SINUMERIK 840di SL Manual: Valid For

General Information 1
Hardware Descriptions 2
Set-Up 3
EMC and ESD Measures 4
SINUMERIK 840Di sl Power-On and Power-Up 5
PLC Start-Up 6
Manual
Ethernet Communication 7
PROFIBUS Communication 8
MPI Communication 9
Drive Start-Up
(SINAMICS) 10
Drive Start-Up
(SIMODRIVE) 11
NCK Start-Up with

HMI Advanced 12
Alarm and Message Texts 13
Axis/Spindle Dry Run 14

Valid for
Drive Optimization with
Control HMI Advanced 15
SINUMERIK 840Di sl/840DiE sl
User Data Backup/
Software Version Series Machine Start-Up 16
System Software for 840Di sl/840DiE sl 1.1
Software Installation/
Update and Data Backup 17
License Management 18
Specific Data
and Functions 19
03/2006 Edition Small SINAMICS Glossary A

Abbreviations B
References C
EC Declaration of
Conformity D
SINUMERIK® documentation
3ls
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the “Remarks” column.
Status code in the “Remarks” column:
A . . . . . New documentation.
B . . . . . Unrevised reprint with new order no.
C . . . . . Revised edition with new status.
Edition Order no. Comments

10/2005 6FC5397-4CP10-0BA0 A
03/2006 6FC5397-4CP10-1BA0 C
Trademarks
All product names mentioned may be trademarks or product designations of Siemens AG or their suppliers,
whose use by third parties for their own purposes may infringe the rights of the
trademark owners.
We have checked the contents of this manual for agreement with the
hardware and software described. Nevertheless, differences might
exist and therefore we cannot guarantee that they are completely
identical. The information given in this publication is reviewed at
regular intervals and any corrections that might be necessary are
made in the subsequent printings. Suggestions for improvement are
also welcome.
Copyright © Siemens AG, 2006. Subject to change without prior notice.
Printed in Germany Siemens Aktiengesellschaft

03/2006 SINUMERIK 840Di sl Manual
Preface
PREFACE
Notes for the The SINUMERIK documentation is subdivided into 3 parts:

Reader
S General documentation
S User Documentation
S Manufacturer/Service documentation
Target group This document is designed for machine tool manufacturers.

The manual is only valid for the specific software version or up to the software
version specified. When a new software version is released, the Description of
Functions for that version must be ordered. Old manuals are only partly applica-
ble for new software versions.
Detailed information about other SINUMERIK sl brochures, and brochures for
all SINUMERIK controllers (e.g. universal interface, measuring cycles, etc.) can
be obtained from your local Siemens representative.
Notice
It may be possible to run functions that are not described in this document in
your controller. This does not, however, represent an obligation to supply such
functions with a new control or when servicing.
Hotline If you have any questions on the control, please get in touch with our hotline:
A&D Technical Support Phone: +49 (0) 180 5050 222

Fax: +49 (0) 180 5050 223
E–mail: [email protected]
Online: www.siemens.com/automation/support–request
If you have any questions about the documentation (suggestions for improve-
ment, corrections), please send a fax to the following number:
Fax: +49 (0) 9131 98 2176
E–mail: [email protected]
Fax form: See the reply form at the end of this publication
Internet address www.siemens.com/motioncontrol
SINUMERIK Search: SINUMERIK 840Di sl

840Di sl
Link box The Link Box on the SINUMERIK 840Di sl page gives you direct access to all
important information about the product.
© Siemens AG, 2006. All rights reserved

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition v
SINUMERIK 840Di sl Manual 03/2006
Preface
Objectives This manual provides detailed information requred for the configuration and
start–up of a SINUMERIK 840Di sl system.
This manual describes the control system design and the interfaces of the indi-
vidual components. The startup procedure with SINUMERIK 840Di sl (NCK,
PLC and drives) is also described.
For detailed information about individual functions, function assignment and
performance data of individual components, please refer to the appropriate
document for the subject concerned (e.g. manuals, function descriptions etc.).
User–oriented activities such as the creation of parts programs and control
operating procedures are described in detail in separate documentation
(Programming Guide, Operator’s Guide, etc.).
Separate descriptions are likewise provided of the tasks to be performed by the
tool manufacturer such as configuring, design and PLC programming.
Target groups The manual contained in the function descriptions is designed for:
S Design engineers
S PLC programmers who create PLC user programs
S Start–up engineers once the system has been configured and set up
S Maintenance personnel inspecting and interpreting status signals and
alarms
Who are qualified For the purpose of this manual and product labels, a qualified person is one
personnel? who is familiar with the installation, mounting, start–up and operation of the
equipment and the hazards involved.
S Training and instruction, i.e. authority to switch on and off, to earth and to
label circuits and equipment according to safety regulations.
S Trained in the proper care and use of protective equipment in accordance
with established safety procedures and first aid.

vi SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
Preface
Danger and The following danger and warning signs are used in this document. Explanation
warning strategy of symbols used:
Danger
! This symbol indicates that death, severe personal injury or substantial property
damage will result if proper precautions are not taken.
Warning
! This symbol indicates that death, severe personal injury or substantial property
damage may result if proper precautions are not taken.
Caution
! This warning (with the triangular symbol) means that minor physical injury or
damage to property can occur if the appropriate precautions are not taken.
Caution
This symbol (without a warning triangle) indicates that damage to property may
result if proper precautions are not taken.
Notice
This warning means that an undesirable result can occur if the information is
ignored.
Additional notes Explanation of symbols
Important
! This notice indicates important facts that must be taken into consideration.
Notice
Is an important item of information about the product, handling of the product or
section of the documentation which requires particular attention.
Machine Manufacturer
This pictorial symbol always appears in this document to indicate that the ma-
chine manufacturer can affect or modify the function described. Never ignore
information provided by the machine manufacturer!

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition vii
Preface
Danger notices The following notices are intended firstly for your personal safety and secondly
to prevent damage occurring to the products described or any connected
devices and machines.
Warning
! When operating electrical devices, it is impossible to avoid applying hazardous
voltages to certain parts of the equipment.
Unqualified operator action of the device/system or failure to observe the war-

ning notices may result in serious physical injury or material damage. Only
suitably qualified personnel trained in assembling, installing, commissioning or
operating the product should work on this device/system.
Should it be necessary to test or take measurements on live equipment, then

the specifications and procedures defined in Accident Prevention Regulation
VBG 4.0 must be adhered to, in particular § 8 ”Permissible deviations when
working on live components”. Suitable electric tools should be used.
Warning
! S Repairs to devices that have been supplied by our company must only be
carried out by SIEMENS Customer Service or by repair centers autho-
rized by SIEMENS. When replacing parts or components, only use those
parts that are included in the spare parts list.
S Before opening the device, always disconnect the power supply.

S EMERGENCY STOP devices complying with EN 60204 IEC 204 (VDE
0113) must remain effective in all automation equipment modes. Resetting
the EMERGENCY STOP device must not cause an uncontrolled or unde-
fined restart.
S Anywhere in the automation equipment where faults might cause major

material damage or even physical injury, in other words, where faults could
be dangerous, additional external precautions must be taken, or facilities
must be provided, that guarantee or enforce a safe operational state, even
when there is a fault (e.g. using an independent limit value switch, mechani-
cal interlocks etc.)
Caution
! S Connecting cables and signal cables should be installed so that inductive
and capacitive interference does not in any way impair the automation func-
tions.

viii SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
Preface
ESDS information Electrostatically Sensitive Devices
Important
! Handling of modules containing devices sensitive to electrostatic discharge:
S When handling electrostatically sensitive devices, make sure that operator,

workplace and packing material are properly grounded.
S Generally, electronic modules must not be touched unless work has to be

carried out on them. When handling PC boards make absolutely sure that
you do not touch component pins or printed conductors.
S Touch components only if

– you are permanently grounded by means of an antistatic chain,
– you are wearing ESD boots or ESD boots with grounding strips in con-
junction with ESD flooring.
S Modules may be placed only on electrically conductive surfaces (table with

ESD top, conductive ESD foam plastic, ESD packing bags, ESD transport
containers).
S Keep modules away from visual display units, monitors or TV sets (mini-
mum distance from screen > 10 cm).
S Do not bring ESD–sensitive modules into contact with chargeable and

highly–insulating materials, such as plastic, insulating table tops or clothing
made of synthetic materials.
S Measurements on modules are allowed only if

– the measuring instrument is properly earthed (e.g. equipment grounding
conductor), or
– before measuring with a potential–free measuring instrument, the probe
is briefly discharged (e.g. touch the unpainted metal parts of the control
housing).
Intended use The device must only be put to the uses prescribed in the manual and only in
conjunction with third party devices and components recommended or ap-
proved by SIEMENS (e.g. SINUMERIK 840D/FM–NC).

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition ix
Preface
Notes

x SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
Contents
1 General Information on the SINUMERIK 840Di sl . . . . . . . . . . . . . . . . . . . . . . . 1-21

1.1 Overview of SINUMERIK 840Di sl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.1.1 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.1.2 System software packages and quantity frameworks . . . . . . . . . . . . . 1-22
1.1.3 Hardware components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.1.4 Software components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.1.5 Real-time properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.1.6 System integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.1.7 Failure safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1.1.8 Deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.1.9 UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.2 Overview of software components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.3 Notes on start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.4 Standard/export version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.5 840Di start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.5.1 Menu command: Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
2 Hardware Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.1 Overview of hardware components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.2 MCI2 board for 840Di sl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.2.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.2.2 Interface description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
2.2.3 Module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
2.2.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
2.3 MCI board extension slot variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
2.3.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
2.3.2 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
2.3.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
2.4 Cable distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
2.5 SINUMERIK Industrial PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
2.5.1 SINUMERIK PCU 50.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
2.6 SINUMERIK operator panel fronts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
2.6.1 Operator panel front OP 012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
2.7 TCU (Thin Client Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
2.8 Floppy disk drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
2.8.1 Floppy disk drive 3.5” (USB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
2.9 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2.9.1 SITOP POWER standard 24V/10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition xi
Contents
2.10 Uninterruptible power supply (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

2.10.1 SITOP POWER DC UPS MODULE 15 . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
2.10.2 SITOP POWER ACCU MODULE 24 V DC/10 A/3,2 AH . . . . . . . . . . . 2-78
2.11 I/O module PP72/48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
2.11.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
2.11.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
2.11.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
2.11.5 Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
2.11.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
2.12 ADI4 (Analog Drive Interface for 4 Axes) . . . . . . . . . . . . . . . . . . . . . . . . 2-91
2.12.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
2.13 Diagnostic repeater for PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
2.13.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
3 Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.1.1 Operator panels and touch panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.1.2 PROFIBUS DP components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.1.3 MPI components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.1.4 PCU components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.2 Electrical design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3.2.1 MCI board and PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3.2.2 MCI board and MPI bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
3.2.3 MCI board extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
3.2.4 PCU 50.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
3.3 Overview of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
3.3.1 MCI board and MCI board extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
3.3.2 PCU50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
4 EMC and ESD Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
4.1 Interference suppression measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
4.2 ESD measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
5 Power-On and Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5.1 Preparing for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5.1.1 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5.1.2 Recommended sequence for first start-up . . . . . . . . . . . . . . . . . . . . . . . 5-108
5.2 First power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5.2.1 Basic start-up of the system software . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5.2.2 Basic start-up of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5.3 Booting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5.3.1 SRAM handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5.3.2 Start-up after battery replacement (PCU backup battery) . . . . . . . . . . 5-112
5.3.3 Start-up after replacement of the MCI board . . . . . . . . . . . . . . . . . . . . . 5-112
5.3.4 Power up after reinstallation/update of the 840Di sl software . . . . . . . 5-114
5.3.5 Start-up after replacement of the PCU or the MCI board . . . . . . . . . . 5-115
5.3.6 Start-up after importing a backup copy . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5.3.7 Start-up after power failure / Power Fail . . . . . . . . . . . . . . . . . . . . . . . . . 5-115

xii SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
Contents
5.3.8 Power-up with shutdown signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116

5.4 Service Desktop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
5.4.1 Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
5.4.2 SINUMERIK-specific applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
5.4.3 Setting the boot response for the Service Desktop . . . . . . . . . . . . . . . 5-119
5.4.4 System information after “Fatal exceptional error” . . . . . . . . . . . . . . . . 5-119
5.4.5 Starting OEM programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-119
5.4.6 User-specific HMI start-up images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120
5.4.7 HMI Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
5.4.8 SW installation/update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
5.5 Configuring the network link of PCU (LAN/WAN) . . . . . . . . . . . . . . . . . 5-123
5.6 License management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
5.6.1 License management with the Automation License Manager . . . . . . . 5-124
5.6.2 License management with SinuCom NC . . . . . . . . . . . . . . . . . . . . . . . . 5-124
6 PLC Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
6.1.1 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
6.1.2 Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
6.1.3 PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-128
6.1.4 Installing the PLC basic program library . . . . . . . . . . . . . . . . . . . . . . . . . 6-128
6.1.5 STEP 7 example projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
6.1.6 PLC user program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
6.2 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
6.2.1 Basic requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
6.2.2 External communications link: Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
6.2.3 External communications link: MPI/PROFIBUS . . . . . . . . . . . . . . . . . . 6-133
6.2.4 Local communications link: SOFTMC . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134
6.2.5 Check PLC status and communication interface . . . . . . . . . . . . . . . . . 6-134
6.2.6 First start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
6.3 Creating a SIMATIC S7 project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-137
6.3.1 Creating a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
6.3.2 Inserting station 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
6.3.3 HW-Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-139
6.3.4 Inserting the 840Di sl Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-140
6.3.5 Parameterizing the PROFIBUS interface (X101) . . . . . . . . . . . . . . . . . 6-140
6.3.6 Parameterizing the PROFIBUS interface (X102) (optional) . . . . . . . . 6-142
6.3.7 Parameterizing the MPI interface (X102) (optional) . . . . . . . . . . . . . . . 6-143
6.3.8 Parameterization of the communications processor (CP 840D sl)
(Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-143
6.3.9 Networking PG/PC and PCU (Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . 6-145
6.4 Creating a PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
6.4.1 PLC basic program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
6.4.2 PLC user program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150
6.5 Creating a PROFIBUS configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150
6.6 Creating a MPI configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150
6.7 Loading the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151
6.7.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151
6.7.2 Loading the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151

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6.7.3 Series machine start-up file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-152

6.8 Testing the PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-153
6.8.1 Start-up behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-153
6.8.2 Cyclic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-154
6.8.3 Monitor/control using the SIMATIC Manager . . . . . . . . . . . . . . . . . . . . . 6-154
6.8.4 Monitor/control using HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-155
7 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-157
7.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-157
7.1.1 Ethernet PCU connections 50.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-157
7.1.2 Determining the PCU Ethernet communication parameters . . . . . . . . 7-157
7.1.3 Checking an Ethernet connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-158
7.2 SINUMERIK 840Di sl commissioning tool: SinuCom NC . . . . . . . . . . 7-159
7.3 SINAMICS drive commissioning tool: STARTER . . . . . . . . . . . . . . . . . 7-159
7.4 External HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-160
7.5 MCP 483C IE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-161
7.5.1 Conditions for general installation and start-up . . . . . . . . . . . . . . . . . . . 7-161
7.5.2 Parameterization of the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-162
7.5.3 MCP functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-164
7.5.4 Linking to the basic PLC and user program . . . . . . . . . . . . . . . . . . . . . . 7-165
7.5.5 Input/output image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-167
8 PROFIBUS DP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-171
8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-171
8.1.1 PROFIBUS DP with Motion Control option . . . . . . . . . . . . . . . . . . . . . . 8-171
8.1.2 Message format for cyclic DP communication . . . . . . . . . . . . . . . . . . . . 8-172
8.1.3 Description of a DP cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-172
8.1.4 Networking rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-174
8.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-175
8.3 Creating a PROFIBUS configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-178
8.3.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-178
8.3.2 Inserting DP slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-179
8.3.3 Final parameterization of the isochronous DP slaves . . . . . . . . . . . . . 8-180
8.3.4 Generating system data blocks (SDB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-185
8.3.5 Loading a configuration into the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-186
8.3.6 PROFIBUS diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-186
8.4 SIMATIC I/O devices (ET200...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-187
8.5 DP slave: I/O Module PP72/48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-187
8.5.1 DMF file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-187
8.5.2 Inserting a DP slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-188
8.5.3 Setting PROFIBUS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-188
8.5.4 Setting the I/O addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-189
8.6 DP slave: MCP 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-190
8.6.1 General conditions for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-190
8.6.3 Functions of the machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . 8-193
8.6.4 Configuring the DP slave: MCP 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-195

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8.7 DP slave: MCP 483 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-204
8.7.1 Conditions for general installation and start-up . . . . . . . . . . . . . . . . . . . 8-204
8.7.3 Functions of the machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . 8-207
8.7.4 Configuring the DP slave: MCP 483 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-208
8.8 DP slave: ADI4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-217
8.8.1 Slave OM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-217
8.8.2 Inserting DP Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-217
8.9 DP slave: SINAMICSS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-218
8.9.1 SlaveOM for SINAMICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-218
8.9.2 Inserting the DP slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-218
8.9.3 Parameterizing DP slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-219
8.9.4 Dependencies of PROFIBUS DP communication . . . . . . . . . . . . . . . . 8-223
8.10 DP slave: SIMODRIVE drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-226
8.10.1 SlaveOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-226
8.10.2 Inserting the DP slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-226
8.10.3 Parameterizing DP slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-227
8.10.4 Dependencies of PROFIBUS DP communication . . . . . . . . . . . . . . . . 8-231
8.11 DP slave: Diagnostic repeater for PROFIBUS DP . . . . . . . . . . . . . . . . 8-233
8.11.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-233
8.11.2 Application range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-234
8.11.3 Connection and start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-234
9 MPI Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-235
9.1 Special points to be noted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-235
9.2 Networking rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-235
9.3 Global data communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-237
9.4 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-238
9.5 Creating a MPI configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-239
9.5.1 Precondition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-239
9.5.2 Inserting the default configuration into the S7 project . . . . . . . . . . . . . 9-239
9.5.3 Adapting organization block OB100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-240
9.5.4 Adapting organization block OB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-240
9.5.5 Loading a configuration into the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-240
9.6 Default configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-241
9.6.1 GD circle parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-241
9.6.2 GD identifiers and MPI addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-241
9.6.3 Recommended MPI addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-242
9.7 Handheld unit (B-MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-243
9.7.1 Conditions for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-243
9.7.2 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-244
9.7.3 MPI parameters of the HHU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-245
9.7.4 MPI parameterization of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-246
9.7.5 GD circle parameters of the HHU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-248
9.7.6 GD circle parameterization of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . 9-249

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9.7.7 Example: Connecting a HHU to SINUMERIK 840Di sl . . . . . . . . . . . . 9-249

9.7.8 Plugging and unplugging handheld unit during operation . . . . . . . . . . 9-251
9.8 HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-252
9.8.1 Conditions for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-252
9.8.2 Parameter assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-252
9.8.3 Default languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-254
10 Drive Start-Up (SINAMICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-257
10.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-257
10.1.1 Basic requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-257
10.1.2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-258
10.2 ONLINE start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-259
10.2.1 Creating a new project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-260
10.2.2 Drive unit: Acquiring the component topology and configuring
automatically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-263
10.2.3 Drive: Configuring the motors and encoder . . . . . . . . . . . . . . . . . . . . . . 10-266
10.2.4 Control Unit: Selecting the PROFIBUS message frame . . . . . . . . . . . 10-268
10.2.5 Supply: Selecting the PROFIBUS message frame . . . . . . . . . . . . . . . . 10-268
10.2.6 Drive unit: Checking the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 10-269
10.2.7 Drive unit: Configuring the PROFIBUS message frame . . . . . . . . . . . 10-271
10.2.8 Control Unit: Error acknowledgement(BICO interconnection) . . . . . . . 10-272
10.2.9 Supply: Error acknowledgement (BICO interconnection) . . . . . . . . . . 10-273
10.2.10 Supply: Enable (BICO interconnection) . . . . . . . . . . . . . . . . . . . . . . . . . 10-274
10.2.11 Supply: Readiness to start (BICO interconnection) . . . . . . . . . . . . . . . 10-275
10.2.12 Supply: Operational readiness (BICO interconnection) . . . . . . . . . . . . 10-277
10.2.13 Drive: Enable OFF3 (BICO interconnection) . . . . . . . . . . . . . . . . . . . . . 10-279
10.2.14 Drive unit: Saving parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-280
10.2.15 Drive: Running the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-280
10.2.16 Settings of specific parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-281
10.3 Example for systems with more than 6 drives . . . . . . . . . . . . . . . . . . . . 10-282
10.3.1 Set-up and basic start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-282
10.3.2 Drives of Control Unit 2: additional BICO interconnection . . . . . . . . . . 10-283
10.4 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-286
10.4.1 Drive unit: Firmware upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-286
11 Drive Start-Up (SIMODRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-289
11.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI . . . . . . . . . . . . 11-289
11.1.1 Start-up variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-289
11.1.2 Preconditions for an online connection . . . . . . . . . . . . . . . . . . . . . . . . . . 11-291
11.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal / E) . . . . . 11-291
11.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA) . . . . 11-293
11.1.5 Setting the MPI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-294
11.1.6 Setting the routing information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-295
11.1.7 Starting online operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-296
11.2 Installing SimoCom U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-297
12 NCK Start-Up with HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-299
12.1 General procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-299
12.2 Machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-299
12.2.1 Display and input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-301

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12.2.2 Protection levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-302

12.2.3 Machine data display filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-305
12.3 System data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-306
12.3.1 Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-306
12.3.2 Normalization of phys. quantities of machine and setting data . . . . . . 12-308
12.3.3 Changing scaling machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-310
12.3.4 Loading default machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-311
12.3.5 Switching over the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . 12-312
12.3.6 Traversing ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-314
12.3.7 Positioning accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-314
12.3.8 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-315
12.3.9 Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-319
12.4 Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-320
12.4.1 DRAM memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-321
12.4.2 SRAM memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-322
12.5 Axes and spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-324
12.5.1 Axis configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-324
12.5.2 Axis names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-327
12.5.3 Drive configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-328
12.5.4 Setpoint/actual value channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-332
12.5.5 Incremental measuring system settings . . . . . . . . . . . . . . . . . . . . . . . . . 12-335
12.5.6 Parameterization of absolute measuring systems . . . . . . . . . . . . . . . . 12-338
12.5.7 Parameterization of a 2nd measuring system with ADI4 . . . . . . . . . . . 12-340
12.5.8 DSC (Dynamic Servo Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-343
12.5.9 Drive optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-344
12.5.10 Rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-345
12.5.11 Positioning axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-346
12.5.12 Indexing axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-347
12.5.13 Parameter sets of axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-348
12.5.14 Position controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-350
12.5.15 Speed setpoint matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-354
12.5.16 Drift compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-357
12.5.17 Velocity matching (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-358
12.5.18 Monitoring functions (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-361
12.5.19 Referencing an axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-369
12.5.20 Spindle basic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-380
12.5.21 Setpoint/actual value channels of spindle . . . . . . . . . . . . . . . . . . . . . . . 12-383
12.5.22 Gear stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-383
12.5.23 Measuring systems of spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-384
12.5.24 Speeds and setpoint adjustment for spindle . . . . . . . . . . . . . . . . . . . . . 12-386
12.5.25 Position spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-388
12.5.26 Synchronizing spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-389
12.5.27 Spindle monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-391
12.5.28 Spindle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-394
12.6 Digital and analog I/O devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-397
12.6.1 Parameterization of the number of inputs/outputs used . . . . . . . . . . . 12-397
12.6.2 Assignment of inputs/outputs to the signal modules . . . . . . . . . . . . . . 12-398
12.6.3 System variable $A_...[n] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-399
12.6.4 Digital input/output bytes and system variables . . . . . . . . . . . . . . . . . . 12-400
12.6.5 Dynamic response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-401
12.6.6 Configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-402

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12.7 Loadable compile cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-407

12.7.1 Loading a compile cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-408
12.7.2 Interface version compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-408
12.7.3 Software version of a compile cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-409
12.7.4 Supplementary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-410
12.7.5 Activating and licensing technology functions . . . . . . . . . . . . . . . . . . . . 12-410
12.7.6 Data descriptions (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-411
12.8 PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-412
12.8.1 Setting the parameters for the shut-down behavior . . . . . . . . . . . . . . . 12-412
12.8.2 Data descriptions (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-412
12.9 Initial settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-413
12.10 NCK/PLC diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-414
12.10.1 Menu: Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-414
12.10.2 Menu: Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-418
13 Alarm and Message Texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-421
13.1 Alarm and message texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-421
13.1.1 Configuration file MBDDE.INI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-421
13.1.2 Standard text files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-422
13.1.3 User text files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-422
13.1.4 Syntax for alarm text files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-424
13.1.5 Setting the alarm log properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-426
14 Axis/Spindle Dry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-429
14.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-429
14.1.1 Drives: SINAMICS S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-429
14.1.2 Drives: SIMODRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-429
14.1.3 NCK/PLC interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-430
14.2 Axis dry run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-431
14.3 Spindle dry run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-432
15 Drive Optimization with HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-435
15.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-435
15.2 Measuring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-436
15.3 Miscellaneous functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-438
15.4 Frequency response measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-440
15.4.1 Measurement of current control loop . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-441
15.4.2 Speed control loop measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-442
15.4.3 Position control measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-445
15.5 Graphic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-448
15.6 Trace function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-451
15.6.1 Trace function properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-451
15.6.2 Main menu and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-452
15.6.3 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-453
15.6.4 Performing the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-455
15.6.5 Display function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-456
15.7 File function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-459

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15.8 Print graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-461

15.9 Automatic controller setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-464
15.9.1 Drives: SINAMICS S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-464
15.9.2 Drives: SIMODRIVE 611 universal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-465
16 User Data Backup/Series Machine Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-467
16.1 Explanations on data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-467
16.2 Creating a series commissioning file . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-468
16.2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-468
16.2.2 HMI Advanced (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-470
16.2.3 SinuCom NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-471
16.3 Considerations when saving PLC data . . . . . . . . . . . . . . . . . . . . . . . . . . 16-472
16.4 Reading in a series machine start-up file with HMI Advanced . . . . . . 16-473
16.5 SINAMICS S120 series machine start-up with STARTER . . . . . . . . . 16-474
17 Software Installation/Update and Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . 17-475
17.1 PTP network connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-475
17.1.1 Establishing a network connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-475
17.1.2 Configuring the external computer (Windows NT) . . . . . . . . . . . . . . . . 17-476
17.1.3 Configuring the external computer (Windows XP) . . . . . . . . . . . . . . . . 17-478
17.1.4 Configuring the PCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-479
17.2 Partitioning of the PCU hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-480
17.3 Software installation/update (Windows) . . . . . . . . . . . . . . . . . . . . . . . . . 17-481
17.4 Restoring the as-delivered state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-482
17.4.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-482
17.4.2 Restoring the partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-482
17.4.3 Installation of the SINUMERIK 840Di sl applications . . . . . . . . . . . . . . 17-483
18 License Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-485
18.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-485
18.1.1 Important terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-485
18.1.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-486
18.1.3 Web License Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-486
18.1.4 Automation License Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-487
18.1.5 License database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-487
18.1.6 MCI board and hardware serial number . . . . . . . . . . . . . . . . . . . . . . . . . 18-488
18.1.7 SINUMERIK License Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-489
18.1.8 Browser settings for using the A&D Mall . . . . . . . . . . . . . . . . . . . . . . . . 18-490
18.1.9 Proxy settings for the download of license information . . . . . . . . . . . . 18-491
18.2 Assigning via Web License Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-492
18.2.1 You can execute an assignment via direct access as follows . . . . . . . 18-492
18.2.2 You can execute an assignment via customer login as follows . . . . . 18-493
18.3 Assigning via Automation License Manager . . . . . . . . . . . . . . . . . . . . . 18-495
18.3.1 Function overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-495
18.3.2 Installing the Automation License Manager . . . . . . . . . . . . . . . . . . . . . . 18-496
18.3.3 Enabling/disabling SINUMERIK plug-ins . . . . . . . . . . . . . . . . . . . . . . . . 18-497
18.3.4 Assigning parameters to the TCP/IP communication with a control
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-498

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18.3.5 How to refresh the navigation view: “Manage” . . . . . . . . . . . . . . . . . . . 18-501

18.3.6 Displaying the license information of a piece of hardware . . . . . . . . . . 18-501
18.3.7 Creating a control image (offline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-502
18.3.8 Performing a license requirement alignment for a piece of hardware 18-503
18.3.9 Transferring license information for a control image (offline) to a control
system (online) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-505
19 840Di sl-specific Data and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-507
19.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-507
19.1.1 840Di sl-specific interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-507
19.1.2 Interface signals not supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-507
19.2 Expanded message frame configuration/evaluation of internal drive
variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-509
19.2.1 Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-509
19.2.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-511
19.2.3 Configuring: SINAMICS S120 and SIEMENS message frame 116 . . 19-512
19.2.4 Configuring: SINAMICS S120 and expanded message frame
configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-512
19.2.5 Configuring: SIMODRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-516
19.2.6 Boundary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-520
19.2.7 Data descriptions (MD, system variable) . . . . . . . . . . . . . . . . . . . . . . . . 19-521
19.2.8 Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-522
19.3 Travel to fixed stop with high-resolution torque reduction . . . . . . . . . . 19-523
19.3.1 Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-523
19.3.2 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-524
19.3.3 Parameterization: SINAMICS S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-524
19.3.4 Parameterization: SIMODRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-524
19.3.5 Parameterization: External drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-525
19.3.6 Parameter assignment: SINUMERIK 840Di sl NCK . . . . . . . . . . . . . . . 19-525
19.3.7 Boundary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-526
19.3.8 Data description (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-527
19.3.9 Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-527
A Small SINAMICS Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-529
B Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-533
C References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-539
D EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-541
E Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-543

xx SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
General Information on the SINUMERIK
840Di sl 1
1.1 Overview of SINUMERIK 840Di sl
With the SINUMERIK 840Di sl, Siemens can provide a complete PC-integrated
control that controls the drive units and I/Os through the standard fieldbus PRO-
FIBUS DP with Motion Control functionality and therefore permits a distributed
design of the overall system. It therefore constitutes the basis for PC-based
automation solutions and is generally designed especially for applications with
the following requirements:
S Distributed automation solutions in the fields of PLC I/Os and drives.
S Fully PC-integrated control, owing to increased integratability in the target or
current automation environment.
Operator panel front

(e.g. OP012)
USB Networking (TCP/IP)

(standard I/O) (e.g. TCU, programming device)
PCU 50.3 Networking (TCP/IP)

(e.g. company network)
MCI board extension

Measuring pulses
(option)
Handwheels
MCI board
Fast I/Os
PROFIBUS DP (2) (12 MBaud) PROFIBUS DP (1) (12 MBaud)

diagnostic repeater
I/O modules
SIMATIC DP
ADI4
PROFIBUS-MCP
(machine control panel)
SINAMICS S120
PROFIBUS DP
PP72/48
ET 200
Analog
drives
Fig. 1-1 System overview of SINUMERIK 840Di sl

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition 1-21
1 General information on the SINUMERIK 840Di sl 03/2006
1.1.1 System components
This manual refers to the following system components:

System components Version
SINUMERIK 840Di sl system software SW 1.0
PCU 50.3-C: 1.5 GHz, 512 MB DRAM
SINUMERIK Industrial PC
PCU 50.3-P: 2.0 GHz, 1024 MB DRAM
PC operating system Windows XP ProEmbSys
MCI board MCI2 board for 840Di sl
Notice
It is not possible to combine the named system components with older ver-
sions.
1.1.2 System software packages and quantity frameworks
System software The following system software packages are available for SINUMERIK 840Di sl:
packages
S 6 axes system software
S 20 axes system software
Quantity frame- The system software packages are each designed for the following quantities:
work
6 axes 20 axes
Basic configu- Maximum Basic configu-
Maximum
ration ration
Axes 3 6 5 20
Channels 1 2 1 10
Mode groups 1 2 1 10
Channels per 1 2 1
10
mode group
Basic configuration: Default number of available components
Maximum: Maximum possible number of components with additional options
1.1.3 Hardware components
The hardware basis for the SINUMERIK 840Di sl 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).
PCU The SINUMERIK 840Di sl is available with the following PCU 50.3 versions,
each with 24 V power supply:
S PCU 50.3-C: 1.5 GHz, 512 MB SDRAM
S PCU 50.3-P: 2.0 GHz, 1024 MB SDRAM

1-22 SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
03/2006 1 General information on the SINUMERIK 840Di sl
PCU interfaces The PCU 50.3 features interfaces to connect the SINUMERIK operator panel
fronts (OP 0xx) as well as standard PC interfaces for connecting, e.g., monitor,
keyboard, mouse, and Ethernet connection.
PCU slot The PCU 50.3 has the following slots:

– 1 x PCI (length: max. 175 mm, occupied with option MCI board exten-
sion and MCI board extension slot variant)
– 1 x PCI (length: max. 265 mm, occupied by the MCI board)
MCI2 board The MCI2 board, further referred to as the MCI board is a short PCI plug-in card
with integrated SIMATIC S7 compatible CPU:
S PLC317-2 DP
as a routing-capable DP Master. The MCI board has the following external inter-
faces:
– PROFIBUS DP with Motion Control Functionality (Master)
– MPI (Multi-Point Interface) / PROFIBUS-DP (Master/Slave)
– MCI board extension (option)
PROFIBUS DP in- This interface (X101) can be used to connect drives, distributed ext. I/Os, ma-
terface X101 chine control panels, programming units, etc. via PROFIBUS DP with motion
control capability (clocked and isochronous data exchange between the DP
master and DP slaves) to the SINUMERIK 840Di sl. Both the PLC and the NC
have direct access to this PROFIBUS interface.
PROFIBUS DP Unlike the PROFIBUS DP interface (X101), interface (X102) can only be ac-
X102 interface cessed via the PLC. As a result, no drives and no NC I/Os can be operated via
this interface.
The interface (X102) can also be operated as an MPI interface.
MCI board exten- A maximum of four fast digital I/Os, two sensing probes and two handwheels
sion slot variation each can be connected using the optional MCI board extension slot variant.
(option) Either differential or TTL handwheels can be operated.
The module is inserted into a slot in the PCU and is connected to the MCI board
via a ribbon cable.
Digital drives SINUMERIK 840Di sl is available with the components from the new
SINAMICS range of drives offering the following characteristics:
– SINAMICS S120
The drive components from the SIMODRIVE range of drives offering the follow-
ing characteristics can also be used:
– SIMODRIVE 611 universal and universal E
with option module MotionControl with PROFIBUS DP

– SIMODRIVE POSMO CD/CA

– SIMODRIVE POSMO SI
– SIMODRIVE POSMO A (not suitable for interpolatory procedures)
Note
SINAMICS S120 and SIMODRIVE drives cannot be operated in parallel on a
SINUMERIK 840Di sl.
Analog drives To operate drives with an analog setpoint interface via PROFIBUS, the following
interface module is available:
– ADI4 (Analog Drives Interface for 4 Axes)
I/Os For use as distributed I/Os, the module range SIMATIC DP ET 200 (for connec-
tion conditions, see SIMATIC documentation) and the I/O module PP 72/48 are
available.
Operator panel You can select one of the operator panel fronts from the SINUMERIK range (OP
front 010, OP 010C, OP 010S, OP 012, OP 012T, OP 015, OP 015A, TP 015A) as
an operator component.
TCU A TCU (Thin Client Unit) permits distributed connection of an operator panel to
the PCU. The TCU and PCU communicate via the Ethernet.
1.1.4 Software components
The SINUMERIK 840Di sl is based on the following software components:
Windows XP SINUMERIK 840Di sl runs on the Windows XP ProEmbSys operating system

with Service Pack 2.
Windows XP is the platform on which all applications, such as the individual
user interfaces of the HMI modular system and the start-up tools run.
As is generally known, Windows XP does not have full real-time capability. We
call this soft real time. So SIEMENS has developed a procedure that allows
operation of NC system software in hard real time without making it necessary
to modify Windows XP (see Subsection 1.1.5, Page 1-26).
NC system soft- The NC system software mostly has the same functionality as the SINUMERIK
ware 840D. It comprises both simple Motion Control processes (positioning and linear
interpolation) and complex automation tasks of the type found on machining
centers, handling and mounting, machine tools, and machine tool-related ap-
plications.

NCK The NCK (Numerik Control Kernel) is part of the NC system software that real-
izes the real-time capability of the SINUMERIK 840Di sl.
The NCK is characterized by the following features:
– The NCK is automatically started when Windows powers up.
– The NCK runs cyclically in the background.
– The current status of the NCK is displayed on the SINUMERIK 840Di sl
standard user interface 840Di start-up:
Menu command Window > Diagnostics > NC/PLC
– The NCK is automatically ended when you exit Windows XP.
– When the NCK is ended, it writes the remanent SRAM data from NCK
and PLC to the hard disk of the PCU as a backup copy.
PLC system soft- The PLC system software, like the NC system software, largely has the same
ware functionality as the SINUMERIK 840D.
SinuCom NC SinuCom NC is a Windows-based tool for starting up the SINUMERIK 840Di sl

NC offering the possibilities for the:
– interactive parameterization of the NC
– option management and license management
– management of series machine start-up files
840Di start-up The Windows-based user interface 840Di start-up (see Section 1.5, Page 1-38)
offers basic operation functionality to allow the operator to become familiar with
the SINUMERIK 840Di sl.
840Di start-up is part of the scope of supply of a SINUMERIK 840Di sl and is
already installed on the hard disk of the PCU.
Optional HMI com- The following components of the SINUMERIK HMI modular system can be used
ponents optionally:
S SINUMERIK HMI Advanced

HMI Advanced is the SINUMERIK standard user interface intended espe-
cially for machine tools.
S SIMATIC Protool/Pro and Protool/Pro option SINUMERIK

SIMATIC Protool/Pro and Protool/Pro Option SINUMERIK are configuring
packages for creating technology-specific user interfaces.
The ProTool/Pro runtime system is required to run a configured user inter-

face.
S SINUMERIK HMI Programming Package

The HMI Programming Package can be used to integrate OEM high-level
language applications using standardized interfaces (COM/OPC). The OEM
obtains as much flexibility as possible for developing user interfaces using
standard development tools such as Visual C++ and VB.

The HMI Programming Package basically contains interface descriptions

and corresponding example applications. Detailed information on the OPC
interface can be called from the Internet at the address of OPC Foundation
(http://www.opcfoundation.org.).
Note
For a detailed list of the installed software components or the ones required to
prepare for installation, please refer to Section 1.2, Page 1-33.
1.1.5 Real-time properties
Windows XP is not an operating system designed for hard real-time require-

ments. Hard real-time requirements mean the operating system will respond to
an external event within a defined time frame of a few µseconds.
The NC system software is therefore integrated into Windows XP as a “Kernel
mode driver”. This means it has its own integrated real-time system that runs
concurrently with Windows XP to ensure the conditions for real-time processing
are met.
Real-time Real-time violations occur when unsuitable PC components block interrupt

violations processing for too long, stopping the NC system software from being activated
at the specified time.
Inappropriate PC components are drivers or hardware extensions that have an
adverse effect on the real-time behavior due to overly long interrupt disable
times or PCI bus disables in PCI bus mastering.
With real-time violations exceeding 200 µs, we cannot guarantee that the NC
system software will operate correctly. The system will respond appropriately for
the magnitude of the real-time violation:
– Display of an error message
– Alarm with axis stop from the NC
– Alarm and drive-independent axis stop
The real-time response can be monitored in the NCK latency displays in the
system diagnostics of the 840Di Start-up (see Section 1.5, Page 1-38) or the
NC/PLC diagnostics of HMI Advanced (see Section 12.10, Page 12-414).
Screen resolution The following points must be taken into account for screen resolution and depth
and depth of color of color settings on the PCU.
S Screen resolution
The standard screen resolution setting depends on the optimized value that
was set for the operator panel. This value was defined for technical reasons
and should be adhered to.

S Color depth
The default color depth setting is 65536 colors. Higher values can, in certain
circumstances, increase the CPU time used by Windows XP and occasion-
ally also by the real-time operating system.
Testing or If it is necessary to test the screen resolution or switch to a different resolution

Switchover and/or color depth, the NCK must be terminated first. Otherwise a malfunction
may occur in the real-time response.
Notice
Screen savers that modify the screen resolution when activated must not be
used in conjunction with SINUMERIK 840Di sl.
Terminating the The NCK is integrated in Windows XP as a “SINUMERIK-NC” service. This ser-
NCK vice must be started and stopped manually in the service dialog box.
Windows Start menu: Start > Programs > Administrative Tools > Services >
“SINUMERIK-NC”
Warning
! The NCK must be stopped before testing/switching the screen resolution
and/or color depth on the PCU and started again explicitly after testing/switch-
ing using the Windows XP service “SINUMERIK-NC”. Otherwise a malfunction
may occur in the real-time response.
1.1.6 System integrity

To offer high quality and wide functionality of the entire system, SINUMERIK
840Di sl comes completely configured and ready to operate.
For this purpose, the system components used are subject to a certification
procedure with Siemens as the system manufacturer. This is to certify and doc-
ument compliance with real-time capability of the whole configuration.
If PC components (hardware or software) are modified or expanded by a third
party, compliance with product features cannot be guaranteed. These are the
sole responsibility of the OEMs or the user who has made the modifications.
The effect of the changes to the system software can be read on the user inter-
face of the “840Di Startup” or “HMI Advanced” start-up tool (see Subsection
12.10.1, Page 12-414). It graphically displays whether the installed hardware or
software violates the real-time conditions.

1.1.7 Failure safety
Fatal exception If Windows XP detects a fatal exception error during the operation of the NC
error (blue screen) system software, the following steps are taken:
S Windows XP stops.
S An error message appears on screen.
S NC and PLC continues to operate normally.
S The NC signals the fatal exception error detected to the PLC via the “PC OS
fault” interface signal.
Depending on the current machining situation, the PLC user program can either
continue or step machining.
After completion of machining, the PLC user program can request a shutdown
of the PC by sending the “PC shutdown” interface signal.
The “PC shutdown” interface signal causes the following actions:
– Retentive NC and PLC data are stored
– NC and PLC are closed down
– The Windows XP “Blue Screen” is displayed
– (Optional) The PCU reboots
The behavior of Windows XP in the event of a fatal exception error (Blue
Screen) can be configured via the Control Panel: Windows Start menu:
Start > Settings > Control Panel > System
Note
For a brief description of the “PC OS fault” and “PC shutdown” interface
signals, please refer to Subsection 19.1.1, Page 19-507.
Notice
The “PC shutdown” interface signal must be reset in the organization block
OB100 (cold restart) of the PLC.
Power failure A power failure lasting more than 5 msecs is detected by the POWER FAIL
functionality of the SINUMERIK 840Di sl as a fault scenario and the following
actions are initiated:
– The background lighting of the operator panel display is switched off
– NC and PLC are closed down properly
– The NC and PLC user data are saved in the SRAM of the MCI board
The battery-backed user data are available again immediately the next time the
SINUMERIK 840Di sl is booted. The SINUMERIK 840Di sl is therefore ready to
use again immediately, without data loss.
If the power supply recovers before final PCU shutdown, the following message
box is displayed:

SINUMERIK 840Di sl NCK/PLC
Interrupt: Power-Fail detected, NCK/PLC restart with OK.
Notice
1. Supply voltage
A supply voltage of the PCU of at least 24 V is required to ensure consis-
tency of the NC and PLC user data.
References /BH/ Operator Components, Manual
Chapter: PCU 50.3
2. UPS system
The internal power backup time after a power failure is not long enough for
Windows NT to shut down correctly. To remedy this, we recommend using
an uninterruptible power system (see Subsection 1.1.9, Page 1-31).
3. Replacing the MCI board or PCU battery
When Windows XP is shut down correctly, the current NCK and PLC user
data are saved to the SRAM of the MCI board and to the PCU’s hard disk. If
the MCI board or PCU battery is replaced after a power failure, this will re-
sult in a data loss of the battery-backed user data on the SRAM of the MCI
board. How to proceed further: see Subsection 5.3.3, Page 5-112.
Temperature The SINUMERIK 840Di sl monitors three different temperatures for their respec-
monitor tive thresholds:
1. Housing temperature
2. CPU module temperature
3. CPU temperature
Error response
S Interrupt: “2110 NCK temperature alarm”

S Logbook entry: “Alarm: Critical temperature”
Cause of errors/error handling
One of the 3 monitored temperatures has reached or exceeded its threshold
value. A temperature change of at least 3°C below the threshold is required for
the alarm to reset.
If the temperature alarm occurs, the user and/or the machine manufacturer
(PLC user program) must decide whether to interrupt machining and end and
shut down the SINUMERIK 840Di sl.

1.1.8 Deactivation
Windows XP To ensure safe operation of the SINUMERIK 840Di sl, Windows XP must be
shut down correctly before the PCU is switched off.
Note
Windows XP is shut down correctly as follows:
– Windows XP start bar: Start > Shutdown
– PLC interface signal: “PC shutdown”, see Subsection 19.1.1, Page
19-507
Failure to shut down Windows XP correctly can damage the Windows XP instal-
lation and prevent the SINUMERIK 840Di sl from operating.
NC and PLC On correct shutdown of Windows XP the following occurs:

– The SINUMERIK 840Di sl components NC and PLC are terminated cor-
rectly
– The NC and PLC user data in the SRAM of the MCI board and on the
hard disk of the PCU are backed up.
If the PCU is switched off without first correctly shutting down Windows XP, the
SINUMERIK 840Di sl’s POWER FAIL functionality:
– ends the NC and PLC correctly;
– saves the NC and PLC user data in the SRAM of the MCI board.
The NC and PLC user data cannot be backed up on the hard disk of the PCU.
Notice
If you switch off the PCU without first having correctly shut down Windows XP,
please observe the following:
1. Supply voltage
A supply voltage of the PCU of at least 24 V is required to ensure consis-
tency of the NC and PLC user data.
References /BH/ Operator Components, Manual
Chapter: PCU 50.3
2. UPS system
The internal power backup time after switch-off is not long enough for Win-
dows NT to shut down correctly. To remedy this, we recommend using an
uninterruptible power system (see Subsection 1.1.9, Page 1-31).
3. Replacing the MCI board or PCU battery
When Windows XP is shut down correctly, the current NCK and PLC user
data are saved to the SRAM of the MCI board and to the PCU’s hard disk. If
the MCI board or the PCU battery is replaced after the abnormal shutdown
of Windows XP, this will result in loss of the battery-backed user data on the
SRAM of the MCI board. How to proceed further: see Subsection 5.3.3,
Page 5-112.

1.1.9 UPS system
Physical SRAM The PCU features POWER FAIL detection that, in conjunction with the NC sys-
tem software, ensures that the user data are backed up in the SRAM of the MCI
board on a PCU power failure or power-off without Windows XP first having
been shut down correctly.
The internal power backup time is not long enough for Windows XP to shut
down correctly.
This can be avoided by using a UPS, e.g. SITOP POWER DC UPS MODULE
15 (see Section 2.10, Page 2-76). The UPS also backs up the power supply of
the PCU for a settable duration or until a set battery voltage limit has been
reached.
This gives the user time to correctly shut down Windows XP manually, or per-
mits automatic shutdown via a status signal from the UPS to the PLC, which
then passes the “PC shutdown” interface signal to the NC.
Connection The above UPS has the following connection options to signal the current sta-
options tus to the SINUMERIK 840Di sl:
Table 1-1 Connection options of the UPS system
Connection Signal to Note

1) UPS –> PCU: Windows XP The UPS functionality is configured: see Con-
USB connection figuration below.
Advantage: also works when the PLC user pro-
gram is not active.
Disadvantage: does not work in the event of
serious exceptions from Windows XP (BlueS-
creen)
2) Signal terminals via PLC The UPS functionality is configured using the
free interconnection –> PLC user program.
S7 I/O inputs Advantage: also works in the event of a fatal
exception error of Windows XP (BlueScreen)
Disadvantage: PLC user program must be ac-
tive
3) Signal terminals via NC The UPS functionality is configured using
free interconnection –> menu: Settings in HMI Advanced (see Subsec-
MCI board extension in- tion 12.10.2, Page 12-418).
puts Advantage: also works in the event of a fatal
exception error of Windows XP (BlueScreen)
and when the PLC user program is not active.
Preconditions: MCI board extension (option)
Note
re 3) For information on the boot response of the SINUMERIK 840Di sl with pending
shutdown signal, see Subsection 5.3.8, Page 5-116.
Notice
One of the following connection variants must be used for full back-up protec-
tion:
– Version 1: Connection 1) and 2)
– Version 2: Connection 3)

Line infeed SITOP POWER SITOP POWER DC UPS module15 with

110/220VAC, 60/50Hz standard 24V/10A SITOP POWER ACCU MODULE
SIEMENS
2) Free wiring
ET 200 I/Os
SINUMERIK 840Di sl
1) USB connection
3) Free wiring
PROFIBUS-DP
1)
2)
1) MCI board
2) MCI board extension (option)
Fig. 1-2 Possible connections: UPS
Configuring The UPS functionality can be configured in two ways:
S When using SITOP POWER DC UPS MODULE 15 (see Section 2.10, Page
2-76) with a special software tool.
Download: www.siemens.de/sitop > Further topics: Download Software
DC UPS 15 A
S With Windows XP standard tools.

Start bar: Start > Settings > Control Panel > Power Options > tab card:
UPS
Notice
If the SINUMERIK user interface HMI Advanced (option) is installed on the
PCU, the following application must be executed with the UPS software:
F:\mmc2\hmiexit.exe to end HMI Advanced before the PCU is shut down.

1.2 Overview of software components

The software components listed below are part of the SINUMERIK 840Di sl sys-
tem software. The first time the PCU is booted, all the software components
required to operate the SINUMERIK 840Di sl are automatically installed. Other
software components including engineering tools or SIMATIC S7 add-on soft-
ware are also available for installation on the PCU or an external computer.
Note
See Subsection 5.4.7, Page 5-121 for information on how to determine the
installation path of the SINUMERIK 840Di sl system software (CD path).
Before installing a software component, please read the information (*.txt, *.rtf,
*.wri) for each application.
Basic software The basic software essentially comprises the following components:
S 840Di sl basic software (installed)
– NCK-specific real-time drivers
– 840Di start-up
S PLC system software (installed)
S NCK system software (installed)
S PCU basic software (installed)
– Windows XP Pro with SP2, English version
– Internet Explorer 6, English version
– HMI Explorer
– MPI driver
– Norton Ghostt
– Norton GhostWalkert
– ServiceCenter under Windows PE
– PCU-specific drivers
– TCU Support
S HMI basic software (installed)
– HMI-specific display and communications drivers
Engineering Tools The Engineering Tools include applications for the start-up of the
SINUMERIK 840Di sl NC and SIMODRIVE drives:
S SinuCom NC (installed)
Commissioning tool for SINUMERIK 840Di sl NC
S SIMODRIVE 611 universal tool box

Contents:
– PLC Parameterization Toolbox
Various files for assigning parameters to an S7 configuration with
SIMODRIVE drives (611U, POSMO SI, CD, CA) and PROFIdrive
communication (see readme.txt)
(example files: <CD path>\611utb\toolbox\<version>\<file>)

– SimoCom U
Commissioning tool for SIMODRIVE 611 universal/E and SIMO-
DRIVE POSMO SI, CD/CA drives
(installed and for installation: <CD path>\611utb\SimoComU\Setup.exe)
– SIMODRIVE 611 universal drive firmware
(firmware file: <CD path>\611utb\Sys611U\<version>\611u.ufw)
– SIMODRIVE 611 universal option module: “Motion Control with PRO-
FIBUS DP” firmware
(firmware file: <CD path>\611utb\dpc31\<version>\v1sl.ufw)
– SIMODRIVE POSMO SI, CD/CA drive firmware
(firmware file: <CD path>\611utb\SysPosmo\<version>\posmo.ufw)
Note
SINAMICS drives
The commissioning tool: STARTER is not included in the SINUMERIK 840Di
scope of supply. The STARTER must be purchased separately.
Literature:
Catalog: NC 61 > SINAMICS S120 Drive System
SIMATIC S7 The SIMATIC S7 add-on software contains sample programs and applications:
add-on software
S PLC Toolbox
The PLC Toolbox contains the following components:
– PLC basic program
– SINUMERIK Add-On for STEP 7
e.g. SlaveOM for SINUMERIK 840Di sl, GSD file for PROFIBUS MCP
– NC variable selector
– PLC Symbol generator
(installation software: <CD path>\installs\add_on\plc_tb\setup.exe)
S GSD file for I/O modules PP72/48

Device master file with the required information in ASCII format required for
integration of the I/O module PP72/48 into a SIMATIC project as DP slave.
(DMF file: <CD path>\support\siem80a2.gsd)
S PLC application example

Sample application of a SIMATIC S7 project for SINUMERIK 840Di sl with
PROFIBUS machine control panel MCP 483 or MCP 310.
(ZIP file: <CD path>\support\840dismp\840disl_smpl.zip)
(archive file: <CD path>\support\840dismp\840disl_smpl.arc)
Note
The PLC Toolbox should be installed on the PG/PC on which the SIMATIC
STEP 7 is already installed.

1.3 Notes on start-up

This SINUMERIK 840Di sl Manual describes the basic start-up of the following
components:
S SINUMERIK 840Di sl NC and PLC

S SINAMICS S120 drives
S Ethernet communication
S MPI bus and components
S PROFIBUS DP and DP components
Notice
We recommend performing start-up of the SINUMERIK 840Di sl according to
the sequence in which the chapters of this manual are laid out.
Software To start up the SINUMERIK 840Di sl, the following software is required (part of a
SINUMERIK 840Di sl):
S NCK start-up:
– 840Di start-up
– SinuCom NC
S PLC start-up, including MPI and PROFIBUS communication:

– SlaveOM for SIMODRIVE drives
S SIMODRIVE drive start-up

– SimoCom U
Additional To start up the SINUMERIK 840Di sl, the following software is needed (not part
software of a SINUMERIK 840Di sl):
S PLC start-up, including MPI and PROFIBUS DP communication:

– SIMATIC Manager STEP 7: as from Version 5.3, Service Pack 2
– SlaveOM for SINAMICS drives (part of STARTER)
S SINAMICS drive start-up

– STARTER
Additional The following hardware components are required for start-up:

hardware
S a programming device with MPI/PROFIBUS interface, e.g., PG740:
– Creation of the SIMATIC S7 project for start-up of the PLC, as well as the
MPI and PROFIBUS communication

– Installation of additional software on the PCU

To install software on the PCU see Chapter 18, Page 18-485.
S Communications link: PG/PC with NC, PLC and drives

– Ethernet cable
– MPI/PROFIBUS cable
Note
No programming device is required in the following cases:
– SIMATIC Manager STEP7 is installed on the SINUMERIK 840Di sl PCU
– A PG/PC is used to install additional software
To install software on the PCU, see Chapter 18, Page 17-475.
Documentation The following documentation is required for start-up:
S /BH/ Operator Components Manual

– Operator panel fronts
– PCU 50.3
– Machine control panels
– Operator panel, handheld terminal HT8
Depending on the NC and PLC functions used, the relevant Descriptions of
Functions:
S /FB/ Description of Functions – Basic Machine

S /FB/ Description of Functions – Extended Functions
S /FB/ Description of Functions – Special Functions
S /LIS/ Lists
– Function overview
– Machine, Setting Data and Variables
– Interface Signals and PLC Blocks
S /DA/ Diagnostics Guide, Contents:

– Interrupts
Drive start-up:
S SINAMICS
– SINAMICS S120 Commissioning Manual
S SIMODRIVE
– /FBU/ SIMODRIVE 611 universal and universal E
Closed-Loop Control Components for Speed Control and Positioning
– /POS3/ SIMODRIVE SI and CD/CA
Distributed Servo Drive Systems

1.4 Standard/export version
1.4 Standard/export version
Export license Because certain control functions require an export license in accordance with
requirement the German Export List, the SINUMERIK 840Di sl is available in two versions.
The standard version SINUMERIK 840Di sl can contain the full scope of
functions of the control, and therefore requires export approval with regard to its
type.
In the export version SINUMERIK 840DiE sl, e.g., the following options are not
available:
S Interpolation with more than 4 axes

S Machining package 5 axes
S Helical interpolation 2D + n (n greater than 2)
S OEM package
The following restrictions apply to options that can be used:
S Sag compensation: limited to traversing a maximum distance of 10 mm.
Note
A complete overview of options not available on the export version are listed
in: Catalog NC 61
The corresponding option bits can be set but they have no effect (alarm output if
functions programmed). The export version requires no export license with
respect to its type.
(This does not mean that there is not export license requirement with respect to
the intended use. This is a separate matter and may apply in addition.)
The characteristics of the control are defined by the system software which is
available in two versions (standard and export). This means that the export
license requirement of the system software (for details see delivery note or
invoice) is passed on to the control system on which it is installed.
It is important to be aware of this in the case of updates/upgrades of the system
software because this might affect the export license requirement.
Identification of In addition to the information provided on the delivery note and invoice, the
the control hardware components supplied with the system software are also clearly
identified by adhesive labels as standard or export versions.
Note
The adhesive labels supplied additionally in the packaging are intended to
identify the control after installation and start-up and must be pasted into the
control log book. In the case of license orders, a corresponding number of
labels is provided, which must also be pasted into the log book.

1.5 840Di start-up
When the control has booted, the export version can be identified by the
additional character ’E’ on the Service screen of the NCU version.
S HMI Advanced (option): Diagnosis operating area > Service displays > Ver-
sion > Version NCU
Identification of control variants in this way is important for service personnel
and can also be helpful as evidence on export, especially when using the
embargo-exempt certificates provided for the export version.
1.5 840Di start-up

The user interface 840Di start-up included in the scope of supply of the SINUM-
ERIK 840Di sl is intended as an initial introduction to SINUMERIK 840Di sl func-
tionality.
Function overview The user interface comprises the following functions:

S Display of main screens
S Display of alarms and messages
S Management of parts programs
S ASCII editor
S NC, PLC, and PROFIBUS diagnoses
S Logbook
Menu bar The menu bar comprises the following menu commands:
S File
S Edit
S Windows
S Display
Context-sensitive The functions that can be called using the menu commands File and Edit are
menu functions context-sensitive, i.e. only those functions are offered that are possible in the
context of the currently active window.
Example:
S The parts program management window is selected. The menu command

Edit provides the following functions:
– Copy
– Paste
– Paste ...
– Load
– Unload
S The window for display of the axis actual values is selected. The menu com-
mand Edit provides no further functions.

1.5 840Di start-up
1.5.1 Menu command: Window
The menu command Window provides the following functions:
Menu command Functionality

Windows
Main screen
General data Display of:
– Channel status
– Program status
Axis actual values Display of:
– Axis names
– Axis positions in the selected coordinate
system
– Distance-to-go
– Feed
– Override
Switchover of the position display between:
– MCS
– WCS
Current block display Display of:
– Parts programs and up to 3 blocks
Program control Selection of:
– Machine function SBL1
– SBL2 after each block
– Program test
G functions / H functions Display of:
– Current G functions
– Current H functions
Program pointer Display of:
– Program name of the selected parts pro-
gram
– Number of passes P
– Block number
– Program levels: Main program and 3
subroutine levels
Alarm Display of current alarms and messages
Alarm log Display of all alarms and messages in chro-
nological order

1.5 840Di start-up

Part programs S Management of parts programs
Menu command File

– New ...
– Open
– Delete
– Quit
Menu command Edit
– Copy
– Paste
– Load
– Unload
– Select
S Editing parts programs:

– Menu command File > Open
– Double-click the file with the left
mouse button
Editor Editing files
Start the editor with:
– Menu command File > Open
– Double-click the file with the left
mouse button
Menu command File
– Open
– Close
– Cut
– Quit
Menu command Edit
– Copy
– Paste
– Load
– Unload
– Select
Diagnostics
PROFIBUS
Bus Display of bus configuration:
– Baud rate
– Cycle time
– synchr. portion (TDX)
Display of status:
– Configuration
– Bus status
Slaves Display of:
– Slave no. (DP address)
– Assignment
– Active on the bus
– Synchr. with NC
– Number of slots
– Details

1.5 840Di start-up

NC / PLC S NC
– Display of NC status
– “NC Reset”
– “Clear NC memory”
S PLC
– Display of PLC status
– “RUN-P”
– “RUN”
– “STOP”
– “MRES”
S Latency display
– Current value
– Maximum value
– Number of violations
– Oscilloscope
Logbook Display of SINUMERIK 840Di sl system
messages

1.5 840Di start-up
Notes

Hardware Descriptions 2
2.1 Overview of hardware components
SINUMERIK A SINUMERIK 840Di sl can only be ordered as a complete system (PCU and
840Di sl: MCI board).
Hardware
S SINUMERIK 840Di sl
PCU 50.3-C 1.5 GHz/512 MB and MCI2 board,
40 GB hard disk and Windows XP ProEmbSys
24 V power supply
Order number: 6FC5 220-0AA31-2AA0
PCU 50.3-P 2.0 GHz/1024 MB and MCI2 board,
40 GB hard disk and Windows XP ProEmbSys
24 V power supply
Order number: 6FC5 220-0AA33-2AA0
Spare parts The following hardware components are available as spare parts:
S MCI2 board for SINUMERIK 840Di sl

Spare parts order number: 6FC5 222-0AA02-2AA0
S Hard disk
for PCU 50.3 with mounting plate and damping elements
Spare parts order number: 6FC5 247-0AF08-4AA0
Optional The following hardware components are optional and can be ordered sepa-
Components rately:
MCI board S SINUMERIK 840Di sl MCI board extension slot variant

extension Order number: 6FC5 222-0AA00-0AA1
Operation and S SINUMERIK operator panel fronts

display – OP 010
Order number: 6FC5 203-0AF00-0AA1
– OP 010C
– OP 010S
– OP 012
– OP 012T
Order number: 6FC5203-0AF06-1AA0
– TP 012

2 Hardware Description 03/2006
– OP 015
– TP 015A
S Components for distributed connection of SINUMERIK

operator panel fronts
– TCU (Thin Client Unit)
Order number: 6FC5 312-0DA00-0AA0
External storage S USB disk drive 3.5’’ incl. 1m connecting cable

media Order number: 6FC5 235-0AA05-1AA2
Power supply of the S SITOP POWER standard 24V/10A

PCU Order number: 6EP1 334-1SH01
Uninterruptible S SITOP POWER DC UPS module 15

power supply (UPS) Order number: 6EP1 931-2EC31
S SITOP POWER ACCU MODULE 24VDC/10A/3,2AH

Order number: 6EP1 935-6MD11
PROFIBUS-DP S7 I/O modules

modules S SIMATIC ET 200 (distributed I/O system)
for detailed order information see:
References: /ST7/ SIMATIC S7 programmable logic controllers
Catalog ST 70
S I/O module PP72/48

Order number: 6FC5 611-0CA01-0AA0
Interface modules
S ADI4 (Analog Drive Interface for 4 Axes)

Order number: 6FC5 211-0BA01-0AA2
SINAMICS drives S SINAMICS S120
For detailed order information on the SINAMICS S120, please refer to:
References: /BU/ SINAMICS
SINAMICS S120
Servo Control Drive System
Catalog D21.2
Drives: SIMODRIVE S SIMODRIVE 611 universal

with optional module MotionControl with PROFIBUS DP
S SIMODRIVE 611 universal E

with option module MotionControl with PROFIBUS-DP
S SIMODRIVE POSMO CD/CA

03/2006 2 Hardware Description
S SIMODRIVE POSMO SI
S SIMODRIVE POSMO A
For detailed ordering information on various drives, see:

References: /BU/ SINUMERIK & SIMODRIVE
Ordering Information
Catalog NC 60

2.2 MCI2 board for 840Di sl
2.2.1 Module
The MC12 board for 840Di sl is a short 32-bit PCI plug&play card. The MCI2
board referred to below simply as MCI board (Motion Control Interface) provides
the following interfaces:
S PROFIBUS DP with Motion Control Functionality (X101)

S MPI (Multi-Point Interface) or PROFIBUS DP without Motion Control Func-
tionality (X102) (alternative)
S MCI board extension (slot variation: Section 2.3, Page 2-53)
The MCI board also provides the following functionality:
S PLC: Compatible with SIMATIC S7 CPU 317-2 DP

S Static memory (SRAM) for storing retentive NCK and PLC-specific user
data.
Backup battery connecting cable

X3: Backup battery
X2: MCI board extension
*)
X102: MPI/DP *)
*) X11: PCI bus
X101: PROFIBUS-DP *)
*) locking screws
Internal thread: UNC 4–40
Fig. 2-1 Module: MCI2 board for 840Di sl
Order number:
MCI2 board Description Order number (MLFB)
MCI2 board for 840Di sl (as spare part) 6FC5 222-0AA02-2AA0

Order No.:
Bus connector Description Order number (MLFB)
Bus connector RS-485 for PROFIBUS DP
and MPI
180°Cable outlet 6GK1 500-0EA02
35°Cable outlet, without PG connection socket 6ES7 972-0BA40-0XA0
35°Cable outlet, with PG connection socket 6ES7 972-0BB40-0XA0
90°Cable outlet, without PG connection socket 6ES7 972-0BA11-0XA0
90°Cable outlet, with PG connection socket 6ES7 972-0BB11-0XA0
2.2.2 Interface description
Interface overview Interfaces of the MCI board module

Table 2-1 Interface overview: MCI board
Port Description Type

PROFIBUS-DP X101 Socket
MPI/DP X102 Socket
MCI board extension X2 Plug connector
Buffer voltage X3 Plug connector
PCI bus X11 Direct connector
LED 1 DP1 LED
LED 2 DP2 LED
PROFIBUS DP Interface description PROFIBUS DP interface (X101):

interface (X101) S Connection: 9-pin SUB-D socket connector
S Pin assignment
Table 2-2 Pin assignment: PROFIBUS DP interface (X101)
Pin Description Type1) Function

1 unassigned – –
3 RS-DP B RS-485 differential signals
4 RTS O Request to Send
5 GNDext VO External ground 2)
6 P5ext VO ext. 5V power supply 2)
8 XRS DP B RS-485 differential signals
1) VO Voltage Output
O Output
B Bidirectional
2) Pin 5 and 6 can only be used to supply the bus termination resistances
S Connecting cable: See Subsection 3.3.2, Page 3-103
MPI/DP interface Interface description MPI/DP interface (X102):

(X102) S Connection: 9-pin SUB-D socket connector
S Pin assignment

Table 2-3 Pin assignment: MPI interface (X102)

3 RS-MPI / DP B RS-485 differential signals
5 GNDext VO External ground 2)
6 P5ext VO ext. 5V power supply 2)
8 XRS-MPI / DP B RS-485 differential signals
O Output
B Bidirectional
2) Pin 5 and 6 can only be used to supply the bus termination resistances
S Connecting cable: See Subsection 3.3.2, Page 3-103
Notice
The PROFIBUS DP (X101) and MPI/DP bus (X102) interfaces are isolated both
from one another and from the PCU.
Backup voltage Interface description of the backup voltage connection (X3):

connection (X3) S Connection: 2-pin plug connector
S Pin assignment
Table 2-4 Pin assignment: Backup voltage connection (X3)

1 BATT– VI Backup voltage minus
2 BATT+ VI Backup voltage plus
1) VI Voltage input
Diagnostic LEDs The LEDs (DP1 / DP2) are only used to display the internal status of the MCI
(DP1 / DP2) board. The LEDs ca not be used to diagnose the SINUMERIK 840Di sl.

2.2.3 Module replacement
License key If the MCI board is to be inserted as a replacement (either only the MCI board or
together with the PCU), you will need a new license key.
Consult the central hotline. You will need the:
– HW series number of the old MCI board
– HW series number of the new MCI board
The HW series number of the MCI board is to be found on the rating plate of the
module (see Fig. 2-2).
HW series number
Fig. 2-2 MCI2 board: HW series number
For instructions on how to enter the license key, see Section 5.6, Page 5-124.
Note
If the MCI board is to be inserted as a replacement (either only the MCI board
or together with the PCU), you will need a new license key.
Warning
! Operating electrical equipment has parts and components that are at hazard-
ous voltage levels.
Failure to properly maintain the equipment can result in death, serious bodily
injury or substantial material damage.
When servicing these devices, you should therefore observe all notices pro-
vided in this section and attached to the product itself.
– This device may only be serviced by appropriately qualified personnel.
– Before starting any maintenance and service work, disconnect the device
from power supply.
– Use authorized spare parts only.
– Strictly observe the prescribed maintenance intervals, as well as the in-
structions for repair and replacement.

Notice
The module contains electrostatically sensitive devices.
Electrostatically discharge your own body before touching the module. The
simplest way of doing this is to touch an electrically conductive grounded object
(e.g. a bare metal part of a cabinet or a power receptacle ground conductor).
Execution To change the module, proceed as follows:

1. Check that there is a suitable series start-up file (NCK and PLC) available
before removing the module.
For information on how to create a series machine start-up file, please refer
to Chapter 16, Page 16-467.
2. Shut down the SINUMERIK 840Di sl and Windows XP correctly.
Use one of the following methods to do this:
S Windows XP taskbar: Start > Shut Down
S Interface signal: “PC shutdown”, see Subsection 19.1.1, Page 19-507
3. Disconnect your PC from power supply.
4. Remove the screws from the cover of the housing (Fig. 2-3) and open the
housing of your PC, observing the relevant safety regulations.
Screws of the
cover of the housing
Fig. 2-3 Cover of the housing of the PCU 50.3
5. Optional:
Remove interconnecting cable to the MCI board extension module, interface
X2.
6. Remove the fastening screw (Fig. 2-4) and remove the module holding-
down device.

Mounting Board
screw retainer
Plastic
support
Fig. 2-4 Mounting of the module
7. Remove the cable connection X3 (backup battery) from the module.
X3 backup battery
Fig. 2-5 Backup battery connector
8. Loosen the fastening screw on the cover plate of the module and remove
the module while observing ESD measures.
9. Insert the new module into the appropriate slot on the mother board and
fasten it using the fastening screw on the cover plate.
10. Insert the cable connection X3 (backup battery) into the module.
11. Mount the board retainer.
12. Optional:
Insert the connecting cable to the MCI board extension module, interface
X2.
13. Close the housing of your PC and fasten the screws from the cover of the
housing (Fig. 2-3).
14. Connect your PC to power supply again and start it.

2.2.4 Technical data

Safety
Degree of protection IP 00
Safety class I, acc. to VDE 0106 P1: 1982 (IEC 536)
Safety regulations EN61131-1
Approvals CE, UL, CSA
Power consumption 5 V
Typically 3.75 W
Maximum 5W
Mechanical data
Dimensions PCI card, short
Weight 140 g
Climatic ambient conditions
Heat dissipation Open circuit ventilation
Temperature limits Operation Storage/transport
– MCI board alone – –40 ... 70 °C
– MCI board in PCU 50.3 5 ... 55 °C –20 ... 60 °C
Tested to DIN IEC 68-2-1, DIN IEC 68-2-2
(DIN EN 60068-2-2), DIN IEC 68-2-14
Limits for relative humidity 5 ... .80 % 5 ... .95 %
Tested to DIN IEC 68-2-30
Per minute Per hour
Temperature change max. 1 K max. 10 K
Condensation Not permissible
Quality assurance to ISO 9001
Vibrational load during operation
Class 3M4
Frequency range 10 ... 58 Hz / 58 ... 200 Hz
Const. excursion / accelera- 0.075 mm / 1 g
tion
Tested to DIN EN 60068-2-6
– module in PCU 50.3
Shock load during operation
Acceleration 50 m/s2
Duration of nominal shock 30 ms
Notice
The specified safety regulations, certifications, degree of protection and safety
class only apply if the module is plugged into a SINUMERIK PCU 50.3.

2.3 MCI board extension slot variant
2.3.1 Module
The MCI board extension slot variant provides the following functions as an
optional expansion board of the MCI board:
– 4 binary inputs (isolated)
– 4 binary outputs (isolated)
– 2 measuring inputs (isolated)
– 2 handwheels (non-isolated)
Either differential or TTL handwheels (switch S1) can be operated on the mod-
ule.
X4: MCI board extension
Switch S1
*)
X121: Cable
distributor
*) PCI bus (mechanical)
*) locking screws
Internal thread: UNC 4–40
Fig. 2-6 MCI board extension slot variation
Order number:
Description Order number (MLFB)
MCI board extension slot variation (option) 6FC5 222-0AA00-0AA1
Caution
Connection or disconnection of the cable distributor to or from interface
X121 on the module is only allowed when the equipment is de-energized.
Before you plug in or remove the cable connector, switch off the PCU (shut
down Windows XP correctly!). Otherwise, short circuits might occur on the
module. This could destroy the module.

Switch S1 With switch S1 you can select the type of handwheel that is to be operated on
the module:
– Differential handwheels:
switch S1 closed (as-delivered state)
– TTL handwheels:
switch S1 open
Differential or TTL handwheels can only be operated alternately.
Switch S1:
Switch position open
Fig. 2-7 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.

2.3.2 Installation instructions
The connecting cable with the MCI board is part of the scope of supply and is
already plugged into the MCI board extension slot variation.
Installation To install the module, proceed in the sequence described below.

execute
Warning
! Operating electrical equipment has parts and components that are at hazard-
ous voltage levels.
Failure to properly maintain the equipment can result in death, serious bodily
injury or substantial material damage.
When servicing these devices, you should therefore observe all notices pro-
vided in this section and attached to the product itself.
– This device may only be serviced by appropriately qualified personnel.
– Before starting any maintenance and service work, disconnect the device
from power supply.
– Use authorized spare parts only.
– Strictly observe the prescribed maintenance intervals, as well as the in-
structions for repair and replacement.
Notice
The module contains electrostatically sensitive devices.
Electrostatically discharge your own body before touching the module. The
simplest way of doing this is to touch an electrically conductive grounded object
(e.g. a bare metal part of a cabinet or a power receptacle ground conductor).
1. Shut down the SINUMERIK 840Di sl and Windows XP correctly.

Use one of the following methods to do this:
S Windows XP taskbar: Start > Shut Down

S Interface signal: “PC shutdown”, see Subsection 19.1.1, Page 19-507
2. Disconnect your PC from power supply.
3. Remove the screws from the cover of the housing (Fig. 2-8) and open the
housing of your PC, observing the relevant safety regulations.

Screws of the
cover of the housing
Fig. 2-8 Cover of the housing of the PCU 50.3
4. Remove the fastening screw of the module holding-down device (Fig. 2-9) of
the MCI board and remove the module holding-down device.
Mounting screw Board
retainer
Plastic
support
Fig. 2-9 Mounting of the module
5. Remove the blanking plate of the free PCI slot.

6. Insert the module carefully but firmly into the PCI slot and tighten the con-
nector plate of the module.
7. Plug the connector of the connecting cable into the MCI board. Make sure
that the latches of the connectors have securely engaged on both modules:
– MCI board: Interface X2
– 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.

Interface overview Interfaces of the MCI board extension slot variant

Table 2-5 Interfaces of the MCI board extension slot variation

Cable distributor X121 Connectors
MCI board extension X4 Plug connector
Cable distributor Interface description of the cable distributor interface (X121):

(X121)
S Connector: 37-way Sub D connector
(see cable distributor Section 2.4, Page2-61)
S Pin assignment:
Table 2-6 Pin assignment: Interface X121

1 M24EXT VI/VO 24 V ground, 24 V output ground
2 M24EXT VI/VO 24 V ground, 24 V output ground
3 DOUT_CON(1) O 2nd output 24 V
4 DOUT_CON(0) O 1st output 24 V
5 DIN_CON(3) I 4th input 24 V
6 DIN_CON(2) I 3rd output 24 V
7 DIN_CON(1) I 2nd input 24 V
8 DIN_CON(0) I 1st input 24 V
9 MEPU0_S I 1st probe input (signal: 24 V)
10 MEPU0_C I 1st probe input (reference: 0 V)
11 MPG1_XA I Input 2nd handwheel, track A inverted
12 P5 VO Optional 5 V handwheel power supply
14 MPG1_XB I Input 2nd handwheel, track B inverted
15 MPG0_XA I Input 1st handwheel, track A inverted
18 MPG0_XB I Input 1st handwheel, track B inverted
20 P24EXT VI 24 V output load power supply
21 P24EXT VI 24 V output load power supply
22 DOUT_CON(3) O 4th output 24 V
23 DOUT_CON(2) O 3rd output 24 V
24 MEXT VO 24 V input ground
28 MEPU1_S I 2nd probe input (signal)
29 MEPU1_C I 2nd probe input (0 V)
30 MPG1_A I Input 2nd handwheel, track A
31 M (GND) VO Handwheel PS ground, TTL handwh.
ground

Table 2-6 Pin assignment: Interface X121

ground
33 MPG1_B I Input 2nd handwheel, track B
34 MPG0_A I Input 1st handwheel, track A
ground
ground
37 MPG0_B I Input 1st handwheel, track B
1) VI/VO Voltage Input/Voltage Output
VI Voltage Input
VO Voltage Input
I Input
O Output
Power supply of the digital inputs

ext. power supply
X121
+24V stabilized
MCI board Pin number:
extension +24V 0V
Optocoupler
5...8
24...27
M
(
G
Power supply of the digital outputs

ext. power supply
X121 +24V stabilized
MCI board Pin number:
+24V 0V
extension
20,21
Optocoupler
3,4,22,23
Relay
Driver
1,2
M
(
G

Digital inputs Electrical data of the digital input interface:

S Isolated from the board electronics
S Common ground (MEXT)
Digital outputs Electrical data of the digital output interface:

S Isolated from the board electronics
S Common ground and with regard to the external power supply (M24EXT)
S Rated current: 500 mA
Differential Electrical data of the differential handwheel interface:

handwheels S Connected to the board electronics
S Signals used:
– MPGx_A
– MPGx_B
– MPGx_XA
– MPGx_XB
TTL handwheels Electrical data of the TTL handwheel interface:

S Connected to the board electronics
S Signals used:
– MPGx_A
– MPGx_B
– M (GND)
Notice
The optional power supply of the handwheels (P5) is electronically protected
with 2A. The maximum continuous load is 1 A. Per handwheel 500 mA.
1st measuring probe Electrical data of the probe interface:

S Isolated both from one another and from all other voltage areas (board elec-
tronics, digital inputs/outputs and handwheels)
S Signal delay active edge: 10 us
S Signal delay inactive edge: 100 us
Note
The maximum cable length is 25 m for all functions.

Table 2-7 Technical data for MCI board extension, slot version
Safety
Safety class Safety class I, in accordance with VDE 0106 P1: 1982
(IEC 536)
Safety regulations EN61131–1
Approvals CE, UL, CSA
Electrical data
Maximum Typical
Power consumption without 500 mW 350 mW
I/Os
Power consumption with I/Os 2.1 W 850 mW
both handwheels per handwheel
Max. current-carrying capacity 1A 500mA
of the 5 V power supply
Mechanical data
Dimensions Short PCI card
Weight 110g
Operation Storage/transport
Temperature limits 5 ... 55°C –40 ... 70°C
Tested to DIN IEC 68-2-1, DIN IEC 68-2-2
(DIN EN 60068-2-2), DIN IEC 68-2-14
Limits for relative humidity 5 ... .80% 5 ... .95%
Tested to DIN IEC 68-2-30
Per minute Per hour
Temperature change max. 1 K Max. 10K
Quality assurance to ISO 9001
Vibrational load during operation
Class 3M4
Frequency range 10 ... 58Hz / 58 ... 200Hz
Const. excursion / accelera- 0,075mm / 1g
tion
Shock load during operation
Acceleration 50m/s2
Duration of nominal shock 30 ms
Notice
The specified safety regulations, certifications, degree of protection and safety
class only apply if the module is plugged into a SINUMERIK PCU 50.3.

2.4 Cable distributor
Order number
Cable distributor 6FX2 006-1BA02
Cable connection The cable distributor consists of a connector jacket for a 37-pin Sub-D
connector with enlarged interior. The cable distributor is used to split the I/O
electronic handwheel extension interface (X121) to a maximum of 7 single
cables. These must be connected in the order shown in Table 2-9, Page 2-63.
To supply the digital outputs, an external 24 V supply is possible at the cable
distributor.
Cable
6FX2002-4AA21-0jjj
Cable
6FX2002-4AA41-0jjj
90
Fig. 2-10 Cable distributor
Plug the appropriate single cable into the opened cable distributor and connect
it to the associated connector X1 to X10. When doing so, place the cable into
the appropriate cable entry.
Make sure that the shield jackets that became free have a large conductive
connection to the metallic contact areas of the cable distributor. See Fig. 2-11,
Page 2-62.

Locate the upper terminal bar in such a way that its “teeth” are facing the “teeth”
of the lower terminal bar and then retain the upper housing section.
This will reliably press the cable shields between the contact areas of the
contact springs and contact them safely. The shield potential is reliably routed to
the housing of the PCU using the contact springs of the cable distributor on the
front panel of the PCU.
Location of
interfaces
Cable inlets
Terminal caps
Contact surfaces
X1 X2 X3 X4 X5 X6 X7 X8 X9 X1 Plug-in connectors
0 X1...X10
S2 S5 S1
S4 S6 S3
S1 to S6:
Closed
X11
Open
Sub-D socket connector
Fig. 2-11 Position of the interfaces of the cable distributor
DIP FIX switches The DIP FIX switches in the cable distributor must be set as follows:
Table 2-8 Setting the DIP-FIX switches in the cable distributor
Switches S1 S2 S3 S4 S5 S6
Open x x x x
Closed x x

Connector
assignments Table 2-9 Connector assignments
Connector No. Cable No. Peripherals

X1 1
1 handwheel
1.
X2 (top)
X3
2 2 handwheel
2.
X4
X5 3 2. probe
X6
4 4 binary inputs
X7
X8 5 4 binary outputs
X9 6 Supply for 4 binary outputs
7
X10 1. probe
(bottom)
Notice
When assembling the cable distributor, make absolutely sure that the supplied
washer is installed correctly and the coding pins are installed.
Mounting The cable distributor is fastened using the two supplied adapter plates at the
X121 cable distributor interface of the MCI board extension module using
screws.
Cable distributor: Top view Cable distributor: Side view
Adapter plate
Fig. 2-12 Mounting the cable distributor

Connection Connector designation: X1...X10

assignment Connector type: DU-BOX plug connectors
Table 2-10 Connector pin assignment of the cable distributor

Pin no. DU BOX Cable Cable order No.
37-pin connector No. 6FX2002-4AA....
Signal name Core color I/Os Terminal
connec- no./pin
tor
– X10/2 rd
9 MEPUS 0 X10/1 or 1st probe Signal +24 V
– X10/4 7 41–0jjj bn
10 MEPUC 0 X10/3 bk 1st probe Reference
shield 0V
1 M24EXT X9/2 rd Parameterizatio Ground
20 P24EXT X9/1 or n of the 24 V
2 M24EXT X9/4 6 41–0jjj bn 4 binary outputs Ground
21 P24EXT X9/3 bk / of the MPI 24 V
shield connector
3 OUTPUT 1 X8/2 rd 2nd output
22 OUTPUT 3 X8/1 or 4th output
4 binary
4 OUTPUT 0 X8/4 5 41–0jjj bn 1st output
outputs
23 OUTPUT 2 X8/3 bk 3rd output
shield
5 INPUT 3 X7/2 rd 4th input
24 MEXT X7/1 or Ground
6 INPUT 2 X7/4 bn 3rd input
25 MEXT X7/3 bk Ground
4 binary
7 INPUT 1 X6/2 4 21–0jjj gn 2nd input
inputs
26 MEXT X6/1 ye Ground
8 INPUT 0 X6/4 vt 1st input
27 MEXT X6/3 bu Ground
shield
– X5/2 rd
28 MEPUS 1 X5/1 or 2nd probe Signal +24 V
– X5/4 3 41–0jjj bn
29 MEPUC 1 X5/3 bk 2nd probe Reference 0
shield V
11 MPG1 XA X4/2 rd XA
30 MPG1 A X4/1 or A
12 MPG1 5V X4/4 bn 5V
31 MPG1 0V X4/3 bk 2nd handwheel 0V
13 MPG1 5V X3/2 2 21–0jjj gn 5V
32 MPG1 0V X3/1 ye 6FC9320-5DB 0V
14 MPG1 XB X3/4 vt XB
33 MPG1 B X3/3 bu B
shield
15 MPG0 XA X2/2 rd XA
34 MPG0 A X2/1 or A
16 MPG0 5V X2/4 bn 5V
35 MPG0 0V X2/3 bk 1st handwheel 0V
17 MPG0 5V X1/2 1 21–0jjj gn 5V
36 X1/1 ye 6FC9320-5DB 0V
MPG0 0V
18 X1/4 vt XB
MPG0 XB
37 X1/3 bu B
MPG0 B
shield

Signal names
MPG0, 1 5 V Supply voltage 1st / 2nd handwheel 5 V
MPG0, 1 0 V Supply voltage 1st / 2nd handwheel 0 V
MPG0, 1 A, XA 1st / 2nd differential handwheel input A, XA
MPG0, 1 B, XB 1st / 2nd differential handwheel input B, XB
MEPUS 0, 1 1st / 2nd meas. pulse signal
MEPUC 0, 1 1st / 2nd meas. pulse common (reference ground)
INPUT [0...3] 1st to 4th binary NC input
MEXT Ext. ground (reference ground for binary NC inputs)
OUTPUT [0...3] 1st to 4th binary NC output
M24EXT External 24 V supply ( – ) for binary NC outputs
P24EXT External 24 V supply ( + ) for binary NC outputs
Notice
The maximum current carrying capacity of the handwheel interface is 1 A for
both handwheels. 500 mA per handwheel.
Colors
rd R ed
or Orange
bn Brown
bk Black
gn Green
ye Y ellow
vt V iolet
bu Blue

2.5 SINUMERIK Industrial PC
2.5.1 SINUMERIK PCU 50.3
**)
top *)
**)
*) Orientation with reference

to operation with OP 012
**) Fixing screws
Housing cover
Fig. 2-13 PCU 50.3: Perspective view with installed hard disk drive
Order number PCU as spare part with MCI board:

with Windows XP ProEmbSys and MCI board:
PCU 50.3–C/1.5 GHz, 512 MB SDRAM 6FC5 220-0AA31-2AA0
PCU 50.3–P/2.0 GHz, 1024 MB SDRAM 6FC5 220-0AA33-2AA0
Properties The SINUMERIK industrial PC “PCU 50.3” provides, together with the MCI
board, the basis for the SINUMERIK 840Di sl. The PCU 50.3 has the following
important features:
S Versions:
– Celeron M, 1.5 GHz, 512 MB SDRAM
– Pentium M, 2.0 GHz, 1024 MB SDRAM
S Hard disk min. 40 GB (replaceable)
S Operating system Windows XP ProEmbSys with Service Pack 2
S Robust design (continuous operation, high noise immunity)
S Space-saving installation thanks to compact dimensions
S Easy installation with four screws on the rear of the operator panel front

S Mounting position and location to a large degree variable

S Screen resolution 640 x 480, up to max. 1600 x 1200
S Power supply: 24 V DC
S Interfaces to peripheral devices:
– 1 x PROFIBUS DP (max. 12 Mbaud)
– 1 x DVI-I interface for external monitor
– 2 x Ethernet connections 10/100 Mbaud
– 1 x CF card shaft (covered)
– 4 x high-speed USB ports (USB 2.0)
S Interfaces to operator panel front:
– LVDS panel interface (channel 1 and optional channel 2)
– I/O USB panel interface
– Additional high-speed USB port (USB 2.0)
S Slots
– 1 x PCI (length: max. 265 mm, occupied by the MCI board)
– 1 x PCI (length: max. 175 mm, occupied with option MCI board exten-
sion slot variant)
Options The following options are offered:

S Memory expansion up to max. 2048 MB
S External floppy disk drive
Mounting bracket Mounting brackets are required to mount the PCU directly behind the operator
panel front:
– Mounting bracket MLFB: 6FC5 248-0AF20-2AA0
Spare part When installing spare parts please note the following:
installation S When replacing the PCU, remove the mounting brackets (MLFB 6FC5
248-0AF20-2AA0) from the defective PCU and attach to the replacement
part.
Literature For the complete documentation on the PCU 50.3, please refer to:
References: /BH/ Operator Components Manual
Component PCU 50.3

Technical data
Table 2-11 Technical data for PCU 50.3 with MCI board
Safety
Safety class I per IEC 60536
Degree of protection per EN IP20
60529
Approvals CE
Electrical data
Input voltage 24 VDC
Max. power consumption 1 x PCI slot (length: min. 140 mm)
1 x PCI slot (length: max. 288 mm)
3.3 V 2A
5V 2A
12 V 0.3 A
–12 V 0.05A
Power consumption PCU PCI slot 1)
Max. 190 W 15 W
Mains buffering time Min. 20 ms
Mechanical data
Dimensions (mm) Width 297 Height 267 Depth 81.7
Weight Approx. 7.2 kg
Mechanical ambient condi- Operation Transport
tions (with OP 012) (in packaging)
Vibration stressing 10 – 58 Hz: 0.075 mm 5 – 9 Hz: 6.2 mm
58 – 200 Hz: 9.8 m/s2 9 – 500 Hz: 19.6 m/s2
DIN IEC 60068-2-6 DIN IEC 60068-2-6
Shock load 50 m/s2, 30 ms, 250 m/s2, 6 ms,
18 shocks 18 shocks
DIN IEC60068-2-27 DIN IEC60068-2-29
Noise < 55 dB(A) to DIN 45635-1
Con., spraying water and icing Not permissible
Air inlet Without caustic gases, dusts and oils
Operation Storage / transport
(in transport packaging)
Applicable standards DIN IEC 60068-2-1 DIN IEC 60068-2-2 /
–2–14
Climate class 3K5 1K3 / 2K4
9W 2): 5 ... 55 °C
Temperature limits 14 W 2): 5 ... 50 °C –20 ... 60 °C
24 W 2): 5 ... 45 °C
Temperature change Max. 10 K/h Max. 18 K/h
Limits for relative humidity 10 ... to 80 % at 25° C 5 ... to 95% at 25° C
Permissible change in the rel- max. 0.1 %/min
ative air humidity
1) All of the slots must not exceed this total output
2) max. power of additional extensions e.g.: MCI board extension, PC card,

USB interface; the MCI board is already plugged in

2.6 SINUMERIK operator panel fronts

SINUMERIK operator panel fronts can be connected to the PCU either centrally,
i.e. directly via LVDS or USB interfaces, or decentrally with TCU (Thin Client
Unit) via Ethernet.
In the following section, the OP 012 operator front is described as an example in
detail.
2.6.1 Operator panel front OP 012
Alphabetic
Softkeys and direct keys
Softkeys and direct keys

key group
Numerical
key group
Cursor
key group
Control
key
group
USB
front
Softkeys interface
Recall Machine area “ETC” key Area switchover Mouse
Fig. 2-14 View of OP 012 operator panel front
Order number
SINUMERIK OP 012 6FC5 203-0AF02-0AA1
Properties The OP 012 operator front provides the following features:
S 12.1” TFT flat screen (color); resolution 800 x 600 pixels

S Membrane keyboard with alpha, numeric cursor, and control keypad
S Soft keys/direct keys:
– 2 x 8 horizontal rows of keys with softkey function
– 2 x 8 vertical key rows with softkey and direct key functions

– Direct keys connectable using PP031–MC or directly to the I/Os
S Shift key for switchover to the second key level (not for switching over the
letters, since uppercase letters only)
S Integrated mouse
S Status LEDs for power supply and overtemperature
S USB interface at front
S IP65 degree of protection
S Can be combined with PCU or TCU
S External floppy disk drive can be connected
Literature For detailed documentation about the operator panel front OP 012 please see:
Operator panel front OP 012

2.7 TCU (Thin Client Unit)
X203/X204: 2 USB-A ports X207/X208: Interfaces for

connection to the operator panel
front (covered)
Ethernet cable
X202: Ethernet port
X201: Compact Flash interface
Fig. 2-15 TCU with Ethernet cable plugged in
Order number
TCU (Thin Client Unit) 6FC5312-0DA00-0AA0
Properties A TCU permits the distributed connection of SINUMERIK OP/TP operator panel
fronts and the SINUMERIK PCU. The features include the following:
S Communication with the PCU is performed via Industrial Ethernet (10/100

Mbaud) in a separate sub-network with DHCP server (on the PCU).
S Permits large distances (maximum possible distance between two network

nodes/access points: approx. 100 m) between the PCU and operator panel
front.
S Graphics resolutions: 640x480 to 1024x768 pixels; depth of color: 16 bits

S Interfaces:
– 1 x Ethernet 10/100 Mbaud
– 1 x Compact Flash
– 2 x USB 1.1 for connection of mouse and keyboard
– Interfaces for operator panel front:
LVDS interface for SINUMERIK OP,
USB interface for SINUMERIK OP (internal)

Literature Comprehensive documentation about the configuration and commissioning of

the TCU are to be found in:
Set-up References: /BH/ Operator Components Manual

Distributed configuration with TCU
Startup References: /IAM/ HMI Installation and Startup Manual

TCU Installation and Startup (IM5)

2.8 Floppy disk drives
2.8 Floppy disk drives
2.8.1 Floppy disk drive 3.5” (USB)
Fig. 2-16 External 3.5” floppy disk drive with USB interface
Order number
3.5” disk drive with USB interface 6FC5 235-0AA05-1AA2
incl. 1 m USB connecting cable
Cover (spare part) 6FC5 247-0AA20-0AA0
Properties The disk drive is used to read in and save data from/to 3.5” disks with a maxi-
mum capacity of 1.44 MB. The disk drive has the following features:
S USB interface: Version 1.1

S Can be inserted into customized operator panel fronts
S Bootable
S Input voltage 5.25 V DC
S Power consumption, max. 2.5 W
S Degree of protection to DIN EN 60529 IP 54 (front)

IP 00 (rear)
Literature For a complete description of the 3.5’’ floppy disk drive (USB), please refer to:
Literature: /BH/ Operator Components Manual
3.5” disk drive (USB)

2.9 Power supply
2.9 Power supply
2.9.1 SITOP POWER standard 24V/10A
Fig. 2-17 View: SITOP POWER standard 24V/10A
Order number
SITOP POWER standard 24V/10A 6EP1 334-1SH01
Properties The SITOP POWER Standard 24V/10A power supply mode provides the follow-
ing features:
S Input voltage nominal value 120/230 V AC
S Input voltage range 93 ... 132 V/187 ... 264 V
S Power failure back-up time > 20 ms
S Line frequency nominal value 50/60 Hz
S Line frequency range 47 ... 63 Hz
S Input current nominal value 3.5/1.7 A
S Inrush current (25 °C) 55 A
S Output voltage nominal value 24 V DC
S Output voltage tolerance ±3%
S Efficiency > 87 %

2.9 Power supply
S Output current nominal value 10 A
S Electron. short-circuit protection with automatic restart

S Galvanic isolation (SELV acc. to EN 60950)
S Class of protection (IEC 536; VDE 1006 T1) class I
S Degree of protection (VDE 0470, IEC 529) IP 20
S Radio interference level (EN 55011) class A

2.10 Uninterruptible power supply (UPS)
2.10.1 SITOP POWER DC UPS MODULE 15
USB interface
Fig. 2-18 View: SITOP POWER, DC-UPS MODULE 15
Order number
SITOP POWER DC UPS module 15 (USB interface) 6EP1 931-2EC41
Properties The SITOP POWER DC UPS module 15 provides the following features:
S Compact design (HxWxD: 125 mm x 50 mm x 125 mm)
S Nominal input voltage 24 V DC
S Nominal output voltage 24 V DC
S Nominal output current 15 A DC
S High efficiency approx. 96 %
S Class of protection (IEC 536; VDE 1006 T1) Class III
S Degree of protection (VDE 0470, IEC 529) IP 20
S Setting options
– Connection threshold
– Charging current
– End-of-charge voltage
– Operating state ON/OFF
– Backup time
– Interruption of output voltage
S Protection and monitoring functions
– Polarity reversal protection
– Overcurrent and short-circuit protection

– Exhaustive discharge protection

– Accu test
S Signaling of current status via LED
– Normal mode
– >85 % full charge
– Battery standby supply
– Buffer standby not available (alarm)
S Additional output of all signals via a PC-capable interface:
– Type ....-2EC31: Serial interface
– Type ....-2EC41: USB interface
USB interface The USB interface corresponds to specification 2.0. Communication is however
only performed at “full speed” corr. to 12 Mbaud. A commercial type four-core
shielded USB cable with a maximum cable length of 3 m can be used.
Table 2-12 Signal assignment of USB connector
Pin Signal Description

1 VBUS Supply voltage
2 D– Transmitted data
3 D+ Transmitted data
4 GRD Ground

2.10.2 SITOP POWER ACCU MODULE 24 V DC/10 A/3,2 AH
Fig. 2-19 View: SITOP POWER lead-acid battery module
Order number
SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH 6EP1 935-6MD11
Properties The SITOP POWER LEAD-ACID MODULE 24 V DC / 10 A / 3.2 AH features

the following:
S It has two maintenance-free, closed lead-acid batteries from the same lot,
which are installed in a holder and connected in series.
S Complete with battery retainer and terminals

S Low self-discharge rate of approx. 3 % per month (at +20 °C)
S Short circuit protection (battery fuse 15 A/32 V)
S Class of protection (IEC 536; VDE 1006 T1) Class III
S Degree of protection (EN 60 529; VDE 0470 T1) IP 00

2.11 I/O module PP72/48
2.11.1 Module
S1: DIL switch for setting the

PROFIBUS address
LED: POWER LED: OVTEMP LED: READY LED: EXCHANGE
X2: PROFIBUS
1 8
X1: Power supply ON
OFF
X333 X222 X111
Digital inputs/outputs
(50-pin ribbon cable con-
nector)
Fig. 2-20 I/O module PP72/48
Order number
I/O module PP72/48 6FC5 611-0CA01-0AA0
Properties I/O module PP72/48 is a simple module (without a separate housing) for con-
necting digital input/outputs as part of an automation system based on PROFI-
BUS DP.
The module has the following important features:
S PROFIBUS DP connection (max. 12 MBaud)

S 72 digital inputs and 48 digital outputs
S Onboard status display by means of 4 diagnostic LEDs
To power the module and the digital outputs, an external power supply source
(+24 V DC) is required.

