Page 1 Manual 06/2003 Edition SINUMERIK 840Di...
Page 3 General Hardware Descriptions Design EMC and ESD Measures MPI Communication SINUMERIK 840Di Turning On and Ramp Up Manual PROFIBUS DP Communication PLC Start-Up Drive Start-Up (Preconditions) NC Start-Up with HMI Advanced Alarm and Message Texts Dry Run of Axis and...
Page 4 11.03 6FC5 298-6CA00-0BG4 Trademarks SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr and SIMODRIVEr are Siemens trademarks. The other designations in this publication may also be trade marks, the use of which by third parties may constitute copyright violation. Further information is available on the Internet under: Other functions not described in this documentation might be http://www.ad.siemens.de/sinumerik...
Page 5: General
Fax form: see reply at the end of the manual Internet address http://www.ad.siemens.de/sinumerik SINUMERIK SW version The SW versions stated in the documentation apply for the SINUMERIK 840Di control. Target readers Configuring engineers, Electricians and start-up specialists Service and operating personnel.
Page 6 Training and education in maintenance and use of adequate safety equip- ment according to safety technology standards. First aid training.  Siemens AG, 2003. All rights reserved SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 7 This symbol appears in this documentation whenever the machine manufac- turer can influence or modify the described functional behavior. Please ob- serve the information provided by the machine manufacturer!  Siemens AG, 2003. All rights reserved SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 8 Suitable electric tools must be used. Warning Repairs to equipment supplied by Siemens must always be carried out by SIEMENS after-sales service personnel or by repair centers authorized by SIEMENS. Parts or components must always be replaced by parts or components specified in the spare parts list.
Page 9 The unit may be used only for the applications described in the catalog, and only in combination with the equipment and components recommended and approved by SIEMENS (e.g. SINUMERIK 840D/FM-NC).  Siemens AG, 2003. All rights reserved SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 13 ........5-164 5.7.4 Example: Connecting an HT 6 to SINUMERIK 840Di ... . . 5-166 5.7.5...
Page 18 ..... . 16-512 16.3.4 Setting parameters for the SINUMERIK 840Di NC ....16-512 16.3.5...
Page 19: General On The Sinumerik 840Di
General on the SINUMERIK 840Di Overview of SINUMERIK 840Di With the SINUMERIK 840Di, Siemens can provide a complete PC-integrated control that controls the drive units and I/Os through the standard field bus PROFIBUS DP with Motion Control functionality and therefore permits a distrib- uted design of the overall system.
Page 20: System Software Packages And Options (Sw 2.1 And Higher)
1.1 Overview of SINUMERIK 840Di 1.1.1 System software packages and options (SW 2.1 and higher) System software For optimum adaptation of the SINUMERIK 840Di to the automation task, Sie- packages mens can provide various system software packages: System software Basic System software Universal System software Plus (requires PCU variant with CPU q500MHz).
Page 21: Hardware Components
1.1 Overview of SINUMERIK 840Di 1.1.2 Hardware components The hardware basis for the SINUMERIK 840Di is an industrial PC (further re- ferred to as PCU (PC Unit) from Siemens A&D in conjunction with the MCI board (Motion Control Interface). The SINUMERIK 840Di is available with the following PCU variants, each with...
Page 22 PCU. from 02.01) Drives For interpolating traversing of axes on the PROFIBUS, the SINUMERIK 840Di uses the functionality defined in the PROFIDrive profile drive technology (Ver- sion 1.4.2, 01. Sept. 00) “Motion Control with PROFIBUS DP”.
Page 23: Software Components
HMI modular system and the start-up tools run. Since Windows NT, however, is only conditionally real-time capable, as known (in this context, the term “soft real time” is used), SIEMENS has developed a method that allows the operation of the NC system software in hard real time, without modifying Windows NT.
Page 24: Real-Time Properties
SINUMERIK 840Di. 840Di start-up is part of the scope of supply of a SINUMERIK 840Di and is al- ready installed on the hard disk of the PCU.
Page 25 The NCK is integrated in Windows NT as a “LogB Service”. To exit or start the function, go to: Windows NT start bar: Start > Settings > Control Panel > Services > “LogB Service” > Exit or Start  Siemens AG, 2003. All rights reserved 1-25 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 26: System Integrity
ERIK 840Di comes completely configured and ready to operate. To this aim, the system components used are subject to a certification proce- dure with Siemens as the system manufacturer. This is to certify and document the compliance with the real-time capability of the whole configuration in impor- tant operating modes.
Page 27 Loss of voltage A loss of voltage lasting more than five msecs is detected by the POWER FAIL functionality of the SINUMERIK 840Di as a fault scenario and the following ac- tions are initiated: – The background lighting of the operator panel display is switched off –...
Page 28: Power Off
2. In the remaining time left by the internal power backup, Windows NT can no longer be ended correctly. This implies the risk that the Windows NT instal- lation can be damaged so that the SINUMERIK 840Di can no longer be run. It is therefore urgently recommended to use an uninterruptible power sys- tem (UPS) (see Subsection 1.1.8, page 1-29).
Page 29: Uninterruptible Power System (Ups)
2. In the remaining time left by the internal power backup, Windows NT can no longer be ended correctly. This implies the risk that the Windows NT instal- lation can be damaged so that the SINUMERIK 840Di can no longer be run. It is therefore urgently recommended to use an uninterruptible power sys- tem (UPS) (see Subsection 1.1.8, page 1-29).
Page 30 Prerequisite: MCI board extension (option) Notes Re.: 3) For details of the start/up behavior of SINUMERIK 840Di with shutdown signal present, refer to Subsection 6.3.9, Page 6-187. Notice One of the follwoing connection variants must be used for full back-up protec- tion: –...
Page 31 Power infeed Standard 24V/10A SITOP POWER ACCU MODULE 110/220VAC, 60/50Hz SIEMENS Free wiring ET 200 I/Os SINUMERIK 840Di PROFIBUS DP Fig. 1-2 Connection options: UPS  Siemens AG, 2003. All rights reserved 1-31 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 32: Overview Of Software Components
Additional soft- The following software components are included in the scope of delivery of the ware components SINUMERIK 840Di system and are either installed on the PCU hard disk or pro- vided on CD for installation: Basic software The basic SINUMERIK 840Di software encompasses the following compo- nents: –...
Page 33 – Basic PLC program – NC variable selector – PLC sample programs (installation software: F:\840DiTools\plcToolbox\<version>\Setup.exe) – DriveOM and SlaveOM for SINUMERIK 840Di Object Manager for the dialog-based configuration of PROFIBUS DP drives using SIMATIC Manager STEP7 especially for SINUMERIK 840Di.
Page 34 1 General on the SINUMERIK 840Di 06.03 1.2 Overview of software components – Sample PLC application Sample application of a SIMATIC S7 project for SINUMERIK 840Di with SIMODRIVE 611 universal drives and SIMATIC ET200 I/Os (ZIP file: F:\840DiTools\support\840dibsp\840dibsp.zip) Note The components supplied as SIMATIC S7 add-on software –...
Page 35: Notes On Start-Up
PROFIBUS DP drives (e.g. SIMODRIVE 611 universal), please refer to the relevant documentation. Notice It is recommended to carry out the start-up of the SINUMERIK 840Di in the order of the sections of the present Manual. Software To start up the SINUMERIK 840Di, the following software is needed, which is...
Page 36: Sinumerik Industrial Pc
1 General on the SINUMERIK 840Di 06.03 1.3 Notes on start-up – for creating a SIMATIC S7 project to start up the SINUMERIK 840Di- PLC, the MPI and PROFIBUS DP communication – for installing additional software on the PCU. an MPI cable for connecting the PCU to the programming unit...
Page 37: Standard/Export Version
Export List, the SINUMERIK 840Di is offered in two variations. export approval The standard version (SINUMERIK 840Di) can contain the full scope of functions of the control but this does mean that it requires export approval with regard to its type.
Page 38: 840Di Start-Up
840Di start-up The user interface 840Di start-up included in the scope of supply of the SINUM- ERIK 840Di is intended as a first introduction to the SINUMERIK 840Di function- ality. Overview of...
Page 39: Menu Command: Window
Program levels: Main program and 3 subroutine levels Alarm Display of current alarms and messages Alarm log Display of all alarms and messages as they occurred in time order  Siemens AG, 2003. All rights reserved 1-39 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 40 Slaves Display of: – Slave no. (DP address) – Assignment – Active at the bus – Synchr. with NC – Number of slots – Details  Siemens AG, 2003. All rights reserved 1-40 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 41 – “MRES” Latency display – Current value – Maximum value – Number of violations – Oscilloscope Log Book Display of SINUMERIK 840Di system mes- sages  Siemens AG, 2003. All rights reserved 1-41 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 43: Hardware Descriptions
Hardware Descriptions Overview of hardware components SINUMERIK 840Di: A SINUMERIK 840Di control system can only be ordered as a complete system (PCU and MCI board). Complete system SINUMERIK 840Di PCU 50 with Pentium II 333MHz, 128MB RAM and MCI board, 24V power supply Order No.: 6FC5 220-0AA00-1AA0...
Page 44: Sinumerik Operator Panel Fronts
Expansion of the Motion Control SINUMERIK 840Di MCI Board Extension Interface Order number: 6FC5 222-0AA00-0AA0 SINUMERIK 840Di MCI Board Extension Slot Variation Order number: 6FC5 222-0AA00-0AA1 SINUMERIK 840Di MCI Board Extension External Variation Order number: 6FC5 222-0AA01-0AA0 Operation and display SINUMERIK operator panel fronts –...
Page 45: I/O Module Pp72/48
SIMODRIVE POSMO CD/CA SIMODRIVE POSMO SI SIMODRIVE POSMO A For detailed ordering information on various drives, see: References: /BU/ SINUMERIK & SIMODRIVE Ordering information Catalog NC 60.2002  Siemens AG, 2003. All rights reserved 2-45 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 46: Mci Board
Some parts of the MCI board are always alive due to the backup battery. To avoid short circuits, do not place the MCI board on electrically conductive mate- rials.  Siemens AG, 2003. All rights reserved 2-46 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 47 Order No. (MLFB) Backup battery 6FC5 247-0AA18-0AA0 Notice For MPI connection on the MCI board, you must use a connector with straight °). cable outlet (  Siemens AG, 2003. All rights reserved 2-47 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 48: Interface Description
2) Pins 5 and 6 are only allowed to be used to supply power to the bus terminators Connection cable see Subsection 3.3.1, Page 3-131.  Siemens AG, 2003. All rights reserved 2-48 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 49 Connection cable see Subsection 3.3.1, Page 3-131. Notice The MPI and PROFIBUS DP interfaces are isolated both to one another and with regard to the PCU.  Siemens AG, 2003. All rights reserved 2-49 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 50: Changing The Battery
The alarm “2101 NCK battery alarm” is output if battery low voltage is detected in cyclic operation. The alarm “2102 NCK battery alarm” is output if battery low voltage is detected during power-up.  Siemens AG, 2003. All rights reserved 2-50 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 51 For information on how to create a series machine start-up file, please refer to Chapter 14, Page 14-449. 2. Shut down the SINUMERIK 840Di and Windows NT correctly. To do so, use one of the following possibilities: Windows NT taskbar: Start > Shut Down Interface signal: “PC shutdown”;...
Page 52: Module
7. Remove the fastening screw of the cover plate of the module. 8. Remove the module, observing the ESD measures. 9. Remove the battery receptacle using an appropriate screw driver (see Fig. 2-4).  Siemens AG, 2003. All rights reserved 2-52 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 53 12. Install the new battery and plug the battery connector onto the connection contacts without applying force (X3). Marking of the battery connector Fig. 2-5 Battery connector  Siemens AG, 2003. All rights reserved 2-53 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 54: Module Replacement
2.2.4 Module replacement For module replacement, a module is installed and removed in an analogous way to changing the battery (see Subsection 2.2.3, page 2-50).  Siemens AG, 2003. All rights reserved 2-54 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 55: Technical Data
The specified safety regulations, certifications, degree of protection and class of protection only apply for the case that the module is plugged in a SINUMERIK PCU 50.  Siemens AG, 2003. All rights reserved 2-55 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 56: Mci Board Extension
Before you plug or remove the cable connector, switch off the PCU (shut down Windows NT correctly!). Otherwise, short circuits might occur on the module, as a result of which the module could be destroyed.  Siemens AG, 2003. All rights reserved 2-56 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 57: Installation Instructions
(e.g. blank cubicle parts, socket protec- tion contact) immediately before starting work on the module. 1. Shut down the SINUMERIK 840Di and Windows NT correctly. To do so, use one of the following possibilities: Windows NT taskbar: Start >...
Page 58 – MCI board extension: Interface X4 8. Mount the module holding-down device again. 9. Close the housing and fix it again with the two housing screws.  Siemens AG, 2003. All rights reserved 2-58 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 59 MPG1 5V MPG1 0V MPG1 XB MPG1 B MPG0 XA MPG0 A MPG0 5V MPG0 0V MPG0 5V MPG0 0V MPG0 XB MPG0 B Not assigned  Siemens AG, 2003. All rights reserved 2-59 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 60 Voltage Input Notice The maximum current carrying capacity of the handwheel interface of the MCI board extension module is 1A for both handwheels. 500mA per handwheel.  Siemens AG, 2003. All rights reserved 2-60 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 61: Technical Data
The specified safety regulations, certifications, degree of protection and class of protection only apply for the case that the module is plugged in a SINUM- ERIK PCU 50.  Siemens AG, 2003. All rights reserved 2-61 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 62: Mci Board Extension Slot Variation (Sw 11.00 And Higher)
Before you plug or remove the cable connector, switch off the PCU (shut down Windows NT correctly!). Otherwise, short circuits might occur on the module, as a result of which the module could be destroyed.  Siemens AG, 2003. All rights reserved 2-62 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 63 Fig. 2-10 Switch S1 switch position open (TTL handwheels) Notice You select between differential and TTL handwheels on the module using switch S1 before installing the module.  Siemens AG, 2003. All rights reserved 2-63 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 64: Installation Instructions
(e.g. blank cubicle parts, socket protec- tion contact) immediately before starting work on the module. 1. Shut down the SINUMERIK 840Di and Windows NT correctly. To do so, use one of the following possibilities: Windows NT taskbar: Start >...
Page 65 – MCI board extension: Interface X4 8. Mount the module holding-down device again. 9. Close the housing and fix it again with the two housing screws.  Siemens AG, 2003. All rights reserved 2-65 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 66: Interface Description
24V input ground MEXT 24V input ground MEXT 24V input ground MEXT 24V input ground MEPU1_S 2nd Sensor probe input (signal: MEPU1_C 2nd Sensor probe input (0V)  Siemens AG, 2003. All rights reserved 2-66 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 67 Ext. power supply X121 +24V stabilized Pin number: MCI board +24V extension 20,21 Optocoupler 3,4,22,23 Relays Driver The maximum cable length is 25m for all functions.  Siemens AG, 2003. All rights reserved 2-67 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 68 (board electronics, dig. inputs, dig. outputs, and handwheels). Sensor probes The sensor probes are isolated among themselves and from the board electron- ics.  Siemens AG, 2003. All rights reserved 2-68 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 69: Technical Data
The specified safety regulations, certifications, degree of protection and class of protection only apply for the case that the module is plugged in a SINUM- ERIK PCU 50.  Siemens AG, 2003. All rights reserved 2-69 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 70: Mci Board Extension External Variation (Sw 02.01 And Higher)
Before you plug or remove the cable connector, switch off the PCU (shut down Windows NT correctly!). Otherwise, short circuits might occur on the module, as a result of which the module could be destroyed.  Siemens AG, 2003. All rights reserved 2-70 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 71 Fig. 2-14 Switch S1 switch position open (TTL handwheels) Notice You select between differential and TTL handwheels on the module using switch S1 before installing the module.  Siemens AG, 2003. All rights reserved 2-71 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 72: Installation Instructions
(e.g. blank cubicle parts, socket protec- tion contact) immediately before starting work on the module. 1. Shut down the SINUMERIK 840Di and Windows NT correctly. To do so, use one of the following possibilities: Windows NT taskbar: Start >...
Page 73 5. Insert the modified housing cover into the guide slot of the PCU and close the housing to the extent that the connecting cable can be plugged into the MCI board extension interface (X2).  Siemens AG, 2003. All rights reserved 2-73 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 74 7. Close the housing completely and fix it again with the two housing screws. 8. Connect your PC to mains again and start it. Fig. 2-17 PCU 50 with MCI board extension external variation  Siemens AG, 2003. All rights reserved 2-74 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 75: Dimension Drawing
The technical data of the MCI board extension external variation are identical with those of the MCI board extension slot variation. See Subsection 2.4.4, page 2-69.  Siemens AG, 2003. All rights reserved 2-75 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 76: Cable Distributor
See Fig. 2-20, Page 2-77. Install the upper terminal clamp such that its “teeth” point towards  Siemens AG, 2003. All rights reserved 2-76 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 77 The DIP-FIX switches in the interior of the cable distributor must be set as follows: Table 2-11 Setting the DIP-FIX switches in the cable distributor Switch open closed  Siemens AG, 2003. All rights reserved 2-77 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 78 X121 cable distributor interface of the MCI board extension module using screws. Cable distributor: Top view Cable distributor: Side view Adapter plate Fig. 2-21 Mounting the cable distributor  Siemens AG, 2003. All rights reserved 2-78 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 79 MPG0 A X2/1 X2/4 MPG0 5V X2/3 1st handwheel MPG0 0V X1/2 21–0jjj MPG0 5V X1/1 6FC9320-5DB MPG0 0V X1/4 MPG0 XB X1/3 MPG0 B Shield  Siemens AG, 2003. All rights reserved 2-79 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 80 The maximum current carrying capacity of the handwheel interface is 1A for both handwheels. 500mA per handwheel. Colors orange brown black green yellow violet blue  Siemens AG, 2003. All rights reserved 2-80 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 81 6FC5 210-0DF22-0AA0 Features Together with the MCI board, the SINUMERIK industrial PC “PCU 50” serves as the basis for the SINUMERIK 840Di control system. The key features of the PCU 50 are as follows: Processor versions: – Pentium II 333MHz, 128MB SDRAM –...
