Page 1 Alarm and message texts Axis and Spindle Test Run Drive Optimization with HMI Advanced User data backup/Series Valid for commissioning SINUMERIK 840Di sl/840DiE sl control Software installation/update and data backup Software Version System software for 840Di sl/DiE sl License management...
Page 2 Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Page 3: Foreword
SINUMERIK 840Di sl system. This manual describes the control system design and the interfaces of the individual components. The commissioning procedure for SINUMERIK 840Di sl (NCK, PLC and drives) is also described. For detailed information about individual functions, function assignment and performance data of individual components, please refer to the appropriate document for the subject concerned (e.g.
Page 4 +1 423 262 2522 +1 423 262 2200 Email mailto:techsupport.sea@siemens.com Asia/Pacific Phone +86 1064 719 990 +86 1064 747 474 Email mailto:adsupport.asia@siemens.com Note Country-specific telephone numbers for technical support are provided under the following Internet address: Enter http://www.siemens.com/automation/service&support Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 5 Products and systems > Automation systems > CNC SINUMERIK > SINUMERIK 840Di sl The link-box (vertical link-bar on the right) "Everything about SINUMERIK 840Di sl" gives you direct access to all important product information. EC Declaration of Conformity...
Page 6 Repairs to devices that have been supplied by our company may only be carried out by SIEMENS customer service or by repair centers authorized by SIEMENS. When replacing parts or components, only use those parts that are included in the spare parts list.
Page 7: Table Of Contents
Table of contents Foreword ..............................3 General Information on the SINUMERIK 840Di sl..................17 Overview of SINUMERIK 840Di sl ....................17 1.1.1 System components ........................18 1.1.2 System software packages and quantity structures ..............18 1.1.3 Hardware Components ........................19 1.1.4 Software components ........................21 1.1.5...
Page 8 Table of contents 2.9.1 Floppy disk drive 3.5" (USB) ....................... 83 2.10 Power supply..........................85 2.10.1 SITOP POWER standard 24V/10A..................... 85 2.11 Uninterrupted power supply (UPS) ..................... 87 2.11.1 SITOP POWER DC UPS MODULE 15..................87 2.11.2 SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH............. 89 2.12 PP72/48 I/O module........................
Page 9 Table of contents 5.3.8 Power-up with shutdown signal ....................133 Service Desktop .........................135 5.4.1 Activating............................135 5.4.2 SINUMERIK-specific applications....................136 5.4.3 Setting the boot response for the Service Desktop ..............138 5.4.4 System information after "Fatal exception error" ...............138 5.4.5 Starting OEM programs ......................138 5.4.6 User-specific HMI startup images ....................139 5.4.7...
Page 10 Determine Ethernet communication partners of the PCU............188 7.1.3 Check Ethernet connection ....................... 188 SINUMERIK 840Di sl commissioning tool SinuCom NC ............188 STARTER SINAMICS drive commissioning tool ..............189 External HMI Advanced ......................189 MCP 483C IE ..........................191 7.5.1...
Page 11 Table of contents Requirements..........................235 Creating a PROFIBUS configuration ..................239 8.3.1 Requirement..........................239 8.3.2 Inserting DP slaves ........................240 8.3.3 Parameterizing the equidistant DP-Slaves finally ..............242 8.3.4 Generating system data blocks (SDB)..................248 8.3.5 Load the configuration in the PLC .....................249 8.3.6 PROFIBUS diagnosis ........................249 SIMATIC I/O devices (ET200...) ....................249 DP slave I/O Module PP72/48 ....................250 8.5.1...
Page 12 Table of contents ONLINE commissioning ......................309 9.2.1 Create new project without Project Wizard ................310 9.2.2 Create new project with Project Wizard ..................313 9.2.3 Drive unit: Enter component topology and configuration automatically........316 9.2.4 Drive: Configuring motors and encoders .................. 318 9.2.5 Control Unit: Selecting the PROFIBUS meassage frame............
Page 13 Table of contents 11.3.4 Loading default machine data....................371 11.3.5 Switching over the measuring system ..................372 11.3.6 Traversing ranges ........................374 11.3.7 Positioning accuracy of the control system................374 11.3.8 Cycle times..........................375 11.3.9 Velocities............................379 11.4 Memory configuration ........................381 11.4.1 DRAM memory...........................382 11.4.2 SRAM memory...........................383 11.5 Axes and spindles........................385 11.5.1...
Page 14 Table of contents 11.8.3 Software version of a compile cycle..................481 11.8.4 Constraints ..........................481 11.8.5 Activating and licensing technology functions................482 11.8.6 Data descriptions (MD) ......................483 11.9 PROFIBUS DP.......................... 484 11.9.1 Setting the parameters for the shut-down behavior..............484 11.9.2 Data descriptions (MD) ......................
Page 15 Software installation/update (Windows)..................559 16.4 Restoring the as-delivered state ....................560 16.4.1 Requirements..........................560 16.4.2 Restoring the partitions ......................561 16.4.3 Installation of the SINUMERIK 840Di sl applications..............561 License management ..........................563 17.1 Basic principles ..........................563 17.1.1 Important terms ..........................563 17.1.2 Overview ............................564 17.1.3 Web License Manager .......................565...
Page 16 Expanded message frame configuration/evaluation of internal drive variables......589 18.2.1 Description of functions......................589 18.2.2 Requirements..........................591 18.2.3 Project design: SINAMICS S120 and SIEMENS message frame 116 ........592 18.2.4 Project design: SINAMICS S120 and expanded message frame configuration....... 592 18.2.5 Project design: SIMODRIVE ..................... 595 18.2.6 Constraints ..........................
Page 17: General Information On The Sinumerik 840Di Sl
General Information on the SINUMERIK 840Di sl Overview of SINUMERIK 840Di sl With the SINUMERIK 840Di sl, Siemens provides a complete PC-integrated control that controls the drive units and I/Os through the standard fieldbus PROFIBUS DP with Motion Control functionality and in this way permits a distributed design of the overall system. It...
Page 18: System Components
It is not possible to combine the named system components with older versions. 1.1.2 System software packages and quantity structures System software packages The following system software packages are available for SINUMERIK 840Di sl: ● 6 axes system software ● 20 axes system software Quantity framework...
Page 19: Hardware Components
PROFIBUS DP with motion control capability (clocked and isochronous data exchange between the DP master and DP slaves) to the SINUMERIK 840Di sl. Both the PLC and the NC have direct access to this PROFIBUS interface.
Page 20 PLC. As a result, no drives and no NC I/Os can be operated via this interface. The interface (X102) can also be operated as an MPI interface. However, using the MPI- communication with SINUMERIK 840Di sl with the present version is no longer recommended.
Page 21: Software Components
● The NCK is automatically started when Windows powers up. ● The NCK runs cyclically in the background. ● The current status of the NCK is displayed via the SINUMERIK 840Di sl-standard operator panel 840Di-Startup: Menu command Window > Diagnosis > NC/PLC ●...
Page 22: License Management
SINUMERIK 840Di sl. 840Di startup is part of the scope of supply of a SINUMERIK 840Di sl and is already installed on the hard disk of the PCU.
Page 23: Real-Time Properties
General Information on the SINUMERIK 840Di sl 1.1 Overview of SINUMERIK 840Di sl 1.1.5 Real-time properties Windows XP is not an operating system designed for hard real-time requirements. Hard real- time requirements mean the operating system will respond to an external event within a defined time frame of a few µ...
Page 24: System Integrity
For this purpose, the system components used are subject to a certification procedure with Siemens as the system manufacturer. The certification process establishes and documents the real-time features of the entire configuration. If PC components (hardware or software) are modified or expanded by a third party, compliance with product features cannot be guaranteed.
Page 25: Failure Safety
General Information on the SINUMERIK 840Di sl 1.1 Overview of SINUMERIK 840Di sl 1.1.7 Failure safety Critical exception error (blue screen) If Windows XP detects a fatal exception error during the operation of the NC system software, the following steps are taken: ●...
Page 26 ● The NC and PLC user data are saved in the SRAM of the MCI board. The battery-backed user data are available again immediately the next time the SINUMERIK 840Di sl is booted. The SINUMERIK 840Di sl is therefore ready to use again immediately, without data loss.
Page 27: Switch Off
SINUMERIK 840Di sl. 1.1.8 Switch off Windows XP To ensure safe operation of the SINUMERIK 840Di sl, Windows XP must be shut down correctly before the PCU is switched off. Note Windows XP is shut down correctly as follows. • Windows XP Start menu: Start > end •...
Page 28 On correct shutdown of Windows XP the following occurs: ● The SINUMERIK 840Di sl components NC and PLC are terminated correctly ● The NC and PLC user data in the SRAM of the MCI board and on the hard disk of the PCU are backed up.
Page 29: Ups System
PLC user program is not active. Prerequisites: MCI board extension (option) Note: For 3) For information on the boot response of the SINUMERIK 840Di sl with pending shutdown signal see Subsection "Power-up with shutdown signal" (Page 133). Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 30 ● When using SITOP POWER DC UPS MODULE 15 (see Section "Uninterrupted Power Supply UPS" (Page 87)) with a special software tool. Download: http://www.siemens.de/sitop > Further topics: Download Software DC UPS 15 ● With Windows XP standard tools. Start menu: Start > Settings > Control Panel > Power Options > Tab: UPS...
Page 31: Overview Of Software Components
1.2 Overview of software components Overview of software components The software components listed below are part of the SINUMERIK 840Di sl system software. The first time the PCU is booted, all the software components required to operate the SINUMERIK 840Disl are automatically installed. Other software components including engineering tools or SIMATIC S7 add-on software are also available for installation on the PCU or an external computer.
Page 32 – SIMODRIVE POSMO SI, CD/CA Drive firmware (Firmware file: <Installation path>\611utb\SysPosmo\<version>\posmo.ufw) Note SINAMICS drives The drive commissioning tool: STARTER is not included in the SINUMERIK 840Di sl scope of supply. The STARTER must be purchased separately. It is recommended that you always use latest version. References: Catalog: NC 61 >...
Page 33 ● PLC Toolbox The PLC Toolbox contains the following components: – PLC basic program – SINUMERIK Add-On for STEP 7 e.g. SlaveOM for SINUMERIK 840Di sl, GSD file for PROFIBUS-MCP – NC variable selector – PLC Symbol generator (installation software: <CD-path>\installs\add_on\plc_tb\setup.exe) ●...
Page 34: Notes On Startup
● SIMODRIVE drive commissioning – SimoCom U Additional software For commissioning the following software is required (not part of a SINUMERIK 840Di sl): ● PLC commissioning, including PROFIBUS DP communication: – SIMATIC Manager STEP 7: as from Version 5.3, Service Pack 2 –...
Page 35 Note No programming device is required in the following cases: • SIMATIC Manager STEP7 is installed on the SINUMERIK 840Di sl PCU • A PG/PC is needed for installing additional software For installing the software on the PCU see Section "License management"...
Page 36: Standard/Export Version
Because certain control functions require an export license in accordance with the German Export List, the SINUMERIK 840Di sl is available in two versions. The Standardversion SINUMERIK 840Di sl can contain the full functional scope of the control, but is subject to the export license requirement owing to its type.
Page 37 General Information on the SINUMERIK 840Di sl 1.4 Standard/export version Identification of the control In addition to the information provided on the delivery note and invoice, the hardware components supplied with the system software are also clearly identified by adhesive labels as standard or export versions.
Page 38: 840Di Startup
1.5 840Di startup 840Di startup The user interface 840Di startup included in the scope of supply of the SINUMERIK 840Disl is intended as an initial introduction to SINUMERIK 840Di sl functionality. Overview of functions The user interface comprises the following functions: ●...
Page 39: Menu Command: Windows
General Information on the SINUMERIK 840Di sl 1.5 840Di startup 1.5.1 Menu command: Windows The menu command Window provides the following functions: Menu command Functionality Windows Main screen General data Display of: Channel status • Program status • Axis actual values...
Page 40 General Information on the SINUMERIK 840Di sl 1.5 840Di startup Menu command Functionality Management of part programs Part programs • – Menu command File New ... Open Delete – Menu command Edit Copy Paste Load Unload Select Editing part programs: •...
Page 41 General Information on the SINUMERIK 840Di sl 1.5 840Di startup Menu command Functionality Slaves Display of: Slave no. (DP address) • Assignment • Active on the bus • Synchr. with NC • Number of slots • Details • NC/PLC •...
Page 42 General Information on the SINUMERIK 840Di sl 1.5 840Di startup Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 43: Hardware Descriptions
Voltage supply 24 V Order number: 6FC5 220-0AA33-2AA0 Spare parts The following hardware components are available as spare parts: ● MCI2 Board for SINUMERIK 840Di sl Spare-part order number: 6FC5 222-0AA02-2AA0 ● Hard disk drive For PCU 50.3 with support plate and damper...
Page 44 Hardware Descriptions 2.1 Overview of hardware components MCI board extension ● SINUMERIK 840Di sl MCI Board Extension, Slot Version Order number: 6FC5 222-0AA00-0AA1 Operation and display ● SINUMERIK operator panel fronts – OP 010 Order number: 6FC5 203-0AF00-0AA1 – OP 010C Order number: 6FC5 203-0AF01-0AA0 –...
Page 45 Hardware Descriptions 2.1 Overview of hardware components External storage media ● USB-diskette drive 3.5'' including 1m connection cable Order number: 6FC5 235-0AA05-1AA2 Power supply of the PCU ● SITOP POWER standard 24V/10A Order number: 6EP1 334-1SH01 Uninterruptible power supply ● SITOP POWER DC UPS module 15 Order number: 6EP1 931-2EC31 ●...
Page 46 Hardware Descriptions 2.1 Overview of hardware components SIMODRIVE drives ● SIMODRIVE 611 universal with options module Motion Control with PROFIBUS DP ● SIMODRIVE 611 universal E with options module Motion Control with PROFIBUS DP ● SIMODRIVE POSMO CD/CA ● SIMODRIVE POSMO SI ●...
Page 47: Mci2 Board For 840Di Sl
Hardware Descriptions 2.2 MCI2 board for 840Di sl MCI2 board for 840Di sl 2.2.1 Assembly The MCI2 board for 840Di sl is a short 32-bit PCI plug&play card. The MCI2 board referred to below simply as MCI board (Motion Control Interface) provides the following interfaces: ●...
Page 48: Interface Description
Hardware Descriptions 2.2 MCI2 board for 840Di sl Order number: MCI2 board Description Order number (MLFB) MCI2 board for 840Di sl (as spare part) 6FC5 222-0AA02-2AA0 Order number: Bus connector Description Order number (MLFB) Bus connector RS-485 for PROFIBUS DP and MPI 180°−Cable outlet 6GK1 500-0EA02 35°−cable outlet, without PG-connection box...
Page 49 Hardware Descriptions 2.2 MCI2 board for 840Di sl PROFIBUS DP interface (X101) Interface description PROFIBUS DP interface (X101): ● Connection: 9-pin sub D socket ● Pin assignment Table 2-2 Pin assignment: PROFIBUS DP interface (X101) Description Type 1) Function Unassigned Unassigned RS-DP RS 485 differential signals...
Page 50: Replace Module
Hardware Descriptions 2.2 MCI2 board for 840Di sl NOTICE The PROFIBUS DP (X101) and MPI/DP bus (X102) interfaces are isolated both from one another and from the PCU. Backup voltage connection (X3) Interface description of the backup voltage connection (X3): ●...
Page 51 Hardware Descriptions 2.2 MCI2 board for 840Di sl Figure 2-2 MCI2 board: HW series number For instructions on how to enter the license key, see Section "License management" (Page 146). Note If the MCI board is to be inserted as a replacement (either only the MCI board or together with the PCU), you will need a new license key.
Page 52 For information on how to create a series startup file, please refer to Chapter "User-data backup/series startup" (Page 541). 2. Shutdown SINUMERIK 840Di sl or Windows XP properly. To do this, use one of the following options: – Windows taskbar: Start > Shut Down.
Page 53 Hardware Descriptions 2.2 MCI2 board for 840Di sl 5. Optional: Remove interconnecting cable to the MCI board extension module, interface X2. 6. Remove the fastening screw (see Fig. below) and remove the module holding-down device. Figure 2-4 Mounting of the module 7.
Page 54: Technical Data
Hardware Descriptions 2.2 MCI2 board for 840Di sl 13. Close the housing of your PC and fasten the screws from the cover of the housing (see third Fig.). 14. Reconnect the power supply and start the computer. 2.2.4 Technical data Safety Degree of protection IP 00...
Page 55 Hardware Descriptions 2.2 MCI2 board for 840Di sl Note The specified safety regulations, certifications, degree of protection and safety class only apply if the module is plugged into a SINUMERIK PCU 50.3. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 56: Mci Board Extension Slot Variation
Hardware Descriptions 2.3 MCI board extension slot variation MCI board extension slot variation 2.3.1 Assembly Functions The MCI board extension slot variant provides the following functions as an optional expansion board of the MCI board: ● 4 binary inputs (isolated) ●...
Page 57 Hardware Descriptions 2.3 MCI board extension slot variation Order Number Description Order number (MLFB) MCI board extension slot variation (option) 6FC5 222-0AA00-0AA1 CAUTION The plugging-in or disconnection of the cable distributor to or from the interface X121 of the module, many be done only in the de-energized state. Before you plug in or remove the cable distributor, switch off the PCU (shut down Windows XP correctly!).
Page 58: Installation Instructions
Hardware Descriptions 2.3 MCI board extension slot variation NOTICE You select between differential and TTL handwheels on the module using switch S1 before installing the module. 2.3.2 Installation instructions The connecting cable with the MCI board is part of the scope of supply and is already plugged into the MCI board extension slot variation.
Page 59 Hardware Descriptions 2.3 MCI board extension slot variation 1. Shutdown SINUMERIK 840Di sl or Windows XP properly. To do this, use one of the following options: – Windows taskbar: Start > Shut Down. – Interface signal: "PC shutdown", see Section "840Di sl-specific interface signals"...
Page 60: Interface Description
Hardware Descriptions 2.3 MCI board extension slot variation 5. Remove the blanking plate of the free PCI slot. 6. Insert the module carefully but firmly into the PCI slot and tighten the connector plate of the module. 7. Plug the connector of the connecting cable into the MCI board. Make sure that the latches of the connectors have securely engaged on both modules: –...
Page 61 Hardware Descriptions 2.3 MCI board extension slot variation Description Type Function MPG1_XA Input 2nd handwheel, track A inverted Optional 5 V handwheel power supply Optional 5 V handwheel power supply MPG1_XB Input 2nd handwheel, track B inverted MPG0_XA Input 1st handwheel, track A inverted Optional 5 V handwheel power supply Optional 5 V handwheel power supply MPG0_XB...
Page 62 Hardware Descriptions 2.3 MCI board extension slot variation Description Type Function Digital inputs Electrical data of the digital input interface: ● Isolated from the board electronics ● Common ground (GNDEXT) Digital outputs Electrical data of the digital output interface: ● Isolated from the board electronics ●...
Page 63: Technical Data
Hardware Descriptions 2.3 MCI board extension slot variation TTL handwheels Electrical data of the TTL handwheel interface: ● Connected to the board electronics ● Signals used: – MPGx_A – MPGx_B – M NOTICE The optional power supply of the handwheels (P5) is electronically protected with 2 A.
Page 64 Hardware Descriptions 2.3 MCI board extension slot variation Climatic environmental conditions Heat dissipation Open-circuit-ventilated operation Storage/transport Temperature limits 5 ... 55°C -40 ... 70°C Tested according to DIN IEC 68-2-1, DIN IEC 68-2-2 (DIN EN 60068-2-2), DIN IEC 68-2-14 Limits for relative humidity 5 ...
Page 65: Cable Distributor
Hardware Descriptions 2.4 Cable distributor Cable distributor Order Number Description Order number (MLFB) Cable distributor 6FX2 006-1BA02 Cable connection The cable distributor consists of a connector jacket for a 37-pin Sub-D connector with enlarged interior. The cable distributor is used to split the I/O-MPG-extension interface (X121) to a maximum of 7 single cables.
Page 66 Hardware Descriptions 2.4 Cable distributor Insert the appropriate individual cable in the opened cable distributor at the associated connector X1 to X10. Place the cable in the appropriate cable guide. Make sure that the shield jackets that became free have a large conductive connection to the metallic contact areas of the cable distributor.
Page 67 Hardware Descriptions 2.4 Cable distributor Connector assignments Table 2-9 Assignment of connector Connector No. Cable No. 1 (top) 1. Handwheel 2. Handwheel 2. Probe 4 binary inputs 4 binary outputs Supply for 4 binary outputs 7 (bottom) 1. Probe NOTICE When assembling the cable distributor, make absolutely sure that the supplied insulating washer is installed correctly and the coding pins are installed.
Page 68 Hardware Descriptions 2.4 Cable distributor Pin assignments Connector designation: X1...X10 Plug-connector type: DU-BOX-plug connectors Table 2-10 Pin assignment of cable distributor Pin-No. Signal name DU-BOX- Cable Cable order No. Wire color I/O device Terminal plug 37-pin 6FX2002-4AA..plug Pin. No./ X10/2 41-0❑❑❑...
Page 69 Hardware Descriptions 2.4 Cable distributor Pin-No. Signal name DU-BOX- Cable Cable order No. Wire color I/O device Terminal plug 37-pin 6FX2002-4AA..plug Pin. No./ MPG1 XA X4/2 21-0❑❑❑ 2. Handwheel MPG1 A X4/1 MPG1 5V X4/4 6FC9320-5DB MPG1 0V X4/3 MPG1 5V X3/2 green...
Page 70 Hardware Descriptions 2.4 Cable distributor Colors: rt: Red or: Orange br: Brown bk: Black gn: Green ye: Yellow vt: Violet bu: Blue Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 71: Sinumerik Industrial Pc
Hardware Descriptions 2.5 SINUMERIK Industrial PC SINUMERIK Industrial PC 2.5.1 SINUMERIK PCU 50.3 Figure 2-13 PCU 50.3: Perspective view with installed hard disk drive Order Number PCU as spare part with MCI board Description Order number (MLFB) with Windows XP ProEmbSys and MCI board: PCU 50.3-C/1.5 GHz, 512 MB SDRAM 6FC5 220-0AA31-2AA0 PCU 50.3-P/2.0 GHz, 1024 MB SDRAM...
Page 72 2.5 SINUMERIK Industrial PC Features The SINUMERIK industrial PC "PCU 50.3" provides, together with the MCI board, the basis for the SINUMERIK 840Di sl. The PCU 50.3 has the following important features: ● Variants: – Celeron M, 1.5 GHz, 512 MB SDRAM –...
Page 73 Hardware Descriptions 2.5 SINUMERIK Industrial PC Replacing a device When installing spare parts please note the following: ● When replacing the PCU, remove the mounting brackets (MLFB 6FC5 248-0AF20-2AA0) from the defective PCU and attach to the replacement part. References: For the complete documentation on the PCU 50.3, please refer to: /BH/ Operator components Manual, Component PCU 50.3 Technical data...
Page 74 Hardware Descriptions 2.5 SINUMERIK Industrial PC Condensation, spraying water and Not permissible icing supply air Without caustic gases, dusts and oils operation Storage/transport (in transport packaging) Applicable standards DIN IEC 60068-2-1 DIN IEC 60068-2-2 / -2-14 Climate class 1K3 / 2K4 Temperature limits ): 5 ...
Page 75: Sinumerik Operator Panel Fronts
Hardware Descriptions 2.6 SINUMERIK operator panel fronts SINUMERIK operator panel fronts SINUMERIK operator panel fronts can be connected to the PCU either centrally, i.e. directly via LVDS or USB interfaces, or decentrally with TCU (Thin Client Unit) via Ethernet. In the following section, the OP 012 operator front is described as an example in detail. 2.6.1 Operator panel front OP 012 Figure 2-14...
Page 76 Hardware Descriptions 2.6 SINUMERIK operator panel fronts Features The OP 012 operator front provides the following features: ● 12.1" TFT flat screen (color) with resolution 800 x 600 pixels ● Membrane keyboard with alphabetic, numeric, cursor, and control keypad ● Softkeys/direct keys: –...
Page 77: Tcu (Thin Client Unit)
Hardware Descriptions 2.7 TCU (Thin Client Unit) TCU (Thin Client Unit) Figure 2-15 TCU with Ethernet cable plugged in Order Number Description Order number (MLFB) TCU (Thin Client Unit) 6FC5312-0DA00-0AA0 Features A TCU permits the distributed connection of SINUMERIK OP/TP operator panel fronts and the SINUMERIK PCU.
Page 78 Hardware Descriptions 2.7 TCU (Thin Client Unit) References: Comprehensive documentation about the configuration and commissioning of the TCU is given in: Configuration: /BH/Operator Components Manual, Distributed configuration with TCU Startup: /IAM/ Commissioning Manual HMI, Startup TCU (IM5) Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 79: Handheld Units
Hardware Descriptions 2.8 Handheld units Handheld units 2.8.1 Handheld Terminal HT 8 Figure 2-16 Operator interface of the HT8 Emergency stop button Handwheel Rotary override switch Protective collar Display / Touch screen Function keys machine control panel HMI control keys Connecting cable Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 80 Hardware Descriptions 2.8 Handheld units Order Number Description Order number (MLFB) HT8 without handwheel 6FC5 403 - 0AA20 - 0AA0 HT8 with handwheel 6FC5 403-0AA20-1AA0 Features The SINUMERIK HT8 is a handheld operating and programming device that combines the functions of an operator panel front and a machine control panel. The HT8 has a 7.5" TFT color display and is operated via a touch screen and membrane keys.