Interface overview Interfaces of I/O module PP72/48
Table 2-13 Interfaces of I/O module PP72/48

Power supply connection X1 Screw-terminal block
PROFIBUS-DP X2 Socket
PROFIBUS DP address S1 DIP switch
Digital input/outputs 1 X111 Ribbon cable connector
External power Interface description of the external power supply (X1):

supply (X1)
S Screw-terminal block MSTBVA 2,5/3-G-5,08, Phoenix
S Pin assignment
Table 2-14 Pin assignment: Ext. power supply (X1)
Pin Description Type Function

1)
1 P24 VI External power supply of the module (+24 V)

2 M24 VI Reference for external supply
3 PI VI Protective conductor of the external supply
1) VI Voltage input
S Connecting cable
The required connecting cables must be provided by the user:
– Wire, conductor cross section: 1.0 – 1.5 mm2 (AWG17 – AWG16)
S Power supply
For data concerning the power supply, see Subsection 2.11.3, Page 2-87.

PROFIBUS-DP Interface description of the PROFIBUS DP interface (X2):

(X2) S Connection: 9-pin SUB-D socket connector
S Pin assignment
Table 2-15 Pin assignment: PROFIBUS DP (X2)
Pin Description Type Function

1)
1 – – –
2 – – –
3 RxD/TxD-P B Receive/transmit data P (B line)
5 DGND VO Data reference potential (M5V)
6 VP VO Supply voltage plus (P5V)
7 – – –
8 RxD/TxD-N B Receive/transmit data N (A line)
9 – – –
O Output
B Bidirectional
S Connectors
– 6ES7972-0BA40-0XA0; cable outlet 350, without PC socket connector
– 6ES7972-0BB40-0XA0; cable outlet 350, with PC socket connector
– 6ES7972-0BA11-0XA0; cable outlet 900, without PG socket connector
– 6ES7972-0BB11-0XA0; cable outlet 900, with PG socket connector
S Cable
– 6XV1830-0EH10; by the meter, non-trailable
– 6XV1830-3BH10; by the meter, trailable
S Additional technical specifications

Maximum possible data rate: 12 Mbits/s
PROFIBUS ad- The PROFIBUS address of the ADI4 can be set in the range 1 to 127 using
dress (S1) switch S1.
Table 2-16 Meaning of switch S1
Switches Meaning
1 PROFIBUS address: 20 = 1
8 Not used
Notice
A newly set PROFIBUS address will only come into effect after power OFF/ON.

Digital inputs/out- Interface description of the digital input/output interfaces (X111/X222/X333):

puts S Connector: 50-pin ribbon cable connector
(X111/X222/X333)
S Pin assignment on each connector.
Table 2-17 Pin assignment (X111/X222/X333)
Pin Signal designation Type 1) Pin Signal designation Type 1)

1 M (GND) VO 26 Input 2.7 I
2 P24OUT VO 27 – –
3 Input 0.0 I 28 – –
4 Input 0.1 I 29 – –
5 Input 0.2 I 30 – –
6 Input 0.3 I 31 Output 0.0 O
22 Input 2.3 I 47 DOCOMx VI
1) VI Voltage Input
VO Voltage Output
I Signal Input
O Signal Output
x with x = 1,2,3

Digital inputs
S Terminal assignment for the digital inputs

The following figure shows an example of the terminal assignment for the
digital inputs on connector X111. Connectors X222 and X333 are assigned
analogously.
X111, X222, X333

PP72/48 P24OUT pin number:
(+24VDC)
1
2
3
Receiver
4
Receiver
: :
: :
: :
: :
26
Receiver
+24V
ext. power supply

P24OUText
+24V stabilized
2
1
0V
M (GND)
Fig. 2-21 Terminal assignment for the digital inputs
1 If you are using the internal power supply P24OUT
2 If you are using an external power supply P24OUText
S Internal power supply (P24OUT)

The internal power supply for the digital inputs (X111, X222, X333: Pin 2) is
derived from the general power supply of module X1, pin 2 (P24). Specifica-
tion: See Subsection 2.11.3, Page 2-87
Caution
A max. current of Iout = 0.5 A on X111, X222, X333: Pin 2 must not be ex-
ceeded. An exceeding of the maximum current might destroy the module.
S External power supply (P24OUText)

If an external power supply is used for the digital inputs, its reference ground
must be connected with X111, X222, X333: Pin 1 (M).
X111, X222, X333: Pin 2 (P24OUT) then remains open.

For specification of the external power supply, see Subsection 2.11.3, Page
2-87.
S Connecting cable: The required connecting cables (ribbon cables) must be
provided by the user.
S Electrical specification of the digital inputs:

Table 2-18 Electrical specification of the digital inputs
Digital inputs Min. Typical max. Nominal

Voltage at high signal level (UH) 15V 1) 30V 24V
Input current IIN at VH 2mA – 15mA –
Voltage at low signal level (UL) –30V – +5V 0V
Signal delay time TPHL 2) 0.5 ms – 3 ms –
S Supply voltage of the digital inputs
1) typical output voltage: VCC – IOUT<RON
VCC: actual operating voltage (P24OUT) at X111,
X222, X333: Pin 2
max. output current IOUT: 500 mA per pin
max. short-circuit current: 4 A (max. 100 ms, VCC= 24 V)
internal resistance RON: 0.4 W
S 2)
Moreover, the PROFIBUS communication time and the application cycle time must
be taken into account.
S Polarity reversal causes neither high level nor destruction of the inputs.

Digital outputs
S Terminal assignment for the digital outputs

The following figure shows an example of the terminal assignment for the
digital outputs on connector X111. Connectors X222 and X333 are assigned
analogously.
ext. power supply

PP72/48 +24V stabilized
X111, X222, X333
+24V 0V
pin number:
47,48,49,50
(DOCOMx)
31
Relay
Driver
Driver 32
: :
: :
: :
: :
Driver 46
1 (M)
M (GND)
Fig. 2-22 Terminal assignment for the digital outputs
S Connecting cable: The required connecting cables (ribbon cables) must be

provided by the user..
S Supply voltage:
To power the digital outputs, an external 24 V DC power supply source must
be connected to DOCOMx (X111, X222, X333: Pin 47, 48, 49, 50).
The reference ground of the external power supply source must be connec-
ted to X111, X222, X333: Pin 1 (M).
For further data, see Subsection 2.11.3, Page 2-87.
Caution
At the user end, it must be ensured that the maximum current drawn per
DOCOMx Pin (X111, X222, X333: Pins 47, 48, 49, 50) does not exceed 1 A.
The power supply (+24 V DC) for the digital outputs must therefore be connec-
ted to all 4 pins (X111, X222, X333: Pin 47, 48, 49, 50) for each DOCOMx.

S Electrical specification of the digital outputs:

Table 2-19 Electrical specification of the digital outputs
Digital outputs Min. Typical max. Nominal

Voltage at high signal level (UH) VCC – 3 V 1) VCC 24V
Output current IOUT – – 250mA –
Voltage at low signal level (UL) – – – Output
open
Leakage current at low level – 50mA 400mA –
Signal delay time TPHL 2) – 0.5 ms – –
Maximum switching frequency 2)
Resistive load 100Hz – – –

Inductive load 2Hz – – –
Lamp 11Hz – – –
S 1)
UH_typical = VCC – IOUT<RON
VCC: actual operating voltage
IOUT: maximum output current (see above)
maximum short-circuit current: 4A (max. 100ms, VCC= 24V)
RON: internal resistance = 0.4W
S 2)
Moreover, the PROFIBUS communication time and the application cycle time must
be taken into account.
S Incorrect connection causes neither high level nor destruction of the outputs.
S General electrical properties

– Galvanic isolation using optocouplers
– Current limitation to maximum 500 mA
– Protection from: short circuit, overtemperature, and loss of ground
– Automatic disconnection in case of undervoltage

LED: Status display The module has 3 LEDs through which the module status is displayed.
Table 2-20 LED: Status display
Description Color Description

POWER Green Supply voltage
OVTEMP Red Overtemperature indication
EXCHANGE Green Cycl. data exchange with DP master in prog-
ress
READY Red Ready for cycl. data exchange with DP master
2.11.3 Power supply
Module The supply voltage (24 V DC) of the I/O module PP72/48 is connected to the
screw terminal block X1. See Subsection 2.11.2, Page 2-80.
Digital outputs To power the digital outputs (+24 V DC), an external power supply source is
required. The power supply is connected through terminals X111, X222, X333,
pins 47, 48, 49, 50 (DOCOMx).
Digital inputs If the internal power supply from X111, X222, X333, Pin 2 (P24OUT) is not used
to power the digital inputs, it can be replaced by an external power supply
source (+24 V DC) as an option.
The reference ground of the power supply source must be connected with X111,
X222, X333, Pin 1 (GND). X111, X222, X333, Pin 2 (P24OUT) then remains
open.
Specification of The external power supply voltages must be generated as functional extra-low
the power supply voltages with safe electrical isolation (according to IEC 204-1, Section 6.4,
voltages (+24 V PELV) and must be grounded centrally by the user.
DC) The reference ground of the terminals X111, X222, X333, pin 1 (GND) must be
connected to a common grounding point with the reference ground of the power
supply of the I/O module PP27/48.
Caution
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.
Moreover, the external power supply voltages for the I/O modules PP72/48, the
digital outputs, and optionally the digital inputs must meet the specifications
according to Table 2-21.

Table 2-21 Specification of the power supply voltage P24OUT,
Voltage
Minimum 20.4V
Nominal 24V
Max. 28.8V
Minimum (dynamic) 18.5V
Maximum (dynamic) 30.2V
Non-cyclic overvoltage
Max. (absolute, transient) 35V
Max. duration 500 ms
Min. recovery time 50 s
Max. events per h 10
Voltage failure for min. power supply voltage
Max. duration 1) 50 ms
Min. recovery time 1s
Max. events per h 10
Power consumption
Max. approx. 40 W
On the module side the power supplies must be protected against:
S Polarity reversal
S Short-circuit (elec. current limitation of the outputs)
S Overload (fuse protection).
2.11.4 Grounding
The module must be installed according to EN 60204.
If a large-area, permanent metallic connection with the central ground point
through the rear panel is not possible, the mounting plate must be connected to
the grounding by means of a line (cross section >10 mm2).
Caution
! A protective conductor must be connected.

2.11.5 Dimension drawing
194
6.5
10.5
325
306
10 10 170
35
35
Fig. 2-23 Dimension drawing: I/O module PP72/48

Technical data of I/O module PP72/48
Safety
Safety class Safety class I, in accordance with VDE 0106 P1: 1982
(IEC 536);
Protection against ingress of foreign bodies and water in
accordance with IEC 529
Approvals UL/CSA, CE
Power consumption
At nominal load 11W
Mechanical data
Dimensions WxHxD [mm] 194 x 325 x 35
Weight Approx. 0.3kg Approx. 1.2kg
without mounting plate with mounting plate
Operation Storage/transport
Temperature limits 0 ... 50°C –20 ... 55°C/–40 ... 70 °C
Limits for relative humidity 5 ... 95 % 5 ... 95 %
without condensation without condensation
Atmospheric pressure 700 ... 1060 hPa 700 ... 1060 hPa
Transportation altitude – –1000 ... 3000 m
Shock stress during transportation
Free fall in transport packag- v1000 mm
ing

2.12ADI4 (Analog Drive Interface for 4 Axes)
2.12 ADI4 (Analog Drive Interface for 4 Axes)
2.12.1 Module
X1: External power supply

24 V DC
OFF
ON
X2: PROFIBUS connection

1
PROFIBUS address:
AH = 10D
corr. to
S2: DIL switch for setting the

PROFIBUS address
8
X3: Analog setpoint outputs

$10 V DC, Axis 1–4
X4–2: Encoder connection X4–1: Encoder connection

for Axis 2 for Axis 1
X5–2: Encoder connection X5–1: Encoder connection

for Axis 4 for Axis 3
X6–2: Connection for digital X6–1: Connection for digital

input signals output signals
Diagnostic LEDs
H1: PW TMP
H2: EXCH RDY Connection for protective ground
Screw M6
Fig. 2-24 Connection overview for ADI4

2.12 ADI4 (Analog Drive Interface for 4 Axes)
Order number
ADI4 6FC5 211-0BA01-0AA2
Properties The interface module ADI4 is suitable for operating up to 4 drives with an ana-
log setpoint interface on the PROFIBUS DP.
The module has the following essential features:
S PROFIBUS DP connection (max 12 Mbits/s)

S 4 servo interfaces each with one:
– Input: TTL/SSI encoder for incremental and absolute measuring systems
– Output: $10 V analog
S General and drive-specific digital input/output signals

S Onboard status display by means of 4 diagnostic LEDs
To power the module and the digital outputs, an external power supply source
(+24 V DC) is required.
Notice
Please observe the following framework conditions for operating the ADI4 DP
slave:
S An ADI4 DP slave can only be operated on an equidistant PROFIBUS DP

(see Section 8.8, Page 8-217).
S 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.
Literature For detailed documentation about the operator panel front OP 012 please see:
References: /ADI4/ Analog drive port for 4 axes

2.13Diagnostic repeater for PROFIBUS DP
2.13 Diagnostic repeater for PROFIBUS DP
2.13.1 Module
Fig. 2-25 View: Diagnostic repeater for PROFIBUS DP
Order number
Diagnostic repeater for PROFIBUS DP 6ES7 972-0AB01-0XA0
Properties The diagnostics repeater with online line diagnostics for PROFIBUS DP offers
the following main features:
S Module-specific features:
– PROFIBUS DP standard slave (DP-V1)
– Data transfer rate: 9.6 kBaud to 12 MBaud
– Maximum depth of cascading: 9
– Redundant operation: no
S Automatic detection of fault type and fault location
S Distance given in line diagonistics:
– Resolution: 0.5 m
– Accuracy: "1 m
S Repeater throughput time:
– Baud rates w1.5 Mbaud: 2.5 TBIT + 153 ns;
(12MBaud: TBIT = 83.3 ns)
– Jitter: 1T = 1/48 MHz = 20.83 ns
S Monitoring function of isosynchronous PROFIBUS
– DP bus cycle (TDP): min. 1 ms, max. 32 ms
– Tolerance range TDP monitoring: "2 ms
– Tolerance range TDX monitoring: "10 ms
S Supply voltage: Rated voltage 24 V DC (20.4 to 28.8 V)

2.13 Diagnostic repeater for PROFIBUS DP
S Permissible ambient conditions:

– Operating temperature 0 °C to +60 °C
– Transport/storage temperature –40 °C to +70 °C
– Relative humidity max. 95 % at 25 °C
S Mechanical design:
– Dimensions (B X H X T) 80 x 125 x 67.5
– Weight 300 g
S Degree of protection: IP20
Literature A full description of the diagnostic repeater for PROFIBUS DP is to be found in:
References:
Manual
SIMATIC diagnostic repeater for PROFIBUS DP
Drawing number: A5E00352937-01, 10/2004 Edition
Order number (MLFB): 6ES7972-0AB00-8AA0
J

Set-Up 3
3.1 System overview
3.1.1 Operator panels and touch panels
OP 010 OP 010S OP 010C OP 012 OP 015
OP 012T TP 012 TP 015A
Possible configurations:
– Centralized configuration: Connection of the OP/TP
directly to the PCU
– Distributed configuration: Connection of the OP/TP to
a TCU (Thin Client Unit). Communication with the
PCU via Ethernet.
PCU 50.3
Fig. 3-1 System overview of SINUMERIK 840Di sl Operator panels and touch panels

3 Set-up 03/2006
3.1 System overview
3.1.2 PROFIBUS DP components
MCI board
X102
X101 Decentr. I/O system SIMATIC

ET 200
PROFIBUS DP (2)
PROFIBUS DP (1)
SINUMERIK 840Di sl
Mini HHU
PCU 50.3
Alternative
1)
I/O Module PP72/48
SINAMICS S120 SIMODRIVE 611 universal

option module: MotionControl Pushbutton Panel
with PROFIBUS DP MPP 438H
Machine control Machine control

panel panel
MCP 310 MCP 483
ADI4
1)
Only the PLC has access to the PROFIBUS DP (2), interface
X102. Therefore no drives and no I/Os of the NC can be
PG/PC e.g. Diagnostic repeater operated via this PROFIBUS line.
SIMATIC Power PG for PROFIBUS DP
Fig. 3-2 System overview of SINUMERIK 840Di sl PROFIBUS DP (schematic)

03/2006 3 Set-up
3.1 System overview
3.1.3 MPI components
MCI board
X102
MPI bus
X101
Industrial PC: PCU 50.3
ÄÄ
ÄÄ
Distributor box
or
PG/PC e.g.
SIMATIC Power PG Handheld unit
type B-MPI
Fig. 3-3 System overview of SINUMERIK 840Di sl MPI (schematic)
3.1.4 PCU components
Mouse CD-ROM 3.5” diskette Keyboard (QWERTY)

drive drive
Industrial PC: PCU 50.3
SITOP POWER SITOP DC UPS module 15 with

standard 24V/10A SITOP POWER lead-acid module
SIEMENS
SIEMENS
PG/PC e.g. Optional

Monitor
SIMATIC Power PG
Fig. 3-4 System overview of SINUMERIK 840Di sl PCU components (as a diagram)

3 Set-up 03/2006
3.2 Electrical design
3.2.1 MCI board and PROFIBUS DP

1)
Only the PLC has access to PROFIBUS DP (2), interface X102.
Therefore no drives and no I/Os of the NC can be operated via
this PROFIBUS line.
Alternatively also parameterizable as an MPI bus.
X102
1)
Diagnostic repeater
for PROFIBUS DP
X101
X2
SIMATIC DP ET200
MCI board
X126
X2
I/O Module
PP72/48
SINAMICS S120
Alternative:
SIMODRIVE 611 universal
with optional module: MotionControl
with PROFIBUS DP
X2
Pushbutton Panel
MPP 438H
ADI4
Machine control panel
MCP 310
Machine control panel

MCP 483
PG/PC e.g.
SIMATIC Power PG
Fig. 3-5 SINUMERIK 840Di sl MCI board and PROFIBUS DP components

03/2006 3 Set-up
Note
For details on general accessories, such cables, connectors and prefabricated
cables, please refer to:
References: Catalog NC 61, MOTION-CONNECT
3.2.2 MCI board and MPI bus
X2 / X5
X20
ÄÄ
X102 Machine control panel
(rear view)
X101
X5
ÄÄ
X4
Distributor box
Handheld unit
type B-MPI
MCI board
PG/PC e.g.
SIMATIC Power PG
Fig. 3-6 SINUMERIK 840Di sl MCI board and MPI bus components
3.2.3 MCI board extension
X4
Cable distributor
X121
2x sensor 2x handwheel 4x digit. input

4x digit. output
MCI board extension
Fig. 3-7 SINUMERIK 840Di sl MCI board extension

3 Set-up 03/2006
3.2.4 PCU 50.3
SITOP POWER 10 with

SITOP DC UPS Module 15and
SITOP POWER lead-acid battery
module
MCI board extension
(option)
SIEMENS X121
Power switch
MCI board
(On/Off switch (only standby)
for the power supply unit) Power Supply
24 V DC X101 X102
Ethernet 2 Ethernet 1 4x PROFIBUS/MPI DVI-I

USB (2.0) CF card slot
System network Company network
Ext. Operator Panel (OP) PG/PC e.g. Keyboard (QWERTY) ext. CD-ROM Mouse Ext. monitor
via a Thin Client Unit (TCU) SIMATIC Power PG drive
Fig. 3-8 SINUMERIK 840Di sl: PCU 50.3 (right housing)
I/O interface for connecting LVDS interface for connecting

the I/O cable of the operator panel front a TFT display cable
Optimum connection for the operator pa-

nel front with USB 2.0 front port
Fig. 3-9 SINUMERIK 840Di sl: PCU 50.3 (rear housing)

03/2006 3 Set-up
3.3 Overview of connections
3.3.1 MCI board and MCI board extension
SINUMERIK 840Di sl
PCU 50.3
4 rapid
digital CNC
v25m I/Oseach
Cable distributor 6FX2006-1BA02
Cable: Probe
6FX2002-4AA41-1jj0 max. 2
MCI board extension
slot variant (option)
v25 m
X121
Electronic
Cable:
handwheel
6FX2002-4AA21-1jj0
max. 2
v25m
Cable: Connection kit 4)

6FX2006-1BG00 Mini HHU
6FX2002-4AA21-1jj0 EMERGENCY
v25m for handwheel signals STOP/
Enabling circuit
Cable: Distributor
X4 4) HHU
6FX2002-4AA21-1jj0 1) 6FX2006-1BC01
v25m for handwheel signals 1BF00 type B-MPI
EMERGENCY
1BH01 STOP/
Enabling circuit
Included in the scope of supply
of the MCI board extension
Mini HHU
EMERGENCY
STOP 4)
Enabling circuit
9)
PROFIBUS DP PLC inputs
diagnostic repeater
Connection kit
1) Machine control 6FX2006-1BG00
X2 2) 6)
panel:
X102 – MCP 483 v5m Electronic
PROFIBUS: – MCP 310
12 Mbaud (100 m)
9) handwheel
Master or Slave
PROFIBUS DP (2)
(I/O) 1)
or 6) Electronic
Pushbutton Panel
MPI MPP 483 v5m handwheel
MCI board
3)
PROFIBUS DP (1): 12 Mbaud (100m)
X101
PROFIBUS:
Master 1) 1) 1) 1)
(drives,
I/O) Drive: SIMATIC
SINAMICS S120 ADI4 7) I/O module
ET 200 DP PP72/48
via CU320
Standard PC
interfaces 5)
Fig. 3-10 Connection overview: MCI board and MCI board extension

3 Set-up 03/2006
1) Connector:
6ES7972-0BA41-0XA0; cable outlet 350, without socket connector for pro-
gramming device
6ES7972-0BB41-0XA0; cable outlet 350, with socket connector for pro-
gramming device
6ES7972-0BA12-0XA0; cable outlet 900, without socket connector for pro-
gramming device
gramming device
Cable:
6XV1830-0EH10; by the meter, not trailable
6XV1830-3EH10; by the meter, trailable
2) Connector:
6GK1500-0EA02; cable outlet 1800, without PG socket connector for pro-
gramming device
Cable:
3) Connector:
gramming device
gramming device
Cable:
4) The cable is included in the scope of supply.
5) For an overview of the standard PC interfaces, see Fig. 3-8, Page 3-100
and Fig. 3-9, Page 3-100, as well as:
Component PCU 50.3
6) Cable: 6FX8002-2CP00-1Aj0
7) For a detailed overview of the connection to the AD14 please refer to
References: /ADI4/ Analog drive interface for four axes
Connection overview
8) Connection via Fast Connect (insulation displacement method) see:
References: SIMATIC Manual: Diagnostic repeater for PROFIBUS DP
9) Can be assigned parameters either as an MPI or a PROFIBUS interface.
Only the PLC has access to this PROFIBUS interface. No drives and no
NCK I/Os can be operated via this PROFIBUS line.
Note
The length codes for preassembled cables 6FXj002-... can be found in:
References: Catalog NC 61, MOTION-CONNECT.

03/2006 3 Set-up
3.3.2 PCU50
SINUMERIK 840Di sl
PCU 50.3
1) SINUMERIK
LVDS/IO operator panel front
1) SINUMERIK
SINUMERIK
Thin Client Unit operator panel
(TCU) front
Ethernet 3)
Machine 2) Electronic
control panel handwheel
MCP 483C IE v5m
3)
Industrial
Ethernet Ethernet
Fig. 3-11 Connection overview: PCU
1) The cable is included in the scope of supply.
2) Cable: 6FX8002-2CP00-1Aj0
3) For information on Ethernet cables, please refer to

References: Catalog NC 61, MOTION-CONNECT
J

3 Set-up 03/2006
Notes

EMC and ESD Measures 4
4.1 Interference suppression measures
Shielded To ensure safe, interference-free operation of the installation, it is essential to

signal cables use the cables specified in the individual diagrams. Both ends of the shield must
always be conductively connected to the equipment housing.
Exception:
S If non-Siemens devices are connected (printers, programming devices, etc.),

you can also use standard shielding cables, which are connected at one
end.
These devices may not be connected to the control during normal operation.
However, if the system cannot be operated without them, then the cable
shields must be connected at both ends. Furthermore, the external device
must be connected to the control via an equipotential bonding lead.
Rules for routing To ensure that the entire installation (control, power section, machine) has the
cables greatest possible immunity to interference, the following EMC measures must
be taken:
S Signal cables and load cables must be routed at the greatest possible
distance from one another.
S Only use SIEMENS signal cables for connecting to and from the NC or PLC.
S Signal cables may not be routed close to strong external magnetic fields
(e.g. motors and transformers).
S Pulse-carrying HC/HV cables must always be laid completely separately

from all other cables.
S If signal cables cannot be laid at a sufficient distance from other cables, then
they must be installed in shielded cable ducts (metal).
S The distance (noise field) between the following leads should be as small as
possible:
– Signal cable and signal cable
– Signal lead and associated equipotential bonding lead
– Equipotential bonding lead and PE conductor (routed together).
Important
! For further notes on interference suppression measures and the connection of
shielded cables, please refer to
References: /EMC/ EMC Installation Guide

4 EMC and ESD Measures 03/2006
4.2 ESD measures
4.2 ESD measures
Notice
Handling of modules containing devices sensitive to electrostatic discharge:
S When handling electrostatically sensitive devices, make sure that operator,

workplace and packing material are properly grounded.
S As a general principle, electronic modules should only be touched if this is

absolutely unavoidable (owing to repair work, etc.). When you are handling
PCBs, therefore, make sure that you never touch any submodule pins or
conducting paths.
S Touch components only if

– you are permanently grounded by means of an antistatic chain,
– you are wearing ESD boots or ESD boots with grounding strips in con-
junction with ESD flooring.
S Modules may be placed only on electrically conductive surfaces (table with

ESD top, conductive ESD foam plastic, ESD packing bags, ESD transport
containers).
Notice
Exceptions to this are modules with their own power source (e.g. battery).
These may not be placed on conductive surfaces, as this might result in
short circuits and thus destroy the component on the module.
S Keep modules away from visual display units, monitors or TV sets (mini-
mum distance from screen > 10 cm).
S Do not bring ESD-sensitive modules into contact with chargeable and

highly-insulating materials, such as plastic, insulating table tops or clothing
made of synthetic materials.
S Measurements on modules are allowed only if

– the measuring instrument is grounded (e.g. via PE conductor) or
– the measuring head on an isolated instrument is discharged briefly (e.g.
by being brought into contact with bare metal part of control housing)
before the measurement is taken.

Power-On and Power-Up 5
5.1 Preparing for start-up
5.1.1 Checklist
SINUMERIK The following checklist will help you to start up the supplied components without
840Di sl undue problems and ensure high availability on your product:
S When handling the components, all ESD measures are observed.
S All screws are tightened with their prescribed torque.
S All connectors are plugged correctly and locked/screwed.
S All components are grounded and connected to shields.
S The load capacity of the central power supply is taken into account.
Drives Additional points should be observed depending on the drive system used. For
detailed information, please refer to:
S SINAMICS S120
Commissioning Manual
Section: Prerequisites for commissioning
S SIMODRIVE 611 universal

/FBU/ Description of Functions SIMODRIVE 611 universal
Section: General commissioning information
Limit values All components are dimensioned for defined mechanical, climatic and electrical
environmental conditions. No limit value may be exceeded, neither during op-
eration, nor during transportation.
In particular, the following must be observed:
S Power supply conditions
S Pollution burden
S Function-impairing gases
S Climatic ambient conditions
S Storage/transport
S Shock load
S Vibration stressing
S Ambient temperature

5 Power-On and Power-Up 03/2006
5.1 Preparing for start-up
5.1.2 Recommended sequence for first start-up
The individual steps for first start-up are listed below in the recommended order.
1. The whole plant is mechanically and electrically connected and tested for
errors acc. to the checklist (see above).
– SINUMERIK 840Di sl
– SINAMICS S120 or SIMODRIVE 611 universal inverter system
– Motors
– SIMATIC S7 I/O components
– HMI user interfaces
2. The order numbers (MLFB) of the SIMODRIVE 611 universal drives and
SIMATIC S7-I/O components should be available.
When creating the SIMATIC S7 project, they are used to check whether the
component chosen from the hardware catalog by “HW Config” corresponds
to the component used on the plant.
3. Configure the SINUMERIK 840Di sl completely on first booting
(Section 5.2, Page 5-109)
4. Take the PLC default program supplied as the installation and start-up file for
the PLC (basic PLC program, PLC user program and configuration) or
create your own SIMATIC S7 project and load it into the PLC
(Section 7, Page 7-157)
5. Prepare the drives on the PROFIBUS DP for communication:
– SINAMICS S120 (Section 10, Page 10-257)
– SIMODRIVE 611 universal (Section 11, Page 11-289)
6. Perform start-up of the NC (channels, axes and spindles, etc. (Section 12.5,
Page 12-324))
7. Set up the alarm texts (Section 13, Page 13-421)
8. Perform the start-up of the drives:
– SINAMICS S120 (Section 10, Page 10-257)
– SIMODRIVE 611 universal (Section 11, Page 11-289)
9. Carry out a dry run for all axes and the spindle.
10. Perform the optimization of the drives:
– SINAMICS S120: STARTER
– SIMODRIVE 611 universal: HMI Advanced (Section 15, Page 15-435)
and/or SimoCom U
11. Carry out a user data backup (series machine start-up file)
12. Optional: Make a complete data backup (partition and/or hard disk image):
Literature
/IAM2/ start-up CNC Part 5
Section: IM8
4 Save and restore data

03/2006 5 Power-On and Power-Up
5.2 First power-up
5.2 First power-up
5.2.1 Basic start-up of the system software
Objective of basic After the basic start-up described in the following two sections, the following
start-up conditions should apply:
S SINUMERIK 840Di sl NC and PLC are operated in cyclical operation

S If a machine control panel is connected, no alarms or messages should be
pending.
S The displayed axes of the NC can be traversed by simulation.
As-delivered state The hard disk of the PCU is already partitioned upon delivery for operating the
SINUMERIK 840Di sl. Additional software applications which have ordered, e.g.
HMI Advanced, are ready for installation under:
S D:\Setup\Apps\<Application1> . . . <Application n>
C: NTFS D: NTFS E: NTFS F: NTFS
Name: EMERGENCY Name: TMP Name: SYSTEM Name: USER

Content: WinPE 2005 Content: Images, Content: Windows Content: 840Di sl
Setups XP
Updates
Primary partition Extended partition with logic drives
Fig. 5-1 Partitioning the hard disk
Installing the soft- When the PCU is first booted, the following menu is displayed:
ware
Welcome to SINUMERIK !
These SINUMERIK products will be installed now:
<Application 1> <Version>

: :
: :
<Application n> <Version>
Install NOW
Install on NEXT REBOOT
CANCEL installation
Menu commands:
S Install NOW
All the applications displayed will be installed in the listed order. During the
installation procedure follow the instructions that appear on the screen.

5.2 First power-up
Notice
You must not switch off the PCU during the entire installation procedure. Loss
of data!
S Install on NEXT REBOOT

None of the listed applications are installed and you are taken to the Win-
dows desktop. The installation menu is displayed again the next time the
PCU is booted.
S CANCEL installation
None of the listed applications are installed.
Application:
Subsequent installation of a hard drive image as part of a series machine
start-up.
Notice
The current installation menu will not be displayed the next time the PCU is
booted. The installation procedure which was cancelled by clicking “Cancel
installing” cannot be repeated
Completion When installation is complete rebooting automatically starts. Once the PCU has
booted again, you can continue with the basic PLC start-up procedure (Section
5.2.2, Page 5-110).
5.2.2 Basic start-up of the PLC

Once the Service Desktop is active the PLC series machine start-up file sup-
plied must be loaded into the PLC for basic start-up. To do so, proceed as fol-
lows:
1. Start the “SinuCom NC” start-up tool from the Windows taskbar: Start > Pro-
grams > SinuCom NC > SinuCom NC
2. Use SinuCom NC to load the series machine start-up file PLC_SMP.ARC
into the PLC.
Menu command: File > Archive > SeriesStart-up archive > ReadIn
Dialog: Read-in archive
– Radio button: Data Storage
– Button: “NEXT”
– Select file PLC_SMP.ARC in directory Archive
– Button: “FINISH”
This executes the PLC basic start-up procedure.NC and PLC run in cyclic
mode.

5.3 Booting
5.3 Booting
5.3.1 SRAM handling

The user data of the NC (machine data, setting data, user variables, parts pro-
grams, cycles, etc.), as well as the retentive data of the PLC are battery-backed
in the static memory area (SRAM) of the MCI board.
With each “NCK power ON RESET” (warm restart) or shutting down Windows
XP correctly, the contents of the SRAM is saved to the hard disk of the PCU as
an SRAM image. In this case, the SRAM image valid until then also be saved to
the hard disk of the PCU as an SRAM backup.
In certain error or servicing instances, the SRAM image or backup can be ac-
cessed so that work can be continued immediately without restarting the SI-
NUMERIK 840Di sl.
Table 5-1 SRAM handling
HW SRAM SRAM image SRAM backup Used user data / remark

serial num- MCI board (hard disk) (hard disk)
ber “OK” “OK” “OK”
MCI board
Known yes not relevant not relevant MCI / Normal power-up
Known no yes not relevant IMAGE / no message box or alarms;
see Section 5.3.3; case 1
Known no no yes BACKUP / message box and alarm;
Known no no no Start-up / Restart-up required
Unknown yes yes not relevant MCI or IMAGE / Request carried out;
See Section 5.3.5
Unknown yes not relevant not relevant MCI / MessageBox;
(SW update) See Section 5.3.4
Unknown yes no Yes MCI or BACKUP / Request carried out; if BACKUP
is selected, message box and alarm will occur;
Unknown yes no no MCI / MessageBox;
See Section 5.3.4
Unknown no yes not relevant IMAGE / MessageBox;
Unknown no no yes BACKUP / message box and alarm;
Unknown no no no Start-up / Restart-up required
HW serial number. MCI board
known: The hardware serial no. of the MCI board matches the
serial number last stored on the PCU.
unknown: The hardware serial no. of the MCI board does not match the
serial number last stored on the PCU.
unknown: Provided that the SRAM of the MCI board is “OK”, the system does not
request which SRAM (MCI or IMAGE) is to be used when booted for
the first time (SW update). The SRAM of the MCI board is always used.
SRAM image or SRAM backup (hard disk) “OK”

yes: The following criteria must be fulfilled:
1. NC and PLC-SW version of SRAM image or
backup must match the installed software version.

5.3 Booting
2. Windows XP must have been shut down correctly (the POWER

FAIL mechanism of the SINUMERIK 840Di sl is also sufficient).
3. The checksum test using the SRAM image or backup must be

successful.
4. The battery status at the time of saving the SRAM image

must be O.K.
Used user data
MCI: The battery-backed user data in the SRAM of the MCI board are used.
IMAGE: The battery-backed user data in the SRAM image on the hard disk of
the PCU are used.
BACKUP: The battery-backed user data in the SRAM backup on the hard disk of
the PCU are used.
Start-up: The user data of the NC are deleted and default machine data loaded.
5.3.2 Start-up after battery replacement (PCU backup battery)
Correct quit Before replacing the PCU backup battery, the SINUMERIK 840Di sl or Windows
XP must be shut down correctly.
For shutting down, use one of the following options:
S Windows taskbar: Start > Shut Down

S Interface signal: “PC shutdown”, see Section 19.1.1, Page 19-507
Inverting SRAM If SRAM memory cells are inverted when changing the battery, this will be de-
memory cells tected during power-up. The SRAM image will then be written back to the
SRAM of the MCI board and the SINUMERIK 840Di sl is now immediately ready
for operation.
Responses
None.
Notice
If Windows XP is shut down not correctly before changing the backup battery,
an inversion of the SRAM memory cells during the battery change cannot reli-
ably be detected.
The SINUMERIK 840Di sl must then be restarted.
5.3.3 Start-up after replacement of the MCI board

After the MCI board has been replaced, the subsequent procedure depends on
the previous history. The following cases are distinguished:
1. An up-to-date SRAM image exists
2. An up-to-date SRAM image does not exist.

5.3 Booting
Case 1: Before the MCI board has been changed, Windows XP could not be shut down
An up-to-date SRAM correctly. An up-to-date SRAM image is thus provided.
image exists During power-up, the MCI board is detected as a new one using the HW serial
number. The SRAM image will then be written back to the SRAM of the MCI
board. The SINUMERIK 840Di sl is immediately ready for operation.
Responses
A note will appear in a message box, which must be acknowledged with “OK”:
Note: User data loaded into MCI card.
Notice
1. If the MCI board is recognised as being faulty while the SINUMERIK
840Di sl is booting, the last SRAM image is retained when Windows XP is
shut down. After the MCI board has been changed, proceed as described
above.
2. If the MCI board is to be replaced as a result of a suspected or actual error
(suspected error, sporadic errors, etc.), the SINUMERIK 840Di sl NC and
PLC should be restarted as possible data errors may otherwise be imported
from the SRAM image.
Case 2: A fault occurred with the MCI board during operation of the SINUMERIK
An up-to-date SRAM 840Di sl. Windows XP has possibly been shut down correctly, but no SRAM
image does not exist image could be created.
After replacement, based on the hardware serial number the MCI board will be
identified as “unknown”. Since no up-to-date SRAM image exists, the SRAM
backup is written back into the SRAM of the MCI board. The SINUMERIK
840Di sl is now immediately “operational”.
The user data, or operating state of the SINUMERIK 840Di sl must be checked
to ascertain if operation can be continued. It might be necessary to restart the
SINUMERIK 840Di sl NC and PLC.
Responses
A note will appear in a message box, which must be acknowledged with “OK”.

5.3 Booting
Alarm: Old backup of user data loaded into MCI card.

The user data were saved on 07.07.2000 10:30
An NC alarm is also generated, which is displayed on the respective SINUM-

ERIK 840Di sl user interface (840Di start-up, HMI Advanced, etc.):
S Alarm: “4065 Battery-backed memory has been restored from the hard
disk (possible data loss)”
To acknowledge the alarm you must first acknowledge the alarm itself with a
special operation before executing the required NCK POWER ON Reset. See
Section 12.10.1, Page 12-414 ff.
5.3.4 Power up after reinstallation/update of the 840Di sl software
If the 840Di sl software is reinstalled on an operational SINUMERIK 840Di sl,

the user data saved in the SRAM of the MCI board is retained.
To achieve this, it is essential that the current NC and PLC software version
complies with the software version with which the battery-backed user data of
the SRAM have been created.
The SINUMERIK 840Di sl is thus ready again immediately.
Responses
A note will appear in a message box, which must be acknowledged with “OK”:
Note: User data from MCI card used.
Notice
If the buffered user data is not going to be used again, the SINUMERIK
840Di sl must be restarted.

5.3 Booting
5.3.5 Start-up after replacement of the PCU or the MCI board
If, during booting, it has been ascertained that both the SRAM image on the
PCU hard disk and the MCI board SRAM have buffered valid, but divergent user
data (both components were already in use in one SINUMERIK 840Di sl), no
automatic selection can be made.
Responses
The following message box is displayed with which the user has to decide
which user data have to be used further.
New MCI card detected. Valid user data are found:

– on MCI card
– on hard disk
If you want to use the user data from MCI card press “Yes”
If you want to use the user data from the hard disk press “No”
Yes No
5.3.6 Start-up after importing a backup copy
If a backup copy (ghost image) of a previously booted SINUMERIK 840Di sl is

loaded into the PCU again, the user data puffered in the SRAM of the MCI bo-
ard will be used again.
5.3.7 Start-up after power failure / Power Fail
Case 1: Thanks to the Power Fail Detection integrated in the PCU, in the event of a
SRAM saved power failure the SINUMERIK 840Di sl saves the user data in the SRAM of the
MCI board. An SRAM image, however, cannot be created any more in this
case.
When the power returns or with the next power-up, the data will be available
again.

5.3 Booting
Notice
Saving of the user data in the SRAM of the MCI board in case of power failure
is only guaranteed if the PCU is operated within its defined specifications.
References: /BH/ Operator Components, Manual
Section: Component PCU 50
Case 2: If the SINUMERIK 840Di sl was operated outside its defined specifications, it
SRAM not may not be possible to save the user data in the SRAM. Therefore, proceed as
saved described in Section 5.3.3, Page 5-112 case 2.
5.3.8 Power-up with shutdown signal
If the SINUMERIK 840Di sl is operated with a UPS unit, the shutdown signal
must be configured accordingly. See Section 12.10.2, Page 12-418. If a shut-
down signal is pending first the NC and PLC and then Windows XP are shut
down correctly.
1. Ramp-up If power-up is executed with a pending shutdown signal Windows XP is immedi-

ately correctly shut down again.
From 2nd pow- The system responds as follows if it is powered up a second time with pending
er-up shutdown signal:
– Windows XP is not immediately shut down correctly
– NC and PLC are not started
– The following message box appears:
Interrupt: NCK started while Power Failure, shutdown with OK
Set
This system response ensures that an error in the protection circuit of the MCI
board extension module or in the configuration of the shutdown signal does not
result in an endless loop (power-up > shutdown signal > power-up > etc.).
As long as the message box has not been acknowledged the protective circuit
of the MCI board extension module and the configuration of the shutdown signal
(see Section 12.10.2, Page 12-418) can be checked and changed, if necessary.
If the shutdown signal has been acknowledged from the message box, the NC
and PLC are started. Otherwise Windows XP is again shut down correctly.

5.4 Service Desktop
5.4 Service Desktop

The Service Desktop is intended for machine manufacturer/service personnel.
Numerous SINUMERIK-specific applications are available on the Service Desk-
top in addition to the standard Windows functions.
5.4.1 Activation
Proceed as follows to enable the Service Desktop:
1. Press “3” as soon as the version is displayed on the bottom right of the
start-up screen.
SINUMERIK
V.00.00.00
Fig. 5-2 Display during start-up of the SINUMERIK 840Di sl
2. Enter the password: “SUNRISE”.

3. Click on the “Service Desktop” button in the selection menu or press the
“Return” key.
5.4.2 SINUMERIK-specific applications

The following SINUMERIK-specific applications are available on the Service
Desktop:
S Ghost Explorer
The Ghost Explorer is used to display the content of Ghost images.
Literature
The Ghost tools documentation is located on the PCU hard drive under:
E:\TOOLS
S HMI Explorer
The HMI Explorer is used to display the version and install or post-install the
supplied SINUMERIK application. See Section 5.4.7, Page 5-121.
S Touchware
Program for calibrating the touchscreen connected to the PCU directly.

5.4 Service Desktop
Literature
/BHsl/ IOperator Components Manual
Section: Configure system
Configure system network with ’Settings system network’
S Settings System Network
Setting up the Ethernet connection of a TCU to the SINUMERIK 840Di sl.
Literature
/IAM2/ Start-up CNC Part 5
Section: Thin Client Configuration (IM5)
Start-up
Calibration of the touchscreen
S HMI Analyzer
Analysis tool for HMI Advanced in conjunction with PCU 50.3
Literature
/IAM/ Start-up CNC Part 2
Section: Start-up HMI Advanced IM4
Diagnosis and Service
HMI Analyzer
S ServiceCenter
Starts the ServiceCenter after the computer reboots under WinPE 2005 to
create and restore partition and hard drive images with the backup software:
“Norton Ghostt”.
Literature
Section: IM8
Save and restore data
S Folder: SINUMERIK 840Di
– SINUMERIK 840Di Startup
Simple SINUMERIK 840Di-specific user interface.
– NT desktop / HMI desktop
Autostart of the HMI application: OFF / ON
See Section 5.4.3, Page 5-119.
– Readme
Notes and conditions concerning the installed SINUMERIK 840Di sl sys-
tem software.
S Folder: SINUMERIK 840Di > tools
– HT8TCU
Activation of the transfer of an HT8 machine control panel signal
Literature
Section: Thin Client Configuration (IM5)
Configure system network
Configure HT 8 in the system network
– Install/uninstall MCIS RCS Host

Installation and uninstall program of the host for remote diagnostics of
SINUMERIK systems with Windows-based HMI within the framework of
Motion Control Information System.
Literature
Catalog NC 61: Motion Control Information System (MCIS)

5.4 Service Desktop
S Folder: SinuCom NC
– CT Editor
Tool for creating test templates
– NC Connect Wizard
Tool for establishing the communications link from SinuCom NC to SI-
NUMERIK 840Di sl.
– SinuCom NC
Note
When Windows starts up, the SINUMERIK 840Di sl NCK system software is
automatically started in the background.
5.4.3 Setting the boot response for the Service Desktop
The NC or MHI desktop settings are used to deterine if the NC-desktop (Win-
dows desktop) is displayed after booting the SINUMERIK 840Di sl, or if the HMI
user interface, e.g. HMI Advanced, is started immediately:
S NC desktop
HMI application autostart: OFF
S HMI desktop
HMI application autostart: ON
5.4.4 System information after “Fatal exceptional error”
After a “fatal exception error” (blue screen), system information is written to the
following file:
S D:\Memory.dmp
5.4.5 Starting OEM programs
OEM directories OEM programs can be executed before starting the SINUMERIK system soft-
ware. These programs or their respective links must be stored in the following
directories:
S C:\RunOEM\SeqOnce
Programs stored here are started once and sequentially.
S C:\RunOEM\Seq
Programs stored here are started on every power-up and sequentially.
Note
Sequential: The subsequent program will only be started when the previous
program has been ended.

5.4 Service Desktop
S C:\RunOEM\ParOnce
Programs stored here are started once. They run parallel with the HMI sys-
tem software.
S C:\RunOEM\Par
Programs stored here are initiated at every boot. They run parallel with the
HMI system software.
Order of execution Directories and programs are processed in the following order:
S Directories
1. C:\RunOEM\SeqOnce
2. C:\RunOEM\Seq
3. C:\RunOEM\ParOnce
4. C:\RunOEM\Par
S Programs
The programs within a subdirectory are started according to the chronologi-
cal order in which they were placed in the subdirectory.
Data files In addition to executable programs, you can also place data files in the subdi-
rectories. They will be opened in the application with which their file type is as-
sociated.
Example:
S File type: “.txt” –> Notepad
S File type: “.htm”–> Internet Explorer
5.4.6 User-specific HMI start-up images
User-specific start-up images can be displayed while the HMI is booting. The
boot images must be stored in bitmap format (*.BMP) in a defined directory
structure.
Directory structure The directory structure must be created under “F:\OEM\IB\DATA” according to
the following schema:
S F:\OEM\IB\DATA\<NCK type>\<screen resolution>\<file name>.BMP
Parameters: The different NCK types are displayed depending on the directory name.
NCK type
The following values may be used as directory names for the SINUMERIK
840Di sl:
S default
If a directory: default is created, the start-up image stored in this directory will
always be displayed irrespective of the NCK type.

5.4 Service Desktop
S 5000
Under directory: 5000 (ID for SINUMERIK 840Di sl) stored start-up images
are only displayed by the HMI application together with a SINUMERIK
840Di sl.
Parameters: The start-up images for the various screen resolutions must be stored in differ-
Screen resolution ent directories. The directory name corresponds to the screen resolution:
S 640
Start-up image for screen resolution: 640 x 480 [dpi]
S 800
start-up image for screen resolution: 800 x 600 [dpi]
S 1024
start-up image for screen resolution: 1024 x 768 [dpi]
Note
Directory: Screen resolution may only contain one file.
Parameters: You can choose any file name.

File name
5.4.7 HMI Explorer

The HMI Explorer is used to manage the Siemens A&D software components
on the PCU. The following main functions are available:
– Version display
– Installation, de–installation, and re–installation
– Application-specific information (detailed information, history, available
language versions, etc.)
– Installation directory
HMI Explorer
File View System Program Install
Info
SINUMERIK Product Current ver- Release ver-

840Di sl Siemens SINUMERIK Pro. sion sion
HMI Base V06.02.11.01 V06.02.11.00
BaseSoftware WinXP V03.02.03.02 V02.03.02.03
HMI Advanced V06.03.11.00 V06.03.11.00
HMI Programming Pac. V06.02.11.00 V06.02.11.00
HMI Service Pack 2 2
840Di sl V06.03.11.00 V06.03.10.00
Siemens Other Products
MPI Driver R06.03.11.00 R06.03.11.00
STEP7 V05.03.01.00 V05.03.01.00
SIMATIC ProTool/ CS V05.02.03.00 V05.02.03.00
Third Party Products
Ready
Fig. 5-3 HMI Explorer: Product/Version Display (Example)

5.4 Service Desktop
Version display The following versions are displayed for each software application:
S Current version
Current version number
S Release version
Version number with which product was first installed.
Installation The path of the installation directory of a software component is displayed in the
directory Install dialog box: Menu command: Install
5.4.8 SW installation/update
The Service Desktop allows you to install or update software directly from an
external computer using a specially configured network link. For a detailed de-
scription see Section 18, Page 17-475.

5.5 Configuring the network link of PCU (LAN/WAN)
5.5 Configuring the network link of PCU (LAN/WAN)

To perform service functions (software installation/update), the SINUMERIK
840Di sl requires an active connection to an external computer at least for the
duration of the service task.
PTP link The PTP link (peer-to-peer) to a single computer is described in Section 17.1,
Page 17-475.
LAN/WAN link The PCU basic software is preconfigured for an Ethernet network link with pro-
tocol: TCP/IP.
The settings for the local network links (Windows taskbar: Start > Settings >
Network Connections >> Local Area Connections) regarding IP address and
domain are assigned as follows:
Dialog: Local Area Connections Properties
S Tab card: General
– IP address via DHCP
Option: Obtain an IP address automatically
– Automatic DNS server address
Option: Obtain a DNS server address automatically
S Tab card: Alternate Configuration

– Automatic IP address as alternative configuration
Option: Automatic private IP address
If changes have been made or a network link cannot be established, settings
regarding:
S TCP/IP protocol
S IP address and subnet mask
S Computer name and domain/workgroup
must be made and/or checked.
Note
You may have to consult your network administrator to obtain the above infor-
mation or any other information required for your current network.

5.6 License management
5.6.1 License management with the Automation License Manager
License management with the Automation License Manager is described a sep-

arate section. Section 18, Page 18-485.
5.6.2 License management with SinuCom NC

To use SINUMERIK 840Di sl system software and the enabled options, the cor-
responding software licenses must be assigned to the SINUMERIK 840Di sl
hardware. During the assignment procedure, you will be given a license key for
each piece of software (system software or options) which electronically links
the respective software to the hardware.
You can also activate options without the license keys and use them for test
purposes. The control will then cyclically display a reminder/alarm that a license
has not yet been registered for the option.
Ordering up to entering the license key of an option is performed as follows:
1. Order and purchase of the relevant license packages and/or single licenses:
Order catalog: NC 61
2. Activate the options SinuCom NC
3. Obtain the license key for the required control: Web License Manager by
Internet connection to the SINUMERIK 840Di sl or external PG/PC via
www.siemens.com/automation/license
4. Enter the license key: SinuCom NC
New license key To obtain and enter a new license key in the control system, proceed as follows:
1. Start SinuCom NC from the Windows taskbar: Start >
Programs > SinuCom NC > SinuCom NC
2. Use SinuCom NC to go online control system.
3. Double-click on the machine data module to open:
SinuCom NC – [[Online]SinuCom_NC_Project]
Machine data
block
Sinumerik – Project objects
Sinumerik 840Di sl(1) [connected]
Machine data MD block1
4. Select the “Options” data field.

In the “Options” dialog, you can:
– Enable/disable options

or
– Obtain new license keys (Web License Manager)
– Enter license keys in the control system
Click on the “Get a new license key” button and follow the instructions in the
subsequent dialogs.
SinuCom NC - [[Online]SinuCom_NC_Project : MD block1]

File Editing Target syst. Diagnosis Tools View Window ?
8080 1 options are activated without setting the license key (Cancel) Alarm log
MD-Block1 Options: /MD-Block1 Input fields:

Options
Show all Show only not licensed Options
Trace Setup Wizard
PROFIBUS assignment Option Set Licensed
Channel modegroup assignment
NCU SW 31A with HMI Embedded
Axis configuration 6FC5840-3xGxx-xYA0
Axis
AX1:X1 (DR1) Programm preprocessing
AX2:Y1 (DR2) 6FC5800-0AM00-0YB0
AX3:Z1 (DR3)
AX4:A1 (DR4) Traversing to fixed stop (with force control)
AX5:B1 (DR5) 6FC5800-0AM01-0YB0
Functions
Pair of synchronized axes (gantry axes)
6FC5800-0AM02-0YB0
Accept Reject
Modifications Modifications
Current License Key is not sufficient

Button:
Get a new License Key License Key
Ready SIN840Di sl sl: 10.113.22.10

Notes

PLC Start-Up 6
6.1 General
6.1.1 Compatibility
The PLC integrated on the MCI board of the SINUMERIK 840Di sl is compatible
with the SIMATIC S7 PLC: AS317-2 DP.
6.1.2 Performance data

The PLC of the SINUMERIK 840Di sl has the following features:
Table 6-1 Performance data of the PLC
PLC317-2DP (6FC5 317-2AJ10-0AB0)

Memory for PLC basic program and user program 768 KB
Data block memory max. 256 KB
Memory submodule no
Bit memories 32768
Timers 512
Meters 512
Clock memories 8
Program and data blocks
OB 1, 10, 20–21, 32–35, 40,
55–57, 80, 82, 85–87, 100,
121–122
FB 0–2048
FC 0–2048
DB 1–2048
Max. length of data block 32 KB
Max. block length FC, FB 64 KB
Inputs/outputs (addressing capacity)
Notice
The inputs/outputs above 4096 are reserved for integrated
drives.
Digital/analog 4096 / 4096 bytes
Incl. reserved area 8192 / 8192 bytes
Process image 256 / 256 bytes
Inputs/outputs (addressing) Through optional configur-
Row 0 is integrated in the NC. Rows 1 to 3 are available for ing of I/O devices
I/O devices

6 PLC Start-Up 03/2006
6.1 General
Table 6-1 Performance data of the PLC
PLC317-2DP (6FC5 317-2AJ10-0AB0)

Digital From I/O byte 0
Analog From PI/PO byte 272 only
Profibus
Processing time
Bit instructions (I/O) <= 0.031 ms/kA
Word instructions 0.1 ms/kA
PDIAG (Alarm S,SQ) Yes
PROFIBUS Master/Slave
Number of PROFIBUS slaves (see note below) max. 125
PBC programmable block communication Yes
Consistent data to standard slave via SFC 14, 15 128
6.1.3 PLC program
The PLC program is modular in design. It comprises the two parts:

The PLC basic program organizes the exchange of signals and data
between the PLC user program and the NC, HMI, and machine control
panel components.
The PLC basic program is part of the PLC Toolbox supplied with SINU-
MERIK 840Di sl.
– PLC user program
The PLC user program is the user-specific part of the PLC program by
which the basic PLC program has been added to or extended.
Literature For a complete description of the basic PLC program, its structure and all mod-
ules including their call parameters, please refer to:
References: /FB1/ Description of Functions, Basic Machine
Section: P3, Basic PLC Program
6.1.4 Installing the PLC basic program library
To be able to use the blocks of the basic PLC program (OBs, FBs, DBs, etc.) in
a SIMATIC S7 project, the library must first be installed in the SIMATIC man-
ager. Information that you need to install the PLC basic program (storage path
of file: setup.exe and additional installation instructions) are included in file:
S <Installation path>\importantinfo.rtf
Notice
The library of the basic PLC program must be installed on the computer on
which the SIMATIC manager for creating the S7 project is already installed.

03/2006 6 PLC Start-Up
6.1 General
6.1.5 STEP 7 example projects
Included in the scope of supply for the SINUMERIK 840Di sl system software
are two STEP 7 projects, on which the basic configuration of the SINUMERIK
840Di sl Station and an MCP (PROFIBUS / Ethernet) is displayed. The example
projects can be used as a basis for your own projects.
Storage path The example projects are on the SINUMERIK 840Di sl CD under:
S Example project with PROFIBUS MCP:

<CD path>\support\840dismp\840Di_sl_DPMCP_smpl.zip
S Example project with Ethernet MCP:

<CD path>\support\840dismp\840Di_sl_ETMCP_smpl.zip
Retrieve Example programs must first be dearchived in the SIMATIC Manager before
they can be used. SIMATIC Manager: File > Dearchive...
The example projects can be dearchived to the default “S7Proj” target directory.
Use The example projects are listed in the SIMATIC Manager under user projects.
SIMATIC Manager: File > Open... > Dialog box: “Open project” > Tab: “User
projects”
S Example project with PROFIBUS MCP: 840Disl_DPMCP

Station
S Example project with Ethernet MCP: 840Disl_ETMCP
Loading into the The communication link from SIMATIC STEP 7 to the SINUMERIK 840Di sl PLC
PLC must be checked and established before loading an example project.
S External connection
The PG/PC runs on the SIMATIC STEP 7, can be connected with the SINU-
MERIK 840Di sl PLC via the MPI connection of the MCI board or via one of
the Ethernet interfaces (Ethernet 1: company network or Ethernet 2: local
network) of the PCU.
– MPI connection
The MPI interface of the MCI board is already configured in both exam-
ple projects. Configuring the PG/PC interface is described in Subsection
6.2.3, Page 6-133.
– Ethernet connection
Configuring the PG/PC interface is described in Subsection 6.2.2, Page
6-133. Configuring the communications processor (CP 840D sl) of the
SINUMERIK 840Di sl is described in Subsection 6.3.8, Page 6-143.
S Internal connection
A local SIMATIC STEP 7 installed on the SINUMERIK 840Di sl is linked via
the preset local “SOFTMC” communications link with the SINUMERIK
840Di sl PLC. Configuring the PG/PC interface is described in Subsection
6.2.4, Page 6-134.

6.1 General
6.1.6 PLC user program
The organization blocks:
S OB100 (cold restart)

S OB1 (cyclic processing)
S OB40 (process alarm)
contain the entry points for the appropriate parts of the PLC user program.
FB 1
ÎÎÎ
OB 100
Start-up:
Restart e.g. HHU parameters
User Program
ÎÎÎÎÎ
OB 1
ÎÎÎÎÎ
FC 27 * * only required, if a MCP or MPI
Cyclic bus is connected
processing MCP_INT
NCK
FC 2 Mode group
Channel
GP-OB 1
Axis
Spindle
FC 14
MCP,
HHU
FC 6
TM
FC 19/25/26
User MCP:
program MCP_IFM
MCP_IFT FC (9/15/16/18)
HPU_MCP ASUB,
con. axes/
FC 7/8/22 spindles
TM:
TM_Trans FB 2/3/4
TM_Dir
Var. read/
write,
FC 17 PI services
Star/delta
FC 10
Error and opera- FC 13
tional messages
HHU:
display contr.
ÎÎÎÎÎ
OB40
ÎÎÎÎÎ
Process alarm
FC3
GP_PRAL G group
Distribution list
User
program
Fig. 6-1 Structure of the PLC program

6.1 General
Processing mod- The individual blocks in the basic PLC program can be processed in the SI-
ules MATIC manager:
S Select the appropriate block, e.g. OB 100 in the folder Blocks of the corre-
sponding Module.
S Use the menu command Edit > Open Object to open the block or double-
click the block with the left mouse button.
S Edit the block using the LAD/STL/CSF editor

Switch over the block display using the menu command View > LAD or STL
or CSF.

6.2 Startup
6.2 Startup
The PLC can be started up by:
S Creating an S7 project and loading the configuration.

For how to create an S7 project using the PLC basic program supplied with
the SINUMIERK 840Di sl and basic parameter assignment for MPI and
PROFIBUS communication please refer to Section 6.3, Page6-137.
S Loading an existing series start-up file.

For how to create and read in a series start-up file please refer to Chapter
16, Page 16-467.
6.2.1 Basic requirements
SINUMERIK The SINUMERIK 840Di sl must be successfully booted to start up the PLC:
840Di sl S NCK in cyclic operation
S PLC in status: RUN
Note
The NCK and PLC status can be checked with:
– User interface 840Di startup
See corresponding online help
– Start-up tool: SinuCom NC
See relevant online help
– User interface HMI-Advanced (optional)
See Section 12.10, Page 12-414.
SIMATIC STEP 7 SIMATIC STEP 7 is required in the following version:
S SIMATIC STEP 7 as from Version 5.3, Service Pack 2

SIMATIC STEP 7 can either be installed directly on the SINUMERIK 840Di sl
PCU or on an external computer (PG/PC).
Communications Depending on which computer is running SIMATIC STEP 7, there must be one
link of the following communications links between SIMATIC STEP 7 and the SINU-
MERIK 840Di sl PLC:
Computer Communications link
External computer (PG/PC) Ethernet
External computer (PG/PC) MPI/PROFIBUS
SINUMERIK 840Di sl Local connection (Softbus)

6.2 Startup
6.2.2 External communications link: Ethernet
To load the configuration from an external computer (PG/PC) into the SINUME-
RIK 840Di sl PLC via an Ethernet connection, the following conditions must be
met on the PG/PC:
S Ethernet communication is possible in principle or set up
S PG/PC interface is parameterized (see below)
S The PG/PC is connected to one of the Ethernet interfaces of the SINUME-
RIK 840Di sl PCU (Ethernet 1: company network or Ethernet 2: local net-
work)
PG/PC interface The PG/PC interface is parameterized in the SIMATIC Manager via menu item:
Options > Set PG/PC interface...:
Dialog box Dialog box: Set PG/PC interface

tab: Access path
Interface parameterization used: <Interface>
Set
Notice
Do not select ISO interfaces as Ethernet interfaces from the list of interfaces,
e.g. “ISO Ind. Ethernet –> Realtek RTL8139...”.
Instead, use the appropriate TCP/IP interfaces, e.g. “TCP/IP –> Realtek
RTL8139...”.
6.2.3 External communications link: MPI/PROFIBUS
To load the configuration from an external computer (PG/PC) into the SINUME-
RIK 840Di sl PLC via an MPI connection, the following conditions must be met
on the PG/PC:
S Communications module (alternative):
– CP5611: MPI/PROFIBUS communications processor (PCI)
– CP5511: MPI/PROFIBUS communications processor (PCMCIA)
S MPI/PROFIBUS driver is installed
S PG/PC interface is parameterized (see below)
S The MPI/PROFIBUS interface of the CP is linked to the MPI/PROFIBUS
interface of the MCI board (X1).
PG/PC interface The PG/PC interface is parameterized in the SIMATIC Manager via menu item:
Options > Set PG/PC interface...:

6.2 Startup

tab: Access path
Interface parameterization used: CP5611(AUTO) or
CP5511(AUTO)
Set
Note
If the MPI/PROFIBUS interface of the MCI board (X1) is configured in the S7
project as a PROFIBUS interface, we recommend you set the PG/PC interface
of the external computer to “CPxxxx(AUTO)”.
The PLC continuously transmits the communication parameters in cyclic opera-
tion, so that the connected devices can adjust automatically.
The default setting of the MPI/PROFIBUS interface of the MCI board (X1) is
MPI. The default setting takes effect after resetting the PLC.
6.2.4 Local communications link: SOFTMC
The configuration is loaded from a local SIMATIC 7 installed on the SINUMERIK

840Di sl to the PLC via the default local “SOFTMC” communications link.
PG/PC interface The PG/PC interface can be parameterized in the SIMATIC Manager via menu
item: Options > Set PG/PC interface...:

tab: Access path
Interface parameterization used: SOFTMC
Set
6.2.5 Check PLC status and communication interface
The PLC status and therefore also the communications link to the PLC can be
checked from “HW Config” via menu item: Target system > Status.
– If the current operating status of the PLC is displayed, the communica-
tions link is operating correctly.
– If the current operating status of the PLC is not displayed, the commu-
nications link must be checked for correct parameterization. If no con-
nection is established to the PLC despite correct parameterization, a
general reset of the PLC is necessary.
PLC general reset General reset of the PLC can be performed using 840Di Start-up or HMI Ad-
vanced (option):
S 840Di start-up

6.2 Startup
– Start 840Di start-up: Windows XP taskbar: Start > Programs > SINU-
MERIK 840Di > 840Di Start-up.
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC.
S HMI Advanced (option).

– Open the dialog box: Operating area switchover > Start-up > NC/PLC
Diagnosis.
S Request general reset of PLC: “PLC Delete Program”.

After general reset the PLC is in RUN mode, i.e. the LED in the display is lit:
“RUN” green.
6.2.6 First start-up
On initial start-up of the PLC, a general reset of the PLC has to be performed
after the SINUMERIK 840Di sl has been switched on and booted.
To obtain a defined initial state of the whole system (NC and PLC), the NC data
should also be deleted.
– PLC general reset
General reset puts the PLC in a defined initial state by deleting and ini-
tializing all system and user data.
– Delete NC data
After a request to delete NC data, all user data are deleted and the sy-
stem data are reinitialized on the next NC power-up, e.g. after NC Reset.
PLC general reset, General reset of the PLC and deletion of NC data can be performed using
deleting NC data 840Di Start-up or HMI Advanced.
S 840Di start-up
– Start: WINDOWS XP taskbar: Start > Programs > SINUMERIK 840Di >
840Di Start-up
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC
S HMI Advanced
Diagnosis
Dialog box Proceed as follows in the dialog boxes:

1. PLC general reset
PLC group
Button: “PLC Delete Program”

6.2 Startup
Notice
After a general reset of the PLC, interface X102 (MPI/DP) of the MCI board is
set to “MPI” and the following MPI parameters are set:
– MPI address of the PLC = 2
– MPI data transfer rate = 187.5 kbaud
2. Delete NC data
NC group
button: “NCK Default Data”
3. Initiate NC Reset
To start cyclic operation or NC/PLC communication, NC reset (button: “NCK
Reset”) must be triggered:
The subsequent SINUMERIK 840Di sl boot has been successfully completed if
the following display appears in the dialog box:
S NC status:
NC group
6 NC in cyclic mode
S PLC status:
PLC group
LED RUN constantly lit
Note
Since no PLC program is executed after PLC general reset, the following
alarms are displayed:
S Interrupt: “120201 Communication failed”
S Interrupt: “380040 PROFIBUS DP: Configuring error 3, parameter”
S Interrupt: “2001 PLC not booted”
These alarms have no influence on how to continue.

6.3 Creating a SIMATIC S7 project

This section describes the creation of an S7 project for basic start-up of the
PLC, the MPI and PROFIBUS communications, and the input/output data areas
of the NC. To do this you will have to perform the following operations:
– Creating a project
– Set up a station
– Parameterizing MPI communications
– Parameterizing PROFIBUS communications
– Parameterize the input/output data areas of the NC
Note
The X102 interface: MPI/DP can either be used as an MPI or PROFIBUS inter-
face.
MPI When setting up the station, parameterization of the MPI communication is lim-
ited to parameterization of the MPI addresses of the PLC and NC and the data
transfer rate in the MPI bus (see Subsection 6.3.4, Page 6-140).
A full description of how to parameterize the MPI communication is given in
Chapter 9, Page 9-235.
PROFIBUS-DP Maximum two PROFIBUS lines can be connected to a SINUMERIK 840Di sl:
S Interface X101: PROFIBUS-DP

In the case of the SINUMERIK 840Di sl, the position controller cycle of the
NC is derived directly from the isochronous PROFIBUS cycle. Defined va-
lues must therefore always be entered for the following PROFIBUS parame-
ters:
– mode: DP master
– Isochronous PROFIBUS: Active
– Isochronous time TDP on PROFIBUS-DP: Position control cycle
Both the PLC and the NC have direct access to this PROFIBUS interface.
PROFIBUS drives and NC-specific I/Os can only be connected via this inter-
face.
S Interface X102: MPI/DP

This PROFIBUS interface is only available to the PLC. It can also be oper-
ated in “DP Master” or “DP Slave” mode.
A full description of how to parameterize PROFIBUS communications is given in
Note
The instructions given in this section are essentially limited to the special char-
acteristics of the SINUMERIK 840Di sl. For more details about working with
SIMATIC STEP 7 please refer to the relevant SIMATIC documentation or On-
line Help.

6.3.1 Creating a project
To create a new project select menu items File > New in the SIMATIC Manager.
Enter the following project data in the dialog box:
– Name (for example: SIN840Di sl)
– Storage location (path)
– Type
and confirm the dialog box with OK. The project window is now displayed show-
ing an empty S7 project structure.
6.3.2 Inserting station 300
Before you can insert the required hardware in the S7 project you must first in-
sert a SIMATIC station 300 in the project. To do that, select menu item: Insert >
Station > SIMATIC Station-300.
SIMATIC Manager – SIN840Di sl

Station Edit Insert Target System View Tools Window Help
<No filter>
SIN840Di sl – <Installation path>\step7\s7proj\SIN840Di sl

SI Cut Ctrl+X
N Copy Ctrl+C
Paste Ctrl+V
Delete Del
Insert new object SIMATIC 400 Station

PLC SIMATIC 300 Station
Rename F2 SIMATIC H Station
SIMATIC PC Station
Object Properties... Alt+Return
Other stations
SIMATIC S5
PG/PC
MPI
Project window PROFIBUS
Industrial Ethernet
PTP
Fig. 6-2 Inserting the SIMATIC 300 station
Starting HW-Con- Start “HW-Config” by opening the station and double-clicking on the hardware
fig icon.
SIN840Di sl – <Installation path>\step7\s7proj\SIN840Di sl

SIN840Di sl Hardware
SIMATIC 300(1)
We recommend giving the inserted SIMATIC Station 300 a meaningful name,

for example 840Di sl.

6.3.3 HW-Config
The user interface of “HW-Config” mainly contains:
– Station window
The station window is split. The upper part displays the structure of the
station graphically, and the lower part provides a detailed view of the
selected module.
– Hardware catalog
If the hardware catalog is not displayed, open it using the menu com-
mand: View > Catalog.
HW Config – [SINUMERIK (configuration) –– SIN840Di sl]

Search:
Profile Standard
: PROFIBUS DP
Stations window: Station structure PROFIBUS PA
PROFINET IO
SIMATIC 300
SIMATIC 400
SIMATIC PC-based Control
SIMATIC PC Station
Hardware catalog
slot Name
Stations window: Detailed view
Fig. 6-4 HW Config: Names of the main areas
Note
To check whether a module selected from the hardware catalog complies with
the module in the automation system, the following procedure is recom-
mended:
1. Put down the MLFB numbers of all modules used in the automation system.
2. Select the appropriate module from the hardware catalog and compare the
order number (MLFB) displayed with the noted MLFB number. The MLFB
numbers must be identical.

6.3.4 Inserting the 840Di sl Rack
The 840Di sl Rack contains the already partially preconfigured components:
S SINUMERIK 840Di sl PLC

Standard designation: PLC 317-2DP 2AJ10
S MPI/DP interface
Standard designation: MPI/DP
S PROFIBUS DP interface
Standard designation: DP
S SINUMERIK 840Di sl NC
Standard designation: NCK 840D sl
S SINUMERIK CP for Industrial Ethernet TCP/IP

Standard designation: CP 840D sl
Inserting the The 840Di sl Rack is located in the hardware catalog under:
840Di sl Rack
Profile: Standard
SIMATIC 300 > SINUMERIK > 840Di sl > 840Di sl
Use the right mouse button to select the 840Di sl Rack and drag it to the Station
window, while holding down the mouse button. When you release the mouse
button, the 840Di sl Rack will be inserted in the S7 project.

Station Edit Insert T arget System View Tools Window Help
Search:
Profile: Standard
SIMATIC 300
C7
CP–300
CPU–300
FM–300
IM–300
M7 EXTENSION
Gateway
PS–300
RACK–300
SM–300
SINUMERIK
840D
i sl840D
i sl
840Disl PLC317–2DP_2AJ10
SINUMERIK 840Di sl
Fig. 6-5 HW Config: SINUMERIK 840Di sl Rack
6.3.5 Parameterizing the PROFIBUS interface (X101)

When you have inserted the 840Di sl Rack, the dialog box for assigning para-
meters to the PROFIBUS interface (X101) opens automatically as for slot X2.
Make the following settings in the Properties box:

S PROFIBUS address of DP master

The default setting of the PROFIBUS address is 2. It is recommended to
keep this setting.
S Subnetwork
S Equidistant DP cycle
S Equidistant time
Equidistant time The SINUMERIK 840Di sl will accept the set isochronous DP cycle as the NC
system clock cycle and position controller cycle.
Position controller cycle = NC system clock cycle = equidistant DP cy-
cle
The time you can set for the equidistant DP cycle depends on:
1. The cyclic communication load by the drives and field devices on the PRO-
FIBUS DP
2. The capacity utilization of the cyclic position controller level by the NC due to
the number of position-controlled machine axes and active functions
Dialog box Dialog box: Properties – PROFIBUS interface DP

T ab: Parameter
Address: 2
Subnetwork:
Button: “New...”
Dialog box: Properties – New PROFIBUS Subnetwork
Tab: General
S7 subnetwork ID: <Subnetwork ID> (see below: Note)
Tab: Network settings
Data transfer rate: 12 Mbits/s
Profile: DP
Button: “Options...”
Dialog box: Options
Tab Equidistance
Activate equidistant bus cycle:
Equidistant DP cycle: <Isochronism time>
OK
OK
Set
Note
SIMODRIVE
We recommend making a note of the S7 subnetwork ID, since it will be
needed later to assign parameters for the routing settings of the drive commis-
sioning tool SimoCom U. See Subsection 11.1.6, Page 11-295.

6.3.6 Parameterizing the PROFIBUS interface (X102) (optional)
When you have completed the “Properties – PROFIBUS Interface DP” dialog
box (see previous Subsection 6.3.5, Page 6-140) the 840Di sl Rack is displayed
in the Station window.

PROFIBUS(1): DP master system(1)

Search:
Profile: Standard
(0) 840Di sl PROFIBUS-DP
2 PLC 317–2DP 2AJ10 PROFIBUS PA
X1 MPI/DP PROFINET IO
X2 DP SIMATIC 300
4 NCK 840D sl C7
5 CP 840D sl CP-300
CPU-300
FM-300
IM-300
M7 EXTENSION
(0) 840Di sl Gateway
PS-300
slot Module... Order number Fi... M.. E... A... K... RACK-300
2 PLC 317-2DP 2AJ10 6FC5 317-2AJ10-0AB0 V2.1 SM-300
X1 MPI/DP 8191 SINUMERIK
X2 DP 8190 840Di sl
4 NCK 840D sl 256* 840Di sl
5 CP 840D sl V0.0 272. 272.
. . 840Disl
PLC317-2DP_2AJ10
SINUMERIK 840Di sl
Fig. 6-6 HW-Config: SINUMERIK 840Di sl Rack
To parameterize the PROFIBUS interface (X102) as for slot X1, set the following
parameters:
S Interface type
S Data transfer rate
Double-click on module: MPI/DP, slot X1 in the 840Di sl Rack, to open the
MPI/DP Properties dialog box.
Dialog box Dialog box: MPI/DP Properties

Register: General
Name: <Designation of 2nd DP interface>
Group: Interface
Type: PROFIBUS
Button: “Properties...”
Dialog box: Properties – PROFIBUS Interface MPI/DP
Tab: Parameter
Address: <Address>
Button: “New...”

Dialog box: Properties – New PROFIBUS Subnetwork

Tab: Network settings
Data transfer rate: <Trans.rate>
Profile: DP
OK
Register: Mode
Radio button: <Mode>
OK
Set
6.3.7 Parameterizing the MPI interface (X102) (optional)

When you have completed the “Properties – PROFIBUS Interface DP” dialog
box (see previous Subsection 6.3.5, Page 6-140) the 840Di sl Rack is displayed
in the Station window.
To parameterize the MPI interface you will have to make the following parame-
ter settings:
S Interface type
Double-click on module: MPI/DP, slot X1 in the 840Di sl Rack, to open the
MPI/DP Properties dialog box.
Dialog box Dialog box: MPI/DP Properties

Register: General
Group box: Interface
Type: MPI
Dialog box: Properties – MPI Interface MPI/DP
Tab: Parameter
Address: 2 (see note)
Subnetwork: MPI(1) 187.5 kbaud
OK
Set
Notice
With SINUMERIK 840Di sl, the MPI address of the PLC must always be set to
2.
6.3.8 Parameterization of the communications processor (CP 840D sl)

(Ethernet)
To parameterize the Ethernet communication between an external PG/PC and

the SINUMERIK 840Di sl, set the following parameters for the integrated com-
munication processor “CP 840D sl”:

S IP address of the PCU

S Subnet mask of the PCU
S Gateway of the PCU
S Subnetwork
Note
Determining the IP address and subnet mask of the PCU:
On the PG/PC: Windows XP taskbar: Start > Run, Command: ipconfig
Double-click on module: CP 840D sl, Slot 5 in the 840Di sl Rack, Properties

dialog box:
Dialog box Dialog box: Properties CP 840D sl

Register: General
Dialog box: Properties – Ethernet interface CP 840D sl
Tab: Parameter
IP address: <IP address of the PCU> (1)
Subnet mask: <Subnet mask of the PCU> (2)
Group: Gateway
Option: No router (3)

Group: Subnet
Button: “New...” (4)
Dialog box: Properties – New subnet Ind. Ethernet
Name: <Name>
OK
OK
OK
Properties – Ethernet interface CP 840D sl (R0/S5)
General Parameter
1 3
Gateway
IP address: 10.113.22.24
No router
Subnet mask: 255.255.255.0
2 Use router
Address: 10.113.22.24
4
Subnet:
––– not networked New...
Ethernet
––– (1)
Properties...
Delete
Fig. 6-7 Parameterize the properties of the CP 840D sl (excerpt)

Notice
The IP address and subnet mask in the image above are example values only!
6.3.9 Networking PG/PC and PCU (Ethernet)
The PG/PC must be networked with the PCU so that the SINAMICS drive com-
missioning tool can communicate from the project directly with the drive units
connected to the SINUMERIK 840Di sl.
Execution Perform the following actions for networking:

1. Start the NetPro configuration tool in HW Config.
(0) 840Di sl
2 PLC 317–2DP 2AJ10
2. From the selection list of the network objects, open Stations and insert a
PG/PC into the project (1).
NetPro – [SIN840Di sl (Netz) –– C:\Program Files\...\s7proj\SIN840_sl]
Network Edit Insert Target System View Tools Window Help
Find
Selecting the network objects

PROFIBUS–DP
PROFIBUS PA
PROFINET IO
Stations
Other stations
PG/PC
SIMATIC 300
1 SIMATIC 400
SIMATIC H Station
SIMATIC DP
SIMATIC PC Station
SIMATIC S5
Subnets
Programming device or
PC
Ready TCP/IP –> Realtek TRL813

3. Double-click on the inserted PG/PC station to open the Properties dialog

box. Select the “Interface (1)” tab. Click on “New...” to open the dialog box
for creating a new interface (2). Select “Industrial Ethernet (3)” as the inter-
face type. Click OK to confirm the dialog.
Properties – PG/PC
General Port Assignment
1
Name New interface – Type selection Subnet
Type: Industrial Ethernet

3 MPI
PROFIBUS
New... Delete
OK Cancel Help
4. After pressing OK, the properties dialog box of the Ethernet interface is dis-
played. Select the “Parameter (1)” tab and enter the IP address and subnet
mask of the PG/PC (2).
Note
Determining the IP address and subnet mask of the PCU:
On the PG/PC: Windows XP taskbar: Start > Run, Command: ipconfig
Select the “Ethernet (1)” (3) connection already parameterized in the pre-
vious Subsection 6.3.8, Page 6-143 as the subnet.
Click OK to confirm the dialog.
Properties – Ethernet interface
General Parameter
1
Set the MAC address / use ISO protocol
MAC address: 09–00–07–01–00–02 When selecting a subnet,

the next available addresses are suggested.
IP protocol is used
2
Gateway
IP Address: 157.174.219.45
No router
Subnet mask: 255.255.248.0
Use router
Address: 157.174.219.45
Subnet:
––– not networked New...
––– (1)
Ethernet
Properties...
3
Delete
OK Cancel Help

Notice
The MAC address, IP address and subnet mask in the image above are exam-
ple values only!
5. The configured Ethernet interface must be assigned to an interface parame-

terization of the PG/PC. Select the “Assignment” (1) tab.
Select the configured “Ethernet (1)” (2) interface from the “Configured inter-
faces” list and the Ethernet interface for connecting to the PCU from the “In-
terface parameterization in the PG/PC” list. In the example: “TCP/IP –>
Realtek RTL8139...” (3).
Notice
Do not select ISO interfaces as Ethernet interfaces from the “Interface parame-
terization in the PG/PC” list, e.g. “ISO Ind. Ethernet –> Realtek RTL8139...”.
Instead, use the appropriate TCP/IP interfaces, e.g. “TCP/IP –> Realtek
RTL8139...”.
Click on the “Assign” button to assign the interface (4).

Confirm the “Edit object properties” dialog by clicking on OK.
General Port Assignment 1
Not assigned
Configured interfaces:
Name Type Subnetwork
Ethernet Interface(1) Industrial Ethernet Ethernet(1) 2
Interface parameterization in PG/PC:

TCP/IP –> NdisWanlp
TCP/IP –> Realtek RTL8139/810x F... 3 4
TCP/IP(Auto) –> Intel(R) PRO/Wireless...
TCP/IP(Auto) –> Realtek RTL8139/81... Assigning
Remove
Assigned:
Port Parameter Assignment Subnetwork S7Online
S7ONLINE access:
active
OK Cancel Help

The assignments made are now displayed in the “Assigned” list (1). If there
are several assignments, make sure that the interface to be used for com-
munication, “Ethernet (1)” in this case, is active (2). Click OK to confirm the
dialog.
General Port Assignment
Not assigned
Configured interfaces:
Name Type Subnetwork
Interface parameterization in PG/PC:

ISO Ind. Ethernet –> Intel(R) PRO/Wire...
ISO Ind. Ethernet –> Realtek RTL8139...
PC Adapter(MPI)
PC Adapter(PROFIBUS) Assigning
Assigned: Remove
Port Parameter Assignment Subnetwork S7Online

1 Ethernet Interfa... TCP/IP –> Realte... Ethernet(1) active
S7ONLINE access:
active 2
OK Cancel Help
6. The PG/PC networking with the Ethernet interface is displayed in the project
view and identified by the yellow link.
NetPro – [SIN840Di sl (Net) –– C:\Program Files\...\s7proj\SIN840_sl]
Network Edit Insert Target System View Tools Window Help
Find
Selecting the network objects

PROFIBUS-DP
PROFIBUS PA
PROFINET IO
Stations
Other stations
PG/PC
SIMATIC 300
SIMATIC 400
SIMATIC H Station
SIMATIC DP
SIMATIC PC Sta-
tion
SIMATIC S5
Subnets
Programming device or
PC
Ready TCP/IP –> Realtek TRL813
7. Then compile and save the project.

