Drive Controllers

P_ST70_XX_08675

SIMATIC Drive Controller Video

The SIMATIC Drive Controller is available in two performance classes and meets even the most demanding Motion Control needs with the two fail-safe technology CPUs (CPU 1504D TF and CPU 1507D TF).

The fail-safe CPUs permit the processing of standard and safety programs on the same controller.

As technology CPUs, they also have extensive Motion Control functions such as:

• Speed and positioning axes
• Synchronous operation functions
  • Synchronizing with/without specifying the synchronization position
  • Actual value coupling
  • Shifting of the master value at following axis
  • Camming
  • Cross-PLC synchronous operation
• Cam
• Up to 4 encoder or measuring systems as actual position for position control
• Cyclic specification of the motion vector from the application (MotionIn interface)
• Kinematics
  • With up to 4 interpolating axes (e.g. cartesian portal, delta picker, roller picker, articulated arm, cylindrical robot, tripod picker and SCARA)
  • User-defined kinematics with up to 4 interpolating axes
  • Up to 6 interpolating axes with the additional Motion Control package "S7-1500T Motion Control KinPlus"
• External encoders, output cams and measuring inputs

The extensive integrated interfaces and technology I/Os are consistently available in all performance classes and enable the efficient implementation of compact and modular automation solutions with Motion Control based on the SINAMICS S120 drive system.

Thanks to fast system response times, the SIMATIC Drive Controller is the ideal solution wherever axes with high configuration limits and the shortest cycle times for high machine cycle rates and optimum product quality through deterministic and reproducible machine behavior are required.

The SIMATIC Drive Controller is configured in TIA Portal V16 or higher with the SIMATIC STEP 7 Professional engineering software and SINAMICS Startdrive.
The SIMATIC Drive Controller can be extended with components from the modular SINAMICS S120 drive system and SIMATIC automation components such as HMI and I/O systems.
Additional drive systems such as e.g SINAMICS S210 or SINAMICS G can easily be integrated via PROFINET.

The SIMATIC Drive Controller combines what demanding machine concepts need: Motion Control functions of the fail-safe technology CPUs with the versatile SINAMICS S120 drive system – all in one compact controller.

The SIMATIC Drive Controller is predestined for applications in which the SINAMICS S120 drive system is used, e.g. because

• A highly dynamic, flexible multi-axis drive system is required:
  • Wide range of performance
  • Comprehensive range of motors
  • Manifold control methods (servo, vector, V/f)
  • Technology extensions (VIBX vibration extinction, etc.)
• Controlled infeed/feedback is needed:
  • To prevent unwanted line harmonic distortions
  • To achieve a high level of mains power variance immunity
  • For regenerative feedback when braking

Typical fields of application are:

• Multi-axis machines (e.g. printing and paper machines)
• High-performance applications with short machine cycles (e.g. packaging machines and handling applications)
• Compact machines with little space for the control and drive system (e.g. with control cabinets in the machine bed)
• Distributed control and drive concepts
• Modular machines in which several SIMATIC Drive Controllers are synchronized with each other or with other SIMATIC S7-1500 controllers via cross-PLC synchronization
• Applications in which the requirements for machine and operator protection require a fail-safe PLC
• Demanding automation solutions with medium to high demands on Motion Control and PLC performance, which require a suitable quantity of interfaces and technology I/Os

Setup of a multi-axis drive line-up with the SIMATIC Drive Controller

A multi-axis drive line-up includes:

• One SIMATIC Drive Controller, designed for closed loop control and open loop control of the multi-axis drive line-up
• One SINAMICS S120 Line Module (infeed unit)
• One or several SINAMICS S120 Motor Modules (power units for connecting the motors)
• Further drive components, such as
  • Sensor Modules, Terminal Modules,
  • power supply,
  • filter,
  • reactor, etc.

The connection between the SIMATIC Drive Controller and the SINAMICS S120 drive components is made via DRIVE-CLiQ.

Drive line-up in the designs Booksize Compact (left) and Booksize (right)

SINAMICS S120 PM240-2 Power Modules in blocksize format can be connected to the SIMATIC Drive Controller via Control Unit Adapters (CUA31 and CUA32).

