Siemens Servo Bench Trainer

Project

Submitted by: Team 1

Control Applications Using PLC’s ELEC-352-0AC

Submitted to: Dr. Savdulla Kazazi

Professor of
Electrical Engineering Technology, Humber College

Program: Electrical Engineering Technology

Date: April 30th , 2021

 Declaration of Authorship

We, the members of Team 1-0AC, declare that this document, submitted for assessment, is our
own and is expressed in our own words. Any use made within this document of the works of
any other authors in any form (ideas, figures, text, tables, and manuals) are properly
acknowledged in a list of references at the end of the document.

Shayan Asad __________________________________ _30/04/2021_.

Signature

Dave Cheriyan __________________________________ _30/04/2021_.

Signature

Olsen Desir __________________________________ _30/04/2021_.

Signature

Eliseu Marcos __________________________________ _30/04/2021_.

Signature

Sarbjit Singh __________________________________ _30/04/2021_.

Signature

i
 Acknowledgments
The team would like to thank Dr. Savdulla Kazazi, Khaled Ibrahim, Collin Buddin, and Maurício
Toigo for their help, support, and encouragement.

ii
 Executive Summary
The task of redesigning the lab workstations of NB115 at Humber College was the scope of the
project. This required updating all existing workstations and their components in order to
create a better learning environment. By doing so, the college can offer a better learning
experience for future students to become accustomed to the new industry standard of
automation. Siemens automation products were selected to introduce future students to a
wide variety of automation possibilities. A combination of PLCS, HMIs, and servo drives and
motors were used to develop skill sets required for a graduate of the Electrical Engineering
Technology program to employ in the field.

iii
Table of Contents

Table of Contents

Declaration of Authorship................................................................................................................ i
Acknowledgments............................................................................................................................ii
Executive Summary.........................................................................................................................iii
Table of Contents ............................................................................................................................ iv
List of Figures ................................................................................................................................. vii
1. Introduction ................................................................................................................................ 1
1.1. Summary of the Project ....................................................................................................... 1
1.2. Team Information ................................................................................................................ 2
1.3. Project Plan .......................................................................................................................... 7
1.3.1. Project Schedule ........................................................................................................... 9
1.3.2. RASCI Matrix ............................................................................................................... 10
1.3.3. Risk Management Assessment ................................................................................... 11
2. Component Overview ............................................................................................................... 12
2.1. Research on Installation of Components ........................................................................... 12
2.1.1. SIEMENS SIMATIC S7-1200 PLC .................................................................................. 13
2.1.2. Siemens Scalance XB005 ............................................................................................. 15
2.1.3. Siemens SITOP PSU100L ............................................................................................. 16
2.1.4. Siemens KTP400 Basics HMI ....................................................................................... 17
2.1.5. Siemens SIMATIC PM 1507 ......................................................................................... 19
2.1.6. Siemens SIMATIC S7-1500T ........................................................................................ 20
2.1.7. Siemens SIMAMICS S210 ............................................................................................ 21
2.1.8. Siemens SIMOTICS S-1FK2 .......................................................................................... 23
2.1.9. Siemens SIMATIC memory card .................................................................................. 25
2.1.10. Siemens Mounting Rail ............................................................................................. 25
2.1.11. Parker Aluminum Extrusions .................................................................................... 25
2.1.12. KRIËGER Transformer ............................................................................................... 28
3. Design Phase ............................................................................................................................. 29
3.1. Design Iteration 1 ............................................................................................................... 29

iv
 3.1.1. CAD Layout .................................................................................................................. 30
3.1.2. Recommendations ...................................................................................................... 30
3.2. Design Iteration 2 ............................................................................................................... 30
3.2.1. CAD Layout .................................................................................................................. 31
3.2.2. Recommendations ...................................................................................................... 31
3.3. Design Iteration 3 ............................................................................................................... 32
3.3.1. CAD Layouts ................................................................................................................ 32
3.3.2. Recommendations ...................................................................................................... 33
3.4. Design Iteration 4 ............................................................................................................... 33
3.4.1. CAD Layout .................................................................................................................. 33
3.4.2. Recommendations ...................................................................................................... 34
3.5. Final Design Iteration ......................................................................................................... 35
3.5.1. CAD Layout .................................................................................................................. 35
3.5.2. Final Modifications...................................................................................................... 35
4. Build Phase ................................................................................................................................ 36
4.1. Mechanical Build ................................................................................................................ 36
4.1.1. Extrusions .................................................................................................................... 36
4.1.2. Acrylic Panels .............................................................................................................. 37
4.1.3. Component Mounting ................................................................................................ 38
4.2. Electrical Wiring ................................................................................................................. 45
4.2.1. 120/230 VAC ............................................................................................................... 45
4.2.2. 24 VDC Power Supply.................................................................................................. 47
4.2.3. Servo Drive/Motor Connections ................................................................................. 48
4.2.4. I/O Terminals .............................................................................................................. 52
4.2.5. Communication Cabling .............................................................................................. 53
5. SIEMENS Software .................................................................................................................... 55
5.1. Required Software ............................................................................................................. 55
5.1.1. SIMATIC STEP 7 ........................................................................................................... 55
5.1.2. SINAMICS Startdrive ................................................................................................... 55
5.1.3. SIMATIC WinCC ........................................................................................................... 56
6. Commissioning .......................................................................................................................... 57

v
 6.1. Commissioning Steps ......................................................................................................... 57
6.1.1. S7-1500 ....................................................................................................................... 59
6.1.2. HMI.............................................................................................................................. 67
6.1.3. S210 Drives.................................................................................................................. 73
6.1.4. SCALANCE XB005 ........................................................................................................ 80
7. Test Program ............................................................................................................................. 81
7.1. Technology Objects ............................................................................................................ 81
7.2. Program Blocks .................................................................................................................. 85
7.3. Programming Ladder Logic ................................................................................................ 87
7.3.1. Ladder Logic ................................................................................................................ 89
7.4. HMI Screens ....................................................................................................................... 91
7.4.1. Completed HMI Screens ............................................................................................. 98
7.5. Downloading ...................................................................................................................... 98
8. Conclusion ................................................................................................................................. 99
9. Appendix A – Layout CAD Drawings ....................................................................................... 100
10. Appendix B – Mechanical CAD Drawings .............................................................................. 108
11. Appendix C – Commissioning Report .................................................................................... 114
12. References ............................................................................................................................ 141
12.1. Siemens Manuals ........................................................................................................... 141
13. Notes ..................................................................................................................................... 142

vi
 List of Figures

Figure 1-1. Workflow Diagram Part 1 ............................................................................................. 7

Figure 1-2. Workflow Diagram Part 2 ............................................................................................. 8
Table 1-1. Project Schedule ............................................................................................................ 9
Table 1-2. RASCI Matrix ................................................................................................................ 10
Figure 2-1. SIMATIC S7-1200 PLC .................................................................................................. 13
Figure 2-2. Connection Diagram S7-1200 1215c PLC.................................................................... 13
Figure 2-3. Dimensional Drawing S7-1200 1215c PLC .................................................................. 14
Figure 2-4. Mounting Diagram S7-1200 1215c PLC ...................................................................... 14
Figure 2-5. SCALANCE XB005 Switch ............................................................................................ 15
Figure 2-6. Dimensional Drawing XB005 ...................................................................................... 15
Figure 2-7. SITOP PSU100L ............................................................................................................ 16
Figure 2-8. Dimensional Drawing PSU100L................................................................................... 16
Figure 2-9. PSU100L Current vs Temperature in Upright Position ............................................... 17
Figure 2-10. KTP400 Basics HMI.................................................................................................... 17
Figure 2-11. Dimensional Drawing KTP400 Basics HMI ................................................................ 18
Figure 2-12. SIMATIC PM 1507 ..................................................................................................... 19
Figure 2-13. Dimensional Drawing PM 1507 ................................................................................ 19
Figure 2-14. SIMATIC S7-1500 1511T-1 PN ................................................................................... 20
Figure 2-15. Dimensional Drawing S7-1500 1511T-1 PN .............................................................. 20
Figure 2-16. Mounting Diagram S7-1500...................................................................................... 20
Figure 2-17. SINAMICS S210 Drive ................................................................................................ 21
Figure 2-18. Connection Diagram S210 Drive ............................................................................... 21
Figure 2-19. Dimensional Drawing S210 Drive ............................................................................. 22
Figure 2-20. Mounting Diagram S210 Drive ................................................................................. 22
Figure 2-21. SIMOTICS S-1FK2 Servo Motor ................................................................................. 23
Figure 2-22. Dimensional Drawing S-1FK2 103-44AG00-1MA0 Servo Motor .............................. 23
Figure 2-23. S-1FK2 Servo Motor Nameplate ............................................................................... 23
Table 2-1. S-1FK2 Mounting Conditions ....................................................................................... 24
Table 2-2. OCC Rotation ................................................................................................................ 24
Figure 2-24. SIMATIC Memory Card ............................................................................................. 25
Figure 2-25. Siemens 155 Mounting Rail ...................................................................................... 25
Figure 2-26. 40 Series 10-161 ....................................................................................................... 26
Figure 2-27. 28 Series 12-128 ....................................................................................................... 26
Figure 2-28. 40 Series 11-040 ....................................................................................................... 26
Figure 2-29. M8 x 1.25 Button Head Bolt 240-110-8 .................................................................... 27
Figure 2-30. 28 Series T-Nut 20-057 ............................................................................................. 27
Figure 2-31. KRIËGER Transformer ............................................................................................... 28
Figure 3-1. CAD Design Iteration 1................................................................................................ 30

