Simulating TIA Portal Startdrive Drives in SIMIT via HWCNExport Hardware Configuration Files

In Siemens SIMIT simulation software (V10.1 / V10.2 / V11), drives configured natively in TIA Portal using SINAMICS Startdrive (such as SINAMICS S120 or G120) cannot have their PROFIdrive telegram addresses (Control Word STW, Status Word ZSW) imported via standard 'Couplings -> TIA Portal Projects'. To import Startdrive telegram signals into SIMIT: install the free Siemens export add-in 'HWCNExport' in TIA Portal, execute the hardware configuration export to generate an XML file, and in SIMIT, import the signals using 'Couplings -> HWCNExport file'. SIMIT then automatically generates all drive control words, status words, speed setpoints, and torque limits in the signal table, which can be connected to the SIMIT DRIVES Component Library.

Executive Summary

Creating high-fidelity Virtual Twins of automated process machinery requires coupling the simulation platform (Siemens SIMIT) with PLC logic and drive subsystems. When integrating SINAMICS variable frequency drives (VFDs) configured via TIA Portal Startdrive, automation engineers encounter a major coupling hurdle: while drives configured via legacy GSD/GSDML files import their telegram signals automatically, native Startdrive objects fail to export their cyclic I/O addresses through standard TIA Portal project couplings. This article provides the definitive solution using the Siemens HWCNExport utility and explains how to model PROFIdrive telegrams in SIMIT.

Architecture and Fundamental Mechanics

In Siemens industrial automation, drive communication is governed by the PROFIdrive profile over PROFINET IO or PROFIBUS DP. Cyclic communication is structured into standardized telegrams (e.g., Standard Telegram 1, Siemens Telegram 20, Telegram 352):
- Master to Drive: Control Word 1 (STW1), Speed Setpoint (NSOLL_A), Torque Limits.
- Drive to Master: Status Word 1 (ZSW1), Actual Speed (NIST_A), Fault Codes.

When a drive is integrated into TIA Portal using a generic GSD/GSDML file, its telegrams are treated as standard peripheral I/O addresses (PIW/PQW), which standard SIMIT couplings parse directly from symbol tables. However, when drives are engineered natively using TIA Portal Startdrive, the drive parameters and telegram slots are encapsulated within proprietary technological object models that standard SIMIT TIA couplings cannot decode.

To bridge this architectural gap, Siemens developed the HWCNExport Tool (Hardware Configuration Export for TIA Portal):
1. HWCNExport executes as a TIA Portal Openness add-in or standalone utility. It interrogates the complete hardware configuration, resolves internal Startdrive telegram structures, and maps all input/output offsets into a standardized XML format (HWCNExport.xml).
2. SIMIT features a dedicated 'HWCNExport file' coupling engine. It parses the XML data, instantly instantiating the entire drive I/O signal tree (e.g., Drive_1_STW1, Drive_1_ZSW1, Drive_1_Speed).
3. The signals are then connected to standard drive simulation macro blocks from the SIMIT DRIVES Library (SIOS 109761007), which simulate motor ramp times, inertia, and operating state machines.

Step-by-Step Implementation Procedure

Install and Configure HWCNExport in TIA Portal:
a. Download the HWCNExport tool package from Siemens Industry Online Support (SIOS entry 109770995).
b. Extract the tool on the engineering PC hosting TIA Portal.
c. Open the TIA Portal project containing the configured S7-1500 / S7-400 CPU and native Startdrive SINAMICS S120/G120 drives.
Export Hardware Configuration to XML:
a. In TIA Portal, ensure the hardware configuration is completely saved and compiled with zero errors.
b. Launch the HWCNExport utility and select the target TIA Portal project.
c. Select the specific PLC station and click 'Export'.
d. Save the generated XML file (e.g., Plant_HWCNExport.xml) to a shared directory.
Create HWCNExport Coupling in SIMIT:
a. Launch SIMIT (V10.1 or higher) and open the target simulation project.
b. In the SIMIT project navigation tree, double-click 'Couplings'.
c. Click 'New coupling' and select 'HWCNExport file' from the list of coupling types.
d. Click 'Browse' and select the Plant_HWCNExport.xml file generated in Step 2.
e. Click 'Import'. SIMIT parses the XML and populates the signal list with all drive inputs and outputs.
Model Drive Dynamics Using SIMIT DRIVES Library:
a. Download and open the 'SIMIT DRIVES Component Library' (SIOS 109761007).
b. Drag the matching telegram component (e.g., PROFIdrive_Telegram_1 or Telegram_352) onto the SIMIT simulation chart.
c. Connect the drive control signals from the HWCNExport coupling (STW1, NSOLL) to the block inputs.
d. Connect the block outputs (ZSW1, NIST) back to the PLC input coupling signals.
e. Configure motor acceleration times, mechanical load inertia, and feedback parameters.
Run Integrated Simulation:
a. Start S7-PLCSIM Advanced (or SIMIT Virtual Controller).
b. Activate simulation in SIMIT.
c. From the PLC or HMI, send a start command: observe that STW1 activates the drive model, the drive responds with ZSW1 (Operation Enabled), and speed ramps up smoothly.

Verification

In SIMIT, open the signal table: verify that all Startdrive drives are listed with their exact telegram symbolic names and byte addresses.
In TIA Portal, monitor the drive cyclic control word online: verify that toggling bits in SIMIT reflects immediately in the PLC telegram inputs.
Trigger a simulated fault on the SIMIT drive block: verify that ZSW1 asserts the fault bit and the PLC program executes its drive fault handling routine.
Confirm that motor speed feedback in SIMIT matches the scaling of the configured PROFIdrive telegram (e.g., 4000 hex = 100% rated speed).

Limitations and Operational Precautions

The HWCNExport file coupling must be re-exported and re-imported whenever drive hardware addresses or telegram types are modified in TIA Portal. HWCNExport captures cyclic telegram data but does not simulate acyclic communication (PKW / parameter channel) unless paired with SIMIT Virtual Controller acyclic communication extensions. Software licenses for SIMIT and PLCSIM Advanced should be confirmed with an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Why doesn't the standard TIA Portal project coupling import Startdrive telegrams?

The standard coupling only extracts standard PLC tag tables and symbols; Startdrive telegram addresses are encapsulated inside technological drive objects that require HWCNExport parsing.

Where can I download the HWCNExport utility?

From Siemens Industry Online Support (SIOS) under entry ID 109770995.

What is the SIMIT DRIVES Component Library?

A pre-built library of simulation blocks (SIOS 109761007) that emulate standard PROFIdrive telegram behavior, speed setpoint scaling, and ramp functions in SIMIT.

Does SIMIT require an extra license to use the HWCNExport coupling?

No. The HWCNExport coupling is a standard feature included with SIMIT Standard, Professional, and Ultimate editions.

Can I use this procedure for third-party drives configured via GSD?

Drives configured via generic GSD/GSDML files can be imported directly via standard TIA Portal couplings; HWCNExport is specifically required for native Startdrive and complex distributed I/O.