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SINUMERIK 840Di Manual

1. 194 a 6 5 22 CRE g q im ci T l D SEVENS A B CDE 10 10 170 35 0 ere p SE Ss G IER AE JG 8 Fig 2 25 Dimension drawing I O module PP72 48 Siemens AG 2005 All rights reserved 2 94 SINUMERIK 840Di Manual HBI 01 05 Edition 2 Hardware Descriptions Technical data 2 11 I O module PP72 48 Technical data of I O module PP72 48 Safety Degree of protection Protective class Approvals Power consumption At nominal load Mechanical data Dimensions WxHxD mm Weight Climatic ambient conditions Heat dissipation Temperature limiting values Relative air humidity limits Condensation Atmospheric pressure Transportation altitude IP 00 Protection class I in accordance with VDE 0106 P1 1982 IEC 536 Protection against ingress of foreign bodies and water in accordance with IEC 529 UL CSA CE 11W 194 x 325 x 35 approx 0 3kg without mounting plate approx 1 2kg with mounting plate
2. 01 05 3 Design 3 3 Overview of connections 3 3 Overview of connections 3 3 1 PCU50 MCI board and MCI board extension SINUMERIK 840Di Maximum 2 handwheels can be PCU 50 connected dig I O max of 4 each Cable 6FX2002 4AA41 1L110 Probe max of 2 55 2a En Electronic 2 Cable 8 6FX2002 4AA2T 1O00 nandwneel 2N lt 25m max of 2 Cit Oo Cable Distributor 4 6FX2002 4AA21 1L1_10 6FX2006 1BG00 Mini HHU lt 25m for handwhee signals Cable UT ooo Distributor Ho mes iy 6FX2006 1BC01 a E B MPI D signals E 6FX2006 1BF00 O J 20 _ Distributor for 4 6 215 Ra core Cable Handheld FX2002 1AA23 1000 i Re 6FX2006 1BH01 aon 7 terminal HT 6 D E 30 2 8 1 z 5 3 Programming device 8 E e g PG740 SE FE ed 7 a a Machine control panel i 83 PROFIBUS DP diagnostic repeater 2 Y a Pushbutton panel 1 PP 031 MC MCPs e g 10 MCP 483 MCP 310 1 1 0 module PP72 48 PROFIBUS DP 2 lt 12 Mbaud lt 100m 3 PROFIBUS DP 1 12 Mbaud lt 100m 1 1 1 PROFIBUS DP drives e g 8 SIMODRIVE 611 universal Seon GE Imeri ADIK AIRE SIMODRIVE POSMO A Se Fig 3 10 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Connection overview PCU 50 MCI board and MCI board extension 3 107 3 Design 01 05
3. SINUMERIK 840Di PROFIBUS DP drive Position setpoint on tie Position RE Speed ke Current RSP aton controller eo controller eee controller Encoder 4 4 Nact iact Actual current value Speed actual value Actual position value Fig 10 16 Control loops Traversing If the axis does not traverse into the desired direction the appropriate direction adaptation is made in e 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 e MD32110 ENC_FEEDBACK_POL sign of actual value adapted Servo gain To obtain high contour accuracy a high loop gain Ky factor of the position controller is required However an excessively high Ky factor causes overshoot instability and impermissibly high machine loads The maximum permissible Ky 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 10 334 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles Definition of The servo gain factor is defined as the ratio of velocity in m min and the Ky
4. analogously ext power supply PP72 48 24V stabilized X111 X222 X333 424V ov pin number 47 48 49 50 DOCOMx lt 31 Px Relays Driver Driver ES 32 Driver LE 46 1 M M Fig 2 24 Terminal assignment for the digital outputs e Connecting cable The required connecting cables ribbon cables must be provided by the user e 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 con nected to X111 X222 X333 Pin 1 M For further data see Subsection 2 11 3 Page 2 92 Caution At the user end it must be ensured that the maximum current drawn per DOCOM x 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 connected to all 4 pins X111 X222 X333 Pin 47 48 49 50 for each DOCOM x 2 90 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 11 1 0 module PP72 48 e Electrical specification of the digital outputs Table 2 20 Electrical specification of the digital outputs Digital outputs Min Typical Max Nominal Voltage at high level Vh Voc 3V 1 V
5. ON 1 PE A 1 2 3 4 5 6 7 _ 8 Note 1 4 32 37 e The valid settable address are 3 to 126 e The set address is read by POSMO SI CD CA and displayed using P0918 PROFIBUS node address Fig 9 2 Setting the PROFIBUS address and terminating resistor Notice To set the PROFIBUS address and terminating resistor it is necessary to remove the PROFIBUS unit 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 Chapter Connecting the PROFIBUS unit Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 9 273 9 Drive Start Up 01 05 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI 9 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 gt 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 gt Programs gt SimoComU gt SimoComU 2 In SimoCom U open the interface dialog using the menu command Tools gt Communication SimoCom U dialog Dialog box Interface box Start Radio button
6. SINUMERIK SINUMERIK SINUMERIK 840D 840Di 840Di 840D 840Di 810D 810D Description of Manual Manual Functions HW Installation Event ISO Dialects for and Start Up SINUMERIK SINUMERIK SIMODRIVE 840D 840Di 810D 611D Motors DOC ON CD The SINUMERIK System Electronic Documentation Recommended minimum scope of documentation General Documentation SINUMERIK SIROTEC SINUMERIK SINUMERIK SIMODRIVE 840D 810D 840D 840Di Accessories 810D Brochure Catalog Catalog Ordering Info Accessories NC 60 NC Z User Documentation wy 7 SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK 840D 840Di 840D 840Di 840D 840Di 840D 840Di 840Di 810D 810D 810D 810D Operating Diagnostics Operating Program Guide System Overview Instructions Guide Instructions Short Guide HT6 Short Guide Fundamentals HMI Embedded Advanced HMI Advanced Cycles Measuring Cyles ISO Turning Milling Manufacturer Service Documentation I MOTION SINUMERIK CONTROL SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK SIMODRIVE SYSTEMS 840D 840Di 840D 840Di 840D 840Di 840D 810D 840D 840Di 840D 840Di 810D 810D 810D 810D 810D 611D Description of Description of Operator Description of Description of Lists EMC directive Functions Functions Components Functions Functions Lists System Var Basic Machine Tool HW
7. lt RESET 2 O 4 NC START 1 H 2 Hi Power ON 0 A 2 a 0 1 2 3 ds ob St o o 8 56 5 8 8 2 29 oo E oo 0 88 2 2 Q Ea Ea Z lt 3 g g Standard setting 2 2 5 N da MD 35020 SPIND DEFAULT MODE Fig 10 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 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 po sition match the programmed one 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 2 3 4 10 366 The feed override switch is active IS Reset DB21 DBX7 7 does not terminate axis mode as standard 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 Axis mode can be activated in all gear stages If the position actual value encoder is installed on the motor indirect measurement system the posi tioning and contouring accuracy can vary for the different gear stages Siemens AG
8. 8 8 DPislave AD ss sus rue ut matter eueune sans 8 8 1 Slave OM E E der th nas tou ruse 8 8 2 Inserting DP Slave 8 9 DP slave SIMODRIVE drives 8 9 1 SIAVEOM tas rs cade gamed nie cages Wh hee ent 8 9 2 Inserting the DP slave 8 9 3 Parameterizing DP slaves 8 9 4 Dependencies of PROFIBUS DP communication 8 10 DP slave Diagnostic repeater for PROFIBUS DP 8 10 1 FUNCION SR ate de ee ee eee 8 10 2 Application range 8 10 3 Connection and start up 9 Drive Start Up Preconditions 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI 9 1 1 Start up Varias 45 su hrrusesuissuspinentideadretuenteininetsd 9 1 2 Preconditions for an online connection 9 1 3 Setting a PROFIBUS address SIMODRIVE 611 universal E 9 1 4 Setting PROFIBUS address SIMODRIVE POSMO SI CD CA 9 1 5 Setting the MPI interface 9 1 6 Setting the routing information 9 1 7 Starting online operation 9 2 Installing SimoCom U 10 NC Start Up w
9. 2 2 9 1 SITOP POWER standard 24V 10A 2 10 Uninterruptible power supply UPS 2 10 1 SITOP POWER DC UPS MODULE 15 2 10 2 SITOP POWER ACCU MODULE 24 V DC 10 A 3 2 AH 2 11 VO module PP72 48 2 11 1 Mod le Sd ann da ie he es 2 11 2 Interface description 2 11 3 PONOT SUPDIV 2 hie cone i axes por ede deed eevee Pr edv deta RSRK ESS 2 11 4 Grounding 22225 2 24 Las BR a or eee AR DR pts a 2 11 5 Dimension drawing 2 11 6 Technical data na Sisal eG otha ped heels pea die 2 12 ADI4 Analog Drive Interface for 4 Axes 2 12 1 Module 5888 ane en A Mane Sn eee 2 13 Diagnostic repeater for PROFIBUS DP 2 13 1 MOGI ieaie a fied went oath gr dome wane H naa piesa ha a Dem ie een E a a 3 Design 2 55 oki ted ieee tena dedans eats 3 1 System overview 3 1 1 Operator panels and touch panels 3 1 2 PROFIBUS DP components 3 1 3 MPI components 3 1 4 PCU components s 2 2 icecccew eae tinni da iaa end dabiwaws 3 2 Electrical design 3 2 1 MCI board and PROFIBUS DP
10. O LED S09 S01 S02 S03 S21 S22 S23 S36 S37 S38 Key O O O O Oo O O O O S10 S11 S12 S04 824 S25 S26 S39 S40 S41 O O O O O O O O O O 13 S14 S15 S05 S27 S28 S29 S42 843 S44 O O O O Q O O O O S16 S17 S18 S06 S30 S31 S32 S45 S46 S47 O O O O O O O O O S19 S20 S07 S33 S34 S35 S48 S49 S50 Fig 8 15 8 240 Designation of keys and LEDs Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 6 DP slave MCP 310 Input image Arrangement of key signals in the input image of DP slave MCP 310 Table 8 4 Input image Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 BitO EB n 0 Spindle override Mode NC stop SP SP 100 SP Single JOG MDA AUTO 19 36 37 38 block S09 10 13 16 EB n 1 Spindle Key Machine function NC Start SPright SP Stop SP left i REF REP TEACH S20 S39 S40 S41 i S02 S01 S11 EB n 2 Feed Mach fu Key Machine function Feed Start Feed Stop INC VAR E INC1000 INC100 INC10 INC1 S35 S34 03 S07 S06 S05 S04 EB n 3 RESET Key Key Feed override S17 Fover 16 Fover 8 Fover 4 Fover 2 F over 1 X30 6 X30 7 X30 8 X30 9 X30 10 EB n 4 Direction keys Optional customer keys Rapid tra KT4
11. 16 2 2 REQUIFEMENS 2 22 nd ied ete de EREEREER REN ERNEA ee nas 16 2 3 Configuring SIMODRIVE drives 16 2 4 ROS ICONS 242 eee heb eed bie ane eee ete mens eee 16 2 5 Data descriptions MD system variable 16 2 6 ARNS 2 ona ina Net me ci nel Pease 16 3 Travel to fixed stop with high resolution torque reduction 16 3 1 Description of Functions 16 3 2 Requirements 16 3 3 Setting parameters for SIMODRIVE drives 16 3 4 Setting parameters for the SINUMERIK 840Di NC 16 3 5 ReStrICTIONS sersrrrnrers tirio Be Sea dns de ee ee wee ee 16 3 6 Data description MD 16 357 AATE 2 880 weed eee wie S we eee esata tre A Abbreviations 22 242828 sua eee aa sind save dia nie eee A 517 B R f rences 2 1 0 1 02 44meu es lect ee eee nett Slee C EC Declaration of Conformity C 535 D Index 5er sean teinte ie asmitum tea Index 537 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition XIX SINUMERIK 840Di Manual 01 05 Contents XX Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition General Notes on the SINUMERIK 840Di 1 1 Overview of SINUMERIK 840Di Wi
12. 3 2 2 MCI board and MPI bus 3 2 3 MCI board extension 3 2 4 PCUSDO ea a E E E 3 3 Overview of connections 3 3 1 PCU50 MCI board and MCI board extension 4 EMC and ESD Measures 4 1 Interference suppression measures 4 2 ESD measures saeide uen anus ea aient 5 Power On and Power Up 5 1 Preparing for start up 5 1 1 Checklist rsrsrs wt eae etna ins ae Naas laitiers 5 1 2 Recommended sequence for first start up 5 2 First POWE UD sass aes LOU wig at Meda ale a eae ee catered 5 2 1 Basic start up of the system software 5 2 2 Basic start up of the PLC 5 2 3 Machine control panel MCP boot 5 2 4 Power up SIMODRIVE 611 universal drives 5 3 BOONG usure bauen a dame btu aaia a ana nari a ade wanda ec anes 5 3 1 Boot manager 5 3 2 SRAM handling 5 3 3 Start up after battery replacement backup battery of the MCI board 5 3 4 Start up after replacement of the MCI board xii Sieme
13. Fig 10 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 10 33 Parameter set dependent machine data Number Name of identifier Name Refer ence Axis channelspecific MA_ 31050 DRIVE_AX_RATIO_DENOM n Denominator load gearbox 31060 DRIVE_AX_RATIO_NUMERAfn Numerator load gearbox 32200 POSCTRL_GAIN n Ky 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 matching 35110 GEAR_STEP_MAX_VELO n Maximum speed for gear change 35120 GEAR_STEP_MIN_VELOfn 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 CELfn 85210 GEAR_STEP_POSCTRL_ACCEL n Acceleration in position control mode 36200 AX_VELO_LIMIT n Threshold value for velocity monitoring Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 333 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 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
14. 10 9 Initial settings 10 10 NC PLC Diagnosis 28483 2286 samba Oh dike whe a EE E 10 400 10 10 1 Menu Diagnostics 10 10 2 Menu Settings 11 Alarm and Message Texts 11 1 Alarm and message texts 11 1 1 Configuration file MBDDE INI 11 1 2 Standard text files 2222408 bu admadun do sas disatreent eine 11 1 3 User text files 32 eve ed sata es etat antenne 11 1 4 Syntax for alarm text files Siemens AG 2005 All rights reserved a SINUMERIK 840Di Manual HBI 01 05 Edition XVII SINUMERIK 840Di Manual 01 05 Contents 12 13 14 15 xviii 11 1 5 Setting the alarm log properties 11 412 Axis Spindle Dry Run 44 s sssss 12 1 12 2 12 3 Preconditions 43228 he AA AXIS UY TUM 44228 4 vertus NERAN REREN EERE ARNOA RRAN Spindle dry run Drive Optimization with HMI Advanced 13 1 13 2 13 3 13 4 13 4 1 13 4 2 13 4 3 13 5 13 6 13 6 1 13 6 2 13 6 3 13 6 4 13 6 5 13 7 13 8 13 9 User Data Backup Series Machine Start Up 14 1 14 2
15. 5 5 2 SINUMERIK tools and options 5 133 5 5 3 DOS Shell ajc dpa ahattinae dee ate ee es alee eae eee 5 133 5 5 4 Starting Windows service mode 5 5 5 SINUMERIK System Check 5 134 5 5 6 Backup Restore 2 20 cece cece eee eens 5 135 5 5 7 Restore Windows Partition E Emergency 5 5 8 840Di services 5 6 Configuring the network link of PCU LAN WAN 5 6 1 Configuring the network link Windows XP 5 6 2 Configuring the network link DOS Service menu 5 7 License management 6 PEC Start Up 125 14s 122104 idee dial eteieawee sei dee er 6 1 G n ral gee cused ears a nied eure ad area nse oak wre ae lta a Rede ae nMe oa ere aha te boa 6 145 6 1 1 COMPAID orere ranr Enne ne E EEE EEE eine 6 1 2 Performance data 6 145 6 1 3 PEC Program 28e woke date ever deka ht Teen ee raret 6 146 6 1 4 Installing the PLC basic program library 6 1 5 PLC user program 6 6 2 SAS ee bet auns 6 2 1 Basic requirements 6 149 6 2 2 Communications link 2 6 2 3 First STATE sel assure hote
16. Start up CHAN1 JOG Ref MPFO Channel Program aborted RESET ROV Fa Settings Signal input for shutdown behavior Signal source deactivated z Signal level j z Modified el Diagnostics Fig 10 36 Menu Settings Modifying data After switching to the menu the displayed data are 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 9 e Signal input for shutdown behavior Signal source This selection field is for configuring the digital input used for the shutdown signal of the UPS e deactivated No input signal is present e 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 61 Siemens AG 2005 All rights reserved 10 404 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 10 NC PLC Diagnosis e Signal input for shutdown behavior Signal level This selection field is for configuring the level of the shutdown signal of the UPS e Low active On detection of the low level 0 at the configured input SINUMERIK 840Di NCK PLC and then Windows XP is ended e High active On detection of the high level 1 at the configured input SINUMERIK 840Di NCK PLC and then Windows XP is ended Making changes To apply the changes you have made press the
17. 15 475 15 5 1 Backing up the hard disk contents in an image file 15 475 15 5 2 Restoring hard disk contents from an image file 15 478 15 5 3 Configuring the Ghost parameters 15 482 15 5 4 Backing up partitions C E a F to local image file 15 486 15 5 5 Changing the maximum number of local image files 15 488 15 5 6 Deleting local image files 15 489 15 5 7 Restoring partitions C E amp F from local image file 15 490 15 5 8 Restoring Partition E Windows from the local image file 15 492 15 5 9 Defining an emergency image for partition E Windows 15 493 15 6 Restoring the as delivered state 15 495 15 6 1 Requirements 15 495 15 6 2 Restoring the partitions 15 496 15 6 3 Installation of the SINUMERIK 840Di applications 15 496 16 840Di specific Data and Functions 16 1 Interface signals 16 499 16 1 1 840Di specific interface signals 16 499 16 1 2 Interface signals not supported 16 499 16 2 Expanded message frame configuration 16 2 1 Description of functions
18. 6 PLC Start Up 01 05 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 lt 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 References The PLC program is modular in design It comprises the two parts PLC basic program 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 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 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 Chapter P3 Basic PLC Program 6 1 4 Installing the PLC basic program library 6 146 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
19. Fig 8 7 Enabled isochronous DP cycle Notice If there are different types of isochronous DP slaves in a S7 project e g different SIMODRIVE 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 219 8 PROFIBUS DP Communication 01 05 8 3 Creating a PROFIBUS configuration Equid master cycl After synchronization to the isochronous DP cycle has been activated for all DP percentage slaves the timer requirement of the cyclic portion of DP communication must be Tox calculated Calculation is performed by the DP master on activation of the isochronous bus cycle Dialog box Tab card General Continuation Group box Station Master System Button PROFIBUS Dialog box Properties PROFIBUS Interface SIMODRIVE Tab card Parameter Button Properties Dialog box Properties PROFIBUS Tab card Network settings Button Options Dialog box Options 1st radio button Activate isochronous bus cycle O 2nd radio button Activate isochronous bus cycle M Isochronous DP When calculating the cyclic portion of the PROFIBUS communication the time cycle Tpp for the isochronous DP cycle is automatically changed to the time required as the minimum This change must b
20. 0 840Di PLC317 2DP ERO SIMOD 15 ADI4 DP master 61 b UMC S7FMNCU ea A a Fig 10 12 Configuration Axis with 2nd measuring system on ADI4 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced l O addresses and message frame types NC machine data 10 5 Axes and spindles The I O addresses and message frame types for the drive and ADI4 axis are set to the following values in the configuration Drive 1 O address 258 Message frame type Message frame 102 DP slave properties x General Configuration Cycle clock synchronization Encoder Word Total length Word Total length Fig 10 13 DP slave properties SIMODRIVE 611U ADI4 I O address 472 Message frame type Standard message frame 3 DP slave properties x General Configuration Cycle clock synchronization Encoder Qdard message frame PROFIBUS partner PR 1 O add IO PDA 5 9 Am 4 axes each with one encoder sta serar Unit Consistency 9 Word Total length Actual point 5 Word Total length Setpoint Fig 10 14 DP slave properties ADI4 The general and axis specific NC machine data are then set as follows Drive assignment The axis of the SIMODRIVE 611U drive module is assigned to the NC as the 1st machine axis This requi
21. Control unit Fig 9 1 Display and control unit Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 9 271 9 Drive Start Up 01 05 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI Requirements Sequence of operations References 9 272 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 To set the PROFIBUS address proceed as follows 1 Setting the PROFIBUS address parameter P0918 Hold down key P longer than 3 seconds gt 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 gt 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 gt After power up the set PROFIBUS address i
22. Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 85 2 Hardware Descriptions 01 05 2 11 1 0 module PP72 48 PROFIBUS DP Interface description of the PROFIBUS DP interface X2 X2 e Connection 9 pin SUB D socket connector e Pin assignment Table 2 16 Pin assignment PROFIBUS DP X2 Pin Designation Type Function 1 2 3 RxD TxD P B Receive transmit data P B line 4 RTS O Request to Send 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 m 1 VO Voltage Output O Output B Bidirectional e Male connector 6ES7972 0BA40 0XA0 cable outlet 359 without PC socket connector 6ES7972 0BB40 0XA0 cable outlet 35 with PC socket connector 6ES7972 0BA11 0XA0 cable outlet 90 without PG socket connector 6ES7972 0BB11 0XA0 cable outlet 900 with PG socket connector e Cable 6XV1830 0EH10 by the meter non trailable 6XV1830 3BH10 by the meter trailable e Additional technical specifications Maximum possible data rate 12 Mbits s PROFIBUS The PROFIBUS address of the ADI4 can be set in the range 1 to 127 using address S1 switch S1 Table 2 17 Meaning of switch S1 Switches Meaning 1 PROFIBUS address 2 1 2 PROFIBUS address 2 2 3 PROFIBUS address 22 4 4 PROFIBUS address 23 8 5 PROFIBUS address 24 16 6 PROFIBUS address 2 32 7 PROFIBUS address
23. IS Travel command minus DB31 DBX64 6 i IS Travel command plus minus F DB31 DBX4 7 and 4 6 IS Referenced synchronized ll nr DB31 DBX60 4 and 60 5 Reference mark length measuring system Velocity MD 34070 REFP_VELO_POS Reference point positioning velocity i MD 34040 REFP_VELO_SEARCH_MARKER j i Reference point shutdown velocity Nok STE z Phase 1 Phase 2 Fig 10 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 e MD11300 JOG_INC_MODE_LEVELTRIGGRD INC REF in jog mode e MD34000 REFP_CAM_IS_ACTIVE axis with reference cam e MD34110 REFP_CYCLE_NR axis sequence for channelspecific reference point approach e MD30240 ENC_TYPE encoder type e MD34200 ENC_REFP_MODE referencing mode e MD 34310 ENC MARKER INC interval between two reference marks e MD 34320 ENC_INVERS inverse measuring system e IS DB21 DBX1 0 Activate referencing e IS DB21 DBX33 0 Referencing active Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 357 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Phase 1 Synchronize by overriding 2 reference marks Phas
24. ManualTurn Synchronized Extended Functions Management ShopMill Actions ShopTurn
25. 01 05 Edition PCU 50 2 70 _ PDA area 8 210 Performance options 1 23 PIV area 8 210 PLC Basic program installation 6 146 Default data 10 402 Delete program General reset 10 402 Performance data 6 145 PLC basic program Processing modules 6 148 PLC general reset 6 151 PLC operating state 10 403 6 146 PLC system errors 10 402 PLC system software 1 26 PLC Toolbox 1 36 PLC user program 6 147 Position control cycle 10 295 Setting 6 157 Position control cycle offset 10 295 Position control cycles Minimum settable 1 23 Position control loop Measurement 13 431 Overshoots 10 336 Reference frequency response Setpoint step change 13 433 Positioning accuracy of the control system 10 294 Positioning axes 10 330 POWER LED PP72 48 2 92 Power failure 1 30 Power supply 2 79 PP72 48 Power On and Power Up 5 113 Power up 5 119 After battery replacement After importing a backup cop After PCU replacement 5 123 After PCU MCI board replacement After power failure After reinstallation update After replacement of the MCI board First PP72 48 Setting the PROFIBUS address 8 226 Preparing for start up 5 113 Index 541 Index 01 05 PROFIBUS Modules 2 46 Node address PROFIBUS address Setting using an operator unit Setting using the PROFIBUS unit 9 273 SIMODRIVE POSMO SI CD CA
26. FBU FBU2 FBW HBA HBI INC PJE IPS POS1 POS2 POS3 B 532 SINUMERIK 840D 810D IT Solutions Description of Functions Tool Information System SinTDI with Online Help SINUMERIK 840D 840Di 810D Motion Control Information System MCIS Description of Functions TPM Total Productive Maintenance SIMODRIVE 611 universal universal E Closed Loop Conirol Component for Speed Control and Positioning Description of Functions SIMODRIVE 611 universal Installation Guide enclosed with SIMODRIVE 611 universal SINUMERIK 840D 840D Description of Functions Tool Management SINUMERIK 840D 840Di 810D Manual Event SINUMERIK 840Di Manual SINUMERIK 840Di SINUMERIK 840D 840Di 810D System Description Commissioning Tool SINUMERIK SinuCOM NC integral part of the online help for the start up tool SINUMERIK 840D 810D Description of Functions Configuring Package HMI Embedded Software Update Configuration Installation SINUMERIK 840D 810D Planning Guide Configuring Syntax The documentation is supplied with the software and available in pdf format SIMODRIVE POSMO A User s Guide Distributed Positioning Motor on PROFIBUS DP SIMODRIVE POSMO A Installation Guide enclosed with POSMO A SIMODRIVE POSMO SI CD CA User s Guide Distributed Servo Drive Systems Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B References POS4 POS5 S7H
27. rs 2 e ADI4 Zl ae option module MotionControl Aco with PROFIBUS DP SIMODRIVE Decentr I O system te POSMO SI SIMATIC ET 200 F zman ee sec ss sun Em Tes suma nun VO Module PP72 48 is COT au nuu Bee Machine control panel Machine control panel MCP 310 MCP 483 1 Only the PLC has access to the PROFIBUS DP 2 interface X102 Therefore no drives and no I Os PG PC e g Diagnostic repeater of the NC can be operated via this PROFIBUS SIMATIC Power PG for PROFIBUS DP line Fig 3 2 SINUMERIK 840Di system overview PROFIBUS DP schematic Siemens AG 2005 All rights reserved 3 102 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 3 Design 3 1 System overview 3 1 3 MPI components MCI board Industrial PC PCU 50 Machine control panel MCP PG PC e g SIMATIC Power PG Handheld Handheld unit terminal HT 6 type B MPI Fig 3 3 SINUMERIK 840Di system overview MPI schematic 3 1 4 PCU components PS 2 mouse CD ROM 3 5 diskette PS 2 keyboard drive drive QWERTY SITOP POWER SITOP DC UPS module 15 with standard 24V 10A SITOP POWER lead acid module i SIEMENS PG PC e g ee Optional SIMATIC Power PG VGA monitor Fig 3 4 SINUMERIK 840Di system overview PCU components
28. 01 05 Edition 2 47 2 Hardware Descriptions 01 05 2 2 MCI2 board 2 2 MCI2 board 2 2 1 Module The MC12 board is a short 32 bit PCI slot card The MCI2 board referred to be low simply as MCI board Motion Control Interface provides the following inter faces e PROFIBUS DP with Motion Control Functionality e MPI Multi Point Interface e MCI board extension slot variation Section 2 3 Page 2 57 The MCI board also provides the following functionality e PLC Compatible with SIMATIC S7 CPU 317 2 DP e Static memory SRAM for storing retentive NCK and PLC specific user data 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 Caution Some parts of the MCI board are always live because of the backup battery To avoid short circuits do not place the MCI board on electrically conductive materials Siemens AG 2005 All rights reserved 2 48 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions Order number MCI2 board Order number Bus connector Order number Backup battery Designation MCI2 board as spare part Designation Bus connector RS 485 for PROFIBUS DP and MPI 180 Cable outlet 35 Cable outlet without PG connection socket 35 Cable outlet with PG connection socket 90 Cable outlet without PG connection soc
29. 10 5 22 GSS SIGES 6 cae sade amsen dedicated Ivan TEDEN EEEa 10 5 23 Measuring systems of spindle 10 5 24 Speeds and setpoint adjustment for spindle 10 5 25 Position SOME 24 es inser cher cadandlecnstnuds mune nue ah ddim edn 10 5 26 Synchronizing spindle 24 seen ends eneaanaden wae des 10 5 27 Spindle monitoring 10528 Spindle data sec hiss oan ele niche Raider tiered 10 6 Digital and analog I O devices 10 6 1 Parameterization of the number of inputs outputs used 10 6 2 Assignment of inputs outputs to the signal modules 10 6 3 System variable A_ N 10 6 4 Digital input output bytes and system variables 10 6 5 Dynamic response 10 6 6 Configuration example 10 7 Loadable compile cycles 10 7 1 Loading compile cycles 10 7 2 Restrictions 10 7 3 Activating and licensing technology functions 10 74 Data descriptions MD 55 cvececkaw unaenea od bende Cetera 10 8 PROS OP ni lue 10 8 1 Setting the parameters for the shut down behavior 10 8 2 Data descriptions MD
30. Cause of errors error handling e t 1 The position control cycle offset chosen is too small The cyclic PROFIBUS DP communication with the drives was not yet completed with the start of the position controller Remedy Increase the position control cycle offset e t 2 The position control cycle offset selected is too large The cyclic PROFIBUS DP communication with the drives started before the position controller was completed The position controller requires more computational time than available within the DP cycle Remedy Decrease the position control cycle offset Or Remedy Increase the DP cycle time The DP cycle time is set using STEP7 HW Config See Section 6 3 Page 6 153f Siemens AG 2005 All rights reserved 10 296 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 3 System data Interpolation cycle The interpolator cycle may be chosen freely as a whole multiple of the position control cycle e MD10070 IPO SYSCLOCK_TIME_ RATIO factor for the interpolation cycle NCK CPU time The processor power of the PCU must be shared between the NC and Win share dows XP By default the NC is assigned 65 The value for the CPU time share of the NC is the maximum value that the NC will only use in the worst case If the NCK requires less CPU time it will cede it dynamically to Windows XP Le Top Le Ty NC NC Part 1 Part
31. DP Slave 611U DP slave interprets the message frames received from the DP master because of the drive parameters e Parameter P0922 PROFIBUS message frame type selection Message frame type set Message frame type 102 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 265 8 PROFIBUS DP Communication 01 05 8 10 DP slave Diagnostic repeater for PROFIBUS DP 8 10 DP slave Diagnostic repeater for PROFIBUS DP 8 10 1 Function Diagnostics SINUMERIK 840Di DP Master PG with SIMATIC STEP 7 Slave distance EJ Segment 1 Start Topology determination Diagnostic repeaters Distance to fault LI LE LEE Dre DP Slave ET200 DP slave MCP 483 POSMO A fm a DP Slave 611U ADI4 DP slave Le Segment 2 gt Le Segment 3 gt Fig 8 22 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 it is possible to display the location and cause of the fault in plaintext The diagnostic repeater primarily performs the following tasks 8 266 Diagnostic functions for two PROFIBUS segments DP2 and DP3 The diagnostic function supplies the location and causes of cable faults such as
32. FBSI FBSP FBST FBSY FBT FBTC SINUMERIK 840D 840Di 810D HMI Configuring Package ProTool Pro Option SINUMERIK supplied with the software SINUMERIK 840D SIMODRIVE 611 digital Description of Functions HLA Module SINUMERIK 840D 840Di 810D Motion Control Information System MCIS Description of Functions TDI Ident Connection SINUMERIK 840D 810D Description of Functions ManualTurn SINUMERIK 840D 810D Description of Functions Configuring OP 030 Operator Interface the various sections are listed below BA Operator s Guide EU Development Environment Configuring Package PSE Introduction to Configuring of Operator Interface IK Screen Kit Software Update and Configuration SINUMERIK 840D Description of Functions C PLC Programming SINUMERIK 840D 810D Description of Functions RPC Computer Link SinCOM NFL Host Computer Interface NPL PLC NCK Interface SINUMERIK 840D SIMODRIVE Description of Functions SINUMERIK Safety Integrated SINUMERIK 840D 840Di 810D Description of Functions ShopMill SIMATIC Description of Functions FM STEPDRIVE SIMOSTEP SINUMERIK 840D 840D Description of Functions Synchronized Actions SINUMERIK 840D 810D Description of Functions ShopTurn SINUMERIK 840D 810D IT Solutions Description of Functions SINUMERIK Tool Data Communication SinTDC Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B 531 B References FBTD FBTP
33. Notice On a DP slave 611U used with SINUMERIK 840Di the ratio between the master application cycle Tac and DP cycle time Tpp must be 1 1 Master application cycle DP cycle Tab card Clock synchronization Master application cycle msec Factor 1 Via parameter Actual value sensing Ti defines the time at which the actual value actual position value can be read in from a DP slave 611U Note You are strongly recommended to use the same value for the time of actual value acquisition Ti for all DP slaves 611U in particular if the axes interpolate Notice The following condition must be observed for the time of actual value sensing Ty DP cycle gt actual value acquisition gt base time Tab card Clock synchronization Actual value acquisition ms Factor Factor Via parameter Setpoint acceptance To defines the time when the speed set point of the NC position controller is accepted by a DP slave 611U Note You are strongly recommended to use the same value for the time of setpoint acceptance To for all DP slaves 611U in particular if the axes interpolate Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 3 Creating a PROFIBUS configuration Notice The following condition must be observed for the time of setpoint acceptance To DP cycle gt setpoint accept gt isochron master cycl percentage b
34. Overview of Documents General Documentation BU KPI IST7 IZI SINUMERIK amp SIMODRIVE Automation Systems for Machine Tools Catalog NC 60 Industrial Communication and Field Devices Catalog IK PI SIMATIC Products for Totally Integrated Automation and Micro Automation Catalog ST 70 MOTION CONNECT Cable Connectors amp System Components for SIMATIC SINUMERIK MASTERDRIVES and SIMOTION Catalog NC Z Safety Integrated Application Manual The safety program for the industries of the world Electronic Documentation CD1 The SINUMERIK System DOC ON CD includes all SINUMERIK 840D 840Di 810D 802D 802SC and SIMODRIVE publications Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B 523 B References 03 04 User Documentation AUK SINUMERIK 840D 810D Short Guide AutoTurn Operation AUP SINUMERIK 840D 810D Operator s Guide AutoTurn Graphic Programming System Programming Setup BA SINUMERIK 840D 810D Operator s Guide MMC BAD SINUMERIK 840D 840Di 810D Operator s Guide HMI Advanced BAH SINUMERIK 840D 840Di 810D Operator s Guide HT 6 BAK SINUMERIK 840D 840Di 810D Short Guide Operation BAM SINUMERIK 840D 810D Operation Programming ManualTurn BAS SINUMERIK 840D 840Di 810D Operation Programming ShopMill BAT SINUMERIK 840D 810D Operation Programming ShopTurn BEM SINUMERIK 840D 810D Operator s Guide HMI Embedded
35. Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup Machine name computer name User name Workgroup Domain 15 2 PTP network link service menu DOS The main service menu is displayed after PCU start up Select one after the other from the main menu Key 7 Backup Restore Key 1 Harddisk Backup Restore with Ghost Key 1 Configure Ghost Parameters 7 Key 6 Manage Network Drives Key 4 Change Network Settings The following menu appears CURRENT NETWORK SETTINGS Machine Name lt COMPUTER_NAME gt User Name auduser Transport Protocol TCP IP Logon to Domain No PLEASE SELECT Change Machine Name for DOS Net only Change User Name Toggle Protocol NetBEUI TCP IP Toggle logon to Domain Yes or No Change Domain Name displayed only when 4 Yes Change TCP IP Settings displayed only when 3 TCP IP o O O1 B ND Back to previous menu Your Choice 1 2 3 4 5 7 8 9 P CURRENT NETWORK SETTINGS Machine Name is where the machine name is displayed The default name is PCUXXXXXXxX You can change the computer name under Change Machine Name with key 1 You can choose any computer name CURRENT NETWORK SETTINGS User Name is where the current user name is displayed The default name is auduser You can change the logon na
36. User defined Partitioning The hard disk partitioning of the PCU can be set manually Image Partitioning The hard disk partitioning is set according to the partition size of the image file Answer the confirmation question with Y to start restoring Norton Ghost is now started The following information is displayed in the message box that opens Transmission progress Paths used Data volume Size of backup copy with compression 4 8 GB harddisk gt approx 330MB image file Time for transfer approx 15 min Notice If you cancel transfer data on the PCU will be inconsistent and it might not be possible to boot the system In that case special boot diskettes with DOS Norton Ghost and network software are required 1 You can make your own boot diskettes using an application supplied The application and a description of how to use it are on the hard disk of the PCU in directory D EBOOT 2 You will find diskettes available for downloading from A amp D MC eSupport at eSupport gt Download gt Sinumerik Software gt 840d 810d fm nc gt addon tools gt bootdisk gt Bootdisk 02 05 00 Norton Ghost closes automatically when the importing is completed 7 With restoring the backup copy to the PCU the last valid computer name with which the PCU has been identified on the network has been overwrit ten To make sure that the PCU is assigned a valid computer name again you must
37. e Activate Step7 for PCU SIMATIC STEP7 is authorized automatically when the PCU is next started up under Windows Note SIMATIC STEP7 will only be authorized on the PCU if the SIMATIC STEP7 software has already been installed on the PCU Authorization can also be performed on the SINUMERIK desktop by starting the function STEP7 Authorizing 5 5 3 DOS Shell Operator action Starting from the main menu see Fig 5 3 Page 5 132 select DOS Shell with key 3 The DOS command interpreter is started To leave the DOS Shell enter exit and conclude the command with the Re turn key Version display The version of the basic software is displayed with the command Basic software e C BaseVers txt Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 133 5 Power On and Power Up 01 05 5 5 Service menu 5 5 4 Starting Windows service mode Operator action Starting from the main menu see Fig 5 3 Page 5 132 select Start Windows ServiceMode with key 4 Following menu PLEASE SELECT 1 Standard Windows without starting SINUMERIK HMI 4 Original SINUMERIK HMI environment 5 Current SINUMERIK HMI environment 9 Return to Main Menu Your Choice 1 4 5 9 Functions You can execute the following functions via the menu e Standard Windows without starting SINUMERIK HMI After the PCU has started up Windows is started without starting a
38. Authorization Dialog box 15 1 PTP network link Windows The last two digits must be in the range 1 254 169 254 10 1 The subnet mask must be permanently set to the specified value 255 255 0 0 Dialog box Network Tab card Protocols Button Properties Dialog box Properties of Microsoft TCP IP Specify IP address IP address lt 169 254 10 1 gt Subnet mask lt 255 255 0 0 gt OK Because it is a PTP link any computer name and workgroup may be selected Tab card Identification Button Change Dialog box Identification change Computer name lt COMPUTER NAME gt Workgroup lt WORKGROUP gt OK 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 Tab card Services Button Add Dialog box Network service selection Network service Server service OK OK You enable network access in properties dialog gt tab card Enable for the di rectory in question select directory with 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 Access authorization to the drive is Everyone and Full access by default
39. Dialog box Properties of lt directory gt Tab card Sharing Shared as Sharing name lt SHARED AS gt OK Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 463 15 Software Installation Update and Data Backup 01 05 15 1 PTP network link Windows 15 1 3 Configuring the external computer Windows XP TCP IP protocol Dialog box IP address and subnet mask Dialog box Computer name and workgroup Dialog box 15 464 This section illustrates how to make and check settings for network configura tion on the external computer e TCP IP protocol e P address and subnet mask e Computer name and workgroup e Service File and Printer Sharing e Directory sharing Go to the properties dialog box of the local network links Windows task bar Start gt Settings gt Network Connections gt gt 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 Local Area Connections Properties Tab card General Internet Protocol TCP IP OK If the protocol is not shown it can be installed now The IP address and the subnet mask are automatically set by Windows XP on connection if the function Automatic Private IP Addressing is active the function is activated in the properties dialog of protocol TCP IP function is active by default Di
40. Measuring system switchover Machine data 10 5 Axes and spindles In the two axis specific machine data e MD30110 CTRLOUT MODULE NR 0 setpoint assignment logic drive number e 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 entered value m refers to the drive whose I O address is defined under the index n m 1 in MD13050 DRIVE LOGIC _ADDRESS fn see Subsection 10 5 3 Page 10 312 Once the drive configuration and setpoint actual value assignment have been parameterized an NCK reset must be executed to initiate a warm restart After the NC has powered up the set configuration is effective The interface signals e DB31 DBX1 5 position measuring system 1 selected e 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 A2 Various Interface Signals Table 10 19 Setpoint actual value channels machine data Number Axisspecific MA_ Name of identifier Name remarks Refer ence 30100 CTRLOUT_SEGMENT_NR Setpoint assignment Drive type 5 PROFIBUS DP 30110 CTRLOUT_MODULE_NR Setpoint assignment Logical drive number 30130 CTRLOUT_TYPE Output type of setpoint 30200 NUM_ENCS 0 simulation 1 speed setpoint
41. References 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 99 2 Hardware Descriptions 01 05 2 13 Diagnostic repeater for PROFIBUS DP Notes Siemens AG 2005 All rights reserved 2 100 SINUMERIK 840Di Manual HBI 01 05 Edition Design 3 1 System overview 3 1 1 Operator panels and touch panels OP 010 OP 010S OP 010C OP 015 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 Fig 3 1 SINUMERIK 840Di system overview Operator panels and touch panels Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 3 101 3 Design 01 05 3 1 System overview 3 1 2 PROFIBUS DP components MCI board 2g F4 gt Industrial PC PCU 50 Qa a a a a o ao gt D m m L iL O Oo a a a a SIMODRIVE POSMO A POSMO CD CA i I Lt E r g aT 3
42. S06 S23 S24 S25 S38 S39 S40 O O O O O O O O O S12 S07 S08 S26 S27 S28 S41 S42 S43 O O O O O O O O O O O O O O 13 14 S15 S16 S29 S30 S31 S44 S45 S46 S47 S48 S49 S50 Fig 8 20 MCP 483 keyboard layout front view Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 255 8 PROFIBUS DP Communication 01 05 8 7 DP slave MCP 483 Input image Arrangement of key signals in the input image of DP slave MCP 483 Table 8 9 Input image Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bito EB n 0 Spindle override Mode 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 02 03 08 S07 S06 S05 S04 EB n 2 Key Key Spindel Spindle Feed Start Feed Stop NC Start NC Stop Pos 0 Pos 2 Start Stop X50 4 X50 1 S48 S47 S50 S49 S20 S15 EB n 3 RESET Key Single Feed override S13 as A Block Override Override Override Override Override S14 Fover 16 Fover 8 Fover 4 Fover2 Fover 1 X30 6 X30 7 X30 8 X30 9 X30 10 EB n 4 Direction keys Key Axis selection R15 R13 R14 ee R1 R4 R7 R10 S46 S44 S45 32 35 38 S41 EB n 5 Axis selection R2 R3 R5 R12 R11 R9 R8 R6 33 34 36 43 42 40 39 37 EB n 6 Freely assignable customer keys F9 F10 F11
43. SIMODRIVE 611 universal 10 374 To allow the spindle to be positioned from the NC its position has to be adjusted 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 e MD34100 REFP_SET_POS reference point value defines the actual position of the spindle at the zero mark position The machine data e MD34090 REFP_MOVE_DIST_CORR reference point offset is used to enter the zero mark offset Machine data e MD 34200 ENC_REFP_MODE referencing mode specifies which signal is used for synchronization 1 encoder zero mark 2 BERO The drive SIMODRIVE 611 universal supports the connection of a BERO as a 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 Chapter Motion Control with PROFIBUS DP as from SW 3 1 Zero mark substitute via PROFIBUS Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles _ Chuck BERO Gearbox Motor Motor encoder Motor Power encoder connection cable Toothed belt SIMODRIVE 611 universal Fig
44. Specification of the power supply voltages 24 V DC 2 92 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 85 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 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 The external power supply voltages must be generated as functional extra low voltages with safe electrical isolation according to IEC 204 1 Section 6 4 PELV and must be grounded centrally by the user 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 me
45. assignment of the NC interface FC 26 References 7 10 6 7 202 Modes WCS MCS switchover commands Traversing keys Override to the NC through the PLC interface Notice Block FC 26 or FC is 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 For a detailed description of FC 26 and FC please refer to FB1 Description of Functions Basic Machine P3 Basic PLC Program Chapter FC 26 HPU_MCP Transfer of HT 6 signals to interface Example Connecting an HT 6 to SINUMERIK 840Di 1 Connect the distributor box electrically to the HT 6 The terminating resistor in the MPI bus connector on the distributor box for connecting the HHU must be disabled An MPI bus terminating resistor is a permanent part of the HT 6 Once power is present on the HT 6 the start screen for communication with the HT 6 system software is displayed for some seconds Press key 6 below the keyboard label PARAM to open the selection menu for the data transmission rate of the serial interface of the HT 6 After a short time or pressing the key message Waiting for PLC V 04 01 01 date time is displayed As function block FB 1 in the PLC basic program is not yet parameterized no communication is established with the PLC Setting the call parameters of function block FB 1 in organization blo
46. 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 9 269 9 Drive Start Up 01 05 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI 3 SimoCom U is installed on the SINUMERIK 840Di and is routed from the PLC to the PROFIBUS Via the PROFIBUS DP interface of the MCI board SimoCom U is connected to all drives using a PROFIBUS cable Recommended Within the framework of SINUMERIK 840Di the procedure described above procedure Point 3 is recommended The advantages of this procedure are e SimoCom U is always available for start up diagnosis controller optimization software upgrade of drive firmware software upgrade of option module firmware e No additional PG PC required e No additional cables required Siemens AG 2005 All rights reserved 9 270 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 9 Drive Start Up 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI 9 1 2 Preconditions for an online connection To be able to establish an online connection between SimoCom U and the SIMODRIVE 611 uni
47. 10 402 Battery replacement Performing Battery type 2 51 Blue screen 1 29 Boot manager 5 119 Bus connector PROFIBUS and MPI 2 49 Cable distributor 2 65 Connector assignments 2 67 Cable outlet Certification Extensions 1 28 Changing the language Channel axes 10 308 Checklist Preparing for start up 5 113 Circularity test Clamping tolerance Cold restart 10 317 Color depth Setting 1 27 Switching over 1 28 Compile cycle SW version 10 395 Compile cycles Restrictions Retrofitting Complete system 2 45 Computational resolution 10 286 Configuration Loading into the PLC 7 174 8 224 Connection assignment Cable distributor 2 68 Consistency check Contour monitoring Control direction Index 537 Index 01 05 Control loops Coordinate axes CPU time share 10 297 Current control loop Measurement 13 427 Current version 5 131 Customizable message frame configuration Cycle times 10 295 Cycles 10 306 Backing up Changing 10 306 Option 10 306 Relocation 10 306 Cyclic operation PLC 6 166 D Data backup PLC data 14 458 Times Various components Data Exchange Time Data transfer rate HHU MCP 7 179 MPI interface 7 186 Declaration of Conformit Default configuration 7 175 Default passwords 10 283 Delete NC data Detailed view Diagnostic repeater for PROFI
48. 2 42 dus sas ient dand ia pale se a end 6 8 2 Cyclic operation 6 8 3 Monitor control using the SIMATIC Manager 6 8 4 Monitor control using HMI Advanced 7 MPI Communication 4 7 1 Special features of SINUMERIK 840Di 7 2 Networking rules 7 3 Global data communication 7 4 Requirements 7 5 Creating a MPI configuration 7 5 1 Pr condition sities mamans tentent oo Wee peas 7 5 2 Inserting the default configuration into the S7 project 7 5 3 Adapting organization block OB100 7 5 4 Adapting organization block OB1 7 5 5 Loading a configuration into the PLC 7 6 Default configuration 7 6 1 GD circle parameters 7 6 2 GD identifiers and MPI addresses 7 6 3 Recommended MPI addresses 7 7 Machine control panel 19 or MCP 7 7 1 Conditions for start up 7 7 2 Parameterization of the MCP 7 7 3 P
49. 3 3 Overview of connections Connector 6ES7972 0BA40 0XA0 c outl 350 without socket conn for progr device 6ES7972 0BB40 0XA0 c outl 350 without socket conn for progr device 6ES7972 0BA11 0XA0 c outl 350 without socket conn for progr device 6ES7972 0BB11 0XA0 c outl 350 without socket conn for progr device Cable 6XV1830 0EH10 available by the meter not trailable 6XV1830 3BH10 available by the meter trailable Connector 6GK1500 0EA02 cable outlet 180 without socket connector for program ming device Cable 6XV1830 0EH10 available by the meter not trailable 6XV1830 3BH10 available by the meter trailable Connector 6ES7972 0BB40 0XA0 cable outlet 35 without socket connector for pro gramming device 6ES7972 0BB11 0XA0 cable outlet 90 with socket connector for pro gramming device Cable 6XV1830 0EH10 available by the meter not trailable 6XV1830 3BH10 available by the meter trailable The cable is included in the scope of supply of the HHU or mini HHU For an overview of the standard PC interfaces see Fig 3 8 Page 3 106 and Fig 3 9 Page 3 106 References BH Operator Components Manual Component PCU 50 HT 6 always connected Max 200 m from connector X102 to HT 6 HT 6 not always connected Max 200 m from connector X102 to HT 6 with repeater RS485 6ES7972 0AA01 1XA0 without repeater Total length from conn X102 to distributors 5 m The line 4EA04 is not per
50. 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 Start up CHAN1 JOG Ref MPFO 7 Channel Program aborted RESET Accepting the changes can lead to loss of NC user data Make sure that this data has been stored in a series start up file 1 Memory settings have been changed Changes will not take effect until the system is rebooted 2 The shutdown response has been changed Incorrect configuration will result in loss of data if there is a power failure Do you really want to accept the changes Cancel Accept Diagnostics Fig 10 37 Making settings Notice We urgently recommend creating a series start up file before changing the data described above See Chapter 14 Page 14 453 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 405 10 NC Start Up with HMI Advanced 01 05 10 10 NC PLC Diagnosis Notes Siemens AG 2005 All rights reserved 10 406 SINUMERIK 840Di Manual HBI 01 05 Edition Alarm and Message Texts 11 1 Alarm and message texts Storing the text files 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 acce
51. Changes effective after POWER ON Protection level 2 7 Unit Data type DWORD Applies as from SW version 2 1 Meaning Meaning of set bits Bit 0 Deactivation of the 611U specific drive alarm mapping Bit Deactivation of the 611U specific drive type detection Bit Deactivation of the 611U specific parameter accesses encoder drivers Bit Deactivation of the 611U specific parameter accesses output drivers Bit Activation third party drive DSC bits STW1 12 STA1 12 Bit Deactivation of the 611U specific drive parking STW2 7 STA2 7 Bit Deactivation of the 611U specific travel to fixed stop STW2 8 STA2 8 Bit Deactivation of the 611U specific internal motor switchover STA2 9 11 Bit Deactivation of the 611U specific ramp block STW1 13 Bit 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 CD NOD OUP GO NEES CTW Control word PDA word in the PROFIDrive message frame to DP slave STW Status word PDA word in the PROF IDrive message frame from DP slave PDA Process data MD irrelevant for Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 509 16 840Di specific Data and Functions 01 05 16 2 Expanded message frame configuration Axisspecific machine data 36730 DRIVE_SIGNAL_T
52. DB2 DBX180 0 set 700001 0 O Lubrication pressure missing MBDDE INI Textfiles UserPLC lt installation path gt dh mb dir myple_ 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 11 409 11 Alarm and Message Texts 01 05 11 1 Alarm and message texts 11 1 4 Syntax for alarm text files Alarm numbers Format of the text file for cycle alarm texts Alarm number Display 11 410 The following alarm numbers are available for the cycle compile cycle and PLC alarms Table 11 2 Alarm numbers for cycle compile cycle and PLC alarms Number range Designation Effect Deletion 60000 60999 Cycle alarms Display NC start disable Reset 61000 61999 Siemens Display NC start disable Reset axis spindle standstill 62000 62999 Display Cancel 63000 64999 Reserved 65000 65999 Cycle 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
53. In unfavorable situations e g if the software causes a high load on the CPU e g due to a large number of axes or short interpolation cycles sporadic real time violations or a time out on the interpolation level of the NCK can occur Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 27 1 General Notes on the SINUMERIK 840Di 01 05 1 1 Overview of SINUMERIK 840Di Testing or switching over Terminating the NCK ZN If it is necessary to test the screen resolution or switch to a different resolution and or color depth the NCK must be terminated first Otherwise a malfunction may occur in the real time response The NCK is integrated in Windows XP as a SINUMERIK NC service This ser vice must be started and stopped manually in the service dialog box Windows Start menu Start gt Programs gt Administrative Tools gt Services gt SINUMERIK NC Warning Please pay attention to the following points with regard to the screen resolution and depth of color of the PCU e The maximum color depth is restricted to 65536 colors and the maximum screen resolution is restricted to 1024 768 pixels Otherwise in unfavorable situations e g if the NC software causes a high load on the CPU sporadic real time violations or a time out on the interpolation level of the NCK can occur e Changing the screen resolution and or depth of color The NCK must be stopped before testing s
54. Open circuit ventilation Operation Transportation storage 0 50 C 20 55 C 40 70 C 5 95 5 95 without condensation without condensation not permissible 700 1060 hPa 700 1060 hPa 1000 3000 m Shock stress during transportation Free fall in transport packag ing Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1000 mm 2 95 2 Hardware Descriptions 01 05 2 12 ADI4 Analog Drive Interface for 4 Axes 2 12 ADIA Analog Drive Interface for 4 Axes 2 12 1 Module x a X1 External power supply 24 V DC LL Zoe 9 O X2 PROFIBUS connection E E eee EQ S2 DIL switch for setting the E 8 D x PROFIBUS address CE 9 CE o L_ E rine g 7 X3 Analog setpoint outputs 10 V DC Axis 1 4 recent m T B X4 2 Encoder connection X4 1 Encoder connection for Axis 2 for Axis 1 mn j Li 3B X5 2 Encoder connection i X5 1 Encoder connection for Axis 4 i for Axis 3 X X6 2 Connection for digital X6 1 Connection for digital input signals ra output signals Diagnostic LEDs a ha H1 PW TMP EH H2 EXCH RDY Connection for protective ground Screw M6 Fig 2 26 2 96 Connection overview for ADI4 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 12 ADI4 Analog Drive Interface for 4 Axes
55. Order number Designation Order number MLFB ADI4 6FC5 211 0BA01 0AA1 Features 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 important features e PROFIBUS DP connection max 12 Mbits s specified by PROF IDrive profile drive technology version 3 Draft V1 4 2 01 September 00 e 4 servo interfaces each with one Input TTL SSI encoder for incremental and absolute measuring systems Output 10 V analog e General and drive specific digital input output signals e On board 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 e An ADI4 DP slave can only be operated on an equidistant PROFIBUS DP see Section 8 8 Page 8 258 e An ADI4 DP slave is not a DP standard slave certified as compliant with the PROF IDrive profile e g the ADI4 DP slave does not support acyclic communication References For detailed documentation about the operator panel front OP 012 please see References ADI4 Analog drive port for 4 axes Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 97 2 Hardware Descriptions 01 05 2 13 Diagnostic repeater for PROFIBUS DP 2 13 Diagnostic rep
56. Please observe the compatibility list available from the Internet See Section 15 4 Page 15 474 References The following manuals are required to start up HMI Advanced NAM Installation and Start Up Guide HMI MMC Installation and Start Up Guide HMI Advanced IM4 IZI Catalog NCZ Connection Components Cables connectors etc 7 11 2 Parameterization Parameterization is performed in menu Operator panel interface parameters Operating area switchover gt Installation gt MMC gt Operator panel Siemens AG 2005 All rights reserved 7 204 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 11 HMI Advanced Internal When an internal HMI Advanced is parameterized the following conditions must be fulfilled Connection Only a 1 1 connection is possible Function M N M SINUMERIK 840Di com municate with N HMI Advanced is not enabled for SINUMERIK 840Di Bus Set Softbus MC as the bus type Highest bus address 31 is the highest permissible bus address MMC address The bus address set here must match the corresponding bus address of the configuration loaded in the SINUMERIK 840Di PLC This is not checked NCK address See MMC address above PLC address See MMC address above External When an external HMI Advanced is parameterized the following conditions must be fulfilled Connection Only a 1 1 connection is possible Function M N M SINUMERIK 840Di com municate with
57. SIMODRIVE POSMO SI 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 configuration and no system data blocks are generated The Slave OM is included in the supply of the SINUMERIK 840Di Once you have installed the SlaveOM the specified DP slave drives are available at the following location in the hardware catalog of HW Config e HW Config hardware catalog Profile Standard PROFIBUS DP gt SIMODRIVE gt SIMODRIVE 611 universal SIMODRIVE POSMO CD SIMODRIVE POSMO CA SIMODRIVE POSMO SI SIMODRIVE POSMO A PROFIBUS DP gt SINUMERIK gt ADI4 Note The slaveOM must be installed on the same computer as SIMATIC STEP 7 To install the Object Managers please refer to the appropriate notes in the file e lt nstallation path gt importantinfo rtf Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 2 Requirements GSD file All properties of a DP slave are stored in a DMF file Device Master File in AS Cll 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 gt
58. 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 The DP master system is displayed in the station window with the following symbol EE 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 dragging the DP slave is positioned exactly on the DP master system so that the DP slave is inserted into the configuration For a complete description of the parameterization of an AD14 DP slave please refer to References ADI4 Analog drive interface for four axes Chapter Parameterization Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 9 DP slave SIMODRIVE drives 8 9 DP slave SIMODRIVE drives Parameterization of the configuration with regards to the SIMODRIVE drives SIMODRIVE 611 universal or universal E SIMODRIVE POSMO CD CA SIMODRIVE POSMO SI is exemplified here by parameterization of the SIMODRIVE 611 universal 8 9 1 SlaveOM The drives are parameterized using the SlaveOM for SINUMERIK 840Di for installation of the SlaveOM see Section 8 1 Page 8 209 DriveOM SlaveOM Note To simplify parameterization of the isochronous communication on the PROFIBUS DP you must first insert all the DP slaves
59. Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 115 5 Power On and Power Up 01 05 5 2 First power up Menu commands e 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 Notice You must not switch off the PCU during the entire installation procedure Loss of data e 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 e CANCEL installation None of the listed applications are installed Attention It is not possible to repeat the installation process at a later time Notice The installation menu is not displayed the next time the PCU is booted It is not possible to repeat the installation process Completion Once the PCU has powered up again you can continue with the basic start up procedure of the PLC Subsection 5 2 2 Page 5 117 Siemens AG 2005 All rights reserved 5 116 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 2 First power up 5 2 2 Basic start up of the PLC SINUMERIK desktop SinuCom NC When installation is complete rebooting automatically starts In the next PCU power up the boot manager menu is displayed see Subsection 5 3 1 Page 5 119 To start
60. Tpp Tpp DP cycle time DP cycle time Tpx Data exchange time Sum of transfer times of all DP slaves Tu Master time Offset of the start time for NC position control T 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 to the cyclic synchronization of the isochronism between the DP master and DP slaves R Computation time for speed position control Dx Exchange of user data between DP master and DP slaves DPV1 After cycl communication an acyclic service is sent if the token holding time Try is not yet exceeded Trp is calculated by the configuring system GAP An attempt is made during GAP to accept new active stations TOKEN The token passing is either to itself or other masters RES The reserve is used as an active pause for the station to send the token to itself until the isochronous cycle is terminated Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 211 8 PROFIBUS DP Communication 01 05 8 1 General G The actual values for the current DP cycles position control cycle are transferred from the DP slave drives to the NC position controller The setpoints computed by the NC position controller are transferred to the D
61. e The EMERGENCY STOP of the HT 6 must be enabled or jumpered e The HT 6 must be connected to the MPI bus through a repeater For a detailed description of the actions to be taken and the devices required please refer to BH Handheld Terminal HT 6 Chapter Handheld Terminal HT 6 Connecting and disconnecting the HT 6 during operation Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 203 7 MPI Communication 01 05 7 11 HMI Advanced 7 11 HMI Advanced Depending on where the user interface is implemented a distinction is made between internal and external HMI Advanced e Internal HMI Advanced SINUMERIK 840Di and HMI Advanced are performed on the same PCU e External HMI Advanced SINUMERIK 840Di and HMI Advanced are performed on different PCU 7 11 1 Conditions for start up Internal If internal HMI Advanced is used the following conditions must be fulfilled e Hardware No special requirements need to be fulfilled e Software Please observe the compatibility list available from the Internet See Sec tion 15 4 Page 15 474 External If external HMI Advanced is used the following conditions must be fulfilled e 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 through the MPI bus A terminating resistor for the MPI bus is not inte grated in the MCP e Software
62. tem of the SINUMERIK 840Di requires configuration of a flash file system FFS The size of the FFS in Kbytes can be set in the machine data e MD18332 MM_FLASH_FILE_SYSTEM_MEM_SIZE size of the FFS Notice The size of the DRAM file system and the FFS should currently be set to be equal but in any case the FFS must be greater than or equal to the DRAM file system The max size per file system is 4 MB In SW 2 2 and higher standard and or user cycles can be relocated to the DRAM file system Relocation does not change the way cycles are used Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 305 10 NC Start Up with HMI Advanced 01 05 10 4 Memory configuration Option Relocation of cycles Backing up cycles Loading of cycles Changing external cycles Alarms 10 306 Relocation of cycles into the DRAM file system is an option Cycle storage separate from the CNC user memory The cycle areas that are to be relocated into the DRAM file system are selected in the machine data e MD11290 DRAM FILESYSTEM MASK selection of directories in the DRAM BitO 1 Siemens cycles CST Bit1 1 Machine manufacturer cycles CMA Bit 2 1 User cycles CUS Cycle areas to be saved to the retentive background memory on NCK POW ER ON Reset warm restart or when Windows NT is properly shut down are selected by machine data e MD11291 DRAM_FILESYST_SAV
63. 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 175 7 MPI Communication 01 05 7 6 Default configuration Default Because of the GD circle parameterization of the default configuration the follo configuration wing MPI addresses must be used for the above components see Table 7 2 Page 7 176 Table 7 2 Default configuration MPI address GD circle parameters Component MPI address Default MPI address Machine control panel 13 14 15 61 MPI interface for customer operator panel 61 Handheld terminal e g HT 6 14 Machine control panel 11 12 61 MPI interface for customer operator panel 61 Handheld unit e g B MPI 9 10 151 1 CAUTION The default MPI addresses must be adapted 7 6 3 Recommended MPI addresses P 1st MCP 2nd MCP rogrammi ng Machine control panel Machine control panel device Interface MPI for customer operator panel Interface MPI for customer operator panel e g PG 740 Handheld terminal e g HT 6 Le a 2 MPI bus 2 User interface PL c e g HMI Advanced PLC routes SINUMERIK 840Di 1 to NC PCU with MCI board NC e Softbus e x
64. 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Master spindle Spindle reset References 10 5 Axes and spindles 5 The gear stage 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 To be able to use various spindle functions such as e Revolutional feed G95 e Tapping with compensation chuck G63 e Thread cutting G33 e Dwell time in spindle revolutions G4 S in a channel a master spindle has to be defined in the corresponding channel e MD20090 SPIND_DEF_MASTER_SPIND master spindle initial setting in channel In machine data e 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 Machine data e MD 35040 SPIND_ ACTIVE _AFTER_RESET spindle active via reset defines whether the spindle is to remain active beyond e Reset IS DB21 DBX7 7 e End of program M02 M30 To cancel spindle movements an independent spindle reset is required e IS DB31 DBX2 2 spindle reset FB1 _ Description of Functions Basic Machine S1 Spindles Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 367 10 N
65. 26 64 8 Not used Notice A newly set PROFIBUS address will only come into effect after power ON Siemens AG 2005 All rights reserved 2 86 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 11 1 0 module PP72 48 Digital Interface description of the digital input output interfaces X111 X222 X333 inputs outputs is Connector 50 pin ribbon cable connector X111 X222 X333 e Pin assignment on each connector Table 2 18 Pin assignment X111 X222 X333 Pin Signal designation Type Pin Signal designation Type 1 1 M vo 26 Input 2 7 I 2 P24OUT vo 27 3 Input 0 0 l 28 4 Input 0 1 I 29 5 Input 0 2 I 30 6 Input 0 3 l 31 Output 0 0 O 7 Input 0 4 l 32 Output 0 1 O 8 Input 0 5 l 33 Output 0 2 O 9 Input 0 6 l 34 Output 0 3 O 10 Input 0 7 I 35 Output 0 4 O 11 Input 1 0 I 36 Output 0 5 O 12 Input 1 1 I 37 Output 0 6 O 13 Input 1 2 l 38 Output 0 7 O 14 Input 1 3 l 39 Output 1 0 O 15 Input 1 4 l 40 Output 1 1 O 16 Input 1 5 l 41 Output 1 2 O 17 Input 1 6 I 42 Output 1 3 O 18 Input 1 7 I 43 Output 1 4 O 19 Input 2 0 l 44 Output 1 5 O 20 Input 2 1 l 45 Output 1 6 O 21 Input 2 2 l 46 Output 1 7 O 22 Input 2 3 l 47 DOCOMx VI 23 Input 2 4 I 48 DOCOMx VI 24 Input 2 5 I 49 DOCOMx VI 25 Input 2 6 50 DOCOMx VI 1 VI Voltage Input VO Voltage Output l Signal Input O Signal Output x withx 1 2 3 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05
66. 6 P5ext VO ext 5V power supply 2 7 Not assigned 8 XRS DP B RS 485 differential signals 9 Not assigned 1 VO Voltage Output O Output B Bidirectional 2 Pin 5 and 6 can only be used to supply the bus termination resistances e Connecting cable See Subsection 3 3 1 Page 3 107 MPI DP Interface description MPI DP interface X102 ri The X102 interface can be operated as an MPI or PROFIBUS DP interface e Connection 9 pin SUB D socket connector e Pin assignment Table 2 4 Pin assignment MPI interface X102 Pin Designation Type 1 Function 1 Not assigned 2 Not assigned 3 RS MPI 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 7 Not assigned 8 XRS MPI DP B RS 485 differential signals 9 Not assigned 1 VO Voltage Output O Output B Bidirectional 2 Pin 5 and 6 can only be used to supply the bus termination resistances e Connecting cable See Subsection 3 3 1 Page 3 107 Notice The PROFIBUS DP X101 and MPI DP bus X102 interfaces are isolated both from one another and from the PCU Siemens AG 2005 All rights reserved 2 50 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 2 MCI2 board 2 2 3 Replacing the battery Battery type Order number Service life General for handling ZN Criteria for Replacing the battery Replacing the battery 3 V lithium bat
67. 8 5 1 GSD File 342 rase rase bush how ead E RA 8 5 2 Inserting a DP slave 8 5 3 Setting PROFIBUS parameters 8 5 4 Setting the I O addresses 8 6 DP slave MCP 310 242 dunes ck oe ia sun das bende Mae ae be 8 6 1 Conditions for general installation and start up 8 6 2 Parameterization of the MCP 8 6 3 Requirements for starting up the DP slave 8 6 4 Functions of the machine control panel 8 6 5 Configuring the DP slave MCP 310 8 6 6 Linking to the basic PLC and user program 8 6 7 Input output image 8 7 DP slave MCP 483 422 ue dane aed beet ahead bade tas 8 7 1 Conditions for general installation and start up 8 7 2 Parameterization of the MCP 8 7 3 Requirements for starting up the DP slave 8 7 4 Functions of the machine control panel 8 7 5 Configuring a DP slave 8 7 6 Linking to the basic PLC and user program Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition XV SINUMERIK 840Di Manual 01 05 Contents 8 7 7 Input output image
68. 8 6 6 Linking to the basic PLC and user program This section describes how to link DP slave MCP 310 e to the basic PLC program for transferring standard I O data to the VDI inter face e to the PLC user program optional to implement a user specific response to a module failure Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 237 8 PROFIBUS DP Communication 01 05 8 6 DP slave MCP 310 Notice Handwheel function The Handwheel function is not currently supported by the basic PLC program Additional I Os function Processing of additional I O data is the sole responsibility of the user machine 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 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 a machine control panel MCP 310 as a DP slave only the following parameters are relevant MCPNum INT See below Note MCP1In POINTER Address o
69. 840Di Start up or HMI Advanced e 840Di start up Start Windows NT taskbar Start gt Programs gt SINUMERIK 840Di gt 840Di Start up Open the dialog box Menu command Window gt Diagnosis gt NC PLC e HMI Advanced Open the dialog box Operating area switchover gt Start up gt NC PLC Diagnosis Proceed as follows in the dialog boxes 1 PLC general reset PLC group Button PLC Delete Program Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 151 6 PLC Start Up 01 05 6 2 Startup 6 152 Notice The following parameters are reset by the PLC general reset 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 power up has been successfully completed if the following display appears in the dialog box e NC status NC group 6 NC in cyclic mode e PLC status PLC group LED RUN constantly lit Note Since no PLC program is executed after PLC general reset the following alarms are displayed e Alarm 120201 Communication failed e Alarm 380040 PROFIBUS DP Configuring error 3 parameter e Alarm 2001 PLC not booted These alarms have no influence on how to continue Siemens AG
70. All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 2 Overview of software components 1 2 Overview of software components Basic software Engineering Tools The software components listed below are part of the SINUMERIK 840Di sys tem software The first time the PCU is powered up all the software compo nents required to operate the SINUMERIK 840Di are automatically installed Other software components including engineering tools or SIMATIC S7 add on software are also available for installation on the PCU or an external computer Note See Subsection 5 4 10 Page 5 131 for how to determine the installation path of the SINUMERIK 840Di system software CD path Before installing a software component please read the information txt rtf wri for each application The basic software essentially comprises the following components e 840Di Base as from Version 03 01 20 00 installed NCk specific real time drivers 840Di specific MPI drivers 840Di start up e PLC as from Version 20 70 23 00 installed e NCK as from Version 06 05 26 00 installed e PCU Base as from Version 07 04 00 00 installed Windows XP Pro SP 1 English version Internet Explorer 6 English version HMI Explorer MS DOS MPI driver Norton Ghost Norton GhostWalker Service menu PCU specific drivers e HMI Base as from Version
71. BH Operator Components Manual Chapter Component PCU 50 Case 2 If the SINUMERIK 840Di has been operated outside its defined specifications it SRAM not is under certain circumstances possible that the user data could not be saved in saved the SRAM Therefore proceed as described in Subsection 5 3 4 Page 5 121 case 2 5 3 9 Power up with shutdown signal 1 Power up From 2nd power up If the SINUMERIK 840Di is operated with a UPS unit the shutdown signal must be configured accordingly See Subsection 10 10 2 Page 10 404 If a shutdown signal is pending first the NC and PLC and then Windows XP are shut down correctly If power up is executed with a pending shutdown signal Windows XP is immedi ately correctly shut down again The system responds as follows if it is powered up a second time with pending shutdown signal Windows XP is not immediately shut down correctly NC and PLC are not started The following message box appears SINUMERIK 840Di NCK PLC x E Alarm NCK started while Power Failure shutdown with OK 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 gt shutdown signal gt power up gt 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 s
72. Bit 0 1 Technology function activated in NC channel 1 Bit n 1 Technology function activated in NC channel n 1 For more details about which NC 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 TES Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 397 10 NC Start Up with HMI Advanced 01 05 10 8 PROFIBUS DP 10 8 PROFIBUS DP 10 8 1 Setting the parameters for the shut down behavior If specific DP slaves react to an abrupt shut down of PROFIBUS DP commu nication with error states e g in response to a power on NC reset warm re start machine data e MD11250 PROFIBUS_SHUTDOWN_TYPE PROFIBUS shutdown han dling can be used to configure the staged shut down of PROFIBUS DP communica tion Note The drives available for SINUMERIK 840Di SIMODRIVE 611U UE SIMODRIVE POSMO SI CD CA can be operated by default with mode 0 abrupt shut down of PROFIBUS DP communication This corresponds to the initialized default setting of the machine data see Subsection 10 8 2 Page 10 398 10 8 2 Data descriptions MD General machine data 11250 PROFIBUS_SHUTDOWN_TYP
73. Definition of The languages to be used on the MMC are configured in file c lt Installations usable languages Presettings without activation of logographic languages Default setting with logographic activation pfad 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 Two languages can be set from selection of several optional languages GR German default SP Spanish FR French UK English default 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 highlighted bold print texts Make sure that your entries are spelled correctly Two languages can be set from selection of several optional languages GR German Standard SP Spanish FR French UK English default 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 207 7 MPI Communication 01 05 7 11 HMI Advanced Extract from MMC INI LANGUAGE Language GR LanguageFont Europe Language2 CH La
74. E mmi CI NO Ewin compensation daa E PLC PROFIBUS drives E Ce rame Svcncet care Series start up Fig 14 1 Menu Creating a series start up archive Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 14 User Data Backup Series Machine Start Up 14 2 Creating a series commissioning file 14 2 3 SinuCom NC Starting SinuCom NC can be started as follows to create a series start up file SINUMERIK Desktop see Section 5 4 Page 5 126 Windows XP taskbar Start gt Programs gt SinuCom NC gt SinuCom NC HMI Advanced Operating area switchover gt ETC key gt SinuCom NC Creating a new file Creating a series start up file with SinuCom NC is subdivided into the following steps see Fig 14 2 below 1 Starting SinuCom NC 2 Selecting the storage location 3 4 Continuing Next gt Selecting the components to back up archive content Create archive E xj Storage location Data management File system Archive content MNC with compensation data IV PLC FN PROFIBUS drives IV muc lt Back Next gt D Finish Cancel Fig 14 2 Menu Creating a series start up archive 5 6 The following data can be selected in the following menus dependening on the selected components NC part programs MMC MMC archives Creating the s
75. 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 e HW Config hardware catalog Profile Standard PROFIBUS DP gt Further field units gt lt DP slave gt Notice The GSD files must be installed on that computer on which the SIMATIC STEP 7 required to install the S7 project is already installed To install a GSD file please refer to the appropriate notes in the file lt installation path gt importantinfo rtf Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 215 8 PROFIBUS DP Communication 01 05 8 3 Creating a PROFIBUS configuration 8 3 Creating a PROFIBUS configuration 8 3 1 Precondition 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 SIMO DRIVE drives AD14 is based on an S7 project created using the description in Section 8 3 Page 8 216 The following status of the S7 project is required S7 project is has been set up name SIN840Di 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 The instructions given in this chapter are essentially limited to the special characteristics of the SINUMERIK 840Di Fo
76. Loo Fan Reset pushbutton switch External floppy disk drive 3 5 Fig 3 8 SINUMERIK 840Di PCU 50 left housing side SITOP DC UPS module 10 with SITOP POWER 10 SITOP POWER lead acid module SIEMENS MCI board Power Supply X101 X102 24 V DC W PS2 mouse d a bso COM1 cdm2 CTT l x OC Je of Je USB H LPT VGA MPI L2 DP Ethernet D of Je of Je o C ye f Tl Q PC card slot PS 2 keyboard 1 X121 MCI board extension option ooo 000 0000 ooo 000000 0o00 0000000 ac ooo 00000000 PS2 keyboard QWERTY ext CD ROM VGA monitor drive JL PG PC e g PG740 1 Only mouse and keyboard can be connected through the USB interface Fig 3 9 SINUMERIK 840Di PCU 50 right housing side Siemens AG 2005 All rights reserved 3 106 SINUMERIK 840Di Manual HBI 01 05 Edition