vii
Figure 3-2. CAD Design Iteration 2................................................................................................ 31
Figure 3-3. CAD Design Iteration 3................................................................................................ 32
Figure 3-4. CAD Design Iteration 3 Enclosure ............................................................................... 32
Figure 3-5. CAD Design Iteration 4................................................................................................ 33
Figure 3-6. CAD Design Iteration 4 Enclosure ............................................................................... 34
Figure 3-7. Final CAD Design ......................................................................................................... 35
Table 4-1. Extrusion Cut-List ......................................................................................................... 36
Figure 4-1. PLC/PSU/Switch Combo Acrylic CAD Drawing............................................................ 37
Figure 4-2. PLC/PSU/Switch Combo Mounted to Frame .............................................................. 38
Figure 4-3. S7-1200 Mounting Instructions .................................................................................. 39
Figure 4-4. PSU100L Mounting Instructions ................................................................................. 39
Figure 4-5. SCALANCE XB005 Mounting Instructions ................................................................... 40
Figure 4-6. HMI Panel Cut-Out Layout .......................................................................................... 41
Figure 4-7. HMI Insertion Method ................................................................................................ 41
Figure 4-8. HMI Pressure Clip Procedure ...................................................................................... 41
Figure 4-9. HMI Awaiting Installation ........................................................................................... 41
Figure 4-10. S7-1500 and PM 1507 Mounted on Siemens 155 Din Rail ....................................... 42
Figure 4-11. S210 Mounting Holes Dimensions............................................................................ 43
Figure 4-12. S210 Drives Mounted ............................................................................................... 43
Figure 4-13. SOLIDWORKS Motor Mount Design ......................................................................... 44
Figure 4-14. S-1FK2 Servo Motor Mounted .................................................................................. 44
Figure 4-15. 220 VAC Power Supply Connections ........................................................................ 45
Figure 4-16. 120 VAC Power Supply Connections ........................................................................ 45
Figure 4-17. PM 1507 Power Supply Connector Instructions....................................................... 46
Figure 4-18. 24VDC PLC and Pushbutton Wiring .......................................................................... 47
Figure 4-19. 24VDC HMI and Pushbutton Wiring ......................................................................... 47
Figure 4-20. 24VDC S7-1500 Wiring.............................................................................................. 48
Table 4-2. X1: Line Connection Terminal Block ............................................................................ 48
Table 4-3. X124 24VDC Connection Terminal Block ..................................................................... 49
Figure 4-21. OCC Wire Terminations ............................................................................................ 49
Table 4-4. X2: Power Connection Terminal Block ......................................................................... 50
Table 4-5. X100: Siemens IX Connection Terminal Block ............................................................. 50
Table 4-6. X107: Motor Holding Brake Terminal Block................................................................. 50
Figure 4-22. OCC Connections Completed.................................................................................... 51
Figure 4-23. Enclosure Wiring Completed .................................................................................... 51
Figure 4-24. Banana Jack Terminals Soldered .............................................................................. 52
Figure 4-25. PLC I/O Terminal Wiring Completed......................................................................... 52
Figure 4-26. Enclosure Ethernet Connections .............................................................................. 53
Figure 4-27. Ethernet Connections at the Switch ......................................................................... 53
Figure 4-28. Preparing Ethernet Cable Ends for Terminations ..................................................... 53
Figure 4-29. RJ45 Termination ...................................................................................................... 54
viii
Figure 4-30. RJ45 Termination Crimper ........................................................................................ 54
Figure 4-31. Completed Custom Ethernet Cable .......................................................................... 54
Figure 4-32. Ethernet Cable Tester ............................................................................................... 54
Figure 6-1. TIA Portal - Create New Project .................................................................................. 57
Figure 6-2. TIA Portal - First Steps Window .................................................................................. 57
Figure 6-3. TIA Portal - Configure a Device ................................................................................... 58
Figure 6-4. TIA Portal - Add a New Device .................................................................................... 58
Figure 6-5. TIA Portal – Choose Your Device S7-1511T ................................................................ 59
Figure 6-6. TIA Portal – Project View Servo PLC Displayed........................................................... 59
Figure 6-7. TIA Portal - S7-1511T Project Information ................................................................. 60
Figure 6-8. TIA Portal - S7-1511T PROFINET Interface.................................................................. 60
Figure 6-9. TIA Portal - S7-1511T Synchronization Role ............................................................... 61
Figure 6-10. TIA Portal - S7-1511T Port 1 Identification ............................................................... 61
Figure 6-11. PC Ethernet TCP/IPv4 Settings.................................................................................. 62
Figure 6-12. PC Ethernet TCP/IPv4 Address Change .................................................................... 62
Figure 6-13. TIA Portal - S7-1511T Download to Device Window ................................................ 63
Figure 6-14. TIA Portal - S7-1511T Search for Compatible Components ..................................... 63
Figure 6-15. TIA Portal - S7-1511T MAC Address Verified ............................................................ 64
Figure 6-16. TIA Portal - S7-1511T Assign IP Address ................................................................... 64
Figure 6-17. TIA Portal - IP Address at the PC Interface Added .................................................... 65
Figure 6-18. TIA Portal - Save Settings to Network Card .............................................................. 65
Figure 6-19. TIA Portal - S7 - 1511T Unprotected Warning .......................................................... 66
Figure 6-20. TIA Portal - S7-1511T Commissioning Completed .................................................... 66
Figure 6-21. TIA Portal - Add New Device from Project Tree ....................................................... 67
Figure 6-22. TIA Portal - HMI Wizard PLC Connection .................................................................. 67
Figure 6-23. TIA Portal - HMI Wizard Screen Layout .................................................................... 68
Figure 6-24. TIA Portal - HMI Wizard Alarm Selection.................................................................. 68
Figure 6-25. TIA Portal - HMI Wizard Add Screens ....................................................................... 69
Figure 6-26. TIA Portal - HMI Wizard System Screens ................................................................. 69
Figure 6-27. TIA Portal - HMI Wizard Add Buttons ....................................................................... 70
Figure 6-28. TIA Portal - HMI General Information ...................................................................... 70
Figure 6-29. TIA Portal - HMI Assigning IP Address ...................................................................... 71
Figure 6-30. TIA Portal - HMI Topology Connections ................................................................... 71
Figure 6-31. TIA Portal - HMI Commissioning Completed ............................................................ 72
Figure 6-32. TIA Portal - Add New Device from Project Tree ....................................................... 73
Figure 6-33. TIA Portal - S210 Drive General Information ............................................................ 74
Figure 6-34. TIA Portal - S210 Drive Assign IP Address ................................................................. 74
Figure 6-35. TIA Portal - S210 Drive Isochronous Mode Selection ............................................... 75
Figure 6-36. TIA Portal - S210 Drive Port 1 Identification............................................................. 75
Figure 6-37. TIA Portal - S210 Drive Port 2 Identification ............................................................. 76
Figure 6-38. TIA Portal - S210 Drive Topology Connections ......................................................... 76
ix
Figure 6-39. TIA Portal - S210 Drive Selecting Servo Motor ......................................................... 77
Figure 6-40. TIA Portal - S210 Drive Download to Device ............................................................ 77
Figure 6-41. TIA Portal - S210 Drive Loading Configuration ......................................................... 78
Figure 6-42. TIA Portal - S210 Drive Configuration Completed .................................................... 78
Figure 6-43. TIA Portal - S-1FK2 Servo Motor One Button Tuning ............................................... 79
Figure 6-44. TIA Portal - S-1FK2 One Button Tuning Commenced ............................................... 79
Figure 6-45. TIA Portal - S-1FK2 One Button Tuning Results ........................................................ 80
Figure 7-1. TIA Portal - Add New Technology Object ................................................................... 81
Figure 7-2. TIA Portal - Portal Technology Object Rotary Selection ............................................. 82
Figure 7-3. TIA Portal - Technology Object Applying Selection .................................................... 82
Figure 7-4. TIA Portal - Technology Object Drive Selection .......................................................... 83
Figure 7-5. TIA Portal - Technology Object Drive Unit_2 .............................................................. 83
Figure 7-6. TIA Portal - Technology Object Setup Completed ...................................................... 84
Figure 7-7. TIA Portal - Program Block Adding a New Block ......................................................... 85
Figure 7-8. TIA Portal - Program Block Program Cycle ................................................................. 85
Figure 7-9. TIA Portal - Adding a Data Block ................................................................................. 86
Figure 7-10. TIA Portal - Data Block Tag Creation......................................................................... 86
Figure 7-11. TIA Portal - Ladder Logic Programming .................................................................... 87
Figure 7-12. TIA Portal - Adding a Motor Control Data Block ....................................................... 87
Figure 7-13. TIA Portal - Motor Control Data Block Added .......................................................... 88
Figure 7-14. TIA Portal - Addressing the Motor Control Data Block ............................................. 88
Figure 7-15. TIA Portal - Program Ladder Logic Part 1.................................................................. 89
Figure 7-16. TIA Portal - Program Ladder Logic Part 2.................................................................. 90
Figure 7-17. TIA Portal – HMI Root Screen ................................................................................... 91
Figure 7-18. TIA Portal - HMI Root Screen Welcome Message .................................................... 91
Figure 7-19. TIA Portal - HMI Motor Control Centre Navigation Button Adding ......................... 92
Figure 7-20. TIA Portal - HMI Motor Control Centre Adding Navigation Buttons ........................ 92
Figure 7-21. TIA Portal - HMI Motor Control Centre Adding Logo ............................................... 93
Figure 7-22. TIA Portal - HMI Motor Control Centre Assigning Function Buttons ....................... 93
Figure 7-23. TIA Portal - HMI Left Side Motor Screen .................................................................. 94
Figure 7-24. TIA Portal - HMI Left Side Motor Screen On/Off Switch Addressing........................ 94
Figure 7-25. TIA Portal - HMI Left Side Motor Run Button General Screen ................................. 95
Figure 7-26. TIA Portal – HMI Left Motor Run Button Event Selection ........................................ 95
Figure 7-27. TIA Portal - HMI Left Side Motor Run Tag Selection................................................. 96
Figure 7-28. TIA Portal - HMI Left Side Motor Run Tag Selection from PLC Data Block ............... 96
Figure 7-29. TIA Portal - HMI Left Side Motor Run Button Addressing Completed ..................... 97
Figure 7-30. TIA Portal - HMI Screens Completed ........................................................................ 98

x
1. Introduction
This section of the report consists of an overall project summary, team member information,
and project management related documentation.

1.1. Summary of the Project

The project consisted creating a workstation for two students with a trainer bench of
automation technology products. All the automation components were supplied by Siemens,
which included PLCs, HMIs, switches, servo drives and motors, and power supplies. The design
was created by the team to satisfy the required parameters stipulated by the project sponsor.
Several designs were created based on manufacturers installation parameters along with the
design limitations set forth by the sponsor. With a final design, the framework was constructed
accordingly. The component mounting proceeded followed by its wiring. Siemens proprietary
software was used for the commissioning and programming of the components. A small
program was written to operate the servo motors from the HMI module.

1
1.2. Team Information

Team Member 1
(Team Leader)
Name: Dave Cheriyan

Student Number: chrd0021

Phone Number: (647) 520-6627

Program: Electrical Engineering Technology

Responsibilities of Team Member 1 (Team Leader):

1. Developing and implementing a timeline for the team to ensure that the project stays
on track.
2. Assign tasks to team members and follow up with them on the status of the task.
3. Aid team members if, and when, necessary.
4. Employ project management skills and techniques to organize and keep track of project
related tasks and documents.

Specific Skills of Team Member 1 Applicable to the PLC Application Project:

1. Project management with strong facilitation skills. This will help in managing the
project progress and team members effectively.
2. A strong knowledge of:
a. Project coordination and management.
b. AutoCAD Electrical.
c. PLC systems.
d. Wiring codes and practices.
3. Excellent problem solving and decision-making capabilities.
4. Great motivator, with a skill for fostering and encouraging team members skill sets.

2
 Team Member 2

Name: Eliseu Marcos

Student Number: N01346921

Phone Number: (416) 566-2208

Program: Electrical Engineering Technology

Responsibilities of Team Member 2:

1. Carrying out tasks as delegated.
2. Design and test acrylic panel layouts.
3. Construct, install, and test framework.
4. Troubleshoot when necessary.

Specific Skills of Team Member 1 Applicable to the PLC Application Project:

1. Practical experience in building from design.
2. Troubleshooting with excellent problem-solving skills.
3. Good working knowledge of:
a. AutoCAD Electrical.
b. PLC systems.
c. Wiring codes and practices.

3
 Team Member 3

Name: Sarbjit Singh

Student number: N01298838

Number: (647) 706-2593

Program: Electrical engineering control systems

Responsibilities of Team Member 3:

1. Research for the HMI and making a basic design for the layout
2. Research on commissioning
3. Installing computers, monitors, and the full bench setup
4. Installing the components on the bench
5. Wiring the PLC (all inputs and out puts)
6. Supplying the 24V to all components
7. Wire management to make the wiring look clean

Specific Skills of Team Member 1 Applicable to the PLC Application Project:

1. Strong research skills to help solve any problems and unanswered questions about the
equipment
2. Experience with tools and all the material which was used in building the bench’s
3. Experienced in wiring and wire management.
4. Always ready to do work and make sure to help others when help is needed.
5. A great attitude towards learning new things and learning new skills like tapping holes
or using the drill press to drill holes.
6. Also making sure to keep calm and make the work environment as friendly as I can.

4
 Team Member 4

Name: Shayan Asad

Student Number: N01156330

Phone Number: (647) 648-0331

Program: Electrical Engineering Technology

Responsibilities of Team Member 4:

1. Researching the servo controller and power supply for our Siemens PLC project.
2. Organization of work documents.
3. Coordinating with team members to work on different design iterations.
4. Commissioning of the components.
5. Installing the desktop computers under the bench as well as installing the monitors and
making all connections in between.
6. Wiring and tagging the input and outputs of the PLC.
7. Adding ferrules to power connection.

Specific Skills of Team Member 1 Applicable to the PLC Application Project:

1. Experienced with tools used with our bench.
2. AutoCAD experience.
3. Working well with team members.
4. Promoting a friendly work environment.
5. Component wiring experience.

5
 Team Member 5

Name: Olson Desir

Student Number: N05599022

Phone Number: (647) 832-9072

Program: Electrical Engineering Technology

Responsibilities of Team Member 5:

1. Research on Parker aluminum products.
2. Research on equipment installation and manufacturer’s recommendations.
3. Work in collaboration with team members on AutoCAD layout.
4. Research on commissioning.
5. Project Technical report writing.

Specific Skills of Team Member 1 Applicable to the PLC Application Project:

1. Strong skills in electrical installation.
2. Well experienced in wiring and PLC programming.
3. Proficient in AutoCAD.
4. Work well with others.
5. Strong knowledge in Structural Design.
6. Great at using hand tools.

6
1.3. Project Plan
The below workflow diagram illustrates the process followed throughout the execution of the
project.

Figure 1-1. Workflow Diagram Part 1

7
Figure 1-2. Workflow Diagram Part 2

8
1.3.1. Project Schedule

Table 1-1. Project Schedule

PERIOD
TASK START FINISH
1 Team Setup January 19, 2021 January 19, 2021
2 Kick-off Meeting January 21, 2021 January 21, 2021
3 Research Components January 22, 2021 January 28, 2021
4 Siemens Bench Layout Design Phase January 26, 2021 March 12, 2021
5 Present Concept of Siemens Bench Layout January 28, 2021 March 12, 2021
6 Make Adjustments to Layout January 29, 2021 March 12, 2021
7 Build Prototype February 22, 2021 March 1, 2021
8 Make Adjustments to Layout March 1, 2021 March 3, 2021
9 Build Prototype v2 March 4, 2021 March 12, 2021
10 Present Prototype v2 March 6, 2021 March 12, 2021
11 Wire / Communication Connections March 15, 2021 April 8, 2021
12 Commissioning of Trainer Bench April 12, 2021 April 12, 2021
13 Siemens Trainer Bench Project Handover April 22, 2021 April 22, 2021
14 Project Close-out Meeting April 27, 2021 April 27, 2021

9
1.3.2. RASCI Matrix
Table 1-2. RASCI Matrix

Project Team Members Instructors/Sponsor

Dave Cheriyan

Eliseu Marcos

Colin Buddin
Shayan Asad

Sarbjit Singh

Olsen Desir

Committee

Committee
Advisory
Role

Savdulla

Steering
Ibrahim
Khaled
Kazazi
Status

(PM)
Project Deliverable
(or Activity)

Team Setup
- Define Project Scope ✓ I I I I I R
- Task Identification ✓ R S I I I I
- Task Assignment ✓ R S I I I I
Initiate Phase Activities
- Research Components ✓ A R R R R C
- Compile/Analyze Data ✓ A R R R R C
- Summarized Results ✓ A R S R S C I
Plan Phase Activities
- Create AutoCAD Layout ✓ A R R S R C C C
- Create Solidworks Motor Mount Drawing ✓ A S S S S I C C
- Engineer Component Frames ✓ A R S R S C C
- Determine required materials ✓ A S R S R C C
- Schedule time for build ✓ A R S R S C I
Execute Phase Activities
- Purchase required materials ✓ I I I I I R C
- Inventory of required materials ✓ A R R S R C I
- Build prototype are per engineered specs ✓ A R S R S C I
Control Phase Activities
- Test performance of prototype ✓ A R R S R C I I
- Compile data from prototype ✓ A R S R S C I I
- Get feedback on prototype ✓ A R R S R C I I
- Optimize prototype from data collected ✓ A R S R S C I I
Close Phase Activities
- Showcase prototype ✓ A R R S R C I I
- Create Lessons Learned ✓ A R S R S C I I
- Create Project Closure Report ✓ A S R S R C I I

Legend
Responsible R Assigned to complete the task or deliverable
Accountable A Has final decision or authority, accountable for completion
Support S Provides support during task or process
Consulted C Advisor, stakeholder, or expert who is consulted
Informed I Must be informed after a decision or action

10
1.3.3. Risk Management Assessment
The major contributing factor of risk to the overall project success was the time factor. Due to
the Covid-19 classroom protocols, the team could not work onsite most of the time. This meant
that time management was crucial for the success of the project. The team needed to maximize
every available on campus day to ensure an overall project success.
The second biggest risk to the project was team members’ schedules. In order to achieve a
complete working Siemens Trainer Bench, the team needed to collaborate on several occasions
to complete different tasks associated with the project. This involved scheduling team meetings
on evenings and weekends to accommodate the majority of the them members.
Additional risks included:
• Access to material in a timely manner
• Defective products
• Wiring issues
• Mounting hazards

11
2. Component Overview
The scope of this project was to redesign a new Siemens Servo Training Bench for Humber
College NB-115 laboratory classroom as a direct replacement to an existing training
arrangement. The project involved the designing, installation, and commissioning phases of the
equipment to be implemented. All the new Siemens components were mounted on laser cut
acrylic panels framed in Parker extruded aluminum. Each component framed panel was
mounted on an additional Parker extruded aluminum structural product attached to a Metric
Storage Systems Double Workstation bench.

