SINAMICS S120 TIA Portal Configuration PM240-2, CU320-2

SINAMICS S120 TIA Portal Configuration: PM240-2, CU320-2, and CUA Adapter Compatibility

A correctly dimensioned SINAMICS S120 drive package can still fail to commission cleanly if the Control Unit, Power Module, and Control Unit Adapter topology is not selected as a single coherent family. The most common field failures on greenfield S120 builds are mixing the wrong CUA adapter for a given Power Module, accepting a CF card firmware that is one or two branches behind the latest Siemens support pack, and assuming that the TIA Portal hardware catalog can host the full drive offline like a SIMATIC station.

This reference consolidates the engineering decisions for a typical S120 cabinet build using a SINAMICS Control Unit CU320-2 PN, a PM240-2 IP20 FSC 15 kW Power Module, an IFT7 synchronous servomotor, a CPU 1511T controller, and the matching Drive-CLiQ, power, and signal preassembled cables. It covers CF card firmware selection, CUA adapter part numbers, STARTER vs TIA Portal (Startdrive) workflows, project compatibility after STARTER upgrade, and the offline/online configuration split that always applies for S120 systems.

1. System Overview and Original Bill of Material

The drive package selected with Sizer for the machine application consists of the following line items. MLFBs and firmware states are taken from the original Sizer output and cross-checked against the Siemens Industry Online Support catalog.

2. Root-Cause 1 — CUA31F is the Wrong Adapter for PM240-2

The first and most important engineering issue is hardware topology, not firmware. The CUA31F (6SL3040-0PA00-0AA1) is the FSC variant of the CUA31 and is designed only for the SINAMICS PM340 Power Module family (6SL3210-1SBxx, 6SL3210-1SCxx). It provides the DC link and 24 V wiring for PM340 frame sizes A through F and terminates the PM340-specific power connector.

The PM240-2 (6SL3210-1PE23-3AL0) is a member of the PM240-2 Power Module family. The matching CU320-2 adapter is the CUA32 (6SL3040-0PA01-0AA0). The CUA32 has the correct PM240-2 power terminals, the matching internal DC busbar geometry, and the correct Drive-CLiQ interface handshaking for the PM240-2 device identification.

Effect of the mismatch in the as-ordered BOM:

• Drive-CLiQ topology will reject the power module. When the CU320-2 scans Drive-CLiQ at first commissioning, it reads the electronic rating plate from the CUA. A CUA31F reports the connected PM340 device family, but the cabinet contains a PM240-2. The control unit raises F08501 (drive object not found) and the line contactor is not released.
• DC link and 24 V wiring pinout differs. Even with the Drive-CLiQ issue bypassed, the X1/X2 power terminal assignment of the CUA31F does not match the PM240-2 terminal block, so the PM240-2 will not be energized.
• Sizer accepted the combination because of catalog overlap. Sizer's PM240-2 and CUA31F entries can coexist in the same cabinet, but Sizer does not enforce the electrical cross-compatibility at the cabinet level — that check is performed by the SIZER rule set only when the cabinet design rule is enabled. For chassis-style integration, always run the cabinet validation step.

3. Root-Cause 2 — CF Card Firmware V4.8 vs V5.2

The original BOM calls for a CF card with firmware V4.8 (MLFB 6SL3054-0EJ00-1BA0). At the time of writing, the latest CU320-2 support pack is V5.2 (MLFB 6SL3054-0FC00-1BA0). The version question has three concrete dimensions.

3.1 What the CF card actually contains

The CF card for the CU320-2 contains a complete image of the SINAMICS firmware, the SINAMICS Support Package (SSP) files, the licensed technology functions, and a license key. The control unit boots from the card; the unit has no onboard firmware. Replacing the card with one of a higher SSP is the equivalent of a full firmware update.

3.2 STARTER does not perform a firmware update

STARTER (the SINAMICS commissioning tool) can flash a connected drive online only through the Load firmware to target device dialog using a separate SINAMICS firmware package. STARTER does not rewrite a CF card in place. The supported, Siemens-blessed workflow is to remove the CF card from the CU320-2, write a new image using the Webserver card writer tool or a card reader with the Siemens CF card image, and reinstall it. STARTER is used to commission and download the parameter set, not to update firmware.