77. NL x 16 No signal NL x 5 Message word MessW 7 6 Encoder 1 status word G1_STW z if Encoder 1 position actual value 1 G1_XACT1 x 8 Encoder 1 position actual value 1 1_XACT1 9 Encoder 1 position actual value 2 G1_XACT2 7 10 Encoder 1 position actual value 2 G1_XACT2 7 11 Currently selected block CurrBlo Analog input T 24 x 20 DC2 42 Analog input T 56 x 14 ADC1 13 Digital inputs DIG_IN Speed actual value A NACT_A 14 No signal NIL 15 No signal NIL x 16 No signal NIL gt v Fig 16 4 Step 3 Configuring the NC Default configuration Extended message frame configuration Configuring the additional drive actual values Before configuring the expanded message frames you first need to perform the standard configuration on the NC for the drive How to proceed with the standard configuration of a drive is described in Sub section 10 5 3 Page 10 312 On the NC for the expanded message frame configuration you only need to activate PDA transfer in the respective system variable Option Evaluation of internal drive variables Order number MLFB 6FC5 251 0AB17 0BAO NC machine data for activating the data transfer in the system variables e MD 36730 DRIVE_SIGNAL_TRACKING n acquisition of additional drive actual values Note After configuring the expanded message frames the standard message frame with
78. Note You may have to consult your network administrator to obtain the information provided below or any other information required for your current network The service menu is activated by the boot manager when the PCU is started up See Subsection 5 3 1 Page 5 119 The main menu of the service menu is displayed when start up is complete PLEASE SELECT Install Update SINUMERIK System SINUMERIK Tools and Options DOS Shell Start Windows service mode SINUMERIK System Check Backup Restore Start PC Link o J O1 BR ND Reboot Warmstart P 840Di Services Your Choice 1 2 3 4 5 7 8 9 P One after the other select Key 7 Backup Restore Key 1 Harddisk Backup Restore with Ghost Key 1 Configure Ghost Parameters Key 6 Manage Network Drives Key 4 Change Network Settings Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up Machine name computer name User name With domain server Without domain server Workgroup domain 5 6 Configuring the network link of PCU LAN WAN The following menu appears CURRENT NETWORK SETTINGS Machine Name lt COMPUTER_NAME gt User Name auduser Transport Protocol TCP IP Logon to Domain No PLEASE SELECT Change Machine Name for DOS Net only Change User Name Toggle Protocol NetBEUI TCP IP Toggle
79. 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 gt 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 gt Close OK Finally the routing information must be set in the interface dialog of Simo Com U Siemens AG 2005 All rights reserved 9 274 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 9 Drive Start Up 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI 9 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 networking of the PLC must be parameterized in the S7 project See Subsection 6 3 3 Page 6 155 SimoCom U dialog Button Reset routing information box End Radio button Export mode MPI No 2 see note PROFIBUS lt Subnetwork ID gt see below OK or Go online Notice With SINUMERIK 840Di the routing of the MPI int
80. SIMATIC S7 AddOn software gt GSD file for I O module PP72 48 For installation of the GSD file see Subsection 8 1 4 Page 8 215 DMF files Note To make parameterization of isochronous communication with PROFIBUS DP easier we recommend inserting all required DP slaves 611U into the configuration before setting the times for isochronous communication Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 225 8 PROFIBUS DP Communication 01 05 8 5 DP slave VO Module PP72 48 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 gt Catalog The DP slave PP72 48 is to be found at e Profile Standard PROFIBUS DP gt Further field units gt Drives gt 10 gt PP input output module Click with the left mouse button on the DP slave PP72 48 PP input output mo dule 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 a NS NN HE 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
81. Select the menu option Service menu hidden using the CursorDown key and then press the Input key The main service menu is displayed after PCU start up Select one after the other from the main menu Key 7 Backup Restore Key 4 Partitions Backup Restore with Ghost locally Key 1 Configure Ghost Parameters The following menu appears GHOST Connection Mode LOCAL Maximum Backup Images lt Max_numbet gt Current Backup Images lt Cur_numbers PLEASE SELECT 1 Change maximum Backup Images 2 Define Emergency Backup Image 9 Back to previous Menu Your Choice 1 2 9 Choose Change maximum Backup Images with key 1 Enter the new maximum number of possible image files in the following menu and confirm the query to back up the Ghost parameters with key Y Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu 15 5 6 Deleting local image files Service menu After the PCU has been switched on the menu of the boot manager is dis played Select the menu option Service menu hidden using the CursorDown key and then press the Input key The main service menu is displayed after PCU start up Select one after the other from the main menu Key 7 Backup Restore Key 4 Partitions Backup Restore with Ghost locally The following men
82. Set Connection Mode LOCAL Change Backup Image Filename Change Restore Image Filename Change Machine Name for Windows and DOS net Manage Network Drives o O O1 PB ND Back to previous Menu Your Choice 1 2 3 4 5 6 9 e Path and file name To set the path or the file name under which you wish the backup copy to be stored on the external computer select the menu option Change Backup Image Filename with key 3 Always state the entire path lt drive letter gt lt full path gt lt file name GHO gt Drive letter The drive letter to specify is the drive letter stated under LETTER FOR NETWORK DRIVE above In this example H Full path optional If applicable enter the path This allows you to place the back up copy in a subdirectory under the shared drive directory of the external computer e g SERVICE PCU File name The image file is stored in this file name e g SICHERO1 GHO Example H SERVICE PCU SICHERO1 GHO e Split mode To set that size of files to split the hard disk image into choose Change Split Mode with key 7 Default file size 640 Mbytes Maximum file size 2048 Mbytes 2 Gbytes Splitting lt file name gt GHO lt file name gt 001 lt file name gt 002 etc Return to the next highest menu level after setting the parameters with Back to previous menu by hitting key 9 Be sure to save the parameter set tings Siemens AG 2005 All rights re
83. Use the cursor keys to move the markers a lt lb gt v slowly Cursor key fast Shift key cursor key Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 435 13 Drive Optimization with HMI Advanced 01 05 13 5 Graphic display Soft keys If a marker is active a 2nd line is shown in the diagram via the 2nd marker soft 2nd 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 MPF DIR Start up J TEST MPF Channel reset Program aborted Graphics1 Scaling trace 1 ROY Scaling trace Z Marker Scaling Auto O Scaling Auto Ymax 20 000000 Y max 180 000000 Xmax 166 666667 Ymin 60 000000 Y min 180 000000 Xmin 0 000000 Identifier on Identifier off Trace 1 Graphics Gra
84. as a diagram Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 3 103 3 Design 01 05 3 2 Electrical design 3 2 Electrical design 3 2 1 MCI board and PROFIBUS DP X102 R 1 X101 wa MCI board 5 with PROFIBUS DP SIMODRIVE POSMO SI SIMODRIVE POSMO A SIMODRIVE POSMO CD CA Machine control panel MCP 310 Machine control panel MCP 483 1 Only the PLC has access to the PROFIBUS DP 2 interface X102 No drives and no I Os of the NC can be operated through this PROFIBUS line Alternatively also parameterizable as an MPI bus SIMODRIVE 611 universal option module MotionControl Diagnostic repeater for PROFIBUS DP 1 O Module PP72 48 DT ae p PG PC e g SIMATIC Power PG 2 PROFIBUS DP connection conditions References POS1 SIMODRIVE POSMO A User Manual POS3 SIMODRIVE POSMO SI CD CA User Manual Fig 3 5 3 104 SINUMERIK 840Di MCI board and PROFIBUS DP components Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 3 Design 3 2 Electrical design Note For details on general accessories such cables connectors and prefabricated cables please refer to References Z Catalog NC Z Accessories and Equipment 3 2 2 MCI board and MPI bus Machine control panel rear
85. case 2 no no Start up Restart up required Yes not applicable MCI or IMAGE Request carried out See Subsection 5 3 6 not applicable not applicable MCI MessageBox See Subsection 5 3 5 no Yes MCI or BACKUP Request carried out if BACKUP is selected message box and alarm will occur see Subsection 5 3 4 case 2 5 3 Booting Table 5 1 SRAM handling Serial No SRAM MCI board MCI board OK Known Yes Known no Known no Known no Unknown Yes Unknown Yes SW update Unknown Yes Unknown Yes Unknown no Unknown no Unknown no 5 120 no no MCI MessageBox See Subsection 5 3 5 Yes not applicable IMAGE MessageBox see Subsection 5 3 4 case 1 no Yes BACKUP message box and alarm see Subsection 5 3 4 case 2 no no Start up Restart up required Serial no of MCI board known The serial no of the MCI board complies with the serial number last stored on the PCU unknown The serial no of the MCI board does not comply with the serial number last stored on the PCU unknown Provided that the SRAM of the MCI board is OK the system does not SW update request which SRAM MCI or IMAGE is to be used when it runs up for the first time 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 2 Windows XP must be shut down correctly f
86. from 10 3 gt z Computational resolution degrees IPO cycle s min for the computational resolution see Subsection 10 3 1 Page 10 286 If Vmin is not reached no traversing movement is carried out FB Description of Functions Basic Machine G2 Velocities Traversing Ranges Accuracies Chapter Velocities Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 4 Memory configuration 10 4 Memory configuration Hardware configuration User data Activation The dynamic DRAM or static SRAM memory available depends on the hardware configuration of the components used PCU and MCI board and the memory available for SINUMERIK 840Di DRAM DRAM SRAM 2 Maximum for 840Di 1 PCU 50 256 MB approx 16 MB MCI board 5 MB 1 DRAM component main memory occupied by SINUMERIK 840Di and thus no longer available for Windows XP 2 5 Mbytes of the SRAM memory of the MCI board are available to the user The individual memory areas of the user data are set to reasonable default val ues during general reset of the NC To obtain optimum utilization of the user memory the size of the individual data areas can be set for e g e Part programs e Tool management e Tool offsets e User variables e R parameters e Compensation e Protection zones e Frames see Subsection 10 4 2 Page 10 303 The memory must be section
87. positioning axes Positioning axis feed Machine data 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 The machine data e 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 If a positioning axis is programmed in the parts program without specifying an axis specific feedrate the feedrate entered in e 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 Table 10 29 Positioning axes machine data Number Name of identifier Name Refer Channelspecific MC_ ence 22240 AUXFU_F_SYNC_TYPE Output timing of F functions H2 Axisspecific MA_ 30450 IS_CONCURRENT_POS_AX Concurrent positioning axis 32060 POS_AX_VELO Interface signals Feedrate for positioning axis Table 10 30 Positioning axes Interface signals DB number Bit byte Axis spindlespecific 31 0 31 2 2 31 74 5 31 78 81 References 10 330 Name Refer ence Signals from PLC to axis spindle Feedrate override axis specific Delete distance to go
88. rapid deceleration with setpoint 0 e Alarm 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 10 19 Overview of end limitations Dynamic The dynamic monitoring functions with reference to a machine axis are monitoring functions Speed setpoint monitoring The speed setpoint monitoring prevents that the max admissible motor speed is exceeded It must be set such that the max speed rapid traverse can be reached and in addition a certain control margin remains e MD36210 CTRLOUT_LIMIT n maximum speed setpoint in Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 347 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles SIMODRIVE 611 universal SIMODRIVE 611 universal 10 348 The max permissible motor speed is specified in P1401 0 Speed for max useful motor speed of the SIMODRIVE 611 universal assigned to the machine axis MD36210 CTRLOUT_LIMIT n corresponds to P1405 0 Monitoring speed of motor of the SIMODRIVE 611 universal assigned to the machine axis Speed setpoint MD36210 CTRLOUT_LIMIT n TOO ne ek ew Mat ee ee ee e g MD36210 CTRLOUT_LIMIT n 1 80 for test mode Fig 10 20 Speed setpoint monitoring Where
89. response 8 7 7 Arrangement 8 7 DP slave MCP 483 to allow the user to intervene when a DP slave MCP 483 the following orga nization blocks are inserted in the PLC user program e OB 82 Diagnostic alarm e 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 OPI MPI the following alarm is tripped by the basic PLC program e 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 machine manufacturer is responsible for triggering a corresponding alarm Input output image Keys and LEDs A key and the LED positioned above it form a logical unit The key and the LED have the same number e Key number xy corresponds to Sxy e LED number xy corresponds to LEDxy Fig 8 20 shows the arrangement of keys and LEDs on the machine control panel For the sake of clarity the LED designations are not shown in full LED34 O O O O O O O O O LED S09 S01 S02 S17 S18 S19 S32 S33 S34 Key O O O O O O O O O S10 S03 S04 S20 S21 S22 S35 S36 S37 O O O O O O O O O S11 S05
90. set amplitude Measurement The transient or positioning response of the position control in the time range parameters and in particular the effect of setpoint filters can be assessed with the step and Setpoint step ramp stimulation functions change and If an offset value other than zero is input the step change is stimulated during setpoint ramp traversal For the sake of clarity the displayed position actual value does not include this speed offset The following quantities can be measured Actual position value active position measuring system Control deviation following error Amplitude This parameter determines the magnitude of the specified setpoint step change or ramp Measurement time This parameter determines the period of time to be recorded maximum 2048 position controller cycles Settling time This value represents the delay between measured data recording test setpoint output and the injection of the offset Ramp duration In basic setting Setpoint ramp the position setpoint is preset according to the set ramp duration In this case the acceleration limits which currently apply to the axis or spindle are effective A jerk controlled motion can be set axis specifically with e MD 32400 AX_JERK_ENABLE axial jerk limitation 1 e 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 Offse
91. the station window To parameterize the MPI interface you will have to make the following parame ter settings e Interface type e Data transfer rate Double click on module MPI DP slot X7 in the 840Di Rack to open the MPI DP Properties dialog box Dialog box Dialog box MPI DP Properties Tab card General Group box Interface Type MPI Button Properties Dialog box Properties MPI Interface MPI DP Tab card Parameter Address 2 see note Subnetwork MPI 1 187 5 kbaud OK OK Notice With SINUMERIK 840Di the MPI address of the PLC must always be set to 2 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 159 6 PLC Start Up 01 05 6 3 Creating a SIMATIC S7 project 6 3 8 Dialog box 6 160 Parameterizing the NC I O data To parameterize the input output data storage areas of the NC you will have to set the following parameters e Beginning of input data e Beginning of output data To do that open the Properties dialog box by double clicking on the NC S7 FM NCU slot 4 in the 840Di Rack Dialog box Properties S7 FM NCU Tab card Addresses Group box Inputs Beginning 256 Group box Outputs Beginning 256 OK Notice The MPI address of the NC and PLC have a fixed relation to each other e MPI bus The PLC routes to the NC MPI address of the NC MPI address of the PLC e Softbus MPI address der NC MPI address of t
92. work access If the SINUMERIK 840Di is not part of a larger network LAN WAN a simple PTP peer to peer link via Ethernet and TCP IP can be established for service applications Note A network link to the PCU already configured under Windows cannot be used for the service menu under DOS For the service menu under DOS a new network link has to be configured 15 2 1 Network link For the network link of the external computer refer to Subsection 15 1 1 Page 15 461 15 2 2 Configuring the external computer Windows NT For the configuration of the external computer refer to Subsection 15 1 2 Page 15 462 15 2 3 Configuring the external computer Windows XP For the configuration of the external computer refer to Subsection 15 1 3 Page 15 464 15 2 4 Configuring the PCU DOS Service menu Service menu 15 466 For data back up a network link with an external computer must be configured in the service menu under DOS The basic PCU software is preconfigured for a PTP network link via the protocol TCP IP If changes have been made or a net work link cannot be established the following settings must be checked e Machine name computer name e Workgroup e TCP IP protocol e TCP IP parameter IP address subnet mask etc After the PCU has been switched on the menu of the boot manager is dis played Select the menu option Service menu hidden using the CursorDown key and then press the Input key
93. 0 Referencing active Phase 1 The following machine data and interface signals are important Traversing to the reference cam MD34010 REFP_CAM_DIR_IS_MINUS approach reference cam in negative direction MD34020 REFP_VELO_SEARCH_CAM reference cam approach velocity MD34030 REFP_MAX_MARKER_DIST maximum distance to reference cam MD 34092 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 10 354 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 MD 34030 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles f Warning If the reference cam i
94. 05 8 PROFIBUS DP Communication 8 2 Requirements 8 2 Requirements SIMATIC STEP 7 SINUMERIK 840Di External computer PG PC 840Di Rack Installation As a condition for creating a PROFIBUS configuration using the default configu ration the following components are required e SIMATIC STEP 7 e 840Di Rack a SIMATIC S7 300 station preconfigured for SINUMERIK 840Di Part of the PLC basic program e SlaveOM part of the scope of supply of a SINUMERIK 840Di SIMATIC S7 add on Software SIMATIC STEP 7 option is required in the following version or later e SIMATIC STEP 7 as from Version 5 2 Service Pack 1 SIMATIC STEP 7 can either be installed directly on the SINUMERIK 840Di PCU or on an external computer PG PC If SIMATIC STEP 7 is installed on the SINUMERIK 840Di no additional MPI cable is required to load the configuration onto the PLC Windows applications executed on the SINUMERIK 840Di have direct access to the PLC through the internal MPI interface of the MCI board Installation of additional software on the SINUMERIK 840Di is described in de tail in Chapter 15 Page 15 461 If SIMATIC STEP 7 is installed on an external computer PG PC it must fulfill the following conditions e PG PC interface is parameterized see Subsection 6 2 2 Page 6 149 e Communications link between the external computer and SINUMERIK 840Di exists The 840Di Rack us a SIMATIC S7 300 station preconfigured for SINUMERI
95. 06 03 14 00 installed HMl specific display and communications drivers The Engineering Tools include applications for start up of the SINUME RIK 840Di NC and SIMODRIVE drives e SinuCom NC as from Version 06 04 01 00 installed Start up tool for SINUMERIK 840Di NC e SIMODRIVE 611 universal tool box Contents PLC Toolbox as from Version 06 05 02 Various files for parameterizing an S7 configuration with SIMODRIVE drives 611U POSMO SI CD CA and PROF Idrive communication see readme txt example files lt CD path gt 611utb toolbox lt version gt lt file gt Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 35 1 General Notes on the SINUMERIK 840Di 01 05 1 2 Overview of software components SimoCom U as from Version 06 03 09 start up tool for SIMODRIVE 611 universal E and SIMODRIVE POSMO SI CD CA drives installed and for installation lt CD path gt 611utb SimoComU Setup exe SIMODRIVE 611 universal drive firmware firmware file lt CD path gt 611utb Sys611U lt version gt 611u ufw SIMODRIVE 611 universal option module Motion Control with PRO FIBUS DP firmware firmware file lt CD path gt 611utb dpc31 lt version gt v1sl ufw SIMODRIVE POSMO Sl CD CA drive firmware firmware file lt CD path gt 611utb SysPosmo lt version gt posmo ufw SIMATIC S7 The SIMATIC S7 add on software contains sample programs and applications add on softw
96. 1 2 Message frame structure Useful data structure 8 1 3 Actual values Position controller Setpoints 8 210 Message frame structure for cyclic DP communication This is the message frame structure for cyclic DP communication using the drive SIMODRIVE 611 universal The message frames for cyclic data transmission have the following basic struc ture Drive A Drive B Protocol Useful data PPO Useful data PPO Protocol frame Parameter Process Parameter Process frame identifier data identifier data header value PDA value PDA rene PIV PIV Note The useful data for drive B are only transmitted when DP slave 611U is operated as a double axis module Fig 8 1 Message frame structure for cyclic data transmission The useful data for cyclic operation are termed parameter process data objects PPO They are subdivided into two areas within the message frame e Parameter area PIV parameter identifier value This part of the message frame is for reading and or writing parameters and for reading out faults e Process data area PDA process data This area contains the control words setpoints or additional information and actual values The following data are transmitted with the process data Control words and setpoints requests master gt drive or Status words and actual values responses drive gt master Description
97. 10 29 Synchronization using BERO When is The spindle will be synchronized synchronization e after the NC has powered up when the spindle is moved using a necessary programming command e after a request to resynchronize from the PLC NST DB31 DBX16 4 Resynchronize spindle 1 NST DB31 DBX16 5 Resynchronize spindle 2 e after each gear stage change when an indirect measuring system is used MD 31040 ENC_IS_DIRECT direct measuring system 0 e when the encoder limit frequency falls below the programmed value after a speed has been programmed which is above the encoder limit frequency Notice e 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 e f 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 e In general backlash gearbox elasticity and proximity switch hysteresis reduce the accuracy achievable during synchronization Machine data Table 10 45 Synchronizing spindle machine data Axisspecific MA_ 34100 REFP_SET_POS
98. 13 444 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 445 13 Drive Optimization with HMI Advanced 01 05 13 7 File function 13 7 File function Description Use the File functions soft key to call the appropriate screen form Here you can save load or delete parameters you set for measuring axis spe cific machine data and measuring results 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 MPF_DIR Start up Jog TEST MPF Channel reset Axis Program aborted ROY Axis a 2 Position control loop measuring Direct File selection IBN001010 Parameter Delete IBN001010 7 Axis MD Graphics1 Save Directory A Standard directory X Graphics2 Error log Editor Axis User Display MD views 0 Fig 13 13 Menu File functions Naming files Selecting the directory Selecting data type 13 446 In the File group you can select an existing file from the drop down list or enter one in the text field underneath In the Directory group you can sel
99. 2 1 Overview of hardware components 2 2 MCA board MARRON REP EE TE rekon 2 2 1 MOUIE sy aseey tarantino opens eae eee eee eaters c 2 2 2 Interface description 2 2 3 Replacing the battery 2 2 4 Module replacement 2 2 5 Technical data 5444 ra yee ede ati eee sda weirs 2 3 MCI board extension slot variant 2 3 1 Mod le a wane eaters 2 3 2 Installation instructions 2 3 3 Interface description 61 2 3 4 Technical data PER TS 2 4 Cable distributor 2 5 SINUMERIK Industrial PC 2 5 1 SINUMERIK PCU 50 2 6 SINUMERIK operator panel fronts 2 6 1 Operator panel front OP 012 2 7 TCU Thin Client Unit 0 eee cee eee 2 8 Floppy disk drives 2 8 1 Floppy disk drive 3 5 2 8 2 3 5 floppy disk drive with USB interface Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition XI SINUMERIK 840Di Manual 01 05 Contents 2 9 Power supply
100. 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 3 Creating a SIMATIC S7 project 6 3 Creating a SIMATIC S7 project MPI PROFIBUS DP 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 Setup 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 interface 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 6 156 A full description of how to parameterize the MPI communication is given in Chapter 7 Page 7 169 Maximum two PROFIBUS lines can be connected to a SINUMERIK 840Di e Interface X101 PROFIBUS DP In the case of the SINUMERIK 840Di the position controller cycle of the NC is derived directly from the isochronous PROFIBUS cycle Defined values must therefore always be entered for the following PROFIBUS parameters Mode DP master lsochronous PROFIBUS Active lsochronous time Tpp on PROFIBUS DP Position control cycle
101. 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 57 2 Hardware Descriptions 01 05 2 3 MCI board extension slot variant 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 9 Switch S1 switch position open TTL handwheels Notice You select between differential and TTL handwheels on the module using switch S1 before installing the module Siemens AG 2005 All rights reserved 2 58 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 3 MCI board extension slot variant 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 Mounting To install the module proceed in the sequence described below battery i Warning When operating electrical devices it is impossible to avoid applying hazardous voltages to certain parts of the equipment 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 provided in this section and attached to
102. 5 DIN_CON 3 l 4th output 24 V 6 DIN_CON 2 l 3rd output 24 V 7 DIN_CON 1 l 2nd input 24 V 8 DIN_CON 0 l 1st input 24 V 9 MEPUO_S l 1st probe input signal 24 V 10 MEPUO_C l 1st probe input reference 0 V 11 MPG1_XA l Input 2nd handwheel track A inverted 12 P5 VO Optional 5 V handwheel power supply 13 P5 VO Optional 5 V handwheel power supply 14 MPG1_XB l Input 2nd handwheel track B inverted 15 MPGO_XA l Input 1st handwheel track A inverted 16 P5 VO Optional 5 V handwheel power supply 17 P5 VO Optional 5 V handwheel power supply 18 MPGO_XB l Input 1st handwheel track B inverted 19 Not assigned 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 8rd output 24 V 24 MEXT VO 24V input ground 25 MEXT VO 24V input ground 26 MEXT VO 24V input ground 27 MEXT VO 24V input ground 28 MEPU1_S l 2nd probe input signal 29 MEPU1_C 2nd probe input 0 V Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 61 2 Hardware Descriptions 01 05 2 3 MCI board extension slot variant Table 2 6 Pin 30 31 32 33 34 35 36 37 1 VI VO l 0 Power Pin assignment Interface X121 Designation Type 1 MPG1_A l M VO M VO MPG1_B l MPGO_A l M VO M VO MPGO_B l Voltage Input Voltage Input VIVO Voltage Input Voltage Output Function Input 2nd handwheel track A Handw
103. 512 Speed setpoint matching manual 10 338 Single license Without data medium 1 22 SinuCom NC 1 35 1 37 Basic start up of the PLC 5 117 Compile c cles 10 393 General 1 26 License management Series start up 14 457 SINUMERIK desktop 5 117 5 126 Activating Setting the power up response 5 127 SITOP POWER 10 2 79 SITOP POWER ACCUMODULE 24N DC 10 A 3 2 AH 2 46 SITOP POWER DC UPS module 15 2 46 _ SITOP POWER lead acid battery module 24 V DC 10 A 3 2 AH 2 83 SITOP POWER standard 24V 10A 2 46 SlaveOM 1 36 8 214 8 259 Softbus 7 176 HMI Advanced Interface signal 16 499 Software components Overview 1 35 Software limit switch Software update service 1 22 Software version MPI interface Specific on CD ROM 1 22 Specific on hard disk 1 22 Spare parts 2 45 Special axes Speed control loop Interference frequency response Reference frequency response 13 428 Setpoint disturbance step changes 13 429 Speed setpoint matching 10 338 Automatic 10 338 Speed setpoint monitoring 10 347 Spindle Axis mode Basic data 10 365 Definition in machine data 10 365 Enabling gear stage change Encoder matching Gear stages 10 368 10 371 Master 10 367 Measuring s stems 10 369 Modes 10 365 Monitoring functions Parameter sets 10 332 10 368 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edi
104. 9 3 Choose Partitions Backup Restore with Ghost with key 4 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 493 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu Following menu Ghost Connection Mode LOCAL Maximum Backup Images lt Max_ number Current Backup Images lt Cur_numbers PLEASE SELECT Configure GHOST Parameters Partitions Backup Mode LOCAL Partitions Restore Mode LOCAL Partition E only Windows Restore Mode LOCAL Delete Image o BR ND Back to previous Menu Your Choice 1 2 3 4 8 9 4 Choose Partitions Restore Mode LOCAL with key 3 Siemens AG 2005 All rights reserved 15 494 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 6 15 6 1 Image file Info file 15 6 Restoring the as delivered state Restoring the as delivered state If the current installation has become unusable for whatever reason it is possi ble to restore the status as delivered of partitions C DOS E Windows XP and F 840Di System of the PCU harddisk This sections describes the basic steps e Up to SW 2 1 Restoring the partitions e As from SW 2 2 Restoring the partitions Installation of the SINUMERIK 840Di applications Notice If the as delivered state is restored all data will be lost on
105. 9004 DISPLAY_RESOLUTION Display resolution G2 9011 DISPLAY_RESOLUTION_INCH Display resolution for INCH system of measurement G2 10200 INT_INCR_PER_MM Computational resolution for linear positions G2 10210 INT_INCR_PER_DEG Computational resolution for angular positions G2 References FB Description of Functions Basic Machine G2 Velocities Traversing Ranges Accuracies Chapter Input display resolution computational resolution Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 287 10 NC Start Up with HMI Advanced 01 05 10 3 System data 10 3 2 Standard Table 10 6 Physical unit Linear position Angular position Linear velocity Angular velocity Linear acceleration Angular acceleration Linear jerk Angular jerk Time Position controller servo gain Rev feedrate Compensation value linear position Compensation value angular position User defined 10 288 Normalization of phys quantities of machine and setting data Machine and setting data having a physical unit are interpreted in the input out put units listed in Table 10 6 by default depending on the scaling system metric inch The internally used units which the NC uses are independent and fixed Normalization of phys units of machine data and setting data Input output units for the Internally used default scaling system Unit Metric Inch 1mm 25 40 mm 1mm 1 degree 1 degree 1 degree 1 mm min 1 inch
106. Adress automatically or manually Change IP Address Change Subnetmask Change Gateway Domain Name Server Change DNS Extension o onahWwh Back to previous menu Your Choice 1 2 3 4 5 7 8 9 The IP address for the PCU is assigned manually Therefore set manually with the 1 key using Toggle Get IP Address The following TCP IP parameters must be set e IP address Select Change IP Address with key 2 The IP address of the PCU must be in the same subnet as the IP address of the external computer Open a DOS prompt on the external computer to ascertain its IP address and the subnet mask Command ipconfig shows the parameters in ques tion 4 Prompt H gt ipconfig Windows NT IP configuration Ethernet Adapter E190x11 IP Address gt 169 254 1041 Subnet Mask 255 255 0 0 Default Gateway Note ipconfig all shows all parameters of the IP configuration and the Ethernet adapter Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 2 PTP network link service menu DOS Restrictions The IP address of the PCU must be different from that of the external com puter but must be in the same subnet The IP address of the PCU must dif fer by at least one digit that is 0 in the subnet mask and all digits that are not 0 must be identical Example Externa
107. After a fatal exception error blue screen system information is written to the following file D Memory dmp 5 4 8 OEM configuration OEM directories Order of execution OEM configuration provides the possibility of running Windows programs before starting the SINUMERIK system software The Windows programs or links must be routed to special directories 1 C RunOEM SeqOnce Programs stored here are started once and sequentially C RunOEM Seq Programs stored here are started on every power up and sequentially Note Sequentially means that a program is not launched until the previous program has been closed C RunOEM ParOnce Programs stored here are started once They run parallel with the HMI sys tem software C RunOEM Par Programs stored here are started on each start up They run parallel with the HMI system software Subdirectories and programs are executed in the order listed above Subdirectories The subdirectories are executed in the order 1 to 4 listed above Programs The programs within a subdirectory are started in the chronological order in which they were placed in the subdirectory Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 129 5 Power On and Power Up 01 05 5 4 SINUMERIK desktop Data files In addition to executable programs you can also place data files in the subdi rectories They will be opened in the app
108. Connect to Network Drive with key 1 TYPE YOUR PASSWORD Enter the Password for accessing the external computer For later verifi cation you may be prompted to confirm saving of the password Note Under Windows NT XP the password entered must belong to a local user set up on the external computer LETTER FOR NETWORK DRIVE Specify the drive letter under which the shared directory is to be ac cessed from the PCU e g H DIRECTORY TO BE MOUNTED Enter the computer name and the directory or sharing name of the shared directory lt COMPUTER NAME gt lt SHARING_NAME gt Example R3344 MY BACKUP The network link is displayed Connected Network Drive last H R3344 MY_BACKUP Note Instead of the computer it is also possible to use the IP address of the external computer lt P_ADDRESS gt lt SHARING_NAME gt Example 169 254 10 1 MY_BACKUP For how to set or ascertain the network parameters of an external computer see Section 15 2 Page 15 466 Siemens AG 2005 All rights reserved 15 484 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu Return to the next highest menu level after setting the parameters with Back to previous menu by hitting key 9 Be sure to save the parameter set tings Following menu PLEASE SELECT Set Connection Mode PARALLEL
109. Control Variable e Monitoring variables Displaying the current value of individual variables of the PLC user program or CPU module e Controlling variables Assigning values to variables of the PLC user program or CPU module Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up Variable types Additional test functions 6 8 Testing the PLC program e Enabling PA and activating control values Assigning values to I O outputs of the PLC user program or CPU module in the STOP state e Forcing variables Assigning values to variables of the PLC user program or CPU module that cannot be overwritten from the PLC user program The values of the following variable types can be defined or displayed Inputs outputs flags timers and counters Contents of data blocks I Os 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 The menu command Target System gt provides the following additional test 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 display Input syntax The PLC status display of HMI Advanced is
110. Description of Functions Basic Machine A2 Various Interface Signals Chapter Interface signals to axis spindle Siemens AG 2005 All rights reserved 10 318 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 5 Incremental measuring system settings Rotary measuring system Linear axis with encoder at motor Linear axis with encoder on the machine The diagrams below show the general possibilities of arranging a rotary incremental measuring system with regard to motor and load as well as the resulting values for the appropriate machine data ENC_IS_LINEAR 0 IS_ROT_AX 0 n Encoder ENC_IS_DIRECT 0 Measurin Load gearbox gearbox Table e 3 de Ti EA Ball screw LEADSCREW_PITCH EN Spindle Motor ENC_RESOL DRIVE_AX_RATIO_NUMERA motor revs DRIVE_AX_RATIO_DENOM spindle revs L DRIVE_ENC_RATIO_NUMERA motor revs DRIVE ENC_RATIO DENOM encoder revs Fig 10 5 Linear axis with encoder on motor DRIVE_AX_RATIO_NUMERA motor revs DRIVE_AX_RATIO_DENOM spindle revs ENC_IS_DIRECT 1 IS_ROT_AX 0 Measuring ENC_IS_LINEAR 0 Table Gearbox A 1 EN WV Ball screw ac ENC_RESOL Gearbox LEADSCREW_PITCH ENC_TYPE 1 n n n T Motor Spindle Spindle Encoder Poe ENC_RESOL motor revs DRIVE_ENC_R
111. Distance to go spindle reset DB31 DBxx DBX2 2 IS Feed stop Spindle stop DB31 DBxx DBX4 3 IS Traversing key lock DB31 DBxx DBX4 4 IS Ramp function generator lock DB31 DBxx DBX20 1 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 12 415 12 Axis Spindle Dry Run 01 05 12 2 Axis dry run References FB Description of Functions Basic Machine A2 Various Interface Signals and Functions Limit switch Setting of hardware limit switches and interface signal check e Hardware limit switch PLUS DB31 DBxx DBX12 1 e Hardware limit switch MINUS DB31 DBxx DBX12 0 12 2 Axis dry run Check enables on drive RF module Terminal 63 pulse enable 64 drive enable 48 start DC link FDD module 663 pulse enable Check interface signals DB 31 48 DBBO Feedrate override switch DBX1 7 Override active DBX1 5 1 6 Position measuring system 1 2 DBX1 4 Follow up mode Select JOG mode a Ld DBX1 3 Axis disable Traverse axis using direction key DBX2 2 Delete distance to go DBX2 1 Servo enable DBX4 3 Feed hold Spindle stop DBX5 0 5 5 JOG INC No DBX4 6 4 7 Travel keys Does the axis move DBX20 1 RFG IS drive DBX21 7 Pulse enable 611D Yes Check machine data MD32000 32050 Velocities MD36000 36620 Monitoring MD32110 Sign actual value MD32250 Rated output vo
112. Drive data 16 Drive data 17 Drive data 308 325 4 Axis 18 Drive data 308 317 4 Axis 19 Drive data 20 Drive data 21 Drive data 326 327 word 22 Drive data 326 327 O word Note Machine data Number of inputs bytes 10 388 The structure of the PROFIBUS message frame is described in Section 8 8 Page 8 258f Parameterization of the NC machine data is shown below ET200 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Number of outputs bytes Hardware assignment input bytes Hardware assignment output bytes 10 6 Digital and analog I O devices ET200 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 The following input bytes are used by the NC ET200 Both input bytes of the input module slot 6 MD10366 HW_ASSIGN_DIG_FASTIN 0 H05000080 1285 MD10366 HW_ASSIGN_DIG_FASTIN 1 H05000081 1295 The 4th of the 4 input bytes of the signal module slot 7 MD10
113. Example pos Semi skiller operator No inputs or program selection Pos 0 poss only machine control panel can be operated Siemens AG 2005 All rights reserved 10 282 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 2 Machine and setting data 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 The following default passwords have been set for protection levels 1 to 3 passwords 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
114. FALSE send and receive active TRUE only receive active The following parameter is used to announce that an MPI configuration exists in system data block SDB210 MCPSDB210 BOOL MPI configuration via SDB210 Notice A maximum of two MCP HT 6 can be operated on an MPI line To be able to use MCP and HT 6 on an automation system alternately or simultaneously the user machine manufacturer has to adapt the PLC program accordingly Siemens AG 2005 All rights reserved 7 182 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 7 Machine control panel 19 or MCP References For a detailed description of the basic PLC program or of function block FB 1 NC interface parameter assignment References 7 7 4 Example please refer to FB1 Description of Functions Basic Machine PLC Basic Program P3 Chapter FB 1 RUN_UP Basic program startup section FC 19 for version M MCP milling or FC 25 for version T MCP turning transfers the signals of the MCP to the NC through the interface Notice Block FC 19 or FC 25 is part of the basic PLC program It is the user s machine manufacturer s responsibility to call the block correctly and or assign the interface the appropriate parameters For a detailed description of FC 19 and FC 25 please refer to FB1 Description of Functions Basic Machine P3 PLC Basic Program Section FC 19 MCP_IFM Transfer of MCP sig
115. Functions the various sections are listed below DB1 Operational Messages Alarm Reactions DD1 Diagnostic Functions DD2 Speed Control Loop DE1 Extended Drive Functions DF1 Enable Commands DG1 Encoder Parameterization DL1 Linear Motor MD DM1 Calculation of Motor Power Section Parameters and Controller Data DS1 Current Control Loop DU1 Monitors Limitations SINUMERIK 840D SIMODRIVE 611 digital Description of Functions ANA MODULE SINUMERIK 840D Description of Functions Digitizing DI Start up DI2 Scanning with Tactile Sensors scancad scan DI3 Scanning with Lasers scancad laser DI4 Milling Program Generation scancad mill SINUMERIK 840D 840Di 810D Description of Functions DNC NC Program Management SINUMERIK 840D 840Di 810D Motion Control Information System MCIS Description of Functions DNC NC Program Management DN1 DNC Plant DNC Cell DN2 DNC IFC SINUMERIK NC Data Transfer via Network SINUMERIK 840D 840Di 810D Description of Functions ISO Dialects for SINUMERIK SINUMERIK 840D 840Di 810D Description of Functions Remote Diagnosis FE1 Remote Diagnosis ReachOut FE3 Remote Diagnosis pcAnywhere SINUMERIK 840D 840Di 810D HMI Configuring Package Order no Supplied with the software Part 1 User s Guide Part 2 Description of Functions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B References FBH1 FBHL FBIC FBMA FBO FBP FBR
116. G2 DRIVE_TELEGRAM_TYPE n Drive message frame type for the drives con G2 nected to PROFIBUS DP ENC_MODULE_NR O Actual value assignment Logic drive number for position measuring system 1 ENC_MODULE_NR 1 Actual value assignment Logic drive number for position measuring system 2 Switching over the position measuring system Interface signals 1 5 1 6 Name Refer ence Signals from PLC to axis spindle Position measuring system 1 Position measuring system 2 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 8 DSC Dynamic Servo Control Requirements Switch ON OFF The DSC function eliminates the deadtime that necessarily exist at the speed setpoint interface normally used between the NC and drive due to relocation of the position controller into the drive That results in the following advantages for an axis operated with DSC e Considerably improved fault response stability of the position control loop e Improved control behavior contour precision if the higher servo gain KV factor that can be set in conjunction with DSC is used e A reduction of the cyclic communication load on the PROFIBUS if the posi tion controller cycle PROFIBUS cycle is reduced by adjusting the above parameters even if the control loop performance is the same Note The speed feedforward control can be used in conj
117. IBNZWST If more than one partition backup is possible the input option of a descrip tion is offered You can store a description text along with the image Description Local Backup When you select a partition backup to restore it this description is displayed together with date and time to identify the partition backup To facilitate the identification of the partition backup a clear description should be used In the example Start up intermediate version 1 When you confirm the specifications above the partition backup will be started After the partition backup has been made a check can then be carried out using CRC Check Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 487 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu Storing a partition backup Saving each of the partitions C E and F creates a separate image file under D IMAGES Its name starts with the name of the partition backup e g for partition C IBNZWST GH1 for partition E IBNZWST GH3 for partition F IBNZWST GH4 When restoring the partition backup however the 3 individual files will be ad dressed as one partition backup with the description entered under Item 5 15 5 5 Changing the maximum number of local image files Service menu 15 488 After the PCU has been switched on the menu of the boot manager is dis played
118. International Association PCU PC Unit PCW Program Control Word PD Process Data Process data part of a PPO PG Programming device PLC Programmable Logic Control Programmable logic control PID Parameter identification Part of a PIV PIV Parameter identification value Parameterizing part of a PPO 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 POSMO CD Positioning Motor Compact DC Like CA but with DC infeed POSMO SI Positioning Motor Servo Integrated Positioning motor DC infeed Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition A 519 A Abbreviations 01 05 PPO PROFIBUS PRT RAM ROV RPA RS 232 C RTS SBL SD SEA SK SKP SLM Software limit switch SPF SRAM SRM SSI STW SW T TC TCPIP TCU TEA TO TOA TRC TTL A 520 Parameter Process data Object Cyclic data message frame for PROFIBUS DP transmission and Variable speed drives profile Process Field Bus Serial data bus Program Test Random Access Memory i e program memory that can be read and written to Rapid OVerride Rapid traverse override R Parameter Active Identifier for R parameters Serial interface Request
119. KT3 KT2 KT1 KTO S50 S48 verse 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 33 T13 T14 T15 S29 30 31 32 12 S14 S15 EB n 7 Freely assignable customer keys 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 1 Line Default designation 2 Line Key number Sxy or feedrate override switch X30 X31 key switch X50 optional customer keys X52 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 241 8 PROFIBUS DP Communication 01 05 8 6 DP slave MCP 310 Output image Arrangement of LED signals in the output image of the DP slave MCP 310 Table 8 5 Output image Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 BitO AB n 0 Spindle override Mode NC Stop SP SP 100 SP Single JOG MDA AUTO LED19 LED36 LED37 LED38 block LEDO9 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 LEDO2 LEDO1 LED11 AB n 2 Feed Mach fu not Machine functions Start Hold var INC used 4000INC 100INC 101NC 1 INC LED35 LED34 LEDO3 LEDO7 LEDO6 LEDO5 LEDO4 AB n 3 not no
120. MPI address on MPI bus Handheld unit User interface MPI address on softbus e g B MPI e g HMI Advanced Fig 7 5 Recommended MPI addresses for SINUMERIK 840Di Siemens AG 2005 All rights reserved 7 176 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 7 Machine control panel 19 or MCP 7 7 Machine control panel 19 or MCP Fig 7 6 Machine control panel front side example Version T turning machine 7 7 1 Conditions for start up Hardware The following hardware components are required to start up the machine con trol panel MCP MPI bus cable The MCP is connected to the SINUMERIK 840Di through the MPI bus A termi nating resistor for the MPI bus is not integrated in the MCP Programming device e g PG740 A programming device is required for the SIMATIC Manager STEP7 as the plat form to match the basic PLC or PLC user program to the requirements of the appropriate 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 How to install additional software is described in Chapter 15 page 15 461 Software To start up an MCP the following software is required MCP firmware At least MCP firmware Version 4 1 5 is required The version number can be checked when the MCP powers up Basic PLC program The MCP r
121. Minimum settable 1 23 _ Isochronous DP cycle 8 220 Isochronous master cycl percentage 8 220 L LAN 5 187 Language default 7 206 Language specific nature of alarm texts 11 409 Latency Index 539 Index 01 05 LED Status display PP72 48 2 92 License key 5 142 License management 5 142 Limit switch 12 416 Linear axis With linear scale 10 321 With rotary encoder on motor 10 319 10 322 With rotary encoder on the machine 10 319 Linear measuring s stem 10 321 Lithium battery Loadable compile cycles 10 392 Machine axes 10 308 Machine control panel MCP 7 177 Power up Machine data 10 279 Activation Bit editor 10 281 Changing scaling Display filter 10 285 Display input screen forms Loading of standard data 10 291 Name of identifier 10 279 Normalization of physical quantities 10 288 Overview 10 280 Machine name computer name 15 463 15 464 Master Application Cycle 8 211 8 222 Master Time 8 211 Max axis velocity 10 342 Cable outlet 2 49 MCI board extension Internal 2 57 Slot variation 2 46 MCI board extension internal 1 24 Switch S1 2 57 2 58 MCI2 board 2 48 MCP 310 See also DP slave MCP 310 8 228 MCP 483 8 228 8 243 See also DP slave MCP 483 Measurement of speed control loop 13 427 Measuring functions 13 421 13 423 Abort 13 424 Starting 13 424 Measu
122. N HMI Advanced is not enabled for SINUMERIK 840Di Bus Set MCI2 840Di 187 5 kbaud as the bus type Highest bus address 31 is the highest permissible bus address MMC address The bus address set here must match the corresponding bus address of the configuration loaded in the SINUMERIK 840Di PLC This is not checked NCK address You do not have to define an NCK address because communication to from the NCK is routed via the PLC PLC address See MMC address above Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 205 7 MPI Communication 01 05 7 11 HMI Advanced 7 11 3 Language switchover HMI Advanced Language switchover concept Switching between two languages Online change of the 2nd language Installing languages packages 7 206 Default languages To be able to switch between the two configured languages even when the op 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 8rd horizontal soft key from right 3 Switch to the highest level with RECALL 4 Select Change language 8rd vertical soft key from top HMI Advanced offers several possibilities to switch over the language during operation e Switchover between two preset languages e Online change of the second language The displayable languages are set and managed in
123. Option Obtain a DNS server address automatically e 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 e TCP IP protocol e IP address and subnet mask e Computer name and domain workgroup must be made and or checked Note You may have to consult your network administrator to obtain the above information or any other information required for your current network Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 137 5 Power On and Power Up 01 05 5 6 Configuring the network link of PCU LAN WAN 5 6 2 Configuring the network link DOS Service menu PTP link LAN WAN link Service menu Network settings 5 138 To perform service functions create import data backup the SINUMERIK 840Di requires an active link under DOS service menu to an external computer at least for the duration of the service task The PTP link peer to peer to a single computer is described in Section 15 2 Page 15 466 An example of how to configure a PCU network link in a larger network LAN WAN using the service menu is given below You must set and check the follo wing parameters e Machine name computer name e User name e Workgroup domain e TCP IP protocol e TCP IP parameters IP address subnet mask etc
124. PLC Note A programming unit PG PC is not required if the SIMATIC Manager is installed on the SINUMERIK 840Di How to install additional software is described in Chapter 15 page 15 461 Software The following software is required e Basic PLC program The MCP relevant modules of the basic PLC program are FB 1 MCP com munication parameters FC 19 interface parameter assignment version milling and FC 25 interface parameter assignment version turning The PLC basic program is included on the SINUMERIK 840Di installation CD The installation of the basic PLC program as a SIMATIC S7 library is described in Section 6 4 page 6 161 in detail e SIMATIC STEP 7 SIMATIC STEP 7 is used for adapting the basic PLC and user programs e g call of FC 25 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 243 8 PROFIBUS DP Communication 01 05 8 7 DP slave MCP 483 References The following manuals are required for installation and start up of the MCP FB1 Description of Functions Basic Machine P3 Basic PLC Program Description of the program structure and modules of the PLC basic program BH Operator Components Manual Description of MCP interfaces electrical connection etc IZI 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
125. PROFIBUS communication Parameterization PROFIBUS DP 10 398 General Interface 1 24 PROFIBUS DP Communication PROFIBUS S7 subnetwork ID Subnetwork ID 9 275 Programmed Spindle speed limitations 10 377 Protection levels Protool Pro 1 26 Pulse multiplication factor 10 369 Q Quantity framework 1 22 R Rapid traverse in JOG mode 10 342 READY LED PP72 48 Real time properties Real time violations 1 27 10 403 Realtime response 10 403 Redefining protection levels 10 283 Reference point approach 10 353 References B 523 Replacing the batter Criteria for 2 51 MCI board 2 51 Requirements Start up PLC Resolutions Restoring Retentive ranges RI suppression measures 4 111 Rotary axes Drive Optimization Rotary axis With rotary encoder on motor 10 320 10 323 With rotary encoder on the machine 10 320 Rotary measuring system 10 319 Routing information Setting Rules for routing cables EMC ESD 4 111 RUN 10 402 S S1 Handwheel type MCI board Ext PROFIBUS address PP72 48 S3 MCP 7 178 MPI interface 7 186 Index 542 Sample PLC application 1 36 Saving measurement results 13 422 Screen resolution Setting 1 27 Switching over Serial mouse 5 128 Series machine start up archive Creation using HMI Advanced 14 459 Series machine start up file Creating 6 164 Series start up 611u Selecting archive content 14 454 Servi
126. Power up NCK reset reset channel or mode group reset and end of parts program and 2 Parts program start The default setting of an NC function remains stored until it is explicitly changed by operation or programming The machine data MD20110 RESET_MODE_MASK Definition of the control default settings in case of reset e MD 20112 START_MODE_MASK Definition of the control default settings in case of NC start e MD20150 GCODE_RESET_VALUES Reset position of the G groups e MD20152 GCODE_RESET_MODE G code initial setting in case of reset are used to define the relevant default settings Table 10 53 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 Parts program start MD20112 START_MODE_MASK MD20110 RESET_MODE_MASK FB1 Description of Functions Basic Machine K2 Axes Coordinate Systems Frames Actual Value System for Workpiece Chapter Workpiece related actual value system reset behavior Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 399 10 NC Start Up with HMI Advanced 01 05 10 10 NC PLC Diagnosis 10 10 NC PLC Diagnosis 10 10 1 Menu Diagnostics Operating path The menu of the NC PLC diagnostics is in the following o
127. Reference marker distance with distancecoded scales encoder number Differential distance between two reference markers with distancecoded scales encoder no Linear measuring system inverse to machine system encoder number Distancecoded linear measurement system without destination point encoder number Spindle speed tolerance S1 Encoder limit frequency resynchronization Zero mark monitoring Absolute encoder position at time of deactiva tion 10 363 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles References FB Description of Functions Basic Machine R1 Reference point approach Siemens AG 2005 All rights reserved 10 364 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 20 Spindle basic data Spindle definition Spindle modes 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 By setting the machine data e MD30300 IS_ROT_AX rotary axis spindle e MD30310 ROT IS MODULO modulo conversion for rotary axis spindle e MD30320 DISPLAY IS MODULO modulo 360 degrees di
128. SIMATIC Manager SN 7 File Edit Insert Target System View Tools Window Help Da aaa FALL sl a Sal ofie En EE lt No filter gt ee a SIN840Di SIMATIC 300 1 PLC 317 2DP 2AJ10 El En S7 Program 1 ri ae gp8x0d65 En gp8xod amp Sources Blocks Fig 6 7 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 161 6 PLC Start Up 01 05 6 5 Creating a MPI 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 6 5 Creating a MPI configuration Creation of a M
129. Several Operator Panels and NCUs B4 Operation via PG PC F3 Remote Diagnostics H1 JOG with without Handwheel K3 Compensations K5 Mode Groups Channels Axis Replacement L1 FM NC Local Bus M1 Kinematic Transformation M5 Measurement N3 Software Cams Position Switching Signals N4 Punching and Nibbling P2 Positioning Axes P5 Oscillation R2 Rotary Axes S3 Synchronous Spindles S5 Synchronized Actions up to and including SW 3 S6 Stepper Motor Control S7 Memory Configuration T1 Indexing Axes W3 Tool Change W4 Grinding FB3 SINUMERIK 840D 840Di 810D Description of Functions Special Functions Part 3 the various sections are listed below F2 G1 G3 K6 M3 S9 T3 TEO TE1 TE2 TE3 TE4 TES TE6 TE7 TE8 V2 W5 3 Axis to 5 Axis Transformation Gantry Axes Cycle Times Contour Tunnel Monitoring Coupled Motion and Leading Value Coupling Constant Workpiece Speed for Centerless Grinding Tangential Control Installation and Activation of Compile Cycles Clearance Control Analog Axis Master Slave for Drives Transformation Package Handling Setpoint Exchange MCS Coupling Retrace Support Path Synchronous Switch Signal Preprocessing 3D Tool Radius Compensation Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B 529 B References FBA FBAN FBD FBDM FBDN FBFA FBFE FBH B 530 SIMODRIVE 611D SINUMERIK 840D 810D Description of Functions Drive
130. Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 343 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Machine data Table 10 37 Velocities machine data Number Name of identifier Name remarks Refer ence Axis spec MA_ 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 traverse 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 10 38 Velocities Setting data Number Name of identifier Name remarks Refer 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 References FB Description of Functions Basic Machine G2 Velocities Setpoint Actual Value Systems Closed Loop Control Chapter Velocities traversing ranges accuracies FB Description of Functions Extended Functions H1Jog with without Handwheel Siemens AG 2005 All rights reserved 10 344 SINUMERIK 840
131. Signal selection list box of the trace con cerned Then activate the desired items by selecting them from the list box The measuring time is written directly into the Measuring duration input field Direct entry of pre triggering and post triggering 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 0 You can select the trigger type from the Trigger drop down list The trigger always refers to Trace 1 If the trigger conditions are met traces 2 to 4 are started simultaneously Settable trigger conditions e No trigger i e measurement starts when you operate the soft key Start all traces are started in synchronism e Positive edge e Negative edge Direct input of the trigger threshold The threshold is only effective with trigger types Positive edge and Negative edge The unit refers to the selected signal Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 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 k
132. To Send Request to send control signal on serial data interfaces Single Block Setting Data Setting Data Active Identifier for setting data SoftKey SKIP Skip block Synchronous Linear Motor Software limit switch Sub Program File Subroutine Static RAM non volatile Synchronous Rotary Motor Synchronous Serial Interface interface type Status word of drive SoftWare Tool Tool Change Transport Control Protocol Internet Protocol Thin Client Unit Testing Data Active Identifier for machine data Tool Offset Tool Offset Active Identifier for tool offsets Tool Radius Compensation Transistor Transistor Logic interface type Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 A Abbreviations VDI interface wcs ZO ZOA uc Data interface between NC and PLC Workpiece Coordinate System Zero Offset Zero Offset Active Identifier for zero offsets Micro Controller Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition A 521 A Abbreviations 01 05 Notes Siemens AG 2005 All rights reserved A 522 SINUMERIK 840Di Manual HBI 01 05 Edition References A list of documents updated on a monthly basis is available in the Internet for the available languages under http www siemens com motioncontrol through Support Technical Documentation
133. Tr 1 X1 axis Tr 2 Y1 axis gt Tr 1 Pos act val meas sys 1 Tr 2 Pos act val meas sys 1 1 0000 mm Fullscreen i L i L i i bsbtamdossbtos Tr 3 Set velocity Tr 4 Set velocity Graphics Trace 3 4 Start Measure Service Axis User Display File ment axis MD views functions Fig 13 11 Measurement results Trace function Soft keys 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 a lt lol gt v slowly Cursor key fast Shift key cursor key Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 443 13 Drive Optimization with HMI Advanced 01 05 13 6 Trace function Soft keys If a marker is active a 2nd line is shown in the diagram via the 2nd marker soft 2nd 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
134. a file When the language is switched in online operation the first language remains as originally set and only the second language can be changed The vertical soft key labeled Change language in the Start up display is used to switch between two languages The switchover takes effect immediately This key can only be used to switch between two predefined languages Different languages are selected in the Start up MMC Languages display pro 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 HMI Advanced contains the languages German and English as default lan guages Supplementary packages 1 and 2 are also available 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 11 HMI Advanced
135. above data Warning For reasons relating to the system the consistency check which is performed during SINUMERIK 840Di boot and based on acyclic communication with the drive runs parallel in time with the already active cyclic communication between NC and drive As setpoint and actual values are already being exchanged between the NC position control and drive as part of the cyclic communication uncontrolled system states can occur on the drive side due to faulty process data configurations 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 machine data e MD 13070 DRIVE FUNCTION MASKfn used DP functions and therefore it is not possible for the NC to perform a consistency check Therefore the responsibility lies with the start up engineer to implement suitable measures e g connecting terminals 64 65A 65B 663 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 16 2 5 Data descriptions MD system variable 13070 MD number Default setting 0 General machine data DRIVE_FUNCTION_MASK Bit coded screen for selecting the functional scope expected by the NCK with PROFIBUS drives Minimum input limit 0 Maximum input limit FFFF FFFF
136. additional drive data is available on the NC 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 e MD 36730 DRIVE_SIGNAL_TRACKINGJn acquisition of additional drive actual values Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 501 16 840Di specific Data and Functions 01 05 16 2 Expanded message frame configuration Specific system variables General system variable Data formats 16 502 The specific drive data listed below is transferred in individually specified sy stem variables with the machine data setting e MD 36730 DRIVE_SIGNAL_TRACKING n 1 The drive data must be configured as additional process data on the drive with the exact meaning in the exact order specified in Table 16 1 Table 16 1 Specific drive data PD Drive data System variables x 1 Load AA_LOAD x 2 Smoothed torque setpoint Mset AA_TORQUE x 3 Active power Pact SAA POWER x 4 Smoothed torque producing current Iq AA CURR IgGl Note Transfer of specific drive data can only take place if the following is applicable Standard message frame data additional data lt max number process data Currently a message frame can contain up to 16 process data items PDA1 to PDA16 The entire message frame wi
137. address gt Button Properties Dialog box Properties PROFIBUS Tab card Network settings Data transfer rate 12 Mbaud Profile DP OK OK Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 235 8 PROFIBUS DP Communication 01 05 8 6 DP slave MCP 310 Adding a module 8 236 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 There is no automatic adjustment The following data must match 1 SIMATIC S7 configuration DP slave MCP 310 PROFIBUS address 2 Machine control panel MCP 310 PROFIBUS address DIP switch S3 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 modules are listed in the hardware catalog under DP slave MCP 310 The follo wing modules are available e Universal module not applicable e standard e standard handwheel e standard extended e standard handwheel extended Module standard The module transfers the data for the Standard function e Input data 8 bytes Standard data 8Byte e Output data 8 bytes Standard data 8Byte Module standard handwheel The module transfers the data for the Standard and Handwheel functions e Input data 12 bytes Absolute value Absolute value no 1st handwheel 2nd handwheel 2By
138. alarms for axis and spindle 700000 799999 PLC alarms for user 800000 899999 PLC alarms for sequence cascades graphs The structure of the text file for cycle and compile cycle alarms is as follows Table 11 3 Structure of text file for 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 References FB Description of Functions Basic Machine P3 PLC Basic Program Chapter Lists List of alarm numbers This number defines the alarm display type 0 Display in alarm line 1 Display in a dialog box Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 11 Alarm and Message Texts Help ID Text or alarm number Format of the text file for PLC alarm texts Display Help ID 11 1 Alarm and message texts 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 11 1 5 Page 11 412 Section HelpContext The associated text is given in inverted commas with the position parameters e Characters and must not be used in alarm texts The character is reserved for displaying parameters e f an
139. also be installed here Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 473 15 Software Installation Update and Data Backup 01 05 15 4 Software installation update Windows 15 4 Software installation update Windows Brief description Compatibility list Requirements Recommended procedure 15 474 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 operation is performed via the SINUMERIK desktop Windows user interface of the SINUMERIK 840Di The SINUMERIK desktop is activated from the service menu See Subsection 5 5 4 Page 5 134 Using the applications e Windows desktop Autostart of the HMI application OFF e 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 s basic software Before installing updating software components check they are compatible with existing software components See the compatibility list for your SINUMERIK 840Di software version in the Internet www siemens com sinumerik gt SINUMERIK 840Di gt Link Box gt Support gt Update gt Tab card Update gt SINUMERIK 840Di Delivery Release System Software gt Com patibility list Compatibi
140. and performance options System software packages Quantity framework 1 22 The following system software packages are available for SINUMERIK 840Di System software Order No 1 Standard 6FC5 258 01BX10 DAI Basic Export 6FC5 258 DIBY10 DA Uni i Standard 6FC5 258 OBX20 DA r niversa Export 6FC5 258 OBY20 OA PI Standard 6FC5 258 OBX30 OA ss Export 6FC5 258 OBY30 OA OBFO current software version on the hard disk YBFO specific software version on hard disk 0BG1 single license without data medium 0BG2 software update service on data medium YBG3 particular software version on CD ROM without license Dre xooxo Single license without data medium previously copy license If a single license without data medium is purchased only the Certificate of Li cense CoL is supplied on paper This allows you to install the system software from a data medium on any number of SINUMERIK 840Di machines and then license them as a single license e Specific software version e g SW 3 1 X 3 Y 1 for more detailed information please refer to Ordering information in Catalog NC 60 The system software packages are each designed for the following quantities Basic Universal Plus Basic Max Basic Max Basic Max Axes 5 6 5 10 5 18 Channels 1 2 1 2 1 6 Mode groups 1 2 1 2 i 6 Channels per 1 2 1 1 2 6 mode group Basic Number of components
141. 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 simply installation and configuration start up a default configuration of the GD communication is included in the sup ply of a SINUMERIK 840Di The default configuration allows the connection of the following components to the MPI bus without further configuration of the GD communication Machine control panel MCP and or interface customer operator panel Handheld t
142. 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 machine start up file with PLC data while the PLC is in the RUN status cyclic operation may result in an inconsistent PLC image in the series machine start up archive After this series machine start up file has been copied back this data inconsistency in the PLC user program may under certain circumstances result in the stop of the PLC Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 14 User Data Backup Series Machine Start Up 14 4 Reading in a series machine start up file with HMI Advanced Changing the PLC To change the PLC operating status proceed as follows operating status p g With 840Di start up Start 840Di start up Windows XP taskbar gt Start gt Programs gt SINUMERIK 840Di gt 840Di Startup Open the dialog box Menu command Window gt Diagnosis gt NC PLC e With HMI Advanced 840Di SW 2 2 and higher and HMI Advanced SW 6 2 and higher Open the dialog box Operating area switchover gt Start up gt NC PLC Diagnosis e Change the PLC operating state Group box PLC buttons STOP and RUN e NC and PLC must then be resynchronized
143. are system variables used to adapt the NC to the machine Name of identifier The identifier of a machine data is subject to the scheme M k _ dentifierString where the following applies System variable M Machine data k Component k identifies the components of the NC parameterizing the appropriate machine data N NC C Channel A Axis D Drive M MMC Activation Activation when referring to a machine data indicates the NC status in which a change to a machine data becomes active Activation categories are e POWER ON e Reconfiguration e Reset e Effective immediately Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 279 10 NC Start Up with HMI Advanced 01 05 10 2 Machine and setting data Setting data Setting data are system variables that indicate the current machine properties to the NC Name of identifier The identifier of a setting data is subject to the scheme S k _ dentifierString where the following applies System variable S Setting data k Component k identifies the components of the NC parameterizing the appropriate machine data N NC C Channel A Axis Activation Unlike machine data changes to setting data always become effective immediately Overview of The machine data are divided into the following areas machine data Table 10 1 Overview of machine data Range Designation from 1000 to 1799 Machine
144. automatically adjusting the torque reduction resolution is not met it is possible to set the parameters manually to achieve consistence if the torque reduction resolution was parameterized in the mappable range 0 01 to 10 The following conditions apply Machine axis X1 corresponds to drive 12A The torque reduction resolution is to be 0 1 Parameterizing the DP slave 611U The value 1638 40 is entered in parameter P0881 The parameters are set with the start up tool SimoCom U menu command Start up gt Additional Parameters gt Expert List gt Number gt 881 The parameter is immediately effective Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 513 16 840Di specific Data and Functions 01 05 16 3 Travel to fixed stop with high resolution torque reduction SimoCom U 12A drive Lof x File Edit Start up Operation Diagnostics Tools Help A e A hs Re He KT A A A PROFIBUS OFF1 Control of clock synchronized PROFIBUS Number 2 881 Evaluation of torque power reduction PRO 1638 40 Fig 16 5 Set parameter P0881 Setting parameters for the SINUMERIK 840Di NC In the axis specific machine data of machine axis X1 e MD 37620 PROFIBUS TORQUE RED RESOL torque reduction resolu tion on PROFIBUS LSB weighting the value 0 1 is entered The machine data is effective after NC reset warm restart 16 3 5 Restrictions Notice It is the start up
145. axis velocities and spindle speeds depend on the ma chine design drive dynamics and the encoder limit frequency of the individual drives The maximum programmable tool path velocity results from the maximum axis velocities of the axes involved in the path programmed The maximum tool path velocity at which traversing is possible within a parts program block results as follows _ Programmed path length in parts program block mm or degrees Vmax IPO cycle s To guarantee that parts program blocks are executed continuously control mar gin the NC limits the tool path velocity within a parts program block to 90 of the max possible tool path velocity as follows Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 299 10 NC Start Up with HMI Advanced 01 05 10 3 System data Lower limit References 10 300 Programmed path length in parts program block mm or degrees 09 Vmax S 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 Chapter Compressor COMPON COMPCURVE The minimum tool path or axis velocity at which traversing is possible results
146. battery falls below its permis sible value e BATF Battery Fault lights up on failure of the 5 V power supply back up battery e 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 e RUN See Table 10 54 below e STOP See Table 10 54 below e BUS1 lights up in case of a bus interface error on PROFIBUS 1 interface X101 e BUS2 lights up in case of a bus interface error on MPI or PROFIBUS 2 de pends on configuration of interface X102 Siemens AG 2005 All rights reserved 10 402 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 10 NC PLC Diagnosis Table 10 54 PLC operating state display by means of RUN STOP evaluation RUN STOP PLC operating state lights up Off RUN The PLC program is being processed Off lights up STOP The PLC program is not being pro cessed STOP can be triggered by the PLC program an error or an operator input Flashes at 0 5 Hz lights up HALT The PLC user program has been halted triggered by a test function Flashes at 2 Hz lights up 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 re 3 sec off quested
147. be selected greater than e MD 36610 AX_EMERGENCY_STOP_TIME Time for braking ramp when an error occurs If this is not the case the braking ramp cannot be kept References FB Description of Functions Basic Machine A3 Axis Monitoring Protection Zones Siemens AG 2005 All rights reserved 10 352 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 19 Referencing an axis Referencing Reference point approach Incremental measuring systems 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 For all machine axes which are not equipped with an encoder providing an ab 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 With incremental measuring systems referencing is carried out using a reference point approach divided into 3 phases 1 Traversing to the reference cam 2 Synchronizing to the encoder zero marker 3 Approac
148. board HW series number For instructions on how to enter the license key see Section 5 7 Page 5 142 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 55 2 Hardware Descriptions 01 05 2 2 MCI2 board 2 2 5 Technical data 2 56 Safety Degree of protection Protective class Safety regulations Approvals Power consumption 5 V Typically Maximum Mechanical data Dimensions Weight Climatic ambient conditions Heat dissipation Temperature limiting values MCI board alone MCI board in PCU 50 Tested to Relative air humidity limits Tested to Rate of temperature change Condensation Quality assurance Vibrational load during operation Class Frequency range Const excursion accelera tion Tested to module in PCU 50 Shock load during operation Acceleration Duration of nominal shock Tested to module in PCU 50 IP 00 Safety class I acc to VDE 0106 P1 1982 IEC 536 EN61131 1 CE UL CSA 3 75 W 5W PCI card short 140 g Open circuit ventilation Transportation storage 40 70 C 20 60 C DIN IEC 68 2 1 DIN IEC 68 2 2 DIN EN 60068 2 2 DIN IEC 68 2 14 5 95 DIN IEC 68 2 30 Per hour max 10K not permissible acc to ISO 9001 3M4 10 5
149. can return to the current graphic display Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 9 Automatic controller setting 13 9 Automatic controller setting An automatic controller adjustment with HMI Advanced is not possible within the framework of SINUMERIK 840Di SIMODRIVE 611 For a description how to carry out an automatic controller adjustment of SIMO universal DRIVE 611 universal drives please refer to References FBU Description of FunctionsSIMODRIVE 611 universal Section Description of Functions Optimization of the Current and Speed Controller Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 451 13 Drive Optimization with HMI Advanced 01 05 13 9 Automatic controller setting Notes Siemens AG 2005 All rights reserved 13 452 SINUMERIK 840Di Manual HBI 01 05 Edition User Data Backup Series Machine Start Up 14 1 Explanations on data backup User data Times for data backup Data backup of various components User data are called all data or data areas that can be entered by the user to achieve the specific functionality of the SINUMERIK 840Di or the connected SIMODRIVE 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 writ
