SINAMICS S120 Commissioning STARTER Software and Drive

SINAMICS S120 System Architecture Overview

The SINAMICS S120 drive system from Siemens is a modular, high-performance variable frequency drive platform designed for complex multi-axis motion control applications. The platform is built around three core components: a Control Unit that handles communication and closed-loop regulation, Line Modules that rectify the DC bus voltage from the AC supply, and Motor Modules that invert the DC bus into variable-frequency motor outputs. The platform is documented in the SINAMICS S120 product family on the Siemens SINAMICS product portal.

For the configuration referenced here, the system consists of:

• A CU320 Control Unit (article number 6SL3040-0MA00-0AA1) that manages drive-axis control, DRIVE-CLiQ communication, and the higher-level fieldbus interface.
• One or more Booksize Double Motor Modules (article number 6SL3120-2TE13-0AA3) that power two independent axes from a common DC link.
• A CompactFlash (CF) memory card (article 6SL3055-0AA00-2AA0 at 512 MB or 6SL3055-0AA00-3AA0 at 1 GB) that stores the device firmware and the parameter image of the drive object.

The CU320 communicates with the Motor Modules over the proprietary DRIVE-CLiQ serial interface, and with the higher-level controller (SIMOTION, SIMATIC S7, or third-party PLC) over PROFIBUS DP, PROFINET, or EtherNet/IP depending on variant. The CU320 reads each Motor Module's electronic nameplate at first power-up, automatically identifies the device, and loads the matching firmware. This mechanism is what enables a like-for-like device swap in the field.

Hardware Identification and Part Numbers

Before installing any software, verify the article numbers on the device nameplates. Each Siemens SINAMICS component carries a rating plate with a 6SL3... or 6SL2... order number that resolves to a specific variant, firmware load, and connector arrangement.

The Motor Module 6SL3120-2TE13-0AA3 belongs to the Booksize form factor (50 mm wide) and accepts a 600 V DC link voltage from a Line Module or Smart Line Module via the integrated DC bus bars. Two motor cables terminate at the X2 motor connector of each axis, and DRIVE-CLiQ is wired to the CU320 to establish the electronic nameplate exchange.

Prerequisites and Required Tooling

For first-time commissioning of a SINAMICS S120 line-up with a Field PG, gather the following before powering the cabinet:

1. Field PG (Siemens SIMATIC Field PG M4/M5 or any Windows-based engineering laptop) with administrator rights for driver installation.
2. STARTER commissioning software (current V5.x release) installed locally. STARTER is available as a free download from the Siemens Industry Online Support portal.
3. Connection cable between the PG and the CU320. The PG side has either a 9-pin D-sub PROFIBUS connector, a USB port (when using an RS232-to-USB adapter), or an RJ45 PROFINET port.
4. CompactFlash card populated with the correct firmware (matching the SINAMICS S120 version on the line-up, e.g., V5.x). The firmware shipped with the device is typically already on the card that ships in the CU320.
5. 24 V DC for the CU320 electronics supply (separate from the line-side power). The CU320 is normally powered through the S120 line-up's 24 V bus.
6. Drive documentation for the project: the S120 Function Manual, the S120 List Manual (parameter reference), and the project-specific drive topology drawing.

STARTER Commissioning Software Installation

STARTER (the SINAMICS commissioning tool) is delivered as a free download from the Siemens Industry Online Support portal. To install:

1. Download the latest STARTER installer (typically a ZIP archive containing a Setup.exe and the SSP – Service and Support Packages for the SINAMICS firmware you intend to commission). Search for "STARTER V5.x" on the Siemens Industry Online Support.
2. Run Setup.exe as administrator. Accept the license terms and install to the default path C:\Program Files (x86)\Siemens\Automation\STARTER.
3. During installation, the installer prompts for the SSP files. Select the SSPs that match the SINAMICS firmware version of the line-up (e.g., STARTER_S120_SSP_V5_x.zip).
4. When prompted, choose whether to install the license certificate. Siemens recommends installing a license certificate for legal traceability even though the runtime use of STARTER remains free. The license is delivered as a separate file (*.zip) and is dragged into the STARTER License Manager.
5. After install completes, the STARTER icon is added to the desktop. Launch STARTER, select Online → Connect to target system, and verify that the CU320 is reachable over PROFIBUS, RS232, or PROFINET.

