Foreword

General Information on the

SINUMERIK 840Di sl 1

Hardware Descriptions 2
SINUMERIK 840Di sl
Configuration 3

EMC and ESD Measures 4

Manual
Power-On and Power-Up 5

Commissioning Manual PLC commissioning 6

Ethernet communication 7
PROFIBUS DP
Communication 8
Drive commissioning
(SINAMICS) 9
Drive commissioning
(SIMODRIVE) 10
NC Commissioning with HMI
Advanced 11

Alarm and message texts 12

Axis and Spindle Test Run 13

Drive Optimization with HMI
Advanced 14
User data backup/Series
Valid for
commissioning 15
SINUMERIK 840Di sl/840DiE sl control
Software installation/update
Software Version and data backup 16
System software for 840Di sl/DiE sl 1.4
License management 17
840Di-specific data and
functions 18
05/2008
6FC5397–4CP10–4BA0

Appendix A
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:

WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.

Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG Ordernumber: 6FC5397–4CP10–4BA0 Copyright © Siemens AG 2008.

Industry Sector Ⓟ 06/2008 Technical data subject to change
Postfach 48 48
90327 NÜRNBERG
GERMANY
Foreword

SINUMERIK documentation
The SINUMERIK documentation is organized in 3 parts:
● General documentation
● User documentation
● Manufacturer/Service documentation
An overview of publications, which is updated monthly and also provides information about
the language versions available, can be found on the Internet at:
http://www.siemens.com/motioncontrol
Select the menu items "Support" → "Technical Documentation" → "Overview of Publications".
The Internet version of DOConCD (DOConWEB) is available at:
http://www.automation.siemens.com/doconweb
Information on the range of training courses and FAQs (frequently asked questions) are
available on the Internet under:
http://www.siemens.com/motioncontrol under menu item "Support".

Target group
This documentation is intended for manufacturers/end users of machine tools and production
machines who use SINUMERIK 840Di sl and SINAMICS S120.

Benefits
This manual provides detailed information required for the configuration and commissioning
of a SINUMERIK 840Di sl system.
This manual describes the control system design and the interfaces of the individual
components. The commissioning procedure for SINUMERIK 840Di sl (NCK, PLC and drives)
is also described.
For detailed information about individual functions, function assignment and performance
data of individual components, please refer to the appropriate document for the subject
concerned (e.g. manuals, description of functions etc.).
Separate documents are available for user-oriented activities. These include, for example,
generating part programs and handling controls.
Separate information is also available for operations that the machine tool manufacturer
must carry out. These include, for example, configuring/engineering, installation and
programming the PLC.

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Foreword

Standard scope
This documentation only describes the functionality of the standard version. Additions or
revisions made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.

Technical support
If you have any technical questions, please contact our hotline:

Europe / Africa
Phone +49 180 5050 222
Fax +49 180 5050 223
Internet http://www.siemens.com/automation/support-request

America
Phone +1 423 262 2522
Fax +1 423 262 2200
Email mailto:[email protected]

Asia/Pacific
Phone +86 1064 719 990
Fax +86 1064 747 474
Email mailto:[email protected]

Note
Country-specific telephone numbers for technical support are provided under the following
Internet address:
Enter http://www.siemens.com/automation/service&support

Manual
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 Foreword

Questions about this documentation

If you have any queries (suggestions, corrections) regarding this documentation, please
send a fax or email to the following address:

Fax +49 9131- 98 63315

Email mailto:[email protected]
A fax form is available in the appendix of this document.

Internet address for SINUMERIK 840Di sl

Product information page: http://www.siemens.com/sinumerik > further via the vertical link-
bar on the left: Products and systems > Automation systems > CNC SINUMERIK >
SINUMERIK 840Di sl
The link-box (vertical link-bar on the right) "Everything about SINUMERIK 840Di sl" gives
you direct access to all important product information.

EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be viewed/downloaded from the
Internet at:
http://support.automation.siemens.com
under the Product Order No. 15257461or at the relevant branch office of the A&D MC group
of Siemens AG.

Danger notices
The following notices are intended firstly for your personal safety and secondly to prevent
damage occurring to the product described or any connected devices and machines. Non-
observance of the warnings can result in severe personal injury or property damage.

DANGER
Only appropriately qualified personnel may commission/start-up SINUMERIK equipment.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
When the system is operating, dangerous axis movements may occur throughout the entire
work area.
A potential fire hazard exists due to the energy being transferred in the equipment and the
work materials used.
All work on the electrical system must be performed after the system has been switched off
and disconnected from the power supply.

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Foreword

DANGER
Proper transportation, expert storage, installation and mounting, as well as careful
operation and maintenance are essential for this SINUMERIK device to operate correctly
and reliably.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
Only protective extra-low voltages (PELVs) that comply with EN 61800-5-1 can be
connected to all connections and terminals between 0 and 48 V.
Should it be necessary to test or take measurements on live equipment, then the
specifications and procedural instructions defined in Accident Prevention Regulation VBG
A2 must be adhered to, in particular § 8 "Permissible deviations when working on live
components". Suitable electric tools should be used.

WARNING
Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a
transmitting power of > 1 W may lead to incorrect functioning of the devices.
Connecting cables and signal lines should be installed so that inductive and capacitive
interference does not in any way impair the automation and safety functions.
SINAMICS equipment with three-phase motors conforms to EMC Directive 89/336/EEC in
the configurations specified in the associated EC Certificate of Conformity.

DANGER
Repairs to devices that have been supplied by our company may only be carried out by
SIEMENS customer service or by repair centers authorized by SIEMENS.
When replacing parts or components, only use those parts that are included in the spare
parts list.
EMERGENCY STOP devices EN 60204-1 (VDE 0113 Part 1) must remain active in all
modes of the automation equipment. Resetting the EMERGENCY STOP device must not
cause an uncontrolled or undefined restart.
Anywhere in the automation equipment where faults might cause physical injury or major
material damage, 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 locking mechanisms, EMERGENCY STOP devices)

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Table of contents
Foreword ................................................................................................................................................... 3
1 General Information on the SINUMERIK 840Di sl.................................................................................... 17
1.1 Overview of SINUMERIK 840Di sl ...............................................................................................17
1.1.1 System components ....................................................................................................................18
1.1.2 System software packages and quantity structures ....................................................................18
1.1.3 Hardware Components ................................................................................................................19
1.1.4 Software components ..................................................................................................................21
1.1.5 Real-time properties.....................................................................................................................23
1.1.6 System integrity ...........................................................................................................................24
1.1.7 Failure safety................................................................................................................................25
1.1.8 Switch off......................................................................................................................................27
1.1.9 UPS system .................................................................................................................................29
1.2 Overview of software components...............................................................................................31
1.3 Notes on startup...........................................................................................................................34
1.4 Standard/export version...............................................................................................................36
1.5 840Di startup................................................................................................................................38
1.5.1 Menu command: Windows...........................................................................................................39
2 Hardware Descriptions ............................................................................................................................ 43
2.1 Overview of hardware components .............................................................................................43
2.2 MCI2 board for 840Di sl ...............................................................................................................47
2.2.1 Assembly......................................................................................................................................47
2.2.2 Interface description.....................................................................................................................48
2.2.3 Replace module ...........................................................................................................................50
2.2.4 Technical data..............................................................................................................................54
2.3 MCI board extension slot variation ..............................................................................................56
2.3.1 Assembly......................................................................................................................................56
2.3.2 Installation instructions.................................................................................................................58
2.3.3 Interface description.....................................................................................................................60
2.3.4 Technical data..............................................................................................................................63
2.4 Cable distributor ...........................................................................................................................65
2.5 SINUMERIK Industrial PC ...........................................................................................................71
2.5.1 SINUMERIK PCU 50.3 ................................................................................................................71
2.6 SINUMERIK operator panel fronts...............................................................................................75
2.6.1 Operator panel front OP 012........................................................................................................75
2.7 TCU (Thin Client Unit)..................................................................................................................77
2.8 Handheld units .............................................................................................................................79
2.8.1 Handheld Terminal HT 8..............................................................................................................79
2.8.2 Handheld Terminal HT 2..............................................................................................................81
2.9 Floppy disk drives ........................................................................................................................83

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2.9.1 Floppy disk drive 3.5" (USB) ....................................................................................................... 83

2.10 Power supply............................................................................................................................... 85
2.10.1 SITOP POWER standard 24V/10A............................................................................................. 85
2.11 Uninterrupted power supply (UPS) ............................................................................................. 87
2.11.1 SITOP POWER DC UPS MODULE 15....................................................................................... 87
2.11.2 SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH............................................................. 89
2.12 PP72/48 I/O module.................................................................................................................... 91
2.12.1 Assembly..................................................................................................................................... 91
2.12.2 Interface description.................................................................................................................... 92
2.12.3 Power supply............................................................................................................................. 100
2.12.4 Grounding.................................................................................................................................. 101
2.12.5 Dimension drawing.................................................................................................................... 102
2.12.6 Technical data........................................................................................................................... 103
2.13 ADI4 (Analog Drive Interface for 4 Axes).................................................................................. 104
2.13.1 Assembly................................................................................................................................... 104
2.14 Diagnostic repeater for PROFIBUS DP .................................................................................... 106
2.14.1 Assembly................................................................................................................................... 106
3 Configuration ......................................................................................................................................... 109
3.1 System overview ....................................................................................................................... 109
3.1.1 Operator panels and touch panels............................................................................................ 109
3.1.2 PROFIBUS DP components ..................................................................................................... 110
3.1.3 PCU components ...................................................................................................................... 111
3.2 Electrical design ........................................................................................................................ 112
3.2.1 MCI board and PROFIBUS DP................................................................................................. 112
3.2.2 MCI board extension ................................................................................................................. 113
3.2.3 PCU 50.3................................................................................................................................... 114
3.3 Connection overview................................................................................................................. 115
3.3.1 MCI board and MCI board extension ........................................................................................ 115
3.3.2 PCU50....................................................................................................................................... 117
4 EMC and ESD Measures....................................................................................................................... 119
4.1 RI suppression measures ......................................................................................................... 119
4.2 ESD measures .......................................................................................................................... 120
5 Power-On and Power-Up....................................................................................................................... 121
5.1 Preparing for commissioning..................................................................................................... 121
5.1.1 Checklist.................................................................................................................................... 121
5.1.2 Recommended sequence for first commissioning .................................................................... 122
5.2 First power-up ........................................................................................................................... 124
5.2.1 Basic commissioning of the system software ........................................................................... 124
5.2.2 Basic commissioning of the PLC .............................................................................................. 126
5.3 Power-up ................................................................................................................................... 127
5.3.1 SRAM handling ......................................................................................................................... 127
5.3.2 Startup after battery replacement (PCU backup battery).......................................................... 129
5.3.3 Startup after replacement of the MCI board.............................................................................. 129
5.3.4 Power up after reinstallation/update of the 840Di sl software................................................... 131
5.3.5 Startup after replacement of the PCU or the MCI board........................................................... 132
5.3.6 Startup after importing a backup copy ...................................................................................... 132
5.3.7 Startup after power failure/Power Fail....................................................................................... 133

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5.3.8 Power-up with shutdown signal .................................................................................................133

5.4 Service Desktop .........................................................................................................................135
5.4.1 Activating....................................................................................................................................135
5.4.2 SINUMERIK-specific applications..............................................................................................136
5.4.3 Setting the boot response for the Service Desktop ...................................................................138
5.4.4 System information after "Fatal exception error" .......................................................................138
5.4.5 Starting OEM programs .............................................................................................................138
5.4.6 User-specific HMI startup images ..............................................................................................139
5.4.7 HMI Explorer ..............................................................................................................................140
5.4.8 SW installation/update ...............................................................................................................141
5.5 ServiceCenter ............................................................................................................................142
5.5.1 Activating....................................................................................................................................142
5.5.2 NC/PLC startup modes ..............................................................................................................143
5.5.3 Backup/restore functions ...........................................................................................................144
5.6 Configuration of the network connection of the PCU (LAN/WAN).............................................145
5.7 License management.................................................................................................................146
5.7.1 License management with the Automation License Manager ...................................................146
5.7.2 License management with SinuCom NC ...................................................................................146
6 PLC commissioning ............................................................................................................................... 149
6.1 General ......................................................................................................................................149
6.1.1 Compatibility...............................................................................................................................149
6.1.2 Performance Data......................................................................................................................149
6.1.3 PLC program..............................................................................................................................150
6.1.4 Installing the PLC basic program library ....................................................................................151
6.1.5 STEP 7 example projects ..........................................................................................................151
6.1.6 PLC user program......................................................................................................................153
6.2 Commissioning...........................................................................................................................155
6.2.1 Basic requirements ....................................................................................................................155
6.2.2 External communications link: Ethernet.....................................................................................156
6.2.3 Local communications link: SOFTMC........................................................................................156
6.2.4 Check PLC status and communication interface .......................................................................157
6.2.5 First commissioning ...................................................................................................................157
6.3 Creating a SIMATIC S7 project..................................................................................................160
6.3.1 Create a project..........................................................................................................................161
6.3.2 Inserting Station 300 ..................................................................................................................161
6.3.3 HW Config..................................................................................................................................163
6.3.4 Inserting the 840Di sl Rack ........................................................................................................164
6.3.5 Parameterizing the PROFIBUS interface (X101).......................................................................165
6.3.6 Parameterizing the PROFIBUS interface (X102) (optional) ......................................................167
6.3.7 Parameterizing the MPI interface (X102) (optional)...................................................................169
6.3.8 Parameterization of the communications processor (CP 840D sl) (Ethernet)...........................170
6.3.9 Networking PG/PC and PCU (Ethernet) ....................................................................................172
6.4 Creating a PLC program ............................................................................................................177
6.4.1 PLC basic program ....................................................................................................................177
6.4.2 PLC user program......................................................................................................................178
6.5 Creating a PROFIBUS configuration .........................................................................................178
6.6 Load configuration (STEP 7 -> PLC) .........................................................................................179
6.6.1 Requirements.............................................................................................................................179
6.6.2 Uploading the configuration .......................................................................................................179
6.6.3 Series startup file .......................................................................................................................180

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6.7 Testing the PLC program .......................................................................................................... 181

6.7.1 Startup characteristics............................................................................................................... 181
6.7.2 Cyclic operation......................................................................................................................... 182
6.7.3 Monitor/control using the SIMATIC Manager............................................................................ 182
6.7.4 Monitor/control using HMI Advanced ........................................................................................ 183
6.8 Load configuration in PG (PLC -> STEP 7) .............................................................................. 185
7 Ethernet communication ........................................................................................................................ 187
7.1 General information................................................................................................................... 187
7.1.1 Ethernet connections of the PCU 50.3...................................................................................... 187
7.1.2 Determine Ethernet communication partners of the PCU......................................................... 188
7.1.3 Check Ethernet connection ....................................................................................................... 188
7.2 SINUMERIK 840Di sl commissioning tool SinuCom NC .......................................................... 188
7.3 STARTER SINAMICS drive commissioning tool ...................................................................... 189
7.4 External HMI Advanced ............................................................................................................ 189
7.5 MCP 483C IE ............................................................................................................................ 191
7.5.1 Conditions for general commissioning ...................................................................................... 191
7.5.2 Parameterization of the MCP .................................................................................................... 192
7.5.3 MCP functions........................................................................................................................... 195
7.5.4 Linking to the basic PLC and user program.............................................................................. 196
7.5.5 Input/output image .................................................................................................................... 198
7.6 HT 8........................................................................................................................................... 201
7.6.1 Conditions for general commissioning ...................................................................................... 201
7.6.2 Parameterization of the power supply unit................................................................................ 202
7.6.3 Parameterization of the HT 8 via the TCU firmware ................................................................. 203
7.6.4 Parameterization of the HT 8 via the system network center ................................................... 204
7.6.5 Linking to the basic PLC and user program.............................................................................. 206
7.6.5.1 Linking to the basic PLC program (FB1)................................................................................... 206
7.6.5.2 Signal transmission from/to NC/PLC interface (FC26) ............................................................. 208
7.6.5.3 Overview of traversing keys ...................................................................................................... 210
7.6.5.4 Activate traversing keys ............................................................................................................ 212
7.6.5.5 Display traversing keys ............................................................................................................. 214
7.6.5.6 Activating user softkeys ............................................................................................................ 216
7.6.5.7 Displaying user softkeys ........................................................................................................... 217
7.6.5.8 MCS/WCS coordinate system switchover ................................................................................ 218
7.6.5.9 Instructions on the evaluation of input signals .......................................................................... 219
7.6.5.10 Input/output image .................................................................................................................... 220
7.7 HT 2........................................................................................................................................... 222
7.7.1 Conditions for general commissioning ...................................................................................... 222
7.7.2 Linking to the basic PLC and user program.............................................................................. 223
7.7.2.1 Interface signals ........................................................................................................................ 223
7.7.2.2 Rotary coding switch ................................................................................................................. 225
7.7.2.3 Write display-line....................................................................................................................... 226
7.7.2.4 Character Map .......................................................................................................................... 227
8 PROFIBUS DP Communication............................................................................................................. 229
8.1 General information................................................................................................................... 229
8.1.1 PROFIBUS DP interfaces of the MCI board ............................................................................. 229
8.1.2 PROFIBUS DP with Motion Control option ............................................................................... 229
8.1.3 Message format for cyclic DP communication .......................................................................... 231
8.1.4 Description of a DP cycle .......................................................................................................... 232
8.1.5 Networking rules ....................................................................................................................... 234

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8.2 Requirements.............................................................................................................................235
8.3 Creating a PROFIBUS configuration .........................................................................................239
8.3.1 Requirement...............................................................................................................................239
8.3.2 Inserting DP slaves ....................................................................................................................240
8.3.3 Parameterizing the equidistant DP-Slaves finally ......................................................................242
8.3.4 Generating system data blocks (SDB).......................................................................................248
8.3.5 Load the configuration in the PLC .............................................................................................249
8.3.6 PROFIBUS diagnosis ................................................................................................................249
8.4 SIMATIC I/O devices (ET200...) ................................................................................................249
8.5 DP slave I/O Module PP72/48 ...................................................................................................250
8.5.1 Parameterization of I/O Module PP72/48 ..................................................................................250
8.5.2 Inserting the DP slave................................................................................................................250
8.5.3 Setting PROFIBUS parameters .................................................................................................251
8.5.4 Setting the I/O addresses ..........................................................................................................252
8.6 DP slave MCP 310.....................................................................................................................253
8.6.1 General commissioning requirements .......................................................................................253
8.6.2 Parameterization of the MCP.....................................................................................................255
8.6.3 Functions of the machine control panel .....................................................................................258
8.6.4 Configure MCP 310 DP slave ....................................................................................................259
8.6.5 Linking to the basic PLC and user program...............................................................................264
8.6.6 Input/Output image ....................................................................................................................267
8.7 DP slave MCP 483.....................................................................................................................270
8.7.1 Conditions for general commissioning.......................................................................................270
8.7.2 Parameterization of the MCP.....................................................................................................272
8.7.3 Functions of the machine control panel .....................................................................................274
8.7.4 Configure MCP 483 DP slave ....................................................................................................275
8.7.5 Linking to the basic PLC and user program...............................................................................280
8.7.6 Input/Output image ....................................................................................................................283
8.8 ADI4 DP slave............................................................................................................................286
8.8.1 SlaveOM ....................................................................................................................................286
8.8.2 Inserting the DP slave................................................................................................................286
8.9 DP slave SINAMICS S120.........................................................................................................287
8.9.1 SlaveOM for SINAMICS.............................................................................................................287
8.9.2 Inserting the DP slave................................................................................................................287
8.9.3 Parameterizing DP slaves..........................................................................................................288
8.9.4 Dependencies of PROFIBUS DP communication .....................................................................294
8.10 DP slave SIMODRIVE drives.....................................................................................................297
8.10.1 SlaveOM ....................................................................................................................................297
8.10.2 Inserting the DP slave................................................................................................................297
8.10.3 Parameterizing DP slaves..........................................................................................................298
8.10.4 Dependencies of PROFIBUS DP communication .....................................................................303
8.11 DP slave diagnostic repeater for PROFIBUS DP ......................................................................305
8.11.1 Function .....................................................................................................................................305
8.11.2 Area of application .....................................................................................................................306
8.11.3 Connection and commissioning .................................................................................................306
9 Drive commissioning (SINAMICS) ......................................................................................................... 307
9.1 Requirements.............................................................................................................................307
9.1.1 Basic requirements ....................................................................................................................307
9.1.2 Safety information ......................................................................................................................308

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9.2 ONLINE commissioning ............................................................................................................ 309

9.2.1 Create new project without Project Wizard ............................................................................... 310
9.2.2 Create new project with Project Wizard .................................................................................... 313
9.2.3 Drive unit: Enter component topology and configuration automatically.................................... 316
9.2.4 Drive: Configuring motors and encoders .................................................................................. 318
9.2.5 Control Unit: Selecting the PROFIBUS meassage frame......................................................... 321
9.2.6 Infeed: Selecting the PROFIBUS meassage frame.................................................................. 321
9.2.7 Drive unit: Check configuration ................................................................................................. 322
9.2.8 Drive unit: Configuring PROFIBUS message frames ............................................................... 324
9.2.9 Control Unit: Acknowledge error (BICO interconnection) ........................................................ 325
9.2.10 Control Unit: Output "Infeed operation" (BICO interconnection) signal ................................... 326
9.2.11 Control Unit: Output "Infeed ready for activation" (BICO interconnection) signal .................... 327
9.2.12 Infeed: Acknowledge error (BICO interconnection) ................................................................. 328
9.2.13 Infeed: Enable/disable drives via ON/OFF1 (BICO interconnection)........................................ 329
9.2.14 Drive: Enable/disable drives via 2nd OFF3 (BICO interconnection)......................................... 330
9.2.15 Drive unit: Backing up parameters............................................................................................ 331
9.2.16 Drive: Testing motor rotation..................................................................................................... 331
9.2.17 Settings of specific parameters................................................................................................. 332
9.3 Example for systems with more than 6 drives .......................................................................... 333
9.3.1 Configuration............................................................................................................................. 333
9.3.2 Basic commissioning................................................................................................................. 334
9.3.3 Drives of Control Unit 2: Additional BICO interconnection........................................................ 335
9.4 Further terminal assignments.................................................................................................... 337
9.4.1 Advice on terminal assignment: 1. CU (X122) .......................................................................... 337
9.4.2 Advice on terminal assignment: 1. CU (X132) .......................................................................... 338
9.4.3 Advice on terminal assignment: 2. up to nth CU (X122)........................................................... 338
9.4.4 Advice on interconnection: 1. CU with 2nd to nth CU............................................................... 340
9.4.5 Example: CU interconnection with line contactor...................................................................... 341
9.5 Basic principles ......................................................................................................................... 342
9.5.1 Drive unit: Upgrade firmware .................................................................................................... 342
10 Drive commissioning (SIMODRIVE) ...................................................................................................... 345
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI............................................................. 346
10.1.1 Commissioning variants ............................................................................................................ 346
10.1.2 Preconditions for an online connection ..................................................................................... 347
10.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal/E) ................................................. 348
10.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA)............................................... 349
10.1.5 Setting the access interface ...................................................................................................... 350
10.1.6 Setting the routing information .................................................................................................. 351
10.1.7 Starting online operation ........................................................................................................... 353
10.2 Installing SimoCom U................................................................................................................ 354
11 NC Commissioning with HMI Advanced ................................................................................................ 355
11.1 General procedure .................................................................................................................... 355
11.2 Machine and setting data .......................................................................................................... 356
11.2.1 Display and input....................................................................................................................... 359
11.2.2 Protection levels........................................................................................................................ 360
11.2.3 Machine data display filter......................................................................................................... 363
11.3 System data .............................................................................................................................. 365
11.3.1 Resolutions ............................................................................................................................... 365
11.3.2 Standardization of physical units of machine data and setting data......................................... 367
11.3.3 Changing scaling machine data................................................................................................ 370

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11.3.4 Loading default machine data....................................................................................................371

11.3.5 Switching over the measuring system .......................................................................................372
11.3.6 Traversing ranges ......................................................................................................................374
11.3.7 Positioning accuracy of the control system................................................................................374
11.3.8 Cycle times.................................................................................................................................375
11.3.9 Velocities....................................................................................................................................379
11.4 Memory configuration ................................................................................................................381
11.4.1 DRAM memory...........................................................................................................................382
11.4.2 SRAM memory...........................................................................................................................383
11.5 Axes and spindles......................................................................................................................385
11.5.1 Axis configuration.......................................................................................................................385
11.5.2 Axis names.................................................................................................................................388
11.5.3 Drive configuration .....................................................................................................................389
11.5.4 Setpoint/actual value channels ..................................................................................................393
11.5.5 Incremental measuring system settings ....................................................................................396
11.5.6 Parameterization of absolute measuring systems .....................................................................399
11.5.7 Parameterization of a 2nd measuring system with ADI4...........................................................402
11.5.8 DSC (Dynamic Servo Control) ...................................................................................................405
11.5.9 Drive Optimization......................................................................................................................407
11.5.10 Rotary axes ................................................................................................................................407
11.5.11 Positioning axes .........................................................................................................................409
11.5.12 Indexing axes .............................................................................................................................410
11.5.13 Parameter sets of axis/spindle...................................................................................................411
11.5.14 Position controller ......................................................................................................................413
11.5.15 Speed setpoint matching ...........................................................................................................417
11.5.16 Drift compensation .....................................................................................................................420
11.5.17 Axis velocity matching................................................................................................................421
11.5.18 Axis monitoring...........................................................................................................................423
11.5.19 Axis homing................................................................................................................................431
11.5.20 Spindle basic data......................................................................................................................441
11.5.21 Setpoint/actual value channels of spindle..................................................................................444
11.5.22 Gear stages................................................................................................................................444
11.5.23 Spindle measuring systems .......................................................................................................445
11.5.24 Speeds and setpoint adjustment for spindle..............................................................................447
11.5.25 Positioning the spindle ...............................................................................................................450
11.5.26 Synchronizing spindle ................................................................................................................451
11.5.27 Spindle monitoring .....................................................................................................................453
11.5.28 Spindle data ...............................................................................................................................456
11.6 Handwheels ...............................................................................................................................460
11.6.1 General information ...................................................................................................................460
11.6.2 Connection via cable distributor.................................................................................................460
11.6.3 Connection via PROFIBUS........................................................................................................461
11.6.4 Connection via Ethernet.............................................................................................................464
11.7 Digital and analog I/O devices ...................................................................................................467
11.7.1 Parameterization of the number of inputs/outputs used ............................................................468
11.7.2 Assignment of inputs/outputs to the signal modules .................................................................469
11.7.3 System variable $A_...[n] ...........................................................................................................470
11.7.4 Digital input/output bytes and system variables.........................................................................471
11.7.5 Dynamic response .....................................................................................................................472
11.7.6 Configuration example ...............................................................................................................473
11.8 Loadable compile cycles............................................................................................................478
11.8.1 Load a compile cycle .................................................................................................................479
11.8.2 Interface version compatibility....................................................................................................479

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11.8.3 Software version of a compile cycle.......................................................................................... 481

11.8.4 Constraints ................................................................................................................................ 481
11.8.5 Activating and licensing technology functions........................................................................... 482
11.8.6 Data descriptions (MD) ............................................................................................................. 483
11.9 PROFIBUS DP.......................................................................................................................... 484
11.9.1 Setting the parameters for the shut-down behavior.................................................................. 484
11.9.2 Data descriptions (MD) ............................................................................................................. 484
11.10 Initial settings ............................................................................................................................ 485
11.11 NC/PLC Diagnosis .................................................................................................................... 486
11.11.1 Menu: Diagnostics..................................................................................................................... 486
11.11.2 Menu: settings........................................................................................................................... 490
12 Alarm and message texts ...................................................................................................................... 493
12.1 Configuration file MBDDE.INI.................................................................................................... 493
12.2 Standard text files ..................................................................................................................... 494
12.3 User text files ............................................................................................................................ 494
12.4 Syntax for alarm text files.......................................................................................................... 497
12.5 Setting the alarm log properties ................................................................................................ 500
13 Axis and Spindle Test Run..................................................................................................................... 501
13.1 Requirements............................................................................................................................ 501
13.1.1 Drives: SINAMICS S120 ........................................................................................................... 501
13.1.2 Drives: SIMODRIVE.................................................................................................................. 502
13.1.3 NC/PLC interface signals .......................................................................................................... 502
13.2 Axis dry run ............................................................................................................................... 504
13.3 Spindle dry run .......................................................................................................................... 505
14 Drive Optimization with HMI Advanced.................................................................................................. 507
14.1 Overview ................................................................................................................................... 507
14.2 Measuring functions .................................................................................................................. 508
14.3 Special functions ....................................................................................................................... 510
14.4 Frequency response measurements ........................................................................................ 512
14.4.1 Measurement of current control loop ........................................................................................ 513
14.4.2 Speed control loop measurement ............................................................................................. 514
14.4.3 Position control measurement .................................................................................................. 518
14.5 Graphic display ......................................................................................................................... 522
14.6 Trace function ........................................................................................................................... 525
14.6.1 Trace function properties .......................................................................................................... 525
14.6.2 Main screen and operation........................................................................................................ 526
14.6.3 Parameter assignment .............................................................................................................. 527
14.6.4 Performing the measurement.................................................................................................... 530
14.6.5 Display function......................................................................................................................... 531
14.7 File Function.............................................................................................................................. 533
14.8 Print graphic .............................................................................................................................. 535
14.9 Automatic controller setting....................................................................................................... 538
14.9.1 Drives: SINAMICS S120 ........................................................................................................... 538
14.9.2 Drives: SIMODRIVE 611 universal ........................................................................................... 539

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15 User data backup/Series commissioning ............................................................................................... 541

15.1 Explanations on data backup.....................................................................................................541
15.2 Creating a series commissioning file .........................................................................................543
15.2.1 General information ...................................................................................................................543
15.2.2 HMI Advanced (option). .............................................................................................................545
15.2.3 SinuCom NC ..............................................................................................................................546
15.3 Considerations when backing up PLC data...............................................................................547
15.4 Importing a series startup file with HMI Advanced.....................................................................548
15.5 SINAMICS S120 standard commissioning with STARTER.......................................................549
16 Software installation/update and data backup........................................................................................ 551
16.1 PTP network connection ............................................................................................................551
16.1.1 Establishing a network connection ............................................................................................551
16.1.2 Configuring the external computer (Windows NT).....................................................................552
16.1.3 Configuring the external computer (Windows XP).....................................................................555
16.1.4 Configuring the PCU ..................................................................................................................557
16.2 Partitioning of the PCU hard disk...............................................................................................558
16.3 Software installation/update (Windows).....................................................................................559
16.4 Restoring the as-delivered state ................................................................................................560
16.4.1 Requirements.............................................................................................................................560
16.4.2 Restoring the partitions ..............................................................................................................561
16.4.3 Installation of the SINUMERIK 840Di sl applications.................................................................561
17 License management ............................................................................................................................ 563
17.1 Basic principles ..........................................................................................................................563
17.1.1 Important terms ..........................................................................................................................563
17.1.2 Overview ....................................................................................................................................564
17.1.3 Web License Manager ...............................................................................................................565
17.1.4 Automation License Manager ....................................................................................................565
17.1.5 License database.......................................................................................................................565
17.1.6 MCI board and hardware serial number ....................................................................................567
17.1.7 SINUMERIK License Key ..........................................................................................................568
17.1.8 Browser settings for using the A&D Mall ...................................................................................569
17.1.9 Proxy settings for the download of license information .............................................................570
17.2 Assigning via Web License Manager.........................................................................................571
17.2.1 Execute assignment via direct access.......................................................................................571
17.2.2 Execute assignment via customer login ....................................................................................572
17.3 Assigning via Automation License Manager..............................................................................574
17.3.1 Overview of functions.................................................................................................................574
17.3.2 Installing Automation License Manager.....................................................................................575
17.3.3 Enable/disable SINUMERIK plug-in ..........................................................................................576
17.3.4 Define parameters of TCP/IP communication with a control .....................................................577
17.3.5 Update the "Management" navigation view ...............................................................................580
17.3.6 Display the license information of a hardware unit ....................................................................581
17.3.7 Create control image (offline).....................................................................................................582
17.3.8 Align license requirement for a hardware unit ...........................................................................583
17.3.9 Transferring license information for a control image (offline) to a control system (online) ........584

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Table of contents

18 840Di-specific data and functions .......................................................................................................... 587

18.1 Interface signals ........................................................................................................................ 587
18.1.1 840Di sl-specific interface signals............................................................................................. 587
18.1.2 Interface signals not supported................................................................................................. 588
18.2 Expanded message frame configuration/evaluation of internal drive variables........................ 589
18.2.1 Description of functions............................................................................................................. 589
18.2.2 Requirements............................................................................................................................ 591
18.2.3 Project design: SINAMICS S120 and SIEMENS message frame 116 ..................................... 592
18.2.4 Project design: SINAMICS S120 and expanded message frame configuration....................... 592
18.2.5 Project design: SIMODRIVE ..................................................................................................... 595
18.2.6 Constraints ................................................................................................................................ 600
18.2.7 Data descriptions (MD, system variable) .................................................................................. 602
18.2.8 Interrupts ................................................................................................................................... 603
18.3 Travel to fixed stop with high-resolution torque reduction ........................................................ 604
18.3.1 Description of functions............................................................................................................. 604
18.3.2 Comparison ............................................................................................................................... 605
18.3.3 Parameter assignment: SINAMICS S120 ................................................................................. 605
18.3.4 Parameter assignment: SIMODRIVE........................................................................................ 606
18.3.5 Parameter assignment: External drives .................................................................................... 606
18.3.6 Parameter assignment: SINUMERIK 840Di sl NC.................................................................... 606
18.3.7 Constraints ................................................................................................................................ 608
18.3.8 Data description (MD) ............................................................................................................... 609
18.3.9 Interrupts ................................................................................................................................... 610
A Appendix................................................................................................................................................ 611
A.1 Abbreviations ............................................................................................................................ 611
A.2 Feedback on the documentation............................................................................................... 616
A.3 Overview ................................................................................................................................... 618
Glossary ................................................................................................................................................ 619
Index...................................................................................................................................................... 625

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16 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
General Information on the SINUMERIK 840Di sl 1
1.1 Overview of SINUMERIK 840Di sl
With the SINUMERIK 840Di sl, Siemens provides a complete PC-integrated control that
controls the drive units and I/Os through the standard fieldbus PROFIBUS DP with Motion
Control functionality and in this way permits a distributed design of the overall system. It
therefore constitutes the basis for PC-based automation solutions and is generally designed
especially for applications with the following requirements:
● Decentralized automation solutions in the fields of PLC I/Os and drives.
● Fully PC-integrated control, owing to increased integratability in the target or current
automation environment.

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General Information on the SINUMERIK 840Di sl
1.1 Overview of SINUMERIK 840Di sl

1.1.1 System components

This manual refers to the following system components:

System component Version

SINUMERIK 840Di sl system software SW 1.4
SINUMERIK Industrial PC PCU 50.3-C: 1.5 GHz, 512 MB DRAM
PCU 50.3-P: 2.0 GHz, 1024 MB DRAM
PC operating system Windows XP ProEmbSys
MCI board MCI2 board for 840Di sl

Note
It is not possible to combine the named system components with older versions.

1.1.2 System software packages and quantity structures

System software packages

The following system software packages are available for SINUMERIK 840Di sl:
● 6 axes system software
● 20 axes system software

Quantity framework
The system software packages are each designed for the following quantity structures:

6 axes 20 axes
Basic Maximum Basic Maximum
configuration configuration
Axes 3 6 5 20
Channels 1 2 1 10
Mode groups 1 2 1 10
Channels per mode 1 2 1 10
group
Basic configuration: Default number of available components
Maximum: Maximum possible number of components with additional options

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1.1 Overview of SINUMERIK 840Di sl

1.1.3 Hardware Components

Hardware Basis:
The hardware basis of a SINUMERIK 840Di sl is an industrial-PC of SIEMENS A&D,
referred to as PCU (PC-Unit) from now on, together with the MCI-Board (Motion Control-
Interface).

PCU
The SINUMERIK 840Disl is available with the following PCU 50.3 versions, each with 24 V
power supply:
● PCU 50.3-C: 1.5 GHz, 512 MB SDRAM
● PCU 50.3-P: 2.0 GHz, 1024 MB SDRAM

PCU interfaces
The PCU 50.3 features interfaces to connect the SINUMERIK operator panel fronts (OP 0xx)
as well as standard PC interfaces for connecting, e.g. monitor, keyboard, mouse, and
Ethernet connection.

PCU slots
The PCU 50.3 has the following slots:
● 1 x PCI (length: max. 175 mm, occupied with option MCI board extension and MCI board
extension slot variant)
● 1 x PCI (length: max. 265 mm, occupied by the MCI board)

MCI2 board
The MCI2-Board, called only as MCI-Board from now on, is a small PCI-slot card with
integrated SIMATIC S7-compatible CPU PLC317-2 DP as the DP-Master with routing
capability. The MCI board has the following external interfaces:
● PROFIBUS DP with Motion Control Functionality (Master)
● MPI (Multi-Point Interface)/PROFIBUS DP (Master/Slave)
● MCI board extension (option)

PROFIBUS DP interface X101

The PROFIBUS DP interface (X101) can be used to connect drives, distributed ext. I/Os,
machine control panels, programming units, etc. via PROFIBUS DP with motion control
capability (clocked and isochronous data exchange between the DP master and DP slaves)
to the SINUMERIK 840Di sl. Both the PLC and the NC have direct access to this PROFIBUS
interface.

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General Information on the SINUMERIK 840Di sl
1.1 Overview of SINUMERIK 840Di sl

PROFIBUS DP X102 interface

Unlike the PROFIBUS DP interface (X101), interface (X102) can only be accessed via the
PLC. As a result, no drives and no NC I/Os can be operated via this interface.
The interface (X102) can also be operated as an MPI interface. However, using the MPI-
communication with SINUMERIK 840Di sl with the present version is no longer
recommended.

MCI board extension slot variation (option)

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 is inserted into a slot in the PCU and is connected to the MCI board via a ribbon
cable.

Digital drives
SINUMERIK 840Disl is available with the components from the new SINAMICS range of
drives offering the following characteristics:
● SINAMICS S120
The drive components from the SIMODRIVE range of drives offering the following
characteristics can also be used:
● SIMODRIVE 611 universal and universal E with option module Motion Control with
PROFIBUS DP
● SIMODRIVE POSMO CD/CA
● SIMODRIVE POSMO SI
● SIMODRIVE POSMO A (not suitable for interpolatory procedures)

Note
SINAMICS S120 and SIMODRIVE drives cannot be operated in parallel on a
SINUMERIK 840Di sl.

Analog drives
To operate drives with an analog setpoint interface via PROFIBUS, the following interface
module is available:
● ADI4 (Analog Drives Interface for 4 Axes)

I/Os
For use as distributed I/Os, the module range SIMATIC DP ET 200 (for connection
conditions, see SIMATIC Documentation) as well as the I/O Module PP 72/48 are available.

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1.1 Overview of SINUMERIK 840Di sl

Operator panel front

The operator panel fronts from the SINUMERIK-spectrum (OP 010, OP 010C, OP 010S, OP
012, OP 012T, OP 015, OP 015A, TP 015A) are optionally available as operating
components.

TCU
A TCU (Thin Client Unit) permits the distributed connection of an operator panel front to the
PCU. The TCU and PCU communicate via the Ethernet.

1.1.4 Software components

The SINUMERIK 840Di sl is based on the following software components:

Windows XP
SINUMERIK 840Di sl runs on the Windows XP ProEmbSys operating system with Service
Pack 2.
Windows XP is the platform on which all applications, such as the individual user interfaces
of the HMI modular system and the commissioning tools run.
As is generally known, Windows XP does not have full real-time capability. We call this soft
real time. So SIEMENS has developed a procedure that allows operation of NC system
software in hard real time without making it necessary to modify Windows XP (see
Subsection "Real-time properties" (Page 23)).

NC system software
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 applications.

NCK
The NCK (Numeric Control Kernel) is part of the NC System software that realizes the real-
time capability of SINUMERIK 840Di sl.
The NCK is characterized by the following features:
● The NCK is automatically started when Windows powers up.
● The NCK runs cyclically in the background.
● The current status of the NCK is displayed via the SINUMERIK 840Di sl-standard
operator panel 840Di-Startup:
Menu command Window > Diagnosis > NC/PLC
● The NCK is automatically ended when you exit Windows XP.
● When the NCK is ended, it writes the remanent SRAM data from NCK and PLC to the
hard disk of the PCU as a backup copy.

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1.1 Overview of SINUMERIK 840Di sl

PLC system software

The PLC system software, like the NC system software, largely has the same functionality as
the SINUMERIK 840D.

SinuCom NC
SinuCom NC is a Windows-based tool for commissioning the SINUMERIK 840Di sl NC
offering options for the:
● interactive parameterization of the NC
● option management and license management
● management of series startup files.

840Di startup
The Windows-based user interface 840Di-Startup (see Section "840Di-Startup" (Page 38))
offers basic operation functionality to allow the operator to become familiar with the
SINUMERIK 840Di sl.
840Di startup is part of the scope of supply of a SINUMERIK 840Di sl and is already installed
on the hard disk of the PCU.

Optional HMI components

The following components of the SINUMERIK HMI modular system can be used optionally:
● SINUMERIK HMI Advanced
HMI Advanced is the SINUMERIK-standard user interface especially for machine tools.
● SIMATIC Protool/Pro and Protool/Pro Option SINUMERIK
SIMATIC Protool/Pro and Protool/Pro Option SINUMERIK are configuring packages
packets for creating the technology-specific user interfaces.
The ProTool/Pro runtime system is the prerequisite for running a configured operator
interface.
● SINUMERIK HMI programming package
The HMI Programming Package can be used to integrate OEM high-level language
applications using standardized interfaces (COM/OPC). The OEM obtains as much
flexibility as possible for developing user interfaces using standard development tools
(such as Visual C++).
The HMI Programming Package basically contains interface descriptions and
corresponding example applications. Detailed information on the OPC interface can be
called from the Internet at the address of OPC Foundation
(http://www.opcfoundation.org.).

Note
For a detailed list of the installed software components or the ones required to prepare for
installation, please refer to Section "Overview of the software components" (Page 31).

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1.1.5 Real-time properties

Windows XP is not an operating system designed for hard real-time requirements. Hard real-
time requirements mean the operating system will respond to an external event within a
defined time frame of a few µ 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
Real-time violations occur when unsuitable PC components block interrupt processing for
too long, stopping the NC system software from being activated at the specified time.
Inappropriate PC components are drivers or hardware extensions that have an adverse
effect on the real-time behavior due to overly long interrupt disable times or PCI bus disables
in PCI bus mastering.
With real-time violations exceeding 200 µs, we cannot guarantee that the NC system
software will operate correctly. The system will respond appropriately for the magnitude of
the real-time violation:
● Display of an error message
● Alarm with axis stop from the NC
● Alarm and drive-independent stopping of the axes
The real-time response can be monitored in the NCK latency displays in the system
diagnostics of the 840Di Startup (see Section "840Di Startup" (Page 38)) or the NC/PLC
diagnostics of HMI Advanced (see Section "NC/PLC Diagnostics").

Screen resolution and depth of color

The following points must be taken into account for screen resolution and depth of color
settings on the PCU.
● 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.
● Color depth
The default color depth setting is 65536 colors. Higher values can, in certain
circumstances, increase the CPU time used by Windows XP and occasionally also by the
real-time operating system.

Testing or switchover
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.

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1.1 Overview of SINUMERIK 840Di sl

NOTICE
Screen savers that modify the screen resolution when activated must not be used in
conjunction with SINUMERIK 840Di sl.

Terminating the NCK

The NCK is integrated in Windows XP as a "SINUMERIK-NC" service. This service must be
started and stopped manually in the service dialog box.
Windows Start menu: Start > Programs > Administrative Tools > Services > "SINUMERIK-
NC"

Note
The NCK must be stopped before testing/switching 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

To offer high quality and wide functionality of the entire system, SINUMERIK 840Disl 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. The certification process establishes and documents
the real-time features of the entire configuration.
If PC components (hardware or software) are modified or expanded by a third party,
compliance with product features cannot be guaranteed. The OEM or user involved must
assume sole responsibility for such components.
The effect of the changes to the system software can be read on the user interface of the
"840Di Startup" or "HMI Advanced" commissioning tool (see Subsection "Menu:
Diagnostics" (Page 486)) are read. It graphically displays whether the installed hardware or
software violates the real-time conditions.

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1.1.7 Failure safety

Critical exception error (blue screen)

If Windows XP detects a fatal exception error during the operation of the NC system
software, the following steps are taken:
● Windows XP stops.
● Otherwise, an error message is output.
● NC and PLC continues to operate normally.
● The NC signals the fatal exception error detected to the PLC via the "PC OS fault"
interface signal.
Depending on the current machining situation, the PLC user program can either continue or
step machining.
After completion of machining, the PLC user program can request a shutdown of the PC by
sending the "PC shutdown" interface signal.
The "PC shutdown" interface signal causes the following actions:
● Retentive NC and PLC data are stored
● NC and PLC are closed down
● The Windows XP "Blue Screen" is displayed
● Execute reboot of the PCU (optional)
The behavior of Windows XP in the event of a fatal exception error (Blue Screen) can be
configured via the Control Panel:
Windows Start menu: Start > Settings > Control Panel > System

Note
For a product brief of the "PC OS fault" and "PC shutdown" interface signals, please refer
to Subsection "840Di sl-specific interface signals" (Page 587).

NOTICE
The "PC shutdown" interface signal must be reset in the organization block OB100 (cold
restart) of the PLC.

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Voltage failure
A power failure lasting more than 5 ms is detected by the POWER FAIL functionality of the
SINUMERIK 840Disl as a fault scenario and the following actions are initiated:
● The background lighting of the operator panel display is switched off
● NC and PLC are closed down properly
● The NC and PLC user data are saved in the SRAM of the MCI board.
The battery-backed user data are available again immediately the next time the SINUMERIK
840Di sl is booted. The SINUMERIK 840Di sl is therefore ready to use again immediately,
without data loss.
If the power supply recovers before final PCU shutdown, the following message box is
displayed:

SINUMERIK 840Di sl NCK/PLC

Alarm: Power-Fail detected, NCK/PLC restart with OK.

NOTICE
The following is to be taken into account:
• Power supply
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, Subsection "PCU 50.3"
• UPS system
The internal power backup time after a power failure is not long enough for Windows NT
to shut down correctly. To remedy this, we recommend using an uninterruptible power
system (see Subsection "UPS-system" (Page 29)).
• Exchange of MCI-boards or PCU-battery
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 MCI board or PCU battery is replaced after a power failure,
this will result in a data loss of the battery-backed user data on the SRAM of the MCI
board.
How to proceed further: See Subsection "Power-up after changing the MCI-
Boards" (Page 129).

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 General Information on the SINUMERIK 840Di sl
1.1 Overview of SINUMERIK 840Di sl

Temperature sensor
The SINUMERIK 840Di sl monitors three different temperatures for their respective
thresholds:
1. Housing temperature
2. CPU module temperature
3. CPU temperature
Error reaction
● Alarm: "2110 NCK temperature alarm"
● Logbook entry: "Alarm: Critical temperature"
Cause of errors/error handling
One of the 3 monitored temperatures has reached its threshold value or exceeded it. A
temperature change of at least 3° C before the threshold value is necessary, so that the
alarm is reset.
If the temperature alarm occurs, the user and/or the machine manufacturer (PLC user
program) must decide whether to interrupt machining and end and shut down the
SINUMERIK 840Di sl.

1.1.8 Switch off

Windows XP
To ensure safe operation of the SINUMERIK 840Di sl, Windows XP must be shut down
correctly before the PCU is switched off.

Note
Windows XP is shut down correctly as follows.
• Windows XP Start menu: Start > end
• PLC interface signal: "PC shutdown", see Subsection "840Di sl-specific interface signals".

Failure to shut down Windows XP correctly can damage the Windows XP installation and
prevent the SINUMERIK 840Di sl from operating.

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General Information on the SINUMERIK 840Di sl
1.1 Overview of SINUMERIK 840Di sl

NC and PLC
On correct shutdown of Windows XP the following occurs:
● The SINUMERIK 840Di sl components NC and PLC are terminated correctly
● The NC and PLC user data in the SRAM of the MCI board and on the hard disk of the
PCU are backed up.
If the PCU is switched off without first correctly shutting down Windows XP, the SINUMERIK
840Di sl's POWER FAIL functionality:
● ends the NC and PLC correctly;
● saves the NC and PLC user data in the SRAM of the MCI board.
The NC and PLC user data cannot be backed up on the hard disk of the PCU.

NOTICE
If you switch off the PCU without first having correctly shut down Windows XP, please
observe the following:
Power supply
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, Subsection "PCU 50.3"
UPS system
The internal power backup time after a power failure is not long enough for Windows NT to
shut down correctly. To remedy this, we recommend using an uninterruptible power system
(see Subsection "UPS-system" (Page 29)).
Exchange of MCI-boards or PCU-battery
When Windows XP is shut down correctly, the current NCK and PLC user data are saved
to the SRAM of the MCI board and to the PCU's hard disk. If the MCI board or the PCU
battery is replaced after the abnormal shutdown of Windows XP, this will result in loss of
the battery-backed user data on the SRAM of the MCI board.
How to proceed further: See Subsection "Power-up after changing the MCI-
Boards" (Page 129).

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 General Information on the SINUMERIK 840Di sl
1.1 Overview of SINUMERIK 840Di sl

1.1.9 UPS system

Physical SRAM
The PCU has POWER FAIL detection in conjunction with the NC system software to ensure
that the user data are backed up in the SRAM of the MCI board during a PCU power failure
or power-off without a proper shut down of Windows XP.
The internal power backup time is not long enough for Windows XP to shut down properly.
This can be avoided by using a UPS, e.g. SITOP POWER DC UPS MODULE 15 (see
Section "Uninterrupted Power Supply UPS" (Page 87)). 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 properly shut down Windows XP manually, or permits automatic
shutdown via a status signal from the UPS to the PLC, which then passes the "PC
shutdown" interface signal to the NC.

Connection options
The above UPS has the following connection options to signal the current status to the
SINUMERIK 840Di sl:

Table 1-1 Connection options of the UPS system

Connection Signal to Comment

1) UPS -> PCU: Windows XP The UPS functionality is configured: see Configuration
USB connection below.
Advantage: Also works when the PLC user program is
not active.
Disadvantage: Does not work in the event of serious
exceptions from Windows XP (BlueScreen)
2) Signal terminals via free PLC The UPS functionality is configured using the PLC
interconnection -> S7 I/O user program.
inputs Advantage: Also works in the event of a fatal
exception error of Windows XP (BlueScreen)
Disadvantage: PLC user program must be active
3) Signal terminals via free NC The UPS functionality is configured using the menu:
interconnection -> MCI Settings in HMI Advanced (see Subsection "Menu:
board extension inputs Settings" (Page 490)).
Advantage: Also works in the event of a fatal
exception error of Windows XP (BlueScreen) and
when the PLC user program is not active.
Prerequisites: MCI board extension (option)
Note:
For 3)
For information on the boot response of the SINUMERIK 840Di sl with pending shutdown signal see
Subsection "Power-up with shutdown signal" (Page 133).

Manual
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General Information on the SINUMERIK 840Di sl
1.1 Overview of SINUMERIK 840Di sl

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)

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Configuration
The UPS functionality can be configured in two different ways:
● When using SITOP POWER DC UPS MODULE 15 (see Section "Uninterrupted Power
Supply UPS" (Page 87)) with a special software tool.
Download: http://www.siemens.de/sitop > Further topics: Download Software DC UPS 15
A
● With Windows XP standard tools.
Start menu: Start > Settings > Control Panel > Power Options > Tab: UPS

Note
If the SINUMERIK user interface HMI Advanced (option) is installed on the PCU, the
application F:\mmc2\hmiexit.exe must be executed with the UPS software, before the
shutdown of the PCU.

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30 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 General Information on the SINUMERIK 840Di sl
1.2 Overview of software components

1.2 Overview of software components

The software components listed below are part of the SINUMERIK 840Di sl system software.
The first time the PCU is booted, all the software components required to operate the
SINUMERIK 840Disl are automatically installed. Other software components including
engineering tools or SIMATIC S7 add-on software are also available for installation on the
PCU or an external computer.

Note
See Subsection "HMI-Explorer" (Page 140)for information on how to determine the
installation path of the SINUMERIK 840Di sl system software (CD path).
Before installing a software component, please read the information in the instruction file
(*.txt, *.rtf, *.wri).

Basic software
The basic software essentially comprises the following components:
● 840Di sl Base software(installed)
– NCK-specific real-time drivers
– 840Di startup
● PLC system software (installed)
● NCK system software(installed)
● PCU basic software(installed)
– Windows XP Pro with SP2, English version
– Internet Explorer 6, English version
– HMI Explorer
– Norton Ghost™
– Norton GhostWalker™
– ServiceCenter under Windows PE
– PCU-specific drivers
– TCU Support
● HMI basic software(installed)
– HMI-specific display and communications drivers

Engineering tools
The Engineering Tools include applications for the commissioning of the SINUMERIK 840Di
sl NC and SIMODRIVE drives:

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General Information on the SINUMERIK 840Di sl
1.2 Overview of software components

● SinuCom NC(installed)
Startup-Tool for the SINUMERIK 840Di sl NC
● SIMODRIVE 611 universal tool box
Contents:
– Toolbox for PLC-parameterization
Various files for assigning parameters to an S7 configuration with SIMODRIVE drives
(611U, POSMO SI, CD, CA) and PROFIdrive communication (see readme.txt)
(Example-files: <Installation path>\611utb\toolbox\<version>\<file>)
– SimoCom U
Startup-Tool for SIMODRIVE 611 universal/E and SIMODRIVE POSMO SI, CD/CA
drives
(installs and in addition to installation: <CD-path>\611utb\SimoComU\Setup.exe)
– SIMODRIVE 611 universal Drive-Firmware
(Firmware file: <Installation path>\611utb\Sys611U\<version>\611u.ufw)
– SIMODRIVE 611 universal option module: "Motion Control with PROFIBUS DP"
firmware
(Firmware file: <Installation path>\611utb\dpc31\<version>\v1sl.ufw)
– SIMODRIVE POSMO SI, CD/CA Drive firmware
(Firmware file: <Installation path>\611utb\SysPosmo\<version>\posmo.ufw)

Note
SINAMICS drives
The drive commissioning tool: STARTER is not included in the SINUMERIK 840Di sl
scope of supply. The STARTER must be purchased separately. It is recommended
that you always use latest version.
References:
Catalog: NC 61 > SINAMICS S120 Drive System

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 General Information on the SINUMERIK 840Di sl
1.2 Overview of software components

SIMATIC S7 add-on software

The SIMATIC S7 add-on software contains sample programs and applications:
● PLC Toolbox
The PLC Toolbox contains the following components:
– PLC basic program
– SINUMERIK Add-On for STEP 7
e.g. SlaveOM for SINUMERIK 840Di sl, GSD file for PROFIBUS-MCP
– NC variable selector
– PLC Symbol generator
(installation software: <CD-path>\installs\add_on\plc_tb\setup.exe)
● GSD file for I/O modules PP72/48
Device master file with the necessary information in ASCII format for inserting the I/O
module PP72/48 as DP slave in a SIMATIC project.
(GSD file: <CD-path>\support\siem80a2.gsd)
● Sample PLC application
The application examples include the basic PLC- rogram and the linking of one of the
following MCP in the form of SIMATIC S7 archives (*.zip) and SINUMERIK archives
(*.arc).
Path: < Installation path>\support\840dismp\
– PROFIBUS-MCP: 840disl_tb<version>_DPMCP.zip and *.arc
– Ethernet MCP: 840disl_tb<version>_ETHMCP.zip and *.arc
– Ethernet-MCP and HT 8: 840disl_tb<version>_ETHMCP_HT8.zip and *.arc

Note
The PLC Toolbox should be installed on the PG/PC on which the SIMATIC STEP 7 is
already installed.

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General Information on the SINUMERIK 840Di sl
1.3 Notes on startup

1.3 Notes on startup

Described components
This SINUMERIK 840Di sl Manual describes the basic commissioning of the following
components:
● SINUMERIK 840Di sl NC and PLC
● SINAMICS S120 drives
● Ethernet communication
● PROFIBUS DP and DP components

Note
We recommend performing commissioning of the SINUMERIK 840Di sl according to the
sequence in which the chapters of this manual are laid out.

Software
For commissioning the following software is required (part of a SINUMERIK 840Di sl):
● NCK commissioning:
– 840Di startup
– SinuCom NC
● PLC commissioning, including PROFIBUS communication:
– SlaveOM for SIMODRIVE drives
– PLC basic program
● SIMODRIVE drive commissioning
– SimoCom U

Additional software
For commissioning the following software is required (not part of a SINUMERIK 840Di sl):
● PLC commissioning, including PROFIBUS DP communication:
– SIMATIC Manager STEP 7: as from Version 5.3, Service Pack 2
– SlaveOM for SINAMICS drives (part of STARTER)
● SINAMICS drive commissioning
– STARTER

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 General Information on the SINUMERIK 840Di sl
1.3 Notes on startup

Additional hardware
The following hardware components are required for commissioning:
● Via the Ethernet interface, e.g. PG740:
– Creation of the SIMATIC S7 project for commissioning of the PLC, as well as the
PROFIBUS communication
– Installation of additional software on the PCU
For installing the software on the PCU see Section "License management" (Page 146).
● Communications link: PG/PC with NC, PLC and drives
– Ethernet cable

Note
No programming device is required in the following cases:
• SIMATIC Manager STEP7 is installed on the SINUMERIK 840Di sl PCU
• A PG/PC is needed for installing additional software
For installing the software on the PCU see Section "License
management" (Page 146).

Documentation
The following documentation is required for commissioning:
● /BH/ Operator Components Manual
– Operator panel fronts
– PCU 50.3
– Machine control panels
– Operator panel, handheld terminal HT8
Depending on the NC and PLC functions used, the corresponding function manuals are
needed:
● /FB/ Function Manual - Basic Functions
● /FB/ Function Manual - Extended Functions
● /FB/ Function Manual - Special Functions
● /LIS/ Lists
– Overview of functions
– Machine, Setting Data and Variables
– Interface Signals and PLC Blocks.
● /DA/ Diagnostics Manual:
– Interrupts

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Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 35
General Information on the SINUMERIK 840Di sl
1.4 Standard/export version

Drive commissioning:
● SINAMICS
– SINAMICS S120 Commissioning Manual
● SIMODRIVE
– /FBU/ SIMODRIVE 611 universal and universal E
Closed-loop control component for speed control and positioning
– /POS3/ SIMODRIVE SI and CD/CA
Distributed Servo Drive Technology

1.4 Standard/export version

Export license requirement

Because certain control functions require an export license in accordance with the German
Export List, the SINUMERIK 840Di sl is available in two versions.
The Standardversion SINUMERIK 840Di sl can contain the full functional scope of the
control, but is subject to the export license requirement owing to its type.
In the Export version SINUMERIK 840DiE sl, e.g. the following options are not available:
● Interpolation with more than 4 axes
● Five axis machining package
● Helical interpolation 2D + n (n greater than 2)
● OEM package
The following restrictions apply to options that can be used:
● Sag compensation: restricted to traversal of max. 10 mm travel path.

Note
A complete overview of options not available on the export version are listed in the
catalog NC 61.

The corresponding option bits can be set but they have no effect (alarm output if functions
programmed). The export version requires no export license with respect to its type.
(This does not mean that there is no export license requirement with respect to the intended
use. This is a separate matter and may apply in addition.)
The instance of the control is determined by the system software, which are available in two
versions (Standard and Export). This means that the licensing requirement of the system
software (for relevant details see delivery note or the invoice) is "inherited" with the
installation of the control system.
It is important to be aware of this in the case of updates/upgrades of the system software
because this might affect the export license requirement.

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 General Information on the SINUMERIK 840Di sl
1.4 Standard/export version

Identification of the control

In addition to the information provided on the delivery note and invoice, the hardware
components supplied with the system software are also clearly identified by adhesive labels
as standard or export versions.

Note
The adhesive labels supplied additionally in the packaging are intended to identify the control
after commissioning 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.

When the control has booted, the export version can be identified by the additional character
'E' on the Service screen of the NCU version.
● HMI Advanced (option): Diagnosis operating area > Service displays > Version > 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.

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General Information on the SINUMERIK 840Di sl
1.5 840Di startup

1.5 840Di startup

The user interface 840Di startup included in the scope of supply of the SINUMERIK 840Disl
is intended as an initial introduction to SINUMERIK 840Di sl functionality.

Overview of functions
The user interface comprises the following functions:
● Display of main screens
● Display of alarms and messages
● Management of part programs
● ASCII editor
● NC, PLC, and PROFIBUS diagnoses
● Logbook

Menu bar
The menu bar comprises the following menu commands:
● File
● Edit
● Windows
● Display

Context-sensitive menu functions

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:
● The part program management window is selected. The menu command Edit provides
the following functions:
– Copy
– Paste
– Paste ...
– Load
– Unload
● The window for display of the axis actual values is selected. The menu command Edit
provides no further functions.

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 General Information on the SINUMERIK 840Di sl
1.5 840Di startup

1.5.1 Menu command: Windows

The menu command Window provides the following functions:

Menu command Functionality

Windows
Main screen
General data Display of:
• Channel status
• Program status
Axis actual values 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:
• Part programs and up to 3 blocks
Program control Selection of:
• Machine function SBL1
• SBL2 after each block
• Program test
G functions/H functions Display of:
• Current G functions
• Current H functions
Program pointer Display of:
• Program name of the selected part program
• 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
chronological order

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General Information on the SINUMERIK 840Di sl
1.5 840Di startup

Menu command Functionality

Part programs • Management of part programs
– Menu command File
New ...
Open
Delete
End
– Menu command Edit
Copy
Paste
Load
Unload
Select
• Editing part programs:
– Menu command File > Open
– Double-click the file with the left mouse
button
Editor Editing files
Start the editor with:
• Menu command File > Open
• Double-click the file with the left mouse button
Menu command File
• Open
• Close
• Cut
• End
Menu command Edit
• Copy
• Paste
• Load
• Unload
• Select
Diagnostics
PROFIBUS
Bus Display of bus configuration:
• Baud rate
• Cycle time
• Synchr. portion (TDX)
Display of status:
• Configuration
• Bus status

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 General Information on the SINUMERIK 840Di sl
1.5 840Di startup

Menu command Functionality

Slaves Display of:
• Slave no. (DP address)
• Assignment
• Active on the bus
• Synchr. with NC
• Number of slots
• Details
NC/PLC • NC
– Display of NC status
– "NC Reset"
– "Clear NC memory"
• PLC
– Display of PLC status
– "RUN-P"
– "RUN"
– "STOP"
– "MRES"
• Latency display
– Current value
– Maximum value
– Number of violations
– Oscilloscope
Logbook Display of SINUMERIK 840Di sl system messages

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General Information on the SINUMERIK 840Di sl
1.5 840Di startup

Manual
42 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Hardware Descriptions 2
2.1 Overview of hardware components

SINUMERIK 840Di sl: Hardware

A SINUMERIK 840Disl can only be ordered as a complete system (PCU and MCI board).
● SINUMERIK 840Di sl
PCU 50.3-C 1.5 GHz/512 MByte and MCI2-Board,
40 GB hard-disk and Windows XP ProEmbSys
Voltage supply 24 V
Order number: 6FC5 220-0AA31-2AA0
● SINUMERIK 840Di sl
PCU 50.3-P 2.0 GHz/1024 MB and MCI2-Board,
40 GB hard-disk and Windows XP ProEmbSys
Voltage supply 24 V
Order number: 6FC5 220-0AA33-2AA0

Spare parts
The following hardware components are available as spare parts:
● MCI2 Board for SINUMERIK 840Di sl
Spare-part order number: 6FC5 222-0AA02-2AA0
● Hard disk drive
For PCU 50.3 with support plate and damper
Spare-part order number: 6FC5 247-0AF08-4AA0

Optional components
The following hardware components are optional and can be ordered separately:

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Hardware Descriptions
2.1 Overview of hardware components

MCI board extension

● SINUMERIK 840Di sl MCI Board Extension, Slot Version
Order number: 6FC5 222-0AA00-0AA1

Operation and display

● SINUMERIK operator panel fronts
– OP 010
Order number: 6FC5 203-0AF00-0AA1
– OP 010C
Order number: 6FC5 203-0AF01-0AA0
– OP 010S
Order number: 6FC5 203-0AF04-0AA0
– OP 012
Order number: 6FC5 203-0AF02-0AA1
– OP 012T
Order number: 6FC5203-0AF06-1AA0
– TP 012
Order number: 6FC5203-0AF07-0AA0
– OP 015
Order number: 6FC5 203-0AF03-0AA0
– TP 015A
Order number: 6FC5203-0AF08-0AA0
● Components for distributed connection of SINUMERIK operator panel fronts
– TCU (Thin Client Unit)
Order number: 6FC5 312-0DA00-0AA0
● Handheld units
– Handheld Terminal HT 8
Order number: 6FC5 403-0AA20-0AA0 (HT8 without handwheel)
Order number: 6FC5 403-0AA20-1AA0 (HT8 with handwheel)
– Handheld Terminal HT 2
Order number: 6FC5 303-0AA00-2AA0

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44 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Hardware Descriptions
2.1 Overview of hardware components

External storage media

● USB-diskette drive 3.5'' including 1m connection cable
Order number: 6FC5 235-0AA05-1AA2

Power supply of the PCU

● SITOP POWER standard 24V/10A
Order number: 6EP1 334-1SH01

Uninterruptible power supply

● SITOP POWER DC UPS module 15
Order number: 6EP1 931-2EC31
● SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH
Order number: 6EP1 935-6MD11

PROFIBUS DP modules
S7 I/O modules
● SIMATIC ET 200 (distributed peripheral system)
Detailed order information is given in:
References:
/ST7/SIMATIC S7 programmable logic controllers Catalog ST 70
● PP72/48 I/O module
Order number: 6FC5 611-0CA01-0AA0
Interface modules
● ADI4 (Analog Drive Interface for 4 Axes)
Order number: 6FC5 211-0BA01-0AA2

SINAMICS drives
● SINAMICS S120
For detailed order information on the SINAMICS S120, please refer to:
References:
/BU/ SINAMICS, SINAMICS S120, Servo Control Drive System, Catalog D21.2

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Hardware Descriptions
2.1 Overview of hardware components

SIMODRIVE drives
● SIMODRIVE 611 universal
with options module Motion Control with PROFIBUS DP
● SIMODRIVE 611 universal E
with options module Motion Control with PROFIBUS DP
● SIMODRIVE POSMO CD/CA
● SIMODRIVE POSMO SI
● SIMODRIVE POSMO A
For detailed ordering information on various drives, see:
References:
/BU/ SINUMERIK & SIMODRIVE, Order Document, Catalog NC 60

Manual
46 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Hardware Descriptions
2.2 MCI2 board for 840Di sl

2.2 MCI2 board for 840Di sl

2.2.1 Assembly
The MCI2 board for 840Di sl is a short 32-bit PCI plug&play card. The MCI2 board referred
to below simply as MCI board (Motion Control Interface) provides the following interfaces:
● PROFIBUS DP with Motion Control Functionality (X101)
● MPI (Multi-Point Interface) or PROFIBUS DP without Motion Control Functionality (X102)
(alternative)
● MCI board extension (slot variation: Section "MCI board extension slot version" (Page 56))
The MCI board also provides the following functionality:
● PLC: Compatible with SIMATIC S7 CPU 317-2 DP
● Static memory (SRAM) for storing retentive NCK and PLC-specific user data.

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 47
Hardware Descriptions
2.2 MCI2 board for 840Di sl

Order number: MCI2 board

Description Order number (MLFB)

MCI2 board for 840Di sl (as spare part) 6FC5 222-0AA02-2AA0

Order number: Bus connector

Description Order number (MLFB)

Bus connector RS-485 for PROFIBUS DP and MPI
180°−Cable outlet 6GK1 500-0EA02
35°−cable outlet, without PG-connection box 6ES7 972-0BA40-0XA0
35°−cable outlet, with PG-connection box 6ES7 972-0BB40-0XA0
90°−cable outlet, without PG-connection box 6ES7 972-0BA11-0XA0
90°−cable outlet, with PG-connection box 6ES7 972-0BB11-0XA0

2.2.2 Interface description

Interface overview
Interfaces of the MCI board module

Table 2-1 Interface overview: MCI board

Interface Description Type

PROFIBUS DP X101 Socket
MPI/DP X102 Socket
MCI board extension X2 Plug connector
Buffer voltage X3 Plug connector
PCI bus X11 Direct connector
LED 1 DP1 LED
LED 2 DP2 LED

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2.2 MCI2 board for 840Di sl

PROFIBUS DP interface (X101)

Interface description PROFIBUS DP interface (X101):
● Connection: 9-pin sub D socket
● Pin assignment

Table 2-2 Pin assignment: PROFIBUS DP interface (X101)

Pin Description Type 1) Function

1 Unassigned - -
2 Unassigned - -
3 RS-DP B RS 485 differential signals
4 RTS O Request to Send
5 GNDext VO External ground2)
6 P5ext VO Ext. 5V power supply2)
7 Unassigned - -
8 XRS DP B RS 485 differential signals
9 Unassigned - -
1) VO: Voltage Output, O: Output, B: Bidirectional
2) in 5 and 6 are permissible only for supplying the bus terminating resistors
● Connection cable: Refer to Subsection "PCU50" (Page 117)

MPI/DP interface (X102)

Interface description MPI/DP interface (X102):
● Connection: 9-pin sub D socket
● Pin assignment

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

Pin Description Type 1) Function

1 Unassigned - -
2 Unassigned - -
3 RS-MPI/DP B RS 485 differential signals
4 RTS O Request to Send
5 GNDext VO External ground2)
6 P5ext VO Ext. 5V power supply2)
7 Unassigned - -
8 XRS-MPI/DP B RS 485 differential signals
9 Unassigned - -
1) VO: Voltage Output, O: Output, B: Bidirectional
2) Pin 5 and 6 are permissible only for supplying the bus terminating resistors
● Connection cable: Refer to Subsection "PCU50" (Page 117)

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Hardware Descriptions
2.2 MCI2 board for 840Di sl

NOTICE
The PROFIBUS DP (X101) and MPI/DP bus (X102) interfaces are isolated both from
one another and from the PCU.

Backup voltage connection (X3)

Interface description of the backup voltage connection (X3):
● Connection: 2-pin plug connector
● Pin assignment

Table 2-4 Pin assignment: Backup voltage connection (X3)

Pin Description Type 1) Function

1 BATT- VI Backup voltage minus
2 BATT+ VI Backup voltage plus
1) VI: Voltage input

Diagnostic LEDs (DP1/DP2)

The diagnostics LEDs "DP 1" und "DP 2" are only used to display the internal status of the
MCI board. A diagnosis with regard to the PROFIBUS DP communication of the interfaces is
not possible via the LEDs.

2.2.3 Replace module

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. ).

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 Hardware Descriptions
2.2 MCI2 board for 840Di sl

+:VHULHVQXPEHU

Figure 2-2 MCI2 board: HW series number

For instructions on how to enter the license key, see Section "License
management" (Page 146).

Note
If the MCI board is to be inserted as a replacement (either only the MCI board or together
with the PCU), you will need a new license key.

WARNING
Operating electrical equipment has parts and components that are at hazardous voltage
levels.
Improper use of these devices can lead to death, severe personal injury, or substantial
property damage.
Therefore, when servicing the equipment, you must follow all the instructions contained in
this section and provided with the product.
• Only qualified personnel should maintain this equipment.
• Before starting any maintenance and service work, disconnect the device from power
supply.
• Only spare parts approved by the manufacturer may be used.
• Strictly observe the prescribed maintenance intervals, as well as the instructions for
repair and replacement.

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Hardware Descriptions
2.2 MCI2 board for 840Di sl

NOTICE
This module contains electrostatically sensitive components.
Discharge yourself of electrostatic energy before touching the components. The easiest
way to do this is to touch a conductive, grounded object immediately beforehand (for
example, bare metal parts of control cabinet or the protective ground contact of a socket
outlet).

Implementation
To change the module, proceed as follows:
1. Check that there is a suitable series startup file (NCK and PLC) available before
removing the module.
For information on how to create a series startup file, please refer to Chapter "User-data
backup/series startup" (Page 541).
2. Shutdown SINUMERIK 840Di sl or Windows XP properly.
To do this, use one of the following options:
– Windows taskbar: Start > Shut Down.
– Interface signal: "PC shutdown", see Subsection "840Di sl-specific interface
signals" (Page 587).
3. Disconnect the device from the mains.
4. Remove the screws from the cover of the housing (Fig. ) and open the housing of your
PC, observing the relevant safety regulations.

Screws of the
cover of housing

Figure 2-3 Cover of the housing of the PCU 50.3

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 Hardware Descriptions
2.2 MCI2 board for 840Di sl

5. Optional:
Remove interconnecting cable to the MCI board extension module, interface X2.
6. Remove the fastening screw (see Fig. below) and remove the module holding-down
device.

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Figure 2-4 Mounting of the module

7. Remove the cable connection X3 (backup battery) from the module.

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Figure 2-5 Backup battery connector

8. Loosen the fastening screw on the cover plate of the module and remove the module
while observing ESD measures.
9. Insert the new module into the appropriate slot on the mother board and fasten it using
the fastening screw on the cover plate.
10.Insert the cable connection X3 (backup battery) into the module.
11.Re-attach the board retainer.
12.Optional:
Remove interconnecting cable to the MCI board extension module, interface X2.

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Hardware Descriptions
2.2 MCI2 board for 840Di sl

13.Close the housing of your PC and fasten the screws from the cover of the housing (see
third Fig.).
14.Reconnect the power supply and start the computer.

2.2.4 Technical data

Safety
Degree of protection IP 00
Safety class I, acc. to VDE 0106 P1: 1982 (IEC 536)
Safety regulations EN61131-1
Certifications CE, UL, CSA
Power consumption 5 V
Standard 3.75 W
Maximum 5W
Mechanical data
Dimensions PCI card, short
Weight 140 g
Climatic environmental conditions
Heat dissipation Open-circuit-ventilated
Temperature limits operation Storage/transport
• MCI board alone - -40 ... 70 °C
• MCI board in PCU 50.3 5 ... 55 °C -20 ... 60 °C
Tested according to DIN IEC 68-2-1, DIN IEC 68-2-2
(DIN EN 60068-2-2), DIN IEC 68-2-14
Limits for relative humidity 5 ... .80 % 5 ... .95 %
Tested according to DIN IEC 68-2-30
Per minute Per hour
Rate of temperature change Max. 1 K Max. 10 K
Condensation Not permissible
Quality assurance to ISO 9001
Vibrational load during operation
Class 3M4
Frequency range 10 ... 58 Hz/58... 200 Hz
Const. excursion/acceleration 0.075 mm / 1 g
Tested as per DIN EN 60068-2-6
Module in PCU 50.3
Shock load during operation
Acceleration 50 m/s2
Duration of nominal shock 30 ms
Tested as per DIN EN 60068-2-6
Module in PCU 50.3

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2.2 MCI2 board for 840Di sl

Note
The specified safety regulations, certifications, degree of protection and safety class only
apply if the module is plugged into a SINUMERIK PCU 50.3.

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Hardware Descriptions
2.3 MCI board extension slot variation

2.3 MCI board extension slot variation

2.3.1 Assembly

Functions
The MCI board extension slot variant provides the following functions as an optional
expansion board of the MCI board:
● 4 binary inputs (isolated)
● 4 binary outputs (isolated)
● 2 measuring inputs (isolated)
● 2 handwheels (non-isolated).
Either differential or TTL handwheels (switch S1) can be operated on the module.

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Figure 2-6 MCI board extension slot variation

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2.3 MCI board extension slot variation

Order Number

Description Order number (MLFB)

MCI board extension slot variation (option) 6FC5 222-0AA00-0AA1

CAUTION
The plugging-in or disconnection of the cable distributor to or from the interface X121 of the
module, many be done only in the de-energized state.
Before you plug in or remove the cable distributor, switch off the PCU (shut down Windows
XP correctly!). Otherwise, short circuits might occur on the module. This could destroy the
module.

With switch S1 you can select the type of handwheel that is to be operated on the module:

Switch S1
● Differential handwheels:
Switch S1 closed (delivery state)
● TTL handwheels:
Switch S1 open
Differential or TTL handwheels can only be operated alternately.

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Figure 2-7 Switch S1 switch position open (TTL handwheels)

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Hardware Descriptions
2.3 MCI board extension slot variation

NOTICE
You select between differential and TTL handwheels on the module using switch S1 before
installing the module.

2.3.2 Installation instructions

The connecting cable with the MCI board is part of the scope of supply and is already
plugged into the MCI board extension slot variation.

Conduct installation
To install the module, proceed in the sequence described below.

WARNING
Operating electrical equipment has parts and components that are at hazardous voltage
levels.
Improper use of these devices can lead to death, severe personal injury, or substantial
property damage.
When servicing this device, you should therefore observe all notices provided in this section
and attached to the product itself.
• Only qualified personnel should maintain this equipment.
• Before starting any maintenance and service work, disconnect the device from power
supply.
• Only spare parts approved by the manufacturer may be used.
• Strictly observe the prescribed maintenance intervals, as well as the instructions for
repair and replacement.

NOTICE
This module contains electrostatically sensitive components.
Discharge yourself of electrostatic energy before touching the components. The easiest
way to do this is to touch a conductive, grounded object immediately beforehand (for
example, bare metal parts of control cabinet or the protective ground contact of a socket
outlet).

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 Hardware Descriptions
2.3 MCI board extension slot variation

1. Shutdown SINUMERIK 840Di sl or Windows XP properly.

To do this, use one of the following options:
– Windows taskbar: Start > Shut Down.
– Interface signal: "PC shutdown", see Section "840Di sl-specific interface
signals" (Page 587).
2. Disconnect the device from the mains.
3. Remove the screws from the cover of the housing (see Fig. below) and open the housing
of your PC, observing the relevant safety regulations.

Screws of the
cover of housing

Figure 2-8 Cover of the housing of the PCU 50.3

4. Remove the fastening screw of the module holding-down device (see Fig. below) of the
MCI board and remove the module holding-down device.

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Figure 2-9 Mounting of the module

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Hardware Descriptions
2.3 MCI board extension slot variation

5. Remove the blanking plate of the free PCI slot.

6. Insert the module carefully but firmly into the PCI slot and tighten the connector plate of
the module.
7. Plug the connector of the connecting cable into the MCI board. Make sure that the
latches of the connectors have securely engaged on both modules:
– MCI board: Interface X2
– MCI board extension: Interface X4
8. Mount the module holding-down device again.
9. Close the housing and fix it again with the two housing screws.

2.3.3 Interface description

Interface overview
Interfaces of the MCI board extension slot variation

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

Interface Description Type

Cable distributor X121 Plug
MCI board extension X4 Plug connector

Cable distributor (X121)

Interface description of the cable distributor interface (X121):
● Connectors: 37-pin sub D connector
(refer to Section Cable distributor "Cable Distributor" (Page 65))
● Pin assignment:

Table 2-6 Pin assignment: Interface X121

Pin Description Type 1) Function

1 M24EXT VI/VO 24 V ground, 24 V output ground
2 M24EXT VI/VO 24 V ground, 24 V output ground
3 DOUT_CON(1) O 2. Output 24 V
4 DOUT_CON(0) O 1. Output 24 V
5 DIN_CON(3) I 4. Input 24 V
6 DIN_CON(2) I 3. Input 24 V
7 DIN_CON(1) I 2. Input 24 V
8 DIN_CON(0) I 1. Input 24 V
9 MEPU0_S I 1. Measurement probe input (signal: 24 V)
10 MEPU0_C I 1. Measurement probe input (Reference: 0V)

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2.3 MCI board extension slot variation

Pin Description Type 1) Function

11 MPG1_XA I 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 I Input 2nd handwheel, track B inverted
15 MPG0_XA I 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 MPG0_XB I Input 1st handwheel, track B inverted
19 Unassigned - -
20 P24EXT VI 24 V output load power supply
21 P24EXT VI 24 V output load power supply
22 DOUT_CON(3) O 4. Output 24 V
23 DOUT_CON(2) O 3. Output 24 V
24 GNDEXT VO 24 V input ground
25 GNDEXT VO 24 V input ground
26 GNDEXT VO 24 V input ground
27 GNDEXT VO 24 V input ground
28 MEPU1_S I 2. Measurement probe input (signal)
29 MEPU1_C I 2. Measurement probe input (0 V)
30 MPG1_A I Input 2nd handwheel, track A
31 M VO Handwheel vers. ground, TTL handwh. Chassis ground
32 M VO Handwheel vers. ground, TTL handwh. Chassis ground
33 MPG1_B I Input 2nd handwheel, track B
34 MPG0_A I Input 1st handwheel, track A
35 M VO Handwheel vers. ground, TTL handwh. Chassis ground
36 M VO Handwheel vers. ground, TTL handwh. Chassis ground
37 MPG0_B I Input 1st handwheel, track B
1)
VI/VO: Voltage Input/Voltage Output
VI: Voltage input
VO: Voltage input
I: Input
O : Output
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Manual
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Hardware Descriptions
2.3 MCI board extension slot variation

Pin Description Type 1) Function

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Digital inputs
Electrical data of the digital input interface:
● Isolated from the board electronics
● Common ground (GNDEXT)

Digital outputs
Electrical data of the digital output interface:
● Isolated from the board electronics
● Common ground and with regard to the external power supply (M24EXT)
● Rated current: 500 mA

Differential handwheels
Electrical data of the differential handwheel interface:
● Connected to the board electronics
● Signals used:
– MPGx_A
– MPGx_B
– MPGx_XA
– MPGx_XB

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2.3 MCI board extension slot variation

TTL handwheels
Electrical data of the TTL handwheel interface:
● Connected to the board electronics
● Signals used:
– MPGx_A
– MPGx_B
– M

NOTICE
The optional power supply of the handwheels (P5) is electronically protected with 2
A. The maximum continuous load is 1 A. Per handwheel 500 mA.

Measuring inputs
Electrical data of the measurement probe interface:
● Isolated both from one another and from all other voltage areas (board electronics, digital
inputs/outputs and handwheels)
● Signal delay active edge: 10 μs
● Signal delay inactive edge: 100 μs

Note
The maximum cable length is 25 m for all functions.

2.3.4 Technical data

Table 2-7 Technical data for MCI board extension, slot version

Safety
Degree of protection IP 20
Safety class Safety class I, in accordance with VDE 0106 P1: 1982 (IEC 536)
Safety regulations EN61131-1
Certifications CE, UL, CSA
Electrical data
Maximum Standard
Power consumption without I/Os 500 mW 350 mW
Power consumption with I/Os 2.1 W 850 mW
both handwheels per handwheel
Max. current-carrying capacity of 1A 500 mA
the 5 V power supply
Mechanical data
Dimensions Short PCI card
Weight 110g

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2.3 MCI board extension slot variation

Climatic environmental conditions

Heat dissipation Open-circuit-ventilated
operation Storage/transport
Temperature limits 5 ... 55°C -40 ... 70°C
Tested according to DIN IEC 68-2-1, DIN IEC 68-2-2
(DIN EN 60068-2-2), DIN IEC 68-2-14
Limits for relative humidity 5 ... .80% 5 ... .95%
Tested according to DIN IEC 68-2-30
Per minute Per hour
Rate of temperature change Max. 1 K Max. 10 K
Condensation Not permissible
Quality assurance to ISO 9001
Vibrational load during operation
Class 3M4
Frequency range 10 ... 58 Hz/58... 200 Hz
Const. excursion/ 0.075 mm / 1g
acceleration
Tested as per DIN EN 60068-2-6
- module in PCU 50.3
Shock load during operation
Acceleration 50 m/s2
Duration of nominal shock 30 ms
Tested as per DIN EN 60068-2-6
- module in PCU 50.3

Note
The specified safety regulations, certifications, degree of protection and safety class only
apply if the module is plugged into a SINUMERIK PCU 50.3.

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2.4 Cable distributor

2.4 Cable distributor

Order Number

Description Order number (MLFB)

Cable distributor 6FX2 006-1BA02

Cable connection
The cable distributor consists of a connector jacket for a 37-pin Sub-D connector with
enlarged interior. The cable distributor is used to split the I/O-MPG-extension interface (X121)
to a maximum of 7 single cables. These must be connected in the order shown in Table
"Plug assignment".
To supply the digital outputs, an external 24 V supply is possible at the cable distributor.

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Figure 2-10 Cable distributor

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Hardware Descriptions
2.4 Cable distributor

Insert the appropriate individual cable in the opened cable distributor at the associated
connector X1 to X10. Place the cable in the appropriate cable guide.
Make sure that the shield jackets that became free have a large conductive connection to the
metallic contact areas of the cable distributor. See the following figure for this purpose. Insert
the upper terminal bar in such a way that its "teeth" are facing the "teeth" of the lower
terminal bar and then secure the upper housing section.
This will reliably press the cable shields between the contact areas of the contact springs
and contact them safely. The shield potential is reliably routed to the housing of the PCU
using the contact springs of the cable distributor on the front panel of the PCU.