150. class A Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 10 Uninterruptible power supply UPS 2 10 Uninterruptible power supply UPS 2 10 1 SITOP POWER DC UPS MODULE 15 i k L 1 k k k i S k i k k C3 LA L 1 Ly Serial interface USB interface Fig 2 20 View SITOP POWER DC UPS MODULE 15 Order number Designation Order number MLFB SITOP POWER DC UPS module 15 serial interface 6EP1 931 2EC31 SITOP POWER DC UPS module 15 USB interface 6EP1 931 2EC41 Features The SITOP POWER DC UPS module 15 provides the following features e Compact design HxWxD 125 mm x 50 mm x 125 mm e Nominal input voltage 24 V DC e Nominal output voltage 24 V DC e Nominal output current 15ADC e High efficiency approx 96 Class of protection IEC 536 VDE 1006 T1 Class III Degree of protection VDE 0470 IEC 529 IP 20 Setting options Connection threshold Charging current End of charge voltage Operating state ON OFF Backup time Interruption of output voltage Protection and monitoring functions Reverse voltage protection Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 81 2 Hardware Descriptions 01 05 2 10 Uninterruptible power supply UPS Serial interface USB interface 2 82 Overcurrent and short circuit protection Exh
151. components recommended or ap proved by SIEMENS e g SINUMERIK 840D FM NC Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition IX SINUMERIK 840Di Manual 01 05 Preface Notes Siemens AG 2005 All rights reserved X SINUMERIK 840Di Manual HBI 01 05 Edition Contents 1 General Notes on the SINUMERIK 840Di 1 21 1 1 Overview of SINUMERIK 840Di 1 1 1 System components 1 1 2 System software packages and performance options 1 1 3 Hardware components 1 1 4 Software components 1 25 1 1 5 Real time properties 1 1 6 System integrity 1 1 7 Failure safety sede ica woke ste ida wai boa ede eda eee 1 29 1 1 8 Switching off kc voce ein ss nh ba eee A oe kee vee aa 1 1 9 WPS SSS wa eta i Gakige ia ne othr echo 1 2 Overview of software components 1 3 Notes on Star U0 5 248142 dunes narration 1 4 Standard export version 1 5 840Di SAM td di te tation 1 5 1 Menu command Window 1 41 2 Hardware Descriptions
152. down device Fastening screw Ba Board retainer Fig 2 11 Mounting of the module Remove the blanking plate of the free PCI slot Insert the module carefully but firmly into the PCI slot and tighten the con nector plate of the module 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 Mount the module holding down device again Close the housing and fix it again with the two housing screws Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 3 MCI board extension slot variant 2 3 3 Interface description Interface overview Cable distributor X121 Interfaces of the MCI board extension slot variant Table 2 5 Interfaces of the MCI board extension slot variation Interface Designation Type Cable distributor X121 Male connector MCI board extension X4 Plug connector Interface description of the cable distributor interface X121 e Connector 37 way Sub D connector see cable distributor Section 2 4 Page2 65 e Pin assignment Table 2 6 Pin assignment Interface X121 Pin Designation Type 1 Function 1 M24EXT VIVO 24 V ground 24 V output ground 2 M24EXT VIVO 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
153. down the SINUMERIK 840Di 1 1 8 Switching off Windows XP NC and PLC To ensure safe operation of the SINUMERIK 840Di WINDOWS NT 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 gt Shutdown PLC interface signal PC shutdown see Subsection 16 1 1 Page 16 499 Failure to shut down Windows XP correctly can damage the Windows XP instal lation leaving the SINUMERIK 840Di unable to operate On correct shutdown of Windows XP the following occurs The SINUMERIK 840Di 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 Windows XP having been correctly shut down the SINUMERIK 840Di 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 31 1 General Notes on the SINUMERIK 840Di 01 05 1 1 Overview of SINUMERIK 840Di 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 consistenc
154. 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 9 2 Inserting the DP slave To insert a DP slave 611U into the configuration open the hardware catalog using the menu command View gt Catalog The DP slave 611U is to be found at e Profile Standard PROFIBUS DP gt SIMODRIVE gt SIMODRIVE 611 universal PROFIBUS 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 The DP master system is displayed in the station window with the following symbol E_E HN HE When you release the left mouse button the DP slave 611U is inserted into the configuration Note Make sure that the cursor which appears as a crossed out circle when dragging the DP slave is positioned exactly on the DP master system so that the DP slave is inserted into the configuration Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 259 8 PROFIBUS DP Communication 01 05 8 9 DP slave SIMODRIVE drives Expanded message frame configuration In SW 2 2 and higher expanded message frame configuration has been pro vided to transfer drive data to the NC in the cyclic PROFIBUS message frame in addition to the process data PDA for the selected standard message frame type 102 to 10
155. enter call CALL FC27 7 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 6 163 Siemens AG 2005 All rights reserved 7 174 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 6 Default configuration 7 6 Default configuration 7 6 1 GD circle parameters The following 3 GD circles are parameterized in the default configuration i MPI 1 global data SIN840Di E 10 x Benes McP1 MCP2 HHU Aas CPU315 CPU315 CPU315 DB77 DBD16 ID36 1 1 DB77 DBD20 OD22 1 DB77 DBB0 8 DB77 DBD40 1 gt DB77 DBB32 8 2 GD circle DB77 DBD44 1 DB77 DBB24 8 DB77 DBD80 ID44 1 1 DB77 DBD84 OD30 3 GD circle 1 DB77 DBb48 6 Fig 7 4 Default configuration 7 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 Handheld terminal e g HT 6 Table 7 1 Correlation 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
156. functions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 73 2 Hardware Descriptions 01 05 2 6 SINUMERIK operator panel fronts References 2 74 Direct keys connectable using PP031 MC or directly to the I Os e Shift key for switchover to the second key level not for switching over the letters since uppercase letters only e Integrated mouse e Status LEDs for power supply and overtemperature e USB interface at front e Degree of protection IP65 e Can be combined with PCU or TCU e External floppy disk drive can be connected For detailed documentation about the operator panel front OP 012 please see References BH Operator Components Manual Operator panel front OP 012 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 7 TCU Thin Client Unit 2 7 TCU Thin Client Unit X207 X208 Interfaces for connection to the operator panel front covered X203 X204 2 USB A ports Ethernet cable X202 Ethernet interface X201 Compact Flash interface Fig 2 17 TCU with Ethernet cable plugged in Order number Designation Order number MLFB TCU Thin Client Unit 6FC5312 0DA00 0AA0 PCU basic software Thin Client for PCU 50 70 with WinXP single license on CD ROM 05 04 software version 1 0 6FC5253 1CX10 0XA8 Features A TCU permits the distributed connection o
157. inserted into customized operator panel fronts e Bootable e Input voltage 24V DC e Power consumption max 5W e Degree of protection to DIN EN 60529 IP 54 front IEC 60529 IP 00 rear Siemens AG 2005 All rights reserved 2 78 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 9 Power supply 2 9 1 SITOP POWER standard 24V 10A 2 9 Power supply Fig 2 19 Order number Designation SITOP POWER standard 24V 10A View SITOP POWER standard 24V 10A Order number MLFB 6EP1 334 1SH01 Features The SITOP POWER Standard 24V 10A power supply mode provides the follo wing features Input voltage nominal value Input voltage range Power failure back up time Line frequency nominal value Line frequency range Input current nominal value Inrush current 25 C Output voltage nominal value Output voltage tolerance Efficiency Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 120 230 V AC 93 132 V 187 264 V gt 20 ms 50 60 Hz 47 63 Hz 3 5 1 7A 55A 24 V DC 3 gt 87 2 79 2 Hardware Descriptions 01 05 2 9 Power supply 2 80 Output current nominal value 10 A Electron short circuit protection with automatic restart Galvanic isolation SELV acc to EN 60950 Class of protection IEC 536 VDE 1006 T1 class Degree of protection VDE 0470 IEC 529 IP 20 Radio interference level EN 55011
158. is detected can be checked as follows e SIMATIC Manager STEP7 The active nodes at the MPI bus are displayed using the SIMATIC Manager STEP7 by menu command Target system gt Display accessible nodes Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 117 5 Power On and Power Up 01 05 5 2 First power up MPI standard The MPI default addresses of the individual components are addresses _ PLC 2 NC 2 PLC routes to the NC 1 Machine control panel or HT 6 14 See default configuration Section 7 6 Page 7 175 HHU 15 If the machine control panel is displayed as an MPI node with the correct ad dress it has been detected correctly 5 2 4 Power up SIMODRIVE 611 universal drives For detailed information on the power up of SIMODRIVE 611 universal drives please refer to References FBU SIMODRIVE 611 Universal Description of Functions Siemens AG 2005 All rights reserved 5 118 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 3 Booting 5 3 Booting 5 3 1 Boot manager The PCU powers up and the menu of the boot manager is displayed OS Loader Please select the operating system to start SINUMERIK Service Menu not visible Use t and to move the highlight to your choice Press Enter to choose Make your selection with the cursor keys and Your selection is automatically started when you press the E
159. min 1 mm s 1 rpm 1 rpm 1 deg s 1 m s2 1 inch s 1 mm s2 1 rev s2 1 rev s2 1 degree s 1 m s3 1 inch s8 1 mm s 1 rev s3 1 rev s3 1 degree s 1s 1s 1s 1 s7 1 s7 1 s7 1 mm rev 1 inch rev 1 mm degree 1mm 25 40 mm 1mm 1 degree 1 degree 1 degree The user can define different input output units for machine and setting data For this purpose e MD 10220 SCALING_USER_DEF_MASK activation of scaling factors and e MD 10230 SCALING FACTORS USER DEFfn 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 Scaling factor activated Internal scaling MD 10230 Scaling factor Internal physical unit Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 3 System data The following applies Selected input output unit MD SCALING_FACTORS_USER_DEF n Internal unit Enter the actual value corresponding to the approached position in MD 10230 SCALING_FACTORS USER DEFfn Table 10 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 K
160. mounting start up and operation of the equipment and the hazards involved e Training and instruction i e authority to switch on and off to earth and to label circuits and equipment according to safety regulations e Trained in the proper care and use of protective equipment in accordance with established safety procedures and first aid Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 SINUMERIK 840Di Manual Danger and warning strategy ZN gt gt Other information o Preface The following danger and warning signs are used in this document Explanation of symbols used Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury or in substantial property damage Warning Indicates a potentially hazardous situation which if not avoided could result in death or serious injury or in substantial property damage Caution Used with the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or in property damage Caution Used without safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage Notice Used without the safety alert symbol indicates a potential situation which if not avoided may result in an undesirable result or state Expl
161. 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 configuration SDB210 is only loaded with the SIMATIC Manager not with HW Config Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 163 6 PLC Start Up 01 05 6 7 Loading the configuration Loading in the module NC Reset triggered Dialog box To load the configuration into the PLC select the following menu item Target System gt Load in Module The dialog box for loading the configuration now displayed offers the following options Setthe 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 The STOP condition of the PLC
162. of the SINUMERIK 840Di is 187 5 kbaud The factory setting of the data transfer rate is 1 5 Mbaud You can make the setting on switch S3 See Table 7 3 Page 7 180 Notice To operate the module on a SINUMERIK 840Di you must set the data transfer rate to 187 5 kbaud MPI address The MPI address factory setting on the machine control panel is 6 This default setting is not suitable for operation on a SINUMERIK 840Di with default configu ration e Default configuration If the default configuration is used the MPI address of the machine control panel must be set to one of the following values As 1st machine control panel 13 14 15 As 2nd machine control panel 11 12 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 179 7 MPI Communication 01 05 7 7 Machine control panel 19 or MCP Notice The factory setting default MPI address 6 is not suitable of operation of the machine control panel on a SINUMERIK 840Di e Plant specific configuration If the module is operated in an MPI configuration other than the standard configuration the GD circle parameterization used will define the MPI ad dress to be set See Subsection 7 6 3 Page 7 176 You can set the MPI address on switch S3 See Table 7 3 below Page 7 180 Switch S3 Set parameters e Data transfer rate e Transmission frequency and receive monitoring e MPI address e Operator component type Table 7
163. of torque reduction the SINUMERIK 840Di NC carries out an automatic matching procedure using the torque reduction resolution parameterized in the drive The following requirements must be met The drive supports acyclic communication and it is enabled on the NC side For information on how to enable acyclic communication on the NC please see the description of NC machine data e MD 13070 DRIVE_FUNCTION_MASK n used DP functions Parameter P881 is present in the drive with the corresponding meaning and a scaling of 16384 A 1 During SINUMERIK 840Di boot and in the state Incoming station of the DP slave 611U the SINUMERIK 840Di NC cyclically reads parameter P881 from the drive and transfers it to the appropriate axis specific NC machine data e MD 37620 PROFIBUS TORQUE RED RESOL torque reduction resolu tion on PROFIBUS LSB weighting Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 511 16 840Di specific Data and Functions 01 05 16 3 Travel to fixed stop with high resolution torque reduction Manual comparison If the requirements are not met for automatic adjustment then the parameters can be set manually for the SINUMERIK 840Di NC if the resolution of the torque reduction is parameterized in principle in the mappable range 0 01 to 10 16 3 3 Setting parameters for SIMODRIVE drives Parameter P0881 Normalization Setpoint torque Tset 16 512 The re
164. 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 Fy 15p Fig 7 15 Software version and MPI address 7 9 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 7 16 Page 7 191 Siemens AG 2005 All rights reserved 7 190 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication Setting the MPI parameters FB 1 7 9 Handheld unit B MPI OB 100 FB1 Start up Cold restart __ e g HHU parameters i User program OB 1 FC 27 Cyclic
165. on the PROFIBUS DP Acyclic services on the PROFIBUS DP are supported by the following SIMODRIVE drives SIMODRIVE 611 universal E SIMODRIVE POSMO CD CA SIMODRIVE POSMO SI and the value 0 must be entered in machine data e MD32250 RATED_OUTVAL rated output voltage During start up of the NC speed setpoint matching between the NC and the drive is then performed automatically Note If automatic speed setpoint matching fails for one axis the following message is output on a traverse request for his axis e Message Wait axis enable missing This axis and any axes that interpolate with it are not traversed If a value not equal to 0 is entered in machine data e MD32250 RATED_OUTVAL rated output voltage the NC assumes that speed setpoint matching will be performed manually The rated motor speed entered in axis specific matching data e MD32260 RATED_VELO rated motor speed rev min with reference to 100 must be equal to the speed evaluation entered in the drive P880 e P880 Speed evaluation PROFIBUS rpm ARM SRM or m min SLM SINUMERIK 840Di NC SIMODRIVE 611 universal MD32260 RATED_VELO P880 MD32250 RATED_OUTVAL Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles ADI4 Because ADI4 does not support acyclic services on the PROFIBUS DP manual
166. options patches etc The numbers in the directory name indicate order in which the installation programs have to be run Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 6 Restoring the as delivered state 3 Next open directory e 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 e D ASETUP APPS 001 001 to xxx as described in item 3 5 Proceed with all existing directories e 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 harddisk are once again restored to their as delivered state Example Fig 15 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 El A setup E A apps El B 001 Installation sequence E A 000 aE SETUPEXE 1 E oot dl SETUPEXE 2 EC o2 8 serupexe 3 E A 002 A CA 000 HE serupexe 4 A CA 001 SA serupexe 5 Fig 15 4 Installation sequence Sie
167. output Number of measuring channels 1 one position measuring system installed 2 two position measuring systems installed 30210 ENC_SEGMENT_NRJ 0 Actual value assignment Drive type 5 PROFIBUS DP 30220 ENC_MODULE_NR O Actual value assignment Logic drive number for position measuring system 1 30220 ENC_MODULE_NR 1 Actual value assignment Logic drive number for position measuring system 2 30230 ENC_INPUT_NR 0 Actual value assignment Position measuring sys tem 1 1 motor measuring system 2 direct measuring system Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 317 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Number Name of identifier Name remarks Refer ence 30230 ENC_INPUT_NRf1 Actual value assignment Position measuring system 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 10 20 Switching over the position measuring system Interface signals DB Bit byte Name Refer Number ence Axis spindlespecific Signals from PLC to axis spindle lt i eee 1 5 Position measuring system 1 ST 1 6 Position measuring system 2 References FB Description of Functions Basic Machine G2 Velocities Setpoint Actual Value Systems Closed Loop Control Chapter Setpoint Actual Value System FB
168. 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 84 There is no automatic adjustment The following data must match 1 SIMATIC S7 configuration of DP slave PP72 48 PROFIBUS address 2 I O module PP72 48 PROFIBUS address switch S1 Siemens AG 2005 All rights reserved 8 226 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 5 DP slave VO Module PP72 48 Dialog box Dialog box PROFIBUS properties Interface PP input output Tab card Parameter Address lt PROFIBUS address gt Button Properties Dialog box Properties PROFIBUS Tab card Network settings 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 ass
169. security the SINUMERIK 840Di system software the Windows system software and the Service software are installed in different partitions Partitions The diagram below shows the partitioning of the harddisk when the control sy stem is supplied Active Name DOS Name TMP Name WinNT Name 840D system Content Tools Content Images Content WinNT 4 0 Content 840Di system Install software Updates further appl Primary partition Extended partition Primary partition Primary partition with logic drive Fig 15 3 Partitioning of the harddisk 1st partition drive C Drive C contains MS DOS 6 2 tools e g Norton Ghost and scripts implemented by the service menu 2nd partition drive D Drive D contains The Images directory with the images preinstalled and created by the user The Install directory into which the software to be installed is to be copied first before the installation process itself is carried out under Windows XP The Update directory for later installation of Windows XP system software 3rd partition drive E Drive E is reserved for the Windows XP system software Ath partition drive F Drive F contains the Windows XP applications e g the SINUMERIK 840Di system software Further applications such as HMI system software HMI OEM applica tions SIMATIC Manager STEP7 or customer specific applications e g user interfaces created using Protocol Pro MC will
170. slave MCP 483 is displayed in SIMATIC STEP 7 in the HW config hard ware catalog in the following path e Profile Standard PROFIBUS DP gt Other field devices gt NC RC gt Motion Control gt SINUMERIK MCP If the module is not displayed the GSD file must be installed To do this in STEP 7 HW config use menu command Tools gt Install new GSD file Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication Graphics files 8 7 DP slave MCP 483 To display the DP slave MCP 483 correctly in the station window of HW config requires the following image files e 18109_N BMP e 18109_S BMP Image files are automatically installed by STEP 7 when the GSD file is installed They must be located in the same directory as the GSD file 8 7 4 Functions of the machine control panel Standard Handwheel Additional I Os The machine control panel offers the following functions e Standard e Handwheel e Additional I Os The function transfers input output data from the function keys and user specific keys and outputs e Input data 8 bytes e Output data 8 bytes 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 The function transfers the absolute values for the two handwheels t
171. soft key OK you can terminate the bit editor and accept the value set e With the soft key Abort you can quit the bit editor and discard the value set The previous setting is then valid again 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 10 3 e 4 password levels for Siemens machine manufacturer and end user e 4keyswitch positions for end user This provides a multilevel safety concept for controlling access rights Table 10 3 Protection levels Protection level Type User 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
172. speed setpoint limitation Monitoring due to the actual velocity of the machine axis determined based on the encoder values e MD36020 AX_VELO_LIMIT threshold value for velocity monitoring Error response e Alarm 25030 Alarm limit of actual velocity and stopping the machine axis using a speed setpoint ramp whose characteristic is set in e MD36610 AX_EMERGENCY_STOP_TIME Time for braking ramp when an error occurs Cause of errors error handling e Check speed setpoint cable e Check actual values e Check position control direction e Threshold value for velocity monitoring is possibly too low Monitoring of the difference between following error measured and following error calculated from the position setpoint e MD36400 CONTOUR_TOL contour monitoring tolerance band Error response e Alarm 25050 Contour monitoring Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 349 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Encoder limit frequency monitoring 10 350 and stopping the machine axis using a speed setpoint ramp whose characteristic is set in e MD36610 AX EMERGENCY STOP TIME Time for braking ramp when an error occurs Cause of errors error handling Contour errors are due to signal distortions in the position control loop Remedy e Increase the tolerance band e Check the Kv factor The real servo gain must correspond
173. the display groups the number of displayed machine data of the current machine data area increases or decreases 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 NC The index filter refers to the machine data fields On the display these machine data can be identified by the field index attached to the machine data string Example 10000 AXCONF_MACHAX_NAME_TAB index If the index filter is activated machine data fields are only displayed in the spe cified index area Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 285 10 NC Start Up with HMI Advanced 01 05 10 3 System data 10 3 System data 10 3 1 Resolutions Input and display resolution Computational resolution Rounding 10 286 The following types of resolution e g resolution of linear and angular positions velocities accelerations and jerk must be differentiated as follows e the input resolution i e the input of data from the user interface or using the parts programs e the display resolution i e the display of data on the user interface e the computational resolution i e the internal representation of the data input through the user interface or the parts program The input and display resolution is determined by the control unit used whereby the display resolution for position values c
174. through this PROFIBUS line The interface X102 can be parameterized as an MPI or PROFIBUS interface Machine control panels handheld operator and programming units such as the PG 740 can be connected via the MPI interface A maximum of four fast digital I Os two sensing probes and two handwheels each can be connected using the optional MCI board extension slot variant Either differential or TTL handwheels can be operated The module occupies a slot in the PCU But the slot is used for mechanical con nection only The electrical connection to the system is made with a ribbon cable to the MCI board For interpolating traversing of axes on the PROFIBUS the SINUMERIK 840Di uses the functionality defined in the PROF IDrive profile drive technology Ver sion 1 4 2 01 Sept 00 called Motion Control mit PROFIBUS DP For this purpose Siemens offers the following drives SIMODRIVE 611 universal with option module MotionControl with PROFIBUS DP SIMODRIVE 611 universal E with option module MotionControl with PROFIBUS DP SIMODRIVE POSMO CD CA SIMODRIVE POSMO SI In addition to traversing axes with interpolation it is also possible to have the drives positioned at PROFIBUS automatically and independently of other drives operating mode positioning For this purpose Siemens offers the following drives SIMODRIVE 611 universal with option module MotionControl with PROFIBUS DP SIMODRIVE 611 u
175. to the desired servo gain set by MD 32200 POSCTRL_GAIN n Kv factor HMI Advanced Operating area DIAGNOSIS gt Service displays gt Service of axis e Check optimization of the speed controller e Check smooth running of the axes e Check machine data for traversing movements feed override acceleration max speeds e Operation with feedforward control MD 32810 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 Monitoring of the limit frequency of the encoder of a machine axis e MD 36300 ENC_FREQ_LIMIT encoder limit frequency Error response e Alarm 21610 Encoder frequency exceeded e IS DB31 DBX60 2 Encoder limit frequency exceeded 1 e IS DB31 DBX60 3 Encoder limit frequency exceeded 2 and stopping the machine axis using a speed setpoint ramp whose characteristic is set in e MD36610 AX_EMERGENCY_STOP_TIME Time for braking ramp when an error occurs Cause of errors error handling The position control resumes automatically after the axes have stopped Notice The axis affected must be rereferenced Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles Encoder The zero mark monitoring of the encoder of a machine axis checks whether zero mark pulse
176. type a new name of the computer The following menu appears PLEASE SELECT 1 Input Machine Name MANUALLY 2 Input Machine Name RANDOMLY 9 Abort Your Choice 1 2 9 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu e Input Machine Name MANUALLY Type the new 10 digit computer name into the input screen form displayed When you confirm the new name using the Input key the computer name is taken over into the system e Input Machine Name RANDOMLY A random computer name is generated and taken over into the system Abort The computer name taken over with the image is kept The computer name can be changed using Norton Ghost Walker Note In networks where the function Microsoft Domain Security is active changing the computer name causes new system and user IDs to be generated even if the same computer name is used The computer and local user must then be re administered in the network 8 After Norton Ghost Walker has updated the computer name the following menu is displayed It seems that Ghost Restore succeeded Hit any Key to reboot the System The next time the PCU is booted under Windows XP partitions E and F will be checked one after the other by the diagnostic program CHKDISK The PCU automatically reboots between checks Aft
177. until the password has been set Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 401 10 NC Start Up with HMI Advanced 01 05 10 10 NC PLC Diagnosis e 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 e 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 e PLC default data The PLC is put in the STOP state with PLC Default Data button and then an extended PLC general reset is performed The actions stated above un der item 1 4 and those under item 5 are reset e Status displays The status displays which are made to look like LEDs indicate the follo wing e SF System Fault lights up on PLC system errors such as Hardware programming para meterizing computing time battery and communication errors e BATL Battery Low lights up if the 5 V power supply back up
178. wire breaks or missing terminating resistors 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 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 Monitoring functions of the clock synchronous PROFIBUS Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 10 DP slave Diagnostic repeater for PROFIBUS DP 8 10 2 Application range A diagnostic repeater is required if one or more of the following requirements exist e Cable diagnosis of PROFIBUS network during operation e Connection of more than 32 nodes on a PROFIBUS line e Implementation of branches e Electrical isolation of two segments e Ungrounded operation of bus segments e Visualization of bus topology with STEP 7 Version 5 2 and higher 8 10 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HB
179. 0 SPIND_DEFAULT_ACT_MASK 35040 SPIND_ACTIVE_AFTER_RESET 35100 SPIND_VELO_LIMIT 35110 GEAR_STEP_MAX_VELO n 35120 GEAR_STEP_MIN_VELO n 35130 GEAR_STEP_MAX_VELO_LIMIT n 35140 GEAR_STEP_MIN_VELO_LIMIT n 35150 SPIND_DES_VELO_TOL 35160 SPIND_EXTERN_VELO_LIMIT 35200 GEAR_STEP_SPEEDCTRL_ACCEL n Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 5 Axes and spindles Name Spindle override with Gray coding Evaluation of spindle speed override switch Override reference velocity Initial setting for master spindle on channel Enabling disabling of spindle converter Allow automatic geometry axis change S function active after RESET Rotary axis Modulo conversion Position display Denominator load gearbox Numerator load gearbox BERO delay time in plus direction BERO delay time in minus direction Servo gain factor Kv Equivalent time constant speed control loop for feedforward control Time constant for dynamic matching Reference point creep speed Monitoring of zero mark distance Reference point distance destination point for distancecoded system Reference point offset absolute offset distancecoded Reference point value Referencing mode Assignment of spindle to machine axis Gear stage change possible Gear stage change position Basic spindle setting Activate initial spindle setting Spindle active after reset Maximum spindle speed Maximum speed for gear change
180. 01 05 3 3 Overview of connections Notes Siemens AG 2005 All rights reserved 3 110 SINUMERIK 840Di Manual HBI 01 05 Edition EMC and ESD Measures 4 1 Shielded signal cables Rules for routing cables Interference suppression measures o To ensure safe interference free operation of the installation it is essential to use the cables specified in the individual diagrams Both ends of the shield must always be conductively connected to the equipment housing Exception e f non Siemens devices are connected printers programming devices etc you can also use standard shielding cables 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 To ensure that the entire installation control power section machine has the greatest possible immunity to interference the following EMC measures must be taken e Signal cables and load cables must be routed at the greatest possible distance from one another e Only use SIEMENS signal cables for connecting to and from the NC or PLC e Signal cables may not be routed close to strong external magnetic fields e g motors and transformers e Pulse carryi
181. 05 PDA 10 10 nset interface with DSC and encoder 2 axes Message frame type 105 PDA 10 10 nset interface with DSC and encod ers 1 and2 1 axis Message frame type 106 107 PDA 7 15 _nset interface with DSC and encod ers 1 and 2 106 or encoders 1 and 3 107 2 axes Message frame type 106 107 PDA 7 15 nset interface with DSC and encod ers 1 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 Encoders 1 N 1 Encoders 2 Encoders 1 iil Encoders 2 UL Encoders 3 SIMODRIVE 611 universal SIMODRIVE 611 universal E Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 261 8 PROFIBUS DP Communication 01 05 8 9 DP slave SIMODRIVE drives Dialog box I O addresses 8 262 Dialog box DP slave properties Tab card Configuration Default lt Message frame type gt 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 There is no automatic adjustment The following data must match 1 SIMATIC S7 configuration DP slave 611U Message frame type 2 SINUMERIK 840Di NC MD13060 DRIVE_TELEGRAM_TYP 3 SIMODRIVE 61
182. 05 Edition 2 67 2 Hardware Descriptions 01 05 2 4 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 Signal DU BOX Cable Cable order No 37 pin connector No 6FX2002 4AA Core color I Os Terminal name connector No pin X10 2 rd 9 MEPUS 0 X10 1 or 1st probe Signal X10 4 7 41 0 bn 24 V 10 MEPUC 0 X10 3 bk 1st probe Reference shield OV 1 M24EXT X9 2 rd Parameterization Ground 20 P24EXT X9 1 or of the 4 binary 24V 2 M24EXT X9 4 6 41 0 bn outputs of the Ground 21 P24EXT X9 3 bk 24V MPI connector shield 3 OUTPUT 1 X8 2 rd 2nd output 22 OUTPUT 3 X8 1 or 4 binary 4th output 4 OUTPUT 0 X8 4 5 41 0 bn outputs 1st output 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 8rd input 25 MEXT X7 3 bk 4 binary Ground 7 INPUT 1 X6 2 4 21 0 gn inputs 2nd input 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 X5 4 3 41 0 bn 24 V 29 MEPUC 1 X5 3 bk 2nd probe shield Reference OV 11 MPG1 XA X4 2 rd XA 30 MPG1 A X4 1 or A 12 MPG1 5V X4 4 bn 5V 31 MPG1 OV X4 3 bk 2nd handwheel OV 13 MPG1 5V X3 2 2 21 0 g
183. 1 05 5 7 License management Notes Siemens AG 2005 All rights reserved 5 144 SINUMERIK 840Di Manual HBI 01 05 Edition PLC Start Up 6 1 6 1 1 6 1 2 Compatibility The PLC integrated on the MCI board of the SINUMERIK 840Di is compatible with the SIMATIC S7 PLC AS317 2 DP Performance data The PLC of the SINUMERIK 840Di 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 kbytes Data block memory max 256 kbytes Memory submodule no Bit memories 32768 Timers 512 Counters 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 kbytes Max block length FC FB 64 kbytes 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 Row 0 is integrated in the NC Rows 1 to 3 are available for I O devices Through optional configur ing of I O devices Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 145
184. 1 universal ADI4 e 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 e Activation of the isochronous DP cycle e __Isochronism master cyclic component Tpx Step2 e lIsochronous DP cycle Tpp e Master application cycle Twapc e Actual value acquisition T e Setpoint acceptance To An overview of the various times of a DP cycle is shown in Fig 8 2 Page 8 211 Note The procedure of final parameterization of isochronous DP communication is exemplified by one DP slave 611U For other isochronous DP slaves e g SIMODRIVE POSMO SI CD CA ADI4 etc proceed analogously Notice If a project you want to perform final parameterization on contains DP slave ADH interfaces certain boundary conditions must be observed See also References ADI4 Analog drive interface for four axes Chapter Parameterization Parameterization of DP communication Boundary conditions Siemens AG 2005 All rights reserved 8 218 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PRO
185. 1 universal Parameter P0922 PROFIBUS message frame type selection For a detailed description of the different message frame types please see e SIMODRIVE 611 universal and universal E References FBU Description of Functions SIMODRIVE 611 universal e SIMODRIVE POSMO SI CD CA References POS3 User Manual SIMODRIVE POSMO SI CD CA in each case in Section Communication on PROFIBUS DP Communication between NC and the individual axes of the DP slaves 611U in the SINUMERIK 840Di can only take place if the I O addresses for setpoint and actual value of an axis are the same This prerequisite is taken into account by SlaveOM automatically when inserting a DP slave 611U into a configuration Notice e The I O addresses for set and actual values of an axis must be the same 1 0 address actual value I O address setpoint If a DP slave 611U is inserted into an S7 project due to a copying process e g from another S7 project the 1 0 addresses are assigned exclusively under the control of HW Config This may have the consequence that one axis are assigned different I O addresses for set and actual values In this case the I O addresses must be corrected manually e To avoid access conflicts between PROFIBUS DP drives and I O modules you need to set values 272 for ADI4 DP slave 611U I O addresses Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP C
186. 14 2 1 14 2 2 14 2 3 14 3 14 4 Software Installation Update and Data Backup 15 1 15 1 1 15 1 2 15 1 3 15 1 4 15 2 15 2 1 15 2 2 15 2 3 15 2 4 Overview 4 44 44 4444 eee eee eee 13 421 Measuring functions 13 423 Miscellaneous functions 13 425 Frequency response measurements Torque control loop measurement Speed control loop measurement Position control measurement Graphic display 13 435 Trace function 2 13 438 Trace function properties 13 438 Main menu and operation 13 439 Parameterization 13 440 Performing the measurement 13 442 Display TUNCHON eriseeria ee nets Ren e men eee 13 443 File TUAGHON 2 ue nanas ee pee durs cet eee nement ea Print graphic isaimini ii hha ae ahd ner edb Ada dd ade 13 448 Automatic controller setting Explanations on data backup Creating a series commissioning file 14 454 G n ral 4444444280 ea bate hel whee E dada ead 14 454 HMI
187. 2 Node address Notes for the Reader O OB1 OB100 7 174 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 Index OEM configuration 5 129 OEM directories 5 129 9 271 Online connection 611u Online operation Starting OP 012 Operator panel front 2 73 General 1 25 Operator panel fronts 2 46 Optional HMI components 1 26 Options Performance 1 23 Order number ADI4 2 97 Backup battery 2 51 Cable distributor 2 65 2 49 MCI board extension 2 57 MCI board extension slot variation 2 46 PCU 50 2 70 PCU basic software Thin Client 2 75 _ PP72 48 2 84 SITOP POWER 10 2 77 2 78 2 79 SITOP POWER lead acid battery module 24 V DC 10 A 3 2 AH 2 83 SITOP POWER DC UPS MODULE 10 2 81 TCU Output Time Overtemperature 1 30 Overview 1 21 Overview of connections MCI board 3 107 MCI board extension 3 107 PCU50 3 107 OVTEMP LED PP72 48 2 92 P Packages system software 1 22 Parameter sets of the position controller 10 332 Parameterization MCP 7 178 8 229 3 244 MPI interface NC Parameterization of PLC HT 6 7 199 MCP 7 181 Password Resetting Setting PC OS fault Interface signal PC shutdown Interface signal PCU 1 23 Interfaces 1 23 Slots 1 23 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI
188. 2 Page 5 133 e DOS Shell The DOS command interpreter is started See Subsection 5 5 3 Page 5 133 e Start Windows The Windows operating system is started See Subsection 5 5 4 Page 5 134 e SINUMERIK System Check Consistency test and if necessary recovery SCANDISK of the file system See Subsection 5 5 5 Page 5 134 e Backup Restore Hard disk backup restore with Norton Ghost See Subsection 5 5 6 Page 5 135 e Start PC Link Installation of the PC link software interlink interserve for data transmission via the parallel interface no longer recommended e Reboot Restart of the system e 840Di services Activate 840Di specific functions See Subsection 5 5 8 Page 5 135 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 5 Service menu 5 5 1 Install update SINUMERIK system Operator action Starting from the main menu see Fig 5 3 Page 5 132 select Install Update SINUMERIK System with key 1 You will find a detailed description of the function SW Installation Update in Section 15 4 Page 15 474 5 5 2 SINUMERIK tools and options Operator action Starting from the main menu see Fig 5 3 Page 5 132 select SINUMERIK Tools and Options with key 2 Following menu PLEASE SELECT 1 Activate Step7 for PCU 9 Return to Main Menu Your Choice 1 9 Functions You can execute the following functions via the menu
189. 2 Page 8 213 The GSD file of the DP slave MCP 310 is required in the following version or later e 1008109 GSD version 1 0 or later Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 231 8 PROFIBUS DP Communication 01 05 8 6 DP slave MCP 310 Graphics files GSD file contains all the properties of a DP slave in ASCII format For each DP slave SIMATIC STEP 7 requires a module specific GSD file so that the DP slave can be found in the hardware catalog The DP slave MCP 310 is displayed in SIMATIC STEP 7 in the HW config hardware catalog in the following path e Profile Standard PROFIBUS DP gt Other field devices gt NC RC gt Motion Control gt SINUMERIK MCP If the module is not displayed the GSD file must be installed To do this in STEP 7 HW config use menu command Tools gt Install new GSD file To display the DP slave correctly MCP 310 correctly in the station window of HW config requires the following image files e 18109_N BMP e 18109_S BMP Image files are automatically installed by STEP 7 when the GSD file is installed They must be located in the same directory as the GSD file 8 6 4 Functions of the machine control panel Standard Handwheel 8 232 The machine control panel offers the following functions e Standard e Handwheel e Additional I Os The function transfers input output data from the function keys and u
190. 2 SIMODRIVE 611 universal Parameter P0918 PROFIBUS node address Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 9 DP slave SIMODRIVE drives Dialog box Dialog box Properties PROFIBUS Interface SIMODRIVE 611U DP2 DP3 Message frame type Tab card Parameter Address PROFIBUS address OK After this dialog has been confirmed using the button OK the dialog box DP Slave Properties 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 11 Message frame types Message frame type Description 1 axis Message frame type 102 PDA 6 10 nset interface with encoder 1 2 axes Message frame type 102 PDA 6 10 nset interface with encoder 1 1 axis Message frame type 103 104 PDA 7 15 nset interface with encoders 1 and 2 103 or encoders 1 and 3 104 2 axes Message frame type 104 PDA 7 15 nset interface with encoders 1 and 3 1 axis Message frame type 1
191. 2 Windows Xp general Windows XP position Part1 Part 2 controller and interpolator Tpp DP cycle time DP cycle time Tu master time Offset of the start time for NC position control Fig 10 3 CPU time division between Windows XP and NC Default value Via machine data item e MD10185 NCK_PCOS_TIME_RATIO CPU time component NCK the maximum CPU time share of the NC is set with reference to a DP cycle The default value is 65 Individual setting An individual setting can only be made by the following formula MD10185 gt 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 gt Diagnosis gt Service displays gt System resources MD10070 IPO_SYSCLOCK_TIME_RATIO factor for interpolation clock pulse MD10071 IPO_CYCLE_TIME interpolator clock pulse ms Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 297 10 NC Start Up with HMI Advanced 01 05 10 3 System data References 10 298 Note e 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 e The values for Tpos max and 1PO max are considerab
192. 22 dig inputs outputs PP72 48 2 87 X3 Battery connection MCI board 2 49 X333 dig inputs outputs PP72 48 2 87 X4 MCI board extension 2 57 Z Zero speed monitoring Delay time 10 345 10 345 Zero speed tolerance Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition To Suggestions SIEMENS AG A amp D MC BMS Postfach 3180 91050 ERLANGEN GERMANY Phone Fax 49 180 5050 222 Hotline Fax 49 9131 98 2176 Documentation Email motioncontrol docu erlf siemens de Manufacturer Service Documentation Corrections For Publication Manual SINUMERIK 840Di Manual From Order No 6FC5 297 7AE60 0BP2 Name Edition 01 2005 Company Dept Should you come across any printing errors when reading this publication please Address oS notify us on this sheet Suggestions for improvement are also Zip code welcome Phone Fax Suggestions and or corrections Overview of SINUMERIK 840Di Documentation 10 2004 Special Functions Manufacturer Service Documentation
193. 22 2AA0 SINUMERIK 840Di The following hardware components are available as spare parts Spare parts e SINUMERIK PCU 50 Celeron 566MHz 256MB DRAM and Windows XP and MC12 board 24 V power supply Spare part order number 6FC5 210 0AA21 2AA0 e SINUMERIK PCU 50 Celeron 1 2 GHz 256MB DRAM and Windows XP and MC12 board 24 V power supply Spare part order number 6FC5 210 0AA22 2AA0 e MCI2 board Spare part order number 6FC5 222 0AA02 1AA0 e Backup battery for MCI board Spare part order number 6FC5 247 0AA18 0AA0 Note The SINUMERIK 840Di can be ordered both as a first order and with spare part orders replacement of PCU where necessary together with the SINUMERIK 840Di system software installed on the hard disk of the PCU see Subsection 1 1 2 Page 1 22 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 45 2 Hardware Descriptions 01 05 2 1 Overview of hardware components Optional components MCI board extension Operation and display External memory medium Power supply of the PCU Uninterruptible power supply UPS PROFIBUS DP modules 2 46 The following hardware components can be ordered as options SINUMERIK 840Di MCI board extension slot variation Order number 6FC5 222 0AA00 0AA1 SINUMERIK operator panel fronts OP010 Order number 6FC5 203 0AF00 0AA0 OP010C Order number 6FC5 203 0AF01 0AA0 OP010S Order number 6FC
194. 249 8 PROFIBUS DP Communication 01 05 8 7 DP slave MCP 483 PROFIBUS Parameters Dialog box 8 250 DP slave MCP 483 is located under e Profile Standard PROFIBUS DP gt Other field devices gt NC RC gt Motion Control gt SINUMERIK MCP Select the DP slave by left clicking it in the hardware catalog MCP 483 SINU MERIK MCP and drag it while holding down the mouse key onto the DP master system in the station window The DP master system is displayed in the station window with the following symbol a NS NN NE 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 cursor with a plus sign and the DP slave can be added to the configuration When you have inserted DP slave MCP 483 into the configuration dialog Properties PROFIBUS Interface SINUMERIK MCP is displayed The following PROFIBUS parameters must either be set or verified PROFIBUS address Data transfer rate Profile Dialog box Properties PROFIBUS Interface SINUMERIK MCP Tab card Parameter Address lt PROFIBUS address gt Button Properties Dialog box Properties PROFIBUS Tab card Network settings Data transfer rate 12 Mbaud Profile DP OK OK Siemens AG 2005 All rights reserved SINUME
195. 3 Meaning of the S3 switch 1 2 3 4 5 6 7 8 Meaning on Data transfer rate 1 5 Mbaud off Data transfer rate 187 5 kbaud on off 200ms Cyclic transmission frequency 2400 ms Reception off on monitoring off off 100ms Cyclic transmission frequency 1200 ms Reception monitoring 50 ms Cyclic transmission frequency 600 ms Reception monitoring on on on on MPI address 15 1st machine control panel on on on off 14 1st machine control panel on on off on 13 1st machine control panel on on off off 12 2nd machine control panel on off on on 11 2nd machine control panel on off on off 10 on off off on 9 on off off off 8 off on on on 7 off on on off 6 default setting 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 on Type interface to customer operator panel off Type machine control panel on off on off on on off off As delivered state off off on on on on off off Recommended setting for 840Di Data transfer rate 187 5 kbaud Cyclic transmission frequency 100 ms MPI address 14 1st machine control panel Type Machine control panel 7 180 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 7 3 Program structure Siemens AG 2005 All rights reserved Parameterization of the PLC 7 7 Machine control panel 19 or MCP The PLC program is modular in design It comprises function blocks e Sta
196. 366 HW_ASSIGN_DIG_FASTIN 2 H05000085 133p ADI4 The high byte of the input word slot 21 MD10366 HW_ASSIGN_DIG_FASTIN 3 H05000147 3275 The following output bytes are used by the NC ET200 The 1st output byte of the output modules slots 4 and 5 MD10368 HW_ASSIGN_DIG_FASTOUT 0 H05000080 128p MD10368 HW_ASSIGN_DIG_FASTOUT 1 H05000082 130p ADI4 Both output bytes of the output word slot 22 MD10366 HW_ASSIGN_DIG_FASTOUT 2 H05000146 326p MD10366 HW_ASSIGN_DIG_FASTOUT 3 H05000147 327p Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 389 10 NC Start Up with HMI Advanced 01 05 10 6 Digital and analog I O devices Machine data Table 10 50 Digital and analog I Os machine data Number Name of identifier Name Refer ence General MN_ 10300 FASTIO_ANA_NUM_INPUTS Number of active analog NC inputs 10310 FASTIO_ANA_NUM_OUTPUTS Number of active analog NC outputs 10320 FASTIO_ANA_INPUT_WEIGHT Weighting factor for analog NC inputs 10330 FASTIO_ANA_OUTPUT_WEIGHT Weighting factor for analog NC outputs 10350 FASTIO_DIG_NUM_INPUTS Number of active digital NC input bytes 10360 FASTIO_DIG_NUM_OUTPUTS Number of active digital NC output bytes 10362 HW_ASSIGN_ANA_FASTIN Hardware assignment of the external analog NC inputs 10364 HW_ASSIGN_ANA_FASTOUT Hardware assignment of the external analog NC outputs 10366 HW_ASSIGN_DIG_FASTIN Hardware assignment of
197. 4 H2 P24 M24 SHIELD Fig 7 11 Interfaces of the interface MPI for customer operator panels For a detailed description of the electrical and mechanical design and interfaces of the module please refer to References BH Operator Components Manual Chapter Multi point interface MPI for the customer operator panel Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 185 7 MPI Communication 01 05 7 8 MPI interface for customer operator panel Display of the software version Data transfer rate MPI address Switch S3 7 186 A label indicating the current software version is to be found on the firmware EPROM The data transfer rate is set with switch S3 The data transfer rate set on the MPI bus of the SINUMERIK 840Di is 187 5 kbaud You can make this setting on switch S3 on the rear of the module see below The MPI address factory setting on the module is 6 This default setting is not suitable for operation on a SINUMERIK 840Di with default configuration The parameters are set using switch S3 on the rear side of the module see below e Default configuration If the default configuration is used the MPI address of the module must be set to one of the following values As 1st machine control panel 13 14 15 As 2nd machine control panel 11 12 Notice The factory setting default MPI address 6 is not suitable of operation of the module on a SI
198. 40Di manual describes start up of the following components e SINUMERIK 840Di NC and PLC e MPI bus e PROFIBUS DP For start up of the components used with the SINUMERIK 840Di such as e operator panel fronts e g SINUMERIK OP 012 e PROFIBUS DP drives e g SIMODRIVE 611 universal please refer to the relevant documentation Notice We recommend performing start up of the SINUMERIK 840Di in the order of the sections of this manual To start up the SINUMERIK 840Di the following software is needed which is part of a SINUMERIK 840Di e To start up the SINUMERIK 840Di NC 840Di start up SinuCom NC e To start up PLC MPI and PROFIBUS DP communication DriveOM SlaveOM PLC basic program e To start up SIMODRIVE 611 universal drives SinuCom U To start up the SINUMERIK 840Di the following software is needed which is not part of a SINUMERIK 840Di e To start up PLC MPI and PROFIBUS DP communication SIMATIC Manager STEP 7 as from Version 5 2 Service Pack 2 To start up the SINUMERIK 840Di the following additional hardware compo nents are needed e a programming device with MPI interface e g PG740 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 37 1 General Notes on the SINUMERIK 840Di 01 05 1 3 Notes on start up Documentation 1 38 for creating a SIMATIC S7 project to start up the SINUMERIK 840Di PLC the MPI and PROFIBU
199. 5 Siemens AG 2005 All rights reserved 5 114 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 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 start up As delivered state Installing the software After the basic start up described in the following two chapters the following conditions should apply e SINUMERIK 840Di NC and PLC are operated in cyclic operation e fa machine control panel is connected no alarms or messages should be pending e The displayed axes of the NC can be traversed by simulation On delivery the hard disk of the PCU is already partitioned for running SINUMERIK 840Di and any other SINUMERIK applications The software ap plications included in the delivery are ready for installation and are located on the hard disk under D Setup Apps lt Application1 gt lt Application n gt active WinXP Name 840D System Content Windows XP Content Empty Setups Updates Primary partition Extended partition Primary partition Primary partition with logic drive Fig 5 1 Partitioning of the harddisk When the PCU is first booted the following menu is displayed Welcome to SINUMERIK These SINUMERIK products will be installed now lt Application 1 gt lt Version gt lt Application n gt lt Version gt Install NOW Install on NEXT REBOOT CANCEL installation
200. 5 203 0AF04 0AA0 OP012 Order number 6FC5 203 0AF02 0AA0 OP015 Order number 6FC5 203 0AF03 0AA0 Components for distributed connection of SINUMERIK operator panel fronts TCU Thin Client Unit Order number 6FC5 312 0DA00 0AA0 Floppy disk drive 3 5 incl 0 5m connecting cable Order number 6FC5 235 0AA05 0AA1 SITOP POWER standard 24V 10A Order number 6EP1 334 1SH01 SITOP POWER DC UPS module 15 Order number 6EP1 931 2EC11 SITOP POWER ACCU MODULE 24VDC 10A 3 2AH Order number 6EP1 935 6MD11 S7 I O modules SIMATIC ET 200 distributed I O system for detailed order information see References ST7 SIMATIC S7 programmable logic controllers Catalog ST 70 1 0 module PP72 48 Order number 6FC5 611 0CA01 0AA0 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 1 Overview of hardware components Interface modules e ADI4 Analog Drive Interface for 4 Axes Order number 6FC5 211 0BA01 0AA1 Drives e SIMODRIVE 611 universal with option module MotionControl with PROFIBUS DP e SIMODRIVE 611 universal E with option module MotionControl with PROFIBUS DP e SIMODRIVE POSMO CD CA e SIMODRIVE POSMO SI e SIMODRIVE POSMO A For detailed ordering information on various drives see References BU SINUMERIK amp SIMODRIVE Ordering Information Catalog NC 60 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI
201. 50 i z MD10210 resolution MD 31020 pulse rev MD 31070 MD 31060 360 1 1 ee Internal 5 1000 0 54932 int increments resolution 9948 128 1 25 encoder pulse One encoder increment corresponds to 0 54932 internal increments One encoder increment corresponds to 0 00054932 degrees highest possible positioning resolution Gear stage 2 360 1 1 se Internal 4660 1 3733 Lemons resolution 2048 128 1 1 encoder pulse One encoder increment corresponds to 1 3733 internal increments An encoder increment corresponds to 0 0013733 degrees highest possible positioning resolution Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 24 Speeds and setpoint adjustment for spindle Speeds gear stages Speeds for conventional operation Direction of rotation Setpoint matching In SINUMERIK 840Di data for five gear stages are implemented These stages are defined by a minimum and maximum speed for the stage itself and by a minimum and maximum speed for the automatic gear stage changeover 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 NC the os cillation function must otherwise be implemented in the PLC The oscillation f
202. 7 The expanded message frame configuration is described in Section 16 2 Page 16 501 8 9 3 Parameterizing DP slaves PROFIBUS address 8 260 Parameterization of the DP slave 611U is divided into 2 steps e Step 1 In Step 1 DP slave 611U specific parameter settings are made for PROFIBUS address 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 e 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 Inserting a DP slave 611U into the configuration will open the dialog for parame 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 There is no automatic adjustment The following data must match 1 SIMATIC S7 configuration of DP slave 611U PROFIBUS address
203. 7 DP slave MCP 483 Setting the 1 0 addresses Module standard extended The module transfers the data for the Standard and Additional I Os functions e Input data 13 bytes Se 8Byte Byte 1Byte 1Byte 1Byte Low byte High byte e Output data 10 bytes Standard data Reserved Customer LEDs 8Byte 1Byte 1Byte Low byte High byte Module standard handwheel extended The module transfers the data for the Standard Handwheel and Additional I Os functions e Input data 17 bytes Absolute value Absolute value Direct control Scena 1st handwheel 2nd handwheel keys OP 012 y 2Byte 2Byte 2Byte Low byte Customer keys 1 Rotary switch 2 Rotary switch 1Byte 1Byte 1Byte High byte e Output data 10 bytes Standard data Reserved Customer LEDs 8Byte 1Byte 1Byte Low byte High byte When you insert a module in slot 1 of DP slave MCP 483 the input output ad 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 8 7 6 Linking to the basic PLC and user program 8 252 This section describes how to link DP slave MCP 483 e to the basic PLC program for transferring standard I O data to the VDI inter face e to the PLC user program optional to implement a user specific response to a module fa
204. 8 Hz 58 200 Hz 0 075 mm 1g DIN EN 60068 2 6 50 m s2 30 ms DIN EN 60068 2 6 Notice The specified safety regulations certifications degree of protection and class of protection only apply if the module is plugged into a SINUMERIK PCU 50 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 3 MCI board extension slot variant 2 3 MCI board extension slot variant 2 3 1 Module Order number The MCI board extension slot variant provides the following functions as an optional expansion board of the MCI board 4binary 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 mo dule X4 MCI board extension n PCI bus mechanical locking screws Internal thread UNC 4 40 Fig 2 8 MCI board extension slot variation Designation 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 Siemens AG
205. 9 871615141812 1 Hardware code off Standard hardware Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 245 8 PROFIBUS DP Communication 01 05 8 7 DP slave MCP 483 Table 8 8 Switch S3 1 7 PROFIBUS address 109 8 716 51413 211 PROFIBUS address off off off off off off off 0 off off off off off off on lon off off off off on off w N off off off off off on on on on on on on on off 126 on on on on on on on 127 Notice In the state as delivered the connection type is MPI 8 7 3 Requirements for starting up the DP slave SIMATIC STEP 7 GSD File 8 246 In order to insert DP slave MCP 483 into the hardware configuration the follo wing components are required e SIMATIC STEP 7 e GSD file of DP slave MCP 483 e Image files of DP slave MCP 483 See Subsection 8 2 Page 8 213 The GSD file of the DP slave MCP 483 is required in the following version or later e 1008109 GSD version 1 0 or later A GSD file contains all the properties of a DP slave in ASCII format For each DP slave SIMATIC STEP 7 requires a module specific GSD file so that the DP slave can be found in the hardware catalog DP
206. 91 S function for spindle Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 5 Axes and spindles A2 A2 A2 A2 A2 A2 A3 vi B1 B1 R1 R1 A3 A3 A2 A2 A2 A2 10 381 10 NC Start Up with HMI Advanced 01 05 10 6 Digital and analog I O devices 10 6 Digital and analog I O devices References 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 57 PP 72 48 The I O module PP 72 48 has 72 digital inputs and 48 digital outputs Section 2 11 Page 2 84 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 96 SIMATIC S7 ET200 modules Via the PROFIBUS DP it is possible to connect all subtypes of SIMAT IC S7 1 0 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 on PROFIBUS DP are provided for both NC and PLC It is the sole responsibility of the user to avoid access conflicts e On the NC side Parts program synchronized action e On the PLC side PLC user program FB Description of Functions Ext
207. 915 x PDA setpoint assignment Parameter P0916 x PDA actual value assignment If the number of process data expected from the NC set in the message frame telegram type parameter in the NC machine data e 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 e DP Slave Properties gt Configuration gt Setpoint Length e DP Slave Properties gt Configuration gt Actual Value Length or if the process data configuration determined at the drive end from the drive parameters e P0922 message frame selection e P0915 x PDA setpoint assignment e P0916 x PDA actual value assignment does not match the message frame type of the NC machine data then the fol lowing alarm is issued e 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 NC machine data possible e MD 13070 DRIVE FUNCTION MASKIn used DP functions Siemens AG 2005 All rights reserved 16 508 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specitic Data and Functions 16 2 Expanded message frame configuration then responsibility lies solely with the start up engineer to perform a consistency check on the
208. A 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 9247 USER_CLASS_BASE_ZERO_OFF_PA 9248 USER_CLASS_BASE_ZERO_OFF_MA References FB Individual data the file SGUD DEF Example Change tool type Basic offset PA Basic offset MA Description of Functions Basic Machine A2 Various Interface Signals Chapter MMC machine data for protection levels The protection level of individual machine and or setting data can be modified in 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 Datei SGUD DEF _N_SGUD_DEF 3 PATH _N_DEF_DIR REDEF MA_C
209. ATIO_NUMERA ERT TAT mu lt encoder revs DRIVE_ENC_RATIO_DENOM Fig 10 6 Linear axis with encoder on the machine Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 319 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Rotary axis with encoder on motor Load ENC_IS DIRECT 0 Encoder Measuring Load IS_ROT_AX 1 _ Rotary table Gearbox Gearbox eee ne DRIVE_AX_RATIO_NUMERA motor revs Motor DRIVE AX RATIO_DENOM Load ENC_TYPE 1 Li z LA SE ENC_IS_LINEAR 0 DRIVE_ENC_RATIO_NUMERA motor revs ENC_RESOL DRIVE_ENC_RATIO_DENOM encoder revs ENC_IS_DIRECT 0 Fig 10 7 Rotary axis with encoder on motor Rotary axis with encoder on the ENC_TYPE 1 machine ENC_IS_LINEAR 0 ENC_IS_DIRECT 1 Motor ENC_RESOL Load Encoder ENC_IS_DIRECT 1 Load ES Measuring gearbox gearbox T DRIVE_ENC_RATIO_NUMERA encoder revs IS ROT AX 1 DRIVE_ENC_RATIO_DENOM Load revs DRIVE_AX_RATIO_NUMERA _ motor revs DRIVE_AX_RATIO_DENOM Load revs Fig 10 8 Linear axis with encoder on the machine Machine data Table 10 21 Incremental measuring systems machine data Number Name of identifier Name remarks Refer ence Axisspecific MA_ 30240 ENC_TYPE n Actual value acquisition modes 1 incremental signal generator 30242 ENC_IS_INDEPENDENT n Encoder is independent 30300 IS_ROT_AX Rotary ax
210. Advanced option 14 456 SINUCOM NC sie sa anana ani taaria a eee ea neaeded wena ede 14 457 Considerations when saving PLC data 14 458 Reading in a series machine start up file with HMI Advanced PTP network link Windows Network link sas has get attendent Configuring the external computer Windows NT Configuring the external computer Windows XP Configuring PCU Windows XP PTP network link service menu DOS Network INK acae Siew ba bise nd awa adden kde tenths Configuring the external computer Windows NT Configuring the external computer Windows XP Configuring the PCU DOS Service menu Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 SINUMERIK 840Di Manual Contents 15 2 5 Show connected network drives 15 470 15 2 6 Disconnecting from network drives 15 471 15 2 7 Restoring Partition E Windows from the emergency image file 15 472 15 3 Partitioning of the PCU harddisk 15 473 15 4 Software installation update Windows 15 474 15 5 Data back up DOS service menu
211. Alarm 10730 Progr end point is behind working area limitation 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles e MD36130 POS LIMIT PLUS2 2nd software limit switch plus e IS DB31 DBX12 2 2nd software limit switch minus e IS DB31 DBX12 3 2nd software limit switch plus e Alarm 10620 Axis reaching software limit switch e Alarm 10621 Axis is at software limit switch JOG e Alarm 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 If the PLC signals that a hardware limit switch has been reached the machine Limit switch axis is stopped with the parameterized brake response e IS DB31 DBX12 1 Hardware limit switch plus e IS DB31 DBX12 0 Hardware limit switch minus e MD36600 BRAKE_MODE_CHOICE brake response at the hardware limit switches 0 brake characteristic is observed 1
212. Axis MD 32300 MAX_AX_ACCEL Spindle MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL MD 35210 GEAR_STEP_POSCTRL_ACCEL e The following applies Acceleration value 0 no ramp Acceleration value gt 0 ramp active e The actual measuring function becomes active only when the offset value is reached Settling time This value represents the delay between measured data recording test setpoint output and the injection of the offset Speed setpoint Amplitude Offset Time 0 Settling time Measurement time ok pa Position characteristic i Time 0 Fig 13 3 Setpoint signal for speed control loop step response measuring function The measurement parameters and measurement results diagrams can be loaded and saved via the soft key File functions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 4 Frequency response measurements 13 4 3 Position control measurement Functionality Procedure Measurement Reference frequency response 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 the NCK generates an error message Depending on which basic measurement setting has been selected various measurement parameters lists as described below are made available 1 Set the traversin
213. BNM SINUMERIK 840D 840Di 810D User s Guide Measuring Cycles BTDI SINUMERIK 840D 840Di 810D Motion Control Information System MCIS User s Guide Tool Data Information CAD SINUMERIK 840D 840Di 810D Operator s Guide CAD Reader is part of the online help DA SINUMERIK 840D 840Di 810D Diagnostics Guide Siemens AG 2005 All rights reserved B 524 SINUMERIK 840Di Manual HBI 01 05 Edition B References KAM KAS KAT PG PGA PGA1 PGK PGM PGT PGZ IPV ISYI SINUMERIK 840D 810D Short Guide ManualTurn SINUMERIK 840D 810D Short Guide ShopMill SINUMERIK 840D 810D Short Guide ShopTurn SINUMERIK 840D 840Di 810D Programming Guide Fundamentals SINUMERIK 840D 840Di 810D Programming Guide Advanced SINUMERIK 840D 840Di 810D List Manual System Variables SINUMERIK 840D 840Di 810D Short Guide Programming SINUMERIK 840D 840Di 810D Programming Guide ISO Milling SINUMERIK 840D 840Di 810D Programming Guide ISO Turning SINUMERIK 840D 840Di 810D Programming Guide Cycles PCIN 4 4 Software for Data Transfer to from MMC Module SINUMERIK 840Di System Overview Manufacturer Service Documentation a Lists LIS SINUMERIK 840D 840Di 810D SIMODRIVE 611D Lists Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B 525 B References b Hardware ASAL APH2 APH4 APH7M APH7S APL6 B
214. BUS DP 8 266 Diagnostics NC PLC PROFIBUS 8 224 Differential handwheels 2 63 Dimension drawing PP72 48 Display resolution 10 286 10 287 Distance coded reference marks 10 357 DOS Shell DP cycle 8 211 8 221 Setting DP cycle time DP Slave 611U Consistency 8 260 3 263 Inserting into an S7 project Parameterization 8 260 PROFIBUS DP Communication 8 264 Set the telegram type Setting the I O addresses Setting the PROFIBUS address DP slave 611u PROFIBUS parameters 8 260 DP slave PP72 48 Inserting 8 226 PROFIBUS parameters 8 226 Setting the I O addresses 8 227 Index 538 DRAM file system Drift compensation Drive configuration ADI4 10 314 10 315 _ I O addresses Message frame type 10 313 Drive Optimization 10 328 Drive optimization with HMI Advanced 13 421 Drive start up i reconditions 9 269 Drive type DP 10 315 Dynamic monitoring functions 10 347 Velocity monitoring 10 349 Dynamic Servo Control 10 327 E EC Declaration of Conformity C 535 Electrical connection HHU 7 188 HT 6 7 198 Electrical design MCI board and MPI bus MCI board and PROFIBUS DP 3 104 MCI board extension 3 105 PCU 50 EMC measures 4 111 Encoder limit frequency 10 377 Encoder Monitoring Cut off frequency 10 350 Cyclic monitoring of position tolerance 10 351 Position tolerance when switching over the encoder 10 351 Zero mark m
215. 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 e Interface X102 MPI DP This PROFIBUS interface is only available to the PLC It can be operated in modes DP Master or DP Slave A full description of how to parameterize PROFIBUS communications is given in Chapter 8 Page 8 209 Note The instructions given in this chapter are essentially limited to the special characteristics of the SINUMERIK 840Di For more details about working with SIMATIC STEP 7 please refer to the relevant SIMATIC documentation or Online Help Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 153 6 PLC Start Up 01 05 6 3 Creating a SIMATIC S7 project 6 3 1 Creating a project To create a new project select menu items File gt New in the SIMATIC Manager Enter the following project data in the dialog box Name for example SIN840Di 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 gt Station gt SIMATIC Station 300 K SIMATIC Manager SIN840Di Station Edit Insert Target System View Tools Window
216. By default all bits are selected The input field Threshold is only used to enter the triggering threshold for the 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 13 6 4 Performing the measurement Soft key Start Terminating the measurement Soft key Stop 13 442 After parameterization has been completed you then enable measurement by pressing soft key Start The measurement is carried out once the set trigger condition of trace 1 is ful filled The measurement is completed after the set measurement duration is expired With the end of the measurement the graphics are prepared automatically Use the Display soft key to call the display functions of the graphics see next Sec tion With the Stop soft key you can cancel a running measurement at any time A canceled measurement cannot be displayed Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 6 Trace function 13 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 MPF DIR TEST MPF Start up Jog Program aborted 00 RO Graphics lt
217. C Technical data Table 2 11 Technical data of the PCU 50 Safety Protective class lll PELV acc to EN 50178 Degree of protection per IP20 EN 60529 Approvals CE Electrical data Input voltage 24 V DC Max power consumption PCI ISA slot Total 5V 2A 3A 12V 0 3 A 0 6 A 12V 0 1 0 15 A Power consumption typically 40 W maximum 130 W Mains buffering time 20 ms Mechanical data Dimensions mm Width 297 Height 267 Depth 77 Weight approx 6 kg Mechanical ambient condi Operation Transport tions with OP 012 in packaging Vibration stressing 10 58 Hz 0 075 mm 5 9 Hz 3 5mm 58 200 Hz 9 8 m s 9 200 Hz 9 8 m s 3M4 per EN 60721 3 3 2M2 per EN 60721 3 2 Shock stressing 50 m s2 30 ms 300 m s2 6 ms 18 shocks 18 shocks 3M2 per EN 60721 3 3 2M2 to EN 60721 3 2 Noise lt 55 dB A to DIN 45635 Climatic ambient conditions Heat dissipation Open circuit ventilation Moisture condensation water spray and the formation of ice not permissible Air inlet without aggressive gases dusts and oils Operation Storage transport in transport packaging Relevant standards EN 60721 3 3 EN 60721 3 1 3 2 Climate class 3K5 1K3 2K4 9W1 5 55 C Temperature limiting values 14W 1 5 50 C 20 60 C 24 W 1 5 45 C Rate of temperature change max 10 K h max 18 K h Relative air humidity limits 10 80 5 95 Permissible change in the rel ative air humidi
218. C STEP 7 For authorizing SIMATIC STEP 7 software previously installed on the PCU you can use the function on the SINUMERIK desktop e STEP 7 authorizing which is available as a script file Note This function can be also be run from the service menu Subsection 5 5 2 Page 5 133 5 4 6 Serial mouse Serial mouse Activating Dialog box 5 128 The two COM interfaces of the PCU are by default set in such a way that serial devices except for a serial mouse can be used connected to them The following settings are required to operate a mouse e Adapt file boot ini With a Windows standard editor open file C boot ini In section operating systems remove the option NoSerialMice Save and close the changed file e Adjust the system setting to serial mouse Select the serial mouse used in the Mouse Properties dialog box from the Control Panel Start gt Settings gt Control gt Mouse Dialog box Mouse Properties Tab card General Button Change Dialog box Select Device Radio button Show all devices Select relevant serial mouse OK OK Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 4 SINUMERIK desktop Note After you have activated the serial mouse a PS 2 mouse that you were previously using will no longer work 5 4 7 System information after Fatal exceptional error
219. C Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 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 10 5 4 Page 10 316 10 5 22 Gear stages Enabling of gear stage change Parameter sets References 10 368 The gear stage change is generally carried out in e MD35010 GEAR STEP CHANGE _ENABLE gear stage change possible spindle has several gear stages If this machine data is not set the system assumes that the spindle has no gear stages In Spindle mode of a spindle the NC will select the parameter set that suits the current gear stage best Gear stage x gt parameter set x 1 gt index x In axis mode of a spindle the NC 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 e MD35110 GEAR_STEP_MAX_VELO n Nmax for gear stage change e MD35120 GEAR_STEP_MIN_VELO n nmin for gear stage change e MD35130 GEAR_STEP_MAX_VELO_LIMIT n Nmax for gear stage e MD35140 GEAR_STEP_MIN_VELO_LIMIT n nmin for gear stage e MD35200 GEAR_STEP_SPEEDCTRL_ACCEL n acceleration in speed control mode e MD35210 GEAR_STEP_POSCTRL_ACCELJn acceleration in position control mode For further inf
220. CA References POS3 User Manual SIMODRIVE POSMO SI CD CA SimoCom U start up tool References Online help for SimoCom U To configure the additional drive actual values modify the standard configura tion of the drive e g starting at standard message frame 102 as follows with the SimoCom U start up 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 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 gt Parameterization Views gt PROFIBUS Parameter Settings with 0 SimoCom U 12A drive TE File Edit Start up Operation Diagnostics Tools Help Fer oF ad pere Got 2 mu Option module type 4 PROFIBUS station address _12 Configuratin Expected option module type 4 Message frame selection C 0 Analog input Messe Received data PDA Sent data PDA Limitation 1 Control word 1 CTW1 1 1 Status word 1 STW1 aha er 2 Speed setpoint B NSET_B 2 Speed actual value B NACT B Analog output 3 Speed setpoint B NSET_B 3 Speed actual value B NACT B SI Een 4 Control word 2 CTW2 4 Status word 2 STW2 2 Traverse bloc 5 Torque red
221. Calculation of the motor speed speed setpoint matching must be performed Via the two axis specific NC machine data e MD32260 RATED_VELO rated motor speed rev min e MD32250 RATED_OUTVAL rated output voltage the reference between the speed setpoint set by the NC and the associated output voltage at the setpoint output of the ADI4 is established reference volt age 10 V SINUMERIK 840Di NC ADI4 MD32250 RATED OUTVAL MD32260 RATED VELO 10 V a0 Note The max upper limit for the speed setpoint is set in machine data e 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 If the motor speed required for speed setpoint matching is not known directly it 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 Vas MD31050 DRIVE_RATIO_DENOM n Motor MD31030 LEADSCREW_PITCH Motor speed for rotary axis spindle MD31060 DRIVE_RATIO_NUMERA Nyotor NLoad MD31050 DRIVE_RATIO_DENOM Vas 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 AMotor rpm MioadlrPm Siemens AG 2005 A
222. Changes effective after POWER ON Protection level 2 7 Unit Data type DWORD Applies as from SW version 2 1 Meaning Meaning of set bits Bit 0 Deactivation of the 611U specific drive alarm mapping Bit Deactivation of the 611U specific drive type detection Bit Deactivation of the 611U specific parameter accesses encoder drivers Bit Deactivation of the 611U specific parameter accesses output drivers Bit Activation third party drive DSC bits STW1 12 STA1 12 Bit Deactivation of the 611U specific drive parking STW2 7 STA2 7 Bit Deactivation of the 611U specific travel to fixed stop STW2 8 STA2 8 Bit Deactivation of the 611U specific internal motor switchover STA2 9 11 Bit Deactivation of the 611U specific ramp block STW1 13 Bit 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 OOADARWNTO CTW Control word PDA word in the PROFIDrive message frame to DP slave STW Status word PDA word in the PROF IDrive message frame from DP slave PDA Process data MD irrelevant for Axisspecific machine data 37620 PROFIBUS_TORQUE_RED_RESOL MD number Torque reduction resolution on PROFIBUS LSB weighting Default setting 1 Minimum input limit 0 01 Maximum input limit 10 Change valid after NEWCONF Protection level 2 7
223. Choose Partitions Restore Mode LOCAL with key 3 Following menu PLEASE SELECT 1 Base software V07 03 02 Win XP 05 09 2004 05 30 32pm 2 Start up intermediate status 1 05 10 2004 04 03 15pm EMERG 3 Data backup1 06 11 2004 10 34 17am 9 Back to previous Menu Your Choice 1 2 3 9 5 The descriptions that have been specified for the individual partition back ups are displayed Select the partition back up that you want to import now e g Start up intermediate version 1 with key 2 After confirmation a warning is displayed Caution All data will be overwritten If you confirm again the partitions of the harddisk are restored Following menu It seems that Ghost Restore succeeded Hit any Key to reboot the System On the next start up of the PCU under Windows partitions E and F by the CHKDISK diagnostics program After partition E has been checked the PCU is automatically started up again After completion of the check of partition F the system with the restored backup copy is active Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 491 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu 15 5 8 Restoring Partition E Windows from the local image file Brief description Requirements Operator actions 15 492 This subsection describes how to restore th