Page 81: Handheld Terminal Ht 2
Hardware Descriptions 2.8 Handheld units 2.8.2 Handheld Terminal HT 2 Figure 2-17 Operator control and display elements of the HT 2 Emergency Stop button (stop button) Rotary override switch Display Keyboard Handwheel Acknowledgement button (left) Acknowledgement button (right) Opening for the cable entry Cable duct cover (10) Type plate...
Page 82 Hardware Descriptions 2.8 Handheld units Features The hand operating device SINUMERIK HT2 (Handheld Terminal 2) is designed for the manual operation of tool machines. The HT2 is preferably designed for the application case, when the emphasis lies on mobility duting operation and observation. In this case the HT2 can be connected to any place in the system via a connection box "Basic PN"...
Page 83: Floppy Disk Drives
Hardware Descriptions 2.9 Floppy disk drives Floppy disk drives 2.9.1 Floppy disk drive 3.5" (USB) Figure 2-18 External 3.5" floppy disk drive with USB interface Order Number Description Order number (MLFB) 3.5" disk drive with USB interface incl. 1 m USB connecting 6FC5 235-0AA05-1AA2 cable Cover (spare part)
Page 84 Hardware Descriptions 2.9 Floppy disk drives Features The disk drive is used to read in and save data from/to 3.5" disks with a maximum capacity of 1.44 MB. The disk drive has the following features: ● USB interface: Version 1.1 ●...
Page 85: Power Supply
Hardware Descriptions 2.10 Power supply 2.10 Power supply 2.10.1 SITOP POWER standard 24V/10A Figure 2-19 View: SITOP POWER standard 24V/10A Order Number Description Order number (MLFB) SITOP POWER standard 24V/10A 6EP1 334-1SH01 Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 86 Hardware Descriptions 2.10 Power supply Features The SITOP POWER Standard 24V/10A power supply mode provides the following features: ● Input voltage - rated value: 120/230 VAC ● Input voltage - range: 93 ... 132 V/187... 264 V ● Power failure buffering: > 20 ms ●...
Page 87: Uninterrupted Power Supply (Ups)
Hardware Descriptions 2.11 Uninterrupted power supply (UPS) 2.11 Uninterrupted power supply (UPS) 2.11.1 SITOP POWER DC UPS MODULE 15 Figure 2-20 View: SITOP POWER DC UPS MODULE 15 Order Number Description Order number (MLFB) SITOP POWER DC UPS module 15 (USB interface) 6EP1 931-2EC42 Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 88 Hardware Descriptions 2.11 Uninterrupted power supply (UPS) Features The SITOP POWER DC UPS module 15 provides the following features: ● Compact design (H x W x D: 125 mm x 50 mm x 125 mm) ● Rated input voltage: 24 VDC ●...
Page 89: Sitop Power Accumodule 24 V Dc/10 A/3.2 Ah
Hardware Descriptions 2.11 Uninterrupted power supply (UPS) USB interface The USB interface corresponds to specification 2.0. Communication is however only performed at "full speed" corr. to 12 Mbaud. A commercial type four-core shielded USB cable with a maximum cable length of 3 m can be used. Table 2-12 Signal assignment of USB connector Signal...
Page 90 Hardware Descriptions 2.11 Uninterrupted power supply (UPS) Order Number Description Order number (MLFB) SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH 6EP1 935-6MD11 Features The SITOP POWER LEAD-ACID MODULE 24 V DC/10 A/3.2 AH features the following: ● It has two maintenance-free, closed lead-acid batteries from the same lot, which are installed in a holder and connected in series.
Page 91: Pp72/48 I/O Module
Hardware Descriptions 2.12 PP72/48 I/O module 2.12 PP72/48 I/O module 2.12.1 Assembly Figure 2-22 PP72/48 I/O module Order Number Description Order number (MLFB) PP72/48 I/O module 6FC5 611-0CA01-0AA0 Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 92: Interface Description
Hardware Descriptions 2.12 PP72/48 I/O module Features I/O module PP72/48 is a simple module (without a separate housing) for connecting digital input/outputs as part of an automation system based on PROFIBUS DP. The module has the following important features: ● PROFIBUS DP connection (max. 12 MBaud) ●...
Page 93 Hardware Descriptions 2.12 PP72/48 I/O module External power supply(X1) Interface description of the external power supply (X1): ● Screw-terminal block MSTBVA 2,5/3-G-5,08, Phoenix ● Pin assignment Table 2-14 Pin assignment: Ext. power supply (X1) Description Type Function External supply for module (+24V) Reference for external supply Protective conductor of the external supply VI: Voltage input...
Page 94 Hardware Descriptions 2.12 PP72/48 I/O module PROFIBUS DP (X2) Interface description of the PROFIBUS DP interface (X2): ● Connection: 9-pin sub D socket ● Pin assignment Table 2-15 Pin assignment: PROFIBUS DP (X2) Description Type Function RxD/TxD-P Receive/transmit data P (B line) Request to Send DGND Data reference potential (M5V)
Page 95 Hardware Descriptions 2.12 PP72/48 I/O module PROFIBUS address (S1) The PROFIBUS address of the ADI4 can be set in the range 1 to 127 using switch S1. Table 2-16 Meaning of switch S1 switch Description PROFIBUS address: 2 PROFIBUS address: 2 PROFIBUS address: 2 PROFIBUS address: 2 PROFIBUS address: 2...
Page 96 Hardware Descriptions 2.12 PP72/48 I/O module Signal designation Type Signal designation Type Input 1.5 Output 1.2 Input 1.6 Output 1.3 Input 1.7 Output 1.4 Input 2.0 Output 1.5 Input 2.1 Output 1.6 Input 2.2 Output 1.7 Input 2.3 DOCOMx Input 2.4 DOCOMx Input 2.5 DOCOMx...
Page 97 Hardware Descriptions 2.12 PP72/48 I/O module (1) If you are using the internal power supply P24OUT (2) If you are using an external power supply P24OUT ● Internal supply voltage (P24OUT) The internal power supply for the digital inputs (X111, X222, X333: Pin 2) is derived from the general power supply of module X1, pin 2 (P24).
Page 98 Hardware Descriptions 2.12 PP72/48 I/O module Figure 2-24 Terminal assignment for the digital outputs ● Connection cable: The required connecting cables (ribbon cables) must be provided by the user ● Supply voltage: To supply the digital outputs, an external 24V DC power supply must be connected to DOCOMx (X111, X222, X333: Pin 47, 48, 49, 50).
Page 99 Hardware Descriptions 2.12 PP72/48 I/O module Digital outputs min. Standard Max. Nominal Maximum switching frequency Resistive load 100Hz Inductive load Lamp 11Hz • <R H_typical current operating voltage maximum output current (see above) maximum short-circuit current: 4A (max. 100ms, V = 24V) : Inner resistance = 0.4W •...
Page 100: Power Supply
Hardware Descriptions 2.12 PP72/48 I/O module 2.12.3 Power supply Assembly The supply voltage (24 V DC) of the I/O module PP72/48 is connected to the screw terminal block X1. Refer to Section "Interface description" (Page 92) Digital outputs To power the digital outputs (+24VDC), an external power supply source is required. The power supply is connected through terminals X111, X222, X333, pins 47, 48, 49, 50 (DOCOMx).
Page 101: Grounding
Hardware Descriptions 2.12 PP72/48 I/O module Max. (absolute, transient) 35 V Max. duration 500 ms min. recovery time 50 s Max. events per h Voltage failure for min. power supply voltage Max. duration 50 ms min. recovery time Max. events per h Power consumption Maximum Approx.
Page 102: Dimension Drawing
Hardware Descriptions 2.12 PP72/48 I/O module 2.12.5 Dimension drawing Figure 2-25 Dimension drawing: PP72/48 I/O module Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 103: Technical Data
Hardware Descriptions 2.12 PP72/48 I/O module 2.12.6 Technical data Table 2-22 Technical data of I/O module PP72/48 Safety Degree of protection IP 00 Safety class Safety class I, in accordance with VDE 0106 P1: 1982 (IEC 536); Protection against ingress of foreign bodies and water in accordance with IEC 529 Certifications UL/CSA, CE...
Page 104: Adi4 (Analog Drive Interface For 4 Axes)
Hardware Descriptions 2.13 ADI4 (Analog Drive Interface for 4 Axes) 2.13 ADI4 (Analog Drive Interface for 4 Axes) 2.13.1 Assembly Figure 2-26 Connection overview for ADI4 Order Number Description Order number (MLFB) ADI4 6FC5 211-0BA01-0AA2 Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 105 Hardware Descriptions 2.13 ADI4 (Analog Drive Interface for 4 Axes) Features The interface module ADI4 is suitable for operating up to 4 drives with analog setpoint interface on PROFIBUS DP. The module has the following essential features: ● PROFIBUS DP connection (max 12 Mbits/s) ●...
Page 106: Diagnostic Repeater For Profibus Dp
Hardware Descriptions 2.14 Diagnostic repeater for PROFIBUS DP 2.14 Diagnostic repeater for PROFIBUS DP 2.14.1 Assembly Figure 2-27 View: Diagnostics Repeater for PROFIBUS DP Order Number Description Order number (MLFB) Diagnostic repeater for PROFIBUS DP 6ES7 972-0AB01-0XA0 Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 107 Hardware Descriptions 2.14 Diagnostic repeater for PROFIBUS DP Features The diagnostics repeater with online line diagnostics for PROFIBUS DP offers the following main features: ● Module-specific features: – PROFIBUS DP standard slave (DP-V1) – Data transmission speed: 9.6 kBaud to 12 MBaud –...
Page 108 Hardware Descriptions 2.14 Diagnostic repeater for PROFIBUS DP Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 109: Configuration
Configuration System overview 3.1.1 Operator panels and touch panels Figure 3-1 System overview of SINUMERIK 840Di sl: Operator panels and touch panels Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 110: Profibus Dp Components
Configuration 3.1 System overview 3.1.2 PROFIBUS DP components Figure 3-2 System overview of SINUMERIK 840Di sl: PROFIBUS DP (schematic) Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 111: Pcu Components
Configuration 3.1 System overview 3.1.3 PCU components SIEMENS SIEMENS Figure 3-3 System overview of SINUMERIK 840Di sl: PCU components (as a diagram) Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 112: Electrical Design
Configuration 3.2 Electrical design Electrical design 3.2.1 MCI board and PROFIBUS DP Figure 3-4 SINUMERIK 840Di sl MCI board and PROFIBUS DP components Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 113: Mci Board Extension
Configuration 3.2 Electrical design Note For details on general accessories, such cables, connectors and prefabricated cables, please refer to: References: Catalog NC 61, MOTION-CONNECT 3.2.2 MCI board extension Figure 3-5 SINUMERIK 840Disl MCI board extension Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 114: Pcu 50.3
Configuration 3.2 Electrical design 3.2.3 PCU 50.3 SIEMENS Figure 3-6 SINUMERIK 840Di sl: PCU 50.3 (right housing) Figure 3-7 SINUMERIK 840Di sl: PCU 50.3 (rear housing) Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 115: Connection Overview
Configuration 3.3 Connection overview Connection overview 3.3.1 MCI board and MCI board extension Figure 3-8 Connection overview: MCI board and MCI board extension Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 116 Configuration 3.3 Connection overview 1. Connectors: 6ES7972-0BA41-0XA0; cable outlet 35 , without PC socket connector 6ES7972-0BB41-0XA0; cable outlet 35 , with PC socket connector 6ES7972-0BA12-0XA0; cable outlet 90 , without PG socket connector 6ES7972-0BB12-0XA0; cable outlet 90 , with PG socket connector Cables: 6XV1830-0EH10;...
Page 117: Pcu50
Configuration 3.3 Connection overview Note The length codes for preassembled cables 6FX_002-... can be found in: References: Catalog NC 61, MOTION-CONNECT. 3.3.2 PCU50 Figure 3-9 Connection overview: PCU 1. The cable is included in the scope of supply 2. Cables: 6FX8002-2CP00-1A⃞0 3.
Page 118 Configuration 3.3 Connection overview Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 119: Emc And Esd Measures
● Signal cables and load cables must be routed at the greatest possible distance from one another. ● Only use SIEMENS signal cables for connecting to and from the NC or PLC. ● Signal cables may not be routed close to strong external magnetic fields (e.g. motors and transformers).
Page 120: Esd Measures
EMC and ESD Measures 4.2 ESD measures Note For further information about RI suppression measures and the connection of shielded cables see: References: /EMC/ EMC Directives ESD measures CAUTION The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic energy before touching the electronic modules. The easiest way to do this is to touch a conductive, grounded object immediately beforehand (for example, bare metal parts of control cabinet or the protective ground contact of a socket outlet).
Page 121: Power-On And Power-Up
Preparing for commissioning 5.1.1 Checklist SINUMERIK 840Di sl The following checklist will help you to commission the supplied components without undue problems and ensure a high availability on your product: ● When handling the components, all ESD measures are observed.
Page 122: Recommended Sequence For First Commissioning
The device manual "Guidelines for machine configuration SINUMERIK 840D sl" currently refers only to SINUMERIK 840D sl with SINAMICS S120. The information contained in this can, in principle, be applied to SINUMERIK 840Di sl with SINAMICS S120. A revised edition for SINUMERIK 840Di sl is in preparation.
Page 123 Power-On and Power-Up 5.1 Preparing for commissioning Implementation 1. Configure the SINUMERIK 840Disl completely on first booting (Section "First power-up" (Page 124)) 2. Take the PLC default program supplied as the commissioning file for the PLC (basic PLC program, PLC user program and configuration) or create your own SIMATIC S7 project and load it into the PLC (Section "PROFIBUS DP Communication"...
Page 124: First Power-Up
After the basic commissioning described in the following two sections, the following conditions should apply: ● SINUMERIK 840Di sl NC and PLC are operated in cyclical operation ● If a machine control panel is connected, no alarms or messages should be pending.
Page 125 Power-On and Power-Up 5.2 First power-up Welcome to SINUMERIK ! These SINUMERIK products will be installed now: <Application 1> <Version> <Application n> <Version> Install NOW Install at NEXT REBOOT CANCEL installing Menu commands: ● Install NOW All the applications displayed will be installed in the listed order. During the installation procedure follow the instructions that appear on the screen.
Page 126: Basic Commissioning Of The Plc
Power-On and Power-Up 5.2 First power-up 5.2.2 Basic commissioning of the PLC After the Service Desktop is active, the series commissioning file (*.arc) of one of the sample applications delivered can be loaded for simplifying the PLC commissioning. An application example includes the basic PLC program and the linking of one of the following MCP.
Page 127: Power-Up
SRAM image valid until then is also saved to the hard disk of the PCU as an SRAM backup. In certain error or servicing instances, the SRAM image or backup can be accessed so that work can be continued immediately without recommissioning the SINUMERIK 840Di sl. Table 5-1 SRAM handling...
Page 128 ● Windows XP must have been shut down correctly (the POWER FAIL mechanism of the SINUMERIK 840Di sl is adequate for this). ● The checksum test on the SRAM image/backup must have been successful. ● The battery status must have been good when the backup of the SRAM image was performed.
Page 129: Startup After Battery Replacement (Pcu Backup Battery)
5.3.2 Startup after battery replacement (PCU backup battery) Proper shutdown Before replacing the PCU backup battery, the SINUMERIK 840Di sl or Windows XP must be shut down correctly. To do this, use one of the following options: ● Windows taskbar: Start > Shut Down.
Page 130 The following is to be taken into account: • If the MCI board is recognized as being faulty while the SINUMERIK 840Di sl is booting, the last SRAM image is retained when Windows XP is shut down. After the MCI board has been changed, proceed as described above.
Page 131: Power Up After Reinstallation/Update Of The 840Di Sl Software
Responses: A note will appear in a message box, which must be acknowledged with "OK": NOTICE If the buffered user data is not going to be used again, the SINUMERIK 840Di sl must be recommissioned. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 132: Startup After Replacement Of The Pcu Or The Mci Board
Startup after importing a backup copy If a backup copy (Ghost image) of a previously booted SINUMERIK 840Di sl is loaded into the PCU again, the user data buffered in the SRAM of the MCI board will be used again.
Page 133: Startup After Power Failure/Power Fail
Thanks to the Power Fail Detection integrated in the PCU, in the event of a power failure the SINUMERIK 840Di sl saves the user data in the SRAM of the MCI board. An SRAM image, however, cannot be created any more in this case.
Page 134 Power-On and Power-Up 5.3 Power-up From 2nd power-up The system responds as follows if it is powered up a second time with pending shutdown signal: ● Windows XP is not immediately shut down correctly. ● NC and PLC are not started ●...
Page 135: Service Desktop
1. As soon as (1) is displayed under the version number on the bottom right of the startup screen, press the key "3". Figure 5-2 Display during startup of the SINUMERIK 840Di sl 2. Enter a password for protection levels 0-2: Protection level...
Page 136: Sinumerik-Specific Applications
Equipment Manual "Operator components and Networking", Chapter: PCU 50.3 > Commissioning > Calibration of the touchscreen ● System Network Center Setting up the Ethernet connection of a TCU to the SINUMERIK 840Di sl. References: Equipment Manual "Operator components and Networking", Chapter: Networking >...
Page 137 – NC Connect Wizard Tool for establishing the communications link from SinuCom NC to SINUMERIK 840Di – SinuCom NC NOTICE When Windows starts up, the SINUMERIK 840Di sl NC system software is automatically started in the background. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 138: Setting The Boot Response For The Service Desktop
Setting the boot response for the Service Desktop The NC or MHI desktop settings are used to determine if the NC desktop (Windows desktop) is displayed after booting the SINUMERIK 840Di sl, or if the HMI user interface, e.g. HMI Advanced, is started immediately: ●...
Page 139: User-Specific Hmi Startup Images
Parameters: NCK type The different NCK types are displayed depending on the directory name. The following values may be used as directory names for the SINUMERIK 840Di sl: ● Default If a directory is created by default, the startup image stored in this directory will always be displayed irrespective of the NCK type.
Page 140: Hmi Explorer
Parameters: File name You can choose any file name. 5.4.7 HMI Explorer The HMI Explorer is used to manage the Siemens A&D software components on the PCU. The following main functions are available: ● Version display ● Installation, de-installation, and re-installation ●...
Page 141: Sw Installation/Update
Power-On and Power-Up 5.4 Service Desktop Version display The following versions are displayed for each software application: ● Current version Current version number ● Release version Version number with which the product was first installed. Installation directory The path of the installation directory of a software component is displayed in the Install dialog box: Menu command: Install 5.4.8 SW installation/update...
Page 142: Servicecenter
ServiceCenter The ServiceCenter is used to create, restore and manage partition and hard disk images. With the SINUMERIK 840Di sl, the startup mode of NCK and PLC can also be specified via the ServiceCenter. The ServiceCenter is intended for the machine manufacturer/service personnel.
Page 143: Nc/Plc Startup Modes
NC/PLC startup modes Setting options In the SINUMERIK 840Di sl-specific part of the ServiceCenter, you can specify the mode that the NCK and PLC are to assume after startup. The following options can be set: ● Start NCK and PLC ●...
Page 144: Backup/Restore Functions
Power-On and Power-Up 5.5 ServiceCenter PLC modes The following PLC modes can be set: ● RUNP In the "RUNP" mode, changes can be made to the PLC user program without activation of the password. ● RUN Only read accesses are possible via a programming device (PG) in the "RUNP" mode. It is not possible to make changes to the PLC user program until the password has been set.
Page 145: Configuration Of The Network Connection Of The Pcu (Lan/Wan)
5.6 Configuration of the network connection of the PCU (LAN/WAN) Configuration of the network connection of the PCU (LAN/WAN) To perform service functions (software installation/update), the SINUMERIK 840Di sl requires an active connection to an external computer at least for the duration of the service task.
Page 146: License Management
5.7.2 License management with SinuCom NC To use SINUMERIK 840Di sl system software and the enabled options, the corresponding software licenses must be assigned to the hardware. During the assignment procedure, you will be given a license key for each piece of software (system software or options) which electronically links the respective software to the hardware.
Page 147 Power-On and Power-Up 5.7 License management 4. Select the data area: "Options". Via the dialog box: "Options", you can: – Enable/disable options or – Obtain new license keys (Web License Manager) – Enter license keys in the control system Click the "Get a new license key" button and follow the instructions in the subsequent dialogs.
Page 148 Power-On and Power-Up 5.7 License management Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 149: Plc Commissioning
PLC commissioning General 6.1.1 Compatibility The PLC integrated on the MCI board of the SINUMERIK 840Di sl is compatible with the SIMATIC S7 PLC: AS317-2 DP. 6.1.2 Performance Data The PLC of the SINUMERIK 840Di sl has the following features:...
Page 150: Plc Program
The PLC basic program organizes the exchange of signals and data between the PLC user program and the NCK, HMI, and machine control panel components. The PLC basic program is part of the PLC Toolbox supplied with SINUMERIK 840Di sl. ● PLC user program The PLC user program is the user-specific part of the PLC program by which the basic PLC program has been added to or extended.
Page 151: Installing The Plc Basic Program Library
6.1.5 STEP 7 example projects Included in the scope of supply for the SINUMERIK 840Di sl system software are two STEP 7 projects, on which the basic configuration of the SINUMERIK 840Di sl Station and an MCP (PROFIBUS/Ethernet) is displayed. The example projects can be used as a basis for your own projects.
Page 152 ● External link That PG/PC is running on SIMATIC STEP 7, can be linked with the SINUMERIK 840Di sl- PLC via one of the Ethernet interfaces of the PCU (Ethernet 1: company network or Ethernet 2: Local network).
Page 153: Plc User Program
PLC commissioning 6.1 General 6.1.6 PLC user program The following organizational blocks contain the entry points for the appropriate parts of the PLC user program. ● OB100 (cold restart) ● OB1 (cyclic processing) ● OB40 (process alarm) Figure 6-1 Structure of the PLC program Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 154 PLC commissioning 6.1 General Processing modules The individual blocks in the basic PLC program can be processed in the SIMATIC manager: ● Select the appropriate block, e.g. OB 100 in the folder blocks of the corresponding module ● Use the menu command Edit > Open Object to open the block or double-click the block with the left mouse button ●...
Page 155: Commissioning
SIMATIC STEP 7 is required in the following version: ● SIMATIC STEP 7 as Version 5.4, Service Pack 2 SIMATIC STEP 7 can either be installed directly on the SINUMERIK 840Di sl PCU or on an external computer (PG/PC). Communications link...
Page 156: External Communications Link: Ethernet
● The computer can communicate via Ethernet or an Ethernet connection has been established ● PG/PC interface is parameterized (see below) ● The PG/PC is connected to one of the Ethernet interfaces of the SINUMERIK 840Di sl PCU (Ethernet 1: company network or Ethernet 2: Local network). PG/PC interface The PG/PC interface parameters can be checked and set in the SIMATIC Manager via menu item: Options Set PG/PC interface...:...
Page 157: Check Plc Status And Communication Interface
On first commissioning of the PLC, a general reset of the PLC has to be performed after the SINUMERIK 840Di sl has been switched on and booted. To obtain a defined initial state of the whole system (NC and PLC), the NC data should also be deleted.
Page 158 3. Initiate NC Reset To start cyclic operation or NC/PLC communication, NC reset (button "NCK Reset") must be activated: The subsequent SINUMERIK 840Di sl boot has been successfully completed if the following display appears in the dialog box: ● NC status:...
Page 159 PLC commissioning 6.2 Commissioning Note Since no PLC program is executed after PLC general reset, the following alarms are displayed: • Alarm "120201 Communication failed" • Alarm "380040 PROFIBUS DP: Configuring error 3, parameter" • Alarm "2001 PLC not booted" These alarms have no influence on how to continue.
Page 160: Creating A Simatic S7 Project
Maximum two PROFIBUS lines can be connected to a SINUMERIK 840Di sl: ● Interface X101: PROFIBUS DP In the case of the SINUMERIK 840Di sl, the position controller cycle of the NC is derived directly from the isochronous PROFIBUS cycle. Defined values must therefore always be entered for the following PROFIBUS parameters: –...
Page 161: Create A Project
PLC commissioning 6.3 Creating a SIMATIC S7 project 6.3.1 Create a project To create a new project select menu command File > New in the SIMATIC Manager. Enter the following project data in the dialog and confirm with OK: ● Name (for example: SIN840Di sl) ●...
Page 162 PLC commissioning 6.3 Creating a SIMATIC S7 project Starting HW Config Start "HW Config" by opening the station and double-clicking the hardware icon. Figure 6-3 Inserting the SIMATIC 300 station We recommend giving the inserted SIMATIC Station 300 a meaningful name, for example 840Di sl Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 163: Hw Config
PLC commissioning 6.3 Creating a SIMATIC S7 project 6.3.3 HW Config The user interface of "HW Config" mainly contains: ● Station window: The station window is split. The upper part displays the structure of the station graphically, and the lower part provides a detailed view of the selected module. ●...