Location of the interfaces

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Figure 2-11 Position of the interfaces of the cable distributor

DIP FIX switches

The DIP FIX switches in the cable distributor must be set as follows:

Table 2-8 Setting the DIP-FIX switches in the cable distributor

switch S1 S2 S3 S4 S5 S6
Open x x x x
Closed x x

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2.4 Cable distributor

Connector assignments
Table 2-9 Assignment of connector

Connector No. Cable No. I/O

X1 1 (top) 1. Handwheel
X2
X3 2 2. Handwheel
X4
X5 3 2. Probe
X6 4 4 binary inputs
X7
X8 5 4 binary outputs
X9 6 Supply for 4 binary outputs
X10 7 (bottom) 1. Probe

NOTICE
When assembling the cable distributor, make absolutely sure that the supplied insulating
washer is installed correctly and the coding pins are installed.

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.

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Figure 2-12 Fixing of the cable distributor

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Hardware Descriptions
2.4 Cable distributor

Pin assignments
Connector designation: X1...X10
Plug-connector type: DU-BOX-plug connectors

Table 2-10 Pin assignment of cable distributor

Pin-No. Signal name DU-BOX- Cable Cable order No. Wire color I/O device Terminal
37-pin plug No. 6FX2002-4AA....
plug Pin. No./
- X10/2 7 41-0❑❑❑ rd
9 MEPUS 0 X10/1 or 1. Measuring Signal+24V
- X10/4 bn inputs
10 MEPUC 0 X10/3 bk Reference 0V
Shielding 1. Measuring
inputs
1 M24EXT X9/2 6 41-0❑❑❑ rd Supply of the 4 Chassis
20 P24EXT X9/1 or binary outputs/of ground
the MPI 24 V
2 M24EXT X9/4 bn
connector
21 P24EXT X9/3 bk Chassis
ground
Shielding
24 V
3 OUTPUT 1 X8/2 5 41-0❑❑❑ rd 4 binary outputs 2. Output
22 OUTPUT 3 X8/1 or 4. Output
4 OUTPUT 0 X8/4 bn 1. Output
23 OUTPUT 2 X8/3 bk 3. Output
Shielding
5 INPUT 3 X7/2 4 21-0❑❑❑ rd 4 binary inputs 4. Input
24 GNDEXT X7/1 or Chassis
6 INPUT 2 X7/4 bn ground
25 GNDEXT X7/3 bk 3. Input
7 INPUT 1 X6/2 green Chassis
ground
26 GNDEXT X6/1 yellow
2. Input
8 INPUT 0 X6/4 vt
Chassis
27 GNDEXT X6/3 bu
ground
Shielding
1. Input
Chassis
ground
- X5/2 3 41-0❑❑❑ rd
28 MEPUS 1 X5/1 or 2. Measuring Signal+24V
- X5/4 bn inputs
29 MEPUC 1 X5/3 bk Reference 0V
Shielding 2. Measuring
inputs

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2.4 Cable distributor

Pin-No. Signal name DU-BOX- Cable Cable order No. Wire color I/O device Terminal
37-pin plug No. 6FX2002-4AA....
plug Pin. No./
11 MPG1 XA X4/2 2 21-0❑❑❑ rd 2. Handwheel XA
30 MPG1 A X4/1 or A
12 MPG1 5V X4/4 bn 6FC9320-5DB 5V
31 MPG1 0V X4/3 bk 0V
13 MPG1 5V X3/2 green 5V
32 MPG1 0V X3/1 yellow 0V
14 MPG1 XB X3/4 vt XB
33 MPG1 B X3/3 bu B
Shielding
15 MPG0 XA X2/2 1 21-0❑❑❑ rd 1. Handwheel XA
34 MPG0 A X2/1 or A
16 MPG0 5V X2/4 bn 6FC9320-5DB 5V
35 MPG0 0V X2/3 bk 0V
17 MPG0 5V X1/2 green 5V
36 MPG0 0V X1/1 yellow 0V
18 MPG0 XB X1/4 vt XB
37 MPG0 B X1/3 bu B
Shielding
Signal names:
MPG0, 1 5 V: Voltage supply 1./2. handwheel 5 V
MPG0, 1 0 V: Voltage supply 1./2. handwheel 0 V
MPG0, 1 A, XA: 1./2. differential handwheel input A, XA
MPG0, 1 B, XB: 1./2. differential handwheel input B, XB
MEPUS 0, 1: 1./2. Measurement impulse signal
MEPUC 0, 1: 1./2. Measuring impulse common (ground reference)
INPUT [0...3]: 1. till 4. binary NC-input
GNDEXT: External mass (ground reference for binary NC-inputs)
OUTPUT [0...3]: 1. till 4. binary NC-output
M24EXT: external 24 V-feed (-) for binary NC-outputs
P24EXT: external 24 V-feed (+) for binary NC-outputs

NOTICE
The maximum current carrying capacity of the handwheel interface is 1 A for both
handwheels. 500 mA per handwheel.

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Hardware Descriptions
2.4 Cable distributor

Colors:
rt: Red
or: Orange
br: Brown
bk: Black
gn: Green
ye: Yellow
vt: Violet
bu: Blue

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 Hardware Descriptions
2.5 SINUMERIK Industrial PC

2.5 SINUMERIK Industrial PC

2.5.1 SINUMERIK PCU 50.3

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Figure 2-13 PCU 50.3: Perspective view with installed hard disk drive

Order Number
PCU as spare part with MCI board

Description Order number (MLFB)

with Windows XP ProEmbSys and MCI board:
PCU 50.3-C/1.5 GHz, 512 MB SDRAM 6FC5 220-0AA31-2AA0
PCU 50.3-P/2.0 GHz, 1024 MB SDRAM 6FC5 220-0AA33-2AA0

Manual
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Hardware Descriptions
2.5 SINUMERIK Industrial PC

Features
The SINUMERIK industrial PC "PCU 50.3" provides, together with the MCI board, the basis
for the SINUMERIK 840Di sl. The PCU 50.3 has the following important features:
● Variants:
– Celeron M, 1.5 GHz, 512 MB SDRAM
– Pentium M, 2.0 GHz, 1024 MB SDRAM
● Hard disk min. 40 GB (replaceable)
● Operating system Windows XP ProEmbSys with Service Pack 2
● Robust design (continuous operation, high noise immunity)
● Compact dimensions for space-saving installation
● Easy installation with four screws on the rear of the operator panel front
● Mounting position and location to a large degree variable
● Screen resolution 640 x 480, up to max. 1600 x 1200
● Power supply: DC 24V
● Interfaces to peripheral devices:
– 1 x PROFIBUS DP (max. 12 Mbaud)
– 1 x DVI-I interface for external monitor
– 2 x Ethernet connections 10/100 Mbaud
– 1 x CF card shaft (covered)
– 4 x high-speed USB ports (USB 2.0)
● Interfaces to operator panel front:
– LVDS panel interface (channel 1 and optional channel 2)
– I/O USB panel interface
– Additional high-speed USB port (USB 2.0)
● Slots
– 1 x PCI (length: max. 265 mm, occupied by the MCI board)
– 1 x PCI (length: max. 175 mm, occupied with option MCI board extension slot variant)

Options
The following options are offered:
● Memory expansion up to max. 2048 MB
● External floppy disk drive

Fastening angle
Mounting brackets are required to mount the PCU directly behind the operator panel front:
● Mounting bracket MLFB: 6FC5 248-0AF20-2AA0

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 Hardware Descriptions
2.5 SINUMERIK Industrial PC

Replacing a device
When installing spare parts please note the following:
● When replacing the PCU, remove the mounting brackets (MLFB 6FC5 248-0AF20-2AA0)
from the defective PCU and attach to the replacement part.
References:
For the complete documentation on the PCU 50.3, please refer to:
/BH/ Operator components Manual, Component PCU 50.3

Technical data

Table 2-11 Technical data for PCU 50.3 with MCI board

Safety
Safety class I per IEC 60536
Degree of protection according to IP20
EN 60529
Certifications CE
Electrical data
Input voltage DC 24 V
Max. power consumption 1 x PCI slot (length: min. 140 mm)
1 x PCI slot (length: max. 288 mm)
3.3 V 2A
5V 2A
12 V 0.3 A
-12 V 0.05A
Power consumption PCU PCI slot 1)
Max. 190 W 15 W
Main power outage buffering time Min. 20 ms
Mechanical data
Dimensions (mm) Width 297 Height 267 Depth 81.7
Weight approx. 7.2 kg
Mechanical ambient conditions operation Transportation
(with OP 012) (in packing)
Vibratory load 10 to 58 Hz: 0.075 mm 5 to 9 Hz: 6.2 mm
58 to 200 Hz: 9.8 m/s2 9 to 500 Hz: 19,6 m/s2
DIN IEC 60068-2-6 DIN IEC 60068-2-6
Shock stressing 50 m/s2, 30 ms, 250 m/s2, 6 ms,
18 shocks 18 shocks
DIN IEC60068-2-27 DIN IEC60068-2-29
Noise < 55 dB(A) according to DIN 45635-1
Climatic environmental conditions
Heat dissipation Open-circuit-ventilated

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Hardware Descriptions
2.5 SINUMERIK Industrial PC

Condensation, spraying water and Not permissible

icing
supply air Without caustic gases, dusts and oils
operation Storage/transport
(in transport packaging)
Applicable standards DIN IEC 60068-2-1 DIN IEC 60068-2-2 / -2-14
Climate class 3K5 1K3 / 2K4
Temperature limits 9 W 2): 5 ... 55 °C -20 ... 60 °C
14 W 2): 5 ... 50 °C
24 W 2): 5 ... 45 °C
Rate of temperature change Max. 10 K/h Max. 18 K/h
Limits for relative humidity 10 ... 80 % at 25 °C 5 ... 95 % at 25 °C
Permissible change in the relative max. 0.1 % / min
air humidity
1) No slots may exceed this total power value
2) max. power of additional extensions e.g. MCI-board-extension, PC-card, USB-interface;
the MCI-board is already plugged in

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 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

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Figure 2-14 View of OP 012 operator panel front

Order Number

Description Order number (MLFB)

SINUMERIK OP 012 6FC5 203-0AF02-0AA1

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Hardware Descriptions
2.6 SINUMERIK operator panel fronts

Features
The OP 012 operator front provides the following features:
● 12.1" TFT flat screen (color) with resolution 800 x 600 pixels
● Membrane keyboard with alphabetic, numeric, cursor, and control keypad
● Softkeys/direct keys:
– 2 x 8 horizontal rows of keys with softkey function
– 2 x 8 vertical rows of keys with softkey and direct control key function
– Direct keys connectable using PP031–MC or directly to the I/Os
● Shift key for switchover to the second key level (not for switching over the letters, since
they are uppercase only)
● Integrated mouse
● Status LEDs for power supply and overtemperature
● USB interface at the front
● Degree of protection IP65
● Can be combined with PCU or TCU
● External floppy disk drive can be connected

References
For detailed documentation about the operator panel front OP 012 please see:
/BH/ Operator Components Manual, Operator panel front OP 012

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 Hardware Descriptions
2.7 TCU (Thin Client Unit)

2.7 TCU (Thin Client Unit)

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Figure 2-15 TCU with Ethernet cable plugged in

Order Number

Description Order number (MLFB)

TCU (Thin Client Unit) 6FC5312-0DA00-0AA0

Features
A TCU permits the distributed connection of SINUMERIK OP/TP operator panel fronts and
the SINUMERIK PCU. The features include the following:
● Communication with the PCU is performed via Industrial Ethernet (10/100 Mbaud) in a
separate sub-network with DHCP server (on the PCU).
● Permits large distances between the PCU and operator panel front (maximum possible
distance between two network nodes/access points: approx. 100 m).
● Graphics resolutions: 640x480 to 1024x768 pixels; depth of color: 16 bits
● Interfaces:
– 1 x Ethernet 10/100 Mbaud
– 1 x Compact Flash
– 2 x USB 1.1 for connection of mouse and keyboard
– Interfaces to operator panel front:
LVDS interface for SINUMERIK-OP,
USB interface for SINUMERIK-OP (internal)

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Hardware Descriptions
2.7 TCU (Thin Client Unit)

References:
Comprehensive documentation about the configuration and commissioning of the TCU is
given in:
Configuration:
/BH/Operator Components Manual, Distributed configuration with TCU
Startup:
/IAM/ Commissioning Manual HMI, Startup TCU (IM5)

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 Hardware Descriptions
2.8 Handheld units

2.8 Handheld units

2.8.1 Handheld Terminal HT 8

   

 

Figure 2-16 Operator interface of the HT8

(1) Emergency stop button

(2) Handwheel
(3) Rotary override switch
(4) Protective collar
(5) Display / Touch screen
(6) Function keys machine control panel
(7) HMI control keys
(8) Connecting cable

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Hardware Descriptions
2.8 Handheld units

Order Number

Description Order number (MLFB)

HT8 without handwheel 6FC5 403 - 0AA20 - 0AA0
HT8 with handwheel 6FC5 403-0AA20-1AA0

Features
The SINUMERIK HT8 is a handheld operating and programming device that combines the
functions of an operator panel front and a machine control panel. The HT8 has a 7.5" TFT
color display and is operated via a touch screen and membrane keys. It is equipped with an
emergency stop button and two 3-position acknowledgement buttons for left and right-
handed operators.
The HT 8 is hot-plug capable. This allows trouble-free connecting and disconnecting of the
connector during operation, without triggering an Emergency Stop.
The HT 8 is available in two variants:
● with acknowledgement button, Emergency Stop button, override rotary switch
● with acknowledgement button, Emergency Stop button, rotary override switch, and
handwheel
The module has the following essential features:
● LC display as a Touch Screen
– 640 x 480 (VGA) Color TFT
– Inverter on board
● 52-key membrane keyboard
– 24 machine control keys
– 28 control keys (number block keys, cursor pad, function keys)
● Emergency stop button
● Rotary override switch (19 positions)
● Handwheel (optional)
● 2 acknowledgement buttons (2-channel, 3-stage)
● Serial interfaces:
– HT 8 connecting cable to terminal box / connection module
– USB interface (with dummy plugs)
● CF Card interface
● Power supply (+24 V)

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 Hardware Descriptions
2.8 Handheld units

2.8.2 Handheld Terminal HT 2












 

 

Figure 2-17 Operator control and display elements of the HT 2

(1) Emergency Stop button (stop button)

(2) Rotary override switch
(3) Display
(4) Keyboard
(5) Handwheel
(6) Acknowledgement button (left)
(7) Acknowledgement button (right)
(8) Opening for the cable entry
(9) Cable duct cover
(10) Type plate
(11) Standard position retaining magnet (optional: mounting bracket)
(12) Standard position mounting bracket (optional: Retaining magnet)
(13) Key-operated switch

Order Number

Description Order number (MLFB)

HT2 6FC5 303-0AA00-2AA0

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Hardware Descriptions
2.8 Handheld units

Features
The hand operating device SINUMERIK HT2 (Handheld Terminal 2) is designed for the
manual operation of tool machines. The HT2 is preferably designed for the application case,
when the emphasis lies on mobility duting operation and observation. In this case the HT2
can be connected to any place in the system via a connection box "Basic PN" or "Plus PN".
This allows trouble-free connecting and disconnecting of the HT2 together with the
connection box PN during operation, without triggering an Emergency Stop.
For a mounting in the cabinet, the HT2 is connected to a connection module Basic PN.
Through two acknowledgement buttons the HT2 is suitable for both right and left-handed
persons. The magnetic handwheel allows intuitive axis feed motion. All of the HT 2 keys can
be freely configured and labeled.
The HT 2 can be mounted using a retaining magnet or an appropriate bracket. Both the
retaining magnet as well as the holder are available as accessory.
The module has the following essential features:
● LC display (black / white)
– Resolution: 168 x 72 pixels
– LCD controller on board
– 4 lines each with 16 characters can be displayed
● 20-key membrane keyboard
– 16 machine control keys
– 4 keys (upper row of keys) can be assigned as softkey or system key
● Emergency Stop button, 2-channel
● Rotary override switch (19 positions)
● Magnetic handwheel
● Recess for the bracket or retaining magnet
● Cable duct for the HT 2 connecting cable to
– terminal box PN (Basic / Plus)
– PN Basic connection module
● Key-operated switch (3 positions, 2 keys)
● two acknowledgement buttons (2-channel, 3-stage)

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 Hardware Descriptions
2.9 Floppy disk drives

2.9 Floppy disk drives

2.9.1 Floppy disk drive 3.5" (USB)

Figure 2-18 External 3.5" floppy disk drive with USB interface

Order Number

Description Order number (MLFB)

3.5" disk drive with USB interface incl. 1 m USB connecting 6FC5 235-0AA05-1AA2
cable
Cover (spare part) 6FC5 247 - 0AA20 - 0AA0

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Hardware Descriptions
2.9 Floppy disk drives

Features
The disk drive is used to read in and save data from/to 3.5" disks with a maximum capacity
of 1.44 MB. The disk drive has the following features:
● USB interface: Version 1.1
● Can be inserted into customized operator panel fronts
● Bootable
● Input voltage: 5.25 V DC
● Power consumption, max.2.5 W
● Degree of protection acc. to EN 60529:
IP 54 (at the front)
IP 00 (rear side)
References:
For a complete description of the 3.5'' floppy disk drive (USB), please refer to:
/BH/Operator Components Manual, 3.5" disk drive (USB)

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 Hardware Descriptions
2.10 Power supply

2.10 Power supply

2.10.1 SITOP POWER standard 24V/10A

Figure 2-19 View: SITOP POWER standard 24V/10A

Order Number

Description Order number (MLFB)

SITOP POWER standard 24V/10A 6EP1 334-1SH01

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Hardware Descriptions
2.10 Power supply

Features
The SITOP POWER Standard 24V/10A power supply mode provides the following features:
● Input voltage - rated value: 120/230 VAC
● Input voltage - range: 93 ... 132 V/187... 264 V
● Power failure buffering: > 20 ms
● Rated power frequency: 50/60 Hz
● Power frequency range: 47 ... 63 Hz
● Input current rated value: 3,5/1,7 A
● Switch-on current (25° C): 55 A
● Output current rated value: 24 VDC
● Output current tolerance: ± 3 %
● Efficiency: > 87 %
● Output current rated value: 10 A
● Electron. short circuit protection with automatic restart
● Electrical isolation (SELV to EN 60950)
● Safety class (IEC 536; VDE 1006 T1) Class I
● Degree of protection (VDE 0470, IEC 529) IP 20
● Radio interference level complying to EN 55011 Class A

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 Hardware Descriptions
2.11 Uninterrupted power supply (UPS)

2.11 Uninterrupted power supply (UPS)

2.11.1 SITOP POWER DC UPS MODULE 15

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Figure 2-20 View: SITOP POWER DC UPS MODULE 15

Order Number

Description Order number (MLFB)

SITOP POWER DC UPS module 15 (USB interface) 6EP1 931-2EC42

Manual
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Hardware Descriptions
2.11 Uninterrupted power supply (UPS)

Features
The SITOP POWER DC UPS module 15 provides the following features:
● Compact design (H x W x D: 125 mm x 50 mm x 125 mm)
● Rated input voltage: 24 VDC
● Rated output voltage: 24 VDC
● Rated output current: 15 A DC
● High efficiency: approx. 96 %.
● Safety class (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
– Incorrect polarity protection
– Overcurrent and short-circuit protection
– Exhaustive discharge protection
– Accu test
● Signaling of current status via LED
– Normal operation
– >85% full charging
– Battery standby supply
– Buffer standby not available (alarm)
● Additional output of all signals via a PC-capable interface:
– Type ....-2EC31: Serial interface
– Type ....-2EC41: USB interface

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2.11 Uninterrupted power supply (UPS)

USB interface
The USB interface corresponds to specification 2.0. Communication is however only
performed at "full speed" corr. to 12 Mbaud. A commercial type four-core shielded USB
cable with a maximum cable length of 3 m can be used.

Table 2-12 Signal assignment of USB connector

Pin Signal Description

1 VBUS Power supply
2 D- Transmitted data
3 D+ Transmitted data
4 GRD Ground

2.11.2 SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH

Figure 2-21 View: SITOP POWER lead-acid battery module

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Hardware Descriptions
2.11 Uninterrupted power supply (UPS)

Order Number

Description Order number (MLFB)

SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH 6EP1 935-6MD11

Features
The SITOP POWER LEAD-ACID MODULE 24 V DC/10 A/3.2 AH features the following:
● It has two maintenance-free, closed lead-acid batteries from the same lot, which are
installed in a holder and connected in series.
● Complete with battery retainer and terminals
● Low self-discharge rate of approximately 3% per month (at +20 °C)
● Short circuit protection (battery fuse 15 A/32 V)
● Safety class (IEC 536; VDE 1006 T1) Class III
● Degree of protection (EN 60 529; VDE 0470 T1) IP 00

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 Hardware Descriptions
2.12 PP72/48 I/O module

2.12 PP72/48 I/O module

2.12.1 Assembly

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Figure 2-22 PP72/48 I/O module

Order Number

Description Order number (MLFB)

PP72/48 I/O module 6FC5 611-0CA01-0AA0

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Hardware Descriptions
2.12 PP72/48 I/O module

Features
I/O module PP72/48 is a simple module (without a separate housing) for connecting digital
input/outputs as part of an automation system based on PROFIBUS DP.
The module has the following important features:
● PROFIBUS DP connection (max. 12 MBaud)
● 72 digital inputs and 48 digital outputs
● On-board status display via four diagnostic LEDs
To power the module and the digital outputs, an external power supply source (+24 V DC) is
required.

2.12.2 Interface description

Interface overview
Interfaces of I/O module PP72/48

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

Interface Description Type

Power supply connection X1 Screw-terminal block
PROFIBUS DP X2 Socket
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

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 Hardware Descriptions
2.12 PP72/48 I/O module

External power supply(X1)

Interface description of the external power supply (X1):
● Screw-terminal block MSTBVA 2,5/3-G-5,08, Phoenix
● Pin assignment

Table 2-14 Pin assignment: Ext. power supply (X1)

Pin Description Type 1) Function

1 P24 VI External supply for module (+24V)
2 M24 VI Reference for external supply
3 PI VI Protective conductor of the external supply
1)
VI: Voltage input
● Connecting cable
The required connecting cables must be provided by the user:
– Wire, conductor cross section: 1.0 - 1.5 mm2 (AWG17 - AWG16)
● Power supply
For data regarding the supply voltage see Section "Voltage supply" (Page 100).

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Hardware Descriptions
2.12 PP72/48 I/O module

PROFIBUS DP (X2)
Interface description of the PROFIBUS DP interface (X2):
● Connection: 9-pin sub D socket
● Pin assignment

Table 2-15 Pin assignment: PROFIBUS DP (X2)

Pin Description Type 1) 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 - - -
1)
VO: Voltage output
O : Output
B: Bidirectional
● Plug
– 6ES7972-0BA40-0XA0; cable outlet 350, without PC socket connector
– 6ES7972-0BB40-0XA0; cable outlet 350, with PC socket connector
– 6ES7972-0BA11-0XA0; cable outlet 900, without PG socket connector
– 6ES7972-0BB11-0XA0; cable outlet 900, with PG socket connector
● Cable
– 6XV1830-0EH10; by the meter, non-trailable
– 6XV1830-3BH10; by the meter, trailable
● Other technical data
Maximum possible data rate: 12 Mbits/s

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2.12 PP72/48 I/O module

PROFIBUS address (S1)

The PROFIBUS address of the ADI4 can be set in the range 1 to 127 using switch S1.

Table 2-16 Meaning of switch S1

switch Description
1 PROFIBUS address: 20 = 1
2 PROFIBUS address: 21 = 2
3 PROFIBUS address: 22 = 4
4 PROFIBUS address: 23 = 8
5 PROFIBUS address: 24 = 16
6 PROFIBUS address: 25 = 32
7 PROFIBUS address: 26 = 64
8 Not used

NOTICE
A newly set PROFIBUS address will only come into effect after power OFF/ON.

Digital inputs/outputs (X111/X222/X333)

Interface description of the digital input/output interfaces (X111/X222/X333):
● Connectors: 50-pin ribbon cable connector
● Pin assignment on each connector.

Table 2-17 Pin assignment (X111/X222/X333)

Pin Signal designation Type 1) Pin Signal designation Type 1)

1 M VO 26 Input 2.7 I
2 P24OUT VO 27 - -
3 Input 0.0 I 28 - -
4 Input 0.1 I 29 - -
5 Input 0.2 I 30 - -
6 Input 0.3 I 31 Output 0.0 O
7 Input 0.4 I 32 Output 0.1 O
8 Input 0.5 I 33 Output 0.2 O
9 Input 0.6 I 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 I 38 Output 0.7 O
14 Input 1.3 I 39 Output 1.0 O
15 Input 1.4 I 40 Output 1.1 O

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Hardware Descriptions
2.12 PP72/48 I/O module

Pin Signal designation Type 1) Pin Signal designation Type 1)

16 Input 1.5 I 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 I 44 Output 1.5 O
20 Input 2.1 I 45 Output 1.6 O
21 Input 2.2 I 46 Output 1.7 O
22 Input 2.3 I 47 DOCOMx VI
23 Input 2.4 I 48 DOCOMx VI
24 Input 2.5 I 49 DOCOMx VI
25 Input 2.6 I 50 DOCOMx VI
1)
VI: Voltage input
VO: Voltage output
I: Signal Input
O : Signal output
x: with x = 1,2,3
Digital inputs:
● 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.

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Figure 2-23 Terminal assignment for the digital inputs

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 Hardware Descriptions
2.12 PP72/48 I/O module

(1) If you are using the internal power supply P24OUT

(2) If you are using an external power supply P24OUText
● Internal supply voltage (P24OUT)
The internal power supply for the digital inputs (X111, X222, X333: Pin 2) is derived from
the general power supply of module X1, pin 2 (P24). Specification: Refer to Section
"Power supply" (Page 100)

CAUTION
A max. current of Iout = 0.5 A on X111, X222, X333: Pin 2 must not be exceeded. An
exceeding of the maximum current might destroy the module.

● External supply voltage (P24OUText)

If an external power supply is used for the digital inputs, their reference ground must be
connected to X111, X222, X333: Pin 1 (M)
X111, X222, X333: Pin 2 (P24OUT) then remains open.
For specification of the external power supply, see Subsection "Power supply" (Page 100).
● Connection cable: The required connecting cables (ribbon cables) must be provided by
the user.
● Electrical specification of the digital inputs:

Table 2-18 Electrical specification of the digital inputs:

Digital inputs min. Standard Max. Nominal

Voltage at high signal level (UH) 15 V 1) 30 V 24 V
Input current IIN at VH 2 mA - 15 mA -
Voltage at low signal level (UL) -30 V - +5 V 0V
Signal delay time TPHL 2) 0.5 ms - 3 ms -
• Supply voltage of the digital inputs
1) Typical output voltage: VCC - IOUT<RON
VCC current operating voltage (P24OUT) to X111, X222, X333: Pin 2
Max. output current IOUT: 500 mA per pin
Max. short-circuit current: 4A (max. 100ms, VCC= 24V)
Internal resistance RON: 0.4 W
• 2)
Moreover, the PROFIBUS communication time and the application cycle time must be taken into
account.
• Incorrect connection causes neither high level nor destruction of the inputs.
Digital outputs:
● Terminal assignment for the digital outputs
The following figure shows an example of the terminal assignment for the digital outputs
on connector X111. Connectors X222 and X333 are assigned analogously.

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Hardware Descriptions
2.12 PP72/48 I/O module

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Figure 2-24 Terminal assignment for the digital outputs

● Connection cable: The required connecting cables (ribbon cables) must be provided by
the user.
● Supply voltage:
To supply the digital outputs, an external 24V DC power supply must be connected to
DOCOMx (X111, X222, X333: Pin 47, 48, 49, 50).
The reference ground of the external power supply source must be connected to X111,
X222, X333: Pin 1 (M)
For further data, see Subsection "Power Supply" (Page 100).

CAUTION
It is the user's responsibility to ensure that the max. current consumption per DOCOMx
pin (X111, X222, X333: Pins 47, 48, 49, 50) does not exceed 1 A. The power supply
(+24 V DC) for the digital outputs must therefore be connected to all 4 pins (X111, X222,
X333: Pin 47, 48, 49, 50) for each DOCOMx.

● Electrical specification of the digital outputs:

Table 2-19 Electrical specification of the digital outputs

Digital outputs min. Standard Max. Nominal

Voltage at high signal level (UH) VCC - 3 V 1) VCC 24V
Output current IOUT - - 250mA -
Voltage at low signal level (UL) - - - Output open
Leakage current at low level - 50mA 400mA -
Signal delay time TPHL 2) - 0.5 ms - -

Manual
98 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Hardware Descriptions
2.12 PP72/48 I/O module

Digital outputs min. Standard Max. Nominal

Maximum switching frequency 2)

Resistive load 100Hz - - -

Inductive load 2Hz - - -
Lamp 11Hz - - -
• 1)
UH_typical = VCC - IOUT<RON
VCC current operating voltage
IOUT maximum output current (see above)
maximum short-circuit current: 4A (max. 100ms, VCC= 24V)
RON: Inner resistance = 0.4W
• 2)
Moreover, the PROFIBUS communication time and the application cycle time must be taken into
account.
• Incorrect connection causes neither high level nor destruction of the outputs.
● General electrical properties
– No electrical isolation
– Current limitation to maximum 500 mA
– Protection against: short-circuit, overtemperature, and loss of ground
– Automatic disconnection in case of undervoltage

LED: Status display

The module has 3 LEDs through which the module status is displayed.

Table 2-20 LED: Status display

Description Color Description

POWER Green Power supply
OVTEMP Red Overtemperature indication
EXCHANGE Green Cycl. data exchange with DP master in progress
READY Red Ready for cycl. data exchange with DP master

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 99
Hardware Descriptions
2.12 PP72/48 I/O module

2.12.3 Power supply

Assembly
The supply voltage (24 V DC) of the I/O module PP72/48 is connected to the screw terminal
block X1. Refer to Section "Interface description" (Page 92)

Digital outputs
To power the digital outputs (+24VDC), an external power supply source is required. The
power supply is connected through terminals X111, X222, X333, pins 47, 48, 49, 50
(DOCOMx).

Digital inputs
If the internal power supply from X111, X222, X333, Pin 2 (P24OUT) is not used to power
the digital inputs, it can be replaced by an external power supply source (+24 V DC) as an
option.
The reference ground of the power supply source must be connected with X111, X222, X333,
Pin 1 (GND). X111, X222, X333, Pin 2 (P24OUT) then remains open.

Specification of the supply voltages (+24V DC)

The external power supply voltages must be generated as functional extra-low voltages with
safe electrical isolation (according to IEC 204-1, 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 meet the specifications according to Table.

Table 2-21 Specification of the supply voltage P24OUT

Voltage
Minimum 20.4 V
Nominal 24 V
Maximum 28.8 V
minimum (dynamic) 18.5 V
maximum (dynamic) 30.2 V
Non-periodic overvoltage

Manual
100 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Hardware Descriptions
2.12 PP72/48 I/O module

Max. (absolute, transient) 35 V

Max. duration 500 ms
min. recovery time 50 s
Max. events per h 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:
● Polarity reversal
● Short-circuit (elec. current limitation of the outputs)
● Overload (fuse protection).

2.12.4 Grounding
The module must be installed according to EN 60204.
If a large-area, permanent metallic connection with the central ground point through the rear
panel is not possible, the mounting plate must be connected to the grounding by means of a
line (cross section > 10 mm2).

CAUTION
A protective conductor must be connected.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 101
Hardware Descriptions
2.12 PP72/48 I/O module

2.12.5 Dimension drawing









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Figure 2-25 Dimension drawing: PP72/48 I/O module

Manual
102 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Hardware Descriptions
2.12 PP72/48 I/O module

2.12.6 Technical data

Table 2-22 Technical data of I/O module PP72/48

Safety
Degree of protection IP 00
Safety class Safety class I, in accordance with VDE 0106 P1: 1982 (IEC
536);
Protection against ingress of foreign bodies and water in
accordance with IEC 529
Certifications UL/CSA, CE
Power consumption
At nominal load 11W
Mechanical data
Dimensions WxHxD [mm] 194 x 325 x 35
Weight approx. 0.3 kg approx. 1.2 kg
without mounting plate with mounting plate
Climatic environmental conditions
Heat dissipation Open-circuit-ventilated
operation Storage/transport
Temperature limits 0 ... 50°C -20 ... 55°C/-40... 70°C
Limits for relative humidity 5 ... 95% 5 ... 95%
Without condensation Without condensation
Condensation Not permissible
Air pressure 700 ... 1060hPa 700 ... 1060hPa
Transportation altitude - -1000 ... 3,000m
Shock stress during transportation
Free fall in transport packaging v1000mm

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 103
Hardware Descriptions
2.13 ADI4 (Analog Drive Interface for 4 Axes)

2.13 ADI4 (Analog Drive Interface for 4 Axes)

2.13.1 Assembly

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Order Number

Description Order number (MLFB)

ADI4 6FC5 211-0BA01-0AA2

Manual
104 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Hardware Descriptions
2.13 ADI4 (Analog Drive Interface for 4 Axes)

Features
The interface module ADI4 is suitable for operating up to 4 drives with analog setpoint
interface on PROFIBUS DP.
The module has the following essential features:
● PROFIBUS DP connection (max 12 Mbits/s)
● 4 servo interfaces each with one:
– Input: TTL/SSI encoder for incremental and absolute measuring systems
– Output: ±10 V analog
● General and drive-specific digital input/output signals
● On-board status display via four 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:
• An ADI4 DP slave can only be operated on an equidistant PROFIBUS DP (see
Subsection "DP-Slave ADI4" (Page 286)).
• An ADI4 DP slave is not a DP standard slave certified as compliant with the PROFIDrive
profile, e.g. the ADI4 DP slave does not support acyclic communication.

References:
For detailed documentation about the interface-module ADI4 please see:
/ADI4/ analog drive interface for 4 axes

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 105
Hardware Descriptions
2.14 Diagnostic repeater for PROFIBUS DP

2.14 Diagnostic repeater for PROFIBUS DP

2.14.1 Assembly

Figure 2-27 View: Diagnostics Repeater for PROFIBUS DP

Order Number

Description Order number (MLFB)

Diagnostic repeater for PROFIBUS DP 6ES7 972-0AB01-0XA0

Manual
106 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Hardware Descriptions
2.14 Diagnostic repeater for PROFIBUS DP

Features
The diagnostics repeater with online line diagnostics for PROFIBUS DP offers the following
main features:
● Module-specific features:
– PROFIBUS DP standard slave (DP-V1)
– Data transmission speed: 9.6 kBaud to 12 MBaud
– Maximum depth of cascading: 9
– Redundant operation: No
● Automatic detection of fault type and fault location
● Distance given in line diagonistics:
– Resolution: 0.5 m
– Accuracy: ±1 m
● Repeater throughput time:
– Baud rates ≥1.5 Mbaud: 2.5 TBIT + 153 ns;
(12 MBaud: TBIT = 83.3 ns)
– Jitter: 1T = 1/48 MHz = 20.83 ns
● Monitoring function of isosynchronous PROFIBUS
– DP bus cycle (TDP): min. 1 ms, max. 32 ms
– Tolerance range TDP monitoring: ± 2 μs
– Tolerance range TDX monitoring: ± 10 μs
● Supply voltage: Rated voltage 24 V DC (20.4 to 28.8 V)
● Permissible ambient conditions:
– Operating temperature 0 °C to +60 °C
– Transportation-/storage temperature -40 °C to +70 °C
– Relative humidity max. 95 % at 25 °C
● Mechanical design:
– Dimensions (B X H X T) 80 x 125 x 67.5
– Weight 300 g
● Degree of protection: IP20
References:
A full description of the diagnostic repeater for PROFIBUS DP is given in:
Manual SIMATIC diagnostic repeater for PROFIBUS DP
Drawing number: A5E00352937-01, 10/2004 Edition
Order number (MLFB): 6ES7972-0AB00-8AA0

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 107
Hardware Descriptions
2.14 Diagnostic repeater for PROFIBUS DP

Manual
108 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Configuration 3
3.1 System overview

3.1.1 Operator panels and touch panels

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 109
Configuration
3.1 System overview

3.1.2 PROFIBUS DP components

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Manual
110 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Configuration
3.1 System overview

3.1.3 PCU components

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 111
Configuration
3.2 Electrical design

3.2 Electrical design

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Manual
112 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Configuration
3.2 Electrical design

Note
For details on general accessories, such cables, connectors and prefabricated cables,
please refer to:
References: Catalog NC 61, MOTION-CONNECT

3.2.2 MCI board extension

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 113
Configuration
3.2 Electrical design

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Manual
114 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Configuration
3.3 Connection overview

3.3 Connection overview

3.3.1 MCI board and MCI board extension

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Figure 3-8 Connection overview: MCI board and MCI board extension

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 115
Configuration
3.3 Connection overview

1. Connectors:
6ES7972-0BA41-0XA0; cable outlet 350, without PC socket connector
6ES7972-0BB41-0XA0; cable outlet 350, with PC socket connector
6ES7972-0BA12-0XA0; cable outlet 900, without PG socket connector
6ES7972-0BB12-0XA0; cable outlet 900, with PG socket connector
Cables:
6XV1830-0EH10; by the meter, non-trailable
6XV1830-3EH10; by the meter, trailable
2. Connectors:
6GK1500-0EA02; cable outlet 1800, without PG-socket connector
Cables:
6XV1830-0EH10; by the meter, non-trailable
6XV1830-3EH10; by the meter, trailable
3. Connectors:
6ES7972-0BB41-0XA0; cable outlet 350, with PC socket connector
6ES7972-0BB12-0XA0; cable outlet 900, with PG socket connector
Cables:
6XV1830-0EH10; by the meter, non-trailable
6XV1830-3EH10; by the meter, trailable
4. The cable is included in the scope of supply
for an overview of the standard PC interfaces see Section "PCU 50.3" (Page 114) as well
as:
References:
/BH/ Operator components Manual, Component PCU 50.3
5. Cables: 6FX8002-2CP00-1A⃞0
6. The detailed connection overview for ADI4 is given in:
References:
/ADI4/ analog drive interface for 4 axes, connection overview
7. Connection with the help of Fast Connect (insulation displacement method) see:
References:
SIMATIC Manual: Diagnostic repeater for PROFIBUS DP
8. Can be parameterized alternatively as MPI or PROFIBUS interface.
Only the PLC can access this PROFIBUS interface. No drives and no NCK I/Os can be
operated via this PROFIBUS line.

Manual
116 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Configuration
3.3 Connection overview

Note
The length codes for preassembled cables 6FX_002-... can be found in:
References:
Catalog NC 61, MOTION-CONNECT.

3.3.2 PCU50

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1. The cable is included in the scope of supply

2. Cables: 6FX8002-2CP00-1A⃞0
3. For information on Ethernet cables, please refer to
References:
Catalog NC 61, MOTION-CONNECT

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 117
Configuration
3.3 Connection overview

Manual
118 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
EMC and ESD Measures 4
4.1 RI suppression measures

Shielded signal cables

To ensure safe, interference-free system operation, 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:
● If non-Siemens devices are connected (printers, programming devices, etc.), you can
also use standard shielding cables, which are connected at one end.
These external 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 cable.

Rules for routing cables

In order to achieve the best-possible noise immunity for the complete system (control, power
section, machine) the following EMC measures must be observed:
● Signal cables and load cables must be routed at the greatest possible distance from one
another.
● Only use SIEMENS signal cables for connecting to and from the NC or PLC.
● Signal cables may not be routed close to strong external magnetic fields (e.g. motors and
transformers).
● Pulse-carrying HC/HV cables must always be laid completely separate from all other
cables.
● If signal cables cannot be laid at a sufficient distance from other cables, then they must
be installed in shielded cable ducts (metal).
● The clearance (interference injection area) between the following lines must be kept to a
minimum:
– Signal cable and signal cable
– Signal lead and associated equipotential bonding lead
– Equipotential bonding lead and PE conductor (routed together).

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 119
EMC and ESD Measures
4.2 ESD measures

Note
For further information about RI suppression measures and the connection of shielded
cables see:
References:
/EMC/ EMC Directives

4.2 ESD measures

CAUTION
The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic
energy before touching the electronic modules. The easiest way to do this is to touch a
conductive, grounded object immediately beforehand (for example, bare metal parts of
control cabinet or the protective ground contact of a socket outlet).

NOTICE
Handling ESDS modules:
• When handling electrostatically sensitive devices, make sure that operator, workplace
and packing material are properly grounded.
• Generally, electronic modules may 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.
• Personnel may only touch components 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.
• Boards/modules must only be placed on conductive surfaces (table with ESDS surface,
conductive ESDS foam, ESDS packaging, ESDS transport container).
NOTICE!
Modules with their own voltage sources (e.g. batteries) are an exception. These may not
be placed on conductive surfaces, as this might result in short circuits and thus destroy
the component on the module.
• Never place modules in the vicinity of display units, monitors, or television sets
(minimum distance to the screen > 10 cm).
• Do not bring 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
– when floating measuring equipment is used, the probe is briefly discharged before
making measurements (e.g. a bare-metal control housing is touched).

Manual
120 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Power-On and Power-Up 5
5.1 Preparing for commissioning

5.1.1 Checklist

SINUMERIK 840Di sl
The following checklist will help you to commission the supplied components without undue
problems and ensure a high availability on your product:
● When handling the components, all ESD measures are observed.
● All screws are tightened with their prescribed torque.
● All connectors are plugged correctly and locked/screwed.
● All components are grounded and connected to shields.
● The load capacity of the central power supply is taken into account.

Drives
Additional points should be observed depending on the drive system used. For detailed
information, please refer to:
● SINAMICS S120
Commissioning Manual, Section "Prerequisites for startup"
● SIMODRIVE 611 universal
/FBU/ Function Manual SIMODRIVE 611 universal, Section "General information on
startup"

Limit values
All components are dimensioned for defined mechanical, climatic and electrical
environmental conditions. No limit value may be exceeded, neither during operation, nor
during transportation.
In particular, the following must be observed:
● Power supply conditions
● Pollution burden

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 121
Power-On and Power-Up
5.1 Preparing for commissioning

● Function-impairing gases
● Climatic environmental conditions
● Storage/transport
● Shock stressing
● Vibratory load
● Ambient temperature

5.1.2 Recommended sequence for first commissioning

Requirements
The individual steps for first commissioning 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 previous section).
– SINUMERIK 840Di sl
– SINAMICS S120
References:
Guide for the SINUMERIK 840D sl machine configuring
– SIMODRIVE 611 universal-converter system
– Motors
– SIMATIC S7 I/O components
– HMI user interfaces

Note
Guidelines for machine configuration
The device manual "Guidelines for machine configuration SINUMERIK 840D sl"
currently refers only to SINUMERIK 840D sl with SINAMICS S120. The information
contained in this can, in principle, be applied to SINUMERIK 840Di sl with
SINAMICS S120. A revised edition for SINUMERIK 840Di sl is in preparation.

2. The order numbers (MLFB) of the SIMODRIVE 611 universal drives and SIMATIC S7-I/O
components should be available. When creating the SIMATIC S7 project you must check,
whether the component chosen from the hardware catalog by "HW Config" corresponds
to the component used on the plant.

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 Power-On and Power-Up
5.1 Preparing for commissioning

Implementation
1. Configure the SINUMERIK 840Disl completely on first booting
(Section "First power-up" (Page 124))
2. Take the PLC default program supplied as the commissioning file for the PLC (basic PLC
program, PLC user program and configuration) or create your own SIMATIC S7 project
and load it into the PLC
(Section "PROFIBUS DP Communication" (Page 229))
3. Prepare the drives on the PROFIBUS DP for communication:
– SINAMICS S120 (Section "Drive-commissioning (SINAMICS)" (Page 307))
– SIMODRIVE 611 universal (Section "Drive-commissioning (SIMODRIVE)" (Page 345))
4. Perform commissioning of the NC (channels, axes and spindles, etc. (Section "Axes and
spindles" (Page 385))
5. Set up the alarm texts (Section "Alarm and message texts" (Page 493))
6. Perform the commissioning of the drives:
– SINAMICS S120 (Section "Drive-commissioning (SINAMICS)" (Page 307))
– SIMODRIVE 611 universal (Section "Drive-commissioning (SIMODRIVE)" (Page 345))
7. Carry out a dry run for all axes and the spindle.
(Section "840Di sl-specific Data and Functions" (Page 587)
8. Perform the optimization of the drives:
– SINAMICS S120: STARTER
– SIMODRIVE 611 universal: HMI Advanced (Section "Drive optimization with HMI
Advanced" (Page 507)) and/or SimoCom U
9. Carry out a user data backup (series startup file)
(Section "User data backup/Series commissioning" (Page 541))
10.Optional: Do a complete data backup (partition and/or hard-disk image):
References:
/IAM2/ Commissioning CNC Part 5, Section "IM8, Backup and restore data"

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Power-On and Power-Up
5.2 First power-up

5.2 First power-up

5.2.1 Basic commissioning of the system software

Objective of basic commissioning

After the basic commissioning described in the following two sections, the following
conditions should apply:
● SINUMERIK 840Di sl NC and PLC are operated in cyclical operation
● If a machine control panel is connected, no alarms or messages should be pending.
● The displayed axes of the NC can be traversed by simulation.

Factory settings
The hard disk of the PCU is already partitioned upon delivery for operating the SINUMERIK
840Di sl. Additional software applications, which have been been ordered, e.g. HMI
Advanced, are ready for installation under:
● D:\Setup\Apps\<Application1> . . . <Application n>

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Installing the software

When the PCU is first booted, the following menu is displayed:

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 Power-On and Power-Up
5.2 First power-up

Welcome to SINUMERIK !
These SINUMERIK products will be installed now:

<Application 1> <Version>

: :
: :
<Application n> <Version>

Install NOW

Install at NEXT REBOOT

CANCEL installing

Menu commands:
● Install NOW
All the applications displayed will be installed in the listed order. During the installation
procedure follow the instructions that appear on the screen.

NOTICE
The PC may not be switched off during the entire installation process. Data loss!

● Install on NEXT REBOOT

None of the listed applications are installed and you are taken to the Windows desktop.
The installation menu is displayed again the next time the PCU is booted.
● CANCEL installation
None of the listed applications are installed.
Application:
Subsequent installation of a hard drive image as part of a standard commissioning.

NOTICE
The current installation menu will not be displayed the next time the PCU is booted. The
installation procedure which was cancelled with "Cancel installing" cannot be repeated

Completion
When installation is complete rebooting automatically starts. Once the PCU has booted
again, you can continue with the basic PLC commissioning (Section "Basic commissioning of
the PLC").

See also
Basic commissioning of the PLC (Page 126)

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Power-On and Power-Up
5.2 First power-up

5.2.2 Basic commissioning of the PLC

After the Service Desktop is active, the series commissioning file (*.arc) of one of the sample
applications delivered can be loaded for simplifying the PLC commissioning. An application
example includes the basic PLC program and the linking of one of the following MCP.
Path: < Installation path>\support\840dismp\
● PROFIBUS-MCP: 840disl_tb<version>_DPMCP.arc
● Ethernet MCP: 840disl_tb<version>_ETHMCP.arc
● Ethernet-MCP and HT 8: 840disl_tb<version>_ETHMCP_HT8.arc
Proceed as follows for loading the series commissioning file:
1. Start the "SinuCom NC" commissioning tool from the Windows taskbar: Start > Programs
> SinuCom NC > SinuCom NC
2. Use SinuCom NC to load the series startup file PLC_SMP.ARC into the PLC.
Menu command: File > Archive > SeriesIBN-Archive > Read
Dialog: Read-in archive
– Radio button: Data management
– Button: "NEXT"
– Select the series commissioning file (*.arc)
– Button: "FINISH".
This executes the PLC basic startup procedure. NC and PLC run in cyclic mode.

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 Power-On and Power-Up
5.3 Power-up

5.3 Power-up

5.3.1 SRAM handling

The user data of the NC (machine data, setting data, user variables, part programs, 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 is also saved to the hard disk of the PCU as an
SRAM backup.
In certain error or servicing instances, the SRAM image or backup can be accessed so that
work can be continued immediately without recommissioning the SINUMERIK 840Di sl.

Table 5-1 SRAM handling

HW SRAM SRAM image SRAM backup Used user data/remark

serial MCI (hard disk) (hard disk)
number board "OK" "OK"
MCI board "OK"
Known yes Not Not applicable MCI/Normal power-up
applicable
Known No yes Not applicable IMAGE/no message box or alarms;
See Section "Power-up after changing the
MCI boards"; case 1
Known No No yes BACKUP/message box and alarm;
See Section "Power-up after changing the
MCI boards"; case 2
Known No No No Commissioning/recommissioning required
Unknown yes yes Not applicable MCI or IMAGE/Request carried out;
See section "Startup after replacement of
the PCU or the MCI board"
Unknown yes Not Not applicable MCI/MessageBox;
(SW applicable See section "Power up after
update) reinstallation/update of the 840Di sl
software"
Unknown yes No yes MCI or BACKUP/Request carried out; if
BACKUP is selected, message box and
alarm will occur;
See Section "Power-up after changing the
MCI boards"; case 2
Unknown yes No No MCI/MessageBox;
See section "Power up after
reinstallation/update of the 840Di sl
software"

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Power-On and Power-Up
5.3 Power-up

HW SRAM SRAM image SRAM backup Used user data/remark

serial MCI (hard disk) (hard disk)
number board "OK" "OK"
MCI board "OK"
Unknown No yes Not applicable IMAGE/MessageBox;
See Section "Power-up after changing the
MCI boards"; case 1
Unknown No No yes BACKUP/message box and alarm;
See Section "Power-up after changing the
MCI boards"; case 2
Unknown No No No Commissioning/recommissioning required
HW serial number. MCI board:
● Known:
The hardware serial no. of the MCI board matches the hardware serial number last stored
on the PCU.
● Unknown:
The hardware serial no. of the MCI board does not match the hardware serial number last
stored on the PCU.
● Unknown:
Provided that the SRAM of the MCI board is "OK", the system does not request, which
SRAM (MCI or IMAGE) is to be used when booted for the first time (SW update). The
SRAM of the MCI board is always used.
SRAM image or SRAM backup (hard disk) "OK":
Yes: The following criteria must be fulfilled:
● The NC and PLC software version of the SRAM image/backup must match the installed
software version.
● Windows XP must have been shut down correctly (the POWER FAIL mechanism of the
SINUMERIK 840Di sl is adequate for this).
● The checksum test on the SRAM image/backup must have been successful.
● The battery status must have been good when the backup of the SRAM image was
performed.
Used user data:
● MCI:
The user data backed up in the SRAM of the MCI boards is 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 image on the hard disk of the PCU are used.
● Commissioning:
The user data of the NC are deleted and default machine data are loaded.

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 Power-On and Power-Up
5.3 Power-up

5.3.2 Startup after battery replacement (PCU backup battery)

Proper shutdown
Before replacing the PCU backup battery, the SINUMERIK 840Di sl or Windows XP must be
shut down correctly.
To do this, use one of the following options:
● Windows taskbar: Start > Shut Down.
● Interface signal: "PC shutdown", see Section "840Di sl-specific interface
signals" (Page 587).

Inverting SRAM memory cells

If SRAM memory cells are inverted when changing the battery, this will be detected during
power-up. The SRAM image will then be written back to the SRAM of the MCI board and the
SINUMERIK 840Di sl is now immediately ready for operation.
Responses:
None.

NOTICE
If Windows XP is not correctly shut down before changing the backup battery, an inversion
of the SRAM memory cells during the battery change cannot reliably be detected.
The SINUMERIK 840Di sl must then be recommissioned.

5.3.3 Startup after replacement of the MCI board

After the MCI board has been replaced, the subsequent procedure depends on the previous
history. There is a distinction between the following situations:
1. An up-to-date SRAM image exists
2. An up-to-date SRAM image does not exist

Case 1: An up-to-date SRAM image exists

Before the MCI board was changed, Windows XP could not be shut down correctly. An up-
to-date SRAM image is thus provided.
During power-up, the MCI board is detected as a new one using the HW serial number. The
SRAM image will then be written back to the SRAM of the MCI board. The SINUMERIK
840Di sl is thus ready again immediately.
Responses:
A note will appear in a message box, which must be acknowledged with "OK":

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Power-On and Power-Up
5.3 Power-up

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NOTICE
The following is to be taken into account:
• If the MCI board is recognized as being faulty while the SINUMERIK 840Di sl is booting,
the last SRAM image is retained when Windows XP is shut down. After the MCI board
has been changed, proceed as described above.
• If the MCI board is to be replaced as a result of a suspected or actual error (suspected
error, sporadic errors, etc.), the SINUMERIK 840Di sl NC and PLC should be
recommissioned, as possible data errors may otherwise be imported from the SRAM
image.

Case 2: An up-to-date SRAM image does not exist

A fault occurred with the MCI board during operation of the SINUMERIK 840Di sl. Windows
XP has possibly been shut down correctly, but no SRAM image could be created.
After replacement, based on the hardware serial number the MCI board will be identified as
"unknown". Since no up-to-date SRAM image exists, the SRAM backup is written back into
the SRAM of the MCI board. The SINUMERIK 840Di sl is now immediately "operational".
The user data or operating state of the SINUMERIK 840Di sl must be checked to ascertain if
operation can be continued. It might be necessary to recommission the SINUMERIK 840Di sl
NC and PLC.
Responses:
A note will appear in a message box, which must be acknowledged with "OK".

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 Power-On and Power-Up
5.3 Power-up

An NC alarm is also generated, which is displayed on the respective SINUMERIK 840Di sl

user interface (840Di startup, HMI Advanced, etc.):
● Alarm "4065 Battery-backed memory has been restored from the hard disk (possible data
loss)"
To acknowledge the alarm you must first acknowledge the alarm itself with a special
operation before executing the required NCK POWER ON Reset. Refer to Section "Menu:
Diagnosis" (Page 486).

5.3.4 Power up after reinstallation/update of the 840Di sl software

If the 840Di sl software is reinstalled on an operational SINUMERIK 840Di sl, the user data
saved in the SRAM of the MCI board is retained.
To achieve this, it is essential that the current NC and PLC software version complies with
the software version with which the battery-backed user data of the SRAM have been
created.
The SINUMERIK 840Di sl is thus ready again immediately.
Responses:
A note will appear in a message box, which must be acknowledged with "OK":

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NOTICE
If the buffered user data is not going to be used again, the SINUMERIK 840Di sl must be
recommissioned.

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Power-On and Power-Up
5.3 Power-up

5.3.5 Startup after replacement of the PCU or the MCI board

If, during booting, it has been ascertained that both the SRAM image on the PCU hard disk
and the MCI board SRAM have buffered valid, but different user data (both components
were already in use in one SINUMERIK 840Disl), no automatic selection can be made.
Responses:
The user must decide through the following message box, which user data are to be used
further.

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5.3.6 Startup after importing a backup copy

If a backup copy (Ghost image) of a previously booted SINUMERIK 840Di sl is loaded into
the PCU again, the user data buffered in the SRAM of the MCI board will be used again.
The SINUMERIK 840Di sl is thus ready again immediately.

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 Power-On and Power-Up
5.3 Power-up

5.3.7 Startup after power failure/Power Fail

Case 1: SRAM saved

Thanks to the Power Fail Detection integrated in the PCU, in the event of a power failure the
SINUMERIK 840Di sl saves the user data in the SRAM of the MCI board. An SRAM image,
however, cannot be created any more in this case.
When the power returns or with the next power-up, the data is available again.
The SINUMERIK 840Di sl is thus ready again immediately.

NOTICE
Saving of the user data in the SRAM of the MCI board in case of power failure/Power Fail is
only guaranteed if the PCU is operated within its defined specifications.
References:
/BH/ Operator components Manual, Section "Component PCU 50"

Case 2: SRAM not backed-up

If the SINUMERIK 840Di sl was operated outside its defined specifications, it may not be
possible to save the user data in the SRAM. Proceed, therefore, as in section "Power-up
after changing the MCI board" (Page 132) Case 2 described.

5.3.8 Power-up with shutdown signal

If the SINUMERIK 840Di sl is operated with a UPS unit, the shutdown signal must be
configured accordingly. Refer to Section "Menu: Settings" (Page 490). If a shutdown signal is
pending, first the NC and PLC and then Windows XP are shut down correctly.

1. Power-up
If power-up is executed with a pending shutdown signal, Windows XP is immediately
correctly shut down again.

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Power-On and Power-Up
5.3 Power-up

From 2nd power-up

The system responds as follows if it is powered up a second time with pending shutdown
signal:
● Windows XP is not immediately shut down correctly.
● NC and PLC are not started
● The following message box appears:

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2.

This system response ensures that an error in the protection circuit of the MCI board
extension module or in the configuration of the shutdown signal does not result in an endless
loop (power-up > shutdown signal > power-up etc.).
As long as the message box has not been acknowledged the protective circuit of the MCI
board extension module and the configuration of the shutdown signal (see Section , "Menu:
Settings" (Page 490)) can be checked and changed, if necessary.
If the shutdown signal has been acknowledged from the message box, the NC and PLC are
started. Otherwise Windows XP is again shut down correctly.

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 Power-On and Power-Up
5.4 Service Desktop

5.4 Service Desktop

The Service Desktop is intended for machine manufacturer/service personnel. Numerous
SINUMERIK-specific applications are available on the Service Desktop in addition to the
standard Windows functions.

5.4.1 Activating
Proceed as follows to enable the Service Desktop:
1. As soon as (1) is displayed under the version number on the bottom right of the startup
screen, press the key "3".

9

Figure 5-2 Display during startup of the SINUMERIK 840Di sl

2. Enter a password for protection levels 0-2:

Protection level Password Area

0 Reserved Siemens
1 SUNRISE (default) Machine manufacturer
2 EVENING (default) Commissioning, service
1. Click the "Service Desktop" button in the displayed selection menu or press the "Return"
key.

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Power-On and Power-Up
5.4 Service Desktop

5.4.2 SINUMERIK-specific applications

The following SINUMERIK-specific applications are available on the Service Desktop:
● Ghost Explorer
The Ghost Explorer is used to display the content of Ghost images.
References:
The Ghost tools documentation is located on the PCU hard drive under: E:\TOOLS
● HMI Explorer
The HMI Explorer is used to display the version and install or post-install the supplied
SINUMERIK application. See Section "HMI Explorer" (Page 140).
● Touchware
Program for calibrating the touchscreen connected to the PCU directly.
References:
Equipment Manual "Operator components and Networking",
Chapter: PCU 50.3 > Commissioning > Calibration of the touchscreen
● System Network Center
Setting up the Ethernet connection of a TCU to the SINUMERIK 840Di sl.
References:
Equipment Manual "Operator components and Networking",
Chapter: Networking > Commission system network > PCU: System Network Center
(SNC)
● HMI Analyzer
Analysis tool for HMI Advanced in conjunction with PCU 50.3
References:
"Base software and HMI-Advanced" Commissioning Manual
Chapter: Diagnosis and Service > HMI-Analyzer
● ServiceCenter
Starts the ServiceCenter after the computer reboots under WinPE to create, restore and
manage partition and hard disk images.
References:
"Base software and HMI-Advanced" Commissioning Manual
Chapter: PCU-Basesoftware 8.x > Save and restore data

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 Power-On and Power-Up
5.4 Service Desktop

● Folder: SINUMERIK 840Di

– SINUMERIK 840Di Startup
Simple SINUMERIK 840Di-specific user interface.
– NT Desktop/HMI Desktop
Autostart of the HMI application: OFF/ON
See Section "Setting the boot response for the service desktop" (Page 138).
– Readme
Tips and boundary conditions for the installed \SINUMERIK 840Di sl-system software.
● Folder: SINUMERIK 840Di > tools
– HT8TCU
Activation of the transfer of an HT8 machine control panel signal
References:
Equipment Manual "Operator components and Networking",
Chapter: Networking
– Install-Deinstall MCIS RCS Host
Installation and uninstall program of the host for remote diagnostics of SINUMERIK
systems with Windows-based HMI within the framework of the Motion Control
Information System.
References:
Catalog NC 61: Motion Control Information System (MCIS)
● Folder: SinuCom NC
– CT Editor
Tool for creating the test templates
– NC Connect Wizard
Tool for establishing the communications link from SinuCom NC to SINUMERIK 840Di
sl.
– SinuCom NC

NOTICE
When Windows starts up, the SINUMERIK 840Di sl NC system software is
automatically started in the background.

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Power-On and Power-Up
5.4 Service Desktop

5.4.3 Setting the boot response for the Service Desktop

The NC or MHI desktop settings are used to determine if the NC desktop (Windows desktop)
is displayed after booting the SINUMERIK 840Di sl, or if the HMI user interface, e.g. HMI
Advanced, is started immediately:
● NC Desktop
Autostart of the HMI application: OFF
● HMI desktop
Autostart of the HMI application: ON

5.4.4 System information after "Fatal exception error"

After a "fatal exception error" (blue screen), system information is written to the following file:
● D:\Memory.dmp.

5.4.5 Starting OEM programs

OEM directories
OEM programs can be executed before starting the SINUMERIK system software. These
programs or their respective links must be stored in the following directories:
● 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
Sequential: The subsequent program will only be started when the previous program has
been ended.

● C:\RunOEM\ParOnce
Programs stored here are started once. They run in parallel with the HMI system software.
● C:\RunOEM\Par
Programs stored here are initiated at every boot. They run in parallel with the HMI system
software.

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5.4 Service Desktop

Order of execution
Directories and programs are processed in the following order:
● Directories
1. C:\RunOEM\SeqOnce
2. C:\RunOEM\Seq
3. C:\RunOEM\ParOnce
4. C:\RunOEM\Par
● Programs
The programs within a subdirectory are started according to the chronological order in
which they were placed in the subdirectory.

Data files
In addition to executable programs, you can also place data files in the subdirectories. They
will be opened in the application with which their file type is associated.
Example:
● File type: ".txt"-> Notepad
● File type: ".htm"-> Internet Explorer

5.4.6 User-specific HMI startup images

User-specific startup images can be displayed while the HMI is booting. The boot images
must be stored in bitmap format (*.BMP) in a defined directory structure.

Directory structure
The directory structure must be created under "F:\OEM\IB\DATA" according to the following
schema:
● F:\OEM\IB\DATA\<NCK-Type>\<screen resolution>\<file name>.BMP

Parameters: NCK type

The different NCK types are displayed depending on the directory name.
The following values may be used as directory names for the SINUMERIK 840Di sl:
● Default
If a directory is created by default, the startup image stored in this directory will always be
displayed irrespective of the NCK type.
● 5000
Under the Directory 5000 (ID for SINUMERIK 840Disl) stored startup images are only
displayed by the HMI application together with a SINUMERIK 840Di sl.

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Power-On and Power-Up
5.4 Service Desktop

Parameters: Screen resolution

The startup images for the various screen resolutions must be stored in different directories.
The directory name corresponds to the screen resolution:
● 640
Startup image for screen resolution: 640 x 480 [dpi]
● 800
Startup image for screen resolution: 800 x 600 [dpi]
● 1024
Startup image for screen resolution: 1024 x 768 [dpi]

Note
in the folder screen resolution only one file may be stored.

Parameters: File name

You can choose any file name.

5.4.7 HMI Explorer

The HMI Explorer is used to manage the Siemens A&D software components on the PCU.
The following main functions are available:
● Version display
● Installation, de-installation, and re-installation
● Application-specific information (detailed information, history, available language versions,
etc.)
● Installation directory

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 Power-On and Power-Up
5.4 Service Desktop

Version display
The following versions are displayed for each software application:
● Current version
Current version number
● Release version
Version number with which the product was first installed.

Installation directory
The path of the installation directory of a software component is displayed in the Install
dialog box: Menu command: Install

5.4.8 SW installation/update
The Service Desktop allows you to install or update software directly from an external
computer using a specially configured network link. For a detailed description see Section
"License management" (Page 146).

Manual
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Power-On and Power-Up
5.5 ServiceCenter

5.5 ServiceCenter
The ServiceCenter is used to create, restore and manage partition and hard disk images.
With the SINUMERIK 840Di sl, the startup mode of NCK and PLC can also be specified via
the ServiceCenter.
The ServiceCenter is intended for the machine manufacturer/service personnel.

5.5.1 Activating
Proceed as follows to enable the Service Desktop:
1. Restart the PCU, e.g. via Power Off/On.
2. While starting up the PCU, press the key "↓" (Cursor Down) in the selection image for the
operting system to be started. (The selection screen is displayed immediately after the
booting of the PCU.)

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1. Press the Enter key for immediate activation of the selection or wait until the selection is
started automatically after the preset wait time has elapsed.

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 Power-On and Power-Up
5.5 ServiceCenter

5.5.2 NC/PLC startup modes

Setting options
In the SINUMERIK 840Di sl-specific part of the ServiceCenter, you can specify the mode
that the NCK and PLC are to assume after startup. The following options can be set:
● Start NCK and PLC
● Do not start NCK and PLC
● Start NCK and PLC in specified mode:

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NC modes
The following NCK modes can be set:
● Normal
● Loading standard machine data
After startup, the NC is in the reset state. All machine and user data are deleted and
standard machine data are loaded.

Note
You may have to consult your network administrator to obtain the above information or
any other information required for your current network.

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Power-On and Power-Up
5.5 ServiceCenter

PLC modes
The following PLC modes can be set:
● RUNP
In the "RUNP" mode, changes can be made to the PLC user program without activation
of the password.
● RUN
Only read accesses are possible via a programming device (PG) in the "RUNP" mode. It
is not possible to make changes to the PLC user program until the password has been
set.
● STOP
Processing of the PLC user program has stopped and all PLC outputs are set to
substitute values in the "STOP" mode.
● MRES (confirm in HMI)
The PLC is switched to STOP mode 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 operating hours
counter are not reset.

Note
After startup in the specified mode, the PLC must be explicitly switched to the desired
following mode, e.g. "RUNP". This can be performed via a programming device (PG) or
via the HMI user interface (see Section "NC/PLC diagnostics" (Page 486)).

5.5.3 Backup/restore functions

The function contained in the standard part of the ServiceCenter for creating, restoring and
managing partition and hard disk images are described in detail in:
References:
/IAM2/ Commissioning Manual CNC Part 5, Section "PCU base software (IM8)", backup and
restore data

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 Power-On and Power-Up
5.6 Configuration of the network connection of the PCU (LAN/WAN)

5.6 Configuration of the network connection of the PCU (LAN/WAN)

To perform service functions (software installation/update), the SINUMERIK 840Di sl
requires an active connection to an external computer at least for the duration of the service
task.

PTP link
The PTP link (peer-to-peer) to a single computer is described in Section "PTP-network
connection" (Page 551).

LAN/WAN link
The PCU basic software is preconfigured for an Ethernet network link with protocol: TCP/IP.
The settings for the local network connection (Windows-Taskbar Start > Settings > Network
Connections > Local Area Connections) with respect to the IP addresses and the domains
are given as follows:
Dialog: Local Area Connections Properties
● Tab: General
– IP address via DHCP
Option: Obtain an IP address automatically
– Automatic DNS server address
Option: Obtain a DNS server address automatically
● Tab: 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, the following settings
are to be done or checked:
● TCP/IP protocol
● IP address and subnet mask
● Computer name and domain/workgroup

Note
You may have to consult your network administrator to obtain the above information or
any other information required for your current network.

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Power-On and Power-Up
5.7 License management

5.7 License management

5.7.1 License management with the Automation License Manager

License management with the Automation License Manager is described in a separate
section: Section "License management" (Page 563).

5.7.2 License management with SinuCom NC

To use SINUMERIK 840Di sl system software and the enabled options, the corresponding
software licenses must be assigned to the hardware. During the assignment procedure, you
will be given a license key for each piece of software (system software or options) which
electronically links the respective software to the hardware.
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.
The procedure for ordering through to entering the license key of an option is as follows:
1. Order and purchase of the relevant license packages and/or single licenses: Order
catalog NC 61
2. Activate the options SinuCom NC
3. Obtain the license key for the required control: Web License Manager by Internet
connection to the SINUMERIK 840Di sl or external PG/PC via
http://www.siemens.com/automation/license
4. Enter the license key: SinuCom NC

New license key

To obtain and enter a new license key in the control system, proceed as follows:
1. Start SinuCom NC from the Windows taskbar: Start > Programs > SinuCom NC >
SinuCom NC
2. Use SinuCom NC to go online control system.
3. Double-click on the machine data module to open:

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 Power-On and Power-Up
5.7 License management

4. Select the data area: "Options".

Via the dialog box: "Options", you can:
– Enable/disable options or
– Obtain new license keys (Web License Manager)
– Enter license keys in the control system
Click the "Get a new license key" button and follow the instructions in the subsequent
dialogs.

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Power-On and Power-Up
5.7 License management

Manual
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PLC commissioning 6
6.1 General

6.1.1 Compatibility
The PLC integrated on the MCI board of the SINUMERIK 840Di sl is compatible with the
SIMATIC S7 PLC: AS317-2 DP.

6.1.2 Performance Data

The PLC of the SINUMERIK 840Di sl has the following features:

Table 6-1 Performance data of the PLC

PLC317-2DP (6FC5 317-2AJ10-0AB0)

Memory for PLC basic program and user program 768 KB
Data block memory Max. 256 KB
Memory submodule No
Bit memories 32768
Timers 512
Counter 512
Clock memory 8
Program and data blocks
OB 1, 10, 20-21, 32-35, 40, 55-57,
80, 82, 85-87, 100, 121-122
FB 0-2048
FC 0-2048
DB 1-2048
Max. length of data block 32 KB
Max. block length FC, FB 64 KB
Inputs/outputs (addressing capacity)
NOTICE!
The inputs/outputs above 4096 are reserved for integrated drives.
Digital/analog 4096/4096 bytes
Incl. reserved area 8192/8192 bytes

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PLC commissioning
6.1 General

PLC317-2DP (6FC5 317-2AJ10-0AB0)

Process image 256/256 bytes
Inputs/outputs (addressing) Through optional configuring
Row 0 is integrated in the NC. Rows 1 to 3 are available for I/O of I/O devices
devices
Digital From I/O byte 0
Analog From PI/PO byte 272 only
PROFIBUS
Processing time
Bit instructions (I/O) <= 0.031 ms/kA
Word instructions 0.1 ms/kA
PDIAG (Alarm S,SQ) Yes
PROFIBUS Master/Slave
Number of PROFIBUS slaves (see note below) max. 125
PBC programmable block communication Yes
Consistent data to standard slave via SFC 14, 15 128

6.1.3 PLC program

The PLC program is constructed modularly. 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 NCK, HMI, and machine control panel components.
The PLC basic program is part of the PLC Toolbox supplied with SINUMERIK 840Di sl.
● PLC user program
The PLC user program is the user-specific part of the PLC program by which the basic
PLC program has been added to or extended.
For a complete description of the basic PLC program, its structure and all modules including
their call parameters, please refer to:
References:
/FB1/ Function Manual, Basic Functions; Subsection "PLC Basic Program" P3

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 PLC commissioning
6.1 General

6.1.4 Installing the PLC basic program library

To be able to use the blocks of the basic PLC program (OBs, FBs, DBs, etc.) in a SIMATIC
S7 project, the library must first be installed in the SIMATIC manager. The information
needed for the installation of the basic PLC program (storage path of the file setup.exe and
other installation instructions) are contained in the file:
● <Installationpath>\importantinfo.rtf

NOTICE
The library of the basic PLC program must be installed on the computer on which the
SIMATIC manager for creating the S7 project is already installed.

6.1.5 STEP 7 example projects

Included in the scope of supply for the SINUMERIK 840Di sl system software are two STEP
7 projects, on which the basic configuration of the SINUMERIK 840Di sl Station and an MCP
(PROFIBUS/Ethernet) is displayed. The example projects can be used as a basis for your
own projects.

Storage path
The example projects are on the SINUMERIK 840Di sl CD under:
● Example project with PROFIBUS MCP:
<CD-path>\support\840dismp\840Di_sl_DPMCP_smpl.zip
● Example project with Ethernet MCP:
<CD-path>\support\840dismp\840Di_sl_ETMCP_smpl.zip

Dearchive
Example projects must first be dearchived in the SIMATIC Manager before they can be used.
SIMATIC Manager: File > Dearchive...
The example projects can be dearchived to the default "S7Proj" target directory.

Use
The example projects are listed in the SIMATIC Manager in the target directory "S7Proj"
under user projects. SIMATIC Manager: File > Open... >Dialog: "Open project" Tab: "User
projects"
● Example project with PROFIBUS MCP: 840Disl_DPMCP
Station
● Example project with Ethernet MCP: 840Disl_ETMCP

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PLC commissioning
6.1 General

Loading into the PLC

The communication link from SIMATIC STEP 7 to the SINUMERIK 840Di sl PLC must be
checked and established before loading an example project.
● External link
That PG/PC is running on SIMATIC STEP 7, can be linked with the SINUMERIK 840Di sl-
PLC via one of the Ethernet interfaces of the PCU (Ethernet 1: company network or
Ethernet 2: Local network).
Configuring the PG/PC interface is described in Section "Commissioning" (Page 155).
Configuring the communication processor (CP 840D sl) of the SINUMERIK 840Di sl is
described in the Subsection "Parameterizing the communication processor (CP 840D sl)
(Ethernet)" (Page 170).
● Internal connection:
A local SIMATIC STEP 7 installed on the SINUMERIK 840Di sl is linked via the preset
local "SOFTMC" communications link with the SINUMERIK 840Di sl PLC.

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 PLC commissioning
6.1 General

6.1.6 PLC user program

The following organizational blocks contain the entry points for the appropriate parts of the
PLC user program.
● OB100 (cold restart)
● OB1 (cyclic processing)
● OB40 (process alarm)

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PLC commissioning
6.1 General

Processing modules
The individual blocks in the basic PLC program can be processed in the SIMATIC manager:
● Select the appropriate block, e.g. OB 100 in the folder blocks of the corresponding
module
● Use the menu command Edit > Open Object to open the block or double-click the block
with the left mouse button
● Processing the blocks in the KOP/AWL/FUP Editor
Switching the block view via the menu command View > KOP or AWL or FUP

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 PLC commissioning
6.2 Commissioning

6.2 Commissioning
The PLC commissioning can be performed by:
● Creating an S7 project and loading the configuration.
Creating an S7 project by using the basic PLC program supplied with SINUMERIK
840Di sl as well as the basic parameterization of MPI and PROFIBUS communication are
described in the Section "Create SIMATIC S7 project" (Page 160).
● Loading an available series commissioning file.
Creating or importing a series commissioning file is described in the Chapter "User-data
backup/series commissioning" (Page 541).

6.2.1 Basic requirements

SINUMERIK 840Di sl
The SINUMERIK 840Di sl must be successfully booted to commission the PLC:
● NCK in the cyclic operation
● PLC in the status: RUN

Note
The NCK and PLC status can be checked with:
• User interface 840Di startup
See corresponding online help
• Commissioning tool: SinuCom NC
See corresponding online help
• User interface HMI Advanced (option)
See Section "NC/PLC Diagnostics" (Page 486).

SIMATIC STEP 7
SIMATIC STEP 7 is required in the following version:
● SIMATIC STEP 7 as Version 5.4, Service Pack 2
SIMATIC STEP 7 can either be installed directly on the SINUMERIK 840Di sl PCU or on an
external computer (PG/PC).

Communications link
Depending on which computer is running SIMATIC STEP 7, there must be one of the
following communications links between SIMATIC STEP 7 and the SINUMERIK 840Di sl
PLC:
● External computer (PG/PC): Ethernet
● PCU of the SINUMERIK 840Di sl: SOFTMC (Local communications link)

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PLC commissioning
6.2 Commissioning

6.2.2 External communications link: Ethernet

To load the configuration from an external computer (PG/PC) into the SINUMERIK 840Di sl
PLC via an Ethernet connection, the following conditions must be met on the PG/PC:
● The computer can communicate via Ethernet or an Ethernet connection has been
established
● PG/PC interface is parameterized (see below)
● The PG/PC is connected to one of the Ethernet interfaces of the SINUMERIK 840Di sl
PCU (Ethernet 1: company network or Ethernet 2: Local network).

PG/PC interface
The PG/PC interface parameters can be checked and set in the SIMATIC Manager via menu
item: Options Set PG/PC interface...:

Dialog: Set PG/PC interface

Tab: Access path
Interface parameterization used <Interface>
OK

NOTICE
Do not select ISO interfaces as Ethernet interfaces from the list of interfaces, e.g. "ISO Ind.
Ethernet - Realtek RTL8139...".
Instead, use the appropriate TCP/IP interfaces, e.g. "TCP/IP - Realtek RTL8139...".

6.2.3 Local communications link: SOFTMC

For loading the configuration from a SIMATIC STEP 7 installed locally on the SINUMERIK
840Di sl in the PLC, the communication link must be set on "SOFTMC".

PG/PC interface
The PG/PC interface parameters can be checked and set in the SIMATIC Manager via menu
item: Options Set PG/PC interface...:

Dialog: Set PG/PC interface

Tab: Access path
Interface parameterization used SOFTMC
OK

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 PLC commissioning
6.2 Commissioning

6.2.4 Check PLC status and communication interface

The PLC status and therefore also the communications link to the PLC can be checked from
"HW Config" via menu item Target system > Operating status.
● If the current operating status of the PLC is displayed, the communications link is
operating correctly.
● If the current operating status of the PLC is not displayed, the communications link must
be checked for correct parameterization. If no connection is established to the PLC
despite correct parameterization, a general reset of the PLC is necessary.

PLC general reset

A general reset of the PLC can be performed using 840Di Startup or HMI Advanced (option):
● 840Di startup
– Start 840Di startup: Windows XP taskbar: Start > Programs > SINUMERIK 840Di >
840Di-Startup.
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC.
● HMI Advanced (option).
– Open the dialog box: Operating area switchover > Start up > NC/PLC Diagnosis
● Request general reset of PLC: "PLC Delete Program".
After general reset the PLC is in RUN mode, i.e. the LED "RUN" in the display is green:

6.2.5 First commissioning

On first commissioning of the PLC, a general reset of the PLC has to be performed after the
SINUMERIK 840Di sl has been switched on and booted.
To obtain a defined initial state of the whole system (NC and PLC), the NC data should also
be deleted.
● PLC general reset
General reset puts the PLC in a defined initial state by deleting and initializing all system
and user data.
● Delete NC data
After a request to delete NC data, all user data are deleted and the system data are
reinitialized on the next NC power-up, e.g. after NC Reset.

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PLC commissioning
6.2 Commissioning

General reset of PLC, delete NC data

General reset of the PLC and deletion of NC data can be performed using 840Di Startup or
HMI Advanced.
● 840Di startup
– Start: WINDOWS XP taskbar: Start > Programs > SINUMERIK 840Di > 840Di-Startup.
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC
● HMI Advanced
– Open the dialog box: Operating area switchover > Start up > NC/PLC Diagnosis

Dialog
Proceed as follows in the dialog boxes:
1. PLC general reset
Group PLC
Button: "PLC Delete Program"

NOTICE
After a general reset of the PLC, interface X102 (MPI/DP) of the MCI board is set to
"MPI" and the following MPI parameters are set:
• MPI address of the PLC = 2
• MPI data transmission rate = 187.5 kbaud

2. Delete NC data
Group NC
Button: "NCK Default Data"
3. Initiate NC Reset
To start cyclic operation or NC/PLC communication, NC reset (button "NCK Reset") must
be activated:
The subsequent SINUMERIK 840Di sl boot has been successfully completed if the following
display appears in the dialog box:
● NC status:
Group NC
6 NC in cyclic operation
● PLC Status:
Group PLC
LED RUN glows constantly

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 PLC commissioning
6.2 Commissioning

Note
Since no PLC program is executed after PLC general reset, the following alarms are
displayed:
• Alarm "120201 Communication failed"
• Alarm "380040 PROFIBUS DP: Configuring error 3, parameter"
• Alarm "2001 PLC not booted"
These alarms have no influence on how to continue.

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PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3 Creating a SIMATIC S7 project

This section describes the creation of an S7 project for basic commissioning 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:
● Create a project
● Set up a station
● Parameterize MPI communications (optional)
● Parameterize PROFIBUS communications
● Parameterize the input/output data areas of the NC

Note
The interface X102 MPI/DP can either be used as an MPI or PROFIBUS interface. The
use of MPI communication is no longer recommended for SINUMERIK 840Di sl.

PROFIBUS DP
Maximum two PROFIBUS lines can be connected to a SINUMERIK 840Di sl:
● Interface X101: PROFIBUS DP
In the case of the SINUMERIK 840Di sl, the position controller cycle of the NC is derived
directly from the isochronous PROFIBUS cycle. Defined values must therefore always be
entered for the following PROFIBUS parameters:
– Mode: DP master
– Isochronous PROFIBUS: Active
– Isochronous time TDP on PROFIBUS DP: Position controller cycle clock
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 interface.
● Interface X102: MPI/DP
This PROFIBUS interface is only available to the PLC. It can also be operated in "DP
Master" or "DP Slave" mode.
A full description of how to parameterize PROFIBUS communications is given in Chapter
"PROFIBUS DP communication" (Page 229).

Note
The instructions given in this section are essentially limited to the special characteristics of
the SINUMERIK 840Di sl. For more details about working with SIMATIC STEP 7 please refer
to the relevant SIMATIC documentation or Online Help.

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 PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3.1 Create a project

To create a new project select menu command File > New in the SIMATIC Manager.
Enter the following project data in the dialog and confirm with OK:
● Name (for example: SIN840Di sl)
● Storage location (path)
● Type
The project window is now displayed showing 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 insert a
SIMATIC Station 300 in the project. Select the menu command Insert > Station > SIMATIC
Station-300.

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Manual
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PLC commissioning
6.3 Creating a SIMATIC S7 project

Starting HW Config
Start "HW Config" by opening the station and double-clicking the hardware icon.

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We recommend giving the inserted SIMATIC Station 300 a meaningful name, for example
840Di sl

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 PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3.3 HW Config
The user interface of "HW Config" mainly contains:
● Station window:
The station window is split. The upper part displays the structure of the station graphically,
and the lower part provides a detailed view of the selected module.
● Hardware catalog
If the hardware catalog is not displayed, open it using the menu command View >
Catalog.

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Figure 6-4 HW Config: Names of the main areas

Note
To check whether a module selected from the hardware catalog complies with the
module in the automation system, the following procedure is recommended:
1. Note 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.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 163
PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3.4 Inserting the 840Di sl Rack

The 840Di sl rack contains the already partially preconfigured components:
● SINUMERIK 840Di sl PLC
Default designation: PLC 317-2DP 2AJ10
● MPI/DP interface
Default designation: MPI/DP
● PROFIBUS DP interface
Default designation: DP
● SINUMERIK 840Di sl NC
Default designation: NCK 840D sl
● SINUMERIK CP for Industrial Ethernet TCP/IP
Default designation: CP 840D sl

Inserting the 840Di sl Rack

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

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Manual
164 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.3 Creating a SIMATIC S7 project

NOTICE
If the interface X102 is not networked with PROFIBUS, then it must at least be networked
with MPI, in order to enable the internal communication via SOFTMC. See Subsection
"Parameterizing the MPI interface (X102) (optional)" (Page 169)

6.3.5 Parameterizing the PROFIBUS interface (X101)

When you have inserted the 840Di sl Rack, the dialog box for assigning parameters to the
PROFIBUS interface (X101) opens automatically as for slot X2. Make the following settings
in the Properties box:
● PROFIBUS address of the DP master
The default setting of the PROFIBUS address is 2. It is recommended to retain this
setting.
● Subnet
● Equidistant DP cycle
● Equidistant time

Equidistant time
The set equidistant DP cycleis accepted in case of SINUMERIK 840Di sl as NC system clock
cycle and position controller cycle.
Position controller cycle = NC system clock cycle = equidistant DP cycle
The time you can set for the equidistant DP cycle depends on:
1. 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

Dialog: Properties - PROFIBUS interface DP

Tab: Parameter
Address: 2
Subnet:
Button: "New..."
Dialog: Properties - New Subnet PROFIBUS
Tab: General
S7 subnet ID: <Subnet ID> (see below: Note)
Tab: Network settings

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PLC commissioning
6.3 Creating a SIMATIC S7 project

Data transfer rate: 12 Mbps

Profile: DP
Button: "Options..."
Dialog: Options
Tab Equidistant
Active equidistant bus cycle: ☑
Equidistant DP cycle: <Equidistant time>
OK
OK
OK

Note
S7-Subnetz-ID (S7 subnet ID)
It is recommended to note the S7-Subnetz-ID (S7 subnet ID) , because it will be needed later
for parameterization of the routing settings:
• SINAMICS: See Section Create new project without Project Wizard (Page 310)
• SIMODRIVE: See Section Setting the routing information (Page 351)

Manual
166 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3.6 Parameterizing the PROFIBUS interface (X102) (optional)

When you have completed the "Properties - PROFIBUS DP Interface" dialog box (see
Subsection "Parameterizing the PROFIBUS interface (X101)" (Page 165)) the 840Di sl Rack
is displayed in the Station window.

