Intent
Machine control programs are very complicated, expensive and fragile. Prototype (single instance) and new control systems are quite often continuously improved and upgraded. Configuration change is frequent.
Multiple people will modify Drive Configuration. Multiple changes might be done concurrently. Communication might be imperfect. Procedures might not be perfectly followed. Copies of the Configuration can be mishandled and become different from the Configuration running in the Drive.
A configuration error can cause a Drive to release a very large amount of energy to a very large motor in a very short time. This can cause energetic motion or acceleration that can damage people and machines. Changes to Drive operation should be carefully planned, reviewed and executed.
To avoid catastrophic loss of our Drive Configurations we save the Configurations in a well defined manner. If the worst happens: we always have a valid and accessible fallback.
It is important to maintain a history of previous running Configurations for redundancy and to provide information for evaluation after a failure, troubleshooting, diagnosis and learning.
Except in rare specific circumstances, the configuration in the Drive is known to be a working configuration. If this is not the case, then a plan should be made to replace the defective program with known working configuration.
Downloading to a Drive risks making unintended changes to the Drive. Avoid downloading to the Drive except when absolutely required and after careful review.
For this Configuration Management process to work it must be used to guide configuration management action and it must be accurate. If you change configuration on any S120 Drive you should reference this procedure. And you should inform the Gatekeeper of errors, omissions or opportunities for improvement.
Simple Rules
Respect running code.
Save Frequently. Do not overwrite previous saves until you are sure they will never be needed.
Identify Projects with unique filename.
Upload to a new Project and save before any Download or any change to a Configuration.
Review with the team before changing Drive Configuration or Download.
Update the Controlled Backup after any change to Configuration.
Never open a Controlled Copy except to Download. Make a copy.
Only make changes to Working Copies.
Everything else is guidance and assistance.
Process flow for managing Drive Configuration
Definitions
Drive | S120 Drive that is configured for use in our installation. Each Drive has a different hardware arrangement and parameter configuration. Drive includes a Control unit and all connected Drive Objects. Each type of object has a unique set of parameters. Connection to a Control Unit is a connection to all Drive objects. Drive Configurations are saved as ‘Projects’. |
Drive Object | Drive includes all objects connected to a Control unit:
|
Configuration | A table of parameters and values that control Drive operation. Configurations are uploaded and downloaded for all Drives in a project. DCCs (if any) can be uploaded and downloaded as part of the Configuration. |
License | Software authorization stored on the Memory Card in each Drive. A license is required for:
Licenses are managed via Siemens Web License Manager |
Project | Any collection of Configurations can be added to and saved as a Project. Our Projects are grouped by function. Open a Project with Starter by double-clicking the file ending with ‘.s7p’ in the Project Folder. Copy or move Projects only as a complete set of files and folders. |
Project Folder | A Project is saved as a collection of files and folders under a single Project Folder. Do not change the name of any files or folders within a Project Folder. |
Master | The Configuration running in a Drive. The Master should always be identical to the most recent Controlled Project. Master is the controlled source configuration. It is the configuration to copy from when making changes. Drive configuration is different from other software environments. We have, and will only ever have, one installation of each Configuration. It is our running configuration. There is one instance. It exists on the Target Device. |
Controlled Project | The Project to be downloaded to the Drives if the running Drive Configuration becomes unusable. Controlled Projects are uploaded from the Drives and saved in Controlled Backup. Controlled Projects should never be opened, except to Upload, Download or verify integrity. Controlled Projects should never be modified. Controlled Projects can be copied to Working Projects. |
Uncontrolled Project / Working Project | All Projects that are not the Controlled Project in the Controlled Backup. These are usually for offline work or study. They may be modified while not online with the Drives. Uncontrolled Projects should have a unique filename + identifier to avoid misidentification as a Controlled Project. Do not save Uncontrolled Projects in Controlled Backup. Uncontrolled Projects should never be downloaded to a Drive, except in rare cases, and only after review. |
Controlled Backup | The file storage location where Controlled Projects are stored. Controlled Backup is located on git. Clones of this backup are installed on your computer when you install and configure git. Do not change the folder name of a Project in Controlled Backup |
Historical Backup | The file storage location where Uncontrolled Projects can be stored. This location contains a history of prior instances of running Configurations for reference purposes, review, troubleshooting, diagnostics and redundancy. All folders and files should be uniquely named. Historical Backups can be deleted if they are no longer useful. |