Page 164: Inserting The 840Di Sl Rack
Right-click to select the 840Di sl Rack and drag it to the Station window, while holding down the mouse button. When you release the mouse button, the 840Di sl Rack will be inserted in the S7 project. Figure 6-5 HW Config: SINUMERIK 840Di sl Rack Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 165: Parameterizing The Profibus Interface (X101)
● Equidistant DP cycle ● Equidistant time Equidistant time The set equidistant DP cycleis accepted in case of SINUMERIK 840Di sl as NC system clock cycle and position controller cycle. Position controller cycle = NC system clock cycle = equidistant DP cycle The time you can set for the equidistant DP cycle depends on: 1.
Page 166 PLC commissioning 6.3 Creating a SIMATIC S7 project Data transfer rate: 12 Mbps Profile: DP Button: "Options..." Dialog: Options Tab Equidistant Active equidistant bus cycle: ☑ < > Equidistant DP cycle: Equidistant time Note S7-Subnetz-ID (S7 subnet ID) It is recommended to note the S7-Subnetz-ID (S7 subnet ID) , because it will be needed later for parameterization of the routing settings: •...
Page 167: Parameterizing The Profibus Interface (X102) (Optional)
Subsection "Parameterizing the PROFIBUS interface (X101)" (Page 165)) the 840Di sl Rack is displayed in the Station window. Suchen: Proﬁl: Figure 6-6 HW Config: SINUMERIK 840Di sl Rack To parameterize the PROFIBUS interface (X102) as for slot X1, set the following parameters: ● Interface type ● Transmission rate MPI/DP...
Page 168 PLC commissioning 6.3 Creating a SIMATIC S7 project Dialog Dialog: MPI/DP Properties Tab: General Name: <Designation of 2nd DP interface> Group: Interface Type: PROFIBUS Button: "Properties..." Dialog: Properties - PROFIBUS interface MPI/DP Tab: Parameter address: <Address> Button: "New..." Dialog: Properties - New Subnet PROFIBUS Tab: Network settings Data transfer rate: <Data transfer rate>...
Page 169: Parameterizing The Mpi Interface (X102) (Optional)
Button: "Properties..." Dialog: Properties - PROFIBUS interface MPI/DP Tab: Parameter address: 2 (see note) Subnet: MPI(1) 187.5 kBaud NOTICE With SINUMERIK 840Di sl, the MPI address of the PLC must always be set to 2. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 170: Parameterization Of The Communications Processor (Cp 840D Sl) (Ethernet)
PLC commissioning 6.3 Creating a SIMATIC S7 project 6.3.8 Parameterization of the communications processor (CP 840D sl) (Ethernet) The following parameters must be set for parameterizing the integrated communications processor "CP 840D sl": ● IP address of the PCU ● Subnet mask of the PCU ●...
Page 171 PLC commissioning 6.3 Creating a SIMATIC S7 project Properties - Ethernet Interface CP 840D sl (R0/S5) Netzübergang Subnetz: Figure 6-7 Parameterize the properties of the CP 840D sl (excerpt) NOTICE The IP address and subnet mask in the figure above are only sample values! Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 172: Networking Pg/Pc And Pcu (Ethernet)
PLC commissioning 6.3 Creating a SIMATIC S7 project 6.3.9 Networking PG/PC and PCU (Ethernet) In order that external components connected via Ethernet, e.g. PG/PC with the SINAMICS drive commissioning tool STARTER or SIMATIC Step 7, can communicate with SINUMERIK 840Di sl and SIMATIC drive units, the PG/PC must be linked to the PCU in the S7 project. Implementation Perform the following actions for networking: 1.
Page 173 PLC commissioning 6.3 Creating a SIMATIC S7 project Subnet Typ: 3. After confirming with OK, the properties dialog box of the Ethernet interface is displayed. Select the "Parameter (1)" tab and enter the IP address and subnet mask of the PG/PC (2).
Page 174 PLC commissioning 6.3 Creating a SIMATIC S7 project NOTICE The MAC address, IP address and subnet mask in the figure above are only sample values! 4. The configured Ethernet interface must be assigned to an interface parameterization of the PG/PC. Select the "Assignment" (1) tab. Select the configured "Ethernet (1)"...
Page 175 PLC commissioning 6.3 Creating a SIMATIC S7 project 5. The PG/PC networking with the Ethernet interface is displayed in the project view and identified by the highlighted connection (1). Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 176 PLC commissioning 6.3 Creating a SIMATIC S7 project 6. Then compile and save the project. NetPro can then be shut down. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 177: Creating A Plc Program
PLC commissioning 6.4 Creating a PLC program Creating a PLC program 6.4.1 PLC basic program Opening the library SIN840Di sl For inserting the basic PLC program in the created S7 project open the library installed in the Subsection "Installation of the basic PLC program library" (Page 151) via the menu command File >...
Page 178: Plc User Program
PLC commissioning 6.5 Creating a PROFIBUS configuration Figure 6-9 Inserting blocks of the PLC basic program Overwrite OB1 Inserting blocks overwrites the existing organization block OB1. Confirm the query as to whether you want to overwrite the block with "Yes". 6.4.2 PLC user program The PLC user program according to its definition contains all functions required to process...
Page 179: Load Configuration (Step 7 -> Plc)
For loading the configuration into the PLC, the following prerequisites must be fulfilled: ● A communications link exists between STEP 7 and the PLC. ● The configuration to be loaded corresponds to the actual station configuration. ● SINUMERIK 840Di sl is active: – NC: Cyclic operation – PLC: RUN or STOP mode 6.6.2...
Page 180: Series Startup File
The PLC user data can be backed up by creating a series-startup file or loading an existing series startup file using the following applications: ● SinuCom NC (part of the SINUMERIK 840Di sl installation) ● HMI Advanced (optional) For detailed information about data back-up please refer to Chapter "User data backup/series commissioning"...
Page 181: Testing The Plc Program
● Restart ● Cold restart (Warm restart) ● Cold restart In case of a SINUMERIK 840Di sl the startup type of the PLC is set permanently to NEW START. It cannot be changed. Startup mode: RESTART Upon NEW START first the block "OB 100" is executed. Then cyclic operation starts with call-up of block "OB1".
Page 182: Cyclic Operation
PLC commissioning 6.7 Testing the PLC program 6.7.2 Cyclic operation In cyclic operation, communication or exchange of data and signals is carried out between the PLC and the components NC, HMI (e.g. HMI Advanced) and MCP (machine control panel). The execution of the PLC program is carried out such that - with regard to time - the basic PLC user program is executed prior to the PLC user program.
Page 183: Monitor/Control Using Hmi Advanced
PLC commissioning 6.7 Testing the PLC program Assignment of values to variables of the PLC user program or of the CPU module. ● Release PA and Activate control values Assignment of values to I/O outputs of the PLC user program or of the CPU module in the operating mode STOP.
Page 184 PLC commissioning 6.7 Testing the PLC program Input syntax Both the following tables show the input syntax of the fields Operand and Format of the PLC status display. Table 6-2 Input field: Operand Syntax Description En.x Input byte n, bit x Input byte n Input word n Input double-word n...
Page 185: Load Configuration In Pg (Plc -> Step 7)
6.8 Load configuration in PG (PLC -> STEP 7) Load configuration in PG (PLC -> STEP 7) The configuration of a SINUMERIK 840Di sl PLC must be loaded onto an external computer (STEP 7 PG/PC) using an Ethernet connection. Requirements The following conditions must be fulfilled: ●...
Page 186 PLC commissioning 6.8 Load configuration in PG (PLC -> STEP 7) Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 187: Ethernet Communication
Ethernet communication General information 7.1.1 Ethernet connections of the PCU 50.3 Figure 7-1 Ethernet connections of the PCU 50.3 The PCU 50.3 has 2 Ethernet connections (10/100 MBaud): ● Ethernet 1 (company network) ● Ethernet 2 (system network) The interface: "Ethernet 1" is preset as a SINUMERIK DHCP client for connecting to a company network or a PTP connection.
Page 188: Determine Ethernet Communication Partners Of The Pcu
7.1.3 Check Ethernet connection If there is an Ethernet connection between a SINUMERIK 840Di sl PCU with a direct operator panel connection and another component, the connection can be checked as followed: 1. Start a Windows console on the PCU: Windows XP Start menu: Start > Run: cmd 2.
Page 189: Starter Sinamics Drive Commissioning Tool
The SINAMICS STARTER drive commissioning tool can only be operated currently on a SINUMERIK 840Di sl PCU if at least one of the two Ethernet interfaces is active. To do this, at least one component must be connected to the relevant Ethernet interface, e.g. an "MCP 483C IE"...
Page 190 Ethernet communication 7.4 External HMI Advanced Note There are no restrictions in terms of Ethernet topology within the SINUMERIK 840Di sl PCU and HMI PCU. Requirements The following requirements must be fulfilled: ● There is an Ethernet connection between SINUMERIK 840Di sl PCU and HMI PCU and both computers communicate.
Page 191: Mcp 483C Ie
FC 19 (Interface parameter assignment, version: milling) and FC 25 (interface parameter assignment version: turning). The library of the PLC basic program is part of the SINUMERIK 840Di sl. How to install the library is described in detail in Section "Create PLC Program" (Page 177).
Page 192: Parameterization Of The Mcp
Ethernet communication 7.5 MCP 483C IE References: The following manuals are required for the commissioning of the MCP: /FB1/Function Manual, Basic Functions Subsection P3, PLC Basic Program, Program structure and modules of the PLC basic program. /FB2/Function Manual, Extended Functions, Section H1, Manual and Handwheel Travel, Commissioning of handwheels /BHsl/Operator Components Manual, Description of MCP (interfaces, electrical connection, etc.)
Page 193 Ethernet communication 7.5 MCP 483C IE References: /BHsl/ Operator Components Manual, Chapter "Machine Control Panel MCP 483C IE" Display of the software version After the MCP has been electrically connected, all LEDs on the front side of the MCP flash until communication is established between MCP and PLC.
Page 194 Ethernet communication 7.5 MCP 483C IE Display of the IP address After the MCP has been electrically connected, all LEDs on the front side of the MCP flash until communication is established between MCP and PLC. To activate the display you must press the "Feed stop" and "Feed enable" keys simultaneously.
Page 195: Mcp Functions
Ethernet communication 7.5 MCP 483C IE Switch S2 Switch S2 is used to set the address by which the MCP is addressed by the PLC user program: Table 7-1 Switch S2: MCP address (1-8) Meaning/value Reserved MCP address 192 (on delivery) 7.5.3 MCP functions The MCP offers the following functions:...
Page 196: Linking To The Basic Plc And User Program
FB1. A maximum of 2 machine control panels are supported by the basic PLC program. To synchronize several MCPs, the PLC program must be adapted accordingly. This is the user's (machine manufacturer's) responsibility. To operate an MCP 483C IE on a SINUMERIK 840Di sl, the following parameters are relevant: MCPNum:...
Page 197 Ethernet communication 7.5 MCP 483C IE VDI interface parameter assignment The following function blocks are available to transfer the MCP signals to the VDI interface: ● FC 19: MCP_IFM, version M (milling) ● FC 24: MCP_IFM2, version M (milling) ● FC 25: MCP_IFT, version T (turning) NOTICE Function blocks FC 19, FC 24 and FC 25 are part of the PLC basic program.
Page 198: Input/Output Image
Ethernet communication 7.5 MCP 483C IE Note The MCP 483C IE is connected via an Ethernet interface of the PCU. Since the communication of the MCP with the SINUMERIK PLC is based on Windows components, the MCP monitoring time may be exceeded in the following cases: •...
Page 199 Ethernet communication 7.5 MCP 483C IE Input image The following information is to be found in the table for each input bit: ● 1. Row: Default designation ● 2. Row: Key number (Sxy) or feedrate override switch (X30/X31), keyswitch (X50) Table 7-2 Assignment of the key signals in the input image Signals from machine control panel (keys)
Page 200 Ethernet communication 7.5 MCP 483C IE Output image The following information is to be found in the table for each output bit: ● 1. Row: Default designation ● 2. Row: LED number Table 7-3 Assignment of the LED signals in the input image Signals to machine control panel (keys) Byte Bit7...
Page 201: Conditions For General Commissioning
HT 8 7.6.1 Conditions for general commissioning Hardware An HT 8 is connected to the SINUMERIK 840Di sl via one of the following interface modules, and not directly: ● Terminal box PN Basic ● Terminal box PN Plus ● Connection module Basic PN ●...
Page 202: Parameterization Of The Power Supply Unit
Ethernet communication 7.6 HT 8 7.6.2 Parameterization of the power supply unit Set identification The following figure displays the relevant position of the rotary coding switches S1 and S2 in the different power supply units. Figure 7-8 Position of the rotary coding switches S1 and S2 The ID of the relevant power supply unit is defined via the rotary coding switches S1 and S2.
Page 203: Parameterization Of The Ht 8 Via The Tcu Firmware
Ethernet communication 7.6 HT 8 7.6.3 Parameterization of the HT 8 via the TCU firmware HT 8 detected as new TCU If the HT 8 is connected to the PCU and it is detected as a new TCU, the TCU firmware for defining the HT 8 parameters is started automatically.
Page 204: Parameterization Of The Ht 8 Via The System Network Center
Ethernet communication 7.6 HT 8 Figure 7-9 <Recall> and <Menu Select> keys Softkey <TCU Settings> The dialog for setting the TCU parameters is called via the <TCU Settings > softkey. The following parameters can be changed: ● Individual Mode: no (recommended setting), yes Index ●...
Page 205 Ethernet communication 7.6 HT 8 4. Change the name of the TCU. In the example: "HT_8_1". The name must be made up of alphanumeric characters and underscores. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 206: Linking To The Basic Plc And User Program
Ethernet communication 7.6 HT 8 NOTICE Changing the parameters Only the name can be changed via the Properties dialog of TCU. All other parameters must be changed either via the TCU firmware on HT 8 (direct key actuation, EKS index) or on power supply unit (MCP address and TCU index by changing the identifier).
Page 207 Ethernet communication 7.6 HT 8 Several MCPs A maximum of 2 machine control panels are supported by the basic PLC program. The communication parameters of the MCP are called MCPx... (x = 1 or 2) in function block FB1. To synchronize several MCPs, the PLC program must be adapted accordingly. This is the user's (machine manufacturer's) responsibility.
Page 208: Signal Transmission From/To Nc/Plc Interface (Fc26)
Ethernet communication 7.6 HT 8 7.6.5.2 Signal transmission from/to NC/PLC interface (FC26) Description of functions The FC 26 function "HPU_MCP (machine control panel signals of the handheld unit HT8" transfers the HT 8 specific signals of the following functions between the HT 8 input/output data area parameterized in the FB 1 function module (parameter: MCPxIn and MCPxOut) and the NC/PLC interface: ●...
Page 209 Ethernet communication 7.6 HT 8 Examples Call of FC 26 for the first MCP, for the first mode group and the first channel of the NC. BAGNo := B#16#01 // 1. MCP, 1st mode group of the NC ChanNo := B#16#01 // 1.
Page 210: Overview Of Traversing Keys
Ethernet communication 7.6 HT 8 7.6.5.3 Overview of traversing keys The following figure shows an overview of the activation, display and inscription of the data relevant to the traversing keys Figure 7-10 Overview of traversing keys (1) Table of the machine axis numbers The table is to record the axis numbers of the machine axes on which the traversing keys are to have an effect.
Page 211 Ethernet communication 7.6 HT 8 (3) HMI file HT8_xx.INI The language-dependent inscription of the traversing keys can be defined in the HMI file HT8_xx.INI in the [Axiskey text] character strings section (4) Mapping of keys The mapping of keys in the NC/PLC interface is shown by the following table: Keyboard layout NC/PLC interface signal SF1, SF2...
Page 212: Activate Traversing Keys
Ethernet communication 7.6 HT 8 (7) Displayed traversing keys The traversing key inscription is displayed at the position of the vertical softkeys of the HMI interface. The character strings for inscription are taken from MD 10000 or the HMI file HT8_xx.INI.
Page 213 Ethernet communication 7.6 HT 8 The value 0 is to be entered as axis number in the table for traversing key signals that are not supposed to act on any machine axis. Specifying an invalid axis number can make the PLC switch to the "stop" state. There is no validation for invalid axis numbers.
Page 214: Display Traversing Keys
Ethernet communication 7.6 HT 8 No traversing key signals to machine axes with active WCS. The FC 26 function can be used to lock the transfer of the traversing key signals to the machine axis with active WCS (AB n + 0, Bit 0 = 1). This functionality is to be activated by the user (machine manufacturer) in the PLC user program by setting the following output signals: ●...
Page 215 HT8_xx.INI files (where xx = language code e.g. GR = German, EN = English) on the basis of language for all the machine axis appearing in the system. These files are stored in the following directory: ● <Installation drive>:/Siemens/Sinumerik/<HMI>/user/language. Note The relevant original HT8_xx.INI file should not be changed, because it is overwritten during an update of the HMI software.
Page 216: Activating User Softkeys
Ethernet communication 7.6 HT 8 The character string for inscription of a traversing key is to be entered between the already existing quotation marks, e.g. "LIN_X". A maximum of 2 lines are available for inscription of a traversing key. It is recommended, the specification in the file notwithstanding, that only a max.
Page 217: Displaying User Softkeys
HT8_xx.INI files (where xx = language code e.g. GR = German, EN = English) on the basis of language. These files are stored in the following directory: ● <Installation drive>:/Siemens/Sinumerik/<HMI>/user/language. Note The relevant original HT8_xx.INI file should not be changed because it is overwritten during an update of the HMI software.
Page 218: Mcs/Wcs Coordinate System Switchover
Ethernet communication 7.6 HT 8 The user softkeys are inscribed as U1 to U16 by default: HT8_xx.INI (excerpt) [CPFSoftkey Text] U1 = "U1" ; max. 2*10 characters, U2 = "U2" ; Line break occurs via %n U3 = "U3" To inscribe a user softkey, the existing character string "Ux" must be replaced by the desired character string, e.g.
Page 219: Instructions On The Evaluation Of Input Signals
Ethernet communication 7.6 HT 8 With active WCS, it is assumed implicitly In FC 26, that the first 3 axes in the machine axis table are geometry axes. If this is not the case e.g. after the axis switchover, then the user (machine manufacturer) must set the following output signal in the PLC user program: ●...
Page 220: Input/Output Image
Ethernet communication 7.6 HT 8 Alternate activation of two functions An implementation option of alternate activation of two functions with each positive edge of an input signal is shown by the following listing: OB 1 (excerpt) // (1) If positive edge of user softkey U2? 102.1 102.3 102.3...
Page 221 {Ux} = User softkeys of the CPF, display via "U" key; standard labeling: U1 - U16; User-specified Inscription possible via language-based file: HT8_xx.INI, path: /Siemens/Sinumerik/<HMI>/mmc2/language/ with xx: GR = German, UK = English, SP = Spanish, IT = Italian, GR = Greek, CH = Chinese Note It is recommended that the original file in .../mmc2/language/ be left unchanged and the user-specific.
Page 222: Conditions For General Commissioning
HT 2 7.7.1 Conditions for general commissioning Hardware An HT 2 is connected to the SINUMERIK 840Di sl via one of the following interface modules, and not directly: ● Terminal box PN Basic ● Terminal box PN Plus ● Connection module Basic PN ●...
Page 223: Linking To The Basic Plc And User Program
Ethernet communication 7.7 HT 2 7.7.2 Linking to the basic PLC and user program 7.7.2.1 Interface signals Number system The following figure shows the number system of the softkeys and LED of the HT 2 operator field. Figure 7-12 Numbering of the softkeys and LEDs Note In order to transfer the user softkeys (SK1, SK6, SK11 and SK16) in the input interface, at least version 8.2 of the software "PCU-Base"...
Page 224 Ethernet communication 7.7 HT 2 Signals from HT 2 acknowledg switch ment display 1) Refer to Chapter: Rotary coding switch (Override) - unassigned signals Note Unassigned signals are transferred from HT 8 with 0. Output image The address specification of the output image EB takes place in the FB 1 function module, parameters: "HHUOut".
Page 225: Rotary Coding Switch
Ethernet communication 7.7 HT 2 7.7.2.2 Rotary coding switch The data of the rotary coding switch (Override) is gray-coded on HT 2. The following table shows the values in the input data for each switch position: Switch setting Input data EB m + 5, Bit 5 - Bit 1 E D C B A (gray-coded) 0 0 0 0 1 0 0 0 1 1...
Page 226: Write Display-Line
Ethernet communication 7.7 HT 2 7.7.2.3 Write display-line The writing of a display line covers the following points: 1. Selection of the display lines to be written in the output area: AB m + 1, Bit 1 and Bit 0 2.
Page 227: Character Map
Ethernet communication 7.7 HT 2 PLC user program: Setting the request. Wait for acknowledgement HT 2: Detects the write request. Sets the acknowledgement after ending the write operation. PLC user program: Detects the acknowledgement. Resets the request. HT 2: Detects and resets the request. Resets the acknowledgement. The write cycle is thus closed.
Page 228 Ethernet communication 7.7 HT 2 Standard characters Special characters 1001 1010 1011 1100 1101 1110 1111 20H - 7FH: Standard characters A0H - FFH: Special characters Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 229: Profibus Dp Communication
PROFIBUS DP Communication General information 8.1.1 PROFIBUS DP interfaces of the MCI board There are two PROFIBUS DP interfaces on the MCI board: ● Interface X101: PROFIBUS DP The NC only has direct access to this PROFIBUS interfaces. Therefore all PROFIBUS drives and NC-specific I/Os, e.g.
Page 230 Examples: Drives, I/O modules Motion Control Option Communication between SINUMERIK 840Di sl (NC and PLC), as the master, and the slave components on PROFIBUS is based on PROFIBUS DP with the Motion Control Extension. The MotionControl extension is characterized by: ●...
Page 231: Message Format For Cyclic Dp Communication
PROFIBUS DP Communication 8.1 General information 8.1.3 Message format for cyclic DP communication Message frame structure A PROFIBUS message generally adopts the following format for cyclic data transmission: Figure 8-1 Main message format for cyclic data transmission User data structure The useful data for cyclic communication are referred to as parameter process data objects (PPO).
Page 232: Description Of A Dp Cycle
PROFIBUS DP Communication 8.1 General information 8.1.4 Description of a DP cycle Actual values At time T the current actual position values are read from all isochronous DP slave drives. In the next DP cycle, the actual values are transferred to the DP master in the time T Position controller The NC position controller is started at the time T with T...
Page 233 8.1 General information Key to Fig. above: ● T MAPC Master application cycle: NC-Position controller cycle the following is always valid for SINUMERIK 840Di sl: T MAPC ● T DP cycle time: DP cycle time ● T Data exchange time: Total transfer time for all DP slaves ●...
Page 234: Networking Rules
PROFIBUS DP Communication 8.1 General information 8.1.5 Networking rules Basic rules The following basic rules must be observed: 1. The bus line must be terminated at both ends. For this purpose, enable the terminating resistor in the PROFIBUS DP connector of the first and of the last nodes and disable the remaining terminators.
Page 235: Requirements
SIMATIC STEP 7 (option) is required in the following version or later: ● SIMATIC STEP 7 as of Version 5.3, Service Pack 2 SIMATIC STEP 7 can either be installed directly on the SINUMERIK 840Di sl PCU or on an external computer (PG/PC).
Page 236 PROFIBUS DP Communication 8.2 Requirements 840Di sl Rack The 840Di sl rack is a SIMATIC-300 station preconfigured for SINUMERIK 840Di sl. The following version is available in the hardware catalog of HW Config: ● SINUMERIK 840Di sl with PLC 317-2DP 2AJ10 –...
Page 237 PROFIBUS DP Communication 8.2 Requirements NOTICE If the SlaveOM is used in conjunction with other PLC CPUs, a consistency error is signaled when compiling the S7 configuration and no system data blocks are generated. Installation The SlaveOM is part of the PLC Toolbox. When the PLC Toolbox is installed, it is automatically installed in SIMATIC STEP 7.
Page 238 PROFIBUS DP Communication 8.2 Requirements NOTICE The GSD files must be installed on the computer on which SIMATIC STEP 7 is already installed. To install a GSD file, please refer to the appropriate notes in the file: < Installation path>\importantinfo.rtf Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 239: Creating A Profibus Configuration
Note The instructions given in this Section are essentially limited to the special characteristics of the SINUMERIK 840Di sl. For more details about working with SIMATIC STEP 7 please refer to the relevant SIMATIC documentation or online help. Starting HW Config Start "HW Config"...
Page 240: Inserting Dp Slaves
PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration Search: Profile: Figure 8-5 HW Config: Insert modules, e.g. SINAMICS S120 8.3.2 Inserting DP slaves In principle, both PROFIBUS interfaces have the same functionality. To be able to utilize the available transmission capacity optimally, it is recommended that drive and I/O modules be operated on dedicated PROFIBUS line in each case.
Page 241 PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration POSMO SI Figure 8-6 Recommended distribution of DP slaves (schematic) 1) Machine control panel: MCP 483, MCP310 2) and 4) ET200... I/Os 3) SIMODRIVE POSMO A 5) SINAMICS S120 6) SIMODRIVE 611 universal 7) SIMODRIVE SI, CD/CA 8) ADI4 If you are using both PROFIBUS interfaces, we recommend the following distribution of DP...