NetPro can then be shut down.

6.4 Creating a PLC program
6.4 Creating a PLC program
6.4.1 PLC basic program
Opening the li- To insert the PLC basic program in the S7 project: SIN840Di sl you have
brary created, open the library installed in Subsection 6.1.4, Page 6-128 with menu
item: Open > File.
Select the library of the PLC basic program: for example, gp8x0d65 and confirm
the dialog box with OK.
Opening a project
User projects Libraries Example projects Multiple proj.
Name Storage path

gp8x0d65 F:\Program Files\Siemens\Step7\S7libs\gp8x0d65
mcp840Di F:\Program Files\Siemens\Step7\S7proj\mcp840Di
SIMATIC_NET_CP F:\Program Files\Siemens\Step7\S7libs\simaticn
Standard Library F:\Program Files\Siemens\Step7\S7libs\StdLib30
stdlibs (V2) F:\Program Files\Siemens\Step7\S7libs\STDLIBS
Fig. 6-8 Opening the library of the PLC basic program
Copying blocks Copy all blocks of the PLC basic program from the library to the block directory
of the PLC.

File Edit Insert Target System View Tools Window Help
< No filter >
SIN840Di sl –– <Installation path>\Step7\S7Proj\SIN840Di sl

SIN840Di sl OB1
SIMATIC 300(1)
PLC 317–2DP 2AJ10
S7–Program(1)
Source
sBlocks
gp8x0d65 –– F:\Siemens\Step7\S7libs\gp8x0d65
gp8x0d65 OB1 OB40 OB100 FB1
gp8x0d FB2 FB3 FB4 FB5
Source FB6 FB7 FB9 FB10
sBlocks
FB11 FB16 FB17 FB18
Fig. 6-9 Inserting blocks of the PLC basic program
Overwriting OB 1 Inserting blocks overwrites the existing organization block OB1. Confirm the
query as to whether you want to overwrite the block with “Yes”.

6.5 Creating a PROFIBUS configuration
6.4.2 PLC user program
The PLC user program according to its definition contains all functions required
to process user-specific automation tasks. Tasks of the PLC user program in-
clude:
– Defining the conditions for a restart (warm restart) and PLC restart.
– Processing process data, for example, combining signals, reading in and
evaluating analog values, defining signals for output and outputting ana-
log values.
– Responding to alarms
– Processing faults in normal program execution
The basis of the PLC user program is the PLC basic program already included
in the S7 project. Now expand and alter the PLC basic program to suit your au-
tomation task.

Creation of a PROFIBUS configuration is described in a separate section. See
6.6 Creating a MPI configuration

Creation of a MPI configuration is described in a separate section. See Chap-
ter 9, Page 9-235.
Note
An MPI configuration only has to be created if a handheld unit (B-MPI) is con-
nected to SINUMERIK 840Di sl.

6.7 Loading the configuration
6.7.1 Requirements
For loading the configuration into the PLC, the following prerequisites must be
fulfilled:
S A communications link exists between STEP 7 and the PLC.

S The configuration to be loaded corresponds to the actual station configura-
tion.
S SINUMERIK 840Di sl is active:

– NC is in cyclic mode
– PLC in RUN or STOP status
6.7.2 Loading the configuration
Note
You are recommended to check consistency of the configuration before loading
it.
HW Config: Station > Check consistency
Supplementary The following supplementary conditions regarding the system data blocks are
condition observed when the configuration is loaded:
– SIMATIC Manager
When loading the configuration via the SIMATIC manager all the system
data blocks are loaded into the module.
– HW-Config
When loading the configuration via HW-Config, only the system data
blocks generated by HW-Config during compilation of the configuration
are loaded into the module.
System data block SDB210 of the MPI configuration is therefore not ad-
ditionally loaded.
First loading As part of the MPI configuration, system data block SDB210 has also been
loaded into the block directory of the PLC. Because of the supplementary condi-
tions stated above, system data block SDB210 is only loaded into the PLC if it is
loaded with the SIMATIC Manager.
When the configuration is loaded into the PLC for the first time, it must be
loaded from the SIMATIC Manager.
Notice
When loading the configuration into the PLC, the system data block of MPI con-
figuration SDB210 is only loaded with the SIMATIC Manager, not with HW-Con-
fig.

Loading in the To load the configuration into the PLC select the following menu item: Target
module System > Load in Module.
The dialog box for loading the configuration now displayed offers the following
options:
– Set the PLC to the operating status STOP. See note below.
– Compress the memory if not enough contiguous free memory is avail-
able
– Reset PLC to operating status RUN
Note
When the PLC program is loaded in the RUN operating status, each block
loaded becomes active immediately. This can result in inconsistencies when
executing the active PLC program. You are therefore advised to place the PLC
in the STOP state before loading the configuration.
NC Reset The STOP condition of the PLC which is taken by the PLC for a short time on
triggered loading is interpreted by the NC as a PLC failure with an appropriate alarm res-
ponse.
Once the configuration has been loaded you must therefore initiate an “NC Re-
set”, for example, via the “840Di-Startup” user interface. In “840Di-Startup” se-
lect menu item: Window > Diagnostics > NC/PLC:
Dialog box Dialog box: NC/PLC Diagnosis

Group box NC
Button: “NC Reset”
6.7.3 Series machine start-up file
The PLC user data can be backed up by creating a series-start-up file or load-
ing an existing series start-up file using the following applications:
– SinuCom NC (part of the SINUMERIK 840Di sl installation)
– HMI Advanced (optional)
For detailed information about data back-up please refer to Chapter 16,
Page 16-467 or:
Literature SinuCom NC
Online Help
HMI Advanced
/BAD/ Operator’s Guide HMI Advanced
Section: Start-up functions

6.8 Testing the PLC program
6.8.1 Start-up behavior
Start-up of a SIMATIC-CPU module can be set for the following start-up modes:
– Restart
– Cold restart (warm restart)
– Cold Restart
With a SINUMERIK 840Di sl, the start-up type of the PLC is permanently set to
RESTART. It cannot be changed.
Start-up mode: With COLD RESTART block “OB100” is executed first. Then cyclic operation
RESTART starts with call-up of block “OB1”.
The following data are kept in the case of COLD RESTART:
– All data blocks and their contents
– Retentive timers, counters and flags
Retentive ranges The ranges of the timers, counters and flags that are to be retentive must be set
using the dialog box Properties, tab Retention of the PLC-CPU module.
Notice
The retention of the data areas can only be achieved with the backup supply
(backup battery) active. If the battery backup is empty, the PLC will not restart.
The following operations are performed during a restart:

– UStack, BStack and non-retentive flags, timers and counters will be de-
leted
– The process output image (POI) will be deleted
– Process and diagnostics alarms will be canceled
– The system status list will be updated
– Parameterization objects of modules (from SD100 onwards) will be eval-
uated or defaults parameters will be output to all modules in single-proc-
essor mode
– OB100 (cold restart) is executed
– The process input image (PII) is read in
– The command output disable (COD) is canceled

6.8.2 Cyclic operation
In cyclic operation, communication or exchange of data and signals is carried

out between the PLC and the components NC, HMI (e.g. HMI Advanced) and
MCP (machine control panel).
The execution of the PLC program is carried out such that – with regard to time
– the basic PLC user program is executed prior to the PLC user program.
NC communication Communication of the PLC with the NC is carried out using the NC/PLC inter-
face. The interface is divided into the following areas:
S Mode groups
S Channels
S Axes/spindles
S General NC data
Data exchange through the NC/PLC interface is carried out in the basic PLC
program at the beginning of “OB1”. This ensures that the data for the PLC re-
main constant over the entire PLC cycle.
The current G functions of the NC channels are transferred to the PLC (pro-
vided function is activated) on the process alarm level (OB40).
Sign-of-life moni- A cyclic, mutual sign-of-life monitoring function is activated between PLC and
toring NCK once power-up and the first OB1 cycle have been completed.
In case of failure of the PLC or in case of STOP of the PLC program execution,
the following alarm is displayed:
S Interrupt: “2000 sign-of-life monitoring for PLC”
6.8.3 Monitor/control using the SIMATIC Manager
The SIMATIC Manager provides extensive functionality for testing the PLC pro-
gram or the module.
Monitoring and The menu command Target System > Monitor/Control Variable is used to
controlling the start the tool “Monitor/control variable”.
variable The following functions can be performed with “Monitor/Control Variable”:
S Monitoring variables
Displaying the current value of individual variables of the PLC user program
or CPU module.
S Controlling variables
Assigning values to variables of the PLC user program or CPU module.

S Enabling PA and activating control values

Assigning values to I/O outputs of the PLC user program or CPU module in
the STOP state.
S Forcing variables
Assigning values to variables of the PLC user program or CPU module that
cannot be overwritten from the PLC user program.
Variable types The values of the following variable types can be defined or displayed:
– Inputs, outputs, flags, timers, and counters
– Contents of data blocks
– Peripherals
The variables that are to be displayed or controlled are grouped in variable
tables.
You determine when and how often variables will be monitored or overwritten
with values by defining trigger points and trigger conditions.
Additional test The menu command Target System > ... provides the following additional test
functions functions:
– Display accessible nodes
– CPU messages ...
– Display force values
– Diagnose hardware
– Module status ...
– Operating status ...
6.8.4 Monitor/control using HMI Advanced
PLC status The PLC status display of HMI Advanced is used to monitor and control:
Display
– Inputs, outputs, flags, timers, and counters
– Contents of data blocks
The menu of the PLC status display is located at operation path: Operating
Area Switchover > Diagnosis > PLC Status.
Input syntax The following two tables show the input syntax of the fields: Operand and For-
mat of the PLC status display.

Table 6-2 Input field: Operand
Syntax Meaning
In.x Input byte n, bit x
IBn Input byte n
IWn Input word n
IDn Input double-word n
DBn.DBXm.x Data block n, byte m, bit x
DBn.DBBm Data block n, byte m
DBn.DBWm Data block n, word m
DBn.DBDm Data block n, double word m
On Output n
Fn Flag n
Tn Timer n
Cn Counter n
Table 6-3 Input field: Format
Syntax Meaning
H Hexadecimal
D Decimal
B Binary
G Floating point (only in conjunction with
double word)
Monitoring After the variable to be displayed has been input in the field Operand using the
syntax described above, the current value of the variable is displayed in the
format you have set.
Controlling: Start Use the softkey Change to switch over to Control mode. Now you can use the
field Value to specify new values for the displayed variables. The entered value
must be within the definition range of the set format.
Controlling: End As long as Control mode is active, the entered values are not imported. Only
when you quit the mode using the soft key Accept, the entered values are writ-
ten to the variables and processed in the PLC program.
J

Ethernet Communication 7
7.1 General information
7.1.1 Ethernet PCU connections 50.3
PCU 50.3
Ethernet 1
(company network)
Ethernet 2
(system network)
Fig. 7-1 Ethernet connections of the PCU 50.3
The PCU 50.3 has 2 Ethernet connections (10/100 MBaud):
S Ethernet 1 (company network)

S Ethernet 2 (system network)
Ethernet 1 The “Ethernet 1” interface is preset as a SINUMERIK DHCP client for connect-
ing to a company network or a PTP connection.
Ethernet 2 The “Ethernet 2” interface is preset as a SINUMERIK DHCP server for connect-
ing to a system network with IP address 192.168.214.241.
The Ethernet components described below, e.g. Machine control panel MCP
483 IE, are connected via this Ethernet interface.
7.1.2 Determining the PCU Ethernet communication parameters
Start a Windows console to establish the Ethernet communication parameters

of the PCU: Windows XP start menu: Start > Run: cmd. Enter the ipconfig
command.

7 Ethernet Communication 03/2006
7.1.3 Checking an Ethernet connection
If there is an Ethernet connection between a SINUMERIK 840Di sl PCU with a

direct operator panel connection and another component, the connection can
be checked as followed:
1. Start a Windows console on the PCU: Windows XP Start menu: Start >
Run: cmd
2. Enter the “ping” command followed by the component IP address.
Example: ping 192.168.214.192
– Positive reply: “Reply from 192.168.214.192: . . . .”
– Negative reply: “Request timed out . . . .”

03/2006 7 Ethernet Communication
7.2 SINUMERIK 840Di sl commissioning tool: SinuCom NC
7.2 SINUMERIK 840Di sl commissioning tool: SinuCom NC

The SINUMERIK 840Di sl commissioning tool: “SinuCom NC” communicates
with a SINUMERIK 840Di sl exclusively via an Ethernet connection independent
of the installation location (externally or internally).
Start the SinuCom NC Connect Wizard from the Windows XP Start menu to
parameterize the Ethernet connection: Start > Programs > SinuCom > NC
Connect Wizard
Make the following settings in the NC Connect Wizard:
1. Control Mode: 840Di (any)
2. Port: RJ-45 (solutionline ONLY)
3. IP address:
The IP address by which the SinuCom NC communicates with the SINUM-
ERIK 840Di sl depends on where SinuCom NC is installed:
– PG/PC (external connection)
Enter the IP address of the PCU Ethernet interface used (Ethernet 1:
company network or Ethernet 2: system network).
To determine the IP address, see Subsection 7.1.2, Page 7-157.
– SINUMERIK 840Di sl PCU (internal connection)
Enter the IP address 127.0.0.1 (Local Host).
7.3 SINAMICS drive commissioning tool: STARTER

The SINAMICS STARTER drive commissioning tool communicates with the
SINAMICS S120 drives via PROFIBUS only.
If the STARTER is connected to the SINUMERIK 840Di sl via Ethernet link,
within the framework of the S7 project for configuring the PLC the PG/PC on
which the STARTER runs must be linked with the SINUMERIK 840Di sl by
means of SIMATIC STEP 7: “NetPro”. The SINUMERIK 840Di sl PLC then
routes the STARTER on the PROFIBUS to the SINAMICS drives.
The networking is described in: Subsection 6.3.9, Page 6-145.
Note
The SINAMICS STARTER drive commissioning tool can currently only be oper-
ated on a SINUMERIK 840Di sl PCU if at least one of the two Ethernet inter-
faces is active. At least one component must be connected to the Ethernet in-
terface concerned, e.g. an “MCP 483C IE” machine control panel to Ethernet
interface 2 (system neowork), and communicate with the SINUMERIK 840Di sl.

7.4 External HMI Advanced
7.4 External HMI Advanced

If the SINUMERIK HMI Advanced user interface is not installed on the SINUM-
ERIK 840Di sl PCU, but on an external computer, e.g. PCU 50.3 with OP 012
(referred to as HMI PCU), there must be an Ethernet connection established
between both computers.
External computer:
PCU 50.3 with OP 012
SINUMERIK 840Di sl PCU
Ethernet 2 (system network) Ethernet 1 (company network)

Default setting: Default setting: DHCP Client
– DHCP server
– IP address: 192.168.214.241
– Subnet mask: 255.255.255.0
Fig. 7-2 Example of a possible Ethernet connection
Note
There are no restrictions in terms of Ethernet topology within the SINUMERIK
840 Di sl PCU and HMI PCU.
Requirements The following conditions must be fulfilled:
S There is an Ethernet connection between SINUMERIK 840Di sl PCU and

HMI PCU and both computers communicate.
S The communication parameters of the SINUMERIK 840Di sl PCU Ethernet

interface with which the HMI PCU is connected are known.
To check an Ethernet connection, see Subsection 7.1.3, Page 7-158.
HMI configuration The configuration of HMI Advanced, with respect to the Ethernet connection to
the SINUMERIK 840Di sl, is performed as follows:
1. Start HMI Advanced.
2. Open the dialog for entering the IP address: Operating area switchover >
Installation > HMI > NCU connection > NCU address
3. Enter the IP address of the interface by which the HMI communicates with
the SINUMERIK 840Di sl.
Example:
Interface: Ethernet 2 (system network)
IP address: 192.168.214.241 (default)

7.5 MCP 483C IE
7.5 MCP 483C IE
Fig. 7-3 MCP 483 Front panel; Version T (turning machines)
7.5.1 Conditions for general installation and start-up
Hardware The following hardware is required:
S Ethernet connecting cable
Software The following software is required:
S PLC basic program

The relevant modules of the basic PLC program are FB 1 (MCP commu-
nication parameters), FC 19 (interface parameter assignment version: mill-
ing) and FC 25 (interface parameter assignment, version: turning).
The library of the PLC basic program is part of the SINUMERIK 840Di sl.
The installation of the library is described in detail in Section 6.4, Page
6-149.
S SIMATIC STEP 7
SIMATIC STEP 7 is needed to customize the PLC basic and user programs
to the requirements of the respective automation system. SIMATIC STEP7
can be installed directly on the PCU of the SINUMERIK 840Di sl. The instal-
lation of the additional software is described in Chapter 18, Page 18-485.
Literature The following manuals are required for installation and start-up of the MCP:
/FB1/ Description of Functions, Basic Machine P3, PLC Basic Program
Description of the program structure and modules of the PLC basic program.
/BHsl/ Operator Components Manual
Description of MCP (interfaces, electrical connection, etc.)
/Z/ Catalog NCZ
Connection Components: Cables, connectors, etc.
Automation To start up the MCP the automation system must be completely electrically and
system mechanically connected with respect to NC, PLC and MCP.
The drives must be secured against accidental moving.

7.5 MCP 483C IE
7.5.2 Parameterization of the MCP
Interfaces Fig. 7-4 shows the interfaces on the rear of the module:
Rotary switch Ethernet connection

Ground terminal X30 / X31 Ethernet 1 X20
Ethernet 2 X21 EMERGENCY STOP
X60 / X61 DIP switch S2 LEDs 1...4 Slots for

Handwheel connection User-defined inputs/ additional
outputs components
Power supply X10 Handwheel signal type S1
Fig. 7-4 Position of interfaces on rear side of machine control panel
For a detailed description of the electrical and mechanical design and of the
machine control panel interfaces, please refer to:
Literature: /BH/ Operator Components Manual
Section: Machine control panel MCP 483C IE
Display of the After the MCP has been electrically connected, all LEDs on the front side of the
software version MCP flash until communication is established between MCP and PLC.
Simultaneously pressing the two keys “Feed stop” and “Feed enable” displays
the version number of the current software by means of the permanently lighting
LEDs.
Example: Software version: V 01.02.00

1. Digit 1) 2. Digit 1) 3. Digit 1)
Simultaneously pressing the keys 1 2 0
“Feed enable” and “Feed stop”
1) Display of the digit by means of continuously illuminated LEDs on the individual LED
blocks according to Fig. 7-5

7.5 MCP 483C IE
1. Digit 2. Digit 3. Digit Activate display

left LED block center LED block right LED block
Fig. 7-5 Display of software version: 1 . 2 . 0
IP address MCP flash until communication is established between MCP and PLC.
Simultaneously pressing the two keys “Feed stop” and “Feed enable” displays
the version number of the current software using the LEDs now continuously
illuminated.
If the “Feed stop” and “Feed enable” keys are pressed, one digit of the IP ad-
dress is displayed with each press of the “Spindle enable” key.
Example default IP address: 192.168.214.192
Pressing the 1. Digit 1) 2. Digit 1) 3. Digit 1) Digit of the
“Spindle enable” key n IP address
times
1 1 9 2 1
2 1 6 8 2
3 2 1 4 3
4 1 9 2 4
1) Display of the digit by means of continuously illuminated LEDs on the individual LED
blocks according to Fig. 7-6
1. Digit 2. Digit 3. Digit Transition

left LED block center LED block right LED block Activate display
Fig. 7-6 Display of the 1st digit of the IP address: 192

7.5 MCP 483C IE
Switch S1 With switch S1 you can select the type of handwheel that is to be operated on
the module:
S Differential handwheels
switch S1 closed (on delivery)
S TTL handwheels
switch S1 open
Switch S2 Switch S2 is used to set the address by which the MCP is addressed by the
PLC user program.
Table 7-1 Switch S2: MCP address (1 – 8)
10 9 8 7 6 5 4 3 2 1 Meaning / value
Off Off – – – – – – – – Reserved
MCP address
– – Off Off Off Off Off Off Off Off 0
– – Off Off Off Off Off Off Off on 1
– – Off on Off Off Off Off on Off 2
– – Off Off Off Off Off Off on on 3
– – : : : : : : : : :
– – on on Off Off Off Off Off Off 192 (on delivery)
– – : : : : : : : : :
– – on on on on on on on Off 254
– – on on on on on on on on 255
7.5.3 MCP functions
The MCP offers the following functions:
S Standard
The input/output data of the MCP 483C IE are compatible with the input/out-
put data from the previous MCP, e.g. MCP 483 and MCP 310.
S Handwheel
Up to 2 handwheels can be connected to the MCP. For each handwheel the
current handwheel value is transferred as a 16-bit absolute value relative to
the starting value. The starting value for the sensor counter in the hand-
wheel is 0.
S Additional I/Os
The additional I/Os include:
– Customer keys (KT1 to KT9)
– Customer key outputs (KT_OUT1 to KT_OUT6)
– RESET output (R14_LED)
– Rotary switch (X31)

7.5 MCP 483C IE
7.5.4 Linking to the basic PLC and user program
This section describes how to link DP slave: MCP 483
S to the PLC basic program for transferring standard I/O data to the VDI inter-
face
S to the PLC user program (optional) to implement a user-specific response to

a module failure
Notice
Processing of additional I/O data is the sole responsibility of the user (machine
manufacturer) and is not supported by the PLC basic program.
PLC basic To transfer standard MCP 483C IE input/output data IE via the PLC basic pro-
program gram, the MCP address configured by means of the S2 switch on the module
must be entered in the communication parameters of the FB 1 function block.
Function block FB 1
The communication parameters of the MCP are called MCPx... (x = 1 or 2) in
function block FB 1. A maximum of 2 machine control panels are supported by
the basic PLC program.
To synchronize several MCPs, the PLC program must be adapted accordingly.
This is the user’s (machine manufacturer’s) responsibility.
To operate an MCP 483C IE on a SINUMERIK 840Di sl, the following parame-
ters are relevant:
MCPNum: INT // Number of the MCPs
MCP1In: POINTER // Address of the input signals

MCP1Out: POINTER // Address of the output signals
MCP1BusAdr Byte // PROFIBUS address of the DP slave MCP
The MCP2... parameters are only needed if a 2nd MCP is used in addition to
the 1st MCP:
Bus type via which the MCP is connected:

MCPBusTyp Byte // MPI =0
// PROFIBUS = B#16#33
// Ethernet = B#16#55
Notice
Parameters: MCPxStop and MCPxNotSend are of no significance.

7.5 MCP 483C IE
Literature
For a detailed description of the PLC basic program or of function block FB 1,
please refer to:
/FB1/ Description of Functions, Basic Machine PLC Basic Program P3
Section: FB 1: RUN_UP Basic program, startup section
VDI interface pa- The following function blocks are available to transfer the MCP signals to the
rameter assignment VDI interface:
S FC 19: MCP_IFM, version M (milling)
S FC 24: MCP_IFM2, version M (milling)
S FC 25: MCP_IFT, version T (turning)
Notice
Function blocks FC 19, FC 24 and FC 25 are part of the PLC basic program. It
is the user’s (machine manufacturer’s) responsibility to call the block correctly
and/or assign the interface the appropriate parameters.
Literature
A detailed description of the function blocks for transferring machine control
panel signals to the VDI interface can be found in:
Section: FC 19: MCP_IFM ...
Section: FC 24: MCP_IFM2 ...
Section: FC 25: MCP_IFT ...
Example The following example shows the communication parameter settings for func-
tion block FB 1 for an MCP:
MCPNum := 1 // Number of MCPs
MCP1In := P#E0.0 // Address: Input data
MCP1Out := P#A0.0 // Address: Output data
MCP1StatRec := P#A8190.0 // Configured diagnostic address
MCP1BusAdr := 192 // MCP address (switch S2)
MCP1Timeout := S5T#700MS // Default setting
MCPMPI := FALSE // No MPI bus
MCP1Stop := FALSE // Deactivation of the DP slave MCP
MCPSDB210 := FALSE // No SDB210 for MCP
MCPCopyDB77 := FALSE // No copying to DB77
MCPBusTyp := B#16#55 // Ethernet
MCP failure An MCP failure is detected by the PLC basic program immediately after restart-
ing the PLC, even if no data have been exchanged between the MCP and PLC.
The monitoring function is activated as soon as all components have signaled
“Ready” after powerup.
An alarm is displayed on the user interface if an MCP fails:
S 1. MCP alarm: “400260 Failure of machine control panel 1”

S 2. MCP alarm: “400261 Failure of machine control panel 2”

7.5 MCP 483C IE
Note
An Ethernet MCP is connected via a PCU Ethernet interface. Since the Ether-
net communication of the MCP with the SINUMERIK system software (PLC) is
based on Windows components, the MCP monitoring time may be exceeded in
the following cases:
1. Cause: Windows XP identifies a fatal exception error (Blue Screen)
Possible measures: none
2. Cause: Impairment of Ethernet communication through unsuitable PC com-
ponents.
Possible measures: Increase in MCP monitoring time (parameter:
MCPxTimeout)
7.5.5 Input/output image
Arrangement: A key and the LED positioned above it form a logical unit. The key and the LED
Keys and LEDs have the same number.
S Key number xy corresponds to Sxy

S LED number xy corresponds to LEDxy
Fig. 7-7 shows the arrangement of keys and LEDs on the machine control pa-
nel. For the sake of clarity, the LED designations are not shown in full.
LED34
LED
S01 S02 S03 S17 S18 S19 S32 S33 S34 Key
S04 S05 S06 S20 S21 S22 S35 S36 S37
S07 S08 S09 S23 S24 S25 S38 S39 S40
S10 S11 S12 S26 S27 S28 S41 S42 S43
S13 S14 S15 S16 S29 S30 S31 S44 S45 S46 S47 S48 S49 S50
Fig. 7-7 Keyboard layout MCP 483C IE (front view)

7.5 MCP 483C IE
Input image The following information is to be found in the table for each input bit:
– 1. line: Default designation
– 2. line: Key number (Sxy) or feedrate override switch (X30 / X31), key-
switch (X50), optional customer keys (X52)
Table 7-2 Assignment of the key signals in the input image
Signals from machine control panel (keys)

Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
EB n+0 Spindle override Operating mode
Override Override Override Override JOG TEACH MDA AUTO
Spindle8 Spindle4 Spindle2 Spindle4
X31.7 X31.8 X31.9 X31.10 S01 S04 S07 S10
EB n+1 Machine functions
REPOS REF var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
S02 S03 S05 S12 S11 S09 S08 S06
EB n+2 Key Pos. 0 Key Pos. 2 Spindle *Spindle Feed Start *Feed Stop NC Start *NC Stop
X50.4 X50.1 Start Stop S50 S49
S48 S47 S20 S15
EB n+3 RESET Key Pos. 1 Single Feed override
X50 6
X50.6 Block
Override Override Override Override Override
S13
F.over.16 F.over.8 F.over.4 F.over.2 F.over.1
S14
X30.6 X30.7 X30.8 X30.9 X30.6
EB n+4 Direction keys Key Pos. 3 Axis selection
X50 3
X50.3 R10
R15 R13 R14 R1 R4 R7
S41
S46 S44 S45 S32 S35 S38
EB n+5 Axis selection MKS/WKS Axis selection
R11 R9
R2 R3 R5 R8 R6
S43 S42 S40
S33 S34 S36 S39 S37
EB n+6 Freely assignable customer keys
T9 T10 T11 T12 T13 T14 T15 –
S25 S26 S27 S28 S29 S30 S31
T1 T2 T3 T4 T5 T6 T7 T8
S17 S18 S19 S20 S21 S22 S23 S24
EB n+8 – – – – – – – –
EB n+9 – – – – – – – –
EB n+10 – – – – – – – –
EB n+11 – – – – – – – –
EB n+12 – – – Override Override Override Override Override

spindle16 spindle8 spindle4 spindle2 spindle1
* Inverse transferred signals
– Free signals
Note
Free signals are transferred from the MCP with 0.

7.5 MCP 483C IE
Output image The following information is contained in the table for each output bit:
– 2. line: LED number
Table 7-3 Assignment of the LED signals in the input image
Signals to machine control panel (LEDs)

AB n+0 Machine function Operating mode
1000 INC 100 INC 10 INC 1 INC JOG TEACH MDA AUTO
LED11 LED09 LED08 LED06 LED01 LED04 LED07 LED10
AB n+1 Feed Start Feed Stop NC Start NC Stop Machine function
LED50 LED49
REPOS REF var. INC 10000 INC
LED16 LED15
LED02 LED03 LED05 LED12
AB n+2 Axis selection Single Spindle Spindle
Block Start Stop
R13 R1 R4 R7 R10 LED48 LED47
LED44 LED32 LED35 LED38 LED41 LED14
AB n+3 Axis selection
R3 R5 R12 R11 R9 R8 R6 R15
AB n+4 Freely assignable customer keys Axis selec-
tion
T9 T10 T11 T12 T13 T14 T15 R2
AB n+5 Freely assignable customer keys
T1 T2 T3 T4 T5 T6 T7 T8
AB n+6 – – – – – – RESET R14
LED13 LED45
(optional) (optional)
AB n+7 – – KT_OUT6 KT_OUT5 KT_OUT4 KT_OUT3 KT_OUT2 KT_OUT1
– Free signals
Note
We recommend setting free signals to 0 in the user program.

7.5 MCP 483C IE
Notes

PROFIBUS DP Communication 8
8.1.1 PROFIBUS DP with Motion Control option
PROFIBUS DP PROFIBUS DP is an international, open fieldbus standard, which is specified in

the European Fieldbus Standard EN 50170 Part 2. PROFIBUS DP is optimized
for fast, data transfer at the field level for time-critical applications.
The components communicating via the PROFIBUS DP are categorized as
either master or slave components.
1. Master (active node)
Components operating on the bus as master determine the data exchange
on the bus and are therefore also designated active nodes.
Masters divide into two classes:
S DP Master class 1 (DPMC1):

These are central master systems that exchange data with the slaves in
defined message cycles.
Examples: SIMATIC S5, SIMATIC –, etc.
S DP Master class 2 (DPMC2):

These are devices for configuring, commissioning, operator control and
monitoring in bus operations.
Examples: Programming devices, operator control and monitoring de-
vices
2. Slaves (passive nodes)
These devices may only receive messages, acknowledge them and transfer
message to the master on its request.
Examples: Drives, I/O modules
Motion Control Communication between SINUMERIK 840Di sl (NC and PLC), as the master,
expansion and the slave components on PROFIBUS is based on PROFIBUS DP with the
MotionControl extension.
The MotionControl extension is characterized by:
S Configurable isochronous DP cycle

S Cyclic synchronization of the DP slaves using GlobalControl message
frames from the DP master
S Automatic maintenance of the internal clock by the DP slaves during a short

communication failure between the DP master and DP slave
References: /PPA/ PROFIDrive Profile Drive Technology Version 3,

Draft V1.4.2, 01. September 00

8 PROFIBUS DP Communication 03/2006
8.1.2 Message format for cyclic DP communication
Message frame A PROFIBUS message generally adopts the following format for cyclic data
structure transmission:
Protocol Useful data (PPO) Protocol

frame frame
(header) Parameter identifier Process data (trailer)
value (PIV) (PDA)
Fig. 8-1 Main message format for cyclic data transmission
Useful data The useful data for cyclic communication are referred to as parameter process
structure data objects (PPO). They are subdivided into two areas within the message
frame:
S Parameter area (PIV, parameter identifier value)
This part of the message frame is for reading and/or writing parameters and
for reading out faults.
S Process data area (PDA, process data)
In the case of a drive, for example, this area contains the control words, set-
points, or additional information and actual values.
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)
8.1.3 Description of a DP cycle
Actual values At time TI, the current actual position values are read from all isochronous DP
slave drives. In the next DP cycle, the actual values are transferred to the DP
master in the time TDX.
Position controller The NC position controller is started at the time TM, with TM > TDX, and com-
putes the new speed setpoint for each axis on the basis of the position setpoint
and the transferred actual position value.
Setpoints At the start of the next DP cycle, the speed setpoints are transferred from the
DP master to the DP slave drives in the time TDX.
At time TO, the speed setpoints are taken as new specified values for all drive
controllers.

03/2006 8 PROFIBUS DP Communication
TMAPC = TDP
NC:
Master or position TM
controller R
TDX TDX
1 2
PROFIBUS-DP
DPV1 G T R GC Dx Dx Dx DPV1 G T R GC Dx Dx Dx
communication
Speed
control
cycle
Drives:
R R R R R R R R R R R R R R R R
DP slaves: 1 ... 3
TO TI
TI TO
Fig. 8-2 Example: Optimized DP cycle with 3 DP 611U slaves
Key to Fig. 8-2:

TMAPC Master application cycle: NC position control cycle
The following always applies for SINUMERIK 840Di sl: TMAPC = TDP
TDP DP cycle time: DP cycle time
TDX Data exchange time: Sum of transfer times of all DP slaves

TM Master time: Offset of the start time for NC position control
TI Input time: Time of the actual value acquisition. The actual values are
transferred to the DP master in the next DP cycle.
TO Output time: Time of the setpoint transfer. The setpoints were
generated by the DP master application in the previous DP cycle.
GC Global control message frame (broadcast message frame) for
cyclic synchronization of the equidistance between the DP
master and DP slaves
R Speed or position controller computing time
Dx Exchange of user data between DP master and DP slaves
DPV1 After cyclic communication, an acyclic service is sent,

if the token holding time TTH is not yet exceeded. TTH is
calculated by the configuring system.
GTR
G: GAP An attempt is made during GAP to accept new active stations.
T: TOKEN The token passing is either to itself or other masters.
D: RES The reserve is used as an “active pause” for the station to send the token
to itself until the isochronous cycle is terminated.

1
The actual values for the current DP cycle / position control cycle
are transferred from the DP slave drives to the NC position controller
2
The setpoints computed by the NC position controller are transferred
to the DP slave drives
8.1.4 Networking rules
The following basic rules must be observed:

1. The bus line must be terminated at both ends. For this purpose, enable the
terminator in the PROFIBUS DP connector of the first and of the last nodes
and disable the remaining terminators.
Notice
Only two enabled terminating resistors are permitted per bus line.
2. At least 1 terminal must be supplied with 5 V.

This is done by connecting an PROFIBUS DP connector with the terminat-
ing resistor inserted to an energized device.
3. No tap lines may be routed on the PROFIBUS DP.
4. Every PROFIBUS DP node must first be connected and then activated.
When disconnecting a node, first deactivate the connection and then re-
move the connector.
5. The cable of a PROFIBUS DP bus segment may be max. 100 m.
Example:
PROFIBUS DP
network Field device Field device
SIMATIC ET200 SIMATIC ET200
installation
SINUMERIK 840Di sl
Off on
PCU
PROFIBUS-DP
on
(max. of 100 m) MCI board
PROFIBUS-DP
Off Off
on
Terminating resistor in
Drive unit Drive unit the connector enabled
SINAMICS S120 SINAMICS S120
Terminating resistor in the
Off
connector not enabled
Fig. 8-3 Example of a PROFIBUS DP network installation

8.2 Requirements
8.2 Requirements
As a condition for creating a PROFIBUS configuration using the default configu-
ration the following components are required:
S SIMATIC STEP 7
S 840Di sl Rack
(a SIMATIC 300 station preconfigured for SINUMERIK 840Di sl. Part of the
PLC basic program)
S SlaveOM
(part of the scope of supply of a SINUMERIK 840Di sl: SIMATIC add-on soft-
ware)
SIMATIC STEP 7 SIMATIC STEP 7 (option) is required in the following version or later:

SINUMERIK If SIMATIC STEP 7 is installed on the SINUMERIK 840Di sl, no additional MPI/
840Di sl PROFIBUS cable is required to load the S7 configuration in the PLC.
Windows applications executed on the SINUMERIK 840Di sl have direct access
to the PLC through the internal MPI interface of the MCI board.
Installation of additional software on the SINUMERIK 840Di sl is described in
detail in Chapter 18, Page 18-485.
External computer If SIMATIC STEP 7 is installed on an external computer (PG/PC), it must fulfill
(PG/PC) the following conditions:
S PG/PC interface is parameterized (see Subsection 6.2.2, Page 6-133)

S An MPI/PROFIBUS connection exists between the external computer
(PG/PC) and the SINUMERIK 840Di sl.
840Di sl Rack The 840Di sl Rack is a SIMATIC-300 station preconfigured for SINUMERIK
840Di sl. The following version is available in the hardware catalog of HW Con-
fig:
S SINUMERIK 840Di sl with PLC 317-2DP 2AJ10

– Slot 2: SINUMERIK 840Di sl PLC
Standard designation: PLC317-2DP 2AJ10
– Slot X1: MPI/PROFIBUS interface (X102)
Standard name: MPI/DP
– Slot X2: PROFIBUS interface (X101)
Standard name: DP
– Slot 4: SINUMERIK 840Di sl NC
Standard designation: NCK 840D sl
– Slot 5: SINUMERIK CP for Industrial Ethernet TCP/IP
Standard designation: CP 840D sl

8.2 Requirements
Installation The 840Di sl Rack is part of the PLC Toolbox. When the PLC Toolbox is
installed, it is automatically installed in SIMATIC STEP 7.
Note
The PLC basic program must be installed on the computer on which SIMATIC
STEP 7 is installed. For installing the PLC basic program, please observe the
appropriate notes in the file:
Once the PLC basic program has been successfully installed the 840Di sl Rack
can be accessed in the hardware catalog of SIMATIC STEP 7, “HW Config”:
S “HW-Config” hardware catalog:

Profile: Standard
SIMATIC 300 > SINUMERIK > 840Di sl > 840Di sl
SlaveOM The SlaveOM (Slave Object Manager) for SINUMERIK 840Di sl permits dialog-
based S7 configuration of the following PROFIBUS drives:
– SIMATIC S120
– SIMODRIVE 611 universal or universal E
– SIMODRIVE POSMO A
– ADI4 (Analog Drive Interface for 4 Axes)
Notice
If the SlaveOM is used in conjunction with other PLC CPUs, a consistency error
is signaled when compiling the S7 configuration and no system data blocks are
generated.
Installation The SlaveOM is part of the PLC Toolbox. When the PLC Toolbox is installed, it
is automatically installed in SIMATIC STEP 7. The DP slave drives specified
above are available in the hardware catalog at the following location:
S HW Config: Hardware catalog:

Profile: Standard
– PROFIBUS DP > SINAMICS > SINAMICS S120
– PROFIBUS DP > SIMODRIVE > SIMODRIVE 611 universal
– SIMODRIVE POSMO CD
– SIMODRIVE POSMO CA
– SIMODRIVE POSMO A
– PROFIBUS DP > SINUMERIK > ADI4

8.2 Requirements
Note
GSD file All properties of a DP slave are stored in a DMF file (Device Master File) in
ASCII format. STEP 7 requires one module-specific GSD file each for each DP
slave so that the DP slave can be selected from the hardware catalog.
If a DP slave is not displayed in the hardware catalog of “HW-Config”, you must
install a GSD file. To do that, use menu command Tools > Install new GSD file.
As soon as you have installed the GSD file the DP slave is available in the hard-
ware catalog at the following location:
S “HW-Config” hardware catalog:

Profile: Standard
PROFIBUS DP > Further field units > <DP slave>
Notice
The GSD files must be installed on the computer on which SIMATIC STEP 7 is
already installed.
To install a GSD file, please refer to the appropriate notes in the file: <Installa-
tion path>\importantinfo.rtf

8.3.1 Prerequisite
S7 project The procedure described in this section for setting up the PROFIBUS configura-
tion as well as the parameterization of various components (for example, SI-
NAMIC drives, AD14), is based on an S7 project created using the description
in Section 8.3, Page 8-178.
The following status of the S7 project is required:
– S7 project is has been set up (name: SIN840Di sl)
– Station 300 has been set up
– Interface (X102) MPI or PROFIBUS is parameterized
– Interface (X101) PROFIBUS is parameterized
– Input/output data areas of the NC are parameterized
Note
SIMATIC STEP 7 please refer to the relevant SIMATIC documentation or online
help.
Starting Start “HW-Config” by opening the station and double-clicking on the hardware
HW-Config icon.
SIN840Di sl – <Installation
path>\step7\s7proj\SIN840Di sl
SIN840Di sl Hardware PLC 317–2DP 2AJ10
SIMATIC
300(1)
PLC 317–2DP 2AJ10
In HW-Config, now insert the required PROFIBUS modules from the hardware
catalog into the S7 project.
HW Config – [SIMATIC 300(1) (Configuration) –– SIN840Di sl]

PROFIBUS(1): DP master system(1) Find
(0) 840Di sl Profile: Standard

2 PLC 317–2DP 2AJ10 (10) SI- SINAMICS
X1 MPI/DP NAM SINAMICSCX32
X2 DP SINAMICS G130
4 NCK 840D sl SINAMICS G150
5 CP 840D sl SINAMICS GM150
SINAMICS NX10
SINAMICS NX15
SINAMICS S120
SINAMICS S150
Fig. 8-5 HW-Config: Inserting modules, e.g. SINAMICS S120

8.3.2 Inserting DP slaves

In principle, both PROFIBUS interfaces have the same functionality. They
merely differ in the way they can be accessed by the NC and the PLC:
S NC
The NC only has access to PROFIBUS(1), interface (X101) corresponding
to slot X2.
S PLC
The PLC has access to both PROFIBUS interfaces.
Note
S PROFIBUS(1), interface (X101) corresponding to slot X2
As the drives are connected via this interface, the PROFIBUS can only be
operated in mode “DP master”.
S PROFIBUS(2), interface (X102) corresponding to slot X1

The interface can be operated in modes: “DP master” and “DP slave”.
Please refer to the relevant SIMATIC documentation for how to connect the
PLC to the higher-level DP master as a DP slave.

PLC-related DP slaves PROFIBUS(2): DP master system(2)
1) 2) 3)
(0) 840Di sl
(5) SINUM (6) IM 153 (7) SIMOD
2 PLC 317–2DP 2AJ10
X1 MPI/DP
X2 DP
4 NCK 840D sl
5 CP 840D sl
NC-related DP slaves PROFIBUS(1): DP master system(1)
4) 5) 6) 7) 8)
(8) IM 153 (9) SINAM (10) SIMOD (11) POSM (12) ADI4
POSMO SI
Attention! Can only be used as an alternative: SINAMICS 4) or SIMODRIVE: 5) ... 7)
Fig. 8-6 Recommended distribution of DP slaves (schematic)
1) Machine control panel: MCP 483, MCP310

2) and 4) ET200... I/Os
3) SIMODRIVE POSMO A
5) SINAMICS S120
6) SIMODRIVE 611 universal
7) SIMODRIVE SI, CD/CA
8) ADI4

If you are using both PROFIBUS connections, we recommend the following

distribution of DP slaves:
S PROFIBUS(1): Interface (X101) corresponding to slot X2

– NC-specific I/Os
– Drives
– ADI4
S PROFIBUS(2): Interface (X102) corresponding to slot X1

– PLC-specific I/Os
– Machine control panel, e.g. MCP 483
8.3.3 Final parameterization of the isochronous DP slaves
Once you have included the DP slaves in the configuration and parameterized
them individually, for concluding parameterization of the isochronous DP com-
munication of the PROFIBUS(1): interface (X101) corresponding to slot X2, you
must set the following parameters of the isochronous DP slaves in two separate
stages:
Step1:
S Activation of the equidistant DP cycle
S Equidistance master cyclic component TDX
Step2:
S Equidistant DP cycle TDP
S Master application cycle TMAPC
S Actual value acquisition TI
S Setpoint acceptance TO
An overview of the various times of a DP cycle is shown in Fig. 8-2, Page 8-173.
Note
The procedure for assigning the final parameters for isochronous DP commu-
nication is exemplified by one DP slave S120. Proceed in the same manner for
other isochronous DP slaves, e.g., SIMODRIVE 611U, ADI4; etc.
Notice
If DP slave ADI4 interfaces are present in an S7 project on which final parame-
terization is to be performed, certain boundary conditions must be observed.
See also:
References /ADI4/ ADI4 Analog drive interface for four axes
Section: Parameterization
Parameterization of DP communication
Boundary conditions

Activation of the If you double-click an S120 DP slave in the station window, the dialog box: “DP
isochronous Slave Properties” opens.
DP cycle It is recommended that the isochronous DP cycle be enabled for all DP slaves
S120 by enabling the isochronous DP cycle for the selected DP slave S120,
and then performing an alignment.
During adjustment all the values displayed in dialog box:
S DP slave properties
Tab card: Isochrone mode
are transferred to all DP slaves of the same type in the configuration, here DP
slave S120.
Dialog: Dialog box: DP slave properties

Start Tab card: Cycle clock synchronization
Radio button: “Synchronize drive to isochronous DP cycle”
Button: “Adjust”
DP slave properties
General Configuration Isochrone mode
Synchronize drive to isochronous DP cycle
Network settings in ms
Isochronous bus cycle activated
Isochronous DP cycle: 2.000 0.414

Component Data_Exchange_Time Tdx:
Factor
Increment/base time [ms]
Master application 2.000 = 1 2.000
x
cycle [ms]:
Factor
DP cycle [msec]: 2.000 = 16 x 0.125
Factor
Time Ti [ms]
0.125 = 1 x 0.125
Actual value acquisition:
Factor
Time To [ms]
0.625 = 5 x 0.125
Setpoint acceptance:
Alignment
OK Cancel Help
Fig. 8-7 Enabled isochronous DP cycle
Notice
If there are different types of isochronous DP slaves in a S7 project, e.g. differ-
ent SINAMICS drives, ADI4, etc., the following steps:
1. Synchronize drive to isochronous DP cycle
2. Perform adjustment
must be performed for each type of DP slave first before you can go on to set
the other parameters.

Equid. master cycl. After synchronization to the isochronous DP cycle has been activated for all DP
component slaves, the timer requirement of the cyclic portion of DP communication must be
TDX calculated.
Calculation is performed by the DP master on activation of the isochronous bus
cycle.
Dialog: Register: General

Continuation Group box: Station/Master System
Button: “PROFIBUS...”
Dialog box: Properties – PROFIBUS interface SINAMICS ...
Tab: Parameter
Dialog box: Properties PROFIBUS
Tab card: Network settings
Button: “Options...”
Dialog box: Options
Radio button: Activate isochronous bus cycle
Equidistant DP cycle When calculating the cyclic portion of the PROFIBUS communication, the time
TDP for the isochronous DP cycle is automatically changed to the time required as
the minimum. This change must be undone by reentering the time intended for
the isochronous DP cycle.
Dialog: Group box: Isochronous time in ms

Continuation Isochronous DP cycle: Isochronism time
OK
OK
OK
Options
Equidistance Lines
Activate isochronous bus cycle
Optimize DP cycle (and, if nec. T i, To): Recalculate
Number of PGs/OPs/TDs on the PROFIBUS
Configured: 0 Total: 0
Graduation:
Isochronous DP cycle: 2.000 ms 0.125 ms Details ...
(min = 1.000 ms; max = 32.000 ms)
Synchronization of the slaves
Times Ti and To same for all slaves

(If not: Set in properties – slaves)
Fig. 8-8 Dialog: Options (excerpt)

Note
You are advised not to activate the option “Times Ti and To same for all slaves”
in the “Synchronization of the slaves” group.
On tab card “Clock synchronization” the following parameters are now set for
each type of DP slave:
– Equidistant DP cycle TDP
– Master application cycle TMAPC
– Actual value acquisition Ti
– Setpoint transfer To
.
DP slave properties
Synchronize drive to Isochronous DP cycle
Network settings in ms
Isochronous bus cycle activated
Isochronous DP cycle: 2.000 1.258

Cyclic portion of isochronous master
Factor
Master application 2.000 = 1 2.000
x
cycle [ms]:
Factor
DP cycle [msec]: 2.000 = 16 x 0.125
Factor
Time Ti [ms] 0.125 = 1 x 0.125
(actual value acquisition):
Factor
Time To [ms] x
1.500 = 12 0.125
(setpoint acceptance):
Alignment
OK Cancel Help
Fig. 8-9 Dialog: DP slave properties
DP cycle The “DP cycle” of DP slave S120 must be set to the cycle time of the DP master
TDP displayed under > “Isochronous DP cycle” in group box “Network settings in
ms”.
Notice
For DP cycle time TDP the following condition must be fulfilled:
DP cycle = isochron. DP cycle

Master application Via parameter: Master Application Cycle TMAPC defines the integer ration be-
cycle TMAPC tween the master application (NC position controller) and the isochronous DP
cycle.
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.
Notice
On a DP slave S120 used with SINUMERIK 840Di sl, the ratio between the
master application cycle TMAC and DP cycle time TDP must be 1:1.
Master application cycle = DP cycle
Dialog: Register: Clock synchronization

Continuation Master application cycle [msec]:
Factor: 1
Actual value Via parameter: Actual-value acquisition Ti defines the time at which the actual
acquisition value (actual position value) can be read in from a DP slave S120.
Ti
Note
You are strongly recommended to use the same value for the time of actual
value acquisition Ti for all DP slaves S120, in particular if the axes interpolate.
Notice
The following condition must be observed for the time of actual-value sensing
TI:
DP cycle >= actual value acquisition >= base time

Continuation Actual value acquisition [ms]:
Factor: Factor
Setpoint Via parameter: Setpoint acceptance To defines the time when the speed set-
acceptance point of the NC position controller is accepted by a DP slave S120.
To
Note
You are strongly recommended to use the same value for the time of setpoint
acceptance To for all DP slaves S120, in particular if the axes interpolate.

Notice
The following condition must be observed for the time of setpoint acceptance
TO:
DP cycle >= setpoint accept. >= isochron. master cycl. component + base
time

Continuation Setpoint acceptance [ms]:
Factor: Factor
Adjustment Activating button: Adjust transfers the values displayed in the “Clock synchro-
nization” tab to all other DP slaves S120 in the configuration.
This adjustment must be carried out at the end, and the dialog box must then be
confirmed with OK.

End Button: “Adjust”
OK
Notice
If there are different types of isochronous DP slaves in a S7 project, e.g. differ-
ent SINAMICS drives, ADI4, etc., the following parameters:
– Equidistant DP cycle TDP
– Master application cycle TMAPC
– Actual value acquisition TI
– Setpoint acceptance TO
must be set for each DP slave type separately as described above, and then
adjusted.
Adjustment only transfers the values displayed on tab card: “Clock Synchro-
nization” to the DP slave of the same type.
8.3.4 Generating system data blocks (SDB)
System data blocks (SDB) contain all the information required for PROFIBUS
communication between the DP master and connected DP slaves. System data
blocks are generated by compiling the current configuration with “HW-Config”.
Consistency check Always check that the system data blocks are error-free before storing and
compiling them. To do that select menu item: Station > Check consistency.

If inconsistencies are detected in the configuration, an error dialog box is dis-

played and the error messages and help are displayed.
Save and The menu command Station > Save and Compile saves the current configura-
compile tion in S7 as object: “Station” and is then compiled.
System data If the configuration is compiled without error the system data blocks are gener-
blocks ated and stored in directory: “Blocks” of the PLC.
In example project: “SIN840Di sl” the system data blocks are located at:
S SIN840Di sl
SIMATIC 300(1)
PLC317-2DP 2AJ10
STEP 7 Program(3)
Blocks > System data
The current system data blocks can be displayed by double-clicking on the

icon: “System data” in dialog box: “System Data Blocks”.
Note
System data blocks cannot be edited individually. Only the configuration as a
whole can be edited.
8.3.5 Loading a configuration into the PLC
Once you have successfully generated the system data blocks you can load the
configuration into the PLC.
Loading of the configuration is described in detail as part of PLC installation and
start-up in Section 6.7, Page 6-151.
8.3.6 PROFIBUS diagnosis
The following specific diagnostic displays are recommended for diagnosis of the
PROFIBUS or DP slave status when checking the configuration or when errors
occur:
S 840Di Startup
menu bar: Window > Diagnosis > Profibus > Bus or Slaves
S HMI Advanced
Operating Area Switchover > Diagnosis > Service Displays > “ETC”
key > Profibus Diagnosis

8.4 SIMATIC I/O devices (ET200...)
8.4 SIMATIC I/O devices (ET200...)

The SIMATIC I/O devices of the series ET200, e.g. ET200M, are integrated into
the S7 project as usual using HW-Config and configured.
Note
To simplify parameterization of the isochronous communication on the PROFI-
BUS DP, you must first insert all the SIMATIC I/Os you require into the configu-
ration before parameterization of the DP drives (e.g. DP slave 611U or ADI4).
Note
To check whether a module selected from the hardware catalog complies with
the module in the automation system, the following procedure is recom-
mended:
1. Put down the MLFB numbers of all modules used in the automation system.
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.
8.5 DP slave: I/O Module PP72/48
8.5.1 DMF file
A PP72/48 I/O module is parameterized with a GSD file.

– The GSD file is part of the SINUMERIK 840Di sl software. See Section
1.2, Page 1-34: SIMATIC add-on software: GSD file for I/O modules
PP72/48
– For installation of a GSD file, see Subsection 8.1.4, Page 8-177: GSD
files.
Note
To make parameterization of isochronous communication with PROFIBUS DP
easier, we recommend inserting all required DP slaves 611U into the configura-
tion before setting the times for isochronous communication.

8.5.2 Inserting a DP slave
To insert a DP slave PP72/48 into the configuration, open the hardware catalog
using menu command View > Catalog.
The DP slave PP72/48 is to be found at:
S Profile: Standard
PROFIBUS DP > Further field units > Drives > IO > PP input//
output module
Click with the left mouse button on the DP slave PP72/48 (PP input/output mod-
ule) in the hardware catalog and drag it onto the DP master system in the sta-
tion window, holding down the left mouse button.
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.
Note
Make sure that the cursor that appears as a crossed-out circle when dragging
the DP slave is positioned exactly on the DP master system so that it can be
inserted into the configuration.
8.5.3 Setting PROFIBUS parameters
As soon as you have inserted DP slave PP72/48 into the configuration, dialog
box “PROFIBUS properties interface PP input/output” is displayed.
The following PROFIBUS parameters must either be set or verified:
– PROFIBUS address
– Data transfer rate
– Profile
Notice
The PROFIBUS address of DP slave PP72/48 set in the S7 project must match
the PROFIBUS address set on the module using switch S1 (see Section 2.11,
Page 2-79).
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of DP slave PP72/48
PROFIBUS address
2. I/O module PP72/48
PROFIBUS address (switch S1)

Dialog box Dialog box: PROFIBUS properties Interface PP input/output

Tab card: Parameter
Address: <PROFIBUS address>
Dialog box: Properties – PROFIBUS
Data transfer rate: 12 Mbaud
Profile: DP
OK
OK
8.5.4 Setting the I/O addresses
When the dialog box is closed DP slave PP72/48 is inserted into the DP master
system and the detail view of DP slave PP72/48 is displayed in the station win-
dow. Select one of the modules listed under DP slave PP72/48 (PP input/output
module) from the hardware catalog and insert it in slot 1 of the detail view.
The I/O addresses are assigned by “HW-Config” automatically and should be
changed taking into account the following supplementary conditions:
S I/O address range of the NC

For compatibility reasons and for future system expansions, the I/O ad-
dresses 256 – 271 should not be assigned.
S Selective access to inputs/outputs by the PLC

The PLC cannot directly access individual inputs/outputs of I/O addresses
>256. The input/output data must first be copied into internal flags of the
PLC with 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.
The dialog box offers the following configurations to choose from:
1. I/O 6/9 O222 I212121
2. I/O 6/9 O411 I212121
3. I/O 6/9 O42 I41
For DP slave PP72/48, select the 1st configuration and click OK to confirm the
dialog box.

8.6 DP slave: MCP 310
Fig. 8-10 MCP 310 front panel
8.6.1 General conditions for start-up
S PROFIBUS connecting cable

No terminating resistor is integrated in the machine control panel.
S PLC basic program

How to install the library is described in Section 6.4, Page 6-149.
S SIMATIC STEP 7
can be installed directly on the PCU of the SINUMERIK 840Di sl. How to
install additional software is described in Section 18, Page 18-485.
S DP slave: MCP 310

The DP slave: MCP 310 is part of the PLC Toolbox. When the PLC Toolbox
is installed, it is automatically installed in SIMATIC STEP 7.
Note

/BH/ Operator Components Manual
Description of MCP 310 (interfaces, electrical connection, etc.)
/Z/ Catalog NCZ
Interfaces Fig. 8-11 below shows the interfaces on the rear of the module:
Power supply X10 Handwheels X60/X61

Rotary switch X30/X31 LEDs 1...4 PROFIBUS X20 Handwheel signal type S1
COM board
COM board
Termination: Keyswitch X50 S3 DIP switch

Equipotential bonding Direct keys X70
conductor
Customer spec. Operating elements X51 ...X54
Fig. 8-11 Rear of the MCP 310 showing the control and display elements and the interfaces

1 2 3
SHIELDM24 P24
Fig. 8-12 Connection overview: Power supply X10
Section: Machine control panel MCP 310
Simultaneously pressing the two keys “Feed stop” and “Feed enable” (in the
bottom right corner) displays the version number of the current software version
using the LEDs now lighting continuously.
Version number = V “Number of lit LEDs on the left LED block”.

“Number of lit LEDs on the center LED block”.
“Number of lit LEDs on the right LED block”
In the example (Fig. 8-18) version number: V 01.02.00 is displayed.
1. Digit 2. Digit 3. Digit

Enable software version display

(press both keys
simultaneously)
Fig. 8-13 MCP 310 front panel

Switch S3 The PROFIBUS address and connection type are set via switch S3 on the rear
of the MCP:
Table 8-1 Switch S3: PROFIBUS address (1 – 7)
10 9 8 7 6 5 4 3 2 1 Meaning / value
on on – – – – – – – – Connection type: PROFIBUS
– – off – – – – – – – Reserved
PROFIBUS address
– – – off off off off off off off 0
– – – off off off off off off on 1
– – – on off off off off on off 2
– – – off off off off off on on 3
– – – : : : : : : : :
– – – on on on on on on off 126
– – – on on on on on on on 127
Switch settings 10 – 8 must be set according to the information in the table.
Notice
In the state as delivered, the connection type is: MPI (10 – 9: off, off) set.
8.6.3 Functions of the machine control panel
The machine control panel offers the following functions:

S Standard
S Handwheel
S Additional I/Os
Standard The function transfers input/output data from the function keys and user-specific
keys and outputs:
S Input data: 8 byte
S Output data: 8 byte
The input/output data for machine control panel MCP 310 is compatible with the
input/output data from the previous machine control panel OP 032S.
Handwheel The function transfers the absolute values for the two handwheels that can be
connected to the machine control panel:
S Input data: 2 x 2 bytes

Absolute value handwheel 1 Absolute value handwheel 2
Low byte High byte
For each handwheel the current handwheel value is transferred as a 16-bit ab-
solute value relative to the starting value. The starting value for the sensor
counter in the handwheel is 0.

The absolute values are transferred in big endian format.

The data for both handwheels is always transferred. The absolute value for a
handwheel that is not connected is always 0.
Additional I/Os The function transfers the data for all non-standard inputs/outputs:
S Direct control key
S Customer keys: 6 signals (bit 0 to bit 6)
S Rotary switch
with the following distribution:

Customer 1. Rotary 2. Rotary
Direct control keys (OP 012) keys switch switch
Low byte High byte

Reserved, Customer
always 0 LEDs
Low byte High byte

8.6.4 Configuring the DP slave: MCP 310
This section describes the configuration of a DP slave: MCP 310 with the aid of
the sample configuration of a SIMATIC S7 project as shown in Fig. 8-14.
The configuration comprises the following modules:
S SIMATIC station 300 with SINUMERIK 810D/840D and PLC 317-2DP
S SINUMERIK MCP with module: standard, handwheel, extended
To configure DP slave: MCP 310 the following steps must be carried out in the
S7 project:
1. Insert DP slave: MCP 310 in the configuration
(see Fig. 8-14, Page 8-195: 1)
2. Set the PROFIBUS address.
3. Insert the modules in DP slave: MCP 310 for the functions required.
(see Fig. 8-14, Page 8-195: 2)
4. Set the I/O addresses for the individual slots.
HW Config – [SINUMERIK840D (configuration) –– PROFIBUS MCP]


(0) 1 Pro- Standard
2 810D/840D
PLC 317–2DP 2AJ10 file: I/O
X1 MPI (9) SINUME NC/RC
X2 DP MOTION CONTROL
3 IM360 SINUMERIK MCP
4 S7 FM NCU Universal module
standard
2 standard, handwheel
standard, extended
standard, handwheel, ex
slot DP ID Order number / designation I address O address Com...

1 55 standard, handwheel, extended 0...7 0...7
2 2IO ––> standard, handwheel, exten 258...261
3 192 ––> standard, handwheel, exten 8...12 8...9
Fig. 8-14 Configuration with DP slave: MCP 310
Requirements: S7 The following status of the S7 project into which DP–Slave: MCP 310 is to be
project inserted is assumed:
– You have created the S7 project
– You have set up a SIMATIC 300 station with PROFIBUS master-capable
SINUMERIK controller
Inserting the DP To insert a DP slave: MCP 310 into the configuration, open the hardware cata-
slave log with menu item View > Catalog.

DP slave: MCP 310 is located under:
S Profile: Standard
PROFIBUS-DP > Other field devices > NC/RC > Motion Control
> SINUMERIK MCP
Select the DP slave by left-clicking it in the hardware catalog: MCP 310 (SI-
NUMERIK MCP) and drag it while holding down the mouse key onto the DP
master system in the station window.
symbol:
When you release the left mouse key, DP slave: MCP is inserted in the configu-
ration.
Note
As you drag the DP slave the cursor appears as a circle with a slash through it.
When the cursor is positioned exactly over the DP master system, it changes to
a plus sign, and the DP slave can be added to the configuration.
PROFIBUS When you have inserted DP slave: MCP 310 into the configuration, dialog
Parameter “Properties – PROFIBUS Interface SINUMERIK MCP” is displayed.
– Profile
Dialog box Dialog box: Properties – PROFIBUS Interface SINUMERIK MCP

Tab card: Parameter
Profile: DP
OK
OK

Notice
The PROFIBUS address set in the S7 project for DP slave: MCP 310 must
match the PROFIBUS address set on the module (DIP switch S3).
1. SIMATIC configuration DP slave: MCP 310
PROFIBUS address
2. Machine control panel MCP 310
PROFIBUS address (DIP switch S3)
Adding a module The active functions and hence the number of user data elements to be trans-
ferred are chosen by selecting the appropriate pre-configured module. The mo-
dules are listed in the hardware catalog under DP slave: MCP 310. The follow-
ing modules are available:
S Universal module (not applicable)
S standard
S standard, handwheel
S standard, extended
S standard, handwheel, extended
Module: standard
The module transfers the data for the “Standard” function:

Standard data
(8 bytes)

Standard data
(8 bytes)
Module: standard, handwheel

The module transfers the data for the “Standard” and “Handwheel” functions:
S Input data: 12 bytes

Absolute value Absolute value
Standard data
2nd handwheel 2nd handwheel
(8 bytes)
(1 bytes) (2 bytes)
Low byte High byte

Standard data
(8 bytes)

Module: standard, extended

The module transfers the data for the “Standard” and “Additional I/Os” functions:

Direct co. keys Customer keys 1. Rotary 2. Rotary
Standard data
(OP 012) switch switch
(8 bytes) (1 byte)
(2 bytes) (1 byte) (1 byte)
Low byte High byte
S Output data: 10 bytes

Customer
Standard data Reserved LEDs
Low byte High byte
Module: standard, handwheel, extended

The module transfers the data for the “Standard”, “Handwheel” and “Additional
I/Os” functions:

Absolute value Absolute value Direct co. keys
Standard data
2nd handwheel 2nd handwheel (OP 012)
(8 bytes)
(1 bytes) (2 bytes) (2 bytes)
Low byte
1. Rotary 2. Rotary
Customer keys
switch switch
(1 byte)
(1 byte) (1 byte)
High byte

Reserved Customer
Standard data LEDs
(8 bytes) (1 byte)
(1 byte)
Low byte High byte
Setting the I/O ad- When you insert a module in slot 1 of DP slave: MCP 310 the input/output ad-
dresses dresses of STEP 7 are automatically assigned.
Double clicking with the left mouse button on a slot opens the “Properties – DP
slave” dialog box. The starting addresses for the I/O data for the slot can be set
here.

face

a module failure

Notice
“Handwheel” function
The “Handwheel” function is not currently supported by the basic PLC program.
“Additional I/Os” function
manufacturer) and is not supported by the basic PLC program.
PLC basic In order to transfer standard input/output data of DP slave: MCP 310 with the
program PLC basic program, the I/O address range in question must be entered in the
communications parameters of function block FB1.
Function block FB1

The communications parameters of the MCP are called MCPx... (x = 1 or 2) in
function block FB1. A maximum of 2 machine control panels are supported by
To operate an MCP 310 as a DP slave on a SINUMERIK 840Di sl, the following
parameters are relevant:

the 1st MCP:

Notice
Literature
please refer to:

VDI interface pa- The following function blocks can be used to assign the VDI interface:
rameter assignment S FC 24: Machine control panel MCP 310, version M (milling)
Notice
Literature
Chapter:FC 25: MCP_IFT ...
MCP1BusAdr := 5 // PROFIBUS address of the DP slave MCP
MCPCopyDB77 := FALSE // No copying to DB 77
MCPBusTyp := B#16#33 // PROFIBUS
PLC user program If an MCP is connected via PROFIBUS DP, the basic PLC program does not
check for module failure.
In this case the MCP is monitored by a standard mechanism to monitor the ac-
tive DP slave:
S PLC operating system

S PROFIBUS controller
If the failure of DP slave: MCP 310 is detected the PLC goes into the STOP
status as default.
Customized To allow the user to intervene when a DP slave: MCP 310, the following orga-
response nization blocks are inserted in the PLC user program:
S OB 82: Diagnostic interrupt

S OB 86: Rack failure

Please refer to the corresponding SIMATIC literature for details of linking orga-
nization blocks and evaluating diagnostic data.
Notice
In the event of the failure of a machine control panel connected via MPI, the
following alarm is triggered by the PLC basic program:
S Alarm “40026x machine control panel (x+1) failure”; with x = 0, 1

If the machine control panel is being operated as a DP slave, the user (ma-
chine manufacturer) is responsible for triggering a corresponding alarm.
S Key: Sxy = Key number xy

S LED: LEDxy = LED number xy
nel together with their internal designation. For the sake of clarity, the LED des-
ignations are not shown in full.
LED09 LED01 LED02 LED03 LED21 LED22 LED23 LED36 LED37 LED38
LED
S09 S01 S02 S03 S21 S22 S23 S36 S37 S38 Key
S10 S11 S12 S04 S24 S25 S26 S39 S40 S41
S13 S14 S15 S05 S27 S28 S29 S42 S43 S44
S16 S17 S18 S06 S30 S31 S32 S45 S46 S47
S19 S20 S07 S33 S34 S35 S48 S49 S50
Fig. 8-15 Designation of keys and LEDs

Input image Arrangement of key signals in the input image of DP slave: MCP 310:
Table 8-2 Input image

*NC stop SP – SP 100% SP + Single JOG MDA AUTO
S19 S36 S37 S38 block S09 S10 S13
S16
EB n+1 Spindle Key Machine function
Pos. 3
Pos
NC Start SP right *SP Stop SP left REF REP TEACH
X50.3
S20 S39 S40 S41 S02 S01 S11
EB n+2 Feed Mach. fu. Key Machine function
Pos. 0
Pos
Feed Start *Feed Stop INC VAR INC1000 INC100 INC10 INC1
X50.4
S35 S34 S03 S07 S06 S05 S04
EB n+3 RESET Key Key Feed override
Pos. 2
Pos Pos. 1
Pos
*F.over.16 *F.over.8 *F.over.4 *F.over.2 *F.over.1
S17 X50.1 X50.6
X30.6 X30.7 X30.8 X30.9 X30.10
EB n+4 Direction keys Optional customer keys
+ – Rapid KT4 KT3 KT2 KT1 KT0
S50 S48 traverse X52.2 X52.1 X51.3 X51.2 X51.1
S49
EB n+5 Free K. Opt. K. Axis selection
T16 KT5 6 5 4 Z Y X
S18 X52.3 S47 S46 S45 S44 S43 S42
EB n+6 Freely assignable customer keys WCS/MCS Freely assignable customer keys
T9 T10 T11 T12 T13 T14 T15
S33
S29 S30 S31 S32 S12 S14 S15
T1 T2 T3 T4 T5 T6 T7 T8
S21 S22 S23 S24 S25 S26 S27 S28
Signals marked with * are inverse signals.

The following information is to be found in the table for each input bit:

Output image Arrangement of LED signals in the output image of the DP slave: MCP 310:
Table 8-3 Output image

AB n+0 Spindle override Operating mode
*NC Stop SP – SP 100% SP + Single JOG MDA AUTO
LED19 LED36 LED37 LED38 block LED09 LED10 LED13
LED16
AB n+1 Spindle Machine functions
NC Start SP right *SP Stop SP left Reset REF REP TEACH
LED20 LED39 LED40 LED41 LED 17 LED02 LED01 LED11
AB n+2 Feed Mach. fu. not Machine functions
used
Start *Hold var. INC 1000 INC 100 INC 10 INC 1 INC
LED35 LED34 LED03 LED07 LED06 LED05 LED04
AB n+3 not not not not not not not not
used used used used used used used used
AB n+4 Direction keys Optional customer keys
+ – Rapid KT4 KT3 KT2 KT1 KT0
LED50 LED48 traverse 24 V 24 V 24 V 24 V 24 V
LED49
AB n+5 Free K. Opt.K. Axis selection
T16 KT5 6 5 4 Z Y X
LED18 24 V LED47 LED46 LED45 LED44 LED43 LED42
AB n+6 Freely assignable customer keys Freely assignable customer keys
WCS/MCS
T9 T10 T11 T12 T13 T14 T15
LED33
LED29 LED30 LED31 LED32 LED12 LED14 LED15
T1 T2 T3 T4 T5 T6 T7 T8
The following information is to be found in the table for each output bit:

Fig. 8-16 MCP 483 Front panel; Version T (turning machines)
8.7.1 Conditions for general installation and start-up
S PROFIBUS connecting cable

No terminating resistor is integrated in the machine control panel.
S PLC basic program

How to install the library is described in Section 6.4, Page 6-149.
S SIMATIC STEP 7
can be installed directly on the PCU of the SINUMERIK 840Di sl. How to
install additional software is described in Chapter 18, Page 18-485.
S DP slave: MCP 483

The DP slave: MCP 483 is part of the PLC Toolbox. When the PLC Toolbox
is installed, it is automatically installed in SIMATIC STEP 7.
Description of MCP (interfaces, electrical connection, etc.)
/Z/ Catalog NCZ

Interfaces Fig. 8-17 below shows the interfaces on the rear of the module:
Termination equipotential
bonding conductor PROFIBUS X20
Power supply X10 Handwheels X60/X61
Rotary switch X30/X31 LEDs 1...4 Handwheel signal type S1
COM board
Keyswitch X50 S3 DIP switch Direct keys X70

Customer spec. Operating elements X51 ...X54
1 2 3
SHIELDM24 P24
Fig. 8-17 Position of interfaces on rear side of machine control panel
Section: Machine control panel MCP 483
Simultaneously pressing the two keys “Feed stop” and “Feed enable” (in the
bottom right corner) displays the version number of the current software version
using the LEDs now lighting continuously.
Version number = V “Number of lit LEDs on the left LED block”.

“Number of lit LEDs on the center LED block”.
“Number of lit LEDs on the right LED block”

In the example (Fig. 8-18) version number: V 01.02.00 is displayed.
Enable software version dis-

1. Digit 2. Digit 3. Digit play
(press both keys
simultaneously)
Fig. 8-18 MCP software version display
Switch S3 The PROFIBUS address and connection type are set with switch S3 on the rear
of the MCP:
Table 8-4 Switch S3: PROFIBUS address (1 – 7)
10 9 8 7 6 5 4 3 2 1 Meaning / value
on on – – – – – – – – Connection type: PROFIBUS
– – off – – – – – – – Reserved
PROFIBUS address
– – – off off off off off off off 0
– – – off off off off off off on 1
– – – on off off off off on off 2
– – – off off off off off on on 3
– – – : : : : : : : :
– – – on on on on on on off 126
– – – on on on on on on on 127
Switch settings 10 – 8 must be set according to the data in the table.
Notice
In the state as delivered, the connection type is: MPI (10 – 9: off, off) set.

8.7.3 Functions of the machine control panel
The machine control panel offers the following functions:

S Standard
S 2nd handwheel
S Additional I/Os
Standard The function transfers input/output data from the function keys and user-specific
keys and outputs:
The input/output data for machine control panel MCP 483 is compatible with the
input/output data from the previous machine control panel:
– Machine control panel (MCP), MPI

– 19” machine control panel
2nd handwheel The function transfers the absolute values for the two handwheels that can be
connected to the machine control panel:
S Input data: 2 x 2 bytes

Absolute value handwheel Absolute value handwheel
1 2
Low byte High byte
For each handwheel the current handwheel value is transferred as a 16-bit ab-
solute value relative to the starting value. The starting value for the sensor
counter in the handwheel is 0.
The absolute values are transferred in big endian format.
The data for both handwheels is always transferred. The absolute value for a
handwheel that is not connected is always 0.
Additional I/Os The function transfers the data for all non-standard inputs/outputs:
S Direct control key
S Customer keys: 6 signals (bit 0 to bit 6)
S Rotary switch
with the following distribution:

Customer 1. Rotary 2. Rotary
Direct control keys (OP 012) keys switch switch
Low byte High byte

Reserved, Customer
always 0 LEDs
Low byte High byte

8.7.4 Configuring the DP slave: MCP 483
This section describes the configuration of a DP slave: MCP 483 by way of ex-
ample of the configuration of a SIMATIC S7 project shown in Fig. 8-19.
The configuration comprises the following modules:
S SIMATIC station 300 with SINUMERIK 810D/840D and PLC 317-2DP
S SINUMERIK MCP with module: standard, handwheel, extended
To configure DP slave: MCP 483 the following steps must be carried out in the
S7 project:
1. Insert DP slave: MCP 1,226.82 cm the configuration
(see Fig. 8-19, Page 8-208: 1)
2. Set the PROFIBUS address.
3. Insert the modules in DP slave: MCP 483 for the functions required.
(see Fig. 8-19, Page 8-208: 2)
4. Set the I/O addresses for the individual slots.
HW Config – [SINUMERIK840D (configuration) –– PROFIBUS MCP]

(0) 810D/840D PROFIBUS(1): DP master system(1) Profile: Standard

1
2 PLC 317–2DP 2AJ10
I/O
X1 MPI (9) SINUME NC/RC
X2 DP MOTION CONTROL
3 IM360 SINUMERIK MCP
4 S7 FM NCU Universal module
standard
2
standard, handwheel
standard, extended
standard, handwheel, ex
slot DP ID Order number / designation I address O address Com...

1 55 standard, handwheel, extended 0...7 0...7
2 2IO ––> standard, handwheel, exten 258...261
3 192 ––> standard, handwheel, exten 8...12 8...9
Fig. 8-19 Configuration with DP slave: MCP 483
Requirements: S7 The following status of the S7 project into which DP-Slave: MCP 483 is to be
project inserted is assumed:
– You have created the S7 project
– You have set up a SIMATIC 300 station with PROFIBUS master-capable
SINUMERIK controller
DP slave: MCP 483 To insert a DP slave: MCP 483 into the configuration, open the hardware cata-
log with menu item View > Catalog.

DP slave: MCP 483 is located under:
S Profile: Standard
PROFIBUS-DP > Other field devices > NC/RC > Motion Control
> SINUMERIK MCP
Select the DP slave by left-clicking it in the hardware catalog: MCP 483 (SI-
NUMERIK MCP) and drag it while holding down the mouse key onto the DP
master system in the station window.
symbol:
When you release the left mouse key, DP slave: MCP 483 is inserted in the con-
figuration.
Note
As you drag the DP slave the cursor appears as a circle with a slash through it.
When the cursor is positioned exactly over the DP master system, it changes to
a plus sign, and the DP slave can be added to the configuration.
PROFIBUS When you have inserted DP slave: MCP 483 into the configuration, dialog
Parameter “Properties – PROFIBUS Interface SINUMERIK MCP” is displayed.
– Profile
Dialog box Dialog box: Properties – PROFIBUS Interface SINUMERIK MCP

Tab card: Parameter
Profile: DP
OK
OK

Notice
The PROFIBUS address set in the S7 project for DP slave: MCP 483 must
match the PROFIBUS address set on the module (DIP switch S3).
1. SIMATIC configuration DP slave: MCP 483
PROFIBUS address
2. Machine control panel MCP 483
PROFIBUS address (DIP switch S3)
Adding a module The active functions and hence the number of user data elements to be trans-
ferred are chosen by selecting the appropriate pre-configured module. The mo-
dules are listed in the hardware catalog under DP slave: MCP 483. The follow-
ing modules are available:
S Universal module (not applicable)
S standard
S standard, handwheel
S standard, extended
S standard, handwheel, extended
Module: standard
The module transfers the data for the “Standard” function:

Standard data
(8 bytes)

Standard data
(8 bytes)
Module: standard, handwheel

The module transfers the data for the “Standard” and “Handwheel” functions:
S Input data: 12 bytes

Absolute value Absolute value
Standard data
2nd handwheel 2nd handwheel
(8 bytes)
(1 bytes) (2 bytes)
Low byte High byte

Standard data
(8 bytes)

Module: standard, extended

The module transfers the data for the “Standard” and “Additional I/Os” functions:

Direct co. keys Customer keys 1. Rotary 2. Rotary
Standard data
(OP 012) (1 byte) switch switch
(8 bytes)
Low byte High byte

Customer
Standard data Reserved
LEDs
(8 bytes) (1 byte)
(1 byte)
Low byte High byte
Module: standard, handwheel, extended

The module transfers the data for the “Standard”, “Handwheel” and “Additional
I/Os” functions:

Absolute value Absolute value Di. co. keys
Standard data
2nd handwheel 2nd handwheel (OP 012)
(8 bytes)
(1 bytes) (2 bytes) (2 bytes)
Low byte
1. Rotary 2. Rotary
Customer keys
switch switch
(1 byte)
(1 byte) (1 byte)
High byte

Reserved Customer
Standard data
(1 byte) LEDs
(8 bytes)
(1 byte)
Low byte High byte
Setting the I/O ad- When you insert a module in slot 1 of DP slave: MCP 483 the input/output ad-
dresses dresses of STEP 7 are automatically assigned.
Double clicking with the left mouse button on a slot opens the “Properties – DP
slave” dialog box. The starting addresses for the I/O data for the slot can be set
here.
face

a module failure

Notice
“Handwheel” function
The “Handwheel” function is not currently supported by the basic PLC program.
“Additional I/Os” function
manufacturer) and is not supported by the basic PLC program.
PLC basic In order to transfer standard input/output data of DP slave: MCP 483 with the
program PLC basic program, the I/O address range in question must be entered in the
communications parameters of function block FB1.
Function block FB1

The communications parameters of the MCP are called MCPx... (x = 1 or 2) in
function block FB1. A maximum of 2 machine control panels are supported by
To operate an MCP 483 as a DP slave on a SINUMERIK 840Di sl, the following
parameters are relevant:

the 1st MCP:

Notice
Literature
please refer to:

VDI interface The following function blocks can be used to assign the VDI interface:
parameter S FC 19: Machine control panel MCP 483, version M (milling)
assignment
S FC 25: Machine control panel MCP 483, version T (turning)
Notice
Literature
Section: FC 25: MCP_IFT ...
MCP1BusAdr := 5 // PROFIBUS address of the DP slave MCP
MCPCopyDB77 := FALSE // No copying to DB77
MCPBusTyp := B#16#33 // PROFIBUS
PLC user program If an MCP is connected via PROFIBUS DP, the basic PLC program does not
check for module failure.
In this case the MCP is monitored by a standard mechanism to monitor the ac-
tive DP slave:
S PLC operating system

S PROFIBUS controller
If the failure of DP slave: MCP 483 is detected the PLC goes into the STOP
status as default.
Customized To allow the user to intervene when a DP slave: MCP 483, the following
response organization blocks are inserted in the PLC user program:
S OB 82: Diagnostic interrupt

S OB 86: Rack failure

Please refer to the corresponding SIMATIC literature for details of linking orga-
nization blocks and evaluating diagnostic data.
Notice
In the event of the failure of a machine control panel connected via MPI, the
following alarm is triggered by the PLC basic program:
S Alarm “40026x machine control panel (x+1) failure”; with x = 0, 1

When connecting the machine control panel via PROFIBUS, the user (machine
manufacturer) is responsible for triggering a corresponding alarm.
S Key number xy corresponds to Sxy

S LED number xy corresponds to LEDxy
nel. For the sake of clarity, the LED designations are not shown in full.
LED34
LED
S09 S01 S02 S17 S18 S19 S32 S33 S34 Key
S10 S03 S04 S20 S21 S22 S35 S36 S37
S11 S05 S06 S23 S24 S25 S38 S39 S40
S12 S07 S08 S26 S27 S28 S41 S42 S43
S13 S14 S15 S16 S29 S30 S31 S44 S45 S46 S47 S48 S49 S50
Fig. 8-20 MCP 483 keyboard layout (front view)

Input image Arrangement of key signals in the input image of DP slave: MCP 483:
Table 8-5 Input image

*Override *Override *Override *Override JOG TEACH MDA AUTO
Spindle8 Spindle4 Spindle2 Spindle4
X31.7 X31.8 X31.9 X31.10 S09 S10 S11 S12
EB n+1 Machine functions
REPOS REF var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
S01 S02 S03 S08 S07 S06 S05 S04
EB n+2 Key Key Spindle *Spindle Feed Start *Feed Stop NC Start *NC Stop
Pos. 0 Pos. 2 Start Stop S50 S49
X50.4 X50.1 S48 S47 S20 S15
EB n+3 RESET Key Single Feed override
Pos.
Pos 1 Block
*Override *Override *Override *Override *Override
S13 X50.6
F.over.16 F.over.8 F.over.4 F.over.2 F.over.1
S14
X30.6 X30.7 X30.8 X30.9 X30.10
EB n+4 Direction keys Key Axis selection
Pos.
Pos 3
R15 R13 R14 R1 R4 R7 R10
X50.3
S46 S44 S45 S32 S35 S38 S41
EB n+5 Axis selection
R2 R3 R5 R12 R11 R9 R8 R6
S33 S34 S36 S43 S42 S40 S39 S37
F9 F10 F11 F12 F13 F14 F15 not
S25 S26 S27 S28 S29 S30 S31 used
F1 F2 F3 F4 F5 F6 F7 F8
S17 S18 S19 S20 S21 S22 S23 S24
Signals marked with * are inverse signals.

The following information is to be found in the table for each input bit:

Output image Arrangement of LED signals in the output image of the DP slave: MCP 483:
Table 8-6 Output image

AB n+0 Machine function Operating mode
1000 INC 100 INC 10 INC 1 INC JOG TEACH MDA AUTO
AB n+1 Feed Start Feed Stop NC Start NC Stop Machine function
LED50 LED49
REPOS REF var. INC 10000 INC
LED16 LED15
LED01 LED02 LED03 LED08
AB n+2 Axis selection Single Spindle Spindle
Block Start Stop
R13 R1 R4 R7 R10 LED48 LED47
LED44 LED32 LED35 LED38 LED41 LED14
AB n+3 Axis selection
R3 R5 R12 R11 R9 R8 R6 R15
AB n+4 Freely assignable customer keys Axis
selection
F9 F10 F11 F12 F13 F14 F15 R2
F1 F2 F3 F4 F5 F6 F7 F8
AB n+6 not not not not not not RESET R14
used used used used used used LED13 LED45
(optional) (optional)
AB n+7 not not not not not not not not
used used used used used used used used
The following information is to be found in the table for each output bit:

8.8 DP slave: ADI4
8.8 DP slave: ADI4
Notice
The ADI4 DP slave can only be operated on an isochronous PROFIBUS DP.
8.8.1 Slave OM
Parameters for the configuration with regard to the ADI4 interface modules,
called DP slave ADI4 here, are assigned with the SlaveOM for SINUMERIK
840Di sl. For how to install the slaveOM, see below: References.
Note
BUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.)
you require into the configuration before parameterization of the DP drives,
before you set the times for isochronous communication.
8.8.2 Inserting DP Slave
To insert an ADI4 DP slave in the configuration, open the hardware catalog us-
ing the View > Catalog menu command.
The DP slave ADI4 is to be found at:
S Profile: Standard
PROFIBUS DP > SINUMERIK > ADI4
Select DP slave ADI4 by clicking it with the left mouse button and drag it to the
DP master system in the Station window holding down the mouse button.
symbol:
When you release the left mouse button, the DP slave ADI4 is inserted into the
configuration.
Note
Make sure that the cursor, which appears as a crossed-out circle when drag-
ging the DP slave, is positioned exactly on the DP master system so that the
DP slave is inserted into the configuration.
Literature For a complete description of the parameterization of an AD14 DP slave please

refer to:
Section: Parameter Assignment

8.9 DP slave: SINAMICSS120

The following SINAMICS drive system is available for SINUMERIK 840Di sl:
– SINAMICS S120 with CU320 on PROFIBUS DP
8.9.1 SlaveOM for SINAMICS
The SlaveOM for SINAMICS is required to configure SINAMICS S120 drives.