224. Configure Ghost Parameters Key 6 Manage Network Drives The following menu appears PLEASE SELECT 1 Connect to Network Drive 2 Show connected Network Drives 3 Disconnect from all Network Drives 9 Back to previous Menu Your Choice 1 2 3 9 Choose Disconnect form all Network Drives using the key 3 Following menu Connected Network Drives last none All network drives have been disconnected Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 471 15 Software Installation Update and Data Backup 01 05 15 2 PTP network link service menu DOS 15 2 7 Restoring Partition E Windows from the emergency image file Brief description Requirements Service menu 15 472 This subsection describes how to restore the operating system partition E from an emergency image file You may have to restore the operating system partition This may be necessary if Windows is no longer bootable or if the realtime properties of the SINUMERIK 840Di are no longer ensured because subsequently installed unsuitable soft ware can no longer be uninstalled The following conditions must be fulfilled e An image file must be present locally on the hard disk of the PCU under D IMAGES see Subsection 15 5 4 Page 15 486 e An image file must have been selected as the emergency image file see Subsection 15 5 9 Page 15 493 After the PCU has bee
225. DRAM_FILESYSTEM_MASK Select directories in DRAM Memory spec MM_ 18332 FLASH_FILE_SYSTEM_SIZE Size of flash file system FFS 18351 DRAM_FILE_MEM_SIZE Size of DRAM file system Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 307 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 5 Axes and spindles 10 5 1 Axis configuration Definition Coordinate Axes Machine axes Channel axes Geometry axes Special axes 10 308 The term axis is often used either as a single term in conjunction with SINU MERIK 840Di 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 Generally 3 types of axes are distinguished 1 Coordinate axes 2 Machine axes 3 Geometry and special axes Coordinate axes abscissa ordinate applicate are the axes of a Cartesian coordinate system 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 The total of all machine geometry and special axes assigned to a channel is designated as channel axes In this context the geometry and special axes constitute the program techno logical part of the machining process i e they are used for programming in the parts program The machine axes constitute the physical part of the mach
226. Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 18 Monitoring functions axis Static monitoring functions Exact stop coarse Exact stop fine Delay time Exact stop fine Zero speed tolerance Delay time Zero speed monitoring Clamping tolerance The static monitoring functions with reference to a machine axis are Window around the setpoint position within which exact stop coarse is detected e MD36000 STOP_LIMIT COARSE exact stop coarse e IS DB31 DBX60 6 Position reached with exact stop coarse Window around the setpoint position within which exact stop fine is detected e MD36010 STOP_LIMIT_FINE exact stop fine e IS DB31 DBX60 7 Position reached with exact stop coarse Delay time after which the actual value must have reached the tolerance window Exact stop fine when the setpoint position is reached e MD36020 POSITIONING_TIME delay time exact stop fine e Alarm 25080 Positioning monitoring and follow up mode Position tolerance which a standing machine axis may not leave e MD36030 STANDSTILL_POS_TOL zero speed tolerance e Alarm 25040 Zero speed control and follow up mode Delay time after which the actual value must have reached the tolerance window Zero speed tolerance when the setpoint position is reached e MD36040 STANDSTILL_DELAY_TIME delay time zero speed control e Alarm 25040 Zero sp
227. Domain Name Server Change DNS Extension o onahwWwh Back to previous menu Your Choice 1 2 3 4 5 7 8 9 If the IP address is assigned for the PCU automatically via a DHCP server set automatically under toggle Get IP Address with key 1 The following TCP IP parameters only have to be set manually because the relevant data are sent by the DHCP server Subnet mask Gateway Domain name server DNS extension The network link with DHGP is now configured Confirm the query whether you want to store the network parameters when you exit the menu with key Y the settings are stored Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 6 Configuring the network link of PCU LAN WAN Manual If the IP address is assigned for the PCU manually because no DHCP server IP addressing exists in the network set manually under toggle Get IP Address with key 4 The following TCP IP parameters must then be set manually e IP address Select Change IP Address with key 2 Enter the IP address of the PCU Syntax In the service menu the IP address of the PCU must be entered with a blank used as the tuple separator Example IP address 169 254 10 1 e Subnet mask Select Change Subnetmask with key 3 Enter the subnet mask Together with the subnet mask the IP address speci fies which n
228. E MD number PROFIBUS shutdown handling Default setting 0 Minimum input limit 0 Maximum input limit 2 Changes effective after RESET Protection level 2 7 Unit Data type UINT8 Applies as from SW version 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 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 with PLC 315 2DP 314 2C 317 2DP Siemens AG 2005 All rights reserved 10 398 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 9 Initial settings 10 9 Initial settings Concept Initial settings parameterization References The status of an NC function e g G codes tool length compensation trans formation coupled motion of an axis 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
229. E_MASK selection of directories in the DRAM Bit 0 1 Siemens cycles CST Bit 1 1 Machine manufacturer cycles CMA Bit 2 1 User cycles CUS The machine data default setting ensures that all specified cycle areas are saved to the retentive background memory by default When loading a serial start up file or a single cycle into the NCK if the function is activated the cycles are first written to the retentive background memory and then loaded into the DRAM file system Cycles relocated into the DRAM file system can be changed edited The changes take effect immediately Retentive storage of the changes in the back ground memory is not effected until the next NCK power ON reset warm start Proper shutdown of Windows NT Notice If the SINUMERIK 840Di is switched off or if a serious exception blue screen has occurred although NCK power ON reset warm start Proper shutdown of Windows NT has not been performed all changes to the cycles made until that time will be lost The following error status can occur in connection with relocation of cycles into the DRAM file system e Too little memory available in the DRAM file system Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 4 Memory configuration During start up of the NCK the cycles are loaded from the background memory into
230. Edition 2 87 2 Hardware Descriptions 01 05 2 11 I O module PP72 48 Digital inputs e 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 P240UT pin number 24VDC mm O 3 Receiver i 1 7 4 Receiver l Receiver 1 26 7 ii 24V x B 3 of CRE a F 1 ax4 77 A PER M Fig 2 23 Terminal assignment for the digital inputs O If you are using the internal power supply P24OUT 2 If you are using an external power supply P24OUText e 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 92 Caution A max current of lout 0 5 A on X111 X222 X333 Pin 2 must not be exceeded An exceeding of the maximum current might destroy the module e External power supply PP24OUText 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 ex
231. F12 F13 F14 F15 not S25 S26 S27 S28 S29 30 31 used EB n 7 Freely assignable customer keys 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 1 Line Default designation 2 Line Key number Sxy or feedrate override switch X30 X31 key switch X50 optional customer keys X52 Siemens AG 2005 All rights reserved 8 256 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication Output image Table 8 10 8 7 DP slave MCP 483 Arrangement of LED signals in the output image of the DP slave MCP 483 Output image Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 BitO AB n 0 Machine function Mode 1000 INC 100 INC 10 INC 1 INC JOG TEACH MDA AUTO LEDO7 LEDO6 LEDO5 LEDO4 LEDO9 LED10 LED11 LED12 AB n 1 Feed Start Feed Stop NC Start NC Stop Machine function REPOS REF var INC 10000 INC LED50 LED49 LED16 LED15 LEDO1 LEDO2 LEDO3 LEDO8 AB n 2 Axis selection Single Spindle Spindle RIS RI Bg ay R10 En ve rae LED44 LED32 LED35 LED38 LED41 AB n 3 Axis selection R3 R5 R12 R11 R9 R8 R6 R15 LED34 LED36 LED43 LED42 LED40 LED39 LED37 LED46 AB n 4 Freely assignable customer keys Axis selec tion F9 F10 F11 F12 F13 F14 F15 R2 LED25 LED26 LED27 LED28 LED29 LED30 LED31 LED33 AB n 5 Freely assignable
232. FC 14 and SFC 15 e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 263 8 PROFIBUS DP Communication 01 05 8 9 DP slave SIMODRIVE drives e 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 e NC e DP master e DP Slave 611U D a NC DP master 1 0 address message frame type PROFIBUS address slot and I O address MD13050 DRIVE LOGIK_ ADDRESS n message frame type 1st machine axis 272 PROFIBUS addr 10 2nd machine axis 292 Axis 1 Slot 5 6 I O addr 272 MD 13060 DRIVE TELEGRAM TYP n Ads 2 EI Le VO zeer ZEE 1st machine axis 102 message frame type 102 2nd machine axis 102 PROFIBUS DP y Cyclic message frame 102 PIV PDA PIV PDA Header Axis 1 Axis2 Trailer Drive A Drive B 10 y DP Slave 611U PROFIBUS address message frame type PRO
233. FIBUS DP Communication Activation of the isochronous DP cycle Dialog box Start 8 3 Creating a PROFIBUS configuration If you double click on a DP slave 611U in the station window the dialog box DP Slave Properties opens We recommend activating the isochronous DP cycle for all DP slaves 611U by activating the isochronous DP cycle within the selected DP slave 611U and fi nally adjusting During adjustment all the values displayed in dialog box e DP slave properties Tab card Cycle clock synchronization are transferred to all DP slaves of the same type in the configuration here DP slave 611U Dialog box DP slave properties Tab card Cycle clock synchronization Radio button Synchronize drive to isochronous DP cycle Button Adjust DP Slave Properties x General Configuration Cycle clock Peer to pe er li synchronization transmission overview C2 drive to equidistant DP cycle i Network settings in ms Equicistant bus cycle activated Equidistant DP cycle 4 000 Component Data_Exchange_Time Tax 0 367 Factor Increm time ms Master application 1 000 1 1 000 x cycle msec Fecir Increment base time ms DP cycle msec 1 000 p a x Jo 125 EGO Increment base time ms Time Ti ms 5 pe Ims o125 4 x 0 125 Actual value acquisition Factor 3 Increment base time ms Time To ms 0 500 2 a x o 125 Setpoint acceptance Cancel Help
234. FIBUS adar 10 Message frame type 102 Axis 1 Drive A Axis 2 Drive B Fig 8 21 Dependencies NC PLC DP master and DP slave SIMODRIVE 611 universal G Ne 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 e MD13050 DRIVE_LOGIC_ADDRESS n e MD13060 DRIVE TELEGRAM_TYP n Siemens AG 2005 All rights reserved 8 264 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 9 DP slave SIMODRIVE drives and the message frame type of the machine axis 1 Machine axis 1 0 address 272 Message frame type 102 2 Machine axis 1 O address 292 Message frame type 102 For configuring the drive within the framework of the NC start up please refer to Subsection 10 5 3 Page 10 312 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 272 Actual value Slot 6 I O address 272 Setpoint Slot 9 I O address 292 Actual value Slot 10 1 0 address 292 Message frame type 102 For a 2 axis closed loop control module of a SIMODRIVE 611 universal the following assignment applies e Slot 5 6 gt Axis 1 or Drive A e Slot9 10 gt Axis 2 or Drive B
235. G 2005 All rights reserved 10 294 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 3 8 System basic cycle Position control cycle Position control cycle offset Cycle times 10 3 System data On the SINUMERIK 840Di the system clock cycle the position controller cycle and the interpolation cycle of the NC are based on the DP cycle time configured in STEP 7 HW Config See Section 6 3 Page 6 153f The system clock cycle is set fixed to the ratio of 1 1 with regard to the DP cycle time In the machine data the active value is displayed It cannot be changed e MD10050 SYSCLOCK_CYCLE_TIME system clock cycle The position control cycle is set to the fixed ratio 1 1 with respect to the system clock cycle It cannot be changed The position controller cycle offset m must be set such that the following condi tions are fulfilled within a PROFIBUS DP system clock cycle The cyclic communication with the DP slaves drives must be com pleted before the position controller is started Condition Ty gt Tpx The position controller must be completed before the DP cycle system clock is completed Condition Ty Tpos lt Tpp p Tpp gt l a Tm Bed Tpos er NC Position cont
236. Group box PLC buttons NC Reset 14 4 Reading in a series machine start up file with HMI Advanced Reading in a series machine start up file is divided into the following steps 1 Open the menu to read in a series machine start up file Operating area switchover gt Services gt key gt gt Series machine start up gt 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 14 459 14 User Data Backup Series Machine Start Up 01 05 14 4 Reading in a series machine start up file with HMI Advanced Notes Siemens AG 2005 All rights reserved 14 460 SINUMERIK 840Di Manual HBI 01 05 Edition Software Installation Update and Data Backup 15 1 PTP network link Windows Brief description The functions described in this section software installation update require a network link with an external computer PG PC on which a directory is shared for network access If the SINUMERIK 840Di is not part of a larger network WAN LAN a simple PTP peer to peer link via Ethernet and TCP IP can be established for service applications 15 1 1 Network link For the network link the PCU 50 is connected with the
237. H BHA EMV GHA PFK6 PFK7 PFS6 PFT5 B 526 SIMODRIVE 611 MASTERDRIVES VC MC Planning Guide General Information for Asynchronous Motors SIMODRIVE 611 Planning Guide 1PH2 Asynchronous Motors SIMODRIVE 611 Planning Guide 1PH4 Asynchronous Motors MASTERDRIVES MC Planning Guide 1PH7 Asynchronous Motors SIMODRIVE 611 Planning Guide 1PH7 Asynchronous Motors MASTERDRIVES VC MC Planning Guide 1PL6 Asynchronous Motors SINUMERIK 840D 840Di 810D Operator Components Manual SIMODRIVE Sensor User s Guide HW Absolute Position Sensor with PROFIBUS DP SINUMERIK SIROTEC SIMODRIVE Planning Guide HW EMC Installation Guide The current Declaration of Conformity is available under the following Internet address htto Awww4 ad siemens de Please enter the ID No 15257461 in the Search field top right and click on go SINUMERIK SIMOTION ADI4 Analog Drive Interface for 4 Axes Manual SIMODRIVE 611 MASTERDRIVES MC Planning Guide 1FK6 Three Phase AC Servomotors SIMODRIVE 611 MASTERDRIVES MC Planning Guide 1FK7 Three Phase AC Servomotors MASTERDRIVES MC Planning Guide 1FS6 Three Phase AC Servomotors SIMODRIVE Planning Guide 1FT5 Three Phase AC Servomotors Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B References IPFT6 PFU PHC PHD PJAL PJAS PJFE PJF1 PJLM PJM2 PJTM
238. Help ioj x D Sle ee def 2 2a Ctrl X Ctrl Ctrl V Delete Del PLC be Rename F2 Object Properties Alt Return oe opy Paste Fig 6 2 Starting HW Config icon 6 154 3 lt No filter gt z SIMATIC 400 Station SIMATIC H Station SIMATIC PC Station Other stations SIMATIC S5 SG PG PC MPI PROFIBUS Industrial Ethernet PTP S7 Program M7 Program SIMOTION drives Inserting the SIMATIC 300 station Start HW Config by opening the station and double clicking on the hardware Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 3 Creating a SIMATIC S7 project D SIN840Di C fil Hardware gt 3 SIMATIC 300 1 Fig 6 3 Inserting the SIMATIC 300 station We recommend giving the inserted station 300 a meaningful name for example 840Di 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 gt Catalog O x tay Station Edit Insert Target System View Tools Window Help la x DSls e e a e d El x Profile Standard PROFIBUS DP TE PROFIBUS PA SIMA
239. I 01 05 Edition 8 267 8 PROFIBUS DP Communication 01 05 8 10 DP slave Diagnostic repeater for PROFIBUS DP Notes Siemens AG 2005 All rights reserved 8 268 SINUMERIK 840Di Manual HBI 01 05 Edition Drive Start Up Preconditions Chapter Drive start up preconditions describes the Preconditions of the SINUMERIK 840Di for optimum start up of the drives as regards 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 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI 9 1 1 Start up variants The following distinction is made between start up of the above SIMODRIVE drives e Initial start up e 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 9 1 2 Page 9 271 Possible The possible ways of starting up a drive are rocedures p e Using a display and operator unit directly on the drive 611U E only e Using SimoCom U
240. IK 840Di 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 koaud IDLE TIME 100 ms MPI address 15p 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 193 7 MPI Communication 01 05 7 9 Handheld unit B MPI 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 7 17 Page 7 192 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 4 HHU is operated on an MPI bus BHGMPI TRUE with 187 5 kbaud BHGiIn P E 0 0 Address of input data BHGOut P A 8 0 Address of output data Caution See below Note BHGiInLen 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 700
241. IK 840Di Manual HBI 01 05 Edition 11 411 11 Alarm and Message Texts 01 05 11 1 Alarm and message texts Text or alarm number The associated text is given in inverted commas with the position parameters 11 1 5 11 412 e Characters and must not be used in alarm texts The character is reserved for displaying parameters e f 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 e 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 e 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 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 11 5 Sections of the MBDDE INI file Section Meaning Alarms General information about the alarm list e g time date format of messages TextFiles Path file specification of the alarm text files e g User
242. K 840Di The following version is available in the hardware catalog of HW Contfig e 840Di with PLC 317 2DP 2AJ10 Slot 2 SINUMERIK 840Di PLC Standard designation PLC317 2DP M S 2AJ10 Slot X1 MPI PROFIBUS interface X102 Standard name MPI DP Slot X2 PROFIBUS interface X101 Standard name DP Slot 4 SINUMERIK 840Di NC Standard designation S7 FM NCU The 840Di Rack is part of the PLC Toolbox When the PLC basic program which is also included in the PLC toolbox is installed it is automatically installed in SIMATIC STEP 7 too Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 213 8 PROFIBUS DP Communication 01 05 8 2 Requirements SlaveOM Installation 8 214 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 e lt nstallation path gt importantinfo rtf Once the PLC basic program has been successfully installed the 840Di Rack can be accessed in the hardware catalog of SIMATIC STEP 7 HW Config e HW Config hardware catalog Profile Default SIMATIC 300 gt SINUMERIK gt 840Di gt 840Di with PLC317 2AJ10 The SlaveOM Slave Object Manager for SINUMERIK 840Di permits dialog based configuration of the following PROFIBUS drives SIMODRIVE 611 universal or universal E SIMODRIVE POSMO CD CA
243. KER_DIST n 34310 ENC_MARKER_INC n 34320 ENC_INVERS encoder 34330 REFP_STOP_AT_ ABS MARKER n 35150 SPIND DES VELO TOL 36302 ENC FREQ LIMIT LOW 36310 ENC ZERO MONITORING 30250 ACT POS ABS Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition NC start disable without reference point Number of encoders G2 Actual value encoder type Encoder is independent G2 BERO delay time in plus direction S1 BERO delay time in minus direction S1 Axis with reference cam Reference point approach in minus direction Reference point approach velocity Maximum distance to reference cam Reference point creep speed encoder number Direction reversal at reference cam encoder number Maximum distance to reference mark Maxi mum distance to 2 reference marks with distancecoded scales encoder number Reference point start velocity Reference point distance destination for distan cecoded system encoder number Reference point absolute offset distancecoded encoder number Electronic reference cam shift for incremental measurement systems with equidistant zero marks Reference point value reference point number Actual value adjustment to the referencing mea surement system Axis sequence for channelspecific Referencing Polarity change of BERO Referencing mode encoder number Status of absolute value encoder encoder number Absolute value encoder range for rotary encod R2 ers
244. LC all system data blocks with the exception of SDB210 are deleted See Subsection 8 3 4 Page 8 223 for how to generate the system data blocks again IK SIMATIC Manager SINS40Di_ ed File Edit Insert Target System View Tools Window Help ole se alee wil eo oft lt Nofiter gt 2 amp lol x Je SIN840Di lt nstallation path gt Step7 S7Proj SIN840Di _ SIN840Di System data 08100 SIMATIC 300 1 FB1 amp FB2 amp rps E res J PLC 317 20P 2au10 EBS amp ree S FB7 reo S S7 Program 1 FB10 g FB1 g Freie g FB17 I Sources FB18 g FB19 Foi Fc2 a FC3 E rca g Fce g Fc7 xl mcp840Di Ei mep4mci2 T Sources a Blocks Fig 7 3 Inserting library mcp849Di already contains PLC basic program 7 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 default MPI address of handheld terminal HT 6 MCPSDB210 system data block SDB210 exists The parameter must be set to value TRUE 7 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
245. LIMS e 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 If the encoder cut off frequency e 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 e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 377 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Spindle speed 4 Maximum encoder limit frequency Maximum spindle speed Maximum spindle speed for current gear stage J Programmable spindle speed limit G26 f Programmable spindle speed limit LIMS RC Programmable minimum spindle speed G25 Minimum spindle speed for current gear stage Max velocity speed Axis spindle stopped 0 D Q _ Q OD E OOD ODC 5 LE 8 o Lo O Sa ay g N a D Do 22 5 2 EEN E
246. LING_SYSTEM Basic system switchover active G2 10270 POS_TAB_SCALING_SYSTEM System of measurement 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 channelspecific MA_ 30300 IS_ROT_AX Rotary axis R2 30310 ROT_IS MODULO Modulo conversion for rotary axis R2 30320 DISPLAY_IS MODULO Position display modulo 360 R2 30500 INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis 30501 INDEX_AX_NUMERATOR Numerator for indexing axes with equidistant positions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 331 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Interface signals Table 10 32 Indexing axes Interface signals DB number Bit byte Name Refer 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 References FB Description of Functions Extended Functions T1 Indexing axes 10 5 13 Parameter sets of axis spindle Per machine axis 6 parameter sets are available They are used as follows e onan axis for accommodation of the own dynamic response to another machine axis e g when tapping or thread cutting e ona spindle quic
247. MES 2 teehee ete ae Me ne seis de nee eme 10 5 3 Drive configuration xvi Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 SINUMERIK 840Di Manual Contents 10 5 4 Setpoint actual value channels 10 5 5 Incremental measuring system settings 10 5 6 Parameterization of absolute measuring systems 10 5 7 Parameterization of a 2nd measuring system with ADI4 10 5 8 DSC Dynamic Servo Conta 24444 oes nice chadecban daieeee es 10 5 9 Drive optimization 10 5 10 Rotary ABS aie ion buses animes teens 10 5 11 Positioning axes 10 5 12 Indexing axes uananan nanana nnu lanta rs ee ade 10 5 13 Parameter sets of axis spindle 10 5 14 Position controller 10 5 15 Speed setpoint matching 10 5 16 Drift compensation 10 5 17 Velocity matching axis 10 5 18 Monitoring functions axis 10 5 19 Referencing an axis 10 5 20 Spindle basic data 444444 view hoes see hace sens 10 5 21 Setpoint actual value channels of spindle
248. MPI configuration via SDB210 4 Insert call of function block FC27 as 1st line in organization block OB1 5 Insert block FC 19 or FC 25 in cyclic part of the PLC program see Fig 7 10 Page 7 181 6 Load the modified blocks into the PLC and then restart the PLC 7 After communication with the PLC has been established the LEDs on the MCP front stop flashing The LED of the basic settings for Mode Referencing Spindle stop Feed stop light up continuously Siemens AG 2005 All rights reserved 7 184 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 8 MPI interface for customer operator panel 7 8 MPI interface for customer operator panel Application The Interface MPI for customer operator panel is a module for connecting cus tom made operator panels to a SINUMERIK 840Di To this aim the module provides 3 I O interfaces with a total of 64 digital outputs with C MOS level 5 V Startup Start up of an Interface MPI module is to a large degree identical to start up of a machine control panel MCP Section 7 7 Page 7 177 Therefore only the differences from an MCP start up are explained below 7 8 1 Parameterization of the MPI interface Interfaces Fig 7 11 below shows the interfaces on the rear of the module Connection Interface I O interfaces for equipotential bonding MPI interface conductor Power supply S3 DIP switch LEDs 1 4 H3 SN HI H
249. MS BHGCycl S5T 400MS BHGRecGDNo 8 GD circle parameters of HHU BHGRecGBZNo 2 Send default configuration BHGRecObjNo BHGSendGDNo 3 GD circle parameters of HHU BHGSendGBZNo i 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 Basic PLC Program Chapter FC 13 BHGDisp Display control for handheld unit Siemens AG 2005 All rights reserved 7 194 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 9 Handheld unit B MPI 7 9 8 Plugging and unplugging handheld unit during operation Automation system PLC user program Programming example 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 e Automation system Connect or disconnect the power supply on the distributor box Enable or jumper
250. Manual parameterization Example In the SINUMERIK 840Di NC system the parameters for the resolution of the torque reduction are set via the axis specific machine data e MD 37620 PROFIBUS TORQUE RED RESOL torque reduction resolu tion on PROFIBUS LSB weighting To simplify the start up of torque reduction as standard the NC tried to perform an automatic matching procedure The adjustment is carried out in the following system states SINUMERIK 840Di boot Incoming station of the DP slave 611U The NC reads the resolution set in the parameters on the drive via parameter P0881 using acyclic communication and transforms the read value into the for mat of the above mentioned machine data If the detected drive end resolution is not equal to the resolution currently set in the parameters in the NC machine data the value determined by the drive is transferred to the NC machine data The resulting NC end rescaling of the torque reduction for this machine axis is indicated in the following alarm e Alarm 26024 Axis axis identifier machine data MA_PROFI BUS_TORQUE_RED_RESOL value adapted If the value of parameter P0881 converted into NC format lies outside the ad missible limit values the value set in the NC machine data is retained An alarm is then not issued Note You can disable automatic adjustment via e MD 13070 DRIVE_FUNCTION_MASK n bit 15 0 If one of the requirements listed above for
251. Minimum speed for gear change Maximum speed of gear stage Minimum speed of gear stage Spindle speed tolerance Spindle speed limitation via PLC Acceleration in speed control mode Refer ence vi vi vi R2 R2 R2 G2 G2 G2 G2 R1 R1 R1 R1 R1 R1 10 379 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Number Name of identifier Name Refer ence Axisspecific MA_ 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 Oscillation speed 35410 SPIND_OSCILL_ACCEL Oscillation acceleration 35430 SPIND_OSCILL_START_DIR Oscillation start direction 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 A3 monitoring Setting data Table 10 48 Spindle Setting data Number Name of identif
252. N E 8 o5 S 5 E EJER S 5 50 55S no n D Of Ob ES eL SS 2 GS Go OO F g dE ON OF o DOD OO OG 2 C o pa LL St D RES g GAee ro x DS DD DS a 25 D OOD o 5 Bo 8 BE BEF 2 Do D HENS A Fig 10 30 Ranges of spindle monitoring functions speeds References FB1 Description of Functions Basic Machine S1 Spindles Chapter Spindle monitoring Siemens AG 2005 All rights reserved 10 378 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 28 Spindle data Machine data Table 10 47 Number Spindle machine data Name of identifier General MN_ 12060 OVR_SPIND_IS_GRAY_CODE 12070 OVR_FACTOR_SPIND_SPEED 12080 OVR_REFERENCE_IS_PROG_FEED Channelspecific MC_ 20090 SPIND_DEF_MASTER_SPIND 20092 SPIND_ASSIGN_TAB_ENABLE 20118 GEOAX_CHANGE_RESET 22400 S_VALUES_ACTIVE_AFTER_RESET Axisspecific MA_ 30300 IS_ROT_AX 30310 ROT_IS_ MODULO 30320 DISPLAY_IS_ MODULO 31050 DRIVE_AX_RATIO_DENOM 31060 DRIVE_AX_RATIO_NUMERA 31122 BERO_DELAY_TIME_PLUS 31123 BERO_DELAY_TIME_MINUS 32200 POSCTRL_GAIN 32810 EQUIV_SPEEDCTRL_TIME 32910 DYN_MATCH_TIME 34040 REFP_VELO_SEARCH_MARKER 34060 REFP_MAX_MARKER_DIST 34080 REFP_MOVE_DIST 34090 REFP_MOVE_DIST_CORR 34100 REFP_SET_POS 34200 ENC_REFP_MODE 35000 SPIND_ASSIGN_TO_MACHAX 35010 GEAR_STEP_CHANGE_ENABLE 35012 GEAR_STEP_CHANGE_POSITION 35020 SPIND_DEFAULT_MODE 3503
253. NC Version 6 2 12 or higher Load Proceed as follows to transfer a compile cycle to the NCK 1 Exit any active HMI Advanced windows and activate the Windows desktop 2 Use the Windows Explorer to copy the compile cycle file e g ccresu elf from the diskette drive or external PC PG to a directory of your choice on the PCU hard disk e g F techfunctions 3 Copy the compile cycle file with SinuCom NC from the directory used in Step 2 on the PCU hard disk to the NCK FFS SinuCom NC menu command File gt Load compile cycle Load compile cycle 21x NC flash file system Loaded compile cycles Name Changed on CCCLC ELF 80 985 7 30 02 10 38 Free memory space bytes 431 015 Deletion m Hard disk Load compile cycle Look in E techtunctions gt c ala Modified Attribute ccclc elf 79kB 7 30 02 10 38 A EEE 64KB 7 30 02 10 38 A 2 cchsic elf 80KB 7 30 02 10 38 A File name ocresu ett Files of type Compile cycles elf 7 Abort Fig 10 34 SinuCom NC Loading a compile cycle After copying the compile to the FFS you need to reset the NCK The com pile cycle is loaded in the NC system software the time the NC is booted Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 393 10 NC Start Up with HMI Advanced 01 05 10 7 Loadable compile cycles Note Several compile cycles can be copied to the NCK FSS in successi
254. NUMERIK 840Di e Plant specific configuration If the module is operated in an MPI configuration other than the standard configuration the GD circle parameterization used will define the MPI ad dress to be set See Subsection 7 6 3 Page 7 176 See Table 7 3 Page 7 180 for settings of switch S3 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 9 Handheld unit B MPI 7 9 Handheld unit B MPI D hi K TTTS Distribution box Fig 7 12 Handheld unit B MPI with distributor box 7 9 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 basic PLC or PLC user program to the requirements of the appropri ate automation system with regard to the operation of an MCP and to l
255. NUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Interface signals 10 6 Digital and analog I O devices Table 10 52 Digital and analog I Os Interface signals DB num Bit byte Name Refer ber ence General Signals from NC to PLC 10 0 122 124 126 128 Disable digital NC inputs 10 1 123 125 127 129 Set digital NC inputs from the PLC 10 4 130 134 138 142 Disable digital NC outputs 10 5 131 135 139 143 Overwrite screen form of digital NC outputs 10 6 132 136 140 144 Setting value of digital NC outputs from PLC 10 7 133 137 141 145 Setting screen form of digital NC outputs 10 146 Disable analog NC inputs 10 147 Setting screen form of analog NC inputs 10 148 163 Setting value for analog NC inputs from PLC 10 166 Overwrite screen form of analog NC outputs 10 167 Setting screen form of analog NC outputs 10 168 Disable analog NC outputs 10 170 185 Setting value for analog NC outputs from PLC Signals from NC to PLC 10 60 186 189 Actual value of digital NC inputs 10 64 190 193 Setpoint of digital NC outputs 10 194 209 Actual value of analog NC inputs 10 210 225 Setpoint of analog NC outputs Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 391 10 NC Start Up with HMI Advanced 01 05 10 7 Loadable compile cycles 10 7 Loadable compile cycles Brief description Siemens compile cycles User compile cycles 10 392 Compile cycles ar
256. N_DIG_FASTIN n 05 00 VOhigh VO low o A_IN 9 A_IN 16 05 00 VOhigh VOlow 1 A_IN 17 A_IN 24 Fig 10 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 385 10 NC Start Up with HMI Advanced 01 05 10 6 Digital and analog I O devices 10 6 5 Dynamic response After the system variables have been set e g A_OUT 8 for setting the 8th digital output of the NC on a SIMATIC S7 signal module connected on PROFI BUS DP the system variable is transferred from DP master to the signal module along 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 mo dule are not synchronized during this process The transmission cycle described is illustrated in Fig 10 32 Page 10 386 The time properties when reading in a digital or analog input are analogously to the properti
257. OP Oxx as well as standard PC interfaces for connecting e g monitor key board mouse and Ethernet connection The PCU 50 has the following expansion slots 1x shared ISA PCI length max 175 mm occupied with option MCI board extension and MCI board extension slot variant 1x PCI length max 265 mm occupied by the MCI board The MCI2 board further referred to as the MCI board is a short PCI card with integrated SIMATIC S7 compatible CPU e PLC317 2 DP as a routing capable DP Master It has the following external interfaces PROFIBUS DP with Motion Control Functionality MPI Multi Point Interface MCI board extension option Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 23 1 General Notes on the SINUMERIK 840Di 01 05 1 1 Overview of SINUMERIK 840Di PROFIBUS DP interfaces MPI interface MCI board extension slot variation option Drives 1 24 This interface X101 can be used to connect drives distributed ext I Os ma 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 Both the PLC and the NC have direct access to this PROFIBUS interface The interface X102 can be parameterized as an MPI or PROFIBUS interface Only the PLC can access this interface No drives and no I Os of the NC can be operated
258. P slave drives 8 1 4 Networking rules Example PROFIBUS DP network installation 8 212 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 Atleast 1 terminal must be supplied with 5 V This is done by connecting an PROFIBUS DP connector with the terminating 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 Field device SIMATIC ET200 Field device SIMATIC ET200 SINUMERIK 840Di off on PCU PROFIBUS DP MCI board on max of 100 m PROFIBUS DP off off 4 on Terminating resistor in Drive Drive the connector enabled SIMODRIVE 611 SIMODRIVE 611 universal universal g Terminating resistor in the o connector not enabled Fig 8 3 Example of a PROFIBUS DP network installation Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01
259. PCU 50 to operation with OP 012 Fixing screws Housing cover Orientation with reference Fig 2 15 PCU 50 Perspective view with installed hard disk drive Order number Features 2 70 PCU as spare part with MCI board Designation Order number MLFB PCU 50 with Windows XP and MCI board Celeron 566 MHz 256 MB DRAM 6FC5 220 0AA21 2AA0 Celeron 1 2 GHz 256 MB DRAM 6FC5 220 0AA22 2AA0 The SINUMERIK Industrial PC PCU 50 provides together with the MCI board the basis for the SINUMERIK 840Di The PCU 50 has the following important features Versions Celeron 566 MHz 256 MB DRAM Celeron 1 2 GHz 256 MB DRAM Hard disk min 4 8 GB replaceable Operating system Windows XP US Robust design continuous operation high noise immunity Space saving installation thanks to compact dimensions LxWxH 296x267x100 mm Easy installation with four screws on the rear of the operator panel front Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 5 SINUMERIK Industrial PC e Mounting position and location to a large degree variable e Screen resolution 640 x 480 VGA up to 1024 x 768 XGA e Power supply 24 V DC e Interfaces Parallel interface LPT1 Serial interfaces 1 x RS 232 C 25 pin 1 x RS 232 C 9 pin PS 2 keyboard interface PS 2 mouse interface MPI PROFIBUS DP max 12 Mbaud VGA interfa
260. PCU as a backup copy The maximum share CPU time allotted to the NCK can be specified via an NC machine data unselect Windows XP and the NCK share the available processor power The CPU time share used by the NCK standard 65 can be altered in the machine data See Subsection 10 3 8 Page 10 295 Cycle times The PLC system software like the NC system software largely has the same functionality as the SINUMERIK 840D SinuCom NC is a Windows based tool for starting up the SINUMERIK 840Di NC using the possibilities for the interactive parameterization of the NC option management and license management management of series machine start up files The Windows based user interface 840Di start up see Section 1 5 Page 1 40 has the basic operation functionality to allow the operator to become familiar with the SINUMERIK 840Di 840Di start up is part of the scope of supply of a SINUMERIK 840Di and is al ready installed on the hard disk of the PCU The following components of the SINUMERIK HMI modular system can be used optionally e SINUMERIK HMI Advanced HMI Advanced is the SINUMERIK standard user interface intended espe cially for machine tools e 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 fa
261. PG PC interface The PG PC interface is parameterized in the SIMATIC Manager via menu item Options gt Set PG PC inierface Dialog box Set PG PC interface Tab card Access path Interface parameters used CP5611 AUTO or CP5511 AUTO OK Note We recommend using CPxxxx AUTO for parameterizing the PG PC interface because the PLC transmits the latest communications parameters of the SINUMERIK 840Di cyclically so that the connected devices are adapted automatically If the configuration is loaded into the PLC from the SINUMERIK 840Di the con ditions are provided by the values preset during installation Parameterizing the PG PC interface The PG PC interface is parameterized in the SIMATIC Manager via menu item Options gt Set PG PC interface Dialog box Set PG PC interface tab card Access path Interface parameters used SOFTMC OK Note Parameterization of the PG PC interface can be performed or changed from the SIMATIC Manager at any time The PLC status and therefore also the communications link to the PLC can be checked from HW Config via menu item Target system gt Status Ifthe current operating status of the PLC is displayed the communica tions link is operating correctly Ifthe 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 parameteri
262. PI configuration is described in a separate chapter See Chapter 7 Page 7 169 6 6 Creating a PROFIBUS configuration Creation of a PROFIBUS configuration is described in a separate chapter See Chapter 8 Page 8 209 Siemens AG 2005 All rights reserved 6 162 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 7 Loading the configuration 6 7 Loading the configuration 6 7 1 Requirements For loading the configuration into the PLC the following prerequisites must be fulfilled e An MPI connection exists between STEP 7 and the PLC e The configuration to be loaded corresponds to the actual station configura tion e SINUMERIK 840Di is active NC is in cyclic mode PLC in RUN or STOP status 6 7 2 Loading the configuration Supplementary condition First loading Note You are recommended to check consistency of the configuration before loading it The following supplementary conditions regarding the system data blocks are 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 As part
263. PJU PKTM SIMODRIVE 611 MASTERDRIVES MC Planning Guide 1FT6 Three Phase AC Servomotors SINAMICS MASTERDRIVES MICROMASTER SIEMOSYN Motors 1FU8 SINUMERIK 810D Configuring Manual CCU HW SINUMERIK 840D Configuring Manual NCU HW SIMODRIVE 611 SIMORVERT MASTERDRIVES MC Planning Guide Three Phase AC Servomotors General Part for motors 1FT 1FK SIMODRIVE 611 MASTERDRIVES VC MC Planning Guide Asynchronous Motors Contents General Part 1PH2 1PH4 1PH7 1PL6 SIMODRIVE Planning Guide 1FE1 Built In Synchronous Motors Three Phase AC Motors for Main Spindle Drives SIMODRIVE Installation Guide 1FE1 051 1FE1 147 Built In Synchronous Motors Three Phase AC Motors for Main Spindle Drives SIMODRIVE Planning Guide 1FN1 1FN3 Linear Motors ALL General Information about Linear Motors 1FN1 1FN1 Three Phase AC Linear Motor 1FN3 1FN3 Three Phase AC Linear Motor CON Connections SIMODRIVE 611 MASTERDRIVES MC Planning Guide Servomotors Contents General Part 1FT5 1FT6 1FK6 1FK7 1FS6 SIMODRIVE Planning Guide 1FW6 Integrated Torque Motors SIMODRIVE 611 Planning Guide Inverters SIMOVERT MASTERDRIVES Planning Guide 1FW3 Complete Torque Motors Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B 527 B References PMH PMH2 PMHS PMS PPH PPM c Software FB1 B 528 SIMODRIVE Sensor Configuring Installation Guide HW Hollow Shaft Measurin
264. PLC lt installation path gt dh mb dir myplc_ HelpContext Name and path of help files e g FileO hip alarm_ DEFAULTPRIO Priority of various alarm types e g POWERON 100 PROTOCOL Properties of the protocol e g file proto txt lt name and path of the protocol file gt KEYS Information about keys that can be used to delete alarms e g Cancel F10 lt Deleting alarms with key combination Shift F10 gt For further details of the file entries refer to References BN User Guide OEM package for MMC Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 11 Alarm and Message Texts 11 1 Alarm and message texts Section Alarms The settings in this section define the following alarm list properties e 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 e MaxNo Defines the maximum size of the alarm list e 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 Siemens AG 2005 All rig
265. PLC to axis spindle Deselection of safe velocity and zero speed deselection of SBH SG Deselection of safe operational stop deselection of SBH Velocity limit bit value 0 SG selection Velocity limit bit value 1 Ration selection bit value 0 to bit value 2 Enable limit switch pair 2 Enable test stop Signals from axis spindle to PLC Setup mode active Torque limit 2 active Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Doc reference Doc reference 16 499 16 840Di specific Data and Functions 01 05 16 1 Interface signals DB number Byte bit Name Doc reference Safety Integrated signals from axis spindle to PLC 913 108 0 Safe velocity or zero speed SBH SG active Ch ere 108 2 Clear status pulses cippa 108 7 Axis referenced safely 31 42 109 0 109 7 Cam signals of plus and minus cams SN1 1 to SN4 4 31 110 1 Safe operational stop active SBH active ST 110 3 110 4 Safe velocity active bit value 0 to bit value 1 31 110 5 n lt n BTE 111 1 Safe operational stop active SBH active Sur 111 4 11 7 Stop A B to Stop E active Siemens AG 2005 All rights reserved 16 500 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specific Data and Functions 16 2 Expanded message frame configuration 16 2 Expanded message frame configuration 16 2 1 Description of functions Message frame structure NC system variables The
266. PROFldrive profile provides two different possibilities for defining the quan tity and meaning of message frame data transferred between the DP master and DP slave drives within the framework of the cyclic PROFIBUS communica tion 1 Select a predefined standard message frame You can uniquely define the quantity and meaning of the transferred data by selecting a standard message frame type in the associated components DP slave drive DP master and NC 2 Customizable message frame configuration With customizable message frame configuration a user specific frame type is defined in which you need to separately inform each associated compo nent DP slave DP master and NC of the quantity and meaning of the transferred data SINUMERIK 840Di supports extended message frame configuration By com bining standard message frame and free message frame configuration it is pos sible to transmit not only the process data PDA configured in the standard message frame but also additional drive data cyclically from the drive DP slave to the NC DP master The drive data transferred in addition to the standard message frame process data must always be appended at the end of the standard message frame PDA for expanded message frame PDA Standard message PDA Additional drive frame data RE Fig 16 1 Standard message frame with additional process data PDA According to the selected functionality for each axis the
267. Page 14 454 Table 10 14 Machine data required to configure the SRAM Number Name of identifier Name remarks Refer 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 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 303 10 NC Start Up with HMI Advanced 01 05 10 4 Memory configuration General MN_ 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_TA Number of tool offsets in NCK 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 sp
268. Parameters with key 1 Configuration of the ghost parameters is described in Subsection 15 5 3 Page 15 482 PLEASE SELECT 1 Configure GHOST Parameters 2 Harddisk Backup to H lt PATH gt SICHERO1 GHO Mode LOCAL 3 Harddisk Backup from H lt PATH gt SICHER01 GHO Mode LOCAL 9 Back to previous Menu Your Choice 1 2 3 9 5 Select Harddisk Backup from with key 3 Following menu For partitioning the disk it s important to know the SYSTEM BASE of the imaged configuration Please select the SYSTEM BASE the image was created by PLEASE SELECT Windows XP Windows NT Win95 WfW3 11 DOS sparepart o O1 B OC ND e Back to previous Menu Your Choice 1 2 3 4 5 9 6 Choose the operating system used as the basis for the backup copy For SINUMERIK 840Di this is in the current version excluding Windows XP Therefore choose Windows XP with key 1 Following menu What kind of disk partitioning do you want 1 Standard Partitioning default 2 User defined Partitioning 3 Image Partitioning Your Choice 1 2 3 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 479 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu 15 480 Standard Partitioning default The hard disk partitioning of the PCU is set to the default partitioning of the as delivered state
269. Project 5 File Editing Targetsyst Diagnosis Tools View Window l x al oie Machine data a LEE Le salsal Es AT block Sinumerik Project objects 6 Sinumerik 840Di 1 connected Px n Machine data MD block1 Fig 5 4 SinuCom NC Main menu The option menu allows setting of new and additional options in the appropriate input fields Fig 5 5 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 7 License management The procedure described above Items 1 to 4 is triggered with button Get a new License Key Fig 5 5 The follow further instructions in the following dia log boxes E SinuCom NC Online SinuCom_NC_ Project MD block1 EP Eile Editing Target syst Diagnosis Tools View Window MD block Options MD block1 Options Channel Mode gro El PROFIBUS assign Option A Licensed E Axis configuration System software AKTI 6FC5251 AX2 Y1 AT AX4 A1 Mode group BAG additional Input fields Options AX3 Z1 6FC5251 0AD00 0AA0 Functions Show all Show not licensed only Processing channel additional 6FC5251 0AA07 0AAO Cycles in DRAM Accept Moditicatorrs Button License key zd WAZA CEPS NUM SCRL Z Fig 5 5 SinuCom NC Option menu Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 143 5 Power On and Power Up 0
270. RACKING MD number Detection of additional drive actual values Default setting 0 Minimum input limit 0 Maximum input limit 4 Changes effective after POWER ON Protection level 2 7 Unit Data type BYTE Applies as from SW version 2 1 Meaning The 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 PROF IDrive message frame VA_DP_ACT_TEL MD irrelevant for System variables Name VA DP ACT TELIn 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 programs Synchronized OPI action Read Read Read Attribute Implicit preprocessing stop Cross channel Read Yes 16 2 6 Alarms Detailed information on the individual alarms can be found in Ref
271. RIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication Adding a module 8 7 DP slave MCP 483 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 There is no automatic adjustment The following data must match 1 SIMATIC S7 configuration DP slave MCP 483 PROFIBUS address 2 Machine control panel MCP 483 PROFIBUS address DIP switch S3 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 modules are listed in the hardware catalog under DP slave MCP 483 The follo wing modules are available e Universal module not applicable e standard e standard handwheel e standard extended e standard handwheel extended Module standard The module transfers the data for the Standard function e Input data 8 bytes Standard data 8Byte e Output data 8 bytes Standard data 8Byte Module standard handwheel The module transfers the data for the Standard and Handwheel functions e Input data 12 bytes Absolute value Absolute value M 1st handwheel 2nd handwheel 2Byte 2Byte Low byte High byte e Output data 8 bytes Standard data 8Byte Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 251 8 PROFIBUS DP Communication 01 05 8
272. RIK 840Di NC Option Evaluation of internal drive variables Order No MLFB 6FC5 251 0AB17 0BAO NC machine data for activating the data transfer for the additional PDA in the system variables e MD 36730 DRIVE_SIGNAL_TRACKING n acquisition of additional drive actual values 16 2 3 Configuring SIMODRIVE drives Expanded message frame configuration in relation to SIMODRIVE drives SIMODRIVE 611 universal or universal E SIMODRIVE POSMO CD CA SIMODRIVE POSMO SI is illustrated on the basis of an example using SIMODRIVE 611 universal DP slave 611U Please adapt your procedure for the other SIMODRIVE drives Recommended We recommend proceeding in the following order to configure the components configuration included in the expanded message frame configuration sequence 1 Configure the DP master with SIMATIC STEP 7 2 Configure the DP slave 611U with the start up tool SimoCom U 3 SINUMERIK 840Di NC with start up tool SinuCom NC or the user interface HMI Advanced option Default Before performing the expanded message frame configuration please define configuration the following Which standard message frame the drive axis axes is supposed to oper ate with How many additional drive actual values PDA are to be transferred Note It is advisable to configure each component first with the appropriate standard message frame and then expand the frame by the additional PDA Si
273. Reference point value 34090 REFP_MOVE_DIST_CORR Reference point offset 34200 REFP_MODE Referencing mode Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 375 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Interface signals Table 10 46 Synchronizing spindle Interface signals DB number Bit byte Axis specific 3f 16 4 Si 16 5 Axis specific 31 60 4 Si 60 5 Name Refer ence Signals from PLC to axis spindle Synchronize spindle 1 Synchronize spindle 2 Signals from axis spindle to PLC Referenced synchronized 1 Referenced synchronized 2 10 5 27 Spindle monitoring Axis spindle at a standstill Spindle in set range Max spindle speed 10 376 If the actual speed entered in machine data e MD36060 STANDSTILL_VELO_TOL maximum velocity speed for axis spindle stopped falls below the programmed velocity speed the interface signal e IS DB31 DBX61 4 axis spindle stationary is set If e MD35510 SPIND STOPPED AT IPO START feed enable for Spindle stopped is set the path feed is enabled If the spindle reaches the tolerance range specified in machine data e MD35150 SPIND DES VELO TOL spindle speed tolerance interface signal e IS DB31 DBX83 5 spindle in setpoint range is set If e MD35510 SPIND STOPPED AT IPO START feed enable for Spindle stopped is set the path feed is enabled The maximum
274. S DP communication for installing additional software on the PCU e anMPI cable for connecting the PCU to the programming unit Note A programming device is not needed if the SIMATIC Manager STEP 7 is installed on the PCU of the SINUMERIK 840Di an existing PC is used to install additional software For installing software on the PCU see Chapter 15 Page 15 461 The following documentation is required for start up e BH Operator Components Manual Operator panel fronts Component PCU 50 Machine control panels Operator panel handheld terminal HT6 Depending on the NC and PLC functions used the relevant Descriptions of Functions e FB Description of Functions Basic Machine e FB Description of Functions Extended Functions e FB Description of Functions Special Functions The list of references in the Appendix provides an overview of the contents of the individual Descriptions of Functions e LIS Lists Overview of functions Machine Setting Data and Variables Interface Signals and PLC Blocks e DA Diagnostics Guide Contents Alarms Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 4 Standard export version 1 4 Standard export version Export license requirement Identification of the control Because certain control functions require an expor
275. S7HT S7HR S7S S7L S7M SP d Installation and Start Up BS NAA NAC SIMODRIVE POSMO SI Installation Guide enclosed with POSMO SI SIMODRIVE POSMO CD CA Installation Guide enclosed with POSMO CD CA SIMATIC S7 300 Installation Manual Technological Functions Reference Manual CPU data HW Description Reference Manual Module Data SIMATIC S7 300 Manual STEP 7 Fundamentals V 3 1 SIMATIC S7 300 Manual STEP 7 Reference Manuals V 3 1 SIMATIC S7 300 FM 353 Positioning Module for Stepper Drive Order together with configuring package SIMATIC S7 300 FM 354 Positioning Module for Servo Drive Order together with configuring package SIMATIC S7 300 FM 357 2 Multimodule for Servo and Stepper Drives Order together with configuring package SIMODRIVE 611 A 611 D SimoPro 3 1 Program for Configuring Machine Tool Drives SIMODRIVE 611 analog Description Start Up Software for Main Spindle and Asynchronous Motor Modules Version 3 20 SIMODRIVE 611A Installation and Start Up Guide SINUMERIK 810D Installation and Start Up Guide incl description of SIMODRIVE 611D start up software Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B 533 B References NAD NAM B 534 SINUMERIK 840D SIMODRIVE 611 Installation and Start Up Guide incl description of SIMODRIVE 611 digital start up software SINUMERIK 840D 840Di 810D Installation
276. SIMATIC HMI SIMATIC NET SIROTEC SINUMERIK and SIMODRIVE are Siemens trademarks Other product names used in this documentation may be trademarks which if used by third parties could infringe the rights of their owners Additional information can be found at Other functions not described in this documentation might be http Awww siemens com motioncontrol executable in the control This does not however represent an obligation to supply such functions with a new control or when servicing We have checked that the contents of this document correspond to 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 subsequent editions We welcome This publication was produced with Interleaf V 7 suggestions for improvement Siemens AG 2005 All rights reserved Subject to technical changes without prior notice Order No 6FC5 297 7AE60 0BP2 Siemens Aktiengesellschaft Printed in Germany 01 05 SINUMERIK 840Di Manual PREFACE Notes for the Reader Hotline Internet address SINUMERIK 840Di Link Box Preface The SINUMERIK documentation is organized in 4 parts e General documentation e User documentation e Manufacturer service documentation e OEM documentation This document is designed for mac
277. SINUMERIK 840Di Manual 01 05 Preface Objective Target groups Who are qualified personnel vi This manual provides detailed information on the specific hardware and installation and start up of a SINUMERIK 840Di system This manual provides information about the control system design and the interfaces of the individual components Furthermore the procedure for starting up the SINUMERIK 840Di with PROFIBUS DP drives for example SIMODRIVE 611 universal is 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 documentations 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 The manual contained in the function descriptions is designed for e Design engineers e PLC programmers who create PLC user programs e Start up engineers once the system has been configured and set up e Maintenance personnel inspecting and interpreting status signals and alarms For the purpose of this manual and product labels a qualified person is one who is familiar with the installation
278. Software procedure for mapping a large quantity of identifiers onto a finite me mory area Hexadecimal number Handheld Unit Human Machine Interface Hardware SIMATIC S7 Tool to configure and parameterize S7 hardware within an S7 proj ect Hardware limit switch Increment INItializing data Internal multiplication Interface Signal Special punched tape code number of holes per character always even JOG mode Manual mode for setting up the machine Channel 1 Transmission ratio Servo gain factor Leadscrew Error Compensation Light Emitting Diode Least Significant Bit Motion Control Interface Machine Control Panel Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 A Abbreviations MCS Machine Coordinate System MD Machine Data MDI Manual Data Automatic NC mode for entering and processing individual part program blocks or block sequences MLFB Machine readable product designation Order number MMC Man Machine Communication SINUMERIK operator interface for operating programming and simulation MPF Main Program File NC part program main program MPI Multi Point Interface Multi point serial interface MSD Main Spindle Drive NC Numerical Control NCK Numerical Control Kernel NC kernel with block preparation traversing range etc NCU Numerical Control Unit NC module OB Organization Block Block type of PLC basic or user program PCMCIA Personal Computer Memory Card
279. Start Up with HMI Advanced 10 6 Digital and analog I O devices 10 6 4 Digital input output bytes and system variables Digital inputs The following configuration example shows the relation between digital input 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 Dig ital input bytes of external signal modules must therefore always be counted as additional input bytes e 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 e MD10366 HW_ASSIGN_DIG_FASTIN 0 gt 1st external input byte e MD10366 HW_ASSIGN_DIG_FASTIN 1 gt 2nd external input byte MD10350 FASTIO_DIG_NUM_INPUTS 3 1 m with 1 gt 1st dig input byte of the MCI board extension module always 1 see text m 2 gt 2nd and 3rd dig input byte via PROFIBUS 1 0 modules number of input bytes used from external signal modules MCI board ex module System variable Pog SPS tages oo S ge aa Sra Sheth es Oy foe IES oy ee 20 SS Le din BE Se ee Bl MD10366 HW_ASSIG
280. Stubs feeding cable from the bus segment to the node should be as short as possible i e lt 5 m Any spur lines that are not assigned should be re moved if possible Note Spur lines should be avoided where possible Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 169 7 MPI Communication 01 05 7 2 Networking rules Example Communication interference 7 170 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 A maximum of 2 of the following components can be connected per bus segment Machine control panel MCP Handheld unit HHU Handheld terminal 6 HT 6 Do not enable the bus terminating resistors at the distributor boxes of an HHU or HT 6 since they are already built into the appropriate device Maximum cable lengths e 200 m per bus segment e 2 000 m overall length with RS 485 repeater PCU 50 HT 6 MCP with OP 012 and HMI Advanced Distribu off off tion box SINUMERIK 840Di off MPI bus PCU 50 on Terminating resistor MCI board inserted in connector on Terminating resistor integrated Fig 7 1 MPI network with terminating resistors If no communication can be established as a whole or with individual node
281. TATE n 1 Activate changed machine data by NCK reset Completing encoder calibration When the NC has started up encoder calibration is completed in mode JOG gt REF for the machine axis by once more pressing the direction key as described in point 2 Select JOG gt REF mode Select machine axis Press traverse direction key Note Pressing the traverse direction key does not move the machine axis The NC then calculates the reference point offset and enters it in the ma chine data e MD34090 MA REFP MOVE _DIST CORRfn 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 e MD34210 MA_ENC_REFP_STATE n 2 The value from the machine data is shown as the actual position of the ma chine axis on the user interface e MD34100 MA_REFP_SET_POSj n reference point value For time optimized calibration of the absolute value encoders of several ma chine axes the following procedure is recommended 1 Depending on the machine design move all or several machine axes to their reference position See above Items 1 4 Perform an NCK reset See above Item 5 Complete encoder calibration for all machine axes See item 6 Recalibration of the absolute encoder is required after Gear change between load and absolute encoder Removal installation of the absolut
282. TEP 7 please refer to the relevant SIMATIC documentation or Online Help The archive file mcp840di has been dearchived using the SIMATIC Manager Library mcp840Di is available in SIMATIC STEP7 See previous Section 7 4 Page 7 172 7 5 2 Inserting the default configuration into the S7 project Opening the library To insert the default configuration in S7 project SIN840Di you have created open the library dearchived in Section 7 4 Page 7 172 with menu command Open gt File Select library mcp840Di and confirm the dialog box with OK Opening a project x User projects Cibraries gt sample projectd Multiple projectd gp8x0d65 F Program Files Siemens Step7 S7libs gp8x0d65 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 7 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 173 7 MPI Communication 01 05 7 5 Creating a MPI configuration Note When you copy the blocks into the block directory of the P
283. TIC 300 G9 c7 CP 300 CPU 300 FM 300 IM 300 M7 EXTENSION Gateway PS 300 RACK 300 SM 300 C9 sinumerik 1 810D 8400 840Di l simatic 3001 Description Z Z 840Di with PLC3 aff 840Di_PLC317M 2DP_2AJ10 Re Stations window Detailed view SINUMERIK 840Di with integrated PLC 317 2DP 2AJ10 ad GZ Hardware catalog Stations window Station structure CeeCeeeeee De ep Fig 6 4 HW Config Names of the main areas Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 155 6 PLC Start Up 01 05 6 3 Creating a SIMATIC S7 project Note To check whether a module selected from the hardware catalog complies with the module in the automation system the following procedure is recommended 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 840Di Rack Inserting 840Di Rack 6 156 840Di Rack contains the already partially preconfigured components e SINUMERIK 840Di PLC Standard designation PLC317 2DP 2AJ10 e MPI DP interface Standard designation MPI DP e PROFIBUS DP interface Standard des
284. TRLOUT_SEGMENT_NR APR3 APW 2 M30 References 10 284 PGA Programming Guide Advanced Chapter File and Program Management Defining protection levels for user data GUD Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 2 Machine and setting data 10 2 3 Machine data display filter Machine data areas Display filter Display groups Expert mode Index from to 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 Display filters are provided for the following machine data areas e General machine data e Channelspecific machine data e Axisspecific machine data e Drive machine data are available 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 gt Machine Data gt Channel MD gt 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 A display group contains machine data within a machine data area that belong to the same topic By selecting deselecting
285. Terminal HT 6 front side 7 10 1 Conditions for start up Hardware The following hardware components are required to start up the HT 6 Distributor box The distributor box incorporates the MPI module interface the HT 6 interface as well as a terminal block for connecting EMERGENCY STOP enable keys handwheel and 24 V power supply For the distributor box see Section 3 3 Page 3 107 HT 6 connection cable The HT 6 is connected to the distributor box using the HT 6 cable For the HT 6 connection cable see Section 3 3 Page 3 107 MPI bus cable Under no circumstances may the MPI bus cable contain an integrated bus ter minating resistor since a bus terminating resistor is already integrated in the HT6 For the MPI cable see Section 3 3 page 3 107 Programming unit PG PC with keyboard mouse CD ROM and Omni drive for writing to the PC card 1 MPI configuration The standard MPI configuration must be adapted for operating an HT6 ona SINUMERIK 840Di Once the MPI configuration has been changed in file NETNAMES INI a new HT 6 system software abb must be generated and written to a PC card The system software is then transferred to the HT 6 via the PC card For how to adapt the MPI configuration see Section 7 10 3 page 7 198 Siemens AG 2005 All rights reserved 7 196 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 10 Handheld Terminal HT 6 2 PLC user program Before an HT6 can
286. UMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Axis specific ST 31 4 Ilt Slik 31 Axis specific Si is Ilya 3T Sr 16 2 16 0 16 3 16 6 18 4 18 5 82 2 82 0 82 3 84 7 84 6 10 5 Axes and spindles Signals from PLC to axis spindle Actual gear step Gear changed No speed monitoring when changing the gear Oscillation via PLC Oscillation speed Signals from axis spindle to PLC Set gear step Change gear Active spindle control mode Active spindle mode oscillation mode 10 5 25 Position spindle Functionality Machine data The NC provides an oriented spindle stop function with which the spindle can be moved into a certain position and held there e g for tool changing pur poses Several programming commands are available for this function which define the approach and program processing References PA Programming Guide S1 Spindles e To absolute position 0 360 degrees e Incremental position 999999 99 degrees e Block change when position reached e 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 Ky factor become active The interface signal Exact stop fine is output to i
287. Unit Data type DOUBLE Applies as from SW version 2 2 Meaning For the drives connected via PROFIBUS the MD defines the resolution of the torque re duction transferred in the cyclic SIMODRIVE standard message frames 102 to 107 control word TorRed The torque reduction is e g required as part of the function Travel to fixed stop FXST At automatic adjustment the machine data must be set so that it is consistent with the mea ning of drive parameter P0881 Torque reduction evaluation or with manual adjustment with the drive end interpretation of the control word TorRed The default value of 1 corresponds to the resolution that was valid prior to SW 2 2 16 3 7 Alarms Detailed information on the individual alarms can be found in References DA Diagnostics Guide For systems with HMI Advanced you can refer to the online help Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 515 16 840Di specific Data and Functions 01 05 16 3 Travel to fixed stop with high resolution torque reduction Notes Siemens AG 2005 All rights reserved 16 516 SINUMERIK 840Di Manual HBI 01 05 Edition Abbreviations ADI4 ARM ASCII ASUB BA BAG BB BCD BP COM CPU CRC DAC DB DBB DBX DHCP DPR DRAM DRF DRY DSR DW EFP EPROM Analog Drive Interface for 4 Axis Asynchronous Rotary M
288. V1 4 2 01 September 00 e 72 digital inputs and 48 digital outputs e On board 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 Siemens AG 2005 All rights reserved 2 84 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 11 2 Interface description 2 11 I O module PP72 48 Interface overview Interfaces of I O module PP72 48 Table 2 14 Interfaces of I O module PP72 48 Interface Designation Type Power supply connection x1 Screw terminal block PROFIBUS DP X2 Socket connector PROFIBUS DP address S1 DIL switch Digital input outputs 1 X111 Ribbon cable connector Digital input outputs 2 X222 Ribbon cable connector Digital input outputs 3 X333 Ribbon cable connector External power Interface description of the external power supply X1 suppl i od y e Screw terminal block MSTBVA 2 5 3 G 5 08 Phoenix e Pin assignment Table 2 15 Pin assignment Ext power supply X1 Pin Designation Type Function 1 P24 VI External power supply of the module 24 V 2 M24 VI Reference for external supply 3 PE VI Protective conductor of the external supply 1 VI Voltage Input e Connecting cable The required connecting cables must be provided by the user Wire conductor cross section 1 0 1 5 mm AWG17 AWG16 e Power supply For data concerning the power supply see Subsection 2 11 3 Page 2 92
289. _ ALUE MM_CHAN_HASH_TABLE_SIZE MM_NCK_HASH_TABLE_SIZE MM_NUM_CEC_NAMES MM_CEC_MAX_POINTS MM_EXTCOM_TASK_STACK_SIZE MM_SERVO_TASK_STACK_SIZE MM_DRIVE_TASK_STACK_SIZE Channelspecific MC_ 20096 27900 28000 28010 28020 28040 28060 28070 10 302 T_M_ADDRESS_EXIT_SPINO REORG_LOG_ LIMIT MM_REORG_LOG_FILE_MEM MM_NUM_REORG_ LUD MODULES MM_NUM_LUD_NAMES_TOTAL MM_LUD_VALUES_MEM MM_IPO_BUFFER_SIZE MM_NUM_BLOCKS_IN_PREP Refer ence Name remarks Display data of the free dynamic memory Number of miscellaneous functions Number of additional parameters User memory in DRAM Hash table size for user variables Maximum field size of the LUD variables Hash table size for channel specific data Hash table size for global data Number of LEC tables Max table size for sag compensation Stack size for external communication task Stack size of servo task Stack size of drive task Spindle number as address extension FBW w1 Percentage of IPO buffer for log file enable Memory size for REORG Number of modules for local user variables with REORG Number of local user variables FB Ki Memory size for local user variables Number of NC blocks in the IPO buffer Number of blocks for block preparation Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 4 Memory configuration Numb
290. 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 10 4 Protection levels machine data Number Name of 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 283 10 NC Start Up with HMI Advanced 01 05 10 2 Machine and setting data Number Name of identifier Name Refer ence 9214 USER_CLASS_WRITE_PRG_CONDIT Program control 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_RP
291. active DBX1 5 DBX1 6 Position measuring system 1 2 x DBX1 3 Axis spindle disable Enable spindle DBX2 1 Servo enable controller enable NC DBX16 7 Delete S value enable on drive DBX3 6 Velocity spindle speed 7 limitation and MD 35160 Specify spindle speed DBX4 3 Feed hold spindle stop DBX20 1 RFG IS DBX2 2 Spindle reset on MD 35050 1 DBX21 7 Pulse enable Check machine and setting data MD32250 Rated output voltage 1 MD32260 Rated output speed Does the No MD 35100 35150 Spindle speed limitation spindle gt 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 Is traversing direction okay Check MD32100 AX_MOTION_DIR Yes Specified speed 100 rev min No ag Check MD31000 31080 encoder matching Yes 1 Speed setpoint matching ADI4 gt MD32250 0 SIMODRIVE 611 universal E POSMO CD CA SI gt MD32250 0 Siemens AG 2005 All rights reserved 12 418 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 12 Axis Spindle Dry Run 12 3 Spindle dry run IS Spindle in setpoint range DB31 DBxx DBX83 5 Change over gear stage All gear stages tested Perform spindle positioning Check machine data and interface signals MD 35110 35140 Speed
292. ailure of DP slave MCP 310 is detected the PLC goes into the STOP status by default Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 239 8 PROFIBUS DP Communication 01 05 8 6 DP slave MCP 310 Customized response 8 6 7 Arrangement to allow the user to intervene when a DP slave MCP 310 the following orga nization blocks are inserted in the PLC user program e OB 82 Diagnostic alarm e 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 OPI MPI the following alarm is tripped by the basic PLC program e 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 machine manufacturer is responsible for triggering a corresponding alarm Input output image Keys and LEDs A key and the LED positioned above it form a logical unit The key and the LED have the same number e Key Sxy Key number xy e LED LEDxy LED number xy Fig 8 20 shows the arrangement of keys and LEDs on the machine control panel together with their internal designation For the sake of clarity the LED designations are not shown in full LEDO9 LEDO1 O Q LEDO2 LEDO3 LED21 LED22 LED23 LED36 LED37 LED38 O Q O O O O O
293. alarm you must first acknowledge the alarm itself with a special operation before executing the required NCK POWER ON Reset See Subsection 10 10 1 Page 10 400ff 5 3 5 Start up after replacement of the PCU new or reinstallation update of the 840Di software If an MCI board used in a new PCU once is further used or if the 840Di software is reinstalled on a SINUMERIK 840Di that is already started up the battery backed user data in the SRAM of the MCI board are kept 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 is thus ready again immediately Responses A note will appear in a message box which must be acknowledged with OK SINUMERIK 840Di NCK PLC x A Note User data from MCI card used Notice If you do not wish to use the battery backed user data further you must repeat start up of the SINUMERIK 840Di Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 123 5 Power On and Power Up 01 05 5 3 Booting 5 3 6 Start up after replacement of the PCU or the MCI board If it is detected during the power up that both the SRAM image on the hard disk of the PCU and the SRAM of the MCI board have battery backed valid but dif ferent user data both components were already used in a SINUMERIK 840Di it is not
294. alized before commencement of the actual NC start up process because all battery backed user data e g part programs tool offsets are lost when the memory is reallocated Machine data setting data and option data are not lost when the memory is reorganized The MDs for the memory configuration are activated by power ON References FB Description of Functions S7 Memory Configuration Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 301 10 NC Start Up with HMI Advanced 01 05 10 4 Memory configuration 10 4 1 Free memory DRAM memory The free DRAM memory is displayed in machine data e MD18050 INFO FR E 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 e MD18050 INFO FR E 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 Machine data Table 10 13 Number Machine data required to configure the DRAM Name of identifier General MN_ 18050 18170 18180 18210 18240 18242 18250 18260 18340 18342 18500 18510 18520 INFO_FREE_MEM_DYNAMIC MM_NUM_MAX_FUNC_NAMES MM_NUM_MAX_FUNC_PARAM MM_USER_MEM_DYNAMIC MM_LUD_HASH_TABLE_SIZE MM_MAX_SIZE_OF_LUD
295. all drives 1 of the NC MD13050 DRIVE_LOGIC_ADDRESSjn NC Machine axis 1 0 1 Machine axis 2 0 2 Machine axis 3 0 3 0 4 0 5 0 6 0 7 0 8 0 I O address of drive 1 I O address of drive 2 I O address of drive 3 I O address of drive 4 I O address of drive 5 I O address of drive 6 I O address of drive 7 O address of drive Fig 10 4 Axis assignment Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 309 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles o 10 310 Machine data e MD13050 DRIVE_LOGIC_ADDRESSJn I O address of the drive tells the NC 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 NC The machine data e MD30110 MODULE_NR O setpoint assignment e 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_ADDRESSjJn Machine data e 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 implicit
296. alog box Internet Protocol TCP IP Properties Tab card Alternate Configuration Automatic Private IP Address OK Because it is a PTP link any computer name and workgroup may be selected The setting is made via the properties dialog box of the Control Panel Windows taskbar Start gt Control Panel gt System Dialog box System Properties Tab card Computer Name Button Change Dialog box Change Computer Name Computer name lt COMPUTER NAME gt Workgroup lt WORKGROUP gt OK Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup Service File and Printer Sharing Dialog box Option Simple File Sharing Dialog box Directory sharing Authorization Dialog box 15 1 PTP network link Windows Go to the properties dialog box of the local network links Windows task bar Start gt Settings gt Network Connections gt gt 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 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 To simplify enabling of directories go to the Windows Explorer menu item Tools gt Folder Options and se
297. amp Caution Changing e MD 32000 MAX_AX_VELO maximum axis velocity e MD 32300 MAX_AX_ACCEL max axis acceleration may only be carried out with utmost care e g by a certain step height These machine data are exactly matched with the machine Siemens AG 2005 All rights reserved 13 434 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 5 Graphic display 13 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 MPF_DIR Start up Jog TEST MPF Channel reset ag Program aborted ROY Y marker Graphics1 lt Tr 1 Y1 axis gt i Tr 1 Amplitude response X marker 1 6276 Hz 0 2277 dB Zoom 20 0000 x BE Fullscreen 60 0000 Scale Tr 3 Phase response X marker 1 6276 Hz 9 1319 deg Graphics 180 0000 gt deg lt rarman rerh 180 0000 Start Measure Measuring Axis User Displa File ment parameters MD views functions Fig 13 6 Menu Display of measurement with marker X ON Soft keys 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
298. 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 NC 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 NC must be started up again or a series start up file read in see Chapter 14 Page 14 453 Acknowledge alarm 4065 Via button Acknowledge alarm 4065 e Alarm 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 NC must be started up again or a series start up file read in see Chapter 14 Page 14 453 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
299. an 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 The computational resolution defines the maximum number of effective decimal 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 e MD 10200 INT_INCR_PER_MM computational resolution for linear posi tions e MD 10210 INT_INCR_PER_DEG computational resolution for angle posi tions The default assignment is e 1000 increments mm e 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 display resolution it should have at least the same resolution The precision of angle and linear positions is limited to the computational reso lution by rounding the product of the programmed value with th
300. anation 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 machine manufacturer can affect or modify the function described Never ignore information provided by the machine manufacturer Siemens AG 2005 All rights reserved K SINUMERIK 840Di Manual HBI 01 05 Edition VII SINUMERIK 840Di Manual 01 05 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 warn ing 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 part