Page 82 In SW 2.2 and higher, distributed connection of PCU and operator panel is pos- higher) sible via Videolink (option). References: /BH/ Operator Components Manual Distributed configuration  Siemens AG, 2003. All rights reserved 2-82 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 83: Sinumerik Pcu 70
Dimensions (W x H x D): 297x267x122mm Easy-to-service design Screen resolution 640x480 (VGA), up to 1024x768 (XGA) Power supply: 24VDC Interfaces: – Parallel interface LPT1  Siemens AG, 2003. All rights reserved 2-83 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 84 In SW 2.2 and higher, distributed connection of PCU and operator panel is pos- higher) sible via Videolink (option). References: /BH/ Operator Components Manual Distributed configuration  Siemens AG, 2003. All rights reserved 2-84 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 85 “ETC” key Area switchover Mouse Fig. 2-24 View of OP 012 operator panel front Order No. Designation Order No. (MLFB) SINUMERIK OP 012 6FC5 203-0AF02-0AA0  Siemens AG, 2003. All rights reserved 2-85 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 86 A complete documentation of the OP 012 operator panel front is to be found in: References: /BH/ Operator Components Manual OP 012 operator panel front.  Siemens AG, 2003. All rights reserved 2-86 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 87 Lowest air temperature 0°C. References For a complete description of the external 3.5’’ floppy disk drive, please refer to: References: /BH/ Operator Components Manual floppy disk drive 3.5’’  Siemens AG, 2003. All rights reserved 2-87 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 88: Power Supply
47 ... 63Hz Input current nominal value 3.5/1.7A Inrush current (25° C) Output voltage nominal value 24VDC ± 3% Output voltage tolerance Efficiency > 87%  Siemens AG, 2003. All rights reserved 2-88 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 89 Class of protection (IEC 536; VDE 1006 T1) class I Degree of protection (VDE 0470, IEC 529) IP 20 Radio interference level (EN 55011) class A  Siemens AG, 2003. All rights reserved 2-89 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 90 Immediate electronic connection of the accumulator once the load voltage or the voltage present between the connections L+/M of the DC-UPS module falls below the value of the connection threshold (18 to 26V).  Siemens AG, 2003. All rights reserved 2-90 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 91 The individual cables are connected 1:1 to the appropriate pins. Table 2-14 Pin assignment of the 9-pin SUB-D connectors Signal Designation Data cable Negative supply voltage Positive supply voltage  Siemens AG, 2003. All rights reserved 2-91 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 92 Short circuit protection (battery fuse 15A/32V) Class of protection (IEC 536; VDE 1006 T1) Class III Degree of protection (EN 60 529; VDE 0470 T1) IP 00  Siemens AG, 2003. All rights reserved 2-92 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 93: I/O Module Pp72/48
On-board status display by means of four diagnostic LEDs To power the module and the digital outputs, an external power supply source (+24VDC) is required.  Siemens AG, 2003. All rights reserved 2-93 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 94: Interface Description
The required connecting cables must be provided by the user: – Wire, conductor cross-section: 1.0–1.5mm (AWG17–AWG16) Power supply For data concerning the power supply, see Subsection 2.12.3, page 2-101.  Siemens AG, 2003. All rights reserved 2-94 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 95 = 16 PROFIBUS address: = 32 PROFIBUS address: = 64 not used Notice A newly set PROFIBUS address will only come into effect after power ON.  Siemens AG, 2003. All rights reserved 2-95 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 96 DOCOMx Input 2.4 DOCOMx Input 2.5 DOCOMx Input 2.6 DOCOMx 1) VI Voltage Input VO Voltage Output Signal Input Signal Output with x = 1,2,3  Siemens AG, 2003. All rights reserved 2-96 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 97 If an external power supply Is used for the digital inputs, its reference ground must be connected with X111, X222, X333: Pin 1 (GND). X111, X222, X333: Pin 1 (P24OUT) then remains open.  Siemens AG, 2003. All rights reserved 2-97 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 98 Moreover, the PROFIBUS communication time and the application cycle time must be taken into account. Polarity reversal causes neither high level nor destruction of the inputs.  Siemens AG, 2003. All rights reserved 2-98 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 99 The power supply (+24VDC) for the digital outputs must therefore be con- nected to all 4 pins (X111, X222, X333: Pin 47, 48, 49, 50) for each DOCOMx.  Siemens AG, 2003. All rights reserved 2-99 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 100 – Galvanic isolation using optocouplers – Current limitation to max. 500mA – Protection from: short-circuit, overtemperature, and loss of ground – Autom. shutdown on undervoltage.  Siemens AG, 2003. All rights reserved 2-100 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 101 The external power supply voltages must be generated as function extra-low voltages with safe electrical isolation (IEC 204-1, Section 6.4, PELV) and must be grounded centrally by the user.  Siemens AG, 2003. All rights reserved 2-101 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 103: Dimension Drawing
2 Hardware Descriptions 06.03 2.12 I/O Module PP72/48 2.12.5 Dimension drawing Fig. 2-32 Dimension drawing: I/O Module PP72/48  Siemens AG, 2003. All rights reserved 2-103 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 104: Technical Data
Atmospheric pressure 700 ... 1060 hPa 700 ... 1060 hPa Transportation height – –1000 ... 3000m Shock loading during transportation v1000mm Free fall in transport package  Siemens AG, 2003. All rights reserved 2-104 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 105 Connection for digital X6-1: Connection for digital input signals output signals Diagnostic LEDs Connection for protective ground EXCH screw M6 Fig. 2-33 Connection overview ADI4  Siemens AG, 2003. All rights reserved 2-105 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 106 An ADI4 DP slave is not a DP standard slave certified as compliant with the PROFIDrive profile, e.g. the ADI4 DP slave does not support acyclic com- munication.  Siemens AG, 2003. All rights reserved 2-106 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 107: Interface Description
The required connecting cables must be provided by the user: – Wire, conductor cross-section: 1.0–1.5mm (AWG17–AWG16) Supply voltage For specification of the supply voltage, see Subsection 2.13.4, page 2-119.  Siemens AG, 2003. All rights reserved 2-107 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 108 Meaning of switch S2 Switch Meaning PROFIBUS address: PROFIBUS address: PROFIBUS address: PROFIBUS address: PROFIBUS address: = 16 PROFIBUS address: = 32 PROFIBUS address: = 64 not used  Siemens AG, 2003. All rights reserved 2-108 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 109 Preassembled cables – Order No. (MLFB) 6FX2 002-3AD01-1jj0 v35m Cable length: Data about the length codes are to be found in: References: Catalog NC Z.  Siemens AG, 2003. All rights reserved 2-109 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 110 Order No. (MLFB): 6FX8 002-2CE02-1jj0 Cable length: See below “Maximum cable lengths”. Data about the length codes are to be found in: References: Catalog NC Z.  Siemens AG, 2003. All rights reserved 2-110 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 111 28.8V Ripple max. 3.6Vpp Current load per encoder connection 0.3A max. 1.35A 1) P5MS: Supply voltage for encoders (+5VDC) P24SSI: Supply voltage for encoders (+24VDC)  Siemens AG, 2003. All rights reserved 2-111 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 112 Further measuring systems: – Encoders with SINE/COSINE signals (e.g. 1Vpp) can be connected through external pulse shaper electronics (EXE) that convert the signals to 5V TTL levels.  Siemens AG, 2003. All rights reserved 2-112 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 113 3) in the case of function “unipolar spindle” Ext. power supply +24V stabilized X6-1 ADI4 +24V Pin number: (P24EXT2) Optocoupler Relays Driver Driver Driver Relays Signal: “Ready” (MEXT2)  Siemens AG, 2003. All rights reserved 2-113 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 114 – Synchronization error – Overtemperature The relay contact is closed when the following conditions are satisfied: – Module status “Ready” – Cyclic communication with the DP master  Siemens AG, 2003. All rights reserved 2-114 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 115 – NC Ready X6-2, pins 10 and 11: Wire, conductor cross-section 1.5–3.5mm (AWG16–AWG12) Notice The lengths of the digital signal lines must not exceed 30m.  Siemens AG, 2003. All rights reserved 2-115 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 116 +24V P24OUText ext. power supply +24V stabilized Connection if the internal power supply voltage P24OUT is used; the connection to is then no longer necessary.  Siemens AG, 2003. All rights reserved 2-116 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 117 Polarity reversal causes neither high level nor destruction of the inputs. Connecting cable: The required connecting cables must be provided by the user.  Siemens AG, 2003. All rights reserved 2-117 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 118 Supply voltage OVTEMP Overtemperature display EXCHANGE green Cyclic data exchange with DP master in progress READY Ready for cyclic data exchange with DP master  Siemens AG, 2003. All rights reserved 2-118 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 119: Cabinet Mounting
1A) as an option. The reference ground (GND) of the external power supply source must be con- nected with X6-2, pin 12. X6-2, pin 1 (P24OUT) remains open.  Siemens AG, 2003. All rights reserved 2-119 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 120 On the module side, power supplies P24EXT1 and P24EXT2 must be protected against: Overvoltage Short-circuit (elec. current limitation of the outputs) Polarity reversal Overload – P24EXT1: Fuse 2.5A/250V – P24EXT2: Fuse 8A/125V.  Siemens AG, 2003. All rights reserved 2-120 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 121 A protective conductor must be connected. The housing front has an M6 screw bottom right for connecting the protective conductor. See Subsection 2.13.1, page 2-105.  Siemens AG, 2003. All rights reserved 2-121 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 122: Connection Overview
Sensors 1–n Cables: Wire (0.14 to 2.5mm X6-2 Actuators 1–n Dig. inputs Max. cable lengths: See Subsection 2.13.2, page 2-107 Fig. 2-34 ADI4 connection overview  Siemens AG, 2003. All rights reserved 2-122 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 123: Dimension Drawing
2.13 ADI4 (analog drive interface for 4 axes) (SW 09.01 and higher) 2.13.7 Dimension drawing 23.25 Necessary clearance for adequate ventilation 163.6 48.5 Max. tightening torque for all screws: 0.8Nm Fig. 2-35 Dimension drawing: ADI4  Siemens AG, 2003. All rights reserved 2-123 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 124: Technical Data
Atmospheric pressure 700 ... 1060hPa 700 ... 1060hPa Transportation height – –1000 ... 3000m Shock loading during transportation v1000mm Free fall in transport package  Siemens AG, 2003. All rights reserved 2-124 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 125: Design
Machine control panel PC/PG e.g. PG740 Terminal HT 6 Ä Ä Distributor Distributor box Fig. 3-1 SINUMERIK 840Di system overview: PROFIBUS DP and MPI (as a diagram)  Siemens AG, 2003. All rights reserved 3-125 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 126 SITOP DC-UPS Module 15 with VGA monitor device, e.g. PG740 Standard 24V/10A SITOP POWER lead-acid module SIEMENS SIEMENS Optional Fig. 3-2 System overview: PCU components (as a diagram)  Siemens AG, 2003. All rights reserved 3-126 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 127: Electrical Design
PROFIBUS DP connection conditions: References /POS1/ SIMODRIVE POSMO A User Manual /POS3/ SIMODRIVE POSMO SI/CD/CA User Manual Fig. 3-3 SINUMERIK 840Di MCI board and PROFIBUS DP components  Siemens AG, 2003. All rights reserved 3-127 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 128: Mci Board And Mpi Bus
Handheld Terminal HT 6 MCI board Distributor box PC/PG e.g. PG740 (4-core confirmation technique) Fig. 3-4 SINUMERIK 840Di MCI board and MPI bus components 3.2.3 MCI board extension Cable distributor X121 4x digital inputs 2x probes 2x handwheels 4x digital output MCI board extension Fig.
Page 129: Pcu 50
(32-pin plug connector) RESET Reset pushbutton switch External floppy disk drive 3.5’’ Fig. 3-6 SINUMERIK 840Di PCU 50, left housing side SITOP DC UPS module 10 with SITOP POWER 10 SITOP POWER lead-acid module SIEMENS SIEMENS...
Page 130: Pcu 70
The MCI board must only be run in slot 1 2) Slot 2 (master/slave) MCI board extension (option) Fig. 3-8 SINUMERIK 840Di PCU 70 (right housing side) Note The connections of the PCU 70 correspond to those of the PCU 50.  Siemens AG, 2003. All rights reserved 3-130 SINUMERIK 840Di Manual (HBI) –...
Page 131: Connection Overview
SIMATIC DP ET200 Interf. modules ADI4 I/O module PP72/48 Standard PC e.g. ET200M interfaces Fig. 3-9 Connection overview PCU 50, MCI board and MCI board extension  Siemens AG, 2003. All rights reserved 3-131 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 132 Always connect the HT 6 at an end of the MPI path (integrated bus ter- mination). Note The HT 6 can also be connected to a distributor with 3-core confirmation. – Distributor: 6FX2006-1BC01 – Cable: 6FX2002-1AA83-1jj0  Siemens AG, 2003. All rights reserved 3-132 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 133 For supplementary conditions (if any) applicable to the individual accessories, please refer to: References: /Z/ SINUMERIK, SIROTEC, SIMODRIVE Accessories and Equipment for Special-Purpose Machines Catalog NC Z.  Siemens AG, 2003. All rights reserved 3-133 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 135: Emc And Esd Measures
EMC measures: Observe maximum clearance between signal and load cables. Use only the cables offered by SIEMENS as the signal lines from and to the NC or PLC. Make sure that the signal lines have a sufficient clearance from strong magnetic fields (e.g.
Page 136: Esd Measures
– the measuring instrument is grounded (e.g. using a protective conduc- tor) or – the measuring head is discharged for a short time prior to the measure- ment (e.g. by touching a bright control housing).  Siemens AG, 2003. All rights reserved 4-136 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 137: Mpi Communication
Each node at the MPI bus must have a bus address in the range (0...31). Data transfer rate Notice The data transfer rate at the MPI bus of the SINUMERIK 840Di must be set to 1.5 Mbaud. Communication If no communication can be established as a whole or with individual nodes at...
Page 138 To this aim, an MPI connector with the terminating resistor enabled must be connected to an enabled device. To this aim, the MPI connection on the MPI board of the SINUMERIK 840Di can be used. 3. Stubs (feeding cable from the bus segment to the node) should be as short as possible, i.e.
Page 139: Default Address Assignment
06.03 5.3 Default address assignment Default address assignment Standard MPI The following figure 5-2 shows a SINUMERIK 840Di with the user interface run- ning on the PCU: addresses 840Di start-up or HMI Advanced and the further components connected on the MPI bus:...
Page 140: Machine Control Panel (Mcp)
In order to start up an MCP, the following hardware is required: MPI bus cable The MCP is connected to the SINUMERIK 840Di through the MPI bus. A termi- nating resistor for the MPI bus is not integrated in the MCP.
Page 141: Parameterization Of The Mcp
5 MPI Communication 06.03 5.4 Machine control panel (MCP) The basic PLC program is part of the SINUMERIK 840Di installation. The installation of the basic PLC program as a SIMATIC S7 library is described in Subsection 8.2.2 (page 8-251) in detail.
Page 142 Data transfer rate The data transfer rate is set using switch S3 on the rear side of the MPI module. It is 1.5 Mbaud on the MPI bus of the SINUMERIK 840Di. Setting on S3: see Table 5-1, page 5-143.
Page 143: Parameterization Of The Plc
The PLC program has a modular structure. It consists of the following function blocks: Runup and synchronization (OB 100) Cyclic operation (OB 1) Process alarm processing (OB 40).  Siemens AG, 2003. All rights reserved 5-143 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 144 In addition to a first MCP, a second MCP or an HT 6 (for HT 6, see Section 5.7, page 5-161) can be active as another operator component at the same time.  Siemens AG, 2003. All rights reserved 5-144 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 145 FC 19 (for version “M” MCP, milling) or FC 25 (for version “T” MCP, turning) parameter transfers the signals of the MCP to the NC through the interface. assignment  Siemens AG, 2003. All rights reserved 5-145 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 146: Example: Connecting An Mcp To Sinumerik 840Di
Section: FC 19: MCP_IFM Transmission of MCP signals tointerface Section: FC 25: MCP_IFT Transfer of MCP/OP signals tointerface 5.4.4 Example: Connecting an MCP to SINUMERIK 840Di 1. Connect the MCP electrically. Use the terminating resistor integrated in the MPI connector according to the general rules for connecting components to the MPI bus.
