840D SL Commissioning Procedure Document

Index
Topic Page Number

1. Hardware Pre-requisites 2
2. Factory Setting 3
3. PLC download 4
4. Drive Configure 7
5. Drive Factory Setting Procedure 18
6. NC Archive Read in Procedure 22
7. Drive & Infeed Parameters 25
8. Axis Kinematics 29
9. License Procedure 30
10.HMI Pro Download Procedure 37
11.Safety Activation 41
12.Software Cams 53
13.External Encoder Activation 54
14.Safety Cam Activation 70
15.X130 Port Activation 72
16.Control On Requirements 77
17.Drive Tuning Procedure 80
18.NC Archive Backup Procedure 112
19.Safety Certification by Sinucom NC 120

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Author- Prasad Tarapure
 840dsl Commissioning Procedure Document

Step1:- Ensure connections & voltages at below points. Ensure CF Card is inserted properly. ALM &
AIM Phase sequence should be correct. All the encoders & motor power cables should be
connected with proper earthing.

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Step2:- Set the DIP Switch setting behind the MCP. For MCP-192(78) and for HT8-144(90)

Step3:- NC & PLC Factory Setting.

• Make switch setting to NC-1 and PLC-3.

• Power off the panel.

• Power on the panel.(Wait till 5 appears on the seven segment display)

• Put switch setting to NC=0 and press reset.

• Then make switch setting to PLC 2-3-2 within a 5 sec and after make it 1-0.(then 6 will appear on
display)

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 Step4:- CPU 319-3 PN/DP Set the IP address for NC PN-IO according to standard IP list.
Configure the PN/PN coupler, change the name according and IP also.
Add PROFIBUS I/O module comparing the Signoff & EPLAN both. Give the node address & I/O
address according to that.
If we have machine on that station communicating using DP/DP coupler than have to configure
that also. Save & Compile the Hardware.

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Step 5:- CPU 315F-3 PN/DP -
- Set the IP address for CPU PN-IO according to standard IP list.
- Configure the PN/PN coupler, change the name according and IP also.
- Add the F-DI/DO moddule as per Signoff & EPLAN.

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Step 6:- Power Up

Power up the Panel, E1 & E2 both

Connect cross cable to laptop Ethernet port to X-127 port of NCU
Download the SINUMERIK Hardware to the NCU controller.
Download the whole SINUMERIK project(Block) to the NCU.

Set all the IP address using Edit Ethernet Node physically.

-CPU315F-PN/DP
-PN/IO of NCU
-Scalance
-PN/PN Coupler X1 & X2 Port

Connect cross cable to laptop Ethernet port to Safety PLC.

Download the SAFETY PLC Hardware to the CPU315F-PN/DP controller.
Download the whole SAFETY PLC project(Block) from Safety Download, option.

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Step 4: Drive Configure

Click to Setup->

And then go through each step as shown in below screenshots.

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Enter password:- SUNRISE
And press Ok.

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Click to Setup->Drives->Configuration

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Press Ok

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Status display..Do not press any tab.

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After all the steps are completed, this screen will be displayed. Press ‘Infeed’ tab to set the
voltage parameters.

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Enter here 400 V for India. When the gantry is dispatched to other county, set the voltage
according to that country standard. For example in US it will be 480V.
Press ‘Next’

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Press Yes.

Go to the Setup/Drive System/Drives/Configuration / Topology. It will show all the

connected drives and component to each other.
Crosscheck whether all the component comes under the topology.
Then Power recycle the power. (Power OFF & then ON)

Note: If a new hardwired component added after making first

topology at that time that component will show red marked. Now
goto Topology & press Add Component. It will automatically
include that component to topology by itself.

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Add component tab will be enabled , if there is a component which is to be assigned
yet. If all the components are added, then this tab will be disabled.

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 Factory Setting
Note:- This is an exceptional case for lower versions of 840dsl. Do not try unless you are sure
about using this option.