Page 242: Parameterizing The Equidistant Dp-Slaves Finally
PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration 8.3.3 Parameterizing the equidistant DP-Slaves finally After the DP-Slaves have been added in the configuration and parameterized individually, the following parameters of the equidistant DP slaves must be set in two separate steps for the final parameterization of the equidistant DP communication of the PROFIBUS(1) Interface (X101) corresponding to Slot X2: Step1:...
Page 243 PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration Dialog: Beginning Dialog: DP slave properties Tab: Cycle synchronization Radio button: "Synchronize drive to equidistant DP cycle" ☑ Button: "Adjust" Figure 8-7 Enabled isochronous DP cycle NOTICE If there are different equidistant DP slave types in an S7 project, e.g. different SINAMICS drives, ADI4, etc., the following steps must first be performed for each DP slave type before continuing with the setting of other parameters.
Page 244 PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration Dialog: Continuation Tab: General Group: Node/Master System Button: "PROFIBUS..." Dialog: Properties - PROFIBUS interface SINAMICS ... Tab: Parameter Button: "Properties..." Dialog: PROFIBUS properties Tab: Network settings Button: "Options..." Dialog: Options ☐ Radio button: Activating the equidistant bus cycle ☑ Equidistant DP cycle T When calculating the cyclic portion of the DP communication, the time for the isochronous DP cycle is automatically changed to the time required as the minimum.
Page 245 PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration Note You are advised not to activate the option "Times Ti and To same for all slaves" in the "Synchronization of the slaves" group. The following parameters are now set for each type of DP slave on the "Clock synchronization"...
Page 246 NOTICE On a DP slave S120 used with SINUMERIK 840Di sl, the ratio between the master application cycle TMAC and DP cycle time TDP must be 1:1. Master application cycle = DP cycle...
Page 247 PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration Setpoint acceptance To The "setpoint transfer to" parameter defines the time when the speed setpoint of the NC position controller is accepted by a DP slave S120. Note You are strongly recommended to use the same value for the time of setpoint acceptance To for all DP slaves S120, in particular if the axes interpolate.
Page 248: Generating System Data Blocks (Sdb)
PROFIBUS DP Communication 8.3 Creating a PROFIBUS configuration NOTICE If an S7 project includes different equidistant DP slave types, such as different SINAMICS drives, ADI4, etc., the following parameter settings must be made separately for each DP slave type as described above, and an alignment must be performed: •...
Page 249: Load The Configuration In The Plc
PROFIBUS DP Communication 8.4 SIMATIC I/O devices (ET200...) 8.3.5 Load the configuration in the PLC The configuration can be loaded in the PLC after generating the system data module successfully. Loading the configuration is descried in detail within the framework of the PLC commissioning in Chapter "Load configuration (STEP 7 ->...
Page 250: Dp Slave I/O Module Pp72/48
A PP72/48 I/O module is parameterized with a GSD file. ● The GSD file is a part of the SINUMERIK 840Di sl software. Refer to Section "Overview of software components" (Page 31): SIMATIC add-on software: GSD file for I/O modules PP72/48 ●...
Page 251: Setting Profibus Parameters
PROFIBUS DP Communication 8.5 DP slave I/O Module PP72/48 8.5.3 Setting PROFIBUS parameters As soon as you have inserted DP slave PP72/48 into the configuration, dialog box "PROFIBUS properties interface PP input/output" is displayed. The following PROFIBUS parameters must either be set or verified: ●...
Page 252: Setting The I/O Addresses
PROFIBUS DP Communication 8.5 DP slave I/O Module PP72/48 8.5.4 Setting the I/O addresses When the dialog box is closed DP slave PP72/48 is inserted into the DP master system and the detail view of DP slave PP72/48 is displayed in the station window. Select one of the modules listed under DP slave PP72/48 (PP input/output module) from the hardware catalog and insert it in slot 1 of the detail view.
Page 253: Dp Slave Mcp 310
FC 19 (interface parameter assignment version: milling) and FC 25 (interface parameter assignment, version: turning). The library of the basic PLC program is a part of the SINUMERIK 840Di sl. The installation of the library is described in detail in the Section "Create PLC Program"...
Page 254 PROFIBUS DP Communication 8.6 DP slave MCP 310 Note The PLC basic program must be installed on the computer on which SIMATIC STEP 7 is installed. To install the basic PLC program, please pay attention to the corresponding instructions in the file: •...
Page 255: Parameterization Of The Mcp
PROFIBUS DP Communication 8.6 DP slave MCP 310 8.6.2 Parameterization of the MCP Interfaces In the following figure, the interfaces are shown on the rear side of the module: COM-Board Figure 8-11 Rear of the MCP 310 showing the control and display elements and the interfaces Figure 8-12 Connection overview: Power supply X10 For a detailed description of the electrical and mechanical design and of the machine control...
Page 256 PROFIBUS DP Communication 8.6 DP slave MCP 310 Display of the software version All the LEDs on the front panel of the MCP flash after the electrical connection of the MCP, provided there is no communication between MCP and PLC. Simultaneously pressing the two keys "Feed stop"...
Page 257 PROFIBUS DP Communication 8.6 DP slave MCP 310 Switch S3 The PROFIBUS address and the connection type are set via Switch S3 on the rear side of the MCP: Table 8-1 Switch S3: PROFIBUS address (1-7) Meaning/value Connection type: PROFIBUS Reserved PROFIBUS address The switch position 10-8 are to be set according to the data in the table.
Page 258: Functions Of The Machine Control Panel
PROFIBUS DP Communication 8.6 DP slave MCP 310 8.6.3 Functions of the machine control panel The machine control panel offers the following functions: ● Standard ● Handwheel ● Additional I/Os Standard The function: "Standard" transfers the I/O data to the function and user-specific keys and outputs: ●...
Page 259: Configure Mcp 310 Dp Slave
PROFIBUS DP Communication 8.6 DP slave MCP 310 Additional I/Os The function: "Additional I/Os" transfers the data of all non-standard I/Os: ● Direct keys ● Customer keys: 6 signals (bit 0 to bit 6) ● Rotary switch with the following distribution: ●...
Page 260 PROFIBUS DP Communication 8.6 DP slave MCP 310 Figure 8-14 Configuration with MCP 310 DP slave Requirements: S7 project The following status with reference to the S7 project in which the MCP 310 DP slave is to be inserted, is required: ●...
Page 261 PROFIBUS DP Communication 8.6 DP slave MCP 310 PROFIBUS parameters As soon as you have inserted MCP 310 DP slave into the configuration, dialog box "PROFIBUS properties interface SINUMERIK MCP" is displayed. The following PROFIBUS parameters must either be set or verified: ●...
Page 262 PROFIBUS DP Communication 8.6 DP slave MCP 310 Insert module The active functions and hence the number of user data elements to be transferred are chosen by selecting the appropriate pre-configured module. The modules in the hardware catalog are arranged under the MCP 310 DP slave. The following modules are available: Universal module ●...
Page 263 PROFIBUS DP Communication 8.6 DP slave MCP 310 Module: standard, extended The module transfers the data for the "Standard" and "Additional I/Os" functions: ● Input data: 13 bytes ● Output data: 10 bytes Customer LEDs Standard Data Reserved (1 byte) (8 bytes) (1 byte) Low-Byte...
Page 264: Linking To The Basic Plc And User Program
To synchronize several MCPs, the PLC program must be adapted accordingly. This is the user's (machine manufacturer's) responsibility. The following parameters are relevant, if you want to operate a machine control panel MCP 310 as DP slave in a SINUMERIK 840Di sl: MCPNum: // Number of MCP...
Page 265 PROFIBUS DP Communication 8.6 DP slave MCP 310 /FB1/ Function Manual - Basic Functions: P3 PLC Basic Program, Chapter "FB 1: RUN_UP Basic Program", Startup section VDI interface parameter assignment The following function modules are available for assigning the VDI interface parameters: ●...
Page 266 PROFIBUS DP Communication 8.6 DP slave MCP 310 Customized response The following organization blocks can be added to the PLC user program to customize the response to a DP slave MCP 310 failure: ● OB 82: Diagnostic interrupt ● OB 86: Rack failure Please refer to the corresponding SIMATIC literature for details of linking organization blocks and evaluating diagnostic data.
Page 267: Input/Output Image
PROFIBUS DP Communication 8.6 DP slave MCP 310 8.6.6 Input/Output image Arrangement: Keys and LEDs A key and the LED positioned above it form a logical unit. The key and the LED have the same number. ● Key: Sxy = Key number xy ●...
Page 268 PROFIBUS DP Communication 8.6 DP slave MCP 310 Table 8-2 Input image Signals from machine control panel (keys) Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 EB n+0 Spindle override Mode *NC stop SP - SP 100% SP + Single AUTO block...
Page 269 PROFIBUS DP Communication 8.6 DP slave MCP 310 Table 8-3 Output image Signals to machine control panel (LEDs) Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 AB n+0 Spindle override Mode *NC Stop SP - SP 100% SP + Single AUTO LED19...
Page 270: Dp Slave Mcp 483
FC 19 (interface parameter assignment version: milling) and FC 25 (interface parameter assignment, version: turning). The library of the basic PLC program is a part of the SINUMERIK 840Di sl. The installation of the library is described in detail in the Section "Create PLC Program"...
Page 271 PROFIBUS DP Communication 8.7 DP slave MCP 483 References: The following manuals are required for the commissioning of the MCP: /FB1/ Function Manual - Basic Functions, P3 PLC Basic Program, Program Structure and the Modules of the PLC Basic Program /FB2/ Function Manual - Extension Functions, H1 Manual and Handwheel Travel, Startup of Handwheels /BH/ Operator Components Manual, Description of MCP (interfaces, electrical connection...
Page 272: Parameterization Of The Mcp
PROFIBUS DP Communication 8.7 DP slave MCP 483 8.7.2 Parameterization of the MCP Interfaces In the following figure, the interfaces are shown on the rear side of the module: Figure 8-17 Position of interfaces on rear side of machine control panel For a detailed description of the electrical and mechanical design and of the machine control panel interfaces, please refer to: References:...
Page 273 PROFIBUS DP Communication 8.7 DP slave MCP 483 Figure 8-18 MCP software version display Switch S3 The PROFIBUS address and the connection type are set via Switch S3 on the rear side of the MCP: Table 8-4 Switch S3: PROFIBUS address (1-7) Meaning/value Connection type: PROFIBUS Reserved...
Page 274: Functions Of The Machine Control Panel
PROFIBUS DP Communication 8.7 DP slave MCP 483 8.7.3 Functions of the machine control panel The machine control panel offers the following functions: ● Standard ● Handwheel ● Additional I/Os Standard The "Standard" function transfers the I/O data to the function and user-specific keys and outputs: ●...
Page 275: Configure Mcp 483 Dp Slave
PROFIBUS DP Communication 8.7 DP slave MCP 483 ● Input data: 5 bytes ● Output data: 2 bytes 8.7.4 Configure MCP 483 DP slave The chapter describes the configuration of an MCP 483 DP slave with the help of the configuration of a SIMATIC S7 project displayed in the following figure.
Page 276 PROFIBUS DP Communication 8.7 DP slave MCP 483 Figure 8-19 Configuration with MCP 483 DP slave Requirements: S7 project The following status with reference to the S7 project in which the MCP 483 DP slave is to be inserted, is required: ●...
Page 277 PROFIBUS DP Communication 8.7 DP slave MCP 483 PROFIBUS parameters As soon as you have inserted MCP 483 DP slave into the configuration, dialog box "PROFIBUS properties interface SINUMERIK MCP" is displayed. The following PROFIBUS parameters must either be set or verified: ●...
Page 278 PROFIBUS DP Communication 8.7 DP slave MCP 483 Insert module The active functions and hence the number of user data elements to be transferred are chosen by selecting the appropriate pre-configured module. The modules in the hardware catalog are arranged under the MCP 483 DP slave. The following modules are available: Universal module ●...
Page 279 PROFIBUS DP Communication 8.7 DP slave MCP 483 Module: standard, extended The module transfers the data for the "Standard" and "Additional I/Os" functions: ● Input data: 13 bytes ● Output data: 10 bytes Customer LEDs Standard Data Reserved (1 byte) (8 bytes) (1 byte) Low-Byte...
Page 280: Linking To The Basic Plc And User Program
To synchronize several MCPs, the PLC program must be adapted accordingly. This is the user's (machine manufacturer's) responsibility. The following parameters are relevant, if you want to operate a machine control panel MCP 483 as DP slave in a SINUMERIK 840Di sl: MCPNum: // Number of MCP...
Page 281 PROFIBUS DP Communication 8.7 DP slave MCP 483 /FB1/ Function Manual - Basic Functions: P3 PLC Basic Program, Chapter "FB 1: RUN_UP Basic Program", Startup section VDI interface parameter assignment The following function modules are available for assigning the VDI interface parameters: ●...
Page 282 PROFIBUS DP Communication 8.7 DP slave MCP 483 PLC user program If an MCP is connected via PROFIBUS DP, the basic PLC program does not check for module failure. In this case the MCP is monitored by a standard mechanism to monitor the active DP slave: ●...
Page 283: Input/Output Image
PROFIBUS DP Communication 8.7 DP slave MCP 483 8.7.6 Input/Output image Arrangement: Keys and LEDs A key and the LED positioned above it form a logical unit. The key and the LED have the same number. ● Key number xy corresponds to Sxy ●...
Page 284 PROFIBUS DP Communication 8.7 DP slave MCP 483 Signals from machine control panel (keys) Key Pos. 0 Key Pos. 2 EB n+2 Spindle *Spindle Feed Start *Feed Stop NC Start *NC Stop X50.4 X50.1 Start Stop Key Pos. 1 Feed override EB n+3 RESET Single...
Page 285 PROFIBUS DP Communication 8.7 DP slave MCP 483 Signals to machine control panel (LEDs) AB n+2 Axis selection Single Spindle Spindle Block Start Stop LED48 LED47 LED14 LED44 LED32 LED35 LED38 LED41 AB n+3 Axis selection LED34 LED36 LED43 LED42 LED40 LED39 LED37...
Page 286: Adi4 Dp Slave
8.8.1 SlaveOM Parameters for the configuration with regard to the ADI4 interface modules, called DP slave ADI4 here, are assigned with the SlaveOM for SINUMERIK 840Di sl. Please see References to ADI4 to install the SlaveOM. Note To simplify parameterization of the isochronous communication on the PROFIBUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.) you require into the...
Page 287: Dp Slave Sinamics S120
PROFIBUS DP Communication 8.9 DP slave SINAMICS S120 DP slave SINAMICS S120 The following SINAMICS drive system is available for SINUMERIK 840Di sl: ● SINAMICS S120 with CU320 on PROFIBUS DP 8.9.1 SlaveOM for SINAMICS The SlaveOM for SINAMICS is required to configure SINAMICS S120 drives. The SlaveOM is automatically installed in SIMATIC STEP7, if the SINAMICS STARTER commissioning tool is installed on the same computer (PG/PC) as SIMATIC STEP7.
Page 288: Parameterizing Dp Slaves
PROFIBUS DP Communication 8.9 DP slave SINAMICS S120 Expanded message frame configuration The "expanded message frame configuration" has been provided to transfer additional drive data to the NC in the cyclic PROFIBUS message frame in addition to the process data (PDA) for the selected standard message frame type (102 to 107).
Page 289 Selecting a message frame defines the process data (PDA) exchanged between the DP master and the DP slave. The following vendor-specific message frames are predefined for exchanging process data between a SINUMERIK 840Di sl (DP master) and a DP slave S120: Table 8-7 Message frames and process data...
Page 290 PROFIBUS DP Communication 8.9 DP slave SINAMICS S120 Antriebsobjekt Message Description frame "Free The transmission and receive messages can be interconnection configured as required by using BICO technology via BICO" to interconnect the send and receive process data. /PDA : Number of process data values: Setpoint/actual values setpoint actual DSC: Function: Dynamic Servo Control...
Page 291 PROFIBUS DP Communication 8.9 DP slave SINAMICS S120 Configuring a message frame in HW-Konfig DP slave properties General Configuration Cycle synchronization Preassignment Object Message frame selection Option Message frame102, PZD-6/10 Message frame 105, PZD-6/10 Message frame 103, PZD 6/10 Overview Details Configuring a message frame in STARTER PROFIBUS message frame...
Page 292 There is no automatic adjustment! The following data must agree: 1. SIMATIC configuration of S120 DP slave: Drive object: "Drive control": Message frame 2. SINUMERIK 840Di sl NC MD13060 $MN_DRIVE_TELEGRAM_TYPE[n] 3. SINAMICS S120 Parameter p0922 (PROFIBUS PDA message frame selection) or STARTER: Drive unit >...
Page 293 PROFIBUS DP Communication 8.9 DP slave SINAMICS S120 Note To prevent changes to the I/O addresses in the NC machine data, we recommend using the default machine data values when assigning I/O addresses: • Drive objects: "Drive control": MD13050 $MN_DRIVE_LOGIC_ADDRESS[n], n = 0,1,... Standard values: 4100 + n*40 •...
Page 294: Dependencies Of Profibus Dp Communication
PROFIBUS DP Communication 8.9 DP slave SINAMICS S120 8.9.4 Dependencies of PROFIBUS DP communication The overview example shows the interrelations or interdependencies when configuring the PROFIBUS DP communication between the components: ● NC ● DP master ● DP slave S120 Figure 8-22 Dependencies: NC, PLC/DP master and DP slave S120 ①...
Page 295 DP slave S120 interprets the PROFIBUS message frames received from the DP master based on the STARTER configuration: PROFIBUS address: 10 Object Antriebsobjekt Frame type Drive_1 SIEMENS message frame 102 Drive_2 SIEMENS message frame 102 Drive_3 SIEMENS message frame 102 Infeed Free message frame configuration with...
Page 296 PROFIBUS DP Communication 8.9 DP slave SINAMICS S120 The process data (message frame type) is read by DP slave S120 to the configured object sequence (object) from the PROFIBUS message frame and transferred to the relevant drive object according to the drive object number. Example: The process data for the first object is read to the PROFIBUS message frame according to message frame 102.
Page 297: Dp Slave Simodrive Drives
● SIMODRIVE POSMO SI 8.10.1 SlaveOM The drives are assigned parameters using the SlaveOM for SINUMERIK 840Di sl (for installation of the SlaveOM, refer to Subsection "General" (Page 229): DriveOM/SlaveOM). Note To simplify parameterization of the isochronous communication on the PROFIBUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.) you require into the...
Page 298: Parameterizing Dp Slaves
PROFIBUS DP Communication 8.10 DP slave SIMODRIVE drives Expanded message frame configuration In SW 2.2 and higher, "expanded message frame configuration" has been provided to transfer drive data to the NC in the cyclic PROFIBUS message frame in addition to the process data (PDA) for the selected standard message frame type (102 to 107).
Page 299 PROFIBUS DP Communication 8.10 DP slave SIMODRIVE drives Dialog Dialog: Properties - PROFIBUS Interface SIMODRIVE 611U DP2, DP3 Tab: Parameter address: PROFIBUS address Frame type After confirming this dialog with "OK", the "DP Slave Properties" dialog box is opened. The corresponding message frame type is to be selected via the Pre-assignment list box, depending on the drive functionality to be used.
Page 300 There is no automatic adjustment! The following data must agree: 1. SIMATIC configuration of 611U DP slave Frame type 2. SINUMERIK 840Di sl NC MD13060 $MN_DRIVE_TELEGRAM_TYPE 3. SIMODRIVE 611 universal Parameter P0922 (PROFIBUS message frame type selection) For a detailed description of the different message frame types, please see: ●...
Page 301 I/O addresses Communication between the NC and the individual axes of the DP slaves 611U in the SINUMERIK 840Di sl can only take place if the I/O addresses for the setpoint and actual value of an axis are the same.
Page 302 PROFIBUS DP Communication 8.10 DP slave SIMODRIVE drives Dialog Dialog: DP slave properties Tab: Configuration Table entry: PROFIBUS Partner, I/O address: <I/O address> On confirming the dialog with "OK", the "DP Slave Properties" dialog box is closed. Step 1 of parameterization of DP slave 611U is then complete.
Page 303: Dependencies Of Profibus Dp Communication
PROFIBUS DP Communication 8.10 DP slave SIMODRIVE drives 8.10.4 Dependencies of PROFIBUS DP communication The overview example shows the interrelations or interdependencies when configuring the PROFIBUS DP communication between the components: ● NC ● DP master ● DP slave 611U Figure 8-23 Dependencies: NC, PLC/DP master and DP slave (SIMODRIVE 611 universal) ①...
Page 304 PROFIBUS DP Communication 8.10 DP slave SIMODRIVE drives For configuring the drive within the framework of the NC commissioning, please refer to Subsection "Drive configuration" (Page 389). ② DP master The information regarding the individual DP slaves are known to the DP masters from the PROFIBUS SDB generated from the configuration.
Page 305: Dp Slave Diagnostic Repeater For Profibus Dp
DP master. Used together with the SINUMERIK 840Di sl it is possible to display the location and cause of the fault in plaintext via SIMATIC STEP 7.
Page 306: Area Of Application
PROFIBUS DP Communication 8.11 DP slave diagnostic repeater for PROFIBUS DP ● Galvanic separation of the PG interface: Galvanically or electrically isolating the PG interface prevents interference with the other bus segments of the PROFIBUS DP if the PG connecting cable is inserted or removed, even at high baud rates.
Page 307: Drive Commissioning (Sinamics)
Basic requirements The following basic requirements must be fulfilled for the commissioning of SINAMICS S120. ● The electronic power supply of PG/PC, SINUMERIK 840Di sl and SINAMICS S120 is switched on. ● The mechanical and electrical elements of the SINAMICS drives are set up and connected correctly, including DRIVE CliQ connections.
Page 308: Safety Information
Drive commissioning (SINAMICS) 9.1 Requirements 9.1.2 Safety information DANGER A hazardous voltage will be present in all components for a further 5 minutes after the system has been shutdown. Please follow the instructions on the component! CAUTION For safety reasons, Safety Integrated must be commissioned using STARTER in online mode.
Page 309: Online Commissioning
If the SINAMICS drive commissioning tool STARTER is installed without SIMATIC STEP 7 on a programmable controller (PG/PC or PCU of the SINUMERIK 840Di sl), the STARTER is started directly (e.g. via the Windows taskbar Start > SIMATIC > STEP 7 > STARTER). After that a new project must be created and the online connection data must be set in the STARTER for executing the drive startup.
Page 310: Create New Project Without Project Wizard
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.1 Create new project without Project Wizard Implementation Perform the following actions for creating the new project and for entering the online connection data: 1. Start the STARTER drive commissioning tool using the icon on the user interface or the Windows taskbar Start >...
Page 311 Drive commissioning (SINAMICS) 9.2 ONLINE commissioning Click OK, when you have finished entering data. Note The name "SINAMICS_S120_CU320" given to the drive unit by default can be changed in the tab "General". 5. The drive unit inserted in the project is now shown in the project structure. For entering the online data, right-click on the drive unit (in the example "SINAMICS_S120_CU320").
Page 312 PCU 50.3 (Page 187) STARTER on the PCU of the SINUMERIK 840Di If the STARTER is running on the PCU of the SINUMERIK 840Di sl, the IP address of the interface Ethernet 2 (Default: 192.168.214.241) is to be set. To determine the IP address, see Section: Ethernet connections of the PCU 50.3 (Page 187)
Page 313: Create New Project With Project Wizard
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.2 Create new project with Project Wizard Implementation Perform the following actions to create a new project: 1. Start the STARTER drive commissioning tool using the icon on the user interface or the Windows taskbar Start > SIMATIC > STEP 7 > STARTER. If the Project Wizard for creating a new project is not opened automatically when initiating the STARTER, open it using menu command Project >...
Page 314 Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 3. Set the PG/PC interface if required and test whether all SINAMICS drive units connected to the PROFIBUS which are to be commissioned as part of this project are accessible via the PG/PC interface. To go to the corresponding dialog box, click the "Change and test.."...
Page 315 Drive commissioning (SINAMICS) 9.2 ONLINE commissioning Note Only Control Units are located when searching for SINAMICS drive units. All of the other available components of a drive unit (infeed, motor module, etc.) are not taken into account at this stage. 5.
Page 316: Drive Unit: Enter Component Topology And Configuration Automatically
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.3 Drive unit: Enter component topology and configuration automatically. Requirement The following example format illustrates the configuration of a drive unit: ● Control Unit: CU320 ● Infeed: Active Line Module (ALM) ● Power module 1: Single Motor Module (SMM) ●...
Page 317 Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 2. After the online connection to the drive unit has been established, click the "Restore factory settings" button: ● Confirm the following dialog with OK to restore the factory settings. 1. Double-click "Automatic configuration" in the project navigator. The navigator then searches for all components connected to the drive unit and loads these into the STARTER.
Page 318: Drive: Configuring Motors And Encoders
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 4. Go offline before configuring the motors and encoder (see next section). Click the "Disconnect from Target System" button. 9.2.4 Drive: Configuring motors and encoders Since no motors/encoders are used in the project with DRIVE CliQ interface, they must be configured manually because the data cannot be determined automatically without DRIVE CliQ.