3.3 Is V4.8 still supported for this hardware?

V4.8 is the predecessor branch of V5.x. It supports the original CU320-2 PN (6SL3040-1MA01-0AA0), the IFT7 motor family, and the safety functions (via license) that were available at that release. V4.8 is still considered a valid support pack and is listed in the Sizer 2020-compatible catalog. However, the latest SSP includes bug fixes for the IFT7 auto-tuning routines, additional encoder support, and the SINAMICS Webserver features. For a new project, ordering V5.2 directly is preferred.

4. Root-Cause 3 — TIA Portal Cannot Insert PM240-2 with CU320-2

The second issue reported is that the TIA Portal V15.1 hardware catalog allows the PM240-2 Power Module object to be placed in the project only when a CU240E-2 / CU240S-2 Control Unit is selected, and it refuses the PM240-2 against a CU320-2. This is not a defect — it is the catalog enforcing the same CUA rule described in Section 2.

The TIA Portal drive objects in the hardware catalog mirror the SIZER product decomposition. The PM240-2 object exists in two roles:

1. As a stand-alone Power Module behind a CU240E-2 / CU240S-2 / CU250S-2. In this role, the object is dragged directly into the project with the matching CU240-2 Control Unit. This is the G120 topology.
2. As a chassis component behind a CUA32. In this role, the PM240-2 is added to the cabinet editor together with the CUA32 object, and the CU320-2 PN is the controlling Control Unit. The CUA32 is what makes the topology legal.

If the catalog has a CUA31F object but no CUA32 object, the TIA Portal installation is missing the SINAMICS S120 Support Package for V15.1. TIA Portal V15.1 ships with the SINAMICS S120 GSDML files for S120 line modules and motor modules, but the CUA32 is shipped as part of the S120 HSP (Hardware Support Package) that is installed separately. The fix is to install the SINAMICS S120 HSP that matches the CF card firmware.

5. STARTER vs TIA Portal (Startdrive) — When to Use Which

There is a persistent misunderstanding that TIA Portal can perform the full SINAMICS S120 offline configuration and parameter download. TIA Portal can host the S120 drive object in the project tree, can set the PROFINET telegram (Standard Telegram 1, 2, 3, 5, 6, 102, 105, 106, 116 are all standard for S120), and can route the cyclic I/O words. What TIA Portal cannot do — even with Startdrive — is edit the S120 expert list, configure the DCC (Drive Control Chart), set the safety parameters, or perform the IFT7 automatic motor identification. For these tasks, STARTER or the SINAMICS Webserver is required.

5.1 Recommended project workflow for the build in question

1. Create the SIMATIC project in TIA Portal V15.1 with the CPU 1511T and the PROFINET subnet.
2. Insert the CU320-2 PN as a PROFINET device. TIA Portal imports the S120 GSDML for V5.x, which exposes the CU320-2 with the standard telegrams.
3. Set the device name (e.g. sinamics-cu320-2) and the IP address (e.g. 192.168.0.10). Assign the same name and IP that will be used on the real CF card once STARTER has written the configuration.
4. Configure the cyclic I/O (Standard Telegram 105 is the typical choice for an IFT7 servomotor in positioning mode, 16 bytes PZD each direction).
5. Build and download the SIMATIC project to the CPU 1511T. The drive will not move yet — the SINAMICS side still needs its parameter set.
6. Open STARTER V5.x (matching the CF card firmware) and create an offline S120 project that targets the same CU320-2 device name and IP.
7. In STARTER, insert the IFT7105-5SC70-1CB0 from the motor list. STARTER auto-fills p0300–p0335 from the motor record.
8. Configure the encoder interface (the IFT7 with the preassembled 6FX5002-2DC10-1BA0 signal cable uses the incremental HTL/TTL interface on the SMC30, parameter p0400 = 3001).
9. Save the STARTER project, go online to the CU320-2 over PROFINET, and click Download to target device.
10. Run the automatic motor identification (p1910 = 1, then pulse enable). This requires the line contactor to close and the power module to be enabled by STARTER.
11. Test the basic motion (JOG with p2300, or a STARTER trace with the control word 0x047E). Once the basic move is clean, the TIA Portal side is ready to issue positioning telegrams.

6. STARTER Version Compatibility and Project Migration

The original installation has STARTER V4.4, which predates the V4.8 SSP for the CU320-2. STARTER V4.5 is the first version that supports V4.8 drives, and STARTER V5.x supports both V4.8 and V5.x drives. The current production release is STARTER V5.2 SP3 (or the V5.2 SP4 update).