301. and Start Up Guide HMI AE1 BE1 HE1 IM2 IM4 TX1 TX2 Updates Supplements Expanding the Operator Interface Online Help Starting up HMI Embedded Starting up HMI Advanced Creating Foreign Language Texts with Windows 95 NT Creating Foreign Language Texts with Windows 2000 XP Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition EC Declaration of Conformity 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 amp D Product Information page 15257461 Internet address www siemens com sinumerik gt Support gt Service gt Automation amp Drives Service amp Support gt Produkt Support gt Search 15257461 gt Go Search Sitemap Information Support Shop Automation and Drives Product Information Service amp Support Product Support Content X Link Box amp more Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition C 535 C EC Declaration of Conformity 01 05 Notes Siemens AG 2005 All rights reserved C 536 SINUMERIK 840Di Manual HBI 01 05 Edition Index Numbers 840Di services 5 135 840Di start up PROFIBUS diagnosis 8 224 A Abbreviations Absolute encod
302. 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 Communication of the PLC with the NC is carried out using the NC PLC inter face The interface is divided into the following areas e Mode groups e Channels e Axes spindles e 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 A cyclic mutual sign of life monitoring function is activated between PLC and 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 e Alarm 2000 sign of life monitoring for PLC 6 8 3 Monitor control using the SIMATIC Manager Monitoring and controlling the variable 6 166 The SIMATIC Manager provides extensive functionality for testing the PLC pro gram or the module The menu command Target System gt Monitor Control Variable is used to start the tool Monitor control variable The following functions can be performed with Monitor
303. anual 01 2005 Edition SINUMERIK 840Di SIEMENS SIEMENS SINUMERIK 840Di Manual Valid for Control Software version SINUMERIK 840DiE 840Di 01 2005 Edition 3 General Notes Hardware Descriptions Design EMC and ESD Measures Power On and Power Up PLC Start Up MPI Communication PROFIBUS DP Communication Drive Start Up Preconditions NC Start Up with HMI Advanced Alarm and Message Texts Axis Spindle Dry Run Drive Optimization with HMI Advanced User Data Backup Series Machine Start Up Software Installation Update and Data Backup 840Di Specific Data and Functions Abbreviations References EC Declaration of Conformity Index 10 12 13 14 15 16 SINUMERIK Documentation 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 Au New documentation B Unrevised reprint with new order no Girit Revised edition with new status If factual changes have been made on the page since the last edition this is indicated by a new edition coding in the header on that page Edition Order No Remarks 07 00 6FC5 297 5AE60 0BP1 A 09 01 6FC5 297 6AE60 0BPO C 09 02 6FC5 297 6AE60 0BP1 C 06 03 6FC5 297 6AE60 0BP2 C 03 04 6FC5 297 7AE60 0BP0 C 08 04 6FC5 297 7AE60 0BP1 C 01 05 6FC5 297 7AE60 0BP2 C Trademarks SIMATIC
304. arameterization of the PLC 7 7 4 Example Connecting an MCP to SINUMERIK 840Di 7 8 MPI interface for customer operator panel 7 8 1 Parameterization of the MPI interface 7 9 Handheld unit B MPI 7 9 1 Conditions for start up 7 9 2 Electrical connection 7 9 3 MPI parameters of the HHU 7 9 4 MPI parameterization of the PLC 7 9 5 GD circle parameters of the HHU 7 9 6 GD circle parameterization of the PLC 7 9 7 Example Connecting a HHU to SINUMERIK 840Di Siemens AG 2005 All rights reserved xiv SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 SINUMERIK 840Di Manual Contents 7 9 8 Plugging and unplugging handheld unit during operation 7 10 Handheld Terminal HT 6 7 10 1 Conditions for start up FAQ CONNECIIONS 44 4428488 are 8 endeeeaad an dan donc n Rae oes dat 7 10 3 Adapting the MPI configuration NETNAMES INI 7 10 4 Display of the current software version 7 10 5 Parameterization of PLC 7 10 6 Example Conn
305. are COLES Content PLC basic program NC variable selector PLC sample programs installation software lt CD path gt installs add_on pic_tb Setup exe e SlaveOM for SINUMERIK 840Di as from Version 05 03 Object Manager for the dialog based configuration of PROFIBUS DP drives using SIMATIC Manager STEP7 especially for SINUMERIK 840Di Installation software SlaveOM lt CD path gt installs add_on slaveom setup exe e GSD file for O modules PP72 48 Device master file with the information in ASCII format required for integra tion of the I O module PP72 48 into a SIMATIC S7 project as DP slave DMF file lt CD path gt support siem80a2 gsd e PLC application example Sample application of a SIMATIC S7 project for SINUMERIK 840Di with SI MODRIVE 611 universal drives and SIMATIC ET200 I Os ZIP file lt CD path gt support 840dismp 840dismp zip archive file lt CD path gt support 840dismp plc_smp arc Note The components supplied as SIMATIC S7 add on software PLC basic program SlaveOM must be installed on the computer PG PC on which the SIMATIC Manager S7 is installed for creating the S7 project for the SINUMERIK 840Di Siemens AG 2005 All rights reserved 1 36 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 3 Software Additional software Additional hardware 1 3 Notes on start up Notes on start up This SINUMERIK 8
306. ase time Dialog box Tab card Clock synchronization Continuation Adjustment Dialog box End Setpoint acceptance ms Factor Factor Activating button Adjust transfers the values displayed in the Clock Synchro nization of current DP slave 611U to all other DP slaves 611U of the configura tion This adjustment must be carried out at the end and the dialog box must then be confirmed with OK Tab card Clock synchronization Button Adjust OK Notice If there are different types of isochronous DP slaves in a S7 project e g different SIMODRIVE drives ADI4 etc the following parameters lsochronous DP cycle Tpp Master application cycle Tywapc Actual value acquisition T 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 Synchronization to the DP slave of the same type 8 3 4 Generating system data blocks SDB Consistency check 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 Always check that the system data blocks are error free before storing and compiling them To do that select menu item Station gt Check configuration in HW Config Siemens AG 2005 All ri
307. austive discharge protection Accu test e Signaling of current status via LED Normal operation gt 85 full charge Battery standby supply Buffer standby not available alarm e Additional output of all signals via a PC capable interface Type 2EC31 Serial interface Type 2EC41 USB interface In the version with serial interface the connection to the PC is implemented with a 1 1 interconnected 9 pin SUB D connecting cable connector socket Only poles 2 3 and 7 are required Table 2 12 Signal assignment of 9 pin SUB D connector Pin Signal Designation 2 RxD Data cable 3 TxD Negative supply voltage 7 RTS Positive supply voltage 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 13 Signal assignment of USB connector Pin Signal Designation 1 VBUS Supply voltage 2 D Transmitted data 3 D Transmitted data 4 GRD Ground Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 10 Uninterruptible power supply UPS 2 10 2 SITOP POWER ACCU MODULE 24 V DC 10 A 3 2 AH Order number Features Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Fig 2 21 Designation View SITOP POWER lea
308. available in the basic version Max Maximum possible number of components with additional options Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 1 Overview of SINUMERIK 840Di Performance In addition to the system software packages the SINUMERIK 840Di can be options adapted to requirements using various Performance options e Option Advanced Processing 1 e Option Advanced Processing 2 IPO cycles The following minimum IPO cycle times can be set with various system software Position controller cycles packages or using the performance options Basic Universal Plus Basic version 8ms 8ms 8ms Adv Processing 1 4 ms 4 ms Adv Processing 2 2ms Option not available The position controller cycle times are not subject to any restrictions concerning system software packages or performance options 1 1 3 Hardware components PCU PCU interfaces PCU expansion slots MCI2 board The hardware basis for the SINUMERIK 840Di is an industrial PC further re ferred to as PCU PC Unit from Siemens A amp D in conjunction with the MCI board Motion Control Interface The SINUMERIK 840Di is available with the following PCU variants each with 24 V power supply e Celeron 566 MHz 256 MB SDRAM 2 expansion slots e Celeron 1 2 GHz 256 MB SDRAM 2 expansion slots The PCU 50 features interfaces to connect the new SINUMERIK front panels
309. axis gt Tr 1 Amplitude response Graphics1 20 0000 dB Graphics2 60 0000 Graphics1 graphics2 Print graphics Select printer Measure Measuring Axis User Displa File ment parameters MD views functions Fig 13 14 Graphics soft keys Soft key Use the soft key Printer selection to open the appropriate menu Fig 13 15 Printer selection Page 13 449 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 al Toggle key av v Siemens AG 2005 All rights reserved 13 448 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 8 Print graphic y MPF_DIR Start up Jog TEST MPF Channel reset Program aborted ROY Printer desired for output of Start up meas function graphics Active printer Output as bitmap file Accept Fig 13 15 Menu Printer selection Output to Choose the printer to which you wish the file to be output from the list field using printer either the Toggle key or by double clicking with the right mouse button on the desired printer Output as a The graphics is to be saved in a bitmap file bmp bitmap file ae f e Inthe selection field for printer setting set Output as bitmap file e Press the soft key Print graphics
310. axis specific Signals from axis spindle to PLC Positioning axis F function feedrate for positioning axis FB Description of Functions Extended Functions P2 Positioning axes Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 12 Indexing axes Indexing axis Indexing position tables Machine data 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 Machine data e MD 30500 INDEX AX ASSIGN POS _TABfn axis is indexing axis assigns the machine axis the relevant table of indexing positions and also defines the machine axis as an indexing axis The indexing positions are stored in one of 2 possible tables e MD10900 INDEX_AX_LENGTH_POS_TAB_1 number of positions of in dexing table 1 e MD10910 INDEX_AX_POS_TAB_1 n indexing position table 1 e MD10920 INDEX_AX_LENGTH_POS_TAB_2 number of positions of in dexing table 2 e MD10930 INDEX_AX_POS_TAB_2 n indexing position table 2 Table 10 31 Indexing axes machine data Number Name of identifier Name Refer ence General MN_ 10260 CONVERT_SCA
311. be operated on a SINUMERIK 840Di the PLC user pro gram must be adapted to SIMATIC STEP 7 and then loaded into the PLC For how to adapt the PLC user program see Chapter 6 page 6 145 Note SIMATIC STEP7 can be installed directly on the PCU of the SINUMERIK 840Di Installation of additional software on the SINUMERIK 840Di is described in Chapter 15 Page 15 461 Software The following software components are required to start up the HT 6 Basic PLC program The basic PLC program is included on the SINUMERIK 840Di installation CD HT 6 relevant modules of the basic PLC program are FB 1 HT 6 PLC commu nication and FC 26 NC PLC communication For the archiving location of the basic PLC program please refer to Section 1 2 Page 1 35 For use of the PLC basic program see 6 Page 6 145 SIMATIC STEP7 SIMATIC STEP 7 is used for adapting the PLC basic program e g parameter ization of FB 1 HT 6 system software CD ROM optional The HT 6 system software provides the following possibilities Changing the MPI configuration Generating system software abb Loading system software onto PC card Order No 6FC5 453 0AX10 0AG2 software maintenance service References The following manuals are required to start up the HT 6 BH Operator Components Manual Description of the HT 6 interfaces electrical connection at the distributor inter face signals etc IZI Catalog NC Z Connection Components Cables connectors etc Further referenc
312. be the workpiece contour The axis names are used for e Path axes e Synchronized axes e Positioning axes e Command axes e Spindles e Gantry axes e Coupled axes e Guide value coupling axes Table 10 17 Axis names machine data Number Name of identifier Name remarks Refer ence General MN_ 10000 AXCONF_MACHAX_NAME_TAB Machine axis name Channelspecific MC_ 20060 AXCONF_GEOAX_NAME_TAB Geometry axis name in channel 20080 AXCONF_CHANAX_NAME_TAB Channel axis name special axis name in channel References FB Description of Functions Basic Machine K2 Axes Coordinate Systems Frames Actual Value System for Workpiece Chapter Axes 10 5 3 Drive configuration 1 0 addresses 10 312 To allow the NC to communicate with the drives connected to PROFIBUS DP it must know the I O addresses of setpoint and actual value of the axes The I O addresses of the axes set in the SIMATIC S7 project are entered in e MD13050 DRIVE_LOGIC_ADDRESSJn logical I O address For parameterizing the drives with regard to PROFIBUS DP see Section 8 9 page 8 259 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Default values Message frame type Default values 10 5 Axes and spindles The default values of the machine data are dimensioned such that they leave sufficient distance per axis with one measuring circuit each beginning fro
313. c IZI 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 MOP The drives must be secured against accidental moving 8 6 2 Parameterization of the MCP 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 5 Q O J 2 IT IT 9 2 Zi 9 ae 2 IT cu 2 I i 5 KO FIG OF a a eei oO e O o ee m o e w 7 E amp a3 a COM board m O oO O O L 18 Q we Termination Keyswitch X50 S3 DIP switch i Equipotential bonding
314. ce e SINUMERIK HMI Programming Package The HMI Programming Package can be used to integrate OEM high level language applications using standardized interfaces COM OPC This gives the OEM the greatest possible flexibility to design user interfaces using stan dard development tools for example Visual C The HMI programming package essentially contains a description of the interfaces and relevant example applications Detailed information on the OPC interface can be called from the Internet at the address of OPC Foundation http www opcfoundation org Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 1 Overview of SINUMERIK 840Di 1 1 5 Real time properties Real time violations Screen resolution and depth of color As already mentioned Windows XP is not an operating system designed for hard real time requirements Hard real time requirements mean the operating system will respond to an external event within a defined time frame of a few seconds 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 violations occur when unsuitable PC components block interrupt processing for too long stopping the NC system software from being act
315. ce for external monitor Ethernet connection 10 100 Mbaud Interfaces for operator panel LVDS interface for SINUMERIK OP USB interface for SINUMERIK OP internal USB interfaces with Celeron 566 MHz 1 2 GHz 2 x USB interfaces e Expansion slots 1 expansion slot length max 265 mm occupied by the MCI board 1 x shared ISA PCI expansion slot length max 175 mm occupied with option MCI board extension and MCI board extension slot variant Options The following options are offered Mounting bracket Spare part installation References e External floppy disk drive e Memory extension up to max 512 MB DRAM e Distributed configuration of PCU and operator panel front via video link References BH Operator Components Manual Distributed configuration Mounting brackets are required to mount the PCU directly behind the operator panel front Mounting bracket MLFB 6FC5 248 0AF20 2AA0 When installing spare parts please note the following e When replacing the PCU remove the mounting brackets MLFB 6FC5 248 0AF20 2AA0 from the defective PCU and attach to the replacement part The complete documentation on the PCU 50 is to be found in References BH Operator Components Manual Component PCU 50 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 71 2 Hardware Descriptions 01 05 2 5 SINUMERIK Industrial P
316. ce menu 5 132 Service mode 5 134 Services 5 135 Servo gain 10 334 Servo gain factor Kv Definition 10 335 Servo trace 13 422 Setpoint acceptance 8 222 Setting data 10 280 Activation 10 280 Name of identifier 10 280 Normalization of physical quantities 10 288 10 280 Overview Setting the axis specific setpoint parameters 10 316 Setting the ae setpoint actual value parameters Setting the HMI environment 5 127 Settings SF 10 402 0 402 Shielded signal cables 4 111 Shutdown behavior 10 404 Shutting down correctly 1 31 1 32 10 306 Sign of life monitoring Signal distortion SIMATIC ET 200 2 46 SIMATIC Manager STEP 7 7 172 3 213 3 231 8 246 On SINUMERIK840Di SIMATIC S7 I O devices SIMATIC S7 project 6 153 3 216 SIMATIC STEP 7 External computer 6 149 SIMODRIVE drives 8 259 SIMODRIVE 611 universal 8 259 9 269 16 504 BERO 10 374 Max useful motor speed 10 348 Motor monitoring speed Power up PROFIBUS speed evaluation Pulse multiplication factor 10 369 Speed setpoint matching manual 10 338 SIMODRIVE 611 universal E 8 259 16 504 SIMODRIVE 611u See also DP slave 611u 8 259 16 504 16 512 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 Index SIMODRIVE POSMO CD CA 8 259 16 504 10 338 Speed setpoint matching manual SIMODRIVE POSMO SI 8 259 16 504 16
317. ck OB 100 HT 6 is parameterized as the first and only MCP as an example MCPNum One HT 6 exists MCP1In P E 0 0 Address of input data 8 bytes MCP1Out P A 0 0 Address of output data 8 bytes MCP1StatSend P A 8 0 Address of send status data 4 bytes MCP1StatRec P A 12 0 Address of receive status data 4 bytes MCP1BusAdr 14 Default MPI address of the HT 6 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 10 Handheld Terminal HT 6 MCP1Timeout S5T 700MS Default setting MCP1Cycl S5T 200MS Default setting MCPMPI FALSE the HT 6 is operated at the extended MPI bus MCP1Stop FALSE MCP1NotSend FALSE MCPSDB210 TRUE MPI configuration via SDB210 3 Insert call of function block FC27 as 1st line in organization block FB1 4 Insert call of function block FC 26 into the cyclic parts of the PLC program see Fig 7 20 Page 7 200 5 Load the modified blocks into the PLC and then restart the PLC 6 After communication with the PLC has been established the message Waiting for PLC will disappear from the HT 6 main screen The MMC user interface is displayed 7 10 7 Connecting and disconnecting the HT 6 during operation References To be able to connect an HT 6 to or disconnect from an automation system with out any trouble during operation make the following arrangements
318. cle by changing the DP cycle time using STEP7 HW Config To do that proceed as you would for final parameterization of a DP slave 611U See Section 8 9 Page 8 259f FB Description of Functions Special Functions G3 Cycle Times Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Machine data 10 3 System data Table 10 12 Cycle times machine data Number Name of identifier Name remarks Refer 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 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 10062 POSCTRL_CYCLE_DELAY Position control cycle offset 10070 IPO_SYSCLOCK_TIME_RATIO Factor for the interpolator cycle can be freely se Z 10 3 9 Velocities Max axis velocity or spindle speed Max progr Path velocity Max tool path velocity Upper limit 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 control quality for the drive and the better the surface quality on the workpiece The maximum possible
319. coder on motor On a machine axis whose measuring system consists of an absolute value en coder on an ADI4 module the fine resolution configured in the ADI4 must be entered in the machine data e MD30260 MA_ABS_INC_RATIO n encoder fine resolution References ADI4 Analog drive interface for four axes Chapter Function parameters SINUMERIK 840Di Machine data Table 10 23 Number and SIMOTION Reserved bits for fine resolution Incremental measuring systems machine data Name of identifier Axisspecific MA_ 30240 30242 30260 30300 31000 31030 31040 31050 31060 31070 31080 34200 34210 34220 ENC_TYPE n ENC_IS_INDEPENDENT n ABS_INC_RATION n IS_ROT_AX n ENC_IS_LINEAR n LEADSCREW_PITCHn ENC_IS_DIRECT n DRIVE_AX_RATIO_DENOM n DRIVE_AX_RATIO_NUMERAIn DRIVE_ENC_RATIO_DENOM n DRIVE_ENC_RATIO_NUMERAIn ENC_REFP_MODE n ENC_REFP_STATE n ENC_ABS TURNS MODULOjn Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Name remarks Actual value acquisition modes Encoder is independent Encoder fine resolution absolute value encoder Rotary axis Direct measuring system linear scale Leadscrew pitch Encoder is connected directly to the machine Denominator load gearbox Numerator load gearbox Denominator measuring gearbox Numerator measuring gearbox Referencing mode State of absolute encoder Absolute value encoder range for rotary encoder
320. compensation machine data Number Name of identifier Name remarks Refer ence Axis spec MA_ 36720 DRIFT_VALUE Basic drift value G2 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 341 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 5 17 Velocity matching axis Max axis velocity Rapid traverse in JOG mode Axis velocity in JOG mode 10 342 The value entered in machine data e 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 GOO is programmed Depending on MD30300 IS_ROT_AX n the maximum linear and rotary axis velocity must be entered in the machine data The value entered in machine data e MD32010 JOG_ VELO RAPIDfn rapid traverse in JOG mode or e 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 GOO The value enter
321. 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 items both 32 bit in the system variable VA_DP_ACT_TEL Fig 16 2 shows how the process data of the message frame are mapped onto system variable VA_DP_ACT_TEL Index n 0 PDA for expanded message frame PDA Standard message PDA Additional frame drive data Indexn x Index n x 1 Index n y System variable VA_DP_ACT_TEL n a Fig 16 2 Mapping principle PDA on system variable VA_DP_ACT_TEL Notice The responsibility for possibly necessary format conversions or correct interpretation 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 16 2 2 Requirements The following conditions must be met to configure an expanded message frame Drive The drive to be used for the expanded message frame configuration must support customizable message frame configuration in addition to selection of standard message frames Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 503 16 840Di specific Data and Functions 01 05 16 2 Expanded message frame configuration e DP master SIMATIC STEP 7 No additional requirements e SINUME
322. comprises the following modules e SIMATIC station 300 with SINUMERIK 810D 840D and PLC 317 2DP e 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 8 249 1 2 Set the PROFIBUS address 3 Insert the modules in DP slave MCP 483 for the functions required see Fig 8 19 Page 8 249 2 4 Set the I O addresses for the individual slots lo x la x Profile Standard A q SINUMERIK MCP f Universal module g standard g standard handwheel standard extended standard handwheel ex Order number designation l address O address Com 3s standard handwheel extended 0 7 210 gt standard handwheel exten 258 261 192 gt standard handwheel exten 8 12 8 9 Fig 8 19 Configuration with DP slave MCP 483 Preconditions The following status of the S7 project into which DP Slave MCP 483 is to be S7 project inserted is assumed You have created the S7 project You have set up a SIMATIC 300 station with PROFIBUS master capable SINUMERIK controller Insert DP slave To insert a DP slave MCP 483 into the configuration open the hardware cata MCP 483 log with menu item View gt Catalog Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8
323. cremental 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 31010 ENC_GRID_POINT_DIST n Distance between reference marks on linear scales 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_NUMERAfn Numerator load gearbox 32110 ENC_FEEDBACK_POLfn Sign actual value feedback polarity Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 321 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 5 6 Parameterization of absolute measuring systems Encoder types EQN 1325 Calibration Rotary measuring systems Linear axis with rotary absolute encoder 10 322 The following encoder types are currently supported e Single turn absolute value encoder e Multi turn absolute value encoder with EnDat protocol and incremental sinusoidal encoder signals A and B e g Haidenhain EQN 1325 The absolute value encoder EQN 1325 from Heidenhain has the following prop erties e EnDat protocol e PPR count 2048 211 encoder fine resolution e Positions revolution 8192 13 bits e Differentiable revolutions 4096 12 bits e Encoder signals A B 1Vpp sin cos Synchronization of the measuring system with the machine positions is per form
324. customer keys F1 F2 F3 F4 F5 F6 F7 F8 LED17 LED18 LED19 LED20 LED21 LED22 LED23 LED24 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 1 Line Default designation 2 Line LED number Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 257 8 PROFIBUS DP Communication 01 05 8 8 DP slave ADI4 8 8 DP slave ADI4 8 8 1 Slave OM Notice The ADI4 DP slave can only be operated on an isochronous PROFIBUS DP Parameterization of the configuration with regard to the ADI4 interface modules called DP slave ADI4 here is performed with the SlaveOM for SINUMERIK 840Di For how to install the slaveOM see below References Note To simplify parameterization of the isochronous communication on the PROFIBUS DP you must first insert all the DP slaves drives ADI4 I O modules etc you require into the configuration before parameterization of the DP drives before you set the times for isochronous communication 8 8 2 Inserting DP Slave References 8 258 To insert an ADI4 DP slave in the configuration open the hardware catalog us ing the View gt Catalog menu command The DP slave ADI4 is to be found at e Profile Standard PROFIBUS DP gt SINUMERIK gt ADI4
325. d to assign the corresponding software licenses to the SINUMERIK 840Di hard ware During the assignment procedure you will be given a license key that electronically links the software system software or options to the SINUMERIK 840Di 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 60 2 Activate the options SinuCom NC on the relevant SINUMERIK 840Di 3 Obtain the license key for the required control Web License Manager through the Internet on the SINUMERIK 840Di or external PC under www siemens com automation license 4 Complete the entry procedure for the license key SinuCom NC on the relevant SINUMERIK 840Di Control spec administration of the options and licenses is performed exclu sively through SinuCom NC on the SINUMERIK 840Di in question Start SinuCom NC from the Windows taskbar Start gt Programs gt SinuCom NC gt SinuCom NC To license the options you can with the SINUMERIK 840Di you can access the machine data block by double clicking with the left mouse button as soon as SinuCom NC has established the online link Fig 5 4 SinuCom NC Online SinuCom_NC_
326. d acid battery module ae Say AT ue wl bie he Tu A i INOS we SU Lune Order number MLFB SITOP POWER ACCUMODULE 24 V DC 10 A 3 2 AH 6EP1 935 6MD11 The SITOP POWER LEAD ACID MODULE 24 V DC 10 A 3 2 AH features the following It has two maintenance free closed lead acid batteries from the same lot which are installed in a holder and connected in series Complete with battery retainer and terminals Low self discharge rate of approx 3 per month at 20 C Short circuit protection battery fuse 15 A 32 V Class of protection IEC 536 VDE 1006 T1 Class III Degree of protection EN 60 529 VDE 0470 T1 IP 00 2 83 2 Hardware Descriptions 01 05 2 11 I O module PP72 48 2 11 1 0 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 R a eT X1 Power supply H EN ba i ee Dig input outputs 50 pin ribbon cable connector Fig 2 22 I O module PP72 48 Order number Designation Order number MLFB I O module PP72 48 6FC5 611 0CA01 0AA0 Features I O module PP72 48 is a simple and low cost module without a separate hous ing for connecting digital input outputs as part of an automation system based on PROFIBUS DP The module has the following important features e PROFIBUS DP connection max 12 Mbaud specified by PROF IDrive profile drive technology version 3 Draft
327. d cannot be changed Logon of the PCU in a domain is deactivated by default Shown under CUR RENT NETWORK SETTINGS Logon to domain No Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 139 5 Power On and Power Up 01 05 5 6 Configuring the network link of PCU LAN WAN Workgroup Domain Protocol TCP IP Setting the TCP IP parameters Automatic IP addressing DHCP 5 140 If the PCU is a node of a network without a domain server the workgroup names of the external computers to which a network link is to be established must be set to WORKGROUP The PCU is logged into a domain with Toggle logon to domain with key 4 In the following dialog you must enter the domain name and the user password of the user entered under the logon name You can change the domain name under Change Domain Name with key 5 TCP IP protocol is set by default If NetBEUI is displayed you must switch to TCP IP under Toggle Protocol NetBEUI TCP IP and key 3 Note If a network link already existed with the displayed protocol the alternative protocol is not activated until the next time the PCU is started up restart To set or check the TCP IP parameters select Change TCP IP Settings with key 6 The following menu appears PLEASE SELECT Toggle Get IP Adress automatically or manually Change IP Address Change Subnetmask Change Gateway
328. data for drives MD_ from 9000 to 9999 Machine data for operator panel MM_ from 10000 to 18999 NC specific machine data MN_ from 19000 to 19999 Reserved from 20000 to 28999 Channel specific machine data MC_ from 29000 to 29999 Reserved from 30000 to 38999 Axis specific machine data MA_ from 39000 to 39999 Reserved 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 10 2 Overview of setting data Range Designation 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 Siemens AG 2005 All rights reserved 10 280 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 2 Machine and setting data A concise table of all machine and setting data is to be found in References LIS Lists Machine and Sett
329. der 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 completely on first booting Section 5 2 Page 5 115 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 Chapter 8 Page 8 209 5 Prepare the SIMODRIVE 611 universal drives for communication on PROFI BUS DP Chapter 9 Page 9 269 6 Perform start up of the NC channels axes and spindles etc Section 10 5 Page 10 308 7 Set up the alarm texts Chapter 11 Page 11 407 8 Carry out start up of the SIMODRIVE 611 universal drives through PROFI BUS DP using SimoCom U References FBU Description of Functions SIMODRIVE 611 universal 9 Carry out a dry run for all axes and the spindle Chapter 12 Page 12 415 10 Carry out the drive optimization of the SIMODRIVE 611 universal drives us ing HMI Advanced Chapter 13 Page 13 421 and or SimoCom U 11 Carry out a user data backup series machine start up file Chapter 14 Page 14 453 12 If necessary also carry out a complete data backup partition and or hard disk image Section 15 5 Page 15 47
330. 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 MPF DIR Start up Jog TEST MPF Channel reset Program aborted Graphics1 ROY Scaling trace 1 Scaling trace 2 Marker Scaling Awo O Scaling Auto Ymax 1 000000 Ymax 124 327000 Xmax 3000 000000 Y min 1 000000 min 68 525000 X min 0 000000 Identifier on Identifier on Trace 1 Graphics1 Graphics2 Scaling trace 3 Scaling trace 4 Marker Graphics2 Scaling Auto Scaling Auto J Couple with graphic ia Ymax 1 000000 Ymax 1999 980000 Xmax 3000 000000 min 1 000000 min 0 000000 X min 0 000000 lariat Identifier on Identifier on Trace 3 Measure Service Axis User Displa File ment axis MD views functions Fig 13 12 Menu Scaling of graphics 13 444 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 6 Trace function Soft keys Use the Graphics soft key shown in Fig 13 11 Page 13 443 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 13 12 Page
331. 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 e MD36720 DRIFT_VALUE basic drive value Manual Manual drift compensation is performed with the axis at zero speed as follows drift compensation Requirements Zero speed of the axis Axis enables pending e 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 depend ing on the direction of the drift until the axis reaches zero speed e 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 gt Diagnosis gt Service displays gt Service axis spindle Warning If an axis is used for the function DSC Direct Servo Control e 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 10 36 Drift
332. e 2 Traversing to the target point Determining the absolute offset 10 358 The following machine data and interface signals are important e MD34010 REFP CAM DIR IS MINUS approach reference cam in negative direction e MD34040 REFP VELO SEARCH MARKER referencing velocity e MD34060 REFP_ MAX MARKER DIST maximum distance between 2 reference marks e MD34300 ENC_REFP_MARKER_DIST reference marker distance e IS DB21 30 DBX36 2 All axes to be referenced are referenced e IS DB31 DBX4 7 DBX4 6 Traversing keys plus minus e IS DB31 DBX12 7 Reference point approach delay e IS DB31 DBX60 4 DBX60 5 Referenced synchronized 1 2 Properties of phase 1 e If the machine axis traverses a distance defined in MD MD 34300 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 The following machine data and interface signals are important e MD 34070 REFP_VELO_POS reference point positioning velocity e MD 34090 REFP_MOVE_DIST_CORR absolute offset e MD 34100 REFP_SET_POS target point e MD 34330 REFP_STOP_AT_ABS_ MARKER with without target point e IS DB31 DBX60 4 DBX60 5 Referenced synchronized 1 2 Properties of phase 2 e The feedrate override feedrate switch is active e The feed stop channelspecific and axi
333. e Enter a file name You can enter a new file name or select an existing file from the drop down list Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 449 13 Drive Optimization with HMI Advanced 01 05 13 8 Print graphic Soft key Print graphic Printer Bitmap file Naming files Selecting the directory 13 450 Use the soft key Print graphics Fig 13 14 Page 13 448 to output the graphics to the set medium Printer Bitmap file The graphics is output directly to the selected printer If you wish the graphics to be output to a bitmap file the following specifications are still required in the submenu File name for bitmap printout File names Directory File name max 25 characters TEST1 Directory Standard directory Fig 13 16 Menu File name for bitmap printing In the File name group you can select an existing file from the drop down list or enter one in the text field underneath In the Directory group you can select the directory where you want to save the file This can also be a directory in the operating area Services gt 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 References BA Operator s Guide e The file is saved using the soft key OK e With the soft key Cancel you
334. e MD 36220 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 e Alarm 25060 Speed setpoint limiting and stopping the machine axis using a speed setpoint ramp whose characteristic is set in e MD36610 AX_EMERGENCY_STOP_TIME Time for braking ramp when an error occurs Cause of errors error handling e A control loop or drive error is present e Too high setpoint specifications accelerations velocities reducing factors e Obstacle in work area e g positioning on a working table gt Remove obstacle The speed setpoint consists of the speed setpoint of the position controller and the feedforward control parameter if feedforward control is active Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Actual velocity monitoring Contour monitoring 10 5 Axes and spindles Feedforward control value if if to are KV speed ollowing controller error ais pee setpoint monitoring Position controller Fig 10 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
335. e Subsection 16 1 1 Page 16 499 3 Disconnect your PC from power supply 4 Remove the screws from the cover of the housing Fig 2 2 and open the housing of your PC observing the relevant safety regulations Screws of the cover of the housing Fig 2 2 Cover of the housing of the PCU 50 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 2 MCI2 board 5 Optional Remove interconnecting cable to the MCI board extension module interface X2 6 Remove the fastening screw of the module holding down device Fig 2 3 and remove the module holding down device Fastening screw lt lt Board retainer Plastic support Fig 2 3 Mounting of the module 7 Remove the fastening screw of the cover plate of the module 8 Remove the module observing the ESD measures 9 Undo the battery receptacle using a suitable screw driver see Fig 2 4 Fig 2 4 Undo the battery receptacle Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 53 2 Hardware Descriptions 01 05 2 2 MCI2 board 10 Remove the cable connection X3 battery connector from the module 11 Remove the used battery and dispose of it acc to the relevant standards 12 Install the new battery and plug the battery connector onto the connection contacts without applying force X3 X3 Back up battery desi
336. e computational resolution to an integer number Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Display resolution Input and display limit values Machine data 10 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 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 The input value limitation depends on the display options and input options of the operator panel This limit is 10 decimal places plus decimal point plus sign Example of programming in the 1 9 um range All the linear axes of a machine are to be programmed and traversed within the value range 0 1 1000 um To position to 0 1 um accuracy the computational resolution must be set to gt 104 incr mm MD 10200 INT_INCR_PER_MM 10000 incr mm Example of related parts program N20 GO X 1 0000 Y 1 0000 Traverse axis to position X 1 0000 mm Y 1 0000 mm N25 GO X 5 0002 Y 2 0003 Traverse axis to position X 5 0002 mm Y 2 0003 mm Table 10 5 Resolutions machine data Number Name of identifier Name remarks Refer ence General MN_
337. e functional expansions of the NC 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 NC 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 NC system software is performed by loading the compile cycle into the file system of the NC The compile cycle can be loaded at any time The generating step that used to be necessary to link the compile cycle with the NCK system software to form a complete system is no longer required The following technological functions are available from Siemens as loadable compile cycles 1D 8D clearance control in position controller cycle Order No 6FC5 251 0AC05 0AA0 References FB3 Description of Functions Special Functions Chapter Distance Control TE1 Continue Machining at the Contour Retrace Support Order No 6FC5 251 0AE72 0AA0 References FB3 Description of Functions Special Functions Chapter Retrace Support TE7 Fast Laser Switching Signal Order No 6FC5 251 0AE74 0AA0 References FB3 Description of Functions Special Functions Chapter Unclocked Path Synchronous Switching Signal Output TE8 When you order one of the listed
338. e operating system partition E only from an image file The following conditions must be fulfilled e The image file must be present locally on the hard disk of the PCU under D IMAGES see Subsection 15 5 4 Page 15 486 Proceed as described in Subsection15 5 7 Page 15 490 Item 1 to Item 3 The following menu appears Ghost Connection Mode LOCAL Maximum Backup Images lt Max_ number Current Backup Images lt Cur_numbers PLEASE SELECT Configure GHOST Parameters Partitions Backup Mode LOCAL Partitions Restore Mode LOCAL Partition E only Windows Restore Mode LOCAL Delete Image o ORUN Back to previous Menu Your Choice 1 2 3 4 8 9 Choose Partition E only Windows Restore Mode LOCAL with key 4 Following menu PLEASE SELECT 1 PCU Base Software V06 01 04 Win NT 4 0 05 09 2000 05 30 32pm 2 Start up intermediate status 1 05 10 2000 04 03 15pm EMERG 3 Data backup1 06 11 2000 10 34 17am 9 Back to previous Menu Your Choice 1 2 3 9 To complete partition restoration proceed as described in Subsection 15 5 7 Page 15 487 Item 5 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu 15 5 9 Defining an emergency image for partition E Windows Brief description This subsection describes how to define an image f
339. e the follo wing settings in the Properties box e PROFIBUS address of DP master The default setting of the PROFIBUS address is 2 It is recommended to keep this setting e Subnetwork e Equidistant DP cycle e Equidistant time The SINUMERIK 840Di will accept the set equidistant DP cycle as the NC system clock cycle and position controller cycle Position controller cycle NC system clock cycle equidistant DP cycle Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 157 6 PLC Start Up 01 05 6 3 Creating a SIMATIC S7 project 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 PROFIBUS 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 Tab card Parameter Address 2 Subnetwork Button New Dialog box Properties New PROFIBUS Subnetwork Tab card General S7 subnetwork ID lt Subnetwork ID gt see below Note Tab card Network settings Data transfer rate 12 Mbits s Profile DP Button Options Dialog box Options Tab Card Equidistance M Activate equidistant bus cycle M Equidistant DP cycle lt Equidistant time gt OK OK OK Note We recommend making a note of the S7 subnetwork ID since it
340. e undone by reentering the time intended for the isochronous DP cycle Dialog box Group box Isochronous time in ms Continuation Isochronous DP cycle Isochronism time OK OK OK Options x Isochronis Network Lines m node Activate isochronous bus cycle Optimize DP cycle and if nec Ti To Recalculate Number of PGs OPs TDs on the PROFIBUS Configured 0 Total 0 Graduation 2 000 al 0 125 ms Details ymax 32 000 ms Isochronous DP cycle min T 0600 M Synchronization of the slaves Times Ti and To same for all slaves If not Set in properties slaves Fig 8 8 Dialog box Options excerpt Siemens AG 2005 All rights reserved 8 220 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 3 Creating a PROFIBUS configuration Note You are advised not to activate the option Times Ti and To same for all slaves in the Synchronization of the slaves group On tab card Clock synchronization the following parameters are now set for each type of DP slave lsochronous DP cycle Tpp Master application cycle Twapc Actual value acquisition Ti Setpoint acceptance To DP Slave Properties _ x General Configuration DEEE Peer to peer synchronizati transmission NF synchronize drive to equRftant DP cycle ov
341. e value encoder Removal installation of the motor with the absolute value encoder NC SRAM data loss battery voltage failure and PRESET Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 361 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles References Interface signals Notice The status of the absolute value encoder is only automatically reset to 0 encoder not calibrated by the NC on gear change e MD34210 MA_ENC_REFP_STATE n 0 In all other cases it is the sole responsibility of the NC user to indicated the uncalibrated state of the absolute value encoder by setting the status to 0 encoder not calibrated manually and to perform calibration again FB1 Description of Functions Basic Machine R1 Reference point approach Chapter Referencing with absolute value encoders Table 10 39 Referencing Interface signals DB number Bit byte Mode group specific 11 0 7 Tiz 1 2 Mode group specific Adi 5 2 Channel specific ZAREN 1 0 Channel specific APES 28 7 Dfa 33 0 21 2 35 7 21220 36 2 Axis specific sc ae 1 5 1 6 12 2 4 2 7 31 4 6 4 7 31 12 7 Axis specific 31 60 4 60 5 ST 64 6 64 7 Machine data Name Refer ence Signals from PLC to mode group Mode group RESET K1 Machine function REF K1 Signals from mode group to PLC Active machine function REF K1 Signals from PLC to channel Activate
342. eater for PROFIBUS DP 2 13 1 Module Fig 2 27 View Diagnostic repeater for PROFIBUS DP Order number Designation Order number MLFB Diagnostic repeater for PROFIBUS DP 6ES7 972 0AB01 0XA0 Features 2 98 The diagnostics repeater with online line diagnostics for PROFIBUS DP offers the following main features e 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 e Automatic detection of fault type and fault location e Distance given in line diagonistics Resolution 0 5 m Accuracy 1m e Repeater throughput time Baudrates 1 5 Mbaud 2 5 Tpyr 153 ns 12MBaud Tpit 83 3 ns Jitter 1T 1 48 MHz 20 83 ns e Monitoring function of isosynchronous PROFIBUS DP bus cycle Tpp min 1 ms max 32 ms Tolerance range Tpp monitoring 2 us Tolerance range Tpx monitoring 10 us e Supply voltage Rated voltage 24 V DC 20 4 to 28 8 V Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 13 Diagnostic repeater for PROFIBUS DP e 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 e Mechanical design Dimensions B X H X T 80 x 125 x 67 5 Weight 300 g e Degree of protection IP20
343. ecific 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 zones in NCK 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 wo 28200 MM_NUM_PROTECT_AREA_CHAN Number of modules for channel specific FB A3 protection zones Axisspecific MA_ 38000 MM_ENC_COMP_MAX_POINTS Number of intermediate points with interpolatory FB K3 compensation Siemens AG 2005 All rights reserved 10 304 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 4 Memory configuration 10 43 DRAM file system Function Retentive background memory Clearing the NC memory Machine data Cycles For hist
344. ect the directory where you want to save the 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 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 7 File function Creating If you do not wish the data of the trace function to be stored in the default direc subdirectories tory you can create user specific directories New directories are created in the operating area Operating area switchover gt Services gt Manage data New subdirectories can be created below the Diag nosis directory For the description of the operating area Services please refer to References BA Operators Guide Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 447 13 Drive Optimization with HMI Advanced 01 05 13 8 Print graphic 13 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 z MPF DIR Start up Jog TEST_MPF Channel reset Program aborted ROY Graphics1 lt Tr 1 Y1
345. ected with respect to NC PLC and MOP The drives must be secured against accidental moving connection To connect HHU electrically and for MPI communication a distributor box is 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 If you wish to connect more than two HHUs to a bus segment or if the HHU can 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 g ana 840Di al OFF Distribution box MCP p Repeater RS 485 HRY EU OFF Open terminating resistor ON ON ON Closed terminating resistor a TE Fig 7 13 Connecting using a repeater Siemens AG 2005 All rights reserved 7 188 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 9 Handheld unit B MPI 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 References BH Operator Components Manual Chapter Handheld Unit and Distributor Box 7 9 3 MPI parameters of the HHU Setting the MPI The HHU parameters required for MPI communicat
346. ecting an HT 6 to SINUMERIK 840Di 7 10 7 Connecting and disconnecting the HT 6 during operation 7 11 HMI Advanced 7 11 1 Conditions for start up 7 11 2 Parameterization 7 11 3 Default languages 8 PROFIBUS DP Communication 8 1 Gen ral s ss uso tee ane due ay ate bea RE wea cer eee 8 1 1 PROFIBUS DP with Motion Control option 8 1 2 Message frame structure for cyclic DP communication 8 1 3 Description of a DP cycle 8 1 4 Networking rules 8 2 Requirements 8 3 Creating a PROFIBUS configuration 8 3 1 Precondition 284 NN Re dk ooh ano bee ah en ee aa Cae ee 8 3 2 Inserting DP slaves 8 3 3 Final parameterization of the isochronous DP slaves 8 3 4 Generating system data blocks SDB 8 3 5 Loading a configuration into the PLC 8 3 6 PROFIBUS diagnosis 8 4 SIMATIC S7 I O devices ET200 8 5 DP slave I O Module PP72 48
347. ed by calibration of the absolute value encoder in absolute measuring sys tems For calibration of the absolute value encoder see Subsection 10 5 19 Page 10 360 An absolute encoder can currently exclusively be used as a motor encoder in direct measuring system DRIVE_ENC_RATIO_NUMERA motor revs DRIVE_ENC_RATIO_DENOM encoder revs ENC_IS_LINEAR 0 ENC_IS_DIRECT 0 IS_ROT_AX 0 Encoder Load x gearbox Table C f s u 7 z ter ES Ball screw io WN O ON S Measuring z x gearbox NS NSpindle LEADSCREW_PITCH Motor ENC_TYPE 4 ENC_ABS_TURNS_MODULO 4096 ENC_REFP_MODE 2 DRIVE_AX_RATIO_NUMERA motor revs a DRIVE_AX_RATIO_DENOM spindle revs Fig 10 10 Linear axis with absolute value encoder on motor Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Rotary axis with absolute value encoder on motor ADI4 10 5 Axes and spindles DRIVE_ENC_RATIO_NUMERA motor revs DRIVE_ENC_RATIO_DENOM encoder revs ENC_IS_LINEAR 0 ENC_IS_DIRECT 0 i Load Encoder Load IS_ROT_AX 1 _ Rotary table i Gearbox HAE s OOO Measuring Gearbox n DRIVE_AX_RATIO_NUMERA motor revs Shae aw eae DRIVE_AX_RATIO_DENOM load revs ENC_ABS_TURNS_MODULO 4096 ENC_REFP_MODE 2 Fig 10 11 Rotary axis with absolute value en
348. ed in machine data e MD32020 JOG_VELO n axis velocity in JOG mode or e 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 e for linear axes D41110 JOG SET VELO 0 e for rotary axes D41130 JOG_ROT_AX_SET_VELO 0 or e at revolutional feed SD41120 JOG_REV_SET_VELO 0 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 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 gt linear feed G94 e Linear axes JOG velocity SD41110 JOG_SET_VELO JOG velocity for G94 e 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 e JOG velocity SD41120 JOG_REV_SET_VELO JOG speed with G95 The entered value may not exceed the max permissible axis velocity Notice e Depending on MD30300 IS_ROT_AX n the velocities have to be entered in mm min inch min or rpm e If the velocities change MD 36200 AX_VELO_LIMIT n threshold value for velocity monitoring must be adapted accordingly
349. eed control and follow up mode Tolerance window for a standing machine axis while the signal Clamping active is present at the PLC interface e MD36050 CLAMP_POS_TOL clamping tolerance e 1S DB31 DBX2 3 clamping active e Alarm 26000 Clamping monitoring Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 345 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Setpoint Actual point RS A CE IS Exact stop coarse IS Exact stop fine IS Clamping active CLAMP_POS_TOL STANDSTILL_POS_TOL STOP_LIMIT_COARSE STOP_LIMIT_FINE STANDSTILL_ DELAY_TIME POSITIONING_TIME Time t Fig 10 18 Static monitoring functions Working area limitation Software Limit switch 10 346 The permissible working area of the machine axes can be adapted to the partic 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
350. elevant modules of the basic PLC program are FB 1 MCP commu nication parameters FC 19 interface parameter assignment version milling and FC 25 interface parameter assignment version turning The PLC basic program is included on the SINUMERIK 840Di installation CD The installation of the basic PLC program as a SIMATIC S7 library is described in Section 6 4 page 6 161 in detail Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 177 7 MPI Communication 01 05 7 7 Machine control panel 19 or MCP SIMATIC Manager SIMATIC Manager is used for adapting the basic PLC and user programs e g call of FC 25 References The following manuals are required to start up an MCP FB1 Description of Functions Basic Machine P3 Basic PLC Program Description of the program structure and modules of the PLC basic program BH Operator Components Manual Description of MCP interfaces electrical connection etc IZI Catalog NCZ Connection Components Cables connectors etc Automation To start up the MOP the automation system must be completely electrically and system mechanically connected with respect to NCK PLC and MOP The drives must be secured against accidental moving 7 7 2 Parameterization of the MCP Interfaces Fig 7 7 below shows the interfaces on the rear of the module Connection for equip
351. emens AG 2005 All rights reserved 16 504 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specific Data and Functions Step 1 Configuring the DP master Default configuration Extended message frame configuration Dialog box 16 2 Expanded message frame configuration Before performing the expanded message frame configuration you need to configure the DP slave 611U with the standard message frame required for this drive For information on how to perform a standard configuration of the DP master please see Section 8 9 Page 8 259ff To transfer the additional process data you need to change the configuration of the DP slave 611U as follows 1 The length of the PDA which is already configured with the standard mes sage frame must been 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 Dialog box DP slave properties Tab card Configuration Actual value gt length lt Length standard PDA length add PDA PDA gt Setpoint gt I O address lt I O address actual value gt see above 2 OK Notice e The I O address for setpoint and actual values of an axis must be the same 1 0 address actual value I O address setpoint e The I O address set by the SlaveOM for an axis mus
352. emens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 51 2 Hardware Descriptions 01 05 2 2 MCI2 board AN 2 52 Warning When operating electrical devices it is impossible to avoid applying hazardous voltages to certain parts of the equipment 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 provided 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 instructions for repair and replacement To change the battery proceed as follows 1 Changing the battery SRAM is not backed up during this time can result in data loss in the SRAM of the MCI board To avoid an expensive new start up make sure that an appropriate series machine start up file NC and PLC exists prior to the battery change For information on how to create a series machine start up file please refer to Chapter 14 Page 14 453 2 Shut down the SINUMERIK 840Di and Windows XP correctly Use one of the following methods to do this e Windows XP taskbar Start gt Shut Down e Interface signal PC shutdown se
353. ended Functions A4 Digital and Analog NCK I Os 10 6 1 Parameterization of the number of inputs outputs used Max number 10 382 The maximum number of digital or analog input outputs that can be used for the NC is Total MCI board PROFIBUS extension Modules Analog inputs 8 8 Analog outputs 8 a 8 Digital inputs 36 4 32 Digital outputs 36 4 32 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Machine data 10 6 Digital and analog I O devices 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 additional input output bytes to the PROFIBUS DP via signal modules See configuration example Subsection 10 6 6 Page 10 387 The number of used analog and digital inputs outputs is set in the following ma chine data parameters Analog I Os e MD10300 FASTIO_ANA_NUM_INPUTS Number of active analog NC in puts e MD10310 FASTIO ANA NUM OUTPUTS Number of active analog NC outputs Digital input outputs e MD10350 FASTIO_DIG_NUM_INPUTS Number of active digital NC input bytes e MD10360 FASTIO DIG_ NUM OUTPUTS Number of active digital NC output bytes 10 6 2 Assignment of inputs outputs to the signal modules Machine data On the NC side the analog and digital inputs outputs are assigned to the re specti
354. engineer s responsibility to ensure that the parameter settings are consistent in the SINUMERIK 840Di NC and all relevant drives for which torque reduction is being performed The following data must be consistent in terms of values and meaning 1 SINUMERIK 840Di NC machine data MD 37620 PROFIBUS_TORQUE_RED_RESOL torque reduction resolution on PROFIBUS LSB weighting 2 Drive with automatic adjustment Parameter P0881 Torque reduction evaluation with manual adjustment parameter that corresponds in meaning to parameter P0881 If automatic adjustment cannot be performed by the SINUMERIK 840Di NC due to requirements that are not met of if the drive returns a value for parameter P0881 that lies beyond the NC machine data limit values or if the torque reduction is not rescaled on the NC end no alarm is issued The machine data e MD 37620 PROFIBUS TORQUE RED RESOL torque reduction resolution on PROFIBUS LSB weighting is effective in all cases independently Siemens AG 2005 All rights reserved 16 514 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specific Data and Functions 16 3 Travel to fixed stop with high resolution torque reduction 16 3 6 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 Minimum input limit 0 Maximum input limit FFFF FFFF
355. ension slot variation Operator panel fronts 2 46 Spare parts 2 45 Hardware limit switches Hazards Backup battery 2 51 HMI Advanced PROFIBUS diagnosis Series start up 14 456 HMI configuring package 1 26 HMI Explorer 5 131 HMI modular system 1 26 HPU Connecting disconnecting during running operation 7 195 7 203 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Digital analog I O modules Max number of inputs outputs 10 382 System variables Identification of the control 1 39 Incremental measuring systems Parameteriza tion 10 319 _ Indexing axes 10 331 Indexing position tables Industrial PC 2 70 Initial settings Initial start up 611 i 9 260 Recommended order 5 114 Initiate NC Reset 6 164 Input limits Input resolution Installation 5 115 5 131 Installation directory 5 131 Installed components Basic software 1 35 Engineering tools 1 35 SIMATIC S7 add on software 1 36 Installing languages packages Interface description MCI board MCI board extension 2 61 PP72 48 2 85 Interface overview ADI4 2 49 2 61 Interface signal PC OS fault 1 29 PC shutdown 1 29 Interface signals 840Di specific 16 499 Not supported Interface version 10 394 Interface versions Dependencies 10 394 Interfaces MPI interface 7 178 7 185 3 229 Interpolation cycle 10 297 IPO cycles
356. enu PLEASE SELECT Set Connection Mode PARALLEL Set Connection Mode LOCAL Change Backup Image Filename Change Restore Image Filename Change Machine Name for Windows and DOS net Manage Network Drives o OnhWN Back to previous Menu Your Choice 1 2 3 4 5 6 9 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu Computer name To change the computer name choose Change Machine Name for Win dows and DOS net with key 5 The computer name is changed at the Windows and DOS levels This function permits assignment of a unique computer name e g on first start up by importing a hard disk image series start up or when replacing a defective hard disk on a PCU Note In networks where the function Microsoft Domain Security is active changing the computer name causes new system and user IDs to be generated This even applies of the same computer name is used again The computer and local user must then be re administered in the network e Phone line type To set the connection mode Network Connection choose the menu item Set Connection Mode LOCAL with key 2 e Network parameters If network parameters have not yet been set for the PCU you can make the settings now To set the network parameters of the PCU choose Manage Network Drives wi
357. er 10 360 Calibration of multiple axes 10 361 Operator assisted calibration Recalibration 10 361 Absolute measuring systems Parameterization 10 322 Acceleration 10 336 Access authorization ACCU 2 83 Actual value sensing 8 222 9 273 2 47 2 96 8 258 _ Drift compensation Drive configuration NC 10 314 10 315 See also ADI4 DP slave Speed setpoint matching ADI4 DP slave inserting 8 258 Adjust 8 223 Advanced Processing 1 1 23 Advanced Processing 2 1 23 Alarm 4065 10 401 Alarm and message texts 11 407 MBDDE INI configuration file 11 407 Standard text files 11 408 User text files 11 408 Alarm numbers 11 410 Alarm text files Syntax 11 410 Alarm texts 11 407 As delivered state 15 495 Assigning actual value channels 10 316 Assigning setpoint channels 10 316 Authorizing SIMATIC STEP 7 Automatic controller setting Axes 10 308 Axis Monitoring functions 10 345 Parameter sets 10 332 Reference point approach Velocity matching Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Axis assignment 10 309 Axis configuration Axis names 10 311 Channel axes 10 311 Geometry axes 10 312 Machine axes 10 311 Axis velocity in JOG mode 10 342 B Background image User specific 5 130 Backup battery 10 402 MCI board 2 49 Monitoring Basic start up 5 117
358. er The 1st digit of the interface version number of a compile cycle and the NC system software must be equal Siemens AG 2005 All rights reserved 10 394 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced SW version of a compile cycle 10 7 Loadable compile cycles e 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 NC system software Caution If alarm 7200 is displayed after start up this means no compile cycle has been loaded The SW version of a compile cycle is displayed under HMI Advanced Diagnosis gt Service displays gt Version gt NCU Version Display excerpt CC Interface Version NCKOPI Loaded Compile Cycles lt ldentifier gt lt Version gt lt Date generated gt CC start address _N_ lt dentifier lt Version gt lF lt 1st digit gt lt 2nd digit gt ELF Code lt Address gt Data lt Address gt Example _N_CLC4071F003001_ELF corresponds to SW version 4 7 Note The display of code and data range start addresses of a compile cycle are provided for diagnostics purposes only and have no significance in normal operation 10 7 2 Restrictions Interface versions Dependencies The following checks are performed for all loaded compile cycles when the NCK boots If the interface version of the compile cycle is
359. er Name of identifier Name remarks Refer ence 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 Axisspecific MA_ 38010 MM_QEC_MAX_POINTS Number of values for quadrant error FB K3 compensation AAD 10 42 SRAM memory Free memory Reconfiguation of the SRAM memory Machine data The free SRAM memory is displayed in machine data e MD18060 INFO FR E 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 Modifying the machine data listed in Table 10 14 results in a reconfiguration of the SRAM with a loss of all user data Before the change comes into effect in the NC the following alarm message is output e Alarm 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 14 2
360. er completion of the check the system with the restored backup copy is ac tive Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 481 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu 15 5 3 Configuring the Ghost parameters Brief description Requirements Operator action 15 482 This subsection describes how to configure the Ghost parameters for transmis sion of image files during hard disk back up from to a shared directory on an external computer No special requirements need to be fulfilled After the PCU has been switched on the menu of the boot manager is dis played Select the menu option Service menu hidden using the CursorDown key and then press the Input key The main service menu is displayed after PCU start up Select one after the other from the main menu Key 7 Backup Restore Key 4 Partitions Backup Restore with Ghost locally The following menu appears PLEASE SELECT 1 Configure GHOST Parameters 2 Harddisk Backup to lt PATH gt Mode 3 Harddisk Backup from lt PATH gt Mode 9 Back to previous Menu Your Choice 1 2 3 9 Choose Configure GHOST parameters with key 1 to set the following param eters Machine name computer name Phone line type Network parameters Network connection Path and file name Split mode Following m
361. er system see Subsection 1 1 9 Page 1 32 3 Replacing the MCI board or 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 its battery is replaced after a power failure this will result in a data loss of the user data battery backed on the SRAM of the MCI board How to proceed further see Subsection 5 3 4 Page 5 121 The SINUMERIK 840Di monitors three different temperatures for their respec tive thresholds 1 Housing temperature 2 CPU module temperature 3 CPU temperature Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 1 Overview of SINUMERIK 840Di Error response e Alarm 2110 NCK temperature alarm e Logbook entry Alarm Critical temperature values Case lt Temp gt C CPU module lt Temp gt C CPU lt Temp gt C On a temperature alarm a logbook entry records the temperature measured in the following components case CPU module and CPU Cause of errors error handling One of the three monitored temperatures has reached or exceeded its thresh old The temperature must fall to at least 7 C below the threshold before the alarm is reset If the temperature alarm occurs the user and or the machine manufacturer PLC program must decide whether to interrupt machining and end and shut
362. erally 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 The NC system software mostly has the same functionality as the SINUMERIK 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 The NCK Numerik Control Kernel is part of the NC system software that real izes the real time capability of the SINUMERIK 840Di 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 standard user interface 840Di start up Menu command Window gt Diagnosis gt NC PLC The NCK is automatically ended when Windows XP is ended Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 25 1 General Notes on the SINUMERIK 840Di 01 05 1 1 Overview of SINUMERIK 840Di Distribution of CPU time PLC system software SinuCom NC 840Di start up Optional HMI components 1 26 When the NCK is ended it writes the SRAM data from NC and PLC to the hard disk of the
363. erences DA Diagnostics Guide For systems with HMI Advanced you can refer to the online help Siemens AG 2005 All rights reserved 16 510 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specific Data and Functions 16 3 Travel to fixed stop with high resolution torque reduction 16 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 Chapter F1 Travel to fixed stop 16 3 1 Description of Functions With 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 For PROFIBUS drives up to now the torque reduction was at a resolution of 1 and could not be changed You can now set the torque reduction in the range from 0 01 to 10 providing the required NC and drive parameters have been set 16 3 2 Requirements Basic requirements Automatic adjustment The following basic requirements must be met to set the parameters for torque reduction resolution There must be a parameter in the drive via which the resolution for the torque reduction can be set at the drive end The drive is operating with a message frame type containing the control word TorRed torque reduction e g SIMODRIVE standard message frame 102 to 107 To simplify the start up
364. erface 2 8 1 Floppy disk drive 3 5 Order number Designation Order number MLFB Floppy disk drive 3 5 incl 0 5m connecting cable 6FC5 235 0AA05 0AA1 Cover spare part 6FC5 247 0AA20 0AA0 Features The diskette drive is used to read in data and programs from to 3 5 diskettes with a 1 44 Mbyte capacity The diskette drive has the following features e Can be inserted into customized operator panel fronts e Bootable e Input voltage 24 V DC e Power consumption max 5W e Degree of protection to DIN EN 60529 IP 54 front IEC 60529 IP 00 rear e Humidity rating based Cl 3K5 without condensation and on DIN EN 60721 3 3 ice formation Lowest air temperature 0 C References For a complete description of the external 3 5 floppy disk drive please refer to References BH Operator Components Manual 3 5 diskette drive Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 77 2 Hardware Descriptions 01 05 2 8 Floppy disk drives 2 8 2 3 5 floppy disk drive with USB interface Order number Designation Order number MLFB 8 5 diskette drive with USB interface 6FC5 235 0AA05 1AA2 incl 1 m USB connecting cable Cover spare part 6FC5 247 0AA20 0AA0 Features The diskette drive is used to read in data and programs from to 3 5 diskettes with a 1 44 Mbyte capacity The diskette drive has the following features e USB interface Version 1 1 e Can be
365. erface 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 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 e Open the appropriate S7 project in the SIMATIC Manager S7 e Select the appropriate station in the example project SIMATIC 300 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 9 275 9 Drive Start Up 01 05 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI e Open the hardware configuration of the station double click with left mouse button on Hardware HW Config will be started e Open DP master in the example project DP master double click with left mouse button on DP master e 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 Group box Inter
366. eries start up file Finish Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 14 457 14 User Data Backup Series Machine Start Up 01 05 14 3 Considerations when saving PLC data 143 Considerations when saving PLC data Original image Instantaneous image Inconsistent image 14 458 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 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 If you cannot use the procedure described above you can use the following 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 An inconsistent image results if a series machine start up file with PLC data is created and the PLC is in the status RUN cyclic operation The data blocks of the PLC
367. erminal e g HT 6 Handheld unit e g B MPI Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 171 7 MPI Communication 01 05 7 4 Requirements 7 4 Requirements As a condition for creating an MPI configuration using the default configuration the following components are required e SIMATIC STEP 7 e 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 supply of the SINUMERIK 840Di SIMATIC STEP 7 SIMATIC STEP 7 option is required in the following version or later e SIMATIC STEP 7 as from Version 5 2 Service Pack 1 SIMATIC STEP 7 can either be installed directly on the SINUMERIK 840Di PCU or on an external computer PG PC SINUMERIK 840Di If SIMATIC STEP 7 is installed in the SINUMERIK 840Di no additional MPI cable is required to load the configuration into the PLC because Windows ap plications that are executed on the SINUMERIK 840Di have direct access to the PLC via the internal MPI interface on the MCI board Installation of additional software on the SINUMERIK 840Di is described in de tail in Chapter 15 Page 15 461 External computer If SIMATIC STEP 7 is installed on an external computer PG PC it must fulfill the following conditions e MPI interface parameterized with 187 5 kbaud e MPI connection between external computer and SINUMERIK 840Di Archive f
368. erview Network settings in ms Equidistant bus cycle activated aes 2 000 Cyclic portion of equidistant master 1 258 ser aaen partoj Increment base time ms yde meed 2 000 1 x 2 000 Factor Increment base time ms DP cycle msec 2 000 fis H x 0 125 Time Ti ms Raita Increment base time ms actual value acquisitign 0 125 X 0125 Tetis Faster Increment base time ms etpoint acceptafice 1 500 T i2 X 0125 Cancel Help Fig 8 9 Dialog box DP slave properties DP cycle The DP cycle of DP slave 611U must be set to the cycle time of the DP master y T displayed under gt Isochronous DP cycle in group box Network settings in DP play ms Notice For DP cycle time Tpp the following condition must be fulfilled DP cycle isochron DP cycle Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 221 8 PROFIBUS DP Communication 01 05 8 3 Creating a PROFIBUS configuration Master application cycle Twapc Dialog box Continuation Actual value acquisition Ti Dialog box Continuation Setpoint acceptance To 8 222 Via parameter Master Application Cycle Tmapc defines the integer ration be 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
369. es described above communication ls Twarc gt lt M NC Position controller R R and interpolator Pos interpol p Tpp a DX p PROFIBUS DP msG RES Gcl DxlDxiDx Mmsal RES ecl DxlDx Dx DP slave Signal module Fig 10 32 Time response when outputting an output signal with optimized DP cycle 10 386 Key to Fig 10 32 Tmapc Top Tpx Tu GC Master application cycle NC position control cycle the following always applies for SINUMERIK 840Di Tuapc Top DP cycle time DP cycle time Data exchange time Sum of transfer times of all DP slaves Master time Offset of the start time for NC position control Global control Broadcast message for cyclic synchronization of the equidistance between DP master and DP slaves Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 6 Digital and analog I O devices R Computational time of position controller and or signal module Dx Exchange of user data between DP master and DP slaves MSG Acyclic services e g DP V1 pass token RES Reserve active break until the equidistant cycle has elapsed G Set the system variables e g A_OUT 8 in the parts program or synchronized action Tran
370. es of the system software because this might affect the export license requirement In addition to the information provided on the delivery note and invoice the hardware components supplied with the system software are also clearly identified by adhesive labels as standard or export versions 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 39 1 General Notes on the SINUMERIK 840Di 01 05 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 e HMI Advanced option Diagnosis operating area gt Service displays gt Version gt 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 Overview of functions Menu bar Context sensitive menu functions 1 40 The user interface 840Di start up included in the scope of supply of the SINU MERIK 840Di is intended as an initial introductio
371. es on the HT 6 FBPH Description of Functions HT 6 Configuring the HT 6 user interface AAM IBN HMI Chapter Installation and Start Up HT 6 Automation To start up the HT 6 the automation system must be completely electrically and system mechanically connected with respect to NC PLC and HT 6 The drives must be secured against accidental moving Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 197 7 MPI Communication 01 05 7 10 Handheld Terminal HT 6 7 10 2 Connections To connect HT 6 electrically and for the MPI communication a distributor box is used Notice Under no circumstances may the MPI connector for connecting the HT 6 be enabled since the HT 6 already contains an integrated bus terminator Please observe the warning notices with respect to the MPI cables and the EMERGENCY STOP jumper in the detailed description see below References For a detailed description of the electrical and mechanical design of the distribu tor box as well as for the electrical and data interfaces of the HT 6 please refer to References BH Operator Components Manual Chapter Handheld Terminal HT 6 7 10 3 Adapting the MPI configuration NETNAMES INI NCK address To operate an HT 6 in combination with a SINUMERIK 840Di the NCK address must be adapted in file NETNAMES INI in section param NCU_1 NCK address for SINUMERIK 840Di nck_address 2 rack_slot 4 sap 1 Examp
372. esponding to slot X2 e PLC The PLC has access to both PROFIBUS interfaces Note e PROFIBUS 1 interface X101 corresponding to slot X2 As this is the interface via which the drives are connected the PROFIBUS can only be operated in DP Master mode e PROFIBUS 2 interface X102 corresponding to slot X1 The interface can be operated both in DP Master and in DP Slave mode Please refer to the relevant SIMATIC documentation for how to connect the PLC to the higher level DP master as a DP slave a HW Config SIMATIC 300 1 Configuration SIN840Di aly Station Edit Insert Target System View Tools Window Help See a e db eS R vi PLC related DP slaves PROFIBUS 2 DP master system 2 0 840Di PLC 317 2DP 2AJ10 PROFIBUS 1 DP master system 1 o e 13 ADI4 4 Fig 8 6 Recommended distribution of DP slaves schematic 1 Machine control panel MCP 483 MCP310 2 and 3 ET200 I Os 4 SIMODRIVE 611 universal 5 SIMODRIVE POSMO A 6 SIMODRIVE SI CD CA 7 ADI4 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 217 8 PROFIBUS DP Communication 01 05 8 3 Creating a PROFIBUS configuration If you are using both PROFIBUS connections we recommend the following distribution of DP slaves e PROFIBUS 1 Interface X101 corresponding to slot X2 NC specific I Os Drives e g SIMODRIVE 61
373. et and made an entry in e MD34090 REFP_MOVE_DIST_CORR absolute offset the position measuring system must be re referenced FB1 Description of Functions Basic Machine R1 Reference point approach Chapter Referencing on linear measuring systems with distance coded reference marks Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 359 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Absolute encoder Follow up referencing Calibration Operator assisted calibration 10 360 Initial referencing of the measuring system of a machine axis with absolute value encoder is performed by calibrating the encoder Follow up referencing of a machine axis is performed automatically while the NC starts up without axis movement The following conditions must be fulfilled e The measuring system of the machine axis active after NC start up works with the absolute value encoder e The absolute value encoder is calibrated MD 34210 ENC_REFP_STATE n 2 absolute value encoder is cali brated To calibrate the the absolute encoder the actual value of the encoder is matched with the machine zero once and then enabled The SINUMERIK 840Di supports the following types of calibration e Operator assisted calibration e Automatic calibration using probe e Calibration using BERO The calibration using the probe and BERO is described in References FB Description of Funct
374. et the specifications according to Table 2 22 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 11 1 0 module PP72 48 Table 2 22 Specification of the power supply voltage P24OUT Voltage Minimum 20 4V Nominal 24V Maximum 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 Maximum approx 40 W On the module side the power supplies must be protected against e Polarity reversal e Short circuit elec current limitation of the outputs e 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 gt 10 mm A Caution A protective conductor must be connected Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 93 2 Hardware Descriptions 01 05 2 11 I O module PP72 48 2 11 5 Dimension drawing