Page 319 Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 2. Then in the Drive Navigator dialog box, click the "Device configuration" button and in the Device Configuration dialog box the "Configure the drive" button. Run through the following dialogs for configuring the drive unit using the "Continue" button without making any changes until you reach the motor dialog.
Page 320 Drive commissioning (SINAMICS) 9.2 ONLINE commissioning ● Exit the dialog box by clicking the "Next >" button. 1. In the configuration dialog for process data exchange, select the message frame according to the PROFIBUS configuration of the drive unit as DP slave S120 with STEP 7 HW Config from Section "DP Slave: SINAMICS S120"...
Page 321: Control Unit: Selecting The Profibus Meassage Frame
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.5 Control Unit: Selecting the PROFIBUS meassage frame Control Unit error acknowledgement is currently performed via the BICO interconnection. As a result, you must configure free message frame configuration with BICO as the PROFIBUS message frame.
Page 322: Drive Unit: Check Configuration
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.7 Drive unit: Check configuration After configuring all of the drives, we recommend checking the DRIVE-CliQ interconnection recognized by the STARTER during automatic configuration with the drive unit interconnection. Implementation Perform the following actions for each drive unit: 1.
Page 323 Drive commissioning (SINAMICS) 9.2 ONLINE commissioning The corresponding DRIVE-CliQ topology in the STARTER must appear as follows: Note Differences must be corrected manually. Click the appropriate component then, keeping the left-hand mouse button depressed, drag it to the correct connection. If the connection is already assigned, you can use a free connection in the topology or the component folder as a buffer.
Page 324: Drive Unit: Configuring Profibus Message Frames
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.8 Drive unit: Configuring PROFIBUS message frames When configuring the PROFIBUS message frame of a drive unit, the following must be considered: ● The process data for the "Drives" drive object must be available before the process data of all other drive objects (Control Unit, infeed, etc.).
Page 325: Control Unit: Acknowledge Error (Bico Interconnection)
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.9 Control Unit: Acknowledge error (BICO interconnection) To acknowledge an error for the Control Unit, use the "PROFIBUS PDA1 received" signal from the first drive. ● Control Unit: p2103 BI: 1. Acknowledge faults ● Drive: Drive_1, r2090: Bit7, BO: PROFIBUS PZD1 receive bit-serial Implementation Perform the following actions: 1.
Page 326: Control Unit: Output "Infeed Operation" (Bico Interconnection) Signal
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.10 Control Unit: Output "Infeed operation" (BICO interconnection) signal To output the "Infeed operation" signal at terminal X132.7 of the Control Unit, parameter: "r863 Bit 0" of the infeed must be connected to parameter: "p742" of the Control Unit via BICO interconnection: ●...
Page 327: Control Unit: Output "Infeed Ready For Activation" (Bico Interconnection) Signal
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.11 Control Unit: Output "Infeed ready for activation" (BICO interconnection) signal To output the "Infeed ready to start" signal at terminal X132.8 of the Control Unit, parameter: "r899, Bit 0" of the infeed must be connected to parameter: "p743" of the Control Unit via BICO interconnection and terminal X132.8 of the control unit must be parameterized as DO13 output: ●...
Page 328: Infeed: Acknowledge Error (Bico Interconnection)
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.12 Infeed: Acknowledge error (BICO interconnection) To acknowledge an error for the infeed, use the "PROFIBUS PDA1 received" signal from the first drive. ● Infeed: p2103[0] BI: 1. Acknowledge faults ● Drive: Drive_1, r2090: Bit7, BO: PROFIBUS PZD1 receive bit-serial Implementation Perform the following actions: 1.
Page 329: Infeed: Enable/Disable Drives Via On/Off1 (Bico Interconnection)
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.13 Infeed: Enable/disable drives via ON/OFF1 (BICO interconnection) To be able to release and stop the drives externally, e.g. via a PLC user program, connect digital input X122.1 on the Control Unit and use the BICO interconnection with parameter "p840[0] BI: ON/OFF1": ●...
Page 330: Drive: Enable/Disable Drives Via 2Nd Off3 (Bico Interconnection)
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.14 Drive: Enable/disable drives via 2nd OFF3 (BICO interconnection) To be able to release and stop the drive externally, e.g. via a PLC user program, connect digital input X122.2 on the Control Unit and use the BICO interconnection with parameter: "p849[0] BI: 2.
Page 331: Drive Unit: Backing Up Parameters
Drive commissioning (SINAMICS) 9.2 ONLINE commissioning 9.2.15 Drive unit: Backing up parameters After completing the configuration, you must load and save the parameters in the drive unit. Implementation Perform the following actions for each drive unit: 1. Access the drive unit with the PG/PC online. 2.
Page 332: Settings Of Specific Parameters
Description Control Unit (CU320) 9906 Topology comparison level of all components, 2: low; comparison of the component type Servo PROFIBUS PZD Message frame selection, SIEMENS Message frame 102, PZD 6/10 2000 Power module monitoring time [ms] 1520 Upper force limit/motor,...
Page 333: Example For Systems With More Than 6 Drives
Drive commissioning (SINAMICS) 9.3 Example for systems with more than 6 drives Example for systems with more than 6 drives 9.3.1 Configuration One control unit CU 320 can control max. 6 drives in "Servo" mode. The following example shows which drive components are required and how they are interconnected to operate more than 6 drives in one configuration.
Page 334: Basic Commissioning
Drive commissioning (SINAMICS) 9.3 Example for systems with more than 6 drives Creating a project The project should be created according to the description in Chapter "ONLINE- Startup" (Page 309). Both drive units must be displayed in the preview window. Figure 9-6 STARTER: Project Wizard (excerpt) Component topology...
Page 335: Drives Of Control Unit 2: Additional Bico Interconnection
Drive commissioning (SINAMICS) 9.3 Example for systems with more than 6 drives 9.3.3 Drives of Control Unit 2: Additional BICO interconnection The infeed can be connected with a Control Unit via DRIVE CliQ. As Control_Unit_1 is connected to the infeed, there is no possibility for the drives (drives_6..._9) controlled by Control_Unit_2 to undertake a BICO connection of drive parameter "p864, BI: Infeed operation"...
Page 336 Drive commissioning (SINAMICS) 9.3 Example for systems with more than 6 drives Figure 9-8 STARTER: Work area (excerpt) 3. Via a BICO interconnection, connect to Control_Unit_2 the parameter "r722: Bit0. CO/BO: CU digital inputs, status: :DI 0" of the input terminal: "DI 0" (X122.1), Project > Drive unit_Adr10 >...
Page 337: Further Terminal Assignments
Drive commissioning (SINAMICS) 9.4 Further terminal assignments Further terminal assignments Note The further terminal assignments should only be considered as recommendations that can be adapted to the requirements of the actual automation system. 9.4.1 Advice on terminal assignment: 1. CU (X122) Table 9-3 Terminal assignment of 1st CU (X122) Pin-No.
Page 338: Advice On Terminal Assignment: 1. Cu (X132)
Drive commissioning (SINAMICS) 9.4 Further terminal assignments 9.4.2 Advice on terminal assignment: 1. CU (X132) Table 9-4 Terminal assignment of 1st CU (X132) Pin-No. Function Pin assignment BICO source/sink Input Line contactor, feedback signal CU: r 0722.7 LM : p 0860 Ground for pins 1...4 Ground for pins 7, 8, 10, 11 Output...
Page 339 Drive commissioning (SINAMICS) 9.4 Further terminal assignments Pin-No. Function Pin assignment BICO source/sink Input SH/SBC 1 - Group 2 2 to nth CU: r 0722.3 p9620 (all drives in the group) SINAMICS Safety Integrated (SH enable = p9601) Ground for pins 1...4 Ground for pins 7, 8, 10, 11 Output SH/SBC 1 - Group 1...
Page 340: Advice On Interconnection: 1. Cu With 2Nd To Nth Cu
Drive commissioning (SINAMICS) 9.4 Further terminal assignments 9.4.4 Advice on interconnection: 1. CU with 2nd to nth CU Note The interconnection proposal refers to the terminal assignment proposals made in the previous sections. Figure 9-10 Advice on interconnection: 1st CU with 2nd - nth CU Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 341: Example: Cu Interconnection With Line Contactor
Drive commissioning (SINAMICS) 9.4 Further terminal assignments 9.4.5 Example: CU interconnection with line contactor Figure 9-11 Example: CU interconnection with line contactor Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 342: Basic Principles
Drive commissioning (SINAMICS) 9.5 Basic principles Basic principles 9.5.1 Drive unit: Upgrade firmware The firmware of a drive unit is upgraded using the STARTER commissioning tool. Requirements This procedure requires a functional project and a CF card with the new firmware. Implementation Perform the following actions to upgrade the firmware: 1.
Page 343 Drive commissioning (SINAMICS) 9.5 Basic principles 6. Go online once again with the PG/PC and load the converted project into the drive by selecting "Load to target system". The first time the project is loaded into the drive it will perform internal calculations. To revert to the current view of the project, select "Load to PG"...
Page 344 Drive commissioning (SINAMICS) 9.5 Basic principles Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 345: Drive Commissioning (Simodrive)
The Chapter "Drive Commissioning (SIMODRIVE)" describes the preconditions of SINUMERIK 840Di sl for optimum commissioning of the drives in terms of material and cost. It is not the section's objective to explain in detail how a drive is commissioned. For commissioning of the drive, please refer to the relevant drive documentation.
Page 346: Simodrive 611 Universal/E, Posmo Cd/Ca And Si
Drive commissioning (SIMODRIVE) 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI 10.1.1 Commissioning variants The following distinction is made between commissioning of the above SIMODRIVE drives: ● First commissioning ● Series machine startup First commissioning A first commissioning must only be carried out if no matching parameter record is available for the drive in the form of the parameter file.
Page 347: Preconditions For An Online Connection
Drive commissioning (SIMODRIVE) 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI Recommended procedure Within the framework of SINUMERIK 840Di sl, the procedure described in Point 3 is recommended: The advantages of this procedure are: ● SimoCom U is always available for: –...
Page 348: Setting A Profibus Address (Simodrive 611 Universal/E)
Drive commissioning (SIMODRIVE) 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI 10.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal/E) For SimoCom U to be able to enter online operation with the SIMODRIVE drives connected to the PROFIBUS, the PROFIBUS address specified in the S7 project (see Chapter "Create SIMATIC S7 Project"...
Page 349: Setting Profibus Address (Simodrive Posmo Si/Cd/Ca)
Drive commissioning (SIMODRIVE) 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI References: For detailed information on commissioning of SIMODRIVE 611 universal drives, refer to: /FBU/ SIMODRIVE 611 universal function description, Chapter "Parameterization of the Module", Parameter definition via display and operator unit and Chapter "Settings in PROFIBUS DP Master", commissioning 10.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA)
Page 350: Setting The Access Interface
Drive commissioning (SIMODRIVE) 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI 10.1.5 Setting the access interface Parameter assignment The access interface through which SimoCom U accesses the drives connected to PROFIBUS by means of routing, must be parameterized as follows: ●...
Page 351: Setting The Routing Information
Go online NOTICE MPI address of the PLC In SINUMERIK 840Di sl, the routing of the Ethernet connection to the PROFIBUS DP is provided by the PLC. Therefore, the MPI address of the PLC must be specified as the "MPI No".
Page 352 Drive commissioning (SIMODRIVE) 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI SimoCom U: 12-digit S7 subnet ID: Determine PROFIBUS S7 subnet ID If you do not have the PROFIBUS S7 subnet ID, you can call it using the SIMATIC Manager STEP 7.
Page 353: Starting Online Operation
Drive commissioning (SIMODRIVE) 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI 10.1.7 Starting online operation After parameterization of the access interface and entry of the routing information, SimoCom U can enter online operation with the SIMODRIVE drives. Start the search. To start the search for connected drives, follow these steps: ●...
Page 354: Installing Simocom U
Installing SimoCom U Installation SimoCom U is part of the 611U toolbox supplied with the SINUMERIK 840Di sl. ● Installation directory: refer to Chapter "Overview of software components" (Page 31) Engineering Tools > SIMODRIVE 611 universal toolbox > SimoCom U To install SimoCom U, start file setup.exe and follow the further installation instructions.
Page 355: Nc Commissioning With Hmi Advanced
NC Commissioning with HMI Advanced 11.1 General procedure The NC is parameterized for the connected machine by setting system variables. These system variables are designated as follows: ● Machine data (MD) ● Setting data (SD). Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 356: Machine And Setting Data
NC Commissioning with HMI Advanced 11.2 Machine and setting data 11.2 Machine and setting data Machine data Machine data are system variables used to adapt the NC to the machine. Name The identifier of a machine data is subject to the scheme: IdentifierString $ M k _ where the following applies:...
Page 357 NC Commissioning with HMI Advanced 11.2 Machine and setting data Name The identifier of a setting data is subject to the scheme: IdentifierString $ S k _ where the following applies: ● $: System variable ● S: Setting data ● k: Component k identifies the components of the NC parameterizing the appropriate machine data: ●...
Page 358 NC Commissioning with HMI Advanced 11.2 Machine and setting data Overview of setting data The setting data are divided into the following areas: Table 11-2 Overview of setting data Area Description from 41000 to 41999 General setting data ($SN_..) from 42000 to 42999 Channel-specific setting data ($SC_..) from 43000 to 43999 Axis-specific setting data ($SA_..)
Page 359: Display And Input
NC Commissioning with HMI Advanced 11.2 Machine and setting data 11.2.1 Display and input Machine data screen forms To display and input machine data, appropriate screen forms are provided. The screen forms are found on the HMI Advanced user interface at: Area switchover >...
Page 360: Protection Levels
Access to programs, data and functions is useroriented and controlled via 8 hierarchical protection levels. These are divided into (see following table ): ● 4 password levels for Siemens, machine manufacturer and end user ● 4 key switch positions for end user This provides a multilevel safety concept for controlling access rights.
Page 361 NC Commissioning with HMI Advanced 11.2 Machine and setting data Possible characters Up to eight characters are possible in a password. We recommend that you restrict yourself to the character set of the operator panel in selecting a password. Where a password consists of less than eight characters, the additional characters are interpreted as blanks.
Page 362 NC Commissioning with HMI Advanced 11.2 Machine and setting data Number Name Name 9219 USER_CLASS_TEACH_IN TEACH IN 9220 USER_CLASS_PRESET PRESET 9221 USER_CLASS_CLEAR_RPA Deleting R parameters 9222 USER_CLASS_WRITE_RPA Write R parameters 9231 USER_CLASS_WRITE_RPA_1 Write protection for first RPA area 9232 USER_BEGIN_WRITE_RPA_1 Start of the first RPA area 9233 USER_END_WRITE_RPA_1...
Page 363: Machine Data Display Filter
NC Commissioning with HMI Advanced 11.2 Machine and setting data 11.2.3 Machine data display filter Through the use of the machine data display filter, it is possible to reduce the number of displayed machine data of a certain area, e.g. general machine data or channel machine data, for special purposes.
Page 364 NC Commissioning with HMI Advanced 11.2 Machine and setting data Index from ... to The index filter refers to the machine data-fields. On the display, these machine data can be identified by the field index attached to the machine data string. Example: 10000 AXCONF_MACHAX_NAME_TAB[index] If the index filter is activated, machine data fields are only displayed in the specified index area.
Page 365: System Data
NC Commissioning with HMI Advanced 11.3 System data 11.3 System data 11.3.1 Resolutions Resolutions, e.g. resolutions of linear and angular positions, velocities, accelerations and jerk, must be differentiated as follows: ● the input resolution, i.e. the input of data from the user interface or using the part programs.
Page 366 NC Commissioning with HMI Advanced 11.3 System data Rounding The precision of angle and linear positions is limited to the computational resolution by rounding the product of the programmed value with the computational resolution to an integer number. Example of rounding: Computational resolution: 1000 increments/mm Programmed path: 97.3786 mm Effective value = 97.379 mm...
Page 367: Standardization Of Physical Units Of Machine Data And Setting Data
NC Commissioning with HMI Advanced 11.3 System data Machine data Table 11-4 Resolutions: Machine data Number Name Name/remarks General ($MN_ ... ) 9004 DISPLAY_RESOLUTION Display resolution 9011 DISPLAY_RESOLUTION_INCH Display resolution for INCH system of measurement 10200 INT_INCR_PER_MM Computational resolution for linear positions 10210 INT_INCR_PER_DEG Computational resolution for angular positions...
Page 368 NC Commissioning with HMI Advanced 11.3 System data User-defined The user can define different input/output units for machine and setting data. For this there must be an adjustment between the newly selected input/output units and the internal units via the following MD: ●...
Page 369 NC Commissioning with HMI Advanced 11.3 System data Physical unit MD10220: MD10230: Bit number Index n Kv factor Rev. feedrate Compensation value linear position Compensation value angular position Example 1: Machine data input/output of the linear velocities is to be in m/min instead of mm/min (initial setting).
Page 370: Changing Scaling Machine Data
NC Commissioning with HMI Advanced 11.3 System data Table 11-7 Normalization of physical units of machine data and setting data: Machine data Number Name Name/remarks General ($MN_ ... ) 10220 SCALING_USER_DEF_MASK Activation of standardizing factors 10230 SCALING_FACTORS_USER_DEF[n] Standardizing factors of physical quantities 10240 SCALING_SYSTEM_IS_METRIC Basic system metric...
Page 371: Loading Default Machine Data
Loading default machine data The default machine data can be loaded in different ways. 840Di startup Via the SINUMERIK 840Di sl standard interface 840Di Startup: Menu command Window > Diagnosis > NC/PLC ● Button: "Delete NC data" ● Button: "NC Reset"...
Page 372: Switching Over The Measuring System
NC Commissioning with HMI Advanced 11.3 System data 11.3.5 Switching over the measuring system The unit system is switched over for the entire machine using a softkey in the HMI Advanced operating area "MACHINE". The switchover is accepted only if: ●...
Page 373 NC Commissioning with HMI Advanced 11.3 System data The following data for which no unique physical units are defined is not converted automatically: ● R parameters ● GUDs (Global User Data) ● LUDs (Local User Data) ● PUDs (Program global User Data) ●...
Page 374: Traversing Ranges
NC Commissioning with HMI Advanced 11.3 System data 11.3.6 Traversing ranges Computational resolution and traversing ranges The range of values of the traversing ranges directly depends on the selected computational resolution (see Subsection "Resolutions" (Page 365)). For the default value assignment of the machine data for the computational resolution 1000 Incr./mm or 1000 Incr./deg.
Page 375: Cycle Times
11.3.8 Cycle times On the SINUMERIK 840Di sl, the system clock cycle, the position controller cycle and the interpolation cycle of the NC are based on the DP cycle time configured in STEP 7 "HW Config" (see Section "Create SIMATIC S7 Project" (Page 160)).
Page 376 NC Commissioning with HMI Advanced 11.3 System data ● MD10062 $MN_POSCTRL_CYCLE_DELAY (position control cycle delay) = T Figure 11-2 Position controller cycle offset compared to PROFIBUS DP cycle Explanations for the figure: Computing time requirements for the position controller DP cycle time: DP cycle time Data exchange time: Total transfer time for all DP slaves Master time: Offset of the start time for NC position control Global Control: Broadcast message for cyclic convergence of the...
Page 377 NC Commissioning with HMI Advanced 11.3 System data Figure 11-3 CPU time division between Windows XP and NC ● MD10185 $MN_NCK_PCOS_TIME_RATIO (CPU time share NC) Individual setting The default value for the NC CPU time share is 50%. An individual setting can only be made by the following formula: MD10185 >= 300 * (T * MD10070 + T...
Page 378 NC Commissioning with HMI Advanced 11.3 System data The maximum value for the NC CPU time share of 75 % must not be exceeded. A value greater than 75 % can lead to significant impairment (slowing down) of Windows XP applications.
Page 379: Velocities
NC Commissioning with HMI Advanced 11.3 System data 11.3.9 Velocities Max. axis velocity or spindle speed The maximum possible axis velocities and spindle speeds depend on the machine design, drive dynamics and the encoder limit frequency of the individual drives. Max.
Page 380 NC Commissioning with HMI Advanced 11.3 System data Lower limit The minimum tool path or axis velocity at which traversing is possible results from: (for the computational resolution, see Subsection "Resolutions" (Page 365)) If V is not reached, no traversing movement is carried out. References: /FB/ Function Manual - Basic Functions, G2 Velocities, Traversing Ranges, Accuracies, Subsection "Velocities"...
Page 381: Memory Configuration
Approx. 16 MB MCI board 5 MB 1) DRAM component (main memory) occupied by SINUMERIK 840Di sl and is thus no longer available for Windows NT. 2) The SRAM memory of the MCI board is divided into: ● Part programs and manufacturer cycles: 3 MB ●...
Page 382: Dram Memory
NC Commissioning with HMI Advanced 11.4 Memory configuration 11.4.1 DRAM memory Free memory The free DRAM memory is displayed via the following machine data: ● MD18050 $MN_INFO_FREE_MEM_DYNAMIC (free dynamic memory) The free DRAM should not be less than 15,000 bytes. CAUTION Before you enlarge DRAM areas, you should first check whether the free memory is sufficient:...
Page 383: Sram Memory
NC Commissioning with HMI Advanced 11.4 Memory configuration Number Name Name/remarks 28060 MM_IPO_BUFFER_SIZE Number of NC blocks in the IPO buffer 28070 MM_NUM_BLOCKS_IN_PREP Number of blocks for block preparation 28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for Compile cycles 28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for Compile cycles 28105 MM_NUM_CC_HEAP_MEM...
Page 384 NC Commissioning with HMI Advanced 11.4 Memory configuration Machine data Table 11-13 Machine data required to configure the SRAM Number Name Name/remarks General ($MN_ ... ) 18060 INFO_FREE_MEM_STATIC Display data of the free static memory 18080 MM_TOOL_MANAGEMENT_MASK Screen form for reserving memory for the tool management 18082 MM_NUM_TOOL Number of tools managed by NC...
Page 385: Axes And Spindles
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5 Axes and spindles 11.5.1 Axis configuration Definition The term "axis" is often used either as a single term in conjunction with SINUMERIK 840Disl or in a compound form, e.g. machine axis, channel axis, etc. To provide an overview of the philosophy used as the basis, here is a brief explanation of this term.
Page 386 NC Commissioning with HMI Advanced 11.5 Axes and spindles Axis assignment The assignment of drives, machine axes, channel axes and geometry axes using the corresponding machine data is shown in the following Fig.: Figure 11-4 Axis assignment ① The NC is informed about the I/O addresses of the drives defined in the S7 project through "HW Config"...
Page 387 NC Commissioning with HMI Advanced 11.5 Axes and spindles ② Each machine axis is assigned to a drive via machine data MD30110 $MA_CTRLOUT_MODULE_NR[0] (setpoint value assignment) and MD30220 $MA_ENC_MODULE_NR[0] (actual value assignment). The logical drive number m to be entered in the two machine data refers to the entry with the index n=(m-1) in the list described under Point 1 MD13050 $MN_DRIVE_LOGIC_ADDRESS[n].
Page 388: Axis Names
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.2 Axis names Each machine, channel and geometry axis can/must be assigned an individual name unambiguously identifying it in its name range. Machine axes The machine axis names are defined via the following machine data: ●...
Page 389: Drive Configuration
NC Commissioning with HMI Advanced 11.5 Axes and spindles Machine data Table 11-15 Axis names: Machine data Number Name Name/remarks General ($MN_ ... ) 10000 AXCONF_MACHAX_NAME_TAB Machine axis name Channelspecific ($MC_ ... ) 20060 AXCONF_GEOAX_NAME_TAB Geometry axis name in channel 20080 AXCONF_CHANAX_NAME_TAB Channel axis name/special axis name in channel...
Page 390 NC Commissioning with HMI Advanced 11.5 Axes and spindles NOTICE Any changes in the I/O addresses must be carried out consistently: • SIMATIC S7 project HW Config: I/O address for actual value and setpoint • NC: MD13050 $MN_DRIVE_LOGIC_ADDRESS[n] MD13120 $MN_CONTROL_UNIT_LOGIC_ADDRESS There is no automatic adjustment! Message frame The process data transferred between the NC and the drives or Control Unit during cyclic...
Page 391 NC Commissioning with HMI Advanced 11.5 Axes and spindles Default values The default values for the machine data are based on the following message frame: ● 102; Speed control with torque reduction, 1 position encoder NOTICE The following is to be taken into account: 1.
Page 392 NC Commissioning with HMI Advanced 11.5 Axes and spindles ADI4 With an ADI4 module you can operate up to 4 drives with analog setpoint interface on an isochronous PROFIBUS. The 611U-specific functions (Bit0 - Bit3) and effects of OFF2/OFF3 on the signal "driveReady"...
Page 393: Setpoint/Actual Value Channels
NC Commissioning with HMI Advanced 11.5 Axes and spindles ADI4 Because a ADI4 module does not support acyclic communication on the PROFIBUS, we recommend entering value 4 as the drive type for any drive operated via ADI4: ● MD13080 $MN_DRIVE_TYP_DP[n] = 4 Note We recommend entering drive type 4 manually for drives connected via ADI4: •...
Page 394 NC Commissioning with HMI Advanced 11.5 Axes and spindles NOTICE The motor measuring system is always used for the speed control function. Motor and motor measuring system must therefore always be connected to the same drive module. In the two following axis-specific machine data, the same logical drive number m of the drive is entered that the machine axis represents: ●...