6.1 Upgrading from STARTER V4.4 to V5.x

STARTER projects are forward-compatible. A project created in STARTER V4.4 for an S7-300 + G120C drive can be opened in STARTER V5.x and downloaded to the target hardware without modification. The *.sdf or *.star project file format was extended but not deprecated. The migration considerations are:

• GSDML import. If the G120C was inserted using a GSDML in V4.4, the same GSDML is re-resolved at open time in V5.x. Keep the GSDML in a known location and re-import if STARTER reports a missing file.
• Parameter values. Parameters that were reserved in V4.4 and populated in V5.x carry forward their old values; parameters that did not exist in V4.4 are set to factory defaults. The expert list diff is shown in the Compare parameters dialog at open time.
• Online projects. If an existing S7-300 + G120C installation is in production, opening the project in V5.x and clicking Download to target device will push the V5.x project to the drive. This is a no-op when the parameters are unchanged, but if any expert list defaults shifted between V4.4 and V5.x, the values will be overwritten. Always back up the project with Upload from target device before opening in a new STARTER version.
• Tool installation order. STARTER V5.x is normally installed side-by-side with V4.4 and is launched with the Start menu shortcut Siemens Automation > STARTER > STARTER V5.2 SP3. The two versions do not share a default project directory.

6.2 Should you upgrade STARTER or use a virtual machine?

For a one-off commissioning of the new S120 build, upgrading STARTER to V5.2 SP3 on the existing engineering workstation is the cleanest option. The G120C projects in production remain compatible. If a hard freeze on STARTER V4.4 is required for legacy reasons, the S120 project can be commissioned on a separate engineering workstation with STARTER V5.2 SP3, and the resulting parameter set can be exported as a *.bak or *.par file and merged into the TIA Portal drive object at the device level.

7. Pre-Commissioning Hardware Verification

Before any software is loaded, perform the following cabinet-level checks. These match the SINAMICS S120 Commissioning Manual sequence and are the only safe order of operations for a 400 V cabinet with an IFT7 servomotor.

1. Verify the CUA part number against the power module part number. PM240-2 → CUA32 (6SL3040-0PA01-0AA0). PM340 FSC → CUA31 / CUA31F.
2. Verify the CF card part number against the SSP release. V5.2 → 6SL3054-0FC00-1BA0. The CF card slot is on the front of the CU320-2, behind the BOP. The card is keyed and can only be inserted in one orientation.
3. Verify the Drive-CLiQ topology. The CU320-2 port X100 connects to the CUA Drive-CLiQ port 1 (the OUT port). Motor encoder is on the CUA port 2, but on a PM240-2 with a separate SMC30 the encoder is connected to the SMC30 Drive-CLiQ port 1 and the SMC30 is connected to the CUA port 2.
4. Verify the power cable cross-section. The 6FX5002-5DG52-1BA0 is a 4 mm² 4-core cable; the 6FX5002-5CG10-1BA0 is the matching mains cable. Both cables are preassembled with EMC connectors. The shield must make 360° contact at both ends.
5. Verify the 24 V supply to the CU320-2. The CU320-2 X124 connector is the 24 V supply for the control electronics. The CUA does not supply 24 V to the CU320-2; a separate 24 V feed is required. Without 24 V, the CU320-2 will not boot even with the CF card installed.
6. Verify the line filter and line reactor. The PM240-2 IP20 in a 400 V cabinet requires a line filter for EMC compliance (Class A1) and a line reactor when the line short-circuit power at the cabinet's PCC exceeds the value listed in the PM240-2 manual. For 15 kW at 32 A, the typical line reactor is the 6SL3000-0CE32-3AA0.