The drive configuration limits of the SIMATIC Drive Controller can be expanded with additional SINAMICS S120 Control Units CU320-2/CU310-2 or with other drive systems (e.g. SINAMICS S210) via PROFINET. For this purpose, the drive systems must support the required PROFIdrive telegrams (e.g. the telegrams 1, 2, 3, 4, 5, 6, 102, 103, 105, 106)

Additional automation components can also be connected, such as:

• HMI systems
• I/O systems (ET 200SP, ET 200MP, etc.)
• Encoder systems
• Stepper motors / analog drives

Interfaces

For the efficient implementation of compact and modular automation solutions, the CPUs feature numerous integrated interfaces and technology I/Os.

Interfaces and display/control elements on the SIMATIC Drive Controller

Onboard I/O

• 12 DI and 8 DI/DQ (X122/X132, assigned to the integrated drive control, can be used by the PLC via telegram 39x)
• 8 DI/DQ (X142, assigned to the PLC, technology I/Os)

Communication interfaces

• 4 × DRIVE-CLiQ (X100 – X103), for the connection of drive components such as Line and Motor Modules, Sensor Modules, etc.
• 1 x PROFINET IO IRT (X150, 3 ports), e.g. for the connection of further drive systems and isochronous I/O systems or for cross-PLC synchronous operation
• 1 x PROFINET IO RT (X160, 1 port), e.g. for network separation or for the connection of further PROFINET devices
• 1 x PROFINET basic services (X130, 1 port), for data transmission at a speed of 1 Gbps
• 1 x PROFIBUS DP (X126, master interface), for the connection of distributed I/Os
• 2 x USB (X125/X135, without function)

The SIMATIC Drive Controller has display and control elements for commissioning and diagnostic purposes.

Display elements

• 3 status LEDs (PLC: RUN/STOP, ERROR, MAINT)
• 3 status LEDs (drive: RDY, COM, not assigned)
• ACT LED for display of read/write access to the SIMATIC Memory Card
• LINK and ACTIVITY LED (for each RJ45 socket at the interfaces X130, X150 and X160)
• 7-segment display for diagnostic purposes

Operator controls

• Mode selector for the PLC (RUN/STOP/MRES)
• FUNCT key (e.g. to write diagnostics data to the SIMATIC Memory Card)
  

Spacer

For flush front mounting with booksize power units, the SIMATIC Drive Controller is supplied with pre-mounted spacers. The spacers increase the overall depth from 226 mm to 270 mm and can be removed if required.

The SIMATIC Drive Controller combines a fail-safe SIMATIC S7-1500 technology CPU and a SINAMICS S120 drive control in one compact unit.

Integrated SIMATIC S7-1500 TF-CPU

TIA Portal V16 or higher with STEP 7 Professional is required to configure the CPU functionality. STEP 7 Safety Advanced is also required to use the F-CPU functionality.

As a technology CPU, the SIMATIC Drive Controller features extended Motion Control functions such as:

• Cam and gear synchronous operation
• Cross-PLC synchronous operation
• Kinematics with up to 4 interpolating axes (up to 6 interpolating axes with the additional Motion Control package "S7-1500T Motion Control KinPlus")

The "Cross-PLC synchronous operation" function integrated in all technology CPUs enables gearing and camming to be implemented across CPUs, so that there are almost no configuration limits for the axes.
In addition to the performance distribution among several CPUs, modular automation concepts can also be easily implemented with cross-PLC synchronous operation.

Cross-PLC synchronous operation

Communication

The powerful interfaces of the CPU permit, for example, the following functions:

• PROFINET IO controller for operating drive systems and distributed I/Os on PROFINET
• PROFINET I-Device for connecting the CPU as an intelligent PROFINET device with a SIMATIC or non-Siemens PROFINET IO controller
• PROFIBUS master interface
• Isochronous mode for PROFINET, PROFIBUS, technology I/Os and integrated drive control
• OPC UA server and client as runtime option for the easy connection of SIMATIC S7-1500 to third-party devices/systems with functions such as OPC UA Data Access, OPC UA Security, OPC UA Methods Call, OPC UA Alarms & Conditions, support of OPC UA Companion specifications

For the SIMATIC Drive Controller, the following runtime options are required when using OPC UA S7-1500:

• CPU 1504D TF: SIMATIC OPC UA S7-1500 Small
• CPU 1507D TF: SIMATIC OPC UA S7-1500 Large

Technology I/Os

The 8 DI/DQ are assigned to the PLC and have technology functions that can be parameterized channel-by-channel:

• DI (hardware interrupt-capable)
• DQ
• Timer DI
• Timer DQ
• Oversampling DI
• Oversampling DQ
• Event/period duration measurement
• Pulse width modulation PWM

The digital inputs can be optimized with regard to high dynamic response and immunity using a parameterizable input filter (1 µs / 125 µs).