The SlaveOM is automatically installed in SIMATIC STEP7, if the SINAMICS
STARTER commissioning tool is installed on the same computer (PG/PC) as
SIMATIC STEP7.
Note
S Configuration and SlaveOM for SINAMICS
The SlaveOM for SINAMICS must be installed to configure SINAMICS
S120 drives. To do this, install the SINAMICS STARTER commissioning
tool on the same computer (PG/PC) as SIMATIC STEP7.
S Assigning parameters for isochronous communication

To simplify the assignment of parameters for isochronous communication
on the PROFIBUS DP, you must first insert all the DP slaves (drives, ADI4,
I/O modules, etc.) you require into the configuration before assigning pa-
rameters on the DP drives, before you set the times for isochronous DP
communication.
8.9.2 Inserting the DP slave
To insert a DP slave S120 into the configuration, open the hardware catalog
using the menu command View > Catalog.
The DP slave S120 is to be found at:
S Profile: Standard
PROFIBUS DP > SINAMICS > SINAMICS S120
Select DP slave S120 by clicking it with the left mouse button and drag it to the
DP master system in the station window while holding down the mouse button.
symbol:
Releasing the mouse button inserts the DP slave S120 in the configuration.
Note

Expanded The “expanded message frame configuration” has been provided to transfer
message frame additional drive data to the NC in the cyclic PROFIBUS message frame in addi-
configuration tion to the process data (PDA) for the selected standard message frame type
(102 to 107).
The expanded message frame configuration is described in Section 19.2, Page
19-509.
8.9.3 Parameterizing DP slaves
The assignment of parameters to DP slave S120 is divided into 2 steps:
S Step 1
In Step 1, DP slave S120-specific parameter settings are made for:
– Device version
– PROFIBUS telegram
– I/O addresses
– Expanded message frame configuration
Step 1 should first be carried out for all DP slaves S120 required for the con-
figuration.
S Step 2
Step 2 includes parameterization of isochronous DP communication. Step 2
can be carried out finally, for any DP slave S120.
The settings made during the operational sequence above can be trans-
ferred to all of the remaining DP slaves S120 using the matching function of
SlaveOM.
PROFIBUS Inserting a DP slave S120 into the configuration will open the dialog for assign-
address ing parameters for PROFIBUS DP properties.
The PROFIBUS address is automatically set to the next free PROFIBUS ad-
dress.
The PROFIBUS address can generally be freely selected. It must, however,
match the PROFIBUS address set in the drive Control Unit (parameter P0918).
Notice
The PROFIBUS address of DP slave S120, which is set using HW Config,
must match the PROFIBUS address set in the drive:
1. SIMATIC configuration of DP slave S120
PROFIBUS address
2. SINAMICS S120, CU320
Parameter P0918 (PROFIBUS node address)

Dialog box Dialog box: Properties – PROFIBUS interface SINAMICS

T ab: Parameter
OK
Device version After this dialog has been confirmed using the button: “OK”, the dialog box:
“SIMOTION drive properties” dialog opens enabling you to set the device ver-
sion used in the drive.
Dialog box Dialog box: Properties – SIMOTION drive

Tab: Drive unit/Bus address
Device version: <Device version>
PROFIBUS After this dialog has been confirmed using the button: “OK”, the dialog box: “DP
telegram Slave Properties” dialog opens.
Telegrams and process data
Selecting a message frame defines the process data (PDA) exchanged be-
tween the DP master and the DP slave.
The following vendor-specific message frames are predefined for exchanging
process data between a SINUMERIK 840Di sl (DP master) and a DP slave
S120:
Table 8-7 Telegrams and process data
Drive Object Telegram PDAset PDAact Description

Closed-loop drive 102 6 10 Speed control with torque reduction, 1 position encoders
control
103 7 15 Speed control with torque reduction, 2 position encoders
105 10 10 DSC with torque reduction, 1 position encoder
Supply 370 1 1 Message frame for the infeed
Control Unit 390 2 2 Message frame for Control Unit (drive object 1, DO1),
Digital inputs/outputs
391 3 3 Message frame for Control Unit (drive object 1, DO1),
Digital inputs/outputs and probe
“Free interconnec- 999 – – The send and receive telegrams can be configured as
tion via BICO” required by using BICO technology to interconnect the
send and receive process data.
PDAset/PDAact Number of process data words: Setpoints/Actual values
DSC function: Dynamic Servo Control
For a detailed description of message frames, please see:

References:
SINAMICS S120 Commissioning Manual,
Section: Communications via PROFIBUS-DP

Message frame structure

The configuration of the PROFIBUS message frame for a DP slave S120 must
observe the following framework conditions:
S The process data of the axes or drive objects: “Drives” must be available
before the process data of all other drive objects (Control Unit, infeed, etc.).
Note
Currently, no message frames must be configured for the Control Unit and in-
feed of a drive unit. Error acknowledgement and release are performed in the
STARTER by means of free message frame configuration with BICO.
S The structure of the process data for the PROFIBUS message frame config-
ured in HW Config (object sequence and message frame type) must be
identical to the structure configured in STARTER.
Configuring a message frame in HW Config

DP slave properties
Default setting
Object Message frame selection Option
1 Message frame 102, PDA–6/10
Overview Details
Configuring a message frame in STARTER

PROFIBUS telegram Version overview
The drive objects are provided with data from the PROFIBUS message frame in the following order:
Object Drive Object No Message frame type

1 Drive_1 .3 SIEMENS telegram 102
2 Drive_2 4 SIEMENS telegram 103
4 Supply 2 Free telegram configuration with BICO
5 Control_Unit 1 Free telegram configuration with BICO
Close Hel
p
Drive_unit_Adr10
Fig. 8-21 Process data structure: HW Config and STARTER

Dialog box Dialog box: DP slave properties

Tab card: Configuration
Tab: Overview
Message frame selection: <Telegram>
OK
Notice
The PROFIBUS message frame of DP slave S120, which is parameterized
using HW Config, must match the corresponding data parameterized in the NC
and in the drive.
1. SIMATIC configuration DP slave S120
Drive object: “Drive control”: Message frame
2. SINUMERIK 840Di sl NC
MD13060 $MN_DRIVE_TELEGRAM_TYP[n]
3. SINAMICS S120
Parameter p0922 (PROFIBUS PDA message frame selection) and
STARTER: Drive unit > Configuration
I/O addresses Communication between the NC and the drive object of a DP slave S120 in the
SINUMERIK 840Di sl can only take place if the I/O addresses for the I/O data of
a drive object are the same.
Notice
S The I/O addresses of the I/O data of a drive object must be the same, e.g.,
drive object: “Drive control”:
I/O address actual value = = I/O address setpoint
S The I/O address set by the HW Config for a drive object must match the I/O
address set in the NC.
S SIMATIC configuration DP slave S120

Drive object: “Drive control”: I/O address
SINUMERIK 840Di sl NC
MD13060 $MN_DRIVE_LOGIC_ADDRESS[n]
S SIMATIC configuration DP slave S120

Drive object: “Control Unit”: I/O address
SINUMERIK 840Di sl NC
MD13120 $MN_CONTROL_UNIT_LOGIC_ADDRESS[n]

Note
To prevent changes to the I/O addresses in the NC machine data, we recom-
mend using the default machine data values when assigning I/O addresses:
S Drive objects: “Drive control”:
MD13050 $MN_DRIVE_LOGIC_ADDRESS[n], n = 0,1,...
Default values: 4100 + n*40
S Drive objects: “Control Unit”:
MD13120 $MN_CONTROL_UNIT_LOGIC_ADDRESS[n], n = 0,1,...
Default values: 6500 (1. CU), 0 (all other CUs)

Tab: Details
Entry in table: PROFIBUS Partner, I/O address: <I/O address>
OK
After you have confirmed this dialog box using the button: “OK”, the dialog box:
“DP slave properties” closes. Step 1 of parameterization of DP slave S120 is
then complete.
Consistency The default setting with regard to the consistency of the I/O data is whole
length.
This setting results in:
S Direct accesses from the PLC user program (e.g. byte, word or double word)
to this address range are not admitted by the PLC operating system.
S Accesses to this address range must be carried out using the system func-
tions SFC 14 and SFC 15.
S The system functions SFC 14 and SFC 15 guarantee consistent reading/

writing of the data of an axis, e.g.:
– Message frame type 102: 6 words for the set value or 10 words for the
actual value
S Because DP slaves 611U can be assigned both to the NC and to the PLC,
check system functions SFC 14 and SFC 15 when writing data to see
whether the drive belongs to the writing component. If this is not the case,
the data access is denied.
8.9.4 Dependencies of PROFIBUS DP communication
The overview example shows the interrelations or interdependencies when con-

figuring the PROFIBUS DP communication between the components:
S NC
S DP master
S DP slave S120

NC DP master (HW Config: DP slave S120)

MD13050 MD 13060
DRIVE_LOGIC_ DRIVE_TELE– PROFIBUS address: 10
ADDRESS[ n ] GRAM_TYP[ n ]
Object I/O address Message frame
1. MA[0]: 4100 102 1 4100 102
2. MA[1]: 4140 102 2 4140 102
3. MA[2]: 4180 102 3 4180 102
1 2
DP slave S120 (STARTER)
PROFIBUS address: 10
Object Drive object No.: Message frame type

1 Drive_1 3 102
2 Drive_2 4 102
3 Drive_3 5 102
3
Drive object no.

1 2 3 4 5
4
Drive Object
ALM SMM DMM
CU 320
Drive_1
Drive_2
Drive_3
Fig. 8-22 Dependencies: NC, PLC/DP master and DP slave S120
1 NC
The NC writes/reads the process data for machine axes 1 to 3 from the I/O ad-
dresses and message frames assigned parameters in machine data:
S MD13050: DRIVE_LOGIC_ADDRESS[ n ]
S MD13060: DRIVE_TELEGRAM_TYP[ n ]
1. Machine axis: I/O address 4100
Message frame 102
Message frame type 102
For configuring the drive within the framework of the NC start-up, please refer to
Subsection 12.5.3, Page 12-328.

2 DP master
The DP master periodically transfers the isochronous process data to/from DP

slaves S120 based on the configuration set in SIMATIC STEP 7 HW Config:
Object I/O address Message frame

1 4100 102
2 4140 102
3 4180 102
Transferring process data to DP slave S120

The process data for the machine axes are read from the configured I/O ad-
dresses by the DP master and transferred to the DP slave S120 in the PROFI-
BUS message frame according to the configured object sequence.
Reading process data from DP slave S120
The process data for the machine axes are read from the PROFIBUS message
frame by the DP master in the configured object sequence and transferred to
the corresponding I/O addresses.
3 DP slave S120
DP slave S120 interprets the PROFIBUS message frames received from the
DP master based on the STARTER configuration:
Object Drive object -Nr. Message frame type

1 Drive_1 3 SIEMENS message frame 102
4 Infeed 2 Free message frame configuration with BICO
5 Control Unit 1 Free message frame configuration with BICO
Transferring process data to the drive object

The process data (message frame type) are read from the PROFIBUS message
frame by DP slave S120 in the configured object sequence (object) and trans-
ferred to the corresponding drive object according to the drive object number.
Example:
The process data for the first object is read to the PROFIBUS message frame
according to message frame 102. The process data is transferred to the drive
object: “Drive_1”, drive object No. 3.
Reading process data from the drive object
The process data (message frame type) are read from the corresponding drive
object by DP slave S120 in the configured object sequence (object) based on
the drive object number and transferred to the PROFIBUS message frame.

8.10 DP slave: SIMODRIVE drives

Parameterization of the configuration with regards to the SIMODRIVE drives:
is exemplified here by parameterization of the SIMODRIVE 611 universal.
8.10.1 SlaveOM
The drives are assigned parameters using the SlaveOM for SINUMERIK
840Di sl (for installation of the SlaveOM, see Section 8.1, Page 8-171: DriveOM
/ SlaveOM).
Note
BUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.)
you require into the configuration before parameterization of the DP drives,
before you set the times for isochronous DP communication.
8.10.2 Inserting the DP slave
To insert a DP slave 611U into the configuration, open the hardware catalog
using the menu command View > Catalog.
The DP slave 611U is to be found at:
S Profile: Standard
PROFIBUS DP > SIMODRIVE > SIMODRIVE 611 universal, PROFI-
BUS DP1
Select DP slave 611U by clicking it with the left mouse button and drag it to the
DP master system in the Station window holding down the mouse button.
symbol:
When you release the left mouse button, the DP slave 611U is inserted into the
configuration.
Note

8.10DP slave: SIMODRIVE drives
Expanded In SW 2.2 and higher, “expanded message frame configuration” has been pro-
message frame vided to transfer drive data to the NC in the cyclic PROFIBUS message frame in
configuration addition to the process data (PDA) for the selected standard message frame
type (102 to 107).
The expanded message frame configuration is described in Section 19.2, Page
19-509.
8.10.3 Parameterizing DP slaves
Parameterization of the DP slave 611U is divided into 2 steps:
S Step 1
In Step 1, DP slave 611U-specific parameter settings are made for:
– Number of axes and encoders (message frame type)
– I/O addresses
– Expanded message frame configuration (SW 2.2 and higher)
Step 1 should first be carried out for all DP slaves 611U required for the con-
figuration.
S Step 2
Step 2 includes parameterization of isochronous DP communication. Step 2
can be carried out finally, for any DP slave 611U.
The settings made during the operational sequence above can be trans-
ferred to all of the remaining DP slaves 611U using the matching function of
SlaveOM.
PROFIBUS Inserting a DP slave 611U into the configuration will open the dialog for parame-
address terizing the PROFIBUS DP properties.
SlaveOM sets the PROFIBUS address to the next free PROFIBUS address
automatically.
The PROFIBUS address can generally be freely selected. It must, however,
match the PROFIBUS address set in the drive (e.g. with SimoCom U) (parame-
ter P0918).
Notice
The PROFIBUS address of DP slave 611U, which is set on the SlaveOM, must
match with the PROFIBUS address set in the drive:
1. SIMATIC configuration of DP slave 611U
PROFIBUS address
2. SIMODRIVE 611 universal
Parameter P0918 (PROFIBUS node address)

Dialog box Dialog box: Properties – PROFIBUS Interface SIMODRIVE 611U DP2, DP3
Tab card: Parameter
Address: PROFIBUS address
OK
Message frame After this dialog has been confirmed using the button: “OK”, the dialog box: “DP
type Slave Properties” dialog opens.
Depending on the drive functionality to be used, you must select the correct
message frame type from the listbox: Default. The selected message frame
type only defines the number of cyclically transferred process data units within
the cyclic message frames.
The number of cyclically transferred process data units depends on:
– The number of axes per drive module
– The number of encoders used per axis
– The drive functionality used
The following message frame types are predefined for parameterization of the
DP slave 611U:
Table 8-8 Message frame types

Message frame type Description
1 axis, Message frame type 102, PDA nset interface with encoder 1
6/10
2 axes, Message frame type 102, PDA nset interface with encoder 1
6/10
1 axis, Message frame type 103/104, nset interface with encoders 1 and 2 (103)
PDA 7/15 or encoders 1 and 3 (104)
2 axes, Message frame type 104, PDA nset interface with encoders 1 and 3
7/15
1 axis, Message frame type 105, PDA nset interface with DSC and encoder
10/10
2 axes, Message frame type 105, PDA nset interface with DSC and encoders 1
10/10 and 2
1 axis, Message frame type 106/107, nset interface with DSC and encoders 1
PDA 7/15 and 2 (106) or encoders 1 and 3 (107)
2 axes, Message frame type 106/107, nset interface with DSC and encoders 1
PDA 7/15 and 2 (106) or encoders 1 and 3 (107)
PDA x/y Number of process data words, x: Setpoints, y: Actual values
DSC Functionality “Dynamic Servo Control”
Encoder 1 Encoder 2 Encoder 1 Encoder 2
Encoder 3
SIMODRIVE 611 universal SIMODRIVE 611 universal E


Default: <Message frame type>
OK
Notice
The message frame type of DP slave 611U, which is set on the SlaveOM, must
match with the PROFIBUS address set on the NC and the drive:
1. SIMATIC configuration DP slave 611U
Message frame type
MD13060 DRIVE_TELEGRAM_TYP
3. SIMODRIVE 611 universal
Parameter P0922 (PROFIBUS message frame type selection)
For a detailed description of the different message frame types, please see:
S SIMODRIVE 611 universal and universal E:

References: /FBU/ Description of Functions SIMODRIVE 611
universal
S SIMODRIVE POSMO SI/CD/CA

References: /POS3/ User Manual SIMODRIVE POSMO SI/CD/CA
in each case in Section: Communication on PROFIBUS DP.
I/O addresses Communication between the NC and the individual axes of the DP slaves 611U
in the SINUMERIK 840Di sl can only take place if the I/O addresses for the set-
point 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.
Notice
S The I/O addresses for set and actual values of an axis must be the same.
If a DP slave 611U is inserted into an S7 project due to a copying process
(e.g. from another S7 project), the I/O addresses are assigned exclusively
under the control of “HW-Config”.
This may have the consequence that an axis is assigned different I/O ad-
dresses for set and actual values. In this case, the I/O addresses must be
corrected manually.

Notice
The I/O address set by the SlaveOM for an axis must match the I/O address
set in the NC.
1. SIMATIC configuration of DP slave 611U
I/O address
MD13060 DRIVE_LOGIC_ADDRESS[n], (logical drive address)
Note
To avoid any subsequent modifications to the I/O addresses in NCK machine
data:
S MD 13050 DRIVE_LOGIC_ADDRESS[n]
it is recommended to use the default values of the machine data when config-
uring the I/O addresses within the configuration:
1st axis: Default I/O address = 4100
mth axis: Default I/O address = 4100 + (m–1)*40
The default setting for the machine data is described in Subsection 12.5.1,
Page 12-324.

Entry in table: PROFIBUS Partner, I/O address: <I/O address>
OK
After you have confirmed this dialog box using the button: “OK”, the dialog box:
“DP slave properties” closes. Step 1 of parameterization of DP slave 611U is
then complete.
Consistency The default setting with regard to the consistency of the I/O data is whole
length.
This setting results in:
S Direct accesses from the PLC user program (e.g. byte, word or double word)
to this address range are not permitted by the PLC operating system.
S Accesses to this address range must be carried out using the system func-
tions SFC 14 and SFC 15.
S The system functions SFC 14 and SFC 15 ensure consistent reading/writing

of the data of an axis, e.g.:
– Message frame type 102: 6 words for the set value or 10 words for the
actual value

S Because DP slaves 611U can be assigned both to the NC and to the PLC,
check system functions SFC 14 and SFC 15 when writing data to see
whether the drive belongs to the writing component. If this is not the case,
the data access is denied.
8.10.4 Dependencies of PROFIBUS DP communication
The overview example shows the interrelations or interdependencies when con-

figuring the PROFIBUS DP communication between the components:
S NC
S DP master
S DP Slave 611U
NC DP master
I/O address, message frame type PROFIBUS address, slot and I/O address (mes-
MD13050: DRIVE_LOGIK_ADDRESS[ n ] sage frame type)
1st machine axis: 4100 PROFIBUS addr.: 10
2nd machine axis: 4140 Axis 1: Slot 5/6, I/O addr. 4100
MD 13060: DRIVE_TELEGRAM_TYP[ n ] Axis 2: Slot 9/10, I/O addr. 4140
1st machine axis: 102 (message frame type: 102)
2nd machine axis: 102
PROFIBUS-DP 2
Cyclic message frame: 102

PIV/PDA PIV/PDA
header Axis 1 / Axis 2 / Trailer
Drive A Drive B
DP Slave 611U
PROFIBUS address, message frame type
PROFIBUS addr.: 10
Message frame type: 102
Axis 1 / Drive A
Axis 2 / Drive B
Fig. 8-23 Dependencies: NC, PLC/DP master and DP slave (SIMODRIVE 611 universal)
1 NC
The NC reads/writes the axis data in the relevant I/O area of the PLC/DP master
on the basis of the I/O address entered in
S MD13050: DRIVE_LOGIC_ADDRESS[ n ]
S MD13060: DRIVE_TELEGRAM_TYP[ n ]

and the message frame type of the machine axis:

For configuring the drive within the framework of the NC start-up, please refer to
2 DP master
The information regarding the individual DP slaves are known to the DP mas-
ters from the PROFIBUS SDB generated from the configuration.
DP master transfers the data to/from the DP slaves in isochronous cycles using
the following information:
PROFIBUS addr. 10: Setpoint: Slot 5, I/O address 4100
Actual value: Slot 6, I/O address 4100
Setpoint: Slot 9, I/O address 4140
Actual value: Slot 10, I/O address 4140
For a 2 axis-closed-loop control module of a SIMODRIVE 611 universal, the
following assignment applies:
S Slot 5 / 6 => Axis 1 or Drive A
S Slot 9 / 10 => Axis 2 or Drive B
3 DP Slave 611U
DP slave interprets the message frames received from the DP master because
of the drive parameters
S Parameter P0922 (PROFIBUS message frame type selection)

Message frame type set:

8.11DP slave: Diagnostic repeater for PROFIBUS DP
8.11 DP slave: Diagnostic repeater for PROFIBUS DP
8.11.1 Function
SINUMERIK 840Di sl
DP Master PG with SIMATIC STEP 7
Segment 1 Start:
Diagnostics Topology determination
Diagnostic repeaters
Slave distance Distance to

fault
DP slave DP-Slave ET200 DP slave MCP 483

POSMO A
DP Slave 611U ADI4 DP slave

Segment 2 Segment 3
Fig. 8-24 Example: PROFIBUS topology with diagnostic repeater
A diagnostic repeater can monitor the segment of an RS 485 PROFIBUS sub-

net (copper cable) during normal operation and report line faults in a diagnostic
message frame to the DP master. Used together with the SINUMERIK 840Di sl
it is possible to display the location and cause of the fault in plaintext.
The diagnostic repeater primarily performs the following tasks:
S Diagnostic functions for two PROFIBUS segments (DP2 and DP3):

The diagnostic function supplies the location and causes of cable faults
such as wire breaks or missing terminating resistors.
S Repeater functions for three PROFIBUS segments (DP1, DP2, DP3):

The diagnostic repeater amplifies the data signals on the bus cables and
connects up individual RS 485 segments.
S Galvanic separation of the PG interface:

Galvanically or electrically isolating the PG interface prevents interference
with the other bus segments of the PROFIBUS-DP if the PG connecting
cable is inserted or removed, even at high baud rates.
S Monitoring functions of the clock-synchronous PROFIBUS

8.11 DP slave: Diagnostic repeater for PROFIBUS DP
8.11.2 Application range
A diagnostic repeater is required if one or more of the following requirements

exist:
S Cable diagnosis of PROFIBUS network during operation

S Connection of more than 32 nodes on a PROFIBUS line
S Implementation of branches
S Electrical isolation of two segments
S Ungrounded operation of bus segments
S Visualization of bus topology with STEP 7 (Version 5.2 and higher)
8.11.3 Connection and start-up
You will find a detailed description of how to connect and start up a diagnostic
repeater in:
References:
SIMATIC
Manual: Diagnostic repeater for PROFIBUS DP
Drawing number: A5E00352937-01, 10/2004 Edition
Order number (MLFB): 6ES7972-0AB00-8AA0
J

MPI Communication 9
Notice
MPI communication only needs to be configured if a handheld unit (B-MPI) is to
be connected to a SINUMERIK 840Di sl.
9.1 Special points to be noted

With SINUMERIK 840Di sl, the following special characteristics should be
noted:

The data transfer rate on the MPI bus must be set to 187.5 Kbaud.
S Insert/remove
No nodes should be plugged into or removed from the MPI bus of the SI-
NUMERIK 840Di sl while it is in operation without performing special mea-
sures.
9.2 Networking rules

Observe the following rules when installing an MPI network:
1. A unique bus address in the range 0...31 must be assigned to every bus
node.
2. An MPI bus line must be terminated at both ends. To this aim, enable the
terminating resistor in the MPI connector of the first and last nodes and dis-
able the remaining terminating resistors.
3. At least one MPI line termination must be supplied with a 5 V voltage.
Note
An MPI connector with terminating resistor inserted to an energized device
must be connected to supply the MPI line with the necessary 5 V voltage.
The MPI connection on the MPI board of the SINUMERIK 840Di sl can be
used for this purpose.
4. Stubs (feeding cable from the bus segment to the node) should be as short
as possible, i.e. < 5 m. Any spur lines that are not assigned should be re-
moved if possible.
Note
Spur lines should be avoided where possible.

9 MPI Communications 03/2006
9.2 Networking rules
5. Every MPI node must first be connected to the bus and then activated.
The node must first be deactivated before it is removed. Then you can dis-
connect the node from the bus.
6. A maximum of 2 of the following components can be connected per bus
segment:
– Machine control panel (MCP)
– Handheld unit (HHU)
7. Do not enable the bus terminating resistors at the distributor boxes of an
HHU, since they are already built into the appropriate device.
8. Maximum cable lengths:
S 200 m per bus segment
S 2,000 m overall length with RS-485 repeater
Example MPI bus SINUMERIK 840Di sl

HHU
PCU 50
on
on
Distrib. MCI board
box
off
on Terminating resistor Terminating resistor inserted

integrated on
in connector
Fig. 9-1 MPI network with terminating resistors
Communication If no communication can be established as a whole or with individual nodes at

interference the MPI bus, check the following:
S Is the data transfer rate of all nodes whose data transfer rate is set manually
(DIP switches) set to 187.5 kbaud.
S Do all nodes have a unique consistent MPI bus address.
– In the S7 configuration
– MPI address set on node
S Are there any loose cable connections.
S Are all bus segments terminated correctly.
Notice
The terminating resistor is built into some components:
S Handheld unit (HHU)

03/2006 9 MPI Communications
9.3 Global data communication
9.3 Global data communication
General GD communication is a simple form of communication integrated in the operat-

information ing system of the PLC that permits cyclic data exchange between the CPUs via
the MPI interface. Data exchange is executed with the normal process image.
Transfer of global data is a system service and therefore not programmed.
GD communication is ordered by GD circles. A GD circle is uniquely identified
by its GD circle number. A GD identifier is structured as follows: GD x.y.z
– x = GD circle number
– y = GI number
– z = Object number
Global data Global data such as are used for GD communication are the following operand
ranges of a CPU:
– Inputs, outputs (from the process image!)
– Flag bits
– Ranges from data blocks
– Timers, counters
Not recommended because the values at the receiver end are no longer
up to date; can only be configured as send operand ranges!
I/O ranges and local data cannot be used for GD communication.
Data transmission GD communication is performed according to the broadcast principle, i.e. GD

procedure reception is not acknowledged! The sender receives no information whether a
recipient and which recipient has received the transmitted global data.
GD table The operand ranges participating in global data communication are configured
in a GD table with STEP 7:
Once the GD table has been filled, compiled and the participating CPUs loaded,
these CPUs send and receive cyclically via these operand ranges at the cycle
control point (i.e. at the same time when process image updating is taking
place).
– Each column is assigned to exactly one CPU, i.e. the columns represent
the CPUs participating in data exchange (maximum 15 CPUs)
– Each row (more precisely: each editable field of a row) represents the
operand ranges via which exactly one CPU sends and one or several
CPUs receive
Default GD communication is configured with STEP 7. To simplify installation and

configuration start-up, a default configuration of the GD communication is included in the
scope of supply of the SINUMERIK 840Di sl. The default configuration allows
the connection of the following components to the MPI bus without further confi-
guration of the GD communication:
– Machine control panel (MCP) and/or interface customer operator panel
– Handheld unit, e.g. B-MPI

9.4 Requirements
9.4 Requirements
As a condition for creating an MPI configuration using the default configuration
the following components are required:
S SIMATIC STEP 7
S Archive file: mcp840di.zip
The archive file contains data and function blocks for a default configuration
of the GD communication. The archive file is included in the scope of supply
of the SINUMERIK 840Di sl.
SIMATIC STEP 7 SIMATIC STEP 7 (option) is required in the following version or later:

SINUMERIK If SIMATIC STEP 7 is installed on the SINUMERIK 840Di sl, no additional MPI
840Di sl cable is required to load the configuration into the PLC because Windows ap-
plications that are executed on the SINUMERIK 840Di sl have direct access to
the PLC via the internal MPI interface on the MCI board.
Installation of additional software on the SINUMERIK 840Di sl is described in
detail in Chapter 18, Page 18-485.
External computer If SIMATIC STEP 7 is installed on an external computer (PG/PC), it must fulfill
the following conditions:
S MPI interface parameterized with 187.5 kbaud

S MPI connection between external computer and SINUMERIK 840Di sl
Archive file: The archive file: mcp840di.zip contains library: mcp840Di with the blocks for GD
mcp840di.zip communication. Before you can use these blocks in a separate SIMATIC S7
project, the archive must first be dearchived via the SIMATIC Manager.
Storage path The archive file is stored at the following address on the PCU’s hard disk:
S D:\SUPPORT\mcp840di.zip
To dearchive in the SIMATIC Manager please use menu item: File > Dearchive.
In dialog box: “Select target directory” select the directory into which you want to
unpack the archive. The existing default setting: “S7Proj” can be kept.

9.5.1 Precondition
S7 project The procedure for creating an MPI configuration described in this section is
based on an S7 project created using the description in Section 6.3, Page
6-137.
The following status of the S7 project is required:
– S7 project is has been set up (name: SIN840Di sl)
– Station 300 has been set up
– MPI interface is parameterized
– PROFIBUS interface is parameterized
– Input/output data areas of the NC are parameterized
Note
SIMATIC STEP 7 please refer to the relevant SIMATIC documentation or On-
line Help.
Archive file: The archive file: mcp840di has been dearchived using the SIMATIC Manager
mcp840di.zip Library mcp840Di is available in SIMATIC STEP7. See previous Section 9.4,
Page 9-238.
9.5.2 Inserting the default configuration into the S7 project
Opening the To insert the default configuration in S7 project: SIN840Di sl the library dear-
library chived in Section 9.4, Page 9-238 with menu item: Open > File.
Select library mcp840Di and confirm the dialog box with OK.
Opening a proj-
ect
User projects Libraries Example pro- Multiple pro-
jects jects
Name Storage path
gp8x0d65 F:\Program Files\Siemens\Step7\S7libs\gp8x0d65
mcp840Di F:\Program Files\Siemens\Step7\S7proj\mcp840Di
SIMATIC_NET_CP F:\Program Files\Siemens\Step7\S7libs\simaticn
Standard Library F:\Program Files\Siemens\Step7\S7libs\StdLib30
stdlibs (V2) F:\Program Files\Siemens\Step7\S7libs\STDLIBS
Fig. 9-2 Opening the library of the default configuration
In the library open directory: “Blocks” of S7 program: mcp4mci2. The S7 pro-

gram contains the following blocks:
– System data: SDB210
– Function block: FC27
– Data block: DB77
Copy all blocks of the library into the block directory of the PLC of project:
SIN840Di sl.

Note
When you copy the blocks into the block directory of the PLC all system data
blocks with the exception of SDB210 are deleted. See Subsection 8.3.4, Page
8-185, for how to generate the system data blocks again.

< No filter >
SIN840Di sl –– <Installation path>\Step7\S7Proj\SIN840Di sl

SIN840Di sl System data OB1 OB40 OB100
SIMATIC 300(1) FB1 FB2 FB3 FB4
PLC 317-2DP 2AJ10 FB5 FB6 FB7 FB9
S7-Program(1)
FB10 FB11 FB16 FB17
Source
FB18 FB19 FC1 FC2
sBlocks
FC3 FC4 FC6 FC7
mcp840Di –– <Installation path>\Step7\S7Proj\mcp840Di

mcp840Di System data FC27 DB77
mcp4mci2
Source
sBlocks
Fig. 9-3 Inserting library: mcp849Di (already contains PLC basic program)
9.5.3 Adapting organization block OB100

The following call parameters must be adapted in organization block OB100 for
calling function block B1 “RUN_UP”:
– MCP1BusAdr (MPI address of 1st machine control panel)
Settable addresses according to default configuration: 13, 14, 15
Recommended address: 14
– MCPSDB210 (system data block SDB210 exists)
The parameter must be set to value: TRUE.
9.5.4 Adapting organization block OB1

In organization block OB1, first function block FC27 “MCP_INT” must be called
up. In the 1st line of OB1 enter call:
CALL FC27
9.5.5 Loading a configuration into the PLC

Once you have inserted and adapted the blocks you can load the configuration
into the PLC.
Loading of the configuration is described in detail as part of PLC installation and
start-up in Section 6.7, Page 6-151.

9.6 Default configuration
9.6.1 GD circle parameters
The following 3 GD circles are parameterized in the default configuration:
MPI(1) (global data) –– SIN840Di sl

840Di sl\
GD identifica- MCP1\ MCP2\ HHU\
PLC 317–2DP
CPU315 CPU315 CPU315
tion 2AJ10
1 GST
2 GDS 1.1 DB77.DBD16 ID36
3 SR 1.1 1 1
4 GD 1.1.1 DB77.DBB8:8 IWO:8
1. GD circuit
5 GDS 1.2 DB77.DBD20 OD22
6 SR 1.2 1 1
7 GD 1.2.1 DB77.DBB0:8 OWO:8
8 GDS 2.1 DB77.DBD40 ID40
9 SR 2.1 1 1
10 GD 2.1.1 DB77.DBB32:8 IW8:8
2. GD circuit
11 GDS 2.2 DB77.DBD44 OD26
12 SR 2.2 1 1
13 GD 2.2.1 DB77.DBB24:8 OW8:8
14 GDS 3.1 DB77.DBD80 ID44
15 SR 3.1 1 1
16 GD 3.1.1 DB77.DBB60:20 IW16:20
17 GDS 3.2 DB77.DBD84 OD30
3. GD circuit
18 SR 3.2 1 1
19 GD 3.2.1 DB77.DBb48:6 OW16:6
Fig. 9-4 Default configuration
9.6.2 GD identifiers and MPI addresses
Correlation In the case of the following components there is a defined correlation between
the MPI address and the GD identifiers which must be taken into account when
setting the MPI address and configuring the GD circles:
– Machine control panel
– MPI interface for customer operator panel
Table 9-1 Context: MPI address / GD circle parameters
MPI address GD identification

Receive Send
13, 14, 15 1.1.1 1.2.1
11, 12 2.1.1 2.2.1
9, 10 3.1.1 3.2.1
7, 8 4.1.1 4.2.1
4, 5 5.1.1 5.2.1
0, 1, 2, 3, 6 Reserved

Default Because of the GD circle parameterization of the default configuration the fol-
configuration lowing MPI addresses must be used for the above components (see Table 9-2,
Page 9-242):
Table 9-2 Default configuration: MPI address / GD circle parameters
Component MPI address Default

MPI address
Handheld unit B-MPI 9, 10 15 1)
1) CAUTION: The default MPI addresses must be adapted!
9.6.3 Recommended MPI addresses
Handheld unit
B-MPI
10 2 2
PLC User interface
MPI bus e.g. HMI Advanced
PLC routes SINUMERIK 840Di sl 1

to NC (PCU with MCI board)
x MPI address on MPI bus
3
x MPI address on softbus NC

Softbus
Fig. 9-5 Recommended MPI addresses for SINUMERIK 840Di sl

9.7 Handheld unit (B-MPI)
Distributor box
Fig. 9-6 Handheld unit (B-MPI) with distributor box
9.7.1 Conditions for start-up
Hardware The following hardware components are required to start up the handheld unit
(HHU):
Distributor box
The distributor box incorporates the MPI module interface, the HHU interface,
as well as a terminal block for connecting EMERGENCY STOP, enable keys,
handwheel and 24 V power supply.
HHU connection cable
The HHU is connected to the distributor box using the HHU cable.
MPI bus cable
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.
Programming device (e.g. PG740)
A programming device is required for the SIMATIC Manager as the platform to
match the PLC basic or PLC user program to the requirements of the appropri-
ate automation system with regard to the operation of an MCP and to load it
then into the PLC.
Note
A programming device is not required if the SIMATIC Manager is installed on
the SINUMERIK 840Di sl. How to install additional software is described in

Software The following software components are required to start up the HHU:
PLC basic program
The PLC basic program is included on the SINUMERIK 840Di sl. This must be
installed before the PLC basic program can be used. See Subsection 6.1.4,
Page 6-128.
Blocks of the PLC basic program relevant to the HHU of the PLC are:
– FB1 (HHU parameters)
– FC13 (display control)
SIMATIC Manager
The SIMATIC Manager is used for adapting the PLC basic and user programs
(e.g. call of FC 13).
Literature The following manuals are required to start up the HHU:

Description of HHU (interfaces, electrical connection, etc.)
/Z/ Catalog NCZ
Automation To start up the HHU, the automation system must be completely electrically and
system mechanically connected with respect to NC, PLC and MCP. The drives must be
secured against accidental moving.
9.7.2 Electrical connection
Connecting the To connect HHU electrically and for MPI communication, a distributor box is
HHU electrically used. The distributor box has an interface to the MPI bus, as well as a terminal
block for connecting EMERGENCY STOP, enable keys, handwheel and 24 V
power supply.
Connecting If you wish to connect more than two HHUs to a bus segment or if the HHU can-
several HHUs not be connected at the bus end, it is generally recommended to use a PROFI-
BUS repeater for connecting the HHUs.
ON OFF
SINUMERIK MPI
840Di sl
ON OFF
Distributor box
HHU MCP HHU

Repeater RS-485
OFF Open terminating resistor ON ON
ON Closed terminating resistor
Fig. 9-7 Connecting using a repeater

Note
If a HHU is connected to the bus end, no repeater is required.
For a detailed description of the electrical and mechanical design, as well as for
the interfaces of the HHU module, please refer to:
Section: Handheld Unit and Distributor Box
9.7.3 MPI parameters of the HHU
Setting the MPI The HHU parameters required for MPI communication:
parameters – MPI address
– IDLE time
are set as follows:
– up to SW V04.01.01: via DIP switch on the HHU
– as from SW V04.01.01: by means of the HHU display
To check or modify the parameters, disconnect the HHU from mains. After loos-
ening the fastening screws, you can remove the HHU front plate.
ON OFF Settings with ON OFF
4 DIL switches via display 4
3 187.5 kbaud 3
S1 S1
2 2
IDLE time Switch setting
100 ms (no function)
1 1
ON OFF
S1 4 4
S2
3 Default MPI Switch setting 3
S2 S2
address 15D (no function)
2 2
1 1
Fig. 9-8 Settings required on the HHU for SINUMERIK 840Di sl
Data transfer rate The data transfer rate must be set to 187.5 kbaud in conjunction with the SI-
NUMERIK 840Di sl.
Notice
To operate the HHU on the MPI bus of the SINUMERIK 840Di sl, the data
transfer rate must be set to 187.5 Kbaud.

MPI address The MPI address is set to FH = 15D by default. This address can normally be
kept.
Table 9-3 MPI addresses that can be set using S2
S2 MPI address
1 2 3 4
on on on on FH = 15D (default address)
on on on off EH = 14D
on on off on DH = 13D
on on off off CH = 12D
on off on on BH = 11D
on off on off AH = 10D
on off off on 9
on off off off 8
off on on on 7
off on on off 6
off on off on 5
off on off off 4
off off on on 3
off off on off 2
off off off on 1
off off off off 0
Display of After the HHU has been electrically connected the following message is dis-
software version played until communication is established between HHU and PLC: “Waiting for
and MPI address PLC”, together with the software version and the MPI address.
SIEMENS
Waiting for PLC

V04.01.01 F
Software version: Version 4.1.1 MPI address: FH = 15D
Fig. 9-9 Software version and MPI address
9.7.4 MPI parameterization of the PLC
Program Structure The PLC program is modular in design. It comprises function blocks:
– Startup and synchronization (OB 100)
– Cyclical mode (OB 1)
– Process interrupt handling (OB 40)
The user (machine manufacturer) must call the appropriate section of the basic
program in OBs 1, 40, and, 100 (see Fig. 9-10, Page 9-247).

FB 1
ÎÎÎ
OB 100
Start-up:
Restart e.g. HHU parameters
User Program
ÎÎÎÎÎ
OB 1
ÎÎÎÎÎ
FC 27
Cyclic
processing MCP_INT
NCK
FC 2 Mode group
Channel
GP-OB 1
Axis
Spindle
FC 14
MCP,
HHU
FC 6
TM
FC 19/25/26
User MCP:
program MCP_IFM
MCP_IFT FC (9/15/16/18)
HPU_MCP ASUB,
con. axes/
FC 7/8/22 spindles
TM:
TM_Trans FB 2/3/4
TM_Dir
Var. read/
write,
FC 17 PI services
Star/delta
FC 10
Error and oper. FC 13
messages
HHU:
display contr.
ÎÎÎÎÎ
OB40 FC3
ÎÎÎÎÎ
G group
Process alarm GP_PRAL
Distribution list
User
program
Fig. 9-10 Structure of the PLC program
Setting the MPI pa- The MPI parameters are set on the PLC side in function block FB 1. Since the
rameters data transfer rate of the MPI bus with SINUMERIK 840Di sl is 187.5 kbaud, the
(FB 1) parameters have to be set as follows:
HHU: INT:= 2; // the HHU is operated on an MPI bus with
BHGMPI BOOL:= FALSE // 187.5 kbaud
Notice
To be able to utilize a HHU alternately or simultaneously with the MCP on an
automation system, the user (machine manufacturer) must customise the PLC
program accordingly.

Literature For a detailed description of the PLC basic program, please refer to:
Section: FB 1: RUN_UP Basic program, start-up section
Section: FC 13: BHGDisp Display control for handheld unit
9.7.5 GD circle parameters of the HHU
Default values The GD circle parameters of the HHU are assigned the following default val-
ues. The default values cannot be kept if the default configuration is used.
Table 9-4 GD circle parameters
Parameter Description HHU Default Value

Display value range
1 GD circle No. Rec-GD-No: 2 1–16
2 Receive GI No. Rec-GI-No: 1 –
3 Object No. Rec-Obj-No: 1 –
4 GD circle No. Send-GD-No: 2 1–16
5 Send GI No. Send-GI-No: 2 –
6 Object No. Send-Obj-No: 1 –
7 Baud rate Baud rate: 1.5M 187.5K/
1.5M
8 MPI bus address Bus address: 15 0–31
Setting the GD The current values of the GD circle parameters of the HHU can be set and/or
circle parameters checked on the HHU display (see Fig. 9-11, Page 9-248).
S Activate display
While the message “Waiting for PLC” is displayed on the HHU display, the
uppermost right and left keys must be pressed simultaneously (see Fig.
9-11). Then the first GD circle parameter is displayed.
S Modify value
The value of a GD circle parameter can be modified within its admissible
range of values using the + or – keys (see Fig. 9-11).
S Display next parameter
Press the 2nd key from the left in the uppermost key row (see Fig. 9-11) to
advance to the next parameter. After the last GD circle parameter has been
reached, the set values will be automatically saved in the Flash-EPROM of
the HHU.
Activate display
(press simultaneously)
Display next
parameter
Actual value + 1
Actual value – 1
Fig. 9-11 Displaying and modifying GD circle parameters

Default If the default configuration is used the GD circle parameters must be set to the
configuration following values:
– Send: 3.2.1
– Receive: 3.1.1
9.7.6 GD circle parameterization of the PLC
Setting the GD The GD circle parameters on the side of the PLC are set side in function block
circle parameters FB 1. For editing FB1, it has to be loaded into SIMATIC Manager STEP 7.
(FB 1) The HHU GD circle parameters of FB1 must comply with the GD circle parame-
ters set in the HHU.
In this context, you should note that the GD circle parameters for sending and
receiving HHU and PLC (FB1) must be identical one across the other, i.e. the
send parameters of the HHU are the receive parameters of the PLC and the
receive parameters of the HHU are send parameters of the PLC.
HHU PLC (FB 1)

GD circle parameters GD circle parameters
Send GD No. HHUSendGD No.

Send GI No. HHUSendGI No.
Send Obj No. HHUSendObj No
Rec GD No. HURecGD No.

Rec GI No. HHURecGI No.
Rec Obj No. HHURecObj No.
Fig. 9-12 Crosswise coincidence of GD circle parameters
Notice
The GD circle parameters of sender and receiver must be identical crosswise.
9.7.7 Example: Connecting a HHU to SINUMERIK 840Di sl
1. Checking the HHU for MPI bus capability:

“B-MPI” must be indicated on the rating plate attached to the HHU’s rear.
2. Check and, if necessary, set the MPI/GD circle parameters:
– Data transfer rate = 187.5 kbaud
– IDLE TIME = 100 ms
– MPI address = 15D
3. The terminating resistor in the MPI bus connector on the distributor box for
connecting the HHU must be disabled. (The HHU has an integrated MPI bus
terminator).

4. Connect the distributor box electrically to the HHU.

As soon as the HHU is under power, message:
Waiting for PLC
V 04.01.01 F is displayed.
5. Setting the HHU GD circle parameters (see: Fig. 9-11, Page 9-248) accord-
ing to the values of the default configuration.
6. Set call parameters of function block FB 1 in organization block OB100 ac-
cording to the values of the default configuration.
HHU := 1 // (HHU is operated on an MPI bus
BHGMPI := TRUE // with 187.5 kbaud)
BHGIn := P#E 0.0 // Address of input data
BHGOut := P#A 8.0 // Address of output data
// (Caution! See below: Note)
BHGInLen := B#16#6 // Length of input data (6 bytes)
BHGOutLen := B#16#14 // Length of output data (20 bytes)
BHGStatSend := P#A 28.0 // Addr. of send status data (4 bytes)
BHGStatRec := P#A 32.0 // Addr. of receive status data (4 bytes)
BHGTimeout := S5T#700MS
BHGCycl := S5T#400MS
BHGRecGDNo := 3 // GD circle parameters of HHU:
BHGRecGBZNo := 2 // Send (default configuration)
BHGRecObjNo := 1
BHGSendGDNo := 3 // GD circle parameters of HHU:
BHGSendGBZNo := 1 // Receive (default configuration)
BHGSendObjNo := 1
MCPSDB210 := TRUE // MPI configuration via SDB210
Notice
BIT7 in 1st output byte (parameter: HHUOut; in the example, O 8.7), must be
permanently set to 1.
7. Insert call of function block FC27 as 1st line in organization block OB1.
8. Load the modified function blocks into the PLC and then restart the PLC.
9. After communication with the PLC has been established, the message
“Waiting for PLC ...” will disappear from the HHU display.
Now, the display set by way of the block FC13 will appear on the display.
References: /FB1/ Description of Functions Fundamentals: P3, PLC Basic

Program
Section: FC 13: BHGDisp Display control for
handheld unit

9.7.8 Plugging and unplugging handheld unit during operation
To be able to connect or disconnect a handheld unit to or from an automation

system without any trouble during operation, make the following arrangements:
S Automation system
– Connect or disconnect the power supply on the distributor box
– Enable or jumper the emergency stop on the handheld unit
– Connect the handheld unit to the MPI bus by means of repeater
S PLC basic program

– Sign-of-life monitoring triggered via the PLC user program if the hand-
held unit is disconnected
Automation For a detailed description of the actions to be taken and the devices required,
system please refer to:
References:
/BH/ Handheld Unit Manual
Section: Handheld Unit and Distribution Box
Plugging and unplugging the handheld unit during operation
PLC user program To prevent an alarm being triggered by the sign-of-life monitoring of the hand-
held unit when it disconnected, the handheld unit sign of life must be triggered
in the PLC user program.
Triggering must take place after FC 27 is called and before FC 27 “PLC Basic
Program” is called.
Programming The following assumptions are made in this programming example:

example
S FB 1 parameter “BHGStatRec”:
BHGStatRec := P#A 32.0 // Receive addr. of the status data (4Byte)
S Symbolic name of DB 17: gp_par

CALL “MCP_INT” // FC27
.....
U “gp_par”.BHGStop; // IF BHG in Stop
S A32.7 // THEN trigger sign of life
.....
CALL “GP_HP” // FC2

9.8 HMI Advanced
9.8 HMI Advanced

Depending on where the user interface is implemented, a distinction is made
between internal and external HMI Advanced:
S Internal HMI Advanced

SINUMERIK 840Di sl and HMI Advanced are performed on the same PCU.
S External HMI Advanced

SINUMERIK 840Di sl and HMI Advanced are performed on different PCUs.
9.8.1 Conditions for start-up
Internal If internal HMI Advanced is used the following conditions must be fulfilled:
S Hardware
No special requirements need to be fulfilled.
S Software
Please observe the compatibility list available from the Internet. See Section
17.3, Page 17-481.
External If external HMI Advanced is used the following conditions must be fulfilled:
S Hardware
To start up an external HMI, Advanced the following hardware is required:
MPI bus cable
The external computer (PCU) is connected to the SINUMERIK 840Di sl
through the MPI bus. A terminating resistor for the MPI bus is not inte-
grated in the MCP.
S Software
Please observe the compatibility list available from the Internet. See Section
17.3, Page 17-481.
Literature The following manuals are required to start up HMI Advanced:

/IAM/ Installation and Start-Up Guide HMI/MMC
Installation and Start-Up Guide HMI Advanced (IM4)
/Z/ Catalog NCZ
9.8.2 Parameter assignment
Parameterization is performed in menu “Operator panel interface parameters”:

Operating area switchover > Installation > MMC > Operator panel

9.8 HMI Advanced
Internal When an internal HMI Advanced is parameterized the following conditions must
be fulfilled:
S Connection
Only a 1:1 connection is possible. Function M:N (M SINUMERIK 840Di sl
communicate with N HMI Advanced) is not enabled for SINUMERIK
840Di sl.
S Bus
Set “Softbus MC” as the bus type.
S Highest bus address

31 is the highest permissible bus address.
S MMC address
The bus address set here must match the corresponding bus address of the
configuration loaded in the SINUMERIK 840Di sl PLC. This is not checked.
S NCK address
See MMC address above.
S PLC address
External When an external HMI Advanced is parameterized the following conditions must
be fulfilled:
S Connection
Only a 1:1 connection is possible. Function M:N (M SINUMERIK 840Di sl
communicate with N HMI Advanced) is not enabled for SINUMERIK
840Di sl.
S Bus
Set “MCI2 (840Di-187.5 kbaud)” as the bus type.
S Highest bus address

31 is the highest permissible bus address.
S MMC address
The bus address set here must match the corresponding bus address of the
configuration loaded in the SINUMERIK 840Di sl PLC. This is not checked.
S NCK address
You do not have to define an NCK address because communication to/from
the NCK is routed via the PLC.
S PLC address

9.8 HMI Advanced
9.8.3 Default languages
Language To be able to switch between the two configured languages even when the op-
switchover erator is not familiar with the selected language, the switchover between the
languages must be performed “blindly”:
1. Select menu bar.
2. Select Start-up (3rd horizontal soft key from right).
3. Switch to the highest level with RECALL.
4. Select Change language (3rd vertical soft key from top).
HMI Advanced HMI Advanced offers several possibilities to switch over the language during
operation:
S Switchover between two preset languages.

S Online change of the second language.
Language The displayable languages are set and managed in a file. When the language is
switchover switched in online operation, the first language remains as originally set and
concept only the second language can be changed.
Switching between The vertical soft key labeled “Change language” in the “Start-up” display is used
two languages to switch between two languages. The switchover takes effect immediately. This
key can only be used to switch between two predefined languages.
Online change of Different languages are selected in the “Start-up/MMC/Languages” display (pro-
the 2nd language vided that languages are loaded).
This screen displays a list from which the user can choose the desired lan-
guage(s). The user selects the desired language and acknowledges his/her
selection with “OK”. The user can then change over between the first language
and the language just set by selecting the “Change language” soft key in the
“Start-up” display.
The 2nd language can always be changed in online mode.
Installing HMI Advanced contains the languages German and English as default lan-
languages guages. Supplementary packages 1 and 2 are also available.
packages Supplementary package 1: European languages:
GR German (default)
SP Spanish
FR French
UK English (default)
IT Italian
Supplementary package 2: Asian languages:
KO Korean logographic language, (Korea)
TW Chinese logographic language, (Taiwan)
CH Chinese logographic language, (Mainland China)

9.8 HMI Advanced
Definition of The languages to be used on the MMC are configured in file c:<Installationsp-
usable languages fad>\mmc2\mmc.ini. Any modifications to the file described in the following can
be made using the editor provided to the user under Start-up/MMC.
Presettings Two languages can be set from selection of several optional languages:
without activation GR German (default)
of logographic SP Spanish
languages FR French
IT Italian
Example:
1st language German, 2nd language English
File MMC.INI must be altered as shown below.
Extract from MMC.INI:
...
[LANGUAGE]
Language=GR
LanguageFont=Europe
Language2=UK
LanguageFont2=Europe
...
Notice
When editing the MMC.INI file, please make sure you only change the high-
lighted (bold print) texts. Make sure that your entries are spelled correctly.
Default setting Two languages can be set from selection of several optional languages:
with logographic GR German (Standard)
activation SP Spanish
FR French
IT Italian
TW Chinese characters, (Taiwan)
CH Chinese characters, (Mainland China)
Example:
1st language German, 2nd language Chinese
File MMC.INI must be altered as shown in the figure.

9.8 HMI Advanced
Extract from MMC.INI:

...
[LANGUAGE]
Language=GR
LanguageFont=Europe
Language2=CH
LanguageFont2=China
;LanguageList=GR, SP, FR, UK, IT

;FontList=Europe, Europe, Europe, Europe, Europe
;LBList=espanol, francais, english, italiano
LanguageList=GR, CH, TW, SP, FR, UK, IT

FontList=Europe, China, China, Europe, Europe, Europe, Europe
LBList=chinese, taiwan, espanol, francais, english, italiano
AddOnProd=c:\cstar20\cstar20.exe
...
Add-on products To be able to operate the control with pictographic languages, the appropriate
add-on product must be installed for each selectable language. Languages
based on different add-on products cannot be configured at the same time.
Notice
When you change the “LanguageList”, “FontList”, “LBList” and
“AddOnProd” lines, make sure that you only manipulate (shift, delete) the “;”
character representing the comment.
When editing file MMC.IN only change highlighted text. Make sure that your
entries are spelled correctly.

Drive Start-Up (SINAMICS) 10
10.1 Requirements
10.1.1 Basic requirements
The following are the basic requirements for commissioning SINAMICS S120
drive systems:
The electronic power supply of PG/PC, SINUMERIK 840Di sl and SINAM-

ICS S120 is switched ON.
The mechanical and electrical elements of the SINAMICS drives are set up
and connected correctly, including DRIVE CliQ connections.
References
SINAMICS S120 Commissioning Manual,
Section: Preparations for Commissioning
The SINAMICS STARTER drive commissioning tool is installed on the

PG/PC. Version: At least V4.0
PG/PC and SINUMERIK 840Di sl communicate:

– Ethernet (recommended)
The Ethernet interface of the PG/PC is connected with the “Ethernet 1” of
the PCU interface and the Ethernet communication is parameterized.
See Start-up of the PLC (Chapter 6, Page 6-127)
PCU 50.3
Ethernet 1 X101 X102
(company network)
– MPI/DP
The MPI/DP interface of the PG/PC (options communications processor
CP 5x11) is connected with the MPI/DP interface of the MCI board
(X102) and the MPI/DP communication is parameterized. See Start-up of
the PLC (Chapter 6, Page 6-127)
SINUMERIK 840Di sl and SINAMICS S120 communicate:

– PROFIBUS
The PROFIBUS interface of the MCI board (X101) is connected to the
PROFIBUS interface of the SINMAICS S120 and the PROFIBUS com-
munication is parameterized. See PROFIBUS communication (Chapter
7, Page 7-157)
 Siemens AG, 2006. All rights reserved

10 Drive Start-up (SINAMICS) 03/2006
10.1 Requirements
10.1.2 Safety information
Danger
! A hazardous voltage will be present in all components for a further 5 minutes after the sys-
tem has been shutdown.
Please follow the instructions on the component!
Caution
! For safety reasons, Safety Integrated must be commissioned using STARTER in online
mode.
Reason:
STARTER should only be used to store the safety parameters of a single Safety Integrated
monitoring channel within a project. Loading the project into a drive unit with active safety
functions would result in differences in both Safety Integrated monitoring channels and sub-
sequently in alarms.
Notice
Before switching on the drive for the first time, check that the screws of the DC link busbars
are tightened to the specified torque (see SINAMICS S120 Equipment Manual).
Residual risk
A risk assessment enables the machine manufacturer to determine the residual
risk for his machine with respect to the drive units. The following residual risks
are defined:
Unexpected drive movement from standstill:

Caused, for example, by installation/operational errors or by a malfunction in
the higher-level controller, drive controller, encoder evaluator, or the en-
coder.
This residual risk can be significantly reduced using the “Safe Standstill”
(safety integrated) safety function.
Unexpected change in speed/velocity during operation:

Caused, for example, by a malfunction in the higher-level controller, drive
controller, or encoder.

03/2006 10 Drive Start-up (SINAMICS)
10.2 ONLINE start-up

The SINAMICS STARTER drive commissioning tool can be started directly or
indirectly from the SIMATIC STEP 7 project created in Section 6.3, Page 6-137ff
for starting up a drive unit.
Starting STARTER If the SINAMICS STARTER drive commissioning tool is started directly (e.g.
directly from the Windows taskbar: Start > SIMATIC > STEP 7 > STARTER), a new proj-
ect must first be created. Continue with: Subsection 10.2.1, Page 10-260.
Starting STARTER If the SINAMICS STARTER drive commissioning tool is started indirectly from a
from STEP 7 SINAMICS STEP 7 project (double-click on the drive object in the detailed view
of the SIMATIC Manager), the automatic recording of the component topology
and the configuration can be started immediately. Continue with: Subsection
10.2.2, Page 10-263.

< No filter >
SIN840Di SINAMICS S120
sl SIMATIC
300(1)
PLC 317-2DP 2AJ10
CP 840D sl
SINAM-
ICS_S120_CU320
Press F1 to open the help. TCP/IP –> Realtek

TRL8139

10.2.1 Creating a new project
Execution Perform the following actions to create a new project:

1. Start the STARTER drive commissioning tool using the icon on the user in-
terface or the Windows taskbar: Start > SIMATIC > STEP 7 > STARTER).
If the Project Wizard for creating a new project is not opened automatically
when initiating the STARTER, open it using menu command: Project > New
with Wizard
Then click button: “Find drive units online”.
STARTER Project Wizard
1. 2. 3. 4.
Introduc- Create a Set PG/PC Insert Summary
tion new project interface drive
device
Compile
drive units offline...
Find drive units

online...
Open existing project

(offline)...
Display Wizard at start-up
Cancel
2. Enter the desired project data. You can enter any of the data.
Then click button: “Next >”
1. 2. 3. 4.
device
Please enter the desired project data:
Project name: Project|
Author:
Comment
< Previous Continue > Cancel
3. Set the PG/PC interface if required and test whether all SINAMICS drive
units connected to the PROFIBUS which are to be started as part of this
project are accessible via the PG/PC interface. To proceed to the next dialog
box click the button: “Change and test...”.

Note
The stations accessible via the PG/PC interface are displayed in the SI-
MATIC NET diagnostic screen.
Then click button: “Next >”
1. 2. 3. 4.
device
Specify the online connection to the drive unit:
Set
interface: CP5611 (PROFIBUS)
Change and test...
4. Add the accessible SINAMICS drive units to the project.

The drive units found are displayed in the preview window. In the example, a
drive unit: “Drive_unit_Adr10” has been located.
Then click button: “Continue >”
1. 2. 3. 4.
device
Preview
Project
Drive_unit_Adr10
Refresh
view
Note
Only Control Units are located when searching for SINAMICS drive units. All of
the other available components of a drive unit (infeed, motor module, etc.) are
not taken into account at this stage.

5. You have now created the project. The Project Wizard then displays a sum-
mary of project data.
Located drive units are displayed in the preview. In the example, a drive unit:
“Drive_unit_Adr10” has been located.
Then click button: “Finish”.
1. 2. 3. 4.
device
The following settings have been selected:

–Project name: Project
Location: C:\SIEMENS\Step7\S7proj
–Interface: CP5611 (PROFIBUS)
–Drive units:
Drive unit_Adr10 (SINAMICS_S120,

Addr. 10)
< Previous Finish Cancel

10.2.2 Drive unit: Acquiring the component topology and configuring

automatically
The following example format illustrates the configuration of a drive unit:
Control Unit: CU 320

Supply: Active Line Module (ALM)
Power module 1: Single Motor Module (SMM)
Power module 2: Double Motor Module (DMM)
Sensor module 1 – 3: Sensor Module Cabinets (SMC)
Motor 1 – 3: Standard motor without DRIVE–CliQ connection
SMC
X500
Motor_1
CU 320 ALM SMM DMM
X103
X102
SMC
X203
X500
Motor_3
X101
X202 X202 X202
X100
X201 X201 X201
X200 X200 X200
SMC
X500
Motor_2
DriveCliQ connection
Note
The following actions refer to recording of the component topology online and
configuring a drive unit. If there are several drive units in a project, you must
perform the actions for each additional drive unit.

Execution Perform the following actions:

1. To create the online connection, select the corresponding drive unit in the
project navigator (1) and click the “Connect to target system” button (2).
STARTER – Project
Project Edit Target System View Tools Window Help
Project
2
Add individual drive
Drive_unit_Adr10 1
2. After the online connection to the drive unit has been established, click but-
ton: “Restore factory settings”.
STARTER – Project
Project
Drive_unit_Adr10
Confirm the following dialog with OK to restore the factory settings.
3. Double-click “Automatic configuration” in the project navigator.

The navigator then searches for all components connected to the drive unit
and loads these into the STARTER.
STARTER – Project
Proj-
ect Add individual
Drive_unit_Adr
drive
10
Automatic configuration
Overview
Configuration
Topology
– In the following dialog box: “Automatic configuration” click the button:

“Start automatic configuration”.
– In the following dialog box: “Drive object type” select the type: “Servo”
and click: “Finish”.

– The following note lists the drives that require offline motor configuration
because the corresponding data cannot be determined online. Confirm
with OK.
Note
Motors with DRIVE CliQ interfaces do not require subsequent offline con-
figuration as the appropriate parameters can be determined online by
the STARTER.
– To close, click the “Close” button in the “Automatic Configuration” dialog.
4. Go offline before configuring the motors and encoder (see next section).
Click the “Disconnect from Target System” button.
STARTER – Project
Proj-
ect Add individual
Drive_unit_Adr
drive
10Automatic configuration
Overview
Configuration
Topology
Control_Unit
Supply
Input/Output components
Drives
Inserting drives
Drive_1
Drive_2
Drive_3

10.2.3 Drive: Configuring the motors and encoder

Since no motors/sensors are used in the project with DRIVE CliQ interface, they
must be configured manually because the data cannot be determined automati-
cally without DRIVE CliQ.
Execution Perform the following actions for all drives of the drive units (Drive_1..._3):
1. In the project navigator select Project > <Drive unit_Adr10> >Drives >
<Drive> and double-click “Drive Navigator”.
STARTER – Project
Supply
Input/Output components
Drives
Inserting drives
Drive_1
Drive Navigator
Configuration
Control logic
Then click on the “Device Configuration” button in the Drive Navigator dialog
and on the “Configure the drive” button in the device configuration dialog.
Skip through the following dialogs for configuring the drive unit using the
“Next >” button without making any changes until you reach the motor dia-
log.
2. Enter a unique name for the motor (1) in the “Motor Name” field in the motor
configuration dialog.
Select the configuration type:
– Select standard motor from list (2)
– Direct entry of motor data
Configuration – Drive unit_Adr10 – Motor
Closed-loop Control Drive: Drive_1, DDS 0, MDS 0

Power module
Power Unit Connection Configure the motor:
Motor
Motor Name: 1 Motor_01
Motor holding brake
Encoders Motor with DRIVE-CliQ interface
Process data exchang Read out motor again
Summary 2 Select standard motor from list
Enter motor data
Motor type: 3 1FK7 synchronous motor
Motor selection list:
Order No. Rated... Rated... Rated...

Select the motor type, e.g., 1FK7 synchronous motor (3), from the drop-
down list and the current motor from the corresponding list based on the
order number (MLFB) (4).
Skip through the following dialogs using the “Next >” button without making
any changes until you reach the encoder dialog.
3. Encoder 1 is activated by default and must be configured. Encoders 2 and 3
are optional. Select the configuration type:
– Select motor encoder from list (1)
– Enter data
Select the current encoder from the list based on the order number (MLFB)
(2).
Configuration – Drive unit_Adr10 – Encoder
Closed-loop Control Drive: Drive_1, DDS 0, MDS 0

Power module
Power Unit Connection Which encoder do you want to use?
Motor
Encoder 1 Encoder 2 Encoder 3
Motor holding brake
Encoders Encoder 1
Process data exchange
Summary Encoder Name: Motor_1
1 Select motor encoder from list

Enter data Encoder
data
Motor encoder selection list:
Type (Order no.): Encoder Resolution Code...
2 type
Sin/Cos incr...
Absolute EnDat
Absolute EnDat
Absolute EnDat
Resolver
Resolver
Close the dialog by clicking the “Next >” button.

4. In the configuration dialog for process data exchange, select the message
frame according to the PROFIBUS configuration of the drive unit as DP
slave S120 with STEP 7 HW Config from Section 8.9, Page 8-218et sqq.
Configuration – Drive unit_Adr10 – Process data exchange PROFIBUS (Drive)
Closed-loop Control Drive: Drive_1, DDS 0

Power module
Power Unit Connection Select as PROFIBUS message frame type:
Motor
Motor holding brake
PROFIBUS PDA message SIEMENS message frame 102
Encoders
frame: (102)
Process data exchange
Summary
Length:
Input data (words): 10
Output data (words): 6
Close the dialog by pressing the “Next >” button.

5. Check the data entered for the drive in the following “Summary” dialog.
Close the dialog by clicking the “Finish” button.
10.2.4 Control Unit: Selecting the PROFIBUS message frame

Control Unit error acknowledgement is currently performed via the BICO inter-
connection. As a result, you must configure free message frame configuration
with BICO as the PROFIBUS message frame.

1. In the project navigator, select Project > Drive unit_Adr10 > Control_Unit >
Communication and double-click PROFIBUS
2. Select “Free message frame configuration with BICO (999)” from the “Mes-
sage frame selection” selection list.
PROFIBUS receive direction PROFIBUS Send Direction
Hide inactive interconnections
Free message frame configuration with BICO (999)
Close Help
Control_Unit
10.2.5 Supply: Selecting the PROFIBUS message frame

Error acknowledgement and infeed release is currently performed via the BICO
interconnection. As a result, you must configure free message frame configura-
tion with BICO as the PROFIBUS message frame.

1. In the project navigator select Project > Drive unit_Adr10 > Infeed > Com-
munication and double-click: PROFIBUS
2. Select “Free message frame configuration with BICO (999)” from the “Mes-
sage frame selection” selection list.

10.2.6 Drive unit: Checking the configuration
After configuring all of the drives, we recommend checking the DRIVE-CliQ in-
terconnection recognized by the STARTER during automatic configuration with
the drive unit interconnection.
Execution Perform the following actions for each drive unit:

1. Open the topology tree: Project navigator > any drive > Drive Navigator
(double-click) > Dialog: “Device configuration” > Button: “Check topology”
Device configuration
What do you want to do?
Configure Check topology

the drive
2. Compare the DRIVE-CliQ topology displayed in the STARTER with the to-
pology of the drive unit.
The following rules must be observed with regard to the DRIVE-CliQ inter-
connection of the components:
– The DRIVE-CliQ cable from the Control Unit to the first power module
must be connected to interface X200.
– The DRIVE-CLiQ connections between each of the power modules
should be connected from interface X201 to X200 on the next compo-
nent.
– The motor encoder must be connected to the associated Motor Module:
Component Motor encoder connection
Single Motor Module (booksize) X202
Double Motor Module (booksize) Motor terminal X1: encoder to X202
Motor terminal X2: encoder to X203
DRIVE-CliQ interconnection of the example structure:
SMC
X500
Motor_1
CU 320 ALM SMM DMM
X103
X102
SMC
X203
X500
Motor_3
X101
X202 X202 X202
X100
X201 X201 X201
X200 X200 X200
SMC
X500
Motor_2

The corresponding DRIVE-CliQ topology in the STARTER must appear as

follows:
Project Set Actual Compari

so
Topology tree
Control_Unit (1)
Infeed.Infeed (2)
Unas-
signed
Unas-
signed
Drive_1.Power_Module_1 (3)
[Drive_2|Drive_3].Power_Module_2 (6|8)
Unassigned
Drive_2.SM_to_Motor_2 (9)
Unassigned
Unassigned
Unassigned
Component folder
Unassigned
Fil- DRIVE CliQ + Option

ter:
Note
Differences must be corrected manually. Click the appropriate component then,
keeping the left-hand mouse button depressed, drag it to the correct connec-
tion. If the connection is already assigned, you can use a free connection in the
topology or the component folder as a buffer.

10.2.7 Drive unit: Configuring the PROFIBUS message frame
When configuring the PROFIBUS message frame of a drive unit, the following
must be considered:
The process data of the drive objects: “Drives” must be available before the
process data of all other drive objects (Control Unit, infeed, etc.).
The structure of the process data for the PROFIBUS message frame config-
ured in the STARTER (object sequence and message frame type) must be
identical to the structure configured in HW Config (see Section 8.9, Page
8-218).

1. Double-click Project > Drive_unit_Adr10 > Configuration to open PROFI-
BUS message frame configuration in the Project Navigator.
2. Move the drive objects according to the guidelines specified above.
Configuring a message frame in HW Config

DP slave properties
Default setting
Object Message frame selection Option
1 Message frame 102, PDA-6/10
Overview Details
Configuring a message frame in STARTER
PROFIBUS tele- Version over-

gram view
The drive objects are provided with data from the PROFIBUS message frame in the following order:
Obj. Drive Object N Message frame type
1 Drive_1 o.
3 SIEMENS telegram 102
4 Supply 2 Free telegram configuration with B
5 Con- 1 Free telegram configuration with BIC
trol_Unit
Close Help
Drive_unit_Adr10

10.2.8 Control Unit: Error acknowledgement(BICO interconnection)

To acknowledge an error for the Control Unit, use the “PROFIBUS PDA1 re-
ceived” signal from the first drive.
Control Unit: p2103 BI: 1. Acknowledge faults
Drive: Drive_1, r2090: Bit7, BO: PROFIBUS PDA1 receive bit-serial

1. Double-click Project > Drive_unit_Adr10 > Control Unit > Control logic to
open control logic configuration in the Project Navigator.
2. Click on the binector input symbol from signal “p2103 BI: 1. Acknowledge
faults” and from the list select Drive_1 > Further interconnections > r2090:
Bit7, BO: PROFIBUS PDA1 receive bit-serial
Control logic
Optimize view
Control word faults/alarms Status word faults/alarms 1
p2103 BI: 1. Acknowledge faults r2139 Bit 0 Acknowledgement running

Drive_01, r2090: Bit7, BO: PROFIB 0 ––
p2104 BI: 2. Acknowledge faults

7 0 is interconnected with...
Drive_1, r2090: Bit7, BO: PROFIBUS PDA1 receive bit-serial: : Bit 7 (0=Out / 1=In)
0
r2139 Bit 6 Internal Message 1 active
p2112 BI: External alarm 1 6 ––

10 1
r2139 Bit 7 Alarm active
Close Help
Control_Unit

10.2.9 Supply: Error acknowledgement (BICO interconnection)
To acknowledge an error for the infeed, use the “PROFIBUS PDA1 received”
signal from the first drive.
Infeed: p2103[0] BI: 1. Acknowledge faults
Drive: Drive_1, r2090: Bit7, BO: PROFIBUS PDA1 receive bit-serial

1. Double-click on Project > Drive_unit_Adr10 > Infeed operations > Infeed
operation > Control logic to open control logic configuration in the Project
Navigator.
2. Click on the binector input symbol from signal “p2103[0] BI: 1. Acknowledge
faults” and from the list select Drive_1 > Further interconnections > r2090:
Bit7, BO: PROFIBUS PDA1 receive bit-serial
Control logic
Optimize view
Control word sequential control infeed Control word faults/alarms
p840[0] BI: ON/OFF1 r2103[0] BI: 1. Acknowledge faults

0 0 Drive_01, r2090: Bit7, BO: PROFIB

is interconnected with...
p844[0] BI: 2. OFF2 Drive_1, r2090: Bit7, BO: PROFIBUS PDA1 receive bit-serial: : Bit 7 (0=Out / 1=In)
1 r2105[0] BI: 3. Acknowledge faults
1 p845[0] BI: 2. OFF2 0
Close Help
Supply

10.2.10 Supply: Enable (BICO interconnection)
To be able to release and stop the drives externally, e.g. via a PLC user pro-
gram, connect digital input X122.1 on the Control Unit and use the BICO inter-
connection with parameter “p840[0] BI: ON/OFF1” to connect:
Infeed: p840[0] BI: ON/OFF1
Control Unit: Control_Unit, r722: Bit0, CO/BO: CU digital inputs, status: :DI 0
(X122.1) (0=Low / 1=High)
Note
With reference to SIMODRIVE drives, this corresponds to the effect of digital
input X122.1 on terminal 63 (pulse enable).

operation > Control logic to open control logic configuration in the Project
Navigator.
2. Click on the binector input symbol from signal “p840[0] BI: ON/OFF1: 1. Ac-
knowledge faults” and from the list select Control_Unit_1 > Further intercon-
nections > r722: Bit0, CO/BO: CU digital inputs, status: :DI 0 (X122.1)
Control logic
Optimize view
Control word sequential control infeed Control word faults/alarms
p840[0] BI: ON/OFF1 r2103[0] BI: 1. Acknowledge faults

0 Control Unit, r722: Bit0, CO/BO: CU Di Drive_01, r2090: Bit7, BO: PROFIB
p840[0] BI: ON/OFF 1

is interconnected with ...
p844[0] Control_Unit, r722: Bit0, CO/BO: CU digital inputs, status: :DI 0 (X122.1) (0=Low / 1=High
1 r2105[0] BI: 3. Acknowledge faults
1 p845[0] BI: 2. OFF2 0
Close Help
Supply

10.2.11 Supply: Readiness to start (BICO interconnection)
To be able to output the “Ready to start” signal to the X132.7, DO13 terminal of
the Control Unit, connect the parameter “r899 Bit 0: Ready to start” of the supply
via the BICO interconnection with parameter “p743, BI: CU signal source for
terminal DI/DO 13”.
Infeed: r899 Bit 0: Ready to start
Control Unit: p743, BI: CU signal source for terminal DI/DO 13
Terminal X132.8 of the Control Unit must then be parameterized as an output.

operation > Control logic to open control logic configuration of the infeed
operation in the Project Navigator.
2. Select the “Sequential control infeed” status word (1) from the drop-down
list.
3. Click on the binector input symbol from signal “r899 Bit 0: Ready to start”
and from the list select Control_Unit_1 > Further interconnections > p743:
BI: CU signal source for terminal DI/DO 13” (2).
Control
logic
Optimize view 1
Status word sequential control infeed Control word fault/alarm
p899 Bit 0 Ready to start 2 p2103[0] BI: 1. Acknowledge faults

0 Control_Unit, p743, BI: CU signal Drive_01, r2090: Bit7, BO: PROF
source
p899 CO/BO: Status word sequential control infeed p2104[0] BI: 2. Acknowledge faults
Bit 0 ready to start is interconnected with ...
p899 Bit 1 Readyp743, BI: CU signal source for terminal 7
Control_Unit, DI/DO 13
0
1 ––
10:2 Close Help
Supply Control_Unit
4. Double-click on Project > Drive_unit_Adr10 > Control Unit > Control logic to
open control logic configuration of the Control Unit in the Project Navigator.
5. Change the status to “Output” (2) in the “Bidirectional digital inputs/outputs”
(1) for the terminals X132.7, DO12.

Digital inputs Bidirectional digital inputs/out- Test sockets

1 puts
Invert output
X132
Output
DO ––
7 12 1
2 Infeed, r899: Bit1, CO/BO
Output
DO ––
8 13 1
Infeed, r899: Bit0, CO/BO
––
10:1 Close Help
Supply Control_Unit

10.2.12 Supply: Operational readiness (BICO interconnection)
To be able to output the “Ready” signal to the X132.7, DO13 terminal of the
Control Unit, connect the parameter “r899 Bit 1: Ready” of the supply via the
BICO interconnection with parameter “p742, BI: CU signal source for terminal
DI/DO 12”.
Infeed: r899 Bit 1: Ready to start
Control Unit: p742, BI: CU signal source for terminal DI/DO 12
Terminal X132.7 of the Control Unit must then be parameterized as an output.

operation > Control logic to open control logic configuration of the infeed
operation in the Project Navigator.
2. Select the “Sequential control infeed” status word (1) from the drop-down
list.
3. Click on the binector input symbol from signal “r899 Bit 1: Ready” and from
the list select Control_Unit_1 > Further interconnections > p742: BI: CU sig-
nal source for terminal DI/DO 12” (2).
Control
logic
Optimize view 1
Status word sequential control infeed Control word fault/alarm
p899 Bit 0 Ready to start p2103[0] BI: 1. Acknowledge faults

0 Control_Unit, p743, BI: CU sign Drive_01, r2090: Bit7, BO: PRO
p2104[0] BI: 2. Acknowledge faults
p899 Bit 1 Ready 2 7 0
1 Control_Unit, p742, BI: CU signal
source
p899 CO/BO: Status word sequential control infeed
Bit 1 ready is interconnected with ...
10:2 Control_Unit, p742, BI: CU signal source for terminal DI/DO 12 Close Hel
p
Supply Control_Unit
4. Double-click on Project > Drive_unit_Adr10 > Control Unit > Control logic to
open control logic configuration of the Control Unit in the Project Navigator.
5. Change the status to “Output” (2) in the “Bidirectional digital inputs/outputs”
(1) for the terminals X132.7, DO12.

Digital inputs Bidirectional digital inputs/out- Test sockets

1 puts
Invert output
X132 2
Output
DO –
7 12 – 1
Output
DO –
8 13 – 1
––
10:1 Close Help
Supply Control_Unit

10.2.13 Drive: Enable OFF3 (BICO interconnection)
To be able to release and stop the drive externally, e.g. via a PLC user program,
connect digital input X122.2 on the Control Unit and use the BICO interconnec-
tion with parameter “p849[0] BI: 2. OFF3” to connect:
Drive: p849[0] BI: 2. OFF3
Control Unit: Control_Unit, r722: Bit1, CO/BO: CU digital inputs, status: : DI 1
(X122.2) (0=Low / 1=High)
With reference to SIMODRIVE drives this corresponds to the effect of digital
input X122.1 on terminal 663 (pulse enable) with prior deceleration of the drive
at the current limit.
Execution Perform the following actions for each drive:

1. Double-click on Project > Drive_unit_Adr10 > Drives > < Drive > > Control
logic to open control logic configuration in the Project Navigator.
2. Click on the binector input symbol from signal “p845[0] BI: 2. OFF2” and
from the list select Control_Unit > Further interconnections > r722: Bit1, CO/
BO: CU digital inputs, status: : DI 1 (X122.2) (0=Low / 1=High)
Control
logic
Optimize view
Control word for the sequence Control word faults/alarms

control
r2103[0] BI: 1. Acknowledge faults

p848[0] BI: 1. OFF3 r2090: Bit0, BO: PROFIBUS PDA
r2090: Bit2, BO: PROFIBUS PDA
2 p849[0] BI: 2. OFF3 7 0
Control_Unit, r722: Bit1, CO/BO Di
p849[0] BI: 2. OFF3
is interconnected with ...
Control_Unit, r722: Bit1, CO/BO: CU digital inputs, status: : DI 1 (X122.2) (0=Low / 1=High)
1
Close Help
Drive_1

10.2.14 Drive unit: Saving parameters
After completing the configuration, you must load and save the parameters in
the drive unit.

1. Access the drive unit with the PG/PC online.
2. Now load the project data into the drive unit: Click Drive_unit_Adr10 > Target
system > Load to target system... in the Project Navigator.
3. Save the project data in the drive unit on the CF card: Click
Drive_unit_Adr10 > Target system > Copy RAM to ROM... in the Project
Navigator.
10.2.15 Drive: Running the motor
You can test the configuration loaded into the drive unit by running the motors of
the drives using the operator control panel in the STARTER.
This can be done once the pulses have been enabled for the infeed and
line/DC link identification has been activated. The infeed then switches to op-
erational mode.
Note
For more information about the operator control panel: see SINAMICS S120
Getting Started with the STARTER Commissioning Tool.
For more information about line/DC link identification, see SINAMICS S120
Function Manual.

10.2.16 Settings of specific parameters
General It is recommended that you use or check the corresponding settings for the pa-
rameters listed in the table.
Table 10-1 Recommended parameter values: General
Parameter Value Description

Control Unit (CU320)
9906 2 Topology comparison level of all components,
2: low; compares the component type
Servo
922 102 PROFIBUS PDA Message frame selection,
SIEMENS Message frame 102, PDA-6/10
857 2000 Power module monitoring time [ms]
1520 0 Upper force limit/motor,
Attention
Negative values when setting the upper torque limit can lead
to motor “runaway”.
1521 0 Lower force limit/generator,
Attention
Positive values when setting the lower torque limit can lead to
motor “runaway”.
1780 0 Motor model adaptation configuration
2038 1 PROFIBUS STW/ZSW Interface Mode
Note
For p0922 = 100 ... 199, p2038 is automatically set to 1 and
p2038 can no longer be changed.
Infeed (ALM)
922 999 PROFIBUS PDA Message frame selection,
Free message frame configuration with BICO
Technology: For all drives used as spindles on which grinding wheels are used, OFF2 “Inter-
Grinding nal/external pulse disable” (coast down) is recommended as fault reaction when
fault 7841 ”” occurs.
Note
Fault reaction OFF3 “Brakes on the OFF3 return ramp and subsequent pulse
disable” (brakes on the current limit) can lead to the destruction of the grinding
wheel.
Table 10-2 Recommended parameter values: Grinding technology
Parameter Value Description

Servo
2100 7841 Setting the fault number for fault response
2101 2 OFF2: Internal/external pulse disable

10.3 Example for systems with more than 6 drives
10.3.1 Set-up and basic start-up
One control unit “CU 320” can control max. 6 drives in “Servo” mode. The fol-
lowing example shows which drive components are required and how they are
interconnected to operate more than 6 drives in one configuration.
Requirement
Control of 9 drives in “Servo” mode.

Components used
1. Control Unit: CU 320 (Control_Unit_1)

2. Control Unit: CU 320 (Control_Unit_2)
Supply: Active Line Module (ALM)
Power module 1: Single Motor Module (SMM), (Drive_1)
Power module 2: Double Motor Module (DMM), (Drive_2 and Drive_3)
Sensor module 1 – 9: Sensor Module Cabinets (SMC) (not shown)
Motor 1 – 9: Standard motor without DRIVE–CliQ connection (not shown)
CU 320 CU 320 ALM SMM DMM DMM DMM DMM

C_U_1 C_U_2 ALM Drive_1 Drive_2 Drive_4 Drive_6 Drive_8
Drive_3 Drive_5 Drive_7 Drive_9
X103 X103
1 1 1 1 1
X102 X102
X403 X203 X203 X203 X203
X101 X101
X402 X202 X202 X202 X202 X202
X100 X100
X401 X201 X201 X201 X201 X201
X400 X200 X200 X200 X200 X200
1 DriveCliQ connection to
each sensor module
Fig. 10-1 Example configuration for 9 drives

Creating a project The project should be created according to the description from Section 10.2,
Page 10-259. Both drive units must be displayed in the preview window.
1. 2. 3. 4.
device
Preview
Project
Drive_unit_Adr10
Drive_Unit_Adr20 Refresh
view
Fig. 10-2 STARTER: Project Wizard (excerpt)
Component The automatic acquisition of the component topology and configuration is per-
topology formed for each drive unit according to Subsection 10.2.2, Page 10-263.
Startup Drive components are to be started up according to the Subsection 10.2.3,

Page 10-266 to Subsection 10.2.15, Page 10-280 listed above.
Supply: Parameter “p864, BI: Infeed operation” of all drives must be connected with the
Operation corresponding release signal “r863: Bit0, Infeed operation”.
Control_Unit_1
Drives controlled by Control_Unit_1 (Drive_1..._5) are interconnected auto-
matically.
Control_Unit_2
Drives controlled by Control_Unit_2 (Drive_6..._9) must be manually inter-
connected (see the following section).
10.3.2 Drives of Control Unit 2: additional BICO interconnection
The infeed can be connected with a Control Unit via DRIVE CliQ. Since Con-
trol_Unit_1 is connected with the infeed, it is not possible to make a BICO inter-
connection from drive parameter “p864, BI: Infeed operation” to the infeed sig-
nal “r863: Bit0, Infeed operation” for the drives controlled by Control_Unit_2
(Drive_6..._9).
Drive: p864, BI: Infeed operation

Infeed: r863: Bit0, Infeed operation

General procedure In order to use the infeed signal for the drives controlled by Control_Unit_2, it
must be transferred via an external interconnection from an output terminal of
Control_Unit_ to an input terminal of Control_Unit_2.
Execution The following input/output terminals of the control units are used as an example
for the following description:
Control_Unit_1: p738, BI: CU signal source for terminal DI/DO 8 (X122.7)

Control_Unit_2: r722: Bit0. CO/BO: CU digital inputs, status: :DI 0 (X122.1)
Perform the following actions to interconnect the drive parameters with the in-
feed signal:
1. Use a BICO interconnection to connect infeed signal “r863: Bit0, Infeed op-
eration”:
– Project > Drive_Unit_Adr10 > Infeed operations > Infeed operation >
Diagnosis > Interconnections > Tab: “BO / CO” > Signal: “r863: Bit0, In-
feed operation”
with the parameter for the output terminal (X122.7) of the Control_Unit_1:
– p783, BI: CU signal source for terminal DI/DO 8
BI/CI BO/CO
r863: Bit0, Infeed operation Control_Unit_1, p738, Bi:CU signal source for term
r863: Bit1, Control line contactor Control_Unit_1 p738, Bi: CU signal source for terminal DI/DO 8
Drive_1 p738, Bi: CU signal source for terminal DI/DO 9
r898: Bit0, ON / OFF1
r898: Bit1, ON / OFF2 Drive_3 p738, Bi: CU signal source for terminal DI/DO 11
r898: Bit3, Enable operation
r898: Bit5, Inhibit motoring operation Supply p738, Bi: CU signal source for terminal DI/DO 14
p738, Bi: CU signal source for terminal DI/DO 15
r898: Bit5, Inhibit generator operation Further interconnections...
Further interconnections...
Fig. 10-3 STARTER: Work area (excerpt)
2. Configure the bidirectional digital input/output “DO 8” (X122.7) of Con-

trol_Unit_1 as an output:
– Project > Drive_Unit_Adr10 > Control_Unit_1 > Double-click on “Inputs/
outputs” > Tab: “Bidirectional digital inputs/outputs” > DO 8 or X122.7 =
output
Digital inputs Bidirectional digital inputs/outputs Test sockets

X122
Output
DO 8 ––
7
Infeed, r863: Bit0, CO/BO:
1 ––
Input
DI 9 ––
8 1 ––
0
M (GND)
9

3. Via a BICO interconnection, connect to Control_Unit_2 the parameter “r722:

Bit0. CO/BO: CU digital inputs, status: :DI 0” of the input terminal “DI 0”
(X122.1):
– Project > Drive_Unit_Adr10 > Control_Unit_1 > Double-click on “Inputs/
outputs” > Tab: “Digital inputs” > Digital input 0 (1)
for all drives of Control_Unit_2 with the parameter:
– p864, BI: Infeed operation (2)
Digital in- Bidirectional digital inputs/ Test sock-

puts
X122 outputs ets 1
Digital input 0
DI0
1 Drive_9, p864, BI: Infeed
1 ––
DI1 Control_Unit_1
2 Drive_9 :
Drive_8 p582[0], BI: Enable operation
DI2
3 Drive_7 p864, BI: Infeed operation 2
Drive_6
DID p1140[0], BI: Enable ramp–function generator
4
Further interconnections... :
4. Connect the output terminal “DO 8” (X122.7) of Control_Unit_1 to the input

terminal “DI 0” (X122.1) of Control_Unit_2 via an external interconnection.
5. The output terminal of Control_Unit_1 must be wired to an input terminal of
Control_Unit_2.
6. The input terminal of Control_Unit_2 must be connected to the drive param-
eters “p864, BI: Infeed operation” of all drives of Control_Unit_2 via a BICO
interconnection.
7. There is no DRIVE CliQ connection between the infeed and Control_Unit_2.

10.4 Basics
10.4 Basics
10.4.1 Drive unit: Firmware upgrade
The firmware of a drive unit is upgraded using the STARTER commissioning

tool.
Requirements This procedure requires a functional project and a CF card with the new firm-
ware.
Execution Perform the following actions to upgrade the firmware:

1. Create a network link between the PG/PC and the drive unit.
2. Access the drive unit with the PG/PC online and load the current project into
the PG/PC from the drive unit.
3. Save the project with a new project name by selecting “Save As...” and
close the old project.
4. Click the drive unit in the project view to convert the project to the new ver-
sion and select “Target system” > “Device version...” (1) from the menu.
In dialog box: “Device version”, select the version to which the project
should be upgraded (2) and start the conversion process using the button:
“Change version” (3).
STARTER – Project
Device version...
current version
SINAMICS S120 V2.2x Close
Project Available versions

Add individual drive SINAMICS S120 V2.3x Changing versions
Drive_unit_Adr10 1 SINAMICS S120 V2.3x
SINAMICS S120 V2.3x
Overview
Overview 3
Open configuration
Configuration 2
Topology
Topology
Insert new object
Open HW configuration
Cut
Copy
Paste
Delete
Rename
Target device Copy from RAM to ROM...

Expert Load to target system...
Print... Load to PG...
Print Preview... Restoring the factory settings
Properties... Online access...
Device version...
Fig. 10-6 Convert Project
5. Switch off the Control Unit and insert the CF card with the new firmware ver-
sion. Then switch the Control Unit on again.

10.4 Basics
6. Go online once again with the PG/PC and load the converted project into the
drive by selecting “Load to target system”.
The first time the project is loaded into the drive it will perform internal cal-
culations. To revert to the current view of the project, select “Load to PG”
immediately after “Load to target system”.
The firmware and project on the Control Unit are now upgraded.
7. If the CF card contains later firmware versions for the components (infeed,
Motor Module, etc.) you must now upgrade these as well. To do this, open
the device unit in the project view and double-click “Configuration” (1).
8. Select the “Version overview” (2) tab from the configuration view and click
“Firmware update” (3).
Click “Select all” (4) to upgrade all components, followed by “Start firmware
update” (5).
Note
The drive recognizes whether the CF card contains a later firmware version
and prevents an upgrade to an unsupported version.
Project 2
Drive_unit_Adr10
PROFIBUS telegram Version overview
Automatic configuration
Project set- Set Actual
Overview
Configuration point
1
Topology Component No. FW version Type Order No. HW version Serial No.
Control_Unit Project setpoint Project set- Project set-

Supply Control_Unit 1 0 Control board 6SL3040–0MA00-0Axx point point
Infeed_Infeed
Input/Output components 2 0 Supply 6SL3130-7TE21-6Axx
Drives Drive_1_Power_Module 3 0 Power module 6SL3120-1TE13-0Axx
Drive_1_Motor 4 ––– Motor 1FK6032-xAK7x-xAxx
Drive_1_Motor 5 ––– Encoders 1FK6xxx-xxxxx-xAxx
Drive_1_SM_to_Motor 7 0 SM 6SL3055-0AA00-5?xx
Filter DRIVE CLiQ + Option Slot Update topology Firmware update
Drive_unit_Adr10
Firmware update
Component No. FW version Typ Order No. HW version FW update Identification Result
e
CU–020.Control_Unit_1 1 2301600 Control board 6SL3040–0MA00–0AA1 E
A_INF_02.Line_module_2 2 2301600 Supply 6SL3130–7TE21–6AA1 A Identification via LED
TB30_08.TB30_23 23 ––– TB30 6SL3055–0AA00–2T A0 B
Axis_1.Motor_Module_3 3 2301600 Power module 6SL3120–1TE23–0AA1 A Identification via LED
Axis_1.SM_to_Motor_22 20 2301600 SMC20 6SL3055–0AA00–5BA1 A Identification via LED
Select all Start firmware update

5
4 Close Help
9. Reload the project by selecting “Load to PG”.