In some cases if the Drive or Motor or Encoder has been changed, normally be using ‘Add
component’ tab in the topology, that particular component should be added. But in the lower
versions of 840dsl this doesn’t work. The Drive configuration screen gets hang, if you try to click
there.

So in this case we have to Factory set all the drives. And then only the new component will be
accepted by drive automatically.
This option is available under Setup→DriveSystem->Drives

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Note:- This is an exceptional case for lower versions of 840dsl. Do not try unless you are sure
about using this option.

Press Drive Device here. So that all of the drives will be set to Factory Setting.

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Note:- This is an exceptional case for lower versions of 840dsl. Do not try unless you are sure
about using this option.

Press OK .

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Note:- This is an exceptional case for lower versions of 840dsl. Do not try unless you are sure
about using this option.

After the Factory setting has completed, this screen will be displayed automatically. From this point
you can configure all the drives. So with this way the new component will also get added.

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Once all the components have been shown in the Topology, now we will load the NC archive.

Please follow through below steps.

Press Setup→Right Click→Setup Archive

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Put the USB drive in & select the desired NC archive that you want to read & press Ok.

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Archive read in process will start. This takes about 15 minutes to complete.

After the Read in archive procedure is completed, it will show the message as
‘Archive read in successfully completed’.

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Now we need to change few parameters as mentioned below.

Click to Setup→Machine Data→ Supply MD/ Infeed Parameter

• Then search Parameter 840. Change the value to BICO 1-2091-0

• Then make P10 to 0.

• Save → Current DO

Click to Setup→Machine Data→Drive Parameter

• Search P10 & make it 1.

• Then search 849 makes it 1-2091-1

• Then make P10 to 0

• By pressing Drive+ tab, change this parameter for all axis.: X,Z1,Z2,C1,C2

Note:- This change is applicable only for gantries, where OFF1 & OFF3 are managed from the
parameters & PLC Program in OB 35. For the gantries whose OFF1 & OFF3 are managed by
hardware relays, this parameter setting is not applicable. Value should be kept default (factory
setted) in such cases.

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Click to In Drive MD:-

• Make P10=3

• 1821=1 for X counter clockwise.

• 9516=2H only for X

• Make P10=0

Axis Using NX Module:

Click to Setup→Right click→Comm Parameter
Comm Parameter:
p8500(0)/(1) BICO 1:2091.1 Source as CU

Note:- This parameter should be changed only in case of 2 channel gantry.

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Drive Parameter to be changed in case of 2 channel gantry.
For Axis,(X2,B1,B2)
p10 Drive Commissioning Parameter filter 1
p849 OFF3 BICO 1:8510.1 Source (As NX)
p10 Drive Commissioning Parameter filter 0
Save → Drive Device

For Safety:
p10 Drive Commissioning Parameter filter 95
p9515 SI Motion Coarse position value config 10001
p10 Drive Commissioning Parameter filter 0
Save → Drive Device

Now, only for X Axis: (Special Case)

p10 Drive Commissioning Parameter filter 3
p1821 Dir or Rot (1)Counterclockwiswe
p9516 SI Motor Encoder Config, Safety Relevant 2H
p10 Drive Commissioning Parameter filter 0

36925 Safe encoder polarity = -1

SPECIAL CASE:- Gantry +Ve Direction in Right Hand Side of Operator,
& -Ve Direction on Left Hand Side of Operator. (X Axis Movement)
p2000 Refrence Speed/Refrence Frequency set this Parameter
according to Kinematic Data.

Save → Current DO
POWER OFF/ON(Panel)

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Kinematics:-

For example:- Kinematics for GL160 Gantry.

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Licensing:-

Initially when license is not entered, the license screen will be showing below message in red
‘License key NOT sufficient[

We need to get the license from Siemens website for Specific OP and Specific CF
Card.
Note down the CF card number from License Screen.

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Go to the website page shown below in red.

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Enter the license number & dispatch note number which is available on the certificates, you’ve
received with the package.