Page 147 6. After communication with the PLC has been established, the LEDs on the MCP front stop flashing. The LED of the basic settings for: Mode: Referencing Spindle Stop Feed hold light up continuously.  Siemens AG, 2003. All rights reserved 5-147 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 148: Mpi Interface
Position of the interfaces on the rear side of the MPI module For a detailed description of the electrical and mechanical design, as well as for the interfaces of the MPI module, please refer to:  Siemens AG, 2003. All rights reserved 5-148 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 149 Data transfer rate The data transfer rate is set using switch S3 on the rear side of the MPI module. It is 1.5 Mbaud on the MPI bus of the SINUMERIK 840Di. Setting on S3: see Table 5-2, page 5-149.
Page 150 Default setting OFF ON OFF ON OFF ON Default setting for 840Di Data transfer rate: 1.5 Mbaud Cyclical transmit pattern: 100msecs MPI address: Type: MPI module  Siemens AG, 2003. All rights reserved 5-150 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 151: Handheld Unit (Hhu)
Under no circumstances may the MPI connector for connecting the HHU con- tain an integrated bus terminating resistor, since a bus terminating resistor is already integrated in the HHU.  Siemens AG, 2003. All rights reserved 5-151 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 152 The following software components are required to start up the HHU: Basic PLC program The basic PLC is included on the SINUMERIK 840Di installation CD. (Start se- tup.exe; Products –> Basic PLC Program.) HHU-related blocks of the basic PLC program are FB1 (HHU parameter) and FC13 (display control).
Page 153: Electrical Connection
For a detailed description of the electrical and mechanical design, as well as for the interfaces of the HHU module, please refer to: References: /BH/ Operator Components, Manual Section: Handheld Unit and Distributor Box.  Siemens AG, 2003. All rights reserved 5-153 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 154: Mpi Parameterization Of The Hhu
1.5 Mbaud. To do so, set switch 3 of DIP switch S1 to ON. Notice To run the HHU on the MPI bus of the SINUMERIK 840Di, the data transfer rate has to be set to 1.5 Mbaud.  Siemens AG, 2003. All rights reserved 5-154 SINUMERIK 840Di Manual (HBI) –...
Page 155: Mpi Parameterization Of The Plc
The user (machine manufacturer) must call the relevant part of the basic program in the OBs 1, 40 and 100, as shown in Fig. 5-12.  Siemens AG, 2003. All rights reserved 5-155 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 156 The MPI parameters are set on the PLC side in function block FB 1. Since the parameters data transfer rate of the MPI bus with SINUMERIK 840Di is 1.5 Mbaud, the pa- rameters have to be set as follows: (FB 1) HHU: INT:= 2;...
Page 157: Gd Circle Parameterization Of The Hhu
Rec-GD-No: 1–16 Receive GBZ No. Rec-GBZ-No: 1–255 Object No. Rec-Obj-No: 1–255 GD circle No. Send-GD-No: 1–16 Send GBZ No. Send-GBZ-No: 1–255 Object No. Send-Obj-No: 1–255  Siemens AG, 2003. All rights reserved 5-157 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 158: Gd Circle Parameterization Of The Plc
HHU are the receive parameters of the PLC and the receive parameters of the HHU are the send parameters of the PLC.  Siemens AG, 2003. All rights reserved 5-158 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 159: Example: Connecting A Hhu To Sinumerik 840Di
The GD circle parameters of sender and receiver must be identical crosswise. 5.6.7 Example: Connecting a HHU to SINUMERIK 840Di 1. Checking the HHU for MPI bus capability: “B-MPI” must be indicated on the rating plate attached to the HHU’s rear.
Page 160 Now, the display set by way of the block FC13 will appear on the display. References: /FB1/ Description of Functions, Basic Machine: P3, Basic PLC Program Section: FC 13: HHUDisp Display control for handheld unit  Siemens AG, 2003. All rights reserved 5-160 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 161: Handheld Terminal Ht
Under no circumstances may the MPI bus cable contain an integrated bus ter- minating resistor, since a bus terminating resistor is already integrated in the HT 6. For the MPI cable, see Section 3.3, page 3-131.  Siemens AG, 2003. All rights reserved 5-161 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 162 A programming device/PC is not required if the SIMATIC Manager STEP7 is installed on the SINUMERIK 840Di. The installation of additional software on the SINUMERIK 840Di is described in Chapter 15, page 15-455. A PC/programming device is also required if the HT 6 user interface or the MPI address is modified using the HT 6 system software and the whole modified software is then to be loaded into the HT 6.
Page 163: Parameterization Of The Ht 6
After power-up of the HT 6, you will get to this menu using the following sequence of operations: 1. Key MENU SELECT 2. Soft keys Diagnosis > Service display > Version > Vers. MMC.  Siemens AG, 2003. All rights reserved 5-163 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 164: Parameterization Of The Plc
OB 40 Î Î Î Î Î G group GP_PRAL Process alarm Î Î Î Î Î distributor User program Fig. 5-16 Structure of PLC program  Siemens AG, 2003. All rights reserved 5-164 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 165 For a detailed description of the basic PLC program or of function block FB1, please refer to: /FB1/ Description of Functions, Basic Machine: P3, Basic PLC Program Section: FB 1: RUN_UP Basic program, start-up section  Siemens AG, 2003. All rights reserved 5-165 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 166: Example: Connecting An Ht 6 To Sinumerik 840Di
Section: FC 26 HPU_MCP Transfer of HPU signals tointerface 5.7.4 Example: Connecting an HT 6 to SINUMERIK 840Di 1. Make the electrical connections on the distribution box and HT 6. The terminating resistor in the MPI bus connector on the distributor box for connecting the HHU must be disabled.
Page 167: Connecting And Disconnecting An Ht 6 During Running Operation
For a detailed description of the actions to be taken and the devices required, please refer to: /BH/ Operator Components Manual Section: Handheld Terminal HT 6 Connecting and disconnecting the HT 6 during operation.  Siemens AG, 2003. All rights reserved 5-167 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 168: External Operator Panel (Pcu With Hmi Advanced)
5.8.1 General settings Data transfer rate With the SINUMERIK 840Di, the data transfer rate at the MPI bus is 1.5 Mbaud. HMI Advanced With HMI Advanced, the data transfer rate must be set to 1.5 Mbaud in the menu “Start-up/MMC/operator panel”.
Page 169: Language Default Setting
German (standard) Spanish French English (standard) Italian Supplementary package 2: Asian languages: Korean (Korea) pictographic language Chinese (Taiwan) pictographic language Chinese (Mandarin) pictographic language  Siemens AG, 2003. All rights reserved 5-169 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 170 English (standard) Italian Chinese (Taiwan) pictographic language Chinese (Mandarin) pictographic language Example: First language German, second language Chinese File MMC.INI must be altered as shown below:  Siemens AG, 2003. All rights reserved 5-170 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 171 When editing file MMC.INI, take care to ensure that you change only the high- lighted (bold print) texts. Make sure that your entries are spelled correctly.  Siemens AG, 2003. All rights reserved 5-171 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 173: Turning On And Ramp Up
In particular, the following must be observed: – Mains conditions – Pollution burden – Hazardous gases – Climatic environmental conditions – Storage/transportation – Shock load – Vibratory load – Ambient temperature.  Siemens AG, 2003. All rights reserved 6-173 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 174: Recommended Order When Commissioning
“HW Config” corresponds to the component used on the plant. 3. Configure the SINUMERIK 840Di completely on first booting (Section 6.2, page 6-175). 4. Create the PLC default program (basic PLC program, PLC user program and configuration) supplied for the PLC or your own SIMATIC S7 project and load it into the PLC (Chapter 7, page 7-203).
Page 175: First Ramp-Up
After a basic start-up described in the following, the following prerequisites must be provided: ramp-up SINUMERIK 840Di-NC and PLC are operated in cyclic operation If a machine control panel is connected, no alarms or messages should be present The displayed axes of the NC can be traversed by simulation.
Page 176 Completion Once the PCU has powered up again, you can continue with the basic start-up procedure of the PLC (Subsection 6.2.3, page 6-179).  Siemens AG, 2003. All rights reserved 6-176 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 177: Basic Start-Up Of The System Software (Sw 2.1 And Lower)
The displayed axes of the NC can be traversed by simulation. Loading the The first step of basic start-up is to copy the SINUMERIK 840Di system soft- system software ware and Windows NT to the PCU hard disk. On delivery, the hard disk of the PCU is already partitioned for operation of the...
Page 179: Basic Start-Up Of The Plc
If a machine control panel is connected, the LEDs of the machine control panel should now no longer flash and no more alarms should be present on the NC.  Siemens AG, 2003. All rights reserved 6-179 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 180: Ramp-Up Of The Machine Control Panel (Mcp)
Ramp-up of the SIMODRIVE 611 universal drives For detailed information on the ramp–up of SIMODRIVE 611 universal drives, please refer to: References: /FBU/ SIMODRIVE 611 Universal, Description of Functions  Siemens AG, 2003. All rights reserved 6-180 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 181: Ramp-Up
In certain error or service cases, it is also possible to use the SRAM image or backup to be able to continue work immediately without recommissioning the SINUMERIK 840Di.  Siemens AG, 2003. All rights reserved 6-181 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 182 2. Windows NT must be shut down correctly (to do so, the POWER FAIL mechanism of the SINUMERIK 840Di is also sufficient) 3. The checksum test using the SRAM image or backup must be successful.
Page 183: Ramp-Up After Battery Replacement (Backup Battery Of The Mci Board)
Ramp-up after battery replacement (backup battery of the MCI board) Correct Before you change the backup battery of the MCI board, the SINUMERIK 840Di shutting down or Windows NT must be shut down correctly. For shutting down, use one of the following options: Windows NT taskbar: Start >...
Page 184 After the MCI board has been changed, it will be identified as “unknown” using the serial number. Since no up-to-date SRAM image exists, the SRAM backup is written back into the SRAM of the MCI board. The SINUMERIK 840Di is thus ready again immediately.
Page 185: Ramp-Up After Replacement Of The Pcu (New) Or Reinstallation
If an MCI board used in a new PCU once is further used or if the 840Di software is reinstalled on a SINUMERIK 840Di that is already started up, then the bat- tery-backed user data in the SRAM of the MCI board are kept.
Page 186: Ramp-Up After Replacement Of The Pcu Or The Mci Board
Ramp-up after power failure (Power Fail) Case 1: In case of a power failure, the SINUMERIK 840Di will save the user data in the SRAM of the MCI board thanks to the Power Fail detection integrated in the SRAM saved PCU.
Page 187: Ramp-Up With Shutdown Signal (Sw 2.3 And Higher)
6.3.9 Ramp-up with shutdown signal (SW 2.3 and higher) If the SINUMERIK 840Di is operated with a UPS system, the shutdown system must be configured appropriately. See Subsection 10.10.2, page 10-399. When the shutdown signal is present, the NC and PLC are terminated first and Win- dows NT then shut down correctly.
Page 188: Sinumerik Desktop
“Obtain an IP address form a DHCP server” If no DHCP server exists in the network, select: “Specify an IP address” and enter the appropriate specifications (see above: Note).  Siemens AG, 2003. All rights reserved 6-188 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 189: Software Installation/Update
Before SINUMERIK HMI is started, the backed up files from the above directo- HMI environment ries are loaded. Note This function can be executed through the service menu (Subsection 6.5.4, page 6-195).  Siemens AG, 2003. All rights reserved 6-189 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 190: Authorizing Simatic Step7
Select the corresponding serial mouse Note After you have activated the serial mouse, a PS/2 mouse that you were pre- viously using will no longer work.  Siemens AG, 2003. All rights reserved 6-190 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 191: Fault Analysis
SINUMERIK System Software. The appropriate Windows programs or links must be routed to special directories. 1. C:\RunOEM\SeqOnce Programs stored here are run once and sequentially  Siemens AG, 2003. All rights reserved 6-191 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 192: Replacing The Sinumerik Background Image
Information and constraints concerning the basic software You will find information and constraints on the current basic software on the SINUMERIK desktop in files: SIEMENSD (German) SIEMENSE (English)  Siemens AG, 2003. All rights reserved 6-192 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 193: Service Menu
The service menu is started from the boot manager with the operating se- quence “Cursor down” and “Enter”. A password of protection levels 0–2 is required to execute the service menu: – System – Manufacturer – Service.  Siemens AG, 2003. All rights reserved 6-193 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 194: Install/Update Sinumerik System
Actual authorization is performed automatically during ensuring ramp-up of the PCU under Windows NT. Note Authorization can also be performed on the SINUMERIK desktop by starting the function “STEP7 Authorizing”.  Siemens AG, 2003. All rights reserved 6-194 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 195: Dos Shell
SINUMERIK HMI is started in the as-delivered state, i.e. the content of the directories: – F:\ADD_ON – F:\USER – F:\OEM – C:\RUNOEM has been backed up and the directories then cleared.  Siemens AG, 2003. All rights reserved 6-195 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 196: Sinumerik System Check
Hard disk of the PCU Partitions C:, D:, E: and F: are tested. Operator action Select SINUMERIK System CHECK with key “5”.  Siemens AG, 2003. All rights reserved 6-196 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 197: Backup/Restore
Reboot (warm restart) 840Di services Your Choice [1,2,3,4,5,7,8,9,P] ? Under menu item: 840Di Services, 840Di-spec. functions are requested that are then executed during the ensuing ramp-up of the SINUMERIK 840Di NC or PLC. PLC functions: Set PLC Mode to STOP...
Page 198 Alarm: System order executed. The message box must be acknowledged with “OK”. The selected function is executed after ramp-up of the corresponding SINUM- ERIK 840Di component.  Siemens AG, 2003. All rights reserved 6-198 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 199: Configuring Ptp Link On An External Computer (Pg/Pc)
In order to check or share access to files for other users, select the: Configura- tion tab and click there the button: “File and Print Sharing...”  Siemens AG, 2003. All rights reserved 6-199 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 200 Dialog: Access by share access rights Button: “Add...” Dialog: Add users and groups Names: Choose a name from the list e.g. “User” or “Everybody” Button: “Add” Access type: <Read>  Siemens AG, 2003. All rights reserved 6-200 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 201: Subsequent Installation Of Windows Nt Components
Programs > SinuCom NC > SinuCom NC Option menu To license the options you can with the SINUMERIK 840Di you can access the machine data block by double-clicking with the left mouse button as soon as SinuCom NC has established the online link (Fig. 6-3).
Page 202 Processing channel, additional 6FC5251-0AA07-0AA0 Cycles in DRAM Current License Key is not sufficient Get a new License Key Button: License Key Fig. 6-4 SinuCom NC: Option menu  Siemens AG, 2003. All rights reserved 6-202 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 203: Profibus Dp Communication
Examples: Drives, I/O modules. PROFIBUS DP with Communication between SINUMERIK 840Di (NC and PLC), as the master, and Motion Control the slave components on PROFIBUS DP is based on PROFIBUS DP with the MotionControl extension.
Page 204: Message Frame Structure For Cyclic Dp Communication
The following data are transmitted with the process data: – Control words and setpoints (requests: master ––> drive) or – status words and actual values (responses: drive ––> master).  Siemens AG, 2003. All rights reserved 7-204 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 205: Description Of A Dp Cycle
Example: Optimized DP cycle with 3 DP slaves 611U Explanations regarding Fig. 7-2: Master Application Cycle: NC position controller cycle MAPC With SINUMERIK 840Di, the following applies in all cases: T MAPC DP cycle time: DP cycle time Data Exchange Time: Total of transfer times of all DP slaves ...
Page 206: Sinumerik 840Di With Profibus Dp
The configuration of PROFIBUS DP is carried out within the framework of a SIMATIC S7 SIMATIC S7 project (further referred to as S7 project). To create an S7 project for a SINUMERIK 840Di, the following components are needed: SIMATIC Manager STEP7 SINUMERIK 840Di Programming device/PC with MPI connection (e.g.
Page 207 (PG)/PC CD-ROM drive MPI connection with 1.5 Mbaud. To transfer the S7 project to the PLC of the SINUMERIK 840Di, the PG/PC must be linked with the MPI interface of the MCI board. SINUMERIK 840Di The SIMATIC Manager STEP7 required to create the S7 project can also be installed on the SINUMERIK 840Di.
Page 208 SIMATIC 300 > SINUMERIK > 840Di > 840Di with PLC315-2AF03 or (SW 2.1 and higher) . . . > 840Di with PLC315-2AF03, P/C bus DriveOM/ The SlaveOM (Slave Object Manager) for SINUMERIK 840Di allows dialog- based configuration of the following drives in conjunction with a SINUMERIK SlaveOM 840Di: –...
Page 209 STEP7 required to install the S7 project is already installed. To install a DMF file, please refer to the appropriate notes in the file: – <installation path>\readme.txt.  Siemens AG, 2003. All rights reserved 7-209 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 210: Network Rules
SIMODRIVE 611 SIMODRIVE 611 universal universal Terminating resistor in the connector not en- abled Fig. 7-3 Example of a PROFIBUS DP network installation  Siemens AG, 2003. All rights reserved 7-210 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 211: Simatic S7 Project
– Right mouse button Insert New Object > SIMATIC Station-300 2. Possibility Menu command Insert > Station > SIMATIC Station-300. Open the station and start “HW Config” by double-clicking the hardware icon.  Siemens AG, 2003. All rights reserved 7-211 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 212: Hw Config
Use the right mouse button to select 840Di Rack and drag it to the Station win- dow, holding down the mouse button. When you release the mouse button, 840Di Rack will be inserted in the S7 project.  Siemens AG, 2003. All rights reserved 7-212 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 213 Subnetwork Equidistant DP cycle Equidistant time. Equidistant time The SINUMERIK 840Di will accept the set equidistant DP cycle as the NC system clock cycle and position controller cycle. position controller cycle = NC system clock cycle = equidistant DP cycle The time that can be set for the equidistant DP cycle depends on: 1.