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To parameterize the PROFIBUS interface (X102) as for slot X1, set the following parameters:
● Interface type
● Transmission rate
By double-clicking the module MPI/DP, slot X1 in the 840Di sl-rack, open the properties
dialog of MPI/DP.

Manual
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PLC commissioning
6.3 Creating a SIMATIC S7 project

Dialog

Dialog: MPI/DP Properties

Tab: General
Name: <Designation of 2nd DP interface>
Group: Interface
Type: PROFIBUS
Button: "Properties..."
Dialog: Properties - PROFIBUS interface MPI/DP
Tab: Parameter
address: <Address>
Button: "New..."
Dialog: Properties - New Subnet PROFIBUS
Tab: Network settings
Data transfer rate: <Data transfer rate>
Profile: DP
OK
Tab: Mode
Radio button: <Mode>
OK
OK

NOTICE
If the interface X102 is not networked with PROFIBUS, then it must at least be networked
with MPI, in order to enable the internal communication via SOFTMC. See Subsection
"Parameterizing the MPI interface (X102) (optional)" (Page 169)

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168 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3.7 Parameterizing the MPI interface (X102) (optional)

The interface X102 needs to be networked only with MPI, if the interface is not networked
with PROFIBUS.
When you have completed the "Properties - PROFIBUS DP Interface" dialog box (see
previous Subsection "Parameterizing the PROFIBUS interface (X101)" (Page 165)) the
840Di sl Rack is displayed in the Station window.
To parameterize the MPI interface you will have to make the following parameter settings:
● Interface type
● Transmission rate
By double-clicking the module MPI/DP, slot X1 in the 840Di sl-rack, open the properties
dialog of MPI/DP.

Dialog

Dialog: MPI/DP Properties

Tab: General
Group: Interface
Type: MPI
Button: "Properties..."
Dialog: Properties - PROFIBUS interface MPI/DP
Tab: Parameter
address: 2 (see note)
Subnet: MPI(1) 187.5 kBaud
OK
OK

NOTICE
With SINUMERIK 840Di sl, the MPI address of the PLC must always be set to 2.

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PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3.8 Parameterization of the communications processor (CP 840D sl) (Ethernet)

The following parameters must be set for parameterizing the integrated communications
processor "CP 840D sl":
● IP address of the PCU
● Subnet mask of the PCU
● PCU gateway type
● Subnet

Note
Determining the IP address and subnet mask of the PCU:
At the PCU: Windows XP taskbar: Start > Execute, command: ipconfig

By double-clicking the module CP 840D sl, slot 5 in the 840Di sl-Rack, open the properties
dialog:

Dialog

Dialog: Properties - CP 840D sl

Tab: General
Group: Interface
Button: "Properties..."
Dialog: Properties - Ethernet interface CP 840D sl
Tab: Parameter
IP Address: <IP address of the PCU> (1)
Subnet mask: <Subnet mask of the PCU> (2)
Group: gateway
Option: Do not use router (3)
Group: Subnet
Button: "New..." (4)
Dialog: Properties - New subnet Ind. Ethernet
Name: <Name>
OK
OK
OK

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 PLC commissioning
6.3 Creating a SIMATIC S7 project

Properties - Ethernet Interface CP 840D sl (R0/S5)

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NOTICE
The IP address and subnet mask in the figure above are only sample values!

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PLC commissioning
6.3 Creating a SIMATIC S7 project

6.3.9 Networking PG/PC and PCU (Ethernet)

In order that external components connected via Ethernet, e.g. PG/PC with the SINAMICS
drive commissioning tool STARTER or SIMATIC Step 7, can communicate with SINUMERIK
840Di sl and SIMATIC drive units, the PG/PC must be linked to the PCU in the S7 project.

Implementation
Perform the following actions for networking:
1. Start the NetPro configuration tool in HW Config.
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2. From the selection list of the network objects, open Stations and insert a PG/PC into the
project (1).
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Double-click on the inserted PG/PC station to open the Properties dialog box. Select the
"Interface (1)" tab. Click on "New..." to open the dialog box for creating a new interface (2).
Select "Industrial Ethernet (3)" as the interface type. Click OK to confirm the dialog.

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172 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.3 Creating a SIMATIC S7 project

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3. After confirming with OK, the properties dialog box of the Ethernet interface is displayed.
Select the "Parameter (1)" tab and enter the IP address and subnet mask of the PG/PC
(2).

Note
Determining the IP address and subnet mask of the PG/PC:
At PG/PC: Windows XP taskbar: Start > Execute, command: ipconfig
Select the "Ethernet (1)" (3) connection already parameterized in the previous Subsection
"Parameterizing the communication processor (CP 840D sl) (Ethernet)" (Page 170) as
the subnet.
Click OK to confirm the dialog.

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Manual
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PLC commissioning
6.3 Creating a SIMATIC S7 project

NOTICE
The MAC address, IP address and subnet mask in the figure above are only sample
values!

4. The configured Ethernet interface must be assigned to an interface parameterization of

the PG/PC. Select the "Assignment" (1) tab.
Select the configured "Ethernet (1)" (2) interface from the "Configured interfaces" list and
the Ethernet interface for connecting to the PCU from the "Interface parameterization in
the PG/PC" list. In the example: "TCP/IP -> Realtek RTL8139..." (3).

NOTICE
Do not select ISO interfaces as Ethernet interfaces from the "Interface parameterization
in the PG/PC" list, e.g. "ISO Ind. Ethernet - Realtek RTL8139...". Instead, use the
appropriate TCP/IP interfaces, e.g. "TCP/IP - Realtek RTL8139...".

Click on the "Assign" button to assign the interface (4).

Confirm the "Edit object properties" dialog by clicking on OK.
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The list "Assigned" now contains the Ethernet interface (1). If several interfaces are
assigned, make sure that the interface to be used for communication, "Ethernet (1)" in
this case, is active. To do this, select the interface (Ethernet (1)) and activate the S7
online access for this interface (2). Click OK to confirm the dialog.

Manual
174 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.3 Creating a SIMATIC S7 project

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5. The PG/PC networking with the Ethernet interface is displayed in the project view and
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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 175
PLC commissioning
6.3 Creating a SIMATIC S7 project

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NetPro can then be shut down.

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176 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.4 Creating a PLC program

6.4 Creating a PLC program

6.4.1 PLC basic program

Opening the library

For inserting the basic PLC program in the created S7 project SIN840Di sl open the library
installed in the Subsection "Installation of the basic PLC program library" (Page 151) via the
menu command File > Open.
Select the library for the PLC basic program, e.g. gp8x0d65, and confirm the dialog with
"OK".

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Figure 6-8 Opening the library of the PLC basic program

Copying blocks
Copy all blocks of the PLC basic program from the library to the block directory of the PLC.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 177
PLC commissioning
6.5 Creating a PROFIBUS configuration

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Overwrite OB1
Inserting blocks overwrites the existing organization block OB1. Confirm the query as to
whether you want to overwrite the block with "Yes".

6.4.2 PLC user program

The PLC user program according to its definition contains all functions required to process
user-specific automation tasks. Tasks of the PLC user program include:
● 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 analog values.
● Responding to alarms
● Error handling 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 automation task.

6.5 Creating a PROFIBUS configuration

Creation of a PROFIBUS configuration is described in a separate section. See Chapter
"PROFIBUS DP communication" (Page 229).

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178 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.6 Load configuration (STEP 7 -> PLC)

6.6 Load configuration (STEP 7 -> PLC)

6.6.1 Requirements
For loading the configuration into the PLC, the following prerequisites must be fulfilled:
● A communications link exists between STEP 7 and the PLC.
● The configuration to be loaded corresponds to the actual station configuration.
● SINUMERIK 840Di sl is active:
– NC: Cyclic operation
– PLC: RUN or STOP mode

6.6.2 Uploading the configuration

Note
It is recommended to check consistency of the configuration before loading it.
HW Config: Station > Check consistency

Supplementary condition
The following boundary 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.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 179
PLC commissioning
6.6 Load configuration (STEP 7 -> PLC)

Download to module
To load the configuration into the PLC select the following menu item Target system > Load
in module.
The dialog box for loading the configuration now displayed offers the following options:
● Set the PLC to the operating status STOP. See note below.
● Compress the memory if not enough contiguous free memory is available
● 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 mode before
loading the configuration.

Initiate NC Reset
The STOP mode of the PLC 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 response.
Once the configuration has been loaded you must therefore initiate an "NC Reset", for
example, via the "840Di-Startup" user interface. In "840Di-Startup" select menu command
Window > Diagnosis > NC/PLC:

Dialog

Dialog: NC/PLC Diagnosis

Group NC
Button: "NC Reset"

6.6.3 Series startup file

The PLC user data can be backed up by creating a series-startup file or loading an existing
series startup file using the following applications:
● SinuCom NC (part of the SINUMERIK 840Di sl installation)
● HMI Advanced (optional)
For detailed information about data back-up please refer to Chapter "User data
backup/series commissioning" (Page 541) or:
References:
SinuCom NC: Online help
HMI Advanced: /BAD/ Operating Manual HMI Advanced

Manual
180 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 PLC commissioning
6.7 Testing the PLC program

6.7 Testing the PLC program

6.7.1 Startup characteristics

Startup of a SIMATIC-CPU module can be set for the following startup modes:
● Restart
● Cold restart (Warm restart)
● Cold restart
In case of a SINUMERIK 840Di sl the startup type of the PLC is set permanently to NEW
START. It cannot be changed.

Startup mode: RESTART

Upon NEW START first the block "OB 100" is executed. Then cyclic operation starts with
call-up of block "OB1".
The following data are kept in the case of COLD RESTART:
● All data blocks and their contents
● Retentive timers, counters and flags

Retentive ranges
The ranges of the times, counters and markers, which are to be retentive, must be set via
the dialog Properties, tab Retention of the PLC-CPU-module.

NOTICE
The retention of the data areas can only be achieved with the backup supply (backup
battery) active. If the battery backup is empty, the PLC will not restart.

The following operations are performed during a restart:

● UStack, BStack and non-retentive flags, timers and counters will be 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 evaluated or defaults
parameters will be output to all modules in single-processor mode
● OB100 (cold restart) is executed
● The process input image (PII) is read in
● The command output disable (COD) is canceled

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PLC commissioning
6.7 Testing the PLC program

6.7.2 Cyclic operation

In cyclic operation, communication or exchange of data and signals is carried out between
the PLC and the components NC, HMI (e.g. HMI Advanced) and MCP (machine control
panel).
The execution of the PLC program is carried out such that - with regard to time - the basic
PLC user program is executed prior to the PLC user program.

NC communication
Communication of the PLC with the NC is carried out using the NC/PLC interface. The
interface is divided into the following areas:
● Mode groups
● Channels
● Axes/spindles
● 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 remain constant over the entire
PLC cycle.
The current G functions of the NC channels are transferred to the PLC (provided function is
activated) at the process alarm level (OB40).

Sign-of-life monitoring
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:
● Alarm "2000 sign-of-life monitoring for PLC"

6.7.3 Monitor/control using the SIMATIC Manager

The SIMATIC Manager provides extensive functionality for testing the PLC program or the
module.

Monitoring and modifying variables

The menu command Target system > Monitor/control variable is used to start the tool
"Monitor/control variable".
The following functions can be performed with "Monitor/Control Variable":
● Monitoring of variables
Display of the actual value of individual variables of the PLC user program or of the CPU
module.
● Monitoring of variables

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6.7 Testing the PLC program

Assignment of values to variables of the PLC user program or of the CPU module.
● Release PA and Activate control values
Assignment of values to I/O outputs of the PLC user program or of the CPU module in the
operating mode STOP.
● Forcing variables
Assigning values to variables of the PLC user program or CPU module that cannot be
overwritten from the PLC user program.

Variable types
The values of the following variable types can be defined or displayed:
● Inputs, outputs, bit memory, timers and counters
● Contents of data blocks
● I/O
The variables that are to be displayed or controlled are grouped in variable tables.
You determine when and how often variables will be monitored or overwritten with values by
defining trigger points and trigger conditions.

Additional test functions

The menu command Target system > ... provides the following additional test functions:
● Displaying accessible devices
● CPU messages ...
● Display force values
● Diagnosing hardware
● Module status ...
● Operating mode ...

6.7.4 Monitor/control using HMI Advanced

PLC status display

The PLC status display of HMI Advanced is 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 range switchover
> Diagnosis > PLC status.

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PLC commissioning
6.7 Testing the PLC program

Input syntax
Both the following tables show the input syntax of the fields Operand and Format of the PLC
status display.

Table 6-2 Input field: Operand

Syntax Description
En.x Input byte n, bit x
EBn Input byte n
EWn Input word n
EDn Input double-word n
DBn.DBXm.x Data block n, byte m, bit x
DBn.DBBm Data block n, byte m
DBn.DBWm Data block n, word m
DBn.DBDm Data block n, double word m
To Output n
Mn Flag n
Tn Timer n
Cn Counter n

Table 6-3 Input field: Format

Syntax Description
H Hexadecimal
D decimal
B Binary
G Floating point (only in conjunction with double word)

Monitoring
After entering the variable to be displayed in the field Operand using the syntax described
above, the actual value of the variable is displayed in the format you have set.

Controlling: Start
Use the softkey Change to switch over to the mode Control. Using the field Value the new
values for the displayed variables can now be displayed. The entered value must be within
the definition range of the set format.

Controlling: End
As long as the mode Control is active, the values entered are not imported. Only when you
quit the mode using the softkey Accept, the entered values are written to the variables and
processed in the PLC program.

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6.8 Load configuration in PG (PLC -> STEP 7)

6.8 Load configuration in PG (PLC -> STEP 7)

The configuration of a SINUMERIK 840Di sl PLC must be loaded onto an external computer
(STEP 7 PG/PC) using an Ethernet connection.

Requirements
The following conditions must be fulfilled:
● The computer can communicate via Ethernet or an Ethernet connection has been
established
● The PG/PC is connected to the Ethernet interface 1 (Company Network) of the
SINUMERIK 840Di sl PCU. (See Subsection "Ethernet connections of the PCU
50.3" (Page 187))
● The IP address of the Ethernet interface 1 (company network) of the SINUMERIK 840Di
sl PCU is known. (See Subsection "Determine Ethernet communication parameters of the
PCU" (Page 188))

Implementation
Perform the following steps to load the configuration from the target system:
1. Start STEP 7 on the external computer (PG/PC).
2. Create a new STEP 7 project to which the configuration shall be loaded.
3. Select in STEP 7 for the project via the menu bar Target system > Load station in PG.
Since the communication parameters have not yet been communicated to STEP 7, the
node address selection dialog is displayed. Enter the following data:

Dialog

Dialog: "Select node address"

Rack: 0
Slot: 2
Target station: Local
IP Address: <IP-Adr. of the Ethernet-SST 1 of the PCU>
Note:
Press the "Return" key to confirm the entry of the IP address
OK
After entering all relevant data, press OK to confirm the dialog.
The configuration is now uploaded from the controller into the project.

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6.8 Load configuration in PG (PLC -> STEP 7)

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7.1 General information

7.1.1 Ethernet connections of the PCU 50.3

3&8

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Figure 7-1 Ethernet connections of the PCU 50.3

The PCU 50.3 has 2 Ethernet connections (10/100 MBaud):

● Ethernet 1 (company network)
● Ethernet 2 (system network)
The interface: "Ethernet 1" is preset as a SINUMERIK DHCP client for connecting to a
company network or a PTP connection.

Ethernet 1
The interface: "Ethernet 2" is preset as a SINUMERIK DHCP server for connecting to a
system network with IP address 192.168.214.241.

Ethernet 2
The Ethernet components described below, e.g. Machine control panel MCP 483C IE, are
connected via this Ethernet interface.

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7.2 SINUMERIK 840Di sl commissioning tool SinuCom NC

7.1.2 Determine Ethernet communication partners of the PCU

Start a Windows console on the PCU to determine the Ethernet communication parameters
of the PCU: Windows XP Start menu Start > Execute: cmd. On the console, enter the
command ipconfig.

7.1.3 Check Ethernet connection

If there is an Ethernet connection between a SINUMERIK 840Di sl PCU with a direct
operator panel connection and another component, the connection can be checked as
followed:
1. Start a Windows console on the PCU: Windows XP Start menu: Start > Run: cmd
2. Enter the "ping" command at the console followed by the component IP address.
Example: ping 192.168.214.192
– Positive answer: "Reply from 192.168.214.192: . . . ."
– Negative answer: Request timed out. . . ."

7.2 SINUMERIK 840Di sl commissioning tool SinuCom NC

The SINUMERIK 840Di sl commissioning tool "SinuCom NC" communicates with a
SINUMERIK 840Di sl exclusively via an Ethernet connection independent of the installation
location (externally or internally).
Start the SinuCom NC Connect Wizard from the Windows XP Start menu to parameterize
the Ethernet connection: Start > Programs > SinuCom > NC Connect Wizard
Make the following settings in the NC Connect Wizard:
1. Control Mode: 840Di (any)
2. Port: RJ-45 (solutionline ONLY)
3. IP Address:
The IP address by which the SinuCom NC communicates with the SINUMERIK 840Di sl
depends on where SinuCom NC is installed:
– PG/PC (external connection)
Enter the IP address of the PCU Ethernet interface used (Ethernet 1: company
network or Ethernet 2: system network).
To determine the IP address, refer to Subsection "Determining the Ethernet
Communication Parameters of the PCU" (Page 188).
– SINUMERIK 840Di sl PCU (internal connection)
Enter the IP address 127.0.0.1 (local host).

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7.3 STARTER SINAMICS drive commissioning tool

7.3 STARTER SINAMICS drive commissioning tool

The SINAMICS STARTER drive commissioning tool communicates with the SINAMCS S120
drives via PROFIBUS only.
If the STARTER is connected to the SINUMERIK 840Di sl via Ethernet link, within the
framework of the S7 project for configuring the PLC the PG/PC on which the STARTER runs
must be linked by means of SIMATIC STEP 7 "NetPro" with the SINUMERIK 840Di sl. The
SINUMERIK 840Di sl PLC then routes the STARTER on the PROFIBUS to the SINAMICS
drives
The networking is described in Subsection "Networking of PG/PC and PCU
(Ethernet)" (Page 172).

Note
The SINAMICS STARTER drive commissioning tool can only be operated currently on a
SINUMERIK 840Di sl PCU if at least one of the two Ethernet interfaces is active. To do this,
at least one component must be connected to the relevant Ethernet interface, e.g. an "MCP
483C IE" machine control panel to Ethernet interface 2 (system network), and communicate
with the SINUMERIK 840Di sl.

7.4 External HMI Advanced

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

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6XEQHWVFUHHQIRUP

Figure 7-2 Example of a possible Ethernet connection

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Ethernet communication
7.4 External HMI Advanced

Note
There are no restrictions in terms of Ethernet topology within the SINUMERIK 840Di sl PCU
and HMI PCU.

Requirements
The following requirements must be fulfilled:
● There is an Ethernet connection between SINUMERIK 840Di sl PCU and HMI PCU and
both computers communicate.
● The communication parameters of the SINUMERIK 840Di sl PCU Ethernet interface with
which the HMI PCU is connected are known.
To check an Ethernet connection, see Subsection "Check Ethernet
Connection" (Page 188).

HMI configuration
The configuration of HMI Advanced, with respect to the Ethernet connection to the
SINUMERIK 840Di sl, is performed as follows:
1. Start HMI Advanced.
2. Open the dialog for entering the IP address: Operating area switchover > Startup > HMI >
NCU link > NCU address
3. Enter the IP address of the interface by which the HMI communicates with the
SINUMERIK 840Di sl.
Example:
Interface: Ethernet 2 (system network)
IP Address: 192.168.214.241 (default)

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7.5 MCP 483C IE

7.5 MCP 483C IE

Figure 7-3 MCP 483 Front panel; Version T (turning machines)

7.5.1 Conditions for general commissioning

Hardware
The following hardware is required:
● Ethernet connecting cable

Software
The following software is required:
● PLC basic program
The relevant modules of the basic PLC program are FB 1 (MCP communication
parameters), FC 19 (Interface parameter assignment, version: milling) and FC 25
(interface parameter assignment version: turning).
The library of the PLC basic program is part of the SINUMERIK 840Di sl. How to install
the library is described in detail in Section "Create PLC Program" (Page 177).
● SIMATIC STEP 7
SIMATIC STEP 7 is needed to customize the PLC basic and user programs to the
requirements of the respective automation system. SIMATIC STEP7 can be installed
directly on the PCU of the SINUMERIK 840Di sl. How to install additional software is
described in the Section "License Management" (Page 563).

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Ethernet communication
7.5 MCP 483C IE

References:
The following manuals are required for the commissioning of the MCP:
/FB1/Function Manual, Basic Functions Subsection P3, PLC Basic Program, Program
structure and modules of the PLC basic program.
/FB2/Function Manual, Extended Functions, Section H1, Manual and Handwheel Travel,
Commissioning of handwheels
/BHsl/Operator Components Manual, Description of MCP (interfaces, electrical connection,
etc.)
/Z/ Catalog NCZ, Connection components: Cables, connectors, etc.

Automation system
To commission the MCP the automation system must be completely electrically and
mechanically connected with respect to NC, PLC and MCP.
The drives must be secured against accidental moving.

7.5.2 Parameterization of the MCP

Interfaces
In the following figure, the interfaces are shown on the rear side of the module:

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Figure 7-4 Position of interfaces on rear side of machine control panel

For a detailed description of the electrical and mechanical design and of the machine control
panel interfaces, please refer to:

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7.5 MCP 483C IE

References:
/BHsl/ Operator Components Manual, Chapter "Machine Control Panel MCP 483C IE"

Display of the software version

After the MCP has been electrically connected, all LEDs on the front side of the MCP flash
until communication is established between MCP and PLC.
To activate the display you must press the "Feed stop" and "Feed enable" keys
simultaneously. The Version No. of the current software version is then displayed with the
help of the continuously illuminated LEDs.
Example: Software version: V 01.02.00

1. Digit 1) 2. Digit1) 3. Digit1)

Pressing the keys "Feed enable" and "Feed stop" 1 2 0
simultaneously
1) Display of the digit by means of continuously illuminated LEDs on the individual LED blocks
according to the following figure

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OHIW/('EORFN PLGGOH/('EORFN ULJKW/('EORFN

Figure 7-5 Display of software version: 1 . 2 . 0

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Ethernet communication
7.5 MCP 483C IE

Display of the IP address

After the MCP has been electrically connected, all LEDs on the front side of the MCP flash
until communication is established between MCP and PLC.
To activate the display you must press the "Feed stop" and "Feed enable" keys
simultaneously. The Version No. of the current software version is then displayed with the
help of the continuously illuminated LEDs first. Press the "Enable spindle" key to switch to
the four positions of the IP address. One position of the IP address is displayed with each
key actuation, starting with the one having the max. value.
Example default IP address: 192.168.214.192

Pressing the "Spindle enable" 1. digit 1) 2. Digit1) 3. Digit1) Digit of the IP

key n times address
1 1 9 2 1
2 1 6 8 2
3 2 1 4 3
4 1 9 2 4
1) Display of the digit by means of continuously illuminated LEDs on the individual LED blocks
according to the following figure

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Figure 7-6 Display of the 1st digit of the IP address: 192

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 (delivery state)
● TTL handwheels
Switch S1 open

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7.5 MCP 483C IE

Switch S2
Switch S2 is used to set the address by which the MCP is addressed by the PLC user
program:

Table 7-1 Switch S2: MCP address (1-8)

10 9 8 7 6 5 4 3 2 1 Meaning/value
off off - - - - - - - - Reserved
MCP address
- - off off off off off off off off 0
- - off off off off off off off on 1
- - off on off off off off on off 2
- - off off off off off off on on 3
- - : : : : : : : : :
- - on on off off off off off off 192 (on delivery)
- - : : : : : : : : :
- - on on on on on on on off 254
- - on on on on on on on on 255

7.5.3 MCP functions

The MCP offers the following functions:
● Standard
The input/output data of the MCP 483 is compatible with the input/output data from the
PROFIBUS MCP: MCP 483 and MCP 310.
● Handwheel
Up to 2 handwheels can be connected to the MCP. For each handwheel the current
handwheel value is transferred as a 16-bit absolute value relative to the starting value.
The starting value for the sensor counter in the handwheel is 0.
● Additional I/Os
Cover the additional I/Os:
– Customer keys (KT1 to KT9)
– Customer key outputs (KT_OUT1 to KT_OUT6)
– RESET output (R14_LED)
– Rotary switch (X31)

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Ethernet communication
7.5 MCP 483C IE

7.5.4 Linking to the basic PLC and user program

This Chapter describes how to link the MCP 483C IE:
● to the PLC basic program for transferring standard I/O data to the VDI interface
● to the PLC user program (optional) to implement a user-specific response to a module
failure

NOTICE
Processing of additional I/O data is the sole responsibility of the user (machine
manufacturer) and is not supported by the PLC basic program.

PLC basic program

To transfer standard MCP 483C IE input/output data via the PLC basic program, the MCP
address configured by means of the S2 switch on the module must be entered in the
communication parameters of the FB 1 function block.
Function module FB 1:
The communication 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 an MCP 483C IE on a SINUMERIK 840Di sl, the following parameters are
relevant:

MCPNum: INT // Number of MCP

MCP1In: POINTER // Address of input signals
MCP1Out: POINTER // Address of output signals
MCP1BusAdr Byte // MCP address (switch S2)
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
MCP2BusAdr Byte // MCP address (switch S2)
Bus type via which the MCP is connected:
MCPBusType Byte // Ethernet = B#16#55

NOTICE
Parameters: MCPxStop and MCPxNotSend are of no significance.

References:
For a detailed description of the PLC basic program or of function block FB 1, please refer to:
/FB1/ Function Manual - Basic Functions; P3 Basic PLC Program, Chapter "FB 1: RUN_UP
Basic program, startup section

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VDI interface parameter assignment

The following function blocks are available to transfer the MCP signals to the VDI interface:
● FC 19: MCP_IFM, version M (milling)
● FC 24: MCP_IFM2, version M (milling)
● FC 25: MCP_IFT, version T (turning)

NOTICE
Function blocks FC 19, FC 24 and FC 25 are part of the PLC basic program. It is the
user's (machine manufacturer's) responsibility to call the block correctly 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/ Function Manual - Basic Functions; P3 Basic PLC Program, Section "FC 19:
MCP_IFM ...", Section "FC 24: MCP_IFM2 ...", Section "FC 25: MCP_IFT ..."

Example
The following example shows the communication parameter settings for function block FB 1
for an MCP:

MCPNum := 1 // Number of MCP

MCP1In := P#E0.0 // Address: Input data
MCP1Out := P#A0.0 // Address: Output data
MCP1BusAdr := 192 // MCP address (switch S2)
MCP1Timeout := S5T#700MS // Default setting
MCPMPI := FALSE // No MPI bus
MCP1Stop := FALSE // Deactivation of the DP slave MCP
MCP1NotSend := FALSE // Send and receive operation activated
MCPSDB210 := FALSE // No SDB210 for MCP
MCPCopyDB77 := FALSE // No copying to DB77
MCPBusType := B#16#55 // Ethernet

MCP failure
The basic PLC program detects an MCL failure even if no data is exchanged between MCP
and PLC. For instance, after a PLC restart.
The monitoring function is activated as soon as all components have signaled "Ready" after
powerup.
An alarm is displayed on the user interface if an MCP fails:
● 1. MCP alarm: "400260 Failure of machine control panel 1"
● 2. MCP alarm: "400261 Failure of machine control panel 2"

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7.5 MCP 483C IE

Note
The MCP 483C IE is connected via an Ethernet interface of the PCU. Since the
communication of the MCP with the SINUMERIK PLC is based on Windows components,
the MCP monitoring time may be exceeded in the following cases:
• 1. Cause: Windows XP identifies a fatal exception error (blue screen)
Possible measure: none
• 2. Cause: Impairment of Ethernet communication through unsuitable PC components.
Possible measure: Increase in MCP monitoring time (parameter: MCPxTimeout)

7.5.5 Input/output image

Arrangement: Keys and LEDs

A key and the LED positioned above it form a logical unit. The key and the LED have the
same number.
● Key number xy corresponds to Sxy
● LED number xy corresponds to LEDxy
The following figure 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.

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/('V

6 6 6 6 6 6 6 6 6 .H\

6 6 6 6 6 6 6 6 6

6 6 6 6 6 6 6 6 6

6 6 6 6 6 6 6 6 6

6 6 6 6 6 6 6 6 6 6 6 6 6 6

Figure 7-7 Keyboard layout MCP 483C IE (front view)

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Input image
The following information is to be found in the table for each input bit:
● 1. Row: Default designation
● 2. Row: Key number (Sxy) or feedrate override switch (X30/X31), keyswitch (X50)

Table 7-2 Assignment of the key signals in the input image

Signals from machine control panel (keys)

Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
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 S01 S04 S07 S10
EB n+1 Machine functions
REPOS REF var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
S02 S03 S05 S12 S11 S09 S08 S06
EB n+2 Key Pos. 0 Key Pos. 2 Spindle *Spindle Feed start *Feed Stop NC Start *NC Stop
X50.4 X50.1 Start Stop S50 S49
S48 S47 S16 S15
EB n+3 RESET Key Pos. 1 Single Feed override
X50.6 block Override Override Override Override Override
S13 S14 F.over.16 Feed 8 F.over.4 F.over.2 F.over.1
X30.6 X30.7 X30.8 X30.9 X30.10
EB n+4 Arrow keys Key Pos. 3 Axis selection
R15 R13 R14 X50.3 R1 R4 R7 R10
S46 S44 S45 S32 S35 S38 S41

EB n+5 Axis selection MKS/WKS R11 R9 Axis selection

R2 R3 R5 S43 S42 S40 R8 R6
S33 S34 S36 S39 S37
EB n+6 Freely assignable customer keys
T9 T10 T11 T12 T13 T14 T15 -
S25 S26 S27 S28 S29 S30 S31
EB n+7 Freely assignable customer keys
T1 T2 T3 T4 T5 T6 T7 T8
S17 S18 S19 S20 S21 S22 S23 S24
EB n+8 - - - - - - - -
EB n+9 - - - - - - - -
EB n+10 - - - - - - - -
EB n+11 - - - - - - - -
EB n+12 - - - Override Override Override Override Override
spindle16 spindle8 spindle4 spindle2 spindle1
* Inverse transferred signals signals
- free signals
Note
Free signals are transferred from the MCP with 0.

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7.5 MCP 483C IE

Output image
The following information is to be found in the table for each output bit:
● 1. Row: Default designation
● 2. Row: LED number

Table 7-3 Assignment of the LED signals in the input image

Signals to machine control panel (keys)

Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
AB n+0 Machine function Mode
1000 INC 100 INC 10 INC 1 INC JOG TEACH MDA AUTO
LED11 LED09 LED08 LED06 LED01 LED04 LED07 LED10
AB n+1 Feed Start Feed Stop NC Start NC Stop Machine function
LED50 LED49 REPOS REF var. INC 10000 INC
LED16 LED15 LED02 LED03 LED05 LED12
AB n+2 Axis selection Single Spindle Spindle
R13 R1 R4 R7 R10 Block Start Stop
LED44 LED32 LED35 LED38 LED41 LED48 LED47
LED14
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
selection
T9 T10 T11 T12 T13 T14 T15 R2
LED25 LED26 LED27 LED28 LED29 LED30 LED31 LED33
AB n+5 Freely assignable customer keys
T1 T2 T3 T4 T5 T6 T7 T8
LED17 LED18 LED19 LED20 LED21 LED22 LED23 LED24
AB n+6 - - - - - - RESET R14
LED13 LED45
(optional) (optional)
AB n+7 - - KT_OUT6 KT_OUT5 KT_OUT4 KT_OUT3 KT_OUT2 KT_OUT1
- Free signals
Note
We recommend setting free signals to 0 in the user program.

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7.6 HT 8

7.6 HT 8

7.6.1 Conditions for general commissioning

Hardware
An HT 8 is connected to the SINUMERIK 840Di sl via one of the following interface modules,
and not directly:
● Terminal box PN Basic
● Terminal box PN Plus
● Connection module Basic PN
● Machine Pushbutton Panel MPP 483 HTC

Software
The following software is required:
● PLC basic program
The relevant modules of the basic PLC program are:
– FB 1 (MCP communication parameters)
– FC 26 (HPU_MCP transfer of HT8 signals from/to the VDI interface)
The library of the PLC basic program is part of the SINUMERIK 840Di sl. How to install
the library is described in detail in Section "Create PLC Program".
● SIMATIC STEP 7
SIMATIC STEP 7 is needed to customize the PLC basic and user programs to the
requirements of the respective automation system. SIMATIC STEP7 can be installed
directly on the PCU of the SINUMERIK 840Di sl. How to install additional software is
described in Chapter "License Management".
References:
The following references are required for connecting and commissioning an HT 8:
Function Manual, Basic Functions,
Chapter P3, PLC Basic Program, Program structure and modules of the PLC basic program
Device Manual - Operator Components and Networking,
Chapter Handheld Terminal HT 8
Catalog NCZ, Connection components: Cables, connectors, etc.

Automation system
To commission an HT 8, the automation system must be completely electrically and
mechanically connected with respect to NC, PLC, connecting device and HT 8.
The drives must be secured against accidental moving.

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7.6.2 Parameterization of the power supply unit

Set identification
The following figure displays the relevant position of the rotary coding switches S1 and S2 in
the different power supply units.

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Figure 7-8 Position of the rotary coding switches S1 and S2

The ID of the relevant power supply unit is defined via the rotary coding switches S1 and S2.
The setting of the ID is hexadecimal. S1 defines the higher value position, while S2 defines
the lower value position.

Ranges of values
The value range that can be defined via S1 and S2 is 0H to 255H.
The valid value range for the ID is 1H to 254H.

Note
The ID must be unique across all the existing power supply units in the system network.

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7.6.3 Parameterization of the HT 8 via the TCU firmware

HT 8 detected as new TCU

If the HT 8 is connected to the PCU and it is detected as a new TCU, the TCU firmware for
defining the HT 8 parameters is started automatically. The following dialog is displayed in the
HT 8:

New TCU
New TCU 'DIP<ID>' registered.
Edit TCU Settings or use defaults?
Def. Edit

Softkey <Def.>
The following default values are taken as TCU parameters via the <Def.> softkey:
● Individual Mode: no
● TCU index: <Identifier>
● MCP address: <Identifier>
● EKS index: 0
● Enable direct keys: no
Softkey <Edit>
The <Edit> softkey is used to open the dialog: "TCU Settings". The following parameters can
be changed:
● Individual Mode: no (recommended setting), yes
● EKS index: <Index> (currently without function)
● Enable direct keys: no, yes

Note
Identifier
The hexadecimal identifier of the power supply unit defined via the rotary coding switches
S1 and S2 is displayed within the framework of the TCU firmware or the system network
center.

Changing TCU parameters subsequently

To change the TCU parameters subsequently, the TCU firmware can be activated at any
time by pressing the "Recall" and "Menu Select" keys simultaneously.

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Figure 7-9 <Recall> and <Menu Select> keys

Softkey <TCU Settings>

The dialog for setting the TCU parameters is called via the <TCU Settings > softkey. The
following parameters can be changed:
● Individual Mode: no (recommended setting), yes
● EKS index: <Index>
● Enable direct keys: no, yes

"MCP Address" and "TCU Index" parameters

The identifier of the power supply unit set is taken as MCP address and TCU index via the
rotary coding switches S1 and S2. The values cannot be changed via the TCU firmware.

"TCU Name" parameter

The name of the TCU or HT 8 is generated automatically. The name is formed from "DIP"
followed by the decimal value of the identifier of the power supply unit. The name cannot be
changed via the TCU firmware.

Table 7-4 Example

Identifier: 27H = 39D TCU name: DIP39

7.6.4 Parameterization of the HT 8 via the system network center

Change the "Name" parameter

The name was set to "DIP<identifier>" via the TCU firmware. The name can be changed in
the system network center. To do so, proceed as follows:
1. Start the system network center via the corresponding connection on the service desktop.
2. Open the tab: OPs
3. Double-click on the line in the "Available OPs" area in which the HT 8 whose Name
parameter is to be changed is displayed. In the example: "DIP39":

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4. Change the name of the TCU. In the example: "HT_8_1".

The name must be made up of alphanumeric characters and underscores.

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NOTICE
Changing the parameters
Only the name can be changed via the Properties dialog of TCU. All other parameters
must be changed either via the TCU firmware on HT 8 (direct key actuation, EKS index)
or on power supply unit (MCP address and TCU index by changing the identifier).

7.6.5 Linking to the basic PLC and user program

7.6.5.1 Linking to the basic PLC program (FB1)

Parameters of the FB1 function block

The following parameters must be set for MCP to operate in a SINUMERIK 840i sl:

MCPNum: INT // Number of MCP

MCP1In: POINTER // Address of the input signals from HT 8
MCP1Out: POINTER // Address of the output signals to HT 8
MCP1Timeout S5TIME // Monitoring time
MCP1BusAdr 1) INT // MCP address
MCPBusType BYTE // Type of connection
1) The identifier of the power supply unit set in decimal form via the rotary coding switches S1 and S2
must be entered in the MCP1BusAdr parameter

Example
The following example shows the communication parameter settings for function block FB 1
for an MCP:

MCPNum := 1 // Number of MCP

MCP1In 1) := P#E0.0 // Address of the input signals from HT 8
MCP1Out 1) := P#A0.0 // Address of the output signals to HT 8
MCP1BusAdr 2) := 39 // MCP address (switches S1 and S2)
MCP1Timeout := S5T#700MS // Default setting
MCPBusType := B#16#55 // Ethernet
1) References
The description of the input and output signals of the HT 8 can be found in:
/LIS2sl/ Lists sl (Book 2), signals from and to the handheld programming device HT 8
2) The identifier of the power supply unit set via the rotary coding switches S1 and S2 or the HT 8
parameter "MCP address" is to be entered as MCP1BusAdr. Set to the value 27H = 39D in the
previous chapters as an example.

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Several MCPs
A maximum of 2 machine control panels are supported by the basic PLC program. The
communication parameters of the MCP are called MCPx... (x = 1 or 2) in function block FB1.
To synchronize several MCPs, the PLC program must be adapted accordingly. This is the
user's (machine manufacturer's) responsibility.

MCP failure
The basic PLC program detects an MCL failure even if no data is exchanged between MCP
and PLC. For instance, after a PLC restart.
The monitoring function is activated as soon as all components have signaled "Ready" after
powerup.
An alarm is displayed on the user interface if an MCP fails:
● 1. MCP alarm: "400260 Failure of machine control panel 1"
● 2. MCP alarm: "400261 Failure of machine control panel 2"

Note
An HT 8 is connected to the PCU via Ethernet. Since the communication of the MCP with
the SINUMERIK PLC is based on Windows components, the MCP monitoring time may
be exceeded in the following cases:
• 1. Cause: Windows XP identifies a fatal exception error (blue screen)
Possible measure: none
• 2. Cause: Impairment of Ethernet communication through unsuitable PC components.
Possible measure: Increase in MCP monitoring time (parameter: MCPxTimeout)

References
For a detailed description of the PLC basic program or of function block FB 1, please refer to:
/FB1/ Function Manual - Basic Functions; P3 Basic PLC Program, Chapter "FB 1: RUN_UP
Basic program, startup section

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7.6.5.2 Signal transmission from/to NC/PLC interface (FC26)

Description of functions
The FC 26 function "HPU_MCP (machine control panel signals of the handheld unit HT8"
transfers the HT 8 specific signals of the following functions between the HT 8 input/output
data area parameterized in the FB 1 function module (parameter: MCPxIn and MCPxOut)
and the NC/PLC interface:
● Operating modes
● INC machine function
● WCS or MCS coordinate system
● Axial traversing keys
● Axis selection
● Feed override
● Rapid traverse override
● Key switch information

Note
The FC 26 function is a part of the basic PLC program. The user (machine manufacturer)
is responsible for calling the function.

Parameter

Parameter Type Comment

BAGNo BYTE Upper Nibble
number of the MCP whose signals are to be transferred. 0 = 1. MCP, 1 =
2nd MCP
Lower Nibble
number of BAG in which the BAG-specific interface signals are to be
transferred. There is no processing of BAG-specific signals for BAG no. 0.
Value range
1st MCP: B#16#00 - B#16#0A
2nd MCP: B#16#10 - B#16#1A
ChanNo BYTE Number of the channel in which the channel-specific interface signals are
to be transferred. There is no processing of channel-specific signals for
Channel no. 0.
Range of values:
B#16#00 - B#16#0A

References
For a detailed description of the FC 26 function, refer to:
/FB1/ Function Manual - Basic Functions; P3 Basic PLC Program, Chapter "FC 26:
HPU_MCP ..."

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Examples
Call of FC 26 for the first MCP, for the first mode group and the first channel of the NC.

BAGNo := B#16#01 // 1. MCP, 1st mode group of the NC

ChanNo := B#16#01 // 1. Channel of NC

Call of FC 26 for the second MCP, for the second data group and the third channel of the NC.

BAGNo := B#16#12 // 2. MCP, 2nd mode group of the NC

ChanNo := B#16#03 // 3. Channel of NC

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7.6.5.3 Overview of traversing keys

The following figure shows an overview of the activation, display and inscription of the data
relevant to the traversing keys

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(1) Table of the machine axis numbers

The table is to record the axis numbers of the machine axes on which the traversing keys
are to have an effect.

(2) Table of the machine axis names

The traversing keys are inscribed with the machine axis names recorded in the table by
default, if no machine axis names are defined in the HMI file.

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(3) HMI file HT8_xx.INI

The language-dependent inscription of the traversing keys can be defined in the HMI file
HT8_xx.INI in the [Axiskey text] character strings section

(4) Mapping of keys

The mapping of keys in the NC/PLC interface is shown by the following table:

Keyboard layout NC/PLC interface signal

SF1, SF2 EB n + 6, Bit 4, Bit 5
SF3, SF4 EB n + 6, Bit 2, Bit 3
Ax<n> + / - EB n + 3 / n + 4, Bit 0 - Bit 5

Note
Keys SF1 - SF4
The SF1 to SF4 softkeys are not assigned. The functionality must be implemented by the
user (machine manufacturer) in the PLC user program. The keys cannot be inscribed.

(5) Switching traversing key signals and axes

Traversing key signals
The traversing key signals are transferred by the FC 26 functions in the active MCS
coordinate system to the traversing key signals of the machine axes recorded in DB 10,
DBB 8 - 13 (1st MCP) or DB 10 DDB 32 - 37 (2nd MCP).

NC/PLC interface signal Signal designation Machine axis from:

EB n + 2 / n + 3, Bit 0 Ax1 + / - DB 10, DBB 8
EB n + 2 / n + 3, Bit 1 Ax2 + / - DB 10, DBB 9
etc.
The FC 26 function transfers the traversing key signals Ax1 to Ax3 +/- to the traversing key
signals of the geometry axes of the specified channel in the active WCS coordinate system
(FC 26 parameter: "ChanNo"). See also Chapter Activate traversing keys (Page 212)
Switch over axes
The axis switchover request can be used to write e.g. the next 6 machine axes in the table in
DB 10, DBB 8 - 13 (1st MCP) or DB 10 DDB 32 - 37 (2nd MCP) in the PLC user program.

(6) Dispay traversing keys

The display of the traversing key inscription can be requested with the output signal in the
PLC user program.

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(7) Displayed traversing keys

The traversing key inscription is displayed at the position of the vertical softkeys of the HMI
interface. The character strings for inscription are taken from MD 10000 or the HMI file
HT8_xx.INI.

(8) No machine axes and Axes 7 - n selected in WCS.

Both output signals can be used to stop the traversing of the machine axis in the active WCS
fully.

See also
Activate traversing keys (Page 212)
Display traversing keys (Page 214)

7.6.5.4 Activate traversing keys

A maximum of 6 machine axes can be traversed via the traversing keys of the HT 8. The
traversing key signals are located in the input data area under:
● EB n + 2, Bit 0 - Bit 5 (positive traversing direction)
● EB n + 3, Bit 0 - Bit 5 (negative traversing direction)
The FC 26 function is used to transfer the traversing key signals from the input data area to
the NC/PLC interface.

Configuration of the machine axes

For the machine axes on which the traversing key signals from the input ranges EB n + 2 /
EB n + 3, Bit 0 - Bit 5 (traversing keys +/-) are to act, the corresponding axis numbers m
(where m = 1, 2, ..., max. number of machine axes) must be entered in the following tables in
bytes:
● Machine axis table, 1st MCP: DB10.DBB8 to DBB13 (Table of machine axis number)
● Machine axis table, 2nd MCP: DB10.DBB32 to DBB37 (Table of machine axis number)
The lengths of the machine axis tables can be specified for FC 26 via the following
parameters:
● Machine axis table, 1st MCP: DB10.DBB30 (upper limit of machine axis table)
● Machine axis table, 2nd MCP: DB10.DBB54 (upper limit of machine axis table)
A value of e.g. 4 means that only the first four table entries or machine axes will be observed
by FC 26. The maximum value for FC 26 is 6. The maximum value is taken for value 0 or
values higher than 6.
The FC 26 function of the basic PLC program transfers the traversing key signals of the HT 8
to the axis-secific interfaces in DB31, ... DBX4.6 and DBX4.7 (traversingkeys +/-) of the
machine axes specified in the table.

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The value 0 is to be entered as axis number in the table for traversing key signals that are
not supposed to act on any machine axis.
Specifying an invalid axis number can make the PLC switch to the "stop" state. There is no
validation for invalid axis numbers.

Changeover axes
A softkey is pre-configured in HT 8 for switching the axes, e.g. the next six machine axes.
● "U" key > vertical "Changeover axis key" softkey.
The following input signal is set via the softkey:
● EB n + 2, Bit 6 = 1 (switch axes)
The actual switching must be undertaken by the user (machine manufacturer) in the PLC
user program. For this, the machine axis table must be overwritten with the new axis
numbers.
With active WCS, it is assumed implicitly In FC 26, that the first 3 axes in the machine axis
table are geometry axes. If this is not the case e.g. after the axis switchover, then the user
(machine manufacturer) must set the following output signal in the PLC user program:
● AB n + 2, Bit 6 (Axes 7 - n selected)

Note
A machine axis table should then be overwritten if no axis traverses.

Transfer of the traversing key signals as a function of the active coordinate system
The switchover between MCS and WCS is described in Chapter: MCS/WCS coordinate
system switchover (Page 218)
The active coordinate system is displayed by FC 26 in the following output signal:
● AB n + 0, Bit 0 (MCS/WCS) with 0 = MCS, 1 = WCS
With active MCS, the traversing key signals of axes 1 to 6 are transferred to the axis-specific
interfaces (DB31, ... DBX4.6 and DBX4.7 (traversing keys +/-)) of the axes specified in the
machine axis table.
For active WCS, it is assumed that the Axes 1 to 3 of the machine axis table are geometry
axes. Hence the traversing key signals:
● of the axes 1 - 3 (EB n + 2 / 3, Bit 0 - Bit 2) are transferred to the interface of the
geometry axes in DB 21, ... DBB 12 + (n * 4), with n = 0, 1, 2), Bit 6 and Bit 7 (traversing
keys +/-) of the channel specified via the "ChanNo" parameter. The assignment of the
traversing key signals of axes 1, 2 and 3 to the geometry axes 1, 2 and 3 of the channel
is permanent and cannot be changed.
● The axes 4 - 6 (EB n + 2 / 3, Bit 3 - Bit 5) are transferred to the axis-specific interfaces
(DB31, ... DBX4.6 and DBX4.7 (traversing keys +/-)) of the 4 - 6 axes entered in the
machine axis table.

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No traversing key signals to machine axes with active WCS.

The FC 26 function can be used to lock the transfer of the traversing key signals to the
machine axis with active WCS (AB n + 0, Bit 0 = 1). This functionality is to be activated by
the user (machine manufacturer) in the PLC user program by setting the following output
signals:
● AB n + 3, Bit 7 (in WCS: no machine axes)
● AB n + 2, Bit 6 (Axes 7 - n selected)

Output signal Value Response

AB n + 3, Bit 7 0 The traversing key signals for Axes 1 - 3 of the machine axis table are output to the
AB n + 2, Bit 6 0 geometry axes of the channel specified via the "ChanNo" parameter.
The traversing key signals for Axes 4 - 6 of the machine axis table are output to the
corresponding axis-specific interfaces.
AB n + 3, Bit 7 0 The traversing key signals for Axes 1 - 6 of the machine axis table are output to the
AB n + 2, Bit 6 1 corresponding axis-specific interfaces.
AB n + 3, Bit 7 1 The traversing key signals for Axes 1 - 3 of the machine axis table are output to the
AB n + 2, Bit 6 0 geometry axes of the channel specified via the "ChanNo" parameter.
The traversing key signals for Axes 4 - 6 of the machine axis table are not output.
AB n + 3, Bit 7 1 The traversing key signals for Axes 1 - 6 of the machine axis table are not output.
AB n + 2, Bit 6 1

7.6.5.5 Display traversing keys

To display the traversing keys on HT 8, the following output signal must be set in the PLC
user program:
● AB n + 6, Bit 7 = 1 (display traversing keys)

Checkback signal from HT 8

HT 8 sets the following input signal as checkback signal that the traversing keys have been
displayed on HT 8:
● DB 10, DBX 72.7 = 1 (Traversing keys displayed)

Inscription of the traversing keys

On displaying the traversing keys, the machine axis names or the traversing key identifiers of
the machine axes recorded in the table (DB 10, DBB 8 - 13) are used as inscriptions. In this
context, the machine axis numbers entered in the table serve as indices in the following
tables:
● HMI file: HT8_xx.INI, Section [Axiskey Text] (Table of traversing key identifiers)
● MD 10000, $MC_AXCONF_MACHAX_NAME_TAB[n] (Table of machine axis names)

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Priority of the traversing key identifiers

If traversing key identifiers are recorded in the HMI file: HT8_xx.INI, the HMI uses the
machine axis names from the machine data automatically.
If traversing key identifiers are recorded in the HMI file: HT8_xx.INI, only these are used for
inscription of the traversing keys.
A combination of the axis names from the machine data and the HMI file is not possible.

Note
By default, no traversing key identifiers are recorded in the HMI file: HT8_xx.INI.

Inscription of the traversing keys via machine data

By default, the first six machine axes in machine data MD 10000,
$MC_AXCONF_MACHAX_NAME_TAB[n] are named as "X1", "Y1", "Z1", "A1", "B1", "C1".
All other machine axes not explicitly mentioned in the machine data are named as "AXn" by
default (where n = number of the machine axis).
The traversing keys are inscribed with the machine axis names defined in the machine data
or with default identifiers: "AXn".

Inscription of the traversing keys via the HMI file: HT8_xx.INI

The inscriptions of the traversing keys can be defined in the [Axis key] section in the
HT8_xx.INI files (where xx = language code e.g. GR = German, EN = English) on the basis
of language for all the machine axis appearing in the system. These files are stored in the
following directory:
● <Installation drive>:/Siemens/Sinumerik/<HMI>/user/language.

Note
The relevant original HT8_xx.INI file should not be changed, because it is overwritten
during an update of the HMI software. To create user-specific inscriptions, the file must
be copied to one of the following directories and changed there:
• .../user/language
• .../oem/language
• .../addon/language

All the axis names in the HT8_xx.INI files carry comments by default.

Table 7-5 Standard setting

HT8_xx.INI (Excerpt)
[Axiskey Text]
;AX1 = "" ; max. 2*10 characters,
;AX2 = "" ; Line break takes place via 2 blanks
;AX3 = ""

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The character string for inscription of a traversing key is to be entered between the already
existing quotation marks, e.g. "LIN_X". A maximum of 2 lines are available for inscription of a
traversing key. It is recommended, the specification in the file notwithstanding, that only a
max. of 8 characters be used per line. For a two-line inscription, the two character strings
must be separated by two blanks following one after the other (line break).

Inscription examples

HT8_xx.INI (Excerpt)
[Axiskey Text]
AX1 = "LIN_X" ; One-line display
AX2 = "LINEAR AXIS_Y" ; Two-line display
AX3 = "LIN Z" ; One-line display

Inscription of the traversing keys + and -

The traversing key inscription for an axis is used for the traversing key "+" as well for the
traversing key "-".

7.6.5.6 Activating user softkeys

A total of 16 user softkeys are available on HT 8. The user softkeys are without any function
by default. The functionality of the user softkeys must be implemented by the user (machine
manufacturer) in the PLC user program. Hence, it is the sole responsibility of the user
(machine manufacturer) to undertake any required interlockings for the activation or
coordination in the process sequence of user functions as compared to other user functions
or default functions.

Display of the user softkeys in the input data area

The user softkeys designated by default as U1 to U16 are displayed in the input data area as
follows:

User softkey Input signal

U1 EB n + 1, Bit 2
U2 EB n + 1, Bit 3
U3 EB n + 1, Bit 5
U4 EB n + 1, Bit 6
U5 EB n + 5, Bit 3
U6 EB n + 5, Bit 4
U7 EB n + 5, Bit 5
U8 EB n + 5, Bit 6
U9 EB n + 4, Bit 0
U10 EB n + 4, Bit 1
U11 EB n + 4, Bit 2
U12 EB n + 4, Bit 3

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User softkey Input signal

U13 EB n + 4, Bit 4
U14 EB n + 4, Bit 5
U15 EB n + 4, Bit 6
U16 EB n + 4, Bit 7

7.6.5.7 Displaying user softkeys

The user softkeys in the horizontal softkey bar of the HMI user interface are displayed via the
"U" key on HT 8. The first 8 user softkeys U1 to U8 are displayed on pressing the "U" key.
The next 8 user softkeys U9 - U16 are displayed on pressing the ETC key ">".
The following figure shows the displayed user softkeys U1 to U8 and the highlighted "U" and
">" keys.

8 8 8 8 8 8 8 8

Figure 7-11 HT 8 with displayed user softkeys

Inscription of the user softkeys via the HMI file: HT8_xx.INI

The inscriptions of the traversing keys can be defined in the [CPF softkey Text] section in the
HT8_xx.INI files (where xx = language code e.g. GR = German, EN = English) on the basis
of language. These files are stored in the following directory:
● <Installation drive>:/Siemens/Sinumerik/<HMI>/user/language.

Note
The relevant original HT8_xx.INI file should not be changed because it is overwritten
during an update of the HMI software. For the creation of user-specific inscriptions, the
file is to be copied to and changed in one of the following directories:
• .../user/language
• .../oem/language
• .../addon/language

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The user softkeys are inscribed as U1 to U16 by default:

HT8_xx.INI (excerpt)
[CPFSoftkey Text]
U1 = "U1" ; max. 2*10 characters,
U2 = "U2" ; Line break occurs via %n
U3 = "U3"

To inscribe a user softkey, the existing character string "Ux" must be replaced by the desired
character string, e.g. "Door open" A maximum of 2 lines are available for inscription of a
traversing key. It is recommended, the specification in the file notwithstanding, that only a
max. of 8 characters be used per line. For a two-line inscription, the two character strings
must be separated by %n (line break), e.g. "Cooling%nOff".

Inscription examples:

HT8_xx.INI (excerpt)
[CPFSoftkey Text]
U1 = "CANCEL" ; One-line display
U2 = "Cooling%nOff" ; Two-line display
U3 = "Door open" ; One-line display

7.6.5.8 MCS/WCS coordinate system switchover

The switching of the coordinate system on HT 8 takes place via the vertical "MCS/WCS"
softkey in the CPF menu (activation via "U" key). The following input signal is set on
actuating the softkey:
● EB n + 0, Bit 0 = 1 (MCS/WCS)
The transfer of the input signal to the HMI input signal (DB 19, DBX 0.7) must be undertaken
by the user (machine manufacturer) via an edge detection in the cyclic part of the PLC user
program (OB 1). The following listing shows an implementation option:

OB 1 (excerpt)
U E 0.0 // Evaluation of positive edge from EB n+0, Bit0
FBD G 200.1 // Store result in Marker 200.1
U G 200.1 // Load result
X DB19.DBX 0.7 // XOR of the result with HMI input signal
= DB19.DBX 0.7 // Write HMI signal
Note
The input data area from E0 and the use of Marker M200.1 are mere assumptions for illustration
purposes.

Result: The HMI signal (DB 19, DBX 0.7) changes its state with each positive edge of the
input signal (EB n + 0, Bit 0).

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7.6 HT 8

With active WCS, it is assumed implicitly In FC 26, that the first 3 axes in the machine axis
table are geometry axes. If this is not the case e.g. after the axis switchover, then the user
(machine manufacturer) must set the following output signal in the PLC user program:
● AB n + 2, Bit 6 (Axes 7 - n selected)

7.6.5.9 Instructions on the evaluation of input signals

Procedure for evaluating input signals

Press a softkey on HT 8 to set the associated signal in the input range to the value 1. A non-
defined number of PLC cycles correspond to the values in the input interface due to the non-
equidistant Ethernet communication. To avoid multiple initiation of functions, the evaluation
of the input signals in the PLC user program must be undertaken edge-triggered on the
positive edge of the signal.

Activating a function
An implementation option of activating a function with each positive edge of an input signal is
shown by the following listing:

OB 1 (excerpt)
CLR
U E 1.2 // If positive edge of user softkey U1?
FBD G 101.1
= G 101.3
UN G 101.3
SPB M005 // THEN
..... // Activating the function
M005: NOP 0 // ENDIF

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Ethernet communication
7.6 HT 8

Alternate activation of two functions

An implementation option of alternate activation of two functions with each positive edge of
an input signal is shown by the following listing:

OB 1 (excerpt)
CLR
U E 1.3 // (1) If positive edge of user softkey U2?
FBD G 102.1
= G 102.3
UN G 102.3
SPB M007
CLR // (1) THEN
U G 102.2 // (2) IF Flip-Flop == 0 ?
SPB M006 // (2) THEN
..... // Activate Function 1 (e.g. display)
I G 102.2 // Flip-Flop = 1
SPA M007
// (2) ELSE (Flip-Flop == 1)
M006: .... // Activate Function 2 (e.g. switch-off)
R G 102.2 // Flip-Flop = 0
// (2) ENDIF
M007: NOP 0 // (1) ENDIF

7.6.5.10 Input/output image

Input image
The address specification of the input image EB takes place in the FB 1 function module,
parameters: "MCPxIn", with x = 1 for the 1st MCP and x = 2 for the 2nd MCP.

Table 7-6 Assignment of the signals in the input image

Signals from HT 8
Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
EB n+0 Function keys
[REF] TEACH AUTO [MDA] JOG QUIT RESET [WCS/
MCS]
EB n+1 Function keys
CPF {U4} {U3} BigFct {U2} {U1} [INC] [REPOS]
(U key)
EB n+2 - Changeove Traversing keys +
r Ax6+ Ax5+ Ax4+ Ax3+ Ax2+ Ax1+
axes
EB n+3 - - Traversing keys -

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Signals from HT 8
Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
Ax6- Ax5- Ax4- Ax3- Ax2- Ax1-
EB n+4 {U16} {U15} {U14} {U13} {U12} {U11} {U10} {U9}
EB n+5 - {U8} {U7} {U6} {U5} (SBL) - -
EB n+6 Res. HT 6/8 SF2 SF1 SF4 SF3 START STOP
EB n+7 - - - Feed override
E D C B A
[xx] = Functions that can be initiated only via the touchscreen softkey
{Ux} = User softkeys of the CPF, display via "U" key; standard labeling: U1 - U16; User-specified Inscription possible via
language-based file: HT8_xx.INI, path: /Siemens/Sinumerik/<HMI>/mmc2/language/
with xx: GR = German, UK = English, SP = Spanish, IT = Italian, GR = Greek, CH = Chinese
Note
It is recommended that the original file in .../mmc2/language/ be left unchanged and the user-specific. file be stored in one
of the following directories: .../user/language, .../oem/language, or /addon/language.
(...) = Signals from the function keys (softkeys) of the CPF, display via the "U" key
- unassigned signals
Note
Unassigned signals are transferred from HT 8 with 0.

Output image
The address specification of the output image EB takes place in the FB 1 function module,
parameters: "MCPxOut", with x = 1 for the 1st MCP and x = 2 for the 2nd MCP.

Table 7-7 Assignment of the signals in the output image

Signals to HT 8
Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
AB n + 0 Function keys
REF TEACH AUTO MDA JOG QUIT RESET WCS/MCS
AB n + 1 Function keys
- FCT15 FCT14 BigFct FCT12 FCT11 INC REPOS
AB n + 2 - Axes 7 - n Traversing keys +
selected Ax6+ Ax5+ Ax4+ Ax3+ Ax2+ Ax1+
AB n + 3 for WCS: - Traversing keys -
no machine Ax6- Ax5- Ax4- Ax3- Ax2- Ax1-
axes
AB n + 4 - - - - - - - -
AB n + 5 - - - - - - - -
AB n + 6 Display - SF2 SF1 SF4 SF3 START STOP
traversing
keys
AB n +7 - - - - - - - -
- unassigned signals
Note
We recommend setting unassigned signals explicitly to 0 in the user program.

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Ethernet communication
7.7 HT 2

7.7 HT 2

7.7.1 Conditions for general commissioning

Hardware
An HT 2 is connected to the SINUMERIK 840Di sl via one of the following interface modules,
and not directly:
● Terminal box PN Basic
● Terminal box PN Plus
● Connection module Basic PN
● Machine Pushbutton Panel MPP 483 HTC

Software
The following software is required:
● PLC basic program
The relevant modules of the basic PLC program are:
– FB 1 (MCP communication parameters)
– FC 13 ("HHUDisp" Display control for handheld unit)
The library of the PLC basic program is part of the SINUMERIK 840Di sl. How to install
the library is described in detail in Section "Create PLC Program".
● SIMATIC STEP 7
SIMATIC STEP 7 is needed to customize the PLC basic and user programs to the
requirements of the respective automation system. SIMATIC STEP7 can be installed
directly on the PCU of the SINUMERIK 840Di sl. How to install additional software is
described in Chapter "License Management".
References:
The following references are required for connecting and commissioning an HT 2:
Function Manual, Basic Functions,
Chapter P3, PLC Basic Program, Program structure and modules of the PLC basic program
Device Manual - Operator Components and Networking,
Chapter Handheld Terminal HT 2
Catalog NCZ, Connection components: Cables, connectors, etc.

Automation system
To commission an HT 2, the automation system must be completely electrically and
mechanically connected with respect to NC, PLC, connecting device and HT 2.
The drives must be secured against accidental moving.

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7.7.2 Linking to the basic PLC and user program

7.7.2.1 Interface signals

Number system
The following figure shows the number system of the softkeys and LED of the HT 2 operator
field.

   

   

   

   

   

Figure 7-12 Numbering of the softkeys and LEDs

Note
In order to transfer the user softkeys (SK1, SK6, SK11 and SK16) in the input interface, at
least version 8.2 of the software "PCU-Base" must be installed.
NO LEDs are available at the HT 2 for the user softkeys (SK1, SK6, SK11 and SK16).

Input image
The address specification of the input image EB takes place in the FB 1 function module,
parameters: "HHUIn".

Table 7-8 Assignment of the signals in the input image

Signals from HT 2
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
EB m + 0 Reserved
EB m + 1 Reserved
EB m + 2 SK8 - SK7 SK5 SK4 SK3 - SK2
EB m + 3 - SK12 SK20 SK19 SK18 SK17 SK10 SK9
EB m + 4 SK25 SK14 SK13 - - - - -
EB m + 5 Write Key- Rotary coding switch (override) 1) -

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Ethernet communication
7.7 HT 2

Signals from HT 2
acknowledg switch E D C B A
ment
display
1) Refer to Chapter: Rotary coding switch (Override)
- unassigned signals
Note
Unassigned signals are transferred from HT 8 with 0.

Output image
The address specification of the output image EB takes place in the FB 1 function module,
parameters: "HHUOut".

Table 7-9 Assignment of the signals in the output image

Signals to HT 2
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
AB m + 0 1) - - - - - - -
AB m + 1 Requireme - - - - - Selection Selection
nt. Write Display-like Display-like
display-line 1-4 1-4
Bit 1 Bit 0
AB m + 2 LED8 LED14 LED7 LED5 LED4 LED3 LED13 LED2
AB m + 3 LED15 LED12 LED20 LED19 LED18 LED17 LED10 LED9
AB m + 4 1. Character of the selected line (outermost right character)

AB m + 5 2. Character of the selected line

AB m + ... .......
AB m + 18 15. Character of the selected line

AB m + 19 16. Character of the selected line (outermost left character)

1) The output mode of the HT 2 display is adjusted via the output signal. The output signal must always be set to the value
1.
- unassigned signals
Note
The LED belonging to the output signal on HT 2 illuminates when the output signal has the value 1.
Unused output signals are to be set to 0.

NOTICE
Output signal AB m + 0, Bit 7
The output mode of the HT 2 display is adjusted via the output signal. The output signal
must always be set to the value 1.

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7.7 HT 2

7.7.2.2 Rotary coding switch

The data of the rotary coding switch (Override) is gray-coded on HT 2. The following table
shows the values in the input data for each switch position:

Switch setting Input data EB m + 5, Bit 5 - Bit 1

E D C B A (gray-coded)
0 00001
1 00011
2 00010
3 00110
4 00111
5 00101
6 00100
7 01100
8 01101
9 01111
10 01110
11 01010
12 01011
13 01001
14 01000
15 11000
16 11001
17 11011
18 11010
The position of the switch positions on HT 2

 

Note
The relevant machine data is to be set to the TRUE value on using the rotary coding switch:
• MD12000 $MN_OVR_AX_IS_GRAY_CODE
• MD12020 $MN_OVR_FEED_IS_GRAY_CODE
• MD12040 $MN_OVR_RAPID_IS_GRAY_CODE
• MD12060 $MN_OVR_SPIND_IS_GRAY_CODE
The effective override value comes from the parameterized values in the machine data:
• MD12010 $MN_OVR_FACTOR_AX_SPEED
• MD12030 $MN_OVR_FACTOR_FEEDRATE
• MD12050 $MN_OVR_FACTOR_RAPID_TRA
• MD12070 $MN_OVR_FACTOR_SPIND_SPEED

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Ethernet communication
7.7 HT 2

7.7.2.3 Write display-line

The writing of a display line covers the following points:
1. Selection of the display lines to be written in the output area: AB m + 1, Bit 1 and Bit 0
2. Writing the data in the output area: AB m + 4 to AB m + 19
3. Setting the write request in the output area: AB m + 1, Bit 7
4. Waiting for the acknowledgement of the write request in the input area: EB n + 5, Bit 7
5. Resetting the write request in the output area: AB m + 1, Bit 7
The user (machine manufacturer) must write a display line in the PLC user program.

Selecting the display-line

The display line in which the data is to be output is selected via the output signals: AB m + 1,
Bit 1 and Bit 0.

AB m + 1, Bit 1 AB m + 1, Bit 0 Selected display-line

0 0 1. Line
0 1 2. Line
1 0 3. Line
1 1 4. Line
/LQH

/LQH

Writing the data

A maximum of 16 characters can be output per display line. The characters must be written
in the output area AB m + 4 (outermost right character) to AB m + 19 (left character). The
character set available in HT 2 is given in the following chapter: Character Map (Page 227)

Write request and acknowledgement

The following figure shows the signal chart of a display-line during the writing:


5HTXLUHPHQW E
$%P%LW 

D
F
G

$FNQRZOHGJPHQW
(%P%LW 

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7.7 HT 2

(a) PLC user program: Setting the request. Wait for acknowledgement
(b) HT 2: Detects the write request. Sets the acknowledgement after ending the write
operation.
(c) PLC user program: Detects the acknowledgement. Resets the request.
(d) HT 2: Detects and resets the request. Resets the acknowledgement.
The write cycle is thus closed.

7.7.2.4 Character Map

ASCII-Code of the characters that can be displayed on HT 2

Standard characters Special characters

0010 0011 0100 0101 0110 0111 1010 1011 1100 1101 1110 1111 ← Bit
7... 4
20H 30H 40H 50H 60H 70H A0H B0H C0H D0H E0H F0H Bit 3...0
↓
0000

21H 31H 41H 51H 61H 71H A1H B1H C1H D1H E1H F1H
0001

22H 32H 42H 52H 62H 72H A2H B2H C2H D2H E2H F2H
0010

23H 33H 43H 53H 63H 73H A3H B3H C3H D3H E3H F3H
0011

24H 34H 44H 54H 64H 74H A4H B4H C4H D4H E4H F4H
0100

25H 35H 45H 55H 65H 75H A5H B5H C5H D5H E5H F5H
0101

26H 36H 46H 56H 66H 76H A6H B6H C6H D6H E6H F6H
0110

27H 37H 47H 57H 67H 77H A7H B7H C7H D7H E7H F7H
0111

28H 38H 48H 58H 68H 78H A8H B8H C8H D8H E8H F8H
1000

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Ethernet communication
7.7 HT 2

Standard characters Special characters

29H 39H 49H 59H 69H 79H A9H B9H C9H D9H E9H F9H
1001

2AH 3AH 4AH 5AH 6AH 7AH AAH BAH CAH DAH EAH FAH
1010

2BH 3BH 4BH 5BH 6BH 7BH ABH BBH CBH DBH EBH FBH
1011

2CH 3CH 4CH 5CH 6CH 7CH ACH BCH CCH DCH ECH FCH
1100

2DH 3DH 4DH 5DH 6DH 7DH ADH BDH CDH DDH EDH FDH
1101

2EH 3EH 4EH 5EH 6EH 7EH AEH BEH CEH DEH EEH FEH
1110

2FH 3FH 4FH 5FH 6FH 7FH AFH BFH CFH DFH EFH FFH
1111

20H - 7FH: Standard characters

A0H - FFH: Special characters

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PROFIBUS DP Communication 8
8.1 General information

8.1.1 PROFIBUS DP interfaces of the MCI board

There are two PROFIBUS DP interfaces on the MCI board:
● Interface X101: PROFIBUS DP
The NC only has direct access to this PROFIBUS interfaces. Therefore all PROFIBUS
drives and NC-specific I/Os, e.g. MCPs with handwheels, must be connected via this
interface.
The NC also derives the position control cycle clock from the parameterized equidistant
PROFIBUS cycle clock of this interface.
The interface is operated exclusively in the "DP-Master" mode.
● Interface X102: MPI/DP
This PROFIBUS interface is only available to the PLC. It can also be operated in "DP
Master" or "DP Slave" mode.

8.1.2 PROFIBUS DP with Motion Control option

PROFIBUS DP
PROFIBUS DP is an international, open fieldbus standard, which is specified in the
European Fieldbus Standard EN 50170 Part 2. PROFIBUS DP is optimized for fast, data
transmission at the field level for time-critical applications.
The components communicating via the PROFIBUS DP are categorized as either master or
slave components.
1. Master (active bus device)
Components operating on the bus as master determine the data exchange on the bus
and are therefore also designated as active bus devices.
There are two classes of master:
– DP master, Class 1 (DPMC1):
Central master devices are thus designated, which exchange information with the
slaves in specified message cycles.
Examples: SIMATIC S5, SIMATIC -, etc.

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PROFIBUS DP Communication
8.1 General information

– DP master, class 2 (DPMC2):

These are devices for configuration, commissioning, and operator control and
monitoring while the bus is in operation.
Examples: Programming units, operator control and visualization devices
2. Slaves (passive bus nodes)
These devices may only receive, acknowledge and transfer messages to a master when
so requested.
Examples: Drives, I/O modules

Motion Control Option

Communication between SINUMERIK 840Di sl (NC and PLC), as the master, and the slave
components on PROFIBUS is based on PROFIBUS DP with the Motion Control Extension.
The MotionControl extension is characterized by:
● Configurable isochronous DP cycle
● Cyclic synchronization of the DP slaves using GlobalControl message frames from the
DP master
● 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, 1. September 2000

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 PROFIBUS DP Communication
8.1 General information

8.1.3 Message format for cyclic DP communication

Message frame structure

A PROFIBUS message generally adopts the following format for cyclic data transmission:

8VHIXOGDWD332
3URWRFRO 3URWRFRO
IUDPH IUDPH
+HDGHU 7UDLOHU
3DUDPHWHULGHQWLILHUYDOXH 3URFHVVGDWD
3.: 3='

Figure 8-1 Main message format for cyclic data transmission

User data structure

The useful data for cyclic communication are referred to as parameter process data objects
(PPO). They are subdivided into two areas within the message frame:
● Parameter area (PIV, parameter identification value)
This telegram section is used to read and/or write parameters and to read out faults.
● Process data area (PDA, process data)
In the case of a drive, for example, 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 (task: Master --> Drive) or
– Status words and actual values (responses: Drive --> Master)

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PROFIBUS DP Communication
8.1 General information

8.1.4 Description of a DP cycle

Actual values
At time TI the current actual position values are read from all isochronous DP slave drives. In
the next DP cycle, the actual values are transferred to the DP master in the time TDX.

Position controller
The NC position controller is started at the time TM, with TM > TDX, and computes the new
speed setpoint for each axis on the basis of the position setpoint and the transferred actual
position value.

Setpoints
At the start of the next DP cycle, the speed setpoints are transferred from the DP master to
the DP slaves (drives) in the time TDX.
At time TO, the speed setpoints are taken as new specified values for all drive controllers.

70$3& 7'3

NC:
Master or 70
position controller 5

7'; 7';

 

352),%86'3 '39 *75 *& '[ '[ '[ '39 *75 *& '[ '[ '[
&RPPXQLFDWLRQ

6SHHG
FRQWUROF\FOH

'ULYHV 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
'36ODYHVWR

7R 7,

7, 7R

Figure 8-2 Example: Optimized DP cycle with 3 DP 611U slaves

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 PROFIBUS DP Communication
8.1 General information

Key to Fig. above:

● TMAPC:
Master application cycle: NC-Position controller cycle
the following is always valid for SINUMERIK 840Di sl: TMAPC = TDP
● TDP:
DP cycle time: DP cycle time
● TDX:
Data exchange time: Total transfer time for all DP slaves
● T M:
Master time: Offset of the start time for NC position control
● T I:
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 acceptance. The setpoints were generated by the DP-
Master-Application in the previous DP-Cycle.
● GC:
Global control message frame (broadcast message frame) for cyclic synchronization of
the equidistance between the DP master and DP slaves
● R:
Computation time for speed or position control
● Dx:
Useful data exchange between the DP master and DP slaves
● DPV1:
After cyclic communication, an acyclic service is sent, if the token holding time TTH has
not yet been exceeded. TTH is calculated by the engineering system.
● G T R:
E: GAP
An attempt is made during this time to accept new active stations.T:
T: TOKEN
The token passing is either to itself or other masters.
R: RES
The reserve is used as an "Active break" for the station to send the token to itself until the
equidistant cycle expires.
● ①
The actual values for the current DP-Cycle/position control cycle are transferred from the
DP-Slave-Drives to the NC position controller.
● ②
The setpoints computed by the NC position controller are transferred to the DP-Slave-
Drives.

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PROFIBUS DP Communication
8.1 General information

8.1.5 Networking rules

Basic rules
The following basic rules must be observed:
1. The bus line must be terminated at both ends. For this purpose, enable the terminating
resistor in the PROFIBUS DP connector of the first and of the last nodes and disable the
remaining terminators.

NOTICE
Only two enabled terminating resistors are permitted per bus line.

2. At least one termination must be supplied with 5 V.

To accomplish this, the PROFIBUS DP Connector with an activated terminating resistor
must be connected to a device that is switched on.
3. No spur lines may be routed to the PROFIBUS DP.
4. Each PROFIBUS DP node must first be connected and then enabled.
When a station is disconnected, the connection must first be deactivated and then the
connector is withdrawn.
5. The cable length of a PROFIBUS DP bus segment may be max. 100 m.

Example: PROFIBUS DP network installation

)LHOGGHYLFH )LHOGGHYLFH
6,0$7,&(7 6,0$7,&(7

6,180(5,.'LVO
RII RQ
3&8
352),%86'3
RQ
PD[P 0&,%RDUG

352),%86'3
RII RII

RQ 7HUPLQDWLQJUHVLVWRULQ
'ULYH8QLW 'ULYH8QLW WKHFRQQHFWRUHQDEOHG
6,1$0,&66 6,1$0,&66
7HUPLQDWLQJUHVLVWRULQ
RII WKHFRQQHFWRUQRWHQDEOHG

Figure 8-3 Example of a PROFIBUS DP network installation

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8.2 Requirements

8.2 Requirements
As a condition for creating a PROFIBUS configuration using the default configuration the
following components are required:
● SIMATIC STEP 7
● 840Di sl Rack
(A preconfigured SIMATIC 300 station for SINUMERIK 840Di sl. Part of the PLC basic
program)
● SlaveOM
(part of the scope of supply of a SINUMERIK 840Di sl: SIMATIC add-on software)

SIMATIC STEP 7
SIMATIC STEP 7 (option) is required in the following version or later:
● SIMATIC STEP 7 as of Version 5.3, Service Pack 2
SIMATIC STEP 7 can either be installed directly on the SINUMERIK 840Di sl PCU or on an
external computer (PG/PC).

SINUMERIK 840Di sl
If SIMATIC STEP 7 is installed on the SINUMERIK 840Di sl, no additional Ethernet cable is
required to load the S7 configuration in the PLC.
Windows applications executed on the SINUMERIK 840Di sl have direct access to the PLC
through the "CP 840D sl" communication processor.
The installation of additional software on SINUMERIK 840Di sl is described in Chapter "SW
Installation/Update and Data Backup" (Page 551).

External computer (PG/PC)

If SIMATIC STEP 7 is installed on an external computer (PG/PC), it must fulfill the following
conditions:
● PG/PC interface is parameterized (see Subsection "External Communication Link:
Ethernet" (Page 156))
● An Ethernet-Connection exists between the external computer (PG/PC) and the
SINUMERIK 840Di sl.

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8.2 Requirements

840Di sl Rack
The 840Di sl rack is a SIMATIC-300 station preconfigured for SINUMERIK 840Di sl. The
following version is available in the hardware catalog of HW Config:
● SINUMERIK 840Di sl with PLC 317-2DP 2AJ10
– Slot 2: SINUMERIK 840Di sl PLC
Default designation: PLC317-2DP 2AJ10
– Slot X1: MPI/PROFIBUS interface (X102)
Default designation: MPI/DP
– Slot X2: PROFIBUS interface (X101)
Default designation: DP
– Slot 4: SINUMERIK 840Di sl NC
Default designation: NCK 840D sl
– Slot 5: SINUMERIK CP for Industrial Ethernet TCP/IP
Default designation: CP 840D sl

Installation
The 840Di sl rack is part of the PLC Toolbox. When the PLC Toolbox is installed, it is
automatically installed in SIMATIC STEP 7.

Note
The PLC basic program must be installed on the computer on which SIMATIC STEP 7 is
installed. For installing the PLC basic program, please observe the appropriate notes in the
file:
• < Installation path>\importantinfo.rtf

Once the PLC basic program has been successfully installed the 840Di sl rack can be
accessed in the hardware catalog of SIMATIC STEP 7, "HW Config":
● "HW Config" hardware catalog:
Profile: Standard
SIMATIC 300 > SINUMERIK > 840Di sl > 840Di sl

SlaveOM
The SlaveOM (Slave Object Manager) for SINUMERIK 840Di sl enables the dialog-based S7
configuration of the following PROFIBUS drives:
● SIMATIC S120
● SIMODRIVE 611 universal or universal E
● SIMODRIVE POSMO CD/CA
● SIMODRIVE POSMO SI
● SIMODRIVE POSMO A
● ADI4 (Analog Drive Interface for 4 Axes)

Manual
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 PROFIBUS DP Communication
8.2 Requirements

NOTICE
If the SlaveOM is used in conjunction with other PLC CPUs, a consistency error is
signaled when compiling the S7 configuration and no system data blocks are generated.

Installation
The SlaveOM is part of the PLC Toolbox. When the PLC Toolbox is installed, it is
automatically installed in SIMATIC STEP 7. The DP slave drives specified above are
available in the hardware catalog at the following location:
● HW Config: Hardware catalog:
Profile: Standard
– PROFIBUS-DP > SINAMICS SINAMICS S120
– PROFIBUS-DP > SIMODRIVE > SIMODRIVE 611 universal
– PROFIBUS-DP > SIMODRIVE > SIMODRIVE POSMO CD
– PROFIBUS-DP > SIMODRIVE > SIMODRIVE POSMO CA
– PROFIBUS-DP > SIMODRIVE > SIMODRIVE POSMO SI
– PROFIBUS-DP > SIMODRIVE > SIMODRIVE POSMO A
– PROFIBUS-DP > SINUMERIK > ADI4

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:
• < Installation path>\importantinfo.rtf

GSD file
A GSD file (device master file) contains all the properties of a DP slave in ASCII format.
Each DP slave SIMATIC STEP 7 requires a module-specific GSD file so that the DP slave
can be found in the hardware catalog.
If a DP slave is not displayed in the hardware catalog of "HW Config", you must install a
GSD file. To do that, use menu command Tools > Install new GSD file.
As soon as you have installed the GSD file the DP slave is available in the hardware catalog
at the following location:
● "HW Config" hardware catalog:
Profile: Standard
PROFIBUS-DP > Other field units > <DP-Slave>

Manual
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PROFIBUS DP Communication
8.2 Requirements

NOTICE
The GSD files must be installed on the computer on which SIMATIC STEP 7 is already
installed.
To install a GSD file, please refer to the appropriate notes in the file: < Installation
path>\importantinfo.rtf

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 PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

8.3 Creating a PROFIBUS configuration

8.3.1 Requirement

S7 project
The procedure described in this Section for setting up the PROFIBUS configuration as well
as the parameterization of various components (for example, SINAMIC drives, ADI4), is
based on an S7 project created using the description in Chapter "Create PROFIBUS
Configuration"
The following status of the S7 project is required:
● S7 project is has been set up (name: SIN840Di sl)
● Station 300 has been set up
● Interface (X102) PROFIBUS is parameterized (optional)
● Interface (X101) PROFIBUS is parameterized
● Input/output data areas of the NC are parameterized

Note
The instructions given in this Section are essentially limited to the special characteristics
of the SINUMERIK 840Di sl. For more details about working with SIMATIC STEP 7
please refer to the relevant SIMATIC documentation or online help.

Starting HW Config
Start "HW Config" by opening the station and double-clicking the hardware icon.

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In HW Config, now insert the required PROFIBUS modules from the hardware catalog into
the S7 project.

Manual
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PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

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8.3.2 Inserting DP slaves

In principle, both PROFIBUS interfaces have the same functionality. To be able to utilize the
available transmission capacity optimally, it is recommended that drive and I/O modules be
operated on dedicated PROFIBUS line in each case.
● Drive modules at the PROFIBUS interface (X101) corresponding to Slot X2.
● I/O modules at PROFIBUS interfaces (X102) corresponding to Slot X1.
The division of the drive and I/O modules is basically random. The following rules must be
met:
● Equidistant DP communication must be configured for the PROFIBUS interface to which
the drive modules are connected. Besides, this interface can be operated only in the DP
Master mode.
● The PROFIBUS interface to which the I/O modules are eventually connected can be
operated in the DP Master as well as 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.
● In principle, equidistant DP communication can be configured for both PROFIBUS
interfaces simultaneously. The isochronous time must be set as identical for both the
interfaces.

Manual
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 PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

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1) Machine control panel: MCP 483, MCP310

2) and 4) ET200... I/Os
3) SIMODRIVE POSMO A
5) SINAMICS S120
6) SIMODRIVE 611 universal
7) SIMODRIVE SI, CD/CA
8) ADI4
If you are using both PROFIBUS interfaces, we recommend the following distribution of DP
slaves:
● PROFIBUS(1): Interface (X101) corresponding to slot X2
– SINAMICS- or SIMODRIVE drives
– ADI4
● PROFIBUS(2): Interface (X102) corresponding to slot X1
– PLC-specific I/Os
– Machine control panel, e.g. MCP 483
– NC-specific I/Os

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PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

8.3.3 Parameterizing the equidistant DP-Slaves finally

After the DP-Slaves have been added in the configuration and parameterized individually,
the following parameters of the equidistant DP slaves must be set in two separate steps for
the final parameterization of the equidistant DP communication of the PROFIBUS(1)
Interface (X101) corresponding to Slot X2:
Step1:
● Activation of the equidistant DP cycle
● Equidistance master cyclic component TDX
Step2:
● Equidistant DP cycle TDP
● Master application cycle TMAPC
● Actual value acquisition TI
● Setpoint acceptance TO
An overview of the different times within a DP cycle is displayed by the figure in Subsection
"Description of a DP cycle" (Page 232).

Note
The procedure for assigning the final parameters for isochronous DP communication is
exemplified by one DP slave S120. Proceed in the same manner for other isochronous DP
slaves, e.g. SIMODRIVE 611U, ADI4; etc.