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Select the appropriate product in the dropdown list.

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Add all license number & dispatch note number one by one , here.

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When you are done with entering all the licenses, press 'Assign Entered License'.

Refer the below image. After completion of above stages, you will get the pdf certificate.

License number is shown in red underlined sentence.

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After entering the license number, screen will show the message as ‘License Key is Sufficient’.

License activation procedure is completed now.

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HMIpro:-

Transline: Using HMI PRO CS

i) Target Computer Setting

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-Select NCU 7x0 based on HMI operate
-Set the target IP,( X127 or X130 )

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Select Installation of transline system on target computer, if you are downloading HMI Pro
software, on the system for the first time.

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Installation of transline system on target computer- should be done only once.

Then if future if you change, add,modify the screens of HMI Pro, then for downloading , we should
use ‘Installation of project on target computer’ option.

After Installation of system on target computer follow below procedure.

Setup→Extended Reset PO → Drive,NC,HMI or POWER OFF/ON(Panel)

After Installation of project on target computer follow below procedure.

Extended Reset PO → Drive, NC,HMI or Reboot HMI.

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Safety Integrated & HMI Advance.
Connect the LAN cable between laptop & X127 port of NCU.
Set IP address as ‘Automatic’ in the laptop.

1. Open HMI ADVANCE SOFTWARE on your laptop.

2. Press F10 on computer Keyboard
Setup → > key → Safety Integrated → Axis MD
3. 36901 $MA_SAFE_FUCTION_ENABLE 41H
Change this for all 3/5/6 axis
4. Copy SI Data.
5. Activate Drive Startup.
6. Deactivate Drive Startup.

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Software Cams:-

NC Settings in General MD:-

MD 19310 = 04H
NCK RESET
MD10450 [0] =1 ; AXIS NO 1 ( eg X)
MD10450 [1] =3 ; AXIS NO 3 ( eg Z)
NCK RESET
GOTO OFFSET → SETTING DATA → MISC
41500[0] = 0.25 ; -VE LIMIT FOR X
41500[1] = 0.25 ; -VE LIMIT FOR Z
41501[0] = -0.25 ; +VE LIMIT FOR X
41501[1] = -0.25 ; +VE LIMIT FOR Z

Software Cams:-

PLC Settings:
DB31.DBX2.0 ; ACTIVATE SOFTWARE CAM FOE X
DB33.DBX2.0 ; ACTIVATE SOFTWARE CAM FOR Z
NOTE: These signals should be continuously set in PLC for respective
axis.
DB10.DBX110.0 IS RELEATED TO 41500[0]
DB10.DBX114.0 IS RELEATED TO 41500[1]
DB10.DBX110.1 IS RELEATED TO 41501[0]
DB10.DBX114.1 IS RELEATED TO 41501[1]
Please refer xx_Master Tag List
PLC Block: FC525
NOTE: At the time of testing please just put the Axis Reading values in the respective
parameters 41500[xx]. NO need to do other settings .

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External Encoder
1. Open HMI Advance / HMI Screen (OP console)
2. For a particular axis, in which External Encoder is to be activate, make
that axis safe disable by making parameter 36901=0 (safety parameter)
then Copy & confirm & Finally Do NC Reset.
Make sure that drive enable is off, or press the Emergency or
Unplug the EP signal connector before start configuring. Either it will
show a massage at Step 5.
3. Click→Setup→Drive System→Drives
5. Select "Change" for particular axis (X Axis).
6. Do "Next".

Note :- configuration of External encoder from NC screen itself, this feature is optional. For the
CNC systems, who do not have below option, have to configure the external encoder, by using
the HMI Advanced software. In the HMI Advanced software also , need to follow the same
procedure as mentioned in this screenshot.

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Note :- configuration of External encoder from NC screen itself, this feature is optional. For the
CNC systems, who do not have below option, have to configure the external encoder, by using
the HMI Advanced software. In the HMI Advanced software also , need to follow the same
procedure as mentioned in this screenshot.