10. We recommend testing the drive unit after upgrading the firmware.


10.4 Basics
Notes

Drive Start-Up (SIMODRIVE) 11
Section “Drive start-up (preconditions)” describes the preconditions of the SI-
NUMERIK 840Di sl for optimum start-up of the drives in terms of material and
cost.
It is not the section’s objective to explain in detail how a drive is started up. For
start-up of the drive, please refer to the relevant drive documentation.
11.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI
11.1.1 Start-up variants
The following distinction is made between start-up of the above SIMODRIVE

drives:
S Initial start-up
S Series start-up
Initial start-up A first start-up must only be carried out if no matching parameter record is avail-
able for the drive in the form of the parameter file.
Series start-up A series machine start-up must only be carried out if no matching parameter
record is available for the drive in the form of the parameter file.
The parameter file is then loaded into the drive to be started up using SimoCom
U in online mode (for online mode, see: Subsection 11.1.2, Page 11-291).
Possible The possible ways of starting up a drive are:

procedures
S Using a display and operator unit directly on the drive (611U/E only)
S Using SimoCom U:
1. SimoCom U is installed on any PG/PC with a serial interface and is direct
connected to the corresponding drive using a RS-232 cable.
2. SimoCom U is installed on any PG/PC with a PROFIBUS DP interface
and connected to all drives using a PROFIBUS cable:
– PG 740 or PCU 50 with integrated PROFIBUS DP interface
– Standard PC with CPU module, e.g. CP 5611

11 Drive Start-up (SIMODRIVE) 03/2006
3. SimoCom U is installed on the SINUMERIK 840Di sl 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.
Recommended Within the framework of SINUMERIK 840Di sl, the procedure described above
procedure (Point 3.) is recommended:
The advantages of this procedure are:
S SimoCom U is always available for:

– start-up
– diagnosis
– controller optimization
– software upgrade of drive firmware
– software upgrade of option module firmware
S No additional PG/PC required

S No additional cables required

03/2006 11 Drive Start-up (SIMODRIVE)
11.1SIMODRIVE 611 universal/E, POSMO CD/CA and SI
11.1.2 Preconditions for an online connection
To be able to establish an online connection between SimoCom U and the SI-

MODRIVE 611 universal drives connected to a SINUMERIK 840Di sl using
PROFIBUS DP, the following preconditions must be fulfilled:
S SimoCom U must be installed.
– For installing SimoCom U, see Section 11.2, Page 11-297
S A PROFIBUS connection must exist from the PROFIBUS interface of the
MCI board to all drives.
– For network rules, see Subsection 8.1.4, Page 8-174
S With all drives, the PROFIBUS address must be set.
– For SIMODRIVE 611 universal/E see Subsection 11.1.3, Page 11-291
– For SIMODRIVE POSMO CD/CA and SI, see Subsection 11.1.4, Page
11-293
S The SINUMERIK 840Di sl PLC must be networked using MPI.
– For networking the PLC, see Subsection 6.3.3, Page 6-139
S The configuration must be loaded into the PLC.
– For creating an S7 project, see Section 6.3, Page 6-137
– For loading the PLC, see Subsection 8.3.3, Page 8-180
S The MPI interface must be set on the “SINUMERIK MCI Card (MPI)”.
– For setting the MPI interface, see Subsection 11.1.5 , Page 11-294
S The routing information must be set.
– For setting the routing Information, see Subsection 11.1.6, Page 11-295
11.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal / E)
For SimoCom U to be able to enter online operation with the SIMODRIVE drives
connected to the PROFIBUS, the PROFIBUS address specified in the S7 proj-
ect (see Section 6.3, Page 6-137f) must be set on DP slave 611U or UE in
question using the display and operator unit.
Display
+ P – Control unit
Fig. 11-1 Display and control unit

Requirements The precondition for setting the PROFIBUS address on the control unit is that
no faults or warnings are displayed.
If faults or warnings are displayed (display: E_xxxx), press the “–” key to switch
from the alarm mode to parameterization mode.
Sequence of To set the PROFIBUS address, proceed as follows:

operations
1. Setting the PROFIBUS address (parameter P0918)
– Hold down key “P” longer than 3 seconds.
=> The current value of the parameter P0918 (PROFIBUS address) is
displayed.
– Use keys “+” and “–” to set the desired PROFIBUS address.
– Press “P” again to quit the input mode.
2. Saving the PROFIBUS node address in the FEPROM
– Press the “+” or “–” key
=> Parameter P0652 (acceptance into FEPROM) is displayed
– Press “P” again to call the input mode.
– Use the “+” key to change the value to 1 (start writing)
and wait until the write process is acknowledged with 0 on the display.
3. Carrying out POWER ON Reset
– Push the “POWER ON-RESET” button on the front panel of the drive
module.
=> After power-up, the set PROFIBUS address is active.
Literature For detailed information on start-up of SIMODRIVE 611 universal drives, refer
to:
/FBU/ SIMODRIVE 611 universal Description of Functions
Section: Parameterizing the Module
Parameterization via display and control unit
and
Section: PROFIBUS-DP master settings
Start-up

11.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA)
For SimoCom U to be able to enter online operation with the SIMODRIVE drives
connected to the PROFIBUS, the PROFIBUS address specified in the S7 proj-
ect (see Section 6.3, Page 6-137f) must be set on DP slave POSMO SI/CD/CA
in question using the DIL switches of the PROFIBUS unit in question.
Switch setting
OFF=0
12 34 1 2345 678
ON=1
Terminating resistor active PROFIBUS address
ÏÏ ÏÏ Ï ÏÏ
ÏÏÏÏ
ÏÏÏÏÏ Ï Ï
ÏÏÏÏÏ
1 2 3 4
ON
ÏÏ
ÏÏÏÏ
1 ÏÏÏÏÏÏÏ
2 3 4 5 6
20 21 22 23 24 25 26 (reserved)
7 8
ON
Terminating resistor (1) (2) (4) (8) (16) (32) (64)

inactive = OFF Example: PROFIBUS address = 37
ON ON
1 2 3 4 1 2 3 4 5 6 7 8
Note: 1 + 4 + 32 = 37
S The valid settable addresses are: 3 to 126
S The set address is read by POSMO SI/CD/CA and displayed using

P0918 (PROFIBUS node address).
Fig. 11-2 Setting the PROFIBUS address and terminating resistor
Notice
To set the PROFIBUS address and terminating resistor it is necessary to re-
move the PROFIBUS unit.
Literature 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

11.1.5 Setting the MPI interface
The MPI interface through which SimoCom U accesses the drives connected to
PROFIBUS by means of routing, must be parameterized as follows:
– Access point of application
S7ONLINE STEP7 ––> SINUMERIK MCI board (MPI)
– Interface parameterization
SINUMERIK MCI board (MPI)
The MPI interface can be parameterized direct from SimoCom U. To do so, pro-
ceed as follows:
1. Start SimoCom U from the WINDOWS NT taskbar:
Start > Programs > SimoComU > SimoComU
2. In SimoCom U, open the interface dialog using the menu command:
Tools > Communication
SimoCom U dialog Dialog box: Interface

box: Start Radio button: “Route through S7-CPU”
Button: “Set PG/PC interface...”
PG/PC interface Dialog box: Setting the PG/PC interface

dialog box: Start Tab card: Access path
Access point of the application:
S7ONLINE STEP7 ––> SOFTMC
Interface parameter assignment used:
SOFTMC
If “SINUMERIK MCI board (MPI)” cannot be selected for the interface parame-
terization, the interface has to be installed first.
PG/PC interface Button: “Select...”

dialog box: End
Dialog box: Install / remove interface
Selection: SOFTMC
Button: “Install––>”
Close
OK
Finally, the routing information must be set in the interface dialog of SimoCom
U.

11.1.6 Setting the routing information
Setting the routing information:

– MPI address of the PLC
– PROFIBUS subnetwork ID
The easiest method to do so is the expert mode after resetting the routing infor-
mation.
Notice
To use the PLC as a router between MPI and PROFIBUS DP, the MPI network-
ing of the PLC must be parameterized in the S7 project. See Subsection 6.3.3,
Page 6-139.
SimoCom U dialog Button: “Reset routing information...”

box: End Radio button: Export mode
MPI No: 2 (see note)
PROFIBUS: <Subnetwork ID> (see below)
OK or Go online
Notice
With SINUMERIK 840Di sl, the routing of the MPI interface to the PROFIBUS
DP is provided by the PLC. Therefore, the MPI address of the PLC must be
specified as the “MPI No”.
With SINUMERIK 840Di sl, the PLC always has the MPI address 2.
Determining the Enter the 8-digit PROFIBUS S7 subnetwork ID of DP master (S7 project) in the
PROFIBUS S7 12-digit input form of the SimoCom U dialog box as follows:
subnetwork ID Example:
S7 project: 8-digit S7 subnetwork ID:
0010 – 0005
SimoCom U: 12-digit S7 subnetwork ID:

00 10 00 00 00 05
Determining the If you do not have the PROFIBUS S7 subnetwork ID, you can call it using the
PROFIBUS S7 SIMATIC Manager STEP 7.
subnetwork ID To do so, proceed as follows:
S Open the appropriate S7 project in the SIMATIC Manager S7.

S Select the appropriate station (in the example project: SIMATIC 300)

S Open the hardware configuration of the station (double-click with left mouse
button on: Hardware; “HW Config” will be started)
S Open DP master (in the example project: DP master) (double-click with left
mouse button on DP master)
S You will find the subnetwork ID as follows using the Properties dialog box of
the DP master:
Dialog box Dialog box: Properties – DP Master

Tab card: General
Type: PROFIBUS
Address: 2
Dialog box: Properties – PROFIBUS interface DP Master
Tab card: Parameter
Subnetwork: PROFIBUS
Dialog box: Properties PROFIBUS
Tab card: General
S7 subnetwork ID: 0010 – 0005 (Example)
Cancel
Cancel
Cancel
The online operation with the drives connected to PROFIBUS can now be
started.
11.1.7 Starting online operation
After parameterization of the MPI interface and entry of the routing information,
SimoCom U can enter online operation with the SIMODRIVE drives.
Start search To start the search for any drives connected,

– quit the above dialog box for setting the MPI interface with button: “Go
online”
or
– use menu command Start-up > Search for online drives
Display of the 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)

11.2 Installing SimoCom U
Installation SimoCom U is part of the 611U toolbox supplied with the SINUMERIK 840Di sl.
S Installation directory: See Section 1.2, Page 1-33ff

Engineering Tools > SIMODRIVE 611 Universal Toolbox > SimoCom U
To install SimoCom U, start file setup.exe and follow the further installation in-
structions.
Note
Before you install SimoCom U please consult the relevant notes in the read-
me.txt file in the installation directory.
Scope of functions SimoCom U provides the following functions:

– Make an online connection to the drives
– Upgrade the firmware
– Optimize the control parameters
– Traversing the axes
– Diagnose the drive status
Online help After installation, the documentation for SimoCom U is available electronically.
Use the menu command Help in SimoCom U to call information on the topics:
– Short introduction...
– How to Use WINDOWS Help...
– Help Topics...
– Key Operation...
– Wiring...
– About SimoCom U...
Literature You will also find a detailed description about SimoCom U in:
/FBU/ SIMODRIVE 611 universal Description of Functions

J

Notes

NCK Start-up with HMI Advanced 12
12.1 General procedure
The NCK is parameterized for the connected machine by setting system vari-
ables.
These system variables are called:
S Machine data (MD)
S Setting data (SD).
12.2 Machine and setting data
Machine data Machine data are system variables used to adapt the NCK to the machine.
Identifier The identifier of a machine data is subject to the scheme:

$ M k _IdentifierString
where the following applies:
– $ System variable
– M Machine data
– k Component
k identifies the components of the NCK parameterizing the appropriate machine
data:
– N NCK
– C Channel
– A Axis
– D Drive
– M MMC
Activation Activation when referring to a machine data indicates the NCK status in which a
change to a machine data becomes active.
Activation categories are:
S POWER ON
S Reconfiguration
S Reset
S Effective immediately.

12 NCK Start-up with HMI Advanced 03/2006
Setting data Setting data are system variables that indicate the current machine properties to
the NCK.
Identifier The identifier of a setting data is subject to the scheme:

$ S k _IdentifierString
where the following applies:
– $ System variable
– S Setting data
– k Component
k identifies the components of the NCK parameterizing the appropriate machine
data:
– N NCK
– C Channel
– A Axis
Activation Unlike machine data, changes to setting data always become effective immedi-
ately.
Overview of The machine data are divided into the following areas:
machine data Table 12-1 Overview of machine data
Area Description
from 1000 to 1799 Machine data for drives ($MD_....)
from 9000 to 9999 Machine data for operator panel ($MM_....)
from 10000 to 18999 NCK-specific machine data ($MN_....)
from 19000 to 19999 Reserved
from 20000 to 28999 Channel-specific machine data ($MC_....)
from 30000 to 38999 Axis-specific machine data ($MA_....)
from 51000 to 61999 General machine data for compile cycles
from 62000 to 62999 Channel-specific machine data for compile cycles
from 63000 to 63999 Axis-specific machine data for compile cycles
Overview The setting data are divided into the following areas:
of setting data Table 12-2 Overview of setting data
Area Description
from 41000 to 41999 General setting data ($SN_....)
from 42000 to 42999 Channel-specific setting data ($SC_....)
from 43000 to 43999 Axis-specific setting data ($SA_....)
Data description For a detailed description of the machine or setting data, please refer to the de-
scription of the function that uses the machine data in question, e.g.:
References: /FB/ Description of Functions – Basic Machine
/FB/ Description of Functions – Extended Functions
/FB/ Description of Functions – Special Functions

03/2006 12 NCK Start-up with HMI Advanced
A concise table of all machine and setting data is to be found in:

References: /LIS/ Lists
Machine and Setting Data
Note
To search for information regarding machine and setting data, it is recom-
mended to use the search functions in the electronic documentation: SINUM-
ERIK DOConCD.
12.2.1 Display and input
Machine data To display and input machine data, appropriate screen forms are provided.
screen forms
The screen forms are found on the HMI Advanced user interface at:
Area Switchover –> Start-up –> Machine Data.
Notice
To input machine data, at least the password of protection level 2 (default:
“EVENING”) must be set.
Bit editor To facilitate the input of machine data in the bit format (HEX), a bit editor is pro-
vided.
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).
Fig. 12-1 Input screen form of the bit editor for HEX machine data

You can set or reset single bits by clicking them with the mouse or by selecting
them with the cursor keys and then pressing the toggle key.
S With the soft key OK, you can terminate the bit editor and accept the value
set.
S With the soft key Abort, you can quit the bit editor and discard the value set.
The previous setting is then valid again.
12.2.2 Protection levels
Access rights Access to programs, data and functions is useroriented and controlled via 8
hierarchical protection levels. These are divided into
(see table 12-3):
S 4 password levels for Siemens, machine manufacturer and end user

S 4 keyswitch positions for end user
This provides a multilevel safety concept for controlling access rights.
Table 12-3 Protection levels

Protection Type User
level Access to (examples)
0 Key Siemens All functions, programs, and data

word
1 Key Machine manufacturer: Defined functions, programs and data;

word Development for example: Enter options
2 Key Machine manufacturer: Defined functions, programs, and data;

word Start-up engineer for example: Majority of machine data
3 Key End user: Assigned functions, programs, and data

word Service
4 Key End user: Lower than protection level 0 to 3;

pos. Programmer Defined by machine manufacturer or
Pos. 3 machine setter End user
5 Key End user: Lower than protection level 0 to 3;

pos. qualified user, Defined by end user
Pos. 2 who does not program Decreasing
access rights
6 Key End user: Example:
pos. Trained user, Program selection only, Tool wear input
Pos. 1 who does not program and input of zero offset
7 Key End user: Example:

pos. Semi-skilled operator No inputs or program selection
Pos. 0 poss., only machine control panel can be operated

Setting the For the four possible password levels with their access permissions, the pass-
password words can be entered in the control area DIAGNOSIS by actuating the soft key
SET PASSWORD.
References: /BA/ Operator’s Guide
Resetting Please note that a password remains valid until access authorization is reset
the password with the soft key DELETE PASSWORD.
Access authorization is therefore not automatically deleted during POWER
ON!
Possible Up to eight characters are possible for a password. We recommend that you
characters restrict yourself to the character set of the operator panel in selecting a pass-
word. Where a password consists of less than eight characters, the additional
characters are interpreted as blanks.
Default passwords The following default passwords have been set for protection levels 1 to 3:
– Protection level 1: SUNRISE
– Protection level 2: EVENING
– Protection level 3: CUSTOMER
Notice
A system power-up with loading the default machine data (after “Delete NCK
data”, e.g. using 840Di Start-up) will reset the passwords to the default values.
These passwords should be changed to ensure effective access protection.
Redefining The protection levels of machine and/or setting data can be modified both with
protection levels respect to complete machine or setting data ranges and for single data.
Data areas
Table 12-4 Protection levels: Machine data
Number Identifier Name Refer-

ence
MMC machine data ($MM_.... )
9200 USER_CLASS_READ_TOA Read tool offsets
9201 USER_CLASS_WRITE_TOA_GEO Write tool geometry
9202 USER_CLASS_WRITE_TOA_WEAR Write tool wear data
9203 USER_CLASS_WRITE_FINE Write Fine
9204 USER_CLASS_WRITE_TOA_SC Change additive tool offsets
9205 USER_CLASS_WRITE_TOA_EC Change tool setup offsets
9206 USER_CLASS_WRITE_TOA_SUPVIS Change tool monitoring limit values
9207 USER_CLASS_WRITE_TOA_ASSDNO Change D No. assigned to a tool edge
9208 USER_CLASS_WRITE_MAG_WGROUP Change wear group magazine location/mag.
9209 USER_CLASS_WRITE_TOA_ADAPT Tool adapter data
9210 USER_CLASS_WRITE_ZOA Write settable zero offset
9213 USER_CLASS_OVERSTORE_HIGH Extended overstore
9214 USER_CLASS_WRITE_PRG_CONDIT Program control


ence
9215 USER_CLASS_WRITE_SEA Write setting data
9218 USER_CLASS_SELECT_PROGRAM Program selection
9219 USER_CLASS_TEACH_IN TEACH IN
9220 USER_CLASS_PRESET PRESET
9221 USER_CLASS_CLEAR_RPA Delete R variables
9222 USER_CLASS_WRITE_RPA Write R parameters
9231 USER_CLASS_WRITE_RPA_1 Write protection for first RPA area
9232 USER_BEGIN_WRITE_RPA_1 Start of the first RPA area
9233 USER_END_WRITE_RPA_1 End of the first RPA area
9234 USER_CLASS_WRITE_RPA_2 Write protection for second RPA area
9235 USER_BEGIN_WRITE_RPA_2 Start of the second RPA area
9236 USER_END_WRITE_RPA_2 End of the second RPA area
9237 USER_CLASS_WRITE_RPA_3 Write protection for third RPA area
9238 USER_BEGIN_WRITE_RPA_3 Start of the third RPA area
9239 USER_END_WRITE_RPA_3 End of the third RPA area
9240 USER_CLASS_WRITE_TOA_NAME Change tool designation and duplo
9241 USER_CLASS_WRITE_TOA_TYPE Change tool type
9247 USER_CLASS_BASE_ZERO_OFF_PA Basic offset PA
9248 USER_CLASS_BASE_ZERO_OFF_MA Basic offset MA
References: /FB/ Description of Functions Basic Machine:

A2 Various Interface Signals
Section: MMC machine data for protection levels
Individual data The protection level of individual machine and/or setting data can be modified in
the file SGUD.DEF.
Example:
The axial machine data item CTRLOUT_SEGMENT_NR requires protection
level 3 for reading and protection level 2 for writing.
Syntax:
REDEF $Machine data string APR n APW m
APR n: Defining the protection level for reading (Read) the data
APW m: Defining the protection level for writing (Write) the data
File SGUD.DEF:
%_N_SGUD_DEF
;$PATH=/_N_DEF_DIR
REDEF $MA_CTRLOUT_SEGMENT_NR APR 3 APW 2
M30
References: /PGA/ Programming Guide Advanced
Section: File and Program Management
Defining protection levels for user data (GUD)

12.2.3 Machine data display filter
Through the use of the machine data display filter, it is possible to reduce the
number of displayed machine data of a certain area, e.g. general machine data
or channel machine data, for special purposes.
Machine data Display filters are provided for the following machine data areas:
areas
S General machine data
S Channelspecific machine data
S Axis-specific machine data
S Drive machine data
are available for this purpose.
Display filter To parameterize the display filter of a machine data area, use the vertical soft
key Display Options... in the appropriate machine data area.
Example:
Display filter for channel machine data
Operating area: Start-up –> Machine Data –> Channel MD –> Display Options...
Note
The parameter: Display Filter of the corresponding machine data description
indicates to which display group a machine data item belongs.
References: /LIS/ Lists
Display groups A display group contains machine data within a machine data area that belong
to the same topic.
By selecting/deselecting the display groups, the number of displayed machine
data of the current machine data area increases or decreases.
Expert mode If the Expert mode display filter is disabled, only the machine data of a machine
data range are displayed that are required for the basic functionality of the NCK.
Index from The index filter refers to the machine data fields. On the display, these machine
to data can be identified by the field index attached to the machine data string.
Example: 10000 AXCONF_MACHAX_NAME_TAB[index]
If the index filter is activated, machine data fields are only displayed in the spe-
cified index area.

12.3 System data
12.3 System data
12.3.1 Resolutions
The following types of resolution, e.g. resolution of linear and angular positions,
velocities, accelerations and jerk, must be differentiated as follows:
S the input resolution, i.e. the input of data from the user interface or using
the parts programs.
S the display resolution, i.e. the display of data on the user interface.
S the computational resolution, i.e. the internal representation of the data
input through the user interface or the parts program.
Input and display The input and display resolution is determined by the control unit used whereby
resolution the display resolution for position values can be modified using the MD 9004:
DISPLAY_RESOLUTION (display resolution).
The MD 9011: DISPLAY_RESOLUTION_INCH (INCH unit system display reso-
lution) can be used to configure the display resolution for position values with
inch setting. This allows you to display up to six decimal places with the inch
setting.
For the programming of parts programs, the input resolutions listed in the Pro-
gramming Guide apply.
Computational The computational resolution defines the maximum number of effective decimal
resolution places for all data the physical unit of which is referred to a length or an angle,
e.g. position values, velocities, tool offsets, zero offsets, etc.
The desired computational resolution is defined using the machine data
S MD 10200: INT_INCR_PER_MM (computational resolution for linear posi-

tions)
S MD 10210: INT_INCR_PER_DEG (computational resolution for angle posi-

tions)
The default assignment is:
S 1000 increments/mm
S 1000 increments/degrees
The computational resolution thus also determines the maximum achievable
precision for positions and selected offsets. However, it is essential that the
measuring system is adapted to this degree of precision.
Note
Although the computational resolution is generally independent of the input/dis-
play resolution, it should have at least the same resolution.
Rounding The precision 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.

12.3 System data
Example of rounding:
Computational resolution: 1000 increments/mm
Programmed path: 97.3786 mm
Effective value = 97.379 mm
Note
To keep rounding easily understandable, it is better to use powers of 10 for the
computational resolution (100, 1000, 10,000).
Display resolution In MD 9004: DISPLAY_RESOLUTION you can set the number of decimal
places after the decimal point for the position values on the operator panel.
Input and display The input value limitation depends on the display options and input options of
limit values the operator panel.
This limit is 10 decimal places plus decimal point plus sign.
Example of programming in the 1 /10 – mm range:

All the linear axes of a machine are to be programmed and traversed within the
value range 0.1 ... 1000 mm.
To position to 0.1 mm accuracy, the computational resolution must be set to
104 incr. / mm:
MD 10200: INT_INCR_PER_MM = 10000 [incr. /mm]:
Example of related parts program:
N20 G0 X 1.0000 Y 1.0000 ; Traverse axis to position
X=1.0000 mm, Y=1.0000 mm;
N25 G0 X 5.0002 Y 2.0003 ; Traverse axis to position
X=5.0002 mm, Y=2.0003 mm
Machine data
Table 12-5 Resolutions: Machine data
Number Identifier Name / remarks Refer-

ence
General ($MN_ ... )
9004 DISPLAY_RESOLUTION Display resolution G2
9011 DISPLAY_RESOLUTION_INCH Display resolution for INCH system of measure- G2
ment
10200 INT_INCR_PER_MM Computational resolution for linear positions G2
10210 INT_INCR_PER_DEG Computational resolution for angular positions G2
Literature /FB/ Description of Functions Basic Machine

G2 Velocities, Traversing Ranges, Accuracies,
Section: Input/display resolution, computational resolution

12.3 System data
12.3.2 Normalization of phys. quantities of machine and setting data
Standard Machine and setting data having a physical unit are interpreted in the input/out-
put units listed in Table 12-6 by default, depending on the scaling system (met-
ric/inch).
The internally used units which the NCK uses are independent and fixed.
Table 12-6 Normalization of phys. units of machine data and setting data
Physical unit Input/output units for the Internally used

default scaling system unit
Metric Inch
Linear position 1 mm 25.40 mm 1 mm
Angular position 1 degree 1 degree 1 degree
Linear velocity 1 mm/min 1 inch/min 1 mm/s
Angular velocity 1 rpm 1 rpm 1 deg./s
Linear acceleration 1 m/s2 1 inch/s2 1 mm/s2
Angular acceleration 1 rev/s2 1 rev/s2 1 degree/s2
Linear jerk 1 m/s3 1 inch/s3 1 mm/s3
Angular jerk 1 rev/s3 1 rev/s3 1 degree/s3
Time 1s 1s 1s
Position controller servo gain 1 s–1 1 s–1 1 s–1
Rev. feedrate 1 mm/rev 1 inch/rev 1 mm/degree
Compensation value linear position 1 mm 25.40 mm 1 mm
Compensation value angular position 1 degree 1 degree 1 degree
User-defined The user can define different input/output units for machine and setting data.
For this purpose,
S MD 10220: SCALING_USER_DEF_MASK (activation of scaling factors) and

S MD 10230: SCALING_FACTORS_USER_DEF[n] (scaling factors of the
physical quantities)
allow you to set the adaptation between the newly selected input/output units
and the internal units.
Input values for machine data
MD 10220 No
Scaling factor Internal scaling
activated?
Yes
MD 10230 Scaling factor
Internal physical unit

12.3 System data
The following applies:
Defined inputoutput unit
MD : SCALING_FACTORS_USER_DEF[n] * internal unit
Enter the actual value corresponding to the approached position in MD 10230:

SCALING_FACTORS_USER_DEF[n].
Table 12-7 Bit number and index for user definition
Physical unit MD 10220: MD 10230:

Bit number Index n
Linear position 0 0
Angular position 1 1
Linear velocity 2 2
Angular velocity 3 3
Linear acceleration 4 4
Angular acceleration 5 5
Linear jerk 6 6
Angular jerk 7 7
Time 8 8
KV factor 9 9
Rev. feedrate 10 10
Compensation value linear position 11 11
Compensation value angular position 12 12
Example 1:
Machine data input/output of the linear velocities is to be in m/min instead of
mm/min (initial setting). The internal unit is mm/s.
MD 10220: SCALING_USER_DEF_MASK Bit2 = 1 is used to enter the scaling
factor for linear velocities as a user-defined value.
The scaling factor is calculated using the following formula:
Defined inputoutput unit

MD : SCALING_FACTORS_USER_DEF[n]
internal unit
m 1000mm
1 min
MD : SCALING_FACTORS_USER_DEF[n] 60s
1000 16, 667;
1 mm
s 1 mm
s
60
MD : SCALING_FACTORS_USER_DEF[2] 16, 667
Index 2 specifies the “linear velocity” (see above).
Example 2:
In addition to the change of example 1, the machine data input/output
of linear accelerations, is to be performed in ft/s2, instead of m/s2 (default). (The
internal unit is mm/s2).

12.3 System data
MD : SCALING_USER_DEF_MASK H14; (Bit no. 4 and Bit no. 2

of example 1 as hex value)
ft
1 12 * 25, 4 mm
s2 s2
MD : SCALING_FACTORS_USER_DEF[n] mm 304, 8;
1 2 1 mm
2
s s
MD : SCALING_FACTORS_USER_DEF[4] 304, 8
Index 4 specifies the “linear acceleration” (see above).
Machine data
Table 12-8 Normalization of phys. units of machine data and setting data: Machine data

ence
General ($MN_ ... )
10220 SCALING_USER_DEF_MASK Activation of scaling factors
10230 SCALING_FACTORS_USER_DEF[n] Scaling factors of physical quantities
10240 SCALING_SYSTEM_IS_METRIC Basic system metric
10250 SCALING_VALUE_INCH Conversion factor for switchover to inch system
10260 CONVERT_SCALING_SYSTEM Basic system switchover active
10270 POS_TAB_SCALING_SYSTEM Measuring system of position tables T1
10290 CC_TDA_PARAM_UNIT Physical units of the tool data for CC
10292 CC_TOA_PARAM_UNIT Physical units of the tool edge data for CC
12.3.3 Changing scaling machine data
The scaling of machine data having physical units is defined by the following
machine data:
S MD 10220: SCALING_USER_DEF_MASK (activation of scaling factors)

S MD 10230: SCALING_FACTORS_USER_DEF (scaling factors of physical
quantities)
S MD 10240: SCALING_SYSTEM_IS_METRIC (basic system metric)

S MD 10250: SCALING_VALUE_INCH (conversion factor for switchover to
INCH system)
S MD 30300: IS_ROT_AX (rotary axis)

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.

12.3 System data
The control has been started up with default values. Axis A1 is declared as a
linear axis.
S MD30300: IS_ROT_AX[A1] = 0 (no rotary axis)

S MD32000: MAX_AX_VELO [A1] = 1000 [mm/min] (max. axis velocity).
Axis A1 is now declared as a rotary axis containing the following machine data:
S MD30300: IS_ROT_AX[A1] = 1 (rotary axis)

S MD32000: MAX_AX_VELO [A1] = 1000 [mm/min] (max. axis velocity).
With the next NCK reset, the control system recognizes that axis A1 is defined
as a rotary axis and rescales MD32000: MAX_AX_VELO to [rev./min] with refer-
ence to a rotary axis.
S MD30300: IS_ROT_AX[A1] = 1 (rotary axis)

S MD32000: MAX_AX_VELO [A1]= 2.778 [rev./min].
Note
If a scaling machine data item is altered, then the control outputs alarm “4070
Scaling data changed”.
Modifying The following procedure is recommended when modifying scaling machine data
manually manually:
1. Set all scaling machine data
2. Carry out NCK reset
3. Set all dependent machine data after the NCK has powered up.
12.3.4 Loading default machine data
The default machine data can be loaded in different ways.
840Di start-up With SINUMERIK 840Di sl standard user interface 840Di start-up:
Menu command Window > Diagnosis > NC/PLC
S Button: “Delete NCK Data”

S Button: “NCK RESET”
Notice
With deleting the NCK data, all user data are lost.
To avoid data loss, a series machine start-up file should be created before the
NCK data are deleted. How to create a series machine start-up file is described
in Section 16.2, Page 16-468.

12.3 System data
MD11200: INIT_MD The input values in MD11200: INIT_MD (loading the default machine data with
the “next” NCK boot), which are listed below, various data areas can be loaded
when the NCK boots next time.
After setting the machine data, NCK reset must be carried out twice:
1. NCK RESET: The machine data is activated.
2. NCK RESET: Depending on the input value, the appropriate machine data
are set to their default values and MD11200: INIT_MD is reset again to the
value “0”.
Input values MD11200: INIT_MD = 1

On the next NCK boot, all machine data (with the exception of the memory con-
figuring data) are overwritten with default values.
MD11200: INIT_MD = 2
On the next NCK boot, all memory-configuring machine data are overwritten
with default values.
12.3.5 Switching over the measuring system
The unit system is switched over for the entire machine using a soft key in the
HMI Advanced operating area “MACHINE”. The switchover is only accepted if:
S MD10260: CONVERT_SCALING_SYSTEM=1.
S Bit 0 of MD20110: RESET_MODE_MASK is enabled in every channel.
S All channels are in the Reset state.
S Axes are not traversing with JOG, DRF or PLC control.
S Constant grinding wheel peripheral speed (GWPS) is not active.
Actions such as part program start or mode change are disabled for the dura-
tion of the switchover.
If the switchover cannot be performed, this is indicated by a message in the
user interface. These measures ensure that a consistent set of data is always
used for a running program with reference to the measuring system.
The actual switchover of the system of measurement is performed internally by
writing all the necessary machine data and subsequently activating them with a
Reset.
MD10240: SCALING_SYSTEM_IS_METRIC and the corresponding settings
G70/G71/G700/G710 in MD20150: GCODE_RESET_VALUES are automati-
cally switched over consistently for all configured channels.
During this process, the value specified in MD20150: GCODE_RE-
SET_VALUES[12] alternates between G700 and G710.
This process takes place independently of the protection level currently set.

12.3 System data
System data When the system of measurement is changed, all lengthrelated parameters are
automatically converted to the new system of measurement from the perspec-
tive of the operator. This includes:
– Positions
– Feedrates
– Acceleration rates
– Jerk
– Tool offsets
– Programmable, settable and work offsets external and DRF offsets
– Compensation values
– Protection zones
– Machine data
– Jog and handwheel factors
After switching, all above mentioned data are available in the physical units as
described in Subsection 12.3.2, Page 12-308.
Data for which no unique physical units are defined, such as:
– R parameters
– GUDs (Global User Data)
– LUDs (Local User Data)
– PUDs (Program global User Data)
– Analog inputs/outputs
– Data exchange via FC21
are not converted automatically. In this case, the user must allow for the current
system of measurement in MD 10240: SCALING_SYSTEM_IS_METRIC.
The current system of measurement setting can be read at the PLC interface
via the “inch system” signal DB10.DBX107.7. DB10.DBB71 can be used to read
out the “system of measurement change counter”.
Machine data
Table 12-9 Switching over the unit system: Machine data

ence
General ($MN_ ... )
10240 SCALING_SYSTEM_IS_METRIC Basic system metric
10250 SCALING_VALUE_INCH Conversion factor for switchover to inch system
10260 CONVERT_SCALING_SYSTEM Basic system switchover active
axis spec. ($MA_ ... )
32711 CEC_SCALING_SYSTEM_METRIC System of measurement of sag compensation G2
Literature /FB/ Description of Functions, Basic Machine,

G2 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control,
Section: Metric/inch measuring system

12.3 System data
12.3.6 Traversing ranges
Computational The range of values of the traversing ranges directly depends on the selected
resolution and computational resolution (see Subsection 12.3.1, Page 12-306).
traversing ranges With the default assignment of the machine data for the computational
resolution
S 1000 inc./mm
S 1000 inc./deg.
the following traversing ranges result:
Table 12-10 Traversing ranges
Traversing range in the metric system Traversing range in the inch system
Linear axes 999,999.999 [mm; deg.] 399,999.999 [inch; deg.]
Rotary axes 999,999.999 [mm; deg.] 999,999.999 [inch; deg.]
Interpolation parameters I, J, K 999,999.999 [mm; deg.] 399,999.999 [inch; deg.]
12.3.7 Positioning accuracy
Computational The positioning accuracy depends on:

resolution and
traversing ranges
S the computational accuracy (internal increments/(mm or degrees))
S the actual-value resolution (encoder increments/(mm or degrees)).
The rougher resolution of both determines the positioning accuracy of the NCK.
The input resolution, the position control and interpolation clock do not affect the
accuracy.
Machine data
Table 12-11 Positioning accuracy: Machine data

ence
General ($MN_ ... )
10200 INT_INCR_PER_MM Computational resolution for linear positions G2
Axisspecific ($MA_ ... )
31020 ENC_RESOL[n] Encoder pulses per revolution

12.3 System data
12.3.8 Cycle times
On the SINUMERIK 840Di sl, the system clock cycle, the position controller
cycle and the interpolation cycle of the NCK are based on the DP cycle time
configured in STEP 7 “HW Config” (see Section 6.3, Page 6-137f).
System basic cycle The DP cycle time configured in STEP 7 is taken as the system clock cycle and
displayed in the machine data:
S MD10050: $MN_SYSCLOCK_CYCLE_TIME (system clock) = DP cycle time
Note
The DP cycle time configured in STEP 7 “HW Config” is only taken as the sys-
tem clock cycle from the NCK if at least one real machine axis is parameterized
in the NCK machine data.
If no real machine axis is parameterized, the value of the machine data func-
tions as the system clock cycle:
S MD10050: $MN_SYSCLOCK_CYCLE_TIME
Position controller The ratio from position controller cycle to system clock cycle for SINUMERIK
cycle 840Di sl is always 1:
S MD10060: $MN_POSCTRL_SYSCLOCK_TIME_RATIO = 1
Note
The machine data is not displayed for 840Di sl.
Position controller The position controller cycle offset (TM) must be set so that the following condi-
cycle offset tions are fulfilled within a DP cycle (TDP):
– The cyclic communication with the DP slaves (drives) must be com-
pleted before the position controller is started.
Condition: TM > TDX
– The position controller must be completed before the DP cycle is com-
pleted.
Condition: TM + TPos < TDP
The following setting is recommended as approximate value for the position
control cycle offset:
TM = TDP – 3*Tpos max
– TDP
The DP cycle time is equivalent to the position controller cycle of the SINUMERIK
840Di sl.
– Tpos max
Display using HMI Advanced (optional):
Operating area switchover > Diagnosis > Service displays >
System resources
S MD10062: $MN_POSCTRL_CYCLE_DELAY (position control cycle delay) =

TM

12.3 System data
TDP
TM TPos
NCK:
R R R
Position controller
TDX
PROFIBUS DP MSG RES GC Dx Dx Dx MSG RES GC Dx Dx Dx

Communication
DP slaves: R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R
R
R
Drives
Fig. 12-2 Position control cycle offset compared to PROFIBUS DP cycle
Key to Fig. 12-2:

TPos CPU time required by position controller
TDX Data exchange time: Sum of transfer times of all

DP slaves
TM Master time: Offset of the start time for NCK

position control
GC Global control: Broadcast message for cyclic

synchronization of the equidistance between DP master
and DP slaves
R CPU time
MSG Acyclic services (e.g. DP/V1, pass token)
RES Reserve: “active break” until the equidistant cycle has elapsed
Interpolation cycle The interpolator cycle may be chosen freely as a whole multiple of the position
control cycle.
S MD10070: $MN_IPO_SYSCLOCK_TIME_RATIO (factor for interpolator

cycle)
NCK CPU time The processor power of the PCU must be shared between the NCK and Win-
share dows XP. The parameterized CPU time share of the NCK is the maximum value
that the NCK will only use in the worst case. If the NCK requires less CPU time
in cyclical operation, it will cede it dynamically to Windows XP.

12.3 System data
TDP
TM
ÉÉÉÉ NCK NCK
ÉÉÉÉ ÉÉÉÉÉ
Part 1 Part 2
(general) (position con-
ÉÉÉÉ ÉÉÉÉÉ
Windows XP Windows XP
Part 1 Part 2 troller and
ÉÉÉÉ ÉÉÉÉÉ
interpolator)

position controller
Fig. 12-3 CPU time division between Windows XP and NCK
S MD10185: $MN_NCK_PCOS_TIME_RATIO (CPU time component NCK)
Individual setting The default value for the NCK CPU time share is 50%. An individual setting can
only be made by the following formula:
MD10185 >= 300 * (Tpos max * MD10070 + TIPO max + 0.2 ms) / MD10071
where:
– Tpos max and TIPO max
Tpos max [ms] and TIPO max [ms] are the maximum net run time of each position
controller or interpolator. The data are displayed by with HMI Advanced (option)
under:
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]
Note
The values displayed in menu: System resources of HMI Advanced refer to the
total power of the CPU, not to the CPU time share of the NCK set in MD 10185:
NCK_PCOS_TIME_RATIO.
The values for Tpos max and IPO max are considerably influenced by applications
active under Windows XP due to cache effects of the PCU processor. To calcu-
late these value, it is therefore necessary to activate Windows XP applications
demanding a lot of CPU time in parallel with execution of NC parts programs.
When the maximum values for Tpos and TIPO displayed as you proceed as de-
scribed above no longer change, you can calculate the above formula with a
value of 200 instead of 300.

12.3 System data
The maximum value for the NCK CPU time share of 75 % must not be ex-
ceeded. A value greater than 75 % can lead to significant impairment (slowing
down) of Windows XP applications. If necessary, the values must be adapted to
the system clock cycle/position controller cycle (DP cycle time) and/or interpola-
tion cycle.
Literature /FB/ Description of Functions – Special Functions

G3 Cycle Times
Machine data
Table 12-12 Cycle times: Machine data

ence
General ($MN_ ... )
10050 SYSCLOCK_CYCLE_TIME System clock cycle/only display data; is always
equal to the equidistant PROFIBUS DP cycle.
Note: With 840Di sl, only for display!
10060 POSCTRL_SYSCLOCK_TIME_RATIO Factor for the position control cycle/is set fixed to
the factor 1.
Note: Is not displayed with the 840Di sl!
10062 POSCTRL_CYCLE_DELAY Position control cycle offset
10070 IPO_SYSCLOCK_TIME_RATIO Factor for the interpolator cycle/can be freely se-
lected in integer multiples.
Caution
! If you change the cycle times, check the behavior of the drive in all operating
modes before you finish commissioning.
Note
The smaller the cycle times (PROFIBUS DP cycle) chosen, the greater the con-
trol quality for the drive and the better the surface quality on the workpiece.

12.3 System data
12.3.9 Velocities
Max. axis velocity The maximum possible axis velocities and spindle speeds depend on the ma-
or spindle speed chine design, drive dynamics and the encoder limit frequency of the individual
drives.
Max. progr. The maximum programmable tool path velocity results from the maximum axis
path velocity velocities of the axes involved in the path programmed.
Max. tool path ve- The maximum tool path velocity at which traversing is possible within a parts
locity program block results as follows:
progr. path length in the part program block [mm or degrees]
Vmax
IPO cycle [s]
Upper limit To guarantee that parts program blocks are executed continuously (control mar-
gin), the NCK limits the tool path velocity within a parts program block to 90% of
the max. possible tool path velocity as follows:
progr. path length in the part program block [mm or degrees]
Vmax * 0, 9
IPO cycle [s]
For example, in the case of parts programs generated by means of CAD sys-
tem, which contain extremely short blocks, this limiting of the path velocity can
result in a strong reduction of the path velocity over several parts program
blocks.
The function “Online compressor” can help to avoid such sudden velocity dips.
References: /PGA/ Programming Guide, Advanced
Section: Compressor COMPON/COMPCURVE
Lower limit The minimum tool path or axis velocity at which traversing is possible results
from:
Vmin 10 3
calculation precision[mm incr.
or degr.
] * IPO cycle [s]
(for the computational resolution, see: Subsection 12.3.1, Page 12-306)
If Vmin is not reached, no traversing is carried out.
Literature /FB/ Description of Functions Basic Machine

G2 Velocities, Traversing Ranges, Accuracies,
Section: Velocities

12.4 Memory configuration
Hardware The dynamic (DRAM) or static (SRAM) memory available depends on the
configuration hardware configuration of the components used (PCU and MCI board) and the
memory available for SINUMERIK 840Di sl.
SDRAM DRAM SRAM

Maximum for 840Di sl 1)
PCU 50.3-C/1.5 GHz 512 MB Approx. 16 MB –
PCU 50.3-P/2.0 GHz 1024 MB Approx. 16 MB –
MCI board – – 5 MB 2)
1) DRAM component (main memory) occupied by SINUMERIK 840Di sl

and thus no longer available for Windows XP.
2) The SRAM memory of the MCI board is divided into:
– Parts programs and manufacturer cycles: 3 MB
– User data: 1 MB
– Siemens cycles: 1 MB
User data The individual memory areas of the user data are set to reasonable default val-
ues during general reset of the NCK. To obtain optimum utilization of the user
memory the size of the individual data areas can be set for, e.g.:
S Part programs
S Tool management
S Tool offsets
S User variables
S R parameters
S Compensation
S Protection zones
S Frames
(see Subsection 12.4.2, Page 12-322):
The memory must be sectionalized before commencement of the actual NCK

start-up process because all user data (e.g. parts programs, tool offsets) will be
lost during the changes.
Machine data, setting data, and option data are not lost when the memory is
reorganized.
Activation The machine data of the memory configuration are activated by power ON.
References: /FB/ Description of Functions
S7 Memory Configuration

12.4.1 DRAM memory
Free memory The free DRAM memory is displayed in machine data

S MD18050: INFO_FREE_MEM_DYNAMIC (free dynamic memory)
displayed.
The free DRAM should not be less than 15,000 bytes.
Caution
Before you enlarge DRAM areas, you should first check whether the free
memory is sufficient:
S MD18050: INFO_FREE_MEM_DYNAMIC (free dynamic memory)

If more dynamic memory is requested than is available, the SRAM and
therefore all user data will be cleared without prior warning on the next NCK
start-up!
To avoid data loss, a series machine start-up file should be created before re-
configuration (see Section 16.2, Page 16-468).
Machine data
Table 12-13 Machine data required to configure the DRAM

ence
General ($MN_ ... )
18050 INFO_FREE_MEM_DYNAMIC Display data of the free dynamic memory
18170 MM_NUM_MAX_FUNC_NAMES Number of miscellaneous functions
18180 MM_NUM_MAX_FUNC_PARAM Number of additional parameters
18210 MM_USER_MEM_DYNAMIC User memory in DRAM
18240 MM_LUD_HASH_TABLE_SIZE Hash table size for user variables
18242 MM_MAX_SIZE_OF_LUD_VALUE Maximum field size of the LUD variables
18250 MM_CHAN_HASH_TABLE_SIZE Hash table size for channel-specific data
18260 MM_NCK_HASH_TABLE_SIZE Hash table size for global data
18340 MM_NUM_CEC_NAMES Number of LEC tables
18342 MM_CEC_MAX_POINTS Max. table size for sag compensation
18500 MM_EXTCOM_TASK_STACK_SIZE Stack size for external communication task
18510 MM_SERVO_TASK_STACK_SIZE Stack size of servo task
18520 MM_DRIVE_TASK_STACK_SIZE Stack size of drive task
Channelspecific ($MC_ ... )
20096 T_M_ADDRESS_EXIT_SPINO Spindle number as address extension /FBW/,
W1
27900 REORG_LOG_LIMIT Percentage of IPO buffer for log file enable
28000 MM_REORG_LOG_FILE_MEM Memory size for REORG /FB/, K1
28010 MM_NUM_REORG_LUD_MODULES Number of modules for local user variables with
REORG
28020 MM_NUM_LUD_NAMES_TOTAL Number of local user variables


ence
28040 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
28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for Compile cycles
28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for Compile cycles
28105 MM_NUM_CC_HEAP_MEM Heap memory for compile cycle applications
28210 MM_NUM_PROTECT_AREA_ACTIVE Number of simultaneously active protection zones /FB/, A3
28500 MM_PREP_TASK_STACK_SIZE Stack size of preparation task
28510 MM_IPO_TASK_STACK_SIZE Stack size of IPO task
28550 MM_PRSATZ_MEM_SIZE Available memory for internal blocks
38010 MM_QEC_MAX_POINTS Number of values for quadrant error /FB/, K3
compensation /IAD/
12.4.2 SRAM memory
Free memory The free SRAM memory is displayed in machine data

S MD18060: INFO_FREE_MEM_DYNAMIC (free static memory)
displayed.
The free SRAM should not be less than 15,000 bytes to ensure that data (e.g.
tool offsets) can be read in at all times.
Reconfiguation of Modifying the machine data listed in Table 12-14 results in a reconfiguration of
the SRAM memory the SRAM with a loss of all user data. Before the change becomes effective in
the NCK, the following alarm message is generated:
S Interrupt: “4400 MD change results in reorganization of the buffered memory

(loss of data!)”
Notice
When reconfiguring the SRAM memory, all user data are lost. To avoid data
loss, a series machine start-up file should be created before reconfiguration
(see Section 16.2, Page 16-468).
Machine data
Table 12-14 Machine data required to configure the SRAM

ence
General ($MN_ ... )
18060 INFO_FREE_MEM_STATIC Display data of the free static memory
18080 MM_TOOL_MANAGEMENT_MASK Screen form for reserving memory for the tool /FBW/
management
18082 MM_NUM_TOOL Number of tools managed by NCK

General ($MN_ ... )

18084 MM_NUM_MAGAZINE Number of magazines managed by NCK /FBW/
18086 MM_NUM_MAGAZINE_LOCATION Number of magazine locations /FBW/
18090 MM_NUM_CC_MAGAZINE_PARAM Compile cycles of tool management: Number of /FBW/
magazine data
18092 MM_NUM_CC_MAGLOC_PARAM Compile cycles of tool management: Number of /FBW/
magazine location data
18094 MM_NUM_CC_TDA_PARAM Compile cycles of tool management: Number of /FBW/
TDA data
18096 MM_NUM_CC_TOA_PARAM Compile cycles of tool management: Number of /FBW/
TOA data
18098 MM_NUM_CC_MON_PARAM Compile cycles of tool management: Number of /FBW/
monitor data
18100 MM_NUM_CUTTING_EDGES_IN_TOA Number of tool offsets
18118 MM_NUM_GUD_MODULES Number of GUD modules
18120 MM_NUM_GUD_NAMES_NCK Number of global user variables
18130 MM_NUM_GUD_NAMES_CHAN Number of channel-specific user variables
18140 MM_NUM_GUD_NAMES_AXIS Number of axis-specific user variables
18150 MM_GUD_VALUES_MEM Memory reserved for global user variables
18160 MM_NUM_USER_MACROS Number of macros
18190 MM_NUM_PROTECT_AREA_NCK Number of protection areas /FB/, A3
18230 MM_USER_MEM_BUFFERED. User memory in SRAM
18270 MM_NUM_SUBDIR_PER_DIR Number of subdirectories
18280 MM_NUM_FILES_PER_DIR Number of files per directory
18290 MM_FILE_HASH_TABLE_SIZE Hash table size for files in a directory
18300 MM_DIR_HASH_TABLE_SIZE Hash table size for subdirectories
18310 MM_NUM_DIR_IN_FILESYSTEM Number of directories in passive file system
18320 MM_NUM_FILES_IN_FILESYSTEM Number of files in passive file system
18330 MM_CHAR_LENGTH_OF_BLOCK Max. length of an NC block
18350 MM_USER_FILE_MEM_MINIMUM Minimum NC program memory
28050 MM_NUM_R_PARAM Number of channel-specific R parameters
28080 MM_NUM_USER_FRAMES Number of settable frames
28085 MM_LINK_TOA_UNIT Allocation of a TO unit to a channel /FBW/,
W1
28200 MM_NUM_PROTECT_AREA_CHAN Number of modules for channel-specific /FB/, A3
protection zones
38000 MM_ENC_COMP_MAX_POINTS Number of intermediate points with interpolatory /FB/, K3
compensation

12.5 Axes and spindles
12.5.1 Axis configuration
Definition The term “axis” is often used either as a single term in conjunction with SINUM-
ERIK 840Di sl or in a compound, e.g. machine axis, channel axis, etc. To pro-
vide an overview of the philosophy used as the basis, here is a brief explanation
of this term.
There are basically 3 types of axes:
1. Coordinate axes
2. Machine axes
3. Geometry and special axes
Coordinate axes Coordinate axes (abscissa, ordinate, applicate) are the axes of a Cartesian
coordinate system.
Machine axes Machine axes are the motion units existing on a machine, which can also be
designated as linear or rotary axes, depending on their usable movement.
Geometry axes The geometry axes constitute the rectangular Cartesian basic coordinate sys-
tem of a channel.
Generally, (Cartesian arrangement of the machine axes) direct imaging of the
geometry axes to the machine axes is possible. If the arrangement of the ma-
chine axes, however, is not Cartesian at right angles, the imaging is performed
using a kinematic transformation.
Special axes Special axes are all axes of a channel that are not geometry or machine axes.
Unlike for geometry axes (Cartesian coordinate system), no geometric context
is defined for additional axes, neither between additional axes or with respect to
geometry axes.
Channel axes The total of all machine, geometry and special axes assigned to a channel is
designated as channel axes.
The geometry and special axes represent the programming side of the machin-
ing process, i.e. they are used for programming in the parts program.
The machine axes constitute the physical part of the machining process, i.e.
they carry out the programmed traversing movements on the machine.
Axis assignment The assignment of drives, machine axes, channel axes and geometry axes
using the corresponding machine data is shown in the following Fig. 12-4:

List of all channel axes

3 of the channel
List of all geometry axes
4
of the channel MD20070: AXCONF_MACHAX_USED[n]
MD20050 AXCONF_GEOAX_ASSIGN_TAB[n] Channel 1
Channel 1 [0] = 1
[0] = 1 [1] = 2
[1] = 2 [2] = 3
[2] = 3 [3] = 4
Special axes
[4] = 5
2 Machine axes of the

NCK
MD30110 CTRLOUT_MODULE_NR[0]
MD30220 ENC_MODULE_NR[0]
Machine axis 1
[0] = 1
Machine axis 2 List of all drives

[0] = 2 1
of the NCK
MD13050 DRIVE_LOGIC_ADDRESS[n]
Machine axis 3
[0] = 3 NCK
[0] = I/O address of drive
. [1] = I/O address of drive
. [0] = 4 [2] = I/O address of drive
[0] = 5 [5] = I/O address of drive
.
[7] = I/O address of drive
.
[0] = 6
.
.
[0] = 7
.
.
[0] = 8
Fig. 12-4 Axis assignment

1 Machine data
MD13050: DRIVE_LOGIC_ADDRESS[n] (I/O address of the drive)

tells the NCK the I/O addresses of the drives defined in the S7 project using
“HW Config”.
The machine data index (n+1) is the logical drive number for the NCK.
2
The machine data
MD30110: MODULE_NR[0] (setpoint assignment)

MD30220: ENC_MODULE_NR[0] (actual-value assignment)
are used to assign each individual machine axis to a drive.
The logical drive number m to be entered in the two machine data refers to the
entry with the index n=(m-1) in the list described under Point 1 MD13050:
DRIVE_LOGIC_ADDRESS[n].
3 Machine data
MD20070: AXCONF_MACHAX_USED[n] (machine axis number valid in

channel)
defines explicitly which channel axis and which machine axis is used and de-
fines implicitly how many channel axes exist in the channel.
The machine axis number m to be entered in the machine data (with m=1,2,3...)
is referred to the appropriate machine axis m.
4
Machine data
MD20050: AXCONF_GEOAX_ASSIGN_TAB[n] (assignment geometry axis

– channel axis) (n = 0...2)
defines explicitly which channel axis is a geometry axis and defines implicitly
how many geometry axes exist in the channel.
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).

Machine data
Table 12-15 Axis configuration: Machine data

ence
General ($MN_ ... )
13050 DRIVE_LOGIC_ADDRESS I/O address of drive
20050 AXCONF_GEOAX_ASSIGN_TAB Assignment of geometry axis to channel axis
20070 AXCONF_MACHAX_USED Machine axis number valid in channel
30110 CTRLOUT_MODULE_NR Setpoint assignment
30220 ENC_MODULE_NR Actual-value assignment
Literature /FB/ Description of Functions, Basic Machine,,

K2 Axes, Coordinate Systems, Frames, Actual-Value System for
Workpiece, Section: Axes
12.5.2 Axis names
Each machine, channel and geometry axis can/must be assigned an individual

name unambiguously identifying it in its name range.
Machine axes Machine data
MD10000: AXCONF_MACHAX_NAME_TAB [n] (machine axis name)

is used to define the machine axis names.
Machine axis names must be unambiguous for the entire NCK.
The names and the corresponding index defined in the machine data above is
used for
Accessing axis-specific machine data (loading, saving, displaying)
Reference point approach from the parts program G74
Measurement
Test point traversing from the parts program G75
Traversing the machine axis from PLC
Display of axis-specific alarms
Display in the actual-value system (machine-related)
DRF handwheel function
Channel axes Machine data
MD20080: AXCONF_CHANAX_NAME_TAB[n] (name of the channel axis in

the channel)
is used to define the channel axis names. Channel axis names must be unam-
biguous for the entire channel.

Geometry axes Machine data
MD20060: AXCONF_GEOAX_NAME_TAB[n] (name of the geometry axis in

the channel)
is used to define the geometry axis names. Geometry axis names must be un-
ambiguous for the entire channel.
The axis names for channel and geometry axes are used in the parts program
for programming general traversing movements or to describe the workpiece
contour. The axis names are used for
Path axes
Synchronized axes
Positioning axes
Command axes
Spindles
Gantry axes
Coupled axes
Guide value coupling axes
Machine data
Table 12-16 Axis names: Machine data

ence
General ($MN_ ... )
10000 AXCONF_MACHAX_NAME_TAB Machine axis name
20060 AXCONF_GEOAX_NAME_TAB Geometry axis name in channel
20080 AXCONF_CHANAX_NAME_TAB Channel axis name/special axis name in channel

Workpiece, Section: Axes
12.5.3 Drive configuration
The following data must be assigned parameters in the NCK for the cyclic pro-
cess data exchange between the NCK and the DP slave drives:
I/O address of the drives
I/O address of the Control Units (optional, only SINAMICS)
Telegram
I/O addresses The I/O address tells the NCK the data areas via which cyclic process data ex-
change occurs with the drive or the Control Unit.
The I/O addresses assigned in the SIMATIC S7 project are entered in the fol-
lowing machine data:

MD13050 $MM_DRIVE_LOGIC_ADDRESS[n] (logical I/O address)

MD13120 $MM_CONTROL_UNIT_LOGIC_ADDRESS (logical I/O address
for the Control Unit (SINAMICS))
To parameterize the PROFIBUS communication for the drives, see:
SINAMICS: Section 8.9, page 8-218

SIMODRIVE: Section 8.10, Page 8-226
Default values: Axes The default values for the I/O addresses of the axes are designed so that there
is sufficient clearance per axle, starting at I/O address 4100, each with a mea-
suring circuit:
MD13050 $MM_DRIVE_LOGIC_ADDRESS[n] = 4100 + n * 40
Notice
Any changes in the I/O addresses must be carried out consistently:
SIMATIC S7 project
HW Config: I/O address for actual value and setpoint
NCK: MD13050 $MM_DRIVE_LOGIC_ADDRESS[n]

or
MD13120 $MM_CONTROL_UNIT_LOGIC_ADDRESS
Message frame The process data transferred between the NCK and the drives or Control Unit
during cyclic process data exchange are defined via the message frame.
To select the message frame, see:
SINAMICS: Section 8.9, Page 8-218

SIMODRIVE: Section 8.10, Page 8-226
Note
You will find a detailed description of the message frame in each case in Sec-
tion: “Communication via PROFIBUS”:
SINAMICS S120
References: SINAMICS S120 Commissioning Manual
SIMODRIVE 611 universal and universal E:
References: /FBU/ Description of Functions SIMODRIVE 611 universal
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: /Section 8.8; Page 8-217.

The message frames set in the SIMATIC S7 project are entered in the following
machine data:
MD13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)
Default values The default values for the machine data are based on the following message
frame:
102; Speed control with torque reduction, 1 position encoder
Notice
1. A change of the message frame type has to be carried out consistently:
SIMATIC S7 project, HW Config: Message frame type

NCK: MD13060: DRIVE_TELEGRAM_TYPE[n]
SINAMICS S120 or SIMODRIVE 611 universal:
Parameter P0922 PROFIBUS message frame selection
2. The order of the drives to which reference is made in the machine data
MD13050: DRIVE_LOGIC_ADDRESS[n]
MD13060: DRIVE_TELEGRAM_TYPE[n]
must be identical in both machine data.
SIMODRIVE 611U If a PROFIBUS drive does not support individual SIMODRIVE 611U-specific
functions functions that are active by default, they must be deactivated on the NCK via
the following drive-specific machine data:
MD13070: DRIVE_FUNCTION_MASK[n] (used DP functions)
Bit Function
0 Deactivation of the 611U-specific drive alarm generation
1 Deactivation of the 611U-specific drive type detection
2 Deactivation of the 611U-specific parameter accesses encoder drivers
3 Deactivation of the 611U-specific parameter accesses output drivers
4 Reserved
5 Deactivation of 611U-specific drive parking (STW2.7/STA2.7)
6 Deactivation of the 611U-specific travel to fixed stop (STW2.8/STA2.8)
7 Deactivation of the 611U-specific motor switchover internal (STW2.9 to 2.11)
8 Deactivation of the 611U-specific ramp block (STW1.11+13)
9 Deactivation of the 611U-specific function generator bits (STW1.8/STA1.13)
10 Deactivation of the parking brake control (STW1.12 / STA2.5)
11 Deactivation of the effect of OFF2/OFF3 on driveReady (DB31,... DBB93, Bit5)
14 Selection of non-cyclic DP communication: 0 = DPT; 1 = DPV1
15 Deactivation of the consistency check of the PROFIBUS message frame configu-
ration
ADI4 With an ADI4 module you can operate up to 4 drives with analog setpoint inter-
face on an isochronous PROFIBUS.

The 611U-specific functions (Bit0 – Bit3) and the effects of OFF2/OFF3 on the
signal “driveReady” (Bit11) must be disabled for this drive. The machine data for
each drive operated via ADI4 must be set:
MD13070: DRIVE_FUNCTION_MASK[n] = 80FH
Notice
The 611U-specific functions (Bit0 – Bit3) and effects of OFF2/OFF3 on the sig-
nal “driveReady” (Bit11) must be disabled for all drives connected via ADI4.
MD13070: DRIVE_FUNCTION_MASK[n] = 80FH
Drive type DP The NCK attempts to ascertain the drive type for each parameterized PROFI-
BUS drive. The drive type is shown in the following machine data:
MD13080: DRIVE_TYP_DP[n] (drive type PROFIBUS DP)

The following drive types are displayed by the NCK:
– 1 FSD (SRM: Synchronous Rotary Motor)
– 2 MSD (ARM: Asynchronous Rotary Motor)
– 3 Linear drive
If the drive type cannot be ascertained by the NCK because, for example, the
drive does not support acyclic communication or it has been deactivated via
machine data:
MD13070: DRIVE_FUNCTION_MASK (DP functions being used)

the following value is displayed:
– 0 No drive or drive type not known
Drive type DP: 4 If drive type 0 is displayed for a parameterized PROFIBUS drive, the value can
be manually set to:
– 4 Drive does not support acyclic communication
are set.
Setting the drive type to value 4 has the following effects in HMI Advanced:
Drive parameters
No drive parameters are read.
Current and speed controller cycles
The current and speed controller cycles are not displayed.
Drive type
ANA is displayed as the drive type.
Speed control loop
The dialog box for measuring the speed control loop only offers measure-
ments of the reference frequency response and setpoint step change.
Current control loop
The dialog box for measuring the current control loop is not offered.

ADI4 Because a ADI4 module does not support acyclic communication on the PRO-
FIBUS, we recommend entering value 4 as the drive type for any drive operated
via ADI4:
MD13080: DRIVE_TYP_DP[n] = 4
Note
We recommend entering drive type 4 manually for drives connected via ADI4:
MD13080: DRIVE_TYP_DP[n] = 4
Machine data
Table 12-17 Drive configuration: Machine data

ence
General ($MN_ ... )
13050 DRIVE_LOGIC_ADDRESS[n] Logical I/O address of drive G2
13060 DRIVE_TELEGRAM_TYPE[n] Drive message frame type for the drives connec- G2
ted to PROFIBUS DP
13070 DRIVE_FUNCTION_MASK[n] 611U-specific DP functions in use G2
13080 DRIVE_TYPE_DP[n] Drive type PROFIBUS DP G2
12.5.4 Setpoint/actual value channels
Note
In order to guarantee that the control runs up reliably, all machine axes are de-
clared as simulation axes (without hardware).
MD30130: CTRLOUT_TYPE (output type of setpoint value) = 0

MD30240: ENC_TYPE (actual-value acquisition mode) = 0
Traversing of the axes in servo mode is simulated without speed setpoint out-
put, and no hardware-specific alarms are output.
Machine data
MD30350: SIMU_AX_VDI_OUTPUT (output of axis signals with simula-

tion axes)
can be used to select whether the interface signals of a simulation axis are
output at the PLC interface (e.g. during program test, if there is no drive hard-
ware).

Assignment of the For each machine axis that a drive is to be assigned,

setpoint/actual-
value channels
a setpoint channel and
at least one actual-value channel
must be parameterized.
A second actual-value channel can be set up as an option.
Notice
The motor measuring system is always used for the speed control function.
Motor and motor measuring system must therefore always be connected to the
same drive module.
In the two axis-specific machine data:
MD30110: CTRLOUT_MODULE_NR[0] (setpoint assignment: logic drive

number)
MD30220: ENC_MODUL_NR[n] (actual-value assignment: logic drive num-

ber)
must always be entered the same logic drive number m of the drive represent-
ing the machine axis.
The input value m refers to the drive whose I/O address is defined under the
index n = (m–1) in MD13050: DRIVE_LOGIC_ADDRESS[n] (see Subsection
12.5.3, Page 12-328).
NCK reset 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 NCK has booted, the new configuration becomes effective.
Measuring system The interface signals

switchover
DB31, ... DBX1.5 (position measuring system 1 selected)
DB31, ... DBX1.6 (position measuring system 2 selected)
can be used to switch from the PLC between the two position measuring
systems of a machine axis.
References: /FB/ Description of Functions Basic Machine
Machine data
Table 12-18 Setpoint/actual value channels: Machine data

ence
30100 CTRLOUT_SEGMENT_NR Setpoint assignment: Drive type
5 = PROFIBUS DP
30110 CTRLOUT_MODULE_NR Setpoint assignment: Logical drive number


ence
30130 CTRLOUT_TYPE Output type of setpoint
0 = simulation
1 = speed setpoint output
30200 NUM_ENCS Number of measuring channels
1 = one position measuring system installed
2 = two position measuring systems installed
30210 ENC_SEGMENT_NR[0] Actual value assignment Drive type
5 = PROFIBUS DP
30220 ENC_MODULE_NR[0] Actual-value assignment: Logic drive number for
position measuring system 1
30230 ENC_INPUT_NR[0] Actual-value assignment: Position measuring sys-
tem 1
1 = motor measuring system
2 = direct measuring system
30230 ENC_INPUT_NR[1] Actual-value assignment: Position measuring sys-
tem 2
1 = motor measuring system
2 = direct measuring system
30240 ENC_TYPE[0] Actual-value acquisition modes
0 = simulation
1 = incremental encoder
4 = absolute encoder with EnDat interface
Interface signals
Table 12-19 Switching over the position measuring system: Interface signals
DB Bit, byte Name Refer-
Number ence
Axis/spindlespecific Signals from PLC to axis/spindle
31, ... 1.5 Position measuring system 1

G2 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control
Section: Setpoint/Actual Value System
/FB/ Description of Functions Basic Machine

Section: Interface signals to axis/spindle

12.5.5 Incremental measuring system settings
Rotary measuring The diagrams below show the general possibilities of arranging a rotary
system incremental measuring system with regard to motor and load, as well as the
resulting values for the appropriate machine data.
Linear axis with

encoder at motor ENC_IS_LINEAR=0 IS_ROT_AX=0
n
Encoders ENC_IS_DIRECT=0
ÍÍÍÍÍ
Measuring Load
gearbox gearbox Table
G M
ÍÍÍÍÍ
nSpindle
Ball screw
LEADSCREW_PITCH
n Motor
ENC_RESOL
DRIVE_AX_RATIO_NUMERA motor revs

=
DRIVE_AX_RATIO_DENOM spindle revs
DRIVE_ENC_RATIO_NUMERA motor revs

=
DRIVE_ENC_RATIO_DENOM encoder revs
Fig. 12-5 Linear axis with encoder on motor
Linear axis with

encoder on the DRIVE_AX_RATIO_NUMERA motor revs
machine =
ENC_IS_DIRECT=1
IS_ROT_AX=0
Measuring ENC_IS_LINEAR=0
ÍÍÍÍÍ
Table Gear
M G
Ball screw ENC_RESOL
Load
Gear LEADSCREW_PITCH
ENC_TYPE=1
n n n ENC_IS_LINEAR=0
Motor Spindle Spindle n
Encoders
ENC_RESOL
motor revs DRIVE_ENC_RATIO_NUMERA

=
encoder revs DRIVE_ENC_RATIO_DENOM
Fig. 12-6 Linear axis with encoder on the machine

Rotary axis with

encoder on motor
n
Load
n ENC_IS_DIRECT=0
Encoders
Measuring Load IS_ROT_AX=1 Rotary table
Gear Gear
G M L
n DRIVE_AX_RATIO_NUMERA motor revs

Motor =
DRIVE_AX_RATIO_DENOM Load revs
ENC_TYPE=1
ENC_IS_LINEAR=0 DRIVE_ENC_RATIO_NUMERA motor revs
=
ENC_RESOL DRIVE_ENC_RATIO_DENOM encoder revs
ENC_IS_DIRECT=0
Fig. 12-7 Rotary axis with encoder on motor
Rotary axis with

encoder on the ENC_TYPE=1
machine ENC_IS_LINEAR=0
n ENC_IS_DIRECT=1
ENC_RESOL
Motor
n Load ENC_IS_DIRECT=1
n
Load Measuring Encoders
gearbox gearbox
M L G
DRIVE_ENC_RATIO_NUMERA encoder revs

=
DRIVE_ENC_RATIO_DENOM Load revs
IS_ROT_AX=1

=
DRIVE_AX_RATIO_DENOM Load revs
Fig. 12-8 Linear axis with encoder on the machine
Machine data
Table 12-20 Incremental measuring systems: Machine data

ence
30240 ENC_TYPE[n] Actual-value acquisition modes
1 = incremental signal generator
30242 ENC_IS_INDEPENDENT[n] Encoder is independent
30300 IS_ROT_AX Rotary axis R2
31000 ENC_IS_LINEAR[n] Direct measuring system (linear scale)
31020 ENC_RESOL[n] Encoder pulses per revolution
31030 LEADSCREW_PITCH Leadscrew pitch
31040 ENC_IS_DIRECT[n] Encoder is connected directly to the machine
31050 DRIVE_AX_RATIO_DENOM[n] Denominator load gearbox
31060 DRIVE_AX_RATIO_NUMERA[n] Numerator load gearbox
31070 DRIVE_ENC_RATIO_DENOM[n] Denominator of resolver gearbox
31080 DRIVE_ENC_RATIO_NUMERA[n] Numerator of resolver gearbox

Linear measuring The diagrams below show the general possibilities of arranging a rotary
system incremental measuring system with regard to motor and load, as well as the
resulting values for the respective machine data.
Linear axis with

linear scale
=
IS_ROT_AX=0
ÍÍÍÍÍÍ
Table
Ball screw
M
LEADSCREW_PITCH
Load gearbox
Linear scale
ENC_IS_LINEAR=1
ENC_IS_DIRECT=1
ENC_GRID_POINT_DIST
ENC_FEEDBACK_POL= [1 or –1]
Fig. 12-9 Linear axis with linear scale
Machine data
Table 12-21 Linear measuring systems: Machine data

ence
1 = incremental signal generator
31010 ENC_GRID_POINT_DIST[n] Distance between reference marks on linear
scales
31030 LEADSCREW_PITCH Leadscrew pitch
32110 ENC_FEEDBACK_POL[n] Sign actual value (feedback polarity)

12.5.6 Parameterization of absolute measuring systems
Encoder types The following encoder types are currently supported:

Single-turn absolute value encoder
Multi-turn absolute value encoder
with EnDat protocol and incremental sinusoidal encoder signals A and B, e.g.
Haidenhain EQN 1325.
EQN 1325 The absolute value encoder EQN 1325 from Heidenhain has the following prop-
erties:
EnDat protocol
PPR count: 2048 = 211 (encoder fine resolution)
Positions/revolution: 8192 (13 bits)
Differentiable revolutions: 4096 (12 bits)
Encoder signals A/B: 1Vpp sin/cos
Calibration Synchronization of the measuring system with the machine positions is per-
formed by calibration of the absolute value encoder in absolute measuring sys-
tems. For calibration of the absolute value encoder, see Subsection 12.5.19,
Page 12-376.
Rotary measuring An absolute encoder can currently exclusively be used as a motor encoder (in-
systems direct measuring system).
Linear axis with DRIVE_ENC_RATIO_NUMERA motor revs

=
rotary absolute en- ENC_IS_LINEAR=0 DRIVE_ENC_RATIO_DENOM encoder revs
coder ENC_IS_DIRECT=0
n IS_ROT_AX=0
Encoders Load
ÍÍÍÍÍÍ
gearbox Table
G M Ball screw
Measuring
gearbox nSpindle LEADSCREW_PITCH
n
ENC_TYPE=4 Motor
ENC_ABS_TURNS_MODULO=4096 DRIVE_AX_RATIO_NUMERA motor revs
ENC_REFP_MODE=2 =
Fig. 12-10 Linear axis with absolute value encoder on motor
Rotary axis with DRIVE_ENC_RATIO_NUMERA motor revs

=
absolute value ENC_IS_LINEAR=0 DRIVE_ENC_RATIO_DENOM encoder revs
encoder on motor ENC_IS_DIRECT=0 n
Load
n Load IS_ROT_AX=1
Encoders
Gear
G M L Rotary table
Measuring
Gear
n DRIVE_AX_RATIO_NUMERA motor revs
ENC_TYPE=4 Motor
DRIVE_AX_RATIO_DENOM
=
ENC_ABS_TURNS_MODULO=4096 Load revs
ENC_REFP_MODE=2
Fig. 12-11 Rotary axis with absolute value encoder on motor

(ADI4) For a machine axis whose measuring system consists of an absolute encoder
on an ADI4 module, the following must be taken into consideration:
Absolute encoder with SSI interface

Since the ADI4 transfers the data from the absolute encoder to the NCK in
EnDat format, encoder type “Absolute encoder gen.“ must be entered as the
encoder type:
– MD30240: $MA_ENC_TYPE (encoder type) = 4 (absolute encoder gen.)
Literature
/ADI4/ Analog drive port for 4 axes
Section: Function parameters (SINUMERIK 840Di sl) and
(SIMOTION)
Encoder type
Encoder fine resolution

The fine resolution configured in the ADI4 (reserved bits for fine resolution)
of the absolute encoder must be assumed by the NCK:
– MD30260: $MA_ABS_INC_RATIO[n] (encoder fine resolution)
Literature
/ADI4/ Analog drive port for 4 axes
Section: Function parameters (SINUMERIK 840Di sl) and
(SIMOTION)
Reserved bits for fine resolution
Boot with For axes with non-calibrated absolute encoder:

non-calibrated
encoder
MD34210 $MA_ENC_REFP_STATE == 0 (encoder not calibrated)
an alarm is displayed each time the NCK is booted:
Alarm: “25022 axis <Axis identifier> Encoder <Number> Alarm 0”
Machine data
Table 12-22 Incremental measuring systems: Machine data

ence
30260 ABS_INC_RATION[n] Encoder fine resolution (absolute value encoder)
30300 IS_ROT_AX[n] Rotary axis R2
31030 LEADSCREW_PITCH[n] Leadscrew pitch
31070 DRIVE_ENC_RATIO_DENOM[n] Denominator measuring gearbox
31080 DRIVE_ENC_RATIO_NUMERA[n] Numerator measuring gearbox
34200 ENC_REFP_MODE[n] Referencing mode
34210 ENC_REFP_STATE[n] Status of absolute value encoder
34220 ENC_ABS_TURNS_MODULO[n] Absolute value encoder range for rotary encoders R2
(multi-turn resolution)

12.5.7 Parameterization of a 2nd measuring system with ADI4
Up to 2 measuring system can be parameterized for a machine axis. If it is not

possible to connect the 2nd measuring system directly to the associated drive
module, it is possible to use a ADI4 module.
Note
Detailed information about the measuring systems that can be connected to the
ADI4 is to be found in:
Section: Hardware description
Parameterization The following parameterization example illustrates the basic procedure for para-
example meterizing the NCK for a 2nd measuring system of a machine axis connected
via ADI4. It assumes the following:
NCK
2 measuring systems are to be parameterized for the 1st machine axis.
– 1. Measuring system: “motor measuring system” of the drive
– 2. Measuring system: “direct measuring system”
Drive
SIMODRIVE 611U 1 axis module is used as the drive with a connection op-
tion for a measuring system (motor encoder).
ADI4
The 2nd measuring system is connected via the encoder interface of the 1st
axis of an ADI4 module. (Connection is possible via any axis of the ADI4
module.)
Configuration The configuration is shown in Fig. 12-12.
840Di sl (configuration) –– 611U_ADI4

PROFIBUS(1): DP master system (1)
(0) 840Di sl
2 PLC317–2DP (10) SIMOD (15) ADI4
X2 DP master
4 S7 FM NCU
Fig. 12-12 Configuration: Axis with 2nd measuring system on ADI4

I/O addresses and The I/O addresses and message frame types for the drive and ADI4 axis are set
message frame to the following values in the configuration:
types Drive
– Message frame type: Message frame 102
– I/O address: 4100
DP slave properties
General Configuration Isochrone mode Encod.
1 axis, message frame 102, PDA–6/10
Slot Drive PROFIBUS partner

Type Addr... Type PR... I/O add... Length Unit Consistency
4 No PKW
5 Actual value PDA1 Input 2 4100 10 Word Total length
6 Setpoint PDA1 Output 2 4100 6 Word Total length
Fig. 12-13 DP slave properties: SIMODRIVE 611U
ADI4
– Message frame type: Standard message frame 3
– I/O address: 4200
DP slave properties
General Configuration Isochrone mode Encod.
4 axes each with one encoder, standard message frame 3+IO, PDA–5/9 A
Slot Drive PROFIBUS partner

Type Addr... Type PR... I/O add... Length Unit Consistency
4 No PKW
5 Actual value PDA1 Input 2 4200 9 Word Total length
6 Setpoint PDA1 Output 2 4200 5 Word Total length
Fig. 12-14 DP slave properties: ADI4
NCK machine data The general and axis-specific NCK machine data should be set as follows:
Drive assignment
The axis of the SIMODRIVE 611U drive module is assigned to the NCK as the
1st machine axis. This requires entry of its I/O address and message frame type
under index 0:
MD13050: DRIVE_LOGIC_ADRESS[0] = 4100
MD13060: DRIVE_TELEGRAM_TYPE[0] = 102
The I/O address and the message frame type of the 1st axis of the ADI4 module
will be entered in the next free machine data (e.g. Index 3):
MD13050: DRIVE_LOGIC_ADRESS[3] = 4200
MD13060: DRIVE_TELEGRAM_TYPE[3] = 3

Assignment of the actual value channels

Assignment of the 1st measuring system (index 0) of the machine axis to the
measuring circuit input of the SIMODRIVE 611U drive module is performed via
the axis-specific machine data:
MD30220: ENC_MODUL_NR[0] = 1
with 1 = (Index 0 of the corresponding MD13050 + 1)
Assignment of the 2nd measuring system (index 1) of the machine axis to the
measuring circuit input of the ADI4 module is performed via the axis-specific
machine data:
MD30220: ENC_MODUL_NR[1] = 4
with 4 = (Index 3 of the corresponding MD13050 + 1)
See Subsection 12.5.4, Page 12-332.
Machine data
Table 12-23 Drive configuration: Machine data

ence
General ($MN_ ... )
13050 DRIVE_LOGIC_ADDRESS[n] Logical I/O address of drive G2
13060 DRIVE_TELEGRAM_TYPE[n] Drive message frame type for the drives connec- G2
ted to PROFIBUS DP
Interface signals
Table 12-24 Switching over the position measuring system: Interface signals
DB Bit, byte Name Refer-
Number ence

12.5.8 DSC (Dynamic Servo Control)
The DSC function eliminates the deadtime that necessarily exists at the speed-
setpoint interface normally used between the NCK and drive due to relocation of
the position controller into the drive.
That results in the following advantages for an axis operated with DSC:
Considerably improved fault response/stability of the position control loop

Improved control behavior (contour precision) if the higher servo gain (KV
factor) that can be set in conjunction with DSC is used.
A reduction of the cyclic communication load on the PROFIBUS, if the posi-

tion control cycle/PROFIBUS cycle is reduced by adjusting the above pa-
rameters, even if the control loop performance is the same.
Note
The speed feedforward control can be used in conjunction with DSC.
Requirements Before you can activate DSC mode, the following preconditions must be fulfilled:
DSC-capable drive, e.g.:

– SINAMICS S120
– SIMODRIVE 611 universal
A DSC-capable message frame type has been parameterized in the S7 proj-

ect for the drive (see Section 8.9, Page 8-218).
Switch ON/OFF The DSC function is switched ON via the following axis-specific NCK machine
data:
MD32640: STIFFNESS_CONTROL_ENABLE (dyn. stiffness control)

If DSC operation is switched ON or OFF, it might be necessary to adjust the
following machine data:
MD32200: POSCRTL_GAIN (KV factor)

MD32610: VELO_FFW_WEIGHT (feedforward control factor)
MD32810: EQUIV_SPEEDCTRL_TIME (substitute time const. of the closed
speed control loop).
Notice
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.

Speed setpoint If you use DSC, a speed setpoint filter for rounding the speed setpoint steps is
filter no longer necessary. The speed setpoint filter is then only of any use with differ-
ence injection to support the position controller, for example, to suppress reso-
nance.
Measuring system DSC is only possible in conjunction with the motor measuring system.
Machine data
Table 12-25 DSC: Machine data

ence
32640 STIFFNESS_CONTROL_ENABLE Dyn. stiffness control DD2
32200 POSCRTL_GAIN Servo gain factor (Kv) G2
12.5.9 Drive optimization
Optimization of the control loop (current, speed, and position control loop) of the
drives can be performed with:
HMI Advanced (see Chapter 15, Page 15-435)

– Depending on the installation version: SINAMICS S120 or SIMODRIVE
drives
SINAMICS STARTER commissioning tool

– SINAMICS S120
SIMODRIVE SimoCom U commissioning tool

– SIMODRIVE 611 universal / E
Note
Detailed information on measuring the filter frequency response and optimizing
torque/current and speed control loop can be found in:
SINAMICS
Online Help for Commissioning Tool: STARTER > Contents > Diagnostics
functions
SIMODRIVE 611 universal/E, POSMO CD/CA and SI

Online Help for SimoCom U Commissioning Tool > Index:
– Measuring function
– Optimization of speed control loop

12.5.10 Rotary axes
Rotary axes A machine axis is parameterized as a rotary axis in
MD30300: IS_ROT_AX (rotary axis) = 1

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.
For the recommended procedure with respect to scaling machine data, please
refer to Subsection 12.3.3, Page 12-310.
Modulo display About the machine data
MD30320: DISPLAY_IS_MODULO (modulo 360 degrees display for rotary

axes)
is used to display the rotary axis position modulo 360 degrees.
Endlessly rotating The machine data

rotary axis
MD30310: ROT_IS_MODULO (modulo conversion for rotary axis)
is used to traverse the rotary axis modulo 360 degrees. The limit switches are
not monitored during this process. The rotary axis can thus rotate endlessly.
Machine data
Table 12-26 Rotary axes: Machine data

ence
General ($MN_ ... )
30300 IS_ROT_AX Axis is rotary axis
30310 ROT_IS_MODULO Modulo conversion for rotary axis
30320 DISPLAY_IS_MODULO Actual value display modulo
36100 POS_LIMIT_MINUS Software limit switch minus A3
36110 POS_LIMIT_PLUS Software limit switch plus A3
Setting data
Table 12-27 Rotary axes: Setting data

ence
General ($SN_ ...)
41130 JOG_ROT_AX_SET_VELO JOG speed for rotary axes H1
Axisspecific ($SA_ ... )
43430 WORKAREA_LIMIT_MINUS Working area limitation minus A3
43420 WORKAREA_LIMIT_PLUS Working area limitation plus A3
Literature /FB/ Description of Functions - Extended Functions

R2 Rotary axes

12.5.11 Positioning axes
Positioning axes are channel axes traversing parallel to the path axes without
interpolating with them.
Positioning axes can be traversed either from the parts program or from the
PLC.
Concurrent The machine data

positioning axes
MD30450: IS_CONCURRENT_POS_AX (concurr. positioning axis) = 1
is used to assign the PLC a channel axis by default. To traverse it from the parts
program later, it must be requested explicitly using a parts program statement
(GET).
Positioning axis If a positioning axis is programmed in the parts program without specifying an
feed axis-specific feedrate, the feedrate entered in
MD32060: POS_AX_VELO (initial setting for positioning axis velocity)

will apply to this axis automatically.
This feedrate will apply until an axis-specific feedrate is programmed in the
parts program for this axis.
Machine data
Table 12-28 Positioning axes: Machine data

ence
22240 AUXFU_F_SYNC_TYPE Output timing of F functions H2
30450 IS_CONCURRENT_POS_AX Concurrent positioning axis
32060 POS_AX_VELO Feedrate for positioning axis
Interface signals
Table 12-29 Positioning axes: Interface signals
DB number Bit, byte Name Refer-

ence
31,... 0 Feedrate override, axis-specific
31,... 2.2 Delete distance-to-go, axis-specific
Signals from axis/spindle to PLC
31,... 74.5 Positioning axis
31,... 78–81 F function (feedrate) for positioning axis
Literature /FB/ Description of Functions – Extended Functions,

P2 Positioning axes

12.5.12 Indexing axes
Indexing axis are rotary or linear axes that may only be traversed within their
traversing range to defined positions, the indexing positions.
Traversing to indexing positions using the parts program or manually is only
effective if the corresponding machine axis has been successfully referenced.
The indexing positions are stored in tables.
Indexing axis About the machine data
MD30500: INDEX_AX_ASSIGN_POS_TAB[n] (axis is indexing axis)

assigns the machine axis the relevant table of indexing positions and also
defines the machine axis as an indexing axis.
Indexing position The indexing positions are stored in one of 2 possible tables.
tables
MD10900: INDEX_AX_LENGTH_POS_TAB_1 (number of positions of in-
dexing table 1)
MD10910: INDEX_AX_POS_TAB_1[n] (indexing position table 1)
MD10920: INDEX_AX_LENGTH_POS_TAB_2 (number of positions of in-

dexing table 2)
MD10930: INDEX_AX_POS_TAB_2[n] (indexing position table 2)
Machine data
Table 12-30 Indexing axes: Machine data

ence
General ($MN_ ... )
10260 CONVERT_SCALING_SYSTEM Basic system switchover active G2
10270 POS_TAB_SCALING_SYSTEM Measuring system of position tables
10900 INDEX_AX_LENGTH_POS_TAB_1 Number of indexing positions used in Table 1
10910 INDEX_AX_POS_TAB_1[n] Indexing position table 1
10920 INDEX_AX_LENGTH_POS_TAB_2 Number of indexing positions used in Table 2
10930 INDEX_AX_POS_TAB_2[n] Indexing position table 2
Axis/spindlespecific ($MA_ ... )
30310 ROT_IS_MODULO Modulo conversion for rotary axis R2
30320 DISPLAY_IS_MODULO Position display modulo 360o R2
30500 INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis
30501 INDEX_AX_NUMERATOR Numerator for indexing axes with equidistant positions

Interface signals
Table 12-31 Indexing axes: Interface signals

ence
Axis/spindle-specific Signals from axis/spindle to PLC
31,... 60.4, 60.5 Referenced/synchronized 1, referenced/synchronized 2 R1
31,... 76.6 Indexing axis in position
Literature /FB/ Description of Functions – Extended Functions,

T1 Indexing axes
12.5.13 Parameter sets of axis/spindle
Per machine axis, 6 parameter sets are available. They are used as follows
on an axis:
for accommodation of the own dynamic response to another machine axis,
e.g. when tapping or thread cutting.
on a spindle:
quick accommodation of the position controller to modified properties of the
machine during operation, e.g. when switching the gearbox.
Tapping, thread The following applies to axes:

cutting
For a machine axis that is not involved in tapping or thread cutting, the 1st
set of parameters (index=0) is active in all cases.
All other parameter sets do not need to be taken into account.
Machine axes involved in tapping or thread cutting: the parameter set is acti-
vated in accordance with the current gear stage.
All parameter sets must be assigned parameters according to the gear

stages of the spindle.
The following applies to spindles:
With spindles, each gear stage is assigned a parameter set of its own. The
parameter set is selected from the PLC using the interface signal DB31, ...
DBX16.0 – 16.2 (actual gear stage).
All parameters sets must be assigned parameters according to the gear

stages of the 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”.

Spindle gear
Parameter set no. Axis Spindle stage
Standard Axis mode As specified by

0 manufacturer
Axis interpolates
1 Spindle mode 1.
with spindle (G33)
Axis interpolates Spindle mode 2.
2 with spindle (G33)
Axis interpolates Spindle mode 3.
3 with spindle (G33)
Axis interpolates
4 Spindle mode 4.
with spindle (G33)
Axis interpolates
5 Spindle mode 5.
with spindle (G33)
Fig. 12-15 Validity of parameter sets for axis and spindle modes
Machine data The following machine data of a machine axis depend on the parameter set:
n = parameter set number (0 ... 5)
Table 12-32 Parameter-set-dependent machine data

ence
Axis/spindlespecific ($MA_ ... )
32200 POSCTRL_GAIN [n] Kv factor
32810 EQUIV_SPEEDCTRL_TIME [n] Equivalent time constant, of speed control loop for
feedforward control
32910 DYN_MATCH_TIME [n] Time constant for dynamic response adaptation
35110 GEAR_STEP_MAX_VELO[n] Maximum speed for gear change
35120 GEAR_STEP_MIN_VELO[n] Minimum speed for gear change
35130 GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed of gear stage
35140 GEAR_STEP_MIN_VELO_LIMIT[n] Minimum 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

12.5.14 Position controller
Control loops The closed-loop control of a machine consists of the cascaded closed-loop
control circuits of current controller, speed controller and position controller.
SINUMERIK 840Di sl PROFIBUS DP drive
Position reference
value from the Position Speed Current
Interpolator nset iset
controller controller controller Encoders
Motor
nact iact
Actual current value
Speed actual value
Actual position value
Fig. 12-16 Control loops
Traversing If the axis does not traverse into the desired direction, the appropriate
direction adaptation is made in
MD32100: AX_MOTION_DIR (traversing direction)

The value “–1” reverses the direction of motion.
Control direction If the control direction of the position measuring system is incorrect, it can be
adjusted with
MD32110: ENC_FEEDBACK_POL (sign of actual value)

adapted.
Servo gain To obtain high contour accuracy, a high loop gain (KV factor) of the position
controller is required. However, an excessively high KV factor causes overshoot,
instability and impermissibly high machine loads.
The maximum permissible KV factor is dependent on the dynamic response of
the drive and the mechanical system of the machine.
If “0” is entered for the loop gain factor, the position controller will be discon-
nected.

Definition of The servo gain factor is defined as the ratio of velocity in m/min and the
KV factor resulting following error in mm
Velocity [m/min]
KV =
Following error [mm]
i.e. with a Kv factor of 1 and a velocity of 1 m/min, the following error will be 1
mm.
Via
MD32200: POSCTRL_GAIN (Kv factor)

is used to specify the Kv factor of the machine axis.
Note
To adapt the input/output unit of the Kv factor selected by default to the internal
unit [1/s], the following machine data are assigned by default:
MD10230: SCALING_FACTORS_USER_DEF[9] = 16.666667

MD10220: SCALING_USER_DEF_MASK = ’H200’; (bit no 9 as hex
value).
When entering the servo gain factor it is important to check that the gain factor
of the whole position control loop is still dependent on other parameters of the
controlled system.
These factors are:
MD32260: RATED_VELO
MD32250: RATED_OUTVAL
Tacho adjustment on the speed controller
Tacho generator on drive.
Notice
Machine axis that interpolate one with another must have the same following
error at the same velocities.
This can be achieved by setting the same KV factor or dynamic response
adaptation in:
MD32900: DYN_MATCH_ENABLE
MD32910: DYN_MATCH_TIME
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.

