Transfer Parameters from Siemens MicroMaster 430 to MM440 via STARTER

The MicroMaster 430 (MM430) and MicroMaster 440 (MM440) share the same STARTER/DriveMonitor commissioning toolchain and a largely overlapping parameter structure, but they target different application classes (constant-torque heavy industrial vs. vector-controlled general purpose) and use different firmware branches. When a spare MM440 must replace a failed MM430, parameters can be cloned through the STARTER XML export/import path — but only with controlled reconciliation, not a blind overwrite. This reference covers the full procedure: compatibility, export, import, parameter mapping, commissioning, and verification.

1. Overview of the Parameter Transfer Problem

The MM430 and MM440 are both members of the Siemens MICROMASTER 4 family. They share:

• The same USS/Modbus RTU/Profibus (via CBP module) fieldbus interface cards.
• The same commissioning tool: STARTER (versions 4.x and 5.x) and the legacy DriveMonitor.
• A common parameter number scheme in the P0000–P3999 range (P-prefixed parameters are commonly called r-parameters for read-only and P-parameters for read/write, e.g., r0000 is the parameter access level, P0010 is the commissioning parameter).
• Parameter upload/download via the RS232 serial interface, the PC-to-drive USB-to-Serial adapter (Siemens 6SE6400-1PC00-0AA0), or Ethernet (via the Ethernet/IP module on the PROFINET side).

What differs is the application firmware, the default values for some motor-control parameters, and the BICO (Binector Connector) interconnection set. A direct in-place parameter copy without reconciliation is not supported by the drives and will result in either:

• Default-value mismatches (motor nameplate data, ramp times, current limits).
• Faults F0001 (overcurrent), F0002 (overvoltage), F0003 (undervoltage), F0004 (inverter overtemperature), F0011 (motor overload I²t), or F0051 (parameter EEPROM fault) at first run.
• Loss of application-specific settings, especially BICO wiring on the MM430 Fast/Standard BOP/AOP parameter access paths.

The only robust transfer path is XML export from the source MM430, XML import into a freshly created MM440 offline project, parameter reconciliation, then download to the physical MM440.

2. MicroMaster 430 vs. MicroMaster 440 — Architectural Differences

Although both drives are MICROMASTER 4, the application targeting is fundamentally different.

The MM440 firmware carries a larger parameter tree, including sensorless vector control, FCC (Flux Current Control), and encoder feedback. When you import MM430 XML into a MM440 project, parameters that do not exist on the MM430 (e.g., the encoder set) are inserted with MM440 default values, which is generally acceptable. The reverse — MM430 parameters that have no equivalent on the MM440 — is the actual problem; STARTER will mark these as "not imported" in the export/import status window.

3. Prerequisites

Before starting the parameter transfer, confirm the following:

1. STARTER version: STARTER V4.x or V5.x with the SP (Service Pack) for MICROMASTER 4 support. STARTER commissioning tool download and documentation (Siemens Support). STARTER 5.4 + HF03 or later is recommended for MM440 firmware ≥ 3.2.
2. PC-to-drive connection: Either
   • RS232 straight-through cable to the MM430/MM440 front panel RJ11 (or 6SE6400-1PC00-0AA0 PC-inverter connection kit), or
   • USB-to-serial adapter (FTDI-based recommended) for laptops without a DB-9.
3. Drive firmware note: The r0018 firmware string of source and target. In STARTER, browse online to read r0018. MM430 firmware 2.02 and MM440 firmware 2.2 are both MM4 firmware branch 2.x; the parameter mapping is therefore wide but not 1:1.
4. Project license (if any): A spare MM440 with the same power rating (110 kW, 400 V class, FS F) and rated current (≈ 360 A; check nameplate, depends on whether the drive is light-overload or heavy-duty rated — see Section 10).
5. Original MM430 commissioning report (printed or PDF) with the motor nameplate data: rated kW, voltage, current, frequency, cos φ, speed.
6. Access to the inverter at the cabinet with the BOP-2 or AOP removed or a STARTER online connection possible.

4. Pre-Transfer Data Capture from the MM430

Even if STARTER already contains the live MM430 project, capture the following data before exporting. This is your fall-back if the XML import diverges.