Unique filename | Project filename of the Project Folder to differentiate from other copies. Project Name + “_mm_dd_yyyy” + <optional descriptor for unusual events or more than one copy per day> |
Starter | Siemens Starter software application used to communicate and configure S120 Drives. Starter allows inspection, modification and upload of the control software while online. |
Memory Card | Compact Flash memory card used to store License and Configuration that is downloaded to the Drive when it is restarted. This is a proprietary Siemens Memory Card. Each Drive requires a Siemens incense stored on the Memory Card to operate. Anytime parameters are changed in a Drive Configuration the Configuration must be copied to the Memory Card using the ‘Copy RAM to ROM’ button in Starter.. |
git | Online file storage service |
git folder | A clone of the file repository used by git |
Upload | Transfer a Project from the Drive to Starter. |
Download | Transfer a Configuration from Starter to the Drive. |
Verify | Confirm (Review) that the Drive Configuration is according to the specification. |
Validate | Confirm (Test) that the Drive Configuration operates according to the specification. |
GateKeeper | Persons responsible for S120 Drive Configurations Management |
Prerequisites
Required
Siemens Starter or equivalent. Click here to learn how to install Starter. Install a recent version of Starter (V5.4 SP2 or later). Starter V4.7 saves in a different format. Projects saved as V4.7 can be opened and upgraded by V5.x. Projects saved as V5.x cannot be opened by V4.7
Git Extensions (or other git management application)
git_copy folder on your computer
Recommended
Siemens Tech Support account https://support.industry.siemens.com/
Documents and Information
Drives and Software Documentation
Information about Drives and software: Dropbox (DKIST)\Electrical Reference\Siemens S120 documents
Siemens Configuration Information
Information related to Drive software and Configuration is located at Dropbox (DKIST)\Siemens Drive Configurations
Historical Backup is located at Dropbox (DKIST)\Siemens Drive Configurations\SINAMICS S120 Drive Configurations
Controlled Projects
Mount
Project Name: MDC1
MDC1 IP 10.0.2.7, mask 255.255.255.0
Project Name: MDC2
MDC2 IP 10.0.2.8, mask 255.255.255.0
Coude
Coude Azimuth
Project Name: CDC1
CDC1 10.0.2.9, mask 255.255.255.0
Project Name: CDC2
CDC2 10.0.2.10, mask 255.255.255.0
Enclosure Azimuth
Project Name: Az_304
Az_304 10.2.9.134, mask 255.255.255.0
Obsolete 10.2.9.133, mask 255.255.255.0 (inhibited)
Project Name: Az_305
Az_305 IP 10.2.9.136, mask 255.255.255.0
Obsolete 10.2.9.135, mask 255.255.255.0 (inhibited)
Enclosure Altitude
Project Name: Al302DRV
Alt 302_DRV IP 10.2.9.132, mask 255.255.255.0
Project Name: Al302D
Alt 302 CU1_INF 10.2.9.131, mask 255.255.255.0
Aperture Cover
Project Name: Aperture
Aperture Cover IP 10.2.9.138, mask 255.255.255.0
Rear Door
Project Name: RearDoor
RearDoorDrive IP 10.2.9.139, mask 255.255.255.0
TEOA Platform
Project Name: TEOA
TEOA IP 10.2.9.137, mask 255.255.255.0
Drive Configuration change plan
Drive Configuration should be changed only after careful consideration, design and review.
Justification, specification, review, progress for configuration changes is typically done and documented using Jira.
Small changes and emergency fixes are managed as required by the circumstance.
Specify the change
Provide a written statement of the issue that requires a Drive Configuration change.
Specification should include requirements or expectation for Verification and Validation.
Design the change
Explain the purpose and method of changing the Drive Configuration. Document the change by marking up a parameter list or marking up a Drive Navigator flowchart to indicate which parameters will be changed.
Prepare a test plan to Validate the changes.
Verification
Document and review all changes to a Configuration before making the changes online.
Review the changes and the Validation plan with someone who understands the problem, the change, S120 drive hardware, and the application.
Installation and Testing
Except in unusual cases, make changes to the Drive online.
Change Configuration in the Drive only after complete review and concurrence of the need to do so.
Install configuration only after review.
Test changes sequentially as they are installed.
Changing Configuration in the Drive
A Drive can release a very large amount of energy to a very large motor in a very short time. This can cause energetic motion or acceleration that can damage people and machines.
Do not change Drive Configuration parameters while operating the equipment.
Fully Test the Drive after making changes to be very sure that the Drive operates properly.
Create a Backup of the Project in case anything goes wrong with the change.
Change the Configuration online
Copy the Controlled Project to a new Project with unique filename.
Open the new Project with Starter.
Change Configuration in the Drive according to your Design Plan. while connected.
Make changes according to the list or markup that has been reviewed and approved.
When changes are complete:
Upload Project and save to a unique filename to indicate that this is not a valid Project.
Save the Project in Historical Backup to a unique filename. This provides a record to aid in troubleshooting if there are problems during testing.
Change the Configuration offline
Are you absolutely sure that you need to download to the Drive???
Have you convinced others that this is the best path???
Then proceed …
Review and get approval from Gatekeeper and Management prior to downloading an untested Project.