Checking the If a KV factor is already known for a machine type in question, this can be set
loop gain and checked. For checking, reduce the acceleration of the axis in
MD32300: MAX_AX_ACCEL (axis acceleration)

to make sure that the drive does not reach its current limit when accelerating
and decelerating.
The KV factor must also be checked for high speeds of the rotary axis and
spindle (e.g. for spindle positioning, tapping).
The approach behavior at various speeds can be checked by means of a
storage oscilloscope or the HMI Advanced servo trace software. The speed
setpoint is recorded for this purpose.
nset nset
[V] [V]
”Badly” ”Well”
selected KV factor selected KV factor
t [ms] t [ms]
Fig. 12-17 Speed setpoint characteristic
No overshoots may occur while the drive is approaching the static states; this
applies to all speed ranges.
Overshoot in the The reasons for an overshoot in the control loop can be:
control loop Acceleration too high (current limit is reached)
Rise time too long (re-optimization necessary)
Mechanical backlash
Mechanical components canted
For safety reasons set the KV factor to a little less than the maximum possible
value.
The real KV factor must precisely match that set because monitoring functions
are derived from the KV factor that would otherwise respond (e.g. contour
monitoring).
Acceleration The machine axes are accelerated and decelerated with the acceleration
entered in
MD32300: MAX_AX_ACCEL (axis acceleration)
This value should allow the axes to be accelerated and positioned rapidly and
accurately while ensuring that the machine is not unduly loaded.
Default values The default values of the acceleration are in the range from 0.5 m/s2 to 2 m/s2

Checking the accel- The sign of a properly adjusted acceleration of a machine axis is acceleration
eration and positioning free from overshoot at rapid traverse rate and maximum load
(heavy workpiece).
After the acceleration has been entered, the axis is traversed rapidly and the
actual current values and current setpoint are recorded.
Note
SINAMICS
The current actual value/setpoint can be recorded using the STARTER
trace function.
SIMODRIVE
The current actual value/setpoint can be recorded using the SimoCom-U
trace function.
The online help provides more detailed information.
This recording shows whether the drive reaches the current limit. Here, the cur-
rent limit can be reached for a short time.
However, the current must be well below the current limit before the rapid tra-
verse velocity or the final position is reached.
Load changes during machining must not cause the current limit to be reached.
Excessive current during machining causes falsification of the contour. For this
reason, the acceleration value should be a little bit less than the maximum ac-
celeration value.
Machine axes can have different acceleration values, even if they interpolate
with each other.
Machine data
Table 12-33 Position control: Machine data

ence
Axis spec. ($MA_ ... )
32100 AX_MOTION_DIR[n] Travel direction
32110 ENC_FEEDBACK_POL[n] Actual value sign
32200 POSCTRL_GAIN [n] Servo gain factor
32300 MAX_AX_ACCEL[n] Axis acceleration
32900 DYN_MATCH_ENABLE[n] Dynamic response adaptation
32910 DYN_MATCH_TIME [n] Time constant for dynamic response adaptation

Section: Closed-loop control

12.5.15 Speed setpoint matching
In the case of speed setpoint comparison, the NCK is informed, which speed
setpoint corresponds to which motor speed in the drive, for parameterizing the
axial control and monitoring. Speed setpoint matching can be performed auto-
matically or manually.
Automatic Automatic speed setpoint matching can be performed for the following drives:
matching – SINAMICS S120
– SIMODRIVE 611 universal / E
If the value 0 is entered in machine data
MD32250: RATED_OUTVAL (rated output voltage) [ % ]

(default value on SINUMERIK 840Di sl), the speed setpoint is automatically
matched between the NCK and drive when the NCK is started up.
Note
If automatic speed setpoint matching fails for one axis, the following message
is output on a traverse request for this axis:
Message: “Wait, axis enable missing”
This axis and any axes that interpolate with it are not traversed.
Manual If a value not equal to 0 is entered in machine data:

matching
no automatic speed setpoint matching is performed. Speed setpoint matching
must be performed manually using the following axis-specific machine data:
MD32260: RATED_VELO (rated motor speed) [ rev/min ]
The rated motor speed entered in axis-specific machine data: MD32260:
RATED_VELO with reference to 100% must be equal to the speed evaluation
parameterized in the drive:
SINUMERIK 840Di sl NCK Drive

MD32260: RATED_VELO
* 100 = Drive-related speed evaluation
ADI4 Because ADI4 does not support acyclic services on the PROFIBUS DP, manual
speed setpoint matching must be performed.
The axis-specific machine data:
MD32260: RATED_VELO (rated motor speed) [ rev/min ]


the reference between the speed setpoint set by the NCK and the associated
output voltage at the setpoint output of the ADI4 is established (reference vol-
tage = 10 V).
SINUMERIK 840Di sl NCK ADI4

MD32260: RATED_VELO 10 V *
100
Note
The max. upper limit for the speed setpoint is set in machine data
MD36210: CTRLOUT_LIMIT (max. speed setpoint) [ % ]

Values greater than 100 % make sense in connection with ADI4 because the
DACs of the ADI4 limit the output voltage to 10 V.
Calculation of the If the motor speed required for speed setpoint matching is not known directly, it
motor speed can be calculated as follows with reference to the required axis velocity (linear
axis) or load speed (rotary axis/spindle):
Motor speed for linear axis

MD31060: DRIVE_RATIO_NUMERA
vAxis * MD31050: DRIVE_RATIO_DENOM
=
nMotor
MD31030: LEADSCREW_PITCH
Motor speed for rotary axis/spindle

MD31060: DRIVE_RATIO_NUMERA
nMotor = nLoad * MD31050: DRIVE_RATIO_DENOM
– vAxis [ mm/min ]
– MD31060: DRIVE_RATIO_NUMERA (numerator load gearbox)
– MD31050: DRIVE_RATIO_DENOM (denominator load gearbox)
– MD31030: LEADSCREW_PITCH (pitch of the ball screw) [ mm/rev ]
– nMotor [ rpm ]
– nLoad [ rpm ]

Checking of Incorrect speed setpoint matching has a negative impact on the real servo gain
matching of the axis.
To check speed setpoint matching it is necessary for a defined traverse velocity
to compare the actual following error with the desired following error that should
be set if speed setpoint matching is correct.
Traverse rate
Desired following error =
MD32200: POSCTRL_GAIN
– Desired following error [ mm ]
– Traversing velocity [ m/min ]
– MD32200: POSCTRL_GAIN (Kv factor) [ (m/min)/mm ]
The actual following error is shown in the axis-specific service data:

HMI Advanced:
Operating area switchover > Diagnosis > Service displays > Service
axis/spindle
Machine data
Table 12-34 Speed setpoint matching: Machine data

ence
32250 RATED_OUTVAL Rated output voltage G2
32260 RATED_VELO[n] Rated motor speed G2

Section: Velocities, Traversing Ranges, Accuracies

12.5.16 Drift compensation
Digital drives Digital drives are not subject to drift or compensate for it automatically.
ADI4 Because ADI4 does not support acyclic services on the PROFIBUS DP, drift
compensation must be performed manually by entering the appropriate
compensation value in the axial machine data
MD36720 DRIFT_VALUE (basic drive value)
Manual drift Manual drift compensation is performed with the axis at zero speed as follows:
compensation
Requirements
– Zero speed of the axis
– Axis enables pending
Speed-controlled axis
The drift causes constant traversing of the axis. To compensate for the drift,
the compensation value is incremented/decremented step by step depen-
ding on the direction of the drift until the axis reaches zero speed.
Position-controlled axis
The drift causes a constant following error or position setpoint 0. To com-
pensate for the drift, the compensation value is incremented/decremented
step by step depending on the direction of the drift until following error or
position setpoint = 0 is displayed.
HMI Advanced:
Operating area switchover > Diagnosis > Service displays > Service
axis/spindle
Warning
! If an axis is used for the function DSC (Direct Servo Control)
MD32640: STIFFNESS_CONTROL_ENABLE (dyn. stiffness control) = 1

drift compensation must not be enabled for that axis.
Drift compensation causes extreme speed fluctuations during switch-on/off of
the DSC function.
Machine data
Table 12-35 Drift compensation: Machine data

ence
36720 DRIFT_VALUE Basic drift value G2

12.5.17 Velocity matching (axis)
Max. axis velocity The value entered in machine data
MD32000: MAX_AX_VELO[n] (max. axis velocity)

entered value is the limit velocity up to which a machine axis can accelerate
(rapid traverse limiting). It depends on the machine and drive dynamics and the
limit frequency of actual-value acquisition.
The max. axis velocity is used for traversing in the parts program when rapid
traverse (G00) is programmed.
Depending on MD30300: IS_ROT_AX[n], the maximum linear and rotary axis
velocity must be entered in the machine data.
Rapid traverse in The value entered in machine data

JOG mode
MD32010: JOG_VELO_RAPID[n] (rapid traverse in JOG mode)
or
MD32040: JOG_REV_VELO_RAPID[n] (revolutional feedrate in JOG mode

with rapid traverse override)
is the velocity at which the machine axis traverses in JOG mode with the rapid
traverse override key actuated and with an axial feedrate override of 100%.
The entered value may not exceed the max. permissible axis velocity.
This machine data will not be used for the programmed rapid traverse G00.
Axis velocity in The value entered in machine data

JOG mode
MD32020: JOG_VELO[n] (axis velocity in JOG mode) or
MD32050: JOG_REV_VELO[n] (revolutional feedrate in JOG mode)
is the velocity at which the machine axis traverses in JOG mode with an axial
feedrate override of 100%.
The velocity defined in MD32020: JOG_VELO[n] or MD32050:
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

or
at revolutional feed: SD41120: JOG_REV_SET_VELO = 0

If the above mentioned setting data are unequal to 0, the JOG velocity results
as follows:
1. SD: JOG_REV_IS_ACTIVE (revolutional feedrate in JOG mode) = 0
=> linear feed (G94)
Linear axes:
JOG velocity = SD41110: JOG_SET_VELO (JOG velocity for G94)
Rotary axes:
JOG velocity = SD41130: JOG_ROT_AX_SET_VELO (JOG velocity for
rotary axes)
2. SD: JOG_REV_IS_ACTIVE (revolutional feedrate in JOG mode) = 1
JOG velocity = SD41120: JOG_REV_SET_VELO (JOG speed with G95)

The entered value may not exceed the max. permissible axis velocity.
Notice
Depending on MD30300: IS_ROT_AX[n], the velocities have to be entered

in mm/min, inch/min, or rpm.
If the velocities change, MD36200: AX_VELO_LIMIT[n] (threshold value for

velocity monitoring) must be adapted accordingly.

Machine data
Table 12-36 Velocities: Machine data

ence
30300 IS_ROT_AX[n] Rotary axis
32000 MAX_AX_VELO[n] Maximum axis velocity G2
32010 JOG_VELO_RAPID[n] Rapid traverse in JOG mode
32020 JOG_VELO[n] JOG axis velocity
32040 JOG_REV_VELO_RAPID[n] Revolutions feedrate in JOG mode with rapid tra-
verse override
32050 JOG_REV_VELO[n] Revolutional feedrate in JOG mode
32060 POS_AX_VELO[n] Initial setting for positioning axis velocity P2
32250 RATED_OUTVAL Rated output voltage
32260 RATED_VELO[n] Rated motor speed
Setting data
Table 12-37 Velocities: Setting data

ence
General ($SN_ ...)
41100 JOG_REV_IS_ACTIVE Revolutional feedrate in JOG mode active
41110 JOG_SET_VELO JOG velocity for linear axes (for G94)
41120 JOG_REV_SET_VELO JOG velocity (for G95)
41130 JOG_ROT_AX_SET_VELO JOG speed for rotary axes
41200 JOG_SPIND_SET_VELO JOG velocity for the spindle

Section: Velocities, Traversing Ranges, Accuracies
/FB/ Description of Functions - Extended Functions,

H1Jog with/without Handwheel

12.5.18 Monitoring functions (axis)
Static monitoring The static monitoring functions with reference to a machine axis are:
functions
Exact stop coarse Window around the setpoint position within which exact stop coarse is detected.
MD36000: STOP_LIMIT_COARSE (exact stop coarse)

IS: DB31,... DBX60.6 (Position reached with exact stop coarse)
Exact stop fine Window around the setpoint position within which exact stop fine is detected.
MD36010: STOP_LIMIT_FINE (exact stop fine)

IS: DB31,... DBX60.7 (Position reached with exact stop coarse)
Delay time Delay time after which the actual value must have reached the tolerance
Exact stop fine window “Exact stop fine” when the setpoint position is reached.
MD36020: POSITIONING_TIME (delay time exact stop fine)

Interrupt: “25080 Positioning monitoring” and follow-up mode.
Zero speed Position tolerance which a standing machine axis may not leave.
tolerance
MD36030: STANDSTILL_POS_TOL (zero speed tolerance)
Interrupt: “25040 Zero speed control” and follow-up mode.
Delay time Delay time after which the actual value must have reached the tolerance
Zero-speed window “Zero speed tolerance” when the setpoint position is reached.
monitoring
MD36040: STANDSTILL_DELAY_TIME (delay time zero speed control)
Interrupt: “25040 Zero speed control” and follow-up mode.
Clamping tolerance Tolerance window for a standing machine axis while the signal “Clamping
active” is present at the PLC interface.
MD36050: CLAMP_POS_TOL (clamping tolerance)

IS: DB31,... DBX2.3 (clamping active)
Interrupt: “26000 Clamping monitoring”

S IS: “Exact stop coarse”
IS: “Exact stop fine”

Actual value
IS: “Clamping active”
CLAMP_POS_TOL
Setpoint
STANDSTILL_POS_TOL
STOP_LIMIT_COARSE
STOP_LIMIT_FINE
Time t
STANDSTILL_
DELAY_TIME
POSITIONING_TIME
Fig. 12-18 Static monitoring functions
Working area The permissible working area of the machine axes can be adapted to the partic-
limitation ular machining situation using the “dynamic” working area limitation.
SD43400: WORKAREA_PLUS_ENABLE (working area limitation active in

the positive direction)
SD43410: WORKAREA_PLUS_ENABLE (working area limitation active in

the negative direction)
SD43420: WORKAREA_LIMIT_PLUS (working area limitation plus)

SD43430: WORKAREA_LIMIT_MINUS (working area limitation minus)
Alarm: “10630 Axis reaching operating range limit +/-”
Alarm: “10631 Axis is at operating range limit +/– (JOG)”
Alarm: “10730 Progr. end point is behind working area limitation +/–”
Software limit switch Two software limit switch pairs are provided per machine axis. The active soft-
ware limit switch pair is selected in the PLC.
MD36100: POS_LIMIT_MINUS (1st software limit switch minus)

MD36110: POS_LIMIT_PLUS (1st software limit switch plus)
MD36120: POS_LIMIT_MINUS2 (2nd software limit switch minus)
MD36130: POS_LIMIT_PLUS2 (2nd software limit switch plus)

IS: DB31,... DBX12.2 (2nd software limit switch minus)

IS: DB31,... DBX12.3 (2nd software limit switch plus)
Interrupt: “10620 Axis reaching software limit switch +/–”
Interrupt: “10621 Axis is at software limit switch +/– (JOG)”
Interrupt: “10720 Progr. end point is behind software limit switch +/–”
Notice
All position monitoring functions are only active with valid reference point of the
corresponding reference point of the machine axis.
Hardware jimit If the PLC signals that a hardware limit switch has been reached, the machine
switch axis is stopped with the parameterized brake response.
IS: DB31, ... DBX12.1 (Hardware limit switch plus)

IS: DB31, ... DBX12.0 (Hardware limit switch minus)
MD36600: BRAKE_MODE_CHOICE (brake response at the hardware limit
switches)
0 = brake characteristic is observed
1 = rapid deceleration with setpoint “0”
Interrupt: “21614 hardware limit switch [+/–]”
EMERGENCY STOP
Working 2. software 1. software Hardware

area limit switch limit switch limit switch
limitation plus plus plus
plus (activated in PLC) Mechanical
traversing end
plus
Fig. 12-19 Overview of end limitations
Dynamic The dynamic monitoring functions with reference to a machine axis are:
monitoring
functions
Speed setpoint The speed setpoint monitoring prevents that the max. admissible motor speed
monitoring is exceeded.
It must be set such that the max. speed (rapid traverse) can be reached and, in
addition, a certain control margin remains.

MD36210: CTRLOUT_LIMIT[n] (maximum speed setpoint in %)
SIMODRIVE 611 The max. permissible motor speed is specified in P1401:0 “Speed for max.
universal useful motor speed” of the SIMODRIVE 611 universal assigned to the machine
axis.
SIMODRIVE 611 MD36210: CTRLOUT_LIMIT[n] corresponds to P1405:0 “Monitoring speed of

universal motor” of the SIMODRIVE 611 universal assigned to the machine axis.
Speed setpoint [ %]
100% MD36210: CTRLOUT_LIMIT[n]
e.g. MD36210: CTRLOUT_LIMIT[n+1]

80% (for test mode)
Fig. 12-20 Speed setpoint limitation
With
MD36220: CTRLOUT_LIMIT_TIME[n] (delay time for speed setpoint

monitoring)
defines how long the speed setpoint may remain within the limits before the
speed setpoint monitoring responses.
Error response
Alarm: “25060 Speed setpoint limiting”

and stopping the machine axis using a speed setpoint ramp whose
characteristic is set in
MD36610: AX_EMERGENCY_STOP_TIME (Time for braking ramp when

an error occurs).
A control loop or drive error is present.

Too high setpoint specifications (accelerations, velocities, reducing
factors)
Obstacle in work area (e.g. positioning on a working table)

=> Remove obstacle.
The speed setpoint consists of the speed setpoint of the position controller and
the feedforward control parameter (if feedforward control is active).

Feedforward control value
+ to
KV speed
Following controller
error
Speed
setpoint
Position controller monitoring
Fig. 12-21 Speed setpoint calculation
Notice
The limitation of the speed setpoint will turn the control loop into a nonlinear
control loop.
Generally, this will result in deviations from the contour and longer dwelling of
the machine axis within the speed setpoint limitation.
Actual velocity Monitoring due to the actual velocity of the machine axis determined based on
monitoring the encoder values
MD36020: AX_VELO_LIMIT (threshold value for velocity monitoring)

Error response
Interrupt: “25030 Alarm limit of actual velocity”


an error occurs).
Check speed setpoint cable

Check actual values
Check position control direction (control sense)
Threshold value for velocity monitoring is possibly too low.
Contour 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”


an error occurs).
Contour errors are due to signal distortions in the position-control loop.
Remedy:
Increase the tolerance band

Check the Kv factor.
The real servo gain must correspond to the desired servo gain set by
MD32200: POSCTRL_GAIN[n](Kv factor).
HMI-Advanced
Operating area DIAGNOSIS > Service displays > Service of axis
Check optimization of the speed controller

Check smooth running of the axes
Check machine data for traversing movements
(feed override, acceleration, max. speeds, ...)
for operation with feedforward control:

MD32810: EQUIV_SPEEDCTRL_TIME (equivalent time constant of speed
control loop for feedforward control)
If the machines are set too inexactly,
MD 36400: CONTOUR_TOL must be increased.
Encoder Monitoring of the limit frequency of the encoder of a machine axis.

limit frequency
monitoring
MD36300: ENC_FREQ_LIMIT (encoder limit frequency)
Error response
Interrupt: “21610 Encoder frequency exceeded”

IS: DB31, ... DBX60.2 “Encoder limit frequency exceeded 1”
IS: DB31, ... DBX60.3 “Encoder limit frequency exceeded 2”

an error occurs).
The position control resumes automatically after the axes have stopped.
Notice
The axis affected must be rereferenced.

Encoder zero mark The zero mark monitoring of the encoder of a machine axis checks whether
monitoring pulses were lost between two zero mark passes. Via
MD36310: ENC_ZERO_MONITORING (zero mark monitoring)

is used to enter the number of detected zero mark errors at which the
monitoring is to respond.
Special feature:
A value of 100 will additionally disable the hardware monitoring of the encoder.
Error response
Interrupt: “25020 Zero mark monitoring”


an error occurs).
MD36300: ENC_FREQ_LIMIT [n] (encoder limit frequency) set too high.

Encoder cable damaged.
Encoder or encoder electronics defective.
Position tolerance It is possible to switch over between the two possible encoders or position
when switching over measuring systems of a machine axis at any time. The permissible position
the encoder difference between the two position measuring systems is monitored.
MD36500 ENC_CHANGE_TOL (Max. tolerance on position actual value

switchover)
Error response
Interrupt: “25100 Measuring system cannot be switched over”

The requested switchover to another encoder is not carried out.
The specified permissible tolerance is too small.

The measuring system to which you will switch over is not referenced.
Continue monitoring The position difference between the two encoders or position measuring
of the encoder systems of a machine axis is monitored with:
position tolerance
MD36510 ENC_DIFF_TOL (measuring system synchronism tolerance)
Error response
Interrupt: “25105 Measuring systems are not synchronous”



an error occurs).
AX_EMERGENCY_STOP_TIME
Setpoints from Setpoint Braking Speed

processing Pos. ramp setpoint
Interpolator
controller
CTRLOUT_LIMIT
Control loop
model
PROFIBUS
DP drive
ENC_CHANGE_TOL
CONTOUR_TOL ENC_DIFF_TOL ENC_ZERO_MONITORING
ENC_FREQ_LIMIT
Following error
Act. val. processing 1
STSTILL_VELO_TOL
STOP_LIMIT_COURSE
STOP_LIMIT_FINE AX_VELO_LIMIT Act. val. processing 2
POSITIONING_TIME
STAND- IS “Position measuring system 1/2 active”
STILL_DELAY_TIME
STANDSTILL_POS_TOL
CLAMP_POS_TOL
Fig. 12-22 Monitoring for SINUMERIK 840Di sl
Notice
MD36620: SERVO_DISABLE_DELAY_TIME (servo enable cutout delay)

must always be selected greater than

an error occurs)
If this is not the case, the braking ramp cannot be kept.

A3 Axis Monitoring, Protection Zones

12.5.19 Referencing an axis
Homing When referencing a machine axis, the actual position value system of the ma-
chine axis is synchronized with the machine geometry. Depending on the en-
coder type used, the machine axis is referenced with or without traversing
movements.
Reference point For all machine axes which are not equipped with an encoder providing an ab-
approach solute actual position value, referencing is carried out by traversing the machine
axis, the so-called reference point approach.
The reference point approach can be carried out either manually in JOG mode,
submode REF or using a parts program. Reference point approach is started
using traverse direction keys PLUS or MINUS (depending on the parameterized
reference point approach direction).
Incremental With incremental measuring systems, referencing is carried out using a

measuring reference point approach divided into 3 phases:
systems 1. Traversing to the reference cam
2. Synchronizing to the encoder zero marker
3. Approach reference point
IS “Approach ref. point delay”

(DB31, ... DBX12.7)
IS “Travel command plus”

(DB31, ... DBX64.7)
IS “Travel command minus”

(DB31, ... DBX64.6)
IS “Travel command plus/minus”

(DB31, ... DBX4.7 and 4.6)
IS “Referenced/synchronized”
(DB31, ... DBX60.4 and 60.5)
Zero-mark positioning
measurement system
Velocity
MD34020: REFP_VELO_SEARCH_CAM
Reference-point approach velocity
MD34070: REFP_VELO_POS
Reference-point positioning velocity
MD34040: REFP_VELO_SEARCH_MARKER
Reference-point shutdown velocity
t
Phase 1 Phase 2 Phase 3
Fig. 12-23 Signal chart: Referencing with an incremental measuring system (principle)

Phase-independent The following machine data and interface signals are independent with re-
data spect to the individual phases of reference point approach:
MD11300: JOG_INC_MODE_LEVELTRIGGRD (INC/REF in jog mode)

MD34000: REFP_CAM_IS_ACTIVE (axis with reference cam)
MD34110: REFP_CYCLE_NR (axis sequence for channel-specific refer-
ence point approach)
MD30240: ENC_TYPE (encoder type)
MD34200: ENC_REFP_MODE (referencing mode)
IS: DB21, ... DBX1.0 (“Activate referencing”)
IS: DB21, ... DBX33.0 (“Referencing active”)
Phase 1: The following machine data and interface signals are important:
Traversing to the
MD34010: REFP_CAM_DIR_IS_MINUS (approach reference cam in
reference cam
negative direction)
MD34020: REFP_VELO_SEARCH_CAM (reference cam approach velocity)
MD34030: REFP_MAX_MARKER_DIST (maximum distance to reference
cam)
MD34092: REFP_CAM_SHIFT (electr. cam offset, incremental measuring

systems with equidistant zero markers)
IS: DB21, ... DBX36.2 (“all axes with obligatory reference point are refer-
enced”)
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”)
Properties of phase 1:
The feedrate override (feedrate switch) is active.
The feed stop (channelspecific and axisspecific) is active.
The machine axis can be stopped and restarted with NC stop/NC start.
If the machine axis traverses a distance defined in
– MD34030: REFP_MAX_CAM_DIST (max. distance to the
reference cam)
without reaching the reference cam
– IS: DB31, ... DBX12.7 (“Reference point approach delayed”) = 0
the axis stops, and
– alarm 20000 “Reference cam not reached”
is output.

Warning
! If the reference cam is not calibrated exactly, it is possible that a wrong zero
marker is evaluated after the reference cam has been left. As a result, the
control system will take a wrong machine zero.
Software limit switches, protection areas and work area limits will thus also be
active for the wrong positions. The difference is equivalent to one encoder
revolution in each case.
Danger for man and machine exists.
Synchronizing to the
MD34040: REFP_VELO_SEARCH_MARKER (creep velocity)
encoder zero marker
MD34050: REFP_SEARCH_MARKER_REVERSE (direction reversal to
reference cam)
MD34060: REFP_MAX_MARKER_DIST (maximum distance from cam to

reference mark)
Feed override (the feed override switch) is not active.

If a feed override of 0% is selected via the feed override switch, the traverse
movement is stopped.
Feed stop (channel-specific and axis-specific) is active.
On a feed stop, the traverse movement is stopped and the following alarm
displayed:
Alarm 20005 “Reference point approach canceled”
NC-Stop/NC-Start is inactive.
If the machine axis travels as from exiting the reference cam:
IS: DB31, ... DBX12.7 (“Reference point approach delay”) = 0
a max. distance parameterized in the machine data:
MD34060: REFP_MAX_MARKER_DIST (max. distance to the reference
mark)
without the zero mark being detected, the machine axis stops and the
following alarm is displayed:
Alarm 20002 “Zero mark missing”

Traversing to the
MD34070: REFP_VELO_POS (reference point positioning velocity)
reference point
MD34080: REFP_MOVE_DIST (reference point distance to zero mark)
MD34090: REFP_MOVE_DIST_CORR (reference point offset, additive)
MD34100: REFP_SET_POS (reference point value)
IS: DB31, ... DBX2.4, 2.5, 2.6, 2.7 (“reference point value 1...4”)
IS: DB31, ... DBX60.4, DBX60.5 (“referenced/synchronized 1, 2”)
Feed override (the feed override switch) is active.

Feed stop (channel-specific and axis-specific) is active.
NC-Stop/NC-Start are active.
Literature /FB1/ Description of Functions, Basic Machine,

R1 Reference point approach
Section: Referencing with incremental measurement systems

Distance-coded When clearance-coded reference marks are used, referencing is divided into 2
reference marks phases:
1. Synchronize by overriding 2 reference marks
2. Traverse to target point
IS “Approach ref. point delay”

(DB31, ... DBX12.7)
IS “Travel command minus”

(DB31, ... DBX64.6)
IS “Travel command plus/minus”

(DB31, ... DBX4.7 and 4.6)
IS Referenced/synchronized”
(DB31, ... DBX60.4 and 60.5)
Reference mark length measuring system
Velocity
MD34070: REFP_VELO_POS
(Reference-point positioning velocity)
MD34040:
REFP_VELO_SEARCH_MARKER
(Reference-point shutdown velocity) t
Phase 1 Phase 2
Fig. 12-24 Signal chart: Distance-coded reference marks (principle)
Phase-independent The following machine data and interface signals are independent with re-
data spect to the individual phases of reference point approach:
MD11300: JOG_INC_MODE_LEVELTRIGGRD (INC/REF in jog mode)

MD34000: REFP_CAM_IS_ACTIVE (axis with reference cam)
MD34110: REFP_CYCLE_NR (axis sequence for channel-specific refer-
ence point approach)
MD30240: ENC_TYPE (encoder type)

MD34200: ENC_REFP_MODE (referencing mode)
MD34310: ENC_MARKER_INC (interval between two reference marks)
MD34320: ENC_INVERS (inverse measuring system)
IS: DB21, ... DBX1.0 (“Activate referencing”)
IS: DB21, ... DBX33.0 (“Referencing active”)

Synchronize by
overriding 2 reference
MD34010: REFP_CAM_DIR_IS_MINUS (approach reference cam in
negative direction)
marks
MD34040: REFP_VELO_SEARCH_MARKER (referencing velocity)
MD34060: REFP_MAX_MARKER_DIST (maximum distance between 2
reference marks)
MD34300: ENC_REFP_MARKER_DIST (reference marker distance)

IS: DB21 .. 30, 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”)
Properties of phase 1
If the machine axis traverses a distance defined in MD

– MD34300: REFP_MARKER_DIST (max. distance to the reference
mark)
without overtraveling the two reference marks, the machine axis stops and
– alarm 20004 “Reference mark missing”
is output.
Traversing to the target
point
MD34070: REFP_VELO_POS (reference point positioning velocity)
MD34090: REFP_MOVE_DIST_CORR (absolute offset)
MD34100: REFP_SET_POS (target point)
MD34330: REFP_STOP_AT_ABS_MARKER (with/without target point)
Properties of phase 2
The feedrate override (feedrate switch) is active.
The feed stop (channelspecific and axisspecific) is active.
The machine axis can be stopped and restarted with NC stop/NC start.
Determining the To determine the absolute offset between the measuring system zero point and
absolute offset the machine zero, the following procedure is recommended:
1. Determining the actual position of the measuring system
After two reference marks following one after the other (synchronized) have
been overtraveled, the actual position of the length measuring system can
be read on the user interface at “Actual position”.
The absolute offset must be zero at this time:
MD34090: REFP_MOVE_DIST_CORR = 0

2. Determine the absolute machine actual position

Determining the absolute machine actual position, e.g., can be performed by
traversing the machine axis to a known position (fixed stop). Or it can be
measured at any position (laser interferometer).
3. Calculate the absolute offset
– Linear measurement system noninverse to machine system:
Absolute offset = machine actual position + actual position of
the measuring system
– Linear measurement system inverse to machine system:
Absolute offset = machine actual position – actual position of
the measuring system
MD34090: REFP_MOVE_DIST_CORR (reference point/absolute offset)
Warning
! After you have determined the absolute offset and made an entry in
MD34090: REFP_MOVE_DIST_CORR (absolute offset)
the position measuring system must be re-referenced.

Section: Referencing on linear measuring systems with
distance-coded reference marks

Absolute encoder Initial referencing of the measuring system of a machine axis with absolute
value encoder is performed by calibrating the encoder.
Follow-up Follow-up referencing of a machine axis is performed automatically during NCK

referencing booting without axis movement. The following conditions must be fulfilled:
The machine axis measuring system which is active after the NCK has
booted works with the absolute value encoder.
The absolute encoder is calibrated:

MD34210: ENC_REFP_STATE[n] = 2 (absolute value encoder is calibrated)
Calibration To calibrate the the absolute encoder, the actual value of the encoder is
matched with the machine zero once and then enabled.
The SINUMERIK 840D sl supports the following types of calibration:
Operator-assisted calibration
Automatic calibration using probe
Calibration using reference cam
The calibration using the probe and reference cam is described in:
References: /FB/, Description of Functions, Basic Machine
Section: Automatic calibration using probe
Calibration with BERO
Operator-assisted During operator-assisted calibration, the machine axis of the absolute value
calibration encoder is move to the known machine position (reference position). The posi-
tion value of the reference position is assume by the NCK as the reference point
value.
Recommended procedure
1. Parameterization of referencing mode
MD34200: $MA_ENC_REFP_MODE[n] = 0
2. Approaching referencing position
Traversing the machine axis to the referencing position in JOG mode. Ap-
proach direction according to machine data:
MD34010: $MA_REFP_CAM_DIR_IS_MINUS (reference point ap-
proach in minus direction) (0 = positive, 1 = negative approach direction)
Notice
To avoid the actual position of the machine axis being falsified by backlash in
the drive train, reference point approach must be performed at low velocity and
always from the same direction.
3. Assumption of the reference position in the NCK

The reference position is entered in the machine data:
MD34100: $MA_REFP_SET_POS[n] (reference point value)

4. Enabling encoder calibration

Encoder calibration is performed in the machine data:
MD34210: $MA_ENC_REFP_STATE[n] = 1
5. Activate changed machine data by NCK reset.
6. Completing encoder calibration
When the NCK has started up, encoder calibration is completed in mode:
JOG > REF for the machine axis by once more pressing the direction key as
described in point 2.:
– Select JOG > REF mode
– Select machine axis
– Press traverse direction key
Note
Pressing the traverse direction key does not move the machine axis!
The NCK then calculates the reference point offset and enters it in the ma-
chine data:
MD34090: $MA_REFP_MOVE_DIST_CORR[n] (reference point offset)
To indicate that calibration has been completed, the value in the machine
data changes from 1 = enable encoder calibration to 2 = encoder calibrated:
The value from the machine data is shown as the actual position of the ma-
chine axis on the user interface:
MD34100: $MA_REFP_SET_POS[n] (reference point value)
Calibrating several For time-optimized calibration of the absolute value encoders of several ma-
absolute value chine axes, the following procedure is recommended:
encoders 1. Depending on the machine design, move all or several machine axes to
their reference position. See above: Items 1. – 4.
2. Perform an NCK reset. See above: Item 5.
3. Complete encoder calibration for all machine axes. See item 6.
Recalibration Recalibration of the absolute encoder is required after:

– Gear change between load and absolute encoder
– Set actual values (PRESETON)
– Removal/installation of the absolute value encoder
– Removal/installation of the motor with the absolute value encoder
– SRAM data loss of the NCK
– Battery failure

Notice
Since the absolute encoder must be recalibrated, the NCK only detects the
following events:
Gear change with a change in the transmission ratio
Response to zero mark monitoring (alarm 25020)
New encoder serial number after replacing the absolute encoder
The status of the absolute encoder is also reset by the NCK to 0 (encoder not
calibrated):
In all other cases, it is the sole responsibility of the user to indicate the uncali-
brated state of the absolute encoder by manually resetting the status to 0 (En-
corder not calibrated) and to repeat the calibration.

Section: Referencing with absolute value encoders
Interface signals
Table 12-38 Referencing: Interface signals

ence
Mode group-specific Signals from PLC to mode group
11, ... 0.7 Mode group RESET K1
11, ... 1.2 Machine function REF K1
Mode group-specific Signals from mode group to PLC
11, ... 5.2 Active machine function REF K1
Channel-specific Signals from PLC to channel
21, ... 1.0 Activate referencing
Channel-specific Signals from channel to PLC
21, ... 28.7 (MMC –––> PLC) REF K1
21, ... 33.0 Referencing active
21, ... 35.7 Reset K1
21, ... 36.2 All axes referenced
Axis-specific Signals from PLC to axis/spindle
31, ... 1.5 / 1.6 Position measurement system 1/Position measurement system 2 A2
31, ... 2.4–2.7 Reference point value 1 to 4
31, ... 4.6 / 4.7 Traversing keys minus / plus H1
31, ... 12.7 Reference point approach delay
Axis-specific Signals from axis/spindle to PLC
31, ... 60.4 / 60.5 Referenced, synchronized 1 / Referenced, synchronized 2
31, ... 64.6 / 64.7 Traverse command minus / plus H1
Machine data
Table 12-39 Referencing: Machine data
ence
General ($MN_ ... )
11300 JOG_INC_MODE_LEVELTRIGGRD INC/REF in jog/continuous mode H1


ence
20700 REFP_NC_START_LOCK NC start disable without reference point
30200 NUM_ENCS Number of encoders G2
30240 ENC_TYP Actual value encoder type
30242 ENC_IS_INDEPENDENT Encoder is independent G2
31122 BERO_DELAY_TIME_PLUS Reference cam delay time in plus direction S1
31123 BERO_DELAY_TIME_MINUS Reference cam delay time in minus direction S1
34000 REFP_CAM_IS_ACTIVE Axis with reference cam
34010 REFP_CAM_DIR_IS_MINUS Reference point approach in minus direction
34020 REFP_VELO_SEARCH_CAM Reference point approach velocity
34030 REFP_MAX_CAM_DIST Maximum distance to reference cam
34040 REFP_VELO_SEARCH_MARKER Reference point creep speed
34050 REFP_SEARCH_MARKER_REVERSE Direction reversal to reference cam
34060 REFP_MAX_MARKER_DIST Maximum distance to reference mark; Maximum
distance to 2 reference marks with
distance-coded scales
34070 REFP_VELO_POS Reference point start velocity
34080 REFP_MOVE_DIST Reference point distance/destination point for dis-
tancecoded system
34090 REFP_MOVE_DIST_CORR Reference point/absolute offset, distancecoded
34092 REFP_CAM_SHIFT Electronic reference cam shift for incremental mea-
surement systems with equidistant zero marks.
34100 REFP_SET_POS Reference point value
34102 REFP_SYNC_ENCS Actual value adjustment to the referencing mea-
surement system
34110 REFP_CYCLE_NR Axis sequence for channelspecific Homing
34120 REFP_BERO_LOW_ACTIVE Polarity change of BERO
34200 ENC_REFP_MODE Referencing mode
34210 ENC_REFP_STATE Status of absolute value encoder
34220 ENC_ABS_TURNS_MODULO Absolute value encoder range for rotary encoders R2
34300 ENC_REFP_MARKER_DIST Reference marker distance with distancecoded
scales
34310 ENC_MARKER_INC Interval between two reference marks with distan-
cecoded scales
34320 ENC_INVERS Linear measurement system inverse to machine
system
34330 REFP_STOP_AT_ABS_MARKER Distance-coded linear measurement system wi-
thout target point
35150 SPIND_DES_VELO_TOL Spindle speed tolerance S1
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency resynchronization
36310 ENC_ZERO_MONITORING Zero mark monitoring
30250 ACT_POS_ABS Absolute encoder position at time of deactivation.


12.5.20 Spindle basic data
The spindle mode of a machine axis is a subset of the general axis functionality.
For this reason, the machine data required to start up an axis have also to be
set for a spindle.
The machine data to parameterize a spindle are therefore to be found under the
axis-specific machine data (from MD 35000 onwards).
Notice
After the default machine data have been loaded, no spindle is defined.
Spindle definition By setting the machine data
MD30300: IS_ROT_AX (rotary axis/spindle)

MD30310: ROT_IS_MODULO (modulo conversion for rotary axis/spindle)
MD30320: DISPLAY_IS_MODULO (modulo 360 degrees display for rotary
axis/spindle)
a machine axis is declared to be an endlessly rotating rotary axis whose pro-
gramming and display is carried out modulo 360 degrees.
The machine axis is converted to a spindle by defining the spindle number x
(with x = 1, 2, ...max. number of channel axes) in machine data
MD35000: SPIND_ASSIGN_TO_MACHAX (spindle number)

The spindle number must be unambiguous within the channel axes of the
channel to which the spindle is assigned, i.e. several spindles can be defined
with spindle number 1 provided they are assigned different channels (for
assigning machine axes to channels, please refer to Subsection 12.5.1, Page
12-324).
Spindle modes The diagram below illustrates the spindle modes and possible transitions
between them.
Oscillation mode Synchronous mode
Gear Gear
change changed COUPON COUPOF
SPOS and SPOSA
Control mode Positioning mode

SPCOF
M3, M4, M5
M4145
M70 SPOS
SPOSA
SPCOF
M3, M4, M5 Axis mode Axis name
M4145
G332 G331
Rigid tapping
Fig. 12-25 Spindle modes

Default operating The machine data

mode
MD35020: SPIND_DEFAULT_MODE (spindle park position)
MD35030: SPIND_DEFAULT_ACT_MASK (effective time of spindle park
position)
can be used to define the default mode of a spindle at a defined time:
MD 35030: SPIND_DEFAULT_ACT_MASK
RESET 2
NC–START 1
Power ON 0
0 1 2 3
Axis mode
Positioning mode
Speed mode w/o pos. contr.
Standard setting Speed mode with pos. contr.
MD35020: SPIND_DEFAULT_MODE
Fig. 12-26 Default setting of spindle mode
Axis mode It is possible to switch directly from spindle mode to axis mode provided the
same drive is used for both modes.
1. Transition to axis mode by programming the spindles using their axis names
or by M70.
2. If the axis is not synchronized, e.g. position control enabled with M70, the
axis has to be referenced with G74 first. Only then does the mechanical
position match the programmed one.
3. It is switched over to the current feedforward control mode marked by the
machine data and commands FFWON and FFWOF.
Special points to be The following characteristics apply to the axis mode of a spindle:
noted
1. The feed override switch is active.
2. IS “Reset” (DB21, ... DBX7.7) does not terminate axis mode as standard.
3. The interface signals DBB16 to DBB19 and DBB82 to DBB91 in DB31, ...
are of no significance if the IS “Axis/no spindle” (DB31, ... DBX60.0) is set to
zero.
4. Axis mode can be activated in all gear steps. If the position actual value en-
coder is installed on the motor (indirect measurement system), the position-
ing and contouring accuracy can vary for the different gear stages.

5. The gear step cannot be changed when the axis mode is active. The spindle
must be switched to control mode This is done using M41 ... M45.
6. In axis mode, the machine data of the 1st parameter record (index zero) will
apply to be able to make adaptations.
Master spindle To be able to use various spindle functions, such as
Revolutional feed (G95)

Tapping with compensation chuck (G63)
Thread cutting (G33)
Dwell time in spindle revolutions (G4 S...)
in a channel, a master spindle has to be defined in the corresponding channel:
MD20090: SPIND_DEF_MASTER_SPIND (master spindle initial setting in

channel)
In machine data
MD35000: SPIND_ASSIGN_TO_MACHAX (spindle number)

the defined spindle number of the spindle of the channel is entered, which will
be the master spindle.
Spindle reset Machine data
MD35040: SPIND_ACTIVE_AFTER_RESET (spindle active via reset)

defines whether the spindle is to remain active beyond
Reset (IS: DB21,... DBX7.7)

End of program (M02/M30).
To cancel spindle movements, an independent spindle reset is required:
IS: DB31,... DBX2.2 (spindle reset)

S1 Spindles

12.5.21 Setpoint/actual value channels of spindle
Parameterization of the setpoint/actual value channels of a spindle is identical

to parameterization of the setpoint and actual value channels of an axis. See
above, Subsection 12.5.4, Page 12-332.
12.5.22 Gear stages
Approval The gear stage change is generally carried out in

gear stage change
MD35010: GEAR_STEP_CHANGE_ENABLE (gear stage change possible,
spindle has several gear stages)
If the machine data is not set, the system assumes that the spindle has no gear
stages.
Parameter sets When a spindle is in Spindle mode the NCK selects the parameter set which
corresponds with the current gear stage.
Gear stage x => parameter set (x+1) => index [x]
In Axis mode of a spindle, the NCK always selects the 1st parameter set (index
[0]), independent of the current gear stage.
The machine data listed in the following are gear stage-dependent machine
data of a spindle:
MD35110: GEAR_STEP_MAX_VELO[n] (nmax for gear stage change)

MD35120: GEAR_STEP_MIN_VELO[n] (nmin for gear stage change)
MD35130: GEAR_STEP_MAX_VELO_LIMIT[n] (nmax for gear stage)
MD35140: GEAR_STEP_MIN_VELO_LIMIT[n] (nmin for gear stage)
MD35200: GEAR_STEP_SPEEDCTRL_ACCEL[n] (acceleration in
speed-control mode)
MD35210: GEAR_STEP_POSCTRL_ACCEL[n] (acceleration in position

control mode)
For further information on parameter sets, see Subsection 12.5.13, Page
12-348.

S1 Spindles
Section: Gear step change

12.5.23 Measuring systems of spindle
Encoder matching When parameterizing the measuring systems of spindles, the same conditions
apply as for parameterization of the measuring systems of rotary axes. This
multiple is 2048.
For incremental measuring systems, see above, Subsection 12.5.5, Page
12-335.
For absolute measuring systems, see above, Subsection 12.5.6, Page 12-338.
Notice
If the motor encoder is used for actual-value sensing, the encoder matching
data must be entered in the machine data for each individual gear stage if
several gear stages are present.
Pulse The maximum multiplication of the appropriate drive is always used as the
multiplication multiplication of the increments.
factor
SIMODRIVE 611 The pulse multiplication with SIMODRIVE 611 universal is 128.
universal
Examples of encoder adaptation
Example A: Supposed the following conditions are provided:

encoder on the
spindle
The incremental encoder is mounted on the spindle.
Encoder pulses = 500 [pulses/rev.]
Pulse multiplication = 128
Internal precision = 1000 [increment/degree]
Encoder gear stage = 1:1
Load gear stage = 1:1
The machine data are set acc. to the values above:
MD10210: INT_INC_PER_DEG (computational resolution) = 1,000 [incr./de-

gree]
MD31020: ENC_RESOL (encoder resolution) = 500 [pulses/rev.]

MD31050: DRIVE_AX_RATION_DENOM (load rev. denominator) = 1
MD31060: 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

Internal 360 degree MD31080 MD31050

resolution = * * * MD10210
MD31020 * pulse rev. MD31070 MD31060
Internal
360 1 1 int. increments
resolution = * * * 1000 = 5,625
500 * 128 1 1 encoder pulse
One encoder increment corresponds to 5.625 internal increments.

One encoder increment corresponds to 0.005625 degrees (highest possible
positioning resolution).
Example B: Supposed the following conditions are provided:

encoder at motor
The incremental encoder is mounted on the motor.
Encoder pulses = 2048 [pulses/rev.]
Pulse multiplication = 128
Internal precision = 1000 [increment/degree]
Encoder gear stage = 1:1
Load gear stage 1= 2.5:1 [motor rev./spindle rev.]
Load gear stage 2= 1:1 [motor rev./spindle rev.]
Gear stage 1
Internal 360 degree MD31080 MD31050

resolution = * * * MD10210
MD31020 * pulse rev. MD31070 MD31060

Internal =
* * * 1000 = 0,54932
resolution 2048 * 128 1 2,5 encoder pulse

One encoder increment corresponds to 0.00054932 degrees (highest possible
Gear stage 2

Internal =
* * * 1000 = 1,3733
resolution 2048 * 128 1 1 encoder pulse

An encoder increment corresponds to 0.0013733 degrees (highest possible

12.5.24 Speeds and setpoint adjustment for spindle
Speeds, gear In SINUMERIK 840Di sl, 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 speed for the automatic gear stage changeover.
A new set gear stage is output only if the new programmed speed cannot be
traversed in the current gear stage. For the sake of simplification, the oscillation
times for gear stage changeovers can be specified directly in the NCK; other-
wise the oscillation function must be implemented in the PLC. The oscillation
function is initiated via the PLC.
Spindle speed
(rev/min)
ÉÉÉ
Maximum spindle speed
Maximum speed of gear stage 2
Maximum speed for gear change 2
ÉÉÉ
ÉÉÉ
ÉÉÉ
Maximum speed of gear stage 1
ÉÉÉ
Maximum speed for gear change 1
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
Minimum speed for gear change 2 ÉÉÉ
ÉÉÉ
ÉÉÉ
Minimum speed for gear stage 2
Minimum speed for gear change 1
Minimum speed for gear stage 1
ÉÉÉ
Min. spindle speed
0
1 2 gear stage
Fig. 12-27 Example for speed ranges for automatic gear stage selection (M40)
Speeds for The speeds of the spindle in conventional mode are entered in the machine
conventional data:
operation
MD32010: JOG_VELO_RAPID (rapid traverse in JOG mode)
MD32020: JOG_VELO (JOG axis velocity)
The direction of rotation is specified via the appropriate directional keys for the
spindle on the MCP.
Direction of The direction of rotation of a spindle corresponds to the traversing direction of

rotation an axis.
Setpoint matching The speeds must be transferred with standardized values for the drive control-
ler. The values are scaled in the NCK using the selected load gear and the ap-
propriate drive parameter.

SIMODRIVE 611 Drive parameter P0880: PROFIBUS speed evaluation

universal
Speed n
Normalization value
P0880
4000H Speed setpoint (low resolution)

4000 0000H Speed setpoint (high resolution)
Fig. 12-28 Speed setpoint normalization
The desired speed on the spindle is obtained using a mechanical gear stage.
Machine data
Table 12-40 Speeds and setpoint adjustment for spindle: Machine data
31050 DRIVE_AX_RATIO_DENOM Denominator load gearbox G2
31060 DRIVE_AX_RATIO_NUMERA Numerator load gearbox G2
32010 JOG_VELO_RAPID Rapid traverse in JOG mode
32020 JOG_VELO JOG axis velocity
35010 GEAR_STEP_CHANGE_ENABLE Gear stage change possible
35020 SPIND_DEFAULT_MODE Basic spindle setting
35030 SPIND_DEFAULT_ACT_MASK Activate initial spindle setting
35040 SPIND_ACTIVE_AFTER_RESET Spindle active after reset
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode
35220 ACCEL_REDUCTION_SPEED_POINT Speed limit for reduced acceleration
35230 ACCEL_REDUCTION_FACTOR Reduced acceleration
35400 SPIND_OSCILL_DES_VELO Reciprocating speed
35410 SPIND_OSCILL_ACCEL Acceleration during oscillation
35430 SPIND_OSCILL_START_DIR Starting direction during oscillation
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction
Interface signals
Table 12-41 Speeds and setpoint adjustment for spindle: Interface signals
ence
31, ... 4.6 Traversing keys minus
31, ... 4.7 Traversing keys plus


31, ... 16.2–16.0 Actual gear step
31, ... 16.3 Gear changed
31, ... 16.6 No speed monitoring when changing the gear
31, ... 18.4 Oscillation via PLC
31, ... 18.5 Reciprocating speed
31, ... 82.2–82.0 Set gear step
31, ... 82.3 Change gear stage
31, ... 84.7 Active spindle control mode
31, ... 84.6 Active spindle mode oscillation mode
12.5.25 Position spindle
The NCK provides an oriented spindle stop function with which the spindle can
be moved into a certain position and held there (e.g. for tool changing pur-
poses). Several programming commands are available for this function which
define the approach and program processing.
References: /PA/ Programming Guide
S1 Spindles
Functionality
To absolute position (0–360 degrees)
Incremental position (+/– 999999.99 degrees)
Block change when position reached
Block change on block end criterion
The control brakes the spindle down to creep speed at the acceleration rate for
speed operation.
If the creep speed has been reached (INT “Spindle in setpoint range”), the con-
trol branches into position control mode and the acceleration rate for position
control mode and the KV factor become active.
The interface signal “Exact stop fine” is output to indicate that the programmed
position has been reached (block change when position reached).
The acceleration rate for position control mode must be set such that the current
limit is not reached. The acceleration rate must be entered separately for each
gear stage.
If the spindle is positioned from zero speed, it is accelerated up to a maximum
speed corresponding to creep speed; the direction is defined via machine data.
The contour monitoring function is activated as soon as the control mode
switches to position control.
Machine data
Table 12-42 Spindle positioning: Machine data

35300 SPIND_POSCTRL_VELO Shutdown speed
35350 SPIND_POSITIONING_DIR Direction of rotation when positioning from the
standstill
35210 GEAR_STEP_POSCTRL_ACCEL Acceleration in position control mode


36000 STOP_LIMIT_COARSE Exact stop coarse
36010 STOP_LIMIT_FINE Exact stop fine
32200 POSCTRL_GAIN KV factor
36400 CONTOUR_TOL Contour monitoring
Interface signals
Table 12-43 Spindle positioning: Interface signals

ence
31, ... 60.6 Position reached with exact stop “fine”
31, ... 60.7 Position reached with exact stop “coarse”
31, ... 84.5 Positioning mode
12.5.26 Synchronizing spindle
To allow the spindle to be positioned from the NCK, its position has to be ad-
justed using the measuring system. This operation is called “synchronization”.
As a rule, synchronizing is done to the zero mark of the connected encoder or
to a BERO as zero mark substitute.
Machine data
MD34100: REFP_SET_POS (reference point value)

defines the actual position of the spindle at the zero mark position.
The machine data
MD34090: REFP_MOVE_DIST_CORR (reference-point offset)

is used to enter the zero mark offset.
Machine data
MD34200 ENC_REFP_MODE (referencing mode)

specifies which signal is used for synchronization:
1 = encoder zero mark
2 = BERO
SIMODRIVE 611 The drive SIMODRIVE 611 universal supports the connection of a BERO as a
universal zero mark substitute for synchronizing the spindle.
For the exact procedure of operating a BERO on SIMODRIVE 611 universal,
see:
References: /FBU/ Descriptions of Functions SIMODRIVE 611 universal
Section: Motion Control with PROFIBUS-DP
(as from SW 3.1)
Zero mark substitute via PROFIBUS

Chuck
BERO
Gear Motor Motor
encoder
Motor en-
Power coder
connec- cable
Toothed belt
tion
Drive
Fig. 12-29 Synchronization using BERO
When is The spindle will be synchronized:

synchronization after the NCK has booted, when the spindle is moved using a programming
necessary? command
after a request to resynchronize from the PLC
NST DB31,... DBX16.4 (Resynchronize spindle 1)
NST DB31,...DBX16.5 (Resynchronize spindle 2)
after each gear stage change when an indirect measuring system is used
MD31040: ENC_IS_DIRECT (direct measuring system) = 0
when the encoder limit frequency falls below the programmed value after a
speed has been programmed which is above the encoder limit frequency.
Notice
To synchronize the spindle, it must always be rotated using a programming

command (e.g. M3, M4, SPOS). The specification of a spindle speed using
the direction keys of the machine control panel is not sufficient.
If the spindle encoder is not mounted directly on the spindle and there are
speed-transforming gears between the encoder and spindle (e.g. encoder
mounted on motor), then a BERO signal connected to the drive module
must be used for synchronization.
The control then automatically resynchronizes the spindle after each gear
change. No manual intervention is required on the part of the user.
In general, backlash, gearbox elasticity and proximity switch hysteresis re-

duce the accuracy achievable during synchronization.
Machine data
Table 12-44 Synchronizing spindle: Machine data

34100 REFP_SET_POS Reference point value
34090 REFP_MOVE_DIST_CORR Reference point offset
34200 REFP_MODE Referencing mode

Interface signals
Table 12-45 Synchronizing spindle: Interface signals

ence
31, ... 16.4 Synchronize spindle 1
31, ... 16.5 Synchronize spindle 2
31, ... 60.4 Referenced/synchronized 1
31, ... 60.5 Referenced/synchronized 2
12.5.27 Spindle monitoring
Axis/spindle at a If the actual speed entered in machine data

standstill
MD36060: STANDSTILL_VELO_TOL (maximum velocity/speed for “axis/
spindle stopped”)
falls below the programmed velocity/speed, the interface signal
IS DB31,... DBX61.4 (axis/spindle stationary)

is set. If
MD35510: SPIND_STOPPED_AT_IPO_START (feed enable for “Spindle

stopped”) is set,
the path feed is enabled.
Spindle in If the spindle reaches the tolerance range specified in machine data
set range
MD35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
interface signal
IS DB31,... DBX83.5 (spindle in setpoint range)

is set. If
MD35510: SPIND_STOPPED_AT_IPO_START (feed enable for “Spindle

stopped”) is set,
the path feed is enabled.
Max. spindle The maximum spindle speed is entered in machine data

speed
MD35100: SPIND_VELO_LIMIT (max. spindle speed)
The NCK limits the spindle speed to this value.
Error response
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”

Machine data
MD36200: AX_VELO_LIMIT (threshold value for velocity monitoring)

also limits the speed of the spindle. When the speed is exceeded, an alarm is
generated.
In position-controlled mode (e.g. SPCON), the NCK limits the specified maxi-
mum speed specified in machine or setting data to 90% of the maximum value
(control reserve).
Gear stage speed The max./min. gear stage speed is entered in:
min. / max.
MD35130: GEAR_STEP_MAX_VELO_LIMIT (maximum speed for gear
stage)
MD35140: GEAR_STEP_MIN_VELO_LIMIT (minimum speed for gear

stage)
The speed cannot leave this range when the appropriate gear stage is en-
gaged.
Progr. spindle The functions

speed limitations
G25 S... (min. spindle speed)
G26 S... (max. spindle speed)
can be used to specify a spindle speed limitation in a parts program. The limita-
tion is active in all operating modes.
The function LIMS=...
LIMS=... (speed limitation (G96))

can be used to specify a spindle speed limit for G96 (constant cutting rate). This
limitation is operative only when G96 is active.
Encoder cut-off If the encoder cut-off frequency

frequency
MD36300: ENC_FREQ_LIMIT (encoder limit frequency)
is exceeded, the synchronization of the spindle is lost and the spindle function-
ality reduced (thread, G95, G96).
The spindle will be resynchronized once the encoder frequency falls below the
value defined in machine data
MD36302: ENC_FREQ_LIMIT_LOW (encoder limit frequency at which the

encoder is turned on again).
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.

Spindle speed
Maximum encoder limit frequency
Maximum spindle speed
Maximum spindle speed for current gear stage
Programmable spindle speed limit G26
Programmable spindle speed limit LIMS
Programmable minimum spindle speed G25
Minimum spindle speed for current gear stage
Max. velocity/speed “Axis/spindle stopped”

0
with constant cutting rate G96 and G97

IS: Axis/spindle stationary (n<nmin )
Speed range of current gear stage

IS: Referenced/synchronized
limited by G25 and G26
Speed range of spindle
or spindle chuck
Fig. 12-30 Ranges of spindle monitoring functions/speeds

S1 Spindles
Section: Spindle monitoring

12.5.28 Spindle data
Machine data
Table 12-46 spindle: Machine data

ence
General ($MN_ ... )
12060 OVR_SPIND_IS_GRAY_CODE Spindle override with Gray coding V1
12070 OVR_FACTOR_SPIND_SPEED Evaluation of spindle speed override switch V1
12080 OVR_REFERENCE_IS_PROG_FEED Override reference velocity V1
20090 SPIND_DEF_MASTER_SPIND Initial setting for master spindle on channel
20092 SPIND_ASSIGN_TAB_ENABLE Enabling/disabling of spindle converter
20118 GEOAX_CHANGE_RESET Allow automatic geometry axis change
22400 S_VALUES_ACTIVE_AFTER_RESET S function active after RESET
30310 ROT_IS_MODULO Modulo conversion R2
30320 DISPLAY_IS_MODULO Position display R2
31050 DRIVE_AX_RATIO_DENOM Denominator load gearbox G2
31060 DRIVE_AX_RATIO_NUMERA Numerator load gearbox G2
31122 BERO_DELAY_TIME_PLUS Reference cam delay time in plus direction
31123 BERO_DELAY_TIME_MINUS Reference cam delay time in minus direction
32200 POSCTRL_GAIN Servo gain factor (Kv) G2
32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant speed control loop for K3
feedforward control
32910 DYN_MATCH_TIME Time constant for dynamic response G2
adaptation
34040 REFP_VELO_SEARCH_MARKER Reference point creep speed R1
34060 REFP_MAX_MARKER_DIST Monitoring of zero mark distance R1
34080 REFP_MOVE_DIST Reference point distance/destination point for R1
distancecoded system
34090 REFP_MOVE_DIST_CORR Reference point offset/absolute offset, R1
distancecoded
34100 REFP_SET_POS Reference point value R1
34200 ENC_REFP_MODE Referencing mode R1
35000 SPIND_ASSIGN_TO_MACHAX Assignment of spindle to machine axis
35010 GEAR_STEP_CHANGE_ENABLE Gear stage change possible
35012 GEAR_STEP_CHANGE_POSITION Gear stage change position
35020 SPIND_DEFAULT_MODE Basic spindle setting
35030 SPIND_DEFAULT_ACT_MASK Activate initial spindle setting
35040 SPIND_ACTIVE_AFTER_RESET Spindle active after reset
35100 SPIND_VELO_LIMIT Maximum spindle speed
35110 GEAR_STEP_MAX_VELO[n] Maximum speed for gear change
35120 GEAR_STEP_MIN_VELO[n] Minimum speed for gear change
35130 GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed of gear stage
35140 GEAR_STEP_MIN_VELO_LIMIT[n] Minimum speed of gear stage
35150 SPIND_DES_VELO_TOL Spindle speed tolerance
35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limitation via PLC
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode


ence
35210 GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode
35220 ACCEL_REDUCTION_SPEED_POINT Speed limit for reduced acceleration
35230 ACCEL_REDUCTION_FACTOR Reduced acceleration
35300 SPIND_POSCTRL_VELO
Position control activation speed
35350 SPIND_POSITIONING_DIR Positioning direction of rotation for
non-synchronized spindle
35400 SPIND_OSCILL_DES_VELO Reciprocating speed
35410 SPIND_OSCILL_ACCEL Acceleration during oscillation
35430 SPIND_OSCILL_START_DIR Starting direction during oscillation
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction
35500 SPIND_ON_SPEED_AT_IPO_START Feed enable with spindle in setpoint range
35510 SPIND_STOPPED_AT_IPO_START Feed enable with stationary spindle
35590 PARAMSET_CHANGE_ENABLE Parameter set definition possible from PLC A2
36060 STANDSTILL_VELO_TOL Threshold velocity “Axis/spindle stationary” A3
36200 AX_VELO_LIMIT Threshold value for velocity monitoring A3
Setting data
Table 12-47 Spindle: Setting data

ence
Spindlespecific ($SA_ ... )
42600 JOG_FEED_PER_REF_SOURCE Revolutional feedrate control in JOG mode V1
42800 SPIND_ASSIGN_TAB Spindle number converter
42900 MIRROR_TOOL_LENGTH Mirror tool length offset W1
42910 MIRROR_TOOL_WEAR Mirror wear values of tool length compensation W1
42920 WEAR_SIGN_CUTPOS Mirror wear values of machining plane W1
42930 WEAR_SIGN Invert sign of all wear values W1
42940 TOOL_LENGTH_CONST Retain the assignment of tool length compo- W1
nents when changing the machining plane
(G17 to G19)
43210 SPIND_MIN_VELO_G25 Progr. Spindle speed limitation G25
43220 SPIND_MAX_VELO_G26 Progr. Spindle speed limitation G26
43230 SPIND_MAX_VELO_LIMS Progr. Spindle speed limitation with G96
43300 ASSIGN_FEED_PER_REF_SOURCE Rotational feedrate for positioning V1, P2
axes/spindles
Interface signals
Table 12-48 Spindle: Interface signals

ence
31, ... 0 Feed override V1
31, ... 1.7 Override active V1
31, ... 1.6 Position measuring system 2 A2


31, ... 1.5 Position measuring system 1 A2
31, ... 1.4 Followup mode A2
31, ... 1.3 Axis/spindle disable A2
31, ... 2.2 Spindle reset/delete distancetogo A2
31, ... 2.1 Servo enable A2
31, ... 3.6 Velocity/spindle speed limitation A3
31, ... 16.7 Delete S value
31, ... 16.5 Resynchronize spindle 2
31, ... 16.4 Resynchronize spindle 1
31, ... 16.3 Gear changed
31, ... 16.2–16.0 Actual gear stage A to C
31, ... 17.6 Invert M3/M4
31, ... 17.5 Resynchronize spindle during positioning 2
31, ... 17.4 Resynchronize spindle during positioning 1
31, ... 18.7 Direction of rotation setpoint left
31, ... 18.6 Direction of rotation setpoint right
31, ... 18.5 Reciprocating speed
31, ... 18.4 Oscillation via PLC
31, ... 19.7 – 19.0 Spindle offset H – A V1
31, ... 60.7 Position reached with exact stop fine B1
31, ... 60.6 Position reached with exact stop coarse B1
31, ... 60.5 Referenced/synchronized 2 R1
31, ... 60.4 Referenced/synchronized 1 R1
31, ... 60.3 Encoder limit frequency exceeded 2 A3
31, ... 60.2 Encoder limit frequency exceeded 1 A3
31, ... 60.0 Axis/no spindle
31, ... 61.7 Current controller active A2
31, ... 61.6 Speed control loop active A2
31, ... 61.5 Position controller active A2
31, ... 61.4 Axis/spindle stationary (n < nmin) A2
31, ... 82.3 Change gear stage
31, ... 82.2–82.0 Set gear stage AC
31, ... 83.7 Actual direction of rotation clockwise
31, ... 83.5 Spindle in setpoint range
31, ... 83.2 Setpoint speed increased
31, ... 83.1 Setpoint speed limited
31, ... 83.0 Speed limit exceeded
31, ... 84.7 Active spindle control mode
31, ... 84.6 Active spindle mode oscillation mode
31, ... 84.5 Active spindle positioning mode
31, ... 84.3 Rigid tapping active
31, ... 86 and 87 M function for spindle
31, ... 88–91 S function for spindle

12.6 Digital and analog I/O devices

The following digital and analog signal modules are available:
Digital I/O modules
– MCI board extension module (option)
On the MCI board extension module (option) there are 4 digital inputs/
outputs (Section 2.3, Page 2-53).
– PP 72/48
The I/O module PP 72/48 has 72 digital inputs and 48 digital outputs
(Section 2.11, Page 2-79).
– ADI4
The ADI4 has two digital input and output bytes that are used for
ADI4-internal functions and as I/O signals at the interfaces of the module
(Section 2.12, Page 2-91).
– SIMATIC S7: ET200 modules
Via the PROFIBUS DP it is possible to connect all subtypes of SIMAT-
IC-S7 I/O modules of type ET200 (e.g. ET200M) as long as they support
a data transmission rate of 12 Mbaud.
Analog I/O modules
– SIMATIC S7: ET200 modules
See above.
Notice
The digital and analog input/outputs connected via the PROFIBUS DP are
equally available to both the NCK and PLC.
It is the sole responsibility of the user to avoid access conflicts:
On the NCK side: Parts program/synchronized action
On the PLC side: PLC user program
Literature /FB/ Description of Functions, Extended Functions,

A4 Digital and Analog NCK I/Os
12.6.1 Parameterization of the number of inputs/outputs used
Max. number The maximum number of digital or analog input/outputs that can be used for the
NCK is:
Total MCI board PROFIBUS
extension modules
Analog inputs 8 – 8
Analog outputs 8 – 8
Digital inputs 36 4 32
Digital outputs 36 4 32

Note
The first digital input and output byte is permanently assigned to the MCI board
extension module (option). Therefore you can connect a maximum of 4 addi-
tional input/output bytes to the PROFIBUS DP via signal modules. See confi-
guration example Subsection 12.6.6, Page 12-402.
Machine data The number of used analog and digital inputs/outputs is set in the following ma-
chine data parameters:
Analog I/Os
MD10300: FASTIO_ANA_NUM_INPUTS (“Number of active analog NCK
inputs”)
MD10310: FASTIO_ANA_NUM_OUTPUTS (“Number of active analog NCK
outputs”)
Digital input/outputs
MD10350: FASTIO_DIG_NUM_INPUTS (“Number of active digital NCK in-
put bytes”)
MD10360: FASTIO_DIG_NUM_OUTPUTS (“Number of active digital NCK
output bytes”)
12.6.2 Assignment of inputs/outputs to the signal modules
On the NCK side, the analog and digital inputs/outputs are assigned to the re-
spective signal modules on the PROFIBUS DP via the appropriate I/O ad-
dresses in the machine data:
Machine data Analog I/Os

MD10362: HW_ASSIGN_ANA_FASTIN[n] (“hardware assignment of exter-
nal analog inputs”), per input, where n = 0–7
MD10364: HW_ASSIGN_ANA_FASTOUT[n] (“hardware assignment of ex-
ternal analog outputs”), per output, where n = 0–7.
MD10366: HW_ASSIGN_DIG_FASTIN[n] (“hardware assignment of external
digital inputs”), per input byte, where n = 0–3
MD10368: HW_ASSIGN_DIG_FASTOUT[n] (“hardware assignment of ex-
ternal digital outputs”), per output byte, where n = 0–3
Input format
05 00 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: PROFI-
BUS I/Os)

Note
The first digital input/output bytes defined via machine data:
MD10350: FASTIO_DIG_NUM_INPUTS
MD10360: FASTIO_DIG_NUM_OUTPUTS
always refers to the 4 digital input/outputs on the MCI board extension
module. Explicit assignment in machine data is not possible. Therefore, the
machine data required to assign the digital and analog input/outputs refer
exclusively to the signal modules connected via the PROFIBUS DP.
The I/O address to be entered in the machine data hexadecimally is the

decimal I/O address of the respective signal module slot allocated by “HW
Config” or set manually.
If a slot comprises several I/O bytes or addresses, the NCK occupies the
entire slot when an I/O byte is assigned. This means I/O bits not used for
the NCK cannot be written by the PLC user program.
12.6.3 System variable $A_...[n]

The digital and analog input/outputs are available in the NCK (parts program,
ASUP, synchronized action, etc.) in the form of system variables.
Analog inputs/outputs
$A_INA[n] (“Read analog input n, where n=1...8”)
$A_OUTA[n] (“Write analog output n, where n=1...8”)
$A_IN[n] (“Read digital input (Bit) n, where n=1...4 and 9...40”)
$A_OUT[n] (“Write digital output n, where n=1...4 and 9...40”)
Hardware assign machine data System variables

Analog inputs/outputs
MD10362: HW_ASSIGN_ANA_FASTIN[ 0–7 ] $A_INA[ 1–8 ]
MD10364: HW_ASSIGN_ANA_FASTOUT[ 0–7 ] $A_OUTA[ 1–8 ]
Digital I/Os
MCI board extension: Digital inputs 1–4 $A_IN[ 1–4 ]
MD10366: HW_ASSIGN_DIG_FASTIN[ 0–3] $A_IN[ 9–40 ]
MCI board extension: Digital outputs 1–4 $A_OUT[ 1–4 ]
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

12.6.4 Digital input/output bytes and system variables
Digital inputs The following configuration example shows the relationship between digital in-
put bytes and system variables by means of the configuration of 3 digital inputs
bytes.
This configuration example requires the following:
– MCI board extension module: 1 input byte
– PROFIBUS-DP signal modules: 2 input bytes
The MCI board extension module is always assigned to a digital input byte. Di-
gital input bytes of external signal modules must therefore always be counted
as additional input bytes:
MD10350: FASTIO_DIG_NUM_INPUTS = 1 + m,
where m = number of inputs bytes of external signal modules
Because the 1st input byte is permanently assigned to the MCI board extension
module, only the input bytes of the external signal modules have to be explicitly
assigned to the system variables.
MD10366: HW_ASSIGN_DIG_FASTIN[0] –> 1st external input byte
MD10366: HW_ASSIGN_DIG_FASTIN[1] –> 2nd external input byte
MD10350: FASTIO_DIG_NUM_INPUTS = 3 = 1 + m
with: 1 –> 1st dig. input byte of the MCI board extension module
(always 1, see text)
m=2 –> 2nd and 3rd dig. input byte via PROFIBUS I/O
modules (number of input bytes used from
external signal modules)
MCI board ex. module System variable:
$A_IN[1] ... $A_IN[4]
MD10366: HW_ASSIGN_DIG_FASTIN [n]

05 00 I/O high I/O low 0 $A_IN[9] ... $A_IN[16]
05 00 I/O high I/O low 1 $A_IN[17] ... $A_IN[24]
:
:
–{
}–
n
Fig. 12-31 Configuration example: 3 digital input bytes
If the optional MCI board extension module does not exist, assignment in the
machine data must still be made as stated because the 1st input byte is inter-
nally permanently assigned to this module. System variables $A_IN[1] to
$A_IN[4] do not then contain information.
Digital outputs Digital outputs must be configured as described above for digital inputs.

12.6.5 Dynamic response

After the system variables have been set, e.g. $A_OUT[8] for setting the 8th
digital output of the NCK on a SIMATIC S7 signal module connected via the
PROFIBUS DP, the system variable is transferred from DP master to the signal
module via the PROFIBUS DP during the next position controller cycle.
The signal module will then provide the signal to the appropriate with the output
next output cycle. The PROFIBUS DP cycle and the cycle of the signal mod-
ule are not synchronized during this process.
The transmission cycle described is illustrated in Fig. 12-32, Page 12-401.
The time properties when reading in a digital or analog input are analogously to
the properties described above.
TMAPC
1
TM
NCK:
Position controller
RPos. RInterpol.
and interpolator
TDP TDX
PROFIBUS-DP MSG RES GC Dx Dx Dx MSG RES GC Dx Dx Dx

communication
DP slave: 3
R R R R R R
Signal module
Fig. 12-32 Time response when outputting an output signal with optimized DP cycle
Key to Fig. 12-32:

TMAPC Master application cycle: NCK position control cycle
The following always applies for SINUMERIK 840Di sl: TMAPC = TDP
TDX Data exchange time: Sum of transfer times of all

DP slaves

position control
GC Global control: Broadcast message for cyclic

synchronization of the equidistance between DP master
and DP slaves

R Computational time of position controller and/or signal module
MSG Acyclic services (e.g. DP/V1, pass token)
RES Reserve: “active break” until the equidistant cycle has elapsed
1
Set the system variables, e.g. $A_OUT[8] in the parts program or
synchronized action
2 Transmit the output signal to the signal module on
PROFIBUS DP
3
Connect the signal to the output of the module.
12.6.6 Configuration example

In the following configuration example, the following digital input/outputs are
available to the NCK:
ET200
– 24 digital inputs
– 16 digital outputs
ADI4
– 8 digital inputs
– 16 digital outputs
Note
The I/O addresses of the modules are assigned automatically by “HW-Con-
fig” (manual adjustment is possible).
Each I/O address refers to an input/output byte.
840Di sl (configuration) –– 840Di sl_ET200_ADI4

PROFIBUS(2): DP master system (2)
(5) IM 153 (6) ADI4

(0) UR
2 PLC317-2DP M/S 2AJ10
X2 DP master
4 CP 342–5
Fig. 12-33 Example configuration: SINUMERIK 840Di sl with ET200 and ADI4

ET200 I/Os: IM 153

Slot Module I address O address Comment
4 SM 322 DO16xDC24V/0.5A – 128...129

5 SM 322 DO32xDC24V/0.5A – 130...133
6 SM 321 DI16xDC24V/0.5A 128...129 –
7 SM 321 DI32xDC24V/0.5A 130...133 –
ADI4
Slot Module I address O address Comment
4 Drive data
5 Drive data 4288...4305 1. Axis
7 Drive data
8 Drive data
10 Drive data 4306...4323 2. Axis
11 Drive data
12 Drive data
13 Drive data 4324...4341 3. Axis
14 Drive data 4324...4341 3. Axis
15 Drive data
16 Drive data
17 Drive data 4342...4359 4. Axis
18 Drive data 4342...4359 4. Axis
19 Drive data
20 Drive data
21 Drive data 4360...3461 I word
22 Drive data 4360...4361 O word
Note:
The structure of the PROFIBUS message frame is described in Section 8.8, Page 8-217f.
Machine data Parameterization of the NCK machine data is shown below:
Number of inputs ET200

bytes 3 input bytes
ADI4
1 input byte
Note
Although only 4 input bytes are used, 5 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

Number of outputs ET200

bytes 2 output bytes
ADI4
2 output bytes
Note
Although only 4 output bytes are used, 5 must be declared. The 1st output byte
is always assigned to the MCI board extension module even if it is not
installed:
– MD10360: FASTIO_DIG_NUM_OUTPUTS = 5
Hardware The following input bytes are used by the NCK:

assignment: ET200
input bytes Both input bytes of the input module (slot 6)
– MD10366: HW_ASSIGN_DIG_FASTIN[0] = H05000080 (128D)
The 4th of the 4 input bytes of the signal module (slot 7)
ADI4
The high byte of the input word (slot 21)
– MD10366: HW_ASSIGN_DIG_FASTIN[3] = H050010E7 (4327D)
Hardware The following output bytes are used by the NCK:

assignment: ET200
output bytes The 1st output byte of the output modules (slots 4 and 5)
– MD10368: HW_ASSIGN_DIG_FASTOUT[0] = H05000080 (128D)
– MD10368: HW_ASSIGN_DIG_FASTOUT[1] = H05000082 (130D)
ADI4
Both output bytes of the output word (slot 22)
– MD10366: HW_ASSIGN_DIG_FASTOUT[2] = H050010E6 (4326D)
– MD10366: HW_ASSIGN_DIG_FASTOUT[3] = H050010E7 (4327D)

Machine data
Table 12-49 Digital and analog I/Os: Machine data

ence
General ($MN_ ... )
10300 FASTIO_ANA_NUM_INPUTS Number of active analog NCK inputs
10310 FASTIO_ANA_NUM_OUTPUTS Number of active analog NCK outputs
10320 FASTIO_ANA_INPUT_WEIGHT Weighting factor for analog NCK inputs
10330 FASTIO_ANA_OUTPUT_WEIGHT Weighting factor for analog NCK outputs
10350 FASTIO_DIG_NUM_INPUTS Number of active digital NCK input bytes
10360 FASTIO_DIG_NUM_OUTPUTS Number of active digital NCK output bytes
10362 HW_ASSIGN_ANA_FASTIN Hardware assignment of external analog NCK in-
puts
10364 HW_ASSIGN_ANA_FASTOUT Hardware assignment of external analog NCK out-
puts
10366 HW_ASSIGN_DIG_FASTIN Hardware assignment of external digital NCK in-
puts
10368 HW_ASSIGN_DIG_FASTOUT Hardware assignment of external digital NCK out-
puts
10380 HW_UPDATE_RATE_FASTIO Update rate of clock-synchronous external NCK
I/Os
10382 HW_LEAD_TIME_FASTIO Rate time for clock-synchronous external NCK
I/Os
10384 HW_CLOCKED_MODULE_MASK Clock-synchronous processing of external NCK
I/Os
10394 PLCIO_NUM_BYTES_IN Number of directly readable input bytes of the PLC
I/Os
10395 PLCIO_LOGIC_ADDRESS_IN Start address of the directly readable input bytes of
the PLC I/Os
10396 PLCIO_NUM_BYTES_OUT Number of directly writable output bytes of the PLC
I/Os
10397 PLCIO_LOGIC_ADDRESS_OUT Start address of the directly writable
output bytes of the PLC I/Os
10530 COMPAR_ASSIGN_ANA_INPUT_1 Hardware assignment of NCK analog inputs for
comparator byte 1
10531 COMPAR_ASSIGN_ANA_INPUT_2 Hardware assignment of NCK analog inputs for
comparator byte 2
10540 COMPAR_TYPE_1 Parameterization for comparator byte 1
10541 COMPAR_TYPE_2 Parameterization for comparator byte 2
21220 MULTFEED_ASSIGN_FASTIN Assignment of input bytes of NCK I/Os for “multi- V1
ple feedrates in one block”
Setting data
Table 12-50 Digital and analog I/Os: Setting data

ence
General ($SN_ ...)
41600 COMPAR_THRESHOLD_1 Threshold values for comparator byte 1
41601 COMPAR_THRESHOLD_2 Threshold values for comparator byte 2

Interface signals
Table 12-51 Digital and analog I/Os: Interface signals

DB num- Bit, byte Name Refer-
ber ence
General Signals from PLC to NCK
10 0, 122, 124, 126, 128 Disable digital NCK inputs
10 1, 123, 125, 127, 129 Setting on PLC of digital NCK inputs
10 4, 130, 134, 138, 142 Disable digital NCK outputs
10 5, 131, 135, 139, 143 Overwrite mask for digital NCK outputs
10 6, 132, 136, 140, 144 Setting value from PLC for the digital NCK outputs
10 7, 133, 137, 141, 145 Setting mask for digital NCK outputs
10 146 Disable analog NCK inputs
10 147 Setting mask for analog NCK inputs
10 148–163 Setting value from PLC for the analog NCK inputs
10 166 Overwrite mask for analog NCK outputs
10 167 Setting mask for analog NCK outputs
10 168 Disable analog NCK outputs
10 170–185 Setting value from PLC for the analog NCK outputs
Signals from NCK to PLC
10 60, 186–189 Actual value for digital NCK inputs
10 64, 190–193 Setpoint for digital NCK outputs
10 194–209 Actual value for analog NCK inputs
10 210–225 Setpoint for analog NCK outputs

12.7 Loadable compile cycles

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. Therefore, you can use compile cycles to expand the functionality of
the NCK as much as you require or redefine it as far as allowed by the inter-
faces.
Including a compile cycle in the NCK system software is performed by loading
the compile cycle into the file system of the NCK. The compile cycle can be
loaded at any time.
Siemens compile The following technological functions and more are available from Siemens as
cycles compile cycles:
– 1D/3D Distance control in the position controller cycle
References: /FB3/ Description of Functions Special Functions
Section Distance Control (TE1)
– Continue machining at the contour (Retrace Support)
References: /FB3/ Description of Functions – Special Functions
Section Retrace Support (TE7)
– Fast laser switching signal
References: /FB3/ Description of Functions – Special Functions
Section Unclocked Path-Synchronous Switching Signal
Output TE8
When you order one of the listed technological functions, you are given the cor-
responding software license number. To obtain the compile cycle in the form of
a loadable file (.ELF extension for executable and linking format), please con-
tact your regional Siemens sales partner.
Note
Compile cycles created by Siemens are options that require explicit activation
and licensing.
References: Ordering information in Catalog NC 61

12.7.1 Loading a compile cycle
Prerequisite To transfer the compile cycle to the control, the following requirements must be
met:
There is a network connection (TCP/IP) between the PCU and an external

computer (PC/PG) on which the compile cycle is located.
Storage media can be connected to the PCU (e.g. USB FlashDrive) on

which the compile cycle is saved.
Execution Perform the following operation to load one or more compile cycles into the
NCK:
1. End the active SINUMERIK user interface (e.g., HMI Advanced) and acti-
vate the SINUMERIK desktop (see Subsection 5.4.1, Page 5-117).
2. Use Windows Explorer to copy the compile cycle file (e.g. ccresu.elf) from
the external computer (PC/PG) or the CD/disk drive to the following directory
on the PCU: F:\card\oem\sinumerik\oa\
3. Trigger a NCK reset to load the compile cycles into the NCK system soft-
ware.
12.7.2 Interface version compatibility

A SINUMERIK-specific interface is used for communication between the com-
pile cycle and NCK system software. Therefore, the interface version of a
loaded compile cycle must be compatible with the interface version of the NCK
system software. Each interface version is displayed under:
Interface version of the NCK system software

HMI Advanced:
Diagnosis > Service displays > Version > NCU Version
Display (excerpt)
CC Interface Version:
@NCKOPI . . . .@Interfaces=<1st digit>.<2nd digit> . . . .
Loaded Compile Cycles:
....
Interface version of a compile cycle that has not yet been loaded
HMI Advanced (excerpt):
Services > <Medium> > Softkey: “Properties”
Display:
Contents: Loadable compile cycle
Interface: . . . . @Interfaces=<1st digit>.<2nd digit> . . . .
Interface version of a loaded compile cycle

HMI Advanced:

Display (excerpt)
@NCKOPI . . . .
<Identifier> <Version> <Date generated>
CC start address
_N_<Identifier><Version>IF<1st digit><2nd digit>_ELF . . .
Example:
_N_CLC407IF003001_ELF corresponds to interface version: 3.1
Dependencies The following dependencies exist between the interface versionsof a compile
cycle and the NCK system software:
1. Digit of the interface version number

The 1st digit of the interface version number of a compile cycle and the NCK
system software must be equal.
2. Digit of the interface version number

The 2nd digit of the interface version number of a compile cycle must be
less than or equal to the 2nd digit of the NCK system software.
Caution
If alarm 7200 is displayed after the NCK has booted, this means no compile
cycle has been loaded!
12.7.3 Software version of a compile cycle

The software version of a compile cycle is displayed under:
HMI Advanced:
Display (excerpt)
@NCKOPI . . . .
<Identifier> <Version> <Date generated>
CC start address
_N_<Identifier><Version>IF<1st digit>.<2nd digit>_ELF . . .
Code=<Address> Data=<Address> . . .
Example:
_N_CLC407IF003001_ELF corresponds to SW version: 4.7
Note
The display of code and data range start addresses of a compile cycle are pro-
vided for diagnostics purposes only and have no significance in normal opera-
tion.

12.7.4 Supplementary conditions

The following checks are performed for all loaded compile cycles when the NCK
boots:
Interface versions If the interface version of the compile cycle is incompatible with the interface
version of the NCK system software, the following alarm is displayed:
Alarm “7200 Version_conflict_with_CCNCKInterfaceVersion”.
Dependencies If one compile cycle has a functional dependency on another, and this has not
been loaded in the NCK, the following alarm is issued:
Alarm “7200 CC<name>_ELF Loader_problem_from_dFixup”
System enables If the compile cycle is not enabled in conjunction with SINUMERIK
840Di sl/840DiE sl, the following alarm is issued:
Not enabled for SINUMERIK 840Di sl
Alarm “7200 CC<name>_ELF NO_840Di”
Not enabled for SINUMERIK 840DiE sl:
Alarm “7200 CC<name>_ELF NO_EMBARGO”
Notice
If alarm “7200 . . . ” is issued after NCK booting, none of the loaded compile
cycles is active.
12.7.5 Activating and licensing technology functions
Activating and To activate the technological function loaded onto the NCK by means of the
licensing the compile cycle, the respective option must be set and licensed.
option For information about how to activate and license options, please see Section
5.6, Page 5-124.
Activating the Each loaded compile cycle generates a technological function-specific global
technological machine data:
function
$MN_CC_ACTIVE_IN_CHAN_<name>[n], where n = 0, 1
in the machine data number range 60900 to 60999.
You can activate the entire technological function in the individual channels or
individual subfunctions via the general NCK machine date mentioned above.
For a description of the machine data, please see Subsection 12.7.6, Page
12-411.
Literature The individual technological functions are described in:

/FB3/ Description of Functions Special Functions
Sections TE1 to TE8

12.7.6 Data descriptions (MD)
General machine
data
60900 + i CC_ACTIV_IN_CHAN_XXXX[n]
where i = 0. 1. 2. 3 ... where: XXXX = function identifier, n = 0 or 1
MD number n = 0: Activating the technology function in channels
n = 1: Additional functions within the technology function
Default setting: 0 Min. input limit: 0 Max. input limit: FFFF
Changes effective after RESET Protection level: 2 / 7 Units: –
Data type: UINT16 Applies as of SW 2.2
Meaning: Activating the technology function in the channels:
The technology function is activated in the channels by means of index n = 0.
Bit 0 = 1: Technology function activated in channel 1
Bit n = 1: Technology function activated in channel n+1
For more details about which channels a technological function can be activated, please
refer to the manuals below.
Additional functions within the technology function:
The MD with index n = 1 activates additional functions within the relevant technology func-
tion. See References below.
References: /FB3/ Description of Functions Special Functions TE1 – TE8.

12.8 PROFIBUS DP
12.8 PROFIBUS DP
12.8.1 Setting the parameters for the shut-down behavior

If DP slaves respond to a shutdown in the PROFIBUS communication, e.g.
NCK reset during operation, with fault conditions, you can assign parameters for
a successive shutdown of the PROFIBUS communication using the following
machine data:
MD11250 $MN_PROFIBUS_SHUTDOWN_TYPE (PROFIBUS shutdown

handling)
Note
The drives:
SINAMICS S120
SIMODRIVE 611U/UE, POSMO SI/CD/CA
can be operated in mode 0 (immediate shutdown).
12.8.2 Data descriptions (MD)
General machine
data
11250 PROFIBUS_SHUTDOWN_TYPE
MD number PROFIBUS shutdown handling
Default setting: 0 Min. input limit: 0 Max. input limit: 2
Changes effective after RESET Protection level: 2 / 7 Units: –
Data type: UINT8 Applies as of SW 2.2
Meaning: Shut-down modes of PROFIBUS DP communication:
0= PROFIBUS DP communication is shut down at the DP master end without any
warning.
1= The PROFIBUS-DP is put into status CLEAR for at least 20 cycles.
Then PROFIBUS-DP communication is deactivated.
If it is not possible to put the PROFIBUS-DP in status CLEAR, proceed as described
under 2.
Use this procedure with: SINUMERIK 840D with DP-Link module.
2= Null vales are transmitted for at least 20 clock cycles for all DP slave drives
connected to PROFIBUS DP for the following frame data:
– Control word 1
– Control word 2
PROFIBUS DP communication is then shut down.
To be used for: SINUMERIK 840Di sl in conjunction with external drives.

12.9 Initial settings
12.9 Initial settings

Concept The status of an NCK function, e.g. G codes, tool length compensation, trans-
formation, coupled motion, etc., which is taken in a certain status of a channel is
a default setting.
Channel states for which default settings can be parameterized are:
1. Power up (NCK reset), reset (channel or mode group reset) and end of parts
program
and
2. Part-program start
The default setting of an NCK function remains stored until it is explicitly
changed by operation or programming.
Initial settings The machine data:

parameter
MD20110: RESET_MODE_MASK (“Definition of the control default settings
configuration
in case of reset”)
MD20112: START_MODE_MASK (“Definition of the control default settings

in case of NC start”)
MD20150: GCODE_RESET_VALUES (“Reset position of the G groups”)

MD20152: GCODE_RESET_MODE (“G code initial setting in case of reset”)
are used to define the relevant default settings.
Table 12-52 Default settings that can be parameterized through MD
State Parameterizable through MD

Power up (POWER ON) MD20110: RESET_MODE_MASK
MD20150: GCODE_RESET_VALUES
RESET/parts program end MD20110: RESET_MODE_MASK
MD20150: GCODE_RESET_VALUES
MD20152: GCODE_RESET_MODE
Part-program start MD20112: START_MODE_MASK
MD20110: RESET_MODE_MASK

Workpiece
Section: Workpiecerelated actual value system/reset response

12.10NCK/PLC diagnostics
12.10 NCK/PLC diagnostics
12.10.1 Menu: Diagnostics
Operating path The menu of the NCK/PLC diagnostics is in the following operating path:
Operating area switchover > Diagnosis > NC/PLC Diagnosis > Diagnosis
Startup
CHAN1 JOG Ref MPF0
Channel RESET Program aborted PLC
ROV RUN-P
PLC
NCK PLC RUN
6 running
PLC
SF
STOP
NCK Reset NCK Default Data RUN-P
BATL
Acknowledge alarm 4065 BATF RUN PLC
Delete Prg.
FORCE STOP
NCK latencies
RUN PLC
200
PLC Delete Default Data
STOP
Program
BUS 1 NCK
PLC Default
s
BUS 2 Data Reset
NCK
Default Data
0
0 Time (sec) 56
>>
Diagnostics Settings
Fig. 12-34 Menu: NCK/PLC diagnostics
Group box: NCK The following functions are grouped together in the NCK group box:
NCK state
The current state of the NCK is displayed via the output field:
– 0 not started
– 1 started
– 2 initializing data
– 3 initializing data
– 4 start-up
– 5 waiting for PLC
– 6 running
– F NCK error

NCK Reset
Via the “NCK reset” button, an NCK POWER ON reset is triggered.
On a NCK POWER ON reset, all active machining operations are stopped.
Drives that are in motion are not decelerated on their acceleration ramp but
at that their current limit.
After booting, the NCK is in the reset state. Machine and user data are not
changed.
NCK Default Data

Via the “NCK reset” button, an NCK POWER ON reset is triggered followed
by NCK general reset. All active machining operations are stopped as de-
scribed under “NCK Reset”.
After start-up, the NCK is in the reset state. All machine and user data are
deleted and standard machine data are loaded.
Notice
After “NCK Default Data” has been triggered, the NCK must be started up again
or a series start-up file read in (see Chapter 16, Page 16-467).
Acknowledge alarm 4065

Via button “Acknowledge alarm 4065”:
Interrupt: “4065 Battery-backed memory has been restored from back-up

copy. (possible data loss!)”
is acknowledged and an NCK-POWER ON reset is triggered.
To acknowledge the alarm via softkey, it is first necessary to switch to the
follow-up softkey bar with the “ETC” key.
Note
Alarm 4065 is also acknowledged by NCK-POWER ON reset via “NCK Default
Data”. Then the NCK must be started up again or a series start-up file read in
(see Chapter 16, Page 16-467).
Group box: PLC The following functions are grouped together in the PLC group box:
PLC RUN-P
With the “PLC RUN-P” button, the PLC is put in the “RUN-PROGRAMMING”
state. In this operating state, changes can be made to the PLC user pro-
gram without activation of the password.
PLC RUN
With the “PLC RUN” button, the PLC is put in the “RUN” state. Only read
accesses are possible via a programming device (PG) in this mode. It is not
possible to make changes to the PLC user program until the password has
been set.