PG-to-Drive Connection Cabling Options

Three connection paths exist between the Field PG and the CU320. Select the one that matches the cabinet I/O and the host PLC topology.

Option A: PROFIBUS DP

The CU320 carries a 9-pin D-sub PROFIBUS connector (X126) terminated with an address selector rotary switch. Use a standard PROFIBUS cable (Siemens article 6XV1830-0EH10, blue, double-shielded) terminated with 9-pin D-sub connectors and PROFIBUS terminating resistors enabled at the bus ends.

• Set the PROFIBUS address on the CU320 via the rotary switch on the front. Valid range: 1 – 126. Switch position 0 reads the address from parameter p0918.
• The PG must be online as a PROFIBUS master or peer with PG/PC functionality. In PG-mode (Siemens PC adapter 6GK1571-1BA00, or CP 5611 A2 / CP 5613 / CP 5622), STARTER routes through Set PG/PC interface.

Option B: RS232 Null-Modem Serial

The CU320 also has a service port (X120) wired as D-sub 9-pin female configured as DCE. Use a null-modem (crossover) RS232 cable – Siemens article 6SX7000-0AJ50 or equivalent – with TxD/RxD and the handshake lines crossed. Modern PGs without an RS232 port require a USB-to-RS232 adapter (FTDI-based recommended).

• The RS232 service interface operates at 9.6 kbit/s to 115.2 kbit/s, with 8-N-1 framing.
• RS232 is intended for service and diagnostics only; it is not a production bus. Use PROFIBUS, PROFINET, or EtherNet/IP for the production connection.

Option C: PROFINET / Ethernet (CU320-2 PN variants)

On the CU320-2 PN variant (6SL3040-1MA01-0AA0), three RJ45 sockets on the front accept a standard Ethernet patch cable for the PROFINET network. For the original CU320 (6SL3040-0MA00-0AA1), PROFINET is only available if the optional CBE30 Communication Board Ethernet is plugged into the option slot on top.

• Default IP after factory reset: 192.168.0.10 / 255.255.255.0.
• Configure the PG side to a compatible subnet and connect directly through a switch or crossed patch cable.

Establishing Online Connection in STARTER

Once the cable is connected, bring the cabinet to a safe state (24 V on, line voltage off, drives in STO or OFF1). Inside STARTER:

1. Launch STARTER and create a new project. Project → New, choose a directory, and accept.
2. Set the PG/PC interface under Options → Set PG/PC interface. Pick the CP 5611/CP 5622 for PROFIBUS, the COM port for RS232, or the Intel/NDIS Ethernet adapter for PROFINET.
3. In the project tree, right-click Drive unit → Accessible nodes. STARTER broadcasts onto the fieldbus and lists every CU320 with its PROFIBUS address and current firmware version.
4. Select the device and click Accept. STARTER uploads the drive topology and parameter set from the CU320 and renders the drive objects in the project tree.
5. Click Online in the toolbar to establish a live connection. The yellow Online indicator turns green when the handshake completes.

If the device is not visible, walk through the following diagnostics:

• Verify 24 V supply to the CU320 (LED RDY must be green).
• Verify terminating resistors on the PROFIBUS connectors at both ends of the segment.
• Confirm the rotary PROFIBUS address does not conflict with another node.
• For RS232, verify the null-modem wiring with a breakout box. Some adapters are straight-through rather than null-modem.

DRIVE-CLiQ Topology and Comparison Quality

The CU320 stores the topology of every DRIVE-CLiQ-connected device along with its serial number. On each power-up the firmware compares the actual topology against the stored one. If a node is replaced, the comparison level determines whether the firmware treats the new device as a like-for-like swap or as a topology error.

The comparison level is set per component through the topology parameter (p9906 in the SERVO/VECTOR object, or the equivalent on the CU320). The valid settings move from loose to strict:

The CU320 also stores the topology in the STARTER project file. After a device swap, the offline topology in the project will show the new serial number and must be reconciled by Target → Actual comparison or by an offline-online sync.