Page 395 NC Commissioning with HMI Advanced 11.5 Axes and spindles Number Name Name/remarks 30210 ENC_SEGMENT_NR[0] Actual value assignment Drive type 5 = PROFIBUS DP 30220 ENC_MODULE_NR[0] Actual value assignment: Logical drive number for position measuring system 1 30220 ENC_MODULE_NR[1] Actual value assignment: Logical drive number for position measuring system 2 30230 ENC_INPUT_NR[0]...
Page 396: Incremental Measuring System Settings
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.5 Incremental measuring system settings Rotary measuring system The diagrams below show the general options of arranging a rotary incremental measuring system with regard to motor and load, as well as the resulting values for the appropriate machine data.
Page 397 NC Commissioning with HMI Advanced 11.5 Axes and spindles Rotary axis with encoder on motor Figure 11-7 Rotary axis with encoder on motor Linear axis with encoder on the machine Figure 11-8 Linear axis with encoder on the machine Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 398 NC Commissioning with HMI Advanced 11.5 Axes and spindles Machine data Table 11-19 Incremental measuring systems: Machine data Number Name Name/remarks Axisspecific ($MA_ ... ) 30240 ENC_TYPE[n] Actual-value acquisition modes 1 = incremental signal generator 30242 ENC_IS_INDEPENDENT[n] Encoder is independent 30300 IS_ROT_AX Rotary axis...
Page 399: Parameterization Of Absolute Measuring Systems
NC Commissioning with HMI Advanced 11.5 Axes and spindles Machine data Table 11-20 Linear measuring systems: Machine data Number Name Name/remarks Axisspecific ($MA_ ... ) 30240 ENC_TYPE[n] Actual-value acquisition modes 1 = incremental signal generator 30242 ENC_IS_INDEPENDENT[n] Encoder is independent 30300 IS_ROT_AX Rotary axis...
Page 400 NC Commissioning with HMI Advanced 11.5 Axes and spindles Adjusting Convergence of the measuring system with the machine positions is performed by calibration of the absolute value encoder in absolute measuring systems. For calibration of the absolute value encoder, see Chapter "Axis Homing" (Page 431). Rotary measuring systems An absolute encoder can currently exclusively be used as a motor encoder (indirect measuring system).
Page 401 NC Commissioning with HMI Advanced 11.5 Axes and spindles Rotary axis with absolute value encoder on motor Figure 11-11 Rotary axis with absolute value encoder on motor ADI4 For a machine axis whose measuring system consists of an absolute encoder on an ADI4 module, the following must be taken into consideration: ●...
Page 402: Parameterization Of A 2Nd Measuring System With Adi4
NC Commissioning with HMI Advanced 11.5 Axes and spindles Boot with non-calibrated encoder For axes with non-calibrated absolute encoder: ● MD34210 $MA_ENC_REFP_STATE == 0 (encoder not calibrated) an alarm is displayed each time the NC is booted: axis identifier number ●...
Page 403 NC Commissioning with HMI Advanced 11.5 Axes and spindles Parameter example The following parameterization example illustrates the basic procedure for parameterizing the NC for a 2nd measuring system of a machine axis connected via ADI4. It assumes the following: ● NC Two measuring systems are to be parameterized for the 1st machine axis.
Page 404 NC Commissioning with HMI Advanced 11.5 Axes and spindles Figure 11-13 DP slave properties: SIMODRIVE 611U ADI4: ● Message frame type: Standard message frame 3 ● I/O address: 4200 Figure 11-14 DP slave properties: ADI4 NC machine data The general and axis-specific NC machine data should be set as follows: Drive assignment: The axis of the SIMODRIVE 611U drive module is assigned to the NC as the 1st machine axis.
Page 405: Dsc (Dynamic Servo Control)
NC Commissioning with HMI Advanced 11.5 Axes and spindles Assignment of the 2nd measuring system (index 1) of the machine axis to the measuring circuit input of the ADI4 module is performed via the axis-specific machine data: ● MD30220 $MA_ENC_MODUL_NR[1] = 4 with 4 = (Index 3 of the corresponding MD13050 + 1) For this, see Subsection "Setpoint value/actual value channels"...
Page 406 NC Commissioning with HMI Advanced 11.5 Axes and spindles Note The speed feedforward control can be used in conjunction with DSC. Requirements Before you can activate DSC mode, the following preconditions must be fulfilled: ● DSC-capable drive, e.g.: – SINAMICS S120 –...
Page 407: Drive Optimization
NC Commissioning with HMI Advanced 11.5 Axes and spindles Table 11-24 DSC: Machine data Number Name Name Axisspecific ($MA_ ... ) 32640 STIFFNESS_CONTROL_ENABLE Dyn. stiffness control 32200 POSCRTL_GAIN Kv factor 11.5.9 Drive Optimization Optimization of the control loop (current, speed, and position control loop) of the drives can be performed with: ●...
Page 408 NC Commissioning with HMI Advanced 11.5 Axes and spindles For the recommended procedure with respect to scaling machine data, please refer to Subsection "Modifying Scaling Machine Data" (Page 370). Modulo display The display of the rotary axis position modulo 360 degrees is displayed via the following machine data: ●...
Page 409: Positioning Axes
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.11 Positioning axes Positioning axes are channel axes traversing parallel to the path axes without interpolating with them. Positioning axes can be traversed either from the parts program or from the PLC. Concurrent positioning axes A channel axis is assigned to the PLC by default via the following machine data: ●...
Page 410: Indexing Axes
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.12 Indexing axes Indexing axis are rotary or linear axes that may only be traversed within their traversing range to defined positions, the indexing positions. Traversing to indexing positions using the part program or manually is only effective if the corresponding machine axis has been successfully referenced.
Page 411: Parameter Sets Of Axis/Spindle
NC Commissioning with HMI Advanced 11.5 Axes and spindles Interface signals Table 11-30 Indexing axes: Interface signals DB number Bit, byte Name Axis/spindle-specific Signals from axis/spindle to PLC 31,... 60.4, 60.5 Referenced/synchronized 1, referenced/synchronized 2 31,... 76.6 Indexing axis in position References: /FB/ Function Manual, Extended Functions,T1 Indexing axes 11.5.13...
Page 412 NC Commissioning with HMI Advanced 11.5 Axes and spindles Figure 11-15 Validity of parameter sets for axis and spindle modes Machine data The following machine data of a machine axis depend on the parameter set: n = parameter set number (0 ... 5) Table 11-31 Parameter-set-dependent machine data Number Name...
Page 413: Position Controller
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.14 Position controller Control loops The closed-loop control of a machine axis consists of the cascaded closed-loop control circuits of current controller, speed controller and position controller. Figure 11-16 Control loops Traversing direction If the axis does not traverse into the desired direction, the appropriate adaptation is made in the following machine data:...
Page 414 NC Commissioning with HMI Advanced 11.5 Axes and spindles Definition of the Kv factor The servo gain factor is defined as the ratio of velocity in m/min and the resulting following error in mm: i.e. with a Kv factor of 1 and a velocity of 1 m/min, the following error will be 1 mm. The Kv factor of the machine axis is entered via the following machine data: ●...
Page 415 NC Commissioning with HMI Advanced 11.5 Axes and spindles Checking the loop gain If a KV factor is already known for the machine type, then this factor can be set and checked. For the test, one reduces the acceleration of the axis via the following machine data to ensure that the drive does not reach its current limit during the acceleration and deceleration operation: ●...
Page 416 NC Commissioning with HMI Advanced 11.5 Axes and spindles Default values The default values of the acceleration are in the range of 0.5 m/s to 2 m/s Checking the acceleration The sign of a properly adjusted acceleration of a machine axis is acceleration and positioning free from overshoot at rapid traverse rate and maximum load (heavy workpiece).
Page 417: Speed Setpoint Matching
● SIMODRIVE POSMO CD/CA ● SIMODRIVE POSMO SI If the value 0 is entered in the following machine data (default in SINUMERIK 840Di sl), then the speed setpoint value between NC and drive is matched automatically during the NC boot: ●...
Page 418 NC Commissioning with HMI Advanced 11.5 Axes and spindles ADI4 As ADI4 does not support acyclic services on the PROFIBUS DP, manual speed setpoint matching must be performed. The reference between the speed setpoint set by the NC and the associated output voltage at the setpoint output of the ADI4 is established (reference voltage = 10 V) via the following axis-specific machine data.
Page 419 NC Commissioning with HMI Advanced 11.5 Axes and spindles Checking the trim Incorrect speed setpoint matching has a negative impact on the real loop gain of the axis. To check speed setpoint matching it is necessary for a defined traverse velocity to compare the actual following error with the desired following error that should be set if speed setpoint matching is correct.
Page 420: Drift Compensation
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.16 Drift compensation Digital drives Digital drives are not subject to drift or compensate for it automatically. ADI4 As ADI4 does not support acyclic services on the PROFIBUS DP, drift compensation must be performed manually by entering the appropriate compensation value in the following axial machine data: ●...
Page 421: Axis Velocity Matching
NC Commissioning with HMI Advanced 11.5 Axes and spindles Machine data Table 11-34 Drift compensation: Machine data Number Name Name/remarks Axisspecific ($MA_ ... ) 36720 DRIFT_VALUE Basic drift value 11.5.17 Axis velocity matching Max. axis velocity The value entered in the following machine data is the limit velocity up to which a machine axis can accelerate (rapid traverse limiting).
Page 422 NC Commissioning with HMI Advanced 11.5 Axes and spindles The velocity from MD32020 $MA_JOG_VELO[n] or MD32050 $MA_JOG_REV_VELO[n] is used only if ● for linear axes: SD41110 $SN_JOG_SET_VELO = 0 ● for rotary axes: SD41130 $SN_JOG_ROT_AX_SET_VELO = 0 ● for reverse feed: SD41120 $SN_JOG_REV_SET_VELO = 0 If the above mentioned setting data are unequal to 0, the JOG velocity results as follows: 1.
Page 423: Axis Monitoring
NC Commissioning with HMI Advanced 11.5 Axes and spindles Setting data Table 11-36 Velocities: Setting data Number Name Name/remarks General ($SN_ ...) 41100 JOG_REV_IS_ACTIVE Revolutional feedrate in JOG mode active 41110 JOG_SET_VELO JOG velocity for linear axes (for G94) 41120 JOG_REV_SET_VELO JOG velocity (for G95) 41130...
Page 424 NC Commissioning with HMI Advanced 11.5 Axes and spindles Zero speed tolerance Position tolerance which a standing machine axis may not leave. ● MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance) ● Alarm "25040 Zero speed control" and follow-up mode Delay time zero speed monitoring Delay time after which the actual value must have reached the tolerance window "Zero speed tolerance"...
Page 425 NC Commissioning with HMI Advanced 11.5 Axes and spindles Working area limitation The permissible working area of the machine axes can be adapted to the particular machining situation using the "dynamic" working area limitation. ● SD43400 $SA_WORKAREA_PLUS_ENABLE (Working area limitation active in the positive direction) ●...
Page 426 NC Commissioning with HMI Advanced 11.5 Axes and spindles Figure 11-19 Overview of end limitations Dynamic monitoring functions The dynamic monitoring functions with reference to a machine axis are: Speed setpoint monitoring The speed setpoint monitoring prevents that the max. admissible motor speed is exceeded. It must be set such that the max.
Page 427 NC Commissioning with HMI Advanced 11.5 Axes and spindles The following machine data is used to define how long the speed setpoint may remain within the limits before the speed setpoint monitoring responds. ● MD36220 $MA_CTRLOUT_LIMIT_TIME[n] (delay time for speed setpoint monitoring) Error reaction: ●...
Page 428 NC Commissioning with HMI Advanced 11.5 Axes and spindles Actual velocity monitoring Monitoring due to the actual velocity of the machine axis determined based on the encoder values ● MD36020 $MA_AX_VELO_LIMIT (velocity-monitoring threshold) Error reaction: ● Alarm "25030 Alarm limit of actual velocity" and stopping the machine axis using a speed setpoint ramp whose characteristic curve is set in the following machine data: ●...
Page 429 NC Commissioning with HMI Advanced 11.5 Axes and spindles ● For operation with feedforward control: MD32810 $MA_EQUIV_SPEEDCTRL_TIME (equivalent time constant of speed control loop for feedforward control) or if the machine data is imprecisely set, the MD36400 $MA_CONTOUR_TOL must be enlarged. Encoder limit frequency monitoring Monitoring of the limit frequency of the encoder of a machine axis.
Page 430 ● MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur) Figure 11-22 Monitoring for SINUMERIK 840Di sl Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 431: Axis Homing
NC Commissioning with HMI Advanced 11.5 Axes and spindles NOTICE The following is to be taken into account: • MD36620 $MA_SERVO_DISABLE_DELAY_TIME (switchoff delay servo enable) must always be selected greater than • MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur) If this is not the case, the braking ramp cannot be kept.
Page 432 NC Commissioning with HMI Advanced 11.5 Axes and spindles Figure 11-23 Signal chart: Referencing with an incremental measuring system (principle) Phase-independent data The following machine data and interface signals are independent with respect to the individual phases of reference point approach: ●...
Page 433 NC Commissioning with HMI Advanced 11.5 Axes and spindles ● IS DB31, ... DBX12.7 ("Reference point approach delay") ● IS DB31, ... DBX60.4, DBX60.5 ("Referenced/synchronized 1, 2") Properties of phase 1: ● The feedrate override (feedrate switch) is active. ● The feed stop (channelspecific and axisspecific) is active. ●...
Page 434 NC Commissioning with HMI Advanced 11.5 Axes and spindles Phase 3: Approach reference point The following machine data and interface signals are relevant: ● MD34070 $MA_REFP_VELO_POS (reference point positioning velocity) ● MD34080 $MA_REFP_MOVE_DIST (reference point distance to zero mark) ● MD34090 $MA_REFP_MOVE_DIST_CORR (reference point offset, additive) ●...
Page 435 NC Commissioning with HMI Advanced 11.5 Axes and spindles Phase-independent data The following machine data and interface signals are independent with respect to the individual phases of reference point approach: ● MD11300 $MN_JOG_INC_MODE_LEVELTRIGGRD (INC/REF in jog mode) ● MD34000 $MA_REFP_CAM_IS_ACTIVE (axis with reference cam) ●...
Page 436 NC Commissioning with HMI Advanced 11.5 Axes and spindles Properties of phase 2: ● The feedrate override (feedrate switch) is active. ● The feed stop (channelspecific and axisspecific) is active. ● The machine axis can be stopped and restarted with NC-stop/NC-start. Determining the absolute offset To determine the absolute offset between the measuring system zero point and the machine zero, the following procedure is recommended:...
Page 437 Adjusting To calibrate the absolute encoder, the actual value of the encoder is matched with the machine zero once and then enabled. The SINUMERIK 840Di sl supports the following types of calibration: ● Operator-assisted calibration ● Automatic calibration using probe ●...
Page 438 NC Commissioning with HMI Advanced 11.5 Axes and spindles 4. Enabling encoder calibration Encoder calibration is performed in the following machine data: – MD34210 $MA_ENC_REFP_STATE[n] = 1 5. Activate changed machine data by NC reset. 6. Completing encoder calibration After the NC booting, the same traverse direction key must be re-actuated as in Point 2, to complete the encoder calibration in the JOG >...
Page 439 NC Commissioning with HMI Advanced 11.5 Axes and spindles NOTICE The NC can detect a required readjustment of the absolute value encoder only during the following events: • Gear change with change of gear ratio • Response to zero mark monitoring (alarm 25020) •...
Page 440 NC Commissioning with HMI Advanced 11.5 Axes and spindles Machine data Table 11-38 Referencing: Machine data Number Name Name General ($MN_ ... ) 11300 JOG_INC_MODE_LEVELTRIGGRD INC/REF in jog/continuous mode Channelspecific ($MC_ ... ) 20700 REFP_NC_START_LOCK NC-Start disable without reference point Axisspecific ($MA_ ...
Page 441: Spindle Basic Data
NC Commissioning with HMI Advanced 11.5 Axes and spindles References: /FB/ Function Manual, Basic Functions, R1 Reference Point Approach 11.5.20 Spindle basic data The spindle mode of a machine axis is a subset of the general axis functionality. For this reason, the machine data required to commission an axis also has to be set for a spindle.
Page 442 NC Commissioning with HMI Advanced 11.5 Axes and spindles Spindle modes The diagram below illustrates the spindle modes and possible transitions between them. Figure 11-25 Spindle modes Default mode The following machine data can be used to define the default mode of a spindle at a defined time: ●...
Page 443 NC Commissioning with HMI Advanced 11.5 Axes and spindles Axis mode It is possible to switch directly from spindle mode to axis mode, provided the same drive is used for both modes. 1. Transition to axis mode by programming the spindles using their axis names or by M70. 2.
Page 444: Setpoint/Actual Value Channels Of Spindle
NC Commissioning with HMI Advanced 11.5 Axes and spindles Spindle reset The following machine data is used to define whether the spindle should remain active via Reset (IS DB21,... DBX7.7) or Program end (M02/M30) even subsequently: ● MD35040 $MA_SPIND_ACTIVE_AFTER_RESET (spindle active after reset) To cancel spindle movements, an independent spindle reset is required: ●...
Page 445: Spindle Measuring Systems
NC Commissioning with HMI Advanced 11.5 Axes and spindles For further information on parameter sets, see Subsection "Axis/spindle parameter sets" (Page 411). References: /FB1/ Function Manual - Basic Functions, S1 Spindles, Chapter "Gear stage change" 11.5.23 Spindle measuring systems Encoder matching When parameterizing the measuring systems of spindles, the same conditions apply as for parameterization of the measuring systems of rotary axes.
Page 446 NC Commissioning with HMI Advanced 11.5 Axes and spindles ● MD10210 $MN_INT_INC_PER_DEG (computational resolution) = 1,000 [incr./degree] ● MD31020 $MA_ENC_RESOL (encoder resolution) = 500 [pulses/revolution] ● MD31050 $MA_DRIVE_AX_RATION_DENOM (load rev. denominator) = 1 ● MD31060 $MA_DRIVE_AX_RATION_NUMERA (load rev. numerator) = 1 ●...
Page 447: Speeds And Setpoint Adjustment For Spindle
Speeds and setpoint adjustment for spindle Speeds, gear stages In SINUMERIK 840Di sl, data for five gear stages are implemented. These stages are defined by a minimum and maximum speed for the stage itself and by a minimum and maximum speed for the automatic gear stage changeover.
Page 448 NC Commissioning with HMI Advanced 11.5 Axes and spindles Speeds for conventional operation The speeds of the spindle in conventional mode are entered in the following machine data: ● MD32010 $MA_JOG_VELO_RAPID (rapid traverse in jog mode) ● MD32020 $MA_JOG_VELO (axis velocity in JOG mode) The direction of rotation is specified via the appropriate directional keys for the spindle on the MCP.
Page 449 NC Commissioning with HMI Advanced 11.5 Axes and spindles Machine data Table 11-39 Speeds and setpoint adjustment for spindle: Machine data Number Name Name Axisspecific ($MA_ ... ) 31050 DRIVE_AX_RATIO_DENOM Denominator load gearbox 31060 DRIVE_AX_RATIO_NUMERA Numerator load gearbox 32010 JOG_VELO_RAPID Rapid traverse in JOG mode 32020 JOG_VELO...
Page 450: Positioning The Spindle
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.25 Positioning the spindle The NC provides an oriented spindle stop function with which the spindle can be moved into a certain position and held there (e.g. for tool changing purposes). Several programming commands are available for this function which define the approach and program processing.
Page 451: Synchronizing Spindle
NC Commissioning with HMI Advanced 11.5 Axes and spindles Interface signals Table 11-42 Spindle positioning: Interface signals DB number Bit, byte Name Axis-specific Signals from axis/spindle to PLC 31, ... 60.6 Position reached with exact stop "fine" 31, ... 60.7 Position reached with exact stop "coarse"...
Page 452 NC Commissioning with HMI Advanced 11.5 Axes and spindles Figure 11-29 Synchronization using BERO When is synchronization necessary? The spindle will be synchronized: ● after the NC has powered up when the spindle is moved using a programming command ● after a request for resynchronization by the PLC IS DB31,...
Page 453: Spindle Monitoring
NC Commissioning with HMI Advanced 11.5 Axes and spindles Machine data Table 11-43 Synchronizing spindle: Machine data Number Name Name Axisspecific ($MA_ ... ) 34100 REFP_SET_POS Reference point value 34090 REFP_MOVE_DIST_CORR Reference point offset 34200 REFP_MODE Referencing mode Interface signals Table 11-44 Synchronizing spindle: Interface signals DB number Bit, byte...
Page 454 NC Commissioning with HMI Advanced 11.5 Axes and spindles Maximum spindle speed The maximum spindle speed is entered in the following machine data: ● MD35100 $MA_SPIND_VELO_LIMIT (max. spindle speed) The NC limits the spindle speed to this value. Error reaction: If the speed is nevertheless exceeded by the speed tolerance (drive error), the following signal is output: ●...
Page 455 NC Commissioning with HMI Advanced 11.5 Axes and spindles Encoder limit frequency If the sensor limit frequency in the following machine data is exceeded, synchronization of the spindle is lost and spindle functionality is reduced (thread, G95, G96): ● MD36300 $MA_ENC_FREQ_LIMIT (encoder limit frequency) The spindle will be re-synchronized automatically once the sensor frequency falls below the value defined in the following machine data: ●...
Page 456: Spindle Data
NC Commissioning with HMI Advanced 11.5 Axes and spindles 11.5.28 Spindle data Machine data Table 11-45 spindle: Machine data Number Name Name General ($MN_ ... ) 12060 OVR_SPIND_IS_GRAY_CODE Spindle override with Gray coding 12070 OVR_FACTOR_SPIND_SPEED Evaluation of spindle speed override switch 12080 OVR_REFERENCE_IS_PROG_FEED Override reference velocity...
Page 457 NC Commissioning with HMI Advanced 11.5 Axes and spindles Number Name Name 35130 GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed of gear stage 35140 GEAR_STEP_MIN_VELO_LIMIT[n] Minimum speed of gear stage 35150 SPIND_DES_VELO_TOL Spindle speed tolerance 35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limitation via PLC 35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode 35210 GEAR_STEP_POSCTRL_ACCEL[n]...
Page 458 NC Commissioning with HMI Advanced 11.5 Axes and spindles Interface signals Table 11-47 spindle: Interface signals DB number Bit, byte Name Axis-specific Signals from PLC to axis/spindle 31, ... Feed override 31, ... Override active 31, ... Position measuring system 2 31, ...
Page 459 NC Commissioning with HMI Advanced 11.5 Axes and spindles DB number Bit, byte Name 31, ... 83.2 Setpoint speed increased 31, ... 83.1 Setpoint speed limited 31, ... 83.0 Speed limit exceeded 31, ... 84.7 Active spindle control mode 31, ... 84.6 Active spindle mode oscillation mode 31, ...
Page 460: Handwheels
Handwheels 11.6.1 General information Connection options Handwheels can be connected to a SINUMERIK 840Di sl via the following interfaces: ● PROFIBUS DP (only via MCI board interface X101) ● Ethernet ● Cable distributor (via MCI board extension) In order to operate handwheels of a SINUMERIK control system, they have to be parameterized via NC machine data.
Page 461: Connection Via Profibus
NC Commissioning with HMI Advanced 11.6 Handwheels Note A maximum of two handwheels can be connected via the cable distributor. Example Direct connection of 2 handwheels via a cable distributor. Table 11-48 Assignment of handwheels in NC machine data Value 1.
Page 462 NC Commissioning with HMI Advanced 11.6 Handwheels Handwheel slot The PROFIBUS module must be configured besides the parameterization of handwheels in the NC machine data in STEP 7. Among others the logical address of the handwheel slot is specified. The handwheel slot is situated at the following slot of the PROFIBUS module: PROFIBUS module Slot Machine control panel MCP 438...
Page 463 NC Commissioning with HMI Advanced 11.6 Handwheels Slot DP ID Order number/ I address O address designation 4. MCP Standard+Handwheel 24 ... 29 24 ... 29 -> Standard+handwheel 330 ... 333 -> Standard+handwheel Parameterizing in the NC machine data: Table 11-50 Handwheel assignment Machine data Value Description...
Page 464: Connection Via Ethernet
NC Commissioning with HMI Advanced 11.6 Handwheels Table 11-51 Logical base addresses Machine data Value Description MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [0] Logical base address handwheel slot 1st MCP MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [1] Logical base address handwheel slot 2nd MCP MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [4] Logical base address handwheel slot 4th MCP MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [5] Logical base address handwheel slot 3rd MCP 11.6.4...
Page 465 NC Commissioning with HMI Advanced 11.6 Handwheels Operator component interface -> MCP1 MCP2 Handwheel interface FB1 Parameter MCP1BusAdr MCP2BusAdr BHGRecGDNo Assignment of the handwheels MCP 483C IE HT 8 HT 2 Handwheel interface at the Ethernet bus (y) > 1) Numbering of the handwheel interfaces within an operator component interface 2) Assignment of the operator component interface to the interface via the corresponding FB1 parameter 3) Assignment of the handwheels of the respective operator components to the handwheel interfaces 4) Numbering of the handwheel interfaces at the Ethernet bus ->...