The digital outputs can be parameterized as high-speed outputs, which results in the following advantages:

• Extremely steep edges (output delay time in the range 1 μs)
• High switching frequencies
• Highest switching precision, e.g. for use as output cam output

Integrated SINAMICS S120 drive control

SINAMICS Startdrive V16 or higher is required to configure the integrated drive control.

The drive control integrated in the SIMATIC Drive Controller is based on the drive control of a SINAMICS S120 Control Unit CU320-2 (firmware version V5.2 / V5.2 SP3). This permits the operation of up to 6 servo, 6 vector or 12 V/f drives directly on the SIMATIC Drive Controller.
If more drives are required, the drive configuration limits of the SIMATIC Drive Controller can be expanded with additional SINAMICS S120 Control Units CU320-2/CU310-2 or other drive systems (e.g. SINAMICS S210) via PROFINET.

SINAMICS Integrated functionality

The SINAMICS Integrated has a functional subset of the drive functions of SINAMICS S120 CU320-2.

The following functions/components are not supported by the integrated drive control of the SIMATIC Drive Controller:

• Free function blocks (FBLOCKS)
• SINAMICS web server
• SINAMICS, SIMOTION and SINUMERIK-specific components (TM17, HLA, CX32-2, NX1x.3, TB30, CBExx)

Note
Additional SINAMICS S120 Control Units CU320-2/CU310-2 connected to the SIMATIC Drive Controller have the full range of functions.

SINAMICS functions requiring a license

The integrated drive control supports the following SINAMICS runtime functions that require a license and Technology Extensions:

For more information on SINAMICS runtime functions and Technology Extensions, see the System Manual SIMATIC Drive Controller under this link.

The purchase of the licenses for the SINAMICS runtime functions requiring a license is confirmed for the integrated drive control – similar to the control functions requiring a license – via TIA Portal (no licensing via memory card).
SINAMICS S120 Control Units CU320-2/CU310-2 connected to the SIMATIC Drive Controller via PROFINET IO are licensed via the CF card of the CU.

Drive I/Os

The 12 DI and 8 DI/DQ are assigned to the integrated drive control and can, for example, be used for drive-integrated safety functions and measuring inputs. These I/Os can also be used by the PLC if configured accordingly (frame 39x).

SINAMICS S220 Booksize power units

With SINAMICS firmware V5.2 SP3 HF10 and higher, it is also possible to use SINAMICS S220 power units on the integrated SINAMICS S120 drive control of the SIMATIC Drive Controller.
For more information on the currently available module range and compatibility information for use with SINAMICS S120 drive controllers, see publications on the SINAMICS S120/S220 drive system, e.g. under this link.

Integrated Safety functions

The SIMATIC Drive Controller has integrated Safety functionality for control and drive, thus enabling integrated solutions that meet even the most demanding requirements for operator and machine safety. Flexible machine concepts with Safety functions can thus be implemented efficiently.

Programming of the safety-related program section with the "STEP 7 Safety Advanced" option package. To use the Safety functions integrated in the drive, SINAMICS runtime licenses are required when using the higher-order Safety Integrated Extended or Advanced Functions. No license is required for using the Safety Integrated Basic Functions.

SINAMICS Startdrive in the "SINAMICS Startdrive Advanced" version is required for a user-friendly, engineering-guided Safety acceptance testing.