375. etwork the PCU belongs to For information on syntax see above IP address e Gateway optional Select Change Gateway with key 4 Enter the IP address of the standard gateway via which the PCU can ex change data with other networks For information on syntax see above IP address e Domain Name Server optional If a domain name server exists in the network select Domain Name Server with key 5 Enter the IP address of the Domain Name Server that is to be contacted when a connection is established to the external computer For information on syntax see above IP address e DNS extension optional If adomain name server exists in the network select Change DNS Exten sion with key 6 Enter the DNS extension to be used to extend the name of the external computer to its full domain name Example Computer name COMPUTER_1 DNS extension COMPANY COM Domain name of external computer COMPUTER_1 COMPANY COM The network link using manual parameterization is now configured Confirm the query whether you want to store the network parameters when you exit the menu with key Y the settings are stored Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 141 5 Power On and Power Up 01 05 5 7 License management 5 7 License management SinuCom NC Option menu License key 5 142 To use SINUMERIK 840Di system software and the activated options you nee
376. existing text is to be used this can be done with a reference to the corresponding alarm 5 digit alarm number instead of text e 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 e Parameter 1 Channel number Parameter 2 Block number The ASCII file for PLC alarm texts has the following structure Table 11 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 FDDISd 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 References FB Description of Functions Basic Machine P3 PLC Basic Program This number defines the alarm display type 0 Display in alarm line 1 Display in a dialog box Default setting O means The help file supplied by Siemens provides a detailed description of the alarm A value between 1 and 9 uses an assignment entry in the MBDDE INI file to refer to a help file created by the user See also Subsection 11 1 5 Page 11 412 Section HelpContext Siemens AG 2005 All rights reserved SINUMER
377. external computer di rectly via a crossed Ethernet cable twisted pair crossed 10baseT 100baseT X ethernet cable SINUMERIK 840Di PCU 50 PG PC e g PG 740 Ethernet cable Twisted pair crossed 10baseT 100baseT X Fig 15 1 PTP link PCU 50 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 4 RD Pin 4 RD UTP connector Fig 15 2 Crossed Ethernet cable twisted pair crossed 10baseT 100baseTX Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 461 15 Software Installation Update and Data Backup 01 05 15 1 PTP network link Windows Network protocol TCP IP Requirements on the ext computer The network protocol used is TCP IP TCP IP permits high data transmission rates and it is simple to configure TCP IP is preconfigured both in the PCU ba sic software and in the service menu The following requirements must apply on the external computer A network adapter is installed The TCP IP network protocol is installed The external computer is connected with the PCU via crossed Ethernet cable The IP address of the external computer is within the same subnet as the PCU A directory is shared as the network drive 15 1 2 Configuring the external computer Windows NT TCP IP protocol Dialog b
378. ey With the Start soft key trace function recording is started an With the Stop or RESET soft key you can cancel a running measurement Soft key Within the framework of the trace function it is also possible to select data using Physical its physical address Physical address f rtace amp Segment address 0000 Hex Offset address 0000 0000 Hex Bit mask FFFFFFFF Hex Threshold 00000000 Hex Fig 13 10 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 information provided by the known signals see Signal selection list field is not adequate 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 OOFF Word 0000 FFFF Double word FFFF FFFF Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 441 13 Drive Optimization with HMI Advanced 01 05 13 6 Trace function Input field Threshold Individual bits xxxx xxxx 1 selected 0 not selected
379. f SINUMERIK OP TP operator panel fronts and the SINUMERIK PCU The features include the following e Communication with the PCU is performed via Industrial Ethernet 10 100 Mbaud in a separate sub network with DHCP server on the PCU e Permits large distances maximum possible distance between two network nodes access points approx 100 m between the PCU and operator panel front e Graphics resolutions 640x480 to 1024x768 pixels depth of color 16 bits e Interfaces Ethernet 10 100 Mbaud Compact Flash 2x USB 1 1 for connection of mouse and keyboard Interfaces for operator panel LVDS interface for SINUMERIK OP USB interface for SINUMERIK OP internal Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 75 2 Hardware Descriptions 01 05 2 7 TCU Thin Client Unit References Comprehensive documentation about the configuration and commissioning of the TCU are to be found in Design References BH Operator Components Manual Distributed configuration with TCU Startup References AAM HMI Installation and Startup Manual TCU Installation and Startup IM5 Siemens AG 2005 All rights reserved 2 76 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 8 Floppy disk drives 2 8 Floppy disk drives g API IE Er EIE a EET PE LE NE SA EE Po 19 Ki A Fig 2 18 External 3 5 diskette drive and 3 5 with USB int
380. f differential handwheels the following signals are used MPGx_A MPGx_B MPGx_XA MPGx_XB e Inthe case of TTL handwheels the following signals are used MPGx_A MPGx_B M 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 Please note the following points about sensor probes The sensor probes are isolated from each other and from all other potential areas board electronics dig inputs dig outputs and handwheels The sensor probes are isolated among themselves and from the board electron ics Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 63 2 Hardware Descriptions 01 05 2 3 MCI board extension slot variant 2 3 4 Technical data Table 2 7 Technical data for MCI board extension slot version Safety Degree of protection IP 20 Protective class Protection 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 Climatic ambient conditions Heat dissipation Open circuit ventilation Operation Transportation storage Temperature limit
381. f input signals MCP1Out POINTER Address of MCP 1 output signals The MCP2 parameters are only needed if a 2nd MCP is used in addition to the 1st MCP MCP2In POINTER Address of input signals MCP2Out POINTER Address of output signals The parameters listed below serve to synchronize two MCPs MCP1Stop BOOL Transfer of each operator component MCP2Stop BOOL FALSE start TRUE stop MCP1NotSend BOOL Send and receive operation of each MCP2NotSend BOOL operator component FALSE send and receive active TRUE only receive active Notice Parameter MCPNum Up to and including version 7 1 of the basic PLC program parameter MCPNum should always be set to 0 Parameter MCPxStop and MCPxNotSend These parameters are irrelevant for connection via PROFIBUS DP Siemens AG 2005 All rights reserved 8 238 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication VDI interface parameter assignment Example PLC user program 8 6 DP slave MCP 310 References For a detailed description of the basic PLC program or of function block FB 1 please refer to FB1 Description of Functions Basic Machine PLC Basic Program P3 Chapter FB 1 RUN_UP Basic program startup section The following function blocks can be used to assign the VDI interface e FC 24 Machine control panel MCP 310 version M milling Notice Function blocks FC 19 FC 24 and FC 25 a
382. f 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 7 5 GD circle parameters Parame Designation HHU Default Value ters 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 7 17 Page 7 192 e 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 7 17 Then the first GD circle parameter is displayed e Modify value The value of a GD circle parameter can be modified within its admissible range of values using the or keys see Fig 7 17 e Display next parameter Press the 2nd key from the left in the uppermost key row see Fig 7 17 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 aa Actual value 1 re feo i MO Ac
383. face Type PROFIBUS Address 2 Button Properties Dialog box Properties PROFIBUS interface DP Master Tab card Parameter Subnetwork PROFIBUS Button Properties 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 9 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 gt 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 Siemens AG 2005 All rights reserved 9 276 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 9 Drive Start Up 9 2 Installing SimoCom U 9 2 Installing SimoCom U Installation Scope of functions Online help References SimoCom U is part of the 611U toolbox supplied with the SINUMERIK 840Di in directory e Installation directory See Section 1 2 Page 1 35ff Engineering Tools gt SIMODRIVE 611 Unive
384. factor resulting following error in mm Velocity m min Ky Following error mm i e with a Kv factor of 1 and a velocity of 1 m min the following error will be 1mm Via e 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 e MD10230 SCALING_FACTORS_USER_DEF 9 16 666667 e 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 e MD32260 RATED_VELO e MD32250 RATED_OUTVAL e Tacho adjustment on the speed controller e 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 Ky factor or dynamic response adaptation in e MD32900 DYN_MATCH_ENABLE e MD32910 DYN_MATCH_TIME The real servo gain factor can be checked with the following error in the service display e e g HMI Advanced Operating area DIAGNOSIS gt Service displays gt Service axis Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 335 10 NC Start Up w
385. fic traversing enable 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 13 1 Page 13 425 MPF_DIR Start up Jog TEST MPF Channel reset Axis Program aborted ROY Axis a 2 Drive test travel enable Status Direct withPLC 0 Inactive selection Travel range Absolute position Start Monitoring Inactive 68 525 mm Upper limit 0 000 Stop Lower limit 0 000 Measurement Type of measurement Ref frequency respo 7 Measured quantity Position actual value position setpoint value Measuring Axis User Display File parameters MD views functions Fig 13 1 Main menu Position control loop measurement Choose the type of traversing enable from the selection list either by using the Toggle key or by clicking with the right mouse button on the desired enable type Without PLC Traversing of the axis to be measured is enabled depending on the interface signals typical for JOG mode servo enable pulse enable etc Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 425 13 Drive Optimization with HMI Advanced 01 05 13 3 Miscellaneous functions Traversing range monitoring Activation 13 426 With PLC Traversing of the axis to be measured is enabled in addition to the interface signals typical for JOG mode depending on the inte
386. ftware lt Version gt lt Date gt On a SINUMERIK 840Di SW 2 1 and lower restoring the as delivered state is now complete because the image file also contains the SINUMERIK 840Di ap plications On a SINUMERIK 840Di SW 2 2 and higher the SINUMERIK 840Di applica tions have to be installed as described in the following Sections after the parti tions have been restored 15 6 3 Installation of the SINUMERIK 840Di applications 15 496 The installation programs of the SINUMERIK 840Di applications under D INSTALL are not executed automatically after restoration of the partitions as they were on initial start up of the PCU To do this manually in the correct se quence proceed as follows 1 Onnext 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 e DASETUP APPS The subdirectories contained in directory APPS 001 contain 001 Installation directories of the 1st application 002 Installation directories of the 2nd application Xxxx 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 e D ASETUP APPS 001 The subdirectories contained in directory 001 contain 000 Installation directories of the application 001 xxx Installation directories of
387. g rotary axis Machine data e MD30320 DISPLAY _IS MODULO modulo 360 degrees display for rotary axes is used to display the rotary axis position modulo 360 degrees The machine data e MD 30310 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 Table 10 27 Rotary axes machine data Number Name of identifier Name Refer ence General MN_ 10210 INT_INCR_PER_DEG Computational resolution for angular positions G2 Axisspecific MA_ 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 10 28 Rotary axes Setting data Number Name of identifier Name Refer 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 References FB Description of Functions Extended Functions R2 Rotary axes Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 329 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 5 11 Positioning axes Concurrent
388. g System SIMAG H SIMODRIVE Sensor Configuring Installation Guide HW Hollow Shaft Measuring System SIMAG H2 SIMODRIVE Installation Guide Measuring System for Main Spindle Drives SIZAG2 Toothed Wheel Encoder SIMODRIVE Planning Guide ECO Motor Spindle for Main Spindle Drives SIMODRIVE Planning Guide 1PH2 1PH4 1PH7 Motors AC Induction Motors for Main Spindle Drives SIMODRIVE Planning Guide Hollow Shaft Motors for 1PM4 and 1PM6 Main Spindle Drives SINUMERIK 840D 840Di 810D Description of Functions Basic Machine Part 1 the various sections are listed below A2 Various Interface Signals A3 Axis Monitoring Protection Zones B1 Continuous Path Mode Exact Stop and Look Ahead B2 Acceleration D1 Diagnostic Tools D2 Interactive Programming F1 Travel to Fixed Stop G2 Velocities Setpoint Actual Value Systems Closed Loop Control H2 Output of Auxiliary Functions to PLC K1 Mode Group Channel Program Operation Mode K2 Axes Coordinate Systems Frames Actual Value System for Workpiece External Zero Offset K4 Communication N2 EMERGENCY STOP P1 Transverse Axes P3 Basic PLC Program R1 Reference Point Approach S1 Spindles V1 Feeds W1 Tool Offset Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition B References FB2 SINUMERIK 840D 840Di 810D Description of Functions Extended Functions Part 2 the various sections are listed below A4 Digital and Analog NCK I Os B3
389. g The diagrams determined can be archived using file functions Thus they can measurement be used both for documenting the machine settings and to facilitate remote results diagnosis Siemens AG 2005 All rights reserved 13 422 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 2 Measuring functions 13 2 Measuring functions Explanation Measurement signal parameters parameters Preconditions for starting measuring functions Z A range of measuring functions allow 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 The test setpoints are adapted to the application in question by means of mea surement or signal parameters the units of which are determined by the rele vant measuring function or operating mode The measurement or signal para meter units are subject to the following conditions Table 13 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 Path 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
390. g range monitoring and enable logic in the basic display You can select one of three possible measurement types e Reference frequency response e Setpoint step change e Setpoint ramp 2 Set the required parameters in the measurement parameter screen 3 Display of the measurement result on the screen with the soft key Display The reference frequency response measurement determines the transmission ratio of the position controller in the frequency range active position measuring system The setpoint filters K value and feedforward control must be parame terized such that resonance is avoided wherever possible over the entire fre quency range In the case of dips in the frequency response the setting of the feedforward control balancing filters should be checked Excessive resonance requires 1 Decrease of the K value 2 Decrease of the feedforward control value 3 Use of setpoint filters The effects of these measures can also be checked in the time range Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 431 13 Drive Optimization with HMI Advanced 01 05 13 4 Frequency response measurements MPF_DIR Pea Jos TEST MPF Y marker On Graphics lt Tr 1 Y1 axis gt Tr 1 Amplitude response 20 0000 BS eee eee eee Fullscreen Graphics Start Measure Measuring Display File ment parameters functions Fig 13 4 Examp
391. ge 15 461 After the PCU has been switched on the menu of the boot manager is dis played 1 Select the menu option Service menu hidden using the CursorDown key and then press the Input key The following menu appears PLEASE SELECT Install Update SINUMERIK System SINUMERIK Tools and Options DOS Shell Start Windows XP Service Mode SINUMERIK System Check Backup Restore Start PC Link Reboot um o NN O1 BR ND Restore Windows Partition E Emergency 840Di Services Your Choice 1 2 3 4 5 7 8 9 E P 2 Choose Backup Restore with key 7 The system prompts you to enter a password You require a password for protection level 0 2 System Manufacturer Service Following menu PLEASE SELECT 1 Harddisk Backup Restore with GHOST 4 Partitions Backup Restore with GHOST 9 Back to previous Menu Your Choice 1 4 9 3 Choose Harddisk Backup Restore with Ghost with key 1 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu Following menu PLEASE SELECT 1 Configure GHOST Parameters 2 Harddisk Backup to lt PATH gt Mode 3 Harddisk Backup from lt PATH gt Mode 9 Back to previous Menu Your Choice 1 2 3 9 4 If necessary to check or configure the ghost parameters select Configure GHOST
392. gear stage 1 1 The machine data are set acc to the values above e MD10210 INT_INC_PER_DEG computational resolution 1 000 incr de gree e MD31020 ENC_RESOL encoder resolution 500 pulses rev e MD31050 DRIVE_AX_RATION_DENOM load rev denominator 1 e MD31060 DRIVE_AX_RATION_NUMERA load rev numerator 1 e MD31070 DRIVE_ENC_RATION_DENOM load rev denominator 1 e MD31080 DRIVE_ENC_RATION_NUMERA load rev numerator 1 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 369 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Example B encoder at motor 10 370 Internal 360 degree MD 31080 MD 31050 resolution i MD10210 MD31020 pulse rev MD 31070 MD 31060 Internal 360 1 1 int increments resolution 7 7 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 Supposed the following conditions are provided The incremental encoder is mounted on the motor e Encoder pulses 2048 pulses rev e Pulse multiplication 128 e Internal precision 1000 increment degree e Encoder gear stage 1 1 e Load gear stage 1 2 5 1 motor rev spindle rev e Load gear stage 2 1 1 motor rev spindle rev Gear stage 1 Internal 360 degree MD 31080 MD 310
393. ghts reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 223 8 PROFIBUS DP Communication 01 05 8 3 Creating a PROFIBUS configuration Save and compile System data blocks If inconsistencies are detected in the configuration an error dialog box is dis played and the relevant error messages and help are displayed The menu command Station gt Save and Compile saves the current configura tion in S7 as object Station and is then compiled If the configuration is compiled without error the system data blocks are gener ated and stored in directory Blocks of the PLC In example project SIN840Di the system data blocks are located at e SIN840Di SIMATIC 300 1 PLC317 2DP 2AJ10 S7 Program 3 Blocks gt 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 6 163 8 3 6 PROFIBUS diagnosis 8 224 The following specific diagnostic displays are recommended for diagnosis of the PROFIBUS or DP slave status when checking the configura
394. ginal SINUMERIK HMI Environment Deactivates the user specific extensions of the SINUMERIK HMI application as delivered state See Subsection 5 4 3 Page 5 127 e Current SINUMERIK HMI Environment Activates the user specific extensions of the SINUMERIK HMI application as delivered state See Subsection 5 4 3 Page 5 127 e Check SINUMERIK System checks all system data relevant to the SINUMERIK See Subsection 5 4 4 Page 5 127 e STEP 7 Authorizing Authorizes a SIMATIC STEP 7 installed on the PCU See Subsection 5 4 10 Page 5 131 e SINUMERIK 840Di Startup Simple SINUMERIK 840Di specific user interface Note When Windows NT starts up the SINUMERIK 840Di NC system software is automatically started in the background Siemens AG 2005 All rights reserved 5 126 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 4 SINUMERIK desktop 5 4 2 Setting the power up response for the SINUMERIK desktop After the service menu has been activated see Subsection 5 5 4 Page 5 134 the SINUMERIK desktop is displayed the next time the PCU is started up When the PCU is next started after that the HMI application is automatically started again If this response is not desired for example when servicing the response can be set after the PCU is powered up with applications on the SINUMERIK desktop e Windows desktop Autostart of the HMI application OFF e HMI desktop Autostart of the HMI applica
395. gnation of the battery connector Fig 2 5 Battery connector 13 Secure the battery to the module again with the battery receptacle Note The terminals must snap into position audibly 14 Insert the module into the appropriate slot on the mother board and fasten it using the fastening screw on the cover plate 15 Mount the board retainer 16 Close the cover of the computer housing and fasten it with the two housing screws Caution Before you put back the cover make sure that the foam plastic pad has been placed on the rear of the module Battery Foam plastic pad Fig 2 6 Foam plastic pad 17 Connect your PC to power supply again and start it Siemens AG 2005 All rights reserved 2 54 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 2 MCI2 board 2 2 4 Module replacement Module replacement involves installing and removing a module in more or less the same way as changing the battery see Subsection 2 2 3 Page 2 51 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 7 HW series number Fig 2 7 MCI2
396. h reference point IS Reference point approach delay DB31 DBX12 7 IS Traversing command plus DB31 DBX64 7 IS Traversing command minus DB31 DBX64 6 IS Traverse key plus minus DB31 DBX4 7 and 4 6 IS Referenced synchronized DB31 DBX60 4 and 60 5 Zero marker of position measuring system MD 34020 REFP_VELO_SEARCH_CAM gt Reference point approach velocity MD 34070 REFP_VELO_POS Reference point positioning velocity MD 34040 REFP_VELO SEARCH _MARKER Reference point shutdown velocity Velocity 4 Phase 1 Phase 2 Phase 3 Fig 10 23 Signal chart Referencing with an incremental measuring system principle Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 353 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 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 channelspecific reference point approach MD30240 ENC_TYPE encoder type MD34200 ENC_REFP_MODE referencing mode IS DB21 DBX1 0 Activate referencing IS DB21 DBX33
397. hard disk MM lt installation path gt dh mb dir alm_XX com NCK lt installation path gt dh mb dir aln_XX com PLC lt installation path gt dh mb dir alp_XX com ZYK lt installation path gt dh mb dir alz_XX com CZYK lt installation path gt dh mb dir alc_XX com XX stands for the abbreviation of the appropriate language see Table 11 1 Page 11 409 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 11 1 3 User text files User text files Storage path 11 408 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 The user specific text files
398. has been started up with default values Axis A1 is declared as a linear axis e MD30300 IS_ROT_AX A1 0 no rotary axis e 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 e MD30300 IS_ROT_AX A1 1 rotary axis e 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 e MD30300 IS_ROT_AX A1 1 rotary axis e 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 The following procedure is recommended when modifying scaling machine data manually 1 Set all scaling machine data 2 Carry out NCK reset 3 Set all dependent machine data after the NC has powered up 10 3 4 Loading default machine data 840Di start up The default machine data can be loaded in different ways With SINUMERIK 840Di standard user interface 840Di start up Menu command Window gt Diagnosis gt NC PLC e Button Delete NCK Data e 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 machi
399. hat can be connected to the machine control panel e 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 The function transfers the data for all non standard inputs outputs e Direct control key e Customer keys 6 signals bit 0 to bit 6 e Rotary switch with the following distribution Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 247 8 PROFIBUS DP Communication 01 05 8 7 DP slave MCP 483 e Input data 5 bytes Customer 1 Rotary 2 Rotary Direct control keys OP 012 keys switch switch Low byte High byte e Output data 2 bytes Reserved Customer always 0 LEDs Low byte High byte Siemens AG 2005 All rights reserved 8 248 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 7 DP slave MCP 483 8 7 5 Configuring a DP slave This chapter describes the configuration of a DP slave MCP 483 by way of ex ample of the hardware configuration of a SIMATIC S7 project shown in Fig 8 19 The hardware configuration
400. he PLC 1 Notice The beginning of the address range of the input output data of the NC must be set to 256 There is no monitoring e Part program processing in der NC If the value is not equal to 256 auxiliary functions that are transferred from the NC to the PLC cannot be acknowledged by the PLC As a result part program processing is not continued by the NC No alarm or error message is output Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 4 Creating a PLC program 6 4 Creating a PLC program 6 4 1 PLC basic program Opening the To insert the PLC basic program in the S7 project SIN840Di you have created library open the library installed in Subsection 6 1 4 Page 6 146 with menu item Open gt File Select the library of the PLC basic program for example go8x0d65 and confirm the dialog box with OK Opening a project xi User projects Cibraries psampie projects Muttipte projects F Program Files Siemens Step7 S7libs gp8x0d65 mcp840Di F Program Files Siemens Step7 S7proj mcp840Di SIMATIC_NET_ CP F Program Files Siemens Step7 S7libs simation Standard Library F Program Files Siemens Step7 S7libs StdLib30 stdlibs V2 F Program Files Siemens Step7 S7libs STDLIBS Fig 6 6 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 Rs
401. he SINUMERIK 840Di PCU or on an external computer PG PC e SINUMERIK 840Di has powered up e NC in cyclic mode e PLC in status RUN The NC and PLC status can be checked with e User interface 840Di startup See corresponding online help e Start up tool SinuCom NC See relevant online help e User interface HMI Advanced optional See Section 10 10 Page 10 400 6 2 2 Communications link To load the configuration into the PLC you must ensure that the communica tions link MPI or PROFIBUS is established We distinguish between two cases depending on which computer SIMATIC STEP 7 is installed External computer PG PC SINUMERIK 840Di PCU External computer If the configuration is to be loaded onto the PLC from an external computer PG PC PG PC the following conditions must be fulfilled e Communications module exits alternative CP5611 MPI PROFIBUS communications processor PCI CP5511 MPI PROFIBUS communications processor PCMCIA Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 149 6 PLC Start Up 01 05 6 2 Startup Dialog box SINUMERIK 840Di Dialog box PLC status and communications interface checked 6 150 e MPI PROFIBUS driver is installed e PG PC interface is parameterized see below e The MPI PROFIBUS interface of the PG PC is linked to the MPI PROFIBUS interface of the MCI board X1 via an MPI cable Parameterizing the
402. he backed up partitions on the PCU hard disk partition image see Subsection 15 5 4 Page 15 486 select Backup WITHOUT Local Images with key 1 Otherwise choose Backup WITH Local Images with key 2 A message box appears You are prompted to check that the connection between the PCU and the external computer is up The destination path is displayed at which the backup copy will be stored on the external computer Press Y to start backup Backup is now performed by Norton Ghost The following information is shown in the message box Transmission progress Paths used Data volume Size of backup copy with compression 4 8 GB harddisk gt approx 330 MB image file Time for transfer approx 15 min Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 477 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu 15 5 2 Restoring hard disk contents from an image file Brief description Requirements Operator actions 15 478 This subsection describes how to restore the hard disk contents of the PCU from a hard disk image created as described in Subsection 15 5 1 Page 15 475 The image file is read from a shared directory on an external computer PC PG via a DOS based network link The following condition must be fulfilled e Network link with an external computer See Section 15 1 Pa
403. he cable distributor Cable 6FX2002 4AA21 0 Cable 6FX2002 4AA41 0 Fig 2 12 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 13 Page 2 66 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 65 2 Hardware Descriptions 01 05 2 4 Cable distributor 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 I N N N N N TE T Terminal caps Contact surface
404. heel PS ground TTL handwh ground Handwheel PS ground TTL handwh ground Input 2nd handwheel track B Input 1st handwheel track A Handwheel PS ground TTL handwh ground Handwheel PS ground TTL handwh ground Input 1st handwheel track B Input Output Power supply of the digital inputs X121 Ext power supply MCI board Pin number 24V stabilized extension iay au Optocoupler 1 24 27 M supply of the digital outputs cae X121 24V stabilized MCI board Pin number extension 24V ov 20 21 Optocoupler lt 3 4 22 23 L Relays Driver 1 2 M e The maximum cable length is 25 m for all functions 2 62 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 3 MCI board extension slot variant Dig inputs Please note the following points about the digital inputs Isolated from the board electronics Connected to the same ground MEXT Dig outputs Please note the following points about the digital outputs Isolated from the board electronics Connected to the same ground GND24EXT as is their the external 24V power supply Handwheels The handwheels are not isolated from the board electronics Sensor probes Sensor probes e Inthe case o
405. hine 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 More detailed information about other SINUMERIK 840D 840Di 810D bro chures and brochures for all SINUMERIK controllers e g universal interface measuring cycles etc can be obtained from your local Siemens representa tive 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 If you have any questions on the control please get in touch with our hotline A amp D Technical Support Phone 49 180 5050 222 Fax 49 180 5050 223 E mail adsupport siemens com Please send any queries about the documentation Suggestions or corrections to the following fax number Fax 49 9131 98 2176 E mail motioncontrol docu erlf siemens de Fax form See the reply form at the end of the document www siemens com motioncontrol Then navigate further with SINUMERIK 840Di The Link Box at the SINUMERIK 840Di end gives you direct access to all impor tant information about the product Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition V
406. hts reserved SINUMERIK 840Di Manual HBI 01 05 Edition 11 413 11 Alarm and Message Texts 01 05 11 1 Alarm and message texts Notes Siemens AG 2005 All rights reserved 11 414 SINUMERIK 840Di Manual HBI 01 05 Edition Axis Spindle Dry Run 12 1 Preconditions Enables for axes To allow an axis to be traversed from the control system it is necessary to supply enabling terminals on the drive and to set enabling bits on the interface DBxx The data block designated DBxx depends on the maximum configuration of the machine axes currently validated for SINUMERIK 840Di Enables on the drive Setup mode 24 V Pulse enable 24 V Drive enable 24 V Mains supply module DC link start 24 V 663 Pulse enable fo 424V Drive module References FBU SIMODRIVE 611 universal Description of Functions Enabling through The following signals must be made available at the PLC interface for axis or PLC interface spindle IS Servo enable DB31 DBxx DBX2 1 IS Pulse enable DB31 DBxx DBX21 7 IS Position measuring system 1 or 2 DB31 DBxx DBX1 5 DBX 1 6 The following signals on the interface must not be set or else the axis spindle motion will be disabled IS Feed spindle override switch DB31 DBxx DBBO not at 0 IS Axis spindle lock DB31 DBxx DBX1 3 IS Follow up mode DB31 DBxx DBX1 4 IS
407. ication 01 05 8 6 DP slave MCP 310 8 6 5 Configuring the DP slave MCP 310 This chapter describes the configuration of a DP slave MCP 310 by way of ex ample of the hardware configuration of a SIMATIC S7 project shown in Fig 8 14 The hardware configuration comprises the following modules e SIMATIC station 300 with SINUMERIK 810D 840D and PLC 317 2DP e 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 8 234 1 2 Set the PROFIBUS address 3 Insert the modules in DP slave MCP 310 for the functions required see Fig 8 14 Page 8 234 2 4 Set the I O addresses for the individual slots a B SINUMERIK MCP f Universal module g standard g standard handwheel standard extended standard handwheel ex Order number designation l address O address Com 36 P standard randwheel extended 0 7 210 gt standard handwheel exten 258 261 192 gt standard handwheel exten 8 12 8 9 Fig 8 14 Configuration with DP slave MCP 310 Preconditions 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 Insert
408. icular 8 Permissible deviations when working on live components Suitable electric tools should be used Warning e Repairs to devices that have been supplied by our company must only be carried out by SIEMENS Customer Service or by repair centers authorized by SIEMENS When replacing parts or components only use those parts that are included in the spare parts list e Before opening the device always disconnect the power supply e 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 undefined restart e 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 mechanical interlocks etc A Caution e Connecting cables and signal lines should be installed so that inductive and capacitive interference does not in any way impair the automation functions she Siemens AG 2005 All rights reserved VIII SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 SINUMERIK 840Di Manual Preface ESD notices Electrostatically Sensitive Devices o Important Handling of
409. ier Name Refer 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 10 49 Spindle Interface signals DB number Bit byte Name Refer ence Axis specific Signals from PLC to axis spindle 31 0 Feed override V1 31 1 7 Override active V1 Siemens AG 2005 All rights reserved 10 380 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Axis specific Sly 31 4 Sa Slik 31 31 Si ie 1x 31 Sr als 31 22 ST ax Si SIs Ch ere Sc ch ee 31 Six Axis specific 31 2 Blink SE 3153 2 31 ST Ifi Ifi as Sr STE STE 31 2 ITs Sy SES aTa 31 Si 3T S13 3T Slits 31 25 Signals from PLC to axis sp
410. igh resolution Fig 10 28 Speed setpoint normalization The desired speed on the spindle is obtained using a mechanical gear stage Machine data Table 10 41 Axisspecific MA_ 31050 DRIVE_AX_RATIO_DENOM 31060 DRIVE_AX_RATIO_NUMERA 32010 JOG_VELO_RAPID 32020 JOG_VELO 35010 GEAR_STEP_CHANGE_ENABLE 35020 SPIND_DEFAULT_MODE 35030 SPIND_DEFAULT_ACT_MASK 35040 SPIND_ACTIVE_AFTER_RESET 35200 GEAR_STEP_SPEEDCTRL_ACCEL n 35220 ACCEL_REDUCTION_SPEED_POINT 35230 ACCEL_REDUCTION_FACTOR 35400 SPIND_OSCILL_DES_VELO 35410 SPIND_OSCILL_ACCEL 35430 SPIND_OSCILL_START_DIR 35440 SPIND_OSCILL_TIME_CW 35450 SPIND_OSCILL_TIME_CCW Interface signals Speeds and setpoint adjustment for spindle machine data Denominator load gearbox G2 Numerator load gearbox G2 Rapid traverse in JOG mode JOG axis velocity Gear stage change possible Basic spindle setting Activate initial spindle setting Spindle active after reset Acceleration in speed control mode Speed limit for reduced acceleration Reduced acceleration Oscillation speed Oscillation acceleration Oscillation start direction Oscillation time for M3 direction Oscillation time for M4 direction Table 10 42 Speeds and setpoint adjustment for spindle Interface signals DB number Bit byte Name Refer ence Axis specific Signals from PLC to axis spindle 31 4 6 Traversing keys minus 31 4 7 Traversing keys plus 10 372 Siemens AG 2005 All rights reserved SIN
411. ignal see Subsection 10 10 2 Page 10 404 can be checked and changed if neces sary 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 125 5 Power On and Power Up 01 05 5 4 SINUMERIK desktop 5 4 SINUMERIK desktop The SINUMERIK desktop is used for servicing and offers various SINUMERIK 840Di specific functions at Windows level together with Windows specific stan dard functions 5 4 1 Activating the SINUMERIK desktop During the standard PCU power up procedure the boot manager activates the SINUMERIK desktop after a set delay see Subsection 5 3 1 Page 5 119 and the relevant HMI application is started automatically In normal cases therefore the SINUMERIK desktop is not visible to the machine operator Activation The SINUMERIK desktop is activated from the service menu See Subsection 5 5 4 Page 5 134 Functions The following SINUMERIK 840Di specific functions can be accessed from the SINUMERIK desktop e Readme Notes and conditions concerning the installed SINUMERIK 840Di system software e Windows desktop Autostart of the HMI application OFF e HMI desktop Autostart of the HMI application ON e HMI Explorer The HMI Explorer is used to display the version and install or post install the supplied SINUMERIK application e Ori
412. ignation DP e SINUMERIK 840Di NC Standard designation S7 FM NCU The 840Di Rack is located in the hardware catalog under Profile Default SIMATIC 300 gt SINUMERIK gt 840Di gt 840Di with PLC317 2AJ10 Use the right mouse button to select 840Di Rack and drag it to the Station win dow holding down the mouse button When you release the mouse button 840Di Rack will be inserted in the S7 project Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 3 Creating a SIMATIC S7 project tay Station Edit Insert Target System View Tools Window Help o x 18 x Fig 6 5 6 3 5 Equidistant time osle le S le a S 2 PROFIBUS 1 DP master system 1 Profile Standard PROFIBUS DP kia PROFIBUS PA PLC 317 20P 2AJID Pre G c7 MPDP C3 cp s00 cpu 300 FM 300 mM 300 J M7 EXTENSION C3 Gateway J Ps 300 Ca rAcKk 300 SM 300 l CA SINUMERIK B Fi M E A H E 810D 8400 Sl ALE 27720 agyi a g sanre e Jes RS ES ES 7 E ewwa w EN ES S7 FNCU 0 e Yv gt 840Di_PLC317M 2DP_2AJ10 z SINUMERIK 840Di with integrated PLC 317 2DP 2AJ10 Sie HW Config SINUMERIK 840Di Rack Parameterizing the PROFIBUS interface X101 When you have inserted the 840Di Rack the dialog box for configuring the PROFIBUS interface X101 opens automatically as for slot X2 Mak
413. igned by HW Config automatically and should be changed taking into account the following supplementary conditions e 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 e Selective access to inputs outputs by the PLC The PLC cannot directly access individual inputs outputs of I O addresses gt 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 VO 6 9 0222 1212121 2 VO 6 9 0411 1212121 3 VO 6 9 042 141 For DP slave PP72 48 select the 1st configuration and click OK to confirm the dialog box Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 227 8 PROFIBUS DP Communication 01 05 8 6 DP slave MCP 310 8 6 8 6 1 Hardware Software 8 228 DP slave MCP 310 SIE hes HATTERE Bee OUR He L ABE REE eee we Fe E3 Eug Fig 8 10 MCP 310 front panel Conditions for general installation and start up The following hardware is required PROFIBUS connecting cable No terminating resistor is integrated in the machine control panel Programming device PG PC A programming device PG PC is required for the SIMATIC Manage
414. ile 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 e DASUPPORT mcp840di zip To dearchive in the SIMATIC Manager please use menu item File gt 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 Siemens AG 2005 All rights reserved 7 172 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 5 Creating a MPI configuration 7 5 Creating a MPI configuration 7 5 1 Precondition S7 project Archive file mcp840di zip The procedure for creating an MPI configuration described in this chapter is based on an S7 project created using the description in Section 6 3 Page 6 153 The following status of the S7 project is required S7 project is has been set up name SIN840Di Station 300 has been set up MPI interface is parameterized PROFIBUS interface is parameterized Input output data areas of the NC are parameterized Note The instructions given in this chapter are essentially limited to the special characteristics of the SINUMERIK 840Di For more details about working with SIMATIC S
415. ile as an emergency image to restore operating system partition E if necessary You may have to restore the operating system partition This may be necessary if Windows is no longer bootable or if the realtime properties of the SINUMERIK 840Di are no longer ensured because subsequently installed unsuitable soft ware can no longer be uninstalled Requirements The following conditions must be fulfilled e At least one image file must be present locally on the hard disk of the PCU under D IMAGES see Subsection 15 5 4 Page 15 486 Operator actions After the PCU has been switched on the menu of the boot manager is dis played 1 Select the menu option Service menu hidden using the CursorDown key and then press the Input key The following menu appears PLEASE SELECT Install Update SINUMERIK System SINUMERIK Tools and Options DOS Shell Start Windows XP Service Mode SINUMERIK System Check Backup Restore Start PC Link Reboot Restore Windows Partition E Emergency 840Di Services um o ONARAN Your Choice 1 2 3 4 5 7 8 9 E P 2 Choose Backup Restore with key 7 The system prompts you to enter a password You require a password for protection level 0 2 System Manufacturer Service Following menu PLEASE SELECT 1 Harddisk Backup Restore with GHOST 4 Partitions Backup Restore with GHOST locally 5 ADDM Backup Restore 9 Back to previous Menu Your Choice 1 4 5
416. ilure Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 7 DP slave MCP 483 Notice Handwheel function The Handwheel function is not currently supported by the basic PLC program Additional I Os function Processing of additional I O data is the sole responsibility of the user machine 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 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 a machine control panel MCP 483 as a DP slave only the following parameters are relevant MCPNum INT See below Note MCP1In POINTER Address of input signals MCP1Out POINTER Address of MCP 1 output signals The MCP2 parameters are only needed if a 2nd MCP is used in addition to the 1st MCP MCP2In POINTER Address of input signals MCP2Out POINTER Address of output signals The parameters listed below serve t
417. in ms Frequency Specified in Hz Note The default setting for all parameters is 0 To ensure that no erroneous traversing movements due to parts programs can be carried out the measuring functions have to be started in JOG mode Caution When traversing movements are carried out within the framework of measuring functions no software limit switches and working area limitations are monitored 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 framework of the measuring functions are sufficient to prevent collision with the machine Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 423 13 Drive Optimization with HMI Advanced 01 05 13 2 Measuring functions Starting measuring functions Further safety notices Canceling measuring functions 13 424 Measuring functions initiating a traversing movement are only selected using 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 with
418. incompatible with the interface version of the NCK system software the following alarm is issued e Alarm 7200 Version contflict_with_ CCNCKinterfaceVersion If a compile cycle has a functional dependency on another one which is not loaded to the NCK the following alarm is issued e Alarm 7200 CC lt name gt _ELF Loader_problem_from_dFixup Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 395 10 NC Start Up with HMI Advanced 01 05 10 7 Loadable compile cycles System enables If the compile cycle is not enabled in conjunction with SINUMERIK 840Di 840DiE the following alarm is issued Not enabled for SINUMERIK 840Di e Alarm 7200 CC lt name gt _ELF NO_840Di Not enabled for SINUMERIK 840DiE e Alarm 7200 CC lt name gt _ELF NO_EMBARGO Notice If alarm 7200 is pending after the NCK has powered up none of the loaded compile cycles is active 10 7 3 Activating and licensing technology functions Activating and licensing the option Activating the technological function References Version display HMI Advanced option 10 396 To activate the technological function loaded with the compile cycle to the NCK you need to set and license the respective option For information about how to activate and license options please see Section 5 7 Page 5 142 Each loaded compile cycle generates a technological function specific global
419. indle 1 6 Position measuring system 2 1 5 Position measuring system 1 1 4 Followup mode 1 3 Axis spindle disable 2 2 Spindle reset delete distancetogo 2 1 Servo enable 3 6 Velocity spindle speed limitation 16 7 Delete S value 16 5 Resynchronize spindle 2 16 4 Resynchronize spindle 1 16 3 Gear changed 16 2 16 0 Actual gear stage A to C 17 6 Invert M3 M4 17 5 Resynchronize spindle during positioning 2 17 4 Resynchronize spindle during positioning 1 18 7 Direction of rotation setpoint left 18 6 Direction of rotation setpoint right 18 5 Oscillation speed 18 4 Oscillation via PLC 19 7 19 0 Spindle offset H A Signals from axis spindle to PLC 60 7 Position reached with exact stop fine 60 6 Position reached with exact stop coarse 60 5 Referenced synchronized 2 60 4 Referenced synchronized 1 60 3 Encoder limit frequency exceeded 2 60 2 Encoder limit frequency exceeded 1 60 0 Axis no spindle 61 7 Current controller active 61 6 Speed control loop active 61 5 Position controller active 61 4 Axis spindle stationary N lt Nmin 82 3 Change gear 82 2 82 0 Set gear stage AC 83 7 Actual direction of rotation clockwise 83 5 Spindle in setpoint range 83 2 Setpoint speed increased 83 1 Setpoint speed limited 83 0 Speed limit exceeded 84 7 Active spindle control mode 84 6 Active spindle mode oscillation mode 84 5 Active spindle positioning mode 84 3 Rigid tapping active 86 and 87 M function for spindle 88
420. ing Data Note To search for information regarding machine and setting data it is recommended to use the search functions in the electronic documentation SINUMERIK DOConCD 10 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 gt Start up gt 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 FDG Mn IMD ni MES vi iam Te A Sim a yo MENEMN X en VS NRO THRFSHNN t HIRI ma nmmn BRE ri Machine data SED PILTE M TPE Ae Bi mak a LE E EE EE EE ED ENEA A E EENE E OCO0008000000000 Fig 10 1 Input screen form of the bit editor for HEX machine data Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 281 10 NC Start Up with HMI Advanced 01 05 10 2 Machine and setting data 10 2 2 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 e With the
421. ing the DP To insert a DP slave MCP 310 into the configuration open the hardware cata slave log with menu item View gt Catalog Siemens AG 2005 All rights reserved 8 234 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication PROFIBUS Parameters Dialog box 8 6 DP slave MCP 310 DP slave MCP 310 is located under e Profile Standard PROFIBUS DP gt Other field devices gt NC RC gt Motion Control gt SINUMERIK MCP Select the DP slave by left clicking it in the hardware catalog MCP 310 SINU MERIK MCP and drag it while holding down the mouse key onto the DP master system in the station window The DP master system is displayed in the station window with the following symbol aaa 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 cursor with a plus sign and the DP slave can be added to the configuration When you have inserted DP slave MCP 310 into the configuration dialog Properties PROFIBUS Interface SINUMERIK MCP is displayed The following PROFIBUS parameters must either be set or verified PROFIBUS address Data transfer rate Profile Dialog box Properties PROFIBUS Interface SINUMERIK MCP Tab card Parameter Address lt PROFIBUS
422. ing values 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 Relative air humidity limits 5 80 5 95 Tested to DIN IEC 68 2 30 Per minute Per hour Rate of temperature change max 1 K max 10K Condensation not permissible Quality assurance acc to ISO 9001 Vibrational load during operation Class 3M4 Frequency range 10 58Hz 58 200Hz Const excursion accelera 0 075mm 1g tion Tested to DIN EN 60068 2 6 module in PCU 50 Shock load during operation Acceleration 50 m s2 Duration of nominal shock 30 ms Tested to DIN EN 60068 2 6 module in PCU 50 Notice The specified safety regulations certifications degree of protection and class of protection only apply if the module is plugged into a SINUMERIK PCU 50 Siemens AG 2005 All rights reserved 2 64 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 4 Cable distributor 2 4 Cable distributor Order number Cable connection Designation Order number MLFB Cable distributor 6FX2 006 1BA02 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 67 To supply the digital outputs an external 24 V supply is possible at t
423. ining process i e they carry out the programmed traversing movements on the machine 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 Additional axes are all other channel axes that are not geometry axes Unlike for geometry axes Cartesian coordinate system no geometric context is de fined for additional axes neither between additional axes or with respect to ge ometry axes Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Axis assignment 10 5 Axes and spindles The assignment of drives machine axes channel axes and geometry axes using the corresponding machine data is shown in the following Fig 10 4 Channel 1 List of all geometry axes of the channel MD20050 AXCONF_GEOAX_ASSIGN_TAB n List of all channel axes of the channel MD20070 AXCONF_MACHAX_USED n Channel 1 0 1 11 2 gt BISS Special axes 0 1 1 2 2 3 3 4 4 5 2 Machine axes of the NC MD30110 CTRLOUT MODULE NR 0 MD30220 ENC MODULE NR 0 List of
424. installed The path of the installation directory of a software component is displayed in the Install dialog box Menu command Install 5 4 11 SW installation update The SINUMERIK desktop allows you to install or update software directly from an external computer using a specially configured network link For a detailed description see Chapter 15 Page 15 461 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 131 5 Power On and Power Up 01 05 5 5 Service menu 5 5 Service menu Activation Functions 5 132 PLEASE SELECT 1 Install Update SINUMERIK System 2 SINUMERIK Tools and Options 3 DOS Shell 4 Start Windows XP Service Mode 5 SINUMERIK System Check 7 Backup Restore 8 Start PC Link 9 Reboot E Restore Windows Partition E Emergency P 840Di Services Your Choice 1 2 3 4 5 7 8 9 E P Fig 5 3 Main menu The service menu is opened from the boot manager with operating sequence Cursor down and Enter see Subsection 5 3 1 Page 5 119 A password of protection levels 0 2 is required to execute the service menu System Manufacturer Service The service menu provides the following functions at DOS level e Install update SINUMERIK system Installation and addition or updating of the SINUMERIK system See Subsection 5 5 1 Page 5 133 e SINUMERIK tools and options Loading additional tools and enabling options See Subsection 5 5
425. ion parameters MPI address Data transfer rate 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 i DIP switch via display 4 3 187 5 kbaud 3 S1 F S1 l 2 IDLE time Switch setting LJ 2 100 ms no function if 1 ON OF i S1 CA 4 4 a Sait i s2 l 3 Default MPI Switch setting u 3 s2 2 address 15p no function 1 2 E 1 Fig 7 14 Settings required on the HHU for SINUMERIK 840Di Data transfer rate The data transfer rate must be set together with the SINUMERIK 840Di to 187 5 kbaud Notice To operate the HHU on the MPI bus of the SINUMERIK 840Di the data transfer rate has to be set to 187 5 kbaud Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 189 7 MPI Communication 01 05 7 9 Handheld unit B MPI MPI address The MPI address is set to FH 15p by default This address can normally be kept Table 7 4 MPI addresses that can be set using S2 2 MPI address on on on on Fy 15p default address on on on off Ex 14p on on off on Dy 13p on on off off Cy 12 on off on on By 11p on off on off Ay 10p on off off on 9 on off
426. ional The range of values of the traversing ranges directly depends on the selected resolution and computational resolution see Subsection 10 3 1 Page 10 286 traversing ranges With the default assignment of the machine data for the computational resolution e 1000 inc mm e 1000 inc deg the following traversing ranges result Table 10 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 J K 999 999 999 mm deg 399 999 999 inch deg 10 3 7 Positioning accuracy Computational The positioning accuracy depends on resolution and 5 traversing ranges the computational accuracy internal increments mm or degrees e the actual value resolution encoder increments mm or degrees The rougher resolution of both determines the positioning accuracy of the NC The input resolution the position control and interpolation clock do not affect the accuracy Machine data Table 10 11 Positioning accuracy machine data Number Name of identifier Name remarks Refer ence General MN_ 10200 INT_INCR_PER_MM Computational resolution for linear positions G2 10210 INT_INCR_PER_DEG Computational resolution for angular positions G2 Axisspecific SMA_ 31020 ENC_RESOLfn Encoder pulses per revolution Siemens A
427. ions Basic Machine R1 Reference point approach Chapter Automatic calibration using probe Calibration with BERO During operator assisted calibration the machine axis of the absolute value encoder is move to the known machine position reference position The posi tion value of the reference position is taken over by the NC as the reference point value Recommended procedure 1 Parameterization of referencing mode e 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 e 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 Taking over the reference position into the NC The reference position is entered in the machine data e MD34100 MA REFP SET POSfn reference point value Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Calibrating several absolute value encoders Recalibration 10 5 Axes and spindles 4 Enabling encoder calibration Encoder calibration is performed in the machine data e MD34210 MA_ENC_REFP_S
428. is R2 31000 ENC_IS_LINEAR n Direct measuring system linear scale 31020 ENC_RESOLfn 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 NUMERAn Numerator load gearbox 31070 DRIVE_ENC_RATIO_DENOM n Denominator of resolver gearbox 31080 DRIVE_ENC_RATIO_NUMERAJn Numerator of resolver gearbox Siemens AG 2005 All rights reserved 10 320 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Linear measuring system Linear axis with linear scale Machine data 10 5 Axes and spindles The diagrams below show the general possibilities of arranging a rotary incremental measuring system with regard to motor and load as well as the resulting values for the respective machine data DRIVE_AX_RATIO_NUMERA motor revs DRIVE _AX RATIO DENOM spindle revs IS_ROT_AX 0 Table u 7711101117 Ball screw Vv 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 10 9 Linear axis with linear scale Table 10 22 Linear measuring systems machine data Number Axisspecific MA_ 30240 ENC_TYPE n Name of identifier Name remarks Refer ence Actual value acquisition modes 1 in
429. is not active Actions such as parts 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 system of measurement 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_RESET_VALUES 12 alternates between G700 and G710 This process takes place independently of the protection level currently set Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 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 s
430. ith HMI Advanced 10 1 General procedure 10 2 Machine and setting data 10 2 1 Display and input 10 2 2 Protection levels 10 2 3 Machine data display filter 10 3 System data 10 286 10 3 1 Resolutions 10 286 10 3 2 Normalization of phys quantities of machine and setting data 10 288 10 3 3 Changing scaling machine data 10 290 10 3 4 Loading default machine data 10 291 10 3 5 Switching over the measuring system 10 292 10 3 6 Traversing ranges 10 294 10 3 7 Positioning accuracy 10 294 10 3 8 Cycle times 10 295 10 3 9 Velocities sisi sure sante gear eile men e decree nee Dents 10 299 10 4 Memory configuration 10 301 10 4 1 DRAM memory 44 420 10 302 10 42 SRAM memory 10 303 10 4 3 DRAM file system 10 305 10 5 Axes and spindles 10 5 1 Axis configuration 10 52 AXIS NA
431. ith HMI Advanced 01 05 10 5 Axes and spindles Checking the If a Ky factor is already known for a machine in question this can be set and loop gain checked For checking reduce the acceleration of the axis in e MD32300 MAX_AX_ACCEL axis acceleration to make sure that the drive does not reach its current limit when accelerating and decelerating The Ky 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 n rv Vi Badly Well selected KV factor selected KV factor t ms t ms Fig 10 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 e Acceleration too high current limit is reached e Rise time too long re optimization necessary e Mechanical backlash e Mechanical components canted For safety reasons set the Ky factor to a little less than the maximum possible value The real Ky factor must precisely match that set because monitoring functions are derived from the Ky factor that would otherwise respond e g contour monitoring Acceleration The machine axes are accele
432. ivated 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 us 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 40 or the NC PLC diagnostics of HMI Advanced see Section 10 10 Page 10 400 The following points must be taken into account for screen resolution and depth of color settings on the PCU e 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 Screen resolutions greater than 1024 768 pixels are not supported e Color depth The default color depth setting is 256 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 For safe operation in all real time operating modes the permissible color depth is restricted to 65536 colors
433. k 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 cuttin g e Fora machine axis that is not involved in tapping or thread cutting the 1st set of parameters index 0 is active in all cases The other parameter sets can be ignored e 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 parameterized in accordance with the gear stages of the spindle The following applies to spindles e 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 parameter sets must be parameterized in accordance with 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 Siemens AG 2005 All rights reserved 10 332 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles Spindle gear Parameter set no Axis Spindle stage 0 Standard Axis mode jee para 1 e Spindle mode 1 2 ee Spindle mode 2 3 RC Spindle mode 3 4 nee Spindle mode 4 5 Ringed eli en Spindle mode 5
434. ket 90 Cable outlet with PG connection socket Designation Backup battery 2 2 2 Interface description Interface overview Battery connection X3 Interfaces of the MCI board module Table 2 1 Interface overview MCI board Interface Designation PROFIBUS DP X101 MPI DP X102 MCI board extension X2 Backup battery X3 PCI bus x11 2 2 MCI2 board Order number MLFB 6FC5 222 0AA02 1AA0 Order number MLFB 6GK1 500 0EA02 6ES7 972 0BA40 0XA0 6ES7 972 0BB40 0XA0 6ES7 972 0BA11 0XA0 6ES7 972 0BB11 0XA0 Order number MLFB 6FC5 247 0AA18 0AA0 Type Socket Socket connector Plug connector Plug connector Direct connector Interface description of the battery connection X3 e Connection 2 pin plug connector e Pin assignment Table 2 2 Pin assignment Battery connection X3 Pin Designation Type 1 Function 1 BATT VI Minus pole of the battery 2 BATT VI Plus pole of the battery 1 VI Voltage Input Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 49 2 Hardware Descriptions 01 05 2 2 MCI2 board PROFIBUS DP Interface description PROFIBUS DP interface X101 interface e Connection 9 pin SUB D socket connector X101 k e Pin assignment Table 2 3 Pin assignment PROFIBUS DP interface X101 Pin Designation Type 1 Function 1 Not assigned 2 Not assigned 3 RS DP B RS 485 differential signals 4 RTS O Request to Send 5 GNDext VO External ground 2
435. l computer IP address 169 254 10 1 Subnet mask 255 255 0 0 PCU IP address 169 254 10 2 Syntax In the service menu the IP address of the PCU must be entered with a blank used as the tuple separator Example IP address 169 254 10 2 e Subnet mask Select Change Subnetmask with key 3 Using command ipconfig enter the subnetmask you have determined for the external computer for the PCU too For information on syntax see above IP address e Gateway No gateway must be specified for a PTP network link Domain name server No domain name server must be specified for a PTP network link e DNS extension No DNS extension must be specified for a PTP network link This completes configuration of the PTP network link Confirm the query whether you want to store the network parameters when you exit the menu with key Y the settings are stored Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 469 15 Software Installation Update and Data Backup 01 05 15 2 PTP network link service menu DOS 15 2 5 Show connected network drives Service menu 15 470 After the PCU has been switched on the menu of the boot manager is dis played Select the menu option Service menu hidden using the CursorDown key and then press the Input key The main service menu is displayed after PCU start up Select one after the other from the main menu Key 1 Instal
436. l update SINUMERIK system Key 3 Install from Network Drive 7 Key 1 Manage Network Drives Key 7 Backup Restore Key 1 Harddisk Backup Restore with Ghost Key 1 Configure Ghost Parameters Key 6 Manage Network Drives The following menu appears 1 2 3 9 PLEASE SELECT Your Choice 1 2 3 9 Connect to Network Drive Show connected Network Drives Disconnect from all Network Drives Back to previous Menu Choose Show Connected Network Drives using the key 2 Following menu Status OK Local Name Remote Name lt Drive gt lt Sharing name gt All currently connected drives are displayed Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 2 PTP network link service menu DOS 15 2 6 Disconnecting from network drives Service menu After the PCU has been switched on the menu of the boot manager is dis played Select the menu option Service menu hidden using the CursorDown key and then press the Input key The main service menu is displayed after PCU start up Select one after the other from the main menu Key 1 Install update SINUMERIK system Key 3 Install from Network Drive 7 Key 1 Manage Network Drives Key 7 Backup Restore Key 1 Harddisk Backup Restore with Ghost Key 1
437. le Measurement results of a reference frequency response measurement Measurement Amplitude parameters This parameter determines the magnitude of the test signal amplitude It should Reference be set to the smallest possible value e g 0 01 mm frequency Bandwidth response The bandwidth parameter is used to set the analyzed frequency range The larger this value the finer the frequency resolution and the longer the measure ment time The maximum value is given by the position control cycle Tposition controller Bandwidthmax HZ 1 2 Tposition controller sec Example Position controller cycle 2 ms Bandwidthmax 1 2 2 1073 250Hz Averaging The accuracy of the measurement but the measurement duration too will in crease with this value A value of 20 is normally suitable Settling time This value represents the delay between recording of the measured data and injection of the test setpoint and offset A value of between 0 2 and 1 s is recom mended Do not set too low a value for the settling times or the frequency re sponse and phase diagrams will be distorted Siemens AG 2005 All rights reserved 13 432 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 4 Frequency response measurements 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
438. le Example of a file NETNAMES INI for SINUMERIK 840Di own owner MMC_1 Description of possible connections conn MMC_1 conn_l NCU_1 Description of significant net parameters param network bus mpi param MMC_1 mmc_address 14 param NCU_1 nck_address 2 rack_slot 4 sap 1 plc_address 2 Standard NC name Description of an standard channel configuration chan MMC_1 ShowChanMenu FALSE TRUE gt activate the channel menue DEFAULT_logChanSet ChannelAreal DEFAULT_logChan Channel11 logChanSetList ChannelAreal Siemens AG 2005 All rights reserved 7 198 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 10 Handheld Terminal HT 6 ChannelAreal logChanList Channel11 Channel11 logNCName NCU_1 ChanNum 1 Transferring the Once you have changed the MPI configuration you must regenerate the system system software software of the HT 6 and transfer it to the HT 6 via PC card This action is described in detail in References IAM IBN HMI Chapter Installation and Start Up of SINUMERIK HT 6 Note e MPI address The default setting of the MPI address is 14p decimal We recommend keeping the MPI address If you change the MPI address you must also adapt the GD circle parameterization See Section 7 6 Page 7 175 e Data transfer rate The data transfer rate is automatically recognized by HT 6 7 10 4 Display of the current software
439. lect option and activate Simple File Sharing Dialog box Folder Options Tab card View Use simple file sharing Recommended OK Network access is enabled in properties dialog gt 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 To allow files to be created in the directory the appropriate authorization must be set Dialog box lt Directory gt Properties Tab card Sharing Share this folder on the network Allow network users to change my files OK 15 1 4 Configuring PCU Windows XP 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 e TCP IP protocol e P address and subnet mask e Computer name and workgroup must be made or checked as described in Subsection 15 1 3 Page 15 1 3 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 465 15 Software Installation Update and Data Backup 01 05 15 2 PTP network link service menu DOS 15 2 PTP network link service menu DOS Brief description Some of the functions described in this section data back up require a network link with an external computer PG PC on which a directory is shared for net
440. lication with which their file type is as sociated Example File type txt gt Notepad File type htm gt Internet Explorer 5 4 9 User specific background images Directory structure Parameter NCK type Parameter Screen resolution Parameter File name 5 130 User specific background images can be displayed while the control is power ing up The background images in question must be stored in bitmap format BMP in a defined directory structure Depending on the NCK type and screen resolution the HMI application then automatically selects the relevant file The directory must be structured as follows e F A OEM IB DATA lt NCK type gt lt screen resolution gt lt file name gt BMP The different NCK types are displayed depending on the directory name Only the following values may be used as directory names for the SINUMERIK 840Di e default If a directory default is created the background image stored under this directory will always be stored irrespective of the existing NCK type e 5000 Background images stored under directory 5000 ID for SINUMERIK 840Di are only displayed by the HMI application together with a SINUMERIK 840Di The different screen resolutions of the individual display units are displayed de pending on the directory name The following values may be used as directory names e 640 ID for screen resolution 640 x 480 e 800 ID for screen
441. 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 e NCK latency The basis of the SINUMERIK 840Di realtime property is activation of the NC system software cyclically in defined time intervals Because the NC and Windows XP share the available processor power of the PCU delays called latencies may occur when calling the NCK If laten cies are longer than 200us they are considered to be violation of realtime with which the NC functionality is now longer ensured 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 realtime response of the NCK has been affected after replacing or expanding hardware and or software components Note For detailed information about the realtime properties of the SINUMERIK 840Di see Subsection 1 1 5 Page 1 27 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 403 10 NC Start Up with HMI Advanced 01 05 10 10 NC PLC Diagnosis 10 10 2 Menu Settings Operating path The menu for the SINUMERIK 840Di specific settings is in the following operat ing path e Operating area switchover gt Diagnosis gt NC PLC Diagnosis gt Settings
442. lity_List PDF Notice We urgently recommend checking compatibility of new software components with existing software components before installing updating them compatibility list The following condition must be fulfilled e Network link with an external computer See Section 15 1 Page 15 461 This is the recommended procedure for installing updating software on the PCU 1 Back up the NC and PLC user data by creating a series machine start up file See Chapter 14 Page 14 453f 2 Establish a network link to a shared directory of an external computer PG PC containing the software to be installed See Section 15 1 Page 15 461 3 Perform installation updating of the software via the network link 4 Initialize the control with Delete NC data and PLC memory reset See Subsection 6 2 1 Page 6 149 5 Import the series machine start up file created in Step 1 See Section 14 4 Page 14 459 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu Note For historical reasons it is still possible to install update software via the service menu However it is not recommended 15 5 Data back up DOS service menu 15 5 1 Backing up the hard disk contents in an image file Brief description This subsection describes backing up the contents of the hard disk of the PCU by
443. ll rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 339 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 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 soeed setpoint matching is correct Traversing velocity MD32200 POSCTRL_GAIN Desired following error 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 gt Diagnosis gt Service displays gt Service axis spindle Machine data Table 10 35 Speed setpoint matching machine data Number Name of identifier Name remarks Refer ence Axis spec MA_ 32250 RATED_OUTVAL Rated output voltage G2 32260 RATED_VELO n Rated motor speed G2 References FB Description of Functions Basic Machine G2 Velocities Setpoint Actual Value Systems Closed Loop Control Chapter Velocities Traversing Ranges Accuracies Siemens AG 2005 All rights reserved 10 340 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 16 Drift compensation Digital drives Digital
444. logon to Domain Yes or No Change Domain Name displayed only when 4 Yes Change TCP IP Settings displayed only when 3 TCP IP o ORUN Back to previous menu Your Choice 1 2 3 4 5 7 8 9 P CURRENT NETWORK SETTINGS Machine Name is where the machine name is displayed The default name is PCUXXXXXXX You can change the computer name under Change Machine Name with key 1 In normal circumstances the computer name displayed is identical to that valid under windows unless it has been changed with menu item Change Machine Name for DOS Net only However this change is only valid at DOS level until the PCU is next started up Restrictions e You can choose any computer name e The computer name must be unique in the domain to which the PCU is linked CURRENT NETWORK SETTINGS User Name is where the current user name is displayed The default name is auduser You can change the logon name under Change User Name with key 2 If the PC is registered in a particular domain the user logon name and the password must be known to the domain server to allow a network link to an en abled directory of an external computer If the PCU is not registered in a domain the user logon name must be set up as the local user on the external computer to allow a network link to an enabled directory of an external computer The workgroup of the PCU is permanently set to Windows default WORK GROUP an
445. lta FC 10 Error and operational EC 13 messages HHU display contr OB 40 FC3 Process alarm GP_PRAL G group eee Distributor User program Fig 7 20 Structure of the PLC program The HT 6 is parameterized as a machine control panel MCP in organization block OB 100 in the call parameters of function block FB 1 The HT 6 can be operated either as an MCP substitute or in addition to an MCP as a 2nd operator component To synchronize several operator components the PLC program must be adapted accordingly This is the user s machine manufacturer s responsibility Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 10 Handheld Terminal HT 6 MCPNum INT 111 1 operator component MCP HT 6 default 2 2 operator components MCP HT 6 MCP14In POINTER Address of input signals MCP HT 6 1 MCP1Out POINTER Address of output signals MCP HT 6 1 MCP1StatSend POINTER Addr of MCP HT 6 1 send status data MCP1StatRec POINTER Addr of MCP HT 6 1 receive status data MCP1BusAdr INT MPI address of HT 6 MCP1Timeout SSTIME Default setting should be kept MCP1Cycl S5TIME Default setting should be kept MCPMPI BOOL MSTT HT 6 operated on extended MPI bus The MCP2 parameters are only needed if in addition to the 1st MCP HT 6 a HT 6 is additionally used MCP2In POINTER Address of input signal
446. ltage 1 MD32260 Rated output speed Service display e snes aa No Check Is traversing direction okay 1MD32100 AX MOTION DIR Yes Specified path 10 mm jp is paih evaluation okan No Check S pati vayalonoray MD31000 31080 encoder matching de 1 Speed setpoint matching Q ADI4 gt MD32250 0 SIMODRIVE 611 universal E POSMO CD CA SI gt MD32250 0 Siemens AG 2005 All rights reserved 12 416 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 12 Axis Spindle Dry Run 12 2 Axis dry run OQ ae Traverse with 1 1000 mm min feedrate 2 rapid traverse Yes 1 Interprete alarm Alarm 2 Check MD of velocity adaptation No No Check machine data Following error correct MD32200 Ky factor MD32410 Time constant of jerk limitation Yes MD32910 Dynamic response adaptation MD31050 31060 Load gearbox End MD32610 Feedforward control MD of velocity adaptation Check drive parameters P880 Speed evaluation PROFIBUS Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 12 417 12 Axis Spindle Dry Run 01 05 12 3 Spindle dry run 12 3 Spindle dry run Check enables from drive RF module 63 pulse enable 64 drive enable 48 start DC link Drive module 663 pulse enable Check interface signals DB31 48 DBBO Spindle speed override DBX1 7 Override
447. lue is displayed O0 No drive or drive type not known 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 Setting the drive type to value 4 has the following effects in HMI Advanced e Drive parameters No drive parameters are read e Current and speed controller cycles The current and speed controller cycles are not displayed e Drive type ANA is displayed as the drive type e 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 e Current control loop The dialog box for measuring the current control loop is not offered 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 e MD13080 DRIVE_TYP_DP n 4 Note We recommend entering drive type 4 manually for drives connected via ADI4 e MD13080 DRIVE_TYP_DP n 4 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 315 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Machine data Table 10 18 Drive configuration machine data Number Name of identifier Name remarks Refer ence General MN_ 13050 DRIVE_LOGIC_ADDRESS n Logical I O address of drive G2 13060 DRIVE_TELEGRAM_TYPE n Dri
448. ly 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 Machine data e 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_USEDJ n see Point 3 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Machine data 10 5 Axes and spindles Table 10 16 Axis configuration machine data Number Name of identifier Name remarks Refer ence General MN_ 13050 DRIVE_LOGIC_ADDRESS I O address of drive Channelspecific MC_ 20050 AXCONF_GEOAX_ASSIGN_TAB Assignment of geometry axis to channel axis 20070 AXCONF_MACHAX_USED Machine axis number valid in channel Axisspecific MA_ 30110 CTRLOUT_MODULE_NR Setpoint assignment 30220 ENC_MODULE_NR Actual value assignment References FB Description of Functions Basic Machine K2 Axes Coordinate Systems Frames Actual Value System for Workpiece Chapter Axes 10 5 2 Axis names Machine axes Channel axes Each machine cha
449. ly influenced by applications active under Windows XP due to cache effects of the PCU processor To calculate 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 described above no longer change you can calculate the above formula with a value of 200 instead of 300 The maximum value for the NCK CPU time share of 75 must not be exceeded A value greater than 75 can lead to significant impairment slowing down of Windows XP applications If necessary the values must be adapted to the system clock cycle position controller cycle DP cycle time and or interpolation cycle Error response e Alarm 4240 CPU time overflow on the IPO or position controller level Cause of errors error handling The DP cycle time position controller cycle the interpolation cycle or the NC CPU time share is set in such a way that not enough CPU time is available for one of the two cyclic levels of the NC position controller or interpolator Remedial action Calculate the maximum values for Tpos max and Tipo max See above and adapt the following machine data e MD10185 NCK_PCOS_TIME_RATIO CPU time component NCK e MD10070 IPO_SYSCLOCK_TIME_RATIO factor for interpolator cycle e MD10050 SYSCLOCK_CYCLE_TIME system basic time Note You must adjust the system clock cy
450. m I O address 272 the I O addresses from 256 plus 16 bytes for the PLC are re served for the PROFIBUS drives Default values e MD13050 DRIVE_LOGIC_ADDRESS r 272 n 20 Notice Any changes in the I O addresses must be carried out consistently e DP slave 611U SIMATIC S7 project HW Config I O address for setpoint and actual value e NC MD13050 DRIVE_LOGIC_ADDRESSj n No automatic adjustment takes place The message frame type describes the data volume and the data structure of the message frames exchanged between NC and drive on PROFIBUS DP dur ing the cyclic communication For parameterizing the message frame type see Section 6 3 page 6 153f Note You will find a detailed description of the message frame structure of each message frame type in the following documents in each case in Section Communication on PROFIBUS DP e SIMODRIVE 611 universal and universal E References FBU Description of Functions SIMODRIVE 611 universal e SIMODRIVE POSMO A References POS1 User Manual SIMODRIVE POSMO A e SIMODRIVE POSMO SI CD CA References POS3 User Manual SIMODRIVE POSMO SI CD CA e ADI4 References Section 8 8 Page 8 258 The message frame type defined in the S7 project is entered in machine data e MD13060 DRIVE_TELEGRAM_TYPE n drive message frame type The default values of the machine data refer to the default message frame type of SIMODRIVE 611 universal with 1 or 2 axes per drive mod