Page 466 NC Commissioning with HMI Advanced 11.6 Handwheels Table 11-53 FB1 parameters (Excerpt) Parameter Value Comment MCPNum := 2 // Number of connected MCP // MCP1 = HT 8 MCP1In // MCP1-Parameter ... MCP1BusAdr := 39 // Via the switch S1 and S2 of the connecting device // set "IP Address"...
Page 467: Digital And Analog I/O Devices
NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices 11.7 Digital and analog I/O devices The following digital and analog signal modules are available: Digital I/O modules ● MCI board extension module (option) There are 4 digital inputs/outputs in each MCI board extension module (option) (Section "MCI board extension slot variant"...
Page 468: Parameterization Of The Number Of Inputs/Outputs Used
NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices 11.7.1 Parameterization of the number of inputs/outputs used Maximum number The maximum number of digital or analog inputs/outputs that can be used for the NC is: Total MCI board extension PROFIBUS modules Analog inputs Analog outputs...
Page 469: Assignment Of Inputs/Outputs To The Signal Modules
NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices 11.7.2 Assignment of inputs/outputs to the signal modules On the NC side, the analog and digital inputs/outputs are assigned to the respective signal modules on the PROFIBUS DP via the appropriate I/O addresses in the machine data: Machine data Analog I/Os ●...
Page 470: System Variable $A
NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices 11.7.3 System variable $A_...[n] The digital and analog inputs/outputs are available in the NC (part program, ASUB, synchronized action, etc.) in the form of system variables. Analog inputs/outputs ● $A_INA[n] ("Read analog input n, where n=1...8") ●...
Page 471: Digital Input/Output Bytes And System Variables
NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices 11.7.4 Digital input/output bytes and system variables Digital inputs The following configuration example shows the relationship between digital input bytes and system variables by means of the configuration of 3 digital inputs bytes. This configuration example requires the following: ●...
Page 472: Dynamic Response
Figure 11-32 Dynamic response when outputting an output signal with optimized DP-Cycle Explanations for the figure: ● T MAPC Master application cycle: NC-Position controller cycle the following is always valid for SINUMERIK 840Di sl: T MAPC ● T DP cycle time: DP cycle time ● T...
Page 473: Configuration Example
NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices ● T Master time: Offset of the start time for NC position control ● GC Global Control: Broadcast message for cyclic convergence of the equidistance between DP master and DP slaves ●...
Page 474 NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices Figure 11-33 Example configuration: SINUMERIK 840Di sl with ET200 and ADI4 ET200 I/Os: IM 153 Slot Assembly I address O address Comment SM 322 DO16xDC24V/0.5A 128...129 SM 322 DO32xDC24V/0.5A 130...133...
Page 475 NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices Slot Assembly I address O address Comment Note: The structure of the PROFIBUS message frame is described in Chapter "DP Slave: ADI4" (Page 286). Machine data Parameterization of the NC machine data is shown below: ET 200 3 input bytes ADI4...
Page 476 NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices ● ADI4 The high byte of the input word (slot 21) – MD10366 $MN_HW_ASSIGN_DIG_FASTIN[3] = H050010E7 (4327 Hardware assignment: output bytes The following output bytes are used by the NC: ●...
Page 477 NC Commissioning with HMI Advanced 11.7 Digital and analog I/O devices Number Name Name 10530 COMPAR_ASSIGN_ANA_INPUT_1 Hardware assignment of NC analog inputs for comparator byte 10531 COMPAR_ASSIGN_ANA_INPUT_2 Hardware assignment of NC analog inputs for comparator byte 10540 COMPAR_TYPE_1 Parameterization for comparator byte 1 10541 COMPAR_TYPE_2 Parameterization for comparator byte 2...
Page 478: Loadable Compile Cycles
NC. The compile cycle can be loaded at any time. Siemens compile cycles The following technological functions and more are available from Siemens in the form of compile cycles: ● 1D/3D clearance control in position controller cycle...
Page 479: Load A Compile Cycle
NC Commissioning with HMI Advanced 11.8 Loadable compile cycles 11.8.1 Load a compile cycle Requirement To transfer the compile cycle to the control, the following requirements must be met: ● There is a network connection (TCP/IP) between the PCU and an external computer (PC/PG) on which the compile cycle is located.
Page 480 NC Commissioning with HMI Advanced 11.8 Loadable compile cycles ● Interface version of a compile cycle that has not yet been loaded HMI Advanced (excerpt): > <Medium> > Services "Properties" softkey Display: ● Interface version of a loaded compile cycle HMI Advanced: Diagnosis >...
Page 481: Software Version Of A Compile Cycle
NC Commissioning with HMI Advanced 11.8 Loadable compile cycles 11.8.3 Software version of a compile cycle The software version of a compile cycle is displayed under: HMI Advanced: Diagnosis > Service Display > Version > NCU Version Display (excerpt) Example: _N_CLC407IF003001_ELF corresponds to software version: 4.7 Note The display of code and data range start addresses of a compile cycle are provided for...
Page 482: Activating And Licensing Technology Functions
NC Commissioning with HMI Advanced 11.8 Loadable compile cycles System enables If the compile cycle is not enabled in conjunction with SINUMERIK 840Di sl or 840DiE sl, the following alarm is issued: Not enabled for SINUMERIK 840Di sl: ● Alarm "7200 CC<Identifier>_ELF NO_840Di"...
Page 483: Data Descriptions (Md)
NC Commissioning with HMI Advanced 11.8 Loadable compile cycles 11.8.6 Data descriptions (MD) General machine data 60900 + i CC_ACTIVE_IN_CHAN_XXXX[n] where i = 0. 1. 2. 3 ... with: XXXX = function identifier, n = 0 or 1 MD number n = 0: Activating the technology function in channels n = 1: Additional functions within the technology function Default setting: 0...
Page 484: Profibus Dp
PROFIBUS DP for the following frame data: Control word 1 • Control word 2 • The PROFIBUS DP communication is finally shut down. To be used with: SINUMERIK 840Di sl in conjunction with external drives. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 485: Initial Settings
NC Commissioning with HMI Advanced 11.10 Initial settings 11.10 Initial settings Concept The status of an NC function, e.g. G codes, tool length offset, transformation, coupled motion, etc., which is taken in a certain status of a channel is a default setting. Channel states for which default settings can be parameterized are: 1.
Page 486: Nc/Plc Diagnosis
NC Commissioning with HMI Advanced 11.11 NC/PLC Diagnosis 11.11 NC/PLC Diagnosis 11.11.1 Menu: Diagnostics Operating path The menu of the NC/PLC diagnostics is located in the following operating path: ● Operating area switchover > Diagnosis > NC/PLC Diagnosis > Diagnosis Figure 11-34 Menu: NC/PLC Diagnosis Group: NC The following functions are grouped together in the NC group box:...
Page 487 NC Commissioning with HMI Advanced 11.11 NC/PLC Diagnosis – 4 startup – 5 waiting for PLC – 6 running – F NC error ● NC Reset Via the "NC reset" button, an NC POWER ON reset is triggered. On a NC POWER ON reset, all active machining operations are stopped. Drives that are in motion are not decelerated on their acceleration ramp but at that their current limit.
Page 488 NC Commissioning with HMI Advanced 11.11 NC/PLC Diagnosis With the "PLC RUN" button, the PLC is put in the "RUN" state. Only read accesses are possible via a programming device (PG) in this mode. It is not possible to make changes to the PLC user program until the password has been set.
Page 489 The following information is grouped together in the NC latency group box: ● NC latency time The basis of the SINUMERIK 840Di sl real-time property is activation of the NC system software cyclically in defined time intervals. Because the NC and Windows XP share the available PCU processor power, delays (latencies) may occur when invoking the NC.
Page 490: Menu: Settings
11.11 NC/PLC Diagnosis 11.11.2 Menu: settings Operating path The menu for the SINUMERIK 840Di sl-specific settings is located in the following operating path: ● Operating area switchover > IBN > NC/PLC Diagnosis > Settings Figure 11-35 Menu: settings Modifying data When switching to the menu the data displayed become read-only.
Page 491 NC Commissioning with HMI Advanced 11.11 NC/PLC Diagnosis Group: settings The following functions are grouped together via the "Settings" group box: ● Signal input for shutdown behavior: Signal source This selection field is for configuring the digital input used for the shutdown signal of the UPS: –...
Page 492 NC Commissioning with HMI Advanced 11.11 NC/PLC Diagnosis Apply changes To apply the changes you have made, press the "Accept" softkey. The message box that is then displayed has to be acknowledged again with the "Accept" softkey. The "Cancel" softkey rejects all changes and displays the original settings again. Figure 11-36 Applies settings.
Page 493: Alarm And Message Texts
Alarm and message texts To enable easy adaptation of alarm and message texts to the specific requirements of an automation system, the alarm and message texts are stored in freely accessible ASCII text files. The alarm and message texts contained in the text files are used commonly by all SINUMERIK user interfaces: ●...
Page 494: Standard Text Files
Alarm and message texts 12.2 Standard text files UserPLC= <Installationspfad>\dh\mb.dir\myplc_ UserZyk= UserCZyk= 12.2 Standard text files Standard text files The standard alarm and message texts in ASCII format are stored in the following files on the hard disk: ● MMC: <Installationspfad>\dh\mb.dir\alm_XX.com ●...
Page 495 Alarm and message texts 12.3 User text files NOTICE The maximum length of an alarm or message text displayed over two lines is 110 characters. Storage path The user-specific text files must be loaded in the Services operating area in the directory <Installationspfad>...
Page 496 Alarm and message texts 12.3 User text files Note If the text file MYPLC_GR.COM is created on an external PC and then read in through the serial interface (e.g. with PCIN), the following lines must be contained at the beginning of the file: %_N_MYPLC_GR_COM ;$Path=/_N_MB_DIR...
Page 497: Syntax For Alarm Text Files
The following alarm numbers are available for the cycle, compile cycle and PLC alarms: Table 12-2 Alarm numbers for cycle, compile cycle and PLC alarms Number range Description Effect Delete 60000-60999 Cycle alarms (Siemens) Display, interlocking NC start Reset 61000-61999 Display, NC start disable, Reset motion standstill 62000-62999 Display...
Page 498 1: Display in a dialog box Help ID The default assignment "0" means: The help file supplied by Siemens provides a detailed description of the alarm. A value between 1 and 9 uses an assignment entry in the MBDDE.INI file to refer to a help file created by the user.
Page 499 Help ID The default assignment "0" means: The help file supplied by Siemens provides a detailed description of the alarm. A value between 1 and 9 uses an assignment entry in the MBDDE.INI file to refer to a help file created by the user. Refer also to Chapter "Setting Alarm Log Properties" (Page 500), Section: HelpContext.
Page 500: Setting The Alarm Log Properties
Alarm and message texts 12.5 Setting the alarm log properties 12.5 Setting the alarm log properties In addition to the current alarms, an alarm log showing the alarms occurred hitherto is displayed on the user interface in the form of a list. The properties of the alarm list can be changed in the MBDDE.INI file.
Page 501: Axis And Spindle Test Run
Axis and Spindle Test Run 13.1 Requirements Enabling signals must be set to allow an axis to be traversed directly from the control: ● Drive: Parameters and terminals ● NC: Interface signals 13.1.1 Drives: SINAMICS S120 Relevant parameters/terminals Infeed Parameter/Terminal Description p0840 ON/OFF1...
Page 502: Drives: Simodrive
Axis and Spindle Test Run 13.1 Requirements 13.1.2 Drives: SIMODRIVE Relevant terminals Applies to the following SIMODRIVE drives: ● SIMODRIVE 611 universal/universal E ● SIMODRIVE POSMO SI, CD/CA The following terminals must be connected: I/RF module Terminal Description Pulse enable Drive enable DC-link start Drive Module...
Page 503 Axis and Spindle Test Run 13.1 Requirements DB number Byte.Bit Value Description 31, ... 5.0 - 5.5 JOG/INC 31, ... 12.0 Hardware limit switch PLUS 31, ... 12.1 Hardware limit switch MINUS 31, ... 20.1 FALSE Rampfunction generator rapid stop 31, ...
Page 504: Axis Dry Run
Axis and Spindle Test Run 13.2 Axis dry run 13.2 Axis dry run Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 505: Spindle Dry Run
Axis and Spindle Test Run 13.3 Spindle dry run 13.3 Spindle dry run Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 506 Axis and Spindle Test Run 13.3 Spindle dry run Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 507: Drive Optimization With Hmi Advanced
Drive Optimization with HMI Advanced 14.1 Overview HMI Advanced offers comprehensive functions for analyzing controller action of drives connected to a SINUMERIK 840Di sl: ● Frequency response measurements for current, speed and position control loop ● Automatic controller setting ● Funktionsgenerator ●...
Page 508: Measuring Functions
Drive Optimization with HMI Advanced 14.2 Measuring functions 14.2 Measuring functions Explanation A range of measuring functions allows the time and/or frequency response of drives and closed-loop controls to be displayed in graphic form on the screen. For this purpose, test signals with an adjustable interval are connected to the drives.
Page 509 Drive Optimization with HMI Advanced 14.2 Measuring functions Starting measuring functions Measuring functions initiating a traversing movement are only selected using the specific softkey. The actual start of the measuring function and thus of the traversing movement is always carried out with NC START on the machine control panel. If the main screen of the measuring function is quitted without the traversing motion being initiated, the selection of the traversing function is canceled.
Page 510: Special Functions
Drive Optimization with HMI Advanced 14.3 Special functions 14.3 Special functions Interface signals: Drive test, traversing request, traversing enable In conjunction with the measuring functions, another 2 axis-specific interface signals are provided: ● DB31-DBx, DBX61.0 "Drive test traversing request" ● DB31-DBx, DBX1.0 "Drive test, traversing enable" In the PLC user program, therefore, an additional axis-specific traversing enable command may be given in conjunction with measuring functions.
Page 511 Drive Optimization with HMI Advanced 14.3 Special functions Traversing of the axis to be measured is enabled in addition to the interface signals typical for JOG mode depending on the interface signal: "Drive test traversing enable". Traversing range monitoring The measuring functions have their own traversing range monitoring. With this monitoring function the traverse range of an axis can be limited or monitored without having to reference this axis.
Page 512: Frequency Response Measurements
Drive Optimization with HMI Advanced 14.4 Frequency response measurements 14.4 Frequency response measurements You can measure both digital and analog drives. However, the bandwidth available for measuring is limited by the position controller or PROFIBUS cycles. Figure 14-2 Example: Measurement results, speed control loop, reference frequency response Note Additional information on the measurement functions or how to optimize the torque/current and speed control loop can be found in:...
Page 513: Measurement Of Current Control Loop
Drive Optimization with HMI Advanced 14.4 Frequency response measurements 14.4.1 Measurement of current control loop Functionality The current control loop only needs to be measured for diagnostic purposes if there is a fault or if no standard data was used for the motor/power module combination, and which resulted in unsatisfactory speed controller frequency responses.
Page 514: Speed Control Loop Measurement
Drive Optimization with HMI Advanced 14.4 Frequency response measurements Measuring parameters ● Amplitude Magnitude of the test signal amplitude. Given in percent of the peak torque. Values from 1% to 5% are suitable. ● Bandwidth The frequency range analyzed with the measurement. The larger this value, the finer the frequency resolution and the longer the measurement time.
Page 515 Drive Optimization with HMI Advanced 14.4 Frequency response measurements Measuring functions The following measurement functions are available for measuring the speed control loop: Measuring type Measured variable Reference frequency response Actual speed value motor encoder/speed setpoint after (downstream of the speed setpoint filter) filter Reference frequency response (upstream Actual speed value motor encoder/speed setpoint after...
Page 516 Drive Optimization with HMI Advanced 14.4 Frequency response measurements Measurement: Reference and interference frequency response The response range should be as wide as possible and without resonance. It may be necessary to use bandstop or low-pass filters. Pay special attention to resonances within the speed controller limit frequency range (stability limit approx.
Page 517 Drive Optimization with HMI Advanced 14.4 Frequency response measurements Measurement: Setpoint/disturbance step changes The transient response (response to setpoint changes or disturbances) of the speed control in the time range can be assessed with the step stimulation function. The test signal is connected to the speed controller output for recording of the response to disturbances.
Page 518: Position Control Measurement
Drive Optimization with HMI Advanced 14.4 Frequency response measurements 14.4.3 Position control measurement Functionality This measuring function basically analyzes the response to the active position measuring system. If the function is activated for a spindle without a position measuring system, an alarm is displayed.
Page 519 Drive Optimization with HMI Advanced 14.4 Frequency response measurements Measurement: Reference frequency response The reference frequency response measurement determines the transmission ratio of the position controller in the frequency range (active position measuring system). The setpoint filters, control loop gain (K factor) and feedforward control must be parameterized such that resonance is avoided wherever possible over the entire frequency range.
Page 520 Drive Optimization with HMI Advanced 14.4 Frequency response measurements Measurement: Setpoint step change and setpoint ramp The transient or positioning response of the position control in the time range, and in particular the effect of setpoint filters, can be assessed with the step and ramp stimulation functions.
Page 521 Drive Optimization with HMI Advanced 14.4 Frequency response measurements Figure 14-4 Signal chart for position setpoint/ramp measuring function At maximum axis velocity, there is a (virtual) step change in the velocity (continuous line). The curves represented by the dashed line correspond to a realistic, finite value. The offset component is excluded from the display graphic in order to emphasize the transient processes.
Page 522: Graphic Display
Drive Optimization with HMI Advanced 14.5 Graphic display 14.5 Graphic display Displaying the measurement results You can have the measurement displayed after the completion of the measurement via the Display softkey in the relevant Main Screen of the measuring function. Figure 14-5 Menu: Display of measurement with marker X = ON Manual...
Page 523 Drive Optimization with HMI Advanced 14.5 Graphic display Softkeys: X-marker on, Y marker on The X-Marker on and Y-Marker on sofkeys are used to display a vertical or horizontal red line with a red circle on the measuring curve in the diagrams. The corresponding values, e.g.
Page 524 Drive Optimization with HMI Advanced 14.5 Graphic display Figure 14-6 Menu: Scaling of graphics Softkeys: Graphics ... Use the Graphics... softkey in the penultimate screen to call the following functions: ● Switching over the display from double to single graphics and vice versa (this function also exists in the scaling menu in the first figure of this chapter) ●...
Page 525: Trace Function
Drive Optimization with HMI Advanced 14.6 Trace function 14.6 Trace function 14.6.1 Trace function properties The trace function with a graphical user interface serves to record the time change of data (values, signals, states, etc.) in the servo range and partially in the range of the drives, too. You can select measuring signals and set the measuring parameters with softkeys and drop- down lists.
Page 526: Main Screen And Operation
Drive Optimization with HMI Advanced 14.6 Trace function 14.6.2 Main screen and operation Basic display of servo trace You can access the main screen of this trace function using the softkeys Area Switchover > Commissioning > Drive/Servo > Servo Trace. Figure 14-7 Main menu: Servo trace Manual...
Page 527: Parameter Assignment
Drive Optimization with HMI Advanced 14.6 Trace function Figure 14-8 Cursor operation 14.6.3 Parameter assignment Parameterization in the basic display The following settings have to be made in the basic screen ● The axis/spindle to be measured ● The signal to be measured ●...
Page 528 Drive Optimization with HMI Advanced 14.6 Trace function Input field: Measurement time The measuring time is written directly into the Measuring duration input field. Input field: Trigger time Direct entry of pre-triggering or post-triggering. With negative input values (leading sign minus -) recording begins at the set time before the trigger event.
Page 529 Drive Optimization with HMI Advanced 14.6 Trace function Softkey: Physical address Within the framework of the trace function, it is also possible to select data using its physical address. Figure 14-9 Menu: Physical address for trace x To do so, proceed as follows: ●...
Page 530: Performing The Measurement
Drive Optimization with HMI Advanced 14.6 Trace function 14.6.4 Performing the measurement Softkey: Start After parameterization has been completed, you enable measurement by pressing the Start softkey. The measurement is carried out once the set trigger condition of trace 1 is fulfilled. Terminating the measurement The measurement is completed after the set measurement duration is expired.
Page 531: Display Function
Drive Optimization with HMI Advanced 14.6 Trace function 14.6.5 Display function If you press the Display softkey after the set measurement time has expired and the measurement results have been prepared automatically, you can call the graphical display function of the measurement results. Figure 14-10 Measurement results: Trace function Softkeys: X-marker on, Y marker on The X marker on and Y marker on sofkeys are used to display a vertical or horizontal red line...
Page 532 Drive Optimization with HMI Advanced 14.6 Trace function Softkeys: 2. Marker, Zoom, Preview If a marker is active, a 2nd line is shown in the diagram via the 2nd marker with the softkey These two lines define the range that you can then have displayed over the entire display range by pressing softkey Zoom.
Page 533: File Function
Drive Optimization with HMI Advanced 14.7 File Function Softkeys: Graphics ... Use the Graphics... softkey in the first screen of this chapter to call the following functions: ● Switching over the display from double to single graphics and vice versa (this function also exists in the scaling menu in the previous screen) ●...
Page 534 Drive Optimization with HMI Advanced 14.7 File Function Naming files You can select an existing file from the drop-down list or enter one in the text field underneath in the File group. Installation Directory You can select the directory where you want to save the file in the Directory group. This can also be a directory in the Services operating area you have created by yourself or the basic directory of the data management (list entry: Standard directory).
Page 535: Print Graphic
Drive Optimization with HMI Advanced 14.8 Print graphic 14.8 Print graphic Printer selection The Graphics softkey in the main screens of the measuring functions opens the menu to select the printer and to print the graphics. Figure 14-13 Graphics softkeys Softkey: Printer selection Use the Printer selection softkey to go to the corresponding menu, refer to the following screen.
Page 536 Drive Optimization with HMI Advanced 14.8 Print graphic Figure 14-14 Menu: Printer selection Output to printer Choose the printer to which you wish the file to be output from the list field using either the Toggle key or by double-clicking with the right mouse button on the desired printer. Output as bitmap file The graphics is to be saved in a bitmap file (*.bmp): ●...
Page 537 Drive Optimization with HMI Advanced 14.8 Print graphic Softkey: Print graphic Use the Print graphics softkey, refer to penultimate screen, to output the graphics on the set medium: ● Printer ● Bitmap file Printer The graphics is output directly to the selected printer. Bitmap file If you wish to output the graphics to a bitmap file, the following specifications are still required in the submenu "File name for bitmap printout":...
Page 538: Automatic Controller Setting
Drive Optimization with HMI Advanced 14.9 Automatic controller setting 14.9 Automatic controller setting 14.9.1 Drives: SINAMICS S120 Functionality The automatic controller setting of the speed control loop offers the following functionality: ● Determining the gain and reset time in these cases: –...
Page 539: Drives: Simodrive 611 Universal
Drive Optimization with HMI Advanced 14.9 Automatic controller setting Measurement The sequence of the automatic controller setting is divided into the following steps: 1. Starting the automatic controller setting. 2. Measurement of the mechanical part 1. For the measurement, you can either retain the default parameters specified by the control or define your own defaults.
Page 540 Drive Optimization with HMI Advanced 14.9 Automatic controller setting Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 541: User Data Backup/Series Commissioning
User data backup/Series commissioning 15.1 Explanations on data backup User data User data refers to all data or data areas that can be entered by the user to achieve the specific functionality of the SINUMERIK 840Di and the connected drives. In the case of a data backup, e.g.
Page 542 User data backup/Series commissioning 15.1 Explanations on data backup SINAMICS S120 Currently, the user data (projects) for SINAMICS S120 drive units must be saved separately with the STARTER commissioning tool. For detailed information on data backup, please refer to: References: SinuCom NC: Online Help HMI Advanced: /BAD/ Operating Manual HMI Advanced Manual...
Page 543: Creating A Series Commissioning File
User data backup/Series commissioning 15.2 Creating a series commissioning file 15.2 Creating a series commissioning file 15.2.1 General information Note Because of its file extension ".arc", the series startup file is also called archive. Archive content The following components can be selected as the content of a series commissioning file: ●...
Page 544 User data backup/Series commissioning 15.2 Creating a series commissioning file The contents of a series startup file created for the PLC comprise all blocks loaded at the time when the data backup was made: ● OB (organization blocks) ● FB (function blocks) ●...
Page 545: Hmi Advanced (Option)
User data backup/Series commissioning 15.2 Creating a series commissioning file 15.2.2 HMI Advanced (option). The creation of a series startup file with HMI Advanced is divided into the following steps: 1. Open the menu to create a series-commissioning file: Operating range switchover > Services > ETC key ">" > Series startup > Startup archive 2.
Page 546: Sinucom Nc
User data backup/Series commissioning 15.2 Creating a series commissioning file 15.2.3 SinuCom NC Starting SinuCom NC can be started as follows to create a series startup file: ● SINUMERIK Desktop (see Chapter "Service Desktop" (Page 135)) Windows taskbar: Start > Programs > SinuCom NC > SinuCom NC ●...
Page 547: Considerations When Backing Up Plc Data
User data backup/Series commissioning 15.3 Considerations when backing up PLC data 15.3 Considerations when backing up PLC data When creating a series startup file that contains PLC data, the PLC image that is saved during this process is dependent on the status of the PLC at the time of creation. Depending on the status of the PLC, the following PLC images result: ●...