Copy the backup just created to a new location with a unique filename to indicate that it is not a Controlled Project.
Open the new Project with Starter.
Connect to the Drive with Starter.
Upload the configuration to Starter.
Disconnect from the Drive.
Make changes to the Working Copy according to your Design Plan.
Confirm that Drive Configuration is not changed since the upload that was used for this offline change.
Open the modified configuration file with Starter.
Connect to the Drive with Starter.
Download the Project to the drive.
Validation
Perform the Validation plan.
If Validation is successful:
If Validation is not successful
Upload the Project and save to a unique filename to indicate that this is not a valid Project.
Do not copy the Project to Controlled Backup.
Verify proper Drive operation.
Connecting to Drives
Configure computer and Starter to communicate on the Drive network
Configure an ethernet port on your computer to the appropriate subnet for Enclosure, Mount.
Or configure an ethernet port on your computer to Port X127 on the front of the Control unit
Port X127default IP is 169.254.11.22, mask 255.255.255.0.
Do not change this IP address.Open Starter.
Configure ethernet communication to connect via the front panel.
Alternate 1 - Connect to Drives network and open existing Project
Copy a recent version of a Project that includes the Drive of interest to a new filename.
Open Starter. Connect to the Project Drives.
Alternate 2 - Connect to Drives network and Upload to new Project
Configure an ethernet port on your computer to the appropriate subnet.
Open Starter.
Configure Starter communication for the appropriate subnet.
Connect to one or more drives.
Working with Starter and Projects
Starter information: Siemens Starter Documentation
When not connected
Starter displays the Project Configuration that was loaded from the Project file
When you make changes to the Configuration they are saved in the Starter memory..
Changes to Projects are not automatically saved to the file copy, but can be saved, if desired..
When connected to a Drive
Starter keeps the loaded Project in memory, but displays the connected Project Configuration.
When you make changes to the Configuration they are saved only in the Drive.
Changes are not mirrored in the Project loaded from a file.
“Upload the Project” uploads all parameters from all Drives in the Project into Starter memory.
“Download the Project” downloads and overwrites all parameters from Starter memory to the Drives.
Downloading interrupts Drive operation. The Drive will stop operating while downloading.
Starter downloads only to Drive memory. After downloading, update the Memory Card.
Some Configurations include a DCC
The only DCC used in our Drives is the Load Sharing DCC in Azimuth, Rear Door and Aperture Cover.
DCC add-on requires a license. The license is stored on the Memory Card.
If Uploading from a Drive that contains a DCC, Starter must be configured with the DCC license. If not, the Drive Configuration will upload but the DCC will not be uploaded. This could cause a problem later. If that Upload was saved as a Controlled Backup then it will not successfully download to a Drive.
Memory Card
For more information on the memory card: open Starter Help and search ‘memory card’.
Only withdraw and insert the memory card when the Control Unit is in a no-voltage
condition.
Insert the memory card as shown in the photo above (arrow at top right).
Only SIEMENS memory cards can be used to operate the Control Unit.
Update Memory Card after download
Anytime parameters are changed in a Drive Object the Configuration must be copied to the Memory Card.
If there is doubt of the state of Memory Card memory then update the Memory Card.
Each Object in a Drive must be updated separately.
To update the Memory Card repeat for each Drive in the Project,:
Click to select the Drive, then use one of the following methods to ‘Copy RAM to ROM’:
Click ""Target system > Copy RAM to ROM". or
Click shortcut menu "Target device > Copy RAM to ROM". or
If the drive unit has a gray background, click on the symbol "Copy RAM to ROM".
To automatically copy RAM to ROM after every download:
Click "Tools > Setting".
Click the "Download" tab and activate the option "After loading, copy RAM to ROM". Click "OK" to confirm this setting.
If a Memory Card is damaged or unusable
…
Comparing parameters for multiple Configurations
More information on Starter Drive Object Comparison:
Export the Configurations from Starter
The parameter list for any Configuration can be displayed in Starter and can be downloaded to an Excel readable file. Up to 4 Configurations can be saved at one time.
Prepare the Drive Parameters Comparison workbook
Copy S120_Drive Parameters Comparison.xlsx workbook to a new file:.
https://www.dropbox.com/s/0d6ktqn0c8tvmyz/S120_Drive%20Parameters%20Comparison.xlsx?dl=0
Name the file to describe the Configurations you are comparing.
Copy the Configurations saved from Starter into Drive Parameters Comparison workbook
Open the workbook of data downloaded from Starter.
There is one column for each drive included in the comparison.:
Open the new Drive Parameters Comparison workbook.
Do not delete the data in the Factory Settings column.
Delete the data in the columns for each drive.
Do not delete the columns. The cells are formatted to highlight a difference of a parameter value between drives.
From the saved Configuration: Select the columns of parameters for each drive to be compared.