1. Connect STARTER to the MM430 online. Right-click the drive → Online → Connect to target device.
2. Navigate to Commissioning → Parameter list. Filter for P0010 = 0 (ready) and capture the full parameter dump to a CSV using Commissioning → Expert list → Print/Export.
3. Record the following critical parameters and values by hand or in a spreadsheet:

   Parameter	Meaning	Why it matters
   P0010	Commissioning filter	Must be 0 in operation; values 1/30 trigger parameter set writes
   P0100	Europe/N. America (50/60 Hz, kW/HP)	0 = 50 Hz / kW; 1 = 60 Hz / HP; 2 = 50 Hz / HP
   P0201	Rated power of drive (kW)	110.0 in your case
   P0205	Inverter rated current (A)	~360 A on FS F 110 kW; verify nameplate
   P0304	Motor rated voltage (V)	e.g., 400 V
   P0305	Motor rated current (A)	e.g., 205 A on a typical 110 kW motor
   P0307	Motor rated power (kW)	110.0
   P0308	Motor rated cos φ	0.85–0.89 typical
   P0310	Motor rated frequency (Hz)	50 or 60
   P0311	Motor rated speed (rpm)	e.g., 1485 rpm on a 4-pole 50 Hz motor
   P0700	Command source selection	2 = terminal, 6 = fieldbus
   P1000	Setpoint source selection	2 = analog, 6 = fieldbus
   P1080 / P1082	Min / max frequency (Hz)	e.g., 0.00 / 50.00
   P1120 / P1121	Ramp-up / ramp-down time (s)	Application-specific
   P1300	Control mode	0 = V/Hz linear, 2 = V/Hz quadratic, 20 = SLVC
   P2000	Reference frequency (Hz)	For fieldbus scaling
   P2150 etc.	Process-controller gains (if used)	For PID/pump applications on the MM430

4. Save the MM430 project (Project → Save) and the online copy (Target system → Upload to PG/PC) so you have an offline copy containing the source settings.
5. Note any BICO connections set on the MM430: P0730…P0733 (DO function), P0770…P0771 (AO function), P2800…P2890 (free function blocks on MM440). MM430 has a smaller free-function-block set, so anything wired on the MM430 to MM430-only parameters will not import.

5. Step-by-Step: Exporting the MM430 Project to XML

This is the offline path that worked in the field case where the source drive was no longer accessible online. The XML file is portable between PCs and can be archived.

1. In STARTER, open the MM430 project (offline is fine).
2. Right-click the MM430 drive object in the project tree.
3. Select Expert → Save and Export… (or the menu path Project → Save and Export in STARTER 5.x). The wording varies slightly by STARTER version: in older versions it appears as Save / Export Project to XML.
4. Choose a target folder (e.g., C:\Temp\MM430_export\). STARTER writes one or more XML files, with the main file ending in _DO.xml (drive object) and supporting index files for parameter indices.
5. Open the export status window when prompted. STARTER will show warnings if any parameter fails to serialize. Typical warnings for an MM430 export are about read-only r- parameters — these can be ignored.
6. Verify the XML header contains the firmware string. Open the *.xml in a text editor and search for <FirmwareVersion> or the equivalent attribute — confirm it matches the source r0018 reading.

6. Step-by-Step: Importing the XML into a New MM440 Project

The most common failure in this procedure is the "Import function is not active" issue raised in the field report. This happens when the active project is not the correct target. The fix is to ensure you are inside an MM440 project, not the MM430 project you just exported.

1. Close the MM430 project. File → Close (do not save again — the export already captured the settings).
2. Create a new offline project: File → New Project. Name it e.g., MM440_110kW_clone.
3. Insert a new drive: right-click the project → Insert Single Drive Unit. Search for the MM440 product family. Select the correct power class — for 110 kW this is typically MICROMASTER 440 / 6SE6440-2UD41-1GA1 (or the equivalent order number for the local mains voltage, 380–480 V 3-ph).
4. Confirm the drive is inserted as an offline object (the green icon, not the yellow "online" icon). If the project was opened with auto-connect, click the disconnect button first.
5. Right-click the MM440 drive object. The menu now shows Expert → Import as active (it is greyed out when the active drive is the wrong model).
6. Select Expert → Import…. Navigate to the *.xml file from Step 5.
7. STARTER raises a warning: You are attempting to overlay an incompatible (different) drive. This is expected and must be accepted. The dialog exists because STARTER is aware the parameter sets do not fully match.
8. After import, STARTER displays the Import status window. Each line shows whether the parameter was imported, kept at default, or rejected. The count of "not imported" lines is the parameter reconciliation work for the next step.
9. Save the project: Project → Save. Archive the resulting *.sdp file alongside the XML.