CompactFlash Memory Card Function

The CF card slot on the front of the CU320 holds a standard CompactFlash card (Type I/II). The card has two distinct storage areas:

1. Firmware area – the SINAMICS S120 firmware binary. When the card is inserted and the CU320 boots, the firmware version on the card takes priority over the firmware in flash. This allows firmware upgrades by simply replacing the card.
2. Parameter image – the complete set of drive parameters for the connected drive objects. When the card boots the drive, the parameters on the card are loaded into the CU320 RAM.

Two key STARTER functions manipulate the CF card:

• Online → Load to PG reads the current parameter set from the CU320 to the STARTER project on the PG.
• Online → Load to CF card writes the current project parameters to the CF card so that a new device boots with the same configuration.

Power-up behavior of the CF card is governed by the rotary switch and DIP switches on the CU320:

• If the card is inserted at boot and the parameters on the card differ from the parameters in flash, the drive prompts to "Copy from card to flash" or "Copy from flash to card" via the basic operator panel.
• If the card is empty, the CU320 boots from its internal flash and writes the active parameters to the card at shutdown.

Drive Replacement Procedure (Device Swap)

When a Motor Module or another DRIVE-CLiQ device fails in the field, the supported swap workflow uses the CF card and STARTER together. The procedure is identical whether the device is a Motor Module, Sensor Module, or Terminal Module, because DRIVE-CLiQ provides the mechanism.

Before the swap

1. Bring the drive line-up to a safe state and lock out the line-side power.
2. In STARTER, connect online and select Online → Load to PG. This ensures the project on the PG has the latest parameters from the failing unit.
3. Insert a CF card populated with the correct firmware. The card may already be the one shipping in the spare Motor Module.

Perform the swap

1. Pull the defective Motor Module out of the rack and insert the spare. Confirm the DC bus bars and PE conductor are mechanically seated.
2. Connect the DRIVE-CLiQ cable from the CU320 (or upstream DRIVE-CLiQ node) to X200 on the spare Motor Module.
3. Connect motor cables to X2 of each axis. Verify torque per the cabinet drawing.
4. Apply 24 V to the electronics supply only. The CU320 reads the new Motor Module's electronic nameplate over DRIVE-CLiQ.

Boot and parameter restore

1. Boot the line-up. The CU320 will compare the new serial number to the stored topology. With p9906 at Medium or lower, the swap is accepted without a topology fault.
2. If a fault is raised (e.g., F01340: "Topology: Comparison error"), navigate to Alarms → Topology in STARTER and accept the new topology. STARTER then writes the corrected topology to flash.
3. Re-trigger the parameter load from the PG: Online → Load to CF card (if the spare did not already have parameters), or Online → RAM to ROM followed by a power cycle.
4. Run a one-axis test jog to verify encoder direction, current limits, and brake control before re-engaging the production process.

Verification, Diagnostics, and Troubleshooting

After commissioning or after a device swap, run through the following verification matrix. Each row is a single field check; record the result on the commissioning sheet.

Common fault codes and remedies

Fault codes follow the SINAMICS S120 standard scheme. The first letter (F = fault, A = alarm, W = warning) defines the class; the five-digit number maps to the relevant subsystem. Always cross-reference with the S120 List Manual for the firmware version installed on your CU320.

License, SSP, and STARTER Variant Notes

STARTER itself is free to download and use. Siemens nevertheless recommends installing a license certificate for legal traceability. The license does not change runtime behavior of STARTER, but it documents that the user has been authorized by Siemens to operate the software.

The SSP – Service and Support Package – is the firmware knowledge base inside STARTER. STARTER is delivered with a baseline SSP; the SSP can be upgraded independently of the STARTER installer to support newer SINAMICS firmware versions. When the firmware on a CU320 is newer than the SSP loaded in STARTER, STARTER will prompt to download the matching SSP from the Siemens Industry Online Support.

Siemens also bundles STARTER functionality into other tools:

• SCOUT (SIMOTION SCOUT) – required when commissioning SIMOTION motion controllers or S7-Technology objects. SCOUT contains STARTER as an embedded component and adds motion-control configuration. SCOUT requires a hardware license key (USB dongle or software license).
• SINAMICS Startdrive – the successor to STARTER for users of the TIA Portal. Startdrive supports the same drive parameter set inside the TIA Portal project tree.

Frequently Asked Questions