Paste (values only) into the 8 columns of the Parameter Comparison Workbook.
Compare differences between Configurations
For each parameter: differences between the first drive configuration and the other drive configurations will be highlighted. The total number of differences for that parameter among all displayed configurations is displayed in the right-most column.
If a Drive Configuration becomes unavailable or unuseable
Save current Configuration in the Drives
Save all Configuration Information from the failed Drives that is accessible
Note: Configurations from failed Drives may not upload.
Upload all Drives from the Project that will upload. The information may be helpful later.
Replace the failed Drive
Service or replace the defective Drive as required.
If the Drive is replaced
Remove the Memory Card from the Drive
Install the Memory Card in the replacement Drive
If the Controlled Project becomes unavailable or unuseable
If the Controlled Project in Controlled Backup fails, then create a new Controlled Backup from the Master.
Update the Controlled Project.
Update a Controlled Project
Note: DCC add-on requires a license. The license is stored on the Memory Card.
If Uploading from a Drive that contains a DCC, Starter must be configured with the DCC license. If not, the Drive Configuration will upload but the DCC will not. This is not a complete backup.
Disconnect Starter from the Drives.
Controlled Projects are saves with a fixed assignment of Configurations as defined in the git folder and in Controlled Projects.
git Folder
In the git folder identify the Project that contains the Drives to be updated.
Open the Project in the git folder with Starter.
Connect to the Drives.
Upload from the Drives to Starter.
Save the uploaded Project.
Disconnect from the Drives.
Open git extensions.
Open the S120 Repository.
Commit and push the Project to bitbucket.
Upload a Project (not a Controlled Project)
Upload is to transfer a Project from the Drives to Starter.
Note: DCC add-on requires a license. The license is stored on the Memory Card.
If Uploading from a Drive that contains a DCC, Starter must be configured with the DCC license. If not, the Drive Configuration will upload but the DCC will not.
Copy a recent Project for the Drives to a new Project with a unique filename.
Or
Create a new Project with a unique filename.
Open the Project with Starter.
Connect to the Drives with Starter.
Upload Project from the Drive to the computer.
Save the Project.
Disconnect the Project. Exit Starter.
Save the Project somewhere other than Controlled Backup.
Download a Project
Download is to transfer a Configuration or Project from Starter to the Drives.
It is possible to connect and download to one or many drives. This should only be done in very unusual circumstances, after review.
In most cases Download is used to transfer a Controlled Project to all Drives at once.
Identify the appropriate Project in Controlled Backup.
Open the Project with Starter.
Connect to the Drives.
Download Project from Starter to the Drives:
Click to select the drive unit and call the menu "Project > Load to target system".
Then do one of the following methods:
Click shortcut menu "Target device > Load to target device". or
Click menu "Target system > Load > Load CPU/drive unit to target device...".
If the drive unit has a gray background, click on the symbol "Load CPU/drive unit to target device...".
Verify proper operation of the Drives.
Update the Memory Card for each Drive.
After any download update the Controlled Project in git.
OA Link
OALink is installed only on Enclosure Azimuth Control Units to implement the Load Sharing DCC across 8 drives.
Manual: Dropbox (DKIST)\Electrical Reference\Siemens S120 documents\OALink
OALINK enables bidirectional communication between Control Units using DRIVE-CLiQ.
License Management
For more information, open Starter Help and search ‘License’
Web License Manager
Licenses are managed via Siemens Web License Manager
Instructions and help are here: https://www.dropbox.com/s/air8nrw50j6er9y/SINAMICS%20RT%20licenses%20and%20Web%20License%20Manager.pdf?dl=0
Control Unit license
A license is installed on the memory Card in the Control Unit of each Drive.
When replacing a Control Unit of a Drive, transfer the Memory Card from the old Control Unit to the replacement Control Unit.
There is one spare Memory Card with a license installed in the Test Bench Control Unit. It is available if a License is unavailable or unusable.
DCC license
License is required for the Load Sharing DCC on Enclosure Azimuth,
OA Link license
License is required for OALink on Enclosure Azimuth. The license is not installed. This causes an alarm, but does not prevent operation.
GIT
Git repository location
Each Drive configuration is stored in a folder with multiple subfolders.
Main folder name may change depending on how the projects are saved.
Save to GIT
Note: DCC add-on requires a license. The license is stored on the Memory Card.
If Uploading from a Drive that contains a DCC, Starter must be configured with the DCC license. If not, the Drive Configuration will upload but the DCC will not. This is not a complete backup.
Disconnect Starter from the Drives.
In the git folder identify the Project that contains the Drives to be updated.
Open the Project in the git folder with Starter.
Connect to the Drives.
Upload from the Drives to Starter.
Save the uploaded Project.
Disconnect from the Drives.
Open git extensions.
Open the S120 Repository.
Commit and push the Project to bitbucket.