Page 214 Dialog: Properties – MPI Tab “Network Settings” Data transfer rate: 1.5 Mbps Notice With SINUMERIK 840Di, the MPI address of the PLC must always be set to “2”.  Siemens AG, 2003. All rights reserved 7-214 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 215 In the case of values other than 256, auxiliary functions provided from the PLC will no longer be acknowledged to the NC and the parts program execution is thus no longer continued.  Siemens AG, 2003. All rights reserved 7-215 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 216: Simatic S7 I/O Devices
2. Select the appropriate module from the hardware catalog and compare the order number (MLFB) with the MLFB number of the module displayed in the hardware catalog. Both MLFB numbers must be the same.  Siemens AG, 2003. All rights reserved 7-216 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 217: I/O Module Pp72/48
The DP master system is displayed in the station window with the following symbol: When you release the left mouse button, the DP slave PP72/48 is inserted into the configuration.  Siemens AG, 2003. All rights reserved 7-217 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 218 Dialog: PROFIBUS properties Interface PP input/output Register: Parameters Address: <PROFIBUS–Adresse> Button: “Properties...” Dialog: Properties – PROFIBUS Tab: Network settings Data transfer rate: 12 Mbps Profile: DP  Siemens AG, 2003. All rights reserved 7-218 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 219 To this aim, use the system functions SFC14 and 15. For the reasons above, it is recommended to assign the I/O addresses to the range between 0 and 255.  Siemens AG, 2003. All rights reserved 7-219 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 220: Adi4 (Sw 2.1 And Higher)
The ADI4 DP slave can only be operated on an equidistant PROFIBUS DP. SlaveOM Parameterization of the configuration with regard to the ADI4 modules, called DP slave ADI4 here, is performed with the SlaveOM for SINUMERIK 840Di. For installing the SlaveOM, see Section 7.1, page 7-203f: DriveOM / SlaveOM Note To simplify parameterization of the equidistant communication on the PROFI- BUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.)
Page 221 Dialog: Properties – PROFIBUS interface ADI4 Tab card: Parameters Address: PROFIBUS address After you have confirmed this dialog using the button: “OK”, the dialog: “DP Slave properties” opened.  Siemens AG, 2003. All rights reserved 7-221 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 222 Dig. inputs 7–8 / Drv_Rdy 1–2 –> X6–2: Pins 8–9 1) Note: To use the I/O words within the NC: See Section 10.6, page 10-379  Siemens AG, 2003. All rights reserved 7-222 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 223 I/O addresses A communication between NC and the individual axes of the DP slaves ADI4 in the SINUMERIK 840Di can only take place if the I/O addresses for setpoint and actual value of an axis are the same. This prerequisite is taken into account by SlaveOM automatically when inserting a DP slave ADI4 into a configuration.
Page 224 Tolerable sign-of-life errors: Shutdown delay [s]: Reserved bits for fine resolution: 611U conformant mode Cancel Help Fig. 7-4 Dialog: DP slave properties, tab card: Encoder  Siemens AG, 2003. All rights reserved 7-224 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 225 The baudrate must be set identically for all SSI encoders. If different baudrates are set, the baudrate of the SSI encoder with the highest encoder number is used.  Siemens AG, 2003. All rights reserved 7-225 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 226 Activate function x mand mand Read value x Read value x Cancel function x Reference mark search (zero mark or BERO) Mode Mode In-process measurement.  Siemens AG, 2003. All rights reserved 7-226 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 227 Via the parameter “Additional substitute bits for fine resolution”, you can specify fine resolution the desired pulse multiplication of the encoder increments currently read in the encoder increments and transferred in the encoder actual value G1_XIST1.  Siemens AG, 2003. All rights reserved 7-227 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 228 7 PROFIBUS DP Communication 06.03 7.3 SIMATIC S7 project In conjunction with SINUMERIK 840Di, the number of additional bits for fine resolution should currently be set to the value 11. This corresponds to a pulse multiplication of: 2 = 2048.
Page 229 Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç 1*125msec 2*125msec 3*125msec 4*125msec 5*125msec 6*125msec 7*125msec 8*125msec Fig. 7-7 Graphical illustration of the boundary conditions  Siemens AG, 2003. All rights reserved 7-229 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 230 If a configuration that deviates from the above/mentioned boundary condi- tions is loaded to this DP slave ADI4, the DP slave ADI4 does not start cy- clic communication with the DP master.  Siemens AG, 2003. All rights reserved 7-230 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 231: Simodrive Drives
– SIMODRIVE POSMO SI is exemplified here by parameterization of the SIMODRIVE 611 universal. SlaveOM The drives are parameterized using the SlaveOM for SINUMERIK 840Di (for installation of the SlaveOM, see Section 7.1, page 7-203: DriveOM / SlaveOM). Note To simplify parameterization of the equidistant communication on the PROFI- BUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.)
Page 232 PROFIBUS address 2. SIMODRIVE 611 universal Parameter P0918 (PROFIBUS node address.) Dialog Dialog: Properties – PROFIBUS Interface SIMODRIVE 611U DP2, DP3 Tab: Parameters Address: PROFIBUS address  Siemens AG, 2003. All rights reserved 7-232 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 233 Encoder 2 Encoder 1 Encoder 2 Encoder 3 SIMODRIVE 611 universal SIMODRIVE 611 universal E Dialog Dialog: DP Slave Properties Tab: Configuration Default: <Message Frame Type>  Siemens AG, 2003. All rights reserved 7-233 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 234 I/O addresses A communication between NC and the individual axes of the DP slaves 611U in the SINUMERIK 840Di can only take place if the I/O addresses for setpoint and actual value of an axis are the same. This prerequisite is taken into account by SlaveOM automatically when inserting a DP slave 611U into a configuration.
Page 236 Message frame type: 102 Axis 1 / Drive A Axis 2 / Drive B Fig. 7-8 Dependencies: NC, PLC/DP master and DP slave (SIMODRIVE 611 universal)  Siemens AG, 2003. All rights reserved 7-236 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 237 After all PROFIBUS components (drives, ADI4, I/O devices, etc.) have been parameterization inserted into the configuration and parameterized, the equidistant DP cycle is parameterized in the final step.  Siemens AG, 2003. All rights reserved 7-237 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 238: Final Parameterization Of The Equidistant Dp Slaves
ADI4 interfaces, please observe the boundary conditions for the following pa- rameters: Equidistant DP cycle T Master cyclic portion T Actual-value sensing T Setpoint acceptance T See also: ADI4-specific boundary conditions, page 7-229.  Siemens AG, 2003. All rights reserved 7-238 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 239 1. Synchronize drive to equidistant DP cycle 2. Adjust must be performed for each type of DP slave first before you can go on to set the other parameters.  Siemens AG, 2003. All rights reserved 7-239 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 240 Number of PGs/OPs/TDs on the PROFIBUS Configured: Total: Equidistant time in msec Equidistant DP cycle 2.000 1.451 minimum) Details ... Cancel Help Fig. 7-10 Dialog: Options  Siemens AG, 2003. All rights reserved 7-240 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 241 Using ratios other then 1:1, the dead times of the position controller can be re- duced if NC hardware of the lower performance range is used.  Siemens AG, 2003. All rights reserved 7-241 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 242 7 PROFIBUS DP Communication 06.03 7.3 SIMATIC S7 project Notice On a DP slave 611U used with SINUMERIK 840Di, the ratio between the mas- ter application cycle T and DP cycle time T must be 1:1. Master application cycle = DP cycle...
Page 243 DP slave as described above and adjustment must be performed. By adjustment, the values displayed on tab card: “Clock Synchronization” are only transmitted to the DP slave of the same type.  Siemens AG, 2003. All rights reserved 7-243 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 244: Loading A Configuration Into The Plc
Current system data blocks are available An MPI connection is established between “HW Config” and the PLC SINUMERIK 840Di is active, i.e. the NC is in cyclic operation and the PLC in either of the states RUN or STOP. Generating system...
Page 245 (X111) using an MPI cable. HW Config on a If the configuration is transferred from the PC in which the MCI board is installed (e.g. SINUMERIK 840Di with PCU50), the following requirements must be ful- local PC filled: The MPI drivers are installed Current interface parameterization: SINUMERIK MCI board (MPI) Data transfer rate: 1.5 Mbps...
Page 246 NC and PLC, NC reset must be initiated, e.g. using 840Di start-up: Start 840Di start-up – Windows NT taskbar: Start > Programs > SINUMERIK 840Di > 840Di Start-up Carry out NC reset – Menu command: Window > Diagnostics > NC/PLC ...
Page 247 7 PROFIBUS DP Communication 06.03 7.3 SIMATIC S7 project – Dialog: NC/PLC Diagnosis Group NC Button: “NC Reset”  Siemens AG, 2003. All rights reserved 7-247 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 249: Plc Start-Up
PLC Start-Up PLC module The PLC integrated on the MCI board of the SINUMERIK 840Di is compatible with the SIMATIC S7-PLC: AS315-2 DP. Start-up prerequisites Start-up of the PLC differs, depending on whether start-up has already been carried out and on whether the PLC program is to be loaded as an S7 project using the SIMATIC Manager STEP7 or as a series machine start-up file.
Page 250 PLC and deleting NC data 840Di start-up – Start: Windows NT taskbar: Start > Programs > SINUMERIK 840Di > 840Di Start-up – Open the dialog box: Menu command Window > Diagnosis > NC/PLC HMI Advanced (840Di SW 2.2 and higher and HMI Advanced SW 6.2) –...
Page 251: Plc Program
The modules of the basic PLC program are part of a SIMATIC S7 library sup- plied with SINUMERIK 840Di. Before you can use it in an S7 project, the library must be installed in the SIMATIC Manager STEP7. 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 or extended.
Page 252 For a complete description of the basic PLC program, its structure and all mod- ules including their call parameters, please refer to: the basic PLC program References: /FB1/ Description of Functions, Basic Machine Section: P3, Basic PLC Program  Siemens AG, 2003. All rights reserved 8-252 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 253: Plc User Program
FC 10 Display control Error and operational messages FC 3 OB 40 G group GP_PRAL Process alarm distributor User program Fig. 8-1 Structure of PLC program  Siemens AG, 2003. All rights reserved 8-253 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 254 Edit the block using the LAD/STL/CSF editor Switch over the block display using the menu command View > LAD or STL or CSF.  Siemens AG, 2003. All rights reserved 8-254 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 255: Loading The Plc Program
The current PLC program is present. An MPI connection is established between SIMATIC Manager and PLC. SINUMERIK 840Di is active, i.e. the NC is in cyclic operation and the PLC in either of the states RUN or STOP. Making the...
Page 256 System > Operating Status, the dialog box Operating Status opens. Use the button “RUN” to bring the PLC to the required operating status. Dialog Dialog: Operating Status Button: “RUN”  Siemens AG, 2003. All rights reserved 8-256 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 257: Series Machine Start-Up File
The creation and loading of a series machine start-up file within the framework of data backup can be carried out using – SinuCom NC (part of the SINUMERIK 840Di installation) – HMI Advanced (option). For detailed information on data backup, please refer to:...
Page 258: Testing The Plc Program
Edit > Object Properties or by double-clicking on the module. SINUMERIK 840Di The start-up mode of the PLC with SINUMERIK 840Di is fixed to COLD RE- START. This setting cannot be modified. Boot type:...
Page 259: Cyclic Operation
In case of failure of the PLC or in case of STOP of the PLC program execution, the following alarm is displayed: Alarm: “2000 sign-of-life monitoring for PLC”.  Siemens AG, 2003. All rights reserved 8-259 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 260: Monitor/Control Using The Simatic Manager Step7
The menu command Target System > ... provides the following further test functions functions: Display accessible nodes CPU messages ... Display force values Diagnose hardware Module status ... Operating status ...  Siemens AG, 2003. All rights reserved 8-260 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 261: Monitor/Control Using Hmi Advanced
Use the soft key Change to switch over to the Control mode. Now you can use the field Value to specifynew values for the displayed variables. The entered value must be within the definition range of the set format.  Siemens AG, 2003. All rights reserved 8-261 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 262 Only when you quit the mode using the soft key Accept, the entered values are written to the variables and processed in the PLC program.  Siemens AG, 2003. All rights reserved 8-262 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 263: Drive Start-Up (Preconditions)
PROFIBUS cable: – PG 740 or PCU 50 with integrated PROFIBUS DP interface – Standard PC with CPU module, e.g. CP 5611  Siemens AG, 2003. All rights reserved 9-263 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 264 06.03 9.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI 3. SimoCom U is installed on the SINUMERIK 840Di and is routed from the PLC to the PROFIBUS. Via the PROFIBUS DP interface of the MCI board, SimoCom U is connected to all drives using a PROFIBUS cable.
Page 265: Preconditions For An Online Connection
– For SIMODRIVE 611 universal/E see Subsection 9.1.3, page 9-265 – For SIMODRIVE POSMO CD/CA and SI see Subsection 9.1.4, page 9-267 The SINUMERIK 840Di PLC must be networked using MPI – For networking the PLC, see Subsection 7.3.2, page 7-212 The configuration must be loaded into the PLC –...
Page 266 For detailed information on start-up of SIMODRIVE 611 universal drives, refer /FBU/ SIMODRIVE 611 universal, Description of Functions Section: Parameterizing the board Parameterization using the display and operator unit Section: PROFIBUS DP master settings Start-up.  Siemens AG, 2003. All rights reserved 9-266 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 267: Setting Profibus Address (Simodrive Posmo Si/Cd/Ca)
For detailed information on start-up of SIMODRIVE POSMO CD/CA and SI uni- versal drives, refer to: /POS3/ SIMODRIVE POSMO SI/CD/CA User Manual Section: Connecting the PROFIBUS unit.  Siemens AG, 2003. All rights reserved 9-267 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 268: Setting The Mpi Interface
Dialog: Install / Remove Interface Selection: SINUMERIK MCI Board (MPI) Button: “Install––>“ Close Finally, the routing information must be set in the interface dialog of Simo- Com U.  Siemens AG, 2003. All rights reserved 9-268 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 269: Setting The Routing Information
PROFIBUS: <Subnetwork ID> (see below) OK or Go online. Notice With SINUMERIK 840Di, the routing of the MPI interface to the PROFIBUS DP is provided the PLC. Therefore, the MPI address of the PLC must be specified as the “MPI No”.
Page 270: Starting Online Operation
The SIMODRIVE drives with which SimoCom U could start the online operation drives are displayed in the SimoCom U main screen: – Drive and dialog browser (left window) – Status overview (upper status bar).  Siemens AG, 2003. All rights reserved 9-270 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 271: Installing Simocom U
06.03 9.2 Installing SimoCom U Installing SimoCom U Installation SimoCom U is part of the 611U toolbox supplied with the SINUMERIK 840Di in directory: <Installationspfad>\siemens\611UToolbox\SimoComU To instal SimoCom U on the PCU, start file setup.exe and follow the further installation instructions.
Page 273: Nc Start-Up With Hmi Advanced
The letters/characters have the following meaning: System variable Machine data Component k identifies the components of the NC parameterizing the appropriate machine data: Channel Axis Drive MMC.  Siemens AG, 2003. All rights reserved 10-273 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 274 General machine data for compile cycles from 62000 to 62999 Channel-specific machine data for compile cycles from 63000 to 63999 Axis-specific machine data for compile cycles  Siemens AG, 2003. All rights reserved 10-274 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 275: Display And Input
If the input cursor is on a machine data in HEX format in the MD list, you can call up the editor by pressing the toggle key (in the middle of the cursor keys).  Siemens AG, 2003. All rights reserved 10-275 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 276: Protection Levels
The access to programs, data and functions is protected user-oriented using eight hierarchical protection levels. These are divided into (see Table 10-3): Four password levels for SIEMENS, machine manufacturers and final users Four keyswitch positions for end users. This provides a multi-stage safety concept to manage the access rights.