2.1. Research on Installation of Components

We started our Siemens project by collecting information on the components that will be used
to create the Siemens servo trainer bench. We used the system manuals to gather relevant
Information regarding technical data, operating instructions, quick installation guides, and
component clearances that needed to be considered in the design phase. The component list
consists of:
1. SIEMENS SIMATIC S7-1200 PLC
2. SIEMENS Scalance XB005
3. SIEMENS SITOP PSU100L
4. SIEMENS KTP400 HMI
5. SIEMENS SIMATIC PM 1507
6. SIEMENS SIMATIC S7-1500T
7. SIEMENS SINAMICS S210
8. SIEMENS SIMOTICS S-1FK2
9. SIEMENS SIMATIC memory card
10. SIEMENS Mounting Rail
11. Parker Aluminum Extrusion
12. KRIËGER Transformer
A detailed description of each component with the relevant sections from the system manuals
pertaining to the installation of the components is provided in the following pages of this
report.

12
2.1.1. SIEMENS SIMATIC S7-1200 PLC
The SIMATIC S7-1200 1215c DC/DC/DC (6ES7 215-
1AG40-0XB0) CPU. Is equipped with two PROFINet ports,
onboard I/O that include 14 DI at 24V DC, 10 DO at 24V
DC that can carry up to 0.5A per channel. The 1215c has
a pair of AI channels that range from 0 –10V DC (10-bit
resolution), and a pair of AO channels that range from 0-
20mA DC (10-bit resolution). The 1215c CPU is powered
by a 24V DC power supply (the power supply can range
from 20.4-28.8V DC). The 1215c has an internal
programable data memory of 125KB. STEP 7 basic is the Figure 2-1. SIMATIC S7-1200 PLC
utility program to be used to setup the PLC.

Figure 2-2. Connection Diagram S7-1200 1215c PLC

13
2.1.1.1. Physical Characteristics

The SIMATIC S7-1200 1215c is 130x100x75mm (WxHxD).

Figure 2-3. Dimensional Drawing S7-1200 1215c

PLC

The weight of the PLC is approximately 500g. The small size and weight allow for an efficient
use of space which make for a good feature as space was a major constraint in the design.

2.1.1.2. Mounting Considerations

The S7-1200 1215c is an easy PLC to install. It can be installed either on a panel or on a standard
35 mm DIN rail, and you can orient it either horizontally or vertically. For our project, the team
opted to mount the PLC on a standard DIN rail. This would allow us to mount the XB005 and the
PSU100L with the 1215c PLC on the same rail, to conserve space and installation time.
When configuring the layout, we considered the proximity to heat-generating devices, high
voltage components, and equipment that produce high electrical noise. As per the
manufacturers specifications when installing the S7-1200 PLCs we needed to allow enough
clearance for the wiring and communications cable connections as well as clearances for heat
dissipation. The image below illustrates the minimum required clearances from the factory.

Figure 2-4. Mounting Diagram S7-1200 1215c PLC

14
2.1.2. Siemens Scalance XB005
The SCALANCE XB005 (6GK5005-0GA10-1AB2) is an unmanaged Industrial
Ethernet Switch suitable for 10 or 100 Mbps. It is ideal for setting up small
star and line topologies. The switch is equipped with diagnostics LEDs to
easily diagnose system troubles. The switch has an IP20 rating which means
that the switch is rated for dust and touchproof (able to withstand basic
touch). A 24 V AC or DC power supply is required for the switch to operate,
this power will be supplied by the PSU100L. The SCALANCE XB005 can
support up to 5 10 or 100 Mbps twisted pair ports with RJ45 sockets.

Figure 2-5. SCALANCE XB005 Switch

2.1.2.1. Physical Characteristics

The SCALANCE XB005 is 45x100x87mm (WxHxD).

Figure 2-6. Dimensional Drawing XB005

The weight of the Scalance XB005 is approximately 165g. The small size and weight allow for an
efficient use of space which make for a good feature as space was a major constraint in the
design.

2.1.2.2. Mounting Considerations

To install the Siemens Scalance XB005 ethernet switch to our bench, we followed the minimum
clearance guidelines provided in the manual so that the convection ventilation of the device is
not blocked, we needed 10 cm on the top and bottom of the switch. The XB005 will be installed
on a standard 35mm DIN rail. This would allow us to mount the PSU100L with the 1215c PLC on
the same rail, to conserve space and installation time.

15
2.1.3. Siemens SITOP PSU100L
The Siemens SITOP PSU100L (6EP1-333-1LB00) DC Power Supply
24V/5A is a single phase 0-230 VAC at 60 Hz stabilized power supply
delivering a constant 24V with a 89% efficiency and 120 W power
rating. It has manual switchover and parallel switching with short-
circuit and overload protection. Operating ambient temperature
ranges from 0° to 60°C (from 45°C with derating). Its cooling is
through natural convection. IP20 Nema Configuration.

Figure 2-7. SITOP PSU100L

2.1.3.1. Physical Characteristics

The SITOP PSU100L is 120x50x125mm (LxWxD).

Figure 2-8. Dimensional Drawing PSU100L

The weight of the SITOP 100L is approximately 500g. The small size and weight allow for an
efficient use of space which make for a good feature as space was a major constraint in the
design.

16
2.1.3.2. Mounting Considerations

The device is mounted on a standard 35mm DIN rail according to EN 60715 35×7,5/15.
The device must be mounted vertically in such a way that the input terminals and the output
terminals are at the bottom to ensure correct cooling. A clearance of at least 50 mm should be
maintained above and below the device. No space is required at the side. It is paramount that
the top and bottom clearances are adhered to as the output current drops linearly as the
temperature rises above 45°C.

Figure 2-9. PSU100L Current vs Temperature in Upright Position

2.1.4. Siemens KTP400 Basics HMI

The SIMATIC KTP400 Basic HMI (6AV2123-2DB03-0AX0) has a 4"
4:3 TFT display offering 65536 colours that can be operated via
the keypad or the touch display. The communication with the
controller is made via the PROFINET, PROFIBUS interface or USB
port. Configuration of the Basic Panel KTP400 is possible from
WinCC Basic V13 and/or STEP7 BASIC V13.

Figure 2-10. KTP400 Basics HMI

17
2.1.4.1. Physical Characteristics

The SIMATIC KTP400 Basic HMI is 100x116x41.2mm (LxWxD).

The back section is 121.9x97.9x35mm (LxWxD).

Figure 2-11. Dimensional Drawing KTP400 Basics HMI

The weight of the SIMATIC KTP400 is approximately 360g. The back section as seen in the
dimensional illustrations above sits behind its mounting panel.

2.1.4.2. Mounting Considerations

The SIMATIC KTP400 Basic HMI is suitable for installing in mounting and control cabinets,
switchboards, and consoles. The SIMATIC KTP400 Basic HMI can be mounted vertically up to +/-
35° and is self-ventilating.

18
2.1.5. Siemens SIMATIC PM 1507
The Siemens SIMATIC PM 1507 24V/3A is a stabilized 70W
power supply (6EP13324-BA00). Input: 1 phase, 120/230VAC,
output: 24VDC/3A. The design and functionality of the SIMATIC
PM 1507 single-phase load power supply with automatic range
selection of the input voltage makes it an optimal match to the
SIMATIC S7-1500 PLC. With features that include LED indicators
for status, an on/off switch, and a hinged access cover.
Figure 2-12. SIMATIC PM 1507

2.1.5.1. Physical Characteristics

The SIMATIC PM 1507 is 129x50x147mm (LxWxD).

Figure 2-13. Dimensional Drawing PM 1507

The weight of the SIMATIC PM 1507 is approximately 450g.

2.1.5.2. Mounting Considerations

There are no clearance requirements for a horizontal system configuration (cable outlet
towards the bottom) for the right side of the module. To the left, there is a required minimum
clearance of 10 mm. A minimum clearance of 25 mm is required to the upper adjacent module
(for vertical system configurations, cable outlet to the right) and a minimum clearance of 20
mm to a lower adjacent module.

19
2.1.6. Siemens SIMATIC S7-1500T
The SIMATIC S7-1500T, CPU 1511T-1 PN, (6ES7-511-1TK01- 0AB0)
controller features a modular design and is fully customizable. The
modules are approved for protection class IP20 and designed for
installation in a control cabinet. The CPU has a work memory of 225
KB for programs and 1 MB for data. The S7-1500T is the first interface
that uses PROFINET IRT with a 2-port switch, 60 ns bit performance,
and the controller requires a SIMATIC Memory Card.

Figure 2-14. SIMATIC S7-1500 1511T-1 PN

2.1.6.1. Physical Characteristics

The Siemens SIMATIC S7-1500T is 35x147x129mm (LxWxD).

Figure 2-15. Dimensional Drawing S7-1500 1511T-1 PN

The weight of the SIMATIC S7-1500T is approximately 405g. The small size and weight allow for
an efficient use of space which make for a good feature as space was a major constraint in the
design.

2.1.6.2. Mounting Considerations

If installing the S7-1500T horizontally (cable outlet towards the

bottom), there is no clearance required to the right-hand side of the
CPU if adding an additional module. If there is a module being
installed to the left-hand side of the CPU then a minimum clearance
of 10mm is required. If installing the CPU vertically (cable outlet to
the right) then a minimum clearance of 25mm must be provided to
the upper module and a minimum of 20mm must be provided to the
lower module. Figure 2-16. Mounting Diagram S7-1500

20
2.1.7. Siemens SIMAMICS S210
The SINAMICS S210 drive (6SL3210-5HB10-4UFO) requires an Input voltage
of 200-240V 1AC (-/+10%), 5.0A at 45-66Hz and can provide an output
voltage of 0-240V, 2.4A at 0-550Hz. A 0.4 kW motor can be operated with
the help of this drive and this drive provides IP20 protection. The S210 drive
is typically suited for robotics handling systems, manufacturing applications
and printing machines.

Figure 2-17. SINAMICS S210 Drive

2.1.7.1. System Overview

The drive system comprises the following system

components tailored to one another:

• SIMANICS S210 Converter

• SIMOTICS S-1FK2 motor
• OCC MOTION-CONNECT Cable
(One Cable Connection)

The converter and the motor are intended

for use with the SIMANICS S7-1500T
controller. Network connections are made
via PROFINET.

Figure 2-18. Connection Diagram S210 Drive

21
2.1.7.2. Physical Characteristics

The SINAMICS S210 drive 55x170x170mm (LxWxD).

Figure 2-19. Dimensional Drawing S210 Drive

The weight of the SINAMICS S210 is approximately 1200g. The rear third of the drive consists of
an aluminum finned heat sink to dissipate heat generated by the drive.

2.1.7.3. Mounting Considerations

The S210 drive requires a minimum clearance of 100mm to other devices at the top and
bottom. Lateral clearance is not required for other S210 drives but a 10mm clearance is
required to other devices. The S210 can only be mounted upright as per manufacturer’s
requirement. Additionally, the unit mounts on a flat surface on pre-installed bolt heads; it does
not mount on a rail.

Figure 2-20. Mounting Diagram S210 Drive

22
2.1.8. Siemens SIMOTICS S-1FK2
The SIMOTICS S-1FK2 Servo motor (1FK2103-4AG00-1MA0) is a
0.4kw motor that requires 200-240V to operate and can operate
at 3000rpm. The servo motor provides IP64 protection and is a
permanent-magnet compact synchronous motor. The 1FK2
comes equipped with a M12 OCC interface connector which can
be rotated 261° and also meets the requirement standards of EN
60034 and EN 60204-1. The 1FK2 is a non-ventilated motor and
the motor thermal losses are dissipated by thermal conduction,
thermal radiation and natural convection.
Figure 2-21. SIMOTICS S-1FK2 Servo Motor

2.1.8.1. Physical Characteristics

SIMOTICS S-1FK2 Dimensions (mm):

Figure 2-22. Dimensional Drawing S-1FK2 103-44AG00-1MA0 Servo Motor

The weight of the 1FK2 is approximately 2150g (without brake, 1630g).