NOTICE
If DP slave ADI4 interfaces are present in an S7 project on which final parameterization is
to be performed, certain boundary conditions must be observed. See also:
References:
/ADI4/ ADI4 analog drive interface for 4 axes, Subsection "Parameterization",
Parameterization of DP Communication, Boundary Conditions

Activation of the equidistant DP cycle

If you double-click an S120 DP slave in the station window, the dialog box "DP Slave
properties" is displayed.
It is recommended that the isochronous DP-Cycle be enabled for all DP slaves S120 by
display the isochronous DP-Cycle for the selected DP slave S120, and then performing an
alignment.
In case of a comparison, all the values displayed in the following dialog box for all the DP-
Slaves of the same type, DP slave S120 here, are transferred to the configuration:
● DP slave properties
Tab: Cycle synchronization

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 PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

Dialog: Beginning

Dialog: DP slave properties

Tab: Cycle synchronization
Radio button: "Synchronize drive to equidistant DP cycle" ☑
Button: "Adjust"

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Figure 8-7 Enabled isochronous DP cycle

NOTICE
If there are different equidistant DP slave types in an S7 project, e.g. different SINAMICS
drives, ADI4, etc., the following steps must first be performed for each DP slave type before
continuing with the setting of other parameters.
1. Synchronize drive to equidistant DP cycle
2. Perform alignment

Equid. master cycl. TDX portion

After synchronization to the isochronous DP-Cycle has been activated for all DP slaves, the
timer requirement of the cyclic portion of DP-Communication must be calculated.
Calculation is performed by the DP-Master on activation of the isochronous bus cycle.

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PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

Dialog: Continuation

Tab: General
Group: Node/Master System
Button: "PROFIBUS..."
Dialog: Properties - PROFIBUS interface SINAMICS ...
Tab: Parameter
Button: "Properties..."
Dialog: PROFIBUS properties
Tab: Network settings
Button: "Options..."
Dialog: Options ☐
Radio button: Activating the equidistant bus cycle ☑

Equidistant DP cycle TDP

When calculating the cyclic portion of the DP communication, the time for the isochronous
DP cycle is automatically changed to the time required as the minimum. This change must
be undone by reentering the time intended for the isochronous DP cycle.

Dialog: Continuation

Group: Equidistant time in ms

Isochronous DP cycle: Equidistant time
OK
OK
OK

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 PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

Note
You are advised not to activate the option "Times Ti and To same for all slaves" in the
"Synchronization of the slaves" group.

The following parameters are now set for each type of DP slave on the "Clock
synchronization" tab :
● Equidistant DP cycle TDP
● Master application cycle TMAPC
● Actual value acquisition Ti
● Setpoint acceptance To

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Figure 8-9 Dialog: DP slave properties

DP cycle TDP
The "DP cycle" of DP slave S120 must be set to the cycle time of the DP master displayed
under group box "Network settings in ms" > Isochronous DP cycle".

NOTICE
The following condition must be fulfilled for the DP cycle time TDP:
DP cycle = isochron. DP cycle

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PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

Master application cycle TMAPC

The "Master application cycle TMAPC parameter specifies the integer ratio between 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 reduced if NC
hardware of the lower performance range is used.

NOTICE
On a DP slave S120 used with SINUMERIK 840Di sl, the ratio between the master
application cycle TMAC and DP cycle time TDP must be 1:1.
Master application cycle = DP cycle

Dialog: Continuation

Tab: Cycle synchronization

Master application cycle [ms]:
Factor: 1

Actual value acquisition Ti

The actual-value acquisition Ti parameter defines the time at which the actual value (actual
position value) can be read in from a DP slave S120.

Note
You are strongly recommended to use the same value for the time of actual value acquisition
Ti for all DP slaves S120, in particular if the axes interpolate.

NOTICE
The following condition must be observed for the time of actual value acquisition TI:
DP cycle >= actual value acquisition >= base time

Dialog: Continuation

Tab: Cycle synchronization

Actual value acquisition [ms]:
Factor: Factor

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 PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

Setpoint acceptance To
The "setpoint transfer to" parameter defines the time when the speed setpoint of the NC
position controller is accepted by a DP slave S120.

Note
You are strongly recommended to use the same value for the time of setpoint acceptance To
for all DP slaves S120, in particular if the axes interpolate.

NOTICE
The following condition must be observed for the time of setpoint value transfer TO:
DP cycle >= setpoint accept. >= equidist. master cycl. component + base time

Dialog: Continuation

Tab: Cycle synchronization

Setpoint transfer [ms]:
Factor: Factor

Comparison
The values of the current DP slave S120 displayed in the "Cycle synchronization" tab are
transferred to all the other DP slave S120 of the configuration via the Comparison interface.
This adjustment must be carried out at the end, and the dialog box must then be confirmed
with OK.

Dialog: End

Tab: Cycle synchronization

Button: "Adjust"
OK

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PROFIBUS DP Communication
8.3 Creating a PROFIBUS configuration

NOTICE
If an S7 project includes different equidistant DP slave types, such as different SINAMICS
drives, ADI4, etc., the following parameter settings must be made separately for each DP
slave type as described above, and an alignment must be performed:
• Equidistant DP cycle TDP
• Master application cycle TMAPC
• Actual value acquisition TI
• Setpoint acceptance TO
The alignment only transfers the values displayed in the "Isochronous mode" tab to the DP
slaves of the same type.

8.3.4 Generating system data blocks (SDB)

System data blocks (SDB) contain all the information required for PROFIBUS
communication between the DP master and connected DP slaves. System data blocks are
generated by compiling the current configuration with "HW Config".

Consistency check
Always check that the system data blocks are error-free before storing and compiling them.
To do that select menu command Station > check consistency in the HW config.
If inconsistencies are detected in the configuration, an error dialog box is displayed and the
error messages and help are displayed.

Save and compile

Use the menu command Station > Save and compile to save the current configuration in the
S7 project as the "station" object and compile it eventually.

System data blocks

If the configuration is compiled without error the system data blocks are generated and
stored in the "Modules" directory of the PLC.
In the "SIN840Di sl" example project, the system data blocks are located at:
SIN840Di sl > SIMATIC 300(1) > PLC317-2DP 2AJ10 > STEP 7-Program(3) > Modules >
System data
The current system data blocks can be displayed by double-clicking the "System data" icon
in the "System data modules" dialog box.

Note
System data blocks cannot be edited individually. Only the configuration as a whole can be
edited.

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 PROFIBUS DP Communication
8.4 SIMATIC I/O devices (ET200...)

8.3.5 Load the configuration in the PLC

The configuration can be loaded in the PLC after generating the system data module
successfully.
Loading the configuration is descried in detail within the framework of the PLC
commissioning in Chapter "Load configuration (STEP 7 -> PLC)" (Page 179).

8.3.6 PROFIBUS diagnosis

The following diagnostic displays are recommended for diagnosing the PROFIBUS or DP
slave status while checking the configuration or if errors occur.
● 840Di startup
Menu bar: Window > Diagnosis > Profibus > Bus or slaves
● HMI Advanced
Operating area switchover > Diagnosis > Service displays > "ETC" key > Profibus
Diagnosis

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

The SIMATIC I/O devices of the Production Series ET200, e.g. ET200M, are brought into the
S7 project as usual, and configured.

Note
To simplify the parameterization of equidistant communication at PROFIBUS DP, all the
required SIMATIC I/O devices must first be added in the configuration before parameterizing
the DP drives (e.g. DP slave 611 U 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. Note the MLFB numbers of all modules used in the automation system.
2. Select the corresponding module in the hardware catalog and compare the MLFB
number of the module used in the automation system with the MLFB number that is
displayed in the hardware catalog. Both MLFB numbers must be the same.

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PROFIBUS DP Communication
8.5 DP slave I/O Module PP72/48

8.5 DP slave I/O Module PP72/48

8.5.1 Parameterization of I/O Module PP72/48

A PP72/48 I/O module is parameterized with a GSD file.
● The GSD file is a part of the SINUMERIK 840Di sl software. Refer to Section "Overview
of software components" (Page 31): SIMATIC add-on software: GSD file for I/O modules
PP72/48
● To install a GSD file, please refer to Subsection "Network rules" (Page 234): GSD files.

Note
To make parameterization of isochronous communication with PROFIBUS DP easier, we
recommend inserting all required DP slaves into the configuration before setting the times
for isochronous communication.

8.5.2 Inserting the DP slave

To insert a PP72/48 DP slave in the configuration, open the hardware catalog via the menu
command View > Catalog.
The DP slave PP72/48 is to be found at:
● Profile: Standard
PROFIBUS-DP > Other field devices > Drives > IO > PP Input/Output module
Click with the left mouse button on the DP slave PP72/48 (PP input/output module) in the
hardware catalog and drag it onto the DP master system in the station window, holding down
the left mouse button.
The DP master system is displayed in the station window with the following symbol:

When you release the left mouse button, the DP slave PP72/48 is inserted into the
configuration.

Note
Make sure that the cursor that appears as a crossed-out circle when dragging the DP slave
is positioned exactly on the DP master system so that it can be inserted into the
configuration.

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 PROFIBUS DP Communication
8.5 DP slave I/O Module PP72/48

8.5.3 Setting PROFIBUS parameters

As soon as you have inserted DP slave PP72/48 into the configuration, dialog box
"PROFIBUS properties interface PP input/output" is displayed.
The following PROFIBUS parameters must either be set or verified:
● PROFIBUS address
● Transmission rate
● Profile

NOTICE
The PROFIBUS address of the DP slave PP72/48 set in Project S7 must be identical to
the PROFIBUS address set in the module with the help of the S1 switch (refer to
Section "PP72/48 I/O module" (Page 91)).
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of DP slave PP72/48
PROFIBUS address
2. I/O Module PP72/48
PROFIBUS address (Switch S1)

Dialog

Dialog: PROFIBUS properties of PP-I/O interface

Tab: Parameter
address: <PROFIBUS address>
Button: "Properties..."
Dialog: PROFIBUS properties
Tab: Network settings
Data transfer rate: 12 Mbps
Profile: DP
OK
OK

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PROFIBUS DP Communication
8.5 DP slave I/O Module PP72/48

8.5.4 Setting the I/O addresses

When the dialog box is closed DP slave PP72/48 is inserted into the DP master system and
the detail view of DP slave PP72/48 is displayed in the station window. Select one of the
modules listed under DP slave PP72/48 (PP input/output module) from the hardware catalog
and insert it in slot 1 of the detail view.
The I/O addresses are assigned by "HW Config" automatically and should be changed
taking into account the following supplementary conditions:
● I/O address area of NC
The 256-271 I/O addresses should not be assigned for compatibility reasons and for
future system extensions.
● Selective access to inputs/outputs via the PLC
The PLC cannot access the individual I/Os directly for I/O address >256. The input/output
data must first be copied into internal flags of the PLC with the system functions SFC14
and 15.
It is therefore recommended for the reasons given above, that the I/O addresses should be
assigned in the 0-255 range.
The dialog box offers the following configurations to choose from:
1. O/I 6/9 A222 E212121
2. O/I 6/9 A411 E212121
3. O/I 6/9 A42 E41
For DP slave PP72/48, select the 1st configuration and click OK to confirm the dialog box.

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 PROFIBUS DP Communication
8.6 DP slave MCP 310

8.6 DP slave MCP 310

Figure 8-10 MCP 310 front panel

8.6.1 General commissioning requirements

Hardware
The following hardware is required:
● PROFIBUS connecting cable
No terminating resistor is integrated in the machine control panel.

Software
The following software is required:
● PLC basic program
The relevant modules of the basic PLC program are FB 1 (MCP communication
parameters), FC 19 (interface parameter assignment version: milling) and FC 25
(interface parameter assignment, version: turning).
The library of the basic PLC program is a part of the SINUMERIK 840Di sl. The
installation of the library is described in detail in the Section "Create PLC
Program" (Page 177).
● SIMATIC STEP 7
SIMATIC STEP 7 is needed to customize the PLC basic and user programs to the
requirements of the respective automation system. SIMATIC STEP 7 can be installed
directly on the PCU of the SINUMERIK 840Di sl. The installation of additional software is
described in the Chapter "SW Installation/Update and Data Backup" (Page 551).
● DP slave MCP 310
The MCP 310 DP slave is an integral part of the PLC toolbox. When the PLC Toolbox is
installed, it is automatically installed in SIMATIC STEP 7.

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PROFIBUS DP Communication
8.6 DP slave MCP 310

Note
The PLC basic program must be installed on the computer on which SIMATIC STEP 7 is
installed. To install the basic PLC program, please pay attention to the corresponding
instructions in the file:
• < Installation path>\importantinfo.rtf

References:
The following manuals are required for the commissioning of the MCP:
/FB1/ Function Manual - Basic Functions, P3 PLC Basic Program, Program Structure and
the Modules of the PLC Basic Program
/FB2/ Function Manual - Extension Functions, H1 Manual and Handwheel Travel, Startup of
Handwheels
/BH/ Operator Components Manual - Description of MCP 310 (interfaces, electrical
connection etc.)
/Z/ Catalog NCZ, Connection components: Cables, connectors, etc.

Automation system
To commission the MCP, the automation system must be fully connected mechanically as
well as electrically, with reference to NC, PLC and MCP.
The drives must be secured against accidental moving.

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 PROFIBUS DP Communication
8.6 DP slave MCP 310

8.6.2 Parameterization of the MCP

Interfaces
In the following figure, the interfaces are shown on the rear side of the module:

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Figure 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 "MCP 310 Machine Control Panel"

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PROFIBUS DP Communication
8.6 DP slave MCP 310

Display of the software version

All the LEDs on the front panel of the MCP flash after the electrical connection of the MCP,
provided there is no communication between MCP and PLC.
Simultaneously pressing the two keys "Feed stop" and "Feed enable" (in the bottom right
corner) displays the version number of the current software version using the LEDs which
are now illuminated continuously.
Version No. = V
"No. of glowing LEDs in the left LED block".
"No. of glowing LEDs of the middle LED block".
"Number of glowing LEDs in the right LED block"
In the example (see Figure. Subsection "Parameterization of the MCP) V 01.02.00 is
displayed.

VWGLJLW QGGLJLW UGGLJLW

OHIW/('%ORFN FHQWHU/('%ORFN ULJKW/('%ORFN

(QDEOH6RWZDUHYHUVLRQGLVSOD\
SUHVVERWKNH\VVLPXOWDQHRXVO\

Figure 8-13 MCP 310 front panel

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 PROFIBUS DP Communication
8.6 DP slave MCP 310

Switch S3
The PROFIBUS address and the connection type are set via Switch S3 on the rear side of
the MCP:

Table 8-1 Switch S3: PROFIBUS address (1-7)

10 9 8 7 6 5 4 3 2 1 Meaning/value
on on - - - - - - - - Connection type: PROFIBUS
- - off - - - - - - - Reserved
PROFIBUS address
- - - off off off off off off off 0
- - - off off off off off off on 1
- - - on off off off off on off 2
- - - off off off off off on on 3
- - - : : : : : : : :
- - - on on on on on on off 126
- - - on on on on on on on 127
The switch position 10-8 are to be set according to the data in the table.

NOTICE
In the delivery condition, MPI is to be set as connection type (10-9: off, off).

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PROFIBUS DP Communication
8.6 DP slave MCP 310

8.6.3 Functions of the machine control panel

The machine control panel offers the following functions:
● Standard
● Handwheel
● Additional I/Os

Standard
The function: "Standard" transfers the I/O data to the function and user-specific keys and
outputs:
● Input data: 8 bytes
● Output data: 8 bytes

Handwheel
The function: "Handwheel" transfers the absolute values of the two to the handwheels that
can be connected to the machine control panel:
● Input data: 2 x 2 bytes

$EVROXWHYDOXH $EVROXWHYDOXH
KDQGZKHHO KDQGZKHHO

/RZ%\WH +LJK%\WH

For each handwheel the current handwheel value is transferred as a 16-bit absolute value
relative to the starting value. The starting value for the sensor counter in the handwheel is 0.
The absolute values are transferred to the Big Endian Format.
The data for both handwheels is always transferred. The absolute value for a handwheel that
is not connected is always 0.

NOTICE
If the "Handwheel" function is used, the MCP must be connected to the PROFIBUS
interface X101 of the MCI board. The handwheel is evaluated by the NC and the NC only
has direct access to this PROFIBUS interface.

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8.6 DP slave MCP 310

Additional I/Os
The function: "Additional I/Os" transfers the data of all non-standard I/Os:
● Direct keys
● Customer keys: 6 signals (bit 0 to bit 6)
● Rotary switch
with the following distribution:
● Input data: 5 bytes

'LUHFWFRQWURONH\V &XVWRPHU VWURWDU\ QGURWDU\

23 NH\V VZLWFK VZLWFK

/RZ%\WH +LJK%\WH

● Output data: 2 bytes

5HVHUYHG&XVWRPHU
DOZD\V/('V

/RZ%\WH +LJK%\WH

8.6.4 Configure MCP 310 DP slave

The chapter describes the configuration of an MCP 310 DP slave with the help of the
configuration of a SIMATIC S7 project displayed in the following figure.
The configuration comprises the following modules:
● SIMATIC Station 300 with SINUMERIK 810D/840D and PLC 317-2DP
● SINUMERIK MCP with module: standard, handwheel, extended
The following steps must be performed within the framework of the S7 project to configure
the MCP 310 DP slave:
1. Insertion of the MCP 310 DP slave in the configuration
(see following figure: 1)
2. Setting the PROFIBUS address
3. Insertion of the corresponding modules in the MCP 310 DP slave as a function of the
desired functions.
(see following figure: 2)
4. Setting the I/O addresses of the individual slots

Manual
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PROFIBUS DP Communication
8.6 DP slave MCP 310

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VWDQGDUGKDQGZKHHOH[WHQGHG
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Figure 8-14 Configuration with MCP 310 DP slave

Requirements: S7 project
The following status with reference to the S7 project in which the MCP 310 DP slave is to be
inserted, is required:
● You have created the S7 project
● You have set up a SIMATIC 300 station with PROFIBUS master-capable SINUMERIK
control

Inserting the DP slave

To insert an MCP 310 DP slave in the configuration, open the hardware catalog via the
menu command View > Catalog.
The MCP 310 DP slave is to be found at:
● Profile: Standard
PROFIBUS-DP > Other field devices > NC/RC > Motion control > SINUMERIK MCP
Left-click on the MCP 310 DP slave (SINUMERIK MCP) in the hardware catalog and drag it
onto the DP master system in the station window, holding down the left mouse button.
The DP master system is displayed in the station window with the following symbol:

When you release the left mouse button, the MCP 310 DP slave is inserted into the
configuration.

Note
As you drag the DP slave the cursor appears as a circle with a slash through it. When the
cursor is positioned exactly over the DP master system, it changes to a plus sign, and the
DP slave can be added to the configuration.

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 PROFIBUS DP Communication
8.6 DP slave MCP 310

PROFIBUS parameters
As soon as you have inserted MCP 310 DP slave into the configuration, dialog box
"PROFIBUS properties interface SINUMERIK MCP" is displayed.
The following PROFIBUS parameters must either be set or verified:
● PROFIBUS address
● Transmission rate
● Profile

Dialog

Dialog: Properties - PROFIBUS interface SINUMERIK MCP

Tab: Parameter
address: <PROFIBUS address>
Button: "Properties..."
Dialog: PROFIBUS properties
Tab: Network settings
Data transfer rate: 12 Mbps
Profile: DP
OK
OK

NOTICE
The PROFIBUS address set in the S7 project for the MCP 310 DP slave must be the same
as the PROFIBUS address (DIP Switch S3) set in the module.
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of MCP 310 DP slave
PROFIBUS address
2. Machine control panel MCP 310
PROFIBUS address (DIP Switch S3)

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PROFIBUS DP Communication
8.6 DP slave MCP 310

Insert module
The active functions and hence the number of user data elements to be transferred are
chosen by selecting the appropriate pre-configured module. The modules in the hardware
catalog are arranged under the MCP 310 DP slave. The following modules are available:
● Universal module (not applicable)
● standard
● standard, handwheel
● standard, extended
● standard, handwheel, extended
Module: standard
The module transfers the data for the "Standard" function:
● Input data: 8 bytes

6WDQGDUGGDWD
E\WHV

● Output data: 8 bytes

6WDQGDUGGDWD
E\WHV

Module: standard, handwheel

The module transfers the data for the "Standard" and "Handwheel" functions:
● Input data: 12 bytes

6WDQGDUGGDWD 5HVHUYHG &XVWRPHU/('

E\WHV E\WH E\WH

/RZ%\WH +LJK%\WH

● Output data: 8 bytes

6WDQGDUGGDWD
E\WHV

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8.6 DP slave MCP 310

Module: standard, extended

The module transfers the data for the "Standard" and "Additional I/Os" functions:
● Input data: 13 bytes

'LUHFWFRQWURO
6WDQGDUG'DWD &XVWRPHUNH\V VWURWDU\VZLWFK QGURWDU\VZLWFK
NH\V23
E\WHV E\WH E\WH E\WH
E\WHV
/RZ%\WH +LJK%\WH

● Output data: 10 bytes

Standard Data Reserved Customer LEDs

(8 bytes) (1 byte) (1 byte)

Low-Byte High-Byte

Module: standard, handwheel, extended

The module transfers the data for the "Standard", "Handwheel" and "Additional I/Os"
functions:
● Input data: 17 bytes

$EVROXWHYDOXH $EVROXWHYDOXH 'LUHFWNH\V

6WDQGDUGGDWD
KDQGZKHHO KDQGZKHHO 23
E\WH
E\WH E\WH E\WH
/RZ%\WH
FXVWRPHUNH\V URWDU\VZLWFK URWDU\VZLWFK
E\WH E\WH E\WH

+LJK%\WH

● Output data: 10 bytes

Standard Data Reserved Customer LEDs

(8 bytes) (1 byte) (1 byte)

Low-Byte High-Byte

Setting the I/O addresses

The input/output addresses are assigned automatically by STEP 7 while inserting a module
in Slot 1 of the MCP 310 DP slave.
Double clicking with the left mouse button on a slot opens the "Properties - DP slave" dialog
box. This dialog box can be used to set the start addresses of the I/O data of the slot.

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PROFIBUS DP Communication
8.6 DP slave MCP 310

8.6.5 Linking to the basic PLC and user program

The chapter describes the principal linking of the MCP 310 DP slave
● to the PLC basic program for transferring the standard I/O data to the VDI interface
● to the PLC user program (optional) to implement a user-specific response to a module
failure

NOTICE
Processing of additional I/O data is the sole responsibility of the user (machine
manufacturer) and is not supported by the PLC basic program.

PLC basic program

To transfer the standard I/O data of the MCP 310 DP slave via the PLC basic program, the
corresponding I/O range must be entered in the communication parameters of the FB1
function block.
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.
The following parameters are relevant, if you want to operate a machine control panel MCP
310 as DP slave in a SINUMERIK 840Di sl:

MCPNum: INT // Number of MCP

MCP1In: POINTER // Address of input signals
MCP1Out: POINTER // Address of output signals
MCP1BusAdr Byte // PROFIBUS address of the MCP DP slave
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
MCP2BusAdr Byte // PROFIBUS address of the MCP DP slave
Bus type via which the MCP is connected:
MCPBusType Byte // MPI =0
// PROFIBUS = B#16#33
// Ethernet = B#16#55

NOTICE
Parameters: MCPxStop and MCPxNotSend are of no significance.

References:
For a detailed description of the PLC basic program or of function block FB 1, please refer to:

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8.6 DP slave MCP 310

/FB1/ Function Manual - Basic Functions: P3 PLC Basic Program, Chapter "FB 1: RUN_UP
Basic Program", Startup section

VDI interface parameter assignment

The following function modules are available for assigning the VDI interface parameters:
● FC 24: Machine control panel MCP 310, version M (milling)

NOTICE
Function blocks FC 19, FC 24 and FC 25 are part of the PLC basic program. It is the
user's (machine manufacturer's) responsibility to call the block correctly 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/ Function Manual - Basic Functions: P3 PLC Basic Program, Section "FC 19:
MCP_IFM ...", Section "FC 24: MCP_IFM2 ...", Section "FC 25: MCP_IFT ..."

Example
The following example shows the communication parameter settings for function block FB 1
for an MCP:

MCPNum := 1 // Number of MCP

MCP1In := P#E0.0 // Address: Input data
MCP1Out := P#A0.0 // Address: Output data
MCP1StatRec := P#A8190.0 // Configured diagnostic address
MCP1BusAdr := 5 // PROFIBUS address of the MCP DP slave
MCP1Timeout := S5T#700MS // Default setting
MCPMPI := FALSE // No MPI bus
MCP1Stop := FALSE // Deactivation of the DP slave MCP
MCPSDB210 := FALSE // No SDB210 for MCP
MCPCopyDB77 := FALSE // No copying to DB 77
MCPBusType := B#16#33 // PROFIBUS

PLC user program

If an MCP is connected via PROFIBUS DP, the basic PLC program does not check for
module failure.
In this case the MCP is monitored by a standard mechanism to monitor the active DP slave:
● PLC operating system
● PROFIBUS controller
On detecting a failure of an MCP 310 DP slave, the PLC is switched to the STOP state by
default.

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PROFIBUS DP Communication
8.6 DP slave MCP 310

Customized response
The following organization blocks can be added to the PLC user program to customize the
response to a DP slave MCP 310 failure:
● OB 82: Diagnostic interrupt
● OB 86: Rack failure
Please refer to the corresponding SIMATIC literature for details of linking organization blocks
and evaluating diagnostic data.

NOTICE
No alarm is initiated by the basic PLC program if there is a failure of an MCP connected via
PROFIBUS. The triggering of a corresponding alarm is the sole responsibility of the user
(machine manufacturer).

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8.6 DP slave MCP 310

8.6.6 Input/Output image

Arrangement: Keys and LEDs

A key and the LED positioned above it form a logical unit. The key and the LED have the
same number.
● Key: Sxy = Key number xy
● LED: LEDxy = LED number xy
The "MCP 483 Keyboard Layout (front view)" screen in the Chapter "MCP 483 DP slave",
"Input/Output image" shows the arrangement of the keys and LEDs in the machine control
panel along with their relevant internal designation. For the sake of clarity, the LED
designations are not shown in full.

/('/('/('/('/('/('/('/('/('/('
/('

666 6666 666 .(<

666 6666 666

666 6666 666

666 6666 666

66 6666 666

Figure 8-15 Designation of keys and LEDs

Input image
Arrangement of the key signals in the input image of the MCP 310 DP slave:

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8.6 DP slave MCP 310

Table 8-2 Input image

Signals from machine control panel (keys)

Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
EB n+0 Spindle override Mode
*NC stop SP - SP 100% SP + Single JOG MDA AUTO
S19 S36 S37 S38 block S09 S10 S13
S16
EB n+1 Spindle Key Pos. 3 Machine function
X50.3
NC Start SP right *SP Stop SP left REF REP TEACH
S20 S39 S40 S41 S02 S01 S11
EB n+2 Feed Mach. fu. Key Pos. 0 Machine function
X50.4
Feed Start *Feed Stop INC VAR INC1000 INC100 INC10 INC1
S35 S34 S03 S07 S06 S05 S04
EB n+3 RESET Key Pos. 2 Key Pos. 1 Feed override
X50.1 X50.6
S17
*F.over.16 *F.over.8 *F.over.4 *F.over.2 *F.over.1
X30.6 X30.7 X30.8 X30.9 X30.10
EB n+4 Arrow keys Optional customer keys
+ - Rapid KT4 KT3 KT2 KT1 KT0
S50 S48 traverse X52.2 X52.1 X51.3 X51.2 X51.1
S49
EB n+5 Free K. Opt. K. Axis selection
T16 KT5 6 5 4 Z Y X
S18 X52.3 S47 S46 S45 S44 S43 S42
EB n+6 Freely assignable customer keys WCS/MCS Freely assignable customer keys

S33
T9 T10 T11 T12 T13 T14 T15
S29 S30 S31 S32 S12 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. Row: Default designation
● 2. Row: Key number (Sxy) or feed override switch (X30/X31), key switch (X50), optionally
assigned customer keys (X52)

Output image
Arrangement of the LED signals in the output image of the MCP 310 DP slave:

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8.6 DP slave MCP 310

Table 8-3 Output image

Signals to machine control panel (LEDs)

Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
AB n+0 Spindle override Mode
*NC Stop SP - SP 100% SP + Single JOG MDA AUTO
LED19 LED36 LED37 LED38 block LED09 LED10 LED13
LED16
AB n+1 Spindle Machine functions
NC Start SP right *SP Stop SP left Reset REF REP TEACH
LED20 LED39 LED40 LED41 LED 17 LED02 LED01 LED11
AB n+2 Feed Mach. fu. not Machine functions
used
Start *Hold var. INC 1000 INC 100 INC 10 INC 1 INC
LED35 LED34 LED03 LED07 LED06 LED05 LED04
AB n+3 not not not not not not not not
used used used used used used used used
AB n+4 Arrow keys Optional customer keys
+ - Rapid KT4 KT3 KT2 KT1 KT0
LED50 LED48 traverse 24 V 24 V 24 V 24 V 24 V
LED49
AB n+5 Free K. Opt.K. Axis selection
T16 KT5 6 5 4 Z Y X
LED18 24 V LED47 LED46 LED45 LED44 LED43 LED42
AB n+6 Freely assignable customer keys Freely assignable customer keys
WCS/MCS
LED33
T9 T10 T11 T12 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
The following information is to be found in the table for each output bit:
● 1. Row: Default designation
● 2. Row: LED number

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PROFIBUS DP Communication
8.7 DP slave MCP 483

8.7 DP slave MCP 483

Figure 8-16 MCP 483 front panel; Version T (turning machines)

8.7.1 Conditions for general commissioning

Hardware
The following hardware is required:
● PROFIBUS connecting cable
No terminating resistor is integrated in the machine control panel.

Software
The following software is required:
● PLC basic program
The relevant modules of the basic PLC program are FB 1 (MCP communication
parameters), FC 19 (interface parameter assignment version: milling) and FC 25
(interface parameter assignment, version: turning).
The library of the basic PLC program is a part of the SINUMERIK 840Di sl. The
installation of the library is described in detail in the Section "Create PLC
Program" (Page 177).
● SIMATIC STEP 7
SIMATIC STEP 7 is needed to customize the PLC basic and user programs to the
requirements of the respective automation system. SIMATIC STEP 7 can be installed
directly on the PCU of the SINUMERIK 840Di sl. The installation of additional software is
described in the Section "SW Installation/Update and Data Backup" (Page 551).
● DP slave MCP 483
The MCP 483 DP slave is an integral part of the PLC toolbox. When the PLC Toolbox is
installed, it is automatically installed in SIMATIC STEP 7.

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8.7 DP slave MCP 483

References:
The following manuals are required for the commissioning of the MCP:
/FB1/ Function Manual - Basic Functions, P3 PLC Basic Program, Program Structure and
the Modules of the PLC Basic Program
/FB2/ Function Manual - Extension Functions, H1 Manual and Handwheel Travel, Startup of
Handwheels
/BH/ Operator Components Manual, Description of MCP (interfaces, electrical connection
etc.)
/Z/ Catalog NCZ, Connection components: Cables, connectors, etc.

Automation system
To commission the MCP, the automation system must be fully connected mechanically as
well as electrically, with reference to NC, PLC and MCP.
The drives must be secured against accidental moving.

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PROFIBUS DP Communication
8.7 DP slave MCP 483

8.7.2 Parameterization of the MCP

Interfaces
In the following figure, the interfaces are shown on the rear side of the module:

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FRQGXFWRU 3RZHUVXSSO\; 352),%86;
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Figure 8-17 Position of interfaces on rear side of machine control panel

For a detailed description of the electrical and mechanical design and of the machine control
panel interfaces, please refer to:
References:
/BH/ Operator Components Manual, Chapter "MCP 483 Machine Control Panel"

Display of the software version

After the MCP has been electrically connected, all LEDs on the front side of the MCP flash
until communication is established between MCP and PLC.
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 which
are now illuminated continuously.
Version No. = V
"Number of glowing LEDs in the left LED block".
"Number of glowing LEDs in the middle LED block".
"Number of glowing LEDs in the right LED block".
In the example (following figure), V 01.02.00 is displayed.

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 PROFIBUS DP Communication
8.7 DP slave MCP 483

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VWGLJLW UGGLJLW SUHVVERWKNH\VVLPXOWDQHRXVO\
OHIW/('%ORFN QGGLJLW ULJKW/('%ORFN
FHQWHU/('%ORFN

Figure 8-18 MCP software version display

Switch S3
The PROFIBUS address and the connection type are set via Switch S3 on the rear side of
the MCP:

Table 8-4 Switch S3: PROFIBUS address (1-7)

10 9 8 7 6 5 4 3 2 1 Meaning/value
on on - - - - - - - - Connection type: PROFIBUS
- - off - - - - - - - Reserved
PROFIBUS address
- - - off off off off off off off 0
- - - off off off off off off on 1
- - - on off off off off on off 2
- - - off off off off off on on 3
- - - : : : : : : : :
- - - on on on on on on off 126
- - - on on on on on on on 127
The switch position 10-8 are to be set according to the data in the table.

NOTICE
In the delivery condition, MPI is to be set as connection type (10-9: off, off).

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PROFIBUS DP Communication
8.7 DP slave MCP 483

8.7.3 Functions of the machine control panel

The machine control panel offers the following functions:
● Standard
● Handwheel
● Additional I/Os

Standard
The "Standard" function transfers the I/O data to the function and user-specific keys and
outputs:
● Input data: 8 bytes
● Output data: 8 bytes

Handwheel
The "Handwheel" function transfers the absolute values of the two to the handwheels that
can be connected to the machine control panel:
● Input data: 2 x 2 bytes

$EVROXWHYDOXH $EVROXWHYDOXH
KDQGZKHHO KDQGZKHHO

/RZ%\WH +LJK%\WH

For each handwheel the current handwheel value is transferred as a 16-bit absolute value
relative to the starting value. The starting value for the sensor counter in the 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.

NOTICE
If the "Handwheel" function is used, the MCP must be connected to the PROFIBUS
interface X101 of the MCI board. The handwheel is evaluated by the NC and the NC only
has direct access to this PROFIBUS interface.

Additional I/Os
The "Additional I/Os" functions transfers the data of all non-standard I/Os:
● Direct keys
● Customer keys: 6 signals (bit 0 to bit 6)
● Rotary switch
with the following distribution:

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8.7 DP slave MCP 483

● Input data: 5 bytes

'LUHFWFRQWURONH\V &XVWRPHU VWURWDU\ QGURWDU\

23 NH\V VZLWFK VZLWFK

/RZ%\WH +LJK%\WH

● Output data: 2 bytes

5HVHUYHG&XVWRPHU
DOZD\V/('V

/RZ%\WH +LJK%\WH

8.7.4 Configure MCP 483 DP slave

The chapter describes the configuration of an MCP 483 DP slave with the help of the
configuration of a SIMATIC S7 project displayed in the following figure.
The configuration comprises the following modules:
● SIMATIC Station 300 with SINUMERIK 810D/840D and PLC 317-2DP
● SINUMERIK MCP with module: standard, handwheel, extended
The following steps must be performed within the framework of the S7 project to configure
the MCP 483 DP slave:
1. Insertion of the MCP 483 DP slave in the configuration
(see following figure: 1)
2. Setting the PROFIBUS address
3. Insertion of the corresponding modules in the MCP 483 DP slave as a function of the
desired functions.
(see following figure: 2)
4. Setting the I/O addresses of the individual slots

Manual
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PROFIBUS DP Communication
8.7 DP slave MCP 483

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352),%86'30DVWHUV\VWHP


6ORW'S,'2UGHU1XPEHUGHVLJQDWLRQ($GGUHVV2$GGUHVV&RP
VWDQGDUGKDQGZKHHOH[WHQGHG
($!VWDQGDUGKDQGZKHHOH[WHQ
!VWDQGDUGKDQGZKHHOH[WHQ

Figure 8-19 Configuration with MCP 483 DP slave

Requirements: S7 project
The following status with reference to the S7 project in which the MCP 483 DP slave is to be
inserted, is required:
● You have created the S7 project
● You have set up a SIMATIC 300 station with PROFIBUS master-capable SINUMERIK
control

Insert MCP 483 DP slave

To insert an MCP 483 DP slave in the configuration, open the hardware catalog via the
menu command View > Catalog.
The MCP 483 DP slave is to be found at:
● Profile: Standard
PROFIBUS-DP > Other field devices > NC/RC > Motion control > SINUMERIK MCP
Left-click on the MCP 483 DP slave (SINUMERIK MCP) in the hardware catalog and drag it
onto the DP master system in the station window, holding down the left mouse button.
The DP master system is displayed in the station window with the following symbol:

When you release the left mouse button, the MCP 483 DP slave is inserted into the
configuration.

Note
As you drag the DP slave the cursor appears as a circle with a slash through it. When the
cursor is positioned exactly over the DP master system, it changes to a plus sign, and the
DP slave can be added to the configuration.

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8.7 DP slave MCP 483

PROFIBUS parameters
As soon as you have inserted MCP 483 DP slave into the configuration, dialog box
"PROFIBUS properties interface SINUMERIK MCP" is displayed.
The following PROFIBUS parameters must either be set or verified:
● PROFIBUS address
● Transmission rate
● Profile

Dialog

Dialog: Properties - PROFIBUS interface SINUMERIK MCP

Tab: Parameter
address: <PROFIBUS address>
Button: "Properties..."
Dialog: PROFIBUS properties
Tab: Network settings
Data transfer rate: 12 Mbps
Profile: DP
OK
OK

NOTICE
The PROFIBUS address set in the S7 project for the MCP 483 DP slave must be the same
as the PROFIBUS address (DIP Switch S3) set in the module.
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of MCP 483 DP slave
PROFIBUS address
2. Machine control panel MCP 483
PROFIBUS address (DIP Switch S3)

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PROFIBUS DP Communication
8.7 DP slave MCP 483

Insert module
The active functions and hence the number of user data elements to be transferred are
chosen by selecting the appropriate pre-configured module. The modules in the hardware
catalog are arranged under the MCP 483 DP slave. The following modules are available:
● Universal module (not applicable)
● standard
● standard, handwheel
● standard, extended
● standard, handwheel, extended
Module: standard
The module transfers the data for the "Standard" function:
● Input data: 8 bytes

6WDQGDUGGDWD
E\WHV

● Output data: 8 bytes

6WDQGDUGGDWD
E\WHV

Module: standard, handwheel

The module transfers the data for the "Standard" and "Handwheel" functions:
● Input data: 12 bytes

6WDQGDUGGDWD 5HVHUYHG &XVWRPHU/('

E\WHV E\WH E\WH

/RZ%\WH +LJK%\WH

● Output data: 8 bytes

6WDQGDUGGDWD
E\WHV

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8.7 DP slave MCP 483

Module: standard, extended

The module transfers the data for the "Standard" and "Additional I/Os" functions:
● Input data: 13 bytes

'LUHFWFRQWURO
6WDQGDUG'DWD &XVWRPHUNH\V VWURWDU\VZLWFK QGURWDU\VZLWFK
NH\V23
E\WHV E\WH E\WH E\WH
E\WHV
/RZ%\WH +LJK%\WH

● Output data: 10 bytes

Standard Data Reserved Customer LEDs

(8 bytes) (1 byte) (1 byte)

Low-Byte High-Byte

Module: standard, handwheel, extended

The module transfers the data for the "Standard", "Handwheel" and "Additional I/Os"
functions:
● Input data: 17 bytes

$EVROXWHYDOXH $EVROXWHYDOXH 'LUHFWNH\V

6WDQGDUGGDWD
KDQGZKHHO KDQGZKHHO 23
E\WH
E\WH E\WH E\WH
/RZ%\WH
FXVWRPHUNH\V URWDU\VZLWFK URWDU\VZLWFK
E\WH E\WH E\WH

+LJK%\WH

● Output data: 10 bytes

Standard Data Reserved Customer LEDs

(8 bytes) (1 byte) (1 byte)

Low-Byte High-Byte

Setting the I/O addresses

The input/output addresses are assigned automatically by STEP 7 while inserting a module
in Slot 1 of the MCP 483 DP slave.
Double clicking with the left mouse button on a slot opens the "Properties - DP slave" dialog
box. This dialog box can be used to set the start addresses of the I/O data of the slot.

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8.7 DP slave MCP 483

8.7.5 Linking to the basic PLC and user program

The chapter describes the principal linking of the MCP 483 DP slave
● to the PLC basic program for transferring the standard I/O data to the VDI interface
● to the PLC user program (optional) to implement a user-specific response to a module
failure

NOTICE
Processing of additional I/O data is the sole responsibility of the user (machine
manufacturer) and is not supported by the PLC basic program.

PLC basic program

To transfer the standard I/O data of the MCP 483 DP slave via the PLC basic program, the
corresponding I/O range must be entered in the communication parameters of the FB1
function block.
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.
The following parameters are relevant, if you want to operate a machine control panel MCP
483 as DP slave in a SINUMERIK 840Di sl:

MCPNum: INT // Number of MCP

MCP1In: POINTER // Address of input signals
MCP1Out: POINTER // Address of output signals
MCP1BusAdr Byte // PROFIBUS address of the MCP DP slave
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
MCP2BusAdr Byte // PROFIBUS address of the MCP DP slave
Bus type via which the MCP is connected:
MCPBusType Byte // MPI =0
// PROFIBUS = B#16#33
// Ethernet = B#16#55

NOTICE
Parameters: MCPxStop and MCPxNotSend are of no significance.

References:
For a detailed description of the PLC basic program or of function block FB 1, please refer to:

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 PROFIBUS DP Communication
8.7 DP slave MCP 483

/FB1/ Function Manual - Basic Functions: P3 PLC Basic Program, Chapter "FB 1: RUN_UP
Basic Program", Startup section

VDI interface parameter assignment

The following function modules are available for assigning the VDI interface parameters:
● FC 19: Machine control panel MCP 483, version M (milling)
● FC 25: Machine control panel MCP 483, version T (turning)

NOTICE
Function blocks FC 19, FC 24 and FC 25 are part of the PLC basic program. It is the
user's (machine manufacturer's) responsibility to call the block correctly 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/ Function Manual - Basic Functions: P3 PLC Basic Program, Section "FC 19:
MCP_IFM ...", Section "FC 24: MCP_IFM2 ...", Section "FC 25: MCP_IFT ..."

Example
The following example shows the communication parameter settings for function block FB 1
for an MCP:

MCPNum := 1 // Number of MCP

MCP1In := P#E0.0 // Address: Input data
MCP1Out := P#A0.0 // Address: Output data
MCP1StatRec := P#A8190.0 // Configured diagnostic address
MCP1BusAdr := 5 // PROFIBUS address of the MCP DP
slave
MCP1Timeout := S5T#700MS // Default setting
MCPMPI := FALSE // No MPI bus
MCP1Stop := FALSE // Deactivation of the DP slave MCP
MCPSDB210 := FALSE // No SDB210 for MCP
MCPCopyDB77 := FALSE // No copying to DB77
MCPBusType := B#16#33 // PROFIBUS

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8.7 DP slave MCP 483

PLC user program

If an MCP is connected via PROFIBUS DP, the basic PLC program does not check for
module failure.
In this case the MCP is monitored by a standard mechanism to monitor the active DP slave:
● PLC operating system
● PROFIBUS controller
On detecting a failure of an MCP 483 DP slave, the PLC is switched to the STOP state by
default.

Customized response
The following organization blocks can be added to the PLC user program to customize the
response to a DP slave MCP 483 failure:
● OB 82: Diagnostic interrupt
● OB 86: Rack failure
Please refer to the corresponding SIMATIC literature for details of linking organization blocks
and evaluating diagnostic data.

NOTICE
No alarm is initiated by the basic PLC program if there is a failure of an MCP connected via
PROFIBUS. The triggering of a corresponding alarm is the sole responsibility of the user
(machine manufacturer).

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8.7.6 Input/Output image

Arrangement: Keys and LEDs

A key and the LED positioned above it form a logical unit. The key and the LED have the
same number.
● Key number xy corresponds to Sxy
● LED number xy corresponds to LEDxy
The following figure 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.

/('
/('

6 6 6 6 6 6 6 6 6 .H\V

6 6 6 6 6 6 6 6 6

6 6 6 6 6 6 6 6 6

6 6 6 6 6 6 6 6 6

6 6 6 6 6 6 6 6 6 6 6 6 6 6

Figure 8-20 MCP 483 keyboard layout (front view)

Input image
Arrangement of the key signals in the input image of the MCP 483 DP slave:

Table 8-5 Input image

Signals from machine control panel (keys)

Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
EB n+0 Spindle override Mode
*Override *Override *Override *Override JOG TEACH MDA AUTO
Spindle 8 Spindle 4 Spindle 2 Spindle 4
X31.7 X31.8 X31.9 X31.10 S09 S10 S11 S12
EB n+1 Machine functions
REPOS REF var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
S01 S02 S03 S08 S07 S06 S05 S04

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8.7 DP slave MCP 483

Signals from machine control panel (keys)

EB n+2 Key Pos. 0 Key Pos. 2 Spindle *Spindle Feed Start *Feed Stop NC Start *NC Stop
X50.4 X50.1 Start Stop S50 S49
S48 S47 S16 S15
EB n+3 RESET Key Pos. 1 Single Feed override
X50.6 Block
S13
S14
*Override *Override *Override *Override *Override
feed over feed over 8 feed over 4 feed over 2 feed over 1
16 X30.7 X30.8 X30.9 X30.10
X30.6
EB n+4 Arrow keys Key Pos. 3 Axis selection
X50.3
R15 R13 R14 R1 R4 R7 R10
S46 S44 S45 S32 S35 S38 S41
EB n+5 Axis selection
R2 R3 R5 R12 R11 R9 R8 R6
S33 S34 S36 S43 S42 S40 S39 S37
EB n+6 Freely assignable customer keys
F9 F10 F11 F12 F13 F14 F15 not
S25 S26 S27 S28 S29 S30 S31 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. Row: Default designation
● 2. Row: Key number (Sxy) or feedrate override switch (X30/X31), keyswitch (X50)

Output image
Arrangement of the LED signals in the output image of the MCP 483 DP slave:

Table 8-6 Output image

Signals to machine control panel (LEDs)

Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
AB n+0 Machine function Mode
1000 INC 100 INC 10 INC 1 INC JOG TEACH MDA AUTO
LED07 LED06 LED05 LED04 LED09 LED10 LED11 LED12
AB n+1 Feed Start Feed Stop NC Start NC Stop Machine function
LED50 LED49
LED16 LED15
REPOS REF var. INC 10000 INC
LED01 LED02 LED03 LED08

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Signals to machine control panel (LEDs)

AB n+2 Axis selection Single Spindle Spindle
Block Start Stop
LED48 LED47
LED14
R13 R1 R4 R7 R10
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
selection
F9 F10 F11 F12 F13 F14 F15 R2
LED25 LED26 LED27 LED28 LED29 LED30 LED31 LED33
AB n+5 Freely assignable 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. Row: Default designation
● 2. Row: LED number

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8.8 ADI4 DP slave

8.8 ADI4 DP slave

NOTICE
The ADI4 DP slave can only be operated on an isochronous PROFIBUS DP.

8.8.1 SlaveOM
Parameters for the configuration with regard to the ADI4 interface modules, called DP slave
ADI4 here, are assigned with the SlaveOM for SINUMERIK 840Di sl. Please see References
to ADI4 to install the SlaveOM.

Note
To simplify parameterization of the isochronous communication on the PROFIBUS DP, you
must first insert all the DP slaves (drives, ADI4, I/O modules, etc.) you require into the
configuration before parameterization of the DP drives, before you set the times for
isochronous communication.

8.8.2 Inserting the DP slave

To insert an ADI4 DP slave in the configuration, open the hardware catalog using the View >
Catalog menu command.
The DP slave ADI4 is to be found at:
● Profile: Standard
PROFIBUS-DP > SINUMERIK > ADI4
Select DP slave ADI4 by clicking it with the left mouse button and drag it to the DP master
system in the Station window holding down the mouse button.
The DP master system is displayed in the station window with the following symbol:

When you release the left mouse button, the DP slave ADI4 is inserted into the configuration.

Note
Make sure that the cursor, which appears as a crossed-out circle when dragging the DP
slave, is positioned exactly on the DP master system so that the DP slave is inserted into the
configuration.

References:
For a complete description of the parameterization of an ADI4 DP slave please refer to:
/ADI4/ Analog Drive Interface for 4 Axes, Subsection "Parameterization"

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8.9 DP slave SINAMICS S120

8.9 DP slave SINAMICS S120

The following SINAMICS drive system is available for SINUMERIK 840Di sl:
● SINAMICS S120 with CU320 on PROFIBUS DP

8.9.1 SlaveOM for SINAMICS

The SlaveOM for SINAMICS is required to configure SINAMICS S120 drives. The SlaveOM
is automatically installed in SIMATIC STEP7, if the SINAMICS STARTER commissioning
tool is installed on the same computer (PG/PC) as SIMATIC STEP7.

Note
• Configuration and SlaveOM for SINAMICS
To configure SINAMICS S120 drives, the SlaveOM for SINAMICS must be integrated in
SIMATIC STEP7. To do this, install the SINAMICS STARTER commissioning tool on the
same computer (PG/PC) as SIMATIC STEP7.
• Parameterization of equidistant communication
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 DP communication.

8.9.2 Inserting the DP slave

To insert a DP slave S120 into the configuration, open the hardware catalog using the menu
command View > Catalog.
The DP slave S120 is to be found at:
● Profile: Standard
PROFIBUS-DP > SINAMICS SINAMICS S120
Select DP slave S120 by clicking it with the left mouse button and drag it to the DP master
system in the station window while holding down the mouse button.
The DP master system is displayed in the station window with the following symbol:

Releasing the mouse button inserts the DP slave S120 in 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.

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PROFIBUS DP Communication
8.9 DP slave SINAMICS S120

Expanded message frame configuration

The "expanded message frame configuration" has been provided to transfer additional drive
data to the NC in the cyclic PROFIBUS message frame in addition to the process data (PDA)
for the selected standard message frame type (102 to 107).
The extended message frame configuration is described in Section "Extended message
frame configuration/evaluation of internal drive variables" (Page 589).

8.9.3 Parameterizing DP slaves

The assignment of parameters to DP slave S120 is divided into 2 steps:
● Step 1
In Step 1, DP slave S120-specific parameter settings are made for:
– PROFIBUS address
– Device version
– PROFIBUS message frame
– I/O addresses
– Expanded message frame configuration
Step 1 should first be carried out for all DP slaves S120 required for the configuration.
● Step 2
Step 2 includes parameterization of isochronous DP communication. Step 2 can be
carried out finally , for any DP slave S120.
The settings made during the operational sequence above can be transferred to all of the
remaining DP slaves S120 using the matching function of SlaveOM.

PROFIBUS address
Inserting a DP slave S120 into the configuration will open the dialog for assigning
parameters for PROFIBUS DP properties.
The PROFIBUS address is automatically set to the next free PROFIBUS address.
The PROFIBUS address can generally be freely selected. It must, however, match the
PROFIBUS address set in the drive Control Unit (parameter P0918).

NOTICE
The PROFIBUS address of DP slave S120, which is set using HW Config, must match the
PROFIBUS address set in the drive:
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of S120 DP slave:
PROFIBUS address
2. SINAMICS S120, CU320
Parameter P0918 (PROFIBUS node address)

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8.9 DP slave SINAMICS S120

Dialog

Dialog: Properties - PROFIBUS interface SINAMICS

Tab: Parameter
address: <PROFIBUS address>
OK

Device version
After confirming the dialog with the "OK" button, the system opens the "SIMOTION DRIVE
Properties" dialog for setting the device version used in the drive.

Dialog

Dialog: Properties - SIMOTION drive

Tab: Drive Unit/Bus Address
Device version : <Device version>

PROFIBUS message frame

After confirming the dialog with "OK", the "DP Slave Properties" dialog box is opened.
Message frames and process data
Selecting a message frame defines the process data (PDA) exchanged between the DP
master and the DP slave.
The following vendor-specific message frames are predefined for exchanging process data
between a SINUMERIK 840Di sl (DP master) and a DP slave S120:

Table 8-7 Message frames and process data

Antriebsobjekt Message PDAset PDAact Description

frame
Closed-loop 102 6 10 Speed control with torque reduction, 1 position
drive control encoders
103 7 15 Speed control with torque reduction, 2 position
encoders
105 10 10 DSC with torque reduction, 1 position encoder
106 11 15 DSC with torque reduction, 2 position encoder
116 11 19 DSC with torque reduction, 2 position encoder
Infeed 370 1 1 Message frame for the infeed
Control Unit 390 2 2 Message frame for Control Unit (drive object 1,
DO1), digital inputs/outputs
391 3 3 Message frame for Control Unit (drive object 1,
DO1),Digital inputs/outputs and probe

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8.9 DP slave SINAMICS S120

Antriebsobjekt Message PDAset PDAact Description

frame
"Free 999 - - The transmission and receive messages can be
interconnection configured as required by using BICO technology
via BICO" to interconnect the send and receive process
data.
PDAsetpoint/PDAactual: Number of process data values: Setpoint/actual values
DSC: Function: Dynamic Servo Control
For a detailed description of message frames, please see:
References:
SINAMCIS S120 Commissioning Manual, Chapter "Communication via PROFIBUS DP"
Message frame structure
The configuration of the PROFIBUS message frame for a DP slave S120 must observe the
following boundary conditions:
● The process data of the axes or drive objects: "Drives" must be available before the
process data of all other drive objects (Control Unit, infeed, etc.).

Note
Currently, no message frames must be configured for the Control Unit and infeed of a
drive unit. Error acknowledgement and release are performed in the STARTER by means
of free message frame configuration with BICO.

● The structure of the process data for the PROFIBUS message frame configured in HW
Config (object sequence and message frame type) must be identical to the structure
configured in STARTER.

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Configuring a message frame in HW-Konfig

DP slave properties

General Configuration Cycle synchronization

Preassignment
Object Message frame selection Option
1 Message frame102, PZD-6/10
2 Message frame 105, PZD-6/10
3 Message frame 103, PZD 6/10

Overview Details

Configuring a message frame in STARTER

PROFIBUS message frame Version overview

The drive objects are provided with data from the PROFIBUS message frame in the following order:

Object Drive object Nr. Message frame

1 'ULYHB 3 6,(0(16PHVVDJHIUDPH
2 'ULYHB 4 6,(0(16PHVVDJHIUDPH
3 'ULYHB 5 6,(0(16PHVVDJHIUDPH
4 ,QIHHG 2 )UHHPHVVDJHIUDPHFRQILJXUDWLRQZLWK%,&2
5 &RQWUROB8QLW 1 )UHHPHVVDJHIUDPHFRQILJXUDWLRQZLWK%,&2

Close Help

Drive_Unit_Addr10

Figure 8-21 Process data structure: HW Config and STARTER

Dialog

Dialog: DP slave properties

Tab: Configuration
Tab card: Overview
Message frame selection: <Message frame>
OK

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8.9 DP slave SINAMICS S120

NOTICE
The PROFIBUS message frame of DP slave S120, which is parameterized using HW
Config, must match the corresponding data parameterized in the NC and in the drive.
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of S120 DP slave:
Drive object: "Drive control": Message frame
2. SINUMERIK 840Di sl NC
MD13060 $MN_DRIVE_TELEGRAM_TYPE[n]
3. SINAMICS S120
Parameter p0922 (PROFIBUS PDA message frame selection) or STARTER: Drive unit
> Configuration

I/O addresses
Communication between the NC and the drive object of a DP slave S120 in the SINUMERIK
840Di sl can only take place if the I/O addresses for the I/O data of a drive object are the
same.

NOTICE
The following is to be taken into account:
• The I/O addresses of the I/O data of a drive object must be the same, e.g. drive object:
"Drive control":
I/O address actual value = = I/O address setpoint
• The I/O address set by the HW Config for a drive object must match the I/O address set
in the NC.
There is no automatic adjustment!
The following data must agree:
• SIMATIC configuration of S120 DP slave:
Drive object:"Drive control": I/O address
SINUMERIK 840Di sl NC
MD13050 $MN_DRIVE_LOGIC_ADDRESS[n]
• SIMATIC configuration of S120 DP slave:
Drive object: "Control Unit": I/O address
SINUMERIK 840Di sl NC
MD13120 $MN_CONTROL_UNIT_LOGIC_ADDRESS[n]

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8.9 DP slave SINAMICS S120

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

Dialog

Dialog: DP slave properties

Tab: Configuration
Tab card: Details
Table entry: PROFIBUS Partner, I/O address: <I/O address>
OK
On confirming the dialog with "OK", the "DP Slave Properties" dialog box is closed. Step 1 of
parameterization of DP slave S120 is then complete.

Consistency
The default setting with regard to the consistency of the I/O data is whole length.
This setting results in:
● Direct accesses from the PLC user program (e.g. byte, word or double word) to this
address range are not permitted by the PLC operating system.
● Accesses to this address range must be carried out using the system functions SFC 14
and SFC 15.
● The system functions SFC 14 and SFC 15 ensure consistent reading/writing of the data
of an axis, e.g.:
– Message frame type 102: 6 words for the set value or 10 words for the actual value
● 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.

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PROFIBUS DP Communication
8.9 DP slave SINAMICS S120

8.9.4 Dependencies of PROFIBUS DP communication

The overview example shows the interrelations or interdependencies when configuring the
PROFIBUS DP communication between the components:
● NC
● DP master
● DP slave S120

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Figure 8-22 Dependencies: NC, PLC/DP master and DP slave S120

① NC
The NC writes/reads the process data for machine axes 1 to 3 from the I/O addresses and
message frames parameterized in the following machine data:
● MD13050 $MN_DRIVE_LOGIK_ADDRESS[ n ]

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8.9 DP slave SINAMICS S120

● MD13060 $MN_DRIVE_TELEGRAM_TYPE[n]
1. Machine axis: I/O address 4100
Message frame 102
2. Machine axis: I/O address 4140
Message frame type 102
3. Machine axis: I/O address 4180
Message frame type 102
For configuring the drive within the framework of the NC commissioning, please refer to
Subsection "Drive configuration" (Page 389).
② DP master
The DP master periodically transfers the isochronous process data to/from DP slaves S120
based on the configuration set in SIMATIC STEP 7 HW Config:
PROFIBUS address: 10

Object I/O address Message frame

1 4100 102
2 4140 102
3 4180 102
Transferring the process data to DP slave S120
The process data of the machine axes are read by the DP master from the configured I/O
addresses and transferred to the DP slave S120 in the PROFIBUS message frame
according to the configured object sequence.
Reading the process data from DP slave S120
The process data of the machine axes are read by the DP master in the configured object
sequence from the PROFIBUS message frame and transferred to the corresponding I/O
addresses.
③ DP slave S120
DP slave S120 interprets the PROFIBUS message frames received from the DP master
based on the STARTER configuration:
PROFIBUS address: 10

Object Antriebsobjekt No. Frame type

1 Drive_1 3 SIEMENS message frame 102
2 Drive_2 4 SIEMENS message frame 102
3 Drive_3 5 SIEMENS message frame 102
4 Infeed 2 Free message frame configuration with
BICO
5 Control Unit 1 Free message frame configuration with
BICO
Transferring the process data to the drive object

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8.9 DP slave SINAMICS S120

The process data (message frame type) is read by DP slave S120 to the configured object
sequence (object) from the PROFIBUS message frame and transferred to the relevant drive
object according to the drive object number.
Example:
The process data for the first object is read to the PROFIBUS message frame according to
message frame 102. The process data is transferred to the drive object: "Drive_1", drive
object No. 3.
Reading the process data from the drive object
The process data (message frame type) is read by the DP slave S120 in the configured
object sequence (object) via the the drive object number and transferred to the PROFIBUS
message frame.

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8.10 DP slave SIMODRIVE drives

8.10 DP slave SIMODRIVE drives

The parameterization of the configuration of the SIMODRIVE drives listed here is done as
follows with the help of SIMODRIVE 611 universal.
● SIMODRIVE 611 universal or universal E
● SIMODRIVE POSMO CD/CA
● SIMODRIVE POSMO SI

8.10.1 SlaveOM
The drives are assigned parameters using the SlaveOM for SINUMERIK 840Di sl (for
installation of the SlaveOM, refer to Subsection "General" (Page 229): DriveOM/SlaveOM).

Note
To simplify parameterization of the isochronous communication on the PROFIBUS DP, you
must first insert all the DP slaves (drives, ADI4, I/O modules, etc.) you require into the
configuration before parameterization of the DP drives, before you set the times for
isochronous DP communication.

8.10.2 Inserting the DP slave

To insert an 611U DP slave in the configuration, open the hardware catalog using the View >
Catalog menu command.
The DP slave 611U is to be found at:
● Profile: Standard
PROFIBUS-DP > SIMODRIVE > 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:

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.

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PROFIBUS DP Communication
8.10 DP slave SIMODRIVE drives

Expanded message frame configuration

In SW 2.2 and higher, "expanded message frame configuration" has been provided to
transfer drive data to the NC in the cyclic PROFIBUS message frame in addition to the
process data (PDA) for the selected standard message frame type (102 to 107).
The extended message frame configuration is described in Section "Extended message
frame configuration/evaluation of internal drive variables" (Page 589).

8.10.3 Parameterizing DP slaves

Parameterization of the DP slave 611U is divided into 2 steps:
● 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 configuration.
● 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 transferred to all of the
remaining DP slaves 611U using the matching function of SlaveOM.

PROFIBUS address
Inserting a DP slave 611U into the configuration will open the dialog for parameterizing 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) (parameter 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 agree:
1. SIMATIC configuration of 611U DP slave
PROFIBUS address
2. SIMODRIVE 611 universal
Parameter P0918 (PROFIBUS node address)

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8.10 DP slave SIMODRIVE drives

Dialog

Dialog: Properties - PROFIBUS Interface SIMODRIVE 611U DP2, DP3

Tab: Parameter
address: PROFIBUS address
OK

Frame type
After confirming this dialog with "OK", the "DP Slave Properties" dialog box is opened.
The corresponding message frame type is to be selected via the Pre-assignment list box,
depending on the drive functionality to be used. The selected message frame type only
defines the number of cyclically transferred process data units within the cyclic message
frames.
The number of cyclically transferred process data units depends on:
● The number of axes per drive module
● The number of encoders used per axis
● The drive functionality used
The following message frame types are predefined for parameterization of the DP slave
611U:

Table 8-8 Message frame types

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 105, PDA 10/10 nset interface with DSC and encoder 1
2 axes, message frame type 105, PDA 10/10 nset interface with DSC and encoders 1 and 2
1 axis, message frame type 106/107, PDA 7/15 nset interface with DSC and encoders 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 encoders 1 and 2
(106) or encoders 1 and 3 (107)
PDA x/y: Number of process data values, x: Setpoints, y: Actual values
DSC: "Dynamic Servo Control" functionality

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8.10 DP slave SIMODRIVE drives

Frame type Description

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Dialog: DP slave properties
Tab: Configuration
Predefined: <Messag frame type>
OK

NOTICE
The message frame type of DP slave 611U, which is set on the SlaveOM, must match with
the PROFIBUS address set on the NC and the drive:
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of 611U DP slave
Frame type
2. SINUMERIK 840Di sl NC
MD13060 $MN_DRIVE_TELEGRAM_TYPE
3. SIMODRIVE 611 universal
Parameter P0922 (PROFIBUS message frame type selection)

For a detailed description of the different message frame types, please see:
● SIMODRIVE 611 universal and universal E:
References:
/FBU/ Function Manual SIMODRIVE 611 universal
● SIMODRIVE POSMO SI/CD/CA
References:
/POS3/ User Manual - SIMODRIVE POSMO SI/CD/CA
In Chapter "Communication via PROFIBUS DP".

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8.10 DP slave SIMODRIVE drives

I/O addresses
Communication between the NC and the individual axes of the DP slaves 611U in the
SINUMERIK 840Di sl can only take place if the I/O addresses for the setpoint and actual
value of an axis are the same.
This prerequisite is taken into account by SlaveOM automatically when inserting a DP slave
611U into a configuration.

NOTICE
The I/O addresses for set and actual values of an axis must be the same.
I/O 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 I/O addresses are assigned exclusively under the control of "HW
Config".
This may have the consequence that an axis is assigned different I/O addresses for set and
actual values. In this case, the I/O addresses must be corrected manually.

NOTICE
The I/O address set by the SlaveOM for an axis must match the I/O address set in the NC.
There is no automatic adjustment!
The following data must agree:
1. SIMATIC configuration of 611U DP slave
I/O address
2. SINUMERIK 840Di sl NC
MD13050 $MN_DRIVE_LOGIC_ADDRESS[n], (logical drive address)

Note
To prevent subsequent changes to the I/O addresses in the NC machine data MD13050
$MN_DRIVE-LOGIC_ADDRESS[n], we recommend using the default machine data values
within the configuration when assigning I/O addresses:
1. Axis: Default I/O address = 4100
mth axis: Default I/O address = 4100 + (m-1)*40
The default setting for the machine data is described in Subsection "Axis
Configuration" (Page 385).

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PROFIBUS DP Communication
8.10 DP slave SIMODRIVE drives

Dialog

Dialog: DP slave properties

Tab: Configuration
Table entry: PROFIBUS Partner, I/O address: <I/O address>
OK
On confirming the dialog with "OK", the "DP Slave Properties" dialog box is closed. Step 1 of
parameterization of DP slave 611U is then complete.

Consistency
The default setting with regard to the consistency of the I/O data is whole length.
This setting results in:
● Direct accesses from the PLC user program (e.g. byte, word or double word) to this
address range are not permitted by the PLC operating system.
● Accesses to this address range must be carried out using the system functions SFC 14
and SFC 15.
● The system functions SFC 14 and SFC 15 ensure consistent reading/writing of the data
of an axis, e.g.:
– Message frame type 102: 6 words for the set value or 10 words for the actual value
● 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.

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 PROFIBUS DP Communication
8.10 DP slave SIMODRIVE drives

8.10.4 Dependencies of PROFIBUS DP communication

The overview example shows the interrelations or interdependencies when configuring the
PROFIBUS DP communication between the components:
● NC
● DP master
● DP slave 611U

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Figure 8-23 Dependencies: NC, PLC/DP master and DP slave (SIMODRIVE 611 universal)

① NC
The NC writes/reads the axis data to the corresponding I/O area of the PLC/DP master on
the basis of the I/O addresses entered in the following machine data and the message frame
type of the machine axis:
● MD13050 $MN_DRIVE_LOGIK_ADDRESS[ n ]
● MD13060 $MN_DRIVE_TELEGRAM_TYPE[n]
1. Machine axis: I/O address 4100
Message frame type 102
2. Machine axis: I/O address 4140
Message frame type 102

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PROFIBUS DP Communication
8.10 DP slave SIMODRIVE drives

For configuring the drive within the framework of the NC commissioning, please refer to
Subsection "Drive configuration" (Page 389).
② DP master
The information regarding the individual DP slaves are known to the DP masters from the
PROFIBUS SDB generated from the configuration.
DP master transfers the data to/from the DP slaves in isochronous cycles using the following
information:
● PROFIBUS address 10:
Setpoint: Slot 5, I/O address 4100
Actual value: Slot 6, I/O address 4100
Setpoint: Slot 9, I/O address 4140
Actual value: Slot 10, I/O address 4140
● Message frame type 102
For a 2 axis-closed-loop control module of a SIMODRIVE 611 universal, the following
assignment applies:
● Slot 5/6 => Axis 1 or Drive A
● Slot 9/10 => Axis 2 or Drive B
③ DP slave 611U
DP slave interprets the message frames received from the DP master because of the
message frame type 102 set in the following drive parameters:
● Parameter P0922 (PROFIBUS message frame type selection)

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 PROFIBUS DP Communication
8.11 DP slave diagnostic repeater for PROFIBUS DP

8.11 DP slave diagnostic repeater for PROFIBUS DP

8.11.1 Function

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Figure 8-24 Example: PROFIBUS topology with diagnostic repeater

A diagnostic repeater can monitor the segment of an RS 485 PROFIBUS subnet (copper
cable) during normal operation and report line faults in a diagnostic message frame to the
DP master. Used together with the SINUMERIK 840Di sl it is possible to display the location
and cause of the fault in plaintext via SIMATIC STEP 7.

Tasks
The diagnostic repeater primarily performs the following tasks:
● Diagnostic function for two PROFIBUS segments (DP2 and DP3):
The diagnostic function supplies the location and causes of cable breakage such as line
faults or missing terminating resistors.
● Repeater function for three PROFIBUS segments (DP1, DP2, DP3):
The Diagnostics Repeater amplifies the data signals on the bus cables and connects
individual RS 485 segments.

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PROFIBUS DP Communication
8.11 DP slave diagnostic repeater for PROFIBUS DP

● Galvanic separation of the PG interface:

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

8.11.2 Area of application

A diagnostic repeater is required if one or more of the following requirements exist:
● Cable diagnosis of PROFIBUS network during operation
● Connection of more than 32 nodes on a PROFIBUS line
● Implementation of branches
● Electrical isolation of two segments
● Ungrounded operation of bus segments
● Visualization of bus topology with STEP 7 (Version 5.2 and higher)

8.11.3 Connection and commissioning

You will find a detailed description of how to connect and commission 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

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Drive commissioning (SINAMICS) 9
9.1 Requirements

9.1.1 Basic requirements

The following basic requirements must be fulfilled for the commissioning of SINAMICS S120.
● The electronic power supply of PG/PC, SINUMERIK 840Di sl and SINAMICS S120 is
switched on.
● The mechanical and electrical elements of the SINAMICS drives are set up and
connected correctly, including DRIVE CliQ connections.
References:
SINAMICS S120, Commissioning Manual, Chapter "Preparations for Commissioning"
● The SINAMICS STARTER drive commissioning tool is installed on the PG/PC. Version:
At least V4.0
● PG/PC and SINUMERIK 840Di sl communication via Ethernet.
The Ethernet interface of the PG/PC must be connected to the Ethernet 1 interface of the
PCU for this, and the Ethernet communication must be parameterized. See Chapter "PLC
Commissioning" (Page 149)
● SINUMERIK 840Di sl and SINAMICS S120 communication via PROFIBUS.
The PROFIBUS interface (X101) of the MCI board must be connected to the PROFIBUS
interface of SINAMICS S120, and the PROFIBUS communication must be parameterized.
See Chapter "PROFIBUS DP communication" (Page 229).

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Drive commissioning (SINAMICS)
9.1 Requirements

9.1.2 Safety information

DANGER
A hazardous voltage will be present in all components for a further 5 minutes after the
system has been shutdown.
Please follow the instructions on the component!

CAUTION
For safety reasons, Safety Integrated must be commissioned using STARTER in online
mode.
Reason:
The STARTER commissioning tool should only be used to store the safety parameters of a
Safety Integrated monitoring channel within a project. Loading the project into a drive unit
with active safety functions would result in differences in both Safety Integrated monitoring
channels and subsequently in alarms.

Note
Before switching on the drive for the first time, check that the screws of the DC link busbars
are tightened to the specified torque (see SINAMICS S120 Equipment Manual).

Residual risk
A risk assessment enables machine manufacturers to determine the residual risk for their
machine with respect to the drive units. The following residual risks are known:
● Unexpected drive movement from standstill:
Caused, for example, by installation/operational errors or by a malfunction in the higher-
level controller, drive controller, encoder evaluator, or the encoder.
This residual risk can be significantly reduced through the "Safe standstill" safety function
(Safety Integrated).
● Unexpected change in speed/velocity during operation:
Caused, for example, by a malfunction in the higher-level controller, drive controller, or
encoder.

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 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2 ONLINE commissioning

Installation variant 1: STARTER and SIMATIC STEP 7

If the SINAMICS drive commissioning tool STARTER and SIMATIC STEP7 are installed
together on the same programmable controller (PG/PC or PCU of SINUMERIK 840 Di sl),
then the STARTER can be started either directly or from a SINAMICS STEP 7 project.
Start STARTER directly
If the STARTER is started directly (e.g. via the Windows taskbar Start > SIMATIC > STEP 7
> STARTER), then a new project must be created in the STARTER for executing the drive
startup. To do this, continue with Section Create new project with Project Wizard (Page 313).
Start STARTER from STEP 7
If the STARTER is started from a SINAMICS STEP 7 Project (See following figure: Double-
click on the drive object in the detail view of the SIMATIC Manager), one can start
immediately with the automatic detection of the component topology and the configuration.
To do this, continue with Section Drive unit: Enter component topology and configuration
automatically. (Page 316).

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Installation variant 2: STARTER without SINAMICS STEP 7

If the SINAMICS drive commissioning tool STARTER is installed without SIMATIC STEP 7
on a programmable controller (PG/PC or PCU of the SINUMERIK 840Di sl), the STARTER is
started directly (e.g. via the Windows taskbar Start > SIMATIC > STEP 7 > STARTER). After
that a new project must be created and the online connection data must be set in the
STARTER for executing the drive startup. To do this, continue with Section Create new
project without Project Wizard (Page 310)

See also
Creating a SIMATIC S7 project (Page 160)

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Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.1 Create new project without Project Wizard

Implementation
Perform the following actions for creating the new project and for entering the online
connection data:
1. Start the STARTER drive commissioning tool using the icon on the user interface or the
Windows taskbar Start > SIMATIC > STEP 7 > STARTER.
Close the Project Wizard which may have been opened when starting the STARTER for
creating a new project.
2. Create a new project via the menu item Project > New ... .
3. For inserting the drive unit in the project navigator right-click on the project element Insert
Single drive unit. Thereupon, the menu "Einfügen - SINAMICS" ("Insert - SINAMICS") is
shown.

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Figure 9-1 Insert single drive unit (Section)

4. Set the corresponding data of the available system in the menu "Insert - SINAMICS" in
the tab "Drive unit/bus address". As an example, the following data is set:

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Figure 9-2 Parameterize drive unit (section)

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 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

Click OK, when you have finished entering data.

Note
The name "SINAMICS_S120_CU320" given to the drive unit by default can be changed in
the tab "General".

5. The drive unit inserted in the project is now shown in the project structure. For entering
the online data, right-click on the drive unit (in the example "SINAMICS_S120_CU320").
Thereafter, select Target system > online access ... in the context menu that opens. After
this, the menu: "Eigenschaften - Antrieb (online)" ("Properties - Drive (online)") displayed.

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Figure 9-3 Open the dialog for entering the online data (section)

6. Enter the online data of the drive unit in the menu "Properties - Drive (online)".

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Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

Configuration data of the PLC

– Rack: The number of the PLC rack is to be entered. This always has the value 0 for
SINUMERIK 840Di sl.
– Slot: The slot number of the PLC is to be entered. This always has the value 2 for
SINUMERIK 840Di sl.
Access to the destination station (drive unit)
– Destination station: To be accessed via gateway
Connection data of the destination station (drive unit)
– Type: PROFIBUS
– Address: PROFIBUS address of the drive unit (parameter P0918)
– S7-Subnetz-ID(S7 subnet ID): the S7 subnet ID was assigned automatically while
parameterizing the PROFIBUS interface (X101) of the MCI board of SIMATIC STEP7.
See Chapter Parameterizing the PROFIBUS interface (X101) (Page 165)
Connection data of the gateway
– Type: IP
– Address:
STARTER on an external computer (PG/PC)
If the STARTER is running on an external computer (PG/PC), the IP address of the
PCU interface of the SINUMERIK 840Di sl is to be entered, with which the external
computer is connected. To determine the IP address, see Section: Ethernet
connections of the PCU 50.3 (Page 187)
STARTER on the PCU of the SINUMERIK 840Di
If the STARTER is running on the PCU of the SINUMERIK 840Di sl, the IP address of
the interface Ethernet 2 (Default: 192.168.214.241) is to be set. To determine the IP
address, see Section: Ethernet connections of the PCU 50.3 (Page 187)
When you are finished, click OK.

NOTICE
STARTER on the PCU of the SINUMERIK 840Di sl
If the STARTER is running on the PCU of the SINUMERIK 840 Di sl, at least one
Ethernet network of the PCU must be active. If no Ethernet network is active, the
Ethernet communication of the STARTER cannot be routed to the drive unit. The
specification of the IP address of the local host (127.0.0.1) is not possible with the
current version of the STARTER.

Note
Several drive units
If several drive units are available in a system, the actions 3 to 6 must be executed again
for each further drive unit.

For automatic detection of the component topology and the configuration, continue with the
Section Drive unit: Enter component topology and configuration automatically. (Page 316)

Manual
312 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.2 Create new project with Project Wizard

Implementation
Perform the following actions to create a new project:
1. Start the STARTER drive commissioning tool using the icon on the user interface or the
Windows taskbar Start > SIMATIC > STEP 7 > STARTER.
If the Project Wizard for creating a new project is not opened automatically when initiating
the STARTER, open it using menu command Project > New with wizard.
Continue via "Search drive unit online" button.

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2. Enter the desired project data. You can enter any of the data.
Then click the "Continue >" button:

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 313
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

3. Set the PG/PC interface if required and test whether all SINAMICS drive units connected
to the PROFIBUS which are to be commissioned as part of this project are accessible via
the PG/PC interface. To go to the corresponding dialog box, click the "Change and
test...." button.

Note
The stations accessible via the PG/PC interface are displayed in the SIMATIC NET
diagnostic screen.

Then click the "Continue >" button:

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4. Add the accessible SINAMICS drive units to the project.

The drive units found are displayed in the preview window. In the example, a drive unit
"Drive_Unit_Addr10" has been located.
Then click the "Continue >" button:

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Manual
314 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

Note
Only Control Units are located when searching for SINAMICS drive units. All of the other
available components of a drive unit (infeed, motor module, etc.) are not taken into
account at this stage.

5. You have now created the project. The Project Wizard then displays a summary of
project data.
Located drive units are displayed in the preview. In the example, a drive unit
"Drive_Unit_Addr10" has been located.
Then click the "Finish" button.

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 315
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.3 Drive unit: Enter component topology and configuration automatically.

Requirement
The following example format illustrates the configuration of a drive unit:
● Control Unit: CU320
● Infeed: Active Line Module (ALM)
● Power module 1: Single Motor Module (SMM)
● Power module 2: Double Motor Module (DMM)
● Sensor module 1-3: Sensor Module Cabinet (SMC)
● Motor 1-3: Standard motor without DRIVE-CliQ connection

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Note
The following actions refer to recording of the component topology online and configuring
a drive unit. If there are several drive units in a project, you must perform the actions for
each additional drive unit.

Implementation
Perform the following actions:
1. To create the online connection, select the corresponding drive unit in the project
navigator (1) and click the "Connect to target system" button (2).

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Manual
316 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

2. After the online connection to the drive unit has been established, click the "Restore
factory settings" button:

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● Confirm the following dialog with OK to restore the factory settings.

1. Double-click "Automatic configuration" in the project navigator.
The navigator then searches for all components connected to the drive unit and loads
these into the STARTER.

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2. In the next dialog box "Automatic configuration", click on the "Start automatic
configuration" button.
Select the Servo type in the next dialog box "Drive object type" and click on the "Finish"
button.
The following note lists the drives that require offline motor configuration because the
corresponding data cannot be determined online. Confirm with OK.
Note:
Motors with DRIVE CliQ interfaces do not require subsequent offline configuration as the
appropriate parameters can be determined online by the STARTER.
3. To close, click the "Close" button in the "Automatic Configuration" dialog.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 317
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

4. Go offline before configuring the motors and encoder (see next section). Click the
"Disconnect from Target System" button.

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9.2.4 Drive: Configuring motors and encoders

Since no motors/encoders are used in the project with DRIVE CliQ interface, they must be
configured manually because the data cannot be determined automatically without DRIVE
CliQ.

Implementation
Perform the following actions for of the drive units (Drive_1..._3) for all drives:
1. In the project navigator open Project > Drive unit_Adr10 > Drives> <Drive> and double-
click on "Drive Navigator".

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Manual
318 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

2. Then in the Drive Navigator dialog box, click the "Device configuration" button and in the
Device Configuration dialog box the "Configure the drive" button.
Run through the following dialogs for configuring the drive unit using the "Continue"
button without making any changes until you reach the motor dialog.
3. Enter a unique name for the motor in the "Motor name" field in the motor configuration
dialog box (1).
Select the configuration type:
– Select standard motor from list (2)
– Direct entry of motor data

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

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 319
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

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● Exit the dialog box by clicking the "Next >" button.

1. In the configuration dialog for process data exchange, select the message frame
according to the PROFIBUS configuration of the drive unit as DP slave S120 with STEP 7
HW Config from Section "DP Slave: SINAMICS S120" (Page 287).

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● Exit the dialog box by clicking the "Next >" button.

1. Check the data entered for the drive in the following "Summary" dialog. Exit the dialog
with the "Finish" button.

Manual
320 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.5 Control Unit: Selecting the PROFIBUS meassage frame

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

Implementation
Perform the following actions:
1. In the project navigator, open Project > Drive unit_Adr10 > Control_Unit > Communication
and double-click on "PROFIBUS".
2. Select from the list: "Message frame selection": "Free message frame configuration with
BICO (999)"

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9.2.6 Infeed: Selecting the PROFIBUS meassage frame

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

Implementation
Perform the following actions:
1. In the project navigator, open Project > Drive unit_Adr10 > Infeed > Communication and
double-click on "PROFIBUS".
2. Select from the list: "Message frame selection": "Free message frame configuration with
BICO (999)"

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 321
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.7 Drive unit: Check configuration

After configuring all of the drives, we recommend checking the DRIVE-CliQ interconnection
recognized by the STARTER during automatic configuration with the drive unit
interconnection.

Implementation
Perform the following actions for each drive unit:
1. Open the topology tree via Project navigator > Any drive > Drive navigator (double-click)
> Dialog > Device configuration" > "Check topology" button.

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2. Compare the DRIVE-CliQ topology displayed in the STARTER with the topology of the
drive unit.
The following rules must be observed with regard to the DRIVE-CliQ interconnection of
the components:
– The DRIVE-CLiQ cable from the Control Unit to the first power module must be
connected to interface X200.
– The DRIVE-CLiQ connections between each of the power modules should be
connected from interface X201 to X200 on the next component.
– The motor encoder must be connected to the associated Motor Module:

Component Motor encoder connection

Single Motor Module (booksize) X202
Double Motor Module (booksize) Motor connection X1: Encoder at X202
Motor connection X2: encoder to X203
DRIVE-CliQ interconnection of the example structure:

Manual
322 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

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

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 323
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.8 Drive unit: Configuring PROFIBUS message frames

When configuring the PROFIBUS message frame of a drive unit, the following must be
considered:
● The process data for the "Drives" drive object must be available before the process data
of all other drive objects (Control Unit, infeed, etc.).
● The structure of the process data for the PROFIBUS message frame configured in the
STARTER (object sequence and message frame type) must be identical to the structure
configured in HW Config (see Section "DP Slave: SINAMICS S120" (Page 287)).

Implementation
Perform the following actions for each drive unit:
1. To open the PROFIBUS message frame configuration in the project navigator, double-
click on Project > Drive unit_Adr10 > Configuration.
2. Move the drive objects using the buttons (1) according to the guidelines specified above.

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Manual
324 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.9 Control Unit: Acknowledge error (BICO interconnection)

To acknowledge an error for the Control Unit, use the "PROFIBUS PDA1 received" signal
from the first drive.
● Control Unit: p2103 BI: 1. Acknowledge faults
● Drive: Drive_1, r2090: Bit7, BO: PROFIBUS PZD1 receive bit-serial

Implementation
Perform the following actions:
1. To open the control logic configuration in the Project Navigator, double-click Project >
Drive unit_Adr10 > Control Unit > Control Logic.
2. Click on the binector input icon of Signal "p2103 BI: 1. Acknowledge Errors" and select
from the "Drive_1 > Other interconnections > r2090: Bit7, BO: PROFIBUS PDA1 receive
bit-serial" list.

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 325
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.10 Control Unit: Output "Infeed operation" (BICO interconnection) signal

To output the "Infeed operation" signal at terminal X132.7 of the Control Unit, parameter:
"r863 Bit 0" of the infeed must be connected to parameter: "p742" of the Control Unit via
BICO interconnection:
● Infeed: r863 Bit 0: BI: Infeed operation
● Control Unit: p742, BI: CU signal source for terminal DI/DO 12
and terminal X132.7 of the Control Unit must then be parameterized as output DO12.

Implementation
Perform the following actions:
1. To open the terminal configuration in the project navigator double-click on. Project > Drive
unit_Adr10 > Control Unit > Inputs/outputs.
2. In the "Bidirectional digital inputs/outputs" tab (1), change the status for terminal X132.7
to "Output" (2)
3. Click the binector input icon of terminal X132.7, DO12 (3) and select the signal: Infeed
"r863: Bit0, ... Infeed operation" (4).

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Manual
326 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.11 Control Unit: Output "Infeed ready for activation" (BICO interconnection) signal
To output the "Infeed ready to start" signal at terminal X132.8 of the Control Unit, parameter:
"r899, Bit 0" of the infeed must be connected to parameter: "p743" of the Control Unit via
BICO interconnection and terminal X132.8 of the control unit must be parameterized as
DO13 output:
● Infeed: r899 Bit 0: Ready to power up
● Control Unit: p743, BI: CU signal source for terminal DI/DO 13

Implementation
Perform the following actions:
1. To open the terminal configuration in the project navigator double-click on. Project > Drive
unit_Adr10 > Control Unit > Inputs/outputs.
2. In the "Bidirectional digital inputs/outputs" tab (1), change the status for terminal X132.8
to "Output" (2)
3. Click the binector input icon of terminal X132.8, DO13 (3) and select the signal: Infeed
"r899: Bit0, ... Infeed ready to start" (4).