Page 277 If the character has less than 8 characters, the remaining characters are interpreted as a blank.  Siemens AG, 2003. All rights reserved 10-277 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 278 USER_BEGIN_WRITE_RPA_1 Start of the first RPA area 9233 USER_END_WRITE_RPA_1 End of the first RPA area 9234 USER_CLASS_WRITE_RP A_2 Protection level for the second RPA area  Siemens AG, 2003. All rights reserved 10-278 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 279: Machine Data Display Filter
Machine data Display filters are provided for the following machine data areas: areas General machine data  Siemens AG, 2003. All rights reserved 10-279 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 280 Example: 10000 AXCONF_MACHAX_NAME_TAB[index] If the index filter is activated, machine data fields are only displayed in the specified index area.  Siemens AG, 2003. All rights reserved 10-280 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 281: System Data
The accuracy of angle and linear positions is limited to the computational reso- lution by rounding the product of the programmed value with the computational resolution to an integer number. Example of rounding:  Siemens AG, 2003. All rights reserved 10-281 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 282 10210 INT_INCR_PER_DEG Computational resolution for angular positions References /FB/ Description of Functions – Basic Machine G2 Velocities, Traversing Ranges, Accuracies, Section: Input/display resolution, calculation resolution  Siemens AG, 2003. All rights reserved 10-282 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 283: Normalization Of Phys. Quantities Of Machine And Setting Data
MD 10230: SCALING_FACTORS_USER_DEF[n] (scaling factors of physi- cal quantities) Input values for machine data MD 10220 Scaling factor Internal scaling activated? MD 10230 Scaling factor Internal physical quantity  Siemens AG, 2003. All rights reserved 10-283 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 284 In addition to the change of example 1, the machine data input/output of linear accelerations, is to be performed in ft/sec , instead of m/sec (default). (The internal unit is mm/sec  Siemens AG, 2003. All rights reserved 10-284 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 285: Changing Scaling Machine Data
When scaling machine data are modified, all machine data affected by this mod- ification due to their physical unit are converted with the next NCK reset. Example: Redefining an A1 axis from linear to rotary axis.  Siemens AG, 2003. All rights reserved 10-285 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 286: Loading Default Machine Data
10.3.4 Loading default machine data The default machine data can be loaded in different ways. 840Di start-up Via the SINUMERIK 840Di standard user interface 840Di start-up: Menu command Window > Diagnosis > NC/PLC Button: “Delete NCK Data” Button: “NCK RESET”...
Page 287: Switching Over The Measuring System
During this process, the value specified in MD20150: GCODE_RE- SET_VALUES[12] changes between G700 and G710. This process is carried out irrespective of the protection level currently set.  Siemens AG, 2003. All rights reserved 10-287 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 288 32711 CEC_SCALING_SYSTEM_METRIC Unit system of sag compensation References /FB/ Description of Functions, Basic Machine, G2 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control, Section: Metric/inch measuring system  Siemens AG, 2003. All rights reserved 10-288 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 289: Traversing Ranges
General ($MN_ ...) 10200 INT_INCR_PER_MM Computational resolution for linear positions 10210 INT_INCR_PER_DEG Computational resolution for angular positions Axis-specific ($MA_ ...) 31020 ENC_RESOL[n] Encoder lines per revolution  Siemens AG, 2003. All rights reserved 10-289 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 290: Cycle Times
10.3 System data 10.3.8 Cycle times On the SINUMERIK 840Di the system clock cycle, the position controller cycle, and the interpolation cycle of the NC are based on the DP cycle time configured in STEP7 “HW Config”. See Section 7.3, page 7-211f.
Page 291 – Remedy: Reducing the position controller cycle offset – Remedy: increasing the DP cycle time. The DP cycle time is set using STEP7 “HW Config”. See Section 7.3, page 7-211f.  Siemens AG, 2003. All rights reserved 10-291 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 292 Operating area switchover > Diagnosis > Service displays > System resources – MD10070: IPO_SYSCLOCK_TIME_RATIO (factor for interpolation clock pulse) – MD10071: IPO_CYCLE_TIME (interpolator clock pulse) [ms].  Siemens AG, 2003. All rights reserved 10-292 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 293 STEP7 “HW Config”. To do that, proceed as you would for final parameteriza- tion of a DP slave 611U. See Subsection 7.3.7, page 7-231f. References /FB/ Description of Functions, Special Functions G3 Cycle Times  Siemens AG, 2003. All rights reserved 10-293 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 294: Velocities
To guarantee that parts program blocks are executed continuously (control mar- gin), the NC limits the tool path velocity within a parts program block to 90% of the max. possible tool path velocity as follows:  Siemens AG, 2003. All rights reserved 10-294 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 295 If V is not reached, no traversing movement is carried out. References /FB/ Description of Functions, Basic Machine G2 Velocities, Traversing Ranges, Accuracies, Section: Velocities  Siemens AG, 2003. All rights reserved 10-295 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 296: Memory Configuration
– – – 1) DRAM component (main memory) occupied by SINUMERIK 840Di and thus no longer available for Windows NT. 2) Virtual SRAM resides in main memory (DRAM) during operation of the SINUMERIK 840Di and retentive on the hard disk of the PCU.
Page 297: Dram Memory
MM_LUD_VALUES_MEM Memory size for local user variables 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  Siemens AG, 2003. All rights reserved 10-297 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 298: Sram Memory
Number of magazines managed by NCK /FBW/ 18086 MM_NUM_MAGAZINE_LOCA TION Number of magazine locations /FBW/ 18090 MM_NUM_CC_MAGAZINE_P ARAM Compile cycles of tool management: Number of /FBW/ magazine data  Siemens AG, 2003. All rights reserved 10-298 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 299 28200 MM_NUM_PROTECT_AREA_CHAN Number of modules for channel-specific /FB/, A3 protection zones Axis-specific ($MA_ ...) 38000 MM_ENC_COMP_MAX_POINTS Number of intermediate points with interpolatory /FB/, K3 compensation  Siemens AG, 2003. All rights reserved 10-299 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 300: Virtual Sram (Sw 2.3 And Higher)
(Blue Screen) detected by Windows The necessary Windows NT system settings are check during start/up of the SINUMERIK 840Di. If setting are incorrect, a message box appears with the appropriate text. The necessary Windows NT system settings have already been made for all new SINUMERIK 840Di systems delivered.
Page 301 – Option: “Overwrite any existing file” selected If settings are incorrect, the following message box appears: SINUMERIK 840Di NCK/PLC Alarm: Wrong Windows ”System Properties” settings for Recovery.  Siemens AG, 2003. All rights reserved 10-301 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 302 PCU. If settings are incorrect, the following message box appears: SINUMERIK 840Di NCK/PLC Alarm: Increase “Initial Size” of pagefile to at least 128 MB.  Siemens AG, 2003. All rights reserved 10-302 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 303 The user data will then be lost however if a subsequent serious exception Win- dows NT (Blue Screen) then occurs. In the start–up of the SINUMERIK 840Di that follows, the last valid version on the user data are loaded to the virtual...
Page 304 SRAM. The SINUMERIK 840Di is thus ready again immediately. The user data or the operating state of the SINUMERIK 840Di must be checked to see whether they are suitable to be worked with in the future. It might be nec- essary to perform commissioning of the SINUMERIK 840Di NC and PLC again.
Page 305: Dram File System (Sw 2.2 And Higher)
DRAM file system requires a retentive background memory. The DRAM file system is reloaded from this retentive background memory every time the NCK is booted. On the SINUMERIK 840Di, the hard disk of the PCU is used as the background memory.
Page 306 – “NCK power ON reset” (warm start) – Proper shutdown of Windows NT. Notice If the SINUMERIK 840Di is switched off or if a “serious exception” (blue screen) has occurred although – “NCK power ON reset” (warm start) – Proper shutdown of Windows NT has not been performed, all changes to the cycles made until that time will be lost.
Page 307 DRAM_FILESYSTEM_MASK Select directories in DRAM ($MM_ ... ) 18332 FLASH_FILE_SYSTEM_SIZE Size of the Flash File System (FFS) 18351 DRAM_FILE_MEM_SIZE Size of the DRAM file system  Siemens AG, 2003. All rights reserved 10-307 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 308: Axes And Spindles
(Cartesian coordinate system), for additionalaxes, no geo- metrical relation is defined, neither between special axes, nor with respect to the geometry axes.  Siemens AG, 2003. All rights reserved 10-308 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 309 [6] = I/O address of drive [7] = I/O address of drive [0] = 6 [0] = 7 [0] = 8 Fig. 10-6 Axis assignment  Siemens AG, 2003. All rights reserved 10-309 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 310 The channel axis number k to be entered in the machine data (k=1,2,3...) is referred to the entry with the index n (n=(k–1)=0,1,2...) in the list of the channel axes MD20070: AXCONFIG_MACHAX_USED[n] (see Point 3).  Siemens AG, 2003. All rights reserved 10-310 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 311: Axis Names
G75 traversing the machine axis from PLC display of axis-specific alarms display in the actual-value system (machine-related) DRF handwheel function.  Siemens AG, 2003. All rights reserved 10-311 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 312 Name of channel axis/special axis in the channel References /FB/ Description of Functions, Basic Machine, K2 Axes, Coordinate Systems, Frames, Actual-Value System for Workpiece IWS, Section: Axes  Siemens AG, 2003. All rights reserved 10-312 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 313: Drive Configuration
SIMODRIVE POSMO A References: /POS1/ User Manual SIMODRIVE POSMO A SIMODRIVE POSMO SI/CD/CA References: /POS3/ User Manual SIMODRIVE POSMO SI/CD/CA ADI4 References: /Subsection 7.3.6; page 7-220.  Siemens AG, 2003. All rights reserved 10-313 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 314 Logical I/O address of drive 13060 DRIVE_TELEGRAM_TYPE[n]. Drive message frame type for the drives con- nected to PROFIBUS DP 13070 DRIVE_FUNCTION_MASK[n] 611U-specific DP functions in use  Siemens AG, 2003. All rights reserved 10-314 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 315: Setpoint/Actual Value Channels
Once the drive configuration and setpoint/actual value assignment have been parameterized, an NCK reset must be executed to initiate a warm restart. After the NC has powered up, the set configuration is effective.  Siemens AG, 2003. All rights reserved 10-315 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 316 Position measuring system 1 31, ... Position measuring system 2 References /FB/ Description of Functions, Basic Machine G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control Section: Setpoint/actual-value system  Siemens AG, 2003. All rights reserved 10-316 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 317: Parameterization Of Incremental Measuring Systems
ENC_RESOL Load gearbox LEADSCREW_PITCH ENC_TYPE=1 ENC_IS_LINEAR=0 Spindle Motor Spindle Encoder ENC_RESOL DRIVE_ENC_RATIO_NUMERA Motor revs DRIVE_ENC_RATIO_DENOM Encoder revs Fig. 10-8 Linear axis with machine-mounted rotary encoder  Siemens AG, 2003. All rights reserved 10-317 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 318 Encoder is directly mounted on the machine 31050 DRIVE_AX_RATIO_DENOM[n] Load gear denominator 31060 DRIVE_AX_RATIO_NUMERA[n] Load gear numerator 31070 DRIVE_ENC_RATIO_DENOM[n] Denominator of resolver gearbox 31080 DRIVE_ENC_RATIO_NUMERA[n] Numerator of resolver gearbox  Siemens AG, 2003. All rights reserved 10-318 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 319 Encoder is directly mounted on the machine 31050 DRIVE_AX_RATIO_DENOM[n] Load gear denominator 31060 DRIVE_AX_RATIO_NUMERA[n] Load gear numerator 32110 ENC_FEEDBACK_POL[n] Sign of actual value (control direction)  Siemens AG, 2003. All rights reserved 10-319 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 320: Parameterization Of Absolute Measuring Systems
10.5 Axes and spindles 10.5.6 Parameterization of absolute measuring systems Encoder types SINUMERIK 840Di currently supports the following absolute encoders: EQN 1325 EQN 1325 Manufacturer of the absolute encoder EQN 1325 is Heidenhain. It is also pos- sible to use compatible encoders of other manufacturers.
Page 321 0 = encoder not adjusted (default setting) 1 = encoder adjustment enabled; encoder not yet adjusted 2 = encoder adjusted 34200 ENC_ABS_TURNS_MODULO[n] Range of absolute encoder with rotary encoders  Siemens AG, 2003. All rights reserved 10-321 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 322: Parameterization Of A 2Nd Measuring Systems With Adi4
PROFIBUS(1): DP master system (1) (0) 840Di PLC315–2DP (10) SIMOD (15) ADI4 DP Master S7 FM NCU. Fig. 10-14 Configuration Axis with 2nd measuring systems on ADI4  Siemens AG, 2003. All rights reserved 10-322 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 323 The I/O address and the message frame type of the 1st axis of the ADI4 module is entered in the next free machine data (e.g. Index 3): MD13050: DRIVE_LOGIC_ADRESS[3] = 472 MD13060: DRIVE_TELEGRAM_TYPE[3] = 3  Siemens AG, 2003. All rights reserved 10-323 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 324 Switching over the position measuring system: Interface signals Bit, Byte Name Ref. Number Axis/spindle-specific Signals from PLC to axis/spindle 31, ... Position measuring system 1 31, ... Position measuring system 2  Siemens AG, 2003. All rights reserved 10-324 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 325: Dsc (Dynamic Servo Control) (Sw 2.1 And Higher)
Before you can switch off DSC operation you might have to adapt (reduce) the KV factor of the axis. Otherwise, instability of the position control loop might result.  Siemens AG, 2003. All rights reserved 10-325 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 326: Drive Optimization
The machine data is a scaling machine data. A change results in a conversion of all machine data of the machine axis with length-related units.  Siemens AG, 2003. All rights reserved 10-326 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 327 JOG speed for rotary axes Axis-specific ($SA_...) 43430 WORKAREA_LIMIT_MINUS Work area limiting minus 43420 WORKAREA_LIMIT_PLUS Work area limiting plus References /FB/ Description of Functions, Extended Functions R2 Rotary Axes  Siemens AG, 2003. All rights reserved 10-327 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 328: Positioning Axes
Signals from axis/spindle to PLC 31,... 74.5 Positioning axis 31,... 78–81 F function (feedrate) for positioning axis References /FB/ Description of Functions, Extended Functions, P2 Positioning axes  Siemens AG, 2003. All rights reserved 10-328 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 329: Indexing Axes
Modulo conversion for rotary axis ° 30320 DISPLAY_IS_MODULO Position display “Modulo 360 ” 30500 INDEX_AX_ASSIGN_POS_T AB Axis is indexing axis 30501 INDEX_AX_NUMERATOR Counter for indexing axes with equidistant positions  Siemens AG, 2003. All rights reserved 10-329 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 330: Parameter Sets Of Axis/Spindle
For example, in HMI Advanced, the active parameter set of a machine axis is displayed in the control area “DIAGNOSIS” in the screen form “Service Axis”.  Siemens AG, 2003. All rights reserved 10-330 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 331 Min. speed of gear stage 35200 GEAR_STEP_SPEEDCTRL_AC- Acceleration in speed control mode CEL[n] 35210 GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode 36200 AX_VELO_LIMIT[n] Threshold value for velocity monitoring  Siemens AG, 2003. All rights reserved 10-331 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 332: Position Controller
If “0” is entered for the loop gain factor, the position controller will be discon- nected.  Siemens AG, 2003. All rights reserved 10-332 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 333 The real servo gain factor can be checked with the following error in the service display. e.g. HMI Advanced: Operating area “DIAGNOSIS” > Service displays > Service axis.  Siemens AG, 2003. All rights reserved 10-333 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 335 Dynamic adaptation 32910 DYN_MATCH_TIME[n] Time constant of dynamic adaptation References /FB/ Description of Functions, Basic Machine, G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control, Section: Closed loop control  Siemens AG, 2003. All rights reserved 10-335 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 336: Speed Setpoint Matching
(P880): P880: Speed evaluation PROFIBUS [rpm] (ARM/SRM) or [ m/min ] (SLM) SINUMERIK 840Di-NC SIMODRIVE 611 universal. MD32260: RATED_VELO P880 * 100 MD32250: RATED_OUTVAL  Siemens AG, 2003. All rights reserved 10-336 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 337 MD31050: DRIVE_RATIO_DENOM (denominator load gearbox) – MD31030: LEADSCREW_PITCH (pitch of the ball screw) [ mm/rev ] – [ rpm ] Motor – [ rpm ] Load  Siemens AG, 2003. All rights reserved 10-337 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 338 Rated output voltage 32260 Rated motor speed RATED_VELO References /FB/ Description of Functions, Basic Machine, G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control, Section: Velocities, traversing Ranges, accuracies  Siemens AG, 2003. All rights reserved 10-338 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 339: Drift Compensation
Drift compensation causes extreme speed fluctuations during switch-on/off of the DSC function. Machine data Table 10-36 Drift compensation: Machine data Number Identifier Name/remarks Ref. Axis-specific ($MA_ ...) 36720 DRIFT_VALUE Basic drift value  Siemens AG, 2003. All rights reserved 10-339 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 340: Velocity Adaptation Of Axis
JOG_REV_VELO[n] will only be used if for linear axes: SD41110: JOG_SET_VELO = 0 for rotary axes: SD41130: JOG_ROT_AX_SET_VELO = 0 at revolutional feed: SD41120: JOG_REV_SET_VELO = 0.  Siemens AG, 2003. All rights reserved 10-340 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 341 Depending on MD30300: IS_ROT_AX[n], the velocities have to be entered in mm/min, inch/min, or rpm. If the velocities change, MD 36200: AX_VELO_LIMIT[n] (threshold value for velocity monitoring) must be adapted accordingly.  Siemens AG, 2003. All rights reserved 10-341 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 342 Description of Functions, Basic Machine, G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control, Section: Velocities, traversing Ranges, accuracies /FB/ Description of Functions – Extended Functions, H1JOG with/without handwheel  Siemens AG, 2003. All rights reserved 10-342 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 343: Monitoring Functions Of Axis
Tolerance window for a standing machine axis while the signal “Clamping process running” is present at the PLC interface. MD36050: CLAMP_POS_TOL (clamping tolerance) IS: DB31,... DBX2.3 (clamping process running) Alarm: “26000 Clamping monitoring”.  Siemens AG, 2003. All rights reserved 10-343 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 344 PLC. limit switches MD36100: POS_LIMIT_MINUS (1st software limit switch minus) MD36110: POS_LIMIT_PLUS (1st software limit switch plus) MD36120: POS_LIMIT_MINUS (2nd software limit switch minus)  Siemens AG, 2003. All rights reserved 10-344 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 345 It must be set such that the max. speed (rapid traverse) can be reached and, in addition, a certain control margin remains.  Siemens AG, 2003. All rights reserved 10-345 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 346 => Remove obstacle. The speed setpoint consists of the speed setpoint of the position controller and the feedforward control parameter (if feedforward control is active).  Siemens AG, 2003. All rights reserved 10-346 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 347 Monitoring of the difference between following error measured and following monitoring error calculated from the position setpoint. MD36400: CONTOUR_TOL (contour monitoring tolerance band) Error response Alarm: “25050 Contour monitoring”  Siemens AG, 2003. All rights reserved 10-347 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 348 MD36610: AX_EMERGENCY_STOP_TIME (time of brake ramp in case of error conditions). Error causes/remedy The position control resumes automatically after the axes have stopped. Notice The axis concerned must be re-referenced.  Siemens AG, 2003. All rights reserved 10-348 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 350 STANDSTILL_DELAY_TIME IS “Position measuring system 1/2 active” STANDSTILL_POS_TOL CLAMP_POS_TOL Fig. 10-24 Monitoring functions with SINUMERIK 840Di Notice MD 36620: SERVO_DISABLE_DELAY_TIME (servo enable cutout delay) must always be selected greater than MD 36610: AX_EMERGENCY_STOP_TIME (time of brake ramp in case of error conditions).