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External Encoder
NC PARAMETERS:
AXIS MD:
1.31040[1]=1
2.30200: Number of Encoder = 2
3.30240[1]=4
4.34200[1]=0
PLC Logic:
FC30:
DB31.DBX1.5 Position Measuring system 1
DB31.DBX1.6 Position Measuring system 2
NOTE: One of these two bits must have to be always ON, according to
the selected measuring system from NC

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INSE(P) & OUTSE(P) Configuration:

Step 1 : Set the following Machine Data.

Settings for INSE(P)
13340 _RDP_ENABLE_MASK 1H (screen F_RECVDP
communication
relationships)
13341 SAFE_RDP_ID 2H (for F_RECVDP communication
relationships)
13342[0] SAFE_RDP_NAME "INSE_01_04" (of SPL connection)
13343[0] SAFE_RDP_CONNECTION_NR 2H (SPL connection to
system variables)
13344[0] SAFE_RDP_LADDR 1312 (address of the input/output data
range F_RECVDP in
pnpngantryopXX)
-----------------------------------------------------------------------------------------------------------------------------------

INSE(P) & OUTSE(P) Configuration:

13345[0] SAFE_RDP_TIMEOUT 3 (time F_RECVDP)

13345[1] SAFE_RDP_TIMEOUT 3
13345[2] SAFE_RDP_TIMEOUT 3
13345[3] SAFE_RDP_TIMEOUT 3
13346[0] SAFE_RDP_ASSIGN 1004/8/16 As per INSE(P)
(assignment.
F_RECVDP user data to $A_INSE)
13347[0] SAFE_RDP_FILTER FFFF (user data filter between
F_RECVDP and $A_INSE)
13348[0] SAFE_RDP_ERR_REAC 0
-----------------------------------------------------------------------------------------------------------------------------------

INSE(P) & OUTSE(P) Configuration:

Settings for OUTSE(P)
13330 SAFE_SDP_ENABLE_MASK 1H
13331[0] SAFE_SDP_ID 1
13332[0] SAFE_SDP_NAME OUTSE_01_16
13333[0] SAFE_SDP_CONNECTION_NR 1
13334[0] SAFE_SDP_LADDR 1312
13335[0] SAFE_SDP_TIMEOUT 3
13336[0] SAFE_SDP_ASSIGN 1016
13337[0] SAFE_SDP_FILTER FFFF
Step 2: Reset (PO)
Step 3: Copy SI Data
Step 4: Confirm SI Data
Step 5: Reset (PO)
-----------------------------------------------------------------------------------------------------------------------------------

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Safe Cam Active

For activating Safe Cam in any OP do as follow:

1. Enable the safe cam's for track1 & Track2 as per OP requirement only
for X Axis. These safe cam's are axis specific.
Cam 0 to Cam 14 are for Track1 & 15 to 29 are for Track2
Track 1: For Machine's.
Track 2: For Auxiliary systems.
For activation of cams follow the XX_Master_Taglist & enable them.
36903 $MA_SAFE_CAM_ENABLE
2. After enabling set the range of cam values in following parameters,
36936 SAFE_CAM_POS_PLUS
36937 SAFE_CAM_POS_MINUS

Note : The range of one cam with another cam in same track must not
overlap each other.
Also in FC527_SafeCamPosition have to check the logic for Track 2 as
per activation of safe cams, in BCD format. And for safety cam position to
Safety PLC check logic in FB900, OUTSE(P) bits.
Error: Axis Not Safely Referenced.
Remedy: Change the parameter 36944 from default value to 1 mm.

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X130 Activation
Step 1: Change the firewall setting of X130 port in "basesys.ini" , by using RCS Commander
software.
Step 2: Set IP address for X130 port (172.16.xxx.21),subnet
mask(255.255.0.0) on HMI, in TCP/IP configuration.
POWER OFF/ON

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Step 3: Change the IP in Sinumerik Hardware for CP840Dsl
(172.16.xxx.21), along with subnet mask (255.255.0.0).
Step 4 : Download the Sinumerik Hardware using X130 port IP
-172.16.xxx.21.