Motor Nameplate:

Figure 2-23. S-1FK2 Servo Motor

Nameplate
23
2.1.8.2. Mounting Considerations

The motor requires a minimum clearance of 100 mm from adjacent components on three sides
to ensure sufficient heat dissipation. These clearances must be maintained irrespective of the
following mounting variants.

2.1.8.2.1. Non-thermally insulated mounting

• some of the motor power loss is dissipated through the flange when the motor is
connected to the mounting surface.
Observe the following mounting conditions for the specified motor data:
Table 2-1. S-1FK2 Mounting Conditions

The data in the table refers to an ambient temperature of 40 °C and an installation

altitude up to 1000 m above sea level. For larger mounting surfaces, the heat dissipation
conditions improve.

2.1.8.2.2. Thermally insulated mounting without additional mounted components

• The subsequent description is only applicable for motors, frame sizes 1FK2☐02 ...
1FK2☐04.
• For naturally cooled motors, you must reduce the S1/characteristic as follows:
➢ Reduce the motor static torque by 20 % to 30 %.
➢ Reduce the torque at 3000 rpm by 40 % to 50 %.

The motor connector can be rotated with a suitable socket connector as a lever to
accommodate proper OCC cable routing (to avoid extreme bends). A maximum of 10 rotations
are permitted so as not to impair the degree of protection of the motor.
Table 2-2. OCC Rotation

24
2.1.9. Siemens SIMATIC memory card
The SIMATIC Memory SD™ Card (6ES7954-8LE03-0AA0) requires 3.3 V
to operate and has 12 MB storage space. The CPU only supports pre-
programmed SIMATIC memory cards and a blank memory card is
required for the first Startup of S7-1500T.

2.1.9.1. Physical Characteristics

Figure 2-24. SIMATIC Memory Card
The SIMATIC Memory card is 21x3x24mm (LxWxD).
The weight of the memory card is approximately 3g.

2.1.10. Siemens Mounting Rail

The Siemens Mounting rail (6ES75901AE800AA0)
is required to install the S7-1500T, SIMATIC PM
1507, and for many more applications. The
mounting rail also comes with grounding screws
and are required for grounding some
components.
Figure 2-25. Siemens 155 Mounting Rail

2.1.10.1. Physical Characteristics

The SIMATIC Mounting rail is 482x155x16mm (LxWxD).

The weight of the Mounding rail is approximately 941g.

2.1.11. Parker Aluminum Extrusions

Parker aluminum extrusions 40 series (11-040 and 10-161) and 28 series (12-128) were used to
construct the structural backplane and component frames for the workbench. The Parker
aluminum extrusions make for a quick, clean and straightforward assembly for a wide variety of
applications. The 40 series (11-040) is ideal for general purpose applications such as
workstations, machine guarding and framework. On the other hand, the 28 series (12-128) is
useful for constructing safety guards, partition frames, light duty enclosures and component
panel frames.

25
2.1.11.1. Physical Characteristics

The 40 series 11-040 is 40mm square with a 6.7mm diameter hole through its center. Each
outer side has a continuous T-slot that measures 8mm at the throat and 20mm at its widest
point, which makes for an easy implementation in fastening hardware.
The 40 series 10-161 is 16mm thick and 160mm tall. Three faces have 5mm and 8mm T-slots
providing convenient attachment points for a wide range of accessories.
The 28 series 12-128 has the same profile as the 11-040 but with different dimensions. As the
name indicates, it is 28mm square. The T-slots measure 8.10mm at the throat and 18.46 at its
widest point.

Figure 2-28. 40 Series 11-040

Figure 2-27. 28 Series 12-128 Figure 2-26. 40 Series 10-161

26
2.1.11.2. Mounting Considerations

A combination of the Parker Series 40 extrusions was used for the structural bench frame and
backplane. The Parker Series 28 was used for the component frames. M8 T-Nuts (20-057) and
M8x1.25 Button Head bolts (240-110-8) were used as the fasteners to attach these extrusions
to each other, for constructing the component frames and for fastening the frames to the
backplane.

Figure 2-30. 28 Series T-Nut 20-057 Figure 2-29. M8 x 1.25 Button Head Bolt 240-110-8

27
2.1.12. KRIËGER Transformer
The KRIGER transformer is a 1150 watt step up/down
transformer which can be used for 110v and 220v
applications. It can convert 220-240v into 110-120v and
from 110-120v to 220-240v. This transformer can be used
for household appliances and heavy-duty machines. This
transformer comes with dual fuse protection and also has 5
outlets on the front side. It is MET certified under UL 1012.
Figure 2-31. KRIËGER Transformer

2.1.12.1. Physical Characteristics

The KRIËGER Transformer is 249x122x183mm (WxHxD) and weighs approximately 5488g.

2.1.12.2. Mounting Considerations

This transformer can only be used indoors placed on a flat surface with space around it for
proper ventilation.

28
3. Design Phase
After completing the research on the components and martials to be used for the project the
team could move into the design phase. This phase would make up the majority of time spent
working on the project and would require several iterations to finalize the design to be used for
the Siemens Bench Trainer in NB-115 at Humber College. After the team decided on the initial
design plan, we would present it to the project sponsor to gage their response to the layout.
This would also give the team valuable feedback for the team to use to make changes to the
design layout, this process would continue for a few iterations of the design. This would allow
the team to get the layout as close to the sponsors requirements wile still adhering to the
manufacture’s installation requirements for the individual components used in the project.

3.1. Design Iteration 1

As previously mentioned in the introduction portion of this report, the Siemens Bench Trainer
would be comprised of two S7-1200 1215C PLCs, two KTP 400 Basic HMIs, two PSU100L power
supplies, and two X500 ethernet switches one set per student workstation. A shared Siemens
servo motor trainer that would be controlled by a S7-1500 PLC powered by a PM1507. The two
servo motors would be driven by two S210 servo drives, one for each motor. All the
components would be mounted on modular removable panels constructed of the Parker
Aluminum 28 Series extrusion. The two-student trainer layout would be a maximum of 150cm
wide with smallest height that could be possible.
The teams first layout was one which saw the 1215C PLC, HMI, S210 Servo Drive, and S-1FK2
Servo Motor, and I/O terminals on one panel. There would be two of these panels in front of
each students workspace. The S7-1500 PLC and PM would be in between the two student
interface panels. This would have allowed for each student to have easy access to all the
Siemens components. The first layout is shown below.

29
3.1.1. CAD Layout

Figure 3-1. CAD Design Iteration 1

3.1.2. Recommendations
After presenting the first layout to the project sponsor and having consulted with other
stakeholders in the project, the design was rejected. Through consultation with the vested
parties, several recommendations were made to alter the design to better meet the
requirements of the project.

3.1.2.1. List of Recommendations

1. The overall height of the layout is too tall and must be reduced.
2. We could use more of the horizontal space to bring the total height down.
3. More of a modular design to allow for ease in maintenance of the components.
4. Servo Drives and motors needed to be contained on their own panels.

3.2. Design Iteration 2

After carefully considering the recommendations from the project sponsor and stakeholders,
the team completed the second design. We also soured the AutoCAD files for each Siemens
components, which enabled us to make a more realistic model for the design layout. The team
created the second version of the bench layout, which can be seen below.

30
3.2.1. CAD Layout

Figure 3-2. CAD Design Iteration 2

3.2.2. Recommendations
After presenting the second layout, the second design was also rejected by the project sponsor.
Through consultation with the vested parties recommendations were made to alter the design
to better meet the requirements of the project. New accommodations were provided to
include a transformer and to cover safety concerns raised by the sponsor around high voltage
components.

3.2.2.1. List of Recommendations

1. All PSU and servo related components must be contained in a protective enclosure.
2. PLC and HMI needed to put on to separate panels and stacked vertically for ease of
maintenance.
3. Change orientation of the servo motors.
4. Remove to space consideration for the computer monitors.
5. Transformer size and position needed to be considered.
6. Comm cable routing.

31
3.3. Design Iteration 3
As the project sponsor and stakeholders made additional change recommendations, the team
worked on completing the third design. In addition, the team sourced the AutoCAD files for the
Parker extruded aluminum products to be included in this design iteration. Due to the new
design conditions, the layout become more complex with added design work.

3.3.1. CAD Layouts

Figure 3-3. CAD Design Iteration 3

Figure 3-4. CAD Design Iteration 3 Enclosure

32
3.3.2. Recommendations
Upon presenting the third design to the project sponsor, further recommendations were made
to reduce the complexity of the enclosure. A discussion was had with vested parties to simplify
the enclosure to facilitate the assembly part of the project. The discussion also raised the point
regarding student accessibility to the servo controller and its power module. Furthermore,
ventilation was another consideration to be had.

3.3.2.1. List of Recommendations

1. Reduce complexity of enclosure.

2. Place servo controller/power module outside of enclosure.
3. Resize/reorient banana jack frames.
4. Implement maintain push button for the PLCs and HMIs.
5. Implement a ventilation fan over the servo drivers.

3.4. Design Iteration 4

The team completed design 4 as per the sponsor’s recommendations. The servo controller and
its power module was placed outside of the enclosure and the banana jack frames were altered
to accommodate a lower overall height. To appropriately size the ventilation fan and decide on
its location, research had to be made for an efficient result.

3.4.1. CAD Layout

Figure 3-5. CAD Design Iteration 4

33
 Figure 3-6. CAD Design Iteration 4 Enclosure

3.4.2. Recommendations
With the team’s fourth design, the project sponsor recommended further changes to the
layout, particularly to the enclosure. At this point, the enclosure was considered to be a difficult
build as far as assembly. This resulting in separating the S7-1500 servo controller and its power
module PM 1507 from the enclosure altogether into a stand-alone extrusion frame. The same
was recommended for the S7-1200 PLC and the HMI both having their own extrusion frames.
Furthermore, the SITOP 100L power supplies were also removed from the enclosure to be
placed beside the S7-1200 PLC along with the SCALANCE XB005 switch. These changes were
intended to create a more modular design in the event that the enclosure was to be removed,
the remaining components could still have power. The banana jack frames were also altered.

3.4.2.1. List of Recommendations

1. Removal of S7-1500 and PM 1507 from the enclosure onto their own frame.
2. Removal of PSUs from enclosure
3. Separation of S7-1200 PLC and HMI onto their own frames
4. Banana jack frame alteration

34
3.5. Final Design Iteration
After several design iterations, the team optimized the sponsor’s requirements while still
maintaining the manufacturer’s installation parameters. This design made for a more complete
modular setup that was not only spatially efficient but also ergonomically friendly with
consideration to the mounting position to the computer monitors. A complete package of the
final CAD drawings can be found in Appendix A.

3.5.1. CAD Layout

Figure 3-7. Final CAD Design

3.5.2. Final Modifications

Although this design was final, a small modification to the banana jack frames was made to
accommodate a fourth panel containing power outputs.

35
4. Build Phase
With the design finalized and approved, the team moved on to the build phase of the project.
This was comprised of two stages: the mechanical build and the electrical wiring.

4.1. Mechanical Build

The mechanical build was further broken down into three categories: extrusions, acrylic panels
and mounting of components.

4.1.1. Extrusions
With the design finalized, we could then crate a cut-list for the aluminum extrusions that were
required to complete the frames for the component(s) and the enclosure (see Table 4-1). This
list was used as reference to cut the pieces to size as well as keep track of the pieces as every
piece was identified by a letter. Each frame was sectioned for ease of assembly.

Table 4-1. Extrusion Cut-List

PLC
Piece ID Qty Length (mm)
A 6 296
B 8 196

HMI
C 6 221
D 8 161

I/O
E 6 296
F 8 148

Servo PLC
G 3 154
H 4 237
I 1 98

HV Enclosure
J 5 296
K 6 356
L 4 231
M 2 240

36
A set of mechanical drawings were drafted to aid in the assembly of each component frame.
The information conveyed in these drawings would denote where holes were to be drilled and
holes to be tapped. It would also show which pieces would connect to one another and how
this connection would be made. All holes were drilled at a 7mm diameter at their identified
locations, and all holes to be tapped were done using an M8 x 1.25 tap. A full set of mechanical
CAD drawings can be found in Appendix B.

4.1.2. Acrylic Panels

All the acrylic panels were cut using a laser cutting machine. The sizing of the panels was done
according to the extrusion frame sizes with an added 6mm on all sides to sit inside the
extrusion’s channel. Each panel was custom designed with etching for component and terminal
identification. Holes were provided at strategic locations around the panel for:
• Electrical wiring (high, low, and signal voltages)
• Network cable routing and coupling
• On/Off switches
• Ventilation perforations and fan
All panels were cut from 12”x 24” white 6mm thick acrylic, except for the front, sides and top
panels of the enclosure, which was clear. In the design stage of the panels, a colour scheme was
required for the laser machine to recognize the type of cut/etch to be made. The outer border
colour was green #00FF00, the holes were red #FF0000, and the etching was black #000000.
The panels were carefully crafted with corner chamfers on all component panels and corner
fillets on the inner banana jack panels for ease of insertion/removal. A full set of acrylic panel
CAD drawings can be found in Appendix C.