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 327
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.12 Infeed: Acknowledge error (BICO interconnection)

To acknowledge an error for the infeed, use the "PROFIBUS PDA1 received" signal from the
first drive.
● Infeed: p2103[0] BI: 1. Acknowledge faults
● Drive: Drive_1, r2090: Bit7, BO: PROFIBUS PZD1 receive bit-serial

Implementation
Perform the following actions:
1. To open the control logic configuration in the Project Navigator, double-click Project >
Drive unit_Adr10 > Infeeds > Infeed > Control logic.
2. Click on the binector input icon of Signal "p2103[0] BI: 1. Acknowledge Errors" and select
from the "Drive_1 > Other interconnections > r2090: Bit7, BO: PROFIBUS PDA1 receive
bit-serial" list.

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Manual
328 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.13 Infeed: Enable/disable drives via ON/OFF1 (BICO interconnection)

To be able to release and stop the drives externally, e.g. via a PLC user program, connect
digital input X122.1 on the Control Unit and use the BICO interconnection with parameter
"p840[0] BI: ON/OFF1":
● Infeed: p840[0] BI: ON/OFF1
● Control Unit: Control_Unit, r722: Bit0, CO/BO: CU digital inputs, status: :DI 0 (X122.1)
(0=Low/1=High)

Note
With reference to SIMODRIVE drives this corresponds to the effect of digital input X122.1
on terminal 63 (pulse enable).

Implementation
Perform the following actions:
1. To open the control logic configuration in the Project Navigator, double-click Project/
Drive unit_Adr10/Infeeds/ Infeed/Control logic.
2. Click on the binector input icon of Signal "p840[0] BI: ON/OFF1" and select from the list
Control_Unit > Other interconnections > r722: Bit0, CO/BO: CU digital inputs, status: :DI 0
(X122.1)

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 329
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.14 Drive: Enable/disable drives via 2nd OFF3 (BICO interconnection)

To be able to release and stop the drive externally, e.g. via a PLC user program, connect
digital input X122.2 on the Control Unit and use the BICO interconnection with parameter:
"p849[0] BI: 2. OFF3":
● Drive: p849[0] BI: 2. OFF3
● Control Unit: Control_Unit, r722: Bit1, CO/BO: CU digital inputs, status: :DI 1 (X122.2)
(0=Low/1=High)
With reference to SIMODRIVE drives this corresponds to the effect of digital input X122.1 on
terminal 663 (pulse enable) with prior deceleration of the drive. The OFF3 braking ramp can
be configured drive-specifically via the parameters: p1135, p1136 and p1137.

Implementation
Perform the following actions for each drive:
1. To open the control logic configuration in the Project Navigator, double-click Project >
Drive unit_Adr10 > Drives > Drive > Control logic.
2. Click on the binector input icon of Signal "p845[0] BI: 2. OFF2" and select from the list
"Control_Unit > Other interconnections > r722: Bit1, CO/BO: CU digital inputs, status: :DI
1 (X122.2) (0=Low/1=High)".

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Manual
330 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.15 Drive unit: Backing up parameters

After completing the configuration, you must load and save the parameters in the drive unit.

Implementation
Perform the following actions for each drive unit:
1. Access the drive unit with the PG/PC online.
2. Now load the project data into the drive unit: Right-click on Drive unit_Adr10 > Target unit
> Load to target system... in the project navigator.
3. Save the project data in the drive unit on the CF card: Click on Drive unit_Adr10 > Target
unit > Copy RAM to ROM... in the project navigator.

9.2.16 Drive: Testing motor rotation

You can test the configuration loaded into the drive unit by running the motors of the drives
using the operator control panel in the STARTER.
Line/DC link identification will be carried out once the pulses for the infeed have been
enabled and line/DC link identification has been activated. The infeed then switches to
operational mode.

Note
For more information about the operator control panel: see SINAMICS S120 Getting Started
with the STARTER Commissioning Tool.
For more information about line/DC-link identification, see SINAMICS S120 Function
Manual.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 331
Drive commissioning (SINAMICS)
9.2 ONLINE commissioning

9.2.17 Settings of specific parameters

General
It is recommended that you use or check the corresponding settings for the parameters listed
in the table.

Table 9-1 Recommended parameter values: General

Parameter Value Description

Control Unit (CU320)
9906 2 Topology comparison level of all components, 2: low; comparison of
the component type
Servo
922 102 PROFIBUS PZD Message frame selection, SIEMENS Message frame
102, PZD 6/10
857 2000 Power module monitoring time [ms]
1520 q0 Upper force limit/motor,
NOTICE!
Negative values when setting the upper torque limit can lead to motor
"runaway".
1521 t0 Force limit, lower/regenerative,
NOTICE!
Positive values while setting the lower torque limit can lead to motor
"runaway".
1780 0 Motor model adaptation configuration
2038 1 PROFIBUS STW/ZSW Interface Mode
Note:
For p0922 = 100 ... 199, p2038 = 1 is set automatically and the change
of p2038 is blocked.
Infeed (ALM)
922 999 PROFIBUS PDA Message frame selection, free message frame
configuration with BICO
For all drives used as spindles on which grinding wheels are used, OFF2 "Internal/external
pulse disable" (coast down) is recommended as fault reaction when fault 7841 occurs.
Technology: Grinding

Table 9-2 Recommended parameter values: Grinding technology

Parameter Value Description

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

Manual
332 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.3 Example for systems with more than 6 drives

9.3 Example for systems with more than 6 drives

9.3.1 Configuration
One control unit CU 320 can control max. 6 drives in "Servo" mode. The following example
shows which drive components are required and how they are interconnected to operate
more than 6 drives in one configuration.
Requirement:
● Control of 9 drives in "Servo" mode.
Components used:
● 1. Control Unit: CU320 (Control_Unit_1)
● 2. Control Unit: CU320 (Control_Unit_2)
● Infeed: Active Line Module (ALM)
● Power module 1: Single Motor Module (SMM), (Drive_1)
● Power module 2: Double Motor Module (DMM), (Drive_2 and Drive_3)
● Power module 3: Double Motor Module (DMM), (Drive_4 and Drive_5)
● Power module 4: Double Motor Module (DMM), (Drive_6 and Drive_7)
● Power module 5: Double Motor Module (DMM), (Drive_8 and Drive_9)
● Sensor module 1-9: Sensor Module Cabinets (SMC) (not shown)
● Motor 1-9: Standard motor without DRIVE-CliQ connection (not shown)

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 333
Drive commissioning (SINAMICS)
9.3 Example for systems with more than 6 drives

Creating a project
The project should be created according to the description in Chapter "ONLINE-
Startup" (Page 309). Both drive units must be displayed in the preview window.

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Component topology
The automatic entry of the component topology and configuration is to be done according to
Chapter "Drive unit: Enter component topology and configuration automatically" (Page 316)
for each drive unit.

9.3.2 Basic commissioning

Commissioning
The startup of the drive components is to be undertaken according to the Chapter "Drive:
Configuring motors and encoders" (Page 318) given above to Chapter "Drive: Running the
motor" (Page 331).

Infeed: operation
The parameter "p864, BI: Infeed operation" of all drives is to be connected with the
corresponding signal of infeed "r863: Bit0, infeed operation".
● Control_Unit_1
Drives controlled by Control_Unit_1 (Drive_1..._5) are interconnected automatically.
● Control_Unit_2
Drives controlled by Control_Unit_2 (Drive_6..._9) must be manually interconnected (see
the following chapter).

Manual
334 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.3 Example for systems with more than 6 drives

9.3.3 Drives of Control Unit 2: Additional BICO interconnection

The infeed can be connected with a Control Unit via DRIVE CliQ. As Control_Unit_1 is
connected to the infeed, there is no possibility for the drives (drives_6..._9) controlled by
Control_Unit_2 to undertake a BICO connection of drive parameter "p864, BI: Infeed
operation" on the infeed signal "r863: Bit0, Infeed operation":
● Drive: p864, BI: BI: Infeed operation
● Infeed: r863: Bit0, Infeed operation

General procedure
In order to use the infeed signal for the drives controlled by Control_Unit_2, it must be
transferred via an external interconnection from an output terminal of Control_Unit_1 to an
input terminal of Control_Unit_2.

Implementation
The following input/output terminals of the control units are used as an example for the
following description:
● Control_Unit_1: p738, BI: CU signal source for terminal DI/DO 8 (X122.7)
● Control_Unit_2: r722: Bit0. CO/BO: CU digital inputs, status: :DI 0 (X122.1)
Perform the following actions to interconnect the drive parameters with the infeed signal:
1. Connect via BICO interconnection the infeed signal "r863: Bit0, Infeed operation", Project
> Drive unit_Adr10 > Infeeds > Infeed > Diagnosis > Connections > Tab "BO/CO" >
Signal: "r863: Bit0, Infeed operation" with the parameter for the output terminal (X122.7)
of the Control_Unit_1 "p738, BI: CU signal source for terminal DI/DO 8"

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Figure 9-7 STARTER: Work area (excerpt)

2. Configure the bidirectional digital input/output: "DO 8" (X122.7) of Control_Unit_1 as

output:
– Project > Drive_Unit_Adr10 > Control_Unit_1 > Double-click: "Inputs/outputs" > Tab:
"Bidirectional digital inputs/outputs" > DO 8 or X122.7 = output

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 335
Drive commissioning (SINAMICS)
9.3 Example for systems with more than 6 drives

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3. Via a BICO interconnection, connect to Control_Unit_2 the parameter "r722: Bit0. CO/BO:
CU digital inputs, status: :DI 0" of the input terminal: "DI 0" (X122.1), Project > Drive
unit_Adr10 > Control_Unit_1 > Double-click on "inputs/outputs" > Tab "Digital inputs" >
Digital input 0 (1) for all drives of Control_Unit_2 with the parameter "p864, BI: Infeed
operation (2).

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4. Connect the output terminal "DO 8" (X122.7) of Control_Unit_1 to the input terminal "DI 0"
(X122.1) of Control_Unit_2 via an external interconnection.
5. The output terminal of Control_Unit_1 must be wired to an input terminal of
Control_Unit_2.
6. The input terminal of Control_Unit_2 is to be connected via the BICO interconnection with
the driver parameters "p864 BI: Infeed operation" to all the drives of Control_Unit_2.
7. There is no DRIVE CliQ connection between the infeed and Control_Unit_2.

Manual
336 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.4 Further terminal assignments

9.4 Further terminal assignments

Note
The further terminal assignments should only be considered as recommendations that can
be adapted to the requirements of the actual automation system.

9.4.1 Advice on terminal assignment: 1. CU (X122)

Table 9-3 Terminal assignment of 1st CU (X122)

Pin-No. Function Pin assignment BICO source/sink

1 Input1) ON/OFF1 infeed for: CU: r 0722.0 Infeed p 0840
Line Module with DRIVE CLiQ connection
Refer to Chapter "Infeed: Enable (BICO
interconnection)" (Page 329)
"Infeed ready signal" for: SLM X21.1 Drive p 0864
Line Module without DRIVE CLiQ connection
2 Input "OFF3-rapid stop" CU: r 0722.1 Each drive
Refer to Chapter "Drive: Enable OFF3 (BICO 2. OFF3, p 0849
interconnection)" (Page 330)
3 Input SH/SBC 1 - Group 1 CU: r 0722.2 p9620 (all drives in the
SINAMICS Safety Integrated (SH enable = group)
p9601)
4 Input SH/SBC 1 - Group 2 CU: r 0722.3 p9620 (all drives in the
SINAMICS Safety Integrated (SH enable = group)
p9601)
5 Ground for pins 1...4
6 Ground for pins 7, 8, 10, 11
7 Output SH/SBC 1 - Group 1 CU: p 0738 p 9774 Bit 1
SINAMICS Safety Integrated BICO from CU after
the first drive in the
group
8 Output SH/SBC 1 - Group 2 CU: p 739 p 9774 Bit 1
SINAMICS Safety Integrated BICO from CU after
the first drive in the
group
9 Ground for pins 7, 8, 10, 11
10 Input Bero 1 – zero mark substitute CU: r 0722.10 Drive p 0495 = 2
11 --- --- --- ---
12 Ground for pins 7, 8, 10, 11
1) Low – high edge required

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 337
Drive commissioning (SINAMICS)
9.4 Further terminal assignments

9.4.2 Advice on terminal assignment: 1. CU (X132)

Table 9-4 Terminal assignment of 1st CU (X132)

Pin-No. Function Pin assignment BICO source/sink

1 --- --- --- ---
2 --- --- --- ---
3 --- --- --- ---
4 Input Line contactor, feedback signal CU: r 0722.7 LM : p 0860
5 Ground for pins 1...4
6 Ground for pins 7, 8, 10, 11
7 Output BI: Infeed operation LM : r 0863.0 p 0742
(LM with DRIVE CLiQ connection)
Refer to Chapter "Control Unit: Infeed operation
(BICO-Interconnection)" (Page 326)
8 Output Infeed ready to start LM : r 0899.0 p 0743
(LM with DRIVE CLiQ connection)
Refer to Chapter "Control Unit: Infeed is ready
to start (BICO-Interconnection)" (Page 327)
9 Ground for pins 7, 8, 10, 11
10 Output Line contactor control LM : r 0863.1 CU: p 0744
Input Bero 2 – zero mark substitute CU: r 0722.14 Drive p 0495 = 5
2. OFF 2 CU: r 0722.14 Drive p 0845
11 --- --- --- ---
12 Ground for pins 7, 8, 10, 11

9.4.3 Advice on terminal assignment: 2. up to nth CU (X122)

Table 9-5 Terminal assignment of 2nd - nth CU (X122)

Pin-No. Function Pin assignment BICO source/sink

1 Input "Infeed ready signal" 2 to nth CU: r 0722.0 Drive p 0864
2 Input "OFF3-rapid stop" 2 to nth CU: r 0722.1 Each drive
Function: Braking with a configurable OFF3 2. OFF3, p 0849
ramp (p1135, p1136, p1137); thereafter, pulse
suppression and starting lockout.
The drive stops controlled.
The braking response can be set separately for
each servo.
Behavior similar to terminal 64
3 Input SH/SBC 1 - Group 1 2 to nth CU: r 0722.2 p9620 (all drives in the
SINAMICS Safety Integrated (SH enable = group)
p9601)

Manual
338 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.4 Further terminal assignments

Pin-No. Function Pin assignment BICO source/sink

4 Input SH/SBC 1 - Group 2 2 to nth CU: r 0722.3 p9620 (all drives in the
SINAMICS Safety Integrated (SH enable = group)
p9601)
5 Ground for pins 1...4
6 Ground for pins 7, 8, 10, 11
7 Output SH/SBC 1 - Group 1 2 to nth CU: p 0738 p 9774.1
SINAMICS Safety Integrated BICO from CU after
the first drive in the
group
8 Output SH/SBC 1 - Group 2 2 to nth CU: p 739 p 9774.1
SINAMICS Safety Integrated BICO from CU after
the first drive in the
group
9 Ground for pins 7, 8, 10, 11
10 Input Bero 1 – zero mark substitute CU: r 0722.10 Drive p 0495 = 2
11 Input Bero 2 – zero mark substitute CU: r 0722.11 Drive p 0495 = 3
2. OFF 2 CU: r 0722.11 Drive p 0845
12 Ground for pins 7, 8, 10, 11

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 339
Drive commissioning (SINAMICS)
9.4 Further terminal assignments

9.4.4 Advice on interconnection: 1. CU with 2nd to nth CU

Note
The interconnection proposal refers to the terminal assignment proposals made in the
previous sections.

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Manual
340 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.4 Further terminal assignments

9.4.5 Example: CU interconnection with line contactor

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 341
Drive commissioning (SINAMICS)
9.5 Basic principles

9.5 Basic principles

9.5.1 Drive unit: Upgrade firmware

The firmware of a drive unit is upgraded using the STARTER commissioning tool.

Requirements
This procedure requires a functional project and a CF card with the new firmware.

Implementation
Perform the following actions to upgrade the firmware:
1. Create a network link between the PG/PC and the drive unit.
2. Access the drive unit with the PG/PC online and load the current project into the PG/PC
from the drive unit.
3. Save the project with a new project name by selecting "Save As..." and close the old
project.
4. Click the drive unit in the project view to convert the project to the new version and select
"Target system" > "Device version..." (1) from the menu.
Select the version to which the project should be upgraded (2) and start the conversion
process using the button "Change version" (3).

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5. Switch off the Control Unit and insert the CF card with the new firmware version. Then
switch the Control Unit on again.

Manual
342 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SINAMICS)
9.5 Basic principles

6. Go online once again with the PG/PC and load the converted project into the drive by
selecting "Load to target system".
The first time the project is loaded into the drive it will perform internal calculations. To
revert to the current view of the project, select "Load to PG" immediately after "Load to
target system".
The firmware and project on the Control Unit are now upgraded.
7. If the CF card contains later firmware versions for the components (infeed, Motor Module,
etc.) you must now upgrade these as well. To do this, open the device unit in the project
view and double-click "Configuration" (1).
8. Select the "Version overview" (2) tab from the configuration view and click on the
"Firmware update" (3) button.
Click the "Select all" (4) button to upgrade all components, followed by the "Start firmware
update" (5) button.

Note
The drive recognizes whether the CF card contains a later firmware version and prevents
an upgrade to an unsupported version.

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9. Reload the project by selecting "Load to PG".

10.We recommend testing the drive unit after upgrading the firmware.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 343
Drive commissioning (SINAMICS)
9.5 Basic principles

Manual
344 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Drive commissioning (SIMODRIVE)
The Chapter "Drive Commissioning (SIMODRIVE)" describes the preconditions of
10
SINUMERIK 840Di sl for optimum commissioning of the drives in terms of material and cost.
It is not the section's objective to explain in detail how a drive is commissioned. For
commissioning of the drive, please refer to the relevant drive documentation.

Manual
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Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

10.1.1 Commissioning variants

The following distinction is made between commissioning of the above SIMODRIVE drives:
● First commissioning
● Series machine startup

First commissioning
A first commissioning must only be carried out if no matching parameter record is available
for the drive in the form of the parameter file.

Series machine startup

A standard commissioning can be carried when a matching parameter record is available for
the drive in the form of the parameter file.
The parameter file is then loaded to the drive using SimoCom U in online mode (for online
mode, see Chapter: "Preconditions of an online connection" (Page 347)).

Possible procedures
The possible ways of commissioning a drive are:
● Using a display and operator unit directly on the drive (611U/E only)
● Using SimoCom U:
1. SimoCom U is installed on any PG/PC with a serial interface and is direct connected to
the corresponding drive using a RS-232 cable.
2. SimoCom U is installed on any PG/PC with a PROFIBUS DP interface and connected to
all drives using a PROFIBUS cable:
– PG 740 or PCU 50 with integrated PROFIBUS DP interface
– Standard PC with CPU module, e.g. CP 5611
3. SimoCom U is installed on the SINUMERIK 840Disl 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.

Manual
346 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

Recommended procedure
Within the framework of SINUMERIK 840Di sl, the procedure described in Point 3 is
recommended:
The advantages of this procedure are:
● SimoCom U is always available for:
– Commissioning
– Diagnostics
– Controller - Tuning
– SW upgrading of drive firmware
– SW upgrading of firmware optional module
● No additional PG/PC required
● No additional cables required

10.1.2 Preconditions for an online connection

To be able to establish an online connection between SimoCom U and the SIMODRIVE 611
universal drives connected using PROFIBUS DP, the following preconditions must be
fulfilled:
● SimoCom U must be installed.
– For installing SimoCom U, see Chapter "Install SimoCom U" (Page 354)
● A PROFIBUS connection must exist from the PROFIBUS interface of the MCI board to all
drives.
– For network rules, see Chapter "Network rules" (Page 234)
● The PROFIBUS address must be set in all drives.
– For SIMODRIVE 611 universal/E refer to Chapter "Set PROFIBUS address
(SIMODRIVE 611 universal/E)" (Page 348)
– For SIMODRIVE POSMO CD/CA and SI, refer to Chapter "Set PROFIBUS address
(SIMODRIVE POSMO SI/CD/CA)" (Page 349)
● The configuration must be loaded into the PLC.
– For creating an S7 project, see Chapter "Create SIMATIC S7 project" (Page 160)
– For loading the PLC, refer to Chapter "Parameterize isochronous DP slaves
finally" (Page 242)
● The access interface of SimoCom U must be set to "SOFTMC".
– To set the interface, refer to Chapter "Set Access Interface" (Page 350)
● The routing information for the PLC must be set.
– For setting the routing Information, see Chapter "Set routing information" (Page 351)

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 347
Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

10.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal/E)

For SimoCom U to be able to enter online operation with the SIMODRIVE drives connected
to the PROFIBUS, the PROFIBUS address specified in the S7 project (see Chapter "Create
SIMATIC S7 Project" (Page 160)) must be set on DP slave 611U or UE in question using the
display and operator unit.

Display

+ P - Control unit

Figure 10-1 Display and operator unit

Requirements
The precondition for setting the PROFIBUS address on the control unit is that no faults or
warnings are displayed.
If faults or warnings are displayed (display: E_xxxx), press the "-" key to switch from the
alarm mode to parameterization mode.

Sequence of operations
To set the PROFIBUS address, proceed as follows:
1. Setting the PROFIBUS address (parameter P0918)
– Hold down key "P" longer than 3 seconds.
=> The current value of the parameter P0918 (PROFIBUS address) is displayed.
– Use keys "+" and "-" to set the desired PROFIBUS address.
– Press "P" again to quit the input mode.
2. Saving the PROFIBUS node address in the FEPROM
– Press the "+" or "-" key
=> Parameter P0652 (acceptance into FEPROM) is displayed
– Press "P" again to call the input mode.
– Use the "+" key to change the value to 1 (start writing) and wait until the write process
is acknowledged with 0 on the display.
3. Execute a POWER-ON RESET
– Push the "POWER ON-RESET" button on the front panel of the drive module.
=> After power-up, the set PROFIBUS address is active.

Manual
348 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

References:
For detailed information on commissioning of SIMODRIVE 611 universal drives, refer to:
/FBU/ SIMODRIVE 611 universal function description, Chapter "Parameterization of the
Module", Parameter definition via display and operator unit and Chapter "Settings in
PROFIBUS DP Master", commissioning

10.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA)

For SimoCom U to be able to enter online operation with the SIMODRIVE drives connected
to the PROFIBUS, the PROFIBUS address specified in the S7 project (see Chapter "Create
SIMATIC S7 Project" (Page 160)) must be set on DP slave POSMO SI/CD/CA in question
using the DIL switches of the PROFIBUS unit in question.

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Figure 10-2 Setting the PROFIBUS address and terminating resistor

NOTICE
To set the PROFIBUS address and terminating resistor it is necessary to remove the
PROFIBUS unit.

References:
For detailed information on commissioning of SIMODRIVE POSMO CD/CA and SI universal
drives, refer to:
/POS3/ SIMODRIVE POSMO SI/CD/CA User Manual, Chapter "Connecting the PROFIBUS
unit"

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 349
Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

10.1.5 Setting the access interface

Parameter assignment
The access interface through which SimoCom U accesses the drives connected to
PROFIBUS by means of routing, must be parameterized as follows:
● Access point of the application
S7ONLINE STEP7 --> SOFTMC
The interface can be parameterized directly from SimoCom U. To do so, proceed as follows:
1. Start SimoCom U via the WINDOWS taskbar:
Start > Programs > SimoComU > SimoComU
2. In SimoCom U, open the interface dialog using the menu command:
Tools > Communication

SimoCom U dialog box: Beginning

Dialog: Interface
Radio button: "Route through S7-CPU" ⊙
Button: "Set PG/PC interface..."

PG/PC interface dialog box: Beginning

Dialog: Setting the PG/PC interface

Tab: Access path
Access point of the application:
S7ONLINE STEP7 --> SOFTMC
Interface parameter assignment used:
SOFTMC

PG/PC interface dialog box: End

If SOFTMC cannot be selected for the interface parameterization, the interface has to be
installed first.

Button: "Select..."
Dialog: Install/remove interface
Selection: SOFTMC
Button: "Install-->"
Close
OK
Finally, the routing information must be set in the interface dialog of SimoCom U.

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 Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

10.1.6 Setting the routing information

Expert mode
The simplest way of setting the following routing information is to use the Experts mode after
resetting the routing information:
● MPI address of the PLC
● PROFIBUS subnet ID

NOTICE
The MPI/DP (X102) interface of the MCI board must be networked for the PLC for
routing on the PROFIBUS. The networking can be undertaken either via MPI or via
PROFIBUS.
Refer to Chapter "Parameterizing the PROFIBUS interface (X102)
(optional)" (Page 167) or Chapter "Parameterizing the MPI interface (X102)
(optional)" (Page 169).

SimoCom U dialog box: End

Button: "Reset routing information..."

Radio button: Expert mode ☑
MPI No: 2 (see note: MPI address of the PLC)
PROFIBUS: <Subnet ID> (see Section: "Determine PROFIBUS S7 subnet ID")
OK or Go online

NOTICE
MPI address of the PLC
In SINUMERIK 840Di sl, the routing of the Ethernet connection to the PROFIBUS DP is
provided by the PLC. Therefore, the MPI address of the PLC must be specified as the "MPI
No".
In SINUMERIK 840Di sl, the PLC always has the MPI address 2.

PROFIBUS S7 subnet ID,

Enter the 8-digit PROFIBUS subnet ID of DP master (S7 project) in the 12-digit input form of
the SimoCom U dialog box as follows:
Example:
S7 project: 8-digit S7 subnet ID:

Manual
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Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

  

SimoCom U: 12-digit S7 subnet ID:

     

Determine PROFIBUS S7 subnet ID

If you do not have the PROFIBUS S7 subnet ID, you can call it using the SIMATIC Manager
STEP 7.
To do so, proceed as follows:
● Open the appropriate S7 project in the SIMATIC Manager S7.
● Select the appropriate station (in the example project: SIMATIC 300)
● Open the hardware configuration of the station (double-click with left mouse button on:
Hardware; "HW Config" will be started)
● Open DP master (in the example project: DP master) (double-click with left mouse button
on DP master)
● You will find the subnet ID as follows using the Properties dialog box of the DP master:

Dialog

Dialog: Properties - DP master

Tab: General
Group: Interface
Type: PROFIBUS
address: 2
Button: "Properties..."
Dialog: Properties - PROFIBUS interface DP master:
Tab: Parameter
Subnet: PROFIBUS
Button: "Properties..."
Dialog: Properties PROFIBUS
Tab: General
S7 subnet ID: 0010 - 0005 (Please note, example only)
Cancel
Cancel
Cancel
The online operation with the drives connected to PROFIBUS can now be started.

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 Drive commissioning (SIMODRIVE)
10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI

10.1.7 Starting online operation

After parameterization of the access interface and entry of the routing information, SimoCom
U can enter online operation with the SIMODRIVE drives.

Start the search.

To start the search for connected drives, follow these steps:
● Quit the dialog box described above for setting the access interface with button: "Go
online"
or
● use menu command Commissioning > Search for online drives

Display of the drives

The SIMODRIVE drives with which SimoCom U could start the online operation are
displayed in the SimoCom U main screen:
● Drive and dialog browser (left window)
● Status overview (upper status bar)

Manual
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Drive commissioning (SIMODRIVE)
10.2 Installing SimoCom U

10.2 Installing SimoCom U

Installation
SimoCom U is part of the 611U toolbox supplied with the SINUMERIK 840Di sl.
● Installation directory: refer to Chapter "Overview of software components" (Page 31)
Engineering Tools > SIMODRIVE 611 universal toolbox > SimoCom U
To install SimoCom U, start file setup.exe and follow the further installation instructions.

Note
Before you install SimoCom U please consult the relevant notes in the readme.txt file in the
installation directory.

Scope of functions
SimoCom U provides the following functions:
● Make an online connection to the drives
● Upgrade firmware
● Optimize the control parameters
● Traversing axes
● Diagnose the drive status

Online help
After installation, the documentation for SimoCom U is available electronically. Use the menu
command Help in SimoCom U to call information on the topics:
● Short introduction...
● How to Use WINDOWS Help...
● Contents...
● Key Operation...
● Wiring...
● About SimoCom U...
References:
Besides, a detailed description of SimoCom U is available in:
/FBU/ Function Manual SIMODRIVE 611 universal

Manual
354 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
NC Commissioning with HMI Advanced 11
11.1 General procedure
The NC is parameterized for the connected machine by setting system variables.
These system variables are designated as follows:
● Machine data (MD)
● Setting data (SD).

Manual
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NC Commissioning with HMI Advanced
11.2 Machine and setting data

11.2 Machine and setting data

Machine data
Machine data are system variables used to adapt the NC to the machine.

Name
The identifier of a machine data is subject to the scheme:
$ M k _IdentifierString
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:
● POWER ON
● Reconfiguration
● Reset
● Effective immediately.

Setting data
Setting data are system variables that indicate the current machine properties to the NC.

Manual
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 NC Commissioning with HMI Advanced
11.2 Machine and setting data

Name
The identifier of a setting data is subject to the scheme:
$ S k _IdentifierString
where the following applies:
● $: System variable
● S: Setting data
● k: Component
k identifies the components of the 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 machine data

The machine data is divided into the following areas:

Table 11-1 Overview of machine data

Area Description
from 1000 to 1799 Machine data for drives ($MD_....)
from 9000 to 9999 Machine data for operator panel ($MM_....)
from 10000 to 18999 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

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NC Commissioning with HMI Advanced
11.2 Machine and setting data

Overview of setting data

The setting data are divided into the following areas:

Table 11-2 Overview of setting data

Area Description
from 41000 to 41999 General setting data ($SN_....)
from 42000 to 42999 Channel-specific setting data ($SC_....)
from 43000 to 43999 Axis-specific setting data ($SA_....)

Data description
For a detailed description of the machine or setting data, please refer to Function Manual of
the function that uses the machine data in question, e.g.:
References:
/FB/ Function Manual - Basic Functions
/FB/ Function Manual - Extended Functions
/FB/ Function Manual - Special Functions
A concise table of all machine and setting data is to be found in:
References:
/LIS/ Lists, Machine- and Setting Data

Note
To search for information regarding machine and setting data, it is recommended to use the
search functions in the electronic documentation of SINUMERIK DOConCD.

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 NC Commissioning with HMI Advanced
11.2 Machine and setting data

11.2.1 Display and input

Machine data screen forms

To display and input machine data, appropriate screen forms are provided.
The screen forms are found on the HMI Advanced user interface at:
Area switchover > Commissioning > Machine data

NOTICE
For the input of machine data, the protection level 2 password (default "EVENING") has to
be set at the least.

Bit editor
To facilitate the input of machine data in the bit format (HEX), a bit editor is provided.
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).

Figure 11-1 Input screen form of the bit editor for HEX machine data

You can set or reset single bits by clicking them with the mouse or by selecting them with the
cursor keys and then pressing the toggle key.
● With the softkey OK, you can terminate the bit editor and accept the value set.
● With the softkey Abort, you can quit the bit editor and discard the value set. The previous
setting is then valid again.

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NC Commissioning with HMI Advanced
11.2 Machine and setting data

11.2.2 Protection levels

Access authorization
Access to programs, data and functions is useroriented and controlled via 8 hierarchical
protection levels. These are divided into (see following table ):
● 4 password levels for Siemens, machine manufacturer and end user
● 4 key switch positions for end user
This provides a multilevel safety concept for controlling access rights.

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Password Set
For the four possible password levels with their access permissions, the passwords can be
entered in the control area DIAGNOSIS by actuating the softkey SET PASSWORD.
References:
/BAD/ Operating Manual HMI Advanced

Resetting the password

Please note that a password remains valid until access authorization is reset with the softkey
DELETE PASSWORD. Access authorization is therefore not automatically deleted during
POWER ON!

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 NC Commissioning with HMI Advanced
11.2 Machine and setting data

Possible characters
Up to eight characters are possible in a password. We recommend that you restrict yourself
to the character set of the operator panel in selecting a password. Where a password
consists of less than eight characters, the additional characters are interpreted as blanks.

Default passwords
The following default passwords have been set for protection levels 1 to 3:
● Protection level 1: SUNRISE
● Protection level 2: EVENING
● Protection level 3: CUSTOMER

NOTICE
A system power-up with loading the default machine data (after "Delete NC data", e.g.
using 840Di Startup) will reset the passwords to the default values.
These passwords should be changed to ensure effective access protection.

Redefining protection levels

The protection levels of machine and/or setting data can be modified both with respect to
complete machine or setting data ranges and for single data.

Data areas

Table 11-3 Protection levels: Machine data

Number Name Name

MMC machine data ($MM_.... )
9200 USER_CLASS_READ_TOA Read tool offsets
9201 USER_CLASS_WRITE_TOA_GEO Write tool geometry
9202 USER_CLASS_WRITE_TOA_WEAR Write tool wear data
9203 USER_CLASS_WRITE_FINE Write Fine
9204 USER_CLASS_WRITE_TOA_SC Change additive tool offsets
9205 USER_CLASS_WRITE_TOA_EC Change tool setup offsets
9206 USER_CLASS_WRITE_TOA_SUPVIS Change tool monitoring limit values
9207 USER_CLASS_WRITE_TOA_ASSDNO Change D No. assigned to a tool edge
9208 USER_CLASS_WRITE_MAG_WGROUP change wear group magazine location/mag.
9209 USER_CLASS_WRITE_TOA_ADAPT Tool adapter data
9210 USER_CLASS_WRITE_ZOA Write settable zero offset
9213 USER_CLASS_OVERSTORE_HIGH Extended overstore
9214 USER_CLASS_WRITE_PRG_CONDIT Program control
9215 USER_CLASS_WRITE_SEA Write setting data
9218 USER_CLASS_SELECT_PROGRAM Program selection

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NC Commissioning with HMI Advanced
11.2 Machine and setting data

Number Name Name

9219 USER_CLASS_TEACH_IN TEACH IN
9220 USER_CLASS_PRESET PRESET
9221 USER_CLASS_CLEAR_RPA Deleting R parameters
9222 USER_CLASS_WRITE_RPA Write R parameters
9231 USER_CLASS_WRITE_RPA_1 Write protection for first RPA area
9232 USER_BEGIN_WRITE_RPA_1 Start of the first RPA area
9233 USER_END_WRITE_RPA_1 End of the first RPA area
9234 USER_CLASS_WRITE_RPA_2 Write protection for second RPA area
9235 USER_BEGIN_WRITE_RPA_2 Start of the second RPA area
9236 USER_END_WRITE_RPA_2 End of the second RPA area
9237 USER_CLASS_WRITE_RPA_3 Write protection for third RPA area
9238 USER_BEGIN_WRITE_RPA_3 Start of the third RPA area
9239 USER_END_WRITE_RPA_3 End of the third RPA area
9240 USER_CLASS_WRITE_TOA_NAME Change tool designation and duplo
9241 USER_CLASS_WRITE_TOA_TYPE Change tool type
9247 USER_CLASS_BASE_ZERO_OFF_PA Basic offset PA
9248 USER_CLASS_BASE_ZERO_OFF_MA Basic offset MA
References:
/FB/ Function Manual, Basic Functions, A2 various Interface Signals, Chapter "MMC
Machine data for protection levels"

Single data units

The protection level of individual machine and/or setting data can be modified in the file
SGUD.DEF.
Example:
The axial machine data item CTRLOUT_SEGMENT_NR requires protection level 3 for
reading and protection level 2 for writing.
Syntax:
REDEF $machine data string APR n APW m
APR n: Defining the protection level for reading (Read) the data
APW m: Defining the protection level for writing (Write) the data
SGUD.DEF file:
%_N_SGUD_DEF
;$PATH=/_N_DEF_DIR
REDEF $MA_CTRLOUT_SEGMENT_NO APR 3 APW 2
M30
References:
/PGA/ Programming Manual, Work Planning, Chapter "File and Program Administration",
defining protection levels for user data (GUD)

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 NC Commissioning with HMI Advanced
11.2 Machine and setting data

11.2.3 Machine data display filter

Through the use of the machine data display filter, it is possible to reduce the number of
displayed machine data of a certain area, e.g. general machine data or channel machine
data, for special purposes.

Machine data areas

Display filters are available for the following machine data areas:
● General machine data
● Channel-specific machine data
● Axis-specific machine data
● Drive machine data

Display filter
To parameterize the display filter of a machine data area, use the vertical softkey Display
options... in the appropriate machine data area.
Example:
Display filter for channel machine data
Operating area: Commissioning -> Machine Data -> Channel MD -> Display Options...

Note
To find out which display group a machine data item belongs to, refer to the display filter
parameter associated with the description of the machine data element in question.
References:
/LIS/ Lists

Display groups
A display group contains machine data within a machine data area that belong to the same
topic.
By selecting/deselecting the display groups, the number of displayed machine data of the
current machine data area increases or decreases.

Expert mode
If the Expert mode display filter is disabled, only the machine data of a machine data range
are displayed that are required for the basic functionality of the NC.

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NC Commissioning with HMI Advanced
11.2 Machine and setting data

Index from ... to

The index filter refers to the machine data-fields. On the display, these machine data can be
identified by the field index attached to the machine data string.
Example: 10000 AXCONF_MACHAX_NAME_TAB[index]
If the index filter is activated, machine data fields are only displayed in the specified index
area.

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 NC Commissioning with HMI Advanced
11.3 System data

11.3 System data

11.3.1 Resolutions
Resolutions, e.g. resolutions of linear and angular positions, velocities, accelerations and
jerk, must be differentiated as follows:
● the input resolution, i.e. the input of data from the user interface or using the part
programs.
● the display resolution, i.e. the display of data on the user interface.
● the computational resolution, i.e. the internal representation of the data input through the
user interface or the part program.

Input and display resolution

The input and display resolution is specified via the control panel being used, whereby the
display resolution of position values can be changed with MD9004
$MM_DISPLAY_RESOLUTION (display resolution).
MD9011 $MM_DISPLAY_RESOLUTION_INCH (INCH unit system display resolution) 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 part programs, the input resolutions listed in the Programming
Manual apply.

Computational resolution
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:
● MD10200 $MN_INT_INCR_PER_MM (computational resolution for linear positions)
● MD10210 $MN_INT_INCR_PER_ DEG (computational resolution for angular positions)
The default assignment is:
● 1000 increments/mm
● 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.

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NC Commissioning with HMI Advanced
11.3 System data

Rounding
The precision of angle and linear positions is limited to the computational resolution by
rounding the product of the programmed value with the computational resolution to an
integer number.
Example of rounding:
Computational resolution: 1000 increments/mm
Programmed path: 97.3786 mm
Effective value = 97.379 mm

Note
To keep rounding easily understandable, it is better to use powers of 10 for the
computational resolution (100, 1000, 10,000).

Display resolution
In MD9004 $MM_DISPLAY_RESOLUTION (display resolution), you can set the number of
decimal places after the decimal point for the position values on the operator panel.

Input and display limit values

Limitation of the input values depends on the display features and on the input options on
the operator panel. The limit is ten digits plus comma and sign.
Example of programming in the 1 /10-μm range:
All the linear axes of a machine are to be programmed and traversed within the value range
0.1 ... 1000 μm.
In order to position accurately to 0.1 μm, the computational resolution must be set to ≥ 104
incr./mm.
MD10200 $MN_INT_INCR_PER_MM = 10000 [Inkr./mm]:
Example of related part program:

N20 G0 X 1.0000 Y 1.0000 ; Axes travel to the position

X=1.0000 mm, Y=1.0000 mm;
N25 G0 X 5.0002 Y 2.0003 ; Axes travel to the position
X=5.0002 mm, Y=2.0003 mm

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11.3 System data

Machine data

Table 11-4 Resolutions: Machine data

Number Name Name/remarks

General ($MN_ ... )
9004 DISPLAY_RESOLUTION Display resolution
9011 DISPLAY_RESOLUTION_INCH Display resolution for INCH system of measurement
10200 INT_INCR_PER_MM Computational resolution for linear positions
10210 INT_INCR_PER_DEG Computational resolution for angular positions
References:
/FB/ Function Manual, Basic Functions, G2 Velocities, Traversing Ranges, Accuracies,
Chapter: I/O Resolution, Computational Resolution

11.3.2 Standardization of physical units of machine data and setting data

Standard
Machine and setting data having a physical unit are interpreted in the input/output units listed
in the following table by default, depending on the scaling system (metric/inch).
The internally used units which the NC uses are independent and fixed.

Table 11-5 Normalization of phys. units of machine data and setting data

Physical unit Input/output units for the standard scaling system Internally used unit
Metric Inch
Linear position 1 mm 1 inch 1 mm
Angular position 1 degrees 1 degrees 1 degrees
Linear velocity 1 mm/min. 1 inch/min. 1 mm/s
Angular velocity 1 rpm 1 rpm 1 deg./s
Linear acceleration 1 m/s2 1 inch/s2 1 mm/s2
Angular acceleration 1 rev/s2 1 rev/s2 1 degree/s2
Linear jerk 1 m/s3 1 inch/s3 1 mm/s3
Angular jerk 1 rev/s3 1 rev/s3 1 degree/s3
Time 1s 1s 1s
Position controller servo gain 1 s-1 1 s-1 1 s-1
Rev. feedrate 1 mm/rev 1 inch/rev 1 mm/degree
Compensation value linear position 1 mm 1 inch 1 mm
Compensation value angular position 1 degrees 1 degrees 1 degrees

Manual
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NC Commissioning with HMI Advanced
11.3 System data

User-defined
The user can define different input/output units for machine and setting data.
For this there must be an adjustment between the newly selected input/output units and the
internal units via the following MD:
● MD10220 $MN_SCALING_USER_DEF_MASK (activation of standardizing factors) and
● MD10230 $MN_SCALING_FACTORS_USER_DEF[n] (standardizing factors of the
physical quantities)

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The following applies:

Selected I/O unit =
MD10230 $MN_SCALING_FACTORS_USER_DEF[n] * internal unit
The selected I/O unit, expressed in the internal units 1 mm, 1 degree and 1 s must therefore
be entered in MD10230 $MN_SCALING_FACTORS_USER_DEF[n].

Table 11-6 Bit number and index for user definition

Physical unit MD10220: MD10230:

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

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 NC Commissioning with HMI Advanced
11.3 System data

Physical unit MD10220: MD10230:

Bit number Index n
Kv factor 9 9
Rev. feedrate 10 10
Compensation value linear position 11 11
Compensation value angular position 12 12
Example 1:
Machine data input/output of the linear velocities is to be in m/min instead of mm/min (initial
setting). The internal unit is mm/s.
MD10220 $MN_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:

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 PLQ  
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V V

ൺ0'01B6&$/,1*B)$&7256B86(5B'()>@ 

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
are to be performed in ft/s2 instead of m/s2 (default setting). (the internal unit is mm/s2).

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Vt Vt

ൺ0'01B6&$/,1*B)$&7256B86(5B'()>@ 

Index 4 specifies the "linear acceleration" (see above).

Manual
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NC Commissioning with HMI Advanced
11.3 System data

Table 11-7 Normalization of physical units of machine data and setting data: Machine data

Number Name Name/remarks

General ($MN_ ... )
10220 SCALING_USER_DEF_MASK Activation of standardizing factors
10230 SCALING_FACTORS_USER_DEF[n] Standardizing factors of physical quantities
10240 SCALING_SYSTEM_IS_METRIC Basic system metric
10250 SCALING_VALUE_INCH Conversion factor for switch-over to inch system
10260 CONVERT_SCALING_SYSTEM Basic system switch-over active
10270 POS_TAB_SCALING_SYSTEM Measuring system of position tables
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

11.3.3 Changing scaling machine data

The scaling of machine data having physical units is defined by the following machine data:
● MD10220 $MN_SCALING_USER_DEF_MASK (activation of standardizing factors)
● MD10230 $MN_SCALING_FACTORS_USER_DEF (standardizing factors of the physical
quantities)
● MD10240 $MN_SCALING_SYSTEM_IS_METRIC (basic system metric)
● MD10250 $MN_SCALING_VALUE_INCH (conversion factor for switchover to INCH
system)
● MD30300 $MA_IS_ROT_AX (rotary axis)
When scaling machine data are modified, all machine data affected by this modification due
to their physical unit are converted with the next NC reset.
Example: Redefining an A1 axis from linear to rotary axis
The control has been commissioned with default values. Axis A1 is declared as a linear axis.
● MD30300 $MA_IS_ROT_AX[A1] = 0 (no rotary axis)
● MD32000 $MA_MAX_AX_VELO [A1] = 1000 [mm/min] (max. axis velocity).
Axis A1 is now declared as a rotary axis containing the following machine data:
● MD30300 $MA_IS_ROT_AX[A1] = 1 (rotary axis)
● MD32000 $MA_MAX_AX_VELO [A1] = 1000 [mm/min] (max. axis velocity).
With the next NC reset, the control system recognizes that axis A1 is defined as a rotary axis
and rescales MD32000 $MA_MAX_AX_VELO related to a rotary axis [rev./min].
● MD30300 $MA_IS_ROT_AX[A1] = 1 (rotary axis)
● MD32000 $MA_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".

Manual
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 NC Commissioning with HMI Advanced
11.3 System data

Modifying manually
The following procedure is recommended when modifying scaling machine data manually:
1. Set all scaling machine data
2. Initiate NC Reset
3. Set all dependent machine data after the NC has powered up.

11.3.4 Loading default machine data

The default machine data can be loaded in different ways.

840Di startup
Via the SINUMERIK 840Di sl standard interface 840Di Startup:
Menu command Window > Diagnosis > NC/PLC
● Button: "Delete NC data"
● Button: "NC Reset"

NOTICE
On deleting the NC data, all user data is lost.
To avoid data loss, a series commissioning file should be created before the NC data
are deleted. The way to create a series machine startup file is described in the Section
"Creating a series machine startup file" (Page 543).

MD11220 $MN_INIT_MD
Using the entry values listed below in MD11200 $MN_INIT_MD (loading the standard
machine data for the "next" NC boot), you can load various data storage areas with default
values at the next NC boot.
After setting the machine data, NC reset must be carried out twice:
1. NC reset: The machine data is activated.
2. NC reset: Depending on the entry value, the corresponding machine data is set to its
standard values and the MD11200 $MN_INIT_MD is reset to value "0".

Input values
MD11200 $MN_INIT_MD = 1
On the next NC boot, all machine data (with the exception of the memory configuring data)
are overwritten with default values.
MD11200 $MN_INIT_MD = 2
During the next NC boot, all memory-configuring machine data is overwritten with default
values.

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NC Commissioning with HMI Advanced
11.3 System data

11.3.5 Switching over the measuring system

The unit system is switched over for the entire machine using a softkey in the HMI Advanced
operating area "MACHINE". The switchover is accepted only if:
● MD10260 $MN_CONVERT_SCALING_SYSTEM=1.
● Bit 0 of MD20110 $MC_RESET_MODE_MASK is set in every channel.
● All channels are in the Reset state.
● Axes are not traversing with JOG, DRF or PLC control.
● Constant grinding wheel peripheral speed (GWPS) is not active.
Actions such as part program start or mode change are disabled for the duration 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 $MN_SCALING_SYSTEM_IS_METRIC and the corresponding
G70/G71/G700/G710 settings in MD20150 $MC_GCODE_RESET_VALUES are switched
over automatically and consistently for all configured channels.
The value of machine data: MD20150 $MC_GCODE_RESET_VALUES[12] varies between
G700 and G710.
This process takes place independently of the protection level currently set.

System data
When changing over the measuring system, from the view of the user, all length-related
specifications are converted to the new measuring system automatically. 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 the changeover, all of the above-mentioned data is available in the physical quantities
described in Subsection "Scaling physical quantities of machine and setting
data" (Page 367).

Manual
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11.3 System data

The following data for which no unique physical units are defined is not converted
automatically:
● R parameters
● GUDs (Global User Data)
● LUDs (Local User Data)
● PUDs (Program global User Data)
● Analog inputs/outputs
● Data exchange via FC21
The user is prompted to take the current valid measuring system MD10240
$MN_SCALING_SYSTEM_IS_METRIC into consideration.
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 11-8 Switching over the unit system: Machine data

Number Name Name/remarks

General ($MN_ ... )
10240 SCALING_SYSTEM_IS_METRIC Basic system metric
10250 SCALING_VALUE_INCH Conversion factor for switch-over to inch system
10260 CONVERT_SCALING_SYSTEM Basic system switch-over active
Axisspecific ($MA_ ... )
32711 CEC_SCALING_SYSTEM_METRIC System of measurement of sag compensation
References:
/FB/ Function Manual, Basic Functions; G2 Velocities, Setpoint/Actual Value Systems,
Control, Chapter "Metric/inch dimension system"

Manual
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NC Commissioning with HMI Advanced
11.3 System data

11.3.6 Traversing ranges

Computational resolution and traversing ranges

The range of values of the traversing ranges directly depends on the selected computational
resolution (see Subsection "Resolutions" (Page 365)).
For the default value assignment of the machine data for the computational resolution 1000
Incr./mm or 1000 Incr./deg. there are the following traversing ranges:

Table 11-9 Traversing ranges

Traversing range in the metric Traversing range in the inch

system system
Linear axes ± 999,999.999 [mm; deg.] ± 399,999.999 [inch; deg.]
Rotary axes ± 999,999.999 [mm; deg.] ± 999,999.999 [inch; deg.]
Interpolation parameters I, J, K ± 999,999.999 [mm; deg.] ± 399,999.999 [inch; deg.]

11.3.7 Positioning accuracy of the control system

Computational resolution and traversing ranges

The positioning accuracy depends on:
● the computational accuracy (internal increments/(mm or degrees))
● the actual-value resolution (encoder increments/(mm or degrees)).
The rougher resolution of both values determines the positioning accuracy of the NC.
The input resolution, the position control and interpolation clock do not affect the accuracy.

Machine data

Table 11-10 Positioning accuracy: Machine data

Number Name Name/remarks

General ($MN_ ... )
10200 INT_INCR_PER_MM Computational resolution for linear positions
10210 INT_INCR_PER_DEG Computational resolution for angular positions
Axisspecific ($MA_ ... )
31020 ENC_RESOL[n] Encoder pulses per revolution

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 NC Commissioning with HMI Advanced
11.3 System data

11.3.8 Cycle times

On the SINUMERIK 840Di sl, the system clock cycle, the position controller cycle and the
interpolation cycle of the NC are based on the DP cycle time configured in STEP 7 "HW
Config" (see Section "Create SIMATIC S7 Project" (Page 160)).

Basic system cycle

The DP cycle time configured in STEP 7 is taken over as the system clock cycle and
displayed in the following machine data:
● MD10050 $MN_SYSCLOCK_CYCLE_TIME (system clock) = DP cycle time

Note
The DP cycle time configured in STEP 7 "HW Config" is only taken as the system clock
cycle from the NC if at least one real machine axis is parameterized in the NC machine
data.
If no real machine axis is parameterized, the value of the machine data functions as the
system clock cycle:
• MD 10050 $MN_SYSCLOCK_CYCLE_TIME

Position controller cycle

The ratio of position controller cycle to system clock cycle for SINUMERIK 840Disl is always
1:
● MD10060 $MN_POSCTRL_SYSCLOCK_TIME_RATIO = 1

Note
The machine data is not displayed for SINUMERIK 840Di sl.

Position controller cycle offset

The position controller cycle offset (TM) must be set so that the following conditions are
fulfilled within a DP cycle (TDP):
● Cyclic communication with the DP slaves (drives) must be completed before the position
controller is started.
Condition: TM > TDX
● The position controller must be completed before the DP cycle is completed.
Condition: TM + TPos < TDP
The following setting is recommended as approximate value for the position control cycle
offset:
TM = TDP - 3*Tpos max
● TDP
The DP cycle time is equivalent to the position controller cycle of the SINUMERIK 840Di
sl.
● TPos max
Display via HMI Advanced (option):
Operating area switchover > Diagnosis > Service Displays > System Resources

Manual
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NC Commissioning with HMI Advanced
11.3 System data

● MD10062 $MN_POSCTRL_CYCLE_DELAY (position control cycle delay) = TM

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Figure 11-2 Position controller cycle offset compared to PROFIBUS DP cycle

Explanations for the figure:

TPos Computing time requirements for the position controller

TDP DP cycle time: DP cycle time
TDX Data exchange time: Total transfer time for all DP slaves
TM Master time: Offset of the start time for NC position control
GC Global Control: Broadcast message for cyclic convergence of the
equidistance between DP master and DP slaves
R CPU time
Dx Useful data exchange between the DP master and DP slaves
MSG Acyclic services (e.g. DP/V1, pass token)
RES Reserve: "Active break" until the equidistant cycle has expired

Interpolation cycle
The interpolator cycle may be chosen freely as a whole multiple of the position control cycle.
● MD10070 $MN_IPO_SYSCLOCK_TIME_RATIO (factor for the interpolation cycle)

NC CPU time share

The processor power of the PCU must be shared between the NC and Windows XP. The
parameterized CPU time share of the NC is the maximum value that the NC will only use in
the worst case. If the NC requires less CPU time in cyclical operation, it will cede it
dynamically to Windows XP.

Manual
376 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.3 System data

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Figure 11-3 CPU time division between Windows XP and NC

● MD10185 $MN_NCK_PCOS_TIME_RATIO (CPU time share NC)

Individual setting
The default value for the NC CPU time share is 50%. An individual setting can only be made
by the following formula:
MD10185 >= 300 * (TPos max * MD10070 + TIPO max + 0.2ms) / MD10071
with:
● TPos max and TIPO max
TPos max [ms] and TIPO max [ms] are the relevant maximum netruntime of the position
controller or interpolator. The data is displayed via HMI Advanced (option) under:
Operating area switchover > Diagnosis > Service Displays > System Resources
● MD10070 $MN_IPO_SYSCLOCK_TIME_RATIO (factor for the interpolation cycle)
● MD10071 $MN_IPO_CYCLE_TIME (interpolator cycle) [ms]

Note
The values displayed by HMI Advanced in the System Resources menu refer to the total
power of the CPU, not just to the CPU time share of the NC set via MD 10185
$MN_NCK_PCOS_TIME_RATIO.

The values for Tpos max and TIPO max are considerably 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 part 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.

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NC Commissioning with HMI Advanced
11.3 System data

The maximum value for the NC CPU time share of 75 % must not be exceeded. A value
greater than 75 % can lead to significant impairment (slowing down) of Windows XP
applications. If necessary, the values must be adapted to the system clock cycle/position
controller cycle (DP cycle time) and/or interpolation cycle.
References:
/FB/ Function Manual - Special Functions, G3 Cycle Times

Machine data

Table 11-11 Cycle times: Machine data

Number Name Name/remarks

General ($MN_ ... )
10050 SYSCLOCK_CYCLE_TIME System clock cycle/only display data; is always equal
to the equidistant PROFIBUS DP cycle.
Note: In 840Di sl only for display!
10060 POSCTRL_SYSCLOCK_TIME_ Factor for the position control cycle/is set fixed to the
RATIO factor 1.
Note: Is not displayed for 840Di sl!
10062 POSCTRL_CYCLE_DELAY Position control cycle offset
10070 IPO_SYSCLOCK_TIME_RATIO Factor for the interpolator cycle/can be freely selected
in integer multiples.

CAUTION
If you change the cycle times, check the behavior of the controller 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.

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11.3 System data

11.3.9 Velocities

Max. axis velocity or spindle speed

The maximum possible axis velocities and spindle speeds depend on the machine design,
drive dynamics and the encoder limit frequency of the individual drives.

Max. programmable path velocity

The maximum programmable tool path velocity results from the maximum axis velocities of
the axes involved in the path programmed.

Max. tool path velocity

The maximum tool path velocity at which traversing is possible within a parts program block
results as follows:

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9PD[
,32F\FOH>V@

High limit
To guarantee that parts program blocks are executed continuously (control margin), the NC
limits the tool path velocity within a parts program block to 90% of the max. possible tool
path velocity as follows:

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9PD[ื 
,32F\FOH>V@

For example, in the case of part programs generated by means of CAD system, which
contain extremely short blocks, this limiting of the path velocity can result in a strong
reduction of the path velocity over several part program blocks.
The function "Online compressor" can help to avoid such sudden velocity dips.
References:
/PGA/ Programming Manual, Advanced, Chapter "Compressor COMPON/COMPCURVE"

Manual
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NC Commissioning with HMI Advanced
11.3 System data

Lower limit
The minimum tool path or axis velocity at which traversing is possible results from:


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(for the computational resolution, see Subsection "Resolutions" (Page 365))

If Vmin is not reached, no traversing movement is carried out.
References:
/FB/ Function Manual - Basic Functions, G2 Velocities, Traversing Ranges, Accuracies,
Subsection "Velocities"

Manual
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 NC Commissioning with HMI Advanced
11.4 Memory configuration

11.4 Memory configuration

Hardware configuration
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 sl.

SDRAM DRAM for 840Di sl 1) SRAM

Maximum
PCU 50.3-C/1.5 GHz 512 MB Approx. 16 MB -
PCU 50.3-P/2.0 GHz 1024 MB Approx. 16 MB -
MCI board - - 5 MB 2)
1) DRAM component (main memory) occupied by SINUMERIK 840Di sl and is thus no
longer available for Windows NT.
2) The SRAM memory of the MCI board is divided into:
● Part programs and manufacturer cycles: 3 MB
● User data: 1 MB
● Siemens cycles: 1 MB

User data
The individual memory areas of the user data are set to reasonable default values 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.:
● Part programs
● Tool management
● Tool offsets
● User data
● R parameters
● Compensations
● Protection zones
● Frames
(See Subsection "SRAM memory" (Page 383))
The memory must be sectionalized before commencement of the actual NC commissioning,
because all user data (e.g. part programs, tool offsets) will be lost during a change.
Machine data, setting data, and option data are not lost when the memory is reorganized.

Activation
The machine data of the memory configuration are activated by power ON.
References:
/FB/ Funktions Manual, S7 Memory Configuration

Manual
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NC Commissioning with HMI Advanced
11.4 Memory configuration

11.4.1 DRAM memory

Free memory
The free DRAM memory is displayed via the following machine data:
● MD18050 $MN_INFO_FREE_MEM_DYNAMIC (free dynamic memory)
The free DRAM should not be less than 15,000 bytes.

CAUTION
Before you enlarge DRAM areas, you should first check whether the free memory is
sufficient:
• MD18050 $MN_INFO_FREE_MEM_DYNAMIC (free dynamic memory)
If more dynamic memory is requested than is available, the SRAM and therefore all user
data will be cleared without prior warning on the next NC startup!
To avoid data loss, a series startup file should be created before reconfiguration (see
Section "Creating a Series Startup File" (Page 543)).

Machine data
Table 11-12 Machine data required to configure the DRAM

Number Name Name/remarks

General ($MN_ ... )
18050 INFO_FREE_MEM_DYNAMIC Display data of the free dynamic memory
18170 MM_NUM_MAX_FUNC_NAMES Number of miscellaneous functions
18180 MM_NUM_MAX_FUNC_PARAM Number of additional parameters
18210 MM_USER_MEM_DYNAMIC User memory in DRAM
18240 MM_LUD_HASH_TABLE_SIZE Hash table size for user variables
18242 MM_MAX_SIZE_OF_LUD_VALUE Maximum field size of the LUD variables
18250 MM_CHAN_HASH_TABLE_SIZE Hash table size for channel-specific data
18260 MM_NCK_HASH_TABLE_SIZE Hash table size for global data
18340 MM_NUM_CEC_NAMES Number of LEC tables
18342 MM_CEC_MAX_POINTS Max. table size for sag compensation
18500 MM_EXTCOM_TASK_STACK_SIZE Stack size for external communication task
18510 MM_SERVO_TASK_STACK_SIZE Stack size of servo task
18520 MM_DRIVE_TASK_STACK_SIZE Stack size of drive task
Channelspecific ($MC_ ... )
20096 T_M_ADDRESS_EXIT_SPINO Spindle number as address extension
27900 REORG_LOG_LIMIT Percentage of IPO buffer for log file enable
28000 MM_REORG_LOG_FILE_MEM Memory size for REORG
28010 MM_NUM_REORG_LUD_MODULES Number of modules for local user variables with REORG
28020 MM_NUM_LUD_NAMES_TOTAL Number of local user variables
28040 MM_LUD_VALUES_MEM Memory size for local user variables

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11.4 Memory configuration

Number Name Name/remarks

28060 MM_IPO_BUFFER_SIZE Number of NC blocks in the IPO buffer
28070 MM_NUM_BLOCKS_IN_PREP Number of blocks for block preparation
28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for Compile cycles
28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for Compile cycles
28105 MM_NUM_CC_HEAP_MEM Heap memory for compile cycle applications
28210 MM_NUM_PROTECT_AREA_ACTIVE Number of simultaneously active protection zones
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 compensation

11.4.2 SRAM memory

Free memory
The free SRAM memory is displayed via the following machine data:
● MD18060 $MN_INFO_FREE_MEM_STATIC (free static memory)
The free SRAM should not be less than 15,000 bytes to ensure that data (e.g. tool offsets)
can be read in at all times.

Reconfiguation of the SRAM memory

Modifying the machine data listed in the following table results in a reconfiguration of the
SRAM with a loss of all user data. Before the change becomes effective in the NC, the
following alarm message is generated:
● 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 losses, a
series startup file should be created before reconfiguration (see Section "Creating a
Series Startup File" (Page 543)).

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11.4 Memory configuration

Machine data

Table 11-13 Machine data required to configure the SRAM

Number Name Name/remarks

General ($MN_ ... )
18060 INFO_FREE_MEM_STATIC Display data of the free static memory
18080 MM_TOOL_MANAGEMENT_MASK Screen form for reserving memory for the tool management
18082 MM_NUM_TOOL Number of tools managed by NC
18084 MM_NUM_MAGAZINE Number of magazines managed by NC
18086 MM_NUM_MAGAZINE_LOCATION Number of magazine locations
18090 MM_NUM_CC_MAGAZINE_PARAM Compile cycles of tool management: Number of magazine data
18092 MM_NUM_CC_MAGLOC_PARAM Compile cycles of tool management: Number of magazine
location data
18094 MM_NUM_CC_TDA_PARAM Compile cycles of tool management: Number of TDA data
18096 MM_NUM_CC_TOA_PARAM Compile cycles of tool management: Number of TOA data
18098 MM_NUM_CC_MON_PARAM Compile cycles of tool management: Number of monitor data
18100 MM_NUM_CUTTING_EDGES_IN_TOA Number of tool offsets
18118 MM_NUM_GUD_MODULES Number of GUD modules
18120 MM_NUM_GUD_NAMES_NCK Number of global user variables
18130 MM_NUM_GUD_NAMES_CHAN Number of channel-specific user variables
18140 MM_NUM_GUD_NAMES_AXIS Number of axis-specific user variables
18150 MM_GUD_VALUES_MEM Memory reserved for global user variables
18160 MM_NUM_USER_MACROS Number of macros
18190 MM_NUM_PROTECT_AREA_NCK Number of protection areas
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
28200 MM_NUM_PROTECT_AREA_CHAN Number of modules for channel-specific protection zones
Axisspecific ($MA_ ... )
38000 MM_ENC_COMP_MAX_POINTS Number of intermediate points with interpolatory compensation

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11.5 Axes and spindles

11.5 Axes and spindles

11.5.1 Axis configuration

Definition
The term "axis" is often used either as a single term in conjunction with SINUMERIK 840Disl
or in a compound form, e.g. machine axis, channel axis, etc. To provide an overview of the
philosophy used as the basis, here is a brief explanation of this term.
There are basically 3 types of axes:
1. Coordinate axes
2. Machine axes
3. Geometry and special axes

Coordinate axes
Coordinate axes (abscissa, ordinate, applicate) are the axes of a Cartesian coordinate
system

Machine axes
Machine axes are the motion units existing on a machine, which can also be designated as
linear or rotary axes, depending on their usable movement.

Geometry axes
The geometry axes constitute the rectangular Cartesian basic coordinate system 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 machine axes, however, is not
Cartesian at right angles, the imaging is performed using a kinematic transformation.

Special axes
Special axes are all axes of a channel that are not geometry or machine axes. Unlike for
geometry axes (Cartesian coordinate system), no geometric context is defined for additional
axes, neither between additional axes or with respect to geometry axes.

Channel axes
The total of all machine, geometry and special axes assigned to a channel is designated as
channel axes.
The geometry and special axes represent the programming side of the machining process,
i.e. they are used for programming in the part program.
The machine axes constitute the physical part of the machining process, i.e. they carry out
the programmed traversing movements on the machine.

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11.5 Axes and spindles

Axis assignment
The assignment of drives, machine axes, channel axes and geometry axes using the
corresponding machine data is shown in the following Fig.:

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Figure 11-4 Axis assignment

①
The NC is informed about the I/O addresses of the drives defined in the S7 project through
"HW Config" via machine data MD13050 $MN_DRIVE_LOGIC_ADDRESS[n] (I/O address of
the drive)
The machine data index (n+1) is the logical drive number for the NC.

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②
Each machine axis is assigned to a drive via machine data MD30110
$MA_CTRLOUT_MODULE_NR[0] (setpoint value assignment) and MD30220
$MA_ENC_MODULE_NR[0] (actual value assignment).
The logical drive number m to be entered in the two machine data refers to the entry with the
index n=(m-1) in the list described under Point 1 MD13050
$MN_DRIVE_LOGIC_ADDRESS[n].

③
Which channel axis will use which machine axis is defined explicitly and how many channel
axis are there in the channel is defined implicitly via machine data MD20070
$MC_AXCONF_MACHAX_USED[n] (machine axis number valid in channel)
The machine axis number m to be entered in the machine data (with m=1,2,3...) is referred
to the appropriate machine axis m.

④
Which channel axis is a geometrical axis is defined explicitly and how many geometry axes
exist in the channel is defined implicitly via machine data MD20050
$MC_AXCONF_GEOAX_ASSIGN_TAB[n] (assignment of geometry axis to channel axis) (n
= 0...2).
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
$MC_AXCONFIG_MACHAX_USED[n] (see Point 3).

Machine data

Table 11-14 Axis configuration: Machine data

Number Name Name/remarks

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/ Function Manual - Basic Functions; K2 Axes, Coordinate Systems, Frames, Workpiece
numbers Actual-Value System, Section "Axes"

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11.5 Axes and spindles

11.5.2 Axis names

Each machine, channel and geometry axis can/must be assigned an individual name
unambiguously identifying it in its name range.

Machine axes
The machine axis names are defined via the following machine data:
● MD10000 $MN_AXCONF_MACHAX_NAME _TAB [n] (machine axis name)
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
● Accessing axis-specific machine data (loading, saving, displaying)
● Reference point approach from the part program G74
● Measurement
● Test point traversing from the part program G75
● Traversing the machine axis from PLC
● Display of axis-specific alarms
● Display in the actual-value system (machine-related)
● DRF handwheel function

Channel axes
The channel axis names are defined via the following machine data:
● MD20080 $MC_AXCONF_CHANAX_NAME_TAB[n] (name of the channel axis in the
channel)
Channel axis names must be unambiguous for the entire channel.

Geometry axes
The geometry axis names are defined via the following machine data:
● MD20060 $MC_AXCONF_GEOAX_NAME_TAB [n] (geometry axis in the channel)
Geometry axis names must be unambiguous for the entire channel.
The axis names for channel and geometry axes are used in the part program for
programming general traversing movements or to describe the workpiece contour. The axis
names are used for:
● Path axes
● Synchronized axes
● Positioning axes
● Command axes
● Spindles
● Gantry axes
● Coupled axes
● Guide value coupling axes

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Machine data

Table 11-15 Axis names: Machine data

Number Name Name/remarks

General ($MN_ ... )
10000 AXCONF_MACHAX_NAME_TAB Machine axis name
Channelspecific ($MC_ ... )
20060 AXCONF_GEOAX_NAME_TAB Geometry axis name in channel
20080 AXCONF_CHANAX_NAME_TAB Channel axis name/special axis name in channel
References:
/FB/ Function Manual - Basic Functions; K2 Axes, Coordinate Systems, Frames, Workpiece
numbers Actual-Value System, Section "Axes"

11.5.3 Drive configuration

The following data must be assigned parameters in the NC for the cyclic process data
exchange between the NC and the DP slave drives:
● I/O address of the drives
● I/O address of the Control Units (optional, only SINAMICS)
● Message frame

I/O addresses
The I/O address tells the NC the data areas via which cyclic process data exchange occurs
with the drive or the Control Unit.
The I/O addresses assigned in the SIMATIC S7 project are entered in the following machine
data:
● MD13050 $MN_DRIVE_LOGIC_ADDRESS[n] (logical I/O address)
● MD13120 $MN_CONTROL_UNIT_LOGIC_ADDRESS (logical I/O address for the Control
Unit (SINAMICS))
To parameterize the PROFIBUS communication for the drives, see:
● SINAMICS: Section "DP slave: SINAMICS S120" (Page 287)
● SIMODRIVE: Section "DP slave: SIMODRIVE drives"

Standard values: Axes

The default values for the I/O addresses of the axes are designed so that there is sufficient
clearance per axle, starting at I/O address 4100, each with a measuring circuit:
● MD13050 $MN_DRIVE_LOGIC_ADDRESS[n] = 4100 + n * 40

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NOTICE
Any changes in the I/O addresses must be carried out consistently:
• SIMATIC S7 project
HW Config: I/O address for actual value and setpoint
• NC:
MD13050 $MN_DRIVE_LOGIC_ADDRESS[n]
or
MD13120 $MN_CONTROL_UNIT_LOGIC_ADDRESS
There is no automatic adjustment!

Message frame
The process data transferred between the NC and the drives or Control Unit during cyclic
process data exchange are defined via the message frame.
To select the message frame, see:
● SINAMICS: Section "DP slave: SINAMICS S120" (Page 287)
● SIMODRIVE: Chapter "DP slave: SIMODRIVE drives" (Page 297)

Note
You will find a detailed description of the message frame in each case in the Section
"Communication via PROFIBUS" in:
• SINAMICS S120
References:
SINAMICS S120 Commissioning Manual
• SIMODRIVE 611 universal and universal E
References:
/FBU/ Function Manual SIMODRIVE 611 universal
• SIMODRIVE POSMO A
References:
/POS1/ SIMODRIVE POSMO A User Manual
• SIMODRIVE POSMO SI/CD/CA
References:
/POS3/ User Manual - SIMODRIVE POSMO SI/CD/CA
• ADI4
References:
/Subsection "DP slave: ADI4" (Page 286)

The message frames set in the SIMATIC S7 project are entered in the following machine
data:
● MD13060 $MN_DRIVE_TELEGRAM_TYPE[n] (drive message frame type)

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Default values
The default values for the machine data are based on the following message frame:
● 102; Speed control with torque reduction, 1 position encoder

NOTICE
The following is to be taken into account:
1. A change of the message frame type has to be carried out consistently:
– SIMATIC S7 project, HW Config: Frame type
– NC: MD13060 $MN_DRIVE_TELEGRAM_TYPE[n]
– SINAMICS S120 or SIMODRIVE 611 universal:
Parameter P0922 PROFIBUS message frame type selection
There is no automatic adjustment!
2. The sequence of the drives referred to in the following machine data must be
identical in both machine data:
– MD13050 $MN_DRIVE_LOGIC_ADDRESS[n]
– MD13060 $MN_DRIVE_TELEGRAM_TYPE[n]

SIMODRIVE 611U functions

If a PROFIBUS drive does not support individual SIMODRIVE 611U-specific functions that
are active by default, they must be deactivated on the NC via the following drive-specific
machine data:
● MD13070 $MN_DRIVE_FUNCTION_MASK[n] (Used DP functions)

Bit Function
0 Deactivation of the 611U-specific drive alarm generation
1 Deactivation of the 611U-specific drive type detection
2 Deactivation of the 611U-specific parameter accesses encoder drivers
3 Deactivation of the 611U-specific parameter accesses output drivers
4 Reserved
5 Deactivation of 611U-specific drive parking (STW2.7/STA2.7)
6 Deactivation of the 611U-specific travel to fixed stop (STW2.8/STA2.8)
7 Deactivation of the 611U-specific motor switchover internal (STW2.9 to 2.11)
8 Deactivation of the 611U-specific ramp block (STW1.11+13)
9 Deactivation of the 611U-specific function generator bits (STW1.8/STA1.13)
10 Deactivation of the parking brake control (STW1.12 / STA2.5)
11 Deactivation of the effect of OFF2/OFF3 on driveReady (DB31,... DBB93, Bit5)
14 Selection of non-cyclic DP communication: 0 = DPT; 1 = DPV1
15 Deactivation of the consistency check of the PROFIBUS message frame configuration

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ADI4
With an ADI4 module you can operate up to 4 drives with analog setpoint interface on an
isochronous PROFIBUS.
The 611U-specific functions (Bit0 - Bit3) and effects of OFF2/OFF3 on the signal
"driveReady" (Bit11) must be disabled for these drives. The machine data must be set for
every drive operated via ADI4:
● MD13070 $MN_DRIVE_FUNCTION_MASK[n] = 80FH

NOTICE
The 611U-specific functions (Bit0 - Bit3) and effects of OFF2/OFF3 on the signal
"driveReady" (Bit11) must be disabled for all drives connected via ADI4.
• MD13070 $MN_DRIVE_FUNCTION_MASK[n] = 80FH

Drive type DP
The NC attempts to ascertain the drive type for each parameterized PROFIBUS drive
independently. The drive type is shown in the following machine data:
● MD13080 $MN_DRIVE_TYP_DP[n] (drive type PROFIBUS DP)
The following drive types are displayed by the NC:
1. VSA (SRM: Synchronous Rotary Motor)
2. HSA (ARM: Asynchronous Rotary Motor)
3. Linear drive
If the NC is not able to determine the drive type because the drive e.g. does not support any
acyclic communication or it was switched off via machine data MD13070
$MN_DRIVE_FUNCTION_MASK (used DP functions), then the following value is displayed:
● 0: No drive or drive type not known

Drive type DP: 4

If drive type 0 is displayed for a parameterized PROFIBUS drive, the value can be manually
set to the following:
● 4: Drive does not support acyclic communication
Setting the drive type to value 4 has the following effects in HMI Advanced:
● Drive parameters
No drive parameters are read.
● Current and speed controller cycle
There is no display of current and speed controller cycle.
● Drive type
ANA is displayed as the drive type.
● Speed control loop
The dialog box for measuring the speed control loop only offers measurements of the
reference frequency response and setpoint step change.
● Current control loop
The dialog box for measuring the current control loop is not offered.

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ADI4
Because a ADI4 module does not support acyclic communication on the PROFIBUS, we
recommend entering value 4 as the drive type for any drive operated via ADI4:
● MD13080 $MN_DRIVE_TYP_DP[n] = 4

Note
We recommend entering drive type 4 manually for drives connected via ADI4:
• MD13080 $MN_DRIVE_TYPE_DP[n] = 4

Table 11-16 Drive configuration: Machine data

Number Name Name/remarks

General ($MN_ ... )
13050 DRIVE_LOGIC_ADDRESS[n] Logical I/O address of drive
13060 DRIVE_TELEGRAM_TYPE[n] Drive message frame type for the drives connected to
PROFIBUS DP
13070 DRIVE_FUNCTION_MASK[n] 611U-specific DP functions in use
13080 DRIVE_TYPE_DP[n] Drive type PROFIBUS DP

11.5.4 Setpoint/actual value channels

Note
In order to guarantee that the control runs up reliably, all machine axes are declared as
simulation axes (without hardware).
• MD30130 $MA_CTRLOUT_TYPE (output type of setpoint value) = 0
• MD30240 $MA_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.
The following machine data 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):
MD30350 $MA_SIMU_AX_VDI_OUTPUT (output of axis signals with simulation axes)

Assignment of the setpoint/actual value channels

The following parameters must be defined for each machine axis that a drive is to be
assigned to:
● a setpoint channel and
● at least one actual-value channel
A second actual-value channel can be set up as an option.

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11.5 Axes and spindles

NOTICE
The motor measuring system is always used for the speed control function. Motor and
motor measuring system must therefore always be connected to the same drive module.

In the two following axis-specific machine data, the same logical drive number m of the drive
is entered that the machine axis represents:
● MD30110 $MA_CTRLOUT_MODULE_NR[0] (setpoint assignment: logical drive number)
● MD30220 $MA_ENC_MODUL_NR[n] (actual value assignment: logical drive number)
The entered value m refers to the drive whose I/O address is defined under the index n = (m-
1) in MD13050 $MN_DRIVE_LOGIC_ADDRESS[n] (see Chapter "Drive
Configuration" (Page 389)).

NC reset
Once the drive configuration and setpoint/actual value assignment have been parameterized,
an NC reset must be executed to initiate a warm restart of the NC. After the NC has powered
up, the set configuration is effective.

Measuring system switchover

The following interface signals can be used to switch between the two position measuring
systems of a machine axis from the PLC.
● DB31, ... DBX1.5 (position measuring system 1 selected)
● DB31, ... DBX1.6 (position measuring system 2 selected)
References:
/FB1/ Function Manual - Basic Functions, A2 various Interface Signals

Machine data

Table 11-17 Setpoint/actual value channels: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
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
0 = simulation
1 = speed setpoint output
30200 NUM_ENCS Number of measurement channels
1 = one position measuring system installed
2 = two position measuring systems installed

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Number Name Name/remarks

30210 ENC_SEGMENT_NR[0] Actual value assignment Drive type
5 = PROFIBUS DP
30220 ENC_MODULE_NR[0] Actual value assignment: Logical drive number for position
measuring system 1
30220 ENC_MODULE_NR[1] Actual value assignment: Logical drive number for position
measuring system 2
30230 ENC_INPUT_NR[0] Actual value assignment: Position measuring system 1
1 = motor measuring system
2 = direct measuring system
30230 ENC_INPUT_NR[1] 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 11-18 Switchover of position measuring system: Interface signals

DB number Bit, byte Name

Axis/spindle-specific Signals from PLC to axis/spindle
31, ... 1.5 Position measuring system 1
31, ... 1.6 Position measuring system 2
References:
/FB/ Function Manual - Basic Functions, G2 Velocities, Setpoint/Actual Value Systems,
Control, Chapter "Setpoint/Actual Value System"
/FB/ Function Manual - Basic Functions, A2 Various Interface Signals, Subsection "Interface
Signals to Axis/Spindle"

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11.5 Axes and spindles

11.5.5 Incremental measuring system settings

Rotary measuring system

The diagrams below show the general options of arranging a rotary incremental measuring
system with regard to motor and load, as well as the resulting values for the appropriate
machine data.

Linear axis with encoder on motor

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(1&B,6B',5(&7 
0HDVXULQJ /RDG
JHDUER[ JHDUER[ 7DEOH
* 0 %DOOVFUHZ

Q6SLQGOH /($'6&5(:B3,7&+
Q0RWRU
(1&B5(62/

'5,9(B$;B5$7,2B180(5$ PRWRUUHYV
'5,9(B$;B5$7,2B'(120 6SLQGOHUHYV

'5,9(B(1&B5$7,2B180(5$ 0RWRUUHYV
'5,9(B(1&B5$7,2B'(120 (QFRGHUUHYV

Figure 11-5 Linear axis with encoder on motor

Linear axis with encoder on the machine

'5,9(B$;B5$7,2B180(5$ PRWRUUHYV
'5,9(B$;B5$7,2B'(120 VSLQGOHUHYV

(1&B,6B',5(&7 
,6B527B$; 
0HDVXULQJ
JHDUER[
(1&B,6B/,1($5 
7DEOH
0 *
/RDG %DOOVFUHZ (1&B5(62/
*HDU
/($'6&5(:B3,7&+ (1&B7<3( 
QPRWRU QVSLQGOH QVSLQGOH QHQFRGHU (1&B,6B/,1($5 
(1&B5(62/

PRWRUUHYV '5,9(B(1&B5$7,2B180(5$
HQFRGHUUHYV '5,9(B(1&B5$7,2B'(120

Figure 11-6 Linear axis with encoder on the machine

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Rotary axis with encoder on motor

QORDG
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Figure 11-7 Rotary axis with encoder on motor

Linear axis with encoder on the machine

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Figure 11-8 Linear axis with encoder on the machine

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

Machine data

Table 11-19 Incremental measuring systems: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
30240 ENC_TYPE[n] Actual-value acquisition modes
1 = incremental signal generator
30242 ENC_IS_INDEPENDENT[n] Encoder is independent
30300 IS_ROT_AX Rotary axis
31000 ENC_IS_LINEAR[n] Direct measuring system (linear scale)
31020 ENC_RESOL[n] Encoder pulses per revolution
31030 LEADSCREW_PITCH Leadscrew pitch
31040 ENC_IS_DIRECT[n] Encoder is connected directly to the machine
31050 DRIVE_AX_RATIO_DENOM[n] Denominator load gearbox
31060 DRIVE_AX_RATIO_NUMERA[n] Numerator load gearbox
31070 DRIVE_ENC_RATIO_DENOM[n] Denominator of resolver gearbox
31080 DRIVE_ENC_RATIO_NUMERA[n] Numerator of resolver gearbox

Linear measuring system

The diagram below shows the general options of arranging a linear incremental measuring
system with regard to motor and load, as well as the resulting values for the respective
machine data.

Linear axis with linear scale

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Figure 11-9 Linear axis with linear scale

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 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Machine data

Table 11-20 Linear measuring systems: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
30240 ENC_TYPE[n] Actual-value acquisition modes
1 = incremental signal generator
30242 ENC_IS_INDEPENDENT[n] Encoder is independent
30300 IS_ROT_AX Rotary axis
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_NUMERA[n] Numerator load gearbox
32110 ENC_FEEDBACK_POL[n] Sign actual value (feedback polarity)

11.5.6 Parameterization of absolute measuring systems

Encoder types
The following encoder types are currently supported:
● Single-turn absolute value encoder
● Multi-turn absolute value encoder
with EnDat protocol and incremental sinusoidal encoder signals A and B, e.g. Haidenhain
EQN 1325.

EQN 1325
The absolute value encoder EQN 1325 from Heidenhain has the following properties:
● EnDat protocol
● PPR count: 2048 = 211 (encoder fine resolution)
● Positions/revolution: 8192 (13 bits)
● Differentiable revolutions: 4096 (12 bits)
● Encoder signals A/B: Sin/cos 1 Vpp

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11.5 Axes and spindles

Adjusting
Convergence of the measuring system with the machine positions is performed by
calibration of the absolute value encoder in absolute measuring systems. For calibration of
the absolute value encoder, see Chapter "Axis Homing" (Page 431).

Rotary measuring systems

An absolute encoder can currently exclusively be used as a motor encoder (indirect
measuring system).

Linear axis with absolute value encoder on motor

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Figure 11-10 Linear axis with absolute value encoder on motor

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 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Rotary axis with absolute value encoder on motor

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Figure 11-11 Rotary axis with absolute value encoder on motor

ADI4
For a machine axis whose measuring system consists of an absolute encoder on an ADI4
module, the following must be taken into consideration:
● Absolute encoder with SSI interface
Since the ADI4 transfers the data from the absolute encoder to the NC in EnDat format,
encoder type "Absolute encoder gen." must be entered as the encoder type:
– MD30240 $MA_ENC_TYPE (encoder type) = 4 (absolute encoder gen.)
References:
/ADI4/Analog drive port for 4 axes, Chapter "Function parameters (SINUMERIK 840Di
sl) and (SIMOTION)"
Encoder type
● Encoder fine resolution
The fine resolution configured in the ADI4 (reserved bits for fine resolution) of the
absolute encoder must be assumed by the NC:
– MD30260 $MA_ABS_INC_RATIO[n] (encoder fine resolution)
References:
/ADI4/Analog drive port for 4 axes, Chapter "Function parameters (SINUMERIK 840Di
sl) and (SIMOTION)"
Reserved bits for fine resolution

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

Boot with non-calibrated encoder

For axes with non-calibrated absolute encoder:
● MD34210 $MA_ENC_REFP_STATE == 0 (encoder not calibrated)
an alarm is displayed each time the NC is booted:
● Alarm "25022 Axis <axis identifier> encoder <number> warning 0"

Machine data

Table 11-21 Incremental measuring systems: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
30240 ENC_TYPE[n] Actual-value acquisition modes
30242 ENC_IS_INDEPENDENT[n] Encoder is independent
30260 ABS_INC_RATION[n] Encoder fine resolution (absolute value encoder)
30300 IS_ROT_AX[n] Rotary axis
31000 ENC_IS_LINEAR[n] Direct measuring system (linear scale)
31030 LEADSCREW_PITCH[n] Leadscrew pitch
31040 ENC_IS_DIRECT[n] Encoder is connected directly to the machine
31050 DRIVE_AX_RATIO_DENOM[n] Denominator load gearbox
31060 DRIVE_AX_RATIO_NUMERA[n] Numerator load gearbox
31070 DRIVE_ENC_RATIO_DENOM[n] Measuring gear denominator
31080 DRIVE_ENC_RATIO_NUMERA[n] Measuring gear numerator
34200 ENC_REFP_MODE[n] Homing mode
34210 ENC_REFP_STATE[n] Status of absolute encoder
34220 ENC_ABS_TURNS_MODULO[n] Absolute value encoder range for rotary encoders (multi-turn
resolution)

11.5.7 Parameterization of a 2nd measuring system with ADI4

Up to 2 measuring system can be parameterized for a machine axis. If it is not possible to
connect the 2nd measuring system directly to the associated drive module, it is possible to
use a ADI4 module.

