 file (the actual HSP descriptor) and accompanying metadata.

3.2 Automated Download (Internet-connected PC)

The Totally Integrated Automation UPDATER fetches and installs matching HSPs in one pass. Reference: How do you update the hardware catalog in TIA Portal?

  1. Open Start > All Programs > Siemens Automation > Totally Integrated Automation UPDATER.
  2. Switch to the Support Packages tab.
  3. Click Find. The tool queries the Siemens update server for all packages compatible with the installed TIA Portal / StartDrive versions.
  4. Select Startdrive_V15_HSP_FW_V4_7_SP10 and click Install. The UPDATER writes the HSP into the TIA Portal installation and updates the device catalog automatically.
When behind a corporate proxy, configure the UPDATER proxy settings under Settings > Proxy before running Find. Otherwise the search returns an empty list and reports a network error.

4. Installing the HSP in TIA Portal V15

For the manual download path, integrate the HSP into TIA Portal as follows.

  1. Launch TIA Portal V15.
  2. From the menu bar, select Options > Support Packages.
  3. In the Support Packages dialog, click Add from file system (folder icon).
  4. Browse to the extracted HSP folder and select the .isp15 file.
  5. Click Install. TIA Portal will close, install the HSP, and prompt to relaunch.
  6. Reopen the project after TIA Portal restarts.

After installation, the device catalog will list the G120 with firmware 4.7.10 as a selectable version. To verify, drag a new G120 device from the catalog into your project; the Device configuration pane will expose the new firmware entry in the firmware version drop-down.

5. Configuring the Project with the New Firmware Version

  1. Open the project containing the four G120C drives.
  2. Select each SINAMICS G120C device in the project tree.
  3. Open Properties > General > Device Information.
  4. In the Firmware version drop-down, change the selection from 4.7.9 to 4.7.10.
  5. Repeat for the remaining three drives.
  6. Project > Save > Save As Version (V15) to lock the project to the matching TIA Portal release.

Offline configuration with the new firmware version is now possible. Existing parameter sets, BICO interconnections, and PROFIdrive telegram configurations remain valid; only newly added parameters and functions introduced in V4.7.10 become accessible.

6. Online Firmware Update of the G120 Drive

With the project aligned to firmware V4.7.10, perform the online flash to match the physical unit.

  1. Connect the engineering PC to the drive network (PROFINET or PROFIBUS) and power the drive on.
  2. In the TIA Portal project tree, right-click the G120C device and select Online & diagnostics.
  3. Navigate to Functions > Firmware Update > Firmware loader.
  4. Click Browse and select the .upd file extracted from SINAMICS_G120_firmware_V4_7_HF11.zip.
  5. Confirm the target device and click Run update.
  6. Wait for the progress bar to reach 100%. The drive will reset and reboot with the new firmware. Do not interrupt power during the flash cycle.
  7. After reboot, the drive reports the new firmware version on its BOP-2/IOP display (e.g. 047.010.11).
If the update fails with F01000 (internal software error) or F30001 (power unit overcurrent during flash), the drive enters a safe state. Power-cycle the unit and retry. Never abort the update at the 50% mark; this can corrupt the firmware image and require a service recovery via the SD card slot on the CU.

7. Alternative Path: SINAMICS Starter

StartDrive inside TIA Portal is the preferred tool, but experienced engineers sometimes prefer the standalone SINAMICS Starter commissioning tool for advanced diagnostics, trace recording, and DCC (Drive Control Chart) editing. To use Starter for the firmware update:

  1. Install SINAMICS Starter V5.4 SP3 (or later, matching the firmware generation).
  2. Connect to the drive via PROFIBUS, PROFINET, or Ethernet/IP and go online.
  3. Right-click the drive > Target device > Firmware update.
  4. Select the .upd file and execute the update.
  5. After completion, switch back to TIA Portal / StartDrive to download the project configuration to the now-updated drive.

Starter does not require the HSP, so it can flash firmware versions newer than what TIA Portal currently exposes. This makes Starter a useful fallback when the matching HSP is not yet available.

8. Verification Procedure

After the firmware update, confirm the drive is operating correctly on the new firmware version.

  1. Version check: On the drive, navigate to Menu > Diagnostics > Drive information and verify the firmware version string.
  2. Online comparison: In TIA Portal, right-click the drive > Online & diagnostics > Compare offline/online. The result must show Identical for all parameters.
  3. Parameter sanity check: Read parameters r0018 (firmware version), r0020 (firmware version, build), r0127 (power unit firmware), and r0148 (control unit firmware). Compare to expected values in the parameter manual.
  4. Functional test: Run a controlled jog command from the BOP-2 or via StartDrive. Verify that the motor accelerates, holds setpoint, and decelerates without triggering any fault (F-class code).
  5. Fault buffer clear: Read the fault buffer (r0945 array, r0947 array, r0949 array) and clear it with p0952 = 0 > ACK before production release.