Figure 4-1. PLC/PSU/Switch Combo Acrylic CAD Drawing

37
4.1.3. Component Mounting
Once the extrusions and panels were cut, the team could start to prepare for assembly
followed by mounting. Standard 35mm din rail was used to mount a majority of the
components as well as some power distribution terminal blocks. There was also a proprietary
Siemens 155mm rail used to mount the S7-1500 controller and power module 1507. The S-210
drives were surface mounted on the Parker series 28 extrusion. A variety of Parker extrusions
and normal hardware was used to complete this task.

4.1.3.1. PLC/PSU/Switch

Measurements were taken to properly size the 35mm din rail to allow for the use of three
mounting holes at a strategic distance from each other. The din rail was fastened to the acrylic
panel with #6-32 x ½ “ machine screw with corresponding washers and nuts.
Following, the PLC, PSU and Switch were mounted onto the din rail fastened to the acrylic
panel. A maintained illuminated push button was installed on the top left corner of the panel to
disconnect power to the PLC when not in use.

Figure 4-2. PLC/PSU/Switch Combo Mounted to Frame

38
4.1.3.1.1. S7-1200

The PLC was mounted according to these step-by-step instructions:

1. Ensure that the CPU and all S7-1200 equipment are
disconnected from electrical power.
2. Hook the CPU over the top of the DIN rail.
3. Pull out the DIN rail clip on the bottom of the CPU
to allow the CPU to fit over the rail.

4. Rotate the CPU down into position on the rail.

5. Push in the clips to latch the CPU to the rail.

Figure 4-3. S7-1200 Mounting Instructions

4.1.3.1.2. PSU100L

To mount the device, position it with the mounting rail guide at the upper edge of the standard
mounting rail and press down to lock it into place. If this is too difficult, press slider ⑥ at the
same time, as depicted in the figure below.

Figure 4-4. PSU100L Mounting Instructions

39
4.1.3.1.3. XB005

1. Place the housing guide of the device on the top edge of the DIN rail.
2. Push the device down against rail until it locks in place.

Figure 4-5. SCALANCE XB005 Mounting Instructions

40
4.1.3.2. KTP400 HMI

The HMI was mounted on its own framed panel. The panel opening was cut to the appropriate
size (for KTP400: 123W x 99H mm, see figure 4-6) to allow the back of the unit fit through the
opening and secured using the provided pressure clips. The clips were placed in predetermined
points – two on the top and two on the bottom – allowing for the most secure mounting (see
figures 4-7 and 4-8).

Figure 4-6. HMI Panel Cut-Out Layout

Figure 4-7. HMI Insertion Method

Figure 4-8. HMI Pressure Clip Procedure

Figure 4-9. HMI Awaiting Installation

41
4.1.3.3. S7-1500T and PM 1507

The S7-1500 PLC and it related Power Module 1507 were both mounted directly to the Siemens
155 din rail. The rail was cut to size to fit within the aluminum extrusion frame (98mm wide)
and secured to the extrusion with M6 bolts and T-nuts. The components were clipped onto the
rail at the top and secured with the provided fastener at the bottom.

Figure 4-10. S7-1500 and PM 1507 Mounted on Siemens 155 Din Rail

42
4.1.3.4. Servo Drive Mounting

The S-210 drive was mounted directly onto the top and bottom aluminum extrusion cross
members as per design. They were secured using M6 bolts and T-nuts.

Figure 4-12. S210 Drives Mounted Figure 4-11. S210 Mounting Holes Dimensions

43
4.1.3.5. Servo Motor Mounting

The S-1FK2 was mounted using M5 socket head bolts on a custom designed 3D printed L-
bracket which was secured using M4 flat head bolts to the bottom panel of the enclosure.

Figure 4-13. SOLIDWORKS Motor Mount Design

Figure 4-14. S-1FK2 Servo Motor Mounted

44
4.2. Electrical Wiring
The components for electrical wiring required to complete the project consisted of 120/230
VAC power supply, 24VDC power supply to components, Servo motor connections, I/O
terminals, and communication cabling. The wiring was completed adhering to ESA standards
and the manufacturer’s specifications.

4.2.1. 120/230 VAC

The SITOP PSU 100L, the PM 1507, and the KRIEGER transformer all required 120VAC from the
existing classroom infrastructure. The 100L and PM 1507 used re-purposed 18 AWG open
wiring power cables, while the transformer came with its own integrated cable. The output
cable of the transformer needed to be cut to expose the conductors in the cable to attach to
the distribution terminal blocks inside the enclosure. Each cable was secured to the panel to
eliminate the possibility of being pulled from its terminal connections using strain relief
connectors. All the conductors were prepared for wiring by stripping away the outer insulation
to the appropriate length to allow for the conductors to safely connect to their respective
terminals. Each individual conductor within the cable was stripped to the exact length so no
bare wire was exposed when the terminal connection was made.

Figure 4-16. 120 VAC Power Supply Connections Figure 4-15. 220 VAC Power Supply Connections

45
The PM 1507 came with an enclosed connector for the power supply cable, which added an
extra level of protection from exposed wires. The connector also had a built-in wire clamp to
help reduce the possibility of the wires being accidently pulled from the terminals.

4.2.1.1. PM 1507 Connection

The following steps describe the connecting method for landing the 120VAC supply to the PM
1507:
1. Swing the front cover of the module up until the front cover latches.
2. Press down the unlocking button of the power cable connector.
Remove the power cable connector from the front of the module.

3. Loosen the screw on the front of the connector. This loosens the
housing latch and the cable relief. With a tightened screw the
connector's cover cannot be removed.

4. Pry off the connector cover using a suitable tool.

5. Strip the cable jacket to a length of 35 mm and the conductors to a
length of 7 to 8 mm. Attach the end sleeves.

6. Connect the wires in the connector according to the connection

diagram.
7. Close the cover.
8. Re-tighten the screw. This effects a strain relief on the lines.

Figure 4-17. PM 1507 Power Supply

Connector Instructions

46
4.2.2. 24 VDC Power Supply
There were two different 24VDC power supplies used in the trainer bench project, the SITOP
PSU 100L, and the PM 1507. Each one could supply a constant 24VDC output, the difference
lied in the amount of output current they could supply. The PSU 100L was capable of 5 Amps
and the PM 1507 was capable of 3 Amps.

4.2.2.1. SITOP PSU 100L

The PSU100L has a two channel 24 VDC supply. The Scalance XB005 unmanaged ethernet
switch needs a constant 24 VDC supply to operate, as such the team needed to connect a direct
run of 18 AWG wire from one of the 24 VDC channels of the power supply directly to the power
terminals of the switch. The other 24 VDC channel on the power supply would be used to
power the PLC and HMI. This meant the team had to connect the 18 AWG wire from the second
24 VDC channel to the NO terminal of the maintained power pushbutton for the PLC. The same
terminal was daisy chained and connected to the NO terminal of the maintained power
pushbutton for the HMI. From the other side of the switch, a wire was also connected to their
respective components, meaning after the power switch has been toggled, our components
would turn on. All connections to the maintain power pushbuttons were done with spade
connectors.

Figure 4-18. 24VDC PLC and Pushbutton

Wiring

Figure 4-19. 24VDC HMI and Pushbutton Wiring

47
4.2.2.2. SIMATIC PM 1507

The PM 1507 has a two channel 24 VDC supply. One channel was used to power
the S7-1500T and the other channel was used to satisfy the low voltage power
requirements of the S210 servo drives. The second channel was also used to
power the ventilation fan. This power supply module comes equipped with an
onboard toggle switch to cut power to the output channels.

Figure 4-20. 24VDC

S7-1500 Wiring

4.2.3. Servo Drive/Motor Connections

The servo drive required 230 VAC to power the servo motor and 24 VDC to power onboard
circuitry.

4.2.3.1. 230 VAC

Each drive was supplied 230 VAC with a dedicated run from the power distribution terminal
block inside the enclosure to power the motor. The power went through an EMC filter to
reduce the noise between the drive and the main power supply and then through a rectifier
and finally through an inverter. With this arrangement, the servo motor can be operated under
different load conditions. Terminations of L1 and Neutral was done at the X1 connector, which
had terminals for an external brake resistor R1 and R2, however, this was not used for our
application. As such, the factory installed jumper remained installed. The grounding for the
drives at the shielding plate was daisy chained and returned to the power distribution terminal
block.
Table 4-2. X1: Line Connection Terminal Block

48
4.2.3.2. 24 VDC

The 24 VDC was supplied by the second output channel of the PM 1507. The 24 VDC supply
wire was terminated at the +24V and 0V pins of the X124 connector. This connection was daisy
chained from the other +24V and 0V pins of the X124 connector to the other servo drive’s X124
connector. The unused pins of the latter connector were used to supply power to the
ventilation fan of the enclosure.

Table 4-3. X124 24VDC Connection Terminal Block

4.2.3.3. ONE CABLE CONNECTION

The One Cable Connection (OCC) was used to interface the

S210 drives with the 1FK2 motors. OCC is a comprehensive
cable in that it carries 230 VAC supply, communication signals,
and holding brake signals. Each wire within the OCC has a
dedicated terminal to connect to at the drive. The motor
phases U,V,and W and the Protective Ground (PE) terminate
at the X2 connector. The encoder interface connects at the
X100 connector. And lastly, the holding brake signals are
terminated at the X107 connector. The braided shielding that
surrounds the inner cable is connected at the shielding plate
of the drive for grounding purpose. More comprehensive pin
out chart can be found on the next page.
Figure 4-21. OCC Wire Terminations

49
 Table 4-4. X2: Power Connection Terminal Block

Table 4-5. X100: Siemens IX Connection Terminal Block

Table 4-6. X107: Motor Holding Brake Terminal Block

50
4.2.3.4. M12 Interface at Motor

The OCC terminates with an M12 connector to interface with the motor. The motor’s connector
is adjustable to accommodate the angle at which the OCC connects up to 261°.

Figure 4-22. OCC Connections Completed

4.2.3.5. Complete Servo Enclosure Assembly

After completing all the necessary wiring, the end result can be seen in the figure below.

Figure 4-23. Enclosure Wiring Completed

51
4.2.4. I/O Terminals
18 AWG wire, as per manufacturer’s requirement, was used to interface the PLC with the
banana jacks. The first step was to cut the wires to the appropriate length with nominal slack so
as to manage troubleshooting with ease. The PLC I/Os comprised of 14 digital inputs, 10 digital
outputs, 2 analog inputs, 2 analog outputs, and power and common I/Os totalling 34 wires. The
PLC end wires were stripped approximately 7mm in order to be inserted into the ferule and
then crimped for a solid connection. The banana jack end wires were stripped approximately
25mm in order to wrap the terminal posts and then soldered. Subsequently, all wires were
tagged on both ends according to the PLC I/O s for easy identification, installation, and
maintenance purposes. The wires were then routed through the slits on the acrylic panels and
connected to their respective terminals.

Figure 4-25. PLC I/O Terminal Wiring Completed Figure 4-24. Banana Jack Terminals Soldered

52
4.2.5. Communication Cabling
Siemens PROFINET green cables were used to communicate from the Humber network to the
SCALANCE XB005 ethernet switch and from the switch to the S7-1200, S7-1500, and HMI. A run
from the second port of the S7-1500 to one S-210 drive which was daisy chained to the other
S-210 drive. All the ethernet cables used in the project were custom made with RJ45
terminations using a crimper and tested with a network cable tester. Heat shrink tubing was
used to cover and isolate exposed termination wires.

Figure 4-27. Ethernet Connections at the Switch Figure 4-26. Enclosure Ethernet Connections

The PROFINET cables were cut to specific lengths with adequate slack to prevent critical bends
that could possibly damage the communication wire. To properly fabricate ethernet cables, we
started by cutting off the outer shielding on each end by approximately 25mm followed by
removing the inner shielding to the same length on each pair of color-coded wires.

Figure 4-28. Preparing Ethernet Cable Ends for Terminations

53
Next, all 8 wires were fed through the supplied wire holder from RJ45 the terminations which
allowed us to set the correct configuration of the RJ45 color code which consisted of white-
orange, orange, white-green, blue, white-blue, green, white-brown, and brown.

Figure 4-29. RJ45 Termination

Then the wire was fed through the RJ45 terminations and crimped once the wires were seen at
the top of the termination. The other end was crimped with the matching configuration.

Figure 4-30. RJ45 Termination Crimper

Finally, with both ends crimped, the tester was used to verify the connections, after which, heat
was applied to shrink the tubing covering the excess shielding/grounding wires.

Figure 4-31. Completed Custom Ethernet Cable Figure 4-32. Ethernet Cable Tester

With all the custom cables completed, all the components requiring an ethernet connection
could then be connected.

54
5. SIEMENS Software
Totally Integrated Automation (TIA) portal is a platform from Siemens for automation control.
This platform offers automation software, PLCs, remote I/O, sensors, actuators and even PCs. It
provides unrestricted access to the complete range of digitalized automation services, from
digital planning to integrated engineering and transparent operation. TIA Portal lets you
integrate all the key components in your automation project, including safety, security, control,
HMI, drives, decentralized peripherals, motion control, and power distribution. It provides an
engineering framework for implementing automation solutions in all industries around the
globe. From designing, commissioning, operating, and maintaining to upgrading automation
systems, the TIA Portal saves engineers time, cost, and effort.

5.1. Required Software

In this project, we will be mainly using the subsection STEP 7, SINAMICS StartDrive
Commissioning software, and SIMATIC WinCC of the TIA portal to help perform engineering
tasks efficiently and effectively. The portal can be used for configuring, programing, testing, and
diagnosing of any generation of controllers, whether it being PLC- or PC-based. The interaction
with the portal consists of basic functions such as drag & drop, copy & paste, and Auto
Complete checkmarks.