Note
Detailed information about the measuring systems that can be connected to the ADI4 is to
be found in:
References:
/ADI4/ Analog Drive Interface for 4 Axes, Chapter "Hardware Description"

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 NC Commissioning with HMI Advanced
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Parameter example
The following parameterization example illustrates the basic procedure for parameterizing
the NC for a 2nd measuring system of a machine axis connected via ADI4. It assumes the
following:
● NC
Two measuring systems are to be parameterized for the 1st machine axis.
– 1. Measuring system: "motor measuring system" of the drive
– 2. Measuring system: "direct measuring system"
● Drive
A SIMODRIVE 611U 1 axis module is used as the drive with a connection option for a
measuring system (motor encoder).
● ADI4
The 2nd measuring system is connected via the encoder interface of the 1st axis of an
ADI4 module. (In principle, connection is possible via any axis of the ADI4 module.)

Configuration
The following figure shows the associated configuration.

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I/O addresses and message frame types

The I/O addresses and message frame types for the drive and ADI4 axis are set to the
following values in the configuration:
Drive:
● Message frame type: Message frame 102
● I/O address: 4100

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

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ADI4:
● Message frame type: Standard message frame 3
● I/O address: 4200

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NC machine data
The general and axis-specific NC machine data should be set as follows:
Drive assignment:
The axis of the SIMODRIVE 611U drive module is assigned to the NC as the 1st machine
axis. This requires entry of its I/O address and message frame type under index 0:
● MD13050 $MN_DRIVE_LOGIC_ADRESS[0] = 4100
● MD13060 $MN_DRIVE_TELEGRAM_TYPE[0] = 102
The I/O address and the message frame type of the 1st axis of the ADI4 module will be
entered in the next free machine data (e.g. Index 3):
● MD13050 $MN_DRIVE_LOGIC_ADRESS[3] = 4200
● MD13060 $MDRIVE_TELEGRAM_TYPE[3] = 3
Assignment of the actual value channels:
Assignment of the 1st measuring system (index 0) of the machine axis to the measuring
circuit input of the SIMODRIVE 611U drive module is performed via the axis-specific
machine data:
● MD30220 $MA_ENC_MODUL_NR[0] = 1
with 1 = (Index 0 of the corresponding MD13050 + 1)

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 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Assignment of the 2nd measuring system (index 1) of the machine axis to the measuring
circuit input of the ADI4 module is performed via the axis-specific machine data:
● MD30220 $MA_ENC_MODUL_NR[1] = 4
with 4 = (Index 3 of the corresponding MD13050 + 1)
For this, see Subsection "Setpoint value/actual value channels" (Page 393).

Machine data

Table 11-22 Drive configuration: Machine data

Number Name Name/remarks

General ($MN_ ... )
13050 DRIVE_LOGIC_ADDRESS[n] Logical I/O address of drive
13060 DRIVE_TELEGRAM_TYPE[n] Drive message frame type for the drives connected to
PROFIBUS DP
30220 ENC_MODULE_NR[0] Actual value assignment: Logical drive number for position
measuring system 1
30220 ENC_MODULE_NR[1] Actual value assignment: Logical drive number for position
measuring system 2

Interface signals

Table 11-23 Switchover of position measuring system: Interface signals

DB number Bit, byte Name

Axis/spindle-specific Signals from PLC to axis/spindle
31, ... 1.5 Position measuring system 1
31, ... 1.6 Position measuring system 2

11.5.8 DSC (Dynamic Servo Control)

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:
● Considerably improved fault response/stability of the position control loop
● Improved control behavior (contour precision) if the higher servo gain (Kv factor) that can
be set in conjunction with DSC is used.
● A reduction of the cyclic communication load on the PROFIBUS, if the position control
cycle/PROFIBUS cycle is reduced by adjusting the above parameters, even if the control
loop performance is the same.

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

Note
The speed feedforward control can be used in conjunction with DSC.

Requirements
Before you can activate DSC mode, the following preconditions must be fulfilled:
● DSC-capable drive, e.g.:
– SINAMICS S120
– SIMODRIVE 611 universal
– SIMODRIVE POSMO CD/CA
– SIMODRIVE POSMO SI
● A DSC-capable message frame type has been parameterized in the S7 project for the
drive (see Section "DP Slave: SINAMICS S120" (Page 287)).

Switch-on/switch-off
The DSC function is switched ON in the following axis-specific NC machine data:
● MD32640 $MA_STIFFNESS_CONTROL_ENABLE (dyn. Stiffness control)
If DSC operation is switched ON or OFF, it might be necessary to adjust the following
machine data:
● MD32200 $MA_POSCTRL_GAIN (Kv factor)
● MD32610 $MA_VELO_FFW_WEIGHT (feedforward control factor)
● MD32810 $MA_EQUIV_SPEEDCTRL_TIME (substitute time const. of the closed speed
control loop).

NOTICE
Before you can switch off DSC operation you might have to adapt (reduce) the Kv factor
of the axis. Otherwise, instability of the position control loop might result.

Speed setpoint filter

If you use DSC, a speed setpoint filter for rounding the speed setpoint steps is no longer
necessary. The speed setpoint filter is then only of any use with differential connection to
support the position controller, for example, to suppress resonance.

Measuring system
DSC is only possible in conjunction with the motor measuring system.

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Table 11-24 DSC: Machine data

Number Name Name

Axisspecific ($MA_ ... )
32640 STIFFNESS_CONTROL_ENABLE Dyn. stiffness control
32200 POSCRTL_GAIN Kv factor

11.5.9 Drive Optimization

Optimization of the control loop (current, speed, and position control loop) of the drives can
be performed with:
● HMI Advanced (see Chapter "Drive Optimization with HMI Advanced" (Page 507))
– Depending on the installation version: SINAMICS S120 or SIMODRIVE drives
● SINAMICS STARTER commissioning tool
– SINAMICS S120
● SIMODRIVE SimoCom U commissioning tool
– SIMODRIVE 611 universal / E
– SIMODRIVE POSMO CD/CA
– SIMODRIVE POSMO SI

Note
Detailed information on measuring the filter frequency response and optimizing
torque/current and speed control loop can be found in:
• SINAMICS
Online Help for Commissioning Tool: STARTER > Content > Diagnosis Functions
• SIMODRIVE 611 universal/E, POSMO CD/CA and SI
Online Help for SimoCom U Commissioning Tool > Index:
– Measuring function
– Optimization of speed control loop

11.5.10 Rotary axes

Rotary axes
A machine axis is parameterized as a rotary axis via:
● MD30300 $MA_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.

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11.5 Axes and spindles

For the recommended procedure with respect to scaling machine data, please refer to
Subsection "Modifying Scaling Machine Data" (Page 370).

Modulo display
The display of the rotary axis position modulo 360 degrees is displayed via the following
machine data:
● MD30320 $MA_DISPLAY_IS_MODULO (modulo 360 degrees display for rotary axes)

Endlessly rotating rotary axis

The traversing of the rotary axis modulo 360 degrees is displayed via the following machine
data:
● MD30310 $MA_ROT_IS_MODULO (modulo conversion for rotary axis)
The limit switches are not monitored during this process. The rotary axis can thus rotate
endlessly.

Machine data

Table 11-25 Rotary axes: Machine data

Number Name Name

General ($MN_ ... )
10210 INT_INCR_PER_DEG Computational resolution for angular positions
Axisspecific ($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
36110 POS_LIMIT_PLUS Software limit switch plus

Setting data

Table 11-26 Rotary axes: Setting data

Number Name Name

General ($SN_ ...)
41130 JOG_ROT_AX_SET_VELO JOG velocity for rotary axes
Axisspecific ($SA_ ... )
43430 WORKAREA_LIMIT_MINUS Working area limitation minus
43420 WORKAREA_LIMIT_PLUS Working area limitation plus
References:
/FB/ Function Manual - Extended Functions, R2 Rotary axes

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11.5.11 Positioning axes

Positioning axes are channel axes traversing parallel to the path axes without interpolating
with them.
Positioning axes can be traversed either from the parts program or from the PLC.

Concurrent positioning axes

A channel axis is assigned to the PLC by default via the following machine data:
● MD30450 $MA_IS_CONCURRENT_POS_AX (concurr. positioning axis) = 1
To traverse it from the part program later, it must be requested explicitly using a part
program statement (GET).

Positioning axis feedrate

If a positioning axis is programmed in the part program without specifying an axis-specific
feedrate, the feedrate entered in the following machine data is applicable to this axis
automatically:
● MD32060 $MA_POS_AX_VELO (initial setting for positioning axis velocity)
This feedrate will apply until an axis-specific feedrate is programmed in the part program for
this axis.

Machine data
Table 11-27 Positioning axes: Machine data

Number Name Name

Channelspecific ($MC_ ... )
22240 AUXFU_F_SYNC_TYPE Output timing of F functions
Axisspecific ($MA_ ... )
30450 IS_CONCURRENT_POS_AX Concurrent positioning axis
32060 POS_AX_VELO Feedrate for positioning axis

Interface signals
Table 11-28 Positioning axes: Interface signals

DB number Bit, byte Name

Axis/spindle-specific Signals from PLC to axis/spindle
31,... 0 Feedrate override, axis-specific
31,... 2.2 Delete distance-to-go, axis-specific
Signals from axis/spindle to PLC
31,... 74.5 Positioning axis
31,... 78-81 F function (feedrate) for positioning axis
References:
/FB/ Function Manual - Extended Functions, P2 Positioning axes

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

11.5.12 Indexing axes

Indexing axis are rotary or linear axes that may only be traversed within their traversing
range to defined positions, the indexing positions.
Traversing to indexing positions using the part program or manually is only effective if the
corresponding machine axis has been successfully referenced.
The indexing positions are stored in tables.

Indexing axis
The following machine data assigns the machine axis the relevant table of indexing positions
and also defines the machine axis as an indexing axis:
● MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB[n] (axis is indexing axis)

Indexing position tables

The indexing positions are stored in one of the 2 tables.
● MD10900 $MN_INDEX_AX_LENGTH_POS_TAB_1 (number of positions of indexing table
1)
● MD10910 $MN_INDEX_AX_POS_TAB_1 [n] (indexing position table 1)
● MD10920 $MN_INDEX_AX_LENGTH_POS_TAB_2 (number of positions of indexing table
2)
● MD10930 $MN_INDEX_AX_POS_TAB_2 [n] (indexing position table 2)

Machine data

Table 11-29 Indexing axes: Machine data

Number Name Name

General ($MN_ ... )
10260 CONVERT_SCALING_SYSTEM Basic system switch-over active
10270 POS_TAB_SCALING_SYSTEM Measuring system of position tables
10900 INDEX_AX_LENGTH_POS_TAB_1 Number of indexing positions used in table 1
10910 INDEX_AX_POS_TAB_1[n] Indexing position table 1
10920 INDEX_AX_LENGTH_POS_TAB_2 Number of indexing positions used in table 2
10930 INDEX_AX_POS_TAB_2[n] Indexing position table 2
Axis/spindlespecific ($MA_ ... )
30300 IS_ROT_AX Rotary axis
30310 ROT_IS_MODULO Modulo conversion for rotary axis
30320 DISPLAY_IS_MODULO Position display modulo 360o
30500 INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis
30501 INDEX_AX_NUMERATOR Numerator for indexing axes with equidistant positions

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Interface signals

Table 11-30 Indexing axes: Interface signals

DB number Bit, byte Name

Axis/spindle-specific Signals from axis/spindle to PLC
31,... 60.4, 60.5 Referenced/synchronized 1, referenced/synchronized 2
31,... 76.6 Indexing axis in position
References:
/FB/ Function Manual, Extended Functions,T1 Indexing axes

11.5.13 Parameter sets of axis/spindle

Per machine axis, six parameter sets are available. They serve the following purpose:
● on an axis:
for accommodation of the own dynamic response to another machine axis, e.g. when
tapping or thread cutting on the relevant spindle.
● on a spindle:
for accommodation of the position controller to modified properties of the machine during
operation, e.g. when switching the gearbox.

Tapping, thread cutting

The following applies to axes:
● For a machine axis that is not involved in tapping or thread cutting, the 1st set of
parameters (index=0) is active in all cases.
The further parameter sets need not be considered.
● Machine axes involved in tapping or thread cutting: the parameter set is activated 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:
● With spindles, each gear stage is assigned a parameter set of its own. The parameter set
is selected by the PLC via 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".

Manual
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NC Commissioning with HMI Advanced
11.5 Axes and spindles

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Machine data
The following machine data of a machine axis depend on the parameter set:
n = parameter set number (0 ... 5)

Table 11-31 Parameter-set-dependent machine data

Number Name Name

Axis/spindlespecific ($MA_ ... )
31050 DRIVE_AX_RATIO_DENOM[n] Denominator load gearbox
31060 DRIVE_AX_RATIO_NUMERA[n] Numerator load gearbox
32200 POSCTRL_GAIN [n] Kv factor
32810 EQUIV_SPEEDCTRL_TIME [n] Equivalent time constant, Speed control loop for feed forward 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_VELO[n] Minimum speed for gear change
35130 GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed of gear stage
35140 GEAR_STEP_MIN_VELO_LIMIT[n] Minimum speed of gear stage
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode
35210 GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode
36200 AX_VELO_LIMIT [n] Threshold value for velocity monitoring

Manual
412 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

11.5.14 Position controller

Control loops
The closed-loop control of a machine axis consists of the cascaded closed-loop control
circuits of current controller, speed controller and position controller.

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Traversing direction
If the axis does not traverse into the desired direction, the appropriate adaptation is made in
the following machine data:
● MD32100 $MA_AX_MOTION_DIR (travel 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
the following machine data:
● MD32110 $MA_ENC_FEEDBACK_POL (sign of actual value)

Servo gain
To obtain high contour accuracy, a high loop gain (Kv factor) of the position controller is
required. However, an excessively high Kv factor causes overshoot, instability and
impermissibly high machine loads.
The maximum permissible Kv factor is dependent on the dynamic response of the drive and
the mechanical system of the machine.
If "0" is entered for the loop gain factor, the position controller will be disconnected.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 413
NC Commissioning with HMI Advanced
11.5 Axes and spindles

Definition of the Kv factor

The servo gain factor is defined as the ratio of velocity in m/min and the resulting following
error in mm:

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i.e. with a Kv factor of 1 and a velocity of 1 m/min, the following error will be 1 mm.
The Kv factor of the machine axis is entered via the following machine data:
● MD32200 $MA_POSCTRL_GAIN (Kv factor)

Note
To adapt the input/output unit of the Kv factor selected by default to the internal unit [1/s],
the following machine data are assigned by default:
• MD10230 $MN_SCALING_FACTORS_USER_DEF[9] = 16.666667
• MD10220 $MN_SCALING_USER_DEF_MASK = 'H200'; (Bit-No. 9 as Hex-Value).

When entering the servo gain factor it is important to check that the gain factor of the whole
position control loop is still dependent on other parameters of the controlled system.
These factors are:
● MD32260 $MA_RATED_VELO
● MD32250 $MA_RATED_OUTVAL
● Tacho adjustment on the speed controller
● Tacho generator on drive.

NOTICE
Machine axes that interpolate one with another must have the same following error at
the same velocities.
This is to be achieved by setting the same KV factor or through the dynamic response
adaptation via the following machine data:
• MD32900 $MA_DYN_MATCH_ENABLE
• MD32910 $MA_DYN_MATCH_TIME
The real servo gain factor can be checked with the following error in the service display.
• e.g. HMI Advanced: Operating area "DIAGNOSIS" > Service displays > Service axis.

Manual
414 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Checking the loop gain

If a KV factor is already known for the machine type, then this factor can be set and checked.
For the test, one reduces the acceleration of the axis via the following machine data to
ensure that the drive does not reach its current limit during the acceleration and deceleration
operation:
● MD32300 $MA_MAX_AX_ACCEL (axis acceleration)
The Kv factor must also be checked for high speeds of the rotary axis and spindle (e.g. for
spindle positioning, tapping).
The approach behavior at various speeds can be checked by means of a storage
oscilloscope or the HMI Advanced servo trace software. The speed setpoint is recorded for
this purpose.

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No overshoots may occur while the drive is approaching the static states; this applies to all
speed ranges.

Overshoot in the position control loop

The reasons for an overshoot in the control loop can be:
● Acceleration too high (current limit is reached)
● Rise time too long (re-optimization necessary)
● Mechanical backlash
● Mechanical components canted
For safety reasons, set the Kv factor to a little less than the maximum possible value.
The real Kv factor must precisely match that set because monitoring functions are derived
from the Kv factor that would otherwise respond (e.g. contour monitoring).

Acceleration
The machine axes are accelerated and braked with the values entered in the following
machine data:
● MD32300 $MA_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.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 415
NC Commissioning with HMI Advanced
11.5 Axes and spindles

Default values
The default values of the acceleration are in the range of 0.5 m/s2 to 2 m/s2.

Checking the acceleration

The sign of a properly adjusted acceleration of a machine axis is acceleration and
positioning free from overshoot at rapid traverse rate and maximum load (heavy workpiece).
After the acceleration has been entered, the axis is traversed rapidly and the actual current
values and current setpoint are recorded.

Note
• SINAMICS
The current actual value/setpoint can be recorded using the STARTER trace function.
• SIMODRIVE
The current actual value/setpoint can be recorded using the trace function of SimoCom
U.
The online help provides more detailed information.

This recording shows whether the drive reaches the current limit. Here, the current limit can
be reached for a short time.
The current must be well below the current limit, however, before the rapid traverse velocity
or the final position is reached.
Load changes during machining must not cause the current limit to be reached. Excessive
current during machining causes falsification of the contour. For this reason, the acceleration
value should be a little bit less than the maximum acceleration value.
Machine axes can have different acceleration values, even if they interpolate with each other.

Machine data

Table 11-32 Position control: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
32100 AX_MOTION_DIR[n] Traversing direction
32110 ENC_FEEDBACK_POL[n] Actual value sign
32200 POSCTRL_GAIN [n] Kv factor
32300 MAX_AX_ACCEL[n] Axis acceleration
32900 DYN_MATCH_ENABLE[n] Dynamic response adaptation
32910 DYN_MATCH_TIME [n] Time constant for dynamic matching
References:
/FB/ Function Manual - Basic Functions, G2 Velocities, Setpoint/Actual Value Systems,
Control, Chapter "Control"

Manual
416 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

11.5.15 Speed setpoint matching

In the case of speed setpoint comparison, the NC is informed, which speed setpoint
corresponds to which motor speed in the drive, for parameterizing the axial control and
monitoring. Speed setpoint matching can be performed automatically or manually.

Automatic adjustment
An automatic speed setpoint matching can be performed for the following drives:
● SINAMICS S120
● SIMODRIVE 611 universal / E
● SIMODRIVE POSMO CD/CA
● SIMODRIVE POSMO SI
If the value 0 is entered in the following machine data (default in SINUMERIK 840Di sl), then
the speed setpoint value between NC and drive is matched automatically during the NC boot:
● MD32250 $MA_RATED_OUTVAL (rated output voltage) [%]

Note
If automatic speed setpoint matching fails for one axis, the following message is output
on a traverse request for this axis:
• Message: "Wait, axis enable missing"
This axis and any axes that interpolate with it are not traversed.

Manual comparison
If a value not equal to 0 is entered in the following machine data, then there is no automatic
speed setpoint value matching:
● MD32250 $MA_RATED_OUTVAL (rated output voltage) [%]
Speed setpoint matching must be performed manually using the following axis-specific
machine data:
● MD32250 $MA_RATED_OUTVAL (rated output voltage) [%]
● MD32260 $MA_RATED_VELO (rated motor speed) [rev/min]
The rated motor speed entered in the axis-specific MD32260 $MA_RATED_VELO with
reference to 100% must be equal to the speed evaluation parameterized in the drive:

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 417
NC Commissioning with HMI Advanced
11.5 Axes and spindles

ADI4
As ADI4 does not support acyclic services on the PROFIBUS DP, manual speed setpoint
matching must be performed.
The reference between the speed setpoint set by the NC and the associated output voltage
at the setpoint output of the ADI4 is established (reference voltage = 10 V) via the following
axis-specific machine data.
● MD32260 $MA_RATED_VELO (rated motor speed) [rev/min]
● MD32250 $MA_RATED_OUTVAL (rated output voltage) [%]

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Note
The maximum upper limit for the speed setpoint is predefined in following machine data:
• MD36210 $MA_CTRLOUT_LIMIT (maximum speed setpoint) [%]
Values greater than 100 % do not make sense in connection with ADI4 because the
DACs of the ADI4 limit the output voltage to 10 V.

Calculation of the motor speed

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):

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● vAxis [mm/min]
● MD31060 $MA_DRIVE_RATIO_NUMERA (load gearbox numerator)
● MD31050 $MA_DRIVE_RATIO_DENOM (load gearbox denominator)
● MD31030 $MA_LEADSCREW_PITCH (leadscrew pitch) [mm/rev]
● nMotor [rpm]
● nLoad [rpm]

Manual
418 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Checking the trim

Incorrect speed setpoint matching has a negative impact on the real loop gain of the axis.
To check speed setpoint matching it is necessary for a defined traverse velocity to compare
the actual following error with the desired following error that should be set if speed setpoint
matching is correct.

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● Desired following error [ mm ]

● Traversing velocity [ m/min ]
● MD32200 $MA_POSCTRL_GAIN (KV factor) [(m/min)/mm]
The actual following error is shown in the axis-specific service data:
HMI Advanced:
Operating area switchover > Diagnosis > Service displays > Service axis/spindle

Machine data

Table 11-33 Speed setpoint matching: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
32250 RATED_OUTVAL Rated output voltage
32260 RATED_VELO[n] Rated motor speed
References:
/FB/ Function Manual - Basic Functions; G2 Velocities, Setpoint/Actual Value Systems,
Control, Section "Velocities, Traversing Ranges, Accuracies"

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 419
NC Commissioning with HMI Advanced
11.5 Axes and spindles

11.5.16 Drift compensation

Digital drives
Digital drives are not subject to drift or compensate for it automatically.

ADI4
As ADI4 does not support acyclic services on the PROFIBUS DP, drift compensation must
be performed manually by entering the appropriate compensation value in the following axial
machine data:
● MD36720 $MA_DRIFT_VALUE (basic drift value)

Manual drift compensation

Manual drift compensation is performed with the axis at zero speed as follows:
Requirements:
● Zero speed of the axis
● Axis enables pending
– Speed-controlled axis
The drift causes constant traversing of the axis. To compensate for the drift, the
compensation value is incremented/decremented step by step depending on the
direction of the drift until the axis reaches zero speed.
– Position-controlled axis
The drift causes a constant following error or position setpoint ≠ 0. To compensate for
the drift, the compensation value is incremented/decremented step by step depending
on the direction of the drift until following error or position setpoint = 0 is displayed.
HMI Advanced:
Operating area switchover > Diagnosis > Service displays > Service axis/spindle

WARNING
If the DSC function (Direct Servo Control) service is used for an axis, then no drift
compensation can be activated for this axis:
• MD32640 $MA_STIFFNESS_CONTROL_ENABLE (dyn. Stiffness control) = 1
Drift compensation causes extreme speed fluctuations during switch-on/off of the
DSC function.

Manual
420 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Machine data

Table 11-34 Drift compensation: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
36720 DRIFT_VALUE Basic drift value

11.5.17 Axis velocity matching

Max. axis velocity

The value entered in the following machine data is the limit velocity up to which a machine
axis can accelerate (rapid traverse limiting).
● MD32000 $MA_MAX_AX_VELO[n] (max. axis velocity)
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 part program when rapid traverse (G00) is
programmed.
Depending on MD30300 $MA_IS_ROT_AX[n], the maximum linear or rotary axis velocity
must be entered in the machine data.

Rapid traverse in JOG mode

the value entered in the following machine data 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%.
● MD32010 $MA_JOG_VELO_RAPID[n] (rapid traverse in JOG mode)
or
● MD32040 $MA_JOG_REV_VELO_RAPID[n] (revolutional feedrate in JOG mode with
rapid traverse override)
The entered value may not exceed the max. permissible axis velocity.
This machine data will not be used for the programmed rapid traverse G00.

Axis velocity in JOG mode

The value entered in this machine data is the velocity at which the machine axis traverses in
JOG mode with an axial feedrate override of 100%:
● MD32020 $MA_JOG_VELO[n] (axis velocity in JOG mode)
or
● MD32050 $MA_JOG_REV_VELO[n] (revolutional feedrate in JOG mode)

Manual
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NC Commissioning with HMI Advanced
11.5 Axes and spindles

The velocity from MD32020 $MA_JOG_VELO[n] or MD32050 $MA_JOG_REV_VELO[n] is

used only if
● for linear axes: SD41110 $SN_JOG_SET_VELO = 0
● for rotary axes: SD41130 $SN_JOG_ROT_AX_SET_VELO = 0
or
● for reverse feed: SD41120 $SN_JOG_REV_SET_VELO = 0
If the above mentioned setting data are unequal to 0, the JOG velocity results as follows:
1. SD JOG_REV_IS_ACTIVE (revolutional feedrate in JOG mode) = 0
=> Linear feedrate (G94)
– Linear axes:
JOG velocity = SD41110 $SN_JOG_SET_VELO (JOG velocity for G94)
– Rotary axes:
JOG velocity = SD41130 $SN_JOG_ROT_AX_SET_VELO (JOG velocity for rotary
axes)
2. SD JOG_REV_IS_ACTIVE (revolutional feedrate in JOG mode) = 1
– JOG velocity = SD41120 $SN_JOG_REV_SET_VELO (JOG velocity for G95)
The entered value may not exceed the max. permissible axis velocity.

NOTICE
The following is to be taken into account:
• Depending on MD30300 $MA_IS_ROT_AX[n], the velocities have to be entered in
mm/min, inch/min, or rpm.
• If the velocities are changed, MD36200 $MA_AX_VELO_LIMIT[n] (threshold value for
velocity monitoring) must be adapted accordingly.

Machine data

Table 11-35 Velocities: Machine data

Number Name Name/remarks

Axisspecific ($MA_ ... )
30300 IS_ROT_AX[n] Rotary axis
32000 MAX_AX_VELO[n] Maximum axis velocity
32010 JOG_VELO_RAPID[n] Rapid traverse in JOG mode
32020 JOG_VELO[n] Axis velocity in JOG mode
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
32250 RATED_OUTVAL Rated output voltage
32260 RATED_VELO[n] Rated motor speed

Manual
422 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Setting data

Table 11-36 Velocities: Setting data

Number Name Name/remarks

General ($SN_ ...)
41100 JOG_REV_IS_ACTIVE Revolutional feedrate in JOG mode active
41110 JOG_SET_VELO JOG velocity for linear axes (for G94)
41120 JOG_REV_SET_VELO JOG velocity (for G95)
41130 JOG_ROT_AX_SET_VELO JOG velocity for rotary axes
41200 JOG_SPIND_SET_VELO JOG velocity for the spindle
References:
/FB/ Function Manual - Basic Functions; G2 Velocities, Setpoint/Actual Value Systems,
Control, Section "Velocities, Traversing Ranges, Accuracies"
/FB/ Function Manual - Extended Functions, H1 Manual and Handwheel Travel

11.5.18 Axis monitoring

Static monitoring functions

The static monitoring functions with reference to a machine axis are:

Exact stop coarse

Window around the setpoint position within which exact stop coarse is detected.
● MD36000 $MA_STOP_LIMIT_COARSE (exact stop coarse)
● IS DB31,... DBX60.6 (position reached with exact stop coarse)

Exact stop fine

Window around the setpoint position within which exact stop fine is detected.
● MD36010 $MA_STOP_LIMIT_FINE (exact stop fine)
● IS DB31,... DBX60.7 (position reached with exact stop coarse)

Delay time exact stop fine

Delay time after which the actual value must have reached the tolerance window "Exact stop
fine" when the setpoint position is reached.
● MD36020 $MA_POSITIONING_TIME (delay time exact stop fine)
● Alarm "25080 Positioning monitoring" and follow-up mode.

Manual
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NC Commissioning with HMI Advanced
11.5 Axes and spindles

Zero speed tolerance

Position tolerance which a standing machine axis may not leave.
● MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance)
● Alarm "25040 Zero speed control" and follow-up mode

Delay time zero speed monitoring

Delay time after which the actual value must have reached the tolerance window "Zero
speed tolerance" when the setpoint position is reached.
● MD36040 $MA_STANDSTILL_DELAY_TIME (Zero-speed monitoring delay time)
● Alarm "25040 Zero speed control" and follow-up mode

Clamping tolerance
Tolerance window for a standing machine axis while the signal "Clamping active" is present
at the PLC interface.
● MD36050 $MA_CLAMP_POS_TOL (clamping tolerance)
● IS DB31,... DBX2.3 (clamping active)
● Alarm "26000 Clamping monitoring"

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Manual
424 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Working area limitation

The permissible working area of the machine axes can be adapted to the particular
machining situation using the "dynamic" working area limitation.
● SD43400 $SA_WORKAREA_PLUS_ENABLE (Working area limitation active in the
positive direction)
● SD43410 $SA_WORKAREA_MINUS_ENABLE (Working area limitation active in the
negative direction)
● SD43420 $SA_WORKAREA_LIMIT_PLUS (Working area limitation plus)
● SD43430 $SA_WORKAREA_LIMIT_MINUS (Working area limitation minus)
● Alarm "10630 Axis reaching operating range limit +/-"
● Alarm "10631 Axis is at operating range limit +/- (JOG)"
● Alarm "10730 Progr. end point is behind working area limitation +/-"

Software limit switches

Two software limit switch pairs are provided per machine axis. The active software limit
switch pair is selected in the PLC.
● MD36100 $MA_POS_LIMIT_MINUS (1st software limit switch minus)
● MD36110 $MA_POS_LIMIT_PLUS (1st software limit switch plus)
● MD36120 $MA_POS_LIMIT_MINUS2 (2nd software limit switch minus)
● MD36130 $MA_POS_LIMIT_PLUS2 (2nd software limit switch plus)
● IS DB31,... DBX12.2 (2nd software limit switch minus)
● IS DB31,... DBX12.3 (2nd software limit switch plus)
● Alarm "10620 Axis reaching software limit switch +/-"
● Alarm "10621 Axis is at software limit switch +/- (JOG)"
● 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 limit switches

If the PLC signals that a hardware limit switch has been reached, the machine axis is
stopped with the parameterized brake response.
● IS DB31, ... DBX12.1 (Hardware limit switch plus)
● IS DB31, ... DBX12.0 (Hardware limit switch minus)
● MD36600 $MA_BRAKE_MODE_CHOICE (Braking behavior on hardware limit switch)
0 = Brake characteristic is complied with
1 = Rapid deceleration with setpoint "0"
● Alarm "21614 Hardware limit switch [+/-]"

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 425
NC Commissioning with HMI Advanced
11.5 Axes and spindles

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Dynamic monitoring functions

The dynamic monitoring functions with reference to a machine axis are:

Speed setpoint monitoring

The speed setpoint monitoring prevents that the max. admissible motor speed is exceeded.
It must be set such that the max. velocity (rapid traverse) can be reached and, in addition, a
certain control margin remains.
● MD36210 $MA_CTRLOUT_LIMIT[n] (maximum speed setpoint in %)

SIMODRIVE 611 universal

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.

SIMODRIVE 611 universal

MD36210 $MA_CTRLOUT_LIMIT[n] corresponds to P1405:0 "Monitoring speed of motor" of
the SIMODRIVE 611 universal assigned to the machine axis.

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Manual
426 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

The following machine data is used to define how long the speed setpoint may remain within
the limits before the speed setpoint monitoring responds.
● MD36220 $MA_CTRLOUT_LIMIT_TIME[n] (delay time for speed setpoint monitoring)
Error reaction:
● Alarm "25060 Speed setpoint limiting"
and stopping the machine axis using a speed setpoint ramp whose characteristic curve is set
in the following machine data:
● MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur)
Causes of error/error handling:
● A measuring circuit error or drive error is present.
● Setpoints are too high (accelerations, velocities, reducing factors).
● Obstacle in work area (e.g. positioning on a working table)
=> Overcome obstacle
The speed setpoint consists of the speed setpoint of the position controller and the
feedforward control parameter (if feedforward control is active).

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NOTICE
The limitation of the speed setpoint will turn the control loop into a nonlinear control loop.
Generally, this will result in deviations from the contour and longer dwelling of the machine
axis within the speed setpoint limitation.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 427
NC Commissioning with HMI Advanced
11.5 Axes and spindles

Actual velocity monitoring

Monitoring due to the actual velocity of the machine axis determined based on the encoder
values
● MD36020 $MA_AX_VELO_LIMIT (velocity-monitoring threshold)
Error reaction:
● Alarm "25030 Alarm limit of actual velocity"
and stopping the machine axis using a speed setpoint ramp whose characteristic curve is set
in the following machine data:
● MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur)
Causes of error/error handling:
● Check speed setpoint cable
● Check actual values
● Check position control direction (control sense)
● Threshold value for velocity monitoring is possibly too low.

Contour monitoring
Monitoring of the difference between following error measured and following error calculated
from the position setpoint.
● MD36400 $MA_CONTOUR_TOL (contour monitoring tolerance range)
Error reaction:
● Alarm "25050 Contour monitoring"
and stopping the machine axis using a speed setpoint ramp whose characteristic curve is set
in the following machine data:
● MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur)
Causes of error/error handling:
Contour errors are caused by signal distortions in the position control loop.
Execute the following steps for error removal:
● Increase the tolerance band
● Check the Kv factor
The real servo gain must correspond to the desired servo gain set by MD32200
$MA_POSCTRL_GAIN[n] (Kv factor).
HMI-Advanced
Operating area: DIAGNOSIS > Service displays > Service axis.
● Check optimization of the speed controller
● Check smooth running of the axes
● Check machine data for traversing motions
(Feedrate override, acceleration, max. velocities, ... )

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● For operation with feedforward control:

MD32810 $MA_EQUIV_SPEEDCTRL_TIME (equivalent time constant of speed control
loop for feedforward control) or if the machine data is imprecisely set, the MD36400
$MA_CONTOUR_TOL must be enlarged.

Encoder limit frequency monitoring

Monitoring of the limit frequency of the encoder of a machine axis.
● MD36300 $MA_ENC_FREQ_LIMIT (encoder limit frequency)
Error reaction:
● Alarm "21610 Encoder frequency exceeded"
● IS DB31, ... DBX60.2 "Encoder limit frequency exceeded 1"
● IS DB31, ... DBX60.3 "Encoder limit frequency exceeded 2"
and stopping the machine axis using a speed setpoint ramp whose characteristic curve is set
in the following machine data:
● MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur)
Causes of error/error handling:
After the axes have stopped, the position control is automatically resumed.

NOTICE
The axis affected must be re-referenced.

Encoder zero mark monitoring

The zero mark monitoring of the encoder of a machine axis checks whether pulses were lost
between two zero mark passes. The following machine data is used to enter the number of
detected zero mark errors at which the monitoring is to respond:
● MD36310 $MA_ENC_ZERO_MONITORING (Zero-mark monitoring)
Special feature:
A value of 100 will additionally disable the hardware monitoring of the encoder.
Error reaction:
● Alarm "25020 Zero mark monitoring"
and stopping the machine axes using a speed setpoint ramp whose characteristic curve is
set in the following machine data:
● MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur)
Causes of error/error handling:
● MD36300 $MA_ENC_FREQ_LIMIT [n] (encoder limit frequency) set too high.
● Encoder cable damaged.
● Encoder or encoder electronics defective.

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11.5 Axes and spindles

Position tolerance when switching over the encoder

It is possible to switch between the two encoders or position measuring systems of a
machine axis at any time. The permissible position difference between the two position
measuring systems is monitored.
● MD36500 $MA_ENC_CHANGE_TOL (Max. tolerance on position actual value switchover)
Error reaction:
● Alarm "25100 Measuring system cannot be switched over"
The requested switchover to another encoder is not carried out.
Causes of error/error handling:
● The specified permissible tolerance is too small.
● The measuring system to which you will switch over is not referenced.

Cycl. Monitoring the encoder position tolerance

The position difference between the two encoders or position measuring systems of a
machine axis is monitored with the following machine data:
● MD36510 ENC_DIFF_TOL (measuring system synchronism tolerance)
Error reaction:
● Alarm "25105 Measuring systems are not synchronous"
and stopping the machine axes using a speed setpoint ramp whose characteristic curve is
set in the following machine data:
● MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors occur)

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11.5 Axes and spindles

NOTICE
The following is to be taken into account:
• MD36620 $MA_SERVO_DISABLE_DELAY_TIME (switchoff delay servo enable)
must always be selected greater than
• MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors
occur)
If this is not the case, the braking ramp cannot be kept.

References:
/FB/ Function Manual, Basic Functions; A3 Axis Monitoring, Protection Zones

11.5.19 Axis homing

Homing
When referencing a machine axis, the actual position value system of the machine axis is
synchronized with the machine geometry. Depending on the encoder type used, the machine
axis is referenced with or without traversing movements.

Reference point approach

For all machine axes which are not equipped with an encoder providing an absolute actual
position value, referencing is carried out by traversing the machine axis to a reference point;
this is called the reference point approach.
The reference point approach can be carried out either manually in JOG mode, submode
REF or using a part program. Reference point approach is started using traverse direction
keys PLUS or MINUS (depending on the parameterized reference point approach direction).

Incremental measuring systems

With incremental measuring systems, referencing is carried out using a reference point
approach divided into three phases:
1. Traversing to the reference cam
2. Synchronizing to the encoder zero mark
3. Approach reference point

Manual
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NC Commissioning with HMI Advanced
11.5 Axes and spindles

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Phase-independent data
The following machine data and interface signals are independent with respect to the
individual phases of reference point approach:
● MD11300 $MN_JOG_INC_MODE_LEVELTRIGGRD (INC/REF in jog mode)
● MD34000 $MA_REFP_CAM_IS_ACTIVE (axis with reference cam)
● MD34110 $MA_REFP_CYCLE_NR (axis sequence for channel-specific reference point
approach)
● MD30240 $MA_ENC_TYPE (encoder type)
● MD34200 $MA_ENC_REFP_MODE (referencing mode)
● IS DB21, ... DBX1.0 ("Activate referencing")
● IS DB21, ... DBX33.0 ("Activate referencing")

Phase 1: Traversing to the reference cam

The following machine data and interface signals are relevant:
● MD34010 $MA_REFP_CAM_DIR_IS_MINUS (approach reference cam in minus direction)
● MD34020 $MA_REFP_VELO_SEARCH_CAM (Reference cam approach velocity)
● MD34030 $MA_REFP_MAX_CAM_DIST (maximum distance to the reference cam)
● MD34092 $MA_REFP_CAM_SHIFT (electr. cam offset, incremental measuring systems
with equidistant zero markers)
● IS DB21, ... DBX36.2 ("All axes with obligatory reference point are referenced")
● IS DB31, ... DBX4.7/DBX4.6 ("Traversing keys plus/minus")

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11.5 Axes and spindles

● IS DB31, ... DBX12.7 ("Reference point approach delay")

● IS DB31, ... DBX60.4, DBX60.5 ("Referenced/synchronized 1, 2")
Properties of phase 1:
● The feedrate override (feedrate switch) is active.
● The feed stop (channelspecific and axisspecific) is active.
● The machine axis can be stopped and restarted with NC-stop/NC-start.
● If the machine axis travels from the starting position in the direction of the reference cam
by a distance defined in MD34030 $MA_REFP_MAX_CAM_DIST (maximum distance to
reference cam) without reaching the reference cam (IS DB31,... DBX12.7 ("delay in
reference point travel") = 0), then the axis stops and Alarm 20000 "Reference cam not
reached" is output.

WARNING
If the reference cam is not calibrated exactly, it is possible that a wrong zero mark 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 ± 1 encoder revolution in each case.
Danger for man and machine exists!

Phase 2: Synchronizing to the encoder zero mark

The following machine data and interface signals are relevant:
● MD34040 $MA_REFP_VELO_SEARCH_MARKER (creep velocity)
● MD34050 $MA_REFP_SEARCH_MARKER_REVERSE (direction reversal on reference
cam)
● MD34060 $MA_REFP_MAX_MARKER_DIST (Maximum distance from cam to reference
mark)
Properties of phase 2:
● Feed override (the feed override switch) is not active.
If a feed override of 0% is selected via the feed override switch, the traverse movement is
stopped.
● Feed stop (channel-specific and axis-specific) is active.
On a feed stop, the traverse movement is stopped and the following alarm displayed:
– Alarm 20005 "Reference point approach canceled"
● NC-Stop/NC-Start is inactive.
● If the machine axis travels, after leaving the reference cam (IS DB31, ...DBX12.7 ("Delay
in reference point travel") = 0), a maximum distance parameterized in machine data
MD34060 $MA_REFP_MAX_MARKER_DIST (max. distance from reference mark)
without detecting the zero mark, the machine axis stops and the following alarm is
displayed:
– Alarm 20002 "Zero mark missing"

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

Phase 3: Approach reference point

The following machine data and interface signals are relevant:
● MD34070 $MA_REFP_VELO_POS (reference point positioning velocity)
● MD34080 $MA_REFP_MOVE_DIST (reference point distance to zero mark)
● MD34090 $MA_REFP_MOVE_DIST_CORR (reference point offset, additive)
● MD34100 $MA_REFP_SET_POS (reference point value)
● IS DB31, ... DBX2.4, 2.5, 2.6, 2.7 ("Reference point value 1...4")
● IS DB31, ... DBX60.4, DBX60.5 ("Referenced/synchronized 1, 2")
Properties of phase 3:
● Feed override (the feed override switch) is active.
● Feed stop (channel-specific and axis-specific) is active.
● NC-Stop/NC start is active.
References:
/FB1/ Function Manual, Basic Functions, R1 Reference point travel, Chapter "Referencing
with incremental measuring systems"

Distancecoded reference marks

When clearance-coded reference marks are used, referencing is divided into 2 phases:
1. Synchronize by overriding 2 reference marks
2. Traverse to target point

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Manual
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11.5 Axes and spindles

Phase-independent data
The following machine data and interface signals are independent with respect to the
individual phases of reference point approach:
● MD11300 $MN_JOG_INC_MODE_LEVELTRIGGRD (INC/REF in jog mode)
● MD34000 $MA_REFP_CAM_IS_ACTIVE (axis with reference cam)
● MD34110 $MA_REFP_CYCLE_NR (axis sequence for channel-specific reference point
approach)
● MD30240 $MA_ENC_TYPE (encoder type)
● MD34200 $MA_ENC_REFP_MODE (referencing mode)
● MD34310 $MA_ENC_MARKER_INC (interval between two reference marks)
● MD34320 $MA_ENC_INVERS (inverse measuring system)
● IS DB21, ... DBX1.0 ("Activate referencing")
● IS DB21, ... DBX33.0 ("Activate referencing")

Phase 1: Synchronize by overriding 2 reference marks

The following machine data and interface signals are relevant:
● MD34010 $MA_REFP_CAM_DIR_IS_MINUS (approach reference cam in minus direction)
● MD34040 $MA_REFP_VELO_SEARCH_MARKER (referencing velocity)
● MD34060 $MA_REFP_MAX_MARKER_DIST (maximum distance between 2 reference
marks)
● MD34300 $MA_ENC_REFP_MARKER_DIST (Reference mark distance)
● IS DB21, ... 30, DBX36.2 ("All axes to be referenced are referenced")
● IS DB31, ... DBX4.7/DBX4.6 ("Traversing keys plus/minus")
● IS DB31, ... DBX12.7 ("Reference point approach delay")
● IS DB31, ... DBX60.4, DBX60.5 ("Referenced/synchronized 1, 2")
Properties of phase 1:
● If the machine axis travels a distance defined in MD34300 $MA_REFP_MARKER_DIST
(max. distance from reference point) from the starting point without overriding two
reference marks, then the machine axis stops and Alarm 20004 "Reference Mark is
missing" is output.

Phase 2: Traversing to the target point

The following machine data and interface signals are relevant:
● MD34070 $MA_REFP_VELO_POS (end point positioning velocity)
● MD34090 $MA_REFP_MOVE_DIST_CORR (absolute offset)
● MD34100 $MA_REFP_SET_POS (target point)
● MD34330 $MA_REFP_STOP_AT_ABS_MARKER (with/without target point)
● IS DB31, ... DBX60.4, DBX60.5 ("Referenced/synchronized 1, 2")

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

Properties of phase 2:
● The feedrate override (feedrate switch) is active.
● The feed stop (channelspecific and axisspecific) is active.
● The machine axis can be stopped and restarted with NC-stop/NC-start.

Determining the absolute offset

To determine the absolute offset between the measuring system zero point and the machine
zero, the following procedure is recommended:
1. Determining the actual position of the measuring system
After two reference marks following one after the other (synchronized) have been
overtraveled, the actual position of the length measuring system can be read on the user
interface at "Actual position".
The absolute offset must be zero at this time:
– MD34090 $MA_REFP_MOVE_DIST_CORR = 0
2. Determine the absolute machine actual position
Determining the absolute machine actual position, e.g. can be performed by traversing
the machine axis to a known position (fixed stop) or measured at a convenient position
(laser interferometer).
3. Calculating the absolute offset
– Linear measurement system non-inverse to machine system:
Absolute offset = machine actual position + actual position of the measuring system
– Linear measuring system inverse to machine system:
Absolute offset = machine actual position - actual position of the measuring system
– MD34090 $MA_REFP_MOVE_DIST_CORR (reference point/absolute offset)

WARNING
The position measuring system must be referenced again after determining the
absolute offset and making the entry in the following machine data:
MD34090 $MA_REFP_MOVE_DIST_CORR (absolute offset)

References:
/FB1/ Function Manual - Basic Functions, R1 Reference point approach, Chapter
"Referencing on length measuring systems with distance-coded reference marks"

Absolute encoders
Initial referencing of the measuring system of a machine axis with absolute encoder is
performed by calibrating the encoder.

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Follow-up referencing
Follow-up referencing of a machine axis is performed automatically while the NC starts up
without axis movement. The following conditions must be fulfilled:
● The measuring system of the machine axis active after the booting of the NC works with
the absolute encoder
● The absolute encoder is calibrated:
MD34210 $MA_ENC_REFP_STATE[n] = 2 (absolute value encoder is calibrated)

Adjusting
To calibrate the absolute encoder, the actual value of the encoder is matched with the
machine zero once and then enabled.
The SINUMERIK 840Di sl supports the following types of calibration:
● Operator-assisted calibration
● Automatic calibration using probe
● Calibration using BERO
The calibration using the probe and BERO is described in:
References:
/FB/ Function Manual - Basic Functions, R1 Reference point approach, Chapter "Automatic
calibration using probe, Calibration with BERO"

Operator-assisted calibration
During operator-assisted calibration, the machine axis of the absolute encoder is moved to
the known machine position (reference position). The position value of the reference position
is taken over by the NC as the reference point value.
Recommended procedure:
1. Parameterization of referencing mode
– MD34200 $MA_ENC_REFP_MODE[n] = 0
2. Approaching referencing position
Traversing the machine axis to the referencing position in JOG mode. Approach direction
according to machine data:
– MD34010 $MA_REFP_CAM_DIR_IS_MINUS (reference point approach in minus
direction) (0 = positive, 1 = negative approach direction)

NOTICE
To avoid the actual position of the machine axis being falsified by backlash in the
drive train, reference point approach must be performed at low velocity and always
from the same direction.

3. Assumption of the reference position in the NC

The reference position is entered in the following machine data:
– MD34100 $MA_REFP_SET_POS[n] (reference point value)

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11.5 Axes and spindles

4. Enabling encoder calibration

Encoder calibration is performed in the following machine data:
– MD34210 $MA_ENC_REFP_STATE[n] = 1
5. Activate changed machine data by NC reset.
6. Completing encoder calibration
After the NC booting, the same traverse direction key must be re-actuated as in Point 2,
to complete the encoder calibration in the JOG > REF mode for the machine axis:
– Select JOG > 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 following machine
data:
● MD34090 $MA_REFP_MOVE_DIST_CORR[n] (reference point offset)
To indicate that calibration has been completed, the value in the machine data changes
from 1 = enable encoder calibration to 2 = encoder calibrated:
● MD34210 $MA_ENC_REFP_STATE[n] = 2
The value from the following machine data is shown as the actual position of the machine
axis on the user interface:
● MD34100 $MA_REFP_SET_POS[n] (reference point value)

Calibrating several absolute encoders

For time-optimized calibration of the absolute encoders of several machine axes, the
following procedure is recommended:
1. Depending on the machine design, move all or several machine axes to their reference
position. See above: Points 1 to 4.
2. Initiate NC reset See above: Point 5.
3. Complete encoder calibration for all machine axes. See above: Point 6.

Recalibration
Recalibration of the absolute encoder is required e.g. after:
● Gear change between load and absolute encoder
● Set actual values (PRESETON)
● Removal/installation of the absolute value encoder
● Removal/installation of the motor with the absolute value encoder
● SRAM data loss of the NC
● Battery failure

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11.5 Axes and spindles

NOTICE
The NC can detect a required readjustment of the absolute value encoder only during
the following events:
• Gear change with change of gear ratio
• Response to zero mark monitoring (alarm 25020)
• New encoder serial number after replacing the absolute encoder
Subsequently, the status of the absolute value encoder will be set back to 0
automatically by the NC (encoder not adjusted):
• MD34210 $MA_ENC_REFP_STATE[n] = 0
In all other cases, it is the sole responsibility of the user to indicate the uncalibrated
state of the absolute encoder by manually resetting the status to 0 (Encorder not
calibrated) and to repeat the calibration.

References:
/FB1/ Function Manual, Basic Functions, R1 Reference point travel, Chapter "Referencing
with absolute value encoders"

Interface signals

Table 11-37 Referencing: Interface signals

DB number Bit, byte Name

Mode-groupspecific Signals from PLC to mode group
11, ... 0.7 Mode group reset
11, ... 1.2 Machine function REF
Mode-groupspecific Signals from mode group to PLC
11, ... 5.2 Active machine function REF
Channel-specific Signals from PLC to channel
21, ... 1.0 Activate referencing
Channel-specific Signals from channel to PLC
21, ... 28.7 (MMC -> PLC) REF
21, ... 33.0 Referencing active
21, ... 35.7 Reset
21, ... 36.2 All axes that must have a reference point are referenced
Axis-specific Signals from PLC to axis/spindle
31, ... 1.5/1.6 Position measuring system 1/position measuring system 2
31, ... 2.4-2.7 Reference point value 1 to 4
31, ... 4.6/4.7 Traversing keys minus/plus
31, ... 12.7 Reference point approach delay
Axis-specific Signals from axis/spindle to PLC
31, ... 60.4/60.5 Referenced, synchronized 1/Referenced, synchronized 2
31, ... 64.6/64.7 Traverse command minus/plus

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11.5 Axes and spindles

Machine data
Table 11-38 Referencing: Machine data

Number Name Name

General ($MN_ ... )
11300 JOG_INC_MODE_LEVELTRIGGRD INC/REF in jog/continuous mode
Channelspecific ($MC_ ... )
20700 REFP_NC_START_LOCK NC-Start disable without reference point
Axisspecific ($MA_ ... )
30200 NUM_ENCS Number of encoders
30240 ENC_TYP Actual value encoder type
30242 ENC_IS_INDEPENDENT Encoder is independent
31122 BERO_DELAY_TIME_PLUS BERO delay time in plus direction
31123 BERO_DELAY_TIME_MINUS BERO delay time in minus direction
34000 REFP_CAM_IS_ACTIVE Axis with reference cam
34010 REFP_CAM_DIR_IS_MINUS Reference point approach in minus direction
34020 REFP_VELO_SEARCH_CAM Reference point approach velocity
34030 REFP_MAX_CAM_DIST Maximum distance to reference cam
34040 REFP_VELO_SEARCH_MARKER Reference point creep speed
34050 REFP_SEARCH_MARKER_REVERSE Direction reversal to reference cam
34060 REFP_MAX_MARKER_DIST Maximum distance to reference mark; Maximum distance to two
reference marks with distance-coded scales
34070 REFP_VELO_POS Reference point positioning velocity
34080 REFP_MOVE_DIST Reference point distance/destination point for distancecoded
system
34090 REFP_MOVE_DIST_CORR Reference point/absolute offset, distancecoded
34092 REFP_CAM_SHIFT Electronic reference cam shift for incremental measurement
systems with equidistant zero marks.
34100 REFP_SET_POS Reference point value
34102 REFP_SYNC_ENCS Actual value adjustment to the referencing measurement system
34110 REFP_CYCLE_NR Axis sequence for channel-specific Homing
34120 REFP_BERO_LOW_ACTIVE Polarity change of BERO
34200 ENC_REFP_MODE Referencing mode
34210 ENC_REFP_STATE Status of absolute encoder
34220 ENC_ABS_TURNS_MODULO Absolute encoder range for rotary encoders
34300 ENC_REFP_MARKER_DIST Reference marker distance with distancecoded scales
34310 ENC_MARKER_INC Interval between two reference marks with distancecoded scales
34320 ENC_INVERS Linear measuring system inverse to machine system
34330 REFP_STOP_AT_ABS_MARKER Distance-coded linear measuring system without destination
destination point
35150 SPIND_DES_VELO_TOL Spindle speed tolerance
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency resynchronization
36310 ENC_ZERO_MONITORING Zero mark monitoring
30250 ACT_POS_ABS Absolute encoder position at time of deactivation.

Manual
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 NC Commissioning with HMI Advanced
11.5 Axes and spindles

References:
/FB/ Function Manual, Basic Functions, R1 Reference Point Approach

11.5.20 Spindle basic data

The spindle mode of a machine axis is a subset of the general axis functionality. For this
reason, the machine data required to commission an axis also has to be set for a spindle.
The machine data to parameterize a spindle are therefore to be found under the axis-specific
machine data (from MD 35000 onwards).

NOTICE
After the default machine data have been loaded, no spindle is defined.

Spindle definition
By setting the following machine data, a machine axis is declared as an endlessly rotating
rotary axis whose modulo 360 degree programming and display take place:
● MD30300 $MA_IS_ROT_AX (rotary axis/spindle)
● MD30310 $MA_ROT_IS_MODULO (modulo conversion for rotary axis/spindle)
● MD30320 $MA_DISPLAY_IS_MODULO (modulo 360 degrees display for rotary
axis/spindle)
The machine axis is converted to a spindle by defining the spindle number x (with x = 1,
2, ...max. number of channel axes) in machine data:
● MD35000 $MA_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 "Axis configuration" (Page 385)).

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11.5 Axes and spindles

Spindle modes
The diagram below illustrates the spindle modes and possible transitions between them.

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Default mode
The following machine data can be used to define the default mode of a spindle at a defined
time:
● MD35020 $MA_SPIND_DEFAULT_MODE (spindle home position)
● MD35030 $MA_SPIND_DEFAULT_ACT_MASK (effective time of spindle home position)
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Manual
442 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Axis mode
It is possible to switch directly from spindle mode to axis mode, provided the same drive is
used for both modes.
1. Transition to axis mode by programming the spindles using their axis names or by M70.
2. If the axis is not synchronized, e.g. position control enabled with M70, the axis has to be
referenced with G74 first. Only then does the mechanical position match the programmed
one.
3. It is switched over to the current feedforward control mode marked by the machine data
and commands FFWON and FFWOF.

Special features
The following characteristics apply to the axis mode of a spindle:
1. The feed override switch is active.
2. IS "Reset" (DB21, ... DBX7.7) does not terminate axis mode as standard.
3. The interface signals DBB16 to DBB19 and DBB82 to DBB91 in DB31, ... are of no
significance if the IS "Axis/no spindle" (DB31, ... DBX60.0) is set to zero.
4. Axis mode can be activated in all gear steps. If the position actual value encoder is
installed on the motor (indirect measurement system), the positioning and contouring
accuracy can vary for the different gear stages.
5. The gear step cannot be changed when the axis mode is active. The spindle must be
switched to control mode. This is done using M41 ... M45.
6. In axis mode, the machine data of the 1st parameter record (index zero) will apply to be
able to make adaptations.

Master spindle
For example, to be able to use the following spindle functions in a channel, a master spindle
has to be defined in the corresponding channel:
● G95 Revolutional feedrate
● Tapping with compensation chuck (G63)
● Thread cutting (G33)
● Dwell time in spindle revolutions (G4 S...)
The master spindle is defined in the following machine data:
● MD20090 $MC_SPIND_DEF_MASTER_SPIND (Position of deletion of the master spindle
in the channel)
The spindle number of the spindle of the channel defined in the following machine data is
entered in the machine data. This spindle should be the master spindle.
● MD35000 $MA_SPIND_ASSIGN_TO_MACHAX (spindle number)

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11.5 Axes and spindles

Spindle reset
The following machine data is used to define whether the spindle should remain active via
Reset (IS DB21,... DBX7.7) or Program end (M02/M30) even subsequently:
● MD35040 $MA_SPIND_ACTIVE_AFTER_RESET (spindle active after reset)
To cancel spindle movements, an independent spindle reset is required:
● IS DB31,... DBX2.2 (spindle reset)
References:
/FB1/ Function Manual - Basic Functions, S1 Spindles

11.5.21 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. For this, see
Subsection "Setpoint value/actual value channels" (Page 393).

11.5.22 Gear stages

Initiation of gear change

The gear stage change is generally carried out in the following machine data:
● MD35010 $MA_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.

Parameter sets
In spindle mode of a spindle, the NC will select the parameter set that suits the current gear
stage best.
Gear stage x => parameter set (x+1) => 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:
● MD35110 $MA_GEAR_STEP_MAX_VELO[n] (nmax for gear stage change)
● MD35120 $MA_GEAR_STEP_MIN_VELO[n] (nmin for gear stage change)
● MD35130 $MA_GEAR_STEP_MAX_VELO_LIMIT[n] (nmax for gear stage)
● MD35140 $MA_GEAR_STEP_MIN_VELO_LIMIT[n] (nmin for gear stage)
● MD35200 $MA_GEAR_STEP_SPEEDCTRL_ACCEL[n] (acceleration in speed-control
mode)
● MD35210 $MA_GEAR_STEP_POSCTRL_ACCEL[n] (acceleration in position control
mode)

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 NC Commissioning with HMI Advanced
11.5 Axes and spindles

For further information on parameter sets, see Subsection "Axis/spindle parameter

sets" (Page 411).
References:
/FB1/ Function Manual - Basic Functions, S1 Spindles, Chapter "Gear stage change"

11.5.23 Spindle measuring systems

Encoder matching
When parameterizing the measuring systems of spindles, the same conditions apply as for
parameterization of the measuring systems of rotary axes. This multiplication is 2048.
For incremental measuring systems see Subsection "Parameterization of incremental
measuring systems" (Page 396).
For absolute measuring systems see Subsection "Parameterization of absolute measuring
systems" (Page 399).

NOTICE
If the motor encoder is used for actual-value sensing, the encoder matching data must be
entered in the machine data for each individual gear stage if several gear stages are
present.

Pulse multiplication factor

The maximum multiplication of the appropriate drive is always used as the multiplication of
the encoder pulses.

SIMODRIVE 611 universal

The pulse multiplication with SIMODRIVE 611 universal is 128.
Examples of encoder adaptation

Example A: encoder on the spindle

Suppose the following conditions are provided:
● The incremental encoder is mounted on the spindle.
● Encoder pulses = 500 [pulses/rev.]
● Pulse multiplication = 128
● Internal precision = 1000 [increment/degree]
● Encoder gear stage = 1:1
● Load gear stage = 1:1
The machine data are set acc. to the values above:

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11.5 Axes and spindles

● MD10210 $MN_INT_INC_PER_DEG (computational resolution) = 1,000 [incr./degree]

● MD31020 $MA_ENC_RESOL (encoder resolution) = 500 [pulses/revolution]
● MD31050 $MA_DRIVE_AX_RATION_DENOM (load rev. denominator) = 1
● MD31060 $MA_DRIVE_AX_RATION_NUMERA (load rev. numerator) = 1
● MD31070 $MA_DRIVE_ENC_RATION_DENOM (load rev. denominator) = 1
● MD31080 $MA_DRIVE_ENC_RATION_NUMERA (load rev. numerator) = 1

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One encoder increment corresponds to 5.625 internal increments.

One encoder increment corresponds to 0,005625 degrees (highest possible positioning
resolution).

Example B: encoder at motor

Suppose the following conditions are provided:
● The incremental encoder is mounted on the motor.
● Encoder pulses = 2048 [pulses/rev.]
● Pulse multiplication = 128
● Internal precision = 1000 [increment/degree]
● Encoder gear stage = 1:1
● Load gear stage 1= 2.5:1 [motor rev./spindle rev.]
● Load gear stage 2= 1:1 [motor rev./spindle rev.]
Gear stage 1:

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One encoder increment corresponds to 0,54932 internal increments.

One encoder increment corresponds to 0.00054932 degrees (highest possible positioning
resolution).

Manual
446 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Gear stage 2:

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One encoder increment corresponds to 1,3733 internal increments.

One encoder increment corresponds to 0,0013733 degrees (highest possible positioning
resolution).

11.5.24 Speeds and setpoint adjustment for spindle

Speeds, gear stages

In SINUMERIK 840Di sl, data for five gear stages are implemented. These stages are
defined by a minimum and maximum speed for the stage itself and by a minimum and
maximum speed for the automatic gear stage changeover.
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 oscillation function must otherwise be
implemented in the PLC. The oscillation function is initiated via the PLC.

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Figure 11-27 Example for speed ranges for automatic gear stage selection (M40)

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NC Commissioning with HMI Advanced
11.5 Axes and spindles

Speeds for conventional operation

The speeds of the spindle in conventional mode are entered in the following machine data:
● MD32010 $MA_JOG_VELO_RAPID (rapid traverse in jog mode)
● MD32020 $MA_JOG_VELO (axis velocity in JOG mode)
The direction of rotation is specified via the appropriate directional keys for the spindle on the
MCP.

Direction of rotation
The direction of rotation of a spindle corresponds to the traversing direction of an axis.

Setpoint matching
The speeds must be transferred with standardized values for the drive controller. The values
are scaled in the NC using the selected load gear and the appropriate drive parameter.

SIMODRIVE 611 universal

Drive parameter P0880: PROFIBUS speed evaluation

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Figure 11-28 Speed setpoint normalization

The desired speed on the spindle is obtained using a mechanical gear stage.

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 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Machine data

Table 11-39 Speeds and setpoint adjustment for spindle: Machine data

Number Name Name

Axisspecific ($MA_ ... )
31050 DRIVE_AX_RATIO_DENOM Denominator load gearbox
31060 DRIVE_AX_RATIO_NUMERA Numerator load gearbox
32010 JOG_VELO_RAPID Rapid traverse in JOG mode
32020 JOG_VELO Axis velocity in JOG mode
35010 GEAR_STEP_CHANGE_ENABLE Gear stage change possible
35020 SPIND_DEFAULT_MODE Basic spindle setting
35030 SPIND_DEFAULT_ACT_MASK Activate initial spindle setting
35040 SPIND_ACTIVE_AFTER_RESET Spindle active after reset
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode
35220 ACCEL_REDUCTION_SPEED_POINT Speed limit for reduced acceleration
35230 ACCEL_REDUCTION_FACTOR Reduced acceleration
35400 SPIND_OSCILL_DES_VELO Oscillation speed
35410 SPIND_OSCILL_ACCEL Oscillation acceleration
35430 SPIND_OSCILL_START_DIR Starting direction during oscillation
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction

Interface signals

Table 11-40 Speeds and setpoint adjustment for spindle: Interface signals

DB number Bit, byte Name

Axis-specific Signals from PLC to axis/spindle
31, ... 4.6 Traversing keys minus
31, ... 4.7 Traversing keys plus
31, ... 16.2-16.0 Actual gear step
31, ... 16.3 Gear changed
31, ... 16.6 No speed monitoring when changing the gear
31, ... 18.4 Oscillation via PLC
31, ... 18.5 Oscillation speed
Axis-specific Signals from axis/spindle to PLC
31, ... 82.2-82.0 Set gear step
31, ... 82.3 Change gear stage
31, ... 84.7 Active spindle control mode
31, ... 84.6 Active spindle mode oscillation mode

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11.5 Axes and spindles

11.5.25 Positioning the spindle

The NC provides an oriented spindle stop function with which the spindle can be moved into
a certain position and held there (e.g. for tool changing purposes). Several programming
commands are available for this function which define the approach and program processing.
References:
/PA/ Programming Manual, S1 Spindles

Functionality
● At absolute position (0-360 degree)
● Incremental position (+/- 999999.99 degree)
● Block change when position reached
● Block change on block end criterion
The control brakes the spindle down to creep speed at the acceleration rate for speed
operation.
If the creep speed has been reached (INT "Spindle in setpoint range"), the control branches
into position control mode and the acceleration rate for position control mode and the KV
factor become active.
The interface signal "Exact stop fine" is output to indicate that the programmed position has
been reached (block change when position reached).
Acceleration rate for position control mode must be set such that the current limit is not
reached. Acceleration rate must be entered separately for each gear step.
If the spindle is positioned from zero speed, it is accelerated up to a maximum speed
corresponding to creep speed; the direction is defined via machine data. The contour
monitoring function is activated as soon as the control mode switches to position control.

Machine data

Table 11-41 Spindle positioning: Machine data

Number Name Name

Axisspecific ($MA_ ... )
35300 SPIND_POSCTRL_VELO Shutdown speed
35350 SPIND_POSITIONING_DIR Direction of rotation when positioning from the standstill
35210 GEAR_STEP_POSCTRL_ACCEL Acceleration in position control mode
36000 STOP_LIMIT_COARSE Exact stop coarse
36010 STOP_LIMIT_FINE Exact stop fine
32200 POSCTRL_GAIN Kv factor
36400 CONTOUR_TOL Contour monitoring

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 NC Commissioning with HMI Advanced
11.5 Axes and spindles

Interface signals

Table 11-42 Spindle positioning: Interface signals

DB number Bit, byte Name

Axis-specific Signals from axis/spindle to PLC
31, ... 60.6 Position reached with exact stop "fine"
31, ... 60.7 Position reached with exact stop "coarse"
31, ... 84.5 Positioning mode

11.5.26 Synchronizing spindle

Implementation
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.
The following machine data defines the actual position of the spindle at the zero mark
position:
● MD34100 $MA_REFP_SET_POS (reference point value)
The zero mark offset is entered in the following machine data:
● MD34090 $MA_REFP_MOVE_DIST_CORR (reference point offset)
The following machine data specifies which signal is used for synchronization:
● MD34200 ENC_REFP_MODE (referencing mode)
1 = Encoder zero mark
2 = Bero

SIMODRIVE 611 universal

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/ Function Manual SIMODRIVE 611 universal, Chapter: "Motion Control with
PROFIBUS DP (from SW 3.1) Zero mark substitute via PROFIBUS"

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11.5 Axes and spindles

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When is synchronization necessary?

The spindle will be synchronized:
● after the NC has powered up when the spindle is moved using a programming command
● after a request for resynchronization by the PLC
IS DB31,... DBX16.4 (resynchronize spindle 1)
IS DB31,... DBX16.5 (resynchronize spindle 2)
● after each gear stage change for an indirect measuring system
MD31040 $MA_ENC_IS_DIRECT (direct measuring system) = 0
● when the encoder limit frequency falls below the programmed value after a speed has
been programmed which is above the encoder limit frequency.

NOTICE
The following is to be taken into account:
• To synchronize the spindle, it must always be rotated using a programming
command (e.g. M3, M4, SPOS). The specification of a spindle speed using the
direction keys of the machine control panel is not sufficient.
• If the spindle encoder is not mounted directly on the spindle and there are speed-
transforming gears between the encoder and spindle (e.g. encoder mounted on
motor), then a reference cam signal connected to the drive module must be used for
synchronization.
The control system then automatically resynchronizes the spindle after each gear
stage change. The user does not have to contribute anything here.
• In general, backlash, gearbox elasticity and reference cam hysteresis reduce the
accuracy achievable during synchronization.

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11.5 Axes and spindles

Machine data

Table 11-43 Synchronizing spindle: Machine data

Number Name Name

Axisspecific ($MA_ ... )
34100 REFP_SET_POS Reference point value
34090 REFP_MOVE_DIST_CORR Reference point offset
34200 REFP_MODE Referencing mode

Interface signals

Table 11-44 Synchronizing spindle: Interface signals

DB number Bit, byte Name

Axis-specific Signals from PLC to axis/spindle
31, ... 16.4 Synchronize spindle 1
31, ... 16.5 Synchronize spindle 2
Axis-specific Signals from axis/spindle to PLC
31, ... 60.4 Referenced/synchronized 1
31, ... 60.5 Referenced/synchronized 2

11.5.27 Spindle monitoring

Axis/spindle stationary
If the velocity falls below the one specified in the following machine data, then the interface
signal IS DB31,... DBX61.4 (axis/spindle stops) is set:
● MD36060 $MA_STANDSTILL_VELO_TOL (maximum velocity/speed for "Axis/Spindle
stopped")
The path feedrate is then released in the following set machine data:
● MD35510 $MA_SPIND_STOPPED_AT_IPO_START (feed enable for "Spindle stopped")
is set,

Spindle in set range

If the spindle reaches the tolerance range specified in the following machine data, then the
interface signal IS DB31,... DBX83.5 (spindle in setpoint range) is set:
● MD35150 $MA_SPIND_DES_VELO_TOL (spindle speed tolerance)
The path feedrate is then released in the following set machine data:
● MD35510 $MA_SPIND_STOPPED_AT_IPO_START (feed enable for "Spindle stopped")
is set,

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Maximum spindle speed

The maximum spindle speed is entered in the following machine data:
● MD35100 $MA_SPIND_VELO_LIMIT (max. spindle speed)
The NC limits the spindle speed to this value.
Error reaction:
If the speed is nevertheless exceeded by the speed tolerance (drive error), the following
signal is output:
● IS DB31,... DBX83.0 (speed limit exceeded) = 1
● Alarm "22150 Maximum number of chucks exceeded"
The following machine data also limits the speed of the spindle:
● MD36200 $MA_AX_VELO_LIMIT (velocity-monitoring threshold)
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 (control reserve).

Gear stage speed min./max.

The default of a max./min. gear stage speed is entered in the following machine data:
● MD35130 $MA_GEAR_STEP_MAX_VELO_LIMIT (maximum speed for gear stage)
● MD35140 $MA_GEAR_STEP_MIN_VELO_LIMIT (minimum speed for gear stage)
The speed cannot leave this range when the appropriate gear stage is engaged.

Progr. Spindle speed limitations

The following functions can be used to specify a spindle speed limitation in an indexing
program:
● G25 S... (min. spindle speed)
● G26 S... (max. spindle speed)
The limitation is active in all operating modes.
The function LIMS=... can be used to specify a spindle speed limit for G96 (constant cutting
rate):
● LIMS=... (speed limitation (G96))
This limitation is operative only when G96 is active.

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Encoder limit frequency

If the sensor limit frequency in the following machine data is exceeded, synchronization of
the spindle is lost and spindle functionality is reduced (thread, G95, G96):
● MD36300 $MA_ENC_FREQ_LIMIT (encoder limit frequency)
The spindle will be re-synchronized automatically once the sensor frequency falls below the
value defined in the following machine data:
● MD36302 $MA_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.

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References:
/FB1/ Function Manual - Basic Functions, S1 Spindles, Chapter "Spindle Monitoring"

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11.5 Axes and spindles

11.5.28 Spindle data

Machine data

Table 11-45 spindle: Machine data

Number Name Name

General ($MN_ ... )
12060 OVR_SPIND_IS_GRAY_CODE Spindle override with Gray coding
12070 OVR_FACTOR_SPIND_SPEED Evaluation of spindle speed override switch
12080 OVR_REFERENCE_IS_PROG_FEED Override reference velocity
Axisspecific ($MA_ ... )
20090 SPIND_DEF_MASTER_SPIND Initial setting for master spindle on channel
20092 SPIND_ASSIGN_TAB_ENABLE Enabling/disabling of spindle converter
20118 GEOAX_CHANGE_RESET Allow automatic geometry axis change
22400 S_VALUES_ACTIVE_AFTER_RESET S function active after RESET
Axisspecific ($MA_ ... )
30300 IS_ROT_AX Rotary axis
30310 ROT_IS_MODULO Modulo conversion
30320 DISPLAY_IS_MODULO Position display
31050 DRIVE_AX_RATIO_DENOM Denominator load gearbox
31060 DRIVE_AX_RATIO_NUMERA Numerator load gearbox
31122 BERO_DELAY_TIME_PLUS BERO delay time in plus direction
31123 BERO_DELAY_TIME_MINUS BERO delay time in minus direction
32200 POSCTRL_GAIN KV factor
32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant speed control loop for feedforward
control
32910 DYN_MATCH_TIME Time constant for dynamic matching
34040 REFP_VELO_SEARCH_MARKER Reference point creep speed
34060 REFP_MAX_MARKER_DIST Monitoring of zero mark distance
34080 REFP_MOVE_DIST Reference point distance/destination point for distancecoded
system
34090 REFP_MOVE_DIST_CORR Reference point offset/absolute offset, distancecoded
34100 REFP_SET_POS Reference point value
34200 ENC_REFP_MODE Homing mode
35000 SPIND_ASSIGN_TO_MACHAX Assignment of spindle to machine axis
35010 GEAR_STEP_CHANGE_ENABLE Gear stage change possible
35012 GEAR_STEP_CHANGE_POSITION Gear stage change position
35020 SPIND_DEFAULT_MODE Basic spindle setting
35030 SPIND_DEFAULT_ACT_MASK Activate initial spindle setting
35040 SPIND_ACTIVE_AFTER_RESET Spindle active after reset
35100 SPIND_VELO_LIMIT Maximum spindle speed
35110 GEAR_STEP_MAX_VELO[n] Maximum speed for gear change
35120 GEAR_STEP_MIN_VELO[n] Minimum speed for gear change

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Number Name Name

35130 GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed of gear stage
35140 GEAR_STEP_MIN_VELO_LIMIT[n] Minimum speed of gear stage
35150 SPIND_DES_VELO_TOL Spindle speed tolerance
35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limitation via PLC
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode
35210 GEAR_STEP_POSCTRL_ACCEL[n] 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 a nonsynchronized
spindle
35400 SPIND_OSCILL_DES_VELO Oscillation speed
35410 SPIND_OSCILL_ACCEL Oscillation acceleration
35430 SPIND_OSCILL_START_DIR Starting direction during oscillation
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction
35500 SPIND_ON_SPEED_AT_IPO_START Feed enable with spindle in setpoint range
35510 SPIND_STOPPED_AT_IPO_START Feed enable with stationary spindle
35590 PARAMSET_CHANGE_ENABLE Parameter set definition possible from PLC
36060 STANDSTILL_VELO_TOL Threshold velocity "Axis/spindle stationary"
36200 AX_VELO_LIMIT Threshold value for velocity monitoring

Setting data

Table 11-46 spindle: Setting data

Number Name Name

Spindlespecific ($SA_ ... )
42600 JOG_FEED_PER_REF_SOURCE Revolutional feedrate control in JOG mode
42800 SPIND_ASSIGN_TAB Spindle number converter
42900 MIRROR_TOOL_LENGTH Mirror tool length offset
42910 MIRROR_TOOL_WEAR Mirror wear values of tool length compensation
42920 WEAR_SIGN_CUTPOS Mirror wear values of machining plane
42930 WEAR_SIGN Invert sign of all wear values
42940 TOOL_LENGTH_CONST Retain the assignment of tool length components when
changing the machining plane (G17 to G19)
43210 SPIND_MIN_VELO_G25 Progr. Spindle speed limiting G25
43220 SPIND_MAX_VELO_G26 Progr. Spindle speed limiting G26
43230 SPIND_MAX_VELO_LIMS Progr. spindle speed limitation with G96
43300 ASSIGN_FEED_PER_REF_SOURCE Rotational feedrate for positioning axes/spindles

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11.5 Axes and spindles

Interface signals

Table 11-47 spindle: Interface signals

DB number Bit, byte Name

Axis-specific Signals from PLC to axis/spindle
31, ... 0 Feed override
31, ... 1.7 Override active
31, ... 1.6 Position measuring system 2
31, ... 1.5 Position measuring system 1
31, ... 1.4 Follow-up mode
31, ... 1.3 Axis/spindle disable
31, ... 2.2 Spindle reset/delete distancetogo
31, ... 2.1 Controller enable
31, ... 3.6 Velocity/spindle speed limitation
31, ... 16.7 Delete S value
31, ... 16.5 Resynchronize spindle 2
31, ... 16.4 Resynchronize spindle 1
31, ... 16.3 Gear changed
31, ... 16.2-16.0 Actual gear stage A to C
31, ... 17.6 Invert M3/M4
31, ... 17.5 Resynchronize spindle during positioning 2
31, ... 17.4 Resynchronize spindle during positioning 1
31, ... 18.7 Set direction of rotation counterclockwise
31, ... 18.6 Set direction of rotation clockwise
31, ... 18.5 Oscillation speed
31, ... 18.4 Oscillation via PLC
31, ... 19.7-19.0 Spindle offset H - A
Axis-specific Signals from axis/spindle to PLC
31, ... 60.7 Position reached with exact stop fine
31, ... 60.6 Position reached with exact stop coarse
31, ... 60.5 Referenced/synchronized 2
31, ... 60.4 Referenced/synchronized 1
31, ... 60.3 Encoder limit frequency exceeded 2
31, ... 60.2 Encoder limit frequency exceeded 1
31, ... 60.0 Axis/no spindle
31, ... 61.7 Current controller active
31, ... 61.6 Speed control loop active
31, ... 61.5 Position controller active
31, ... 61.4 Axis/spindle stationary (n < nmin)
31, ... 82.3 Change gear stage
31, ... 82.2-82.0 Set gear stage AC
31, ... 83.7 Actual direction of rotation clockwise
31, ... 83.5 Spindle in set range

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11.5 Axes and spindles

DB number Bit, byte Name

31, ... 83.2 Setpoint speed increased
31, ... 83.1 Setpoint speed limited
31, ... 83.0 Speed limit exceeded
31, ... 84.7 Active spindle control mode
31, ... 84.6 Active spindle mode oscillation mode
31, ... 84.5 Active spindle positioning mode
31, ... 84.3 Tapping with compensation chuck active
31, ... 86 and 87 M function for spindle
31, ... 88-91 S function for spindle

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NC Commissioning with HMI Advanced
11.6 Handwheels

11.6 Handwheels

11.6.1 General information

Connection options
Handwheels can be connected to a SINUMERIK 840Di sl via the following interfaces:
● PROFIBUS DP (only via MCI board interface X101)
● Ethernet
● Cable distributor (via MCI board extension)
In order to operate handwheels of a SINUMERIK control system, they have to be
parameterized via NC machine data. If handwheels are not connected via a cable distributor,
additional measures may be required. For example, with connection via PROFIBUS DP, the
module must also be configured with SIMATIC STEP 7, HW Config.

Note
• Only six handwheels can be parameterized on a SINUMERIK 840Di sl.
• It is possible to operate handwheels that are connected via different interfaces (cable
distributor, PROFIBUS, Ethernet) at the same time.

11.6.2 Connection via cable distributor

Parameter assignment
Parameterization of handwheels connected via cable distributor is done via the following NC
machine data:
● MD11350 $MN_HANDWHEEL_SEGMENT[x] = 1
with x = Handwheel No._in_NCK - 1
When connected via cable distributor, the hardware segment has always to be entered as
1 (local hardware segment).
● MD11351 $MN_HANDWHEEL_MODULE[x] = 1
with x = Handwheel No._in_NCK - 1
When connected via cable distributor, the hardware module has always to be entered as
1.
● MD11352 $MN_HANDWHEEL_INPUT[x] = <handwheel connection>
with x = Handwheel No._in_NCK - 1
Handwheel connection used: 1 or 2

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11.6 Handwheels

Note
A maximum of two handwheels can be connected via the cable distributor.

Example
Direct connection of 2 handwheels via a cable distributor.

Table 11-48 Assignment of handwheels in NC machine data

Value
1. Handwheel
MD11350 $MN_HANDWHEEL_SEGMENT[0] 1 Connection via cable distributor always 1
MD11351 $MN_HANDWHEEL_MODULE[0] Connection via cable distributor always 1
MD11352 $MN_HANDWHEEL_INPUT[0] 1. Handwheel connection at cable distributor
2. Handwheel
MD11350 $MN_HANDWHEEL_SEGMENT[1] Connection via cable distributor always 1
MD11351 $MN_HANDWHEEL_MODULE[1] Connection via cable distributor always 1
MD11352 $MN_HANDWHEEL_INPUT[1] 2. Handwheel connection at cable distributor

11.6.3 Connection via PROFIBUS

Parameter assignment
Parameterization of handwheels connected via PROFIBUS modules, e.g. machine control
panel "MCP 483", is done with the following NC machine data:
● MD11350 $MN_HANDWHEEL_SEGMENT[x] = 5
with x = Handwheel No._in_NCK - 1
When connected via PROFIBUS module, the hardware segment has always to be
entered as 5 (PROFIBUS).
● MD11351 $MN_HANDWHEEL_MODULE[x] = <Index + 1>
with x = Handwheel No._in_NCK - 1
The reference to the MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS[<Index>]
containing the logical base address of the handwheel slot is to be entered.
● MD11352 $MN_HANDWHEEL_INPUT[x] = <number_in_handwheel slot>
with x = Handwheel No._in_NCK - 1
A handwheel slot can contain several handwheels. The number of the handwheel within
the handwheel slot has to be entered: 1, 2, ...
● MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS[<Index>] = 1
<Logical base address>
The logical base address of the handwheel slot, specified in SIMATIC STEP 7, HW-
Config, has to be entered.

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11.6 Handwheels

Handwheel slot
The PROFIBUS module must be configured besides the parameterization of handwheels in
the NC machine data in STEP 7. Among others the logical address of the handwheel slot is
specified.
The handwheel slot is situated at the following slot of the PROFIBUS module:

PROFIBUS module Slot

Machine control panel MCP 438 2
Machine control panel MCP 310 2
Handwheel connection module 1

Example
Parameterization of 5 handwheels, connected via 4 machine control panels "MCP 483". A
maximum of two handwheels can be connected to a machine control panel "MCP 483".
The fourth handwheel in the NC has not been used (gap in machine data).

Handwheel number Machine data set (index) Connection

in the NC
1 0 1. MCP, 1st handwheel in handwheel slot
2 1 1. MCP, 2nd handwheel in handwheel slot
3 2 2. MCP, 1st handwheel in handwheel slot
5 4 3. MCP, 1st handwheel in handwheel slot
6 5 4. MCP, 2nd handwheel in handwheel slot

Note
Machine data gaps are allowed when parameterizing handwheels in NC machine data.