7. Parameter Reconciliation Procedure

After import, manually verify the parameters that drive behavior. The reconciliation list below is the minimum check; add application-specific parameters as needed.

For each "not imported" parameter in STARTER's status window, consult the MM440 parameter manual. The most common omissions are MM430-specific parameters with no MM440 equivalent (legacy free-function-block parameter slots, customer-specific firmware extensions).

8. Drive Commissioning on the MM440 Hardware

Once the offline MM440 project is reconciled, download to the physical drive. The MM440 first-time commissioning sequence:

1. Verify mains voltage at the disconnect: 380–480 V 3-phase ±10% (or 200–240 V for the 230 V class). Phase rotation L1-L2-L3 must match the drive's markings.
2. Connect STARTER online to the MM440 via RS232. Right-click the drive → Online → Connect. The status icon turns yellow.
3. Set P0010 = 30 to allow factory reset, then P0970 = 1 to clear all parameters to factory default if you want a clean slate. (Skip this step if you want to preserve any settings already on the spare MM440.)
4. Reconnect, then download the reconciled project: right-click → Target system → Download to target device. STARTER prompts for P0010 = 30 first — accept.
5. Wait for the green "Download complete" message. The drive will reset, then show "Ready to run" (display: 0000 or ready pattern).
6. Set P0010 = 0 for normal operation. P0700, P1000, ramp times, and the process controller are now armed.
7. Set the access level for the user: P0003 = 1 (standard) or P0003 = 3 (expert) per site policy.

9. Motor Identification and Verification

The MM440, when set to P1300 = 20 (SLVC) or P1300 = 21 (vector with encoder), requires motor data identification at first start. Even on V/Hz mode (P1300 = 0 or 2), a static motor identification improves low-speed torque.

1. Set P1910 = 1 (motor data identification, static). The drive prompts: Press the green start button on the BOP to begin identification.
2. Apply the run command but do not load the motor. The drive injects a brief current pulse and measures stator resistance (r1912), leakage inductance, and rotor time constant. The motor emits a single low-frequency hum for ~3–10 s.
3. For P1960 = 1 (rotating identification), the motor must be uncoupled from the load. P1960 accelerates the motor to a configured speed and back, computing the moment of inertia. Skip this if the load is not decoupled.
4. After identification, the drive returns to "Ready". The computed values are written to r1912–r1925 and copied to P0350–P0360 for the controller.

9.1 No-Load Test (Mandatory Before Coupling to Load)

1. Verify the run command source matches expectations: with the fieldbus disconnected, force P0700 = 2 and P1000 = 2, then apply 24 V to DIN 0 (terminal 5) on the MM440. The drive should ramp to P1080.
2. Step the setpoint to 25%, 50%, 75%, and 100% of P2000. At each step, log:
   • Output frequency (r0024)
   • Output current (r0027 or r0068)
   • DC bus voltage (r0026)
   • Motor torque (if P1300 = 20: r0031)
3. For 110 kW at 400 V, the no-load current should be 30–50% of P0305 on SLVC, 25–40% on V/Hz. If the no-load current is above 60% of nameplate, the motor data is wrong or P0310/P0311 is mis-set.
4. Verify the ramp timing matches P1120 and P1121 with a stopwatch. A discrepancy greater than 10% indicates ramp rounding (P1130–P1134) is not what the original setting implied.