PLC STOP
With the “PLC STOP” button, the PLC is put in the STOP state. Processing
of the PLC user program has stopped and all outputs are set to substitute
values.
PLC Delete Program

The PLC is put in the STOP state with “PLC Delete Program” button and
then PLC general reset (default data) is performed. The following actions are
performed by the PLC:
1. The PLC disconnects all links.
2. The user data are deleted (data and program blocks)
3. The system data blocks (SDB) are deleted.
4. Battery-backed data are copied back into the RAM area from the PLC
after general reset.
5. The diagnostics buffer, the MPI parameters, the clock time, and the oper-
ating hours counter are not reset.
PLC default data

The PLC is put in the STOP state via the “PLC Default Data” button and
then an extended PLC general reset is performed. The actions stated above
under item 1. - 4. and those under item 5. are reset.
Status displays
The status displays, which are made to look like LEDs, indicate the follow-
ing:
SF (System Fault)
lights up on PLC system errors, such as: Hardware, programming, para-
meterizating, computing, time, battery, and communication errors.
BATL (Battery Low)

lights up if the 5 V power supply (back-up battery) falls below its permis-
sible value.
BATF (Battery Fault)

lights up on failure of the 5 V power supply (back-up battery).
FORCE
lights up if the FORCE function is active.
The FORCE function sets user variables to permanent values that can-
not be overwritten by the user program. For detailed information on this,
see the Online Help of the SIMATIC Manager STEP 7.
RUN: See Table 12-53 below.

STOP: See Table 12-53 below.
BUS 1
lights up in case of a bus/interface error on PROFIBUS (1) (interface
X101)
BUS 2
lights up in case of a bus/interface error on MPI or PROFIBUS (2) (de-
pends on configuration of interface X102)

Table 12-53 PLC operating state display by means of RUN/STOP evaluation
RUN STOP PLC operating state

On Off RUN: The PLC program is being processed.
Off On STOP: The PLC program is not being pro-
cessed. STOP can be triggered by the PLC pro-
gram, an error, or an operator input.
Flashes at 0.5 Hz On HALT: The PLC user program has been halted
(triggered by a test function)
Flashes at 2 Hz On RESTART: A PLC start-up is performed (transi-
tion from STOP to RUN). Transition to STOP
occurs on start-up abort.
Off – lit MEMORY RESET: A general reset is requested.
– 3 sec off
– lit
Off – lit MEMORY RESET: A general reset is active
– flashing at 2 Hz
for at least 3 sec
– lit
Group box: NCK The following information is grouped together in the NCK latency group box:
latency
NCK latency
The basis of the SINUMERIK 840Di sl real-time property is activation of the
NCK system software cyclically in defined time intervals.
Because the NCK and Windows XP share the available PCU processor
power, delays (latencies) may occur when invoking the NCK. If latencies are
longer than 200µs, they are considered real-time violations, as a result of
which the NCK functionality can no longer be guaranteed.
On the NCK latency display it is possible to observe the NCK’s latency be-
havior continuously for a period of 50 seconds. This can be used, for exam-
ple, ascertaining to what extent the real-time response of the NCK has been
affected after replacing or expanding hardware and/or software components.
Note
For detailed information about the real-time properties of the SINUMERIK
840Di sl, see Subsection 1.1.5, Page 1-26.

12.10.2 Menu: Settings
Operating path The menu for the SINUMERIK 840Di sl specific settings is in the following oper-
ating path:
Operating area switchover > IBN > NC/PLC Diagnosis > Settings
Startup
CHAN1 JOG Ref MPF0
Channel RESET Program aborted
ROV
Settings
Signal input for shutdown behavior

Signal source Disabled
Signal level –
Modified
Fig. 12-35 Menu: Settings
Modifying data When switching to the menu the data displayed become read-only. To change
the data, press the “Change” softkey first.
Group box: The following functions are grouped together via the “Settings” group box:
Settings
Signal input for shutdown behavior: Signal source
This selection field is for configuring the digital input used for the shutdown
signal of the UPS:
Disabled
No input signal is present.
NCK input 0...3

The shutdown signal of the UPS is connected to the configured digital
input of the MCI board extension module (See Subsection 2.3.3, Page
2-57).

Signal input for shutdown behavior: Signal level

This selection field is for configuring the level of the shutdown signal of the
UPS:
Low active
Upon detection of the low level (0) at the configured input, first the SI-
NUMERIK 840Di sl NCK / PLC and then Windows XP are closed.
High active
Upon detection of the high level (1) at the configured input, first the SI-
NUMERIK 840Di sl NCK / PLC and then Windows XP are closed.
Making changes To apply the changes you have made, press the “Accept” softkey. The message
box that is then displayed has to be acknowledged again with the “Accept” soft-
key.
The “Cancel” softkey rejects all changes and displays the original settings
again.
Startup
CHAN1 JOG Ref MPF0
ROV
Settings
Accepting user
Non-volatile the changes
memorycan lead to loss of NC user
2560data.
KB RAM / HD backed up
Make sure that this data has been stored in a series start-up file.
1. Memory
Signal settings
input for havebehavior
shutdown been changed.
Changes will not take effect until the system is rebooted.
Signal source Disabled
2. The shutdown response hasSignal
been changed.
level –
Incorrect configuration will result in loss of data if there is a power failure.
Do you really want to accept the changes?
Cancel
reuse
Fig. 12-36 Making settings
Notice
We urgently recommend creating a series start-up file before changing the data
described above. See Chapter 16, Page 16-467.

Notes

Alarm and Message Texts 13
13.1 Alarm and message texts
To enable easy adaptation of alarm and message texts to the specific require-
ments of an automation system, the alarm and message texts are stored in
freely accessible ASCII text files.
The alarm and message texts contained in the text files are used commonly by
all SINUMERIK user interfaces:
S SinuCom NC
S 840Di start-up
S HMI Advanced
By changing/modifying the texts or files or by creating new texts/files, a flexible
adaptation to the current requirements is possible.
Storing the Files containing the alarm and message texts are stored on the hard disk in
text files directory <installation path>\dh\mb.dir\.
13.1.1 Configuration file MBDDE.INI
Structure of the The alarm and message texts to be used are set in the file <installation
file MBDDE.INI path>\mmc2\mbdde.ini. For this purpose, the appropriate paths to the applica-
tion-specific standard and user files must be stored in the [Textfiles] section of
file MBDDE.INI.
Extract from 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=
UserCyk=
...

13 Alarm and Message Texts 03/2006
13.1.2 Standard text files
Default text files The standard alarm and message texts in ASCII format are stored in the
following files on the hard disk:
– MMC : <installation path>\dh\mb.dir\alm_XX.com
– NCK : <installation path>\dh\mb.dir\aln_XX.com
– PLC : <installation path>\dh\mb.dir\alp_XX.com
– ZYK : <installation path>\dh\mb.dir\alz_XX.com
– CZYK : <installation path>\dh\mb.dir\alc_XX.com
“XX” stands for the abbreviation of the appropriate language (see Table 13-1,
Page 13-423).
The standard text files should not be modified for adaptation of the alarm and
message texts. In the case of a software update, the inserted or modified user-
specific texts would be lost by overwriting the existing data. It is therefore ur-
gently recommended to store user-specific alarm and message texts in sepa-
rate user text files.
13.1.3 User text files
User text files You can replace the alarm and message texts stored in the standard text files
by your own user-specific text files or extend them.
Note
To edit the text files, any ASCII editor can be used.
When editing the text files with a different editor, make sure that they are then
stored in ASCII format.
The alarm and message texts from the user files replace the standard texts with
the same alarm and message numbers.
Texts for alarm or message numbers not contained in the standard texts are
additionally provided.
Notice
The maximum length of an alarm or message text displayed over two lines is
110 characters.
Storage path The user-specific text files must be copied with operating area:
Services into directory:
<installation path> \dh\mb.dir.

03/2006 13 Alarm and Message Texts
Language-specific Language assignment of the user-specific alarm texts is achieved via the name
nature of alarm of the text file. The appropriate code and the file extension .com are added to
texts the user file name entered in MBDDE.INI:
Table 13-1 Language codes
Language Abbreviation
German gr
English uk
French fr
Italian it
Spanish sp
Announcement in The user-specific text files that are now in the directory: <installation
the system path>\dh\mb.dir are announced to the system using an appropriate entry in the
file MBDDE.INI.
Note
To make sure that the modified file MBDDE.INI is not overwritten when the soft-
ware is updated, it is strictly recommended to store it in the intended USER
path (<installation path>\user\mbdde.ini).
Example Example of adding an additional text file MYPLC_GR.COM:
Note
If the text file MYPLC_GR.COM is created on an external PC and then read in
through the serial interface (e.g. with PCIN), the following lines must be con-
tained at the beginning of the file:
%_N_MYPLC_GR_COM
;$Path=/_N_MB_DIR
MYPLC_GR.COM: user-spec. file for user’s own German PLC alarm texts
%_N_MYPLC_GR_COM
;$Path=/_N_MB_DIR
700000 0 0 “DB2.DBX180.0 set”
700001 0 0 “Lubrication pressure missing”
....
MBDDE.INI:
[Textfiles]
UserPLC= <installation path>\dh\mb.dir\myplc_
Notice
Any modifications to alarm texts come only into effect after the appropriate user
interface has been rebooted.
When creating text files, make sure that the date and time are correctly set on
the PCU. Otherwise, the user texts may not appear on screen.

13.1.4 Syntax for alarm text files
Alarm numbers The following alarm numbers are available for the cycle, compile cycle and PLC
alarms:
Table 13-2 Alarm numbers for cycle, compile cycle and PLC alarms
Number range Description Effect Delete

60000 – 60999 Cycle
y alarms Display, NC start disable Reset
61000 – 61999 (Si
(Siemens) ) Display, NC start disable, Reset
axis/spindle standstill
62000 – 62999 Display Cancel
63000 – 64999 Reserved
65000 – 65999 Cycle
y alarms Display, NC start disable Reset
66000 – 66999 (
(user)
) Display, NC start disable, Reset
axis/spindle standstill
67000 – 67999 Display Cancel
68000 – 69000 Reserved
70000 – 79999 Compile cycle alarms
400000 – 499999 PLC alarms general
500000 – 599999 PLC alarms for channel
600000 – 699999 PLC alarms for axis and
spindle
700000 – 799999 PLC alarms for user
800000 – 899999 PLC alarms for sequence
cascades/graphs
Format of the The structure of the text file for cycle and compile cycle alarms is as follows:
text file for Table 13-3 Structure of text file for cycle alarm texts
cycle alarm texts
Alarm number Display Help ID Text or alarm number
60100 1 0 “No D number %1 is programmed”
60101 1 0 60100
... ... ... ...
65202 0 1 “Axis %2 in channel %1 is still moving”
// Alarm text file for cycles in German

P3 PLC Basic Program
Section: Lists
Alarm number List of alarm numbers
Display This number defines the alarm display type:

0: Display in alarm line
1: Display in a dialog box

Help ID The default assignment “0” means:

The help file supplied by Siemens provides a detailed description of the alarm.
A value between 1 and 9 uses an assignment entry in the MBDDE.INI file to
refer to a help file created by the user. See also Subsection 13.1.5, Page
13-426, Section: HelpContext.
Text or alarm number The associated text is given in inverted commas with the position parameters.
S Characters ” and # must not be used in alarm texts.

The % character is reserved for displaying parameters.
S If an existing text is to be used, this can be done with a reference to the

corresponding alarm. 5-digit alarm number instead of “text”.
S The alarm file can contain comment lines, these must start with “//”. The
maximum length of the alarm text is 110 characters for a 2-line display. If the
text is too long, it is truncated and the symbol “*” is added to indicate missing
text.
S Parameter “%1”: Channel number

Parameter “%2”: Block number
Format of the The ASCII file for PLC alarm texts has the following structure:
text file for
PLC alarm texts Table 13-4 Structure of text file for PLC alarm texts
Alarm Display Help ID Text Text on MMC

no.
510000 1 0 “Channel %K FDDIS all” Channel 1 FDDIS all
600124 1 0 “Feed disable axis %A” Feed disable axis 1
600224 1 0 600124 Feed disable axis 2
600324 1 0 600224 Feed disable axis 3
703210 1 1 “User Text” User Text
...
703211 1 1 “ User text%A ...” User Text
Axis 1 ...
// Alarm text file for PLC alarm

P3 PLC Basic Program
Display This number defines the alarm display type:

0: Display in alarm line
1: Display in a dialog box
Help ID 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 13.1.5, Page
13-426, Section: HelpContext.

Text or alarm number The associated text is given in inverted commas with the position parameters.
S Characters “ and # must not be used in alarm texts.

The % character is reserved for displaying parameters.
S If an existing text is to be used, this can be done with a reference to the

corresponding alarm. 6-digit alarm number instead of “text”.
S The alarm file can contain comment lines, these must start with “//”. The
maximum length of the alarm text is 110 characters for a 2-line display. If the
text is too long, it is truncated and the symbol “*” is added to indicate missing
text.
S Parameter “%K”: Channel number (2nd digit of alarm number)

Parameter “%A”: The parameter is replaced by the signal group no. (e.g.
axis no., user area no., sequence cascade no.)
Parameter “%N”: Signal number
Parameter “%Z”: Status number
13.1.5 Setting the alarm log properties
In addition to the current alarms, an alarm log showing the alarms occurred hith-
erto is displayed on the user interface in the form of a list. The properties of the
alarm list can be changed in the MBDDE.INI file.
Table 13-5 Sections of the MBDDE.INI file
Section Meaning
Interrupts General information about the alarm list:
e.g. time/date format of messages
TextFiles Path/file specification of the alarm/text files:
e.g. UserPLC = <installation path>\dh\mb.dir\myplc_
HelpContext Name and path of help files: e.g. File0 = hlp\alarm_
DEFAULTPRIO Priority of various alarm types: e.g. POWERON = 100
PROTOCOL Properties of the protocol:
e.g. file=.\proto.txt <name and path of the protocol file>)
KEYS Information about keys that can be used to delete alarms:
e.g. Cancel = +F10 <Deleting alarms with key combination
Shift+F10>
For further details of the file entries, refer to

References: /BN/ User Guide: OEM package for MMC

Section: [Alarms] The settings in this section define the following alarm list properties:
S TimeFormat
Here, the pattern is entered which is to be used for output of date and time.
It is the same as the CTime::Format of the Microsoft Foundation Classes.
S MaxNo
Defines the maximum size of the alarm list.
S ORDER
Defines the sequence in which alarms are sorted in the alarm list:
FIRST places the most recent alarms at the top of the list,
LAST places the most recent alarms at the bottom of the list.
Example Example for the section: [Alarms]

– Time format: day.month.year hour:minute:second
– 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
MaxNr=50
ORDER=FIRST
J

Notes

Axis/Spindle Dry Run 14
14.1 Prerequisites
Enabling signals must be set to allow an axis to be traversed directly from the
control:
S Drive: Parameters and terminals

S NCK: Interface signals
14.1.1 Drives: SINAMICS S120

Supply
Parameter/Terminal Meaning
p0840 ON/OFF1
p0844 1. OFF2
p0845 2. OFF2
p0852 Enable operation
X21.3 (+24 V) and X21.4 (ground) EP terminals enable (pulse enable)
Drive
Parameter/Terminal Meaning
p0840 ON/OFF1
p0844 1. OFF2
p0845 2. OFF2
p0848 1. OFF3
p0849 2. OFF3
p0852 Enable operation
X21.3 (+24 V) and X21.4 (ground) EP terminals enable (pulse enable)
p0864 Infeed enable
p1140 Ramp-function generator enable
p1141 Ramp-function generator Start
p1142 Setpoint enable
Literature SINAMICS S120 Commissioning Manual

/GH2/ Booksize Power Modules Manual
14.1.2 Drives: SIMODRIVE
Applies to the following SIMODRIVE drives:
S SIMODRIVE 611 universal/universal E

S SIMODRIVE POSMO SI, CD/CA

14 Axis/Spindle Dry Run 03/2006
14.1 Prerequisites
The following terminals must be connected:

I/RF module
Terminal Meaning
63 Pulse enable
64 Drive enable
48 DC-link start
Drive Module
Terminal Meaning
663 Pulse enable
Signal TRUE: +24 V (e.g. from terminal 9)
Literature /FBU/ SIMODRIVE 611 universal Description of Functions

/POS3/ SIMODRIVE SI/CD/CA User Manual
14.1.3 NCK/PLC interface signals

The following NCK/PLC interface signals must be set:
DB number Byte.Bit Value Meaning
31, ... 0 <> 0% Feedrate/spindle override
31, ... 1.3 FALSE Axis/spindle disable
31, ... 1.4 FALSE Followup mode
31, ... 1.5 TRUE Position measuring system 1 1)
31, ... 1.6 TRUE Position measuring system 2 1)
31, ... 1.7 TRUE Override active
31, ... 2.1 TRUE Servo enable
31, ... 2.2 FALSE Distance-to-go/Spindle reset
31, ... 4.3 FALSE Feed stop/spindle stop
31, ... 4.4 FALSE Traversing-key lock
31, ... 4.6 3) Traversing key –
31, ... 4.7 3) Traversing key +
31, ... 5.0 – 5.5 3) JOG/INC
31, ... 12.0 2) Hardware limit switch PLUS
31, ... 12.1 2) Hardware limit switch MINUS
31, ... 20.1 FALSE Rampfunction generator rapid stop
31, ... 21.7 TRUE Pulse enable
1) Alternative
2) Checking the function of the hardware limit switch and the relevant interface signals
3) Function-dependent
Literature /FB1/ Description of Functions Basic Functions

A2 Various Interface Signals and Functions

03/2006 14 Axis/Spindle Dry Run
14.2 Axis dry run
14.2 Axis dry run
– Select JOG mode

– Traverse axis using direction key – Check the enables on the drive
– Check the interface signals
– Check the machine data
MD32000-32050 Velocities
no MD36000-36620 Monitoring functions
Does the axis move? MD32110 Actual value sign
MD32250 Rated output voltage 1)1
Yes MD32260 Rated output speed
– Service display
no Check:
Is traversing direction okay?
MD32100: AX_MOTION_DIR
Yes
Specified path 10 mm
no Check:
Is path evaluation okay?
MD31000 – 31080: (encoder matching)
Yes
Traverse with
1. 1000 mm/min feedrate
2. rapid traverse
Yes 1. Interpret alarm

Alarm? 2. Check:
MD of velocity adaptation
no
no Check machine data

Following error correct? MD32200 KV factor
MD32410 Time constant of jerk limitation
Yes MD32910 Dynamic response adaptation
MD31050/31060 Load gearbox
End MD32610 Feedforward control
All MDs of velocity adaptation
Check drive parameters
P880 Speed evaluation PROFIBUS
1) Speed setpoint matching

– ADI4: MD32250 00
– SINAMICS S120: MD32250 = 0
– SIMODRIVE 611 universal/E; POSMO CD/CA, SI: MD32250 = 0

14.3 Spindle dry run
Enable spindle
(controller enable NC,
enable on drive)
Specify spindle speed

– Check the enables on the drive
– Check the interface signals
– Check the machine and setting data
MD32250 Rated output voltage 1)
MD32260 Rated output speed
Does the no MD 35100-35150 Spindle speed limitation
spindle MD 36200 AX_VELO_LIMIT
rotate? SD 41200 JOG_SPIND_SET_VELO
SD 43220 SPIND_MAX_VELO_G26
SD 43210 SPIND_MIN_VELO_G25
– Service display
Yes
Is
traversing no Check:
direction MD32100: AX_MOTION_DIR
okay?
Yes
Specified speed 100 rev/min
Actual
speed no
= Check:
Set MD31000 – 31080: (encoder matching)
speed?
Yes
IS Check machine data

“Spindle in MD 35110-35140 Speeds for gear stages
no
setpoint range” MD 35150 Spindle speed tolerance
(DB31-DBxx, Check interface signals (DB31, ...)
DBX83.5)? DBB16 Actual gear stage
DBB21 Select drive parameter set
DBB8 Set gear stage
Change over
DBB93 Active drive parameter set
gear stage Yes
All gear
no
stages tested?
1) Speed setpoint matching

– ADI4: MD32250 00
Yes – SINAMICS S120: MD32250 = 0
– SIMODRIVE 611 universal/E; POSMO CD/CA, SI: MD32250 = 0
1

03/2006 14 Axis/Spindle Dry Run
Perform no
spindle End
positioning?
Yes
Check machine data

Position MD 36000 Exact stop coarse
reached from: no MD 36010 Exact stop fine
1. high speed MD 32200 KV factor
2. zero speed MD 35210 Acceleration in position control range
Change over MD 35300 Creep speed
gear stage MD 36300 Encoder limit frequency
MD34200 Spindle synchronization
Yes MD of encoder matching
no All
gear stages
tested?
Yes
End

Notes

Drive Optimization with HMI Advanced 15
15.1 Overview
HMI Advanced offers comprehensive functions for analyzing controller action of
drives connected to a SINUMERIK 840Di sl:
S Frequency response measurements for current, speed and position control

loop
S Automatic controller setting

S Function Generator
S Circularity test
S Servo trace
Measuring The measuring functions make it possible to assess the automatic controller
functions action of the respective control loop (frequency response) by the integrated FFT
analysis (Fast Fourier Transformation) without external measuring equipment.
The measurement results are represented graphically as a Bode diagram. HMI
Advanced file functions can be used to archive the diagrams for documentation
purposes and to simplify remote diagnostics.
Circularity test The circularity test serves to analyze the contour accuracy on the quadrant tran-
sitions of circular contours achieved by means of friction compensation (con-
ventional or neural quadrant error compensation).
References: /FB/, Description of Functions
K3 Compensation
Section: Circularity test
Servo trace Servo trace provides a graphically assisted analysis of the time response of
position controller and drive data.

15 Drive Optimization with HMI Advanced 03/2006
15.2 Measuring functions
Explanation A range of measuring functions allows the time and/or frequency response of
drives and closed-loop controls to be displayed in graphic form on the screen.
For this purpose, test signals with an adjustable interval are connected to the
drives.
Measurement/ The test setpoints are adapted to the application in question by means of mea-
signal parameters surement or signal parameters, the units of which are determined by the rele-
vant measuring function or operating mode. The measurement or signal param-
eter units are subject to the following conditions:
Table 15-1 Quantity and units for measurement or signal parameters
Size Unit
Velocity Metric system:
Data in mm/min or rev/min for translation and rotation respectively
Inch system:
Data in inch/min or rev/min for translation and rotation respectively
Distance Metric system:
Data in mm or degrees for translation and rotation respectively
Inch system:
Data in mm or degrees for translation and rotation respectively
Time Specified in ms
Frequency Specified in Hz
Note
The default setting for all parameters is 0.
Preconditions for To ensure that no erroneous traversing movements due to parts programs can
starting measuring be carried out, the measuring functions have to be started in JOG mode.
functions
Caution
! When traversing movements are carried out within the framework of measuring
functions, no software limit switches and working area limitations are moni-
tored, since these are carried out in follow-up mode.
Prior to starting traversing motions, the user must therefore ensure that the
axes are positioned such that the traversing limits specified within the frame-
work of the measuring functions are sufficient to prevent collision with the ma-
chine.

03/2006 15 Drive Optimization with HMI Advanced
Starting measuring Measuring functions initiating a traversing movement are only selected using
functions the specific soft key. The actual start of the measuring function and thus of the
traversing movement is always carried out with NC START on the machine con-
trol panel.
If the main screen of the measuring function is quitted without the traversing
motion being initiated, the selection of the traversing function is canceled.
Once the traversing function has been started, the main screen can be quitted
without any affect on the traversing motion.
Note
JOG mode must be selected when measuring functions are started.
Further safety The user must ensure that when the measuring functions are used:
notices
– The EMERGENCY STOP button is always within the reach.
– No obstacles are in the traversing range.
Canceling The following events will cancel active measuring functions:

measuring
– Hardware limit switch reached
functions
– Traversing range limits exceeded
– Emergency stop
– Reset (mode group, channel)
– NC STOP
– No controller enabling command
– Canceling drive enable
– Canceling traversing enable
– Selection of parking (in position-controlled operation).
– Feed override = 0%
– Spindle override = 50%
– Change in operating mode (JOG) or operating mode JOG not selected
– Actuation of traversing keys
– Actuation of handwheel
– Alarms leading to axis shutdown

15.3 Miscellaneous functions
Interface signals: In conjunction with the measuring functions, another 2 axis-specific interface
Drive test signals are provided:
Traversing
S DB31–DBx, DBX61.0 “Drive test traversing request”
request,
Traversing enable S DB31–DBx, DBX1.0 “Drive test traversing enable”
In the PLC user program, therefore, an additional axis-specific traversing enable
command may be given in conjunction with measuring functions.
Activation The interface signals are activated from the main menu of the appropriate mea-
suring function in the group “Drive test traversing enable”. See Fig. 15-1, page
15-438.
Fig. 15-1 Main menu: Position control loop measurement
Choose the type of traversing enable function from the selection list either by
using the toggle key or by double-clicking the selection with the right-hand
mouse button:
– 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.).

– With PLC
Traversing of the axis to be measured is enabled in addition to the
interface signals typical for JOG mode depending on the interface signal.
“Drive test traversing enable”.
Toggle key
Traversing range The measuring functions have their own traversing range monitoring. With this
monitoring monitoring function the traverse range of an axis can be limited or monitored
without having to reference this axis.
The basis is the absolute axis position displayed in the “Status” group at the
time of measurement.
Activation The traversing range monitoring is activated from the main menu of the ap-
propriate measuring function in the group “Traversing range”. See Fig. 15-1,
page 15-438.
Choose the traversing range monitoring from the selection list “Monitoring” via
the Toggle key or by clicking with the right-hand mouse button on the required
monitoring type:
– Inactive
The axis is traversed without monitoring of the traversing range.
– Active
The axis is traversed with monitoring of the traversing range, depending
on the traversing range limits set:
– Upper limit
– Voltage limit

15.4 Frequency response measurements

You can measure both digital and analog drives. However, the bandwidth avail-
able for measuring is limited by the position controller or PROFIBUS cycles.
Fig. 15-2 Example: Measurement results, speed control loop, reference frequency response
Note
Additional information on the measurement functions or how to optimize the
torque/current and speed control loop can be found in:
S SINAMICS S120
Online Help for Commissioning Tool: STARTER > Contents > Diagnostics
functions
S SIMODRIVE 611 universal

Online Help for Commissioning Tool SimoCom U > Index:
– Measuring function
– Optimization of speed control loop

15.4Frequency response measurements
15.4.1 Measurement of current control loop

Functionality The current control loop only needs to be measured for diagnostic purposes if
there is a fault or if no standard data was used for the motor/power module com-
bination, and which resulted in unsatisfactory speed controller frequency re-
sponses.
Caution
The user must take special safety measures when measuring the current con-
trol loop (e.g. secure drive clamping) for hanging axes without external counter-
weight.
Operating path Operating path for measuring the current control loop: Operating area switch-
over > Start-up > Optimization / test > Current control loop
Measuring The following measurement functions are available for measuring the current
functions control loop:
Measuring type Measured variable
Reference frequency response Torque-generating. Actual current value / torque-
(downstream of the current setpoint generating. Current setpoint
filter)
Setpoint step change Measured variable 1: Torque-generating. Current
(downstream of the current setpoint setpoint
filter) Measured variable 2: Torque-generating. Actual
current value
Measurement The measurement sequence is divided into the following steps:

1. Setting the traverse range monitoring and the enable logic.
2. Selecting the measurement type
3. Setting the parameters, softkey “Measuring parameters”
4. Displaying the measurement results, softkey “Display”
Measuring parameters
S Amplitude
Magnitude of the test signal amplitude. Given in percent of the peak torque.
Values from 1 through 5% are suitable.
S Bandwidth
The frequency range analyzed with the measurement. The larger this value,
the finer the frequency resolution and the longer the measurement time. The
maximum value is given by the position control cycle (Tposition controller):
Bandwidthmax [ Hz ] = 1 / (2 * Tposition controller [ sec ])
Example:
Position control cycle: 2 ms
Bandwidthmax = 1 / ( 2 * 2*10–3 ) = 250 Hz
S Averaging
The accuracy of the measurement and measurement duration increase with
this value. A value of 20 is normally suitable.
S Settling time
This value represents the delay between recording of the measured data
and injection of the test setpoint and offset. A value of approx. 10 ms is rec-
ommended. A settling time which is too low will result in frequency response
and phase diagrams distortions.

15.4.2 Speed control loop measurement
Functionality The response characteristics for the motor measuring system are analyzed
when measuring the speed control loop. Various measurement parameter lists
are available depending on the basic measurement setting which has been se-
lected.
Operating path Operating path for measuring the speed control loop: Operating area switch-
over > Start-up > Optimization / test > Speed control loop
Measuring The following measurement functions are available for measuring the speed
Reference frequency response Speed actual value motor encoder / speed set-
(downstream of the speed setpoint point after filter
filter)
Reference frequency response Speed actual value motor encoder / speed set-
(upstream of the speed setpoint fil- point after filter
ter)
Setpoint step change Measured variable 1:
(downstream of the speed setpoint – Speed setpoint after filter
filter) – Torque actual value
Measured variable 2: Speed actual value motor
encoder
Interference frequency response Speed actual value motor encoder / torque set-
(fault downstream of the current setpoint value fct. generator
point filter)
Disturbance variable step change Measured variable 1:
(fault downstream of the current set- – Torque setpoint value fct. generator
point filter) – Torque actual value
Measured variable 2: Speed actual value motor
encoder
Speed-controlled system Speed actual value motor encoder / torque actual
(excitation downstream of the cur- value
rent setpoint filter)
Frequency response of the mechani- Speed actual value measuring system 1 / speed
cal parts 1) actual value measuring system 2
1) The machine axis in question must have both a direct and an indirect measuring
system to determine the frequency response of the mechanical parts.

2. Selecting the measuring type and measured variable
Measurement: The reference frequency response measurement determines the transmission

Reference and in- ratio of the speed controller.
terference fre- The response range should be as wide as possible and without resonance. It
quency response may be necessary to use bandstop or low-pass filters. Particular care must be
taken to prevent resonance within the speed controller limit frequency range
(stability limit approx. 200-500 Hz).
Alternatively, the interference frequency response can be recorded in order to
assess how well the control suppresses interference.

S Amplitude
This parameter determines the magnitude of the test signal amplitude. This
should give rise to only a very low speed of a few (approximately 1 to 2)
rev/min at the motor end.
S Bandwidth
The bandwidth parameter is used to set the analyzed frequency range. The
larger this value, the finer the frequency resolution and the longer the mea-
surement time. The maximum value is given by the position control cycle
(Tposition controller): Bandwidthmax [ Hz ] = 1 / (2 * Tposition controller [ sec ])
Example:
Bandwidthmax = 1 / ( 2 * 2*10–3 ) = 250 Hz
S Averaging
S Settling time
and injection of the test setpoint and offset. A value of between 0.2 and 1 s
is recommended. Do not set too low a value for the settling times or the fre-
quency response and phase diagrams will be distorted.
S Offset
The measurement requires a slight speed offset of a few motor revolutions
per minute. The offset must be set to a higher value than the amplitude.
– The offset is run up via an acceleration ramp.
– The acceleration value is defined for one
Axis: MD 32300: MAX_AX_ACCEL
Spindle: MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL
MD 35210: GEAR_STEP_POSCTRL_ACCEL
– The following applies:
Acceleration value = 0, no ramp
Acceleration value > 0, ramp active
– The actual measuring function becomes active only when the offset
value is reached.
Measurement The transient response (response to setpoint changes or disturbances) of the

setpoint/ speed control in the time range can be assessed with the step stimulation func-
disturbance step tion. The test signal is connected to the speed controller output for recording of
changes the response to disturbances.
S Amplitude
Magnitude of the setpoint or disturbance step change.
S Measurement time
The period of time recorded (maximum: 2048 speed controller cycles).
S Offset
To exclude the influence of static friction, an offset of a few motor revolutions
per minute is sufficient.

– The offset is run up via an acceleration ramp.

– The acceleration value is defined for one
Axis: MD 32300: MAX_AX_ACCEL
Spindle: MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL
MD 35210: GEAR_STEP_POSCTRL_ACCEL
– The following applies: Acceleration value = 0, no ramp
Acceleration value > 0, ramp active
– The actual measuring function becomes active only when the offset
value is reached.
S Settling time
This value represents the delay between measured data recording/setpoint
output and the injection of the offset.
Speed setpoint
Amplitude
Offset
0 Time
Settling time Measurement time
Position
characteristic
0 Time
Fig. 15-3 Setpoint course for speed control loop/step response measuring function

15.4.3 Position control measurement
Functionality This measurement function basically analyzes the response to the active posi-
tion measuring system. If the function is activated for a spindle without a posi-
tion measuring system, an alarm is displayed. Depending on the measured vari-
able selected, various measurement parameter lists are displayed.
Operating path Operating path for measuring the speed control loop: Operating area switch-
over > Start-up > Optimization / test > Speed control loop
Measuring The following measurement functions are available for measuring the position
Reference frequency response Actual position/position setpoint
Setpoint step change Measured variable 1: Position reference value
Measured variable 2:
– Position actual value
– Control deviation
– Following error
– Speed actual value
Setpoint ramp Measured variable 1: Position reference value
Measured variable 2:
– Position actual value
– Control deviation
– Following error
– Speed actual value

2. Selecting the measuring type and measured variable
Measurement: The reference frequency response measurement determines the transmission

Reference ratio of the position controller in the frequency range (active position measuring
frequency system).
response The setpoint filters, control loop gain (Kv factor) and feedforward control must be
parameterized such that resonance is avoided wherever possible over the en-
tire frequency range. In the case of dips in the frequency response, the setting
of the feedforward control balancing filters should be checked.
S Amplitude
This parameter determines the magnitude of the test signal amplitude. It
should be set to the smallest possible value (e.g. 0.01 mm).
S Bandwidth
The bandwidth parameter is used to set the analyzed frequency range. The
larger this value, the finer the frequency resolution and the longer the mea-
surement time. The maximum value is given by the position control cycle
(Tposition controller): Bandwidthmax [ Hz ] = 1 / (2 * Tposition controller [ sec ])
Example:
Bandwidthmax = 1 / ( 2 * 2*10–3 ) = 250 Hz

S Averaging
S Settling time
and injection of the test setpoint and offset. A value of between 0.2 and 1 s
is recommended. Do not set too low a value for the settling times or the fre-
quency response and phase diagrams will be distorted.
S Offset
The measurement requires a slight speed offset of a few motor revolutions
per minute. The offset must be set such that no speed zero crossings occur
at the set amplitude.
Measurement: The transient or positioning response of the position control in the time range,
Setpoint step and in particular the effect of setpoint filters, can be assessed with the step and
change and ramp stimulation functions.
setpoint ramp Possible measured variables:
S Position actual value (active position measuring system)

S Control deviation (following error)
S Amplitude
Determines the magnitude of the specified setpoint step change or ramp.
S Measurement time
This parameter determines the period of time to be recorded (maximum:
2048 position controller cycles).
S Settling time
This value represents the delay between measured data recording/test set-
point output and the injection of the offset.
S Ramp time
The position reference value is specified with the “Setpoint ramp” basic
measurement according to the set ramp time.In this case, the acceleration
limits which currently apply to the axis or spindle are effective.
A jerk-controlled motion can be set for a specific axis with:
– MD 32400 AX_JERK_ENABLE (axial jerk limitation) =1
– MD34210 AX_JERK_TIME (time constant for the axial jerk filter).
The position setpoint and the actual value of the active measuring system
are recorded in each case.
S Offset
The step is stimulated from standstill or starting from the constant traverse
speed set in this parameter.
If an offset value other than zero is input, the step change is stimulated dur-
ing traversal. For the sake of clarity, the displayed position actual value does
not include this speed offset.

Position
Amplitude
t
0
Settling time Measurement time
Ramp time
Spindle speed
Offset
t
0
Fig. 15-4 Signal chart for position setpoint/ramp measuring function
At maximum axis velocity, there is a (virtual) step change in the velocity

(continuous line).
The curves represented by the dashed line correspond to a realistic, finite
value. The offset component is excluded from the display graphic in order to
emphasize the transient processes.
Measurement: To prevent the machine mechanics from overloading, the step height is limited
Setpoint step to the value specified in the machine data during the “Setpoint step change”
change measurement.
S MD 32000 MAX_AX_VELO (maximum axis velocity)

This may result in failure to achieve the desired step height.
Measurement: With measurement “Setpoint ramp”, the following machine data influence the
Setpoint ramp measurement result:
S MD 32000 MAX_AX_VELO (max. axis velocity)

The maximum axis velocity limits the ramp slope (velocity limiter). The drive
does not reach the programmed end position (amplitude).
S MD 32300 MAX_AX_ACCEL (max. axis acceleration)

The maximum axis acceleration limits the change in speed (acceleration
limiter). This leads to “rounding” on the transitions at the beginning and end
of the ramp.
Caution
In normal cases the machine data correspond exactly with the load capacity of
the machine kinematics and should not be changed (increased) as part of the
measurements:
S MD 32000 MAX_AX_VELO (maximum axis velocity)
S MD 32300 MAX_AX_ACCEL (max. axis acceleration)

15.5 Graphic display
Display of You can have the measurement results displayed by pressing soft key Display
measurement in the relevant main menu of the measuring function after completion of mea-
results surement.
Fig. 15-5 Menu: Display of measurement with marker X = ON
Softkeys: When the softkeys X marker ON and Y marker ON are pressed, a vertical or
X marker ON horizontal red line with a circle is displayed the measurement curve.
Y marker ON The corresponding values, e.g., for damping, frequency, phase displacement,
etc. are displayed in red in the appropriate diagram.
Use the cursor keys to move the markers:
– slowly: Cursor key

– fast: Shift key + cursor key

Softkeys: If a marker is active, a 2nd line is shown in the diagram via the 2nd marker soft-
2. marker, key. These two lines define the range that you can then have displayed over the
zoom, entire display range by pressing soft key Zoom.
fullscreen The process of zooming a range (marker ON, 2nd marker, zoom) can be re-
peated as often as required until the maximum size of representation is
reached.
Use the soft key Fullscreen to switch the display of the diagrams back to their
original size.
Note
X and Y markers can be active at a time.
Soft key: Use the soft key Scale to change the scaling of the traces and of the marker
Scale ranges in the two graphs.
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. 15-6 Menu: Scaling of graphics

Softkeys: Use the Graphics ... soft key shown in Fig. 15-5, Page 15-448 to call the follow-
Graphics ... ing functions:
– Switching over the display from double to single graphics and vice versa
(this function also exists in the scaling menu Fig. 15-6, Page 15-449)
– Printing graphics
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.

15.6 Trace function
15.6 Trace function
15.6.1 Trace function properties
The trace function with a graphical user interface serves to record the time
change of data (values, signals, states, etc.) in the servo range and partially in
the range of the drives, too.
You can select measuring signals and set the measuring parameters with soft
keys and drop-down lists.
The function is operated using the mouse or keyboard.
Function The trace function offers the following features:

overview
S Four trace buffers with up to 2,048 values each
S Selection of SERVO and drive signals (in position control cycle)
S Trace/trigger signals can be set using absolute address and value masking
S Different trigger conditions to start recording
(triggering always on Trace 1)
S Both pre- and post-triggering.

S Measuring signal display.
S Selection of fixed Y scaling for each trace.
S Marker function selectable for each trace
S Expand function in the time axis
S Selective loading and saving of the measurement parameters and traces

15.6 Trace function
15.6.2 Main menu and operation
Basic display You can access the main screen of this trace function using the soft keys Area
Servo trace switchover > Start-up > Drives/servo > Servo trace.
Fig. 15-7 Main menu: Servo trace
The cursor is controlled using

If the cursor is placed on the arrow keys on the operator Toggle key
a list box, press the panel or with the mouse.
Insert key
to open the list box.
You can scroll down

by using the arrow
keys.
You accept a
value using the
input key.
Fig. 15-8 Cursor operation

15.6 Trace function
15.6.3 Parameterization
Basic screen The following settings have to be made in the basic screen
settings
– The axis/spindle to be measured
– The signal to be measured
– Measurement time
– Trigger time
– Trigger type
– Trigger threshold
Signal selection
Input field: The cursor must be positioned on the Axis/spindle name list box of the trace
Axis/spindle name concerned. You can select it with the soft keys Axis+ and Axis– or by accepting
a value from the dropdown list.
Input field: The cursor must be positioned on the Signal selection list box of the trace con-
Signal selection cerned. Then activate the desired items by selecting them from the list box.
Measuring
parameters
Input field: The measuring time is written directly into the Measuring duration input field.
Measurement time
Input field: Direct input of pretriggering or posttriggering.
Trigger time With negative input values (leading sign minus –) recording begins at the set
time before the trigger event.
With positive input values (without sign) recording starts
the time set after the triggering event.
Condition: Trigger time + measuring period y 0.
Input field: You can select the trigger type from the Trigger drop-down list.
Trigger The trigger always refers to Trace 1. If the trigger conditions are met
traces 2 to 4 are started simultaneously.
Settable trigger conditions:
S No trigger, i.e. measurement starts when you operate the soft key Start (all
traces are started in synchronism).
S Positive edge
S Negative edge
Input field: Direct input of the trigger threshold.

Threshold
The threshold is only effective with trigger types “Positive edge” and
“Negative edge”.
The unit refers to the selected signal.

15.6 Trace function
Soft key: To select the axis/spindle, position the cursor on the appropriate “Axis/spindle
Axis + name” list field.
Axis – You can also select the axis/spindle directly in the list box from the dropdown list
using the cursor.
Soft key: With the Start soft key, trace function recording is started.
Start
With the Stop or RESET soft key, you can cancel a running measurement.
Stop
Soft key: Within the framework of the trace function, it is also possible to select data using
Physical address its physical address.
Fig. 15-9 Menu: Physical address for trace x
To do so, proceed as follows:

– Choose the signal type Physical address from the desired trace.
– Press the soft key Physical address.
– Enter the desired values in the input screen form.
– Press the soft keys OK to complete your input.
Notice
This function is only required in exceptional cases, for example, if the informa-
tion provided by the known signals (see Signal selection list field) is not ade-
quate.
Before using this function, you should contact the SINUMERIK hotline.
The input of all parameters is carried out in the hexadecimal number format.
Input field: 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
– Individual bits: xxxx xxxx

15.6 Trace function
– 1: selected
– 0: not selected.
By default, all bits are selected.
Input field: The input field Threshold is only used to enter the triggering threshold for the
Threshold physical address of trace 1. If you exit the input screen form with the Ok soft
key, this hex value is then entered in the field Threshold of the main screen of
the trace function.
15.6.4 Performing the measurement
Soft key: After parameterization has been completed, you then enable measurement by
Start pressing soft key Start.
The measurement is carried out once the set trigger condition of trace 1 is ful-
filled.
Terminating the The measurement is completed after the set measurement duration is expired.
measurement
The graphics are generated automatically when the measurements are finished.
Use the Display soft key to call the display functions of the graphics (see next
Section).
Soft key: With the Stop soft key, you can cancel a running measurement at any time. A
Stop canceled measurement cannot be displayed.

15.6 Trace function
15.6.5 Display function
If you press the Display soft key after the set measurement time has expired
and the measurement results have been prepared automatically, you can call
the graphical display function of the measurement results.
Fig. 15-10 Measurement results: Trace function
Softkeys: When the soft keys X marker ON and Y marker ON are pressed, a vertical or
X marker ON horizontal line with a circle is displayed on the measurement curve.
Y marker ON 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

15.6 Trace function
Softkeys: If a marker is active, a 2nd line is shown in the diagram via the 2nd marker soft-
2. marker, key. These two lines define the range that you can then have displayed over the
zoom, entire display range by pressing soft key Zoom.
fullscreen The process of zooming a range (marker ON, 2nd marker, zoom) can be re-
peated as often as desired until the maximum size of representation is reached.
Use the soft key Fullscreen to switch the display of the diagrams back to their
original size.
Note
X and Y markers can be active at a time.
Soft key: Use the soft key Scale to change the scaling of the traces and of the marker
Scale ranges in the two graphs.
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. 15-11 Menu: Scaling of graphics

15.6 Trace function
Softkeys: Use the Graphics ... soft key shown in Fig. 15-10, Page 15-456 to call the fol-
Graphics ... lowing functions:
– Switching over the display from double to single graphics and vice versa
(this function also exists in the scaling menu Fig. 15-11, Page 15-457)
– Printing graphics
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.

15.7 File function
15.7 File function
Description Use the File functions soft key to call the appropriate screen form.
The parameters set for the measurements, axis-spec. machine data and mea-
surement results can be saved, loaded and deleted here.
The file functions are not intended as a replacement for a complete copy of the
system and user data, e.g. for archiving or series machine start-up, but only for
the simplified and flexible management of the specific measurement data.
Fig. 15-12 Menu: File functions
Naming files In the File group, you can select an existing file from the drop-down list or enter
one in the text field underneath.
Selecting the In the Directory group, you can select the directory where you want to save the
directory file. This can also be a directory in the Services operating area you have
created by yourself or the basic directory of the data management (list entry:
Standard directory).
Selecting data type In the Data group, you can select the data you want to save.
Only one data type can be selected at once. Use either the mouse button or the
cursor or toggle key for selection.

15.7 File function
Creating subdirec- If you do not wish the data of the trace function to be stored in the “default direc-
tories tory”, you can create user-specific directories.
New directories are created in the operating area Operating area switchover >
Services > Manage data. New subdirectories can be created below the Diag-
nosis directory.
For the description of the operating area Services, please refer to:

15.8 Print graphic
15.8 Print graphic
Printer selection The soft key Graphics in the main screens of the measuring functions opens
the menu to select the printer and to print the graphics.
Fig. 15-13 Graphics soft keys
Soft key: Use the soft key Printer selection to open the appropriate menu, Fig. 15-14,
Printer selection Page 15-462.
Choose the type of file output from the selection list of the menu “Select printer”
using either the Toggle key or by double-clicking with the right mouse button on
the desired file output type:
– Bitmap file
– Printer
Toggle key

15.8 Print graphic
Fig. 15-14 Menu: Printer selection
Output to printer Choose the printer to which you wish the file to be output from the list field using
either the Toggle key or by double-clicking with the right mouse button on the
desired printer.
Output as a bitmap The graphics is to be saved in a bitmap file (*.bmp):

file
S In the selection field for printer setting, set Output as bitmap file
S Press the soft key Print graphics
S Enter a file name.
You can enter a new file name or select an existing file from the drop-down
list.

15.8 Print graphic
Soft key: Use the soft key Print graphics Fig. 15-13, Page 15-461 to output the graphics
Print graphic to the set medium:
– Printer
– Bitmap file
Printer The graphics is output directly to the selected printer.
Bitmap file If you wish to output the graphics to a bitmap file, the following specifications are
still required in the submenu “File name for bitmap printout”:
– File names
– Directory
Fig. 15-15 Menu: File name for bitmap printing
Naming files In the File name group, you can select an existing file from the drop-down list or
enter one in the text field underneath.
Selecting the In the Directory group, you can select the directory where you want to save the
directory file.
This can also be a directory in the operating area Services > Data you have
created by yourself or the basic directory of the data management (list entry:
Standard directory).
For the description of the operating area Services, please refer to:
S The file is saved using the soft key OK.

S With the softkey Cancel you can return to the current graphic display.

15.9 Automatic controller setting
15.9.1 Drives: SINAMICS S120
Functionality The automatic controller setting of the speed control loop offers the following
functionality:
S Determining the gain and reset time in these cases:

– Standard setting
– Critical damping
– Good damping
S Determining current setpoint filters which may be required

S Display of the measured or calculated frequency responses
Startup
CHAN1 JOG Ref
MPF0
ROV Axis +
Automatic controller setting Axis: X1 1 SRM: 1 Axis –
Drive-test travel enable Status

without PLC Inactive Direct
selection...
Traversing range Absolute position:
Start
Monitoring: Inactive 0.000 mm
Upper limit: 0.000 mm

Stop
Lower limit: 0.000 mm
Operating mode
Setting type Speed controller: Standard setting
Measured variable: Torque actual value/ torque setpoint
Aut. Controller Service Service Drive User File

Display
setting axis drive MD views functions
Fig. 15-16 Menu: Automatic controller setting
Operating path Operating path of the automatic controller setting: Operating area switchover
> Start-up > Optimization / test > “>” > Aut. controller setting

Measurement The sequence of the automatic controller setting is divided into the following
steps:
1. Starting the automatic controller setting.
2. Measuring the mechanical system Part 1.
For the measurement, you can retain the standard parameters specified by
the control or enter your own. Start the measurement with the “OK” softkey.
Enable the traversing movement via NC START.
3. Measuring the mechanical system Part 2.
Set the measuring parameters, start the measurement and enable the tra-
versing movement as for 2.
4. Measuring the current control loop.
versing movement as for 2.
5. Calculating the controller data.
Set the measuring parameters for gain and reset time. Start the calculation
with the “OK” softkey.
6. Optional: Retentive storage of the newly calculated drive parameters in the
drive
7. Measuring the speed control loop.
versing movement similar to point 2.
8. Check the controller setting based on the displayed measurement results.
15.9.2 Drives: SIMODRIVE 611 universal
An automatic controller setting of SIMODRIVE 611 universal drives is only cur-

rently possible with the SimoCom U drive commissioning tool.
References: /FBU/ Description of FunctionsSIMODRIVE 611 universal
Section:Description of Functions
Optimization of the Current and Speed
Controller
SimoCom U Online Help

J

Notes

User Data Backup/Series Machine Start-up 16
16.1 Explanations on data backup
User data User data refers to all data or data fields that can be entered by the user to
achieve the specific functionality of the SINUMERIK 840Di sl and the connected
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.
After a series machine start-up file has been read in, the control system is in its
original status again as it was at the time of data backup.
Times for The past has shown that the following times are recommended to carry out data
data backup backups:
– After start-up
– After changing machine-specific settings
– After service, e.g., after replacement of a hardware component, software
upgrade, etc.
– Before activation of memory-configuring machine data. A warning
prompting you to back up is displayed automatically.
Data backup of You can save user data using one of the following applications:
various
components
S SINUMERIK user interfaces: HMI Advanced (option).
S Commissioning tool: SinuCom NC
You can save user data for the following components either individually or to-
gether.
– NCK
– PLC
– HMI
– SIMODRIVE PROFIBUS drives
SINAMICS S120 Currently, the user data (projects) for SINAMICS S120 drive units must be
saved separately with the STARTER commissioning tool.
For detailed information on data backup, please refer to:
References: SinuCom NC:
Online Help
HMI Advanced:
/BAI/ Operator’s Guide HMI Advanced

16 User Data Backup/Series Machine Start-up 03/2006
16.2 Creating a series commissioning file
16.2.1 General information
Note
Because of its file extension “.arc”, the series machine start-up file is also called
archive.
Archive content The following components can be selected as the content of a series commis-
sioning file:
S NCK with/without compensation data (see below: Note)

S PLC
S HMI
S SIMODRIVE PROFIBUS drives
When selecting, any combinations are possible. However, it is recommended to
save the individual components separately in separate series machine start-up
files. It is thus possible to reload them independently of each other and with
maximum flexibility.
Note
Machine-specific compensation data only needs to be archived if the series
machine start-up file is to be reloaded into the same control system (backup).
NCK The contents of a series machine start-up file created for the NCK comprises
mainly the following data:
– Machine data
– Setting data
– Option data
– Global (GUD) and local (LUD) user data
– Tool and magazine data
– Protection zone data
– R parameters
– Work offsets
– Compensation data
– Display machine data
– Workpieces, global part programs and subroutines
– Standard and user cycles
– Definitions and macros

03/2006 16 User Data Backup/Series Machine Start-up
PLC The contents of a series machine start-up file created for the PLC comprise all
blocks loaded at the time when the data backup was made:
– OB (organization blocks)
– FB (function blocks)
– SFB (system function blocks)
– FC (functions)
– SFC (system functions)
– DB (data blocks)
– SDB (system data blocks).
HMI The contents of a series machine start-up file created for the HMI Advanced
comprise all data stored in the HMI database in the directory dh at the moment
when the data backup was made.

16.2.2 HMI Advanced (option)
The creation of a series machine start-up file with HMI Advanced is divided into
the following steps:
1. Open the menu to create a series-commissioning file:
Operating area switchover > Services > ETC key “>” > Series machine
start-up > Create start-up archive
2. Selection of components to be backed up (see figure: archive content)
3. Assignment of a filename (see figure: archive name)
4. Setting of the series machine start-up file via the vertical “Archive” softkey.
The series machine start-up file is stored in the archive directory on the hard
disk of the PCU.
Sevices CHAN1 AUTO MPF0
Channel RESET Program aborted HMI data

ROV selection
Read in
Creating a series start-up start-up archive
archive
Archive content
HMI
NC with compensation data
PLC
PROFIBUS drives Archive
Archive name MMCNCPLCANTR
Series
start-up
Fig. 16-1 Menu: Creating a series start-up archive

16.2.3 SinuCom NC
Starting SinuCom NC can be started as follows to create a series start-up file:
S SINUMERIK Desktop (see Section 5.4, Page 5-117)

Windows XP taskbar: Start > Programs > SinuCom NC > SinuCom NC
S HMI Advanced
Operating area switchover > ETC key “>” SinuCom NC
Creating a new file Creating a series start-up file with SinuCom NC is subdivided into the following
steps (see Fig. 16-2 below):
1. Starting SinuCom NC
2. Selecting the storage location
3. Selecting the components to back up (archive content)
4. Continuing (“Next >”)
Storage location
Data Storage
File system
Archive content
NC with compensation data
PLC
PROFIBUS drives
MMC
Next >
Fig. 16-2 Menu: Creating a series start-up archive
5. The following data can be selected in the following menus, depending on

the selected components:
– NCK: Part programs
– MMC: MMC archives
6. Creating the series start-up file (“Finish”)

16.3 Considerations when saving PLC data
16.3 Considerations when saving PLC data
When creating a series machine start-up file that contains PLC data, the PLC
image that is saved during this process is dependent on the status of the PLC at
the time of creation.
Depending on the status of the PLC, the following PLC images result:
– Original image
– Instantaneous image
– Inconsistent image
Original image The original image of the PLC is represented by the PLC data immediately after
loading the S7 project into the PLC.
Operating sequence:
1. Set the PLC to the operating status STOP
2. Load the appropriate S7 project into the PLC using the SIMATIC Manager
STEP 7
3. Create a series machine start-up file with PLC data
4. Set the PLC to the operating status RUN
Instantaneous If you cannot use the procedure described above, you can use the following
image alternative procedure to save an original image:
Operating sequence:
1. Set the PLC to the operating status STOP
2. Archive PLC data
3. Set the PLC to the operating status RUN
Inconsistent An inconsistent image results if a series machine start-up file with PLC data is
image created and the PLC is in the status RUN (cyclic operation).
The data blocks of the PLC are saved at different times with contents that under
certain circumstances may meanwhile have changed. This may result in a data
inconsistency that after copying the data backup back into the PLC may under
certain circumstances result in PLC stop in the user program.
Notice
The creation of a series-commissioning file with PLC data while the PLC is in
the RUN status (cyclic operation) may result in an inconsistent PLC image in
the series commissioning archive.
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.

16.4Reading in a series machine start-up file with HMI Advanced
Changing the PLC To change the PLC operating status, proceed as follows:
operating status
S With 840Di start-up:
– Start 840Di start-up Windows XP taskbar > Start > Programs > SI-
NUMERIK 840Di > 840Di Startup.
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC.
S With HMI Advanced

Diagnosis
S Change the PLC operating state: Group box PLC, buttons: “STOP” and
“RUN”.
S NCK and PLC must then be resynchronized: Group box PLC, buttons: “NC
Reset”.
16.4 Reading in a series machine start-up file with HMI Ad-

vanced
The process of reading in a series machine start-up file is broken down into the
following steps:
1. Open the menu to read in a series machine start-up file:
Operating area switchover > Services > key: “>” > Series machine
start-up > Read in start-up archive
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.

16.5 SINAMICS S120 series machine start-up with STARTER
16.5 SINAMICS S120 series machine start-up with STARTER

A project must be available, created or loaded from a drive unit into the pro-
gramming device for the series machine start-up of SINAMICS S120. This proj-
ect is loaded as a reference project in the other drive units still to be commis-
sioned.
S The reference drive unit is fully configured.

S You can create an online connection to all drive units.
S The reference project is loaded into the STARTER.
Execution Perform the following actions in the STARTER for each drive unit to be commis-
sioned.
1. Create a backup copy of the project: Project > Save As...
2. Access the drive unit online: Project > Connect to target system
3. Load the project into the drive unit: Target system > Load > Load to target
system
The drive unit applies the serial number from the previously located compo-
nents in the reference topology. This results in an inconsistency, which is
displayed in the project navigator.
4. Read the project back into the programming device: Target system > Load
> Load fully into the programming device (all p and r parameters)
5. Save your project: Project > Save
The configuration is now consistent, i.e., the same project states exist in the
target system and in the project.
J

Software Installation/Update and Data
Backup 17
17.1 PTP network connection
The functions described in this section (software installation/update) require a
network connection to an external computer (PG/PC) which contains an en-
abled network access directory.
If the SINUMERIK 840Di sl is not part of a larger network (WAN, LAN), a simple
PTP (peer-to-peer) connection via Ethernet and TCP/IP can be established for
service applications.
17.1.1 Establishing a network connection
For the network link, the PCU 50.3 is connected with the external computer di-
rectly via a crossed Ethernet cable (twisted pair crossed 10baseT/100baseTX
Ethernet cable).
SINUMERIK 840Di sl PG/PC e.g. PG 740

PCU 50.3
2) 1)
Ethernet cable
“Twisted pair crossed 10baseT/100baseTX”
Functionality of the Ethernet interfaces

under Windows XP
1) DHCP client
2) DHCP server
Fig. 17-1 PTP link: PCU 50.3 – External computer (PG/PC)
Signal Signal
name name
RJ–45 Pin 1: TD+ Pin 1: TD+

Pin 2: TD– Pin 2: TD–
Pin 3: RD+ Pin 3: RD+
Pin 6: RD– Pin 6: RD–
UTP connector
Fig. 17-2 Crossed Ethernet cable (twisted pair crossed 10baseT/100baseTX)

17 Software Installation/Update and Data Backup 03/2006
Network protocol The network protocol used is: TCP/IP. TCP/IP permits high data transmission
TCP/IP rates and it is simple to configure. TCP/IP is already pre-configured in the basic
PCU software.
Requirements on The following requirements must apply on the external computer:

the ext. computer S A network adapter is installed.
S The TCP/IP network protocol is installed.
S The external computer is connected to the PCU via a crossed Ethernet
cable.
S The IP address of the external computer is within the same subnet as the
PCU.
S A directory is shared as the network drive.
17.1.2 Configuring the external computer (Windows NT)
This section illustrates how to make and check settings for network configura-
tion on the external computer:
S TCP/IP protocol
S Computer name and workgroup
S Service: “Server service”
S Directory sharing
TCP/IP protocol Go to the network dialog box on the control panel (Windows task bar: Start >
Settings > Control Panel >> Network) to display the installed network proto-
cols on the “Protocols” tab. If the TCP/IP protocol is not shown, it can be
installed now.
Dialog box: Dialog box: Network
Start Tab card: Protocols
Button: “Add...”
Dialog box: Network protocol selection
Network protocol: TCP/IP protocol
Note
The question about DHCP must be answered “No”.
OK
IP address and After installation of the protocol and to simplify setting up communication with
subnet mask the PCU, it is necessary to check the IP address and the subnet mask and set
them, if necessary:
IP address We recommend using an IP address from the address range used by Windows
XP for automatic configuration, if no DHCP server is accessible (Automatic Pri-
vate IP Addressing: 169.254.x.x).
The last two digits must be in the range 1 – 254.
S 169.254. 10. 1

03/2006 17 Software Installation/Update and Data Backup
Subnet mask The subnet mask must be permanently set to the specified value:
S 255.255. 0. 0
Dialog box: Dialog box: Network
Continuation Tab card: Protocols
Dialog box: Properties of Microsoft TCP/IP
Specify IP address
IP address: <169.254. 10. 1>
Subnet mask: <255.255. 0. 0>
OK
Computer name Because it is a PTP link, any computer name and workgroup may be selected.
andworkgroup
Dialog: Register: Identification
Continuation Button: “Change...”
Dialog box: Identification change
Computer name: <COMPUTER NAME>
Workgroup: <WORKGROUP>
OK
Server service The “Services” tab card must contain “Server service”. This corresponds to gen-
eral sharing: “File and Printer Sharing” under Windows 9x or Windows XP. If this
service is not active, no directories can be shared.
If the service is not running, it can be installed now:
Dialog: Register: Services
End Button: “Add...”
Dialog box: Network service selection
Network service: Server service
OK
OK
Directory sharing Network access is enabled in properties dialog> tab card: “Enable” of the direc-
tory in question (select the directory with the right mouse key)
The directory name is the default name for sharing. If a different sharing name is
specified, it must be stated on activating the directory connection.
Authorization Access authorization to the drive is “Everyone” and “Full access” by default.
Dialog box Dialog box: Properties of <directory>
Tab card: Sharing
Shared as:
Sharing name: <SHARED AS>
OK

17.1.3 Configuring the external computer (Windows XP)
This section illustrates how to make and check settings for network configura-
tion on the external computer:
S TCP/IP protocol
S Service: “File and Printer Sharing”
S Directory sharing
TCP/IP protocol Go to the properties dialog box of the local network links (Windows task bar:
Start > Settings > Network Connections >> Local Area Connections) to
have the installed network protocols displayed on the “General” tab card.
The TCP/IP protocol must be installed and active:
Dialog box Dialog box: Local Area Connections Properties
Tab card: General
Internet Protocol (TCP/IP)
OK
If the protocol is not shown, it can be installed now.
IP address and The IP address and the subnet mask are automatically set by Windows XP on
subnet mask connection The “Automatic Private IP Addressing” function must be enabled.
the function is activated in the properties dialog of protocol: TCP/IP (function is
active by default).
Dialog box Dialog box: Internet Protocol (TCP/IP) Properties
Tab card: Alternate Configuration
Automatic Private IP Address
OK
Computer name Because it is a PTP link, any computer name and workgroup may be selected.
and workgroup
The setting is made via the properties dialog box of the Control Panel. Windows
taskbar: Start > Control Panel > System.
Dialog box Dialog box: System Properties
Tab card: Computer Name
Button: “Change...”
Dialog box: Change Computer Name
Computer name: <COMPUTER NAME>
Workgroup: <WORKGROUP>
OK

Service: “File and Go to the properties dialog box of the local network links (Windows task bar:
Printer Sharing” Start > Settings > Network Connections >> Local Area Connections) to
have the installed services displayed on the “General” tab card.
Service: “File and Printer Sharing for Microsoft Networks” must be installed and
active:
Dialog box Dialog box: Local Area Connections Properties
Tab card: General
File and Printer Sharing for Microsoft Networks
OK
If the service is not running, it can be installed now.
Option: “Simple File To simplify enabling of directories, go to the Windows Explorer, menu item:
Sharing” Tools > Folder Options, and select option: and activate “Simple File Sharing”.
Dialog box Dialog box: Folder Options
Tab card: View
Use simple file sharing (Recommended)
OK
Directory sharing Network access is enabled in properties dialog> tab card: “Sharing” of the direc-
tory in question (select the directory with the right mouse key)
The directory name is the default name for sharing. If a different sharing name is
specified, it must be stated on activating the directory connection.
Authorization To allow files to be created in the directory, the appropriate authorization must
be set.
Dialog box Dialog box: <Directory> Properties
Tab card: Sharing
Share this folder on the network
Allow network users to change my files
OK
17.1.4 Configuring the PCU
The PCU basic software is preconfigured for a PTP network link with protocol:
TCP/IP. If changes have been made or a network link cannot be established,
settings regarding:
S TCP/IP protocol
must be made or checked as described in Subsection 17.1.3, Page 17-478.

17.2 Partitioning of the PCU hard disk
17.2 Partitioning of the PCU hard disk

The PCU hard disk is divided into 4 partitions (3 primary partitions and an ex-
tended partition). For data security purposes, the SINUMERIK 840Di sl system
software, the Windows system software and the Service software are installed
on different partitions.
Partitions The diagram below shows the partitioning of the hard disk when the control sys-
tem is supplied:
active
C: NTFS D: NTFS E: NTFS F: NTFS
Name: EMERGENCY Name: TMP Name: SYSTEM Name: USER

Content: Tools Content: Images, Content: Windows XP Content: 840Di sl System
Install, Software
Updates
Primary partition Extended partition Primary partition Primary partition

with logical drive
Fig. 17-3 Partitioning the hard disk
1st partition / drive C:

Drive C: is reserved for service tasks under WinPE 2005.
2nd partition / drive D:
Drive D: contains the following directories:
– Images
Contains preinstalled and own images
– Install
The software to be installed is first copied into this directory before
actual installation under Windows XP.
– Update
The directory is used for subsequent installation of Windows XP sys-
tem software.
3rd partition / drive E:
Drive E: is reserved for the Windows XP system software.
4th partition / drive F:
Drive F: contains the SINUMERIK-specific applications, e.g. the SINUM-
ERIK 840Di sl system software.
It is also used for installing user-specific applications, e.g. SINUMERIK
user interfaces, HMI OEM applications or SIMATIC STEP7.

17.3Software installation/update (Windows)
17.3 Software installation/update (Windows)

Brief description This section describes how to install/update software via a Windows-based net-
work link to an external computer (PC/PG) in which a directory is shared for this
purpose.
The entire procedure is carried out from the SINUMERIK desktop. To activate
the SINUMERIK desktop, see Subsection 5.4.1, Page 5-117.
Using the applications
S NT desktop
Autostart of the HMI application: OFF
S HMI desktop
Autostart of the HMI application: ON
it is possible to activate the SINUMERIK desktop permanently and deactivate it
again after completion of service actions. These applications are part of the SI-
NUMERIK 840Di sl basic software
Compatibility list Before installing/updating software components, check they are compatible with
existing software components. See the compatibility list for your SINUMERIK
840Di sl software version on the Internet:
www.siemens.de/sinumerik> SINUMERIK 840Di sl > Link Box > Support > Update >
Tab: Update > SINUMERIK 840Di sl: Delivery Release System Software ... > Compati-
bility list: Compatibility_List.PDF
Notice
We urgently recommend checking compatibility of new software components
with existing software components before installing/updating them (compatibil-
ity list).
Requirements The following condition must be fulfilled:
S Network link with an external computer. See Section 17.1, Page 17-475.
Recommended This is the recommended procedure for installing/updating software on the

procedure PCU:
1. Back up the NCK and PLC user data by creating a series machine start-up
file. See Chapter 16, Page 16-467f.
2. Establish a network link to a shared directory of an external computer
(PG/PC) containing the software to be installed. See Section 17.1, Page
17-475.
3. Perform installation/updating of the software via the network link.
4. Initialize the control with “Delete NCK data” and “PLC memory reset”. See
5. Import the series machine start-up file created in Step 1. See Section 16.4,
Page 16-473.

17.4 Restoring the as-delivered state

If for some reason the current installation cannot be used, you have the option
of restoring the partitions C: (DOS), E: (Windows XP) and F: (840Di sl system)
of the PCU hard disk to their ex-works state.
This sections describes the basic steps:
S Restoring the partitions

S Installation of the SINUMERIK 840Di sl applications
Notice
When restoring the hard disk to the ex-works state, all data on the partitions C:,
E: and F: are lost.
17.4.1 Requirements
To restore the ex-works state, the following files supplied with the SINUMERIK
840Di sl must be saved locally on the PCU hard disk:
S D:\IMAGES\base_ou.gho (image file)

S D:\IMAGES\base_ou.inf
Image file The image file *.gho contains the data to be restored.
Info file The info file *.inf contains the description of the data to be restored.
The information in this file is required by the services menu to configure the
image program Norton Ghostt.
Notice
If the info file is not available, the service menu cannot restore the partitions.
17.4.2 Restoring the partitions

The procedure for restoring partitions C:, E: and F: from a local image file is de-
scribed in:
Literature
Section: IM8
4 Backing up and restoring data
Save/restore local partitions
Select the image file from which the partitions are to be restored in accordance
with the existing SINUMERIK 840Di sl software version:
S Basic software <Version> <Date>

17.4Restoring the as-delivered state
After the partitions have been restored, the SINUMERIK 840Di sl applications
must be reinstalled.
17.4.3 Installation of the SINUMERIK 840Di sl applications

The installation programs for the SINUMERIK 840Di sl applications saved on
D:\INSTALL are not executed automatically after partition restoration, as was
the case during the initial boot. To do this manually in the correct sequence,
proceed as follows:
1. On next PCU start-up after restoration of the partitions, you are prompted to
enter the password for the SINUMERIK desktop.
Start the Windows Explorer on the SINUMERIK desktop and open the direc-
tory:
S D:\SETUP\APPS
The subdirectories of directory APPS contain:
– \001 Installation directories of the 1st application
– \002 Installation directories of the 2nd application
– ....
– \xxx Installation directories of the xxxth application
The numbers in the directory name indicate order in which the applications
have to be installed.
2. Next open directory:
S D:\SETUP\APPS\001
The subdirectories contained in directory \001 contain:
– \000 Installation directories of the application
– \001 – \xxx Installation directories of options, patches,
etc.
The numbers in the directory name indicate order in which the installation
programs have to be run.
3. Next open directory:
S D:\SETUP\APPS\001\000
and start the installation program in the directory
(SETUP.EXE).
Then following the installation instructions shown.
Notice
If you are prompted to reboot during installation, always confirm this with “Yes”
and reboot.
4. Proceed with all (existing) directories
S D:\SETUP\APPS\001\001 to \xxx
as described in item 3.

5. Proceed with all (existing) directories
S D:\SETUP\APPS\002 to \xxx
as described in item 2.
Once all the installation programs have been executed in the described se-
quence, partitions C:, E:, and F: of the PCU hard disk are once again restored
to their as delivered state.
Example Fig. 17-4 shows an example of a directory structure under directory

D:\SETUP\APPS with 2 applications and the resulting installation sequence.
The first application contains 3, the second application 2 installation programs.
INSTALL (D:)
SETUP
APPS
Installation sequence
001
000 SETUP.EXE 1.
001 SETUP.EXE 2.
002 SETUP.EXE 3.
002
000 SETUP.EXE 4.
001 SETUP.EXE 5.
Fig. 17-4 Installation sequence

License Management 18
18.1 Basics
18.1.1 Important terms
The terms below are important for understanding the license management of
SINUMERIK software products.
Term Description
Software product A software product is generally used to describe a product that is installed on a piece of
hardware to process data. Within the license management of SINUMERIK software prod-
ucts, a corresponding license is required to use each software product.
Hardware Hardware in the framework of the license management of SINUMERIK software products is
a SINUMERIK control (CNC). With SINUMERIK 840Di sl represented by the appropriate
MCI board.
License A license gives the user a legal right to use the software product. Evidence of this right is
provided by the following:
S CoL (Certificate of License)
S License Key
CoL The CoL is the proof of the license. The product may only be used by the holder of the li-
(Certificate of License) cense or authorized persons. The CoL includes the following data relevant for the license
management:
S Product name
S License number
S Delivery note number
S Hardware serial number
Note
The hardware serial number is located only on a CoL of the system software or if the li-
cense was ordered bundled, in other words the system software came together with op-
tions.
License number The license number is the feature of a license that is used for its unique identification.
MCI board The MCI board represents, as the carrier of all the remanent data of a SINUMERIK solution
line control system, the identity of this control system. The MCI board includes the following
data relevant for the license management:
S License information including the License Key
Hardware serial number The hardware serial number is a permanent part of the MCI board. It is used to identify a
control system uniquely. The hardware serial number can be determined by:
S CoL (see Certificate of License “Note”)
S SINUMERIK user interface: HMI Advanced or HMI Embedded
S SINUMERIK Commissioning tool: SinuCom NC
S Automation License Manager
S Inscription on the MCI board

18 License Management 03/2006
18.1 Basics
Term Description
License Key The License Key is the “technical representative” of the sum of all the licenses that are
assigned to one particular piece of hardware, which is uniquely marked by its hardware
serial number.
Option One option is a SINUMERIK software product that is not contained in the basic version and
which requires the purchase of a license for its use.
Product A product is marked by the data below within the license management of SINUMERIK soft-
ware products:
S Product name:
S Order no.
S License number
18.1.2 Overview
The use of the installed system software and the options activated on a SINUM-
ERIK control system require that the licenses purchased for this purpose are
assigned to the hardware. In the course of this assignment, a License Key is
generated from the license numbers of the system software, the options, as well
as the hardware serial number. Here, access occurs to a license database
administered by Siemens A&D via the Internet. Finally, the license information
including the License Key is transferred to the hardware.
There are two ways to access the license database:
S Web License Manager

S Automation License Manager
Note
Using SINUMERIK software products for testing purposes
SINUMERIK software products may be temporarily activated and used for test-
ing purposes on a SINUMERIK control system, even without the corresponding
License Key.
The license key is displayed as “insufficient” on the SINUMERIK user interface,
e.g. HMI Advanced” in the “Overview” dialog of the license information.Also the
control system will repeatedly display a corresponding message.
18.1.3 Web License Manager
By using the Web License Manager, you can assign licenses to hardware in a
standard Web browser. To conclude the assignment, the License Key must be
entered manually at the control system via the HMI user interface.
Internet address The Internet address of the Web License Managers is:
http://www.siemens.com/automation/license

03/2006 18 License Management
18.1 Basics
18.1.4 Automation License Manager
Via the Automation License Manager, individual licenses can be assigned and
the automatic assignment of all the licenses required for a piece of hardware
can be carried out (license requirement alignment). The transfer of the license
information including the License Key occurs electronically via Ethernet.
Requirements:
S The Automation License Manager must be installed on the computer

(PC/PG) that is used to assign the licenses to the hardware.
S The computer (PC/PG) must be able to connect to the license database and
the SINUMERIK control system via Ethernet link (TCP/IP):
– License database: Internet connection
– SINUMERIK control system: Intranet or PTP connection (Ethernet, Peer-
To-Peer)
18.1.5 License database
The license database contains all the customer-specific, relevant license infor-
mation for the license management of SINUMERIK software products. The cen-
tral management of the license information in the license database ensures that
the existing license information regarding a piece of hardware is always up to
date.
The following functions are available:
S Management of the hardware purchased with the related licenses assigned

S Management of the licenses purchased and not yet assigned to any hard-
ware
S Assignment of licenses to a piece of hardware according to the current li-

cense requirement (license requirement alignment)
S Assignment of individual licenses to a piece of hardware

S Generating license keys
S Transferring license information including the License Key into a control sys-
tem
License database License database access occurs via:

access
S Direct access
The direct access occurs with:
– Delivery note number
– License number

18.1 Basics
The direct access enables the direct assignment of licenses for which the
license numbers are available, e.g., in the form of a CoL. In the Web License
Manager you can also assign all other licenses provided in relation to this
delivery note.
S Customer login
The customer login occurs with:
– User name
– Password
The customer login enables the assignment of all the licenses available to
the user that are delivered at the time of the login and have not yet been
assigned to any hardware. Here, the license numbers of licenses that can
still be assigned need not be directly at hand, instead these are displayed
from within the license database.
Note
S You can obtain a customer login via Siemens A&D Mall at menu item: “Reg-
istration”. The Internet address is:
http://mall.automation.siemens.com/
Currently, access is not yet possible for all countries.
S Browser settings for using the A&D Mall, see Subsection 18.1.8, Page
18-490.
Various license As indicated above, only the license information in the license database repre-
information sents the current status regarding a piece of hardware. Differences may arise
between the license information available for a piece of hardware and that of the
license database due to:
S loading older archive data into the NCK (data restoration from a series-com-
missioning file after a service job)
S assigning licenses to hardware without transferring the modified license in-

formation for the hardware control system (online)
As a result, a more limited license requirement (possibly no license require-
ment) may be displayed than indicated on the HMI user interface of the control
system for a license requirement alignment by Automation License Manager.
To align the license information, a transfer should be carried out for the current
license information of the license database for the hardware control system (on-
line).
18.1.6 MCI board and hardware serial number
In addition to the retentive system and user data, the MCI board contains the
data of a control system relevant for the license management of SINUMERK
software products:

S License information including the License Key

18.1 Basics
The MCI board thus represents the identity of a SINUMERIK control system.
For this reason, assigning licenses to a control system always occurs using the
hardware serial number.
This has the advantage that the MCI board can be slotted into a replacement
PCU in the event of failure and all data, including licensing information, are re-
tained.
Automation Thus, the hardware serial number is always decisive during the transfer of li-
License Manager cense information to a control system in Automation License Manager and not
the set IP address of the control system with which Automation License Man-
ager is currently communicating.
Determining the The hardware serial number is a permanent part of the MCI board. It is used to
hardware serial identify a control system uniquely. The hardware serial number can be deter-
number mined by:
S CoL (Certificate of License) (see note)

S SINUMERIK user interfaces: HMI Advanced or HMI Embedded
S SINUMERIK Commissioning tool: SinuCom NC
S Inscription on the MCI board
S Automation License Manager: Control system file data
– Control system (online)
– Control image (offline)
Note
S Hardware serial number and CoL
The hardware serial number is located only on a CoL of the system soft-
ware or if the license was ordered bundled, in other words the system soft-
ware came together with options.
On the SINUMERIK 840Di sl the MCI board is used to save data and print
the hardware serial number.
18.1.7 SINUMERIK License Key
Basic information If a license is required for a product, then with the purchase of the license the
on License Keys purchaser receives a CoL as proof of the rights to use this product and a corre-
sponding License Key as the “technical representative” of this license. In con-
junction with software products, the License Key usually must be available on
the hardware on which the software product executed.

18.1 Basics
SINUMERIK Depending on the software product, there are License Keys with different tech-
License Keys nical properties. The essential properties of a SINUMERIK License Key are:
S Hardware reference
The hardware serial number included in the SINUMERIK License Key pro-
vides a direct link between the License Key and the hardware on which it
can be used. In other words, a License Key created for the hardware serial
number of a specific MCI board is only valid for this MCI board and will be
rejected on other MCI board as invalid.
S Total number of assigned licenses

A SINUMERIK License Key not only refers to one single license, instead it is
the “technical representative” of all licenses that are assigned to the hard-
ware at the time of its generation.
Copying By the fixed reference to certain hardware, a SINUMERIK License Key may, for
SINUMERIK example, be copied to various computers (PC/PG) and/or storage media for
License Keys security or archiving purposes.
18.1.8 Browser settings for using the A&D Mall
The browser settings required to use the A&D Mall are provided below based
on Microsoft Internet Explorer 6.0.x. When using another browser the settings
should be modified as necessary.
Session cookies Session cookies must be enabled to use the A&D Mall. The corresponding set-
ting can be activated using the slider control for the general security settings. If
you are using custom security settings, you must explicitly allow session cook-
ies.
Settings
S General security settings:

Menu bar: Tools > Internet Options > Tab: “Security” >Slider control: “me-
dium” or “medium-high”.
S Custom security settings:

Menu bar: Tools > Internet Options > Tab: “Security” > Group “Settings”: But-
ton: “Advanced...” > Group “Cookies”: Select “Always allow session cook-
ies”.
Note
A cookie is a small text file, which is transferred from a Web server to the Web
browser. The text file cannot exceed 4000 characters (bytes) and is never exe-
cuted as a program by the Web browser. Session cookies are a specific ap-
plication format of cookies, which are not saved permanently on the computer,
but instead are deleted immediately when the user ends the session.

18.1 Basics
JavaScript In addition to session cookies, you must also allow the execution of JavaScript
programs to use A&D Mall.
As the running of JavaScript programs is critical to security, you should only
activate the “Active Scripting” option for Web pages from trusted sources. Inter-
net Explorer 6.0 x offers four different zones for this.
Settings
S Add Web pages from Siemens to the “Trusted Sites” zone:

Menu bar: Tools > Internet Options > Tab: “Security”> Zone: “Trusted Sites”
> Button: “Sites...” > “Add this Web site to the zone”: “*.siemens.com” >
Button: “Add”
S Enable “Active Scripting”:

Menu bar: Tools > Internet Options > Tab: “Security”> Zone: “Trusted Sites”
> Button: “Custom Level...” > Zone: “Scripting” > “Active Scripting” = “En-
able”
18.1.9 Proxy settings for the download of license information
As part of licensing, the Automation License Manager downloads license infor-

mation, including the License Key, from the license database to the local com-
puter via the download server. You should apply the settings for long-distance
data transmission/VPN and LAN so that you can access the download server
via port 80 and port 443:
S Internet address: http://software-download.automation.siemens.com

S IP Address: 146.254.187.20
Settings
In Internet Explorer 6.0 x via:
Menu command: “Tools” > “Internet Options...” > Tab: “Connections” >
Group: “Dial-up and Virtual Private Network settings” and “Local Area Network
(LAN) settings”
Note
The Automation License Manager must be allowed to establish an Internet
connection to the download server. To do this you may need to enable a fire-
wall for the download server.
In the event of queries and problems, please contact your local system admin-
istrator.

18.2 Assigning via Web License Manager
18.2.1 You can execute an assignment via direct access as follows
Background For direct access, log on to a computer connected to the Internet (PC/PG) with
the delivery note and license number in the Web License Manager. All licenses
of the delivery note numbers entered at the login may then be assigned to a
piece of hardware. After completing the assignment process, the new License
Key is displayed. This must then be entered in the licensing dialog of the HMI
components used.
Requirements The following prerequisites must be met in order to assign a license to a piece
of hardware via direct access and HMI user interfaces:
S The HMI component is connected with the control system (NCU) on which
the license should be assigned. Both components have been booted.
S A computer (PC/PG) with Internet connection and browser is available.

S The login data for the direct access (e.g., per CoL) are available:
– License number
Execution Assigning a license to a piece of hardware:

1. Determine the hardware serial number and product designation (HMI Ad-
vanced / HMI Embedded: “Type of hardware”) from the HMI licensing dialog.
HMI Advanced/HMI Embedded:
Operating-area switchover: Start-up > key: etc. (“>”) > Licenses > Over-
view
Note
Ensure that the hardware serial number displayed is also really the one you
want to make the assignment for. The assignment of a license to a piece of
hardware cannot be reversed via the Web License Manager.
2. Go to the Internet page of the Web License Manager:

3. Login via “Direct access”:
– License number
4. Follow the additional instructions in the Web License Manager.

18.2Assigning via Web License Manager
5. After completing the assignment process, enter the License Key displayed
on the Web License Manager into the licensing dialog of the HMI user inter-
face.
view
6. Confirm the entry of the new License Key by pressing the softkey: “Trans-
fer”.
18.2.2 You can execute an assignment via customer login as follows
Background For the customer login, log on to a computer connected to the Internet (PC/PG)
with the user name and password in the Web License Manager. All licenses
released for this user name in the framework of the license management may
then be assigned to a piece of hardware. After completing the assignment pro-
cess, the new License Key is displayed. This must then be entered in the li-
censing dialog of the HMI components used.
Requirements The following prerequisites must be met in order to assign a license to a piece
of hardware via customer login and HMI user interface:
S The HMI component is connected with the control system (NCU) on which
the license should be assigned. Both components have been booted.
S A computer (PC/PG) with Internet connection and browser is available.

S The login data for the customer login is available:
– User name
– Password
Execution Assigning a license to a piece of hardware:

1. Determine the hardware serial number and product designation (HMI Ad-
vanced / HMI Embedded: “Type of hardware”) from the HMI licensing dialog.
view
Note
Ensure that the hardware serial number displayed is also really the one you
want to make the assignment for. The assignment of a license to a piece of
hardware cannot be reversed via the Web License Manager.

2. Go to the Internet page of the Web License Manager:

3. Login via “Customer login”:
– User name
– Password
4. Follow the additional instructions in the Web License Manager.
Note
If you have an e-mail address, you have the option (checkbox) of receiving the
License Key by e-mail. Advantage: the entry of the License Key to the control
system is simplified.
5. After completing the assignment process, enter the License Key displayed
on the Web License Manager into the licensing dialog of the HMI user inter-
face.
view
6. Confirm the entry of the new License Key by pressing the softkey: “Trans-
fer”.

18.3Assigning via Automation License Manager
18.3 Assigning via Automation License Manager
18.3.1 Function overview
The following figure provides an overview of the functions available and the
sequence in which they should be applied.
Section: Installing the advanced Automation

License Manager
Checking the SINUMERIK plug-ins

Section: Enabling/disabling SINUMERIK
plug-ins
Section: Assigning parameters to the TCP/

IP communication with a control system
Section: Displaying the license information Section: Updating the “Management” view
of a piece of hardware
Assigning the license to the hardware:

License requirement alignment
with with
control system (online) control image (offline)
Section: Performing a license requirement Section: Creating a control image (offline)

alignment for a piece of hardware
Section: Performing a license requirement

alignment for a piece of hardware
Section: Transferring license information

for a control image (offline) to a control
system (online)
Fig. 18-1 Function overview

18.3.2 Installing the Automation License Manager
Background As a basic software component, the Automation License Manager comprises

the Automation License Manager itself, as well as additional SINUMERIK-spe-
cific plug-ins and the HMI basic software component, HMI basic software, for
the license management of SINUMERIK License Keys.
Note
The basic software component, Automation License Manager, is used for all
Siemens A&D products, e.g., SIMATIC STEP7. Versions of the basic software
component, Automation License Manager, are upward compatible. We recom-
mend always using the version with the highest version number, irrespective of
the source of supply (e.g., SINUMERIK or SIMATIC product CD, download via
A&D Mall, etc.).
The following components are installed:
S Basic software component: Automation License Manager (optional)

The basic software component is only installed if not already installed on the
computer or if a version with a lower version number is installed on the com-
puter (PC/PG).
S SINUMERIK plug-ins
S HMI basic software (optional)
The HMI basic software component is only installed if not already installed
on the computer or if a version with a lower version number is installed on
the computer (PC/PG).
System Hardware
requirements
S Computer: Industrial PC, programming device, etc.
S Work memory: >= 128 MB
S Free hard-disk storage:
5 MB or above (SINUMERIK plug-ins)
+ 32 MB (Automation License Manager)
+ 300 MB (HMI basic software)
Operating system
The Automation License Manager, SINUMERIK plug-ins and HMI basic soft-
ware are 32-Bit Windows programs executable on the following operating sys-
tems:
S Windows 2000
S Windows XP
Execution Launch the installation program for the Automation License Manager “SE-
TUP.EXE” and follow the instructions for the installation.

Further settings Please note the following settings:
S Browser settings for using the A&D Mall:

S Proxy settings for the download of license information:

Subsection 18.1.9, Page 18-491
18.3.3 Enabling/disabling SINUMERIK plug-ins
Background All plug-ins enabled for the Automation License Manager scan the communica-
tion interfaces when booting according to specific operations. If there is a large
number of enabled plug-ins, this can result in a significantly longer boot and
refresh time for the user interface.
To prevent this delay, you can disable the plug-in installed for handling the SI-
NUMERIK License Keys in dialog: “Connect to target system”.
Execution Perform the following actions to enable/disable the SINUMERIK plug-ins:

1. Start the Automation License Manager
2. Open the “Connect to target system” dialog via menu command: Edit >
Connect to target system > PlugIn SINUMERIK
3. In the dialog, open tab: Settings
4. Enable/disable the plug-in by selecting/deselecting the appropriate check-
box.
5. Close the dialog by pressing the button: OK
Result The Automation License Manager displays the data in the navigation and object
area according to the status of the SINUMERIK plug-in.
The folder symbols and names are displayed in the navigation area depending
on the status of the SINUMERIK plug-in and the communication link to the SI-
NUMERIK control:
S SINUMERIK plug-in disabled:

PlugIn SINUMERIK – – – – disabled – – – –
S SINUMERIK plug-in enabled, but no communication link with SINUMERIK

control:
SINUMERIK – online – – – – no link available – – – –
SINUMERIK – offline – – – – no data available – – – –
S SINUMERIK plug-in enabled, communication link established with SINUM-

ERIK control:
SINUMERIK <Control type> – <Hardware serial number>

Note
If the view is not automatically refreshed, you can refresh the view manually.
See Subsection 18.3.5, Page 18-501.
18.3.4 Assigning parameters to the TCP/IP communication with a con-

trol system
Background To be able to read or transfer license information to or from the MCI board of a
control system, the Automation License Manager must communicate with the
control system via TCP/IP.
Requirements
S HMI basic software is installed

S SINUMERIK-specific plug-ins are enabled
Note
If the SINUMERIK user interface “HMI Advanced” is installed on the same
computer (PC/PG) as the Automation License Manager you can set the IP ad-
dress using the user interface.
The IP address for the control system with which both HMI Advanced as well
as the Automation License Manager communicate is set via the following dia-
log:
Operating area switchover > Installation > HMI > NCU connection
This requires at least the password of protection level 2 (manufacturer) to be
set.
General communication parameters

The default general communication parameters for the HMI basic software are
stored in the following initialization file:
<Installation drive>:\Siemens\Sinumerik\HMI-Advanced\mmc2\MMC.INI
User-specific communication parameters
The user-specific communication parameters for the HMI basic software are
stored in the following initialization file:
<Installation drive>:\Siemens\Sinumerik\HMI-Advanced\user\MMC.INI
During evaluation of the initialization data when booting the HMI basic software,
user-specific communication parameters have priority over general communica-
tion parameters.