Page 548: Importing A Series Startup File With Hmi Advanced
User data backup/Series commissioning 15.4 Importing a series startup file with HMI Advanced NOTICE The creation of a series-commissioning file with PLC data while the PLC is in RUN status (cyclic operation) may result in an inconsistent PLC image in the series commissioning archive.
Page 549: Sinamics S120 Standard Commissioning With Starter
User data backup/Series commissioning 15.5 SINAMICS S120 standard commissioning with STARTER 15.5 SINAMICS S120 standard commissioning with STARTER A project must be available, created or loaded from a drive unit into the programming device for the standard commissioning of SINAMICS S120. This project is loaded as a reference project in the other drive units still to be commissioned.
Page 550 User data backup/Series commissioning 15.5 SINAMICS S120 standard commissioning with STARTER Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 551: Software Installation/Update And Data Backup
(PG/PC) which contains an enabled network access directory. If the SINUMERIK 840Di sl is not part of a larger network (WAN, LAN), a simple PTP (peer- to-peer) connection via Ethernet and TCP/IP can be established for service applications.
Page 552: Configuring The External Computer (Windows Nt)
Software installation/update and data backup 16.1 PTP network connection TCP/IP network protocol The network protocol used is: TCP/IP. TCP/IP permits high data transmission rates and it is simple to configure. TCP/IP is already pre-configured in the basic PCU software. Requirements on the ext. computer The following requirements must apply on the external computer: ●...
Page 553 Software installation/update and data backup 16.1 PTP network connection IP address and subnet mask After installation of the protocol and to simplify setting up communication with the PCU, it is necessary to check the IP address and the subnet mask and set them, if necessary: IP address We recommend using an IP address from the address range used by Windows XP for automatic configuration, if no DHCP server is accessible (Automatic Private IP Addressing:...
Page 554 Software installation/update and data backup 16.1 PTP network connection Server service The "Services" tab card must contain "Server service". This corresponds to general sharing: "File and Printer Sharing" under Windows 9x or Windows XP. If this service is not active, no directories can be shared.
Page 555: Configuring The External Computer (Windows Xp)
Software installation/update and data backup 16.1 PTP network connection 16.1.3 Configuring the external computer (Windows XP) This section illustrates how to make and check settings for network configuration on the external computer: ● TCP/IP protocol ● IP address and subnet mask ●...
Page 556 Software installation/update and data backup 16.1 PTP network connection Computer name and workgroup Because it is a PTP link, any computer name and workgroup may be selected. The setting is made via the properties dialog box of the Control Panel. Windows taskbar: Start >...
Page 557: Configuring The Pcu
Software installation/update and data backup 16.1 PTP network connection Directory sharing Release for network access takes place in the Properties dialog > "Sharing" tab of the corresponding directory (selection of the directory with the right mouse key) The directory name is the default name for sharing. If a different sharing name is specified, it must be stated on activating the directory connection.
Page 558: Partitioning Of The Pcu Hard Disk
Partitioning of the PCU hard disk The PCU hard disk is divided into 4 partitions (3 primary partitions and an extended partition). For data security purposes, the SINUMERIK 840Di sl system software, the Windows system software and the Service software are installed on different partitions.
Page 559: Software Installation/Update (Windows)
See the compatibility list for your SINUMERIK 840Di sl software version on the Internet: http://www.siemens.de/sinumerik > SINUMERIK 840Di sl > Link Box > Support > Current > Tab: Update > SINUMERIK 840Di sl: Delivery Release System Software ... > Compatibility list: Compatibility_List.PDF...
Page 560: Restoring The As-Delivered State
When restoring the hard disk to the ex-works state, all data on the partitions C:, E: and F: are lost. 16.4.1 Requirements To restore the as-delivered state, the following files supplied with the SINUMERIK 840Di sl must be saved locally on the PCU hard disk: ● D:\IMAGES\base_ou.gho (image file) ● D:\IMAGES\base_ou.inf Image file The image file *.gho contains the data to be restored.
Page 561: Restoring The Partitions
Version Date ● Basic software < > < > After the partitions have been restored, the SINUMERIK 840Di sl applications must be reinstalled. 16.4.3 Installation of the SINUMERIK 840Di sl applications Procedure The installation programs for the SINUMERIK 840Di sl applications saved on D:\INSTALL are not executed automatically after partition restoration, as was the case during the initial boot.
Page 562 Software installation/update and data backup 16.4 Restoring the as-delivered state Then following the installation instructions shown. NOTICE If you are prompted to reboot during installation, always confirm this with "Yes" and reboot. 1. Proceed with all other (existing) directories according to Point 3: ●...
Page 563: License Management
Hardware Hardware in the framework of the license management of SINUMERIK software products is a SINUMERIK control (CNC). With SINUMERIK 840Di sl represented by the appropriate MCI board. License A license gives the user a legal right to use the software product. Evidence of this right is...
Page 564: Overview
License Key is generated from the license numbers of the system software, the options, as well as the hardware serial number. Here, access occurs to a license database administered by Siemens A&D via the Internet. Finally, the license information including the License Key is transferred to the hardware.
Page 565: Web License Manager
To conclude the assignment, the License Key must be entered manually at the control system via the HMI user interface. The Internet address of the Web License Managers is: http://www.siemens.com/automation/license Internet address 17.1.4 Automation License Manager Via the Automation License Manager, individual licenses can be assigned and the automatic assignment of all the licenses required for a piece of hardware can be carried out (license requirement alignment).
Page 566 Note The following is to be taken into account: • You can obtain a customer login via Siemens A&D Mall at menu item "Registration". The Internet address is: http://mall.automation.siemens.com/ Currently, access is not yet possible for all countries.
Page 567: Mci Board And Hardware Serial Number
● SINUMERIK 840Di sl On the SINUMERIK 840Di sl, the MCI board is used to save data and print the hardware serial number. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 568: Sinumerik License Key
License management 17.1 Basic principles 17.1.7 SINUMERIK License Key Basic information on License Keys If a license is required for a product, then with the purchase of the license the purchaser receives a CoL as proof for the rights to use this product and a corresponding License Key as to the "technical representative"...
Page 569: Browser Settings For Using The A&D Mall
● Internet pages of Siemens to the zone: Add "Trusted Sites": Menu bar: Tools > Internet Options > Tab: "Security" > Zone: "Trusted Sites" > Button: "Sites..." > "Add this Web site to the zone": "*.siemens.com" > Button: "Add" ● Enable "Active Scripting": Menu bar: Tools >...
Page 570: Proxy Settings For The Download Of License Information
License Key, from the license database to the local computer via the download server. You should apply the settings for long-distance data transmission/VPN and LAN so that you can access the download server via port 80 and port 443: ● Internet address: http://software-download.automation.siemens.com ● IP Address: 146.254.187.20 settings In Internet Explorer 6.0 x via:...
Page 571: Assigning Via Web License Manager
The assignment of a license to a piece of hardware cannot be reversed via the Web License Manager. 2. Go to the Internet page of the Web License Manager: http://www.siemens.com/automation/license 3. Login via "Direct access": – license number –...
Page 572: Execute Assignment Via Customer Login
License management 17.2 Assigning via Web License Manager 5. After completing the assignment process, enter the License Key displayed on the Web License Manager into the licensing dialog of the HMI user interface. HMI Advanced/HMI Embedded: Operating-area switchover: Commissioning > Key: etc. (">") > Licenses > Overview 6.
Page 573 License management 17.2 Assigning via Web License Manager 2. Go to the Internet page of the Web License Manager: http://www.siemens.com/automation/license 3. Login via "Customer login": – User name – Password 4. Follow the additional instructions in the Web License Manager.
Page 574: Assigning Via Automation License Manager
License management 17.3 Assigning via Automation License Manager 17.3 Assigning via Automation License Manager 17.3.1 Overview of functions The following figure provides an overview of the functions available and the sequence in which they should be applied. Figure 17-1 Overview of functions Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 575: Installing Automation License Manager
License Keys. Note The basic software component, Automation License Manager, is used for all Siemens A&D products, e.g. SIMATIC STEP7. Versions of the basic software component, Automation License Manager, are upward compatible. We recommend always using the version with the highest version number, irrespective of the source of supply (e.g.
Page 576: Enable/Disable Sinumerik Plug-In
License management 17.3 Assigning via Automation License Manager Implementation Launch the installation program for the Automation License Manager "SETUP.EXE" and follow the instructions for the installation. Further settings Note the following settings: ● Browser settings for using the A&D Mall: Subsection "Browser settings for using the A&D Mall"...
Page 577: Define Parameters Of Tcp/Ip Communication With A Control
This requires at least the password of protection level 2 (manufacturer) to be set. General communication parameters The default general communication parameters for the HMI basic software are stored in the following initialization file: <installation drive>:\Siemens\Sinumerik\HMI-Advanced\mmc2\MMC.INI Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 578 User-specific communication parameters The user-specific communication parameters for the HMI basic software are stored in the following initialization file: <Installation drive>:\Siemens\Sinumerik\HMI-Advanced\user\MMC.INI During evaluation of the initialization data when booting the HMI basic software, user-specific communication parameters have priority over general communication parameters.
Page 579 SINUMERIK control system with which the Automation License Manager communicates: 1. Close the Automation License Manager. (See note "Changing the IP address" above.) 2. Open the file <installation drive>:\Siemens\Sinumerik\HMI-Advanced\user\MMC.INI with a text editor. 3. In the [GLOBAL] section, replace the current address string with the section name for the SINUMERIK control system with which the Automation License Manager should communicate after booting.
Page 580: Update The "Management" Navigation View
License management 17.3 Assigning via Automation License Manager Result After booting the Automation License Manager communicates with the SINUMERIK control system defined in the user-specific communication parameters. The control system to which you have switched is represented by an "online" control system file in the navigation area of the Automation License Manager.
Page 581: Display The License Information Of A Hardware Unit
License management 17.3 Assigning via Automation License Manager 17.3.6 Display the license information of a hardware unit Background To perform the following tasks with the Automatic License Manager, the system should display the license information of a hardware unit: ● Check the license information for the hardware ●...
Page 582: Create Control Image (Offline)
License management 17.3 Assigning via Automation License Manager 17.3.7 Create control image (offline) Background It is essential to create a control image (offline) for the following reasons: ● The license information must be later transferred to the hardware. ● The control system (online) is not connected to the Internet, e.g. for security reasons. Consequently, the license information must be transferred to the hardware in three individual stages.
Page 583: Align License Requirement For A Hardware Unit
License management 17.3 Assigning via Automation License Manager 17.3.8 Align license requirement for a hardware unit Background If one or more options are active on a SINUMERIK control system, you must assign each license to the hardware. Next, the updated license information including the License Key is transferred to the hardware.
Page 584: Transferring License Information For A Control Image (Offline) To A Control System (Online)
License management 17.3 Assigning via Automation License Manager NOTICE Carefully check the suggested license assignment. An adjustment may be required if: • you wish to use a license number that differs from the number suggested • you wish to use a license package rather than single licenses •...
Page 585 License management 17.3 Assigning via Automation License Manager Procedure using drag-and-drop Perform the following actions to transfer a control image (offline) to the hardware using drag and drop: 1. Open the "online" control system file in the navigation area of the Automation License Manager and select the control image (offline).
Page 586 License management 17.3 Assigning via Automation License Manager Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 587: 840Di-Specific Data And Functions
840Di-specific data and functions 18.1 Interface signals For detailed information on interface signals, please refer to the function manuals: ● /FB1/Function Manual - Basic Functions ● /FB2/ Function Manual - Extended Functions ● /FB3/ Function Manual - Special Functions ● /FBSY/ Function Manual Synchronous Actions For a complete list of all existing interface signals, please refer to: ●...
Page 588: Interface Signals Not Supported
840Di-specific data and functions 18.1 Interface signals 18.1.2 Interface signals not supported DB number Byte, bit Name Axis/spindlespecific signals from PLC to axis/spindle 31, ... 20.0 Acceleration switch V/Hz operation 31, ... 20.2 Torque limit 2 Safety Integrated signals from PLC to axis/spindle 31, ...
Page 589: Expanded Message Frame Configuration/Evaluation Of Internal Drive Variables
840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables 18.2 Expanded message frame configuration/evaluation of internal drive variables 18.2.1 Description of functions To ensure that the internal drive variables are available for evaluation in the NC, these are transferred from the drive as additional process data (PDA) during cyclic PROFIBUS communication and saved by the operating system in system variables.
Page 590 840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables General system variables The entire message frame with standard process data and additional process data is transferred in a general system variable as an array of 16-bit integer data words via: ●...
Page 591: Requirements
18.2.2 Requirements The following conditions must be fulfilled for the transfer of additional drive variables: ● Drive The drive must support SIEMENS message frame 116 or free message frame configuration. ● DP master/SIMATIC STEP 7 No additional requirements ● SINUMERIK 840Di sl NC –...
Page 592: Project Design: Sinamics S120 And Siemens Message Frame 116
1. Configuring the DP Master: Standard engineering When using the extended message frame configuration, you must first apply the standard configuration to the DP master with respect to the DP slave S120 with the SIEMENS message frame required for cyclic communication.
Page 593 There is no automatic adjustment! The following data must agree: – SIMATIC S7 configuration DP slave S120 I/O address – SINUMERIK 840Di sl NC MD13060 $MN_DRIVE_LOGIC_ADDRESS[n] (logical drive address) Note After the above mentioned length increase of the PDA actual value (DP Slave Properties dialog box >...
Page 594 840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables 2. Configuring the DP slave S120/drive Before performing the extended message frame configuration in the STARTER commissioning tool, you must first perform the standard configuration or commissioning of the drive.
Page 595: Project Design: Simodrive
840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables 3. Configuring the NC Before configuring the expanded message frame configuration, you first need to perform the standard configuration on the NC for the drive. Standard configuration How to proceed with the standard configuration of a drive is described in Subsection "Drive configuration"...
Page 596 1. DP master 2. DP Slave 611U 3. SINUMERIK 840Di sl NC Step 1: Configuring the DP master Before performing the expanded message frame configuration, you need to configure the DP slave 611U with the standard message frame required for this drive.
Page 597 The following data must agree: – 1. SIMATIC S7 configuration DP slave 611U I/O address – 2. SINUMERIK 840Di sl NC MD13060 $MN_DRIVE_LOGIC_ADDRESS[n] (logical drive address) Note After the length increase of the actual value PDA (DP slave properties dialog > Configuration >Actual value >Length) described above, a renewed opening of the properties dialog and the...
Page 598 840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables References: /POS3/ User Manual - SIMODRIVE POSMO SI/CD/CA – SimoCom U commissioning tool References: Online Help of SimoCom U Expanded message frame configuration To configure the additional drive actual values, modify the standard configuration of the drive e.g.
Page 599 840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables Figure 18-5 Configuring the additional drive actual values Step 3: Configuring the NC Before configuring the expanded message frame configuration, you first need to perform the standard configuration on the NC for the drive. Standard configuration How to proceed with the standard configuration of a drive is described in Subsection "Drive configuration"...
Page 600: Constraints
The following restrictions are applicable with regard to the "expanded message frame configuration" function: ● Additional data can only be transferred from the drive to the SINUMERIK 840Di sl NC (actual value channel). You cannot transfer data in the other direction, i.e. from the NC to the DP slave drive (setpoint channel).
Page 601 840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables No acyclic communication possible If a drive does not support acyclic communication, of if the acyclic communication via the following axis-specific NC machine data was switched off explicitly for a drive, a consistency check of the above-mentioned data is the sole responsibility of the person who performs the startup: ●...
Page 602: Data Descriptions (Md, System Variable)
840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables 18.2.7 Data descriptions (MD, system variable) General machine data 13070 DRIVE_FUNCTION_MASK MD number Bit-coded screen for selecting the functional scope expected by the NC with PROFIBUS drives Default setting: 0 Min.
Page 603: Interrupts
840Di-specific data and functions 18.2 Expanded message frame configuration/evaluation of internal drive variables Axis-specific machine data 36730 DRIVE_SIGNAL_TRACKING MD number Detection of additional drive actual values Default setting: 0 Min. input limit: 0 Max. input limit: 4 Changes effective after POWER ON Protection level: 2/7 unit: - Data type: BYTE...
Page 604: Travel To Fixed Stop With High-Resolution Torque Reduction
840Di-specific data and functions 18.3 Travel to fixed stop with high-resolution torque reduction 18.3 Travel to fixed stop with high-resolution torque reduction The full description of functions for "Travel to fixed stop" can be found in: References: /FB1/ Function Manual, Basic Functions; Section "F1 Travel to Fixed Stop" 18.3.1 Description of functions As part of the NC function "Travel to fixed stop", you specify the reduction of the drive torque...
Page 605: Comparison
Comparison Automatic adjustment To simplify the torque reduction commissioning, the SINUMERIK 840Di sl NC tries to perform, by default, an automatic adjustment using the torque reduction evaluation configured in the drive. To do this the NC reads the relevant drive parameters and applies the value converted to NC format in the machine data: ●...
Page 606: Parameter Assignment: Simodrive
18.3.6 Parameter assignment: SINUMERIK 840Di sl NC In the SINUMERIK 840Di sl NC system, the parameters for evaluating torque reduction are assigned via the axis-specific machine data: ● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL Automatic adjustment...
Page 607 SimoCom U commissioning tool: Menu command Commission > Other parameters > Expert List > Number > 881 Torque reduction: P0881 = 1638.40 (≙ 0.1%) The parameter is immediately effective. Parameterization of SINUMERIK 840Di sl NC Machine axis X1: ● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL == 0.1 Manual...
Page 608: Constraints
NOTICE It is the system startup engineer's responsibility to ensure that the parameter settings are consistent in the SINUMERIK 840Di sl NC and all relevant drives for which torque reduction is being performed. The following data must be consistent in terms of values and meaning: 1.
Page 609: Data Description (Md)
840Di-specific data and functions 18.3 Travel to fixed stop with high-resolution torque reduction 18.3.8 Data description (MD) General machine data 13070 DRIVE_FUNCTION_MASK MD number Bit-coded screen for selecting the functional scope expected by the NC with PROFIBUS drives Default setting: 0 Min.
Page 610: Interrupts
840Di-specific data and functions 18.3 Travel to fixed stop with high-resolution torque reduction 18.3.9 Interrupts Detailed information on the individual alarms can be found in: References: /DA/ Diagnostics Manual For systems with HMI Advanced you can refer to the online help. Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 611: Appendix
Appendix Abbreviations ADI4 (Analog drive interface for 4 axes) Active Line Module Rotating induction motor Automation system ASCII American Standard Code for Information Interchange: American coding standard for the exchange of information ASUB Asynchronous subroutine Mode Mode group Mode group Command output disable Command output disable Ready...
Page 612 Appendix A.1 Abbreviations Dual-Port RAM DRAM Dynamic memory (non-buffered) Differential Resolver Function: Differential function for handwheel signaling DRIVE-CLiQ Drive Component Link with IQ Dry Run: Dry run feedrate Dynamic Servo Control Data Send Ready: Signals that data is ready to be sent from the serial data interfaces Data word DWORD Double Word (currently 32 bits)
Page 613 Appendix A.1 Abbreviations Channel 1 Gear ratio Servo gain factor Local Area Network Light-Emitting Diode: Light emitting diode PMS1 Position measuring system 1 PMS2 Position measuring system 2 Least significant bit Local User Data Media Access Control Motion Control Interface MCIS Motion Control Information System Machine Control Panel...
Page 614 Appendix A.1 Abbreviations POSMO CA Positioning Motor Compact AC: Complete drive unit with integrated power and control module as well as positioning unit and program memory; AC infeed. POSMO CD Positioning Motor Compact DC: Like CA but with DC infeed POSMO SI Positioning Motor Servo Integrated: Positioning motor, DC infeed Parameter process data object...
Page 615 Appendix A.1 Abbreviations Universal Serial Bus Serial interface Association of Electrical Engineering, Electronics and Information Technology (Germany) VDI interface: Data interface between NC and PLC Voltage input Voltage output Feed drive Tool coordinate system Tool Tool Radius Compensation Tool Tool offset Tool change Zero Offset Active: Identifier for zero offsets Status word (of drive)
Page 616: Feedback On The Documentation
This document will be continuously improved with regard to its quality and ease of use. Please help us with this task by sending your comments and suggestions for improvement via e-mail or fax to: E-mail: mailto:docu.motioncontrol@siemens.com Fax: +49 9131 - 98 63315 Please use the fax form on the back of this page.
Page 617 Appendix A.2 Feedback on the documentation Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 618: Overview
Appendix A.3 Overview Overview Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 619: Glossary
Glossary Active Line Module Controlled, self-commutating feed/feedback unit (with -"IGBT"s in feed/feedback direction), which supplies the DC link voltage for the -> "Motor module". Antriebsobjekt A drive object is an autonomous, individual software function with its own -> "Parameters" and may also have its own -> "Fault"s and -> "Alarm"s. Drive objects may exist by default (e.g.
Page 620 Glossary Control word Bit-coded -"Process data" word, transmitted by -> "PROFIdrive" at cyclic intervals to control the drive states. Double motor module Two motors can be connected to and operated with a Double Motor Module. See -> "Motor module" - "Single motor module". Former name: –> "Double-axis module" Drive The term "drive"...
Page 621 Glossary Drive unit The drive unit includes all the components connected via –> "DRIVE-CLiQ" that are required for carrying out a drive task: -> "Motor module" -> "Control unit" -> "Line module", and the required -> "Firmware" and -> "Motor"s, but not additional components (such as filters or reactors).
Page 622 Glossary Motor For the electric motors that can be driven by –> "SINAMICS", a basic distinction is made between rotary and linear motors with regard to their direction of motion, and between synchronous and induction motors with regard to their electromagnetic operating principle. For SINAMICS, the motors are connected to a ->...
Page 623 Glossary Servo control For -> Motors equipped with a -> "Motor encoder", this control type allows operation with a high level of -> "Accuracy" and -> "Dynamic response". In addition to speed control, position control can be implemented. Servo drive An electric servo drive comprises a motor, a –>...
Page 624 Glossary Manual Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0...
Page 625: Index
Index BICO interconnection Control Unit, 325 ８ Drive, 330 Infeed, 326, 327, 328, 329 840Di sl Rack, 164, 236 Blue screen, 25 840Di startup BUS 1, 488 PROFIBUS diagnosis, 249 BUS 2, 488 ＡＣ Absolute encoders, 402 Cable distributor Absolute measuring systems Connector assignments, 67 Parameter assignment, 399...
Page 626 Index Current control loop Dynamic monitoring functions Measurement, 513 Velocity monitoring, 428 Current version, 141 Dynamic Servo Control, 405 Cycle times, 375 Cyclic operation Ｅ PLC, 182 EMC measures, 119 Equidistant DP cycle, 244 Ｄ Setting, 165 Data backup, 541 Equidistant master cycl.
Page 627 Index PP72/48, 101 Basic software, 31 GSD file Engineering tools, 31 General information, 237 SIMATIC S7-AddOn-Software(SIMATICS7 add-on I/O module PP72/48, 33 software), 33 Interface description MCI board, 48 Ｈ MCI board extension, 60 PP72/48, 92 Handwheel connection Interface overview Cable distributor, 460 ADI4, 60 Ethernet, 464 MCI board, 48...
Page 628 Using the SIMATIC Manager STEP7, 182 OP 012, 44 OP 012T, 44 Interface, 20 OP 015, 44 Interface signal, 587 SINUMERIK 840Di sl, 43 Parameterization of, 167, 169 TCU, 44 Setting, 350 TP 012, 44 TP 015A, 44 Order Number Ｎ...
Page 629 Index PCU 50.3 Power-up Ethernet connections, 187 After PCU/MCI board replacement, 132 PDA area, 231 Power-up Pin assignments After importing a backup copy, 132 Cable distributor, 68 Power-up PIV area, 231 After power failure, 133 PP72/48 Basic program installation, 151 Setting the PROFIBUS address, 251 Default data, 488 PP72/48 I/O module, 45...
Page 630 Index EMC/ESD, 119 Commissioning, 307 RUN, 488 Configuration: Motors and encoders, 318 Configuring PROFIBUS message frames, 324 Control Unit: BICO interconnection, 325 Ｓ Control Unit: PROFIBUS message frame, 321 Drive: BICO interconnection, 330 Entering component topology automatically, 316 Handwheel type, MCI board Ext., 57 Firmware upgrade, 342 MCP 483C IE, 194 Infeed: BICO interconnection, 326, 327, 328, 329...
Page 631 Index ONLINE commissioning, 313 Requirements, 501 Startup, 38 Spindle, 505 General information, 22 Testing the PLC program, 181 Menu command: Windows, 39 Text file for cycle alarm texts, 497 Startup characteristics Text file for PLC alarm texts, 498 PLC, 181 Thin Client Startup image, HMI HT 8, 80...
Page 632 Index Ｘ I/O MPG extension, MCI board Ext., 60 PROFIBUS DP, PP72/48, 94 Ext. power supply, PP72/48, 93 X222 X101, 160, 165, 307 dig. inputs/outputs, PP72/48, 95 PROFIBUS DP, MCI board, 49 X102, 160, 167, 169 Battery connection, MCI board, 50 MPI/DP interface, MCI board, 49 X333 X111...

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