9. Troubleshooting Matrix

Symptom Root cause Remediation
HSP not visible in Options > Support Packages after extraction User selected the outer ZIP instead of the inner .isp15 file Extract the archive fully and select the .isp15 in the inner directory
New firmware V4.7.10 absent from the firmware version drop-down after HSP install TIA Portal V15 base build without matching StartDrive HSP, or wrong SP level Run TIA UPDATER and install all matching support packages, then restart TIA Portal
Firmware loader reports "No compatible device found" Wrong CU type selected in the firmware file or the drive is offline Confirm the .upd file is for the correct CU variant (e.g. CU240E-2 vs CU250S-2) and that the drive shows as online
Update aborts at 50% Power loss or communication interruption Power cycle, reflash via SD card using the recovery image, then retry online flash
Drive reports F01000 / F30001 after update Firmware / parameter set mismatch Perform a factory reset (p0970 = 1), then download the project from TIA Portal
PROFINET name or IP lost after firmware update Update reset the device name (expected for some HF versions) Re-assign PROFINET device name and IP, then download the project

10. Version Compatibility Reference

TIA Portal StartDrive G120 HSP CU firmware selectable
V15 (base) V15 V4.7 SP9 (default) 4.7.9
V15 V15 + HSP V4.7 SP10 V4.7 SP10 4.7.10 (and earlier)
V15.1 V15.1 V4.7 SP13 (typical) 4.7.13
V16 V16 V4.7 SP14+ / V5.x 4.7.14+ and G120 V5.x variants

The release pairing is strict. For background on the firmware update workflow in TIA Portal, see the S7-1200 manual collection reference Updating firmware. Although the page references S7-1200 CPUs, the same Online and Diagnostics > Firmware update workflow applies to SINAMICS G120 control units and StartDrive.

11. Field-Commissioning Checklist

  • Verify TIA Portal and StartDrive versions match (Help > About).
  • Install matching HSP via TIA UPDATER or manually via Options > Support Packages.
  • Confirm drive catalog now lists target firmware (4.7.10 or later).
  • Update the project to the new firmware version for every G120 device.
  • Back up the current parameter set: Online > Upload from device (RAM to ROM).
  • Extract the .upd firmware file from the firmware ZIP.
  • Execute the firmware update via Online & diagnostics > Functions > Firmware loader.
  • Power-cycle the drive to complete the flash.
  • Re-assign PROFINET name and IP if cleared by the update.
  • Download the project configuration to the drive.
  • Clear the fault buffer and verify parameter p0952 / p2100 values.
  • Run a controlled motion test before handing back to production.

12. Safety Considerations

STO / Safety Integrated: If the drive is wired into a Safety Integrated chain (STO via terminals, PROFIsafe, or Failsafe over PROFINET), firmware updates may reset the safety configuration checksum. After the update, re-validate the safety function by executing the configured test stop sequence. The acceptance test per EN ISO 13849-1 and EN 62061 must be repeated whenever a safety-related parameter changes.
Hot plugging: Never disconnect the PROFINET cable or power the drive off during the firmware flash. Interruption at the 50% mark is the most common cause of unrecoverable firmware corruption requiring SD-card recovery.

FAQ

Why does TIA Portal V15 only show firmware 4.7.9 for the G120C when my drive is 4.7.10?

Because TIA Portal V15 was released before firmware 4.7.10 was available. The hardware catalog only ships with the firmware versions current at the release date. Install the matching Startdrive_V15_HSP_FW_V4_7_SP10 HSP via Options > Support Packages to add V4.7.10 to the catalog.

Can I install the SINAMICS_G120_firmware_V4_7_HF11.zip file directly inside TIA Portal?

No. That ZIP contains only the .upd file used for online flashing, not an installer. To make the firmware selectable in the TIA Portal device catalog, install the corresponding HSP from the Siemens support entry 109754382 instead.

Do I need to match StartDrive version exactly to TIA Portal V15?

Yes. StartDrive and TIA Portal must be the same major version, service pack, and update level (e.g. TIA V15.1 + StartDrive V15.1 + Update 4). A mismatch blocks the HSP install and prevents the new firmware from appearing in the catalog.

How do I update the firmware on the drive once the HSP is installed?

Right-click the G120 device in the project tree, choose Online & diagnostics > Functions > Firmware Update > Firmware loader, browse to the extracted .upd file, and run the update. The drive will reset and boot into the new firmware.

Can I use SINAMICS Starter to update firmware if TIA Portal cannot?

Yes. SINAMICS Starter V5.4 SP3 or later can flash a .upd firmware file without the TIA Portal HSP, making it a practical fallback when the matching HSP is not yet available. After flashing, switch back to TIA Portal / StartDrive to download the project configuration.

What fault codes should I watch for after a firmware update?

Common post-update faults include F01000 (internal software error), F30001 (power unit overcurrent), and F08501 (PROFINET communication fault after name reset). Clear the fault buffer with p0952 = 0 and ACK, then run a controlled motion test before returning the drive to production.

David KrauseIndustrial Controls Specialist – Siemens Platforms

Industrial controls specialist focused on Siemens SIMATIC S7 platform, from the S7-300/400 series through the latest S7-1200/1500 controllers. Expert in TIA Portal configuration and WinCC SCADA integration.

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