5.1.1. SIMATIC STEP 7

STEP 7 was the main interface used in the programming portion of the project. It allowed us to
assign and tag I/Os, program ladder logic, and interface with the drive components on the
bench trainer. With the use of STEP 7, we could commission all the non-driver related
components (PLCs and HMIs IP address assignment).

5.1.2. SINAMICS Startdrive

SINAMICS Startdrive is needed for the integration of SINAMICS drives. This software is an add-
on to the TIA portal and is required to commission and program the servo drives. We used the
Startdrive software in our project to have access to assign motion control functions such as
velocity control, start/stop, reset, set home, etc.

55
5.1.3. SIMATIC WinCC
SIMATIC WinCC is another add-on of the TIA portal which is required to communicate and
program the HMI. We used the SIMATIC WinCC program in our project to create a motion
control process on the HMI, correlating to StartDrive motion control functions.

56
6. Commissioning
The commissioning consisted of initialization of the Siemens components, assigning IP
addresses, and communicating with the TIA portal.
The commissioning for all the components followed the same basic guidelines.

6.1. Commissioning Steps

The following steps outline the process for the basic commissioning for the components:
1. Open TIA portal, create new project

Figure 6-1. TIA Portal - Create New Project

2. Click First steps, the window on the right side of the workspace will change to display
sub-menu that guides the user through the steps that needs to be taken.

Figure 6-2. TIA Portal - First Steps Window

57
3. Click Configure a device.

Figure 6-3. TIA Portal - Configure a Device

4. Click Add new device to configure. The right-hand side of the screen will display a menu
of devices to choose from according to the component section chosen from the icons
(immediate left of menu).

Figure 6-4. TIA Portal - Add a New Device

58
6.1.1. S7-1500
5. Choose your device (in this case, from Controllers, expand CPU 1511T1 PN and choose
6ES7-511-1TK01-0AB0).

Figure 6-5. TIA Portal – Choose Your Device S7-1511T

6. Once you have selected the right device, the following screen will be displayed where the
user is presented with a graphical representation of the device under Device view tab
(top right of center window). The user can also have an overview of the system’s
network connections under Topology and Network views.

Figure 6-6. TIA Portal – Project View Servo PLC Displayed

59
7. Under General tab (bottom center), in the General section, the user can fill out project
information, i.e., name devices, project author, etc.

Figure 6-7. TIA Portal - S7-1511T Project Information

8. Under General tab, click PROFINET interface [X1]. This is where the user can define the
subnet, IP address, time of day synchronization, and operating mode. In the Interface
networked with section click Add new subnet button and it will automatically populate
with the available subnet (PN/IE_1).

a. Next, in the IP protocol section, click Set IP address in the project button and
enter the new IP address in the provided field along with the subnet mask.

Figure 6-8. TIA Portal - S7-1511T PROFINET Interface

60
9. Under the Synchronization section (still within PROFINET interface [X1]), this PLC needed
to be identified with the role of Sync master. The reason for setting the S7-1500 as the
Sync master was to make it the highest level component in the project.

Figure 6-9. TIA Portal - S7-1511T Synchronization Role

10. Under the Port [X1 P1 R] section, the port was named (Port_1)and any relevant
comments were entered (not an absolute necessity but in a large scale project, this can
be important). This step was also performed for Port_ 2 (in the Port [X1 P2 R] section).

Figure 6-10. TIA Portal - S7-1511T Port 1 Identification

61
11. An important step to perform in order for the PC to communicate with the devices, was
to make sure the PC itself was using the same network as all the devices. Go to your PC’s
Network Connections.

Figure 6-11. PC Ethernet TCP/IPv4 Settings

Select TCP/IPv4 and enter a valid address within the same network that has not been or
going to be assigned.

Figure 6-12. PC Ethernet TCP/IPv4 Address Change

62
12. Once all the necessary information was entered to commission the S7-1500, the
download to device button (top tool ribbon button with down arrow) can be clicked.
The subsequent window will show the relevant information (device name, type, slot,
interface type, IP address, and subnet) entered in previous steps.

Figure 6-13. TIA Portal - S7-1511T Download to Device Window

13. In order to find the S7-1500 at our trainer bench, the type of PG/PC interface at the
component and at the PC we used to connect required to be identified. Additionally, we
had to define the subnet connection. At this point, under Show all compatible devices
menu, the default setting was used and the Start search button could be pressed.

Figure 6-14. TIA Portal - S7-1511T Search for Compatible Components

63
 With the Accessible device found, we verified the MAC Address, and selected it. Now
the Load button activated and could be pressed.

Figure 6-15. TIA Portal - S7-1511T MAC Address Verified

14. Pressing the Load button a verification window pops up to which we clicked Yes (as
shown).

Figure 6-16. TIA Portal - S7-1511T Assign IP Address

64
Confirm by clicking OK.

Figure 6-17. TIA Portal - IP Address at the PC Interface Added

Click Yes to save the settings to the PC’s network card.

Figure 6-18. TIA Portal - Save Settings to Network Card

65
 15. At this point, the PLC was ready to accept a program. However, the warning seen below
was to notify the user that the network was not protected – not of immediate concern
as the network was a LAN with no access to the WAN.

Figure 6-19. TIA Portal - S7 - 1511T Unprotected Warning

The result of the commissioning process can be seen below – the Status of the device and the
green check marks denote its ready condition with an optional prompt to flash the LED of the
device for communication confirmation. The Online access shows the defined user settings that
were saved (note the IP address).

Figure 6-20. TIA Portal - S7-1511T Commissioning Completed

66
6.1.2. HMI
5. To add another device, in this case, the HMI, there was no need to return to the Portal
view as one can accomplish this through the Project tree located on the left side of the
screen. As previously done, we selected the component from the left icon list in the Add
new device window. Once HMI icon is selected, a list of possible devices is displayed. We
selected the correct HMI that was used in the trainer bench (KTP400 Basic – 6AV2 123-
2DB03-0AX0).

Figure 6-21. TIA Portal - Add New Device from Project Tree

6. Following the selection process of the component, the HMI Wizard opens to help with
configuration of the HMI. The Wizard is an option for configuration; it can be done
trough the normal procedure as any other device, for example, the S7-1500.
Nonetheless, the Wizard is the easier procedure.
a. We simply added the S7-1500 as the controller and all the other fields self
populated.

Figure 6-22. TIA Portal - HMI Wizard PLC Connection

67
b. Next, we setup the Screen layout. This can be as elaborate as the options allow.

Figure 6-23. TIA Portal - HMI Wizard Screen Layout

c. In the Alarms section of the Wizard, windows for unacknowledged alarms,

pending alarms, and active system events can be added to your HMI layout. For
the purpose of our project, none of these were required.

Figure 6-24. TIA Portal - HMI Wizard Alarm Selection

68
d. The Screens page of the Wizard was used to setup the skeleton pages of the
HMI. By doing so, when the HMI loaded into the Project tree, we did not need
to add screens.

Figure 6-25. TIA Portal - HMI Wizard Add Screens

e. Systems screens can be more useful for real world applications where, for
example, user administration can be setup. For the purpose of our project, we
did not require the use of these functions.

Figure 6-26. TIA Portal - HMI Wizard System Screens

69
 f. Buttons can be added for a log on feature and for language selection. The button
orientation can be chosen from this screen. For this project, we used the
default layout.

Figure 6-27. TIA Portal - HMI Wizard Add Buttons

7. As previously done to the S7-1500, after filling out the General information of the device,
we assigned an IP address.

Figure 6-28. TIA Portal - HMI General Information

70
8. Under the PROFINET Interface [X1] section, the subnet was defined and the IP address
was assigned.

Figure 6-29. TIA Portal - HMI Assigning IP Address

9. Under Topology view, the PN/IE_1 connection was made to the S7-1500 in order for the
devices to communicate.

Figure 6-30. TIA Portal - HMI Topology Connections

71
 10. After the communication was established, we could proceed to download the device
definitions. The remaining portion of this procedure is basically the same as the
procedure performed for the previous device, the S7-1500.

The result of the commissioning process can be seen below – the Status of the device and the
green check marks denote its ready condition.

Figure 6-31. TIA Portal - HMI Commissioning Completed

72
6.1.3. S210 Drives
The commissioning of the servo drives required a more advanced commissioning procedure.
The first 3 steps are identical to the other devices.

5. To add another device, in this case, the servo drives, once again there was no need to
return to the Portal view as one can accomplish this through the Project tree located on
the left side of the screen. As previously done, we selected the component from the left
icon list in the Add new device window. Once drive icon is selected, a list of possible
drives was displayed. We selected the correct drive that was used in the trainer bench
(SINAMICS S210, 1 AC 200-240V, 0.4kW, 6SL3210-5HB10-4xFx). While selecting this
drive, the device needed to revert to version 5.2.

Figure 6-32. TIA Portal - Add New Device from Project Tree

73
6. Once you have selected the right device, the following screen will be displayed where the
user is presented with a graphical representation of the device under Device view tab
(top right of center window). In the Comments, we specified the drives and their
corresponding servo motors.

Figure 6-33. TIA Portal - S210 Drive General Information

7. Under General tab, click PROFINET interface [X1]. This is where the user can define the
subnet, IP address, time of day synchronization, and operating mode. In the Interface
networked with section click Add new subnet button and it will automatically populate
with the available subnet (PN/IE_1).

a. Next, in the IP protocol section, click Set IP address in the project button and
enter the new IP address in the provided field along with the subnet mask.

Figure 6-34. TIA Portal - S210 Drive Assign IP Address

74
8. In the Isochronous mode for local modules section, check the Isochronous mode box and
select Automatic minimum for Ti/To values. The use of isochronous mode enables high-
precision control loops.

Figure 6-35. TIA Portal - S210 Drive Isochronous Mode Selection

9. In Port interconnection we defined the Local port for the drives.

a. For port 1 on drive 2 the connection is made to port 2 on the S7-1500. This needs
to be specified in comment box for discernment.

Figure 6-36. TIA Portal - S210 Drive Port 1 Identification

75
 b. For port 2 on drive 2 the connection is made to port 1 on drive 1. Once again,
this needs to be specified in comment box for discernment.

Figure 6-37. TIA Portal - S210 Drive Port 2 Identification

10. The above procedure was reflected in Topology view where the PN/IE_1 connection was
made to the S7-1500 in order to establish communication.

Figure 6-38. TIA Portal - S210 Drive Topology Connections

76
11. Following the communication setup, we added the servo motor under Motor-selection-
1FK2 under the General tab. We chose the 1FK2103-4AG0x-xDxx.

Figure 6-39. TIA Portal - S210 Drive Selecting Servo Motor

12. Once all the necessary information was entered to commission the S210 drive, the
download to device button can once again be clicked. The following window will show
the relevant information (device name, type, slot, interface type, IP address, and
subnet) entered in previous steps.

Figure 6-40. TIA Portal - S210 Drive Download to Device

13. At this point, under Show all compatible devices menu, the default setting was used
and the Start search button could be pressed.

77
14. With the Accessible device found, we verified the MAC Address, and selected it. The
Load button was activated and could be pressed. The same pop up windows as in the
S7-1500 commissioning, asking for verification to change the IP address for each drive
were displayed.

Figure 6-41. TIA Portal - S210 Drive Loading Configuration

15. The result of the commissioning process can be seen below – the Status of the device
shows its ready condition with an optional prompt to flash the LED of the device for
communication confirmation. The Online access shows the defined user settings that
were saved.

Figure 6-42. TIA Portal - S210 Drive Configuration Completed

78
16. Once the device parameters were downloaded, we could move to commissioning the
servo motors. For this, we used the One Button Tuning. First, we activate One Button
Tuning and we changed the value of the Path limit from 0° to undefined to the value of
360° allowing for a full rotation of the motor.

Figure 6-43. TIA Portal - S-1FK2 Servo Motor One Button Tuning

17. At this point, we were able to press the Start button of the One Button Tuning.

Figure 6-44. TIA Portal - S-1FK2 One Button Tuning Commenced

79
The results of the One Button Tuning can be seen below. Note the Optimization result
displaying data for Proportional gain, Integral Time, etc. The servo motors were ready to be
operated.

Figure 6-45. TIA Portal - S-1FK2 One Button Tuning Results

6.1.4. SCALANCE XB005

To create a network within the trainer bench, the unmanaged switch can be simply interfaced
with all the components and to the Humber local network. As such, the switch does not require
any commissioning, however, it needs to be identified and connected in the topology of the
network of the TIA environment.

80
7. Test Program
With the commissioning complete, the team proceeded to construct a test program with
technology objects and program blocks in order to test the system’s functionality using the S7-
1500, S210 drives and 1FK2 motors.

7.1. Technology Objects

Technology objects (TOs) can be considered as a bridge between how the motors are used and
how the ladder logic perceives and controls them. The following is the procedure that Team 1
performed to have the motors operate, where TOs were added and programmed in ladder
logic.

1. Under the PLC tab in the Project tree, Add new object from the Technology objects tab
(further down the tree). An Add new object window opens with icon choices on the left
with corresponding TOs that can be added to the Project tree. For our project, we used
TO_PositioningAxis to map a physical drive in the controller to have the motor operate
with options of direction, speed and stop positions.

Figure 7-1. TIA Portal - Add New Technology Object

81
2. With a default of linear positioning in Axis type, change to rotary and a pop up prompts
to either keep or change the default parameters.