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Troubleshooting Parameters:- (parameter settings will vary from axis to axis depending upon
the payload)

JERK PARAMETER:
Applicable for all axis
32400 $MA_AX_JERK_ENABLE - 1
32410 $MA_AX_JERK_TIME-0.1s -- Default-0.001s
32430 $MA_JOG_AND_POS_MAX_JERK-10 -- Default-1000ms3
32431 $MA_MAX_AX_JERK-10
32402 $MA_AX_JERK_MODE-1
32420 $MA_JOG_AND_POS_JERK_ENABLE-1(Xaxis) --Default-0

Drive Parameters:- (parameter settings will vary from axis to axis depending upon the payload)
p1460(0)= Speed controller P gain
p1461(0)=15ms
p1278 = Brake control Diagnostic Evaluation

NC Parameters:- (parameter settings will vary from axis to axis depending upon the payload)
36100 $MA_POS_LIMIT_MINUS
36110 $MA_POS_LIMIT_PLUS
31030 $MA_LEADSCREW_PITCH
31050 $MA_DRIVE_AX_RATIO_DENOM
31060 $MA_DRIVE_AX_RATIO_NUMERA
32000 $MA_MAX_AX_VELO
32300 $MA_MAX_AX_ACCEL
32200 $MA_POSCTRL_GAIN
30200 $MA_NUM_ENCS
34210 $MA_ENC_REFP_STATE
34100 $MA_REFP_SET_POS
36400 $MA_CONTOUR_TOL
36930 $MA_SAFE_STANDSRTILL_TOL

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After all of the above the process clear all Estops from PLC.

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If below error pops up then please check the followings:
1. Communication between F-PLC & NCU PLC through
PN/PN Coupler broken.
2. NC/PLC of NCU in Fault Mode.
3. Safety PLC in STOP Mode/Faulty.
4. PN/PN Coupler Not configured.(Or configured incorrectly)
5. Check profinet cable connections. Ping the IP addresses.

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 Optimization Test (Drive Tuning)

Click to Setup→Optimization Test

Note:- It is recommended that gripper should have the part & then tuning should be carried out.
So that drive will calculate the gain & current with load for the particular axis. So Pick the part
manually in the gripper for the particular axis, of which, you want to perform, drive tuning.

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Select the desired axis that you want to tune.

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Make sure that your axis is at the middle position from negative & positive softlimit.

If its very near (5mm + or – from the soft limit value) the drive tuning will give error.

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Press cycle start at this stage.

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Press Ok, when Finished , ready to rerun message appears in green baground.

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System screen will display the date & time of the tuning completed. Select the different axis &
perform the tuning procedure. It is recommended that gripper should have the part & then
tuning should be carried out. So that drive will calculate the gain & current with load for the
particular axis.

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 NC Archive Backup Procedure

We need to take archive of the system periodically. Especially before dispatch or when we are
about to make major changes in the system & we are unaware of results. It is always
advisable to take NC archive in such circumstances. Below is the procedure to take archive.

Click to Setup → Right Click→ Setup Archive

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Here you have option of archive

1) Either you can take all inclusive archive – NC, PLC, Drive, HMI in one file itself.
2) Or you can take individual archive of each section. It is advised that, we should take individual
backup & all inclusive as well. This is easy , when we need to check some parameters offline.
Always select drive parameters data options should be ‘ASCII format’.

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Below is the example of, individual section’s archive procedure.

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Once archive procedure is completed, you can get the file stored at Manufacturer’s directory. You
can copy & save it to USB for backup.

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 Safety SI Report Certification Procedure

1) Laptop IP address should be kept is ‘Automatically’

2) Connect the lan cable between laptop & X127 port of NCU
3) And follow through below steps

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