451. machine data e MN_CC_ACTIVE_IN_CHAN_ lt name gt n where n 0 1 in the machine data number range 60900 to 60999 You can activate the entire technological function in the individual NC channels or individual subfunctions via the above mentioned general NCK machine date For a description of the machine data please see Subsection 10 7 4 Page 10 397 The individual technological functions are described in FB3 Description of Functions Special Functions Chapters TE1 to TE8 The compile cycles loaded in the FSS NCK are displayed together with the re spective version of HMI Advanced option in the following menu Operating area switchover gt Service gt Version gt Compile cycles Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 7 Loadable compile cycles 10 7 4 Data descriptions MD General machine data 60900 i CC_ACTIV_IN_CHAN_XXXX n wherei 0 1 2 3 where XXXX function identifier n 0 or 1 MD number n 0 Activate technology function in NC channels n 1 Additional functions within the technology function Default setting 0 Minimum input limit 0 Maximum input limit FFFF Changes effective after RESET Protection level 2 7 Unit Data type UINT16 Applies as from SW version 2 2 Meaning Activate technology function in NC channels The technology function is activated in the NC channels by means of index n 0
452. me under Change User Name with key 2 Because a PTP link does not use a domain server which would process the password query automatically in the background the user login name must be set up as the local user on the external computer The workgroup of the PCU is permanently set to Windows default WORK GROUP and cannot be changed The workgroup name of the PCU and the external computer must be identical Logon of the PCU in a domain is deactivated by default Shown under CUR RENT NETWORK SETTINGS Logon to domain No CURRENT NETWORK SETTINGS If Logon to domain Yes is displayed here connection with the domain must be deactivated with Toggle logon to do main with key 4 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 467 15 Software Installation Update and Data Backup 01 05 15 2 PTP network link service menu DOS Protocol TCP IP Setting the TCP IP parameters IP address 15 468 Protocol TCP IP is set as the default If NetBEUI is displayed you must switch to TCP IP under Toggle Protocol NetBEUI TCP IP and key 3 Note If a network link already existed with the displayed protocol the alternative protocol is not activated until the next time the PCU is started up restart To set or check the TCP IP parameters select Change TCP IP Settings with key 6 The following menu appears PLEASE SELECT Toggle Get IP
453. means of a hard disk image The image file is transferred to a shared direc tory on an external computer PC PG via a DOS based network link The entire operation is performed via the service menu DOS user interface of the SINUMERIK 840Di Requirements The following condition must be fulfilled e Network link with an external computer See Section 15 1 Page 15 461 e There is sufficient free space in the shared directory Notice Before transferring hard disk back up image file make sure there is enough free space on the drive of the external computer PC PG Operator actions After the PCU has been switched on the menu of the boot manager is dis played 1 Select the menu option Service menu hidden using the CursorDown key and then press the Input key The following menu appears PLEASE SELECT Install Update SINUMERIK System SINUMERIK Tools and Options DOS Shell Start Windows XP Service Mode SINUMERIK System Check Backup Restore Start PC Link Reboot Warmstart Restore Windows Partition E Emergency 840Di Services um o NN O1 BR ND Your Choice 1 2 3 4 5 7 8 9 E P Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 475 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu 2 Choose Backup Restore with key 7 The system prompts you to enter a password You require a password for pro
454. mens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 497 15 Software Installation Update and Data Backup 01 05 15 6 Restoring the as delivered state Notes Siemens AG 2005 All rights reserved 15 498 SINUMERIK 840Di Manual HBI 01 05 Edition 840Di specific Data and Functions 16 1 16 1 1 DB number 10 10 10 10 16 1 2 DB number Interface signals For detailed information on interface signals please refer to the descriptions of functions FB1 Description of Functions Basic Machine FB2 Description of Functions Extended Functions FB3 Description of Functions Special Functions FBSY Description of Functions Synchronized Actions For a complete list of all existing interface signals please refer to LIS Lists Chapter Interface signals 840Di specific interface signals Byte bit 108 2 108 3 109 4 57 3 Name Signals from NC to PLC MMC ready communication via MPI MMC ready communication via Softbus PC OS fault PC shutdown Interface signals not supported Byte bit Axis spindlespecific 31 31 cs aes IT 31 Sty 31 31 Ole 9 31 20 0 20 2 22 0 22 1 22 3 22 4 23 0 23 2 23 5 23 7 92 0 92 2 Name Signals from PLC to axis spindle Acceleration switch V Hz operation Torque limit 2 Safety Integrated signals from
455. mitted Always conn the HT 6 at the end of the MPI line integr bus termination Note The HT 6 can also be connected to a distributor with 3 core confirmation Distributor 6FX2006 1BC01 Cable 6FX2002 1AA83 1 0 10 3 108 Mach contr panel and pushbutton pan PP 031 MC can be oper to gether For a detailed overview of the connection to the AD14 please refer to References ADI4 Analog drive interface for four axes Connection overview Connection via Fast Connect insulation displacement method see References SIMATIC Manual Diagnostic repeater for PROFIBUS DP Can be parameterized either as MPI or PROFIBUS DP 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 PROFI BUS line Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 3 Design 3 3 Overview of connections Note The length codes for preassembled cables 6FXL1002 can be found in References BU SINUMERIK 840D 840Di 810D FM NC Ordering information Catalog NC 60 2000 2001 For conditions that may be applicable to the individual accessories please refer to References Z SINUMERIK SIROTEC SIMODRIVE Accessories and Equipment for Special Purpose Machines Catalog NC Z Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 3 109 3 Design
456. modules containing devices sensitive to electrostatic discharge When handling electrostatically sensitive devices make sure that operator workplace and packing material are properly grounded 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 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 conjunction with ESD flooring Modules may be placed only on electrically conductive surfaces table with ESD top conductive ESD foam plastic ESD packing bags ESD transport containers Keep modules away from visual display units monitors or TV sets minimum distance from screen gt 10 cm 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 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
457. must be copied with operating area Services into directory lt installation path gt dh mb dir Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 11 Alarm and Message Texts Language specific nature of alarm texts Announcement in the system Example 11 1 Alarm and message texts Language assignment of the user specific alarm texts is achieved via the name of the text file The appropriate code and the file extension com are added to the user file name entered in MBDDE INI Table 11 1 Language codes Language Abbreviation German gr English uk French fr Italian it Spanish sp The user specific text files that are now in the directory lt installation path gt 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 software is updated it is strictly recommended to store it in the intended USER path lt installation path gt user mbdde ini 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 contained 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 O
458. n 5V 32 MPG1 OV X3 1 ye 6FC9320 5DB OV 14 MPG1 XB X3 4 vt XB 33 MPG1 B X3 3 bu B shield 15 MPGO XA X2 2 rd XA 34 MPGO A X2 1 or A 16 MPGO 5V X2 4 bn 5V 17 MPGO 5V X1 2 1 21 0 gn 5V 36 MPG0 OV x1 1 ye 6FC9320 5DB OV 18 MPGO XB X1 4 vt XB 37 MPGo0 B X1 3 bu B shield Siemens AG 2005 All rights reserved 2 68 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions Signal names 2 4 Cable distributor MPGo 1 5V Supply voltage 1st 2nd handwheel 5 V MPGo 1 0 V Supply voltage 1st 2nd handwheel 0 V MPGO 1 A XA 1st 2nd differential handwheel input A XA MPGO 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 or bn bk gn ye vt bu Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Red Orange Brown Black Green Yellow Violet Blue 2 69 2 Hardware Descriptions 01 05 2 5 SINUMERIK Industrial PC 2 5 SINUMERIK Industrial PC 2 5 1 SINUMERIK
459. n switched on the menu of the boot manager is dis played Select the menu option Service menu hidden using the CursorDown key and then press the Input key The following menu appears PLEASE SELECT Install Update SINUMERIK System SINUMERIK Tools and Options DOS Shell Start Windows XP Service Mode SINUMERIK System Check Backup Restore Start PC Link Reboot um o J O1 BR ND Restore Windows Partition E Emergency 840Di Services Your Choice 1 2 3 4 5 7 8 9 E P Choose Restore Windows Partition E Emergency using key E The system prompts you to enter a password You require a password for protection level 0 3 System Manufacturer Service Customer For safety reasons the following warning is shown before the partition is over written Caution Partition E is overwritten After confirming again partition E is restored from the emergency image file On next start up of the PCU under Windows partition E is checked by the CHKDISK diagnostic program After completion of the check the system with the restored backup copy is ac tive Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 3 Partitioning of the PCU harddisk 15 3 Partitioning of the PCU harddisk The PCU harddisk is divided into 4 partitions 3 primary partitions and an ex tended partition For reasons of data
460. n to SINUMERIK 840Di func tionality The user interface comprises the following functions e Display of main screens e Display of alarms and messages e Management of parts programs e ASCII editor e NC PLC and PROFIBUS diagnoses e Logbook The menu bar comprises the following menu commands e File e Edit e Window e display The functions that can be called using the menu commands File and Edit are context sensitive i e only those functions are offered that are possible in the context of the currently active window Example e The parts program management window is selected The menu command Edit provides the following functions Copy Paste Paste Load Unload e The window for display of the axis actual values is selected The menu com mand Edit provides no further functions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 5 840Di start up 1 5 1 Menu command Window The menu command Window provides the following functions Menu command Functionality Window Basic 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 a
461. nals to the interface Section FC 25 MCP_IFT Transfer of MCP signals to the interface Connecting an MCP to SINUMERIK 840Di 1 Connect the MCP electrically Use the terminating resistor integrated in the MPI connector according to the general rules for connecting components to the MPI bus As function block FB1 is not yet parameterized in the basic PLC program communication with the PLC is not yet established and all LEDs on the MCP front panel flash Checking the software version Simultaneously pressing the keys Feed stop and Feed enable displays the software version with the LEDs located on the front side Set call parameters of function block FB 1 in organization block OB 100 Example of a machine control panel parameterization MCPNum 41 an MCP is available MCP1In P E 0 0 Address of input data 8 bytes MCP1Out P A 0 0 Address of output data 8 bytes MCP1StatSend P A 8 0 Address of send status data 4 bytes MCP1StatRec P A 12 0 Address of receive status data 4 bytes MCP1BusAdr 14 Standard address MCP1Timeout S5T 700MS Default setting MCP1Cycl S5T 200MS Default setting Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 183 7 MPI Communication 01 05 7 7 Machine control panel 19 or MCP MCPMPI FALSE MCP HT 6 operated on extended MPI bus MCP1Stop FALSE MCP1NotSend FALSE MCPSDB210 TRUE
462. nction with ESD flooring e 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 e Keep modules away from visual display units monitors or TV sets minimum distance from screen gt 10 cm e 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 e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition Power On and Power Up 5 1 Preparing for start up 5 1 1 Checklist SINUMERIK 840 Di SIMODRIVE 611 universal Limit values The following checklist will help you to start up the supplied components without undue problems and ensure high availability on your product e When handling the components all ESD measures are observed e All screws are tightened with their
463. nd 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 41 1 General Notes on the SINUMERIK 840Di 01 05 1 5 840Di start up Menu command Part programs Editor Diagnostics PROFIBUS Bus Slaves 1 42 Functionality e Management of parts programs Menu command File New Open Deletion Exit Menu command Edit Copy Paste Load Unload Select e Editing parts programs Menu command File gt Open Double click the file with the left mouse button Editing files Start the editor with Menu command File gt Open Double click the file with the left mouse button Menu command File Open Close Cut Exit Menu command Edit Copy Paste Load Unload Select Display of bus configuration Baud rate Cycle time synchr portion Tpx Display of status Config
464. ndicate 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 Table 10 43 Spindle positioning machine data Axisspecific MA_ 35300 SPIND_POSCTRL_VELO Creep speed 35350 SPIND_POSITIONING_DIR Direction of rotation when positioning from the standstill 35210 GEAR_STEP_POSCTRL_ACCEL Acceleration in position control mode Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 373 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Axisspecific MA_ 36000 STOP_LIMIT_COARSE Exact stop coarse 36010 STOP_LIMIT_FINE Exact stop fine 32200 POSCTRL_GAIN Ky factor 36400 CONTOUR_TOL Contour monitoring Interface signals Table 10 44 Spindle positioning Interface signals DB number Bit byte Name Refer ence Axis specific cie 60 6 31 60 7 Styx 84 5 Signals from axis spindle to PLC Position reached with exact stop fine Position reached with exact stop coarse Positioning mode 10 5 26 Synchronizing spindle
465. ne start up file is described in Section 14 2 Page 14 454 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 291 10 NC Start Up with HMI Advanced 01 05 10 3 System data MD11200 INIT_MD Input values The input values in MD11200 INIT_MD loading the default machine data with the next NC boot which are listed below various data areas can be loaded when the NC 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 MD11200 INIT_MD 1 On the next NC power up all machine data with the exception of the memory configuring data are overwritten with default values MD11200 INIT_MD 2 On the next NC power up all memory configuring machine data are overwritten with default values 10 3 5 Switching over the measuring system 10 292 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 e MD10260 CONVERT_SCALING_SYSTEM 1 e Bit 0 of MD20110 RESET_MODE_MASK is enabled in every channel e All channels are in the Reset state e Axes are not traversing with JOG DRF or PLC control e Constant grinding wheel peripheral speed GWPS
466. ng HC HV cables must always be laid completely separately from all other cables e f signal cables cannot be laid at a sufficient distance from other cables then they must be installed in shielded cable ducts metal e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 4 111 4 EMC and ESD Measures 01 05 4 2 ESD measures 4 2 4 112 ESD measures Notice Handling of modules containing devices sensitive to electrostatic discharge e When handling electrostatically sensitive devices make sure that operator workplace and packing material are properly grounded e 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 e 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 conju
467. ng the PLC program Text file for cycle alarm texts 11 410 Text file for PLC alarm texts 11 411 Thin Client Unit 2 75 Thread Tapping thread cutting 10 332 TI 8 211 3 222 TM 8 211 TMAPC 8 211 3 222 8 211 3 222 Torque control loop Measurement 13 427 Torque reduction 16 511 Trace function Basic screen 13 439 Creating subdirectories Display function Drive Optimization Measuring parameters Operation Parameterization Performing the measurement 13 442 Printer selection 13 448 Signal selection Traversing direction 10 334 Traversing ranges 10 294 TTL handwheels 2 63 Index 544 U Update UPS 2 81 SITOP POWER DC UPS module 15 2 81 UPS s stem 1 32 USB 2 78 _ User data 10 301 Velocities Max axis velocity 10 299 Max tool path velocity 10 299 Maximum spindle speed 10 299 Upper limit 10 299 Voltage limit 10 300 Velocity monitoring Actual Version display Basic software Voltage failure 1 30 W WAN Windows NT General 1 25 Windows XP 15 463 15 464 Working area limitation 10 346 X X1 Ext power supply PP72 48 2 85 X10 MP 7 178 X101 PROFIBUS DP MCI board 2 50 X102 MPI DP interface MCI board 2 50 X111 Dig inputs outputs PP72 48 2 87 X121 I O MPG extension MCI board Ext X121 1 0 MPG extension 2 57 X2 PROFIBUS DP PP72 48 2 86 X20 MCP 7 178 X2
468. nguageFont2 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 Siemens AG 2005 All rights reserved 7 208 SINUMERIK 840Di Manual HBI 01 05 Edition PROFIBUS DP Communication 8 1 General 8 1 1 PROFIBUS DP with Motion Control option PROFIBUS DP Motion Control expansion PROFIBUS DP is an international open field bus standard defined in the Euro pean field bus standard EN 50170 Part 2 PROFIBUS DP is optimized for fast time critical data communication on the field level The components communicating via the PROFIBUS DP are categorized as either master or slave components 1 Master active n
469. niversal E with option module MotionControl with PROFIBUS DP SIMODRIVE POSMO CD CA SIMODRIVE POSMO SI SIMODRIVE POSMO A To operate drives with an analog setpoint interface the following PROFIBUS module is available ADI4 Analog Drives Interface for 4 Axes Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 1 Overview of SINUMERIK 840Di I Os For use as distributed I Os the module range SIMATIC DP ET 200 for connec Operator panel front TCU tion conditions see SIMATIC documentation and the low cost I O module PP 72 48 are available Choose one of the new operator panel fronts from the SINUMERIK range OP 010 OP 010C OP 010S OP 012 OP 015 as an operator component 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 Windows XP NC system software NCK The SINUMERIK 840Di is based on the following software components 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 35 The operating system basis of the SINUMERIK 840Di is Windows XP 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 gen
470. nnel and geometry axis can must be assigned an individual name unambiguously identifying it in its name range Machine data e 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 NC The names and the corresponding index defined in the machine data above is used for e Accessing axis specific machine data loading saving displaying e Reference point approach from the parts program G74 e Measuring e Test point traversing from the parts program G75 e Traversing the machine axis from PLC e Display of axis specific alarms e Display in the actual value system machine related e DRF handwheel function Machine data e MD20080 AXCONF CHANAX_NAME_TABfn 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 311 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Geometry axes Machine data Machine data e MD20060 AXCONF_ GEOAX_NAME_TABfn 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 descri
471. ns AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 SINUMERIK 840Di Manual Contents 5 3 5 Start up after replacement of the PCU new or reinstallation update of the 840Di software 5 3 6 Start up after replacement of the PCU or the MCI board 5 3 7 Start up after importing a backup copy 5 3 8 Start up after power failure Power Fail 5 3 9 Power up with shutdown signal 5 4 SINUMERIK desktop 5 4 1 Activating the SINUMERIK desktop 5 4 2 Setting the power up response for the SINUMERIK desktop 5 4 3 Setting the SINUMERIK HMI environment 5 127 5 4 4 Testing system components 5 127 5 4 5 Authorizing SIMATIC STEP 7 5 4 6 Serial MOUSE 444 4444 5 4 7 System information after Fatal exceptional error 5 129 5 4 8 OEM configuration nus ndenae Gana ke hwnd dandian wed eked 5 4 9 User specific background images 5 4 10 AMI EXplOrer 2 24 cee dete ete eee eet eee ee ee eee eee eee ee 5 131 5 4 11 SW installation update nonna cane coun ta oe aes cane ehaaake 5 5 Service Menu TE OP TE I UP ER I een 5 5 1 Install update SINUMERIK system
472. nter key or after expiry of a defined time The following functions are available e SINUMERIK normal case See Section 5 4 Page 5 126 e Service menu service case See Section 5 5 Page 5 132 Note The functions of the service menu are password protected You require a password for protection levels 0 2 System Manufacturer Service 5 3 2 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 service cases it is also possible to use the SRAM image or backup to be able to continue work immediately without recommissioning the SINUMERIK 840Di Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 119 5 Power On and Power Up 01 05 SRAM image SRAM backup Used user data remark hard disk hard disk OK OK not applicable not applicable MCI Normal power up Yes not applicable IMAGE no message box or alarms see Subsection 5 3 4 case 1 no Yes BACKUP message box and alarm see Subsection 5 3 4
473. ntrolled system Frequency response of the mechanical parts The machine axis in question must have both a direct and an indirect measuring system Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 427 13 Drive Optimization with HMI Advanced 01 05 13 4 Frequency response measurements Measurement Reference frequency response 2 Set the required parameters in the measurement parameter screen 3 Display of the measurement result on the screen with the soft key Display The reference frequency response measurement determines the transmission ratio of the speed controller The response range should be as wide as possible and without resonance It 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 Start up 20 0000 Program aborted M ROY Graphics1 lt Tr 1 Y1 axis gt Tr 1 Amplitude response Measure Measuring ment parameters AMPF DIR Jos TEST MPF Fullscreen SS eee eee ee Scale Graphics dj oboe TITTET PRE t 1 1 ee ee ee Start User Display File views functions Fig 13 2 Example Measurement results of a reference frequency response measurement Measurement Interference frequency response Measurement parameters Reference and interference frequency
474. ny SINUMERIK HMI application e Original SINUMERIK HMI environment SINUMERIK HMI is started in the as delivered state i e the content of the directories F AADD_ON FUSER F AOEM CARUNOEM has been backed up and the directories then cleared e Current SINUMERIK HMI environment Before SINUMERIK HMI is started the backed up files from the above direc tories are loaded After you have selected the function the system is rebooted The function is actually executed during the ensuing start up of Windows before the HMI sys tem software is started Note The HMI environment can also be set on the SINUMERIK desktop by starting the functions Original SINUMERIK HMI Environ Current SINUMERIK HMI Environ 5 5 5 SINUMERIK System Check Operator action Starting from the main menu see Fig 5 3 Page 5 132 select SINUMERIK System CHECK with key 5 Functions You can execute the following functions via the menu Siemens AG 2005 All rights reserved 5 134 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 5 Service menu e Hard disk of the PCU Partitions C D E and F are tested After you have selected the function the system is rebooted The function is actually executed during the ensuing start up of Windows before the HMI sys tem software is started Note You can also starting testing of the system components from the SINUMERIK desktop by sta
475. o be entered in the machine data hexadecimally is the decimal I O address of the slot of the signal module allocated by HW Config or set manually e If aslot comprises several I O bytes or addresses the NC occupies the entire slot when an I O byte is assigned So the PLC user program can not write to the I O bytes not used by the NC 10 6 3 System variable A_ n The digital and analog input outputs are available in the NC parts program ASUP synchronized action etc in the form of system variables Analog I Os e A_INA n Read analog input n where n 1 8 e A OUTAfn Write analog output n where n 1 8 Digital input outputs e SA INfn Read digital input Bit n where n 1 4 and 9 40 e A _OUT n Write digital output n where n 1 4 and 9 40 Hardware assign machine data System variables Analog I Os MD10362 HW_ASSIGN_ANA_FASTIN 0 7 A_INA 1 8 MD10364 HW_ASSIGN_ANA_FASTOUT 0 7 A_OUTAI 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 e Hardware assign machine data Byte by byte e System variables Bit by bit Siemens AG 2005 All rights reserved 10 384 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC
476. o synchronize two MCPs MCP1Stop BOOL Transfer of each operator component MCP2Stop BOOL FALSE start TRUE stop MCP1NotSend BOOL Send and receive operation of each MCP2NotSend BOOL operator component FALSE send and receive active TRUE only receive active Notice Parameter MCPNum Up to and including version 7 1 of the basic PLC program parameter MCPNum should always be set to 0 Parameter MCPxStop and MCPxNotSend These parameters are irrelevant for connection via PROFIBUS DP Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 253 8 PROFIBUS DP Communication 01 05 8 7 DP slave MCP 483 References For a detailed description of the basic PLC program or of function block FB 1 please refer to FB1 Description of Functions Basic Machine PLC Basic Program P3 Chapter FB 1 RUN_UP Basic program startup section VDI interface The following function blocks can be used to assign the VDI interface parameter e FC 19 Machine control panel MCP 483 version M milling assignment e FC 25 Machine control panel MCP 483 version T turning Notice Function blocks FC 19 FC 24 and FC 25 are part of the basic PLC program It is the user s machine manufacturer s responsibility to call the block correctly and or assign the interface the appropriate parameters References A detailed description of the function blocks for transferring machine con
477. oad it then into the PLC Note A programming device is not required if the SIMATIC Manager is installed on the SINUMERIK 840Di How to install additional software is described in Chapter 15 page 15 461 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 187 7 MPI Communication 01 05 7 9 Handheld unit B MPI Software References Automation system 7 9 2 Connecting the HHU electrically Connecting several HHUs Electrical The following software components are required to start up the HHU Basic PLC program The PLC basic program is included on the SINUMERIK 840Di installation CD This must be installed before the PLC basic program can be used See Subsec tion 6 1 4 Page 6 146 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 The following manuals are required to start up the HHU BH Operator Components Manual Description of HHU interfaces electrical connection etc FB1 Description of Functions Basic Machine P3 Basic PLC Program Description of the program structure and modules of the PLC basic program IZI Catalog NCZ Connection Components Cables connectors etc To start up the HHU the automation system must be completely electrically and mechanically conn
478. oc 24V Output voltage lout 250mA Voltage at low level Vi Output open Leakage current at low level 5OuA 400uA Signal delay time TpHL 2 0 5 ms Maximum switching frequency 2 Resistive load 100Hz Inductive load 2Hz Lamp 11Hz e 1 UH typical Voc lout Ron Vcc actual operating voltage lout maximum output current see above maximum short circuit current 4A max 100us Vec 24V Ron internal resistance 0 4Q e 2 Moreover the PROFIBUS communication time and the application cycle time must be taken into account e Incorrect polarization causes neither high level nor destruction of the outputs e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 91 2 Hardware Descriptions 01 05 2 11 I O module PP72 48 LED Status display The module has 3 LEDs through which the module status is displayed Table 2 21 LED Status display Designation Color Description POWER Green Supply voltage OVTEMP Red Overtemperature indication EXCHANGE Green cycl data exchange with DP master in progress READY Red Ready for cycl data exchange with DP master 2 11 3 Power supply Module Digital outputs Digital inputs
479. ode 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 e DP master class 1 DPMC1 This term denotes central master devices that exchange information with the slaves within defined message cycles Examples SIMATIC S5 SIMATIC S7 etc e DP master class 2 DPMC2 These are devices for configuring start up operation and monitoring during running bus operation 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 Communication between SINUMERIK 840Di NC and PLC as the master and the slave components on PROFIBUS DP is based on PROFIBUS DP with the MotionControl extension The MotionControl extension is characterized by e Configurable isochronous DP cycle e Cyclic synchronization of the DP slaves using GlobalControl message frames from the DP master e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 209 8 PROFIBUS DP Communication 01 05 8 1 General 8
480. of a DP cycle At time T4 the current actual values are read from all isochronous drives DP slaves In the next DP cycle the actual values are transferred to the DP master in the time Tpx The NC position controller is started at the time Ty with Tu gt Tpx and com putes the new speed setpoints on the basis of the transferred actual positions At the start of the next DP cycle the speed setpoints are transferred from the DP master to the DP slaves drives in the time Tpx At time To the speed setpoints are taken as new specified values for all drive controllers Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 1 General Tmapc Tpp ni NC Master or position Tu controller i gt R Tpx Tpx lt m PROFIBUS DP opvi RGT Gc Dx Dx bx IbPv1 RGT lac Dx Dx Dx communication T T4 Speed conoi TITI ITITTI cycle Drives DP slaves 1 to 3 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 Tmarc
481. ommunication Dialog box Consistency 8 9 DP slave SIMODRIVE drives Notice The I O address set by the SlaveOM for an axis must match the I O address set in the NC There is no automatic adjustment The following data must match 1 SIMATIC S7 configuration of DP slave 611U 1 0 address 2 SINUMERIK 840Di NC MD13060 DRIVE_LOGIC_ADDRESSJn logical drive address Note To avoid any modifications to the I O addresses in NC machine data e MD 13050 DRIVE_LOGIC_ADDRESSjn it is recommended to use the default values of the machine data when configuring the I O addresses within the configuration 1st axis Default I O address 272 mth axis Default I O address 272 m 1 20 The default setting for the machine data is described in Subsection 10 5 1 Page 10 308 Dialog box DP slave properties Tab card Configuration Entry in table PROFIBUS Partner I O address lt I O address gt 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 The default setting with regard to the consistency of the I O data is whole length This setting results in e 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 e Accesses to this address range must be carried out using the system func tions S
482. on you do not need to perform an NCK reset after each copy procedure Interface version The NC system software accesses the compile cycles via a special interface The interface version used by the compile cycle and the NC system software must therefore be compatible Each interface version is displayed under e Interface version of the NC system software HMI Advanced Diagnosis gt Service displays gt Version gt NCU Version Display excerpt CC Interface Version NCKOPI Interfaces lt 1st digit gt lt 2nd digit gt Loaded Compile Cycles e Interface version of a compile cycle that has not yet been loaded HMI Advanced excerpt Services gt lt Medium gt gt Sofikey Properties Display Content Loadable compile cycle Interface lnterfaces lt 1st digit gt lt 2nd digit gt e Interface version of a loaded compile cycle HMI Advanced Diagnosis gt Service displays gt Version gt NCU Version Display excerpt CC Interface Version NCKOPI Loaded Compile Cycles lt ldentifier gt lt Version gt lt Date generated gt CC start address _N_ lt dentifies lt Version gt F lt 1st digit gt lt 2nd digit gt _ELF Example _N_CLC4071IF003001_ELF corresponds to interface version 3 1 Dependencies The following dependencies exist between the interface versionsof a compile cycle and the NC system software e 1 Digit of the interface version numb
483. on difference between the two encoder or position measuring systems of a machine axis is monitored with e MD36510 ENC_DIFF_TOL measuring system synchronism tolerance Error response e Alarm 25105 Measuring systems are not synchronous and stopping the machine axis using a speed setpoint ramp whose characteristic is set in e MD36610 AX_EMERGENCY_STOP_TIME Time for braking ramp when an error occurs Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 351 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles AX_EMERGENCY_STOP_TIME Setpoints from i Braking Setpoint Pos Speed bar g i 7 e Interpolator Processing Zi eontro oe Qu setpoint A CTRLOUT_LIMIT Control loop model PROFIBUS DP drive _ a r E ENC_CHANGE_TOL L CONTOUR_TOL ENC_DIFF_TOL ENC_ZERO_MONITORING ENC_FREQ_LIMIT Z Following error Act val processing 1 lg 1 val STSTILL VELO TOL j p g e STOP_LIMIT_COURSE 4 STOP_LIMIT_FINE AX_VELO_LIMIT Act val processing 2 lt ______ POSITIONING_TIME STANDSTILL_DELAY_TIME a ve de STANDSTILL_POS TOL IS Position measuring system 1 2 active CLAMP_POS_TOL Fig 10 22 Monitoring functions with SINUMERIK 840Di Notice e MD 36620 SERVO_DISABLE_DELAY_TIME servo enable cutout delay must always
484. on of the SRAM memory cells during the battery change cannot reliably be detected The SINUMERIK 840Di must then be restarted 5 3 4 Start up after replacement of the MCI board After the MCI board has been changed the further procedure depends on the past history The following cases are distinguished 1 An up to date SRAM image exists 2 An up to date SRAM image does not exist 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 serial num ber The SRAM image will then be written back to the SRAM of the MCI board The SINUMERIK 840Di is thus ready again immediately Responses A note will appear in a message box which must be acknowledged with OK Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 121 5 Power On and Power Up 01 05 5 3 Booting Case 2 An up to date SRAM image does not exist 5 122 SINUMERIK 840Di NCK PLC ET A Note User data loaded into MCI card Notice 1 If the MCI board is detected defective during the power up of the SINUMERIK 840Di the last SRAM image is kept when shutting down Windows XP After the MCI board has been changed proceed as described above 2 If the MCI board is changed due to a supposed or an actual error in the case of suspec
485. onitoring 10 351 Encoder types Absolute measuring system 10 322 Endlessly ee rotary axis 10 329 EQN 1325 10 322 Equidistant DP cycle Setting 6 157 Equidistant time 6 157 ESD measures 4 112 ET 200 Exact stop Coarse Fine Exact stop fine Delay time EXCHANGE LED PP72 48 Expanded message frame configuration 8 260 16 501 6 501 Expert mode Export version 1 39 External Floppy disk drive External power supply PP72 48 2 85 _ Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 Index F Failure safety 1 29 I O Assignment to hardware 10 383 Fatal exception error 1 29 I O addresses Drive configuration 10 312 System information 5 129 I O Module PP72 48 See also DP slave FB 1 PP72 48 8 225 HPU I O module PP72 48 2 46 2 84 MCP I Os FFT analysis 13 421 Final parameterization DP slaves gen 8 218 7 177 With USB interface 2 78 FORCE 10 402 Frequency response measurements 13 427 G GC 8 211 GD circle parameterization GD circle parameters Gear stage speed General 1 21 Geometry axes Global control telegram Global data communication Graphic display Drive Optimization Grounding PP72 48 2 93 GSD file General 8 215 1 O module PP72 48 H Handheld Terminal HT 6 Handheld unit HHU Handwheels Differential 2 63 TTL Hardware components 2 45 Complete system 2 45 MCI board ext
486. op Deactivation of the 611U specific motor switchover internal IN IR WOW MY O Deactivation of the 611U specific ramp block With an ADI4 module you can operate up to 4 drives with analog setpoint inter face on an isochronous PROFIBUS For these drives the 611U specific functions are deactivated according to the machine data bits 0 to 3 This requires that the value OFy be entered for each drive operated via ADI4 e MD13070 DRIVE_FUNCTION_MASK n OF Notice For all drives connected via ADI4 the 611U specific functions are deactivated according to the machine data bits 0 to 3 e MD13070 DRIVE_FUNCTION_MASK n OF y Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Drive type DP Drive type DP 4 ADI4 10 5 Axes and spindles The NC attempts to ascertain the drive type for each parameterized PROFIBUS drive The drive type is shown in the following machine data e MD13080 DRIVE_TYP_DP n drive type PROFIBUS DP The following drive types are shown by the NC 1 FSD SRM Synchronous Rotary Motor 2 MSD ARM Asynchronous Rotary Motor 3 Linear drive If the drive type cannot be ascertained by the NC because for example the drive does not support acyclic communication or it has been deactivated via machine data e MD13070 DRIVE_FUNCTION_MASK DP functions being used the following va
487. operator component at the same time To synchronize several operator components the PLC program must be adapted accordingly This is the user s machine manufacturer s responsibility MCPNum INT Number of active operator components MCP HT 6 default 1 max 2 MCP1In POINTER Address of MCP 1 input signals MCP1Out POINTER Address of MCP 1 output signals MCP1StatSend POINTER Addr of MCP 1 send status data MCP1StatRec POINTER Addr of MCP 1 receive status data MCP1BusAdr INT Default MPI address of MCP MCP1Timeout S5TIME Default setting should be kept MCP1Cycl S5TIME Default setting should be kept MCPMPI BOOL MCP HT 6 operated on extended MPI bus The MCP2 parameters are only needed if in addition to the 1st MCP a 2nd MCP or HT 6 is used MCP2In POINTER Address of input signals MCP HT 6 2 MCP2Out POINTER Address of output signals MCP HT 6 2 MCP2StatSend POINTER Addr of MCP HT 6 2 send status data MCP2StatRec POINTER Addr of MCP HT 6 2 receive status data MCP2BusAdr INT MPI address MCP2Timeout SSTIME Default setting should be kept MCP2Cycl S5TIME Default setting should be kept The parameters listed below serve to synchronize two operator components MCP1Stop BOOL Transfer of each operator component MCP2Stop BOOL FALSE start TRUE stop MCP1NotSend BOOL Send and receive operation of each MCP2NotSend BOOL operator component
488. or this POWER FAIL mechanism of the SINUMERIK 840Di 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 3 Booting 5 3 3 Start up after battery replacement backup battery of the MCI board Correct Before you replaced the backup battery of the MCI board the SINUMERIK Exit 840Di or Windows XP must be shut down correctly For shutting down use one of the following options e Windows taskbar Start gt Shut Down e Interface signal PC shutdown see Subsection 16 1 1 Page 16 499 Inverting SRAM If SRAM memory cells are inverted when changing the battery this will be de memory cells tected during power up In this case the SRAM image will be written back to the SRAM of the MCI board and the SINUMERIK 840Di is thus ready immediately Responses None Notice If Windows XP is shut down not correctly before changing the backup battery an inversi
489. orical reasons the passive file system of the NCK in which the user data such as parts programs user cycles etc are located is in the SRAM area of the NCK The SINUMERIK 840Di has retained this system architecture among other rea sons because of the increased data security Data retention also in case of a power fail event Protection from overwriting because no access to this memory area is possible by Windows XP applications The function DRAM file system permits relocation of data areas are in the SRAM area of the NCK by default into the DRAM file system by activating a machine data The memory that that releases in the SRAM can be used for example for more or larger parts programs Because when you switch off the NCK the memory content of the DRAM is lost the DRAM file system requires a retentive background memory The DRAM file system is reloaded from this retentive background memory every time the NCK is booted On the SINUMERIK 840Di the hard disk of the PCU is used as the background memory To ensure data consistency not only the entire SRAM but also the retentive background memory of the DRAM file system is cleared with the function Clear NC data for example before restart up of the NCK The maximum size of the DRAM file system in Kbytes can be set in the ma chine data e MD18351 MM DRAM FILE SIZE size of DRAM file system To ensure system compatibility with the SINUMERIK 840D the DRAM file sys
490. ormation on parameter sets see above Subsection 10 5 13 Page 10 332 FB1 Description of Functions Basic Machine S1 Spindles Chapter Gear step change Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles 10 5 23 Measuring systems of spindle Encoder matching Pulse multiplication factor SIMODRIVE 611 universal Example A encoder on the Spindle 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 10 5 5 Page 10 319 For absolute measuring systems see above Subsection 10 5 6 Page 10 322 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 The maximum multiplication of the appropriate drive is always used as the multiplication of the increments The pulse multiplication with SIMODRIVE 611 universal is 128 Examples of encoder adaptation Supposed the following conditions are provided e The incremental encoder is mounted on the spindle e Encoder pulses 500 pulses rev e Pulse multiplication 128 e Internal precision 1000 increment degree e Encoder gear stage 1 1 e Load
491. otential bonding conductor LEDs 1 4 1234 me Bae 7 X20 a lh 0 so Moon 4 2 ee x10 Power supply MPI interface S3 DIP switch EMERGENCY STOP button connections SHIELD M24 P24 Fig 7 8 Position of interfaces on rear panel of MCP For a detailed description of the electrical and mechanical design and of the MCP interfaces please refer to References BH Operator Components Manual Chapter Machine control panel MCP 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 Siemens AG 2005 All rights reserved 7 178 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 7 Machine control panel 19 or MCP 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 7 9 version number V 4 1 5 is displayed BEE LL BEE BEG Left key LED group Right key LED group Enable software version display Middle key LED group bs ig Fig 7 9 MCP software version display Data transfer rate The data transfer rate on the MPI bus
492. otes on the SINUMERIK 840Di 1 1 Overview of SINUMERIK 840Di 1 1 7 Failure safety Fatal exception If Windows XP detects a fatal exception error during the operation of the NC error system software the following steps are taken blue screen e Windows XP stops e An error message appears on screen e NC and PLC continues to operate normally e 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 retentive NC and PLC data to be stored the NC and PLC to be ended Note For a brief description of the PC OS fault and PC shutdown interface signals please refer to Subsection 16 1 1 Page 16 499 You can configure the response of Windows XP to a fatal exception error in the control panel Windows start menu Start gt Settings gt Control Panel gt System Dialog box Dialog box System Properties Tab card Advanced Button Settings Dialog box Startup Recovery Properties Group box System failure Radio button Automatically restart OK OK Option Automatically restart Not selected Stop blue screen default Selected Automa
493. otor American Standard Code for Information Interchange American coding standard for the exchange of information Asynchronous Subroutine Mode Mode group Ready Binary Coded Decimals Decimals with each digit coded in binary Basic Program Communication Central Processing Unit Cutter Radius Correction Digital to Analog Converter Data Block Data Block Byte Data Block Bit Dynamic Host Configuration Protocol Protocol for automatic assignment of IP addresses from a DHCP server to a client computer Dual Port RAM Dynamic memory volatile Differential Resolver Function Differential function for handwheel signaling Dry Run Dry run feedrate Data Send Ready Signal to indicate that serial data interfaces are ready Data Word Compact I O module PLC I O module Erasable Programmable Read Only Memory Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition A 517 A Abbreviations 01 05 ETC FC FDD FEPROM FIFO FIPO FST GEO GND HASH HEX HHU HMI HW HW Config HW limit switch INC INI INTV IS ISO code JOG K1 A 518 ETC key gt extension of softkey menu in the same menu Function Call function block on the PLC Feed Drive Flash EPROM Read and write memory First In first Out Memory that works without address specification and whose data are read in the same order in which they were stored Fine InterPOlator Feed Stop Geometry Signal GRouNd
494. out any affect on the traversing motion Note JOG mode must be selected when measuring functions are started The user must ensure that when the measuring functions are used the EMERGENCY STOP button is always within the reach no obstacles are in the traversing range The following events will cancel active measuring functions Hardware limit switch reached Traversing range limits exceeded Emergency stop Reset mode group channel NC STOP Nocontroller 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 3 Miscellaneous functions 13 3 Miscellaneous functions Interface signals In conjunction with the measuring functions another 2 axis specific interface Drive test signals are provided Traversing e DB31 DBx DBX61 0 Drive test traversing request request Traversing enable DB31 DBx DBX1 0 Drive test traversing enable In the PLC user program this can be used in conjunction with measuring func tions to realize an additional axis speci
495. ox Start IP address and subnet mask IP address 15 462 This section illustrates how to make and check settings for network configura tion on the external computer TCP IP protocol e IP address and subnet mask e Computer name and workgroup e Service Server service e Directory sharing The network protocols that have been installed are displayed in the network dialog box of the Control Panel Windows task bar Start gt Settings gt Control Panel gt gt Network under tab card Protocols If the TCP IP protocol is not shown it can be installed now Dialog box Network 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 After installation of the protocol and to simplify setting up communication with the PCU it is necessary to check the IP address and the subnet mask and set them if necessary 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup Subnet mask Dialog box Continuation Computer name and workgroup Dialog box Continuation Server service Dialog box End Directory sharing
496. p alarm ie ee Distributor User program Fig 6 1 Structure of the PLC program Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 147 6 PLC Start Up 01 05 6 1 Processing modules 6 148 General The individual blocks in the basic PLC program can be processed in the SIMATIC manager Select the appropriate block e g OB 100 in the folder Blocks of the corre sponding Module Use the menu command Edit gt Open Object to open the block or double click the block with the left mouse button Edit the block using the LAD STL CSF editor Switch over the block display using the menu command View gt LAD or STL or CSF Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 2 Startup 6 2 Startup The PLC can be started up by e 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 and basic parameterization of MPI and PROFIBUS communication please refer to Section 6 3 Page 6 153 e Loading an existing series start up file For how to create and read in a series start up file please refer to Chapter 14 Page 14 453 6 2 1 Basic requirements The following basic requirements for PLC start up must be met e SIMATIC STEP 7 as from Version 5 2 Service Pack 1 SIMATIC STEP 7 can either be installed directly on t
497. perating path e Operating area switchover gt Diagnosis gt NC PLC Diagnosis gt Diagnosis Start up CHAN1 JOG Ref M Channel RESET MPFO Program aborted ROV NCK 6 running SF NCKR NCK Default D RUN P CK Reset CK Default Data D BATL Acknowledge alarm 4065 g BATF RUN FORCE srop g RUN PLC PLC Delete Default Data SUO Program sus1 PLC Default Bus 2 Data PLC NCK latencies NCK Default Data Time sec Fig 10 35 Menu NC PLC Diagnosis Group box NCK The following functions are grouped together in the NCK group box e NCK state The current state of the NCK is displayed via the output field 0 not started 1 started 2 initializing data initializing data 4 start up 5 waiting for PLC 6 running F NCK error Siemens AG 2005 All rights reserved 10 400 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Group box PLC 10 10 NC PLC Diagnosis 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 start up the NC is in the reset state Machine and user data are not changed NCK Default Data Via the NCK reset button
498. phics2 Scaling trace 3 Scaling trace 4 Marker Graphics2 Scaling Auto Scaling Auto Couple with graphic1 Ea Ymax 180 000000 Y mag 1 000000 Xmax 166 666667 Y min 180 000000 Y min 1 000000 Xmin 0 000000 lariat Identifier on Identifier off Trace 3 Measure Service Axis User Displa File ment axis MD views functions Fig 13 7 Menu Scaling of graphics 13 436 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 5 Graphic display Soft keys Use the Graphics soft key shown in Fig 13 6 Page 13 435 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 13 7 Page 13 436 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 437 13 Drive Optimization with HMI Advanced 01 05 13 6 Trace function 13 6 Trace function 13 6 1 Trace function properties Function overview 13 438 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 selec
499. position control loop e Function Generator e Circularity test e Servo trace Notice A measurement of the torque control loop with HMI Advanced is not possible within the framework of SINUMERIK 840Di The measuring functions make it possible to evaluate the most important speed and position control loop quantities in the time and frequency range of a drive without any external measuring instruments The integrated FFT analysis Fast Fourier Transformation provides a powerful means to assess the control loop quality and in addition also to analyze the given mechanical properties The FFT analysis should be used whenever unsteady speed or position signal curves indicate problems with stability only long rise times can be obtained in the speed loop 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 Chapter Circularity test Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 421 13 Drive Optimization with HMI Advanced 01 05 13 1 Overview Servo trace Servo trace provides a graphically assisted analysis of the time response of servo and drive data For example e Actual position value e Position setpoint e Following error e Contour deviation Savin
500. possible to make an automatic selection Responses The following message box is displayed with which the user has to decide which user data have to be used further SINUMERIK 840Di NCK PLC xX IN New MCI card detected Valid user data are found on MCI card on harddisk If you want to use the user data from MCI card press Yes If you want to use the user data from the harddisk press No 5 3 7 Start up after importing a backup copy If a backup copy ghost image of a SINUMERIK 840Di already started up is loaded into the PCU again the battery backed user data in the SRAM of the MCI board will be used further The SINUMERIK 840Di is thus ready again immediately 5 3 8 Start up after power failure Power Fail Case 1 In case of a power failure the SINUMERIK 840Di will save the user data in the SRAM saved SRAM of the MCI board thanks to the Power Fail detection integrated in the PCU 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 The SINUMERIK 840Di is thus ready again immediately Siemens AG 2005 All rights reserved 5 124 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 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
501. prescribed torque e All connectors are plugged correctly and locked screwed e All components are grounded and connected to shields e The load capacity of the central power supply is taken into account With regard to the SIMODRIVE 611 universal inverter systems some additional points must be observed For more detailed information please refer to the fol lowing references References FBU Description of Functions SIMODRIVE 611 universal 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 Power supply conditions Pollution burden Function impairing gases Climatic ambient conditions Transportation storage Shock stressing Vibration stressing Ambient temperature Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 113 5 Power On and Power Up 01 05 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 SIMODRIVE 611 universal inverter system Motors SIMATIC S7 I O components HMI user interfaces 2 The or
502. processing MCP_INT NCK FC 2 Mode group Channel GP OB 1 Axis Spindle FC 14 MCP HHU FC 6 TM moan ee 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 OB 40 FC3 Process alarm GP_PRAL G group RU PA Distributor User program Fig 7 16 Structure of the PLC program The MPI parameters are set on the PLC side in function block FB 1 Since the data transfer rate of the MPI bus with SINUMERIK 840Di is 187 5 kbaud the 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 use HHU on an automation system alternately or simultaneously together with MCP HT 6 the user machine manufacturer has to adapt the PLC program accordingly Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 191 7 MPI Communication 01 05 7 9 Handheld unit B MPI References For a detailed description of the PLC basic program please refer to FB1 Description of Functions Basic Machine PLC Basic Program P3 Chapter FB 1 RUN_UP Basic program start up section Chapter FC 13 BHGDisp Display control for handheld unit 7 9 5 GD circle parameters o
503. quirements for an automatic or manual adjustment of the following SIMO DRIVE drives SIMODRIVE 611 universal or universal E SIMODRIVE POSMO CD CA SIMODRIVE POSMOS SI are met with SW 4 1 and higher The following describes the function on the basis of a SIMODRIVE 611 univer sal DP slave 611U drive Please adapt your procedure for the other SIMO DRIVE drives Note If third party drives are used please read the manufacturer s documentation to see whether and how to set the parameters on the drive The resolution of the torque reduction is parameterized in the DP slave 611U in parameter e P0881 Torque reduction evaluation As standard in the DP slave parameter P0881 is scaled to 16384 00 A 1 Examples for other resolutions 1638 40 40 1 163 84 l gt 0 01 Setpoint torque Tset of the drive is therefore calculated by P0881 TorRed i 16384 100 Tset Tmax t Max Maximum possible drive torque from rated motor torque and parameter P1230 Torque limit value MomRed The percent specified via FXST for the reduced drive control word in SIMO DRIVE standard message frame 102 to 107 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specific Data and Functions 16 3 Travel to fixed stop with high resolution torque reduction 16 3 4 Setting parameters for the SINUMERIK 840Di NC Automatic parameterization
504. quires a slight speed offset of a few motor revolutions per minute The offset must be set to a higher value than the amplitude e The Offset is run up via an acceleration ramp e 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 e The following applies Acceleration value 0 no ramp Acceleration value gt 0 ramp active e The actual measuring function becomes active only when the offset value is reached The transient response response to setpoint changes or disturbances of the speed control in the time range can be assessed with the step stimulation func tion The test signal is connected to the speed controller output for recording of the response to disturbances Amplitude This parameter determines the magnitude of the specified setpoint or distur bance step change Measurement time This parameter determines the period of time to be recorded maximum of 2048 x speed controller cycles Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 429 13 Drive Optimization with HMI Advanced 01 05 13 4 Frequency response measurements Additional information 13 430 Offset A low offset of a few motor revolutions per minute can be selected to rule out an influence of the static friction e The Offset is run up via an acceleration ramp e The acceleration value is defined for one
505. r STEP7 as the platform to match the basic PLC or PLC user program to the requirements of the appropriate automation system with regard to the opera tion of an machine control panel MCP and to then load it into the PLC Note A programming device PG PC is not required if the SIMATIC Manager is installed on the SINUMERIK 840Di How to install additional software is described in Chapter 15 page 15 461 The following software is required PLC basic program The MCP relevant modules of the basic PLC program are FB 1 MCP com munication parameters FC 19 interface parameter assignment version milling and FC 25 interface parameter assignment version turning The PLC basic program is included on the SINUMERIK 840Di installation CD The installation of the basic PLC program as a SIMATIC S7 library is described in Section 6 4 page 6 161 in detail SIMATIC STEP 7 SIMATIC STEP 7 is used for adapting the basic PLC and user programs e g call of FC 25 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 6 DP slave MCP 310 References The following manuals are required for installation and start up of the MCP FB1 Description of Functions Basic Machine P3 Basic PLC Program Description of the program structure and modules of the PLC basic program BH Operator Components Manual Description of MCP 310 interfaces electrical connection et
506. r more details about working with 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 F PLC 317 2DP 2AJ10 q N840Di t E PLC 317 2DP 2AJ10 Fig 8 4 Inserting the SIMATIC 300 station In HW Config now insert the required PROFIBUS modules from the hardware catalog into the S7 project EI HW Config SIMATIC 300 1 Configuration SIN840Di loj xj l Station Edit Insert Target System View Tools Window Help l x Dlala e le si sold ED E 22 de A PROFIBUS 1 DP master system 1 Profile Standard z A nc Network components fa Controller Switchgear Sensor equipment SIMADYN SIMATIC simoprive WB SIMODRIVE 611 universa es SIMODRIVE 611 universa HAE PLC 317 2DP 2AJ10 MPI DP S7 FM NCU 1 e Fig 8 5 HW Config Insert modules e g SIMODRIVE 611universal Siemens AG 2005 All rights reserved 8 216 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 3 Creating a PROFIBUS configuration 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 e NC The NC only has access to PROFIBUS 1 interface X101 corr
507. rated and decelerated with the acceleration entered in e MD 32300 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 s to 2 m s2 Siemens AG 2005 All rights reserved 10 336 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Checking the acceleration Machine data 10 5 Axes and spindles The sign of a properly adjusted acceleration of a machine axis is acceleration and positioning free from overshoot at rapid traverse rate and maximum load heavy workpiece After the acceleration has been entered the axis is traversed rapidly and the actual current values and current setpoint are recorded Note With SIMODRIVE 611 universal drives the current actual value and the current setpoint can be recorded using the SimoCom U start up tool trace function For further information please refer to the online help of SimoCom U This recording shows whether the drive reaches the current limit During this the current 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 d
508. re part of the basic PLC program It is the user s machine manufacturer s responsibility to call the block correctly and or assign the interface the appropriate parameters References A detailed description of the function blocks for transferring machine control panel signals to the VDI interface can be found in FB1 Description of Functions Basic Machine P3 Basic PLC Program Chapter FC 19 MCP_IFM Chapter FC 24 MCP_IFM2 Chapter FC 25 MCP_IFT The following example shows the communication parameter settings for func tion block FB 1 for a machine control panel MCPNum 0 Number of active MCPs MCP1In P E 0 0 Address of input data 8 bytes MCP1Out P A 0 0 Address of output data 8 bytes MCP1StatSend P A 0 0 Default setting no meaning MCP1StatRec P A0 0 Default setting no meaning MCP1BusAdr 0 Preset no significance MCP1 Timeout SST 700MS Default setting no meaning MCP1Cycl SST 200MS Default setting no meaning MCPMPI FALSE MCP HT 6 operated on extended MPI bus MCP1Stop FALSE Default setting no meaning MCP1NotSend FALSE Default setting no meaning MCPSDB210 FALSE Preset no significance 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 e PLC operating system e PROFIBUS controller If the f
509. referencing Signals from channel to PLC MMC gt PLC REF K1 Referencing active Reset K1 All axes referenced Signals from PLC to axis spindle Position measurement system 1 Position measurement system 2 A2 Reference point value 1 to 4 Traversing keys minus plus H1 Reference point approach delay Signals from axis spindle to PLC Referenced synchronized 1 Referenced synchronized 2 Traverse command minus plus H1 Table 10 40 Referencing machine data 10 362 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles Number Name of identifier Name Refer ence General MN_ 11300 JOG_INC_MODE_LEVELTRIGGRD INC REF in jog continuous mode H1 Channelspecific MC_ 20700 REFP_NC_START_LOCK Axisspecific MA_ 30200 NUM_ENCS 30240 ENC_TYP 30242 ENC_IS_INDEPENDENT 31122 BERO_DELAY_TIME_PLUS 31123 BERO_DELAY_TIME_MINUS 34000 REFP_CAM_IS_ACTIVE 34010 REFP_CAM_DIR_IS_ MINUS 34020 REFP_VELO_SEARCH_CAM 34030 REFP_MAX_CAM_DIST 34040 REFP_VELO_SEARCH_MARKER n 34050 REFP_SEARCH_MARKER_REVERSENn 34060 REFP_MAX_MARKER_DISTn 34070 REFP_VELO_POS 34080 REFP_MOVE_DISTIn 34090 REFP_MOVE_DIST_CORR n 34092 REFP_CAM_SHIFT 34100 REFP_SET_POSjn 34102 REFP_SYNC_ENCS 34110 REFP_CYCLE_NR 34120 REFP_BERO_LOW_ACTIVE 34200 ENC_REFP_MODE n 34210 ENC_REFP_STATE n 34220 ENC_ABS_TURNS_MODULO 34300 ENC_REFP_MAR
510. require a password for protection level 0 2 System Manufacturer Service Following menu PLEASE SELECT 1 Harddisk Backup Restore with GHOST 4 Partitions Backup Restore with GHOST locally 5 ADDM Backup Restore 9 Back to previous Menu Your Choice 1 4 5 9 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu 3 Choose Partitions Backup Restore with Ghost locally with key 4 Following menu Ghost Connection Mode LOCAL Maximum Backup Images lt Max_ number Current Backup Images lt Cur_number PLEASE SELECT Configure GHOST Parameters Partitions Backup Mode LOCAL Partitions Restore Mode LOCAL Partition E only Window Restore Mode LOCAL Delete Image o ORWN Back to previous Menu Your Choice 1 2 3 4 8 9 Make sure that the displayed max number of possible partition backups is not yet reached Note Changing the max number of partition back ups Subsection 15 5 5 Page 15 488 Deleting partition back ups Subsection 15 5 6 Page 15 489 4 Choose Partitions Backup Mode LOCAL with key 2 Following menu You must specify the image name max 7 characters long Image Name 5 Type the name under which you wish the partition backup to be stored max 7 characters In the example
511. res entry of its I O address and message frame type under index 0 e MD13050 DRIVE_LOGIC_ADRESS 0 258 e MD13060 DRIVE_TELEGRAM_TYPE O 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 e MD13050 DRIVE_LOGIC_ADRESSJ3 472 e MD13060 DRIVE_TELEGRAM_TYPE 3 3 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 325 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Machine data Table 10 24 Number General MN_ 13050 13060 30220 30220 Interface signals Table 10 25 DB Number Axis spindlespecific 91 5 312 10 326 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 e MD30220 ENC MODUL NR 0O 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 e MD30220 ENC_MODUL_NR 1 4 with 4 Index 3 of the corresponding MD13050 1 See Subsection 10 5 4 Page 10 316 Drive configuration machine data Name of identifier Name remarks Refer ence DRIVE_LOGIC_ADDRESS n Logical I O address of drive
512. resolution 800 x 600 e 1024 ID for screen resolution 1024x 768 Note Directory Screen resolution may only contain one file You can choose any file name Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 4 SINUMERIK desktop 5 4 10 HMI Explorer Version display Installation directory The HMI Explorer is used to manage the Siemens A amp 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 fi HMI Explorer BEG File View System Program Install Info BERE J SINUMERIK I 840Di a HMI Base V06 02 11 01 V06 02 11 00 Bil BaseSoftware WinXP V03 02 03 02 V02 03 02 03 p HMI Advanced V06 03 11 00 V06 03 11 00 ud HMI Programming Package V06 02 11 00 V06 02 11 00 ial HMI Service Pack 2 2 mi 840Di V06 03 11 00 V06 03 10 00 MPI Driver R06 03 11 00 R06 03 11 00 ii STEP7 V05 03 01 00 V05 03 01 00 si SIMATIC ProTool Pro CS V05 02 03 00 V05 02 03 00 Ready Jz Fig 5 2 HMI Explorer Product Version Display Example The following versions are displayed for each software application e Current version Current version number e Release version Version number with which product was first
513. response 13 428 Alternatively the interference frequency response can be recorded in order to assess how well the control suppresses interference 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced Measurement parameters Setpoint disturban ce step changes 13 4 Frequency response measurements 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 measure ment time The maximum value is given by the position control cycle Tposition controller Bandwidthmax HZ 1 2 Tposition controller sec Example Position controller cycle 2 ms Bandwidthmax 1 2 2 1078 250Hz Averaging The accuracy of the measurement but the measurement duration too will in crease with this value A value of 20 is normally suitable Settling time This value represents the delay between recording of the measured data and injection of the test setpoint and offset A value of between 0 2 and 1 s is recom mended Do not set too low a value for the settling times or the frequency re sponse and phase diagrams will be distorted Offset The measurement re
514. rface signal Drive test traversing enable al Toggle key lt UT gt v The measuring functions have their own traversing range monitoring This tra versing range monitoring can be used to limit or monitor the traversing range of an axis to be measured without referencing this axis The basis is the absolute axis position displayed in the Status group at the time of measurement The traversing range monitoring is activated from the main menu of the ap propriate measuring function in the group Traversing range See Fig 13 1 Page 13 425 Choose the type of traversing range monitoring from the selection list Monito ring either using the Toggle key or by clicking with the right mouse button on the desired type of traversing range monitoring 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 4 Frequency response measurements 13 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 Note You will find detailed information abou
515. ring system switchover Interface signals 10 317 Memory DRAM 10 302 Free DRAM memory 10 302 Free SRAM memory 10 303 Reconfiguration of SRAM 10 303 SRAM 10 303 Memory configuration 10 301 Hardware configuration 10 301 Message frame configuration Expanded 16 501 Message frame type Drive configuration 10 313 Message texts 11 407 Index 540 Module ADI4 2 96 Diagnostic repeater for PROFIBUS DP 2 98 MCI board 2 48 MCI board extension internal 2 57 PP72 48 2 84 Module replacement MCI board Modulo display 10 329 Monitor control Using HMI Advanced 6 167 Using the SIMATIC Manager STEP7 6 166 ee MCI board extension slot variation MPI Interface MPI interface 7 179 7 186 Recommended 7 176 MPI bus 7 176 MPI Communication 7 169 MPI configuration 7 173 Precondition 7 173 MPI interface 7 185 Parameterization 6 150 5 158 5 159 Setting 9 274 MPI parameterization of the PLC HHU 7 190 MPI parameters HHU 7 189 N NC system clock cycle Setting 6 157 NC system software 1 25 NCK Default data 10 401 Distribution of CPU time 1 26 General 1 25 Reset 10 401 Setting the CPU time component 10 297 NCK address HT 6 NCK CPU time share 10 297 NCK General Reset NCK interface HPU NCK interface parameter assignment MCP NCK latenc NCK state 10 400 Network link Networking rules 7 169 3 21
516. rol 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition MPI Communication 7 1 Special features of SINUMERIK 840Di Data transfer rate The data transfer rate at the MPI bus of the SINUMERIK 840Di must be set to 187 5 kbaud Notice The data transmission rate must be set to 187 5 kbaud Insertion removal No nodes must be plugged in or removed without special measures from the MPI bus of the SINUMERIK 840Di while it is in operation Notice No nodes must be plugged in or removed without special measures during operation 7 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 Atleast 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 For this purpose the MPI connection on the MPI board of the SINUMERIK 840Di can be used 4
517. roller 2 TDX PROFIBUS DP MSG RES GC bxbxDx Msa RES GC DxDx Dx communication DP slaves RI IRI IRV RW IRI RI RW IRI IR RW RW RW IRR Drives Fig 10 2 Position control cycle offset compared to PROFIBUS DP cycle Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 295 10 NC Start Up with HMI Advanced 01 05 10 3 System data Key to Fig 10 2 TPos CPU time required by position controller Tpp DP cycle time DP cycle time Tpx Data exchange time Sum of transfer times of all DP slaves Tu Master time Offset of the start time for NC position control GC Global control Broadcast message for cyclic synchronization of the equidistance between DP master and DP slaves R CPU time Dx Exchange of user data between DP master and DP slaves MSG Acyclic services e g DP V1 pass token RES Reserve active break until the equidistant cycle has elapsed e MD10062 POSCTRL_CYCLE_DELAY position control cycle offset The following setting is recommended as approximate value for the position control cycle offset Tw Top 3 Tpos max Top The DP cycle time is equivalent to the position controller cycle of the SINUMERIK 840Di Thos max Display using HMI Advanced optional Operating area switchover gt Diagnosis gt Service displays gt System resources Error response e Alarm 380005 PROFIBUS DP Bus access conflict type t counter z
518. rsal Toolbox gt 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 readme txt file in the installation directory SimoCom U provides the following functions Make an online connection to the drives Upgrade the firmware Optimize the control parameters Traverse the axes Diagnose the drive status 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 Howto Use WINDOWS Help Help Topics Key Operation Wiring About SimoCom U You will also find a detailed description about SimoCom U in FBU SIMODRIVE 611 universal Description of Functions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 9 277 9 Drive Start Up 01 05 9 2 Installing SimoCom U Notes Siemens AG 2005 All rights reserved 9 278 SINUMERIK 840Di Manual HBI 01 05 Edition NC Start Up with HMI Advanced 10 1 General procedure The NC is parameterized for the connected machine by setting system vari ables These system variables are called e Machine data MD e Setting data SD 10 2 Machine and setting data Machine data Machine data
519. rting the function Check SINUMERIK System 5 5 6 Backup Restore Operator action Starting from the main menu see Fig 5 3 Page 5 132 select Backup Restore with key 7 You will find a detailed description of the backup restore functions data backup in Section 15 5 Page 15 475 5 5 7 Restore Windows Partition E Emergency Operator action Starting from the main menu see Fig 5 3 Page 5 132 select Restore Win dows Partition E Emergency with key E A detailed description of the restore function is to be found in Subsection 15 2 7 Page 15 472 5 5 8 840Di services Operator action Functions Starting from the main menu see Fig 5 3 Page 5 132 select 840Di Services with key P Following menu PLEASE SELECT 1 Set PLC Mode to STOP 2 Set PLC Mode to RUN 3 Set PLC Mode to RUNP 4 Initialize NCK Data You will loose all NCK user data 5 Boot without starting NCK PLC 9 Return to Main Menu Your Choice 1 2 3 4 9 You can execute the following functions via the menu e Set PLC Mode to STOP e Set PLC Mode to RUN Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 135 5 Power On and Power Up 01 05 5 5 Service menu 5 136 e Set PLC Mode to RUNP e Initialize NCK Data You will loose all NCK user data Notice This function deletes all user data e Boot without starting NCK PLC After you have selected
520. rtup and synchronization OB 100 e Cyclical mode OB 1 e 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 7 10 FC 9 15 16 18 ASUB con axes spindles FB 2 3 4 Var read write PI services FC 13 HHU OB 100 FB1 __ Start up Cold restart __ e g HHU parameters ly User program OB 1 FC 27 Cyclic processing MCP_INT NCK pee Mode group ____ Channel GP OB 1 aye Spindle FC 14 MCP HHU FC 6 TM Er FC 19 25 26 User program FC 7 8 22 TM ____ TM _ Trans TM_Dir FC 17 Star delta FC 10 Error and opera tional messages OB 40 FC3 Process alarm GP_PRAL G group Fie ot a ll Distributor User program display contr Fig 7 10 Structure of the PLC program SINUMERIK 840Di Manual HBI 01 05 Edition 7 181 7 MPI Communication 01 05 7 7 Machine control panel 19 or MCP Setting the The communications parameters of the MCP are called MCPx x 1 or 2 in communication function block FB1 parameters FB1 In addition to a first MCP a second MCP or an HT 6 for HT 6 see Section 7 10 page 7 196 can be active as another
521. rved 8 244 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 7 DP slave MCP 483 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 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 SIEMENS Ww HEE BEE 00G ee aus pont o Mt 5 Go Go 4 LE BEE BEA f 7 10 100 i eg EE H le A EEE BEG aa re LPs a en Re eS Enable software version display 1 Digit 2 Digit 3 Digit left LED block center LED block right LED block press both keys simultaneously Fig 8 18 MCP software version display Switch S3 The following parameters are set with switch S3 on the rear of the MCP e Connection type e Hardware code e PROFIBUS address Table 8 6 Switch S3 9 10 Connection type 109 8 71651413 21 1 Connection type onjoni I l I PROFIBUS DP Table 8 7 Switch S3 8 Hardware code 101
522. s 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 14 455 14 User Data Backup Series Machine Start Up 01 05 14 2 Creating a series commissioning file 14 2 2 14 456 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 machine start up file Operating area switchover gt Services gt ETC key gt gt Series machine start up gt 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 Create the series machine start up file by selecting the device to which you wish the file to be output see figure RS 232 C parameterizable COM1 or COM2 Output to a device connected to the serial interface PG parameterizable COM1 or COM2 Output to a programming device e g PG740 or PC Diskette Output to diskette drive that can optionally be connected to the 840Di Archive Storage of the file in the archive directory on the hard disk of the PCU Service CHAN AUTO MPFO CA Cartel Program aborted RESET RE Archive content
523. s multi turn resolution Refer ence R2 R2 10 323 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 5 7 Parameterization of a 2nd measuring system with ADI4 Parameterization example Configuration 10 324 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 References ADI4 Analog drive interface for four axes Chapter Hardware Description The following parameterization examples illustrates the basic procedure for parameterizing the NC for a 2nd measuring system of a machine axis con nected via ADI4 It assumes the following e NC 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 e Drive SIMODRIVE 611U 1 axis module is used as the drive with a connection op tion for a measuring system motor encoder e 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 The configuration is shown in Fig 10 12 U 840Di configuration 611U ADI4 PROFIBUS 1 DP master system 1
524. s sioning file e NC with without compensation data see below Note e PLC e HMI e 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 The contents of a series machine start up file created for the NC 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 14 User Data Backup Series Machine Start Up 14 2 Creating a series commissioning file 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 block
525. s ai ty ist My as my lo Vv vV F xal xoll xsl xa Ixsllxel xz xel xol kid Plug in connectors X1 X10 S2 S5 S1 S4 S s3 amp S1 to S6 Closed je x11 U Open P Sub D socket connector Fig 2 13 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 2 S3 S4 S5 S6 Open x x x x Closed x x Siemens AG 2005 All rights reserved 2 66 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 4 Cable distributor Connector assignments Table 2 9 Connector assignments Connector No Cable No I Os A 1 Handwheel x2 top nandawnee 73 2 2 Handwheel x4 nandawnee X5 3 2 probe x 4 4 bi input x7 inary inputs X8 5 4 binary outputs X9 6 Supply for 4 binary outputs 7 X10 bottom 1 probe 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 Adapter plate Cable distributor Side view Fig 2 14 Mounting the cable distributor Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01