Figure 7-2. TIA Portal - Portal Technology Object Rotary Selection

Click Yes.

Figure 7-3. TIA Portal - Technology Object Applying Selection

82
3. Once the rotary option was selected, we proceeded to Hardware interface where the
Drive type is defaulted as PROFIdrive and to choose the Drive click the ellipses where
options are given.

Figure 7-4. TIA Portal - Technology Object Drive Selection

4. Choose the appropriate drive that you are trying to connect to. In our case it was Drive
unit_2(RS) as the right side drive.

Figure 7-5. TIA Portal - Technology Object Drive Unit_2

83
The following screenshot displays the complete configuration of the drive. To configure the
other drive, we followed the same steps.

Figure 7-6. TIA Portal - Technology Object Setup Completed

84
7.2. Program Blocks
Program blocks are added from the Project tree under the Program block folder.

1. Once the Add new block is clicked, the window below appears. We named the block
MOTOR_CONTROL . The type was defaulted as Global DB.

Figure 7-7. TIA Portal - Program Block Adding a New Block

2. An Organization block was chosen from the left side icon list which displayed a list of
different types. Program cycle was the one we used for our test. The language was
defaulted as LAD (ladder) and Automatic numbering was left as defaulted. Click OK for
the selected options to take effect.

Figure 7-8. TIA Portal - Program Block Program Cycle

85
3. Next, we added a Data block named LS_Motor1 (for left side motor) to create the
program tags to be used. The same procedure was used for the right side motor and the
Type and Numbering were kept defaulted. Click OK.

Figure 7-9. TIA Portal - Adding a Data Block

4. Tags were created for the left and right side motor. The tags names were identical for
both sides except the pre-fix to differentiate the left from the right side motor.
• ls_mot_en = left side motor enable
• ls_mot_run = left side motor run
• ls_mot_pas = left side motor pause

Figure 7-10. TIA Portal - Data Block Tag Creation

86
7.3. Programming Ladder Logic
At this point, we proceeded to write the ladder logic. In order to do so, we returned to motor
control Organization block options. The screen below depicts the ease of creating a program
with the ladder logic window on the left, tags window in the center, and the instructions
window on the right. With this convenient layout it was easy to add instructions.

Figure 7-11. TIA Portal - Ladder Logic Programming

1. From the right side menu under Instructions and then Technology, in the Motion
Control folder, the MC_Power data block was selected and the name was edited for
distinction between motors.

Figure 7-12. TIA Portal - Adding a Motor Control Data Block

87
 After clicking OK, the block was added to the network it was assigned to.

Figure 7-13. TIA Portal - Motor Control Data Block Added

2. With the block inserted in the network, we could attach the PositioningAxis_2 to the
Axis terminal on the MC_Power block by dragging and dropping the name from the
Project tree. Next, we added an NO contact to the EN (enable) rung serving as a
disconnect to the enable command which was controlled at the HMI.

Figure 7-14. TIA Portal - Addressing the Motor Control Data Block

The same process was performed for the remaining Motion Control blocks for each motor. The
complete ladder logic can be found on the following pages.

88
7.3.1. Ladder Logic

Figure 7-15. TIA Portal - Program Ladder Logic Part 1

89
Figure 7-16. TIA Portal - Program Ladder Logic Part 2

90
7.4. HMI Screens
Following the creation of the ladder logic with its associated tags, the team moved on to create
the HMI screens with corresponding tag assignments.

1. From the Project tree, we opened HMI and the Screens folder within. We then chose
Root screen to start the HMI process.

Figure 7-17. TIA Portal – HMI Root Screen

2. Our next step was to add a Local welcome message. This was achieved by selecting the
text field under the toolbox of the basic object on the right hand side of the workspace.

Figure 7-18. TIA Portal - HMI Root Screen Welcome Message

91
3. Next, we inserted a navigation button to move from the root screen to the Motor
Control Centre. This was done using drag and drop from the Project tree to the HMI
screen.

Figure 7-19. TIA Portal - HMI Motor Control Centre Navigation Button Adding

4. With the root screen complete, we moved on to the Motor Control screen. Again, we
dragged and dropped from the Project tree.

Figure 7-20. TIA Portal - HMI Motor Control Centre Adding Navigation Buttons

92
5. In order to add the Humber logo, we inserted a graphic from Basic objects.

Figure 7-21. TIA Portal - HMI Motor Control Centre Adding Logo

6. We proceeded to added the motor graphics from the Graphics menu on the right side of
the workspace. The Function buttons (F1 to F4) were programmed using the drag and
drop feature.
• F1 = root screen
• F2 = left side motor control
• F3 = right side motor control
• F4 = power

Figure 7-22. TIA Portal - HMI Motor Control Centre Assigning Function Buttons

93
7. The screenshot below depicts the left side motor arrangement with assigned buttons
corresponding to the tags programmed in the ladder logic. The ON/OFF switch and the
Run and Stop buttons were imported from the Toolbox under Elements. As a new
screen, the F buttons had to be re-assigned.

Figure 7-23. TIA Portal - HMI Left Side Motor Screen

8. To assign the ON/OFF switch, double click on the icon and slide the properties window
up. In the General section in the property list, under the Process pane click on the
ellipses in the tag field. A window will open to display a list of tags under HMI tags under
PLC_1. Click on the required tag and click the check mark to assign. In this case, the tag
is LS_Motor1_ls_mot_en.

Figure 7-24. TIA Portal - HMI Left Side Motor Screen On/Off Switch Addressing

94
9. For the Run and Stop buttons, the process is the same. Click on the Run button, with the
properties window slid up, click the Events tab.

Figure 7-25. TIA Portal - HMI Left Side Motor Run Button General Screen

10. In the Events tab, choose the Event style to be used. For our purpose, we used the Press
function. In the area to the right of the Events styles pane, we clicked on the arrow in
the first field to open a menu. From this menu, under System functions under Edit bit
we chose SetBitWhileKeyPressed.

Figure 7-26. TIA Portal – HMI Left Motor Run Button Event Selection

95
11. Once selected, the options for that function were displayed below. From here, we
clicked the pink field.

Figure 7-27. TIA Portal - HMI Left Side Motor Run Tag Selection

12. From the pop up window, under PLC_1 in the Program blocks folder, we found the
corresponding data block and selected the appropriate tag. In this case it was
ls_mot_run tag from LS_Motor(DB4) data block.

Figure 7-28. TIA Portal - HMI Left Side Motor Run Tag Selection from PLC Data Block

96
As depicted below, the left side run button has been assigned. Note that in the tag field the tag
itself is named LS_Motor1_ls_mot_run to reflect the name of the block and tag.

Figure 7-29. TIA Portal - HMI Left Side Motor Run Button Addressing Completed

This process was also used for the left side Stop, right side Run and right side Stop buttons.
However, the appropriate tags were selected for the corresponding functions.

97
7.4.1. Completed HMI Screens

Figure 7-30. TIA Portal - HMI Screens Completed

7.5. Downloading
As a last step, the PLC and HMI hardware/software parameters needed to be compiled and
downloaded into their respective devices.

98
8. Conclusion
The Siemens Servo Trainer Bench project was an all-encompassing endeavour. Starting with a
project kick-off meeting which comprised of an introduction to the scope of the project. After a
brief meeting with the project sponsor, the team was formed and roles were identified for each
member. A plan was created which dissected the project into manageable work packets –
research, design, build, commission, and operate. With the packets identified, the team could
look at the project in manageable phases as opposed to a compound project. Risks were
identified and a mitigation plan was developed.
Following the development of the project plan, research could commence. The research
consisted of component analysis and their characteristic boundaries. These included spatial
considerations for installation, electrical supply and distribution involving wire size, safety
concerns, circuit control and wire management, use and functionality of each component,
network connection requirements.
Moving forward with the project plan, the team progressed into the design phase. Several
design iterations were created and improved upon in conformity to the sponsor and vested
parties’ recommendations. Multiple contentions were addressed regarding space, modularity,
and component relative locations. With the vast majority of the conditions met, the design was
finalized and approved by the project sponsor.
The build phase followed with the frame construction according to the mechanical drawings.
Concomitantly, the acrylic panels were laser cut to the corresponding sizes after which, the
assemblies took place. The assemblies were then dry fitted to test for functionality. Wiring took
place following the assemblies and consisted of all the electrical and communications
connections.
In the operational phase, we used Siemens proprietary software STEP 7 from TIA to commission
the components consisting of discovering the network devices and IP addressing. The team
could then continue with writing a small program to test the components’ functionality.
Throughout the duration of the project, the team accomplished many milestones. Through this
achievement, the team solidified the knowledge gained in the Electrical Engineering Technology
program and developed soft skills within a project team environment. This enabled the team to
produce a tangible deliverable to the project sponsor.

99
9. Appendix A – Layout CAD Drawings

Layout CAD Drawings

100
101
102
103
104
105
106
107
10. Appendix B – Mechanical CAD Drawings

Mechanical CAD Drawings

108
109
110
111
112
113
11. Appendix C – Commissioning Report

Commissioning Report
This Commissioning Report was produced for the team to use as a quick access guide to aid in
the commissioning of the components. All information was sourced directly from the Siemens
manuals. Page numbers are given in the event that during commissioning more information
was necessary to complete the commissioning process.

114
Legend:
Page#

Application to Project

Key Topics

Additional sources

Commissioning the S7-1200 programmable controller

Page# 132:
Ethernet to USB adapter card:
- This adapter is useful if the CPU is not being connected with the help of a LAN cable and
this adapter is also useful when doing the initial tests for the S7-1200 PLC

Page# 170
Watch tables and force tables.
- Watch tables are used when monitoring and modifying the values of a user program
while the S7-1200 PLC is online. We have the option to create different watch tables to
support multiple test environments, this will be useful when reproducing tests during
commissioning or maintenance.
- Force tables are used for "forcing" a tag to a specific value. (more information on page#
689)

Page# 365
Commissioning the PID controller
- We can use the commissioning editor to set up the PID controller to autotune at starting
or in the operation. To open the commissioning editor, click the icon on either the
instruction or the project navigator.
- Enter the sample time and click start
- We can tune the PID loop by going into the tuning mode and selecting either pre tuning
or fine tuning and click the start button. The tuning will happen automatically
- The new parameters will be calculated and can be saved by clicking on upload PID
parameter

115
 - If the output value goes to 0 that means an error has occurred and the PID will go into
inactive mode.

Commissioning the servo controller

Using the commissioning editor
- Configure controller for autotuning at start-up and operation
- To open the commissioning editor,
- click the icon on either the instruction or the project navigator.

Page# 370

116
Page# 372
Using the Commissioning control panel, we can test the functionality of the controller
independently from our user program.

Page# 390
Using the MC_MoveJog instruction we will be able to move the axis constantly at the specified
velocity in jog mode.
- This instruction is typically used for testing and commissioning purposes. In order to use
the MC MoveJog instruction, the axis must first be enabled

117
Page# 407

118
119
 Commissioning the HMI - KTP400 Basics/XB005
The Start Centre opens after the HMI device has been switched on. Use the "Settings" button to
open the settings for parameter assignment of the device
You can make the following settings:
1. Settings for operation
2. Communication settings
3. Password protection
4. Transfer settings
5. Screen saver
6. Acoustic signals

120
Page# 58
Changing the IP address and device name of a controller
1.Touch the "Service & Commissioning" icon.
2.Press the "Assign PLC Address" button. With "Assign PLC Address" you can assign
configuration-independent IP addresses and device names to controllers that are connected to
the HMI device. The address assignment is available only for controllers of type S7-1200 (>
V2.0) and S7-1500. The "IP address is set directly at the device" option must be enabled in the
configuration of the controller.
3.Specify the MAC address of a controller or select automatic search: "MAC Address": Indicate a
specific controller –"Accessible devices in target subnet": Find all accessible controllers in the
subnet of the HMI device.
4.If you have selected automatic search, all controllers that were found are displayed in a list in
the next window. Select a controller from the list.
5.Change the IP address and device name of the selected controller.
6.Use the "Accept" button to confirm. The displayed IP address and device name are assigned
to the controller.

Page# 59
Editing communication connections
1.Touch the "Service & Commissioning" icon.
2.Press the "Edit Connections" button. With "Edit Connections", you overwrite the parameters
of configured controller connections in the current project.
3.A list of how all communication connections to controllers. Select a communication
connection from the list.
4.The configured name and IP address are displayed. You can enter a new IP address.
5.Set the "Override" switch to "ON". The connection parameters will only be overwritten if
"Override" is enabled
6.Use the "Accept" button to confirm. The configured IP address is overwritten.

121
Page# 72
Calibrating the touch screen
1.Touch the "Touch" icon.
2.Press the "Recalibrate" button and then press any spot on the touch screen within the next 15
seconds.
3.Touch the five calibration crosses one after the other. If you have not touched a calibration
cross within the expected range, calibration will start once again. If you have touched all
calibration crosses within the expected range, calibration is complete and will be saved.

Page# 60
Enter time and date
1.Touch the " Date & Time" icon.
2.Press the "Date & Time" button.
3.If you are using a time server (NTP=ON), set a time shift with the selection wheel under "Time
shift", if required. If you are not using a time server (NTP=OFF), set the desired time and the
desired time shift with the selection wheel. The resulting local time is displayed under
"Localtime".