Machine control panels have been configured in SIMATIC STEP 7, HW Config as follows:

Table 11-49 Configuration

Slot DP ID Order number/ I address O address

designation
1. MCP 1 55 Standard+Handwheel 0 ... 7 0 ... 7
2 2AE -> Standard+handwheel 288 ... 291
3 1 -> Standard+handwheel
2. MCP 1 55 Standard+Handwheel 8 ... 15 8 ... 15
2 2AE -> Standard+handwheel 304 ... 307
3 1 -> Standard+handwheel
3. MCP 1 55 Standard+Handwheel 16 ... 23 16 ... 23
2 2AE -> Standard+handwheel 320 ... 323
3 1 -> Standard+handwheel

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11.6 Handwheels

Slot DP ID Order number/ I address O address

designation
4. MCP 1 55 Standard+Handwheel 24 ... 29 24 ... 29
2 2AE -> Standard+handwheel 330 ... 333
3 1 -> Standard+handwheel
Parameterizing in the NC machine data:

Table 11-50 Handwheel assignment

Machine data Value Description

1. Handwheel in the NC
MD11350 $MN_HANDWHEEL_SEGMENT[0] 5 Hardware segment: PROFIBUS
MD11351 $MN_HANDWHEEL_MODULE[0] 1 Reference to logical base address of the handwheel slot of the
1st MCP
MD11352 $MN_HANDWHEEL_INPUT[0] 1 1. Handwheel in handwheel slot
2. Handwheel in the NC
MD11350 $MN_HANDWHEEL_SEGMENT[1] 5 Hardware segment: PROFIBUS
MD11351 $MN_HANDWHEEL_MODULE[1] 1 Reference to logical base address of the handwheel slot of the
1st MCP
MD11352 $MN_HANDWHEEL_INPUT[1] 2 2. Handwheel in handwheel slot
3. Handwheel in the NC
MD11350 $MN_HANDWHEEL_SEGMENT[2] 5 Hardware segment: PROFIBUS
MD11351 $MN_HANDWHEEL_MODULE[2] 2 Reference to logical base address of the handwheel slot of the
2nd MCP
MD11352 $MN_HANDWHEEL_INPUT[2] 1 1. Handwheel in handwheel slot
4. Handwheel in the NC
MD11350 $MN_HANDWHEEL_SEGMENT[3] 0 No handwheel parameterized
MD11351 $MN_HANDWHEEL_MODULE[3] 0 No handwheel parameterized
MD11352 $MN_HANDWHEEL_INPUT[3] 0 No handwheel parameterized
5. Handwheel in the NC
MD11350 $MN_HANDWHEEL_SEGMENT[4] 5 Hardware segment: PROFIBUS
MD11351 $MN_HANDWHEEL_MODULE[4] 6 Reference to logical base address of the handwheel slot of the
3rd MCP
MD11352 $MN_HANDWHEEL_INPUT[4] 1 1. Handwheel in handwheel slot
6. Handwheel in the NC
MD11350 $MN_HANDWHEEL_SEGMENT[5] 5 Hardware segment: PROFIBUS
MD11351 $MN_HANDWHEEL_MODULE[5] 5 Reference to logical base address of the handwheel slot of the
4th MCP
MD11352 $MN_HANDWHEEL_INPUT[5] 2 2. Handwheel in handwheel slot

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11.6 Handwheels

Table 11-51 Logical base addresses

Machine data Value Description

MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [0] 288 Logical base address handwheel slot 1st MCP
MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [1] 304 Logical base address handwheel slot 2nd MCP
MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [4] 330 Logical base address handwheel slot 4th MCP
MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [5] 320 Logical base address handwheel slot 3rd MCP

11.6.4 Connection via Ethernet

Parameter assignment
Parameterization of handwheels connected via Ethernet modules, e.g. machine control
panel "MCP 483C IE", "HT 8" or "HT 2" is done with the following NC machine data:
● MD11350 $MN_HANDWHEEL_SEGMENT[< x - 1 >] = 7
When connected via Ethernet module, the segment always has to be entered as 7
(Ethernet).
● MD11351 $MN_HANDWHEEL_MODULE[< x - 1 >] = 1
When connected via Ethernet module, the module always has to be entered as 1.
● MD11352 $MN_HANDWHEEL_INPUT[< x - 1 >] = y
with y = 1, 2, 3, ... (handwheel interface at the Ethernet bus)
with x = 1, 2, 3, ... (handwheel number in the NC)

Handwheel interfaces at Ethernet Bus

The numbering of the handwheel interfaces at the Ethernet bus results from the following
considerations:
● The sequence of the operator component interfaces is: MCP1, MCP2, BHG
● Each operator component interface has two handwheel interfaces
● Operator components: MCP 483C IE
A maximum of two handwheels can be connected to an MCP 483C IE via the
connections X60 and X61. The assignment of the connections in the operator component
interface is:
– Connection X60: 1. Handwheel in the operator component interface MCP1 / MCP2
– Connection X61: 2. Handwheel in the operator component interface MCP1 / MCP2
● Operator components: HT 8
The handwheel of the HT 8 is always assigned to the 1st handwheel of the operator
component interface MCP1 / MCP2.
● Operator components: HT 2
The handwheel of the HT 2 is always assigned to the 1st handwheel of the operator
component interface BHG.

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11.6 Handwheels

Operator component interface -> MCP1 MCP2 HHU

Handwheel interface 1) 1 2 1 2 1 2
FB1 Parameter 2) MCP1BusAdr MCP2BusAdr BHGRecGDNo
Assignment of the handwheels 3)
MCP 483C IE X60 X61 X60 X61 - -
HT 8 x - x - - -
HT 2 - - - - x -
Handwheel interface at the Ethernet bus (y) 4) - 1 2 3 4 5 6
>
1) Numbering of the handwheel interfaces within an operator component interface
2) Assignment of the operator component interface to the interface via the corresponding FB1 parameter
3) Assignment of the handwheels of the respective operator components to the handwheel interfaces
4) Numbering of the handwheel interfaces at the Ethernet bus -> MD11352 $MN_HANDWHEEL_INPUT[< x - 1 >] = y

Example
Parameterization of 3 handwheels, connected via the following operator components:

Operator component interface -> MCP1 MCP2 HHU

Operator components HT 8 MCP 483C HT 2
FB1 parameters MCP1BusAdr := 39 MCP2BusAdr := 192 BHGRecGDNo := 40
Handwheel interface x - - X61 x -
Handwheel interfaces at Ethernet Bus -> 1 2 3 4 5 6

Table 11-52 NCK machine data for the handwheel assignment

Machine data Value Description

HT 8: Handwheel number in the NC = 1
MD11350 $MN_HANDWHEEL_SEGMENT[ 0 ] 7 Segment: Ethernet
MD11350 $MN_HANDWHEEL_MODULE[ 0 ] 1 Module: Ethernet
MD11350 $MN_HANDWHEEL_INPUT[ 0 ] 1 Handwheel interface at Ethernet Bus
MCP 483C IE: Handwheel number in the NC = 2
MD11350 $MN_HANDWHEEL_SEGMENT[ 1 ] 7 Segment: Ethernet
MD11350 $MN_HANDWHEEL_ MODULE [ 1 ] 1 Module: Ethernet
MD11350 $MN_HANDWHEEL_ INPUT [ 1 ] 4 Handwheel interface at Ethernet Bus
HT 2: Handwheel number in the NC = 3
MD11350 $MN_HANDWHEEL_SEGMENT[ 2 ] 7 Segment: Ethernet
MD11350 $MN_HANDWHEEL_ MODULE [ 2 ] 1 Module: Ethernet
MD11350 $MN_HANDWHEEL_ INPUT [ 2 ] 5 Handwheel interface at Ethernet Bus

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11.6 Handwheels

Table 11-53 FB1 parameters (Excerpt)

Parameter Value Comment

MCPNum := 2 // Number of connected MCP
// MCP1 = HT 8
MCP1In ... // MCP1-Parameter ...
... ...
MCP1BusAdr := 39 // Via the switch S1 and S2 of the connecting device
// set "IP Address"
// MCP2 = MCP 483C IE
MCP2In ... // MCP2-Parameter ...
... ...
MCP2BusAdr := 192 // Via switch S2 at the MCP 483C
// set "IP Address"
MCPBusType := b#16#55 // Bus type: Ethernet
// BHG = HT 2
HHU := 5 // Bus type: Ethernet
BHGIn ... // BHG Parameter ...
... ...
BHGRecGDNo := 40 // Via the switch S1 and S2 of the connecting device
// set "IP Address"

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11.7 Digital and analog I/O devices

11.7 Digital and analog I/O devices

The following digital and analog signal modules are available:
Digital I/O modules
● MCI board extension module (option)
There are 4 digital inputs/outputs in each MCI board extension module (option) (Section
"MCI board extension slot variant" (Page 56)).
● PP 72/48
The I/O module PP 72/48 has 72 digital inputs and 48 digital outputs (Section "Device
Module PP72/48" (Page 91)).
● 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 (Chapter "ADI4 (Analog Drive Interface
for 4 Axes)" (Page 104)).
● SIMATIC S7: ET200 modules
Via the PROFIBUS DP, it is possible to connect all subtypes of SIMATIC-S7 I/O modules
of type ET200 (e.g. ET200M) as long as they support a data transmission rate of 12
Mbaud.
Analog I/O modules
● SIMATIC S7: ET200 modules
See above.

NOTICE
The digital and analog inputs/outputs connected via the PROFIBUS DP are equally
available to both the NC and PLC.
It is the sole responsibility of the user to avoid access conflicts:
• NC side: Part program/synchronized action
• On the PLC side: PLC user program

References:
/FB/ Function Manual for Extended Functions, A4 Digital and Analogue NC I/Os

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NC Commissioning with HMI Advanced
11.7 Digital and analog I/O devices

11.7.1 Parameterization of the number of inputs/outputs used

Maximum number
The maximum number of digital or analog inputs/outputs that can be used for the NC is:

Total MCI board extension PROFIBUS modules

Analog inputs 8 - 8
Analog outputs 8 - 8
Digital inputs 36 4 32
Digital outputs 36 4 32

Note
The first digital input and output byte is permanently assigned to the MCI board extension
module (option). Therefore you can connect a maximum of 4 additional input/output bytes to
the PROFIBUS DP via signal modules. See configuration example Subsection
"Configuration example" (Page 473).

Machine data
The number of used analog and digital inputs/outputs is set in the following machine data
parameters:
Analog I/Os
● MD10300 $MN_FASTIO_ANA_NUM_INPUTS ("number of active analog NC inputs")
● MD10310 $MN_FASTIO_ANA_NUM_OUTPUTS ("number of active analog NC outputs")
Digital inputs/outputs
● MD10350 $MN_FASTIO_DIG_NUM_INPUTS ("number of active digital NC input bytes")
● MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS ("number of active digital NC output
bytes")

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11.7 Digital and analog I/O devices

11.7.2 Assignment of inputs/outputs to the signal modules

On the NC side, the analog and digital inputs/outputs are assigned to the respective signal
modules on the PROFIBUS DP via the appropriate I/O addresses in the machine data:

Machine data
Analog I/Os
● MD10362 $MN_HW_ASSIGN_ANA_FASTIN[n] ("hardware assignment of external analog
inputs") per input, where n = 0-7
● MD10364 $MN_HW_ASSIGN_ANA_FASTOUT[n] ("hardware assignment of external
analog outputs") per output, where n = 0-7
Digital inputs/outputs
● MD10366 $MN_HW_ASSIGN_DIG_FASTIN[n] ("hardware assignment of external digital
inputs"), per input byte - where n = 0-3
● MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[n] ("hardware assignment of external
digital outputs"), per outputbyte - where n = 0-3
Input format:

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Note
• The relevant firstdigital inputs/outputs bytes defined via the following machine data is
related to the 4 digital inputs/outputs of the MCI board extension module:
– MD10350 $MN_FASTIO_DIG_NUM_INPUTS
– MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS
Explicit assignment in machine data is not possible. Therefore, the machine data
required to assign the digital and analog inputs/outputs refer exclusively to the signal
modules connected via the PROFIBUS DP.
• The I/O address to be entered in the machine data hexadecimally is the decimal I/O
address of the respective signal module slot allocated by "HW Config" or set manually.
• If a slot comprises several I/O bytes or addresses the NC occupies the entire slot when
an I/O byte is assigned. This means I/O bits not used for the NC cannot be written by the
PLC user program .

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NC Commissioning with HMI Advanced
11.7 Digital and analog I/O devices

11.7.3 System variable $A_...[n]

The digital and analog inputs/outputs are available in the NC (part program, ASUB,
synchronized action, etc.) in the form of system variables.
Analog inputs/outputs
● $A_INA[n] ("Read analog input n, where n=1...8")
● $A_OUTA[n] ("Write analog output n, where n=1...8")
Digital inputs/outputs
● $A_IN[n] ("Read digital input (Bit) n, where n=1...4 and 9...40")
● $A_OUT[n] ("Write digital output Bit) n, where n=1...4 and 9...40")

Hardware assign machine data System variable

Analog inputs/outputs
MD10362 $MN_HW_ASSIGN_ANA_FASTIN[0-7] $A_INA[1-8]
MD10364 $MN_HW_ASSIGN_ANA_FASTOUT[0-7] $A_OUTA[1-8]
Digital inputs/outputs
MCI board extension: Digital inputs 1-4 $A_IN[1-4]
MD10366 $MN_HW_ASSIGN_DIG_FASTIN[0-3] $A_IN[9-40]
MCI board extension: Digital outputs 1-4 $A_OUT[1-4]
MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[0-3] $A_OUT[9-40]

Note
The digital inputs/outputs are organized as follows:
• Hardware assign machine data: Byte by byte
• System variables: Bit by bit

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11.7 Digital and analog I/O devices

11.7.4 Digital input/output bytes and system variables

Digital inputs
The following configuration example shows the relationship between digital input bytes and
system variables by means of the configuration of 3 digital inputs bytes.
This configuration example requires the following:
● 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. Digital input
bytes of external signal modules must therefore always be counted as additional input bytes:
● MD10350 $MN_FASTIO_DIG_NUM_INPUTS = 1 + m,
with m = number of input bytes of external signal modules
Because the 1st input byte is permanently assigned to the MCI board extension module, only
the input bytes of the external signal modules have to be explicitly assigned to the system
variables.
● MD10366 $MN_HW_ASSIGN_DIG_FASTIN[0] -> 1. external input byte
● MD10366 $MN_HW_ASSIGN_DIG_FASTIN[1] -> 2. external input byte

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Figure 11-31 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 internally 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.

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NC Commissioning with HMI Advanced
11.7 Digital and analog I/O devices

11.7.5 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 via the PROFIBUS DP, the system
variable is transferred from DP master to the signal module via the PROFIBUS DP during
the next position controller cycle.
The signal module will then provide the signal to the appropriate with the output next output
cycle. The PROFIBUS DP cycle and the cycle of the signal module are not synchronized
during this process.
The described transfer cycle is illustrated in the following diagram.
The dynamic response while importing a digital or analog input are similar to the properties
described above.

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Figure 11-32 Dynamic response when outputting an output signal with optimized DP-Cycle

Explanations for the figure:

● TMAPC
Master application cycle: NC-Position controller cycle
the following is always valid for SINUMERIK 840Di sl: TMAPC = TDP
● TDP
DP cycle time: DP cycle time
● TDX
Data exchange time: Total transfer time for all DP slaves

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11.7 Digital and analog I/O devices

● TM
Master time: Offset of the start time for NC position control
● GC
Global Control: Broadcast message for cyclic convergence of the equidistance between
DP master and DP slaves
● R
Computational time of position controller or signal module
● Dx
Useful data exchange between the DP master and DP slaves
● MSG
Acyclic services (e.g. DP/V1, pass token)
● RES
Reserve: "Active break" until the equidistant cycle has expired
● ①
Set the system variables, e.g. $A_OUT[8] in the part program or synchronized action
● ②
Transmit the output signal to the signal module via the PROFIBUS DP
● ③
Connect the signal to the output of the module.

11.7.6 Configuration example

In the following configuration example, the following digital input/outputs are available to the
NC:
ET 200
● 24 digital inputs
● 16 digital outputs
ADI4
● 8 digital inputs
● 16 digital outputs

Note
The following is to be taken into account:
• The I/O addresses of the modules are assigned automatically by "HW Config" (manual
adjustment is possible).
• Each I/O address is related to an input/output byte.

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NC Commissioning with HMI Advanced
11.7 Digital and analog I/O devices

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Figure 11-33 Example configuration: SINUMERIK 840Di sl with ET200 and ADI4

ET200 I/Os: IM 153

Slot Assembly I address O address Comment

4 SM 322 DO16xDC24V/0.5A - 128...129
5 SM 322 DO32xDC24V/0.5A - 130...133
6 SM 321 DI16xDC24V/0.5A 128...129 -
7 SM 321 DI32xDC24V/0.5A 130...133 -
ADI4

Slot Assembly I address O address Comment

4 Drive data
5 Drive data 4288...4305 1. Axis
6 Drive data 4288...4305 1. Axis
7 Drive data
8 Drive data
9 Drive data 4306...4323 2. Axis
10 Drive data 4306...4323 2. Axis
11 Drive data
12 Drive data
13 Drive data 4324...4341 3. Axis
14 Drive data 4324...4341 3. Axis
15 Drive data
16 Drive data
17 Drive data 4342...4359 4. Axis
18 Drive data 4342...4359 4. Axis
19 Drive data
20 Drive data
21 Drive data 4360...3461 I word
22 Drive data 4360...4361 O word

Manual
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11.7 Digital and analog I/O devices

Slot Assembly I address O address Comment

Note:
The structure of the PROFIBUS message frame is described in Chapter "DP Slave:
ADI4" (Page 286).

Machine data
Parameterization of the NC machine data is shown below:
ET 200
3 input bytes
ADI4
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 is not installed:

● MD10350 $MN_FASTIO_DIG_NUM_INPUTS = 5

Number of output bytes

ET 200
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 $MN_FASTIO_DIG_NUM_OUTPUTS = 5

Hardware assignment: input bytes

The following input bytes are used by the NC:
● ET 200
Both input bytes of the input module (slot 6)
– MD10366 $MN_HW_ASSIGN_DIG_FASTIN[0] = H05000080 (128D)
– MD10366 $MN_HW_ASSIGN_DIG_FASTIN[1] = H05000081 (129D)
The 4th of the 4 input bytes of the signal module (slot 7)
– MD10366 $MN_HW_ASSIGN_DIG_FASTIN[2] = H05000085 (133D)

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11.7 Digital and analog I/O devices

● ADI4
The high byte of the input word (slot 21)
– MD10366 $MN_HW_ASSIGN_DIG_FASTIN[3] = H050010E7 (4327D)

Hardware assignment: output bytes

The following output bytes are used by the NC:
● ET 200
The 1st output byte of the output modules (slots 4 and 5)
– MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[0] = H05000080 (128D)
– MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[1] = H05000082 (130D)
● ADI4
Both output bytes of the output word (slot 22)
– MD10366 $MN_HW_ASSIGN_DIG_FASTOUT[2] = H050010E6 (4326D)
– MD10366 $MN_HW_ASSIGN_DIG_FASTOUT[3] = H050010E7 (4327D)

Machine data

Table 11-54 Digital and analog I/Os: Machine data

Number Name Name

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 external analog NC inputs
10364 HW_ASSIGN_ANA_FASTOUT Hardware assignment of external analog NC outputs
10366 HW_ASSIGN_DIG_FASTIN Hardware assignment of external digital NC inputs
10368 HW_ASSIGN_DIG_FASTOUT Hardware assignment of external digital NC outputs
10380 HW_UPDATE_RATE_FASTIO Update rate of clock-synchronous external NC I/Os
10382 HW_LEAD_TIME_FASTIO Rate time for clock-synchronous external NC I/Os
10384 HW_CLOCKED_MODULE_MASK Clock-synchronous processing of 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 writable
output bytes of the PLC I/Os

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11.7 Digital and analog I/O devices

Number Name Name

10530 COMPAR_ASSIGN_ANA_INPUT_1 Hardware assignment of NC analog inputs for comparator byte
1
10531 COMPAR_ASSIGN_ANA_INPUT_2 Hardware assignment of 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 input bytes of NC I/Os for "multiple feedrates in
one block"

Setting data

Table 11-55 Digital and analog I/Os: Setting data

Number Name Name

General ($SN_ ...)
41600 COMPAR_THRESHOLD_1 Threshold values for comparator byte 1
41601 COMPAR_THRESHOLD_2 Threshold values for comparator byte 2

Interface signals

Table 11-56 Digital and analog I/Os: Interface signals

DB number Bit, byte Name

General Signals from PLC to NC
10 0, 122, 124, 126, 128 Disable digital NC inputs
10 1, 123, 125, 127, 129 Setting on PLC of digital NC inputs
10 4, 130, 134, 138, 142 Disable digital NC outputs
10 5, 131, 135, 139, 143 Overwrite mask for digital NC outputs
10 6, 132, 136, 140, 144 Setting value from PLC for the digital NC outputs
10 7, 133, 137, 141, 145 Setting mask for digital NC outputs
10 146 Disable analog NC inputs
10 147 Default mask for analog NC inputs
10 148-163 Setting value from PLC for the analog NC inputs
10 166 Overwrite mask for analog NC outputs
10 167 Default mask for analog NC outputs
10 168 Disable analog NC outputs
10 170-185 Setting value from PLC for the analog NC outputs
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

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11.8 Loadable compile cycles

11.8 Loadable compile cycles

Product brief
Compile cycles are 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 comprehensive access to
data and functions of the NC system level via defined software interfaces. Therefore, you
can use compile cycles to expand the functionality of the NC as much as you require or
redefine it as far as allowed by the interfaces.
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.

Siemens compile cycles

The following technological functions and more are available from Siemens in the form of
compile cycles:
● 1D/3D clearance control in position controller cycle
References:
/FB3/ Function Manual - Special Functions
Chapter "Clearance Control" (TE1)
● Continue machining at the contour (retrace support)
References:
/FB3/ Function Manual - Special Functions
Chapter "Continue Machining Retrace Support (TE7)
● Fast laser switching signal
References:
/FB3/ Function Manual - Special Functions
Chapter "Cycle-independent Path-Synchronous Control Signal Output (TE8)
When you order one of the listed technological functions, you are given the corresponding
software license number. To obtain the compile cycle in the form of a loadable file (.ELF
extension for executable and linking format), please contact your regional Siemens sales
partner.

Note
Compile cycles created by Siemens are options that require explicit activation and licensing.
References:
Ordering information in Catalog NC 61

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11.8 Loadable compile cycles

11.8.1 Load a compile cycle

Requirement
To transfer the compile cycle to the control, the following requirements must be met:
● There is a network connection (TCP/IP) between the PCU and an external computer
(PC/PG) on which the compile cycle is located.
● Storage media can be connected to the PCU (e.g. USB FlashDrive) on which the compile
cycle is saved.

Implementation
Perform the following operation to load one or more compile cycles into the NC:
1. End the active SINUMERIK user interface (e.g. HMI Advanced) and activate the
SINUMERIK desktop (see Chapter "Activation" (Page 135)).
2. Use Windows Explorer to copy the compile cycle file (e.g. ccresu.elf) from the external
computer (PC/PG) or the CD/disk drive to the following directory on the PCU:
F:\card\oem\sinumerik\oa\
3. Trigger an NC reset to load the compile cycles into the NC system software.

11.8.2 Interface version compatibility

A SINUMERIK-specific interface is used for communication between the compile cycle and
NC system software. Therefore, the interface version of a loaded compile cycle must be
compatible with the interface version of the NC system software. Each interface version is
displayed under:
● Interface version of the NC system software
HMI Advanced:
Diagnosis > Service Display > Version > NCU Version
Display (excerpt)

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11.8 Loadable compile cycles

● Interface version of a compile cycle that has not yet been loaded
HMI Advanced (excerpt):
Services > <Medium> > "Properties" softkey
Display:

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● Interface version of a loaded compile cycle

HMI Advanced:
Diagnosis > Service Display > Version > NCU Version
Display (excerpt)

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Example:
_N_CLC407IF003001_ELF corresponds to interface version: 3.1

dependencies
The following dependencies exist between the interface versions of a compile cycle and the
NC system software:
● 1. Digit of the interface version number
The 1st digit of the interface version number of a compile cycle and the NC system
software must be the same.
● 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 the NC has booted, this means no compile cycle has
been loaded!

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11.8 Loadable compile cycles

11.8.3 Software version of a compile cycle

The software version of a compile cycle is displayed under:
HMI Advanced:
Diagnosis > Service Display > Version > NCU Version
Display (excerpt)

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Example:
_N_CLC407IF003001_ELF corresponds to software version: 4.7

Note
The display of code and data range start addresses of a compile cycle are provided for
diagnostics purposes only and have no significance in normal operation.

11.8.4 Constraints
The following checks are performed for all loaded compile cycles when the NC boots:

Interface versions
If the interface version of the compile cycle is incompatible with the interface version of the
NC system software, the following alarm is displayed:
● Alarm "7200 Version_conflict_with_CCNCKInterfaceVersion".

dependencies
If one compile cycle has a functional dependency on another, and this has not been loaded
in the NC, the following alarm is issued:
● Alarm "7200 CC<Identifier>_ELF Loader_problem_from_dFixup"

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11.8 Loadable compile cycles

System enables
If the compile cycle is not enabled in conjunction with SINUMERIK 840Di sl or 840DiE sl, the
following alarm is issued:
Not enabled for SINUMERIK 840Di sl:
● Alarm "7200 CC<Identifier>_ELF NO_840Di"
Not enabled for SINUMERIK 840DiE sl:
● Alarm "7200 CC<Identifier>_ELF NO_EMBARGO"

CAUTION
If alarm "7200 . . . " is present after an NC startup, none of the loaded compile cycles is
active.

11.8.5 Activating and licensing technology functions

Activating and licensing the option

To activate the technological function loaded onto the NC by means of the compile cycle, the
respective option must be set and licensed.
For information about how to activate and license options, please see Chapter "License
Management" (Page 146).

Activating the technological function

Each loaded compile cycle generates a technological function-specific global machine data:
● $MN_CC_ACTIVE_IN_CHAN_<identifier>[n], with n = 0, 1
in the machine data number range 60900 to 60999.
You can activate the entire technological function in the individual channels or individual
subfunctions via the general NC machine date mentioned above.
For a description of the machine data, please see Chapter "Data Descriptions
(MD)" (Page 483).
References:
The individual technological functions are described in:
/FB3/ Function Manual - Special Functions, Chapters TE1 to TE8

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11.8 Loadable compile cycles

11.8.6 Data descriptions (MD)

General machine data

60900 + i CC_ACTIVE_IN_CHAN_XXXX[n]
where i = 0. 1. 2. 3 ... with: XXXX = function identifier, n = 0 or 1
MD number n = 0: Activating the technology function in channels
n = 1: Additional functions within the technology function
Default setting: 0 Min. input limit: 0 Max. input limit: FFFF
Changes effective after RESET Protection level: 2/7 unit: -
Data type: UINT16 Valid as of software version: 2.2
Meaning: Activating the technology function in the channels:
The technology function is activated in the channels by means of index n = 0.
Bit 0 = 1: Technology function activated in Channel 1
Bit n = 1: Technology function activated in channel n+1
For more details about which channels a technological function can be activated, please
refer to the manuals below.
Additional functions within the technology function:
The MD with index n = 1 activates additional functions within the relevant technology
function. See References below.
References:
/FB3/ Function Manual - Special Functions TE1-TE8.

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11.9 PROFIBUS DP

11.9 PROFIBUS DP

11.9.1 Setting the parameters for the shut-down behavior

If D-Slaves respond to a shutdown in the PROFIBUS communication, e.g. NC reset during
operation, with fault conditions, you can assign parameters for a successive shutdown of the
PROFIBUS communication using the following machine data:
● MD11250 $MN_PROFIBUS_SHUTDOWN_TYPE (PROFIBUS shutdown handling)

Note
The following drives can be operated in mode 0 (immediate shutdown).
• SINAMICS S120
• SIMODRIVE 611U/UE, POSMO SI/CD/CA

11.9.2 Data descriptions (MD)

General machine data

11250 PROFIBUS_SHUTDOWN_TYPE
MD number PROFIBUS shutdown handling
Default setting: 0 Min. input limit: 0 Max. input limit: 2
Changes effective after RESET Protection level: 2/7 unit: -
Data type: UINT8 Valid as of software version: 2.2
Meaning: Shut-down modes of PROFIBUS DP communication:
0 = The PROFIBUS DP communication is shut down at the DP master end without any
warning.
1 = The PROFIBUS DP is moved to the CLEAR state for at least 20 cycles. The PROFIBUS
DP communication is finally shut down. If the PROFIBUS DP cannot be switched to the
CLEAR state, please proceed as described in 2.
The following is to be used with: SINUMERIK 840D with DP-Link module.
2 = Zero values 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
The PROFIBUS DP communication is finally shut down.
To be used with: SINUMERIK 840Di sl in conjunction with external drives.

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11.10 Initial settings

11.10 Initial settings

Concept
The status of an NC function, e.g. G codes, tool length offset, transformation, coupled motion,
etc., which is taken in a certain status of a channel is a default setting.
Channel states for which default settings can be parameterized are:
1. Power up (NC reset), reset (channel or mode group reset) and end of part program
and
2. Part program start
The default setting of an NC function is stored until it is explicitly changed by operation or
programming.

Parameterize initial settings

The relevant initial settings are parameterized via the following machine data:
● MD20110 $MC_RESET_MODE_MASK ("Definition of the control default settings in case
of reset")
● MD20112 $MC_START_MODE_MASK (Definition of the control default settings in case
of NC start)
● MD20150 $MC_GCODE_RESET_VALUES ("Delete position of the G codes")
● MD20152 $MC_GCODE_RESET_MODE ("G code default setting in case of reset")

Table 11-57 Default settings that can be parameterized through MD

Status can be parameterized via MD

Power up (POWER ON) MD20110 $MC_RESET_MODE_MASK
MD20150 $MC_GCODE_RESET_VALUES
RESET/part program end MD20110 $MC_RESET_MODE_MASK
MD20150 $MC_GCODE_RESET_VALUES
MD20152 $MC_GCODE_RESET_MODE
Part program start MD20112 $MC_START_MODE_MASK
MD20110 $MC_RESET_MODE_MASK
References:
/FB1/ Function Manual - Basic Functions; K2 Axes, Coordinate Systems, Frames, Workpiece
numbers IWS Chapter: "Workpiecerelated actual value system/reset response"

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11.11 NC/PLC Diagnosis

11.11 NC/PLC Diagnosis

11.11.1 Menu: Diagnostics

Operating path
The menu of the NC/PLC diagnostics is located in the following operating path:
● Operating area switchover > Diagnosis > NC/PLC Diagnosis > Diagnosis

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Group: NC
The following functions are grouped together in the NC group box:
● NC status
The current state of the NC is displayed via the output field:
– 0 not started
– 1 started
– 2 initializing data
– 3 initializing data

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11.11 NC/PLC Diagnosis

– 4 startup
– 5 waiting for PLC
– 6 running
– F NC error
● NC Reset
Via the "NC reset" button, an NC POWER ON reset is triggered.
On a NC POWER ON reset, all active machining operations are stopped. Drives that are
in motion are not decelerated on their acceleration ramp but at that their current limit.
After startup, the NC is in the reset state. Machine and user data are not changed.
● NC default data
Via the "NC Default Data" button, an NC POWER ON reset is triggered followed by NC
general reset. All active machining operations are stopped as described under "NC
Reset".
After startup, the NC is in the reset state. All machine and user data are deleted and
standard machine data are loaded.

NOTICE
After "NC Default Data" has been triggered, the NC must be commissioned again or a
series startup file read in (see Chapter "NC Default Data" (Page 541)).

● Acknowledge alarm 4065

The following alarm is acknowledged via the "Acknowledge alarm 4065" button and an
NC POWER ON reset is initiated:
– Alarm "4065 Battery-backed memory has been restored from back-up copy (possible
data loss!)".
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 NC POWER ON reset via "NC Default Data".
Then the NC must be commissioned again or a series startup file read in (see Chapter
"Application data backup/series startup" (Page 541)).

Group: PLC
The following functions are grouped together in the PLC group box:
● PLC RUN-P
With the "PLC RUN-P" button, the PLC is put in the "RUN-PROGRAMMING" state. In this
operating state, changes can be made to the PLC user program without activation of the
password.
● PLC RUN

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11.11 NC/PLC Diagnosis

With the "PLC RUN" button, the PLC is put in the "RUN" state. Only read accesses are
possible via a programming device (PG) in this mode. It is not possible to make changes
to the PLC user program until the password has been set.
● PLC STOP
With the "PLC STOP" button, the PLC is put in the STOP state. Processing of the PLC
user program has stopped and all outputs are set to substitute values.
● PLC Delete Program
The PLC is put in the STOP state with "PLC Delete Program" button and then PLC
general reset (default data) is performed. The following actions are performed by the PLC:
– The PLC disconnects all links.
– The user data are deleted (data and program blocks)
– The system data blocks (SDB) are deleted.
– Battery-backed data are copied back into the RAM area from the PLC after general
reset.
– The diagnostics buffer, the MPI parameters, the clock time, and the operating hours
counter are not reset.
● PLC default data
The PLC is put in the STOP state via the "PLC Default Data" button and then an
extended PLC general reset is performed. The actions stated above under Points 1 to 4
are executed and the parameters mentioned in Point 5 are additionally reset.
● Status displays
The status displays, which are made to look like LEDs, indicate the following:
– SF (System Fault)
Lights up in case of PLC system errors such as e.g. hardware, programming,
parameterizing, computing, time, battery, and communication errors.
– BATL (Battery Low)
Lights up if the 5 V supply voltage (buffer battery) falls below its permissible value.
– BATF (Battery Fault)
Lights up if the 5 V supply voltage (buffer battery) fails.
– FORCE
Lights up if the FORCE function is active.
The FORCE function sets user variables to permanent values that cannot be
overwritten by the user program. For detailed information on this, see the Online Help
of the SIMATIC Manager STEP 7.
– RUN: See the following table.
– STOP: See the following table.
– BUS 1
lights up in case of a bus/interface error on PROFIBUS (1) (interface X101)
– BUS 2
Lights up in case of a bus/interface error on MPI or PROFIBUS (2) (depends on
configuration of interface X102)

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11.11 NC/PLC Diagnosis

Table 11-58 PLC operating state display by means of RUN/STOP evaluation

RUN STOP PLC operating state

On off RUN: The PLC program is being processed.
off On STOP: The PLC program is not being processed.
STOP can be triggered by the PLC program, an
error, or an operator input.
Flashes at 0.5 Hz On HALT: The PLC user program has been halted
(triggered by a test function)
Flashes at 2 Hz On RESTART: A PLC start is executed (transition from
STOP to RUN). Transition to STOP takes place if the
run is cancelled.
off • On MEMORY RESET: A general reset is requested.
• 3 seconds
• On
off • On MEMORY RESET: A general reset is active
• flashes at 2 Hz for
minimum 3
seconds
• On

Group: NC latency time

The following information is grouped together in the NC latency group box:
● NC latency time
The basis of the SINUMERIK 840Di sl real-time property is activation of the NC system
software cyclically in defined time intervals.
Because the NC and Windows XP share the available PCU processor power, delays
(latencies) may occur when invoking the NC. If latencies are longer than 200 μs they are
considered to be violation of real-time with which the NC functionality is now longer
ensured.
On the NC latency display it is possible to observe the NC's latency behavior
continuously for a period of 50 seconds. This can be used, for example, ascertaining to
what extent the real-time response of the NC has been affected after replacing or
expanding hardware and/or software components.

Note
For detailed information about the real-time-based reactions of the SINUMERIK 840Di,
see Chapter "Real-time-based reactions" (Page 23).

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11.11 NC/PLC Diagnosis

11.11.2 Menu: settings

Operating path
The menu for the SINUMERIK 840Di sl-specific settings is located in the following operating
path:
● Operating area switchover > IBN > NC/PLC Diagnosis > Settings

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Figure 11-35 Menu: settings

Modifying data
When switching to the menu the data displayed become read-only. To change the data,
press the "Change" softkey first.

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11.11 NC/PLC Diagnosis

Group: settings
The following functions are grouped together via the "Settings" group box:
● Signal input for shutdown behavior: Signal source
This selection field is for configuring the digital input used for the shutdown signal of the
UPS:
– Disabled
No input signal is present.
– NC input 0...3
The shutdown signal of the UPS is connected to the configured digital input of the MCI
board extension module (Chapter "Interface description" (Page 60)).
● Signal input for shutdown behavior: Signal level
This selection field is for configuring the level of the shutdown signal of the UPS:
– Low active
Upon detection of the low level (0) at the configured input, first the SINUMERIK 840Di
sl NC / PLC and then Windows XP are closed.
– High active
Upon detection of the high level (1) at the configured input, first the SINUMERIK 840Di
sl NC / PLC and then Windows XP are closed.

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11.11 NC/PLC Diagnosis

Apply changes
To apply the changes you have made, press the "Accept" softkey. The message box that is
then displayed has to be acknowledged again with the "Accept" softkey.
The "Cancel" softkey rejects all changes and displays the original settings again.

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Figure 11-36 Applies settings.

NOTICE
We urgently recommend creating a series startup file before changing the data described
above. See Chapter "User data backup/Series Statup" (Page 541).

Manual
492 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Alarm and message texts 12
To enable easy adaptation of alarm and message texts to the specific requirements of an
automation system, the alarm and message texts are stored in freely accessible ASCII text
files.
The alarm and message texts contained in the text files are used commonly by all
SINUMERIK user interfaces:
● SinuCom NC
● 840Di startup
● HMI Advanced
By changing/modifying the texts or files or by creating new texts/files, a flexible adaptation to
the current requirements is possible.

Storing the text files

The files containing the alarm and message texts are stored on the hard disk in the directory
<Installationpfad>\dh\mb.dir\.

12.1 Configuration file MBDDE.INI

Structure of the file MBDDE.INI

The alarm and message texts that are to be used are set in the
<Installationspfad>\mmc2\mbdde.ini file. For this purpose, the appropriate paths to the
application-specific standard and user files must be stored in the [Textfiles] section of file
MBDDE.INI.
Excerpt of the "MBDDE.INI" file:
...
[Textfiles]
MMC= <Installationspfad>\dh\mb.dir\alm_
NCK= <Installationspfad>\dh\mb.dir\aln_
PLC= <Installationspfad>\dh\mb.dir\plc_
ZYK= <Installationspfad>\dh\mb.dir\alz_
CZYK= <Installationspfad>\dh\mb.dir\alc_
UserMMC=
UserNCK=

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 493
Alarm and message texts
12.2 Standard text files

UserPLC= <Installationspfad>\dh\mb.dir\myplc_
UserZyk=
UserCZyk=
...

12.2 Standard text files

Standard text files

The standard alarm and message texts in ASCII format are stored in the following files on
the hard disk:
● MMC: <Installationspfad>\dh\mb.dir\alm_XX.com
● NCK: <Installationspfad>\dh\mb.dir\aln_XX.com
● PLC: <Installationspfad>\dh\mb.dir\alp_XX.com
● ZYK: <Installationspfad>\dh\mb.dir\alz_XX.com
● CZYK: <Installationspfad>\dh\mb.dir\alc_XX.com
"XX" stands for the abbreviation of the appropriate language (see Table in Chapter "User
Text Data" (Page 494)).
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 urgently recommended to store user-specific
alarm and message texts in separate user text files.

12.3 User text files

User text files

You can replace the alarm and message texts stored in the standard text files by your own
user-specific text files or extend them.

Note
To edit the text files, any ASCII editor can be used.
When editing the text files with a different editor, make sure that they are then stored in
ASCII format.

The alarm and message texts from the user files replace the standard texts with the same
alarm and message numbers.
Texts for alarm or message numbers not contained in the standard texts are additionally
provided.

Manual
494 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Alarm and message texts
12.3 User text files

NOTICE
The maximum length of an alarm or message text displayed over two lines is 110
characters.

Storage path
The user-specific text files must be loaded in the Services operating area in the directory
<Installationspfad> \dh\mb.dir.

Language-specific nature of alarm 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 12-1 Language codes

Language Abbreviation
German gr
English uk
French fr
Italian it
Spanish sp

Announcement in the system

The user-specific text files that are now in the directory: <Installationspfad>\dh\mb.dir are
disclosed to the system via a corresponding entry in the MBDDE.INI file.

Note
To prevent a modified MBDDE.INI file from being overwritten when the software is updated,
it must be stored in the path designated for that purpose: USER Path
(<Installationspfad>\user\mbdde.ini).

Example
Example of adding an additional text file MYPLC_GR.COM:

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 495
Alarm and message texts
12.3 User text files

Note
If the text file MYPLC_GR.COM is created on an external PC and then read in through the
serial interface (e.g. with PCIN), the following lines must be contained at the beginning of the
file:
%_N_MYPLC_GR_COM
;$Path=/_N_MB_DIR

MYPLC_GR.COM: user-spec. File for internal German PLC alarm texts

%_N_MYPLC_GR_COM
;$Path=/_N_MB_DIR
700000 0 0 "DB2.DBX180.0 set"
700001 0 0 "Lubrication pressure missing"
....
MBDDE.INI:
[Textfiles]
UserPLC= <Installationspfad>\dh\mb.dir\myplc_

NOTICE
Any modifications to alarm texts come only into effect after the appropriate user interface
has been rebooted.
When creating text files, make sure that the date and time are correctly set on the PCU.
Otherwise, the user texts may not appear on screen.

Manual
496 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Alarm and message texts
12.4 Syntax for alarm text files

12.4 Syntax for alarm text files

Alarm numbers
The following alarm numbers are available for the cycle, compile cycle and PLC alarms:

Table 12-2 Alarm numbers for cycle, compile cycle and PLC alarms

Number range Description Effect Delete

60000-60999 Cycle alarms (Siemens) Display, interlocking NC start Reset
61000-61999 Display, NC start disable, Reset
motion standstill
62000-62999 Display Cancel
63000-64999 Reserved
65000-65999 Cycle alarms (user) Display, interlocking NC start Reset
66000-66999 Display, NC start disable, Reset
motion standstill
67000-67999 Display Cancel
68000-69000 Reserved
70000-79999 Compile cycle alarms
400000-499999 PLC alarms general
500000-599999 PLC alarms for channel
600000-699999 PLC alarms for axis and spindle
700000-799999 PLC alarms for users
800000-899999 PLC alarms for sequence
cascades/graphs

Format of the text file for cycle alarm texts

The structure of the text file for cycle and compile cycle alarms is as follows:

Table 12-3 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 English
References:
/FB/ Function Manual - Basic Functions; P3 Basic PLC Program, Chapter "Lists"

Alarm number
List of alarm numbers

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 497
Alarm and message texts
12.4 Syntax for alarm text files

Display
This number defines the alarm display type:
0: Display in alarm line
1: Display in a dialog box

Help ID
The default assignment "0" means: The help file supplied by Siemens provides a detailed
description of the alarm.
A value between 1 and 9 uses an assignment entry in the MBDDE.INI file to refer to a help
file created by the user. Refer also to Chapter "Setting Alarm Log Properties" (Page 500),
Context Help Section.

Text or alarm number

The associated text is given in inverted commas with the position parameters.
● Characters " and # must not be used in alarm texts.
The % character is reserved for displaying parameters.
● If an existing text is to be used, this can be done with a reference to the corresponding
alarm. 5-digit alarm number instead of "text".
● 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.
● Parameter "%1": Channel number
Parameter "%2": Block number

Format of text file for PLC alarm texts

The ASCII file for PLC alarm texts has the following structure:

Table 12-4 Structure of text file for PLC alarm texts

Alarm no. Display Help ID Text Text on MMC

510000 1 0 "Channel %K FDDIS all" Channel 1 FDDIS all
600124 1 0 "Feed disable axis %A" Feed disable axis 1
600224 1 0 600124 Feed disable axis 2
600324 1 0 600224 Feed disable axis 3
703210 1 1 "User Text" User Text
...
703211 1 1 " User text%A ..." User Text
Axis 1 ...
// Alarm text file for PLC alarm
References:
/FB/ Function Manual - Basic Functions; P3 Basic PLC Program

Manual
498 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Alarm and message texts
12.4 Syntax for alarm text files

Display
This number defines the alarm display type:
0: Display in alarm line
1: Display in a dialog box

Help ID
The default assignment "0" means:
The help file supplied by Siemens provides a detailed description of the alarm.
A value between 1 and 9 uses an assignment entry in the MBDDE.INI file to refer to a help
file created by the user. Refer also to Chapter "Setting Alarm Log Properties" (Page 500),
Section: HelpContext.

Text or alarm number

The associated text is given in inverted commas with the position parameters.
● Characters " and # must not be used in alarm texts.
The % character is reserved for displaying parameters.
● If an existing text is to be used, this can be done with a reference to the corresponding
alarm. 6-digit alarm number instead of "text".
● 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.
● Parameter "%K": Channel No. (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

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 499
Alarm and message texts
12.5 Setting the alarm log properties

12.5 Setting the alarm log properties

In addition to the current alarms, an alarm log showing the alarms occurred hitherto is
displayed on the user interface in the form of a list. The properties of the alarm list can be
changed in the MBDDE.INI file.

Table 12-5 Sections of the MBDDE.INI file

Section Description
Interrupts General information of the alarm list: For example, time/date format of
messages
TextFiles Path/file specification of alarm text files: For example UserPLC =
<Installationspfad>\dh\mb.dir\myplc_
HelpContext Name and path of help files: E.g., File0 = hlp\alarm_
DEFAULTPRIO Priority of various alarm types: e.g. POWERON = 100
PROTOCOL Properties of the log: E.g., File=.\proto.txt <Name and path of the log file>)
KEYS Information about keys that can trigger the alarms: E.g., Cancel = +F10
<Deletion of alarms with the key combination Shift+F10>
For further details of the file entries, refer to
References:
/BN/ User guide: OEM package for MMC

Section: [Alarms]
The settings in this section define the following alarm list properties:
● 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.
● MaxNo
Defines the maximum size of the alarm list.
● ORDER
Defines the sequence in which the alarms are sorted in the alarm list:
– In FIRST, the alarms with the latest dates are placed at the top of the list,
– In LAST, the new alarms appear at the end.

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

Manual
500 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Axis and Spindle Test Run 13
13.1 Requirements
Enabling signals must be set to allow an axis to be traversed directly from the control:
● Drive: Parameters and terminals
● NC: Interface signals

13.1.1 Drives: SINAMICS S120

Relevant parameters/terminals

Infeed
Parameter/Terminal Description
p0840 ON/OFF1
p0844 1. OFF2
p0845 2. OFF2
p0852 Enable operation
X21.3 (+24 V) and X21.4 (ground) EP terminals enable (pulse enable)
Drive
Parameter/Terminal Description
p0840 ON/OFF1
p0844 1. OFF2
p0845 2. OFF2
p0848 1. OFF3
p0849 2. OFF3
p0852 Enable operation
X21.3 (+24 V) and X21.4 (ground) EP terminals enable (pulse enable)
p0864 Infeed enable
p1140 Ramp-function generator enable
p1141 Ramp-function generator Start
p1142 Setpoint enable
References:
SINAMICS S120 Commissioning Manual
/GH2/ Equipment Manual for Booksize Power Units

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 501
Axis and Spindle Test Run
13.1 Requirements

13.1.2 Drives: SIMODRIVE

Relevant terminals
Applies to the following SIMODRIVE drives:
● SIMODRIVE 611 universal/universal E
● SIMODRIVE POSMO SI, CD/CA
The following terminals must be connected:

I/RF module
Terminal Description
63 Pulse enable
64 Drive enable
48 DC-link start
Drive Module
Terminal Description
663 Pulse enable
Signal TRUE: +24 V (e.g. from terminal 9)
References:
/FBU/ Function Manual SIMODRIVE 611 universal
/POS3/ User Manual - SIMODRIVE SI/CD/CA

13.1.3 NC/PLC interface signals

Relevant NC/PLC interface signals

The following NC/PLC interface signals must be set:

DB number Byte.Bit Value Description

31, ... 0 <> 0% Feedrate/spindle override
31, ... 1.3 FALSE Axis/spindle disable
31, ... 1.4 FALSE Follow-up mode
31, ... 1.5 TRUE Position measuring system 1 1)
31, ... 1.6 TRUE Position measuring system 2 1)
31, ... 1.7 TRUE Override active
31, ... 2.1 TRUE Controller enable
31, ... 2.2 FALSE Distance-to-go/Spindle reset
31, ... 4.3 FALSE Feed stop/spindle stop
31, ... 4.4 FALSE Traversing-key lock
31, ... 4.6 3) Traversing key -
31, ... 4.7 3) Traversing key +

Manual
502 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Axis and Spindle Test Run
13.1 Requirements

DB number Byte.Bit Value Description

31, ... 5.0 - 5.5 3) JOG/INC
31, ... 12.0 2) Hardware limit switch PLUS
31, ... 12.1 2) Hardware limit switch MINUS
31, ... 20.1 FALSE Rampfunction generator rapid stop
31, ... 21.7 TRUE Pulse enable
1) Alternative
2) Checking the function of the hardware limit switch and the relevant interface signals
3) Function dependent
References:
/FB1/ Function Manual - Basic Functions; A2 Various Interface Signals and Functions

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 503
Axis and Spindle Test Run
13.2 Axis dry run

13.2 Axis dry run

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Manual
504 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Axis and Spindle Test Run
13.3 Spindle dry run

13.3 Spindle dry run

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 505
Axis and Spindle Test Run
13.3 Spindle dry run

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Manual
506 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Drive Optimization with HMI Advanced 14
14.1 Overview
HMI Advanced offers comprehensive functions for analyzing controller action of drives
connected to a SINUMERIK 840Di sl:
● Frequency response measurements for current, speed and position control loop
● Automatic controller setting
● Funktionsgenerator
● Circularity test
● Servo trace

Measuring functions
The measuring functions make it possible to assess the automatic controller action of the
respective control loop (frequency response) by the integrated FFT analysis (Fast Fourier
Transformation) without external measuring equipment.
The measurement results are represented graphically as a Bode diagram. HMI Advanced file
functions can be used to archive the diagrams for documentation purposes and to simplify
remote diagnostics.

Circularity test
The circularity test serves to analyze the contour accuracy on the quadrant transitions of
circular contours achieved by means of friction compensation (conventional or neural
quadrant error compensation).
References:
/FB/ Function Manual - Extended Functions, K3 Compensation, Chapter "Circularity test"

Servo trace
Servo trace provides a graphically assisted analysis of the time response of position
controller and drive data.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 507
Drive Optimization with HMI Advanced
14.2 Measuring functions

14.2 Measuring functions

Explanation
A range of measuring functions allows the time and/or frequency response of drives and
closed-loop controls to be displayed in graphic form on the screen. For this purpose, test
signals with an adjustable interval are connected to the drives.

Measurement/signal parameters
The test setpoints are adapted to the application in question by means of measurement or
signal parameters, the units of which are determined by the relevant measuring function or
operating mode. The measurement or signal parameter units are subject to the following
conditions:

Table 14-1 Quantity and units for measurement or signal parameters

Size Unit
Velocity Metric system:
Specification in mm/min or rev/min for translatory or rotary movements
Inch system:
Specification in inch/min or rev/min for translatory or rotary movements
Distance Metric system:
Specification in mm or degrees for translatory or rotary movements
Inch system:
Specification in inch or degrees for translatory or rotary movements
Time Specified in ms
Frequency Specified in Hz

Note
The default setting for all parameters is 0.

Preconditions for starting measuring functions

To ensure that no erroneous traversing movements due to part programs can be carried out,
the measuring functions have to be started in the 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 movements, 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.

Manual
508 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.2 Measuring functions

Starting measuring functions

Measuring functions initiating a traversing movement are only selected using the specific
softkey. The actual start of the measuring function and thus of the traversing movement is
always carried out with NC START on the machine control panel.
If the main screen of the measuring function is quitted without the traversing motion being
initiated, the selection of the traversing function is canceled.
Once the traversing function has been started, the main screen can be exited without any
affect on the traversing movement.

Note
JOG mode must be selected when measuring functions are started.

Further safety notices

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.

Canceling measuring functions

The following events will cancel active measuring functions:
● Hardware limit switch reached
● Traversing range limits exceeded
● Emergency stop
● Reset (mode group, channel)
● NC STOP
● No controller enabling command
● Canceling drive enable
● Canceling traversing enable
● Selection of parking (in position-controlled operation).
● Feed override = 0%
● Spindle override = 50%
● Change in operating mode (JOG) or operating mode JOG not selected
● Actuation of traversing keys
● Actuation of handwheel
● Alarms leading to axis shutdown

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 509
Drive Optimization with HMI Advanced
14.3 Special functions

14.3 Special functions

Interface signals: Drive test, traversing request, traversing enable

In conjunction with the measuring functions, another 2 axis-specific interface signals are
provided:
● DB31-DBx, DBX61.0 "Drive test traversing request"
● DB31-DBx, DBX1.0 "Drive test, traversing enable"
In the PLC user program, therefore, an additional axis-specific traversing enable command
may be given in conjunction with measuring functions.

Activating
The interface signals are activated from the main menu of the appropriate measuring
function in the group "Drive test traversing enable", see following screen.

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Choose the type of traversing enable function from the selection list either by using the
toggle key or by double-clicking the selection with the right-hand mouse button:
● without PLC
Traversing of the axis to be measured is enabled depending on the interface signals
typical for JOG mode (controller enable, pulse enable, etc.).
● with PLC

Manual
510 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.3 Special functions

Traversing of the axis to be measured is enabled in addition to the interface signals

typical for JOG mode depending on the interface signal: "Drive test traversing enable".

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Traversing range monitoring

The measuring functions have their own traversing range monitoring. With this monitoring
function the traverse range of an axis can be limited or monitored without having to reference
this axis.
The basis is the absolute axis position displayed in the "Status" group at the time of
measurement.

Activating
The traversing range monitoring is activated from the main menu of the appropriate
measuring function in the group "Traversing range". Refer to figure in Section "Special
Functions".
Choose the traversing range monitoring from the selection list "Monitoring" via the Toggle
key or by clicking with the right-hand mouse button on the required monitoring type:
● Inactive
The axis is traversed without monitoring the traversing range.
● Active
The axis is traversed with monitoring of the traversing range, depending on the traversing
range limits set:
● High limit
● Lower limit

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 511
Drive Optimization with HMI Advanced
14.4 Frequency response measurements

14.4 Frequency response measurements

You can measure both digital and analog drives. However, the bandwidth available for
measuring is limited by the position controller or PROFIBUS cycles.

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Figure 14-2 Example: Measurement results, speed control loop, reference frequency response

Note
Additional information on the measurement functions or how to optimize the torque/current
and speed control loop can be found in:
• SINAMICS S120
Online Help for Commissioning Tool: STARTER > Content > Diagnosis Functions
• SIMODRIVE 611 universal
Online Help for SimoCom U Commissioning Tool > Index:
– Measuring function
– Optimization of speed control loop

Manual
512 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.4 Frequency response measurements

14.4.1 Measurement of current control loop

Functionality
The current control loop only needs to be measured for diagnostic purposes if there is a fault
or if no standard data was used for the motor/power module combination, and which resulted
in unsatisfactory speed controller frequency responses.

CAUTION
The user must take special safety measures when measuring the current control loop (e.g.
secure drive clamping) for hanging axes without external counterweight.

Operating path
Operating path for measuring the current control loop: Operating area switchover >
Commissioning > Optimization/Test > Current control loop

Measuring functions
The following measuring functions are available for measuring the current control loop:

Measuring type Measured variable

Reference frequency response Torque-generating actual current value/torque-
(downstream of the current setpoint filter) generating current setpoint
Setpoint step change (downstream of the Measured variable 1: Torque-generating current setpoint
current setpoint filter) Measured variable 2: Torque-generating actual current
value

Measurement
The measurement sequence is divided into the following steps:
1. Setting the traverse range monitoring and the enable logic
2. Selecting the measurement type
3. Setting the parameters, softkey "Measuring parameters"
4. Displaying the measurement results, softkey "Display"

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 513
Drive Optimization with HMI Advanced
14.4 Frequency response measurements

Measuring parameters
● Amplitude
Magnitude of the test signal amplitude. Given in percent of the peak torque. Values from
1% to 5% are suitable.
● Bandwidth
The frequency range analyzed with the measurement. The larger this value, the finer the
frequency resolution and the longer the measurement time. The maximum value is
specified by the position controller cycle (Tposition controller): Bandwidthmax [Hz] = 1 / (2 *
Tposition controller [sec])
Example:
Position controller cycle: 2 ms
Bandwidthmax = 1 / (2 * 2*10-3) = 250 Hz
● Averaging
The accuracy of the measurement and measurement duration increase 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 approx. 10 ms is recommended. A settling time
which is too low will result in frequency response and phase diagrams distortions.

14.4.2 Speed control loop measurement

Functionality
The response characteristics for the motor measuring system are analyzed when measuring
the speed control loop. Various measurement parameter lists are available depending on the
basic measurement setting which has been selected.

Operating path
Operating path for measuring the speed control loop: Operating area switchover >
Commissioning > Optimization/Test > Speed control loop

Manual
514 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.4 Frequency response measurements

Measuring functions
The following measurement functions are available for measuring the speed control loop:

Measuring type Measured variable

Reference frequency response Actual speed value motor encoder/speed setpoint after
(downstream of the speed setpoint filter) filter
Reference frequency response (upstream Actual speed value motor encoder/speed setpoint after
of the speed setpoint filter) filter
Setpoint step change (downstream of the Measured variable 1:
speed setpoint filter) • Speed setpoint downstream of the filter
• Actual torque value
Measured variable 2: Actual speed value motor encoder
Interference frequency response (fault Actual speed value motor encoder / torque setpoint fct.
downstream of the current setpoint filter) generator
Disturbance variable step change (fault Measured variable 1:
downstream of the current setpoint filter) • Torque setpoint fct. generator
• Actual torque value
Measured variable 2: Actual speed value motor encoder
Speed-controlled system (excitation Actual speed value motor encoder/actual torque value
downstream of the current setpoint filter)
Frequency response of the mechanical Actual speed value measuring system 1/actual speed
parts 1) value measuring system 2
1) The machine axis in question must have both a direct and an indirect measuring system to
determine the frequency response of the mechanical parts.

Measurement
The measurement sequence is divided into the following steps:
1. Setting the traverse range monitoring and the enable logic
2. Selecting the measuring type and measured variable
3. Setting the parameters, softkey "Measuring parameters"
4. Displaying the measurement results, softkey "Display"
The reference frequency response measurement determines the transmission ratio of the
speed controller.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 515
Drive Optimization with HMI Advanced
14.4 Frequency response measurements

Measurement: Reference and interference frequency response

The response range should be as wide as possible and without resonance. It may be
necessary to use bandstop or low-pass filters. Pay special attention to resonances within the
speed controller limit frequency range (stability limit approx. 200-500 Hz).
Alternatively, the interference frequency response can be recorded in order to assess how
well the control suppresses interference.
Measuring parameters
● 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.
● 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 measurement time. The
maximum value is specified by the position controller cycle (Tposition controller): Bandwidthmax
[Hz] = 1 / (2 * Tposition controller [sec])
Example:
Position controller cycle: 2 ms
Bandwidthmax = 1 / (2 * 2*10-3) = 250 Hz
● Averaging
The accuracy of the measurement and measurement duration increase 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 recommended. Do not set
too low a value for the settling times or the frequency response and phase diagrams will
be distorted.
● Offset
The measurement requires a slight speed offset of a few motor revolutions per minute.
The offset must be set to a higher value than the amplitude.
– The offset is run up via an acceleration ramp.
– The acceleration value is defined for one
Axis: MD 32300 $MA_MAX_AX_ACCEL
spindle: MD 35200 $MA_GEAR_STEP_SPEEDCTRL_ACCEL
MD 35210 $MA_GEAR_STEP_POSCTRL_ACCEL
– The following applies: Acceleration value = 0, no ramp
Acceleration value > 0, ramp is active
– The actual measuring function becomes active only when the offset value is reached.

Manual
516 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.4 Frequency response measurements

Measurement: Setpoint/disturbance step changes

The transient response (response to setpoint changes or disturbances) of the speed control
in the time range can be assessed with the step stimulation function. The test signal is
connected to the speed controller output for recording of the response to disturbances.
Measuring parameters
● Amplitude
Magnitude of the setpoint or disturbance step change.
● Measurement time
The period of time recorded (maximum: 2048 speed controller cycles).
● Offset
To exclude the influence of static friction, an offset of a few motor revolutions per minute
is sufficient.
– The offset is run up via an acceleration ramp.
– The acceleration value is defined for one
Axis: MD32300 $MA_MAX_AX_ACCEL
spindle: MD35200 $MA_GEAR_STEP_SPEEDCTRL_ACCEL
MD35210 $MA_GEAR_STEP_POSCTRL_ACCEL
– The following applies: Acceleration value = 0, no ramp
Acceleration value > 0, ramp is active
– The actual measuring function becomes active only when the offset value is reached.
● Settling time
This value represents the delay between measured data recording / setpoint output and
the injection of the offset.

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Figure 14-3 Setpoint course for speed control loop/step response measuring function

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 517
Drive Optimization with HMI Advanced
14.4 Frequency response measurements

14.4.3 Position control measurement

Functionality
This measuring function basically analyzes the response to the active position measuring
system. If the function is activated for a spindle without a position measuring system, an
alarm is displayed. Depending on the measured variable selected, various measurement
parameter lists are displayed.

Operating path
Operating path for measuring the speed control loop: Operating area switchover >
Commissioning > Optimization/Test > Speed control loop

Measuring functions
The following measuring functions are available for measuring the position control loop:

Measuring type Measured variable

Reference frequency response Actual position/position setpoint
Setpoint step change Measured variable 1: Position setpoint
Measured variable 2:
• Actual position value
• System deviation
• Following error
• Speed actual value
Setpoint ramp Measured variable 1: Position setpoint
Measured variable 2:
• Actual position value
• System deviation
• Following error
• Speed actual value

Measurement
The measurement sequence is divided into the following steps:
1. Setting the traverse range monitoring and the enable logic
2. Selecting the measuring type and measured variable
3. Setting the parameters, softkey "Measuring parameters"
4. Displaying the measurement results, softkey "Display"

Manual
518 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.4 Frequency response measurements

Measurement: Reference frequency response

The reference frequency response measurement determines the transmission ratio of the
position controller in the frequency range (active position measuring system).
The setpoint filters, control loop gain (Kv factor) and feedforward control must be
parameterized such that resonance is avoided wherever possible over the entire frequency
range. In the case of dips in the frequency response, the setting of the feedforward control
balancing filters should be checked.
Measuring parameters
● Amplitude
This parameter determines the magnitude of the test signal amplitude. It should be set to
the smallest possible value (e.g. 0.01 mm).
● 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 measurement time. The
maximum value is specified by the position controller cycle (Tposition controller): Bandwidthmax
[Hz] = 1 / (2 * Tposition controller [sec])
Example:
Position controller cycle: 2 ms
Bandwidthmax = 1 / (2 * 2*10-3) = 250 Hz
● Averaging
The accuracy of the measurement and measurement duration increase 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 recommended. Do not set
too low a value for the settling times or the frequency response and phase diagrams will
be distorted.
● Offset
The measurement requires a slight speed offset of a few motor revolutions per minute.
The offset must be set such that no speed zero crossings occur at the set amplitude.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 519
Drive Optimization with HMI Advanced
14.4 Frequency response measurements

Measurement: Setpoint step change and setpoint ramp

The transient or positioning response of the position control in the time range, and in
particular the effect of setpoint filters, can be assessed with the step and ramp stimulation
functions.
Possible measured variables:
● Actual position value (active position measuring system)
● Control deviation (following error)
Measuring parameters
● Amplitude
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 time
With default setting: The position reference value is specified with the "Setpoint ramp"
according to the set ramp time. In this case, the acceleration limits which currently apply
to the axis or spindle are effective.
A jerk-controlled motion can be set for a specific axis with:
● MD32400 $MA_AX_JERK_ENABLE (axial jerk limitation) = 1
● MD32410 $MA_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.
● Offset
The step is stimulated from standstill or starting from the constant traverse speed set in
this parameter.
If an offset value other than zero is input, the step change is stimulated during traversal.
For the sake of clarity, the displayed actual position value does not include this constant
component.

Manual
520 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.4 Frequency response measurements

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At maximum axis velocity, there is a (virtual) step change in the velocity (continuous line).
The curves represented by the dashed line correspond to a realistic, finite value. The offset
component is excluded from the display graphic in order to emphasize the transient
processes.

Measurement: Setpoint step change

To avoid overloading the mechanical system of the machine, the step height is limited to the
value specified in the machine data during the "Setpoint step change" measurement:
● MD32000 $MA_MAX_AX_VELO (maximum axis velocity).
This may result in failure to achieve the desired step height.

Measurement: Setpoint ramp

With measurement "Setpoint ramp", the following machine data influence the measurement
result:
● MD32000 4MA_AX_AX_VELO (max. axis velocity)
The maximum axis velocity limits the ramp gradient (velocity limitation). The drive does
not reach the programmed end position (amplitude).
● MD32300 $MA_MAX_AX_ACCEL (maximum axis acceleration)
The maximum axis acceleration limits the velocity change (acceleration limitation). This
leads to "rounding" on the transitions at the beginning and end of the ramp.

CAUTION
In normal cases the machine data corresponds exactly with the load capacity of the
machine kinematics and should not be changed (increased) as part of the
measurements:
• MD32000 $MA_MAX_AX_VELO (maximum axis velocity).
• MD32300 $MA_MAX_AX_ACCEL (maximum axis acceleration)

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 521
Drive Optimization with HMI Advanced
14.5 Graphic display

14.5 Graphic display

Displaying the measurement results

You can have the measurement displayed after the completion of the measurement via the
Display softkey in the relevant Main Screen of the measuring function.

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Figure 14-5 Menu: Display of measurement with marker X = ON

Manual
522 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.5 Graphic display

Softkeys: X-marker on, Y marker on

The X-Marker on and Y-Marker on sofkeys are used to display a vertical or horizontal red
line with a red circle on the measuring curve in the diagrams.
The corresponding values, e.g. for damping, frequency, phase displacement, etc. are
displayed in red in the appropriate diagram.
Use the cursor keys to move the markers:

● Slow: Cursor key

● Fast: Shift key + cursor key

Softkeys: 2. Marker, Zoom, Preview

If a marker is active, a 2nd line is shown in the diagram via the 2nd marker with the softkey
These two lines define the range that you can then have displayed over the entire display
range by pressing softkey Zoom.
The process of zooming a range (marker ON, 2nd marker, zoom) can be repeated as often
as desired until the maximum size of representation is reached.
Use the softkey Fullscreen to switch the display of the diagrams back to their original size.

Note
X and Y markers can be active at a time.

Softkey: Scale
Use the Scale softkey to change the scaling of the traces and of the marker 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.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 523
Drive Optimization with HMI Advanced
14.5 Graphic display

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Softkeys: Graphics ...

Use the Graphics... softkey in the penultimate screen to call the following functions:
● Switching over the display from double to single graphics and vice versa (this function
also exists in the scaling menu in the first figure of this chapter)
● Print graphic
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.

Manual
524 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.6 Trace function

14.6 Trace function

14.6.1 Trace function properties

The trace function with a graphical user interface serves to record the time change of data
(values, signals, states, etc.) in the servo range and partially in the range of the drives, too.
You can select measuring signals and set the measuring parameters with softkeys and drop-
down lists.
The function is operated using the mouse or keyboard.

Overview of functions
The trace function offers the following features
● Four trace buffers with up to 2,048 values each
● Selection of SERVO and drive signals (in position control cycle)
● Trace/trigger signals can be set using absolute address and value masking
● Different trigger conditions for the recording start
(Triggering always on Trace 1)
● Both pre- and post-triggering.
● Measuring signal display.
● Selection of fixed Y scaling for each trace.
● Marker function selectable for each trace
● Expand function in the time axis
● Selective loading and saving of the measurement parameters and traces

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 525
Drive Optimization with HMI Advanced
14.6 Trace function

14.6.2 Main screen and operation

Basic display of servo trace

You can access the main screen of this trace function using the softkeys Area Switchover >
Commissioning > Drive/Servo > Servo Trace.

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Manual
526 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.6 Trace function

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14.6.3 Parameter assignment

Parameterization in the basic display

The following settings have to be made in the basic screen
● The axis/spindle to be measured
● The signal to be measured
● Measurement time
● Trigger time
● Trigger type
● Trigger threshold

Input field: Axis/spindle name

The cursor must be positioned on the Axis/Spindle name of the relevant trace. You can
select it with the softkeys Axis+ and Axis- or by accepting a value from the dropdown list.

Input field: Signal selection

The cursor must be positioned on the Signal selection list field of the relevant trace. Then
activate the desired items by selecting them from the list box.
Measuring parameters

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 527
Drive Optimization with HMI Advanced
14.6 Trace function

Input field: Measurement time

The measuring time is written directly into the Measuring duration input field.

Input field: Trigger time

Direct entry of pre-triggering or post-triggering.
With negative input values (leading sign minus -) recording begins at the set time before the
trigger event.
With positive input values (without sign) recording starts the time set after the triggering
event.
Condition: Trigger time + measuring period y 0.

Input field: Trigger

The trigger type is selected in the Trigger drop-down list.
The trigger always refers to Trace 1. When the trigger condition is satisfied, Traces 2 to 4 are
started simultaneously.
Settable trigger conditions:
● No trigger, i.e. measurement starts when you operate the Start softkey (all traces are
started in synchronism).
● Positive edge
● Negative edge

Input field: Threshold

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.

Softkey: Axis +/Axis -

Selection of the axis/spindle when the cursor is positioned on the appropriate "Axis/spindle
name" list field.
You can also select the axis/spindle directly in the list box from the dropdown list using the
cursor.

Softkey: Start/Stop
Recording of the trace function is started with the Start softkey.
With the Stop or RESET softkey, you can cancel a running measurement.

Manual
528 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.6 Trace function

Softkey: Physical address

Within the framework of the trace function, it is also possible to select data using its physical
address.

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To do so, proceed as follows:

● Choose the signal type Physical address from the desired trace.
● Press the softkey Physical address.
● Enter the desired values in the input screen form.
● Press the softkeys 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: Screen form

This screen form is used to select the data format to be evaluated when recording.
● Byte: 0000 00FF
● Word: 0000 FFFF
● Double word: FFFF FFFF
● Individual bits: xxxx xxxx
● 1: selected
● 0: not selected.
By default, all bits are selected.

Input field: Threshold

The Threshold input field 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 softkey, this hex value is
then entered in the field Threshold of the main screen of the trace function.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 529
Drive Optimization with HMI Advanced
14.6 Trace function

14.6.4 Performing the measurement

Softkey: Start
After parameterization has been completed, you enable measurement by pressing the Start
softkey.
The measurement is carried out once the set trigger condition of trace 1 is fulfilled.

Terminating the measurement

The measurement is completed after the set measurement duration is expired.
The graphics are generated automatically when the measurements are finished. Use the
Display softkey to call the display functions of the graphics (see next Section).

Softkey: Stop
You can cancel a running measurement at any time with the Stop softkey. A canceled
measurement cannot be displayed.

Manual
530 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.6 Trace function

14.6.5 Display function

If you press the Display softkey after the set measurement time has expired and the
measurement results have been prepared automatically, you can call the graphical display
function of the measurement results.

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Softkeys: X-marker on, Y marker on

The X marker on and Y marker on sofkeys are used to display a vertical or horizontal red line
with a red circle on the measuring curve in the diagrams.
The associated values, e.g. for damping, frequency, degrees, etc. are displayed in the
appropriate diagram.
Use the cursor keys to move the markers:

● Slow: Cursor key

● Fast: Shift key + cursor key

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 531
Drive Optimization with HMI Advanced
14.6 Trace function

Softkeys: 2. Marker, Zoom, Preview

If a marker is active, a 2nd line is shown in the diagram via the 2nd marker with the softkey
These two lines define the range that you can then have displayed over the entire display
range by pressing softkey Zoom.
The process of zooming a range (marker ON, 2nd marker, zoom) can be repeated as often
as desired until the maximum size of representation is reached.
Use the softkey Fullscreen to switch the display of the diagrams back to their original size.

Note
X and Y markers can be active at a time.

Softkey: Scale
Use the Scale softkey to change the scaling of the traces and of the marker 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.

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532 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Drive Optimization with HMI Advanced
14.7 File Function

Softkeys: Graphics ...

Use the Graphics... softkey in the first screen of this chapter to call the following functions:
● Switching over the display from double to single graphics and vice versa (this function
also exists in the scaling menu in the previous screen)
● Print graphic
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.

14.7 File Function

Description
Use the File Functions softkey to call the appropriate menu.
You can store, load and delete the parameters, axis-specific machine data and
measurement results here.
The file functions are not intended as a replacement for a complete copy of the system and
user data, e.g. for archiving or standard commissioning, but only for the simplified and
flexible management of the specific measurement data.

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Drive Optimization with HMI Advanced
14.7 File Function

Naming files
You can select an existing file from the drop-down list or enter one in the text field
underneath in the File group.

Installation Directory
You can select the directory where you want to save the file in the Directory group. This can
also be a directory in the Services operating area you have created by yourself or the basic
directory of the data management (list entry: Standard directory).

Selecting data type

You can select the data you want to save in the Data group.
Only one data type can be selected at once. Use either the mouse button or the cursor or
toggle key for selection.

Creating subdirectories
If you do not wish the data of the trace function to be stored in the "default directory", you
can create user-specific directories.
New directories are created in the operating area Operating area switchover > Services >
Manage data. New subdirectories can be created below the Diagnosis directory.
For the description of the operating area Services, please refer to:
References:
/BAD/ Operating Manual HMI Advanced

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 Drive Optimization with HMI Advanced
14.8 Print graphic

14.8 Print graphic

Printer selection
The Graphics softkey in the main screens of the measuring functions opens the menu to
select the printer and to print the graphics.

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Softkey: Printer selection

Use the Printer selection softkey to go to the corresponding menu, refer to the following
screen.
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

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Drive Optimization with HMI Advanced
14.8 Print graphic

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Output to printer
Choose the printer to which you wish the file to be output from the list field using either the
Toggle key or by double-clicking with the right mouse button on the desired printer.

Output as bitmap file

The graphics is to be saved in a bitmap file (*.bmp):
● In the selection field for printer setting, set Output as bitmap file
● Press the softkey Print graphics
● Enter the desired filename.
You can input a new filename or select an existing one from the drop-down list.

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 Drive Optimization with HMI Advanced
14.8 Print graphic

Softkey: Print graphic

Use the Print graphics softkey, refer to penultimate screen, to output the graphics on the set
medium:
● Printer
● Bitmap file

Printer
The graphics is output directly to the selected printer.

Bitmap file
If you wish to output the graphics to a bitmap file, the following specifications are still
required in the submenu "File name for bitmap printout":
● File names
● Directory

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Naming files
You can select an existing file from the drop-down list or enter one in the text field
underneath in the Filename group.

Installation Directory
You can select the directory where you want to save the file in the Directory group.
This can also be a directory in the operating area Services > Manage 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:
/BAD/ Operating Manual HMI Advanced
● The file is saved using the softkey OK.
● With the softkey Cancel you can return to the current graphic display.

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Drive Optimization with HMI Advanced
14.9 Automatic controller setting

14.9 Automatic controller setting

14.9.1 Drives: SINAMICS S120

Functionality
The automatic controller setting of the speed control loop offers the following functionality:
● Determining the gain and reset time in these cases:
– Standard setting
– Critical damping
– Good damping
● Determining current setpoint filters which may be required
● Display of the measured or calculated frequency responses

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Operating path
Operating path of the automatic controller setting: Operating area switchover >
Commissioning > Optimization/Test > ">" > Automatic Controller Setting

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 Drive Optimization with HMI Advanced
14.9 Automatic controller setting

Measurement
The sequence of the automatic controller setting is divided into the following steps:
1. Starting the automatic controller setting.
2. Measurement of the mechanical part 1.
For the measurement, you can either retain the default parameters specified by the
control or define your own defaults. Start the measurement with the "OK" softkey. Enable
the traversing movement via NC START.
3. Measurement of the mechanical part 2.
Set the measuring parameters, start the measurement and enable the traversing
movement as for Point 2.
4. Measurement of current control loop.
Set the measuring parameters, start the measurement and enable the traversing
movement as for Point 2.
5. Calculation of controller data.
Setting the measuring parameters for reinforcing and readjusting time. Start the
calculation with the "OK" softkey.
6. Optional: Retentive storage of the newly calculated drive parameters in the drive
7. Measurement of the speed control loop
Set the measuring parameters, start the measurement and enable the traversing
movement as for Point 2.
8. Check the controller setting based on the displayed measurement results.

14.9.2 Drives: SIMODRIVE 611 universal

An automatic controller setting of SIMODRIVE 611 universal drives is only currently possible
with the SimoCom U drive commissioning tool.
References:
/FBU/ SIMODRIVE 611 universal Function Manual, Section "Description of Functions",
Optimization of Current and Speed Controller, SimoCom U, Online Help

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Drive Optimization with HMI Advanced
14.9 Automatic controller setting

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User data backup/Series commissioning 15
15.1 Explanations on data backup

User data
User data refers to all data or data areas that can be entered by the user to achieve the
specific functionality of the SINUMERIK 840Di and the connected drives.
In the case of a data backup, e.g. after commissioning of the control system, the user data
selected through the user interface are written to a so-called series startup file.
After a series startup file has been read in, the control system is in its original status again as
it was at the time of data backup.

Time of data backup

Experience has shown that the following times can be recommended for carrying out data
backups:
● After commissioning
● After changing machine-specific settings
● After service, e.g. after replacement of a hardware component, software upgrade, etc.
● Before activation of memory-configuring machine data. A warning prompting you to back
up is displayed automatically.

Data backup of various components

You can save user data using one of the following applications:
● SINUMERIK user interfaces: HMI Advanced (option).
● Commissioning tool: SinuCom NC
You can save user data for the following components either individually or together.
● NCK
● PLC
● HMI
● SIMODRIVE PROFIBUS drives

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User data backup/Series commissioning
15.1 Explanations on data backup

SINAMICS S120
Currently, the user data (projects) for SINAMICS S120 drive units must be saved separately
with the STARTER commissioning tool.
For detailed information on data backup, please refer to:
References:
SinuCom NC: Online Help
HMI Advanced: /BAD/ Operating Manual HMI Advanced

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 User data backup/Series commissioning
15.2 Creating a series commissioning file

15.2 Creating a series commissioning file

15.2.1 General information

Note
Because of its file extension ".arc", the series startup file is also called archive.

Archive content
The following components can be selected as the content of a series commissioning file:
● NCK with/without compensation data (see below: Note)
● PLC
● HMI
● SIMODRIVE PROFIBUS drives
When selecting, any combinations are possible. However, it is recommended to save the
individual components separately in separate series startup 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 startup file is to
be reloaded into the same control system (Backup).

NCK
The contents of a series startup file created for the NCK comprises mainly the following data:
● Machine data
● Setting data
● Option data
● Global (GUD) and local (LUD) user data
● Tool and magazine data
● Protection zone data
● R parameters
● Work offsets
● Compensation data
● Display machine data
● Workpieces, global part programs and subroutines
● Standard and user cycles
● Definitions and macros

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User data backup/Series commissioning
15.2 Creating a series commissioning file

PLC
The contents of a series startup file created for the PLC comprise all blocks loaded at the
time when the data backup was made:
● OB (organization blocks)
● FB (function blocks)
● SFB (system function blocks)
● FC (functions)
● SFC (system functions)
● DB (data blocks)
● SDB (system data blocks).

HMI
The contents of a series startup file created for the HMI Advanced comprise all data stored in
the HMI database in the dh directory at the moment when the data backup was made.

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 User data backup/Series commissioning
15.2 Creating a series commissioning file

15.2.2 HMI Advanced (option).

The creation of a series startup file with HMI Advanced is divided into the following steps:
1. Open the menu to create a series-commissioning file:
Operating range switchover > Services > ETC key ">" > Series startup > Startup archive
2. Selection of components to be backed up (see screen: Archive content)
3. Assignment of a filename (see screen: Archive name)
4. Setting of the series startup file via the vertical "Archive" softkey. The series startup file is
stored in the archive directory on the hard disk of the PCU.

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User data backup/Series commissioning
15.2 Creating a series commissioning file

15.2.3 SinuCom NC

Starting
SinuCom NC can be started as follows to create a series startup file:
● SINUMERIK Desktop (see Chapter "Service Desktop" (Page 135))
Windows taskbar: Start > Programs > SinuCom NC > SinuCom NC
● HMI Advanced
Operating area switchover > ETC key ">" SinuCom NC

Creating a new file

Creating a series startup file with SinuCom NC is subdivided into the following steps (see the
following screen):
1. Starting SinuCom NC
2. Selecting the storage location
3. Selecting the components to back up (archive content)
4. Continuing ("Next >")

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5. The following data can be selected in the following menus, depending on the selected
components:
– NCK: Part programs
– MMC: MMC archive
6. Creating the series startup file ("Finish")

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 User data backup/Series commissioning
15.3 Considerations when backing up PLC data

15.3 Considerations when backing up PLC data

When creating a series startup file that contains PLC data, the PLC image that is saved
during this process is dependent on the status of the PLC at the time of creation.
Depending on the status of the PLC, the following PLC images result:
● Original image
● Instantaneous image
● Inconsistent image

Original image
The original image of the PLC is represented by the PLC-data state 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 startup file with PLC data
4. Set the PLC to the operating status RUN

Instantaneous image
If you cannot create an original image, you can save an instantaneous image as an
alternative.
Operating sequence:
1. Set the PLC to the operating status STOP
2. Archive PLC data
3. Set the PLC to the operating status RUN

Inconsistent image
An inconsistent image results if a series-commissioning file with PLC data is created and the
PLC is in the RUN state (cyclic operation).
The data blocks of the PLC are saved at different times with contents that under certain
circumstances may meanwhile have changed. This may result in a data inconsistency that
after copying the data backup back into the PLC may under certain circumstances result in
PLC stop in the user program.

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User data backup/Series commissioning
15.4 Importing a series startup file with HMI Advanced

NOTICE
The creation of a series-commissioning file with PLC data while the PLC is in RUN status
(cyclic operation) may result in an inconsistent PLC image in the series commissioning
archive.
After this series startup file has been copied back, this data inconsistency in the PLC user
program may under certain circumstances result in the stop of the PLC.

Changing the PLC operating status

To change the PLC operating status, proceed as follows:
● With 840Di startup:
– Start 840Di startup via the Windows taskbar > Start > Programs > SINUMERIK 840Di
> 840Di Startup.
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC.
● With HMI Advanced
– Open the dialog box: Operating area switchover > Start up > NC/PLC Diagnosis
● Change the PLC operating state: PLC group buttons:"STOP"and "RUN".
● NCK and PLC must then be resynchronized: PLC group buttons: "NC Reset".

15.4 Importing a series startup file with HMI Advanced

The process of reading in a series startup file is broken down into the following steps:
1. Open the menu to read in a series startup file:
Operating range switchover > Services > Key ">" > Series startup > Import startup
archive
2. Select the series startup file
3. Start read in: START

Note
Because of the file extension ".arc" of the series startup file, this is also called archive.

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 User data backup/Series commissioning
15.5 SINAMICS S120 standard commissioning with STARTER

15.5 SINAMICS S120 standard commissioning with STARTER

A project must be available, created or loaded from a drive unit into the programming device
for the standard commissioning of SINAMICS S120. This project is loaded as a reference
project in the other drive units still to be commissioned.

Requirements
The following requirements must be fulfilled:
● The reference drive unit is fully configured.
● You can create an online connection to all drive units.
● The reference project is loaded into the STARTER.

Implementation
Perform the following actions in the STARTER for each drive unit to be commissioned:
1. Create a backup copy of the project: Project > Save as
2. Access the drive unit online: Project > Connect to target system
3. Load the project into the drive unit: Target system > Download > To target device
The drive unit applies the serial number from the previously located components in the
reference topology. This results in an inconsistency, which is displayed in the project
navigator.
4. Read the project back into the programming device: Target system > Load > Load fully
into the programming device (all p and r parameters)
5. Save your project: Project > Save
The configuration is now consistent again, i.e. the same project states exist in the target
system and in the project.

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User data backup/Series commissioning
15.5 SINAMICS S120 standard commissioning with STARTER

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Software installation/update and data backup 16
16.1 PTP network connection
The functions described in this section (software installation/update) require a network
connection to an external computer (PG/PC) which contains an enabled network access
directory.
If the SINUMERIK 840Di sl is not part of a larger network (WAN, LAN), a simple PTP (peer-
to-peer) connection via Ethernet and TCP/IP can be established for service applications.

16.1.1 Establishing a network connection

For the network link, the PCU 50.3 is connected with the external computer directly via a
crossed Ethernet cable (twisted pair crossed 10baseT/100baseTX Ethernet cable).

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Software installation/update and data backup
16.1 PTP network connection

TCP/IP network protocol

The network protocol used is: TCP/IP. TCP/IP permits high data transmission rates and it is
simple to configure. TCP/IP is already pre-configured in the basic PCU software.

Requirements on the ext. computer

The following requirements must apply on the external computer:
● A network adapter is installed.
● The TCP/IP network protocol is installed.
● The external computer is connected to the PCU via a 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.

16.1.2 Configuring the external computer (Windows NT)

This section illustrates how to make and check settings for network configuration on the
external computer:
● TCP/IP protocol
● IP address and subnet mask
● Computer name and workgroup
● Service: "Server service"
● Directory sharing

TCP/IP protocol
The installed network protocols are displayed in the "Protocols" tab via the network dialog of
the system control (Windows taskbar Start > Settings > System Control > Network). If the
TCP/IP protocol is not shown, it can be installed now.

Dialog: Beginning

Dialog: Network
Tab: Protocols
Button: "Add..."
Dialog: Network protocol selection
Network protocol: TCP/IP protocol
Note:
The query for DHCP is to answered with "No".
OK

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16.1 PTP network connection

IP address and subnet mask

After installation of the protocol and to simplify setting up communication with the PCU, it is
necessary to check the IP address and the subnet mask and set them, if necessary:

IP address
We recommend using an IP address from the address range used by Windows XP for
automatic configuration, if no DHCP server is accessible (Automatic Private IP Addressing:
169.254.x.x).
The last two digits must be in the range of 1 to 254.
● 169.254. 10. 1

Subnet mask
The subnet screen must be permanently set to the specified value:
● 255.255. 0. 0

Dialog: Continuation

Dialog: Network
Tab: Protocols
Button: "Properties..."
Dialog: Properties of Microsoft TCP/IP
Specify IP address
Specify IP address
IP Address: <169.254. 10. 1>
Subnet mask: <255.255. 0. 0>
OK

Computer name and workgroup

Because it is a PTP link, any computer name and workgroup may be selected.