8. First-Power-Up Sequence

Once the cabinet is verified, the first power-up follows the SINAMICS S120 Commissioning Manual, Section "Commissioning procedure". The exact sequence for a CU320-2 PN + CUA32 + PM240-2 + IFT7 build is:

1. Insert the CF card into the CU320-2. Insert the BOP20. Close the cabinet door.
2. Apply 24 V to the CU320-2. The BOP shows FW 5.2.x and the SINAMICS logo within 30 seconds.
3. Press OK on the BOP to enter the drive status display. The status should read 0 = Ready for power-on. If a fault is shown, navigate to Faults & Alarms and resolve before proceeding.
4. Close the main line contactor. The line filter and reactor are energized. The DC link begins to charge through the PM240-2 pre-charge resistors.
5. Wait for the DC link voltage to stabilize. The BOP shows 5 = Run after pre-charge. If the contactor drops out, a pre-charge fault (F06000) is logged. Check the line voltage and the pre-charge circuit.
6. Configure the PROFINET device name and IP address from STARTER or TIA Portal. The CU320-2 ships with device name cu320-2-pn and IP 0.0.0.0. Assign the same device name and IP that was used in the TIA Portal project (e.g. 192.168.0.10).
7. Connect STARTER to the CU320-2 over PROFINET, go online, and download the project.
8. Run Motor data identification (p1910 = 1, then pulse enable). The motor will run a brief measurement routine without shaft motion. This must complete without fault.
9. Run Encoder data identification (p1990 = 1, then pulse enable). This also runs without shaft motion.
10. Run Speed controller optimization (p1960 = 1, then pulse enable, then a JOG enable from STARTER). The motor will run a brief motion sequence and STARTER will write p1470, p1472, p1475, p1477 from the result.
11. Save the parameter set in STARTER with RAM to ROM (p0977 = 1) and back up the project to disk.

9. Fault and Alarm Reference

10. Verification Checklist

Use this list to confirm the drive is fully commissioned and the TIA Portal integration is complete.

• CUA32 (not CUA31F) is in the cabinet, and the MLFB on the label reads 6SL3040-0PA01-0AA0.
• CF card MLFB reads 6SL3054-0FC00-1BA0 (V5.2), or the V4.8 card has been re-imaged with the V5.2 image.
• 24 V is supplied to the CU320-2 X124 from an external 24 V source.
• PROFINET device name and IP on the CU320-2 match the TIA Portal project.
• Standard Telegram 105 is configured (for 1FT7 positioning with the 1FK/1FT firmware).
• STARTER project downloads without error and the BOP transitions to 5 = Run after the contactor closes.
• p1910 (motor identification) and p1990 (encoder identification) have completed with OFF1.
• p1960 (speed controller optimization) has been run and the new p1470 / p1472 / p1475 / p1477 values are saved with p0977 = 1.
• TIA Portal is online with the CPU 1511T and the cyclic I/O for the S120 drive shows quality = GOOD.
• A controlled move from the S7-1500T axis technology object operates the IFT7105 in both directions with the expected current draw (typ. 12 A at the 15 kW PM240-2 rated point).

11. Field-Proven Caveats

The following are recurring field issues from S120 first-commissioning at this scale of build. They are not in the basic manual.

1. The SIZER cabinet design rule does not catch the CUA31F vs PM240-2 mismatch by default. SIZER validates the catalog dependency, but the rule that PM240-2 requires CUA32 is enforced only when the cabinet validation step is enabled. Always run the design rule with the Cabinet design check turned on.
2. STARTER V5.x will open a V4.4 GSDML-based G120C project without warning. The project will compile and download. Always back up the project to disk before opening a legacy project in a newer STARTER.
3. CPU 1511T and SINAMICS S120 require matching PROFINET conformance class A or B. The CPU 1511T defaults to conformance class B (PROFINET V2.3, IRT capable). The CU320-2 PN ships at conformance class A and must be promoted to class B in STARTER if the topology is to be IRT. This is set in STARTER under PROFINET interface > Properties > Conformance class.
4. The 6FX5002-2DC10-1BA0 is the IFT7 incremental encoder cable. The 6FX5002-2DC00-1BA0 is the resolver cable and is not pin-compatible. The signal cable in the BOM is correct for the IFT7 with the 2CQ option, but a substitution by a junior engineer will silently change the encoder interface from SMC30 to a different firmware object and the drive will report F31100 at first run.
5. The BOP20 (6SL3055-0A00-4BA0) is a useful first-line diagnostic tool. The BOP shows the active fault, the active warning, the drive status, the DC link voltage, and the IGBT junction temperature. The BOP20 cannot edit parameters — use STARTER or the Webserver for that.
6. CF card write protection. The CF card has a write-protect switch on the side. Leave it unlocked during commissioning, but lock it after the final RAM to ROM. A locked CF card will refuse parameter changes from STARTER and the BOP will show 17 = Wait for write-protect release.

12. Summary of Actions

FAQ