9.2 Loaded Test

1. Couple the motor to the load (pump, fan, conveyor).
2. Run at process setpoint. Monitor r0027 (motor current) and r0034 (motor I²t utilization). r0034 should remain below 100% sustained. r0034 > 100% trips F0011 after the I²t timer expires.
3. Verify the fieldbus (if used) reads the correct actual frequency. The PLC should be reading r0024 (or the fieldbus-mapped r0021). A scaling mismatch (PLC sees 100% when the drive is at 50 Hz) is a P2000 problem on the drive side, not a PLC scaling problem.
4. Capture a STARTER trace of r0024, r0027, and r0034 for 60 s of normal operation. Archive this trace with the project as proof of commissioning.

10. Sizing and Current Verification

The 110 kW power class on both MM430 and MM440 maps to roughly 360 A rated output. Verify by reading the inverter nameplate (printed on the side of the unit) — Siemens part numbers for the 400 V class 110 kW range include:

• 6SE6440-2UD41-1FA1 (MM440, 110 kW, 250 A heavy-duty, 290 A light-duty)
• 6SE6430-2UD41-1FA1 (MM430, 110 kW, 250 A heavy-duty, 290 A light-duty)

These are for the 400 V / 480 V three-phase mains class. The exact part number depends on the regional variant and overload rating. Always cross-check against the physical nameplate.

For a 110 kW, 400 V three-phase motor with a typical 89% efficiency, the input line current is approximately:

I_line = (P_out / (sqrt(3) * V_LL * eta)) = (110000 / (1.732 * 400 * 0.89)) = 182.7 A (motor input)
I_inverter = I_motor / 0.97 (inverter efficiency ~97%) ≈ 188 A

The 250 A heavy-duty rating of the FS F drive gives 1.36× service factor above the motor FLA, which is the standard Siemens 110 kW configuration. If the replacement MM440 is the same FS F, the parameter set transfers cleanly. If the spare is a different FS, P0205 must be re-entered from the new nameplate and motor nameplate scaling (P2000) re-checked.

11. Troubleshooting Matrix

12. Field-Proven Caveats

1. Don't skip the no-load test. A 110 kW MM440 is not a small inverter. The difference between V/Hz and SLVC at first start can be the difference between a 1-second ramp and a 10-second ramp with full magnetizing current. Always test no-load before coupling the load.
2. Check the firmware string, not the major version. MM430 firmware 2.02 and MM440 firmware 2.2 share the major "2.x" branch, but the parameter index mapping differs even within a major. Always archive r0018 for both drives and note them in the project README.
3. Save the XML, not just the SDP project. STARTER projects (.sdp) are PC-installation-specific. The XML is portable across PCs, STARTER versions, and is the only thing you can hand off to a colleague without sending the full project tree.
4. MM440 has more DO/RO and DI than MM430. The MM430 has 3 digital inputs, the MM440 has 6. If the original wiring used 4 or 5 DIN, the MM430 was probably a non-standard config — verify before assuming the MM440 is one-to-one pin-compatible.
5. The BOP-2 is not fully compatible across MM4 generations. A BOP-2 from an MM420/430 may not display the full parameter tree on an MM440 firmware ≥ 2.0. Use the AOP or STARTER for first-time commissioning of the MM440.
6. Archive the as-exported XML, the as-imported project, and the as-commissioned project. Three files, three timestamps. If a fault occurs in six months, you have the trail to prove the original settings.
7. Current ratings: A 110 kW MM440 is the FS F chassis and weighs about 110 kg. Two people plus a hoist, or the lifting eye on top of the unit, is the minimum safe handling plan.

13. Standards and Compliance References

The MM440 family is CE-marked and complies with the following standards as of the relevant firmware:

• EN 61800-5-1 — Adjustable speed electrical power drive systems — Part 5-1: Safety requirements — Electrical, thermal and energy
• EN 61800-3 — EMC requirements and test methods for adjustable speed power drive systems
• UL 508C — Power Conversion Equipment (for the UL-listed variants of the MM440)
• IEC 61131-3 — For the PLC-side interface (relevant when the drive is controlled by a Siemens PLC like S7-1200/1500 via the PN or CBP module)

These standards define the safe operating envelope (overvoltage category, pollution degree, ambient temperature range 0–40 °C without derating up to 50 °C with derating). Verify the specific rating on the drive nameplate and in the operating instructions linked at the top of this article.