S7-1500T Motion Control KinPlus

SIMATIC Drive Controllers support kinematics with up to 4 interpolating axes, e.g. for handling tasks such as pick & place, assembly and palletizing.
With the Motion Control package "S7-1500T Motion Control KinPlus", this scope of functions is expanded so that kinematics with up to 6 interpolating axes can be controlled – e.g. for "oriented" handling of products by means of rotary and swivel axes.
The following additional kinematics are available with "S7-1500T Motion Control KinPlus":

• Predefined kinematics:
  • Cartesian portal 3D with 2 orientations
  • Delta picker 3D with 2 orientations
  • 6-axis articulated arm with central hand
• User-defined kinematics 3D with 3 orientations

Prerequisites:

• TIA Portal V18 with STEP 7 Professional
• SIMATIC Drive Controller CPU 1507D TF, from FW version V3.0 to 3.1
• Motion Control package "S7-1500T Motion Control KinPlus" with up-to-date Motion Control firmware part
• Special SIMATIC Memory Card of the type "S7-1500T Motion Control KinPlus" (required for each CPU, available as 2 GB and 32 GB variant)

The Motion Control package "S7-1500T Motion Control KinPlus" contains the complete Motion Control firmware part of a T-CPU and additionally the function extensions for up to 6 interpolating axes.
This package must be copied to a SIMATIC Memory Card of the type "S7-1500T Motion Control KinPlus" and is loaded by the controller at runtime.

SIMATIC Safe Kinematics

SIMATIC Safe Kinematics enables safe monitoring of the movement of predefined kinematics with up to 12 interpolating axes in multidimensional space. Monitoring functions such as safe speed monitoring, safe zone monitoring and safe orientation monitoring are available for this purpose.

SIMATIC Safe Kinematics is a TIA Portal option package and is installed as setup in TIA Portal.
SIMATIC Safe Kinematics V17 can be used on SIMATIC Drive Controllers on CPU 1507D TF from FW version V2.9 to 3.1.

SINAMICS Drive Control Chart (DCC)

SINAMICS Drive Control Chart (DCC) expands the functionality of SINAMICS Integrated with freely available control, computing and logic blocks, and therefore provides the option to configure your own technological functions in the drive system through graphical configuration.
Requirements: SINAMICS DCC as of V17, CPU FW as of V2.9 and SINAMICS Integrated FW as of V5.2 SP3.

The Drive Control Block (DCB) standard library is included in the scope of supply of SINAMICS DCC and contains approx. 140 block types for configuring logic and technology functions. Additions to the DCB standard library can be introduced via DCB Extension libraries. A runtime license is required to use blocks from DCB Extension libraries.

SIMATIC Memory Card

A SIMATIC Memory Card is required for the SIMATIC Drive Controller. When using the integrated SINAMICS S120 drive control, a memory card size of at least 12 MB is recommended (at least 24 MB for extensive DCC use, e.g. with a DCB Extension Library). A memory card size of at least 256 MB is required for firmware updates.
The project data for control and integrated drive control is saved on the SIMATIC Memory Card.
In addition, the SIMATIC Memory Card can be used for firmware updates of the SIMATIC Drive Controller.
The control and integrated drive control are upgraded using two separate firmware update files.

SIMATIC S7-PLCSIM Advanced

With SIMATIC S7-PLCSIM Advanced, virtual controllers can be used for simulation and for extensive function simulation.
The virtual controllers can also be tested and validated in conjunction with a plant/machine. An extensive API is available for interfacing plant/machine simulations.
SIMATIC Drive Controller requires S7-PLCSIM Advanced ≥V4.0, TIA Portal ≥V17 and CPU FW ≥V2.9 to 3.1.

More information and downloads

Supported firmware version

The following firmware versions are supported by the SIMATIC Drive Controller:

• SIMATIC S7-1500 firmware ≤ V3.1 (technology version ≤ V8.0)
• SINAMICS Integrated firmware V5.2 and V5.2 SP3

Manuals

The SIMATIC Drive Controller manuals can be downloaded free of charge from the Internet (SIMATIC Customer Support) under this link.

TIA Portal - An Overview of the Most Important Documents and Links

You can find the overview under this link.

Safety Integrated

Information on functional safety, including for S7-1500F Controllers, can be found under this link.

General information

can be found here and here.

The TIA Selection Tool

is available under this link.

With the TIA Selection Tool, you can select, configure and order devices for Totally Integrated Automation (TIA). The TIA Selection Tool supports you in selecting the right controller depending on:

• Axis configuration limits
• Axis technologies
• Control performance

With the TIA Selection Tool you can create a complete order list from your product selection or product configuration.