Page 351: Referencing An Axis
MD 30240: ENC_TYPE (encoder type) Set MD 34200: ENC_REFP_MODE (referencing mode) IS: DB21, ... DBX1.0 (“Activate referencing”) IS: DB21, ... DBX33.0 (“Referencing active”).  Siemens AG, 2003. All rights reserved 10-351 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 352 IS: DB21, ... DBX36.2 (“All axes to be referenced are referenced” IS: DB31, ... DBX4.7/DBX4.6 (“Traversing keys plus/minus”) IS: DB31, ... DBX12.7 (“Reference point approach delay”) IS: DB31, ... DBX60.4, DBX60.5 (“Referenced/synchronized 1, 2”).  Siemens AG, 2003. All rights reserved 10-352 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 353 DB31, ... DBX12.7 (“Reference point approach delayed”) = 0 – MD 34060: REFP_MAX_MARKER_DIST (max. distance to the reference mark) and the zero mark is not detected, the machine axis stops and  Siemens AG, 2003. All rights reserved 10-353 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 354 The machine axis can be stopped and started again using NC Stop/NC Start. References /FB1/ Description of Functions, Basic Machine, R1 Reference Point Approach Section: Referencing with incremental measurement systems  Siemens AG, 2003. All rights reserved 10-354 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 355 Phase 1: The following machine data and interface signals are important: Synchronizing by MD34010: REFP_VELO_SEARCH_CAM (reference cam approach in the overtraveling 2 negative direction) reference marks  Siemens AG, 2003. All rights reserved 10-355 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 356 Traverse the machine axis to a position at which the actual machine position can be exactly measured with reference to machine zero, e.g. using a laser interferometer. 3. Calculate the absolute offset.  Siemens AG, 2003. All rights reserved 10-356 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 357 The adjustment can be carried out in three different ways: Operator-assisted adjustment Automatic adjustment with probe Adjustment with BERO. Any other kinds of referencing with absolute encoders will not be supported.  Siemens AG, 2003. All rights reserved 10-357 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 358 MD34210: ENC_REFP_STATE[n] (status of absolute encoder) from 1 = “Encoder adjustment enabled” to 2 = “Encoder is adjusted”.  Siemens AG, 2003. All rights reserved 10-358 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 359 Signals from channel to PLC 21,... 28.7 (MMC –––> PLC) REF 21,... 33.0 Referencing active 21,... 35.7 Reset 21,... 36.2 All axes to be referenced are referenced.  Siemens AG, 2003. All rights reserved 10-359 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 360 Axis order on channel-specific referencing 34120 REFP_BERO_LOW_ACTIVE Polarity change of BERO Referencing mode [encoder number] 34200 ENC_REFP_MODE[n] Status of absolute encoder [encoder number] 34210 ENC_REFP_STATE[n]  Siemens AG, 2003. All rights reserved 10-360 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 361 Encoder limit frequency for re-synchronization 36310 ENC_ZERO_MONITORING Zero mark monitoring 30250 ACT_POS_ABS Absolute encoder position on switching off References /FB/ Description of Functions, Basic Machine, R1 Reference Point Approach  Siemens AG, 2003. All rights reserved 10-361 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 362: Spindle Basic Data
Positioning mode SPCOF M3, M4, M5 M41–45 SPOS SPOSA SPCOF M3, M4, M5 Axis name Axis mode M41–45 G332 G331 Rigid tapping Fig. 10-27 Spindle modes  Siemens AG, 2003. All rights reserved 10-362 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 363 4. The axis mode can be enabled in any gear stage. If the positional actual- value encoder is mounted on the motor (indirect measuring system), differ- ent positioning and contour accuracies may result between the gear stages.  Siemens AG, 2003. All rights reserved 10-363 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 364 (M02/M30). To cancel spindle movements, an independent spindle reset is required: IS: DB31,... DBX2.2 (spindle reset). References /FB1/ Description of Functions, Basic Machine, S1 Spindles  Siemens AG, 2003. All rights reserved 10-364 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 365: Setpoint/Actual-Value Channels Of Spindle
For further information with respect to parameter records, see above, Subsection 10.5.13, page 10-330. References /FB1/ Description of Functions, Basic Machine, S1 Spindles Section: Gear stage change  Siemens AG, 2003. All rights reserved 10-365 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 366: Measuring Systems Of Spindle
MD31050: DRIVE_AX_RATION_DENOM (load rev. denominator) = 1 MD 31060: DRIVE_AX_RATION_NUMERA (load rev. numerator) = 1 MD31070: DRIVE_ENC_RATION_DENOM (load rev. denominator) = 1 MD31080: DRIVE_ENC_RATION_NUMERA (load rev. numerator) = 1  Siemens AG, 2003. All rights reserved 10-366 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 367 Encoder pulse 2048 * 128 One encoder increment corresponds to 1.3733 internal increments. An encoder increment corresponds to 0.0013733 degrees (highest possible positioning resolution).  Siemens AG, 2003. All rights reserved 10-367 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 368: Speeds And Setpoint Adjustment For Spindle
10.5 Axes and spindles 10.5.24 Speeds and setpoint adjustment for spindle Speeds, gear In SINUMERIK 840Di, data for five gear stages are implemented. These stages stages are defined by a minimum and maximum speed for the stage itself and by a minimum and maximum sped for the automatic gear stage changeover.
Page 369 Speeds and setpoint adjustment for spindle: Interface signals DB number Bit, Byte Name Ref. Axis-specific Signals from PLC to axis/spindle 31, ... Traversing keys minus 31, ... Traversing keys plus  Siemens AG, 2003. All rights reserved 10-369 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 370: Positioning The Spindle
Spindle positioning: Machine data Axis-specific ($MA_ ...) 35300 SPIND_POSCTRL_VELO Creep speed 35350 SPIND_POSITIONING_DIR Direction of rotation when positioning from the standstill 35210 GEAR_STEP_POSCTRL_ACCEL Acceleration in position control mode  Siemens AG, 2003. All rights reserved 10-370 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 371: Synchronizing The Spindle
For the exact procedure of operating a BERO on SIMODRIVE 611 universal, see: References: /FBU/ SIMODRIVE 611 universal, Description of Functions Section:Motion Control with PROFIBUS DP (from SW 3.1) Zero mark substitute on PROFIBUS  Siemens AG, 2003. All rights reserved 10-371 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 372 Machine data Table 10-45 Synchronizing spindle: Machine data Axis-specific ($MA_ ...) 34100 REFP_SET_POS Reference point value 34090 REFP_MOVE_DIST_CORR Reference point offset 34200 REFP_MODE Referencing mode  Siemens AG, 2003. All rights reserved 10-372 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 373: Monitoring Functions Of The Spindle
If the speed is nevertheless exceeded by the speed tolerance (drive error), the following signal is output: IS DB31,... DBX83.0 (speed limit exceeded) = 1 Alarm “22150 Maximum number of chucks exceeded”  Siemens AG, 2003. All rights reserved 10-373 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 374 The encoder limit frequency value must be such that the mechanical encoder speed limit is not exceeded or else the synchronization from high speeds will be incorrect.  Siemens AG, 2003. All rights reserved 10-374 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 375 Min. spindle speed of current gear stage Max. velocity/speed “Axis/spindle stopped” Fig. 10-32 Ranges of spindle monitoring functions/speeds References /FB1/ Description of Functions, Basic Machine, S1 Spindles Section: Spindle monitoring  Siemens AG, 2003. All rights reserved 10-375 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 376: Spindle Data
GEAR_STEP_MIN_VELO_LIMIT[n] Min. speed of gear stage 35150 SPIND_DES_VELO_TOL Spindle speed tolerance 35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limiting from PLC 35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode  Siemens AG, 2003. All rights reserved 10-376 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 377 Table 10-49 Spindle: Interface signals DB number Bit, Byte Name Ref. Axis-specific Signals from PLC to axis/spindle 31, ... Feed override 31, ... Override active  Siemens AG, 2003. All rights reserved 10-377 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 378 Active spindle mode “Positioning mode” 31, ... 84.3 Tapping without compensating chuck active 31, ... 86 and 87 M function for spindle 31, ... 88–91 S function for spindle  Siemens AG, 2003. All rights reserved 10-378 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 379: Digital And Analog I/O Devices
The maximum number of digital or analog input/outputs that can be used for the NC is: Total MCI board PROFIBUS extension modules Analog inputs – Analog outputs – Digital inputs Digital outputs  Siemens AG, 2003. All rights reserved 10-379 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 380: Assignment Of The Inputs/Outputs To The Signal Modules
Input format I/O high I/O low S7 I/O address Low part (hexadecimal) S7 I/O address High part (hexadecimal) always 00 always 05 (identifier: PROFIBUS I/Os)  Siemens AG, 2003. All rights reserved 10-380 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 381: System Variable $A_...[N]
MD10368: HW_ASSIGN_DIG_FASTOUT[ 0–3] $A_OUT[ 9–40 ] Note The digital input/outputs are organized as follows: Hardware assign machine data: Byte by byte System variables: Bit by bit  Siemens AG, 2003. All rights reserved 10-381 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 382: Digital I/O Bytes And System Variables
$A_IN[4] then do not contaion any information. Digital outputs The configuration of digital outputs is analogous to the example described above for digital inputs.  Siemens AG, 2003. All rights reserved 10-382 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 383: Time Behavior
Fig. 10-34 Time behavior when outputting an output signal with optimized DP cycle Explanations regarding Fig. 10-34: Master application cycle: NC position controller cycle MAPC With SINUMERIK 840Di, the following applies in all cases: T MAPC DP cycle time: DP cycle time Data exchange time: Total of transfer times of all...
Page 384: Configuration Example
(5) IM 153 (6) ADI4 (0) UR (0) 840Di PLC315-2DP M/S 2AF03 DP Master CP 342–5 Fig. 10-35 Example configuration: SINUMERIK 840Di with ET200 and ADI4  Siemens AG, 2003. All rights reserved 10-384 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 385 Although only four input bytes are used, five must be declared. The 1st input byte is always assigned to the MCI board extension module, even if it does not exist: – MD10350: FASTIO_DIG_NUM_INPUTS = 5  Siemens AG, 2003. All rights reserved 10-385 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 386 – MD10368: HW_ASSIGN_DIG_FASTOUT[1] = H05000082 (130 ADI4 Both output bytes of the output word (slot 22) – MD10366: HW_ASSIGN_DIG_FASTOUT[2] = H0500014A (330 – MD10366: HW_ASSIGN_DIG_FASTOUT[3] = H0500014B (331  Siemens AG, 2003. All rights reserved 10-386 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 387 Digital and analog I/Os: Setting data Number Identifier Name Ref. General ($SN_ ...) 41600 COMPAR_THRESHOLD_1 Threshold values for comparator byte 1 41601 COMPAR_THRESHOLD_2 Threshold values for comparator byte 2  Siemens AG, 2003. All rights reserved 10-387 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 388 Actual value of digital NC inputs 64, 190–193 Setpoint of digital NC outputs 194–209 Actual value of analog NC inputs 210–225 Setpoint of analog NC outputs  Siemens AG, 2003. All rights reserved 10-388 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 389: Loadable Compile Cycles (Sw 2.2 And Higher)
Brief description Compile cycles are functional expansions of the NCK system software that can be created by the operator and/or by Siemens and then imported in the control later. As part of the open NCK system architecture, compile cycles have comprehen- sive access to data and functions of the NCK system level via defined software interfaces.
Page 390: Loading Compile Cycles
After copying the compile to the FFS, you need to reset the NCK. The com- pile cycle is loaded in the NCK system software the time the NCK is booted.  Siemens AG, 2003. All rights reserved 10-390 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 391: Boundary Conditions
Each loaded compile cycle generates a technological function-specific global technological machine data: function $MN_CC_ACTIVE_IN_CHAN_<identifier>[n], with n = 0, 1 in the machine data number range 60900 to 60999.  Siemens AG, 2003. All rights reserved 10-391 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 392: Data Descriptions (Md)
Additional functions within the individual technological function can be activated via the MD with the index n = 1. See References below. References: /FB3/ Description of Functions Special Functions TE1 – TE8.  Siemens AG, 2003. All rights reserved 10-392 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 393: Profibus Dp
– Control word 1 – Control word 2 PROFIBUS DP communication is then shut down. To be used for: SINUMERIK 840Di with PLC 315-2DP, 314-2C, 317-2DP.  Siemens AG, 2003. All rights reserved 10-393 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 394: Initial Settings
MD20110: RESET_MODE_MASK References /FB1/ Description of Functions, Basic Machine, K2 Axes, Coordinate Systems, Frames, Actual-Value System for Workpiece IWS Section: Workpiece-related actual value system/reset behavior  Siemens AG, 2003. All rights reserved 10-394 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 395: Nc/Plc Diagnosis (840Di Sw 2.3 And Higher)
– 1 started – 2 Initialize data – 3 Initialize data – 4 Start–up – 5 Wait for PLC – 6 Running – F NCK error  Siemens AG, 2003. All rights reserved 10-395 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 397 BUSF (Bus fault) Lights up in connection with PROFIBUS–DP, e.g.: – Bus fault (e.g. short/circuit or interruption) – Interface error (e.g. error in S7 configuration)  Siemens AG, 2003. All rights reserved 10-397 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 399: Menu: Settings
06.03 10.10 NC/PLC diagnosis (840Di SW 2.3 and higher) 10.10.2 Menu: Settings Operating path The menu for the SINUMERIK 840Di–specific settings is located under the foll- woing operating path: Operating area switchover > Diagnosis > NC/PLC Diagnosis > Settings Start-up...
Page 400 Use the list boc to configure the level of the shutdown signal of the UPS: Low active On detection of the low level (0) at the configured input, SINUMERIK 840Di NCK / PLC and then Windows NT are terminated High active On detection of the high level (1) at the configured input, SINUMERIK 840Di NCK / PLC and then Windows NT are terminated.
Page 401 It is strongly recommended that you create a series machine start-up file as described above prior to making any changes. See Chapter 14, page 14-449.  Siemens AG, 2003. All rights reserved 10-401 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 403: Alarm And Message Texts
Extract of the file “MBDDE.INI”: [Textfiles] MMC= <installation path>\dh\mb.dir\alm_ NCK= <installation path>\dh\mb.dir\aln_ PLC= <installation path>\dh\mb.dir\plc_ ZYK= <installation path>\dh\mb.dir\alz_ CZYK= <installation path>\dh\mb.dir\alc_ UserMMC= UserNCK= UserPLC= <installation path>\dh\mb.dir\myplc_ UserZyk= UserCZyk=  Siemens AG, 2003. All rights reserved 11-403 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 404: Standard Text Files
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 copied with operating area: Services into the directory: <installation path> \dh\mb.dir.  Siemens AG, 2003. All rights reserved 11-404 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 405 When creating text files, make sure that the date and time are correctly set on the PCU. Otherwise the user texts might not be displayed on the screen cor- rectly.  Siemens AG, 2003. All rights reserved 11-405 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 406: Syntax For Alarm Text Files
Section: Lists Alarm number Alarm number list Display This number defines the alarm display type: 0: Display in alarm line 1: Display in a dialog box  Siemens AG, 2003. All rights reserved 11-406 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 407 Help ID The default setting “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. See also Subsection 11.1.5, page 11-408, section: HelpContext.