Sections of the initialization file: MMC.INI

The parameters relevant to TCP/IP communication with SINUMERIK control
systems are stored in the following sections:
S [ GLOBAL ]
Section: [ GLOBAL ] specifies the section (e.g. AddressParameter) that con-
tains the communication parameters for the current SINUMERIK control
system.
S [ AddressParameter ]
The name of this section can be any unique ASCII string within the file. The
specified IP address is crucial for communication with the current SINUM-
ERIK control system: IP address.
[ GLOBAL ]
NcddeMachineName = AddressParameter
NcddeDefaultMachineName = AddressParameter
NcddeMachineNames = AddressParameter
[ AddressParameter ]
ADDRESS0 = IP-Address, LINE=10, NAME=/NC, SAP=030d, PROFILE=CLT1__CP_L4_INT
ADDRESS1 = IP-Address, LINE=10, NAME=/PLC, SAP=0201, PROFILE=CLT1__CP_L4_INT
ADDRESS2 = IP-Address, LINE=10, NAME=/DRIVE0, SAP=0900, PROFILE=CLT1__CP_L4_INT
ADDRESS3 = IP-Address, LINE=10, NAME=/DRIVE1, SAP=0a00, PROFILE=CLT1__CP_L4_INT
ADDRESS4 = IP-Address, LINE=10, NAME=/DRIVE2, SAP=0b00, PROFILE=CLT1__CP_L4_INT
ADDRESS5 = IP-Address, LINE=10, NAME=/DRIVE3, SAP=0c00, PROFILE=CLT1__CP_L4_INT
ADDRESS6 = IP-Address, LINE=10, NAME=/DRIVE4, SAP=0d00, PROFILE=CLT1__CP_L4_INT
ADDRESS7 = IP-Address, LINE=10, NAME=/DRIVE5, SAP=0e00, PROFILE=CLT1__CP_L4_INT
Fig. 18-2 User-specific file: MMC.INI
Multiple SINUMERIK control systems

If you require communication with multiple SINUMERIK control systems you
must create a section [ AddressParameter ] with a unique name e.g.,
[ 840D_001 ], [ 840D_002 ], etc. for each control system with the relevant IP
address.
In the [ GLOBAL ] section, you must specify the section name for the SINUM-
ERIK control system, e.g. [ 840D_001 ], with which communication should occur
once the Automation License Manager has booted.
Notice
The IP address specified in the user-specific initialization file MMC.INI in-
fluences not only the Automation License Manager but also all other applica-
tions installed on the same computer (PC/PG) that use HMI basic software (e.g.
HMI Advanced).
To apply the change to the active IP address, you must close all active applica-
tions using HMI basic software (e.g. HMI Advanced). Once you have closed all
applications, restart the computer to activate the new IP address.

S HMI Basic is installed on the computer (PC/PG) on which the Automation

License Manager is running.
S The IP addresses of the SINUMERIK control systems with which the Au-
tomation License Manager must communicate are known.
Procedure: Perform the following actions when creating user-specific communication pa-
Creating rameters for the first time:
parameters for the 1. Create the text file:
first time <Installation drive>:\Siemens\Sinumerik\HMI-Advanced\user\MMC.INI if it
does not already exist.
2. Open the file MMC.INI with a text editor.
3. Copy the [ GLOBAL ] section from the table given above: “User-specific file:
MMC.INI” to the open file MMC.INI.
4. Copy the [ AddressParameter ] section from the table given above: “User-
specific file: MMC.INI” to the open file MMC.INI according to the number of
available SINUMERIK control systems.
5. For all [ AddressParameter ] sections replace the string: “AddressParame-
ter” with a unique name.
6. In all [ AddressParameter ] sections replace the string: “IP-Address” with the
relevant IP address for the corresponding SINUMERIK control system.
7. In the [ GLOBAL ] section replace the string: “AddressParameter” with the
section name for the SINUMERIK control system with which the Automation
License Manager should communicate after booting. (See note “Changing
the IP address” above.)
Procedure: Perform the following actions to change the active control system (online), i.e.,
Changing the the SINUMERIK control system with which the Automation License Manager
active control communicates:
system (online) 1. Close the Automation License Manager.
(See note “Changing the IP address” above.)
2. Open the file: <Installation drive>:\Siemens\Sinumerik\HMI-Ad-
vanced\user\MMC.INI with a text editor.
3. In the [ GLOBAL ] section, replace the current address string with the sec-
tion name for the SINUMERIK control system with which the Automation
License Manager should communicate after booting.
4. Start the Automation License Manager.
Result After booting the Automation License Manager communicates with the SINUM-
ERIK control system defined in the user-specific communication parameters.
The control system to which you have switched is represented by an “online”
control system file in the navigation area of the Automation License Manager.
The control system to which the Automation License Manager was connected
before switching is represented by an “offline” control system file, if a control
image (offline) exists.

18.3.5 How to refresh the navigation view: “Manage”
Background After actions which add or remove elements in the navigation area of the navi-
gation view: “Manage” of the Automation License Manager (e.g. deletion of a
control image (offline), enabling/disabling of plug-ins), the view is normally re-
freshed automatically. If the view does not refresh automatically after an opera-
tion, you can refresh the view manually.
Execution Perform the following actions to manually refresh the navigation view: “Manage”
manually:
1. Select the following nodes in the navigation area of the Automation License
Manager: My Computer
2. Refresh the view using one of the following options:
– Menu command: View > Refresh
– Key F5
– Toolbar:
Result The navigation view of the Automation License Manager is refreshed: All sub-
nodes under the node: My Computer are closed.
The object view of the Automation License Manager shows the current nodes
and drives of the navigation area.
18.3.6 Displaying the license information of a piece of hardware
Background To perform one of the following tasks with the Automation License Manager:
S Check the license information for the hardware

S Ascertain the license requirement for the hardware and align if necessary
S Assign new licenses to hardware and transfer updated license information
including License Keys to the hardware
you must display the license information for a piece of hardware.
Requirements The license information can only be displayed if the Automation License Man-
ager is communicating with the relevant SINUMERIK control system. A descrip-
tion of how to assign parameters for TCP/IP communication with a control sys-
tem is given in Subsection 18.3.4, Page 18-498.

Procedure with Perform the following actions to display the license information for the control
current control system currently connected to the Automation License Manager:
system (online) 1. Open the control system file in the navigation area of the Automation Li-
cense Manager and select the control system (online).
2. Enable the default object view: “SINUMERIK”.
Procedure with Perform the following actions to display the license information for a control sys-
control system tem not connected to the Automation License Manager:
change over 1. Exit the Automation License Manager and all other applications using HMI
(online) basic software (e.g. HMI Advanced).
2. Switch the active communication parameters to the required control system.
For a detailed description see Subsection 18.3.4, Page 18-498.
3. Start the Automation License Manager
4. Open the control system file in the navigation area of the Automation Li-
cense Manager and select the control system (online).
Result The license information for the control system is displayed in the object area of
the Automation License Manager.
18.3.7 Creating a control image (offline)
Background It is essential to create a control image (offline) for the following reasons:
S The license information must be later transferred to the hardware.

S The control system (online) is not connected to the Internet, e.g., for security
reasons. Consequently, the license information must be transferred to the
hardware in three individual stages.
S Internet or PTP link: Creating a control image (offline) in the Automation Li-
cense Manager
– Internet: Transferring license information to the control image (offline) by
means of a license requirement alignment
– Internet or PTP link: Transferring license information from the control
image (offline) to the control system (online) in the Automation License
Manager
S The license information for a control system should be saved as an archive

file for the purpose of archiving or customer support.
Requirements A control image (offline) can only be created if the Automation License Manager
is communicating with the control system.

A detailed description of how to establish TCP/IP communication with the con-

trol system is given in Subsection 18.3.4, Page 18-498.
A PTP link (Peer-To-Peer) via Ethernet and TCP/IP requires a crossed Ethernet
cable (twisted pair crossed 10baseT/100baseTX Ethernet cable).
Procedure using Perform the following actions to create a control image (offline) using menu
menu command: command: “Upload from target system”:
“Upload from 1. Open the “online” control system file in the navigation area of the Automa-
target system” tion License Manager and select the control system (online).
2. Create the control image (offline) using menu command: License Key >
Upload from target system
Result The control image (offline) is displayed in the “online” control system file with the
current license information for the control system. If a control image (offline) al-
ready exists in the “online” control system file, the image is overwritten with the
current license information.
18.3.8 Performing a license requirement alignment for a piece of hard-

ware
Background If one or more options are active on a SINUMERIK control system, you must
assign each license to the hardware. Next, the updated license information in-
cluding the License Key is transferred to the hardware.
Via the function: “Align requirement” you can perform the alignment automati-
cally for all required licenses based on the control system (online) or a control
image (offline). The following actions are performed:
S Determining the hardware serial number for the control system

S Determining the license requirement for the control system
S Taking the required licenses from the customer-specific licenses and assign-
ing these to the hardware
S Transferring the updated license information including License Key to the

control system (online) or the control image (offline)

Requirements The following requirements must be met for the license requirement alignment:
S The address data for the customer login (personalized login) is available:
– User name
– Password
S Control system (online) or control image (offline)

An “online” control system file or an “offline” control system file with the rele-
vant control image (offline) is available.
The procedure for creating a control image (offline) is described in Subsec-
tion 18.3.7 Page 18-502.
A description of how to assign parameters for TCP/IP communication with a
control system is given in Subsection 18.3.4, Page 18-498.
Execution Perform the following actions for license requirement alignment with a control
system (online) or a control image (offline):
1. Open the corresponding control system file in the navigation area of the Au-
tomation License Manager and select the control system (online) or the con-
trol image (offline).
2. Select the menu command: License Key > Align requirement
3. Login via your customer login.
4. Start the Automation License Manager and perform the following actions:
“Align requirement”, “Confirm requirement list” and “Transfer licenses”. Fol-
low the instructions displayed on the screen.
Notice
Carefully check the suggested license assignment. An adjustment may be re-
quired if:
S you wish to use a license number that differs from the number suggested
S you wish to use a license package rather than single licenses
S you wish to assign greater or fewer licenses than suggested for any reason
You can no longer undo the assignment independently.
The procedure for transferring the updated license information from a control
image (offline) to a control system (online) is described in Subsection 18.3.9
Page 18-505.
Result The license information for the control system (online) or control image (offline)
is now identical to the information for the relevant hardware in the license data-
base, including the License Key.

18.3.9 Transferring license information for a control image (offline) to a

control system (online)
Background It is essential to transfer the license information for a control image (offline) to a
control system (online), i.e., the hardware for a SINUMERIK control, for the fol-
lowing reasons:
S The control system (online) is not connected to the Internet, e.g., for security
reasons. License information is initially only updated based on a control
image (offline). The computer on which the Automation License Manager is
running is then disconnected from the Internet and connected to the relevant
SINUMERIK control system to transfer the license information.
S After a service call, the license information should be transferred from an

archive file to a SINUMERIK control system.
Requirements To transfer license information for a control image (offline) to a control system
(online) the following requirements must be met:
S The Automation License Manager must communicate with the control sys-
tem.
A detailed description of how to establish TCP/IP communication with the
control is given in Subsection 18.3.4, Page 18-498.
S The hardware serial number of the control image (offline) and the control
system (online) must be identical.
Procedure using Perform the following actions to transfer a control image (offline) to the hardware
drag and drop using drag and drop:
1. Open the “online” control system file in the navigation area of the Automa-
tion License Manager and select the control image (offline).
2. Select any line from the license information displayed in the object area.
3. Drag the selected line to the control system (online) release the mouse key.
Procedure using Perform the following actions to transfer a control image (offline) to the hardware
menu commands using menu command: “Download to target system”:
1. Open the “online” control system file in the navigation area of the Automa-
tion License Manager and select the control image (offline).
2. To transfer the control image (offline) to the hardware, select menu com-
mand: License Key > Download to target system
Result The license information for the hardware is now identical to the information for
the control image (offline), including the License Key.
J

Notes

840Di sl-specific Data and Functions 19
19.1 Interface signals
For detailed information on interface signals, please refer to the descriptions of
functions:
S /FB1/ Description of Functions – Basic Machine
S /FB2/ Description of Functions – Extended Functions
S /FB3/ Description of Functions – Special Functions
S /FBSY/ Description of Functions – Synchronized Actions

For a complete list of all existing interface signals, please refer to:
S /LIS/ Lists, Section: Interface signals
19.1.1 840Di sl-specific interface signals

DB number Byte, bit Name Doc.
reference
Signals from NC to PLC
10 108.2 MMC ready, communication via MPI
10 108.3 MMC ready, communication via Softbus
10 109.4 PC OS fault
10 57.3 PC shutdown
19.1.2 Interface signals not supported

reference
31, ... 20.0 Acceleration switch V/Hz operation
31, ... 20.2 Torque limit 2
Safety Integrated signals from PLC to axis/spindle
31, ... 22.0 Deselection of safe velocity and zero speed (deselection of SBH/SG)
31, ... 22.1 Deselection of safe operational stop (deselection of SBH)
31, ... 22.3 Velocity limit, bit value 0 (SG selection)
31, ... 22.4 Velocity limit, bit value 1
31, ... 23.0–23.2 Ration selection, bit value 0 to bit value 2
31, ... 23.5 Enable limit switch pair 2
31, ... 23.7 Activate test stop
Signals from axis/spindle to PLC
31, ... 92.0 Setup mode active
31, ... 92.2 Torque limit 2 active

19 840 si-specific Data and Functions 03/2006
19.1 Interface signals

reference
Safety Integrated signals from axis/spindle to PLC
31, ... 108.0 Safe velocity or zero speed (SBH/SG active)
31, ... 108.2 Clear status pulses
31, ... 108.7 Axis safely referenced
31, ... 109.0–109.7 Cam signals of plus and minus cams (SN1+/1– to SN4+/4–)
31, ... 110.1 Safe operational stop active (SBH active)
31, ... 110.3–110.4 Safe velocity active, bit value 0 to bit value 1
31, ... 110.5 n < nx
31, ... 111.1 Safe operational stop active (SBH active)
31, ... 111.4–11.7 Stop A/B to Stop E active

03/2006 19 840 si-specific Data and Functions
19.2Expanded message frame config./evaluation of internal drive variables
19.2 Expanded message frame config./evaluation of internal

drive variables
19.2.1 Function description
To ensure that the internal drive variables are available for evaluation in the
NCK, these are transferred from the drive as additional process data (PDA) dur-
ing cyclic PROFIBUS communication and saved by the operating system in
system variables.
The additional PDA is appended at the end of the standard message frame.
PDA for expanded message frame
PDA: Standard message frame PDA: Additional

drive data
PDA1 ..... PDAx PDAx+1 ..... PDAy
Fig. 19-1 Standard message frame with additional process data (PDA)
NC system According to the selected functionality, for each axis the additional PDA is avail-
variables able on the NCK side in individual specified system variables or the entire frame
as an array of neutral data words via a general system variable. In both cases,
the system variables are read-only.
Select the required setting in the NC machine data:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] (acquisition of additional drive

actual values)
Specific To transfer drive variables to individual system variables you must set the fol-
system variables lowing machine data:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] = 1
The additional PDA must be configured in the message frame in the exact se-
quence specified in table 19-1.
Table 19-1 Specific drive variables
PDA Drive variables System variables

x+1 Load $AA_LOAD
x+2 Smoothed torque setpoint (Mset) $AA_TORQUE
x+3 Active power (Pact) $AA_POWER
x+4 Smoothed torque-producing current Iq $AA_CURR
(IqGl)
General The entire message frame with standard process data and additional process
system variable data is transferred in a general system variable as an array of 16-bit integer
data words via:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] = 2
S System variable: $VA_DP_ACT_TEL[n, a]
where n = Index: 0,2,...15
a = machine axis identifier.

19.2 Expanded message frame config./evaluation of internal drive variables
Note
S The message frame configuration must meet the following condition:
( Standard PDA + Additional PDA) – 1 v n
where n = maximum possible index for system variable $VA_DP_ACT_TEL
S When using the system variables $VA_DP_ACT_TEL[n, a] in a user pro-

gram, it is only permissible to use one constant as index n.
Application example for system variables in a synchronized action:

IDS=1 DO $AC_MARKER[0] = $VA_DP_ACT_TEL[12, X]
Data formats The user must take the following points into account with regard to the data for-
mats of the process data stored in the system variables:
S The process data are transferred in the message frame in the following for-
mat:
– unsigned 16-bit integer (UINT16)
are transferred. They are stored in the system variables in the format
– signed 32-bit integer (INT32)
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. For the physical unit as well as the drive-end weighting
of the drive actual values transferred in the additional PDA, please refer to
the data description of the specific drive documentation.
S Drive actual values composed of 2 PDAs (both 16-bit) e.g.

– Encoder 2 position actual value 1 (G2_XACT1)
– Encoder 2 position actual value 2 (G2_XACT2)
are mapped on two separate data words (both 32-bit) in the system variable
$VA_DP_ACT_TEL.
Fig. 19-2 shows how the process data of the message frame are mapped onto
system variable $VA_DP_ACT_TEL:
PDA for expanded message frame
PDA: Standard message frame PDA: Additional drive

data
15 0 15 0 15 0 15 0
Bit 31...16 = bit 15 Bit 31...16 = bit 15 Bit 31...16 = bit 15 Bit 31...16 = bit 15
31 16 15 0 31 16 15 0 31 16 15 0 31 16 15 0
Index n = 0 Index n = x Index n = x+1 Index n = y
System variable $VA_DP_ACT_TEL[n, a]
Fig. 19-2 Mapping principle: PDA on system variable $VA_DP_ACT_TEL

Notice
The responsibility for possibly necessary format conversions or correct inter-
pretation of the physical unit and significance of a system variable used in parts
programs or synchronized actions lies exclusively with the user. Due to system
restrictions, it is not possible for the NC to perform a consistency check.
19.2.2 Requirements
The following conditions must be fulfilled for the transfer of additional drive vari-
ables:
S Drive
The drive must support SIEMENS message frame 116 or free message
frame configuration.
S DP master / SIMATIC STEP 7

No additional requirements
S SINUMERIK 840Di sl NCK

– The following option must be available:
“Evaluation of internal drive variables”,
Order No. (MLFB): 6FC5 251-0AB17-0BA0
– The following must be set in the NCK machine data:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] (acquisition of additional
drive actual values)

19.2.3 Configuring: SINAMICS S120 and SIEMENS message frame 116
When using SIEMENS message frame 116 no further measures are required
other than those applied for standard configuration.
19.2.4 Configuring: SINAMICS S120 and expanded message frame con-

figuration
Default Before configuring the additional drive variables, please define the following:
configuring
– The SIEMENS message frame that is to be used.
– The additional drive variables/PDA that are to be transferred.
Note
When transferring additional drive variables to the specific system variables, we
recommend always using SIEMENS message frame 116.
Recommended When configuring the components included in the frame, we recommend the
configuration following sequence:
sequence 1. DP master
2. DP slave S120/Drive
3. SINUMERIK 840Di sl NCK
1. Configuring the DP master
Default When using the extended message frame configuration, you must first apply the
configuring standard configuration to the DP master with respect to the DP slave S120 with
the SIEMENS message frame required for cyclic communication.
For information on how to perform a standard configuration of the DP master,
please see Section 8.9, Page 8-218et sqq.
Expanded Perform the following actions to configure the additional PDA:

message frame
1. Open the dialog: “DP slave properties” for the drive unit by double-clicking
configuration the relevant DP slave S120 in the HW Config station window.
2. Expand the length of the PDA already configured with the SIEMENS mes-
sage frame in the actual value slot of the relevant drive by the length of the
additional PDA.
3. The setpoint and actual value of an axis must have the same I/O address. If
HW Config changes the I/O address of the actual value slot as a result of
expanding the PDA, you must modify the I/O address of the setpoint slot
accordingly.


Tab: Details
Actual value > Length: <Length standard PDA + length
additional PDA PDA>
Setpoint > I/O address: <I/O address actual value> (see above 2.)
OK
Notice
S The setpoint and actual value of a drive must have the same I/O address.
Actual value: I/O address = = Setpoint: I/O address
S The I/O address configured in HW Config for a drive must match the I/O
address set in the NCK.
1. SIMATIC S7 configuration of DP slave S120
I/O address
MD13060: DRIVE_LOGIC_ADDRESS[n] (logical drive address)
Note
After increasing the length of the actual value PDA (dialog box: DP slave prop-
erties > Configuration > Details > Actual value > Length), when the Properties
dialog box is opened again, in message frame type:
Dialog box: DP slave properties
Tab: Overview
the message frame type that was originally selected is no longer displayed, but
the message frame that matches the modified PDA or no message frame type.

2. Configuring the DP slave S120/drive

Before performing the extended message frame configuration in the STARTER
commissioning tool, you must first perform the standard configuration or start-up
of the drive.
Default For the standard configuration/start-up of the drive, please see:

configuring
S Start-up (requirements)
– Section 10.1, Page 10-257
S Standard configuration/start-up
– References SINAMICS S120
Commissioning Manual
Expanded Perform the following actions to configure the additional PDA:

message frame
configuration 1. Open the PROFIBUS dialog for the drive.
Project navigator: Project > <Drive unit > > Drives > <Drive> > Communica-
tion > PROFIBUS (double-click)
2. Open the tab: “PROFIBUS send direction” (1).
3. Select the option “Hide inactive interconnections” (2).
4. Under message frame type select: “Free message frame configuration with
BICO (999)” (3).
5. Interconnect the free PDA with the relevant drive variables.
PROFIBUS receive direction PROFIBUS Send Direction 1

Hide inactive interconnections 2
Message frame selection: Free message frame configuration with BICO (999) 3
Binector-connector r2089[0], CO: PROFIBUS state

converter
0
0
r63, CO: Actual speed smoothed
0
0
r2089[1], CO: PROFIBUS state
Exit Help
Drive_3
Fig. 19-3 Free message frame configuration with BICO (999)

3. Configuring the NCK

Before configuring the expanded message frames, you first need to perform the
standard configuration on the NCK for the drive.
Default How to proceed with the standard configuration of a drive is described in Sub-
configuration section 12.5.3, Page 12-328.
Expanded Perform the following actions to transfer the additional PDA to the general sys-
message frame tem variables:
configuration 1. Select the option: “Evaluation of internal drive variables”.
2. Activate the transfer to general system variable:
S MD36730: $MA_DRIVE_SIGNAL_TRACKING[n] = 2
Note
After configuring the expanded message frames, the original configured mes-
sage frame for the cyclic communication of the drive is only explicitly visible in
the following machine data:
S MD13060: $MN_DRIVE_TELEGRAM_TYP[n] (drive message frame type)

19.2.5 Configuring: SIMODRIVE
Expanded message frame configuration in relation to drives:

is illustrated on the basis of an example using SIMODRIVE 611 universal (DP
slave 611U). Please adapt your procedure for the other SIMODRIVE drives.
Default Before performing the expanded message frame configuration, please define
configuring the following:
– The standard message frame that is to be used for the DP slave drive.
– How many drive actual values/PDA are also to be transferred.
Note
It is advisable to configure each component first with the standard message
frame and then expand the frame by the additional PDA.
Recommended When configuring the components included in the expanded message frame
configuration configuration, we recommend the following sequence:
sequence 1. DP master
2. DP Slave 611U

Step 1: Before performing the expanded message frame configuration, you need to
Configuring the configure the DP slave 611U with the standard message frame required for this
DP master drive.
Default For information on how to perform a standard configuration of the DP master,

Configuring please see Section 8.10, Page 8-226ff.
Extended To transfer the additional process data, you need to change the configuration of
message frame the DP slave 611U as follows:
configuration 1. The length of the PDA ,which is already configured with the standard mes-
sage frame, must be expanded by the length of the additional PDA.
2. As the I/O address of setpoint and the actual value of an axis must be the
same, change the I/O address of the setpoint to the I/O address of the ac-
tual value which is automatically adapted by the HW Config if necessary.

Actual value > length: <Length standard PDA + length additional PDA
PDA>
Setpoint > I/O address: <I/O address actual value> (see above 2.)
OK
Notice
S The I/O address for setpoint and actual values of an axis must be the same.
S The I/O address set by the SlaveOM for an axis must match the I/O ad-
dress set in the NC.
1. SIMATIC S7 configuration of DP slave 611U
I/O address
MD13060: DRIVE_LOGIC_ADDRESS[n] (logical drive address)
Note
After increasing the length of the actual value PDA (dialog box: DP slave Prop-
erties > Configuration > Actual value > Length), when the Properties dialog box
is opened again, in message frame type:
Dialog box: DP slave properties
the message frame type that was originally selected is no longer displayed, but
the message frame that matches the modified PDA or no message frame type.

Step 2: Before performing the extended message frame configuration, you must first
Configuring the perform the standard configuration or start-up of the drive.
DP slave 611U
Default For the standard configuration/start-up of the drive, please see:

configuring
S Start-up (requirements)
– Section 10.1, Page 10-257
S Standard configuration/start-up
– SIMODRIVE 611 universal and universal E:
References: /FBU/
Description of Functions SIMODRIVE 611 universal
– SIMODRIVE POSMO SI/CD/CA
References: /POS3/
User Manual SIMODRIVE POSMO SI/CD/CA
– SimoCom U start-up tool
References: Online help for SimoCom U.
Extended To configure the additional drive actual values, modify the standard configura-
message frame tion of the drive e.g. starting at standard message frame 102 as follows with the
configuration SimoCom U commissioning tool:
Notice
Before configuring the additional drive actual values, please ensure that the
correct drive – and if using a multiple axis module, the correct axis – was
selected in the SimoCom U start-up tool.
S Activating the customizable message frame configuration.

To activate the customizable message frame configuration, replace the mes-
sage frame type of the selected standard message frame in the menu: PRO-
FIBUS Parameter Settings (menu command Start-up > Parameterization
Views > PROFIBUS Parameter Settings) with “0”.
SimoCom U 12A drive

File Edit Startup Operation Diagnostics Tools Help
Online to drive 12A => data are modified directly in the drive!
Option module type 4 PROFIBUS station address 12

Configurati Expected option module type 4 Message frame selection 0
Analog inp Received data PDA Sent data PDA
Mechanics
Limitation 1 Control word 1 (CTW1) 1 Status word 1 (STW1)
Digital inpu 2 Speed setpoint B (NSET_B) 2 Speed actual value B (NACT_B)
Digital outp
Analog out 3 Speed setpoint B (NSET_B) 3 Speed actual value B (NACT_B)
Monitoring 4 Control word 2 (CTW2) 4 Status word 2 (STW2)
Controller
Traverse bl 5 Torque reduction (TorRed) 5 Torque reduction (TorRed)
Shaft-angle 6 Encoder 1 control word (G1_CTW) 6 Encoder 1 status word (G1_STW)
PROFIBUS
Spindle pos 7 No signal (NIL) 7 Enc. 1 pos. act. val. 1 (G1_XACT1)
8 No signal (NIL) 8 Enc. 1 pos. act. val. 1 (G1_XACT1)
9 No signal (NIL) 9 Enc. 1 pos. act. val. 2 (G1_XACT2)
Fig. 19-4 Activating the customizable message frame configuration

S Configuring the additional drive actual values

The drive utilization for PDA11 is configured via the selection list of the cor-
responding parameter (PROFIDrive parameter P0916[x]) in Fig. 19-5.
SimoCom U 12A drive

File Edit Startup Operation Diagnostics Tools Help
Online to drive 12A => data are modified directly in the drive!
PROFIBUS OFF1 Control of clock-synchronized PROFIBUS
5 Torque reduction (TorRed) 5 Message word (MessW)
6 Encoder 1 control word (G1_CTW) 6 Encoder 1 status word (G1_STW)

Configuration
Analog input 7 No signal (NIL) 7 Enc. 1 pos. actual value 1 (G1_XACT1)
Mechanics
8 No signal (NIL) 8 Encoder 1 pos. actual value 1 (G1_XACT1)
Limitation
Digital input 9 No signal (NIL) 9 Encoder 1 position actual value 2 (G1_XACT2)
Digital output
10 No signal (NIL) 10 Encoder 1 pos. act. value 2 (G1_XACT2)
Analog output
Monitoring 11 No signal (NIL) 11 Currently selected block (CurrBlo)
Analog input T. 24.x/20 (ADC2)
Controller
12 No signal (NIL) 12 Analog input T. 56.x/14 (ADC1)
Traverse blocks Load
Shaft-angle enc 13 No signal (NIL) 13 Digital inputs (DIG_IN)
Speed actual value A (NACT_A)
PROFIBUS
14 No signal (NIL) 14 No signal (NIL)
Spindle position
Fig. 19-5 Configuring the additional drive actual values
Step 3: Before configuring the extended message frames, you must first perform the
Configuring the standard configuration on the NC for the drive.
NC
Default How to proceed with the standard configuration of a drive is described in Sub-
configuration section 12.5.3, Page 12-328.
Extended On the NC for the expanded message frame configuration, you only need to
message frame activate PDA transfer in the respective system variable.
configuration – Option: “Evaluation of internal drive variables”,
Order number (MLFB): 6FC5 251-0AB17-0BA0
– NC machine data for activating the data transfer in the system variables:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] (acquisition of additional
drive actual values)
Note
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:
S MD 13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)

19.2.6 Boundary conditions
Slot assignment Die NC always occupies an entire slot. The data of the slot not used by the
NCK, e.g. data from the extended message frame configuration, cannot by writ-
ten by the PLC user program.
Restrictions The following restrictions are applicable with regard to the “expanded message
frame configuration” function:
S Additional data can only be transferred from the drive to the SINUMERIK
840Di sl NC (actual value channel). You cannot transfer data in the other
direction, i.e. from the NC to the DP slave drive (setpoint channel).
S You can only have read access to the drive data stored in the system vari-
ables.
Check consistency When the SINUMERIK 840Di sl boots, the NCK checks the consistency of the
parameters relevant to the process data configuration of the cyclic PROFIBUS
communication:
S NC
– MD 13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)
S DP master (configuration)
– DP slave properties: Setpoint: Length
– DP slave properties: Actual value: Length
S Drive
– Message frame selection
– PDA setpoint assignment
– PDA actual value assignment
If the number of process data expected from the NCK set in the message frame
type parameter in the NC machine data:
S MD 13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)
is greater than the number of process data configured with STEP7: HW Config
for the DP slave drive:
S DP slave properties: Setpoint: Length
S DP slave properties: Actual value: Length
or if the process data configuration for the drive parameters does not match the
message frame type for the NCK machine data, the following message is dis-
played:
S Alarm 26015 “Axis axis identifier machine data $MN_DRIVE_TELE-
GRAM_TYPE[index] value not permissible”.
No acyclic If acyclic communication is not supported by a drive, or if acyclic communication

communication was not explicitly deactivated for a drive via the axis-specific NCK machine
possible data:
S MD13070: $MN_DRIVE_FUNCTION_MASK[n] (used DP functions)

then responsibility lies solely with the start-up engineer to perform a consistency
check on the above-mentioned data.

Warning
! For system purposes, the consistency check, which is performed when the
SINUMERIK 840Di sl boots and which is based on acyclic communication with
the drive, is performed in conjunction with the cyclical communication - which is
already active – between NCK and drive.
As setpoint and actual values are already being exchanged between the NCK
position control and drive as part of the cyclic communication, uncontrolled
system states can occur on the part of the drive due to faulty process data con-
figurations which cannot be detected yet at this point in time.
The same applies if acyclic communication is not supported by a drive, or if
acyclic communication was deactivated for a drive via the axis-specific NC ma-
chine data:
S MD13070: $MN_DRIVE_FUNCTION_MASK[n] (used DP functions)

and therefore it is not possible for the NCK to perform a consistency check.
Therefore, the responsibility lies with the start-up engineer to implement suit-
able measures to avoid uncontrolled traversing of the drives during start-up,
caused by inconsistencies in the above mentioned data.
An error can present a risk of danger to person or machine.
19.2.7 Data descriptions (MD, system variable)
General machine data
13070 DRIVE_FUNCTION_MASK
MD number Bit-coded screen for selecting the functional scope expected by the NCK with PROFIBUS
drives
Default setting: 0 Min. input limit: 0 Max. input limit: FFFF FFFF
Changes effective after POWER ON Protection level: 2/7 Units: –
Data type: DWORD Applies as of SW 2.1
Meaning: Meaning of set bits:
Bit 0: Deactivation of the 611U-specific drive alarm mapping
Bit 1: Deactivation of the 611U-specific drive type detection
Bit 2: Deactivation of the 611U-specific parameter accesses encoder drivers
Bit 3: Deactivation of the 611U-specific parameter accesses output drivers
Bit 4: Activation external drive: DSC bits (STW1.12/STA1.12)
Bit 5: Deactivation of the 611U-specific drive parking (STW2.7/STA2.7)
Bit 6: Deactivation of the 611U-specific travel to fixed stop (STW2.8/STA2.8)
Bit 7: Deactivation of the 611U-specific internal motor switchover (STA2.9–11)
Bit 8: Deactivation of the 611U-specific ramp block (STW1.13)
Bit 9: Deactivation of the 611U-specific function generator functions (STW1.8/STA1.13)
Bit 14: Selection of non-cyclic DP communication: 0=DPT; 1=DPV1
Bit 15: Deactivation of consistency check for PROFIBUS message frame configuration
CTW: Control word (PDA word in the PROFIDrive message frame to DP slave)
STW: Status word (PDA word in the PROFIDrive message frame from DP slave)
PDA: Process data
MD irrelevant for ... ... –––

Axis-specific machine data
36730 DRIVE_SIGNAL_TRACKING
MD number Detection of additional drive actual values
Default setting: 0 Min. input limit: 0 Max. input limit: 4
Data type: BYTE Applies as of SW 2.1
Meaning: MD: DRIVE_SIGNAL_TRACKING (acquisition of additional drive actual values) informs the
NC which additional drive actual values are transferred in the PROFIDrive message frame
and in which system variables they should be stored.
Coding:
0: No additional drive actual values
1: The following drive actual values are transmitted and stored in system variables:
Actual value System variable
Load $AA_LOAD
Torque setpoint $AA_TORQUE
Active power $AA_POWER
Current actual value t$AA_CURR
2: The entire PROFIDrive message frame is stored in a system variable:
Actual value System variable
PROFIDrive message frame $VA_DP_ACT_TEL
MD irrelevant for ... ... –––
System variables
Name $VA_DP_ACT_TEL[n, a]
Meaning Word by word mapping of the PROFIBUS message frame from the DP
slave
Data type INTEGER
Value range [0, 65535]
Indices n: Array index Value range [0,20]
a : Machine axis Value range Machine axis identifier
Accesses Parts program Synchronized OPI
action
Read Read Read
Attributes Implicit preprocessing stop Cross-channel
Read Yes
19.2.8 Interrupts
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.

19.3Travel to fixed stop with high-resolution torque reduction
19.3 Travel to fixed stop with high-resolution torque reduc-

tion
The full description of functions for “Travel to fixed stop” can be found in:
References: /FB1/ Description of Functions, Basic Machine
Section: F1 Travel to fixed stop
19.3.1 Function description
With the NCK function “Travel to fixed stop”, you specify the torque reduction of
the drive torque effective in the drive (terminal torque) via the parts program
instruction FXST. The torque reduction value specified via FXST is transferred
cyclically to the drive in the PROFIBUS message frame as “MomRed” process
data.
The effective drive torque Mset is calculated from:
Drive parameters[%] MomRed

Mset = Mmax * MAXIMUM( 0; 1 – * )
100 16384
Mmax: Maximum possible drive torque from rated motor torque and
parameter P1230 Torque limit value.
MomRed: Control word in cyclic PROFIBUS message frame;
16384D = 4000H ¢1, i.e., if MomRed = 16384 the
drive torque will be reduced by the value of the drive parameter.
Drive torque Mset

Mmax
APMin
APMax
MomRed
0
16384D 65535D
4000H FFFFH
Fig. 19-6 Drive torque for the evaluation (drive parameter AP) and torque reduction
(MomRed) (Not true to scale)
The evaluation of the torque reduction must be identical in the drive and in the
NCK. The settings range for torque reduction is defined by the limit values
(0.005% to 10%) for the NCK machine data:
S MD37620: $MA_PROFIBUS_TORQUE_RED_RESOL

19.3 Travel to fixed stop with high-resolution torque reduction
19.3.2 Alignment
Automatic To simplify the torque reduction start-up, the SINUMERIK 840Di sl NC tries to
adjustment perform, as standard, an automatic adjustment using the torque reduction eval-
uation configured in the drive. To do this the NCK reads the relevant drive pa-
rameters and applies the value converted to NCK format in the machine data:
The following requirements must be met:
S The drive supports acyclic PROFIBUS communication.

S The drive has a parameter to standardize torque reduction.
S In the NCK, acyclic communication with the drive is enabled with:
– MD13070: $MN_DRIVE_FUNCTION_MASK[n], Bit 15 == 1
Manual If the requirements for automatic adjustment of the NCK and drive are not met,
comparison the adjustment must be performed manually in the drive and NCK.
19.3.3 Parameterization: SINAMICS S120
Telegram The drive must be operated with one of the following message frames:
S Message frame 102, 103, 105, 106 ,116
Drive parameters The evaluation of torque reduction is set using the parameter:
S p1544 Torque reduction evaluation [%]

Normalization: 1% ¢16384D = 4000H
19.3.4 Parameterization: SIMODRIVE
The following SIMODRIVE drives support high-resolution torque reduction:
S SIMODRIVE 611 universal, universal E

S SIMODRIVE POSMO SI, CD, CA
Telegram The drive must be operated with one of the following message frames:
S Message frame 102 to 107

Drive parameters The evaluation of torque reduction is set using the parameter:
S P0881 Torque reduction evaluation [%]

Normalization: 1% ¢16384D = 4000H
19.3.5 Parameterization: External drives
If third-party drives are used, please read the manufacturer’s documentation to

see whether and how to set the parameters on the drive.
19.3.6 Parameter assignment: SINUMERIK 840Di sl NCK
In the SINUMERIK 840Di sl NCK system, the parameters for evaluating torque
reduction are assigned via the axis-specific machine data:
Automatic During automatic adjustment, the NCK attempts to read the drive parameters in
adjustment the following system states:
– SINUMERIK 840D sl boot.
– Status: “Incoming station” of the DP slave drive
If the value set for the drive does not match the parameter assigned in the NCK
evaluation, the value defined by the drive is applied to the NCK machine data.
The resulting renormalization of the machine axis in question is shown by the
following message:
S Alarm 26024 “Axis axis identifier machine data $MA_PROFI-
BUS_TORQUE_RED_RESOL value adapted”.
If the value of the drive parameter converted into NCK format lies outside the
machine data limit values, the value set in the machine data is retained. No
message is displayed.
Note
You can disable automatic adjustment via:
S MD13070: $MN_DRIVE_FUNCTION_MASK[n], Bit 15 = 0
Manual If any of the aforementioned requirements for automatic adjustment is not met,
parameterization the NCK machine data and drive parameters must be adjusted manually.
S MD37620: $MA_PROFIBUS_TORQUE_RED_RESOL = drive parameter:

“Torque reduction evaluation”
Example for Assumptions:

SIMODRIVE 611U – Machine axis X1 corresponds to drive 12A
– The torque reduction evaluation is to be 0.1%

Assigning parameters for the DP slave 611U/Drive 12A

SimoCom U commissioning tool: menu command Start-up > Additional Pa-
rameters > Expert List > Number > 881
Torque reduction: P0881 = 1638.40 (¢0.1%)

The parameter is immediately effective.
Assigning parameters for the SINUMERIK 840Di sl NCK

Machine axis X1:
S MD37620: $MA_PROFIBUS_TORQUE_RED_RESOL == 0.1
19.3.7 Boundary conditions

No message is displayed in the following cases:
S If any of the requirements are not met, no automatic adjustment can be per-
formed for the SINUMERIK 840Di sl NCK.
S The parameter assigned in the drive for the torque reduction evaluation lies
outside of the NCK machine data limit values.
S The torque reduction is not renormalized for the NCK.
Irrespective of whether or not a message is displayed, the following NCK ma-
chine data is effective in all cases:
Notice
It is the system start-up engineer’s responsibility to ensure that the parameter
settings are consistent in the SINUMERIK 840Di sl NCK and all relevant drives
for which torque reduction is being performed.
The following data must be consistent in terms of values and meaning:
1. SINUMERIK 840Di sl NCK machine data
MD37620: $MA_PROFIBUS_TORQUE_RED_RESOL
2. Drive
S Automatic adjustment:
Parameter for torque reduction evaluation:
– SINAMICS: p1544
– SIMODRIVE: P0881
S Manual adjustment:
Drive parameter for torque reduction evaluation.

19.3.8 Data description (MD)
General machine
data
13070 DRIVE_FUNCTION_MASK
MD number Bit-coded screen for selecting the functional scope expected by the NCK with PROFIBUS
drives
Default setting: 0 Min. input limit: 0 Max. input limit: FFFF FFFF
Data type: DWORD Applies as of SW 2.1
Meaning: Meaning of set bits:
Bit 0: Deactivation of the 611U-specific drive alarm mapping
Bit 1: Deactivation of the 611U-specific drive type detection
Bit 2: Deactivation of the 611U-specific parameter accesses encoder drivers
Bit 3: Deactivation of the 611U-specific parameter accesses output drivers
Bit 4: Activation external drive: DSC bits (STW1.12/STA1.12)
Bit 5: Deactivation of the 611U-specific drive parking (STW2.7/STA2.7)
Bit 6: Deactivation of the 611U-specific travel to fixed stop (STW2.8/STA2.8)
Bit 7: Deactivation of the 611U-specific internal motor switchover (STA2.9–11)
Bit 8: Deactivation of the 611U-specific ramp block (STW1.13)
Bit 9: Deactivation of the 611U-specific function generator functions (STW1.8/STA1.13)
Bit 14: Selection of non-cyclic DP communication: 0=DPT; 1=DPV1
Bit 15: Deactivation of consistency check for PROFIBUS message frame configuration
CTW: Control word (PDA word in the PROFIDrive message frame to DP slave)
STW: Status word (PDA word in the PROFIDrive message frame from DP slave)
PDA: Process data
Axis-specific
machine data
37620 PROFIBUS_TORQUE_RED_RESOL
MD number Torque reduction resolution on PROFIBUS (LSB weighting)
Default setting: 1 Min. input limit: 0.005 Max. input limit: 10
Change valid after NEWCONF Protection level: 2 / 7 Units: %
Data type: DOUBLE Applies as of SW 2.2
Meaning: The default value 1% refers to the original weighting: The torque limit value is transferred to
the Profibus in increments of 1%; the value 100 in the corresponding Profibus data cell
signifies full torque reduction (i.e., without power).
Bu changing the torque to 0.005%, for example, you can specify value increments of
0.005%, i.e., the torque limit value is incremented more precisely by a factor of 200.
In this case the value 0 is transferred to limit the value to the rated torque. A full torque
reduction (i.e. without power) is given by the value 10000.
To prevent an incorrect adaptation, the set value of the torque must be selected to match
the interpretation of the torque reduction value configured and defined for the drive.
19.3.9 Interrupts
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.
J

Notes

Small SINAMICS Glossary A
Active Line Module Controlled, self-commutating feed/feedback unit (with –> “IGBT”s in feed/feed-
back device), which supplies the DC link voltage for the –> “Motor module”s.
Basic Infeed Overall functionality of an infeed with –> Basic Line Module, including the requi-
red additional components (filters, switching devices, etc.).
Basic Line Module Unregulated line infeed unit (diode bridge or thyristor bridge, without feedback)
for rectifying the line voltage of the –> DC Link.
Compact Flash Memory card for non-volatile storage of the drive software and corresponding
Card –> Parameters. The memory card can be plugged into the –> “Control unit” from
outside.
Control Unit Central control module in which the closed-loop and open-loop functions for one
or more –> “SINAMICS” –> “Line module”s and/or –> “Motor module”s are im-
plemented.
There are three types of Control Units:
– SINAMICS Control Units, e.g. –> “CU320”
– SIMOTION Control Units, e.g. –> “D425” and –> “D435”
– SINUMERIK solution line Control Units, e.g. NCU710, NCU720 and NCU730
Control Word Bit-coded –> “Process data” word, –> which “PROFIdrive” transmits at cyclic
intervals to control the drive states.
Double Motor Two motors can be connected to and operated with a double motor module.
Modules See –> “Motor module” –> “Single motor module”. Previous designation: –>
“Double-axis module”
Drive The drive includes the motor (electric or hydraulic), the actuator (converter,
valve), the control unit, measuring system, and supply components (line infeed
module, pressure reservoir). For electric drives, a distinction is made between a
converter system and an inverter system. With a converter system (e.g. –> MI-
CROMASTER 4), from the point of view of the user the line infeed, actuator, and
control component form a single device; with an inverter system (e.g. –> SI-
NAMICS S), the supply is ensured by means of –> Line Modules, thereby realiz-
ing a DC line to which the –> Inverters (–> Motor Modules) are connected. The
–> “Control unit” is implemented as a separate device and connected to the
other components by means of –> “DRIVE-CLiQ”.
DRIVE-CLiQ Abbreviation of “Drive Component Link with IQ”.

Communication system for connecting the different components of a SINAMICS
drive system (e.g. –> “Control Unit”, –> “Line Module”s, –> “Motor Module”s, –>
“Motor”s, and speed/position encoders.
The DRIVE-CLiQ hardware is based on the Industrial Ethernet standard with
twisted-pair lines. The DRIVE-CLiQ line provides the transmit and receive sig-
nals, as well as the +24 V power supply.

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition A-529
A Abbreviations 03/2006
Drive Component Hardware component connected to a –> “Control unit” via –> “DRIVE-CLiQ”, for
example. Drive components include: –> “Motor Module”s, –> “Line Module”s, –>
“Motor”s, –> “Sensor Module”s and –> “Terminal Module”s. The overall layout of
a Control Unit together with the connected drive components is called –> “Drive
unit”.
Drive Line-up A drive line-up comprises a –> “Control unit” and the –> “Motor module”s and –>
“Line module”s connected via –> “DRIVE-CLiQ”.
Drive Object A drive object is an autonomous, individual software function with its own –>
“Parameter”s. It may also have its own –> “Fault”s and –> “Alarm”s. The drive
objects may exist by default (e.g. On Board I/O) and may be easy to create (e.g.
–> Terminal Board 30, TB30). It may also be possible to create them more than
once (e.g. –> Servo Control). As a rule, each drive object has its own window
for parameterization and diagnostic purposes.
Drive Parameters Parameters of a drive axis that include, for example, the parameters of the cor-
responding controllers, as well as the motor and encoder data. The parameters
of the higher-level technology functions (positioning, ramp-function generator),
however, are called –> Application Parameters. See –> Basic Unit System.
Drive System The drive system includes all the components in a product family (e.g. SINAM-
ICS). A drive system comprises, for example, –> “Line module”s, –> “Motor mo-
dule”s, –> “Encoder”s, –> “Motor”s, –> “Terminal module”s, and –> “Sensor mo-
dule”s, as well as additional components (reactors, filters, cables, etc.). See –>
“Drive unit”
Drive Unit The drive unit includes all the components connected via –> “DRIVE-CLiQ” that
are required for carrying out drive tasks: –> “Motor module” –> “Control unit” –>
“Line module”, and the required –> “Firmware” and –> “Motor”s, but not addi-
tional components (such as filters or reactors). Several –> “Drive”s can be im-
plemented in a drive unit. See –> “Drive system”
Encoders Records and makes positions available for electronic processing. Depending on
the mechanical construction, encoders can be integrated in the –> “Motor” (–>
“Motor encoder”) or mounted on the external mechanics (–> “External enco-
der”). Depending on the type of movement, a distinction is made between rotary
encoders (“rotary transducers”) and translatory encoders (e.g. –> Linear Encod-
ers). In terms of measured value provision, a distinction is made between –>
“Absolute encoder”s (code sensors) and –> “Incremental encoder”s. See –>
“Incremental encoder TTL/HTL” –> “Incremental encoder sin/cos 1 Vpp” –> “Re-
solver”
External Encoder Position encoder that is not built in or mounted on the –> Motor, but via a me-
chanical transmission element or mechanical intermediate element. The exter-
nal encoder (see –> “Externally-mounted encoder”) is used for –> “Direct posi-
tion detection”.
Line Module A line module is a power component that generates the DC link voltage for one
or more –> “Motor module”s from a three-phase mains voltage. The following
three line module types are used for SINAMICS: –> Basic Line Module, –>
Smart Line Module and –> Active Line Module.
The overall function of an infeed, including the required additional components
such as –> Line Reactor, proportional computing power in a –> Control Unit,
switching devices, etc. is called –> Basic Infeed, –> Smart Infeed, and –> Active
Infeed.

A-530 SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
03/2006 A Abbreviations
Motor For the electric motors that can be driven by –> SINAMICS, a basic distinction is
made between rotary and linear motors in terms of direction of motion, and be-
tween synchronous and induction motors in terms of electromagnetic operating
principle. For SINAMICS, the motors are connected to a –> Motor Module. See
–> “Synchronous motor” –> “Induction motor” –> “Built-in motor” –> “Motor en-
coder” –> “External encoder” –> “Third-party motor”
Motor Encoder An –> “Encoder” (e.g. –> “Resolver”, –> “Incremental encoder TTL/HTL” or –>
“Incremental encoder sin/cos 1 Vpp”), which is integrated in or attached to the
motor. The encoder detects the motor speed and, in the case of synchronous
motors, also the rotor position angle (of the commutation angle for the motor
currents). For drives without an additional –> Direct Position Measuring System,
it is also used as a –> Position Encoder for position control. In addition to the
motor encoders, –> External Encoders for –> Direct Position Sensing are avail-
able.
Motor Module A motor module is a power component (DC-AC inverter) that supplies the power
for the connected motor(s). Power is supplied through the –> “DC link” of the
–>“Drive unit”. A motor module must be connected to a –> Control Unit via a –>
DRIVE-CLiQ. The open-loop and closed-loop control functions of the motor mo-
dule are stored in the control unit. –> “Single motor module”s and –> “Double
motor module”s are available.
Option Slot Slot for an optional module (e.g. in the –> Control Unit).
Parameter Variable quantity within the drive system that the user can read and, in some
cases, write. For –> SINAMICS, all specifications defined in the –> PROFIdrive
profile are defined by a parameter. See –> “Visualization parameter” –> “Adjust-
able parameter”
PROFIBUS Field bus to IEC 61158, Sections 2 to 6. The suffix “DP” is no longer included
because PROFIBUS FMS is not standardized and PROFIBUS PA (for Process
Automation) is now part of the “general” –> PROFIBUS.
Sensor Modules Hardware module for evaluating speed/position encoder signals and providing
detected actual values as numerical values at a –> “DRIVE-CLiQ socket”. There
are 3 mechanical versions of sensor modules:
SMCxx = Sensor Module Cabinet Mounted = Sensor modules for cabinet
mounting
SME = Sensor Module Externally Mounted = Sensor modules with a high de-
gree of protection for mounting outside the cabinet
Servo Control For –> “Motor”s equipped with a –> “Motor encoder”, this control type allows
operation with a high level of –> “Accuracy” and –> “Dynamic response”. In
addition to speed control, position control can be implemented.
Servo Drive An electric servo drive comprises a motor, a –> “Motor Module”, a –> “Servo
Control” and, in most cases, a speed and position –> “Encoder”. Electric servo
drives are normally extremely precise and have a high dynamic response. They
are designed for cycle times to less than 100 ms, and often have a short-time
overload capacity, which enables quick acceleration. Servo drives are available
as rotary and linear drives and are used for machine tools, handling robots, and
packaging machines.
SITOP Power –> “Electronic power supply” component. Example: 24 V DC
Smart Line Mod- Unregulated line infeed/feedback unit with a diode bridge for the infeed and
ules stall-protected, line-commutated feedback via –> “IGBT”s. The Smart Line Mo-
dule supplies the DC link voltage for the –> “Motor Module”s.

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition A-531
A Abbreviations 03/2006
Status Word Bit-coded –> “Process data” word, –> which “PROFIdrive” transmits at cyclic
intervals to control the drive states.
Supply Input component of a converter system for generating a DC link voltage to sup-
ply one or more –> “Motor module”s, including all the required components (e.g.
–> “Line module”s, fuses, reactors, line filters, and firmware, as well as propor-
tional computing power (if required) in a –> “Control unit”.
Vector Control Vector control (field-oriented control) is a high-performance control type for in-
duction machines. It is based on an exact model calculation of the motor and
two current components that simulate and accurately control the flux and torque
by means of software algorithms, thereby enabling predefined speeds and
torques to be observed and limited accurately and with a good dynamic re-
sponse. Two vector control types exist: The frequency control (–> “Sensorless
vector control”) and the speed-torque control with speed feedback (–> “Enco-
der”).
J

A-532 SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
Abbreviations B
ADI4 Analog Drive Interface for 4 Axis
ALM Active Line Module
ARM Asynchronous Rotary Motor
AS Automation System
ASCII American Standard Code for Information Interchange: American coding

standard for the exchange of information
ASUB Asynchronous Subroutine
BB Ready
BCD Binary Coded Decimals: Decimals with each digit coded in binary
BERO Proximity limit switch
BI Binector Input
BICO Binector Connector
BO Binector Output
BO Mode
BP Basic Program
CF card Compact Flash Card
CI Connector Input
CNC Computerized Numerical Control
CO Connector Output
CoL Certificate of License
COM Communication
CP Communication Processor
CPU Central Processing Unit
CRC Cutter Radius Correction
CU Control Unit
DAC Digital-to-Analog Converter
DB Data Block

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition B-533
Abbreviations 03/2006
DBB Data Block Byte (currently 8 Bit)
DBX Data Block Bit
DHCP Dynamic Host Configuration Protocol: Protocol for automatic assignment of IP

addresses from a DHCP server to a client computer
DO Drive Object
DPR Dual-Port RAM
DRAM Dynamic memory (volatile)
DRF Differential Resolver Function: Differential function for handwheel signaling
DRIVE-CLiQ Drive Component Link with IQ
DRY Dry Run: Dry run feedrate
DSC Dynamic Servo Control
DSR Data Send Ready:

Signal to indicate that serial data interfaces are ready
DW Data Word
DWORD Double word (currently 32 Bit)
EMC Electromagnetic Compatibility
EN European Standard
EPROM Erasable Programmable Read-Only Memory
EQN Designation for an absolute encoder with 2048 sine signals per revolution
ESD Electrostatic Sensitive Device
ETC ETC key “>”; extension of softkey menu in the same menu
FC Function Call, function block on the PLC
FEPROM Flash EPROM: Read and write memory
FIFO First In first Out: Memory that works without address specification and whose
data are read in the same order in which they were stored.
FIPO Fine InterPOlator
FSD Feed Drive
FST Feed Stop
GC Global Control
GEO Geometry
GND Signal Ground
GPUD Global Program User Data
GSD Device master file

B-534 SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
03/2006 Abbreviations
GUD Global User Data
HASH Software procedure for mapping a large quantity of identifiers onto a finite me-
mory area
HEX Hexadecimal number
HHU Handheld Unit
HMI Human Machine Interface
HW Hardware
HW Config SIMATIC S7 Tool to configure and parameterize S7 hardware within an S7 pro-

ject
HW limit switch Hardware limit switch
IBN Start-up
INC Increment
INI INI (Initializing Data)
INTV Internal multiplication
IPO Interpolator
IS Interface Signal
ISO code Special punched tape code, number of holes per character always even
JOG JOG mode: Manual mode for setting up the machine
K1 Channel 1
KUE Transmission ratio
KV Servo gain factor
LAN Local Area Network
LEC Leadscrew Error Compensation
LED Light Emitting Diode
LSB Least Significant Bit
LUD Local User Data
MAC Media Access Control
MCI Motion Control Interface
MCIS Motion Control Information System
MCP Machine Control Panel
MCS Machine Coordinate System
MD Machine Data

MDA Manual Data Automatic: NC mode for entering and processing individual part
program blocks or block sequences
MLFB Machine-readable product designation: Order no.
MM Motor Module
MMC Man Machine Communication
MPF Main Program File: NC part program (main program)
MPI Multi Point Interface
MSD Main Spindle Drive
MSGW Message word
NC Numerical Control
NCK Numerical Control Kernel: NC kernel with block preparation, traversing range,
etc.
NCU Numerical Control Unit: NC module
NX Numerical extension (axis extension module)
OB Organization Block: Block type of PLC basic or user program
OLP Optical Link Plug: Fibre-optic bus connector
PCMCIA Personal Computer Memory Card International Association
PCU PC Unit
PCW Program Control Word
PDA Process Data: Process data part of a PPO
PG Programming device
PID Parameter identification: Part of a PIV
PII Process Image of Inputs
PIO Process Image of Outputs
PIV Parameter identification: Value: Parameterizing part of a PPO
PLC Programmable Logic Control Programmable logic control
PMS1 Position measuring system 1
PMS2 Position measuring system 2
PNO PROFIBUS user organization
PO Power ON
POSMO A Positioning Motor Actuator: positioning motor
POSMO CA Positioning Motor Compact AC: Complete drive unit with integrated power and
control module as well as positioning unit and program memory; AC infeed.

03/2006 Abbreviations
POSMO CD Positioning Motor Compact DC: Like CA but with DC infeed
POSMO SI Positioning Motor Servo Integrated: Positioning motor, DC infeed
PPO Parameter Process data Object

Cyclic data message frame for PROFIBUS DP transmission and
“Variable speed drives” profile
PROFIBUS Process Field Bus: Serial data bus
PRT Program Test
RAM Random Access Memory, i.e. program memory that can be read and written to
REF Reference point
RES Reset
ROV Rapid Override: Rapid traverse override
RPA R Parameter Active: Identifier for R parameters
RS-232-C Serial interface
RTCP Real Time Control Protocol
RTS Request To Send: Request to send, control signal on serial

data interfaces
SBC Safe brake activation
SBL Single Block
SEA Setting Data Active: Identifier for setting data
SD Setting Data
SH Safe Standstill
SIM Single Inline Module
Single I/O module Compact I/O module (PLC I/O module)
SK SoftKey
SKP SKiP: Skip block
SLM Synchronous Linear Motor
SMC Sensor Module Cabinet Mounted
SME Sensor Module Externally Mounted
SPF Sub Program File: Subprogram
Software Software
SW limit switch Software limit switch
SRAM Static RAM (non-volatile)
SRM Synchronous Rotary Motor

SSI Synchronous Serial Interface (interface type)
STW Control Word
T Tool
TC Tool Change
TCPIP Transport Control Protocol - Internet Protocol
TCU Thin Client Unit
TEA Testing Data Active: Identifier for machine data
TO Tool Offset
TOA Tool Offset Active: Identifier for tool offsets
TRC Tool Radius Compensation
TTL Transistor-Transistor Logic (interface type)
USB Universal Serial Bus
VDE Association of Electrical Engineering, Electronics and Information Technology

(Germany)
VDI VDI interface: Data interface between NC and PLC
VI Voltage Input
VO Voltage Output
WCS Workpiece Coordinate System
WO Zero Offset
WZ Tool
ZOA Zero Offset Active: Identifier for zero offsets
ZSW Status word (of drive)
µC Micro Controller


References C
You will find a list that is updated monthly of the documentation available in
each language on the Internet at:
www.siemens.com/motioncontrol
Select: “Support” > “Technical documentation” > “Overview of publica-
tions” or “DOConWEB”

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition C-539
B References 03/2006
Notes

C-540 SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
EC Declaration of Conformity D
In order to provide the most recent version, the EC Declaration of Conformity is
no longer included as part of this manual.
The EC Declaration of Conformity is available in PDF format under Product ID
on Siemens A&D Product Information page: 15257461.
– Internet address: www.siemens.com/sinumerik > Support > Service >
Automation & Drives Service & Support > Product Support > Search:
15257461 > Go
15257461

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition D-541
19 EC Declaration of Conformity 03/2006
Notes

D-542 SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
Index
Axis
Monitoring, 12-361
Parameter sets, 12-348
Reference point approach, 12-369
Spaces Velocity matching, 12-358
Start-up image, HMI, User-specific, 5-120 Axis assignment, 12-325
Axis configuration, 12-324
Axis names, 12-327
Channel axes, 12-327
Numbers
Geometry axes, 12-328
1st measuring probe, 2-59 Machine axes, 12-327
840Di Rack, inserting, 6-140 Axis velocity in JOG mode, 12-358
840Di sl Rack, 6-140, 8-175
840Di start-up, PROFIBUS diagnosis, 8-186
B
Backup battery, 12-416
A Basic start-up, 5-110
Abbreviations, A-529, B-533 BATF, 12-416
Absolute encoder, 12-339, 12-376 BATL, 12-416
Calibration of multiple axes, 12-377 BICO interconnection
Operator-assisted calibration, 12-376 Control Unit, 10-272
Recalibration, 12-377 Drive, 10-279
Absolute measuring systems, Parameter assign- Supply, 10-273, 10-274, 10-275, 10-277
ment, 12-338 Blue screen, 1-28
Acceleration, 12-352 BUS 1, 12-416
Checking, 12-353 BUS 2, 12-416
Access authorization, 12-302 Bus connector, PROFIBUS and MPI, 2-47
Accumulator, 2-78
Actual-value acquisition, 8-184
Address, 11-293
ADI4, 2-44, 2-91, 8-217
C
Drift compensation, 12-357 Cable distributor, 2-61
Drive configuration NC, 12-330, 12-332 Connector assignments, 2-63
See also: ADI4 DP slave, 8-217 Cable outlet, 2-47
Speed setpoint matching, 12-354 Changing the language, 9-254
ADI4 DP slave, inserting, 8-217 Channel axes, 12-324
Alarm, 4065, 12-415 Check Consistency, 8-185
Alarm and message texts, 13-421 Checklist, Preparing for start-up, 5-107
MBDDE.INI configuration file, 13-421 Circularity test, 15-435
Standard text files, 13-422 Clamping tolerance, 12-361
User text files, 13-422 Color depth
Alarm numbers, 13-424 Setting, 1-27
Alarm text files, Syntax, 13-424 Switching over, 1-27
Alarm texts, 13-421 Communications processor (CP), Parameter con-
Alignment, 8-185 figuration, 6-143, 6-145
As-delivered state, 17-482 Compile cycle, SW version, 12-409
Assigning actual-value channels, 12-333 Compile cycles, 12-407
Assigning setpoint channels, 12-333 Boundary conditions, 12-410
Automatic controller setting, 15-464 Retrofitting, 12-408
Axes, 12-324 Computational resolution, 12-306

SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition I-543
Index 03/2006
Configuration, Loading into the PLC, 8-186, 9-240 Drift compensation, 12-357
Connection assignment, Cable distributor, 2-64 Drive configuration, 12-328
Contour monitoring, 12-365 ADI4, 12-330, 12-332
Control direction, 12-350 I/O addresses, 12-328
Control loops, 12-350 Telegram, 12-329
Coordinate axes, 12-324 Drive Optimization, 12-344
CP, Parameter configuration, 6-143, 6-145 Drive Optimization with HMI Advanced, 15-435
CP 5611, 6-133 Drive start-up (preconditions), 10-257, 11-289
CP5511, 6-133 Drive type DP, 12-331
CPU time share, 12-316 Drive variables, Evaluation, internal, 19-509
Current control loop, Measurement, 15-441 Drives
Current version, 5-122 Analog, 1-24
Cycle times, 12-315 Digital, 1-23
Cyclic operation, PLC, 6-154 General information, 1-23
SIMODRIVE, 2-44
DSC, 12-343
Dx, 8-173
D Dynamic monitoring functions, 12-363
Data Backup, 16-467 Velocity monitoring, 12-365
PLC data, 16-472 Dynamic servo control, 12-343
Times, 16-467
Various components, 16-467
Data Exchange Time, 8-173
Data transfer rate, HHU, 9-245
E
Declaration of Conformity, D-541 Earthing, PP72/48, 2-88
Default configuration, 9-241 EC declaration of conformity, D-541
Default passwords, 12-303 Electrical connection, HHU, 9-244
Delete NC data, 6-135 Electrical design
Detailed view, 6-139 MCI board and MPI bus, 3-99
Diagnostic repeater for PROFIBUS DP, 8-233 MCI board and PROFIBUS DP, 3-98
Diagnostics, PROFIBUS, 8-186 MCI board extension, 3-99
Diagnostics PCU 50, 3-100
NC, 12-414 PCU 50.3, 3-100
PLC, 12-414 EMC measures, 4-105
Differential handwheels, 2-59 Encoder limit frequency, 12-392
Dimension drawing, PP72/48, 2-89 Encoder Monitoring
Disabling, PCU, 1-30 Cut-off frequency, 12-366
Display resolution, 12-306, 12-307 Cyclic monitoring of position tolerance, 12-367
Distance-coded reference marks, 12-373 Position tolerance when switching over the
DMF file encoder, 12-367
General information, 8-177 Zero mark monitoring, 12-367
I/O module PP72/48, 1-34 Encoder types, Absolute measuring system,
DP cycle, 8-173, 8-183 12-338
Setting, 6-141 Endlessly rotating rotary axis, 12-345
DP cycle time, 8-173 EQN 1325, 12-338
DP Slave 611U Equidistant DP cycle, 8-182
Consistency, 8-219, 8-223, 8-227, 8-230 Setting, 6-141
Inserting into an S7 project, 8-218, 8-226 Equidistant master cycl. component, 8-182
Parameter configuration, 8-219, 8-227 Equidistant time, 6-141
PROFIBUS DP Communication, 8-223, 8-231 ESD measures, 4-106
Set the message frame type, 8-228 ET 200, 2-44
Setting the I/O addresses, 8-222, 8-229 Ethernet
Setting the PROFIBUS address, 8-219, 8-227 Communication data, 7-157
DP slave 611u, PROFIBUS parameters, 8-219, Communications link, 7-158
8-227 Connections PCU 50.3, 7-157
DP slave PP72/48 Ethernet communication, 7-157
Inserting, 8-188 Ethernet port, Parameter configuration, 6-133
PROFIBUS parameters, 8-188 Evaluation of internal drive variables, 19-509
Setting the I/O addresses, 8-189

I-544 SINUMERIK 840Di sl Manual (HBIsl) – 03/2006 Edition
03/2006 Index
Exact stop HPU, Connecting/disconnecting during running

Coarse, 12-361 operation, 9-251
Fine, 12-361 HW-Config, 6-139
Exact stop fine, Delay time, 12-361
EXCHANGE, LED: PP72/48, 2-87
Expanded message frame configuration, 8-219,
8-227, 19-509
I
Expert mode, 12-305 I/O, Assignment to hardware, 12-398
Export version, 1-37 I/O addresses, Drive configuration, 12-328
External power supply, PP72/48, 2-80 I/O Module PP72/48, See also: DP slave
PP72/48, 8-187
I/O module PP72/48, 2-44, 2-79
Identification of the control, 1-37
F Incremental measuring systems, Parameter as-
Failure safety, 1-28 signment, 12-335
Fatal exception error, 1-28 Indexing axes, 12-347
System information, 5-119 Indexing position tables, 12-347
Final parameterization, DP slaves gen., 8-180 Industrial PC, 2-66
Floppy disk drive 3.5’’, 2-73 Initial settings, 12-413
FORCE, 12-416 Initial start-up
Frequency response measurements, 15-440 611u, 11-289
FXST, 19-523 Recommended order, 5-108
Initiate NC Reset, 6-152
Input limits, 12-307
Input resolution, 12-306
G Input time, 8-173
GC, 8-173 Installation, 5-109, 5-122
GD circle parameterization MCI board extension slot variation, 2-55
HHU, 9-248 Installation directory, 5-122
PLC: HHU, 9-249 Installed components
GD circle parameters, 9-241 Basic software, 1-33
GD identification, 9-241 Engineering tools, 1-33
Gear stage speed, 12-392 SIMATIC S7 add-on software, 1-34
General information, 1-21 Installing languages packages, 9-254
Geometry axes, 12-324 Interface description
Ghost Explorer, 5-117 MCI board, 2-47
Global control frame, 8-173 MCI board extension, 2-57
Global data communication, 9-237 PP72/48, 2-80
Graphic display, Drive Optimization, 15-448 Interface overview
ADI4, 2-57
MCI board, 2-47
H Interface signal
PC OS fault, 1-28
Handheld unit (HHU), 9-243 PC shutdown, 1-28
Handwheels Interface signals
Differential, 2-59 840Di sl-specific, 19-507
TTL, 2-59 Not supported, 19-507
Hardware Components, 2-43 Interface version, 12-408
MCI board extension slot variation, 2-43 Interface versions, Dependencies, 12-409
Operator panel fronts, 2-43 Interpolation cycle, 12-316
Spare parts, 2-43 Interrupt: 25022, 12-339
Hardware limit switches, 12-363 IP address, MCP 483C IE, 7-163
HMI Advanced, 9-252
PROFIBUS diagnosis, 8-186
Series start-up, 16-470
HMI Analyzer, 5-118 L
HMI configuring package, 1-25 LAN, 5-123
HMI Explorer, 5-117, 5-121 Language default, 9-254
HMI modular system, 1-25 Language-specific nature of alarm texts, 13-423

Index 03/2006
Latency, 12-417 Message frame configuration, Extended, 19-509

LED, Status display: PP72/48, 2-87 Message texts, 13-421
License management, 5-124 Module
Limit switch, 14-430 ADI4, 2-91
Linear axis Diagnostic repeater for PROFIBUS DP, 2-93
With linear scale, 12-337 MCI board extension internal, 2-53
With rotary encoder on motor, 12-335, 12-338 MCI board for 840Di sl, 2-46
With rotary encoder on the machine, 12-335 PP72/48, 2-79
Linear measuring system, 12-337 Module replacement, MCI board, 2-49
Literature, C-539 Modulo display, 12-345
Loadable compile cycles, 12-407 Monitor/control
Using HMI Advanced, 6-155
Using the SIMATIC Manager STEP7, 6-154
MPI
M Interface signal, 19-507
Machine axes, 12-324 Port, 1-23
Machine data, 12-299 MPI address, 9-241
Activation, 12-299 HHU, 9-246
Bit editor, 12-301 Recommended, 9-242
Changing scaling, 12-310 MPI bus, 9-242
Display filter, 12-305 MPI Communication, 9-235
Display/input screen forms, 12-301 MPI configuration, 9-239
Identifier, 12-299 Prerequisite, 9-239
Loading of default data, 12-311 MPI interface
Normalization of physical quantities, 12-308 Parameter configuration, 6-133, 6-142, 6-143
Overview, 12-300 Setting, 11-294
Machine name (computer name), 17-477, 17-478 MPI parameterization of the PLC, HHU, 9-246
Master application cycle, 8-173, 8-184 MPI parameters, HHU, 9-245
Master Time, 8-173
Max. axis velocity, 12-358
MCI board, 1-23
Cable outlet, 2-47
N
MCI board extension NC system clock cycle, Setting, 6-141
Internal, 2-53 NC system software, 1-24
slot variation, 2-43 NCK
MCI board extension internal, 1-23 Default data, 12-415
Switch S1, 2-53, 2-54 General information, 1-25
MCI2 board for 840Di sl, 2-46 Reset, 12-415
MCP 310, See also: DP slave MCP 310, 8-190 NCK CPU time share, 12-316
MCP 483, 8-190, 8-204 NCK General Reset, 12-415
See also: DP slave MCP 483, 8-204 NCK latency, 12-417
MCP 483C IE, 7-161 NCK state, 12-414
MD13070, 19-524, 19-525 Network connection, 5-123
MD34210, 12-339 Networking rules, 8-174, 9-235
MD37620, 19-523, 19-524, 19-525, 19-526 Node address, 11-293
Measurement of speed control loop, 15-442 Notes for the Reader, v
Measuring functions, 15-435, 15-436
Abort, 15-437
Start, 15-437
Measuring system switchover, Interface signals,
O
12-333 OB1, 9-240
Memory OB100, 9-240
DRAM, 12-321 OEM configuration, 5-119
Free DRAM memory, 12-321 OEM directories, 5-119
Free SRAM memory, 12-322 Online connection, 611u, 11-291
Reconfiguration of SRAM, 12-322 Online operation, Starting, 11-296
SRAM, 12-322 OP 012, 2-69
Memory configuration, 12-320 Operator panel front, 2-69
Hardware configuration, 12-320 General information, 1-24

03/2006 Index
Operator panel fronts, 2-43 PG/PC interface

Optional HMI components, 1-25 Parameter configuration, 6-133
Order no. Parameterize, 6-134
ADI4, 2-92 PIV area, 8-172
Cable distributor, 2-61 PLC
MCI board extension, 2-53 Basic program installation, 6-128
MCI board extension slot variation, 2-43 Default data, 12-416
MCI2 board for 840Di sl, 2-46 Delete program, 12-416
OP 010, 2-43 Overall reset, 12-416
OP 010C, 2-43 Power Data, 6-127
OP 010S, 2-43 Program, 6-128
OP 012, 2-43, 2-69 RUN, 12-415
OP 012T, 2-43 RUN-P, 12-415
OP 015, 2-44 STOP, 12-416
PCU 50, 2-66 PLC basic program, Processing modules, 6-131
PCU basic software Thin Client, 2-71 PLC general reset, 6-134, 6-135
PP72/48, 2-79 PLC operating state, 12-417
SITOP POWER 10, 2-73, 2-74 PLC program, 6-128
SITOP POWER lead-acid battery module 24 Load, 6-149, 6-151
V DC/10 A/3.2 AH, 2-78 PLC start-up, 6-127
SITOP POWER, DC-UPS MODULE 10, 2-76, PLC system errors, 12-416
2-93 PLC system software, 1-25
TCU, 2-44, 2-71 PLC Toolbox, 1-34
TP 012, 2-43 PLC user program, 6-130
TP 015A, 2-44 Ports, MPI interface, 7-162, 8-191, 8-205
Output time, 8-173 Position control cycle offset, 12-315
Overview, 1-21 Position control loop
Overview of connections Measurement, 15-445
MCI board, 3-101 Overshoots, 12-352
MCI board extension, 3-101 Reference frequency response, 15-445
PCU50, 3-103 Setpoint step change, 15-446
OVTEMP, LED: PP72/48, 2-87 Step height, 15-447
Position controller, 12-350
Position Controller cycle, 12-315
Position Controller cycle , Setting, 6-141
P Positioning accuracy of the control system,
P0881, 19-525, 19-526 12-314
p1544, 19-524, 19-526 Positioning axes, 12-346
Packages, System software, 1-22 Concurrent, 12-346
Parameter Assignment Feed, 12-346
MCP, 8-191, 8-205 POWER, LED: PP72/48, 2-87
MCP 483C IE, 7-162 Power failure, 1-28
Parameter sets of the position controller, 12-348 Power supply, 2-74
Password Power-On and Power-Up, 5-107
Resetting, 12-303 PP72/48, 2-79
Setting, 12-303 Setting the PROFIBUS address, 8-188
PC OS fault, Interface signal, 19-507 Preparing for start-up, 5-107
PC shutdown, Interface signal, 19-507 PRESETON, 12-377
PCU, 1-22 PROFIBUS
Ports, 1-23 Modules, 2-44
Slots, 1-23 Node address, 11-293
PCU 50, 2-66 PROFIBUS address
PCU 50.3, Ethernet connections, 7-157 Setting using an operator unit, 11-291
PDA area, 8-172 Setting using the PROFIBUS unit, 11-293
Peripherals SIMODRIVE POSMO SI / CD / CA, 11-293
Digital/analog, 12-397 PROFIBUS communication, Parameter Assign-
I/O modules, 1-24 ment, 6-140
Max. number of inputs/outputs, 12-397 PROFIBUS DP Communication, 8-171
System variables, 12-399

Index 03/2006
PROFIBUS S7 subnetwork ID, 11-295 S

Subnetwork ID, 11-295
PROFIBUS-DP, 12-412 S1
General, 8-171 Handwheel type, MCI board Ext., 2-54
Port, 1-23 MCP 483C IE, 7-164
Programmed Spindle speed limitations, 12-392 PROFIBUS address, PP72/48, 2-81
Protection levels, 12-302 S2, MCP 483C IE, 7-164
Protool/Pro, 1-25 Sample PLC application, 1-34
Pulse multiplication factor, 12-384 Screen resolution
Setting, 1-26
Switching over, 1-27
Series machine start-up archive, Creation using
Q HMI Advanced, 16-473
Quantity framework, 1-22 Series machine start-up file, Creating, 6-152
Series start-up, 16-467
611u, 11-289
Selecting archive content, 16-468
R ServiceCenter, 5-118
Ramp-Up, 5-111 Servo gain, 12-350
First, 5-109 Checking, 12-352
Ramp-Up Servo gain factor (Kv), Definition, 12-351
After battery replacement, 5-112 Servo trace, 15-435
After importing a backup copy, 5-115 Setpoint acceptance, 8-184
After PCU replacement, 5-114 Setting data, 12-300
After PCU/MCI board replacement, 5-115 Activation, 12-300
After power failure, 5-115 Identifier, 12-300
After reinstallation/update, 5-114 Normalization of physical quantities, 12-308
After replacement of the MCI board, 5-112 Overview, 12-300
Rapid traverse in JOG mode, 12-358 Setting the axis-specific setpoint parameters,
READY, LED: PP72/48, 2-87 12-332
Real-time properties, 1-26 Setting the axis-specific setpoint/actual value pa-
Real-time property, 12-417 rameters, 12-332
Real-time violations, 1-26, 12-417 Settings, 12-418
Realtime response, 12-417 Settings System Network, 5-118
Redefining protection levels, 12-303 SF, 12-416
Reference point approach, 12-369 Shielded signal cables, 4-105
Requirements, Start-up, PLC, 6-132 Shutdown behavior, 12-418
Resolutions, 12-306 Shutting down correctly, 1-30, 1-31
Restart, 12-333 Sign-of-life monitoring, 6-154
Restoring, 17-482 Signal distortion, 12-366
Retentive ranges, 6-153 SIMATIC ET 200, 2-44
RI suppression measures, 4-105 SIMATIC Manager STEP 7, 8-175, 9-238
Rotary axes, Drive Optimization, 12-345 SIMATIC S7 I/O devices, 8-187
Rotary axis SIMATIC S7 project, 6-137, 8-178
With rotary encoder on motor, 12-336, 12-338 SIMODRIVE drives, 8-226
With rotary encoder on the machine, 12-336 SIMODRIVE 611 universal, 8-226, 11-289,
Rotary measuring system, 12-335 19-516, 19-524
Routing information, Setting, 11-295 BERO, 12-389
Rules for routing cables, EMC / ESD, 4-105 Max. useful motor speed, 12-364
RUN, 12-416 Motor monitoring speed, 12-364

03/2006 Index
PROFIBUS speed evaluation, 12-387 Speed control loop

Pulse multiplication factor, 12-384 Interference frequency response, 15-442
SIMODRIVE 611 universal E, 8-226, 19-516, Reference frequency response, 15-442
19-524 Setpoint/disturbance step changes, 15-443
SIMODRIVE 611u, See also: DP slave 611u, Speed setpoint matching, 12-354
8-226, 19-516, 19-524 Automatic, 12-354
SIMODRIVE POSMO CD/CA, 8-226, 19-516, Speed setpoint monitoring, 12-363
19-524 Spindle
SIMODRIVE POSMO SI, 8-226, 19-516 Axis mode, 12-381
SINAMICS Basic data, 12-380
Acquiring the component topology automati- Definition in machine data, 12-380
cally, 10-263 Enabling gear stage change, 12-383
Checking the configuration, 10-269 Encoder matching, 12-384
Configuration: Motors and encoder, 10-266 Gear stages, 12-383, 12-386
Configuring the PROFIBUS message frame, Master, 12-382
10-271 Measuring systems, 12-384
Control Unit: BICO interconnection, 10-272 Monitoring, 12-391
Control Unit: PROFIBUS telegram, 10-268 Operating modes, 12-380
Drive: BICO interconnection, 10-279 Parameter sets, 12-348, 12-383
Firmware upgrade, 10-286 Positioning, 12-388
Running the motor, 10-280 Reset, 12-382
Saving parameters, 10-280 Setpoint matching, 12-386
Specific parameters, 10-281 Setpoint/actual value channels, 12-383
Startup, 10-257 Synchronization, 12-389
Supply: BICO interconnection, 10-273, Velocities, 12-386
10-274, 10-275, 10-277 Spindle data, 12-394
Supply: PROFIBUS telegram, 10-268 Spindle in setpoint range, 12-391
SINAMICS drives, 8-218 Spindle is stationary, 12-391
SINAMICS S120, 8-218, 19-524 Spindle speed, Maximum, 12-391
See also: DP slave S120, 8-218 Spindles, 12-324
SinuCom NC, 1-33, 1-35, 7-159 SRAM, Physical, 1-31
General information, 1-25 SRAM handling, 5-111
Series start-up, 16-471 Standard version, 1-37
SINUMERIK Desktop, 5-117 Start-up, 1-38
SINUMERIK desktop General information, 1-25
Activating, 5-117 Menu command: Windows, 1-39
Setting the power-up response., 5-119 Start-up behavior, PLC, 6-153
SITOP POWER 10, 2-74 Start-up mode, Restart, 6-153
SITOP POWER ACCUMODULE 24 V DC/10 STARTER, ONLINE start-up, 10-260
A/3.2 AH, 2-44 Startup
SITOP POWER DC UPS module 15, 2-44 611u, 11-289
SITOP POWER lead-acid battery module 24 V First, PLC, 6-135
DC/10 A/3.2 AH, 2-78 HHU, 9-243, 9-252
SITOP POWER standard 24V/10A, 2-44 MCP, 8-204
SlaveOM, 8-176, 8-218, 8-226 MCP 310, 8-190
Softbus, 9-242 MCP 483C IE, 7-161
HMI Advanced, 9-253 NC with HMI Advanced, 12-299
Interface signal, 19-507 Static monitoring functions, 12-361
Software components, Overview, 1-33 Status displays, 12-416
Software limit switch, 12-362 STOP, 12-416
Software Version PLC, 12-416
HHU, 9-246 Storing the text files, 13-421
MCP, 8-192, 8-205 SUB-D, socket, 2-47
MCP 483C IE, 7-162 SW version, 12-409
Spare parts, 2-43 Switching over the measuring system, 12-312
Special axes, 12-324 System basic cycle, 12-315

Index 03/2006
System components, 1-22 Trace function

System data, 12-306 Creating subdirectories, 15-460
System data blocks, Creating, 8-185 Display function, 15-456
System integrity, 1-27 Drive Optimization, 15-451
System overview, 3-95 Main screen, 15-452
MPI components, 3-97 Measuring parameters, 15-453
Operator panels, 3-95 Operation, 15-452
PCU components, 3-97 Parameter assignment, 15-453
PROFIBUS DP components, 3-96 Performing the measurement, 15-455
Touch panels, 3-95 Printer selection, 15-461
System software, 1-22 Signal selection, 15-453
System software packages, 1-22 Travel direction, 12-350
Traversing ranges, 12-314
TTL handwheels, 2-59
T
TCU, 2-71
General information, 1-24
U
Set-up, 2-72 Update, 5-122
Startup, 2-72 UPS, 2-76
TDP, 8-173, 8-182, 8-183 SITOP POWER DC UPS module 15, 2-76
TDX, 8-173 UPS system, 1-31
Technical data USB disk drive, 2-44
MCI board, 2-52 User data, 12-320
MCI board extension, 2-60
PP72/48, 2-90
Technology functions
V
Activation, 12-410
Licensing, 12-410 Velocities, 12-319
Telegram, Drive configuration, 12-329 Max. axis velocity, 12-319
Temperature Max. tool path velocity, 12-319
Casing, 1-29 Maximum spindle speed, 12-319
CPU, 1-29 Upper limit, 12-319
CPU module, 1-29 Voltage limit, 12-319
Temperature monitoring, 1-29 Velocity monitoring, Actual, 12-365
Terminator resistor Version display, 5-122
MCP 483, 8-190, 8-204 Voltage failure, 1-28
PCU, 9-252 Voltage supply, PP72/48, 2-87
Test run
Axis, 14-431
Axis and spindle, 14-429 W
Drive enable, 14-429
Requirements, 14-429 WAN, 5-123
Spindle, 14-432 Windows NT, General information, 1-24
Testing the PLC program, 6-153 Windows XP, 1-24
Text file for cycle alarm texts, 13-424 WinPE, 5-109, 5-118
Text file for PLC alarm texts, 13-425 Workgroup, 17-477, 17-478
Thin Client Unit, 2-71 Working area limitation, 12-362
Thread, Tapping/thread cutting, 12-348
TI, 8-173, 8-184
TM, 8-173 X
TMAPC, 8-173, 8-184
TO, 8-173, 8-184 X1, Ext. power supply, PP72/48, 2-80
Torque reduction, 19-524 X101, PROFIBUS DP, MCI board, 2-47
High-resolution, 19-523 X102, MPI/DP interface, MCI board, 2-47
Touchware, 5-117 X111, dig. inputs/outputs, PP72/48, 2-82

03/2006 Index
X121, I/O MPG extension, MCI board Ext., 2-57 X4: MCI board extension, 2-53
X121: I/O MPG extension, 2-53
X2, PROFIBUS DP, PP72/48, 2-81
X222, dig. inputs/outputs, PP72/48, 2-82
Z
X3, Battery connection, MCI board, 2-48
X333, dig. inputs/outputs, PP72/48, 2-82 Zero speed tolerance, 12-361
Zero-speed monitoring, Delay time, 12-361

To Suggestions
SIEMENS AG Corrections
A&D MC MS For publication/manual:
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SINUMERIK 840Di sl
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(Phone / Fax: +49 (180) 5050 – 222 [Hotline]
Fax: +49 (9131) 98 – 63315 [Documentation]
Email: [email protected]) Manufacturer/service documentation
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Edition: 03/2006
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Overview of SINUMERIK 840Di sl Documentation (03/2006)
General Documentation
SINUMERIK SINUMERIK SINAMICS

840D sl S120
840Di sl
Brochure Catalog NC 61 *) Catalog

D21.2 Servo Control *)
User Documentation
SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK

840D sl 840D sl 840D sl 840D sl 840D sl
840Di sl 840Di sl 840Di sl 840Di sl 840Di sl
Operator’s Guide Programming Guide Description of Description of Equipment Manual

– HMI Advanced *) – Fundamentals *) Functions Functions Operator Components *)
– Programming com- – Advanced *) – Basic Machine *) – Tool Management
pact – Programming – Extended Functions
– Lists System Variables – Special Functions
– ISO Turning/Milling
Manufacturer/Service Documentation
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840D sl 840D sl 840D sl 840D sl 840D sl
840Di sl 840Di sl 840Di sl 840Di sl 840Di sl
Operator’s Guide List Manual *) EMC Guidlines Manual Description of

– HMI Embedded – Part 1 @ Event Functions
– ShopMill – Part 2 – Synchronized Actions
– ShopTurn – Iso Dialects
Manufacturer/Service Documentation Electronic Documentation
SINUMERIK
SINUMERIK SINUMERIK SINAMICS SINAMICS
840Di sl Motors
840D sl S120
840Di sl
Programming Manual *) Description of Functions DOCONCD *)

Guide – Hardware Drive Functions DOCONWEB
– Cycles – Commissioning
– Measuring cycles
*) These documents are a minimum requirement

Overview of SINAMICS S120 Documentation (03/2006)
General Documentation/Catalogs
SINAMICS
S120
D21.2 *)
Servo Control
Drive System
(including servo motors)
Manufacturer/Service-Documentation
SINAMICS SINAMICS SINAMICS SINAMICS SINAMICS SINAMICS

S120 S120 S120 S120 S120 S120
Equipment Manual *) Equipment Installation & Getting Started List Manual *) Function Manual
Control Unit, Manual *) Start–Up Manual *) Parameters, Alarms,
Additional System Booksize Function Drawings
Components Power Sections
Manufacturer/Service-Documentation
G110/G130/
G150/
S120/S150
Motors
DocOnCD Planning Guide EMC
Motors Installation Guideline
1FK6; 1FK7;
1PH7; 1PH4; 1PH2
*) These documents are a minimum requirement

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General Information 1

EMC and ESD Measures 4

SINUMERIK 840Di sl Power-On and Power-Up 5

NCK Start-Up with

Alarm and Message Texts 13

Axis/Spindle Dry Run 14

03/2006 Edition Small SINAMICS Glossary A

Status code in the “Remarks” column:

Edition Order no. Comments

Copyright © Siemens AG, 2006. Subject to change without prior notice.

Printed in Germany Siemens Aktiengesellschaft

Notes for the The SINUMERIK documentation is subdivided into 3 parts:

Target group This document is designed for machine tool manufacturers.

A&D Technical Support Phone: +49 (0) 180 5050 222

Internet address www.siemens.com/motioncontrol

SINUMERIK Search: SINUMERIK 840Di sl

© Siemens AG, 2006. All rights reserved

© Siemens AG, 2006. All rights reserved

Additional notes Explanation of symbols

© Siemens AG, 2006. All rights reserved

Unqualified operator action of the device/system or failure to observe the war-

Should it be necessary to test or take measurements on live equipment, then

S Before opening the device, always disconnect the power supply.

S Anywhere in the automation equipment where faults might cause major

© Siemens AG, 2006. All rights reserved

ESDS information Electrostatically Sensitive Devices

S When handling electrostatically sensitive devices, make sure that operator,

S Generally, electronic modules must not be touched unless work has to be

S Touch components only if

S Modules may be placed only on electrically conductive surfaces (table with

S Do not bring ESD–sensitive modules into contact with chargeable and

S Measurements on modules are allowed only if

© Siemens AG, 2006. All rights reserved

© Siemens AG, 2006. All rights reserved

1 General Information on the SINUMERIK 840Di sl . . . . . . . . . . . . . . . . . . . . . . . 1-21

© Siemens AG, 2006. All rights reserved

2.10 Uninterruptible power supply (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

© Siemens AG, 2006. All rights reserved

5.3.8 Power-up with shutdown signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116

© Siemens AG, 2006. All rights reserved

6.7.3 Series machine start-up file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-152

© Siemens AG, 2006. All rights reserved

8.6.6 Input/output image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-201

© Siemens AG, 2006. All rights reserved

9.7.7 Example: Connecting a HHU to SINUMERIK 840Di sl . . . . . . . . . . . . 9-249

© Siemens AG, 2006. All rights reserved

12.2.2 Protection levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-302

© Siemens AG, 2006. All rights reserved

12.7 Loadable compile cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-407

© Siemens AG, 2006. All rights reserved

15.8 Print graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-461

© Siemens AG, 2006. All rights reserved

18.3.5 How to refresh the navigation view: “Manage” . . . . . . . . . . . . . . . . . . . 18-501

© Siemens AG, 2006. All rights reserved

Operator panel front

USB Networking (TCP/IP)

PCU 50.3 Networking (TCP/IP)

MCI board extension

PROFIBUS DP (2) (12 MBaud) PROFIBUS DP (1) (12 MBaud)