526. s MCP HT 6 2 MCP2Out POINTER Address of output signals MCP HT 6 2 MCP2StatSend POINTER Addr of MCP HT 6 2 send status data MCP2StatRec POINTER Addr of MCP HT 6 2 receive status data MCP2BusAdr INT MPI address MCP2Timeout SSTIME Default setting should be kept MCP2Cycl S5TIME Default setting should be kept The parameters listed below serve to synchronize two operator components MCP1Stop BOOL 0 Start trans of MCP HT 6 signals MCP2Stop BOOL 1 Stop transfer of MCP HT 6 signals MCP1NotSend BOOL 0 Send and receive mode is active MCP2NotSend BOOL 1 Only reception of MCP HT 6 signals The following parameter is used to announce that an MPI configuration exists in system data block SDB210 MCPSDB210 BOOL MPI configuration via SDB210 Notice A maximum of two MCP HT 6 can be operated on an MPI line To be able to use MCP and HT 6 on an automation system alternately or simultaneously the user machine manufacturer has to adapt the PLC program accordingly References For a detailed description of the PLC basic program or of function block FB1 please refer to FB1 Description of Functions Basic Machine PLC Basic Program P3 Chapter FB 1 RUN_UP Basic program startup section Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 201 7 MPI Communication 01 05 7 10 Handheld Terminal HT 6 Parameter The FC 26 transfers the signals of the HT 6 with regard to
527. s active For detailed information on start up of SIMODRIVE 611 universal drives refer to FBU SIMODRIVE 611 universal Description of Functions Chapter Parameterizing the Module Parameterization via display and control unit and Chapter PROFIBUS DP master settings Start up Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 9 Drive Start Up 9 1 SIMODRIVE 611 universal E POSMO CD CA and SI 9 1 4 Setting PROFIBUS address SIMODRIVE POSMO SI CD CA References 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 153f must be set on DP slave POSMO SI CD CA in question using the DIL switches of the PROFIBUS unit in question Keyswitch pos ET mee i OFF 0 B DOUTE 1234 12345678 4 d ON 1 x PROFIBUS address TY 2 a oe ES OMe GeO 20 21 22 23 24 25 26 reserved 1 2 4 8 16 32 64 Example PROFIBUS address 37
528. s and the following alarm is displayed e Alarm 20002 Zero mark missing Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 355 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Phase 3 The following machine data and interface signals are important ae reterenge MD34070 REFP_VELO_POS reference point positioning velocity e MD34080 REFP_MOVE_DIST reference point distance to zero mark e MD34090 REFP_MOVE_DIST_CORR reference point offset additive e MD34100 REFP_SET_POS reference point value e IS DB31 DBX2 4 2 5 2 6 2 7 Reference point value 1 4 e IS DB31 DBX60 4 DBX60 5 Referenced synchronized 1 2 Properties of phase 3 e Feed override the feed override switch is active e Feed stop channel specific and axis specific is active e NC Stop NC Start are active References FB1 Description of Functions Basic Machine R1 Reference point approach Chapter Referencing with incremental measurement systems Siemens AG 2005 All rights reserved 10 356 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles Distance coded When clearance coded reference marks are used referencing is divided into reference marks 2 phases 1 Synchronize by overriding 2 reference marks 2 Traverse to target point IS Approach ref point delay DB31 DBX12 7
529. s at the MPI bus check the following Is the data transfer rate of all nodes whose data transfer rate is set manually DIP switches set to 187 5 kbaudl Do all nodes have a unique consistent MPI bus address Inthe S7 configuration MPI address set on node Are there any loose cable connections Are all bus segments terminated correctly Notice The terminating resistor is built into some components Handheld unit HHU Handheld terminal 6 HT 6 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 3 Global data communication 7 3 Global data communication General GD communication is a simple form of communication integrated in the operat 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 QD 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 Markers Ranges from data blocks Timers counters Not recommended because the values at the receiver end
530. s cuisines 6 3 Creating a SIMATIC S7 project 6 3 1 Creating a project 6 15 6 3 2 Inserting station 300 6 3 3 HW Config Sade Bias TT eae eat awed hee UT 6 3 4 Inserting 840Di Rack 6 156 6 3 5 Parameterizing the PROFIBUS interface X101 6 157 6 3 6 Parameterizing the PROFIBUS interface X102 optional 6 158 Siemens AG 2005 All rights reserved a SINUMERIK 840Di Manual HBI 01 05 Edition XIII SINUMERIK 840Di Manual 01 05 Contents 6 3 7 Parameterizing the MPI interface X102 optional 6 3 8 Parameterizing the NC I O data 6 4 Creating a PLC program 6 4 1 PLC basic program 6 4 2 PLC user program 6 5 Creating a MPI configuration 6 6 Creating a PROFIBUS configuration 6 7 Loading the configuration 6 7 1 R quir ments 224448 abat apparament aident s 6 7 2 Loading the configuration 6 7 3 Series machine start up file 6 8 Testing the PLC program 6 8 1 start up behavior
531. s executed first Then cyclic operation 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 The ranges of the timers counters and flags that are to be retentive must be set using the dialog box Properties tab card 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 deleted 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 165 6 PLC Start Up 01 05 6 8 Testing the PLC program 6 8 2 Cyclic operation NC communication Sign of life monitoring In cyclic operation communication or exchange of data and signals is carried out between the PLC
532. s for gear stages MD 35150 Spindle speed tolerance IS Actual gear stage DB31 DBxx DBB16 IS Drive parameter set selection DB31 DBxx DBB21 IS Set gear stage DB31 DBxx DBB82 IS Active drive parameter set DB31 DBxx DBB93 Position reached from 1 high speed 2 zero speed Change over gear stage All gear stages tested Check machine data MD 36000 Exact stop coarse MD 36010 Exact stop fine MD 32200 Ky factor MD 35210 Acceleration in position control range MD 35300 Creep speed MD 36300 Encoder limit frequency MD34200 Spindle synchonization MD of encoder matching Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 12 419 12 Axis Spindle Dry Run 01 05 12 3 Spindle dry run Notes Siemens AG 2005 All rights reserved 12 420 SINUMERIK 840Di Manual HBI 01 05 Edition Drive Optimization with HMI Advanced 13 1 Overview Start up drive servo Measuring functions Integrated FFT analysis Circularity test In the operating area Start up of HMI Advanced the following functions can be chosen from the menu item Drives Servo for analyzing speed and position con troller of a drive as well as individual drive servo data e Frequency response measurement of speed control loop e Frequency response measurement of
533. s 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 Phase 2 The following machine data and interface signals are important Synchronizing to the e MD 34040 REFP_VELO_SEARCH_MARKER creep velocity encoder zero marker e MD 34050 REFP_SEARCH_MARKER_REVERSE direction reversal to reference cam e MD 34060 REFP_MAX_MARKER_DIST maximum distance from cam to reference mark Properties of phase 2 e 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 e Feed stop channel specific and axis specific is active On a feed stop the traverse movement is stopped and the alarm displayed e Alarm 20005 Reference point approach canceled e NC Stop NC Start is inactive e If the machine axis travels as from exiting the reference cam e 1S DB31 DBX12 7 Reference point approach delay 0 a max distance parameterized in the machine data e MD 34060 REFP_MAX_MARKER_DIST max distance to the reference mark without the zero mark being detected the machine axis stop
534. s were lost between two zero mark passes Via monitoring Position tolerance when switching over the encoder Cycl monitoring of the encoder position tolerance e MD 36310 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 e Alarm 25020 Zero mark monitoring and stopping the machine axis using a speed setpoint ramp whose characteristic is set in e MD36610 AX_EMERGENCY_STOP_TIME Time for braking ramp when an error occurs Cause of errors error handling e MD36300 ENC_FREQ_LIMIT n encoder limit frequency set too high e Encoder cable damaged e Encoder or encoder electronics defective It is possible to switch over between the two possible encoders or position measuring systems of a machine axis at any time The permissible position difference between the two position measuring systems is monitored e MD 36500 ENC_CHANGE_TOL maximum tolerance when switching over the actual position value Error response e Alarm 25100 Measuring system cannot be switched over The requested switchover to another encoder is not carried out Cause of errors error handling e The specified permissible tolerance is too small e The position measuring system to which you will switch over is not referenced The positi
535. sa far Inactive Physical Meas parameters address Meas time 3000 Trigger No trigger x Triggertime 9 Threshold 9 001 mm Service Axis User Display File axis MD views functions Fig 13 8 Main menu Servo trace The cursor is controlled If the cursor is placed on Toggle key a list box press the using the arrow keys on the Insert key operator panel or with the to open the mouse list box You can scroll down KI o D by using the arrow keys You accept a value using the gt input key Fig 13 9 Cursor operation Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 439 13 Drive Optimization with HMI Advanced 01 05 13 6 Trace function 13 6 3 Basic screen settings Signal selection Input field Axis spindle name Input field Signal selection Measuring parameters Input field Measurement time Input field Trigger time Input field Trigger Input field Threshold 13 440 Parameterization The following settings have to be made in the basic screen The axis spindle to be measured The signal to be measured Measurement time Trigger time Trigger type Trigger threshold The cursor must be positioned on the Axis spindle name list box of the trace concerned You can select it with the soft keys Axis and Axis or by accepting a value from the dropdown list The cursor must be positioned on the
536. ser specific keys and outputs e Input data 8 bytes e Output data 8 bytes 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 The function transfers the absolute values for the two handwheels that can be connected to the machine control panel e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 6 DP slave MCP 310 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 e Direct control key e Customer keys 6 signals bit 0 to bit 6 e Rotary switch with the following distribution e Input data 5 bytes Direct control keys OP 012 goo an ek Low byte High byte e Output data 2 bytes Reserved Customer always 0 LEDs Low byte High byte Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 233 8 PROFIBUS DP Commun
537. served SINUMERIK 840Di Manual HBI 01 05 Edition 15 485 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu 15 5 4 Backing up partitions C E a F to local image file Brief description Requirements Operator actions 15 486 This subsection describes how to create an image file of partitions C E and F The image file is stored under D IMAGES The image files can be back up onto an external medium hard disk of an exter nal computer CD DVD etc while backing up the entire contents of the hard disk see Subsection 15 5 1 Page 15 475 The following conditions must be fulfilled e Partition D must contain enough free space because the image files are always stored under D IMAGES e The maximum number of possible partition backups may not yet be re ached After the PCU has been switched on the menu of the boot manager is dis played 1 Select the menu option Service menu hidden using the CursorDown key and then press the Input key The following menu appears PLEASE SELECT Install Update SINUMERIK System SINUMERIK Tools and Options DOS Shell Start Windows XP Service Mode SINUMERIK System Check Backup Restore Start PC Link Reboot Restore Windows Partition E Emergency 840Di Services um o ONARAN Your Choice 1 2 3 4 5 7 8 9 E P 2 Choose Backup Restore with key 7 The system prompts you to enter a password You
538. smit the output signal to the signal module on PROFIBUS DP Connect the signal to the output of the module 10 6 6 Configuration example In the following configuration example the following input outputs are available to the NC ET200 24 digital inputs 16 digital outputs ADI4 8 digital inputs 16 digital outputs Note e The I O addresses of the modules are assigned automatically by HW Config Manual adjustment is possible e Each I O address refers to an input output byte A 840Di configuration 840Di_ET200_ADI4 PROFIBUS 2 DP master system 2 Ga IM 153 a IT PLC317 2DP M S 2AJ10 X2 DP master 4 JE CP 342 5 Fig 10 33 Example configuration SINUMERIK 840Di with ET200 and ADI4 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 387 10 NC Start Up with HMI Advanced 01 05 10 6 Digital and analog I O devices ET200 I Os IM 153 Slot Module 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 address O address Comment 4 Drive data 5 Drive data 272 289 1 Axis 6 Drive data 272 281 1 Axis 7 Drive data 8 Drive data 9 Drive data 290 307 2 Axis 10 Drive data 290 299 2 Axis 11 Drive data 12 Drive data 13 Drive data 332 349 3 Axis 14 Drive data 332 341 3 Axis 15
539. spindle speed is entered in machine data e MD35100 SPIND_VELO_LIMIT max spindle speed The NC 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 e IS DB31 DBX83 0 speed limit exceeded 1 e Alarm 22150 Maximum number of chucks exceeded Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Gear stage speed min max Progr Spindle speed limitations Encoder cut off frequency 10 5 Axes and spindles Machine data e 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 NC limits the specified maximum speed specified in machine or setting data to 90 of the maximum value con trol reserve The max min gear stage speed is entered in e MD35130 GEAR_STEP_MAX_VELO_LIMIT maximum speed for gear stage e 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 The functions e G25 S min spindle speed e 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
540. splay 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 e 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 10 5 1 Page 10 308 The diagram below illustrates the spindle modes and possible transitions between them Oscillation mode Synchronous mode Gearbox Gearbox change Fees SPOS and SPOSA couron JoouroF Positioning mode Control mode SPCOF M3 M4 M5 M4145 Axis mode case G331 Rigid tapping Fig 10 25 Spindle modes Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 365 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles Default 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
541. ssible ASCII text files The alarm and message texts contained in the text files are used commonly by all SINUMERIK user interfaces e SinuCom NC e 840Di start up e HMI Advanced By changing modifying the texts or files or by creating new texts files a flexible adaptation to the current requirements is possible Files containing the alarm and message texts are stored on the hard disk in directory lt installation path gt dh mb dir 11 1 1 Configuration file MBDDE INI Structure of the file MBDDE INI The alarm and message texts to be used are set in the file lt installation path gt 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 lt installation path gt dh mb dir alm_ NCK lt installation path gt dh mb dir aln_ PLC lt installation path gt dh mb dir pic_ ZYK lt installation path gt dh mb dir alz_ CZYK lt installation path gt dh mb dir alc_ UserMMC UserNCK UserPLC lt installation path gt dh mb dir myplc_ UserZyk UserCZyk Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 11 407 11 Alarm and Message Texts 01 05 11 1 Alarm and message texts 11 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
542. sspecific is active e The machine axis can be stopped and restarted with NC stop NC start To determine the absolute offset between the measuring system zero point and 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 e MD 34090 REFP_MOVE_DIST_CORR 0 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced ZN References 10 5 Axes and spindles 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 e MD34090 REFP_MOVE_DIST_CORR reference point absolute offset Warning After you have determined the absolute offs
543. t The step is stimulated from standstill or starting from the constant traverse speed set in this parameter Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 13 433 13 Drive Optimization with HMI Advanced 01 05 13 4 Frequency response measurements Position fe A Amplitude z D a a Settling time Ramp time Measurement time Fig 13 5 Signal chart for position setpoint ramp measuring function At maximum axis velocity there is a virtual step change in the velocity conti nuous line The curves represented by the dashed line correspond to a realistic finite va lue The offset component is excluded from the display graphic in order to em phasize the transient processes Step height To avoid damage to the machine the step height for the setpoint step change is limited to the value specified in e MD 32000 MAX_AX_VELO maximum axis velocity This can prevent the desired step height from being achieved Similarly the following apply to the setpoint ramp in the ramp range e MD 32000 MAX_AX_VELO maximum axis velocity e MD 32300 MAX_AX_ACCEL max axis acceleration The max axis velocity limits the ramp rate of rise velocity limitation whereby the drive does not reach the programmed end position amplitude The acceleration limitation caused by the max acceleration rounds the transi tion at the beginning and end of the r
544. t frequency measurement and optimization of the torque current and speed control loop of the SIMODRIVE 611 universal E POSMO CD CA and SI drives in the online help of the start up tool SimoCom U Menu command Help gt Help topics gt Index Measuring function Optimization of speed control loop 13 4 1 Torque control loop measurement A measurement of the torque control loop with HMI Advanced is not possible within the framework of SINUMERIK 840Di 13 4 2 Speed control loop measurement Functionality Procedure Note You will find information about optimization of the torque current and speed control loop of the SIMODRIVE 611 universal universal E POSMO CD CA and SI drives in the online help of the start up tool SimoCom U Index Optimization of speed control loop This measurement function basically analyses the response to the motor mea suring system Depending on which basic measurement setting has been se lected various measurement parameters lists as described below are made available The traversing range monitoring function is set and the enabling logic external internal selected in the speed control loop measurement main screen 1 Set the traversing range monitoring and enable logic in the basic display You can select one of the following measurement types Reference frequency response Setpoint step change Interference frequency response Disturbance step change Speed co
545. t license acc to the German Export List the SINUMERIK 840Di is available in two variations The standard version SINUMERIK 840Di can contain the full scope of functions of the control but this does mean that it requires export approval with regard to its type In the export version SINUMERIK 840DiE e g the following options are not available e Interpolation with more than 4 axes e Machining package 5 axes e Helical interpolation 2D n n greater than 2 e OEM package The following restrictions apply to options that can be used e The sag compensation is limited to traversing a maximum distance of 10 mm Note For a complete overview of the options not available with the export version please refer to SINUMERIK Order Catalog NC 60 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 upgrad
546. t match the I O address set in the NC There is no automatic adjustment The following data must match 1 SIMATIC S7 configuration of DP slave 611U 1 0 address 2 SINUMERIK 840Di NC MD13060 DRIVE_LOGIC_ADDRESSjn logical drive address Note After increasing the length of the actual value PDA dialog box DP slave Properties gt Configuration gt Actual value gt Length when the Properties dialog box is opened again in message frame type Dialog box DP slave properties Tab card Configuration Default lt Message frame type gt 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 505 16 840Di specific Data and Functions 01 05 16 2 Expanded message frame configuration Step 2 Configuring the DP slave 611U Default configuration Extended message frame configuration 16 506 Before performing expanded message frame configuration you first need to perform the standard configuration or start up of the drive For the standard configuration start up of the drive please see e Start up requirements Section 9 1 Page 9 269 e Standard configuration start up SIMODRIVE 611 universal and universal E References FBU Description of Functions SIMODRIVE 611 universal SIMODRIVE POSMO SI CD
547. t measuring signals and set the measuring parameters with soft keys and drop down lists The function is operated using the mouse or keyboard The trace function offers the following features e Four trace buffers with up to 2 048 values each e Selection of SERVO and drive signals in position control cycle e Trace trigger signals can be set using absolute address and value masking e Different trigger conditions to start recording triggering always on Trace 1 e Both pre and post triggering e Measuring signal display e Selection of fixed Y scaling for each trace e Marker function selectable for each trace e Expand function in the time axis e Selective loading and saving of the measurement parameters and traces Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 13 Drive Optimization with HMI Advanced 13 6 Trace function 13 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 gt Start up gt Drives servo gt Servo trace MPF_DIR Start up Jog TEST MPF Channel reset Axis Program aborted ROY Axis Signal selection Trace Axis spindle name Signal select Status Trace 1 x1 x Followingerror Inactive Start Trace 2 ji oO n Position actual value meas system1 7 Inactive Trace 3 zao O Position actual value meas system1 gt Inactive Stop Tre
548. t not not not not not not used used used used used used used used AB n 4 Direction keys Optional customer keys Rapid tra KT4 KT3 KT2 KT1 KTO LED50 LED48 verse 24V 24V 24V 24V 24V LED49 AB n 5 Free K Opt K Axis selection T16 KT5 6 5 4 Z Y X LED18 24V LED47 LED46 LED45 LED44 LED43 LED42 AB n 6 Freely assignable customer keys Freely assignable customer keys T9 T10 T11 T12 Miss T13 T14 T15 LED29 LED30 LED31 LED32 LED12 LED14 LED15 AB n 7 Freely assignable customer keys T1 T2 T3 T4 T5 T6 T7 T8 LED21 LED22 LED23 LED24 LED25 LED26 LED27 LED28 Siemens AG 2005 All rights reserved 8 242 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 7 DP slave MCP 483 8 7 DP slave MCP 483 E SIEMENS y Ww HEE BEE Bee ae a po tee BE Bae mao n VAR 1 Ti 7 DHE BEE HEHEH EA gt 00 000 aava vw EEE BEE Fig 8 16 MCP 483 Front panel Version T turning machines 8 7 1 Conditions for general installation and start up Hardware The following hardware is required e PROFIBUS connecting cable No terminating resistor is integrated in the machine control panel e Programming device PG PC A programming device PG PC is required for the SIMATIC Manager STEP7 as the platform to match the basic PLC or PLC user program to the requirements of the automation system with regard to the operation of an machine control panel MCP and then load it into the
549. taneously Fig 8 13 MCP 310 front panel The following parameters are set with switch S3 on the rear of the MCP e Connection type Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 6 DP slave MCP 310 e Hardware code e PROFIBUS address Table 8 1 Switch S3 9 10 Connection type 109 8 71651413 21 1 Connection type on on PROFIBUS DP Table 8 2 Switch S3 8 Hardware code 1019 871615141812 1 Hardware code off Standard hardware Table 8 3 Switch S3 1 7 PROFIBUS address 1019 817 6154131211 PROFIBUS address off off off off off off off off off off off off off on on off off off off on off w D off off off off off on on on on on on on on off 126 on on on on on on on 127 Notice In the state as delivered the connection type is MPI 8 6 3 Requirements for starting up the DP slave SIMATIC STEP 7 GSD File To insert DP slave MCP 310 into the hardware configuration the following com ponents are required e SIMATIC STEP 7 e GSD file of DP slave MCP 310 e Image files of DP slave MCP 310 See Subsection 8
550. tdown via a status signal from the UPS to the PLC which then passes the PC shutdown interface signal to the NC The above UPS has the following connection options to signal the current sta tus to the SINUMERIK 840Di Table 1 1 Connection options of the UPS system Connection Signal to Remarks 1 UPS gt PCU Windows XP The UPS functionality is configured see Con depending on the UPS figuration below type used Advantage also works when the PLC user pro Serial link gram is not active USB link Disadvantage does not work in the event of serious exceptions from Windows XP BlueScreen Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 1 Overview of SINUMERIK 840Di 2 Signal terminals via PLC The UPS functionality is configured using the free interconnection gt 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 gt menu Settings in HMI Advanced see Subsec MCI board extension in tion 10 10 2 Page 10 404 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 po
551. te 2Byte Low byte High byte e Output data 8 bytes Standard data 8Byte Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication Setting the 1 0 addresses 8 6 DP slave MCP 310 Module standard extended The module transfers the data for the Standard and Additional I Os functions e Input data 13 bytes Standard data ee Cpa Customer keys 1 Rotary switch 2 Rotary switch 8Byte RE J 1Byte 1Byte 1Byte Low byte High byte e Output data 10 bytes Standard data Reserved Customer LEDs 8Byte 1Byte 1Byte Low byte High byte Module standard handwheel extended The module transfers the data for the Standard Handwheel and Additional I Os functions e Input data 17 bytes Absolute value Absolute value Direct control Scena 1st handwheel 2nd handwheel keys OP 012 y 2Byte 2Byte 2Byte Low byte Customer keys 1 Rotary switch 2 Rotary switch 1Byte 1Byte 1Byte High byte e Output data 10 bytes Standard data Reserved Customer LEDs 8Byte 1Byte 1Byte Low byte High byte When you insert a module in slot 1 of DP slave MCP 310 the input output ad 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
552. 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 60 To create your own compile cycles in addition to the necessary NCK specific development environment you need the SINUMERIK Open Architecture com ponent OA package NCK Note To use the SINUMERIK Open Architecture component OA package NCK you need to conclude an OEM contract Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 7 Loadable compile cycles 10 7 1 Loading compile cycles Preconditions The following requirements must be met to enable loading a compile cycle to Control the NC 1 A flash file system FFS of at least 512KB is set up on the NC e MD18332 MM_FLASH_FILE_SYSTEM_MEM_SIZE size of the FFS 2 To transfer the compile cycle to the control you need one of the following transfer media Floppy disk drive option Network connection via the Ethernet interface of the PCU with the exter nal PC PG containing the compile cycles file 3 To copy the compile cycle to the FFS of the NCK you need SinuCom
553. tection level 0 2 System Manufacturer Service Following menu PLEASE SELECT 1 Harddisk Backup Restore with GHOST 4 Partitions Backup Restore with GHOST 9 Back to previous Menu Your Choice 1 4 9 3 Choose Harddisk Backup Restore with Ghost with key 1 Following menu PLEASE SELECT 1 Configure GHOST Parameters 2 Harddisk Backup to lt PATH gt Mode 3 Harddisk Backup from lt PATH gt Mode 9 Back to previous Menu Your Choice 1 2 3 9 4 If necessary to check or configure the ghost parameters select Configure GHOST Parameters with key 1 Configuration of the ghost parameters is described in Subsection 15 5 3 Page 15 482 PLEASE SELECT 1 Configure GHOST Parameters 2 Harddisk Backup to H lt PATH gt SICHER01 GHO Mode LOCAL 3 Harddisk Backup from H lt PATH gt SICHERO1 GHO Mode LOCAL 9 Back to previous Menu Your Choice 1 2 3 9 5 To start the data transfer choose Hard disk Backup to with key 2 Following menu PLEASE SELECT 1 Backup WITHOUT Local Images 2 Backup WITH Local Images 9 Back to previous Menu Your Choice 1 2 9 Siemens AG 2005 All rights reserved 15 476 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu 6 If you do not want to additionally back up the image files of t
554. ted errors sporadic errors etc we recommend starting up the SINUMERIK 840Di NC and PLC otherwise data errors could be taken over from the SRAM image A defect of the MCI board has occurred during operation of the SINUMERIK 840Di Windows XP has possibly been shut down correctly but no SRAM image could be created After the MCI board has been changed it will be identified as unknown using the serial number Since no up to date SRAM image exists the SRAM backup is written back into the SRAM of the MCI board The SINUMERIK 840Di is thus ready again immediately The user data or the operating state of the SINUMERIK 840Di must be checked to see whether they are suitable to be worked with in the future It might be nec essary to perform commissioning of the SINUMERIK 840Di NC and PLC again Responses A note will appear in a message box which must be acknowledged with Ok SINUMERIK 840Di NCK PLC Eg Alarm Old backup of user data loaded into MCI card The user data were saved at 07 07 2000 10 30 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 3 Booting In addition an NC alarm is output which is displayed on the appropriate user interface of the SINUMERIK 840Di 840Di start up HMI Advanced etc e Alarm 4065 Battery backed memory has been restored from the hard disk possible data loss To acknowledge the
555. ten 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 The past has shown that the following times are recommended to carry out data 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 back up is performed with one of the applications e HMI Advanced option e SinuCom NC For the components of a SINUMERIK 840Di NC PLC HMI SIMODRIVE PROFIBUS drives data back up can be performed separately for each component or jointly For detailed information on data backup please refer to References SinuCom NC Online Help HMI Advanced BAI Operator s Guide HMI Advanced Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 14 453 14 User Data Backup Series Machine Start Up 01 05 14 2 Creating a series commissioning file 14 2 Creating a series commissioning file 14 2 1 General Archive content NC 14 454 Note Because of its file extension arc the series machine start up file is also called archive The following components can be selected as the content of a series commi
556. ternal power supply see Subsection 2 11 3 Page 2 92 Siemens AG 2005 All rights reserved 2 88 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 11 I O module PP72 48 e Connecting cable The required connecting cables ribbon cables must be provided by the user e Electrical specification of the digital inputs Table 2 19 Electrical specification of the digital inputs Digital inputs Min Typical Max Nominal Voltage at high level Vy 15V 1 30V 24V Input current lin at Vy 2mA 15mA Voltage at low level Vi 30V 5V oV Signal delay time Tpy 2 0 5 ms 3ms Supply voltage of the digital inputs 1 typical output voltage Voc lout Ron Voc actual operating voltage P24OUT at X111 X222 X333 Pin 2 max output current lout 500 mA per pin max short circuit current 4 A max 100 us Voc 24 V internal resistance Ron 0 4 Q e 2 Moreover the PROFIBUS communication time and the application cycle time must be taken into account e Polarity reversal causes neither high level nor destruction of the inputs Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 89 2 Hardware Descriptions 01 05 2 11 I O module PP72 48 Digital outputs e 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
557. tery Designation Order number MLFB Backup battery 6FC5 247 0AA18 0AA0 Typical battery service life gt 3 years Please observe the following general rules when handling batteries e Do not recharge them e Do not heat or throw into fires e Do not pierce or crush e Do not tamper with mechanically or electrically in any way Caution Improper handling of backup batteries results in the hazard of inflammation burning or explosion The 3 V lithium battery to back up the SRAMs and the clock module is moni tored in stages Battery voltage Signal 2 7 2 9V Alarm 2100 NCK battery warning threshold reached 2 4 2 6 V Alarm 2101 NCK battery alarm Alarm 2102 NCK battery alarm The alarm 2101 NCK battery alarm is output if battery low voltage is detected in cyclic operation The alarm 2102 NCK battery alarm is output if battery low voltage is detected during power up As soon as alarm 2100 NCK battery warning threshold reached is output and certainly no later than output of alarm 210x NCK battery alarm you should replace the battery on the MCI board to avoid loss of data 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 Si
558. th key 6 and then Change Network Settings with key 4 Following menu CURRENT NETWORK SETTINGS Machine Name lt COMPUTER_NAME gt User Name auduser Transport Protocol TCP IP Logon to Domain No Connect Network Drive last PLEASE SELECT Change Machine Name for DOS Net only Change User Name Toggle Protocol NetBEUI TCP IP Toggle logon to Domain Yes or No Change Domain Name displayed only when 4 Yes Change TCP IP Settings displayed only when 3 TCP IP o ORUN Back to previous menu Your Choice 1 2 3 4 5 7 8 9 P Setting network parameters for a PTP network link is described in Section 15 2 Page 15 466 Return to the next highest menu level after setting the parameters with Back to previous menu by hitting key 9 Be sure to save the parameter set tings Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 483 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu Following menu CURRENT NETWORK SETTINGS Machine Name lt COMPUTER_NAME User Name auduser Transport Protocol TCP IP Logon to Domain No Connect Network Drive last PLEASE SELECT Connect to Network Drive Show connected Network Drives Disconnect from all Network Drives Change Network Settings D o Back to previous Menu Your Choice 1 2 3 9 e Network link Choose
559. th standard process data and additional process data is transferred in a general system variable as an array of 16 bit integer data words via e MD 36730 DRIVE_SIGNAL_TRACKING n 2 e System variable VA_DP_ACT_TEL n a where n Index 0 2 15 a machine axis identifier Note When using the system variable VA DP ACT TELfn a it is only permissible to use a constant as index n Application example for system variables in a synchronized action IDS 1 DO AC_MARKERI0 VA_DP_ACT_TEL 12 X 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 e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specitic Data and Functions 16 2 Expanded message frame configuration 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 Drive actual values
560. th the SINUMERIK 840Di Siemens can provide a complete PC integrated control that controls the drive units and I Os through the standard field bus PROFIBUS DP with Motion Control functionality and therefore permits a distrib uted design of the overall system It therefore constitutes the basis for PC based automation solutions and is gen erally especially designed for applications e where distributed automation solutions are required in the fields of PLC I Os and drives and or e acomplete PC integrated control system is preferred since this solution better fits into the intended or existing automation environment T 5 a x 19 N co TZ a PROFIBUS DP 2 12 MBaud PROFIBUS DP 1 12 MBaud 1 either MPI or PROFIBUS DP Fig 1 1 SINUMERIK 840Di System Overview Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 21 1 General Notes on the SINUMERIK 840Di 01 05 1 1 Overview of SINUMERIK 840Di 1 1 1 System components This manual refers to the following system components System components Version SINUMERIK 840Di system software SW 3 2 PCU 50 Celeron 566 MHz 256 Mbytes DRAM SINUMERIK Industrial EG PCU 50 Celeron1 2 GHz 256 Mbytes DRAM PC operating system Windows XP Pro ServicePack 1 MCI board MCI2 board Notice It is not possible to combine the named system components with older versions 1 1 2 System software packages
561. the DRAM file system If the configured memory is no longer sufficient during loading from this time on cycles still to be loaded will be loaded into the SRAM file system If there is insufficient space in the SRAM too loading is stopped and the following alarm is output Alarm 6690 cycles from the NC card cannot be copied into the passive file system Remedy Adapt the DRAM file system size in the machine data MD18351 MM_DRAM_FILE_MEM_SIZE size of DRAM file system e Too little memory available in the FFS When a cycle is stored in the DRAM file system it is also stored in the FFS If there is not enough free space in the FFS the following alarm is output Alarm 6691 cycles in the passive file system cannot be saved to the NC card Remedy Adapt the FFS size in the machine data MD18332 MM_FLASH_FILE_ SYSTEM SIZE size of the FFS or deletion of cycles from the DRAM file system the cycles are also deleted from the FFS 11290 DRAM_FILESYSTEM_MASK select directories in DRAM e Changed cycles cannot be saved in the background memory If the control is switched off although the cycles have not been saved in the background memory the following alarm is output the next time the NC starts up Alarm 6692 cycle has been lost Machine data Table 10 15 Machine data required to configure the FFS Number Name of identifier Name remarks Refer ence General MN_ 11290
562. the PLC basic program storage path of file setup exe and additional installation instructions are included in file e _ lt installation path gt importantinfo rtf Notice The basic PLC program must be installed on that computer on which the SIMATIC manager required to install the S7 project is already installed Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 1 5 PLC user program The organization blocks e B100 cold restart e OB1 cyclic processing e OB40 process alarm 6 1 General contain the entry points for the appropriate parts of the PLC user program OB 100 FB1 Start up Cold restart __ e g HHU parameters i User program OB 1 FC 27 Only necessary if a MCP Cyclic is connected via MPI bus processing MCP_INT NCK FC 2 Mode group ___ Channel GP OB 1 Axis Spindle FC 14 MCP HHU FC 6 TM ee 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 OB 40 FC 3 Process GP_PRAL G grou
563. the SINUMERIK desktop Windows XP confirm the active selection SINUMERIK with the input key or wait the preset time until the boot process is automatically continued Once the SINUMERIK desktop is active the supplied PLC series machine start up has to be loaded into the PLC for basic start up To do so proceed as follows 1 Start the SinuCom NC start up tool from the Windows taskbar Start gt Programs gt SinuCom NC gt SinuCom NC 2 Use SinuCom NC to load the supplied series machine start up file PLC_SMP ARC into the PLC Menu command File gt SeriesStart up archive gt Readin Dialog box Read in archive Radio button Data management Button NEXT Select file PLC_SMP ARC in directory Archive Button FINISH The PLC is now ready NC and PLC run in cyclic mode If a machine control panel is connected the LEDs of the machine control panel should now no longer flash and no more alarms should be present on the NC 5 2 3 Machine control panel MCP boot System software test Check the MPI communication When you press the keys Feed Start and Feed Stop when the machine con trol panel powers up all LEDs flash the software version of the machine con trol panel is displayed This means that the system software of the machine control panel has booted correctly and waits until the cyclic communication is established by the PLC Whether the machine control panel on the MPI bus
564. the emergency stop on the handheld unit Connect the handheld unit to the MPI bus by means of repeater e PLC basic program Sign of life monitoring triggered via the PLC user program if the hand held unit is disconnected For a detailed description of the actions to be taken and the devices required please refer to References BH Handheld Unit Manual Chapter Handheld Unit and Distribution Box Plugging and unplugging the handheld unit during operation 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 The following assumptions are made in this programming example e FB 1 parameter BHGStatRec BHGStatRec P A 32 0 Receive addr of the status data 4Byte e Symbolic name of DB 17 gp_par CALL MCP_INT 11 FC27 U gp_par BHGStop IF BHG in Stop S A32 7 THEN trigger sign of life CALL GP_HP FC2 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 195 7 MPI Communication 01 05 7 10 Handheld Terminal HT 6 7 10 Handheld Terminal HT 6 The HT 6 Handheld Terminal with 6 screen diagonal is a compact operator component consisting of an HMI and a machine control panel component Fig 7 19 Handheld
565. the external digital NC inputs 10368 HW_ASSIGN_DIG_FASTOUT Hardware assignment of the external digital NC outputs 10380 HW_UPDATE_RATE_FASTIO Update rate of the synchronous external NC I Os 10382 HW_LEAD_TIME_FASTIO Lead time of the synchronous external NC I Os 10384 HW_CLOCKED MODULE MASK Synchronous processing of the external NC 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 writeable output bytes of the PLC I Os 10397 PLCIO_LOGIC_ADDRESS_OUT Start address of the directly writeable output bytes of the PLC I Os 10530 COMPAR_ASSIGN_ANA_INPUT_1 Hardware assignment of the NC analog inputs for comparator byte 1 10531 COMPAR_ASSIGN_ANA_INPUT_2 Hardware assignment of the NC analog inputs for comparator byte 2 10540 COMPAR_TYPE_1 Parameterization for comparator byte 1 10541 COMPAR_TYPE_2 Parameterization for comparator byte 2 Channelspecific MC_ 21220 MULTFEED_ASSIGN_FASTIN Assignment of the input bytes of the NC I Os for V1 Several feedrates in a block Setting data Table 10 51 Digital and analog I Os Setting data Number Name of identifier Name Refer ence General SN_ 41600 COMPAR_THRESHOLD_1 41601 COMPAR_THRESHOLD_2 10 390 Threshold values for comparator byte 1 Threshold values for comparator byte 2 Siemens AG 2005 All rights reserved SI
566. the following partitions of the PCU hard disk C DOS E Windows XP F 840Di System Requirements The precondition that must be met before restoring the as delivered state is that the following files supplied with the SINUMERIK 840Di be stored locally on the hard disk of the PCU e Up to SW 2 1 D IMAGES sin840di gho image file D AIMAGES sin840di inf e As from SW 2 2 D IMAGES base_ou gho image file D AIMAGES base_ou inf The image file gho contains the data to be restored 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 Ghost Notice If the info file is not available the service menu cannot restore the partitions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 495 15 Software Installation Update and Data Backup 01 05 15 6 Restoring the as delivered state 15 6 2 Restoring the partitions SW 2 1 and lower SW 2 2 and higher The procedure for restoring partitions C E and F from a local image file is de scribed in Subsection 15 5 7 Page 15 490 Select the image file from which the partitions are to be restored in accordance with the existing SINUMERIK 840Di software version e Name up to SW 2 1 Sinumerik 840Di Software lt Version gt lt Date gt e Name as from SW 2 2 Basic so
567. the function the system is rebooted The function is actually executed when the PCU is next started up The following message box is displayed to show that 840Di Service is being SINUMERIK 840Di NCK PLC A Alarm System order executed executed The message box must be acknowledged with Ok The selected function is executed after start up of the corresponding SINUME RIK 840Di component Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 5 Power On and Power Up 5 6 Configuring the network link of PCU LAN WAN 5 6 Configuring the network link of PCU LAN WAN 5 6 1 Configuring the network link Windows XP To perform service functions software installation update the SINUMERIK 840Di 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 15 1 Page 15 461 LAN WAN link The PCU basic software is preconfigured for a PTP network link via Ethernet with the TCP IP protocol The settings for the local network links Windows taskbar Start gt Settings gt Network Connections gt gt Local Area Connections regarding IP address and domain are assigned as follows Dialog box Local Area Connections Properties e Tab card General IP address via DHCP Option Obtain an IP address automatically Automatic DNS server address
568. 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 instructions 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 and Windows XP correctly Use one of the following methods to do this e Windows XP taskbar Start gt Shut Down e Interface signal PC shutdown see Subsection 16 1 1 Page 16 499 2 Disconnect your PC from power supply 3 Remove the screws from the cover of the housing Fig 2 10 and open the housing of your PC observing the relevant safety regulations Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 2 59 2 Hardware Descriptions 01 05 2 3 MCI board extension slot variant Screws of the cover of the housing 2 60 Fig 2 10 Cover of the housing of the PCU 50 4 Remove the fastening screw of the module holding down device Fig 2 11 of the MCI board and remove the module holding
569. tic restart reboot Notice The PC shutdown interface signal must be reset in the organization block OB100 cold restart of the PLC Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 29 1 General Notes on the SINUMERIK 840Di 01 05 1 1 Overview of SINUMERIK 840Di Power failure Overtemperature 1 30 A power failure lasting more than 5 msecs is detected by the POWER FAIL functionality of the SINUMERIK 840Di as a fault scenario and the following ac tions are initiated The background lighting of the operator panel display is switched off 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 after the next SINUMERIK 840Di power up The SINUMERIK 840Di 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 x Alarm 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 consistency of the NC and PLC user data References BH Operator Components Manual Chapter PCU 50 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 pow
570. tion nano Reset 10 367 Setpoint matching 10 371 Setpoint actual value channels 10 368 Synchronization Velocities Spindle data 10 379 Spindle in setpoint range 10 376 Spindle is stationary 10 376 Spindle speed Maximum Spindles SRAM Physical 1 32 SRAM handling Standard version Start up 1 40 General 1 26 Menu command Window Start up behavior PLC Start up mode Cold restart Startup 611u First PLC HHU 7 177 3 228 3 243 Static monitoring functions 10 345 Storing the text files 11 407 SUB D Socket connector 2 49 SW version Switching off PCU 1 31 Switching over the measuring System basic cycle System Check System components 1 22 System data 10 286 System data blocks Creating 8 223 System integrity 1 28 System overview 3 101 MPI components Operator panels PCU components PROFIBUS DP components 3 102 Touch panels 3 101 System software 1 22 System software packages 1 22 system 10 202 Index 543 Index 01 05 Technical data MCI board 2 56 MCI board extension 2 64 PP72 48 2 95 Technological functions Activation Licensing Version display 10 396 Temperature CPU 1 30 CPU module 1 30 Housing Terminating resistor MCP 7 177 _ MCP 483 8 228 8 243 PCU Test run Axis 12 416 Axis and spindle 12 415 Axis enabling Drive enable Requirements Spindle Testi
571. tion ON 5 4 3 Setting the SINUMERIK HMI environment The data of the user specific HMI system environment are located in the follo wing directories F AADD_ON FAUSER F OEM CARUNOEM The following functions are available as script files on the SINUMERIK desktop for setting the HMI system environment e Original HMI environment Before the HMI application is started the HMI system environment is re stored to its as delivered state For this the content of the above mentioned directories are saved Then the directories are cleared e Current HMI environment Before the HMI application is started the user specific HMI system environ ment is loaded For this the saved user specific data are loaded into the above mentioned directories Note This function can be also be run from the service menu Subsection 5 5 4 Page 5 134 5 4 4 Testing system components The following function on the SINUMERIK desktop is used to check the system components e Check SINUMERIK System Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 5 127 5 Power On and Power Up 01 05 5 4 SINUMERIK desktop which is available as a script file The function tests the following system com ponents Harddisk of PCU Partitions C D E and F are tested Note This function can be also be run from the service menu Subsection 5 5 5 Page 5 134 5 4 5 Authorizing SIMATI
572. tion or when errors occur e 840Di Startup menu bar Window gt Diagnosis gt Profibus gt Bus or Slaves e HMI Advanced Operating Area Switchover gt Diagnosis gt Service Displays gt ETC key gt Profibus Diagnosis Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication 8 4 SIMATIC S7 I O devices ET200 8 4 SIMATIC S7 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 PROFIBUS DP you must first insert all the SIMATIC S7 I Os you require into the configuration 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 recommended 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 GSD File A PP72 48 I O module is parameterized with a GSD file The GSD file is part of the SINUMERIK 840Di software See Section 1 2 Page 1 36
573. to NC PLC and MOP The drives must be secured against accidental moving 8 7 2 Parameterization of the MCP 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 A Handwheel signal type S1 fe ea O arer Ta ae 2 8 o oS a 3 N I N N o m ol H E ei Le 4 E Els HT 8 h 2 COM board z ICE pa pi a E o DH 9 T e l Se a as Keyswitch X50 S3 DIP switch Direct keys X70 Customer spec operating elements X51 X54 SHIELD M24 P24 Fig 8 17 Position of interfaces on rear side of machine control panel For a detailed description of the electrical and mechanical design and of the machine control panel interfaces please refer to References BH Operator Components Manual Chapter Machine control panel MCP 483 Siemens AG 2005 All rights rese
574. trol panel signals to the VDI interface can be found in FB1 Description of Functions Basic Machine P3 Basic PLC Program Chapter FC 19 MCP_IFM Chapter FC 24 MCP_IFM2 Chapter FC 25 MCP_IFT Example The following example shows the communication parameter settings for func tion block FB 1 for a machine control panel MCPNum 0 Number of active MCPs MCP1In P E 0 0 Address of input data 8 bytes MCP1Out P A 0 0 Address of output data 8 bytes MCP1StatSend P A 0 0 Default setting no meaning MCP1StatRec P A 0 0 Default setting no meaning MCP1BusAdr 0 Preset no significance MCP1 Timeout SST 700MS Default setting no meaning MCP1Cycl SST 200MS Default setting no meaning MCPMPI FALSE MCP is operated at the extended MPI bus MCP1Stop FALSE Default setting no meaning MCP1NotSend FALSE Default setting no meaning MCPSDB210 FALSE Preset no significance PLC user program If the 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 e PLC operating system e PROFIBUS controller If the failure of DP slave MCP 483 is detected the PLC goes into the STOP status as default Siemens AG 2005 All rights reserved 8 254 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 8 PROFIBUS DP Communication Customized
575. tual value 1 aag Fig 7 17 Displaying and modifying GD circle parameters Siemens AG 2005 All rights reserved 7 192 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 7 MPI Communication 7 9 Handheld unit B MPI 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 7 9 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 HHUSendG No Send Obj No HHUSendObj No Rec GD No HURecGD No Rec GI No HHURecGI No Rec Obj No HHURecObj No Fig 7 18 Crosswise coincidence of GD circle parameters Notice The GD circle parameters of sender and receiver must be identical crosswise 7 9 7 Example Connecting a HHU to SINUMER
576. ty max 0 1 min 1 MCI board already plugged in max power of additional expansions e g PCI ISA slots PC card USB interface Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 2 Hardware Descriptions 2 6 SINUMERIK operator panel fronts 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 ao 7 A m oo gt Alpha key a a E ag group TIE m og o B is 3 i H E g m ot Frise 9 g 2 pa gg ey group xX xs ar m B B a Cursor al AE key group Control D SEEEEERE key z z rou ie ne ee ee E pii am RX uss front Softkeys interface Recall Machine area ETC key Area switchover Mouse Fig 2 16 View of OP 012 operator panel front Order number Designation Order number MLFB SINUMERIK OP 012 6FC5 203 0AF02 0AA0 Features The OP 012 operator front provides the following features e 12 1 TFT flat screen color resolution 800 x 600 pixels e Membrane keyboard with alpha numeric cursor and control keypad e 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
577. u hidden using the CursorDown key and then press the Input key The following menu appears PLEASE SELECT Install Update SINUMERIK System SINUMERIK Tools and Options DOS Shell Start Windows XP Service Mode SINUMERIK System Check Backup Restore Start PC Link Reboot Restore Windows Partition E Emergency 840Di Services um o NN O1 BR ND Your Choice 1 2 3 4 5 7 8 9 E P 2 Choose Backup Restore with key 7 The system prompts you to enter a password You require a password for protection level 0 2 System Manufacturer Service Following menu PLEASE SELECT 1 Harddisk Backup Restore with GHOST 4 Partitions Backup Restore with GHOST locally 5 ADDM Backup Restore 9 Back to previous Menu Your Choice 1 4 5 9 3 Choose Partitions Backup Restore with Ghost with key 4 Siemens AG 2005 All rights reserved 15 490 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 15 Software Installation Update and Data Backup 15 5 Data back up DOS service menu Following menu Ghost Connection Mode LOCAL Maximum Backup Images lt Max_ number Current Backup Images lt Cur_numbers PLEASE SELECT Configure GHOST Parameters Partitions Backup Mode LOCAL Partitions Restore Mode LOCAL Partition E only Windows Restore Mode LOCAL Delete Image o BR ND Back to previous Menu Your Choice 1 2 3 4 8 9 4
578. u appears Ghost Connection Mode LOCAL Maximum Backup Images lt Max_number Current Backup Images lt Cur_numbers PLEASE SELECT Configure GHOST Parameters Partitions Backup Mode LOCAL Partitions Restore Mode LOCAL Partition E only Windows Restore Mode LOCAL Delete Image o BR OC ND Back to previous Menu Your Choice 1 2 3 4 8 9 Choose Delete Image with key 8 Following menu PLEASE SELECT 1 PCU Base Software V06 01 04 Win NT 4 0 05 09 2000 05 30 32pm 2 Start up intermediate status 1 05 10 2000 04 03 15pm EMERG 3 Data backup1 06 11 2000 10 34 17am 9 Back to previous Menu Your Choice 1 2 3 9 Select the partition back up to be deleted and confirm the query with key Y Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 15 489 15 Software Installation Update and Data Backup 01 05 15 5 Data back up DOS service menu 15 5 7 Restoring partitions C E amp F from local image file Brief description This chapter describes how you restore partitions C E and F from an image file Requirements The following conditions must be fulfilled e The image file must be present locally on the hard disk of the PCU under D IMAGES see Subsection 15 5 4 Page 15 486 Operator actions After the PCU has been switched on the menu of the boot manager is dis played 1 Select the menu option Service men
579. uction TorRed i 5 Torque reduction TorRed Shaft angle 6 Encoder 1 control word G1_CTW 6 Encoder 1 status word G1_STW encoder inter PROFIBUS 7 INo signal NIL 7 Encod 1 pos act val 1 G1_XACT1 8 INo signal NIL 8 Encod 1 pos act val 1 Gt_XACT1 El 9 No signal NIL 9 Encod 1 pos act val 2 G1_XACT2 1 gj Fig 16 3 Activating the customizable message frame configuration Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 16 840Di specific Data and Functions SimoCom U 12A drive File Edit Start up Operation Diagnostics Tools Help 16 2 Expanded message frame configuration e 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 16 4 lel Es PROFIBUS OFF1 Configuration Analog input Mechanics Limitation Digital input Digital output Analog output Monitoring Controller Traverse blocks Shaft angle encoder interfa PROFIBUS Spindle position aix lou x og SSM iP ect hg Re He KT A ASS me Control of clock synchronized PROFIBUS orque reduction TorRed z 6 Encoder 1 control word G1_CTW x 8 No signal NIL 9 No signal NIL h to No signal NL xl 11 No signal NIL b 12 o signal NIL gt 13 No signal NIL z 14 No signal NL x 15 No signal
580. ule and 1 motor encoder per axis Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 313 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles SIMODRIVE 611U functions ADI4 10 314 Notice 1 A change of the message frame type has to be carried out consistently e DP slave 611U SIMATIC S7 project HW Config Message frame type e NC MD13060 DRIVE_TELEGRAM_TYPE n e SIMODRIVE 611 universal Parameter P0922 message frame selection PROFIBUS No automatic adjustment takes place 2 The order of the drives to which reference is made in the machine data e MD13050 DRIVE_LOGIC_ADDRESSjn e MD13060 DRIVE_TELEGRAM_TYPE n must be identical in both machine data If a PROFIBUS drive does not support individual SIMODRIVE 611U specific functions that are active by default they must be deactivated on the NC side via the following drive specific machine data e MD13070 DRIVE_FUNCTION_MASK n used DP functions es Function Deactivation of the 611U specific drive alarm generation Deactivation of the 611U specific drive type detection Deactivation of the 611U specific parameter accesses encoder drivers Deactivation of the 611U specific parameter accesses output drivers Activation third party drive DSC functions Direct Servo Control Deactivation of 611U specific drive parking Deactivation of the 611U specific travel to fixed st
581. umber Name of identifier Name remarks Refer 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 System of measurement 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 10 3 3 Changing scaling machine data The scaling of machine data having physical units is defined by the following machine data e MD 10220 SCALING_USER_DEF_MASK activation of scaling factors e MD 10230 SCALING_FACTORS_USER_DEF scaling factors of physical quantities e MD 10240 SCALING_SYSTEM_IS_METRIC basic system metric e MD 10250 SCALING_VALUE_INCH conversion factor for switchover to INCH system e 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 Siemens AG 2005 All rights reserved 10 290 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced Modifying manually 10 3 System data The control
582. unction is initiated via the PLC Spindle speed 4 rev min Maximum spindle speed Maximum speed of gear stage 2 Maximum speed for gear change 2 Maximum speed of gear stage 1 Maximum speed for gear change 1 Minimum speed for gear change 2 Minimum speed for gear stage 2 Minimum speed for gear change 1 Minimum speed for gear stage 1 Min spindle speed 0 wy gt 1 2 Gear stage Fig 10 27 Example for speed ranges for automatic gear stage selection M40 The speeds of the spindle in conventional mode are entered in the machine data e MD32010 JOG_VELO_RAPID rapid traverse in JOG mode e MD32020 JOG_VELO JOG axis velocity The direction of rotation is specified via the appropriate directional keys for the spindle on the MCP The direction of rotation of a spindle corresponds to the traversing direction of an axis The speeds must be transferred with standardized values for the drive control ler The values are scaled in the NC using the selected load gear and the ap propriate drive parameter Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 371 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles SIMODRIVE 611 universal Drive parameter P0880 PROFIBUS speed evaluation Speed n Normalization value P0880 4000H Speed setpoint low resolution 4000 0000H Speed setpoint h
583. unction with DSC Before you can activate DSC mode the following preconditions must be fulfilled e DSC capable drive e g SIMODRIVE 611 universal SIMODRIVE POSMO CD CA SIMODRIVE POSMO SI e ADSC capable message frame type has been parameterized in the S7 proj ect for the drive see Section 8 9 Page 8 259 The DSC function is switched ON in the axis spec NC machine data e MD32640 STIFFNESS CONTROL_ENABLE dyn stiffness control activated If DSC operation is switched ON or OFF it might be necessary to adjust the following machine data e MD32200 POSCRTL_GAIN KV factor e MD32610 VELO_FFW_WEIGHT feedforward control factor e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 327 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 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 s
584. uration Bus status Display of Slave no DP address Assignment Active on the bus Synchr with NC Number of slots Details Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General Notes on the SINUMERIK 840Di 1 5 840Di start up Menu command Functionality NC PLC e NC Display of NC status NC Reset Clear NC memory e PLC Display of PLC status RUN P RUN STOP MRES e Latency display Current value Maximum value Number of violations Oscilloscope Logbook Display of SINUMERIK 840Di system mes sages Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 43 1 General Notes on the SINUMERIK 840Di 01 05 1 5 840Di start up Notes Siemens AG 2005 All rights reserved 1 44 SINUMERIK 840Di Manual HBI 01 05 Edition Hardware Descriptions 2 1 Overview of hardware components SINUMERIK 840Di A SINUMERIK 840Di control system can only be ordered as a complete system Complete system PCU and MCI board e SINUMERIK 840Di PCU 50 with Celeron 566 MHz 256 MB DRAM and MCI2 board 24 V power supply Order number 6FC5 220 0AA21 2AA0 e SINUMERIK 840Di PCU 50 with Celeron 1 2 GHz 256 MB DRAM and MCI2 board 24 V power supply Order number 6FC5 220 0AA
585. uring 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 Table 10 34 Position control machine data Number Name of identifier Name remarks Refer ence Axis spec MA_ 32100 AX_MOTION_DIR n Traversing direction 32110 ENC_FEEDBACK_POL n Actual value sign 32200 POSCTRL_GAIN n Servo gain factor Kv 32300 MAX_AX_ACCELfn Axis acceleration 32900 DYN_MATCH_ENABLE n Dynamic response adaptation 32910 DYN_MATCH_TIME n Time constant for dynamic matching References FB Description of Functions Basic Machine G2 Velocities Setpoint Actual Value Systems Closed Loop Control Chapter Closed loop control Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 337 10 NC Start Up with HMI Advanced 01 05 10 5 Axes and spindles 10 5 15 Speed setpoint matching Automatic matching Manual matching SIMODRIVE 611 universal E POSMO CD CA POSMO SI 10 338 In speed setpoint matching the NC is informed for parameterization of the axial control and monitoring which motor speed in the drive corresponds to which speed setpoint Speed setpoint matching can be performed automatically or manually It is possible to perform automatic speed setpoint matching if the drive supports acyclic services
586. used to monitor and control 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 gt Diagnosis gt PLC Status The following two tables show the input syntax of the fields Operand and For mat of the PLC status display Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 6 167 6 PLC Start Up 01 05 6 8 Testing the PLC program Monitoring Controlling Start Controlling End 6 168 Table 6 2 Syntax In x IBn IWn IDn DBn DBXm x DBn DBBm DBn DBWm DBn DBDm On Fn Tn Cn Table 6 3 Syntax H D B G Input field Operand Meaning Input byte n bit x Input byte n Input word n Input double word n Data block n byte m bit x Data block n byte m Data block n word m Data block n double word m Output n Flag n Timer n Counter n Input field Format Meaning Hexadecimal Decimal Binary Floating point only in conjunction with double word 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 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 As long as Cont
587. ve message frame type for the drives con G2 nected to PROFIBUS DP 13070 DRIVE_FUNCTION MASKfn 611U specific DP functions in use G2 13080 DRIVE_TYPE_DPfn Drive type PROFIBUS DP G2 10 5 4 Setpoint actual value channels Assignment of the setpoint actual val ue channels 10 316 Note In order to guarantee that the control runs up reliably all machine axes are declared as simulation axes without hardware e MD30130 CTRLOUT TYPE output type of setpoint value 0 e MD30240 ENC_ TYPE actual value acquisition mode 0 Traversing of the axes in servo mode is simulated without speed setpoint output and no hardware specific alarms are output Machine data e MD 30350 SIMU_AX_VDI_OUTPUT output of axis signals with simulation 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 hardware For each machine axis that a drive is to be assigned e a setpoint channel and e 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced NCK reset
588. ve signal modules on the PROFIBUS DP via the appropriate I O ad dresses in the machine data Analog I Os e MD10362 HW_ASSIGN_ANA_FASTIN n hardware assignment of exter nal analog inputs per input where n 0 7 e MD10364 HW_ASSIGN_ANA_FASTOUT n hardware assignment of ex ternal analog outputs per output where n 0 7 Digital input outputs e MD10366 HW_ASSIGN_DIG_FASTIN n hardware assignment of external digital inputs per input byte where n 0 3 e MD10368 HW_ASSIGN_DIG_FASTOUT nr hardware assignment of ex ternal digital outputs per output byte where n 0 3 Input format 05 00 I O high 1 0 low S7 I O address Low part hexadecimal S7 I O address High part hexadecimal always 00 always 05 identifier PROFIBUS I Os Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 383 10 NC Start Up with HMI Advanced 01 05 10 6 Digital and analog I O devices Note e The first digital input output bytes defined via machine data e MD10350 FASTIO_DIG_NUM_INPUTS e 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 e The I O address t
589. versal drives connected using PROFIBUS DP the following preconditions must be fulfilled SimoCom U must be installed For installing SimoCom U see Section 9 2 Page 9 277 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 8 212 With all drives the PROFIBUS address must be set For SIMODRIVE 611 universal E see Subsection 9 1 3 Page 9 271 For SIMODRIVE POSMO CD CA and SI see Subsection 9 1 4 Page 9 273 The SINUMERIK 840Di PLC must be networked using MPI For networking the PLC see Subsection 6 3 3 Page 6 155 The configuration must be loaded into the PLC For creating an S7 project see Section 6 3 Page 6 153 For loading the PLC see Subsection 8 3 3 Page 8 218 The MPI interface must be set on the SINUMERIK MCI Card MPI For setting the MPI interface see Subsection 9 1 5 Page 9 274 The routing information must be set For setting the routing Information see Subsection 9 1 6 Page 9 275 9 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 153f must be set on DP slave 611U or UE in question using the display and operator unit Display 888888 P
590. version The current software version of the HT 6 is displayed in a menu on the user interface After power up of the HT 6 you will get to this menu using the follo wing sequence of operations 1 Key MENU SELECT 2 Softkeys Diagnosis gt Service Display gt Version gt Vers MMC 7 10 5 Parameterization of PLC Program structure The PLC program is modular in design It comprises function blocks e Startup and synchronization OB 100 e Cyclical mode OB 1 e Process interrupt handling OB 40 The user machine manufacturer must call the relevant part of the basic program in the OBs 1 40 and 100 as shown in Fig 7 20 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 7 199 7 MPI Communication 01 05 7 10 Handheld Terminal HT 6 Setting the communication parameters FB1 7 200 OB 100 FB 1 __ Start up Cold restart __ e g HHU parameters if User program OB 1 FC 27 Cyclic processing MCP_INT FC 2 NCK Mode group GP OBI Channel Axis Spindle FC 14 MCP HHU FC 6 TM FC 19 25 26 User MOP program __ MCP_IFM pica FC 9 15 16 18 HPU_MCP ASUB con axes FC 7 8 22 spindles TM TM_Trans TM Dir FB 2 3 4 Var read write FC 17 PI services Star de
591. view X102 X101 X20 X5 A MCI board H PC PG e g PG740 X4 QA AN Distribution box X5 Or Y QX DS Distributor box S 4 core confirmation technique Handheld unit type B MPI Handheld terminal HT 6 Fig 3 6 SINUMERIK 840Di MCI board and MPI bus components 3 2 3 MCI board extension Cable distributor X121 MCI board extension lt o 2x sensor R PR 2x handwheel 4x 4x TS LE digit input digit output Fig 3 7 SINUMERIK 840Di MCI Board Extension Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 3 105 3 Design 01 05 3 2 Electrical design 3 2 4 PCU 50 E 7 Connection for an external floppy disk drive o AATER e 32 pin plug connector JASSA M NS _ PACE OE 1e d SE RESET J z
592. wer up response of the SINUMERIK 840Di with pending shutdown signal see Subsection 5 3 9 Page 5 125 Notice One of the following connection variants must be used for full back up protection Variant 1 Connection 1 and 2 Variant 2 Connection 3 Line infeed SITOP POWER SITOP POWER DC UPS module 15 with 110 220VAC 60 50Hz standard 24V 10A SITOP POWER ACCU MODULE 1 SIEMENS _ _ 2 Free wiring ET200 Os SINUMERIK 840Di 3 Free wiring 1 Serial or or USB connection PROFIBUS DP Fig 1 2 Possible connections UPS Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 1 33 1 General Notes on the SINUMERIK 840Di 01 05 1 1 Overview of SINUMERIK 840Di Configuration 1 34 The UPS functionality can be configured as follows e When using SITOP POWER DC UPS MODULE 15 see Section 2 10 Page 2 81 with a special software tool Download www siemens com sitop gt More topics Download Software DC UPS 15 A e With Windows XP standard tools Start bar Start gt Settings gt Control Panel gt Power Options gt 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 close HMI Advanced before the PCU is shut down Siemens AG 2005
593. which is taken by the PLC for a short time on 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 gt Diagnostics gt NC PLC Dialog box NC PLC Diagnosis Group box NC Button NC Reset 6 7 3 Series machine start up file References 6 164 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 component of the SINUMERIK 840Di installation HMI Advanced optional For detailed information about data back up please refer to Chapter 14 Page 14 453 or SinuCom NC Online Help HMI Advanced BAD Operator s Guide HMI Advanced Chapter Start up functions Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 8 Testing the PLC program 6 8 Testing the PLC program 6 8 1 Start up behavior Start up mode RESTART Retentive ranges Start up of a SIMATIC CPU module can be set for the following start up modes Restart Cold restart warm restart Cold start With SINUMERIK 840Di the start up type of the PLC is permanently set to COLD RESTART It cannot be changed With COLD RESTART block OB100 i
594. which the axis is driven is only explicitly visible in the NC machine data e MD 13060 DRIVE_TELEGRAM_TYPE n drive message frame type Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 16 507 16 840Di specific Data and Functions 01 05 16 2 Expanded message frame configuration 16 2 4 Restrictions Slot assignment Die NC always occupies an entire slot This means that data of the slot that is not used by the NC such as extended message frame configuration cannot by written to by the PLC Restrictions The following restrictions are applicable with regard to the expanded message frame configuration function e Additional data can only be transferred from the drive to the SINUMERIK 840Di NC actual value channel You cannot transfer data in the other direc tion i e from the NC to the DP slave drive setpoint channel e You can only have read access to the drive data stored in the system vari ables Consistency check At SINUMERIK 840Di boot the NC checks the consistency of the process data configuration PDA of the parameters relevant to the cyclic PROFIBUS commu nication e NC MD 13060 DRIVE_TELEGRAM_TYPE n drive message frame type e DP master configuration DP Slave Properties gt Configuration gt Setpoint Length DP Slave Properties gt Configuration gt Actual Value Length e Drive Parameter P0922 message frame selection Parameter P0
595. will be needed later to parameterize the routing settings of the drive start up tool SimoCom U See Subsection 9 1 6 Page 9 275 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 6 157 the 840Di Rack is displayed in the station window To parameterize the PROFIBUS interface X102 as for slot X1 set the following parameters e Interface type e Data transfer rate Double click on module MPI DP slot X7 in the 840Di Rack to open the MPI DP Properties dialog box Dialog box Dialog box MPI DP Properties Siemens AG 2005 All rights reserved 6 158 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up 6 3 Creating a SIMATIC S7 project Tab card General Name lt Designation of 2nd DP interface gt Group Interface Type PROFIBUS Button Properties Dialog box Properties PROFIBUS Interface MPI DP Tab card Parameter Address lt Address gt Button New Dialog box Properties New PROFIBUS Subnetwork Tab card Network settings Data transfer rate lt Trans rate gt Profile DP OK Tab card Mode Radio button lt Mode gt OK OK 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 6 157 the 840Di Rack is displayed in
596. witching all above mentioned data are available in the physical units as described in Subsection 10 3 2 Page 10 288 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 I Os 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 10 9 Switching over the unit system machine data Number Name of identifier Name remarks Refer 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 References FB Description of Functions Basic Machine G2 Velocities Setpoint Actual Value Systems Closed Loop Control Chapter Metric inch measuring system Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 293 10 NC Start Up with HMI Advanced 01 05 10 3 System data 10 3 6 Traversing ranges Computat
597. witching the screen resolution and or color depth on the PCU and started again explicitly after testing switching using the Windows XP service SINUMERIK NC Otherwise a malfunction may occur in the real time response 1 1 6 System integrity Certification of extensions 1 28 To offer high quality and wide functionality of the entire system SINUMERIK 840Di 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 do cument compliance with real time capability of the whole configuration In the case of any modifications to or expansions of PC components hardware or software no binding statements can be made regarding compliance with the product features if any amendments are made by third persons These are the sole responsibility of the OEMs or the user who has made the modifications A PC generally constitutes an open system and expansions of and or modifica tions to the software and hardware to achieve a certain functionality are in some cases inevitable SIEMENS therefore offers testing and documentation of the real time response of system configurations for systems deviating from the factory settings as a service Please contact your local SIEMENS sales representative Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 1 General N
598. y 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 MD SCALING_FACTORS_USER_DEF n 2e ected input output unit Internal unit m 1000mm MD SCALING_FACTORS_USER_DEFIN pa S 1000 16 667 s RSE 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 s default the internal unit is mm s Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 10 289 10 NC Start Up with HMI Advanced 01 05 10 3 System data MD SCALING_USER_DEF_MASK H14 bit no 4 and bit no 2 from example 1 as hex value 14 12 25 400 MD SCALING_FACTORS_USER_DEF n 7a Tm s 304 8 s2 2 MD SCALING_FACTORS_USER_DEF 4 304 8 Index 4 specifies the linear acceleration see above Machine data Table 10 8 Normalization of phys units of machine data and setting data machine data N
599. y of the NC and PLC user data References BH Operator Components Manual Chapter PCU 50 2 UPS system The internal power backup time after switch off 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 32 3 Replacing the MCI board or 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 its battery is replaced after incorrect shutdown of Window 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 4 Page 5 121 1 1 9 UPS system Physical SRAM Connection options 1 32 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 81 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 shu
600. y os 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 Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 8 229 8 PROFIBUS DP Communication 01 05 8 6 DP slave MCP 310 Display of the software version Switch S3 8 230 SHIELD M24 P24 Fig 8 12 Connection overview Power supply X10 For a detailed description of the electrical and mechanical design and of the machine control panel interfaces please refer to References BH Operator Components Manual Chapter Machine control panel MCP 310 After the MCP has been electrically connected all LEDs on the front side of the MCP flash until communication is established between MCP and PLC 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 SIEMENS SPHERE EE OUR EEE BE EEE Bee BRE AEE Aaa 1 Digit 2 Digit 3 Digit left LED block center LED block right LED block Enable software version display press both keys simul
601. ystem Machine data Table 10 26 DSC machine data Number Name of identifier Name Refer ence Axisspecific MA_ 32640 STIFFNESS_CONTROL_ENABLE Dyn stiffness control DD2 32200 POSCRTL_GAIN Servo gain factor Kv G2 10 5 9 Drive optimization Optimization of the control loop current speed and position control loop of the drives can be performed with e HMI Advanced see Chapter 13 Page 13 421 Alldrives e Start up tool SimoCom U SIMODRIVE 611 universal E SIMODRIVE POSMO CD CA SIMODRIVE POSMO SI Note You will find detailed information about frequency measurement and optimization of the SIMODRIVE 611 universal E POSMO CD CA and SI drives in the online help of the start up tool SimoCom U under Menu command Help gt Help topics gt Index Measuring function Optimization of speed control loop 10 5 10 Rotary axes Rotary axes A machine axis is parameterized as a rotary axis in e 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 Siemens AG 2005 All rights reserved 10 328 SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 10 NC Start Up with HMI Advanced 10 5 Axes and spindles For the recommended procedure with respect to scaling machine data please refer to Subsection 10 3 3 Page 10 290 Modulo display Machine data Endlessly rotatin
602. zation a general reset of the PLC is necessary Siemens AG 2005 All rights reserved SINUMERIK 840Di Manual HBI 01 05 Edition 01 05 6 PLC Start Up PLC general reset 6 2 Startup General reset of the PLC can be performed using 840Di Start up or HMI Advanced option e 840Di start up Start 840Di start up Windows XP taskbar gt Start gt Programs gt SINUMERIK 840Di gt 840Di Startup Open the dialog box Menu command Window gt Diagnosis gt NC PLC e HMI Advanced option Open the dialog box Operating area switchover gt Start up gt NC PLC Diagnosis e 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 3 First start up PLC general reset deleting NC data Dialog box On initial start up of the PLC a general reset of the PLC has to be performed after the SINUMERIK 840Di 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 sys tem data are reinitialized on the next NC power up e g after NC Reset General reset of the PLC and deletion of NC data can be performed using

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