Page 408: Setting The Alarm Log Properties
Cancel = +F10 <Use key combination Shift+F10 to delete an alarm> You will find further details of file entries in: References: /BN/ User’s Guide: OEM package for MMC  Siemens AG, 2003. All rights reserved 11-408 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 409 – Maximum size of alarm list: 50 – Order: New alarms are to be put at the end of the list [Alarms] TimeFormat=%d.%m.%y %H:%M:%S MaxNo=50 ORDER=FIRST  Siemens AG, 2003. All rights reserved 11-409 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 411: Dry Run Of Axis And Spindle
DBxx The data block designated DBxx depends on the maximum configuration of the machine axes currently validated for SINUMERIK 840Di. Enables on the drive Setting-up mode...
Page 412 A2, Various Interface Signals and Functions Limit switches Setting the limit switches and checking the interface signals: Hardware limit switch PLUS DB31-DBxx.DBX12.1 Hardware limit switch MINUS DB31-DBxx.DBX12.0.  Siemens AG, 2003. All rights reserved 12-412 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 413: Dry Run Of Axis
MD31000–31080: (encoder matching) O.K.? 1) Speed setpoint matching – ADI4: –> MD32250 00 – SIMODRIVE 611 universal / E; POSMO CD/CA, SI –> MD32250 = 0  Siemens AG, 2003. All rights reserved 12-413 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 414 MD32910 Dynamic response adaptation error OK? MD31050/31060 Load gearing MD32610 Feedforward control MD of the velocity matching Check the drive parameters P880 PROFIBUS speed evaluation  Siemens AG, 2003. All rights reserved 12-414 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 415: Dry Run Of Spindle
MD31000–31080: (encoder matching) speed? 1) Speed setpoint matching – ADI4: –> MD32250 00 – SIMODRIVE 611 universal / E; POSMO CD/CA, SI –> MD32250 = 0  Siemens AG, 2003. All rights reserved 12-415 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 416 Acceleration in position control range MD 35300 Creep speed Change over MD 36300 Encoder limit frequency gear stage MD34200 Spindle synchronization MD of encoder matching All gear stages tested?  Siemens AG, 2003. All rights reserved 12-416 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 417: Drive Optimization Using Hmi Advanced
(con- ventional or neural quadrant error compensation). References: /FB/, Description of Functions, Extended Functions K3, Compensations Section: Circularity test  Siemens AG, 2003. All rights reserved 13-417 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 418 The diagrams determined can be archived using file functions. Thus, they can measurement be used both for documenting the machine settings and to facilitate remote diagnosis. results  Siemens AG, 2003. All rights reserved 13-418 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 420 – Change in operating mode (JOG) or operating mode JOG not selected – Actuation of traversing keys – Actuation of handwheel – Alarms leading to axis shutdown.  Siemens AG, 2003. All rights reserved 13-420 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 421: Additional Functions
– Without PLC Traversing of the axis to be measured is enabled depending on the interface signals typical for JOG mode (servo enable, pulse enable, etc.).  Siemens AG, 2003. All rights reserved 13-421 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 422 – Active The axis is traversed with monitoring of the traversing range, depending on the traversing range limits set: – Upper limit – Lower limit.  Siemens AG, 2003. All rights reserved 13-422 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 423: Frequency Response Measurement
Four different types of measurement are available for testing the speed con- trol loop: – Reference frequency response – Setpoint step change – Interference frequency response – Disturbance step change – Speed controller system  Siemens AG, 2003. All rights reserved 13-423 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 425 This parameter determines the height of the preset setpoint step change or dis- turbance change. Measuring time This parameter determines the recorded time range (maximum 2048 x speed controller cycles).  Siemens AG, 2003. All rights reserved 13-425 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 426 Fig. 13-3 Setpoint signal with measuring function speed control loop – step response Additional The measurement parameters and the measurement results (diagrams) can be information loaded and/or saved using the soft key File functions.  Siemens AG, 2003. All rights reserved 13-426 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 427: Position Control Loop Measurement
2. Decrease of the feedforward control value 3. Use of setpoint filters. The effects of these measures can also be checked in the time range.  Siemens AG, 2003. All rights reserved 13-427 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 428 A value of between 0.2 and 1sec is rec- ommended. Do not set too low a value for the settling times or the frequency response and phase diagrams will be distorted.  Siemens AG, 2003. All rights reserved 13-428 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 429 The position setpoint and the actual value of the active measuring system are recorded. Offset The step is stimulated from standstill or starting from the constant traverse speed set in this parameter.  Siemens AG, 2003. All rights reserved 13-429 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 430 MD 32300 MAX_AX_ACCEL (max. axis acceleration) may only be carried out with utmost care, e.g. by a certain step height. These machine data are exactly matched with the machine!  Siemens AG, 2003. All rights reserved 13-430 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 431: Graphic Display
The corresponding values, e.g. for damping, frequency, degrees, etc. are dis- played in the appropriate diagram. Use the cursor keys to move the markers: – slowly: Cursor key – fast: Shift key + cursor key  Siemens AG, 2003. All rights reserved 13-431 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 432 The scaling can be switched over between auto (default setting) and fixed. The Y range (Y min/max) to be displayed can only be changed in fixed mode. Fig. 13-7 Menu: Scaling of graphics  Siemens AG, 2003. All rights reserved 13-432 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 433 Printing the graphics into a file (bitmap) or output to a connected printer. – Printer selection Selecting the output of the graphics to a bitmap file or to a connected printer.  Siemens AG, 2003. All rights reserved 13-433 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 434: Trace Function
Fixed Y-scaling selectable for each trace Marker function selectable for each trace Expand function in the time axis Selective loading and saving of the measurement parameters and traces.  Siemens AG, 2003. All rights reserved 13-434 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 435: Main Menu And Operation
You page in the list using the arrow keys. You accept a value using the input key. Fig. 13-9 Cursor control  Siemens AG, 2003. All rights reserved 13-435 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 436: Parameterization
Direct input of the triggering threshold. Threshold The threshold is only active with the types of triggering “Positive edge” and “Negative edge”. The unit refers to the signal selected.  Siemens AG, 2003. All rights reserved 13-436 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 437 This screen form is used to select the data format to be evaluated when record- Screen form ing. – Byte: 0000 00FF – Word: 0000 FFFF – Double word: FFFF FFFF  Siemens AG, 2003. All rights reserved 13-437 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 438: Measuring
“Display” soft key to call the display functions of the graphics (see next Sec- tion). Soft key: With the Stop soft key, you can cancel a running measurement at any time. A Stop canceled measurement cannot be displayed.  Siemens AG, 2003. All rights reserved 13-438 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 439: Display Function
The corresponding values, e.g. for damping, frequency, degrees, etc. are dis- played in the appropriate diagram. Use the cursor keys to move the markers: – slowly: Cursor key – fast: Shift key + cursor key  Siemens AG, 2003. All rights reserved 13-439 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 440 The scaling can be switched over between auto (default setting) and fixed. The Y range (Y min/max) to be displayed can only be changed in fixed mode. Fig. 13-12 Menu: Scaling of graphics  Siemens AG, 2003. All rights reserved 13-440 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 441 Printing the graphics into a file (bitmap) or output to a connected printer. – Printer selection Selecting the output of the graphics to a bitmap file or to a connected printer.  Siemens AG, 2003. All rights reserved 13-441 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 442: File Function
In the Data group, you can select the data you want to save. data type You can only select one data type. Use either the mouse button or the cursor or toggle key for selection.  Siemens AG, 2003. All rights reserved 13-442 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 443 Services > Manage data. New subdirectories can be created below the Diag- nosis directory. For the description of the operating area Services, please refer to: References: /BA/ Operator’s Guide  Siemens AG, 2003. All rights reserved 13-443 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 444: Print Graphics
Toggle key or by double-clicking with the right mouse button on the desired file output type: – Bitmap file – Printer Toggle key  Siemens AG, 2003. All rights reserved 13-444 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 445 Press the soft key Print graphics Enter the desired file name. You can enter a new file name or choose an existing file from the drop-down list.  Siemens AG, 2003. All rights reserved 13-445 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 446 References: /BA/ Operator’s Guide The file is saved using the soft key OK. Use the soft key Abort to return to the current graphic display.  Siemens AG, 2003. All rights reserved 13-446 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 447: Automatic Controller Setting
For a description how to carry out an automatic controller adjustment of SIMO- universal DRIVE 611 universal drives, please refer to: References: /FBU/ SIMODRIVE 611 Universal, Descriptions of Function Section:Description of Functions Optimizing current and speed controllers  Siemens AG, 2003. All rights reserved 13-447 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 449: User Data Backup/Series Machine Start-Up
User data User data are called all data or data areas that can be entered by the user to achieve the specific functionality of the SINUMERIK 840Di or the SIMODRIVE 611 universal drives. In the case of a data backup, e.g. after start-up of the control system, the user data selected through the user interface are written to a so-called series ma- chine start-up file.
Page 450 SimoCom U. When doing so, one parameter file each is saved per drive on the hard disk of the PCU. drive data SimoCom U is part of the SINUMERIK 840Di installation. For detailed information on the data backup of SIMODRIVE 611 universal drives, please refer to:...
Page 451: Creating A Series Machine Start-Up File Using Hmi Advanced
Note Compensation data must only be archived if the series machine start-up file is to be reloaded into the same control system (backup).  Siemens AG, 2003. All rights reserved 14-451 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 452 – PG (programming device, e.g. PG740) – Floppy disk drive (option) – Archive (HMI data management on the hard disk of the PCU) – NC Card.  Siemens AG, 2003. All rights reserved 14-452 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 453: Considerations When Saving Plc Data
After this series machine start-up file has been copied back, this data inconsis- tency in the PLC user program may under certain circumstances result in the stop of the PLC.  Siemens AG, 2003. All rights reserved 14-453 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 454: Reading In A Series Machine Start-Up File With Hmi Advanced
2. Select the series machine start-up file 3. Start read in: Start Note Because of the file extension “.arc” of the series machine start-up files, this is also called archive.  Siemens AG, 2003. All rights reserved 14-454 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 455: Sw Installation/Update And Data Backup
For information on the PCU basic software, please refer to the file C:\Siemensd.rtf. For the versions of the system components contained in the PCU basic soft- ware, please refer to the file C:\BaseVers.txt.  Siemens AG, 2003. All rights reserved 15-455 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 456: Partitioning Of The Hard Disk
The PCU hard disk is divided into four partitions (three primary partitions and an extended partition). For reasons of data security, the SINUMERIK 840Di system software, the Windows NT system software and the Service software are installed in dif- ferent partitions.
Page 457: Boot Manager
– through the network connection (log: NetBEUI) install and update Windows NT applications make backup copies (GHOST images) of the entire hard disk or of individual partitions and restore them.  Siemens AG, 2003. All rights reserved 15-457 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 458: Setting/Determining The Network Parameters Of An External Computer
(PG/PC), either use only uppercase letters or connect a standard PC keyboard to the PCU.  Siemens AG, 2003. All rights reserved 15-458 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 459 Dialog: Access by share access rights Button: “Add...” Dialog: Add users and groups Names: Choose a name from the list e.g. “User” or “Everybody” Button: “Add” Access type: <Read>  Siemens AG, 2003. All rights reserved 15-459 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 460: Software Installation/Update
1. Backup the NC and PLC user data by creating a series machine start-up file. See Chapter 14, page 14-449. 2. Install//update the SINUMERIK 840Di system software. According to your requirements, please see: – Parallel link and external FAT16 drive: Subsection 15.2.2, page 15-460.
Page 461 C: <size> Transfer Port: Speed: Alt + F4=Exit Notice The PCU must be switched OFF. If the PCU is switched ON, switch it OFF now.  Siemens AG, 2003. All rights reserved 15-461 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 462 NT procedure is carried out and the software that is to be found under D:\INSTALL is installed automatically. 9. Exit the Server mode on the external computer (PG/PC): Key combination: Alt + F4  Siemens AG, 2003. All rights reserved 15-462 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 463: Parallel Link And External Fat32 Drive
2. Use a parallel data transfer cable (PC-Link or LapLink cable) to link the par- allel port of the external PC (LPT1) with the parallel port of the PCU (LPT1).  Siemens AG, 2003. All rights reserved 15-463 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 464 The following menu will appear: Microsoft Interlnk Server Version <version> This Computer Other Computer (Server) (Client) C: <size> D: <size> LPT1: Transfer Port: Speed: Alt + F4=Exit  Siemens AG, 2003. All rights reserved 15-464 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 465 When the control is booted for the next time under Windows NT, the software (setup.exe) contained in the installation directory D:\INSTALL of the PCU is installed automatically.  Siemens AG, 2003. All rights reserved 15-465 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 466: Network Link (Ethernet)
After the PCU has been turned on, the menu of the boot manager is displayed. 1. Select the menu option Service menu (hidden) using the CursorDown key and then press the Input key.  Siemens AG, 2003. All rights reserved 15-466 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 467 – Type the user name and the password you want to use for access to the external computer. Windows NT 4.0 User name and password of the local user of the PG/PC  Siemens AG, 2003. All rights reserved 15-467 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 468 The complete network settings are displayed in the Service menu, and the installation directory in the menu item Install from ..., (in the example: H:<PATH>).  Siemens AG, 2003. All rights reserved 15-468 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 469 When the control is booted for the next time under Windows NT, the software (setup.exe) contained in the installation directory D:\INSTALL is installed auto- matically.  Siemens AG, 2003. All rights reserved 15-469 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 470 Choose Disconnect form all Network Drives using the key “3”. The network connections are then displayed in the Service menu as -none-. Connected Network Drives (last): -none- Install Directory: H:\<PATH>  Siemens AG, 2003. All rights reserved 15-470 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 471: Data Backup
Start Windows NT (Service Mode) SINUMERIK System Check Backup/Restore Start PC Link Reboot (warm restart) 840Di Services Your Choice [1,2,3,4,5,7,8,9,P] ? 2. Choose Backup/Restore using the key “7”.  Siemens AG, 2003. All rights reserved 15-471 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 472 To set the path or the file name under which you wish the backup copy to be stored on the external computer, select the menu option Change Backup Image Filename using the key “3”.  Siemens AG, 2003. All rights reserved 15-472 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 473 – Now start Norton Ghostt on the external computer (PG/PC) under DOS or Windows 95/ 3.11 in a DOS prompt window with: ghost –lps – Then press the “Y” key to start the backup process.  Siemens AG, 2003. All rights reserved 15-473 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 474 – The volume of data to be transferred is displayed. Size of backup copy with compressing: 4.8GB hard disk –> approx. 330MB file Time for transfer: approx. 50min.  Siemens AG, 2003. All rights reserved 15-474 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 475: Restoring The Hard Disk Backup Using Parallel Link
2. Choose Backup/Restore using the key “7”. The system prompts you to enter a password: 3. Type one of the passwords of protection levels 0–2. – System – Manufacturer – Service.  Siemens AG, 2003. All rights reserved 15-475 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 476 Use the key “9” to return to the previous menu after you have confirmed the modified GHOST parameters.  Siemens AG, 2003. All rights reserved 15-476 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 477 Your Choice [1,2,3,4,9]? 7. Use this menu to choose the operating system used as the basis for the backup copy. In the case of SINUMERIK 840Di, this is exclusively Windows NT. Therefore, choose Windows NT using the key “1”. Following menu:...
Page 478 The computer name taken over with the image is kept. Changes to the computer name and system ID are made using the program Norton Ghost Walkert.  Siemens AG, 2003. All rights reserved 15-478 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 479 F: will be checked by the diagnostic program CHKDISK in succession whereby the PCU is rebooted automatically. After completion of the check, the system with the restored backup copy is ac- tive.  Siemens AG, 2003. All rights reserved 15-479 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 480: Saving The Hard Disk Using A Network Link (Ethernet)
After the PCU has been turned on, the menu of the boot manager is displayed. 1. Select the menu option Service menu (hidden) using the CursorDown key and then press the Input key. The following menu will appear:  Siemens AG, 2003. All rights reserved 15-480 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 481 – Network parameters of the PCU – Path or File name under which you wish the backup copy to be stored on the external computer.  Siemens AG, 2003. All rights reserved 15-481 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 482 How to set or determine the network parameters of an external computer is described in Subsection 15.1.4 (page 15-458). The set network information is displayed.  Siemens AG, 2003. All rights reserved 15-482 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 483 6. To start the data transfer, choose the menu item Hard disk Backup to ... using the key “2”. Following menu: PLEASE SELECT Backup WITHOUT Local Images Backup WITH Local Images Back to previous Menu Your Choice [1,2,3,9] ?  Siemens AG, 2003. All rights reserved 15-483 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 484 – The volume of data to be transferred is displayed. Size of backup copy with compressing: 4.8GB hard disk –> approx. 330MB image file. Time for transfer: approx. 15min.  Siemens AG, 2003. All rights reserved 15-484 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 485 Disconnect from all Network Drives Back to previous Menu Your Choice [1,2,3,9] ? Choose Disconnect form all Network Drives using the key “3”. Connected Network Drives (last): -none-  Siemens AG, 2003. All rights reserved 15-485 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 486: Restoring The Hard Disk Backup Using A Network Link (Ethernet)
After the PCU has been turned on, the menu of the boot manager is displayed. 1. Choose the menu item Service Menu (hidden). The following menu will appear:  Siemens AG, 2003. All rights reserved 15-486 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 487 – Network parameters of the PCU – Path or File name under which you wish the backup copy to be stored on the external computer.  Siemens AG, 2003. All rights reserved 15-487 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 488 How to set or determine the network parameters of an external computer is described in Subsection 15.1.4 (page 15-458). The set network information is displayed.  Siemens AG, 2003. All rights reserved 15-488 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 489 Your Choice [1,2,3,4,9]? 7. Use this menu to choose the operating system used as the basis for the backup copy. In the case of SINUMERIK 840Di, this is exclusively Windows NT. Therefore, choose Windows NT using the key “1”.  Siemens AG, 2003. All rights reserved 15-489 SINUMERIK 840Di Manual (HBI) –...