Page# 62
Configuring Auto Start or wait time
You specify in the "System Control/Info" dialog whether the project starts immediately after
the device powers up or after a wait time.
1.Touch the "System Control/Info" icon.
2.Set the "Auto Start" switch to "ON".
3.Set the wait time with the selection wheel under "Wait". The wait time is the time in seconds
between the appearance of the Start Centre and the automatic start of the project. Value
range: 0 ... 60 sec.

122
 Commissioning the Servo Controllers
SIMATIC S7-1500T - CPU 1511T-1 PN

Page# 229

Overview for the S7-1500T controller

Section 1.1 will include:
- Software tools for commissioning.

- Checklist to go through before the first power up of the S7-1500T controller.

- Procedure for commissioning the S7-1500T controller.

- Removing/ inserting the SIMATIC memory card
- First power on of the S7-1500T controller

- Operation modes of the S7-1500T controller

- START UP
- STOP
- RUN
- Operating mode transition

- CPU memory reset

- Automatic
- Manual

123
Page# 230
Software tools for commissioning
We will use the following software tools to help during commissioning:
● SIEMENS PRONETA in commissioning PROFINET systems.
You can find more information on what SIEMENS PRONETA and the SIMATIC Automation Tool is
on (Page 87).

- SIEMENS PRONETA (PROFINET network analysis)

- We will be able to analyse Humber’s network during commissioning. PRONETA features
two core functions:
- The topology overview independently scans PROFINET and all connected
components.
- The IO check is a fast test of the wiring and the module configuration of a plant.

Check before powering on for the first time

Before the first power-on we should...
- Check the installation and the wiring of the S7-1500T automation system/ET
200MP distributed I/O system. (not needed for our application)

Checklist to go through before the first power up

124
125
Page# 231

Procedure for commissioning the S7-1500T automation system

Requirements
● We must make sure that the S7-1500T controller is in the Factory settings state or has
been reset to factory settings. If needed, we can find additional information in the section
Resetting the CPU to factory settings (Page 292).

● The SIMATIC memory card is as delivered or has been formatted

Commissioning procedure

When we first commission the S7-1500T automation system, it's recommend that we go
through this procedure:

126
Page# 232

Requirements: CPU as bus device

The requirements for operation of the S7-1500T controller as bus device:

● PROFIBUS interface – The integrated PROFIBUS interface of the CPU is configured

using STEP 7 (device address and bus parameters configured). – The CPU is connected to the
subnet. – The terminating resistors at the segment boundaries are switched on. You can find
additional information in the PROFIBUS function manual
(http://support.automation.siemens.com/WW/view/en/59193579)

● PROFINET interface – The integrated PROFINET interface of the CPU is configured

using STEP 7 (IP address and device name configured). – The CPU is connected to the subnet.
You can find additional information in the PROFINET function manual
(http://support.automation.siemens.com/WW/view/en/49948856)

Removing/inserting a SIMATIC memory card on the CPU

Requirements
The S7-1500T controller only supports pre-formatted SIMATIC memory cards. If required,
delete all previously stored data before using the SIMATIC memory card. Additional information
about deleting the contents of the SIMATIC memory card can be found in the function manual
Structure and use of the CPU memory
(https://support.industry.siemens.com/cs/ww/en/view/59193101).

When working with the SIMATIC memory card, make sure that the memory card is not write-
protected. For this purpose, slide the slider on the SIMATIC memory card out of the lock
position.

If the inserted memory card is write-protected, the CPU display outputs the symbol in the
menu "Memory card" > "Overview". also, the display shows a message in the lower level of the
menu

127
Page# 233

https://support.industry.siemens.com/cs/ww/en/view/59457183

128
Page# 235

First power-on of the CPU

Requirements:
● An S7-1500 automation system is installed, and the assembly is wired.
● The SIMATIC memory card is inserted in the CPU.

To commission the controller:

We must switch on the system power supply and load current supply.
Result:
● When the controller executes a flash test:
– All LEDs flash at 2 Hz
– RUN/STOP LED flashes alternately yellow/green – ERROR LED flashes red
– MAINT LED flashes yellow

● The CPU runs the system initialization and evaluates

the SIMATIC memory card:
– RUN/STOP LED flashes yellow at 2 Hz

● After the system initialization has been completed,

the CPU goes to STOP mode:
– The RUN/STOP LED lights up yellow

129
 Commissioning the S210 servo drives

Page# 27

Software needed.

The motor, converter, and associated connection cables – are optimally tailored to one another
and thereby facilitate the installation and commissioning in a few steps.

We can perform commissioning and diagnostics with a commissioning device (PG/PC) via the
web server integrated in the converter or using the Startdrive engineering tool.

You can find more information under "Commissioning and diagnostics using the web server
(Page 185)" or under "Commissioning and diagnostics with Startdrive (Page 253)".

Page# 41

Commissioning, diagnostics, and data backup

Commissioning, diagnostics and data backup are performed using a PC

The following commissioning tools are available to us:

• Web server (integrated in the converter): "Commissioning and diagnostics using the web
server (Page 185)"

• Startdrive (commissioning software): "Commissioning and diagnostics with Startdrive (Page

253)"

130
Page# 94

You must enable the function when commissioning in order that SBC can become active.

Page# 98

Set the SS1 response for Safety commissioning in the "Parameterization" step.

131
Page# 181

Commissioning and diagnostics using the web server.

Page# 185

The web server integrated in the S210 converter is particularly suitable for online diagnostics
as well as configuration if a separate engineering tool (e.g. Startdrive) will not be used. If the
configuration is to take place completely in the TIA Portal, the Startdrive engineering tool
integrated in the TIA Portal can be used.

To be able to perform commissioning and diagnostics, you need to physically (LAN cable)
connect your PG/PC to the converter and establish an online connection between your PG/PC
and the web server. As soon as you have connected your PG/PC to the converter and started
the web server, all converter settings are made in the screen forms of the web server. The
settings made are applied directly and transferred to the converter.

132
Page# 186
Access via the service interface X127
The web server is accessed per default via the service interface X127. The service interface has
the following default setting:
• IP address: 169.254.11.22
• Subnet mask: 255.255.0.0
For commissioning or for diagnostics using mobile devices, interface X127 can be temporarily
connected to an external WLAN access point, and an IP address can be sourced via DHCP.

Page# 186

Preparations

1. Install the motor and converter according to the specifications in the section "Installing (Page 147)".
2. Mount the motor on the mechanical system. Connect the motor to the converter.
3. Connect the converter to your commissioning device via the service interface (X127).
4. Switch the converter on. The converter powers up and reads the motor data. 5. Start the browser for
commissioning.
6. Enter the IP address of the converter in the input line of your browser.
Default IP address: 169.254.11.22

133
Page# 188

Page# 191

Assigning the administrator password.

You must log in as administrator to obtain complete access to the converter. A password is required for
access as administrator.
Proceed as follows to assign an administrator password:
1. Switch the converter on.
2. Connect the commissioning device to the service interface (X127) using a LAN cable.

134
3. Call the web server of the converter (standard IP address: 169.254.11.22). The following screen form
is only displayed if an administrator password has still not been assigned.

If, within ten minutes after the line cable was inserted, no password is assigned, then the display
transitions into the login screen. To return to the "Initial Setup" screen form, you must withdraw the
LAN cable from the service interface and reinsert again.

Page# 198

Using the control panel

The control panel is used to control and monitor the drive during the commissioning phase. Apply the
safety measures required when using the control panel. The control panel offers the following functions:
• Checking missing enables
• Testing drive movements or traversing manually
• Monitoring drive movements

You can always call the control panel when you access the web server in the converter with your
commissioning device.
• To call the control panel, click "Control panel" in the footer of the web server. The control panel
is started in monitoring mode.
• To close the control panel again, click the "Control panel" button again in the footer of the web
server or on the X at the top right in the header of the control panel.

135
Page# 200

commissioning step or save all the settings made and the tuning results at the end of the
commissioning.

Page# 201

Requirements for commissioning

• The motor and converter have been installed according to the specifications in the following section.
You can find additional information in section "Installing (Page 147)".
• The mechanical system is mounted onto the motor.
• The converter is connected to the commissioning device via the service interface (X127).
• You have assigned the administrator password. You can find additional information in section "Logging
on for the first time and assigning an administrator password (Page 190)".

136
Page# 202

Page# 203

Assigning the drive name

During converter commissioning you can allocate a specific system name.

Page# 205

Changing the direction of rotation of the motor via the web server Procedure
1. Select "Commissioning > Device properties " in the navigation.
2. Change the direction of rotation in the dialog screen form.
3. Apply the changes.
4. Check the new setting.
5. Save the setting using. You have changed the motor direction of rotation.

137
Page# 206

Performing One Button Tuning

An important part of the basic commissioning is the "One Button Tuning" (OBT). The converter closed-
loop control is optimally set using the One Button Tuning

Procedure
1. Select "Commissioning > Tuning" in the navigation. Figure 6-11 View before performing the One
Button Tuning
2. Click "Take Control". Confirm the safety prompt. The master control is indicated by a broken orange
bar.
3. Select the desired dynamic response setting for the One Button Tuning corresponding to the
mechanical system of your machine. One Button Tuning optimizes the drive based on the selected
dynamic response setting. – "Conservative": 60 % speed control dynamic performance without pre-
control – "Standard": 80 % speed control dynamic performance with torque pre-control – "Dynamic":
100 % speed control dynamic performance with fast torque pre-control You can activate the higher
dynamic performance if your machine satisfies the conditions listed under "Machine property".
4. Click "Start Tuning...". A prompt for the permissible angle of rotation (rotation limit) of the motor
shaft appears. Figure 6-12 Rotation limit
5. Enter the angle through which the motor and the connected machine are permitted to turn for the
required measurements (e.g. 360 °) without the mechanical system being damaged. Useful controller
parameters result from an angle greater than 90 °.
6. Click "OK". Tuning through One Button Tuning starts. No entries are possible during the tuning. After
the tuning has been completed, a message appears as to whether the "One Button Tuning" was
successful - or not. If the OBT was not successful, then optimization must be repeated, possibly with
modified entries.
7. After you have optimized the controller, you must relinquish master control to the converter. Click
"Return control".
8. Confirm the confirmation prompt with “Confirm”. The color bar is no longer displayed.
9. Click to save the data permanently. You have now performed One Button Tuning

138
Page #220

Commissioning steps

• Safety settings are carried out step-by-step in the individual screen forms. A green checkmark
indicates that a commissioning step has been completed. Entries mandatory
• The commissioning steps marked with a checkmark do not require any entries. Entries are mandatory
for the commissioning steps marked with a red pen. Safety Integrated password
• A Safety Integrated password can be defined to protect against unauthorized changes to Safety
settings. This can either be done at the beginning or at the end of the Safety commissioning.
• The drive issues an alarm if a password has not been defined.

Commissioning and diagnostics with Startdrive

Page# 255

Commissioning sequence
The following steps are involved in commissioning a drive configuration consisting of a SIMATIC S7
controller and a SINAMICS S210 drive:
1. Inserting a SIMATIC S7 controller into the project (Page 263)
2. Inserting a SINAMICS S210 converter into the project (Page 265)
3. Networking a SIMATIC S7 controller and S210 drive (Page 267)
4. Inserting a technology object into the SIMATIC S7 controller (Page 269)
5. Interconnecting the technology object and S210 drive (Page 271)
6. Configuring a SINAMICS S210 drive (Page 273)
– Basic parameter assignment of the S210 drive and motor selection (Page 273)
– Checking the pre-assignment of the digital inputs (Page 275)
– Activating the Safety Integrated (Page 277)
7. Commissioning the S210 drive (Page 277)
8. Commissioning Safety Integrated (Page 282)
9. Using diagnostics functions (Page 299)

139
Page# 260

Supported firmware versions.

The Startdrive commissioning tool in version 15.1 or higher integrated in the TIA Portal only supports
S210 drives with firmware version 5.2 or higher.

Page# 263

Commissioning with a SIMATIC S7-1500

To commission an S210 drive with a SIMATIC S7 controller, you need to follow the instructions described
in this section 7.2.
1) Inserting a SIMATIC S7 controller into the project (page# 263)
2) Inserting a SINAMICS S210 converter into the project (page# 265)
3) Networking a SIMATIC S7 controller and S210 drive (page# 267)
4) Inserting a technology object into the SIMATIC S7 controller (page# 269)
5) Interconnecting the technology object and S210 drive (page# 271)
6) Configuring a SINAMICS S210 drive (page# 273)
7) Commissioning the S210 drive (page# 277)

Page# 282

Offline commissioning

Page# 313

Series commissioning

If we need to transfer the same settings to multiple machines, you have the option of carrying out series
commissioning.

140
12. References
12.1. Siemens Manuals

AG, S. (01/2019). Basic Panels 2nd Generation Operating Instructions (A5E33293231-AC ed.).
AG, S. (06/2020). SINAMICS S210 servo drive system Operating Instructions (A5E41702836B AE
ed.).
AG, S. (08/2016). SITOP PSU100L Manual (C98130-A7603-A1-2-7629 ed.).
AG, S. (12/2017). CPU 1511T-1 PN (6ES7511-1TK01-0AB0) Manual (A5E36270833-AB ed.).
AG, S. (12/2018). SCALANCE XB-000 Operating Instructions (A2B00077300-10 ed.).
AG, S. (12/2019). SIMOTICS Drive technology 1FK2 synchronous motors for SINAMICS S210
(A5E46927724B AC ed.).
AG, S. (n.d.). S7-1200 Programmable controller System Manual (A5E02486680-06 ed., 04/2012).

141
13. Notes

142