Page 490 The following menu will appear: PLEASE SELECT Input Machine Name MANUALLY Input Machine Name RANDOMLY Abort Your Choice [1,2,9]?  Siemens AG, 2003. All rights reserved 15-490 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 491 F: will be checked by the diagnostic program CHKDISK in succession whereby the PCU is rebooted automatically. After completion of the check, the system with the restored backup copy is ac- tive.  Siemens AG, 2003. All rights reserved 15-491 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 492: Display Connected Drives
Back to previous Menu Your Choice [1,2,3,9] ? the menu option Disconnect form all Network Drives using the key “3”. Connected Network Drives (last): -none-  Siemens AG, 2003. All rights reserved 15-492 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 493: Saving Partitions (Local)
Hard disk Backup/Restore with GHOST Partitions Backup/Restore with GHOST Back to previous Menu Your Choice [1,4,9]? 4. Choose the menu option Partitions Backup/Restore with Ghost using key “4”.  Siemens AG, 2003. All rights reserved 15-493 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 494 When you confirm the specifications above, the partition backup will be started. After the partition backup has been made, a check can then be carried out using CRC Check.  Siemens AG, 2003. All rights reserved 15-494 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 495: Changing The Number Of Partition Backups
Choose the menu item Change Maximum Backup Images using key “1”. Type the new number in the following menu and confirm the question: “Save GHOST parameters” with “Yes”.  Siemens AG, 2003. All rights reserved 15-495 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 496: Deleting Partition Backups
Choose the menu item Delete Image using key “4”. Choose the partition backup you want to delete from the next following menu and confirm the warning questions with “Yes”.  Siemens AG, 2003. All rights reserved 15-496 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 497: Restoring A Partition Backup (Local)
Hard disk Backup/Restore with GHOST Partitions Backup/Restore with GHOST Back to previous Menu Your Choice [1,4,9]? 4. Choose the menu option Partitions Backup/Restore with Ghost using key “4”.  Siemens AG, 2003. All rights reserved 15-497 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 498 F: will be checked by the diagnostic program CHKDISK in succession whereby the PCU is rebooted automatically. After completion of the check, the system with the restored backup copy is active.  Siemens AG, 2003. All rights reserved 15-498 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 499: Di Specific Data And Functions
Signals from axis/spindle to PLC 31, ... 92.0 Setup mode active 31, ... 92.2 Torque limit 2 active Safety Integrated signals from axis/spindle to PLC  Siemens AG, 2003. All rights reserved 16-499 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 500 Safe velocity active – bit value 0 through bit value 1 31, ... 110.5 n < n 31, ... 111.1 Safe operational stop active (SBH active) 31, ... 111.4–11.7 Stop A/B through Stop E active  Siemens AG, 2003. All rights reserved 16-500 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 501: Expanded Message Frame Configuration (Sw 2.2 And Higher)
– DP slave, DP master and NC – of the quantity and meaning of the transferred data. With SW 2.2 and higher, the SINUMERIK 840Di system offers expanded message frame configura- tion which allows you to cyclically transfer drive data in addition to process data from the drive (DP slave) to the NC (DP master) by combining standard message frames and customized message frame configuration.
Page 502 In the necessary format conversion, bit 15 of the unsigned 16-bit integer PDA value is transferred to bits 16 to 31 of the signed 32-bit integer value in the system variable.  Siemens AG, 2003. All rights reserved 16-502 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 503: Requirements
The drive to be used for the expanded message frame configuration must support customizable message frame configuration in addition to selection of standard message frames.  Siemens AG, 2003. All rights reserved 16-503 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 504: Configuring Simodrive Drives
1. Configure the DP master with SIMATIC STEP 7 2. Configure the DP slave 611U with the start-up tool: SimoCom U 3. SINUMERIK 840Di NC with start-up tool: SinuCom NC or the user interface: HMI Advanced (option). Standard Before performing the expanded message frame configuration, please define...
Page 506 8 Enc. 1 pos. act. val. 1 (G1_XACT1) 9 No signal (NIL) 9 Enc. 1 pos. act. val. 2 (G1_XACT2) Fig. 16-3 Activating the customizable message frame configuration  Siemens AG, 2003. All rights reserved 16-506 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 507 After configuring the expanded message frames, the standard message frame with which the axis is driven is only explicitly visible in the NC machine data: MD 13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)  Siemens AG, 2003. All rights reserved 16-507 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 508: Boundary Conditions
You can only have read access to the drive data stored in the system vari- ables. Consistency check At SINUMERIK 840Di boot, the NC checks the consistency of the process data configuration (PDA) of the parameters relevant to the cyclic PROFIBUS commu- nication: –...
Page 509: Data Descriptions (Md, System Variable)
Warning For reasons relating to the system, the consistency check – which is performed during SINUMERIK 840Di boot and based on acyclic communication with the drive – runs parallel in time with the already active cyclic communication be- tween NC and drive.
Page 510: Alarms
Detailed information on the individual alarms can be found in: References: /DA/ Diagnostics Guide For systems with HMI Advanced you can refer to the online help.  Siemens AG, 2003. All rights reserved 16-510 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 511: Description Of Functions
16384 ¢ 1%. During SINUMERIK 840Di boot and in the state: “Incoming station” of the DP slave 611U, the SI- NUMERIK 840Di NC cyclically reads parameter P881 from the drive and transfers it to the appropri-...
Page 512: Setting Parameters For Simodrive Drives
102 to 107). 16.3.4 Setting parameters for the SINUMERIK 840Di NC In the SINUMERIK 840Di NC system, the parameters for the resolution of the torque reduction are set via the axis-specific machine data: MD 37620: PROFIBUS_TORQUE_RED_RESOL (torque reduction resolu- tion on PROFIBUS (LSB weighting)).
Page 513 Online to drive 12A => data are modified directly in the drive! PROFIBUS OFF1 Control of clock-synchronized PROFIBUS Number Text Value Unit Effective Evaluation of torque/power reduction PRO 1638.40 % immediately Fig. 16-5 Set parameter P0881  Siemens AG, 2003. All rights reserved 16-513 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 514: Boundary Conditions
Notice It is the start-up engineer’s responsibility to ensure that the parameter settings are consistent in the SINUMERIK 840Di 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 515: Data Description (Md)
Detailed information on the individual alarms can be found in: References: /DA/ Diagnostics Guide For systems with HMI Advanced you can refer to the online help.  Siemens AG, 2003. All rights reserved 16-515 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 516 16 840Di Specific Data and Functions 06.03 16.3 Travel to fixed stop with high-resolution torque reduction (SW 2.2 and higher) Notes  Siemens AG, 2003. All rights reserved 16-516 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 517 Data Word Simple I/O module (PLC I/O module) EPROM Erasable Programmable Read-Only Memory ETC key > extension of soft key bar in the same menu  Siemens AG, 2003. All rights reserved A-517 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 518: A Abbreviations
Jogging: Setting-up mode Channel 1 Transmission ratio Servo gain factor Light Emitting Diode: Last significant Bit Motion Control Interface Machine Control Panel Machine Coordinate System  Siemens AG, 2003. All rights reserved A-518 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 519 Positioning Motor Servo Integrated: Positioning motor, DC infeed Parameter Process data ObjectCyclic data message frame for PROFIBUS DP transmissionand “Variable speed drives” profile PROFIBUS Process Field Bus: Serial data bus  Siemens AG, 2003. All rights reserved A-519 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 520 Tool Radius Offset Transistor-Transistor Logic (interface type) VDI interface Data interface between NC and PLC Tool Coordinate System Zero Offset Active: Identifiere for zero offset  Siemens AG, 2003. All rights reserved A-520 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 523 Catalog NC Z Order No.: E86060-K4490-A001-B1-7600 Electronic Documentation /CD1/ The SINUMERIK System (11.02 Edition) DOC ON CD (includes all SINUMERIK 840D/840Di/810D/802D/802SC and SIMODRIVE publications) Order No.: 6FC5298-6CA00-0BG3  Siemens AG, 2003. All rights reserved B-523 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 524: B References
Order No.: 6FC5298-6AD10-0BP1 /BAT/ SINUMERIK 840D/810D (06.03 Edition) Operation/Programming ShopTurn Order No.: 6FC5298-6AD50-0BP2 /BEM/ SINUMERIK 840D/810D (11.02 Edition) Operator’s Guide HMI Embedded Order No.: 6FC5298-6AC00-0BP2  Siemens AG, 2003. All rights reserved B-524 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 525 Order No.: 6FC5298-6AB10-0BP2 /PGK/ SINUMERIK 840D/840Di/810D (10.00 Edition) Short Guide Programming Order No.: 6FC5298-6AB30-0BP0 /PGM/ SINUMERIK 840D/840Di/810D (11.02 Edition) Programming Guide ISO Milling Order No.: 6FC5298-6AC20-0BP2  Siemens AG, 2003. All rights reserved B-525 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 526 Order No.: 6SN1197-0AC63-0BP0 /APH4/ SIMODRIVE (07.03 Edition) Planning Guide 1PH4 Asynchronous Motors Order No.: 6SN1197-0AC64-0BP0 /APH7/ SIMODRIVE (06.03 Edition) Planning Guide 1PH7 Asynchronous Motors Order No.: 6SN1197-0AC65-0BP0  Siemens AG, 2003. All rights reserved B-526 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 527 SIMODRIVE (05.03 Edition) Planning Guide 1FT5 Three-Phase AC Servomotors Order No.: 6SN1197-0AD01-0BP0 /PFT6/ SIMODRIVE (05.03 Edition) Planning Guide 1FT6 Three-Phase AC Servomotors Order No.: 6SN1197-0AD02-0BP0  Siemens AG, 2003. All rights reserved B-527 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 528 Three-Phase AC Servo Motors for Feed and Main Spindle Drives Order No.: 6SN1197-0AC20-0BP0 /PJM2/ SIMODRIVE (07.03 Edition) Planning Guide Servomotors Three-Phase AC Motors for Feed and Main Spindle Drives Order No.: 6SN1197-0AA20-0BP4  Siemens AG, 2003. All rights reserved B-528 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 529 (the various sections are listed below) Order No.: 6FC5297-6AC20-0BP1 Various Interface Signals Axis Monitoring, Protection Zones Continuous Path Mode, Exact Stop and Look Ahead Acceleration Diagnostic Tools  Siemens AG, 2003. All rights reserved B-529 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 530 3-Axis to 5-Axis Transformation Gantry Axes Cycle Times Contour Tunnel Monitoring Coupled Motion and Leading Value Coupling Constant Workpiece Speed for Centerless Grinding Tangential Control  Siemens AG, 2003. All rights reserved B-530 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 531 DNC Plant / DNC Cell DNC IFC SINUMERIK, NC Data Transfer via Network /FBFA/ SINUMERIK 840D/840Di/810D (11.02 Edition) Description of Functions ISO Dialects for SINUMERIK Order No.: 6FC5297-6AE10-0BP3  Siemens AG, 2003. All rights reserved B-531 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 532 Introduction to Configuring of Operator Interface Screen Kit: Software Update and Configuration /FBP/ SINUMERIK 840D (03.96 Edition) Description of Functions C-PLC Programming Order No.: 6FC5297-3AB60-0BP0  Siemens AG, 2003. All rights reserved B-532 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 533 SINUMERIK 840D/840Di/810D (01.03 Edition) Motion Control Information System (MCIS) Description of Functions TPM Total Productive Maintenance, Version 3.0 Order No.: Document is supplied with the software  Siemens AG, 2003. All rights reserved B-533 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 534 SIMODRIVE POSMO SI/CD/CA (07.03 Edition) User’s Guide Distributed Servo Drive Systems Order No.: 6SN2197-0AA20-0BP4 /POS4/ SIMODRIVE POSMO SI (04.02 Edition) Installation Guide (enclosed with POSMO SI)  Siemens AG, 2003. All rights reserved B-534 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 535 FM 357-2 Multimodule for Servo and Stepper Drives Order together with configuring package /SP/ SIMODRIVE 611–A/611–D SimoPro 3.1 Program for Configuring Machine-Tool Drives Order No.: 6SC6111-6PC00-0BAj, Order from: WK Fürth  Siemens AG, 2003. All rights reserved B-535 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 536 Installation and Start-Up Guide HMI/MMC Order No.: 6FC5297-6AE20-0BP2 Updates/Supplements Expanding the Operator Interface Online Help Starting up HMI Embedded Starting up HMI Advanced Creating Foreign Language Texts  Siemens AG, 2003. All rights reserved B-536 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 537 The EC Declaration of Conformity is available in PDF format under Product ID on Siemens A&D Product Information page: 15257461. – Internet address: www.ad.siemens.de > Support > Service & Support > Produkt Support > Search: 15257461 > Go Support Service &...
Page 539 Boot type, cold restart, 8-258 Setting message frame type, 7-222 Buffer battery, 10-397 Adjustment, 7-243 Bus connector, PROFIBUS and MPI, 2-47 Advanced Processing 1, 1-20  Siemens AG, 2003. All rights reserved Index-539 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 540 PROFIBUS parameters, 7-218 Relocation, 10-306 Selecting the set configuration, 7-218 Saving, 10-306 Setting the I/O addresses, 7-219 Swapping, 10-306 DP-Slave 611U, Parameterization, 7-232 Cyclic operation, PLC, 8-259  Siemens AG, 2003. All rights reserved Index-540 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 541 H2, Module status, ADI4, 2-118 ESD measures, 4-136 Handheld terminal HT 6, 5-161 ET 200, 2-45 Handheld unit (HHU), 5-151 Exact stop Coarse, 10-343 Fine, 10-343  Siemens AG, 2003. All rights reserved Index-541 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 542 MCI board extension, 2-59, 2-66 Backpack, 2-44 MCI board extension backpack, 2-75 PP72/48, 2-94 Internal, 2-62, 2-70 Slot variation, 2-44 Interface overview, ADI4, 2-48, 2-66, 2-107  Siemens AG, 2003. All rights reserved Index-542 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 543 NCK latency time, 10-398 MPI interface, 5-148 NCK reset, 10-396 Parameterization of the PLC NCK status, 10-395 NetBEUI, 6-199 HT 6, 5-164 MCP, 5-143 Network operation, 6-188  Siemens AG, 2003. All rights reserved Index-543 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 544 Setting the PROFIBUS address, 7-218 Preparing for start-up, 6-173 PROFIBUS Handwheel type, MCI board Ext., 2-63 Modules, 2-45 PROFIBUS address, PP72/48, 2-95 Node address, 9-267  Siemens AG, 2003. All rights reserved Index-544 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 545 SIMATIC ET 200, 2-45 SIMATIC Manager STEP7, 7-207 On an external PG/PC, 8-255 On SINUMERIK840Di, 8-255 SIMATIC S7 I/O devices, 7-216 SIMATIC S7 project, 7-211 SIMODRIVE drives, 7-231  Siemens AG, 2003. All rights reserved Index-545 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 546 System clock cycle, 10-290 Universal, 1-20 System data, 10-281 UPS, 2-90 System data blocks, 7-244 SITOP POWER DC UPS module 15, 2-90 System information, 6-191  Siemens AG, 2003. All rights reserved Index-546 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 547 X6-2, Digital inputs, ADI4, 2-116 Workgroup, 6-200 Working area limitation, 10-344 Zero speed control, Delay time, 10-343 External power supply ADI4, 2-107 External power supply, PP72/48, 2-94  Siemens AG, 2003. All rights reserved Index-547 SINUMERIK 840Di Manual (HBI) – 06.03 Edition...
Page 549 Suggestions SIEMENS AG Corrrections A&D MC BMS for publication: P.O. Box 3180 SINUMERIK 840Di D-91050 Erlangen/Germany (Tel. ++49–(0)180 / 5050–222 [Hotline] Fax: ++49–(0)9131 / 98–2176 [Documentation] Manufacturer/Service documentation email: motioncontrol.docu@erlf.siemens.de) Manual From Order No.: 6FC5 297-6AE60-0BP2 Edition: 06.2003 Name Company/Department...
Page 551 Overview of SINUMERIK 840D/840Di/810D Documentation General Documentation User Documentation SINUMERIK SIROTEC SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK SIMODRIVE 840D/810D 840D/810D/ 840D/840Di/ 840D/840Di/ 840D/840Di/ Accessories 840D/840Di/ FM-NC 810D 810D 810D 810D/ Brochure Catalog Catalog AutoTurn Operator’s Guide *) Operator’s Guide Diagnostics Ordering Info.
Page 552 Siemens AG Automation & Drives Motion Control Systems © Siemens AG, 2003 P.O. Box 3180, D-91050 Erlangen Subject to change without prior notice Germany Order No.: 6FC5297-6AE60-0BP2 Printed in Germany www.ad.siemens.de...

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