Dialog: Continuation

Tab: Identification
Button: "Change..."
Dialog: Identification change
Computer name: <COMPUTER NAME>
Workgroup: <WORKGROUP>
OK

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Software installation/update and data backup
16.1 PTP network connection

Server service
The "Services" tab card must contain "Server service". This corresponds to general sharing:
"File and Printer Sharing" under Windows 9x or Windows XP. If this service is not active, no
directories can be shared.
If the service is not running, it can be installed now:

Dialog: End

Tab: Services
Button: "Add..."
Dialog: Selection of network service
Network service: Server service
OK
OK

Directory sharing
Release for network access takes place in the Properties dialog > "Release" tab of the
corresponding directory (selection of the directory with the right mouse key)
The directory name is the default name for sharing. If a different sharing name is specified, it
must be stated on activating the directory connection.

Authorization
Access authorization to the drive is "Everyone" and "Full access" by default.

Dialog

Dialog: Properties of <directory>

Tab: Release
Release as:
Release name: <RELEASE NAME>
OK

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 Software installation/update and data backup
16.1 PTP network connection

16.1.3 Configuring the external computer (Windows XP)

This section illustrates how to make and check settings for network configuration on the
external computer:
● TCP/IP protocol
● IP address and subnet mask
● Computer name and workgroup
● Service: "File and Printer Sharing"
● Directory sharing

TCP/IP protocol
The installed network protocols are displayed in the General tab index via the properties
dialog of the local network connections (Windows taskbar Start > Settings > Network
connections >> Local Area Connections).
The TCP/IP protocol must be installed and active:

Dialog

Dialog: Local Area Connection Properties

Tab: General
☑ Internet Protocol (TCP/IP)
OK
If the protocol is not shown, it can be installed now.

IP address and subnet mask

The IP address and the subnet mask are automatically set by Windows XP on connection
Precondition is that the "Automatic Private IP Addressing" function is active.
The function is activated in the properties dialog of the TCP/IP protocol (the function is active
by default).

Dialog

Dialog: Internet Protocol (TCP/IP) properties

Tab: Alternate Configuration
Automatic private IP address
OK

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Software installation/update and data backup
16.1 PTP network connection

Computer name and workgroup

Because it is a PTP link, any computer name and workgroup may be selected.
The setting is made via the properties dialog box of the Control Panel. Windows taskbar:
Start > Control Panel > System.

Dialog

Dialog: System properties

Tab: Computer name
Button: "Change..."
Dialog: Change computer name
Computer name: <COMPUTER NAME>
Workgroup: <WORKGROUP>
OK

Service: "File and Printer Sharing"

The installed services are displayed in the General tab index via the properties dialog of the
local network connections (Windows taskbar Start > Settings > Network connections >>
Local Area Connections).
The "File and Printer Sharing for Microsoft Networks" service must be installed and active:

Dialog

Dialog: Local Area Connection Properties

Tab: General
☑ File and Printer Sharing for Microsoft Networks
OK
If the service is not running, it can be installed now.

Option: "Simple file sharing"

To simplify the directory release, the "Simple File Sharing" under the Tools > Folder Options
menu option in Internet Explorer option should be activated.

Dialog

Dialog: Folder options

Tab: View
☑ Use simple file sharing (Recommended)
OK

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16.1 PTP network connection

Directory sharing
Release for network access takes place in the Properties dialog > "Sharing" tab of the
corresponding directory (selection of the directory with the right mouse key)
The directory name is the default name for sharing. If a different sharing name is specified, it
must be stated on activating the directory connection.

Authorization
To allow files to be created in the directory, the appropriate authorization must be set.

Dialog

Dialog: <Directory> Properties

Tab: Sharing
☑ Share this folder on the network
☑ Allow network users to change my files
OK

16.1.4 Configuring the PCU

The PCU basic software is preconfigured for a PTP network link with the TCP/IP protocol. It
is not possible to establish a network link if changes were made and the following settings
must be made or checked according to Subsection "Configuring External Computer
(Windows XP)":
● TCP/IP protocol
● IP address and subnet mask
● Computer name and workgroup

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16.2 Partitioning of the PCU hard disk

16.2 Partitioning of the PCU hard disk

The PCU hard disk is divided into 4 partitions (3 primary partitions and an extended partition).
For data security purposes, the SINUMERIK 840Di sl system software, the Windows system
software and the Service software are installed on different partitions.

Partitions
The diagram below shows the partitioning of the hard disk when the control system is
supplied:

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● 1st partition/drive C:
Drive C: is reserved for service tasks under WinPE 2005.
● 2nd partition/drive D:
Drive D contains the following directories:
– Graphics
The directory contains preinstalled and own images.
– Install
The software to be installed is first copied into this directory before actual installation
under Windows XP.
– Update
The directory is used for subsequent installation of Windows XP system software.
● 3rd partition/drive E:
Drive E: is reserved for the Windows XP system software.
● 4th partition/drive F:
Drive F: contains the SINUMERIK-specific applications, e.g. the SINUMERIK 840Di sl
system software.
It is also used for installing user-specific applications, e.g. SINUMERIK user interfaces,
HMI OEM applications or SIMATIC STEP7.

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16.3 Software installation/update (Windows)

16.3 Software installation/update (Windows)

Product brief
This section describes how to install/update software via a Windows-based network link to
an external computer (PC/PG) in which a directory is shared for this purpose.
The entire procedure is carried out from the SINUMERIK desktop. To activate the
SINUMERIK desktop, see Subsection "Activation" (Page 135).
It is possible to activate the SINUMERIK desktop permanently via the following applications
and to deactivate it again after completion of service actions. These applications are part of
the SINUMERIK 840Di sl basic software
● NT Desktop
Autostart of the HMI application: OFF
● HMI desktop
Autostart of the HMI application: ON

Compatibility list
Before installing/updating software components, check they are compatible with existing
software components. See the compatibility list for your SINUMERIK 840Di sl software
version on the Internet:
http://www.siemens.de/sinumerik > SINUMERIK 840Di sl > Link Box > Support > Current >
Tab: Update > SINUMERIK 840Di sl: Delivery Release System Software ... > Compatibility
list: Compatibility_List.PDF

NOTICE
We strongly recommend checking compatibility of new software components with existing
software components before installing/updating them (compatibility list).

Requirements
The following condition must be fulfilled:
● Network link with an external computer. See Section "PTP network
connection" (Page 551).

Recommended procedure
This is the recommended procedure for installing/updating software on the PCU:
1. Back up the NCK and PLC user data by creating a series startup file. See Chapter "User
data backup/Series Statup" (Page 541).
2. Establish a network link to a shared directory of an external computer (PG/PC) containing
the software to be installed. See Section "PTP network connection" (Page 551).
3. Perform installation/updating of the software via the network link.
4. Initialize the control with "Delete NC data" and "PLC memory reset". Refer to Subsection
"Basic Preconditions".
5. Import the series startup file created in Step 1. Refer to Section "Importing a series
startup file with HMI Advanced" (Page 548).

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16.4 Restoring the as-delivered state

16.4 Restoring the as-delivered state

If the current installation is damaged such that continuation is no longer possible, the as-
delivered state of the partitions C: (WinPE), E: (Windows XP) and F: (840Di sl system) of the
PCU hard disk can be restored.
This section describes the actions for:
● Restoring the partitions
● Installation of the SINUMERIK 840Di sl applications

NOTICE
When restoring the hard disk to the ex-works state, all data on the partitions C:, E: and
F: are lost.

16.4.1 Requirements
To restore the as-delivered state, the following files supplied with the SINUMERIK 840Di sl
must be saved locally on the PCU hard disk:
● D:\IMAGES\base_ou.gho (image file)
● D:\IMAGES\base_ou.inf

Image file
The image file *.gho contains the data to be restored.

Info file
The info file *.inf contains the description of the data to be restored.
The information in this file is required by the services menu to configure the image program
Norton Ghost™.

NOTICE
If the info file is not available, the service menu cannot restore the partitions.

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16.4 Restoring the as-delivered state

16.4.2 Restoring the partitions

The procedure for restoring partitions C:, E: and F: from a local image file is described in:
References:
/IAM2/ CNC Startup Part 5, Chapter IM8, "Backup and restore data", Backing up/restoring
partitions locally
Select the image file from which the partitions are to be restored in accordance with the
existing SINUMERIK 840Di sl software version:
● Basic software <Version> <Date>
After the partitions have been restored, the SINUMERIK 840Di sl applications must be
reinstalled.

16.4.3 Installation of the SINUMERIK 840Di sl applications

Procedure
The installation programs for the SINUMERIK 840Di sl applications saved on D:\INSTALL
are not executed automatically after partition restoration, as was the case during the initial
boot. To do this manually in the correct sequence, proceed as follows:
1. On next PCU startup 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 directory:
● D:\SETUP\APPS
The sub-directories contained in directory APPS contain:
– \001 Installation directories of the 1st application
– \002 Installation directories of the 2nd application
– ....
– \xxx Installation directories of the xxx th. Application
The numbers in the directory name indicate order in which the applications have to be
installed.
1. Next open directory:
● D:\SETUP\APPS\001
The subdirectories contained in directory \001 contain:
– \000 Installation directory of the application
– \001-\xxx Installation directories of options, patches,etc.
The numbers in the directory name indicate order in which the installation programs have
to be run.
1. Open the following directory as the next step and start the installation program in the
directory (SETUP.EXE).
● D:\SETUP\APPS\001\000

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16.4 Restoring the as-delivered state

Then following the installation instructions shown.

NOTICE
If you are prompted to reboot during installation, always confirm this with "Yes" and
reboot.

1. Proceed with all other (existing) directories according to Point 3:

● D:\SETUP\APPS\001\001 to \xxx
1. Proceed with all other (existing) directories according to Point 2:
● D:\SETUP\APPS\002 to \xxx
Once all the installation programs have been executed in the described sequence, partitions
C:, E:, and F: of the PCU hard disk are once again restored to their as delivered state.

Example
The following figure 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.

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License management 17
17.1 Basic principles

17.1.1 Important terms

The terms below are important for understanding the license management of SINUMERIK
software products.

Term Description
Software product A software product is generally used to describe a product that is installed on a piece of
hardware to process data. Within the license management of SINUMERIK software products,
a corresponding license is required to use each software product.
Hardware Hardware in the framework of the license management of SINUMERIK software products is a
SINUMERIK control (CNC). With SINUMERIK 840Di sl represented by the appropriate MCI
board.
License A license gives the user a legal right to use the software product. Evidence of this right is
provided by the following:
• CoL (Certificate of License)
• License key
CoL The CoL is the proof of the license. The product may only be used by the holder of the license
(Certificate of License) or authorized persons. The CoL includes the following data relevant for the license
management:
• Product name
• license number
• Delivery note number
• Hardware serial number
Note:
The hardware serial number is located only on a CoL of the system software or if the license
was ordered bundled, in other words the system software came together with options.
license number The license number is the feature of a license that is used for its unique identification.
MCI board The MCI board represents, as the carrier of all the remanent data of a SINUMERIK solution
line control system, the identity of this control system. The MCI board includes the following
data relevant for the license management:
• Hardware serial number
• License information including the License Key

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17.1 Basic principles

Term Description
Hardware serial number The hardware serial number is a permanent part of the MCI board. It is used to identify a
control system uniquely. The hardware serial number can be determined by:
• CoL (see: Certificate of License "Note")
• SINUMERIK user interfaces: HMI Advanced or HMI Embedded
• SINUMERIK Commissioning tool: SinuCom NC
• Automation License Manager
• Inscription on the MCI board
License key The License Key is the "technical representative" of the sum of all the licenses that are
assigned to one particular piece of hardware, which is uniquely marked by its hardware serial
number.
Option One option is a SINUMERIK software product that is not contained in the basic version and
which requires the purchase of a license for its use.
Product A product is marked by the data below within the license management of SINUMERIK
software products:
• Product name
• Order Number
• license number

17.1.2 Overview
The use of the installed system software and the options activated on a SINUMERIK control
system require that the licenses purchased for this purpose are assigned to the hardware. In
the course of this assignment, a License Key is generated from the license numbers of the
system software, the options, as well as the hardware serial number. Here, access occurs to
a license database administered by Siemens A&D via the Internet. Finally, the license
information including the License Key is transferred to the hardware.
There are two ways to access the license database:
● Web License Manager
● Automation License Manager

Note
Using SINUMERIK software products for testing purposes
SINUMERIK software products may be temporarily activated and used for testing
purposes on a SINUMERIK control system, even without the corresponding License Key.
On the SINUMERIK user interface, e.g. HMI Advanced, the License Key is then displayed
as "not sufficient" in the "Overview" dialog box. Also the control system will repeatedly
display a corresponding message.

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17.1.3 Web License Manager

By using the Web License Manager, you can assign licenses to hardware in a standard Web
browser. To conclude the assignment, the License Key must be entered manually at the
control system via the HMI user interface.
The Internet address of the Web License Managers is:
http://www.siemens.com/automation/license Internet address

17.1.4 Automation License Manager

Via the Automation License Manager, individual licenses can be assigned and the automatic
assignment of all the licenses required for a piece of hardware can be carried out (license
requirement alignment). The transfer of the license information including the License Key
occurs electronically via Ethernet.
Requirements:
● The Automation License Manager must be installed on the computer (PC/PG) that is
used to assign the licenses to the hardware.
● The computer (PC/PG) must be able to connect to the license database and the
SINUMERIK control system via Ethernet link (TCP/IP):
– License database: Internet connection
– SINUMERIK control system: Intranet or PTP connection (Ethernet, Peer-To-Peer)

17.1.5 License database

The license database contains all the customer-specific, relevant license information for the
license management of SINUMERIK software products. The central management of the
license information in the license database ensures that the existing license information
regarding a piece of hardware is always up to date.
The following functions are available:
● Management of the hardware purchased with the related licenses assigned
● Management of the licenses purchased and not yet assigned to any hardware
● Assignment of licenses to a piece of hardware according to the current license
requirement (license requirement alignment)
● Assignment of individual licenses to a piece of hardware
● Generating license keys
● Transferring license information including the License Key into a control system

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License management
17.1 Basic principles

License database access

License database access occurs via:
● Direct access
The direct access occurs with:
– Delivery note number
– license number
The direct access enables the direct assignment of licenses for which the license
numbers are available, e.g. in the form of a CoL. In the Web License Manager you can
also assign all other licenses provided in relation to this delivery note.
● Customer login
The customer login occurs with:
– User Name
– Password
The customer login enables the assignment of all the licenses available to the user that
are delivered at the time of the login and have not yet been assigned to any hardware.
Here, the license numbers of licenses that can still be assigned need not be directly at
hand, instead these are displayed from within the license database.

Note
The following is to be taken into account:
• You can obtain a customer login via Siemens A&D Mall at menu item "Registration".
The Internet address is:
http://mall.automation.siemens.com/
Currently, access is not yet possible for all countries.
• For browser settings for using the A&D Mall please refer to Subsection "Browser
settings for using the A&D Mall" (Page 569).

Various license information

As indicated above, only the license information in the license database represents the
current status regarding a piece of hardware. Differences may arise between the license
information available for a piece of hardware and that of the license database due to:
● Loading older archive data into the NC (data restoration from a series-commissioning file
after a service job)
● assigning licenses to hardware without transferring the modified license information for
the hardware control system (online)
As a result, a more limited license requirement (possibly no license requirement) may be
displayed than indicated on the HMI user interface of the control system for a license
requirement alignment by Automation License Manager.
To align the license information, a transfer should be carried out for the current license
information of the license database for the hardware control system (online).

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17.1.6 MCI board and hardware serial number

In addition to the retentive system and user data, the MCI board contains the data of a
control system relevant for the license management of SINUMERK software products:
● Hardware serial number
● License information including the License Key
The MCI board thus represents the identity of a SINUMERIK control system. For this reason,
assigning licenses to a control system always occurs using the hardware serial number.
This has the advantage that the MCI board can be slotted into a replacement PCU in the
event of failure and all data, including licensing information, is retained.

Automation License Manager

Thus, the hardware serial number is always decisive during the transfer of license
information to a control system in Automation License Manager and not the set IP address of
the control system with which Automation License Manager is currently communicating.

Determining the hardware serial number

The hardware serial number is a permanent part of the MCI board. It is used to identify a
control system uniquely. The hardware serial number can be determined by:
● CoL (Certificate of License) (see note)
● SINUMERIK user interfaces: HMI Advanced or HMI Embedded
● SINUMERIK Commissioning tool: SinuCom NC
● Inscription on the MCI board
● Automation License Manager: Control system file data
– Control system (online)
– Control image (offline)

Note

● Hardware serial number and CoL

The hardware serial number is located only on a CoL of the system software or if the
license was ordered bundled, in other words the system software came together with
options.
● SINUMERIK 840Di sl
On the SINUMERIK 840Di sl, the MCI board is used to save data and print the hardware
serial number.

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License management
17.1 Basic principles

17.1.7 SINUMERIK License Key

Basic information on License Keys

If a license is required for a product, then with the purchase of the license the purchaser
receives a CoL as proof for the rights to use this product and a corresponding License Key
as to the "technical representative" of this license. In conjunction with software products, the
License Key usually must be available on the hardware on which the software product
executed.

SINUMERIK License Keys

Depending on the software product, there are License Keys with different technical
properties. The essential properties of a SINUMERIK License Key are:
● Hardware reference
The hardware serial number included in the SINUMERIK License Key provides a direct
link between the License Key and the hardware on which it can be used. In other words,
a License Key created for the hardware serial number of a specific MCI board is only
valid for this MCI board and will be rejected on other MCI board as invalid.
● Total amount of the assigned licenses
A SINUMERIK License Key not only refers to one single license, instead it is the
"technical representative" of all licenses that are assigned to the hardware at the time of
its generation.

Copying SINUMERIK License Keys

By the fixed reference to certain hardware, a SINUMERIK License Key may, for example, be
copied to various computers (PC/PG) and/or memory media for security or archiving
purposes.

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17.1.8 Browser settings for using the A&D Mall

The browser settings required to use the A&D Mall are provided below based on Microsoft
Internet Explorer 6.0.x. When using another browser the settings should be modified as
necessary.

Session cookies
Session cookies must be enabled to use the A&D Mall. The corresponding setting can be
activated using the slider control for the general security settings. If you are using custom
security settings, you must explicitly allow session cookies.
settings
● General data protection settings:
Menu bar: Tools > Internet Options > Tab: "Security" > Slider control: "medium" or
"medium-high".
● User-defined data protection settings:
Menu bar: Tools > Internet Options > Tab: "Security" > "Settings" Group: Button:
"Advanced..." > "Cookies" Group: Select "Always allow session cookies".

Note
A cookie is a small text file, which is transferred from a Web server to the Web browser.
The text file cannot exceed 4000 characters (bytes) and is never executed as a program
by the Web browser.
Session cookies are a specific application format of cookies, which are not saved
permanently on the computer, but instead are deleted immediately when the user ends
the session.

JavaScript
In addition to session cookies, you must also allow execution of JavaScript programs to use
A&D Mall.
As the running of JavaScript programs is critical to security, you should only activate the
"Active Scripting" option for Web pages from trusted sources. Internet Explorer 6.0 x offers
four different zones for this.
settings
● Internet pages of Siemens to the zone: Add "Trusted Sites":
Menu bar: Tools > Internet Options > Tab: "Security" > Zone: "Trusted Sites" > Button:
"Sites..." > "Add this Web site to the zone": "*.siemens.com" > Button: "Add"
● Enable "Active Scripting":
Menu bar: Tools > Internet Options > Tab: "Security" > Zone: "Trusted Sites" > Button:
"Custom Level..." > Zone: "Scripting" > "Active Scripting" = "Enable"

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17.1 Basic principles

17.1.9 Proxy settings for the download of license information

As part of licensing, the Automation License Manager downloads license information,
including the License Key, from the license database to the local computer via the download
server. You should apply the settings for long-distance data transmission/VPN and LAN so
that you can access the download server via port 80 and port 443:
● Internet address: http://software-download.automation.siemens.com
● IP Address: 146.254.187.20
settings
In Internet Explorer 6.0 x via:
Menu command: "Tools" > "Internet Options..." > Tab: "Connections" > Group: "Dial-up and
Virtual Private Network settings" and "Local Area Network (LAN) settings"

Note
The Automation License Manager must be allowed to establish an Internet connection to the
download server. To do this you may need to enable a firewall for the download server.
In the event of queries and problems, please contact your local system administrator.

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17.2 Assigning via Web License Manager

17.2 Assigning via Web License Manager

17.2.1 Execute assignment via direct access

Background
For the direct access, log on to a computer connected to the Internet (PC/PG) with the
delivery note and license number in the Web License Manager. All licenses of the delivery
note numbers entered at the login may then be assigned to a piece of hardware. After
completing the assignment process, the new License Key is displayed. This must then be
entered in the licensing dialog of the HMI components used.

Requirements
The following prerequisites must be met in order to assign a license to a piece of hardware
via direct access and HMI user interface:
● The HMI component is connected with the control system (NCU) on which the license
should be assigned. Both components have been booted.
● A computer (PC/PG) with Internet connection and browser is available.
● The login data for the direct access (e.g. per CoL) are available:
– license number
– Delivery note number

Implementation
Assigning a license to a piece of hardware:
1. Determine the HW serial number and the product name (HMI Advanced/HMI Embedded:
"Type of hardware") via the HMI Licensing dialog box.
HMI Advanced/HMI Embedded:
Operating-area switchover: Commissioning > Key: etc. (">") > Licenses > Overview

Note
Ensure that the hardware serial number displayed is also really the one you want to make
the assignment for. The assignment of a license to a piece of hardware cannot be
reversed via the Web License Manager.

2. Go to the Internet page of the Web License Manager:

http://www.siemens.com/automation/license
3. Login via "Direct access":
– license number
– Delivery note number
4. Follow the additional instructions in the Web License Manager.

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17.2 Assigning via Web License Manager

5. After completing the assignment process, enter the License Key displayed on the Web
License Manager into the licensing dialog of the HMI user interface.
HMI Advanced/HMI Embedded:
Operating-area switchover: Commissioning > Key: etc. (">") > Licenses > Overview
6. Confirm the entry of the new License Key by pressing the softkey: "Transfer".

17.2.2 Execute assignment via customer login

Background
For the customer login, log on to a computer (PC/PG) connected to the Internet with the user
name and password in the Web License Manager. All licenses released for this user name in
the framework of the license management may then be assigned to a piece of hardware.
After completing the assignment process, the new License Key is displayed. This must then
be entered in the licensing dialog of the HMI components used.

Requirements
The following prerequisites must be met in order to assign a license to a piece of hardware
via customer login and HMI user interface:
● The HMI component is connected with the control system (NCU) on which the license
should be assigned. Both components have been booted.
● A computer (PC/PG) with Internet connection and browser is available.
● The login data for the customer login is available:
– User name
– Password

Implementation
Assigning a license to a piece of hardware:
1. Determine the HW serial number and the product name (HMI Advanced/HMI Embedded:
"Type of hardware") via the HMI Licensing dialog box.
HMI Advanced/HMI Embedded:
Operating-area switchover: Commissioning > Key: etc. (">") > Licenses > Overview

Note
Ensure that the hardware serial number displayed is also really the one you want to make
the assignment for. The assignment of a license to a piece of hardware cannot be
reversed via the Web License Manager.

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17.2 Assigning via Web License Manager

2. Go to the Internet page of the Web License Manager:

http://www.siemens.com/automation/license
3. Login via "Customer login":
– User name
– Password
4. Follow the additional instructions in the Web License Manager.

Note
If you have an e-mail address, you have the option (checkbox) of receiving the License
Key by e-mail. Advantage: the entry of the License Key to the control system is simplified.

5. After completing the assignment process, enter the License Key displayed on the Web
License Manager into the licensing dialog of the HMI user interface.
HMI Advanced/HMI Embedded:
Operating-area switchover: Commissioning > Key: etc. (">") > Licenses > Overview
6. Confirm the entry of the new License Key by pressing the softkey: "Transfer".

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17.3 Assigning via Automation License Manager

17.3 Assigning via Automation License Manager

17.3.1 Overview of functions

The following figure provides an overview of the functions available and the sequence in
which they should be applied.

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Manual
574 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 License management
17.3 Assigning via Automation License Manager

17.3.2 Installing Automation License Manager

Background
As a basic software component, the Automation License Manager comprises the Automation
License Manager itself, as well as additional SINUMERIK-specific plug-ins and the HMI
basic software component, HMI basic software, for the license management of SINUMERIK
License Keys.

Note
The basic software component, Automation License Manager, is used for all Siemens A&D
products, e.g. SIMATIC STEP7. Versions of the basic software component, Automation
License Manager, are upward compatible. We recommend always using the version with the
highest version number, irrespective of the source of supply (e.g. SINUMERIK or SIMATIC
product CD, download via A&D Mall, etc.).

The following components are installed:

● Basic software component: Automation License Manager (optional)
The basic software component is only installed if not already installed on the computer or
if a version with a lower version number is installed on the computer (PC/PG).
● SINUMERIK plug-ins
● HMI basic software (optional)
The HMI basic software component is only installed if not already installed on the
computer or if a version with a lower version number is installed on the computer (PC/PG).

System requirements
Hardware
● Computer: Industrial PC, programming device, etc.
● Work memory: >= 128 MB
● Free hard-disk storage:
more than 5 MByte (SINUMERIK plug-ins)
+ 32 MByte (Automation License Manager)
+ 300 MByte (HMI Basic software)
Operating system
The Automation License Manager, SINUMERIK plug-ins and HMI basic software are 32-Bit
Windows programs executable on the following operating systems:
● Windows 2000
● Windows XP

Manual
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License management
17.3 Assigning via Automation License Manager

Implementation
Launch the installation program for the Automation License Manager "SETUP.EXE" and
follow the instructions for the installation.

Further settings
Note the following settings:
● Browser settings for using the A&D Mall:
Subsection "Browser settings for using the A&D Mall" (Page 569)
● Proxy settings for downloading license information:
Subsection "Proxy Settings for downloading license information" (Page 570)

17.3.3 Enable/disable SINUMERIK plug-in

Background
All plug-ins enabled for the Automation License Manager scan the communication interfaces
when booting according to specific operations. If there is a large number of enabled plug-ins,
this can result in a significantly longer boot and refresh time for the user interface.
To prevent this delay, you can disable the plug-in installed for handling the SINUMERIK
License Keys via the dialog "Connect destination system":

Implementation
Perform the following actions to enable/disable the SINUMERIK plug-ins:
1. Run Automation License Manager.
2. Open the "Connect destination system" dialog via the menu command Machine >
Connect destination system > PlugIn SINUMERIK.
3. Open the Settings tab in the dialog
4. Enable/disable the plug-in by selecting/deselecting the appropriate checkbox.
5. Click OK to close the dialog box.

Manual
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 License management
17.3 Assigning via Automation License Manager

Result
The Automation License Manager displays the data in the navigation and object area
according to the status of the SINUMERIK plug-in.
The folder symbols and names are displayed in the navigation area depending on the status
of the SINUMERIK plug-in and the communication link to the SINUMERIK control:
● SINUMERIK plug-in disabled:
PlugIn SINUMERIK - - - - disabled - - - -
● SINUMERIK plug-in enabled, but no communication link with SINUMERIK control:

SINUMERIK - online - - - - no connection available - - - -

SINUMERIK - offline - - - - no data available - - - -
● SINUMERIK plug-in enabled, communication link established with SINUMERIK control:

SINUMERIK <control type> - <hardware serial number>

Note
If the view is not automatically refreshed, you can refresh the view manually. Refer to
Subsection "Update the "Manage" Navigation view" (Page 580).

17.3.4 Define parameters of TCP/IP communication with a control

Background
To be able to read or transfer license information to or from the MCI board of a control
system, the Automation License Manager must communicate with the control system via
TCP/IP.
Requirements:
● HMI basic software is installed
● SINUMERIK-specific plug-ins are enabled

Note
If the SINUMERIK user interface "HMI Advanced" is installed on the same computer
(PC/PG) as the Automation License Manager you can set the IP address using the user
interface.
The IP address for the control system with which both HMI Advanced as well as the
Automation License Manager communicate is set via the following dialog:
Operating area switchover > Startup > HMI > NCU link
This requires at least the password of protection level 2 (manufacturer) to be set.

General communication parameters

The default general communication parameters for the HMI basic software are stored in the
following initialization file:
<installation drive>:\Siemens\Sinumerik\HMI-Advanced\mmc2\MMC.INI

Manual
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License management
17.3 Assigning via Automation License Manager

User-specific communication parameters

The user-specific communication parameters for the HMI basic software are stored in the
following initialization file:
<Installation drive>:\Siemens\Sinumerik\HMI-Advanced\user\MMC.INI
During evaluation of the initialization data when booting the HMI basic software, user-specific
communication parameters have priority over general communication parameters.
Sections of the initialization file: MMC.INI
The parameters relevant to TCP/IP communication with SINUMERIK control systems are
stored in the following sections:
● [ GLOBAL ]
The [GLOBAL] section specifies the section (e.g. AddressParameter) that contains the
communication parameters for the current SINUMERIK control system.
● [ AddressParameter ]
The name of this section can be any unique ASCII string within the file. The specified IP
address is crucial for communication with the current SINUMERIK control system: IP
address.

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Several SINUMERIK controls

If you require communication with multiple SINUMERIK control systems you must create an
[ AddressParameter ] section with a unique name e.g. [ 840D_001 ], [ 840D_002 ], etc. for
each control system with the relevant IP address.
In the [GLOBAL] section, you must specify the section name for the SINUMERIK control
system, e.g. [840D_001], with which communication should occur once the Automation
License Manager has booted.

NOTICE
The IP address specified in the user-specific initialization file MMC.INI influences not only
the Automation License Manager but also all other applications installed on the same
computer (PC/PG) that use HMI basic software (e.g. HMI Advanced).
To apply the change to the active IP address, you must close all active applications using
HMI basic software (e.g. HMI Advanced). Once you have closed all applications, restart the
computer to activate the new IP address.

Manual
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 License management
17.3 Assigning via Automation License Manager

Requirements
The following conditions must be fulfilled:
● HMI Basic is installed on the computer (PC/PG) on which the Automation License
Manager is running.
● The IP addresses of the SINUMERIK control systems with which the Automation License
Manager must communicate are known.

Procedure: Creating parameters for the first time

Perform the following actions when creating user-specific communication parameters for the
first time:
1. Create the following text file, if it does not already exist:
<Installation drive>:\Siemens\Sinumerik\HMI-Advanced\user\MMC.INI
2. Open the file MMC.INI with a text editor.
3. Copy the [GLOBAL] section from the above-mentioned table "User-specific file: MMC.INI"
to the open file MMC.INI.
4. Copy the [AddressParameter] section from the above-mentioned table "User-specific file:
MMC.INI" to the open file MMC.INI according to the number of available SINUMERIK
control systems.
5. Replace the "AddressParameter" string by a relevant unique designation for all sections
[AddressParameter]
6. Replace the IP address string by the relevant IP address of the corresponding
SINUMERIK control system in all the sections [AddressParameter].
7. In the [GLOBAL] section, replace the "AddressParemeter" string with the section name
for the SINUMERIK control system with which the Automation License Manager should
communicate after booting. (See note "Changing the IP address" above.)

Procedure: Changing the active control system (online)

Perform the following actions to change the active control system (online), i.e. the
SINUMERIK control system with which the Automation License Manager communicates:
1. Close the Automation License Manager.
(See note "Changing the IP address" above.)
2. Open the file <installation drive>:\Siemens\Sinumerik\HMI-Advanced\user\MMC.INI with a
text editor.
3. In the [GLOBAL] section, replace the current address string with the section name for the
SINUMERIK control system with which the Automation License Manager should
communicate after booting.
4. Run Automation License Manager.

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License management
17.3 Assigning via Automation License Manager

Result
After booting the Automation License Manager communicates with the SINUMERIK control
system defined in the user-specific communication parameters.
The control system to which you have switched is represented by an "online" control system
file in the navigation area of the Automation License Manager.
The control system to which the Automation License Manager was connected before
switching is represented by an "offline" control system file, if a control image (offline) exists.

17.3.5 Update the "Management" navigation view

Background
Actions that delete or add elements in the navigation area of the "Management" navigation
view of the Automation License Manager (e.g. deleting a control image (offline),
enabling/disabling plug-ins) are generally followed by an automatic refresh of the view. If the
view does not refresh automatically after an operation, you can refresh the view manually.

Implementation
Perform the following actions to manually refresh the "Management" navigation view:
1. Select the following nodes in the navigation area of the Automation License Manager by
clicking on the Dedicated computer node with the left mouse key.
2. Refresh the view using one of the following options:
– Menu command View > Refresh
– Key F5

– Tool bar

Result
The navigation view of the Automation License Manager is refreshed. All sub-nodes under
the Dedicated computer node are closed.
The object view of the Automation License Manager shows the current nodes and drives of
the navigation area.

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 License management
17.3 Assigning via Automation License Manager

17.3.6 Display the license information of a hardware unit

Background
To perform the following tasks with the Automatic License Manager, the system should
display the license information of a hardware unit:
● Check the license information for the hardware
● Ascertain the license requirement for the hardware and align if necessary
● Assign new licenses to hardware and transfer updated license information including
License Keys to the hardware

Requirements
The license information can only be displayed if the Automation License Manager is
communicating with the relevant SINUMERIK control system. A description of how to assign
parameters for TCP/IP communication with a control system is given in Subsection
"Parameterize TCP/IP communication with a control system" (Page 577).

Procedure with current control system (online)

Perform the following actions to display the license information for the control system
currently connected to the Automation License Manager:
1. Open the control system file in the navigation area of the Automation License Manager
and select the control system (online).
2. Enable the default object view "SINUMERIK".

Procedure with control system change over (online)

Perform the following actions to display the license information for a control system not
connected to the Automation License Manager:
1. Exit the Automation License Manager and all other applications using HMI basic software
(e.g. HMI Advanced).
2. Switch the active communication parameters to the required control system. A detailed
description is available in Subsection "Parameterize TCP/IP communication with a control
system" (Page 577).
3. Start the Automation License Manager
4. Open the control system file in the navigation area of the Automation License Manager
and select the control system (online).

Result
The license information for the control system is displayed in the object area of the
Automation License Manager.

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License management
17.3 Assigning via Automation License Manager

17.3.7 Create control image (offline)

Background
It is essential to create a control image (offline) for the following reasons:
● The license information must be later transferred to the hardware.
● The control system (online) is not connected to the Internet, e.g. for security reasons.
Consequently, the license information must be transferred to the hardware in three
individual stages.
● Internet or PTP link: Creating a control image (offline) in the Automation License Manager
– Internet: Transferring license information to the control image (offline) by means of a
license requirement alignment
– Internet or PTP link: Transferring license information from the control image (offline) to
the control system (online) in the Automation License Manager
● The license information for a control system should be saved as an archive file for the
purpose of archiving or customer support.

Requirements
A control image (offline) can only be created if the Automation License Manager is
communicating with the control system.
A detailed description of how to define parameters for TCP/IP communication with a control
system is given in Subsection "Parameterize TCP/IP communication with a control
system" (Page 577).
A PTP link (Peer-To-Peer) via Ethernet and TCP/IP requires a crossed Ethernet cable
(twisted pair crossed 10baseT/100baseTX Ethernet cable).

Procedure using the menu command: "Load from target system"

Perform the following actions to create a control image (offline) via the "Load from target
system" menu command:
1. Open the "online" control system file in the navigation area of the Automation License
Manager and select the control system (online).
2. Create the control image (offline) using the menu command: License Key > Load from
target system

Result
The control image (offline) is displayed in the "online" control system file with the current
license information for the control system. If a control image (offline) already exists in the
"online" control system file, the image is overwritten with the current license information.

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 License management
17.3 Assigning via Automation License Manager

17.3.8 Align license requirement for a hardware unit

Background
If one or more options are active on a SINUMERIK control system, you must assign each
license to the hardware. Next, the updated license information including the License Key is
transferred to the hardware.
You can use the "Align requirement" function to perform the alignment automatically for all
required licenses based on the control system (online) or a control image (offline). The
following actions are performed:
● Determining the hardware serial number for the control system
● Determining the license requirement for the control system
● Taking the required licenses from the customer-specific licenses and assigning these to
the hardware
● Transferring the updated license information including License Key to the control system
(online) or the control image (offline)

Requirements
The following requirements must be met for the license requirement alignment:
● The address data for the customer login (personalized login) is available:
– User Name
– Password
● Control (online) or control image (offline)
An "online" control system file or an "offline" control system file with the relevant control
image (offline) is available.
How to create a control system image (offline) is described in Subsection "Creating a
control system image (offline)".
A description of how to assign parameters for TCP/IP communication with a control
system is given in Subsection "Parameterize TCP/IP communication with a control
system" (Page 577).

Implementation
Perform the following actions for license requirement alignment with a control system (online)
or a control image (offline):
1. Open the corresponding control system file in the navigation area of the Automation
License Manager and select the control system (online) or the control image (offline).
2. Select menu command "License Key" > "Align requirement".
3. Login via your customer login.
4. Execute the following steps in the Automation License Manager:
"Align requirement", "Confirm requirement list" and "Transfer licenses".
Follow the instructions displayed on the screen.

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License management
17.3 Assigning via Automation License Manager

NOTICE
Carefully check the suggested license assignment. An adjustment may be required if:
• you wish to use a license number that differs from the number suggested
• you wish to use a license package rather than single licenses
• you wish to assign greater or fewer licenses than suggested for any reason
You can no longer undo the assignment independently.

The procedure for transferring the updated license information from a control image (offline)
to a control system (online) is described in Subsection "Transfer license information of a
control image (offline) to a control (online)" (Page 584).

Result
The license information for the control system (online) or control image (offline) is now
identical to the information for the relevant hardware in the license database, including the
License Key.

17.3.9 Transferring license information for a control image (offline) to a control system
(online)

Background
It is essential to transfer the license information for a control image (offline) to a control
system (online), i.e. the hardware for a SINUMERIK control, for the following reasons:
● The control system (online) is not connected to the Internet, e.g. for security reasons.
License information is initially only updated based on a control image (offline). The
computer on which the Automation License Manager is running is then disconnected from
the Internet and connected to the relevant SINUMERIK control system to transfer the
license information.
● After a service call, the license information should be transferred from an archive file to a
SINUMERIK control system.

Requirements
To transfer license information for a control image (offline) to a control system (online) the
following requirements must be met:
● The Automation License Manager must be communicating with the control system.
A detailed description of how to define parameters for TCP/IP communication with a
control system is given in Subsection "Parameterize TCP/IP communication with a control
system" (Page 577).
● The hardware serial number of the control image (offline) and the control system (online)
must be identical.

Manual
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 License management
17.3 Assigning via Automation License Manager

Procedure using drag-and-drop

Perform the following actions to transfer a control image (offline) to the hardware using drag
and drop:
1. Open the "online" control system file in the navigation area of the Automation License
Manager and select the control image (offline).
2. Select any line from the license information displayed in the object area.
3. Drag the selected line to the control system (online) release the mouse key.

Procedure using menu commands

Perform the following actions to transfer a control image (offline) to the hardware using the
menu command: "Load to target system":
1. Open the "online" control system file in the navigation area of the Automation License
Manager and select the control image (offline).
2. To transfer the control image (offline) to the hardware select the menu command License
Key > Load to target system

Result
The license information for the hardware is now identical to the information for the control
image (offline), including the License Key.

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17.3 Assigning via Automation License Manager

Manual
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840Di-specific data and functions 18
18.1 Interface signals
For detailed information on interface signals, please refer to the function manuals:
● /FB1/Function Manual - Basic Functions
● /FB2/ Function Manual - Extended Functions
● /FB3/ Function Manual - Special Functions
● /FBSY/ Function Manual Synchronous Actions
For a complete list of all existing interface signals, please refer to:
● /LIS/Lists, Section "Interface signals"

18.1.1 840Di sl-specific interface signals

DB number Byte, bit Name

Signals from NC to PLC
10 108.2 MMC ready, communication via MPI
10 108.3 MMC ready, communication via Softbus
10 109.4 PC OS fault
10 57.3 PC shutdown

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840Di-specific data and functions
18.1 Interface signals

18.1.2 Interface signals not supported

DB number Byte, bit Name

Axis/spindlespecific signals from PLC to axis/spindle
31, ... 20.0 Acceleration switch V/Hz operation
31, ... 20.2 Torque limit 2
Safety Integrated signals from PLC to axis/spindle
31, ... 22.0 Deselection of safe velocity and zero speed (deselection of SBH/SG)
31, ... 22.1 Deselection of safe operational stop (deselection of SBH)
31, ... 22.3 Velocity limit, bit value 0 (SG selection)
31, ... 22.4 Velocity limit, bit value 1
31, ... 23.0-23.2 Speed ratio selection, bit value 0 to bit value 2
31, ... 23.5 Enable limit switch pair 2
31, ... 23.7 Activate test stop
Signals from axis/spindle to PLC
31, ... 92.0 Setup mode is active
31, ... 92.2 Torque limit 2 active
Safety Integrated signals from axis/spindle to PLC
31, ... 108.0 Safe velocity or zero speed (SBH/SG active)
31, ... 108.2 Clear status pulses
31, ... 108.7 Axis safely referenced
31, ... 109.0-109.7 Cam signals of plus and minus cams (SN1+/1- to SN4+/4-)
31, ... 110.1 Safe operational stop active (SBH active)
31, ... 110.3-110.4 Safe velocity active, bit value 0 to bit value 1
31, ... 110.5 n < nx
31, ... 111.1 Safe operational stop active (SBH active)
31, ... 111.4-11.7 Stop A/B to Stop E active

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 840Di-specific data and functions
18.2 Expanded message frame configuration/evaluation of internal drive variables

18.2 Expanded message frame configuration/evaluation of internal drive

variables

18.2.1 Description of functions

To ensure that the internal drive variables are available for evaluation in the NC, these are
transferred from the drive as additional process data (PDA) during cyclic PROFIBUS
communication and saved by the operating system in system variables.
The additional PDA is appended at the end of the standard message frame.

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NC system variable
According to the selected functionality, for each axis the additional PDA 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:
● MD36730 $MA_DRIVE_SIGNAL_TRACKING[n] (acquisition of additional drive actual
values)

Specific system variables

To transfer drive variables to individual system variables you must set the following machine
data:
● MD36730 $MA_DRIVE_SIGNAL_TRACKING[n] = 1
The additional PDA must be configured in the message frame in the exact sequence
specified in the following table.

Table 18-1 Specific drive variables

PZD Drive variables System variable

x+1 Load $AA_LOAD
x+2 Smoothed torque setpoint (Mset) $AA_TORQUE
x+3 Active power (Pact) $AA_POWER
x+4 Smoothed torque-producing current Iq (IqGl) $AA_CURR

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840Di-specific data and functions
18.2 Expanded message frame configuration/evaluation of internal drive variables

General system variables

The entire message frame with standard process data and additional process data is
transferred in a general system variable as an array of 16-bit integer data words via:
● MD36730 $MA_DRIVE_SIGNAL_TRACKING[n] = 2
● System variable: $VA_DP_ACT_TEL[n, a]
where n = Index: 0,2,...15
a = machine axis identifier

Note
• The message frame configuration must meet the following condition:
(Standard PDA + Additional PDA) - 1 ≤ n
where n = maximum possible index for system variable $VA_DP_ACT_TEL
• When using the system variables $VA_DP_ACT_TEL[n, a] in a user program, it is only
permissible to use one constant as index n.

Application example for system variables in a synchronized action:

IDS=1 DO $AC_MARKER[0] = $VA_DP_ACT_TEL[12, X]

Data formats
The user must take the following points into account with regard to the data formats of the
process data stored in the system variables:
● The PDA is transferred to the message frame in the 16Bit integer without prefix (UINT16)
format. They are stored in the system variables in the 32Bit-Integer with prefix (INT32)
format.
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 values combined from 2 PDA (16Bit each) are mapped in the $VA_DP_ACT_TEL
system variable to 2 separate data words (32Bit each), e.g.:
– Encoder 2 position actual value 1 (G2_XIST1)
– Encoder 2 position actual value 2 (G2_XIST2)
How the process data of the message frame is mapped onto system variable
$VA_DP_ACT_TEL is illustrated by the following figure:

Manual
590 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 840Di-specific data and functions
18.2 Expanded message frame configuration/evaluation of internal drive variables

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Figure 18-2 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 part 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.

18.2.2 Requirements
The following conditions must be fulfilled for the transfer of additional drive variables:
● Drive
The drive must support SIEMENS message frame 116 or free message frame
configuration.
● DP master/SIMATIC STEP 7
No additional requirements
● SINUMERIK 840Di sl NC
– The option must be avaliable:
"Evaluation of internal drive variables",
Order No. (MLFB): 6FC5 251-0AB17-0BA0
– The NC machine data should be set:
MD36730 $MA_DRIVE_SIGNAL_TRACKING[n] (acquisition of additional drive actual
values)

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18.2 Expanded message frame configuration/evaluation of internal drive variables

18.2.3 Project design: SINAMICS S120 and SIEMENS message frame 116
When using SIEMENS message frame 116 no further measures are required other than
those applied for standard configuration.

18.2.4 Project design: SINAMICS S120 and expanded message frame configuration

Standard engineering
Before configuring the additional drive variables, please define the following:
● The SIEMENS message frame that is to be used.
● The additional drive variables/PDA that are to be transferred.

Note
When transferring additional drive variables to the specific system variables, we
recommend always using SIEMENS message frame 116.

Recommended configuration sequence

When configuring the components included in the frame, we recommend the following
sequence:
1. DP master
2. DP slave S120/Drive
3. SINUMERIK 840Di sl NC

1. Configuring the DP Master: Standard engineering

When using the extended message frame configuration, you must first apply the standard
configuration to the DP master with respect to the DP slave S120 with the SIEMENS
message frame required for cyclic communication.
For information on how to perform a standard configuration of the DP master, please see
Section "DP slave SINAMICS S120" (Page 287).

Expanded message frame configuration

Perform the following actions to configure the additional PDA:
1. Open the "DP slave properties" dialog for the drive unit by double-clicking the relevant DP
slave S120 in the HW Config station window.
2. Expand the length of the PDA already configured with the SIEMENS message frame in
the actual value slot of the relevant drive by the length of the additional PDA.
3. The setpoint and actual value of an axis must have the same I/O address. If HW Config
changes the I/O address of the actual value slot as a result of expanding the PDA, you
must modify the I/O address of the setpoint slot accordingly.

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18.2 Expanded message frame configuration/evaluation of internal drive variables

Dialog

Dialog: DP slave properties

Tab: Configuration
Page: Details
Actual value > Length:: <Length standard PDA + length additional PDA>
Setpoint > I/O address: <I/O address actual value> (see above 2.)
OK

NOTICE
The following is to be taken into account:
• The setpoint and actual value of a drive must have the same I/O address.
Actual value: I/O address = = Setpoint: I/O address
• The I/O address configured in HW Config for a drive must match the I/O address set in
the NC.
There is no automatic adjustment!
The following data must agree:
– SIMATIC S7 configuration DP slave S120
I/O address
– SINUMERIK 840Di sl NC
MD13060 $MN_DRIVE_LOGIC_ADDRESS[n] (logical drive address)

Note
After the above mentioned length increase of the PDA actual value (DP Slave Properties
dialog box > Configuration > Details >Actual Value > Length), the originally selected
message frame type is not displayed if the Property dialog box is reopened. Either no
message frame type is displayed or the one incidentally fitting the changed PDA message
frame type is displayed:
Dialog: DP slave properties
Tab: Configuration
Page: Overview
Predefined: <Messag frame type>

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18.2 Expanded message frame configuration/evaluation of internal drive variables

2. Configuring the DP slave S120/drive

Before performing the extended message frame configuration in the STARTER
commissioning tool, you must first perform the standard configuration or commissioning of
the drive.

Standard engineering
For the standard configuration or commissioning of the drive, please see:
● Commissioning (requirements)
– Chapter Drive Commissioning (SINAMICS), "Requirements" (Page 307)
● Standard configuration or commissioning
– References:
SINAMICS S120 Commissioning Manual

Expanded message frame configuration

Perform the following actions to configure the additional PDA:
1. Open the PROFIBUS dialog for the drive.
Project navigator: Project > <Drive unit > > Drives > <Drive> > Communication >
PROFIBUS (double-click)
2. Open the tab: "PROFIBUS send direction" (1).
3. Select the option "Hide inactive interconnections" (2).
4. Select "Free message frame configuration with BICO (999)" (3) as message frame.
5. Interconnect the free PDA with the relevant drive variables.

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18.2 Expanded message frame configuration/evaluation of internal drive variables

3. Configuring the NC
Before configuring the expanded message frame configuration, you first need to perform the
standard configuration on the NC for the drive.

Standard configuration
How to proceed with the standard configuration of a drive is described in Subsection "Drive
configuration" (Page 389).

Expanded message frame configuration

Perform the following actions to transfer the additional PDA to the general system variables:
1. Activate the option “Evaluation of internal drive variables”.
2. Activate the transfer to general system variable:
● MD36730 $MA_DRIVE_SIGNAL_TRACKING[n] = 2

Note
After configuring the expanded message frames, the original configured message frame
for the cyclic communication of the drive is only explicitly visible in the following machine
data:
• MD13060 $MN_DRIVE_TELEGRAM_TYP[n] (drive message frame type)

18.2.5 Project design: SIMODRIVE

The extended message frame configuration with reference to the following drives is
illustrated on the basis of an example using SIMODRIVE 611 universal (DP slave 611U).
● SIMODRIVE 611 universal or universal E
● SIMODRIVE POSMO CD/CA
● SIMODRIVE POSMO SI
Please adapt your procedure for the other SIMODRIVE drives.

Standard engineering
Before performing the expanded message frame configuration, please define the following:
● The standard message frame that is to be used for the DP slave drive.
● How many drive actual values/PDA are also to be transferred

Note
It is advisable to configure each component first with the standard message frame and
then expand the frame by the additional PDA.

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18.2 Expanded message frame configuration/evaluation of internal drive variables

Recommended configuration sequence

When configuring the components included in the expanded message frame configuration,
we recommend the following sequence:
1. DP master
2. DP Slave 611U
3. SINUMERIK 840Di sl NC

Step 1: Configuring the DP master

Before performing the expanded message frame configuration, you need to configure the DP
slave 611U with the standard message frame required for this drive.

Standard engineering
For information on how to perform a standard configuration of the DP master, please see
Section "DP slave SIMODRIVE drives" (Page 297).

Expanded message frame configuration

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 message frame,
must be expanded by the length of the additional PDA.
2. As the I/O address of setpoint and the actual value of an axis must be the same, change
the I/O address of the setpoint to the I/O address of the actual value which is
automatically adapted by the HW Config if necessary.

Dialog

Dialog: DP slave properties

Tab: Configuration
Actual value > Length: <Length standard PDA + length additional PDA>
Setpoint > I/O address: <I/O address actual value> (see above 2.)
OK

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18.2 Expanded message frame configuration/evaluation of internal drive variables

NOTICE
The following is to be taken into account:
• The I/O address for setpoint and actual values of an axis must be the same.
I/O address actual value = = I/O address setpoint
• 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 agree:
– 1. SIMATIC S7 configuration DP slave 611U
I/O address
– 2. SINUMERIK 840Di sl NC
MD13060 $MN_DRIVE_LOGIC_ADDRESS[n] (logical drive address)

Note
After the length increase of the actual value PDA (DP slave properties dialog > Configuration
>Actual value >Length) described above, a renewed opening of the properties dialog and the
following message frame type does not lead to the display of the originally selected message
frame. Instead, no message frame or the one matching the changed PDA is displayed:
Dialog: DP slave properties
Tab: Configuration
Predefined: <Messag frame type>

Step 2: Configuring the DP slave 611U

Before performing the extended message frame configuration, you must first perform the
standard configuration or commissioning of the drive.

Standard engineering
For the standard configuration or commissioning of the drive, please see:
● Commissioning (requirements)
– Chapter Drive Commissioning (SINAMICS), "Requirements" (Page 307)
● Standard configuration or commissioning
– SIMODRIVE 611 universal and universal E:
References:
/FBU/ Function Manual SIMODRIVE 611 universal
– SIMODRIVE POSMO SI/CD/CA

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18.2 Expanded message frame configuration/evaluation of internal drive variables

References:
/POS3/ User Manual - SIMODRIVE POSMO SI/CD/CA
– SimoCom U commissioning tool
References:
Online Help of SimoCom U

Expanded message frame configuration

To configure the additional drive actual values, modify the standard configuration of the drive
e.g. starting at standard message frame 102 as follows with the SimoCom U commissioning
tool:

NOTICE
Before configuring the additional drive actual values, please ensure that the correct drive -
and if using a multiple axis module, the correct axis - was selected in the SimoCom U
commissioning tool.

● Activating the customizable message frame configuration

To activate the free message frame configuration, the message frame type of the
selected standard message frame in the PROFIBUS parameterization menu (menu
command Commission > Parameterization views > PROFIBUS Parameterization) is to be
replced by "0".

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Figure 18-4 Activating the customizable message frame configuration

● Configuring the additional drive actual values

The drive utilization for PDA11 is configured via the selection list of the corresponding
parameter (PROFIDrive parameter P0916[x]) in the following figure.

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18.2 Expanded message frame configuration/evaluation of internal drive variables

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Figure 18-5 Configuring the additional drive actual values

Step 3: Configuring the NC

Before configuring the expanded message frame configuration, you first need to perform the
standard configuration on the NC for the drive.

Standard configuration
How to proceed with the standard configuration of a drive is described in Subsection "Drive
configuration" (Page 389).

Expanded message frame configuration

For the expanded message frame configuration on the NC, you only need to activate PDA
transfer in the respective system variable.
● Option "Evaluation of internal drive variables", Order number (MLFB): 6FC5 251-0AB17-
0BA0
● NC machine data for activating the data transmission in the system variables:
– MD36730 $MA_DRIVE_SIGNAL_TRACKING[n] (acquisition of additional drive actual
values)

Note
After configuring the expanded message frame configuration, the standard message
frame with which the axis is driven is only explicitly visible in the NC machine data:
• MD13060 $MN_DRIVE_TELEGRAM_TYP[n] (drive message frame type)

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18.2 Expanded message frame configuration/evaluation of internal drive variables

18.2.6 Constraints

Slot assignment
The NC always occupies an entire slot. The data of the slot not used by the NC, e.g. data
from the extended message frame configuration therefore, cannot be written by the PLC
user program.

Constraints
The following restrictions are applicable with regard to the "expanded message frame
configuration" function:
● Additional data can only be transferred from the drive to the SINUMERIK 840Di sl NC
(actual value channel). You cannot transfer data in the other direction, i.e. from the NC to
the DP slave drive (setpoint channel).
● You can only have read access to the drive data stored in the system variables.

Consistency check
When the SINUMERIK 840Di sl boots, the NC checks the consistency of the parameters
relevant to the process data configuration of the cyclic PROFIBUS communication:
● NC
– MD13060 $MN_DRIVE_TELEGRAM_TYPE[n] (drive message frame type)
● DP master (configuration)
– DP slave properties: Setpoint: Length
– DP slave properties: Actual value: Length
● Drive
– Message frame selection
– PDA setpoint assignment
– PDA actual value assignment
If the number of process data expected by the NC, parameterized via the message frame
type in NC machine data MD13060 $MN_DRIVE_TELEGRAM_TYPE[n] (drive message
frame type) is bigger than the number configured with STEP 7 HW Config for the DP slave
drive (DP slave properties: Setpoint: Length/DP slave properties: Actual value: Length) or if
the process data configuration for the drive parameters does not match the message frame
type for the NC machine data, then the following alarm is displayed:
● Alarm 26015 "Axis axis identifier machine data $MN_DRIVE_TELEGRAM_TYPE[index]
value not permissible".

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18.2 Expanded message frame configuration/evaluation of internal drive variables

No acyclic communication possible

If a drive does not support acyclic communication, of if the acyclic communication via the
following axis-specific NC machine data was switched off explicitly for a drive, a consistency
check of the above-mentioned data is the sole responsibility of the person who performs the
startup:
● MD13070 $MN_DRIVE_FUNCTION_MASK[n] (Used DP functions)

WARNING
For system purposes, the consistency check, which is performed when the SINUMERIK
840Disl boots and which is based on acyclic communication with the drive, is performed
in conjunction with the cyclical communication - which is already active - 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 part of the drive 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 and
hence, no consistency check by NC is possible:
• MD13070 $MN_DRIVE_FUNCTION_MASK[n] (Used DP functions)
Therefore, the responsibility lies with the commissioning engineer to implement suitable
measures to avoid uncontrolled traversing of the drives during startup, caused by
inconsistencies in the above mentioned data.
An error can present a risk of danger to person or machine.

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18.2 Expanded message frame configuration/evaluation of internal drive variables

18.2.7 Data descriptions (MD, system variable)

General machine data

13070 DRIVE_FUNCTION_MASK
MD number Bit-coded screen for selecting the functional scope expected by the NC with PROFIBUS
drives
Default setting: 0 Min. input limit: 0 Max. input limit: FFFF FFFF
Changes effective after POWER ON Protection level: 2/7 unit: -
Data type: DWORD Valid as of software version: 2.1
Meaning: Description of the set bits:
Bit 0: Deactivation of the 611U-specific drive alarm generation
Bit 1: Deactivation of the 611U-specific drive type detection.
Bit 2: Deactivation of the 611U-specific parameter access encoder drivers
Bit 3: Deactivation of the 611U-specific parameter access output drivers.
Bit 4: Activation of external drive: DSC bits (STW1.12/STA1.12)
Bit 5: Deactivation of 611U-specific drive parking (STW2.7/STA2.7)
Bit 6: Deactivation of the 611U-specific travel to fixed stop (STW2.8/STA2.8)
Bit 7: Deactivation of the 611U-specific internal motor switchover (STA2.9 to 11)
Bit 8: Deactivation of the 611U-specific ramp block (STW1.13)
Bit 9: Deactivation of the 611U-specific function generator functions (STW1.8/STA1.13)
Bit 14: Selection of non-cyclic DP communication: 0=DPT; 1=DPV1
Bit 15: Deactivation of consistency check of PROFIBUS message frame configuration
STW: Control word (PDA word in PROFIDrive message frame to DP slave)
STW: Control word (PDA word in PROFIDrive message frame from DP slave)
PDA: Process data
MD irrelevant for ... ---

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Axis-specific machine data

36730 DRIVE_SIGNAL_TRACKING
MD number Detection of additional drive actual values
Default setting: 0 Min. input limit: 0 Max. input limit: 4
Changes effective after POWER ON Protection level: 2/7 unit: -
Data type: BYTE Valid as of software version: 2.1
Meaning: 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.
Encoding:
0: No additional drive actual values
1: The following drive actual values are transferred and stored in the system variables:
actual value, system variable
Utilization, $AA_LOAD
Torque setpoint value, $AA_TORQUE
Power, $AA_POWER
Current actual value, t$AA_CURR
2: The total PROFIDrive message frame is stored in a system variable:
actual value, system variable
PROFIDrive message frame, $VA_DP_ACT_TEL
MD irrelevant for ... ---

System variables

Name $VA_DP_ACT_TEL[n, a]
Description 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
Access Part program Synchronized action OPI
Read Read Read
Attributes Implicit preprocessing stop Cross-channel
Read yes

18.2.8 Interrupts
Detailed information on the individual alarms can be found in:
References:
/DA/ Diagnostics Manual
For systems with HMI Advanced you can refer to the online help.

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18.3 Travel to fixed stop with high-resolution torque reduction

18.3 Travel to fixed stop with high-resolution torque reduction

The full description of functions for "Travel to fixed stop" can be found in:
References:
/FB1/ Function Manual, Basic Functions; Section "F1 Travel to Fixed Stop"

18.3.1 Description of functions

As part of the NC function "Travel to fixed stop", you specify the reduction of the drive torque
effective in the drive (terminal torque) via the part program instruction FXST. The torque
reduction value specified via FXST is transferred cyclically to the drive in the PROFIBUS
message frame as "MomRed" process data.
The effective drive torque Msetpoint is calculated from:

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● Mmax:
Maximum possible drive torque from rated motor torque and parameter P1230 torque
limit value.
● MomRed:
Control word in cyclic PROFIBUS message frame:
16384D = 4000H ≙ 1, i.e. at MomRed = 16384, the drive moment is reduced by the
amount of the drive parameter.

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Figure 18-6 Drive torque for the evaluation (drive parameter AP) and torque reduction (MomRed)
(Not true to scale)

The evaluation of the torque reduction must be identical in the drive and in the NC. The
settings range for torque reduction is defined by the limit values (0.005% to 10%) for the NC
machine data:
● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL

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18.3 Travel to fixed stop with high-resolution torque reduction

18.3.2 Comparison

Automatic adjustment
To simplify the torque reduction commissioning, the SINUMERIK 840Di sl NC tries to
perform, by default, an automatic adjustment using the torque reduction evaluation
configured in the drive. To do this the NC reads the relevant drive parameters and applies
the value converted to NC format in the machine data:
● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL
The following requirements must be met:
● The drive supports acyclic PROFIBUS communication.
● The drive has a parameter to standardize torque reduction.
● In the NC, acyclic communication with the drive is enabled with:
– MD13070 $MN_DRIVE_FUNCTION_MASK[n], Bit 15 == 1

Manual comparison
If the requirements for automatic adjustment of the NC and drive are not met, the adjustment
must be performed manually in the drive and NC.

18.3.3 Parameter assignment: SINAMICS S120

Message frame
The drive must be operated with one of the following message frames:
● Message frame 102, 103, 105, 106 ,116

Drive parameters
The evaluation of torque reduction is set using the parameter:
● p1544 Torque reduction evaluation [%]
Normalization: 1% ≙ 16384D = 4000H

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18.3 Travel to fixed stop with high-resolution torque reduction

18.3.4 Parameter assignment: SIMODRIVE

The following SIMODRIVE drives support high-resolution torque reduction:
● SIMODRIVE 611 universal, universal E
● SIMODRIVE POSMO SI, CD, CA

Message frame
The drive must be operated with one of the following message frames:
● Message frame 102 to 107

Drive parameters
The evaluation of torque reduction is set using the parameter:
● P0881 Torque reduction evaluation [%]
Normalization: 1% ≙ 16384D = 4000H

18.3.5 Parameter assignment: External drives

If third-party drives are used, please read the manufacturer's documentation to see whether
and how to set the parameters on the drive.

18.3.6 Parameter assignment: SINUMERIK 840Di sl NC

In the SINUMERIK 840Di sl NC system, the parameters for evaluating torque reduction are
assigned via the axis-specific machine data:
● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL

Automatic adjustment
During automatic adjustment, the NC attempts to read the drive parameters in the following
system states:
● SINUMERIK 840Di sl boot
● State: "Incoming station" of the DP slave drive
If the value set for the drive does not match the parameter assigned in the NC evaluation,
the value defined by the drive is applied to the NC machine data. The resulting
renormalization of the machine axis in question is shown by the following message:
● Alarm 26024 "Axis axis identifier machine data
$MA_PROFIBUS_TORQUE_RED_RESOL value adapted".
If the value of the drive parameter converted into NC format lies outside the machine data
limit values, the value set in the machine data is retained. No message is displayed.

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18.3 Travel to fixed stop with high-resolution torque reduction

Note
You can disable automatic adjustment via:
• MD13070 $MN_DRIVE_FUNCTION_MASK[n], Bit 15 = 0

Manual parameterization
If any of the aforementioned requirements for automatic adjustment is not met, the NC
machine data and drive parameters must be adjusted manually.
● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL = drive parameter: "Torque
reduction evaluation"

Example for SIMODRIVE 611U

Assumptions:
● Machine axis X1 corresponds to drive 12A
● The torque reduction evaluation is to be 0.1%
Assigning parameters for the DP slave 611U/Drive 12A
SimoCom U commissioning tool: Menu command Commission > Other parameters > Expert
List > Number > 881
Torque reduction: P0881 = 1638.40 (≙ 0.1%)
The parameter is immediately effective.
Parameterization of SINUMERIK 840Di sl NC
Machine axis X1:
● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL == 0.1

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 607
840Di-specific data and functions
18.3 Travel to fixed stop with high-resolution torque reduction

18.3.7 Constraints
No message is displayed in the following cases:
● If any of the requirements are not met, no automatic adjustment can be performed for the
SINUMERIK 840Di sl NC.
● The parameter assigned in the drive for the torque reduction evaluation lies outside of the
NC machine data limit values.
● The torque reduction is not renormalized for the NC.
Irrespective of whether or not a message is displayed, the NC machine data is effective in all
cases:
● MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL

NOTICE
It is the system startup engineer's responsibility to ensure that the parameter settings
are consistent in the SINUMERIK 840Di sl NC and all relevant drives for which torque
reduction is being performed.
The following data must be consistent in terms of values and meaning:
1. SINUMERIK 840Di sl NC machine data
MD37620 $MA_PROFIBUS_TORQUE_RED_RESOL
2. Drive
– Automatic adjustment:
The parameter for evaluating the torque reduction:
SINAMICS: p1544
SIMODRIVE: P0881
– Manual comparison:
Drive parameter corresponding to the parameter for the evaluation of the torque
reduction.

Manual
608 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 840Di-specific data and functions
18.3 Travel to fixed stop with high-resolution torque reduction

18.3.8 Data description (MD)

General machine data

13070 DRIVE_FUNCTION_MASK
MD number Bit-coded screen for selecting the functional scope expected by the NC with PROFIBUS
drives
Default setting: 0 Min. input limit: 0 Max. input limit: FFFF FFFF
Changes effective after POWER ON Protection level: 2/7 unit: -
Data type: DWORD Valid as of software version: 2.1
Meaning: Description of the set bits:
Bit 0: Deactivation of the 611U-specific drive alarm generation
Bit 1: Deactivation of the 611U-specific drive type detection.
Bit 2: Deactivation of the 611U-specific parameter access encoder drivers
Bit 3: Deactivation of the 611U-specific parameter access output drivers.
Bit 4: Activation of external drive: DSC bits (STW1.12/STA1.12)
Bit 5: Deactivation of 611U-specific drive parking (STW2.7/STA2.7)
Bit 6: Deactivation of the 611U-specific travel to fixed stop (STW2.8/STA2.8)
Bit 7: Deactivation of the 611U-specific internal motor switchover (STA2.9 to 11)
Bit 8: Deactivation of the 611U-specific ramp block (STW1.13)
Bit 9: Deactivation of the 611U-specific function generator functions (STW1.8/STA1.13)
Bit 14: Selection of non-cyclic DP communication: 0=DPT; 1=DPV1
Bit 15: Deactivation of consistency check of PROFIBUS message frame configuration
STW: Control word (PDA word in PROFIDrive message frame to DP slave)
STW: Control word (PDA word in PROFIDrive message frame from DP slave)
PDA: Process data

Axis-specific machine data

37620 PROFIBUS_TORQUE_RED_RESOL
MD number Torque reduction resolution on PROFIBUS (LSB weighting)
Default setting: 1 Min. input limit: 0.005 Max. input limit: 10
Change valid after NEWCONF Protection level: 2/7 unit: %
Data type: DOUBLE Valid as of software version: 2.2
Meaning: The default value 1% refers to the original weighting: The torque limit value is transferred to
the PROFIBUS in increments of 1%; the value 100 in the corresponding PROFIBUS data
cell signifies full torque reduction (i.e. without power).
By changing the MD to e.g. 0.005%, the raster conversion of the value in 0.005% can be
specified, i.e. the torque limit value is rasterized by the factor 200.
For restriction to the rated torque, the value 0 is transferred in this case, a full torque
reduction (i.e. without power) denotes the transferred value 10000.
To avoid wrong adaptation, the adjusted value of the machine data must be configured
according to the drive, or the permanently defined interpretation of the torque reduction
value must be selected.

Manual
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840Di-specific data and functions
18.3 Travel to fixed stop with high-resolution torque reduction

18.3.9 Interrupts
Detailed information on the individual alarms can be found in:
References:
/DA/ Diagnostics Manual
For systems with HMI Advanced you can refer to the online help.

Manual
610 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Appendix A
A.1 Abbreviations

ADI4 (Analog drive interface for 4 axes)

ALM Active Line Module
ARM Rotating induction motor
DE Automation system
ASCII American Standard Code for Information Interchange: American coding standard for the
exchange of information
ASUB Asynchronous subroutine
BA Mode
Mode group Mode group
Command output disable Command output disable
BB Ready
BCD Binary Coded Decimals: Decimals with each digit coded in binary
BERO Proximity limit switch
HHU Handheld unit
BI Binector Input
BICO Binector Connector
BO Binector output
CF card Compact Flash Card
CI Connector Input
CNC Computerized Numerical Control: Computerized numerical control
CO Connector Output
CoL Certificate of License
COM Communication
CP Communication Processor
CPU Central Processing Unit: Central processing unit
CU Control Unit
DAU Digital-to-Analog Converter
DB Data block
DBB Data block byte (currently 8 bits)
DBX Data-block bit
DHCP Dynamic Host Configuration Protocol: Protocol for automatic assignment of IP addresses
from a DHCP server to a client computer
DO Drive Object

Manual
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Appendix
A.1 Abbreviations

DPR Dual-Port RAM

DRAM Dynamic memory (non-buffered)
DRF Differential Resolver Function: Differential function for handwheel signaling
DRIVE-CLiQ Drive Component Link with IQ
DRY Dry Run: Dry run feedrate
DSC Dynamic Servo Control
DSR Data Send Ready: Signals that data is ready to be sent from the serial data interfaces
DW Data word
DWORD Double Word (currently 32 bits)
SIOM Compact I/O module (PLC I/O module)
ESD Electrostatic Sensitive Devices
EMC Electromagnetic Compatibility
EN European Standard
EPROM Program memory with fixed program
EQN Designation for an absolute encoder with 2048 sine signals per revolution
ETC ETC key ">"; Softkey bar extension in the same menu
FC Function call, function block on the PLC
FEPROM Flash-EPROM: Read and write memory
FIFO First In First Out: Memory that works without address specification and whose data are
read in the same order in which they were stored.
FIPO Fine interpolator
CRC Cutter radius compensation
FST Feed Stop: Feed stop
GC Global control
GEO Geometry
GND Signal ground (electric reference point)
BP Basic program
GSD Device master file
GUD Global User Data
HASH Is a software procedure for mapping a large quantity of identifiers onto a finite memory
area
HEX Abbreviation for hexadecimal number
HMI Human Machine Interface: Mensch-Maschine-Schnittstelle
MSD Main Spindle Drive
HW Hardware
HW limit switch Hardware limit switches
HW Config SIMATIC S7 tool for configuring and parameterizing S7 hardware within an S7 project
IBN Commissioning
INC Increment: Increment
INI Initialization data (Initializing data)
INTV Internal multiplication
IPO Interpolator
ISO code Special punched tape code, number of holes per character always even
JOG JOG mode: manual mode for setting up the machine

Manual
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 Appendix
A.1 Abbreviations

K1 Channel 1
KUE Gear ratio
KV Servo gain factor
LAN Local Area Network
LED Light-Emitting Diode: Light emitting diode
PMS1 Position measuring system 1
PMS2 Position measuring system 2
LSB Least significant bit
LUD Local User Data
MAC Media Access Control
MCI Motion Control Interface
MCIS Motion Control Information System
MCP Machine Control Panel
MD Machine data
MDA Manual Data Automatic: NC mode for entering and processing individual part program
blocks or block sequences
MELDW Message word
MCS Machine coordinate system
MLFB Machine Readable Product Designation: Order Number
MM Motor Module
MMC Man-Machine Communication
MPF Main Program File: NC part program (main program)
MPI Multi-Point Interface Multi-point serial interface
MCP Machine control panel
NC Numerical Control: Numerical control
NCK Numerical Control Kernel: NC kernel with block preparation, traversing range, etc.
NCU Numerical Control Unit: NC module
IS Interface signal
ZO Zero Offset
NX Numerical eXtension (axis extension module)
OB Organization block: Block type of PLC basic or user program
OLP Optical Link Plug: Fiber-optic bus connector
POI Process output image
PII PII Process input image
PCMCIA Personal Computer Memory Card International Association (plug-in memory card
standardization)
PCU PC Unit
PG Programming device
PKE Parameter identification: Part of a PIV
PIV Parameter identification: Value: Parameterizing part of a PPO
PLC Programmable Logic Control: Adaptation control
PNO PROFIBUS User Organization
PO Power On
POSMO A Positioning Motor Actuator: positioning motor

Manual
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Appendix
A.1 Abbreviations

POSMO CA Positioning Motor Compact AC: Complete drive unit with integrated power and control
module as well as positioning unit and program memory; AC infeed.
POSMO CD Positioning Motor Compact DC: Like CA but with DC infeed
POSMO SI Positioning Motor Servo Integrated: Positioning motor, DC infeed
PPO Parameter process data object
Cyclic data message frame when transferring data with PROFIBUS DP and the "variable-
speed drives" profile
PROFIBUS Process Field Bus: Serieller Datenbus
PRT Program test
PSW Program control word
PUD Global Program User Data
PZD Process Data: Process data part of a PPO
RAM Program memory which can be read and written into
REF Reference point
RES Reset
ROV Rapid override: Rapid traverse override
RPA R-Parameter Active: Identifier for R parameters
RTCP Real Time Control Protocol
RTS Request To Send: RTS, control signal of serial data interfaces
SBC Safe brake activation
SBL Single Block: Single Block
SD Setting Data
SEA Setting Data Active: Identifier for setting data
SH Safe standstill
SIM Single Inline Module
SK Softkey
SKP SKiP: Skip block
SLM Synchronous Linear Motor
SMC Cabinet-mounted sensor module
SME Sensor Module Externally Mounted
SPF Sub Routine File: Subprogram
SRAM Static RAM (non-volatile)
SRM Synchronous Rotary Motor
LEC Leadscrew error compensation
SSI Synchronous serial interface (interface type)
STW Control word
SW Software
SW limit switch Software limit switches
TCPIP Transport Control Protocol - Internet Protocol
TCU Thin Client Unit
TEA Testing Data Active: Identifier for machine data
TO Tool Offset Tool offset
TOA Tool Offset Active: Identifier for tool offsets
TTL Transistor-Transistor Logic (interface type)

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 Appendix
A.1 Abbreviations

USB Universal Serial Bus

V24 Serial interface
VDE Association of Electrical Engineering, Electronics and Information Technology (Germany)
VDI VDI interface: Data interface between NC and PLC
VI Voltage input
VO Voltage output
FDD Feed drive
WCS Tool coordinate system
T Tool
TRC Tool Radius Compensation
WZ Tool
TO Tool offset
TC Tool change
ZOA Zero Offset Active: Identifier for zero offsets
ZSW Status word (of drive)
μC Micro Controller

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 615
Appendix
A.2 Feedback on the documentation

A.2 Feedback on the documentation

This document will be continuously improved with regard to its quality and ease of use.
Please help us with this task by sending your comments and suggestions for improvement
via e-mail or fax to:

E-mail: mailto:[email protected]

Fax: +49 9131 - 98 63315

Please use the fax form on the back of this page.

Manual
616 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
 Appendix
A.2 Feedback on the documentation

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Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 617
Appendix
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Manual
618 Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0
Glossary

Active Line Module

Controlled, self-commutating feed/feedback unit (with -"IGBT"s in feed/feedback direction),
which supplies the DC link voltage for the -> "Motor module".

Antriebsobjekt
A drive object is an autonomous, individual software function with its own -> "Parameters"
and may also have its own -> "Fault"s and -> "Alarm"s. Drive objects may exist by default
(e.g. On Board I/O) can be created individually (e.g. –> "Terminal Board" 30, TB30) or also
as multiples (e.g. –> "Servo Control"). As a rule, each drive object has its own window for
parameterization and diagnostic purposes.

Basic infeed
Overall functionality of an infeed with –> "Basic Line Module" including the required
additional components (filters, switching devices, etc.).

Basic line module

Unregulated line infeed unit (diode bridge or thyristor bridge, without feedback) for rectifying
the line voltage of the -> ”intermediate circuit".

Compact Flash Card

Memory card for non-volatile storage of the drive software and corresponding –>
"Parameters". The memory card can be plugged into the –> "Control Unit" from outside.

Control Unit
Central control module in which the control and monitoring functions for one or several ->
SINAMICS -> Line modules, and/or -> Motor modules are implemented.
There are three types of control units:
● SINAMICS Control Units, e.g. -> "CU320"
● SIMOTION Control Units, e.g. -> "D425" and -> "D435"
● SINUMERIK solution line control units, e.g. NCU710, NCU720 and NCU730

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 619
Glossary

Control word
Bit-coded -"Process data" word, transmitted by -> "PROFIdrive" at cyclic intervals to control
the drive states.

Double motor module

Two motors can be connected to and operated with a Double Motor Module. See -> "Motor
module" - "Single motor module". Former name: –> "Double-axis module"

Drive
The term "drive" comprises the following components: motor (electric or hydraulic), final
controlling element (converter, valve), control unit, measuring system, and supply
components (line infeed, pressure accumulator). For electric drives, a distinction is made
between a converter system and an inverter system. With a converter system (e.g. ->
"MICROMASTER 4"), from the point of view of the user the line infeed, actuator, and control
component form a single device; with an inventor system (e.g. -> "SINAMICS S"), the supply
is ensured by means of -> "Line Module", thereby realizing a DC line to which the ->
"Invertors" (-> "Motor Module"s) are connected. The (–> "Control unit") is implemented as a
separate device and connected to the other components by means of –> "DRIVE-CLiQ".

Drive component
Hardware component connected to a -> "Control unit" via -> "DRIVE-CLiQ" or in some other
way. Drive components include: -> "Motor Module"s, -> "Line Module"s, -> "Motor"s, -
> "Sensor Module"s and -> "Terminal Module"s. The overall layout of a Control Unit together
with the connected drive components is called -> "Drive unit".

Drive group
A drive group comprises a -> "Control Unit" and the -> "Motor Module"s and -> "Line
Module"s connected via -> "DRIVE CLiQ".

Drive parameters
Parameters of a drive axis that include, for example, the parameters of the corresponding
controllers, as well as the motor and encoder data. The parameters of the higher-level
technology functions (positioning, ramp-function generator), however, are called ->
"Application Parameters". See -> "Basic Unit System".

Drive system
The drive system includes all the components in a product family belonging to a drive, e.g.
SINAMICS. A drive system comprises, for example, -> "Line Module"s, -> "Motor Module"s, -
> "Sensors", -> "Motors", -> "Terminal Module"s and -> "Sensor Module"s as well as
additional components such as throttles, filters, cables etc.. See -> "Drive unit"

Manual
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 Glossary

Drive unit
The drive unit includes all the components connected via –> "DRIVE-CLiQ" that are required
for carrying out a drive task: -> "Motor module" -> "Control unit" -> "Line module", and the
required -> "Firmware" and -> "Motor"s, but not additional components (such as filters or
reactors). Several -> "Drive"s can be implemented in a drive unit. See -> "Drive system"

DRIVE-CLiQ
Abbreviation for "Drive Component Link with IQ".
Communication system for connecting the various components of a SINAMICS drive system,
such as e.g. -> Control unit, -> "Line modules", -> "Motor modules", -> "Motors", and
speed/position encoders.
The DRIVE-CLiQ hardware is based on the Industrial Ethernet standard and uses twisted-
pair lines. The DRIVE-CLiQ line provides the transmit and receive signals, as well as the +24
V power supply.

Encoder
Records and makes positions available for electronic processing. Depending on the
mechanical construction, encoders can be integrated in the –> "Motor" (–> "Motor Sensor")
or mounted on the external mechanics (– "External Sensor"). Depending on the type of
movement, a distinction is made between rotary sensors ("rotary transducers") and
translatory sensors (e.g. - Linear Sensors). In terms of measured value provision, a
distinction is made between -> "Absolute encoders" (code sensors) and -> "Incremental
encoders". See -> "Incremental encoder TTL/HTL" -> "Incremental encoder sin/cos 1Vpp" ->
"Resolver".

External encoder
Position encoder that is not built in or mounted on the -> motor, but is attached outside to the
working machine or via a mechanical intermediate element. The external encoder (see ->
"Attachment encoder") is used for -> "direct position detection".

Infeed
Input component of a converter system for generating a DC link voltage to supply one or
more -> "Motor module"s, including all the required components (e.g. -> "Line module"s,
fuses, reactors, line filters, and firmware, as well as proportional computing power (if
required) in a -> "Control unit".

Line Module
A line module is a power component that generates the DC link voltage for one or more -
"motor modules" from a three-phase mains voltage. The following three line module types
are used for SINAMICS: -> Basic line module, -> Smart line module and -> Active line
module.
The overall function of an infeed, including the required additional components such as ->
Line reactor, proportional computing power in a -> control unit, switching devices, etc. is
called -> Basic infeed, -> Smart infeed, and -> Active infeed.

Manual
Commissioning Manual, 05/2008, 6FC5397–4CP10–4BA0 621
Glossary

Motor
For the electric motors that can be driven by –> "SINAMICS", a basic distinction is made
between rotary and linear motors with regard to their direction of motion, and between
synchronous and induction motors with regard to their electromagnetic operating principle.
For SINAMICS, the motors are connected to a -> motor module. See -> "Synchronous
motor" -> "Asynchronous motor" -> "Built-in motor" -> "Motor encoder" -> "External encoder"

Motor encoder
An -> "Encoder", e.g. -> "Resolver", -> "Incremental encoder TTL/HTL" or -> "Incremental
encoder sin/cos 1 Vpp"), which is integrated in or attached to the motor. The encoder detects
the motor speed and, in the case of synchronous motors, also the rotor position angle (of the
commutation angle for the motor currents). For drives without an additional -> "direct position
measuring system", it is also used as a -> "position encoder" for position control. In addition
to the motor encoders, -> there are "external encoders" for -> "direct position sensing".

Motor Module
A motor module is a power unit (DC-AC inverter) that provides the power supply for the
motor(s) connected to it. Power is supplied through the -> "DC link" of the -> "Drive unit". A
motor module must be connected via a -> DRIVE-CLiQ to a control unit in which the control
and regulation functions of the motor module are stored. There are -> "Single motor
modules" and -> "Double motor modules".

Option slot
Slot for an optional module (e.g. in the –> "Control Unit").

Parameter
Variable used on the drive system that the user can read and, in some cases, write. In ->
SINAMICS, all specifications defined in the -> "PROFIdrive" profile are fulfilled by a
parameter. See -> "Visualization parameters" -> "Adjustable parameters"

PROFIBUS
Field bus standardized in accordance with IEC 61158, Sections 2 to 6. The suffix "DP" is no
longer included because PROFIBUS FMS is not standardized and PROFIBUS PA (for
process automation) is now part of the "general" - PROFIBUS.

Sensor Module
Hardware module for evaluating speed/position encoder signals and providing detected
actual values as numerical values at a -> "DRIVE-CLiQ socket". There are three mechanical
variants of sensor modules:
SMCxx = Sensor Module Cabinet-Mounted = Sensor module for the snap on installation in
the cabinet
SME = Sensor Module Externally Mounted = Sensor module with higher protection type for
installation outside the control cabinet

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 Glossary

Servo control
For -> Motors equipped with a -> "Motor encoder", this control type allows operation with a
high level of -> "Accuracy" and -> "Dynamic response". In addition to speed control, position
control can be implemented.

Servo drive
An electric servo drive comprises a motor, a –> "Motor module", a –> "Servo control" and, in
most cases, a speed and position –> "Sensor". Electric servo drives are normally extremely
precise and have a high dynamic response. They are designed for cycle times to less than
100 ms, and often have a short-time overload capacity, which enables quick acceleration.
Servo drives are available as rotary and linear drives Servo drives are e.g. used in the
machine tools, robotics and packaging machines sectors.

SITOP power
Component for the -> Electronic power supply. Example: 24 V DC

Smart line modules

Unregulated line infeed/feedback unit with a diode bridge for the infeed and stall-protected,
line-commutated feedback via -> "IGBTs". The smart line module supplies the DC link
voltage for the -> "Motor modules".

Status Word
Bit-coded -> "Process data" word, transmitted by -> "PROFIdrive" at cyclic intervals to
control the drive states.

Vektorregelung
Vector control (field-oriented control) is a high-performance control method for induction
machines. It is based on an exact model calculation of the motor and two current
components that simulate and accurately control the flux and torque by means of software
algorithms, thereby enabling predefined speeds and torques to be observed and limited
accurately and with a good dynamic response. Two types of vector control exist: The
frequency control (-> "Sensorless vector control") and the speed-torque control with speed
feedback (-> "Encoder").

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Glossary

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Index
BICO interconnection
Control Unit, 325
８ Drive, 330
Infeed, 326, 327, 328, 329
840Di sl Rack, 164, 236
Blue screen, 25
840Di startup
BUS 1, 488
PROFIBUS diagnosis, 249
BUS 2, 488

Ａ Ｃ
Absolute encoders, 402
Cable distributor
Absolute measuring systems
Connector assignments, 67
Parameter assignment, 399
Cable outlet, 48
Actual value acquisition, 246
Checklist
ADI4, 45, 286
Preparing for commissioning, 121
See also: ADI4 DP slave, 286
Circularity test, 507
ADI4 DP slave
Color depth
Paste, 286
Setting, 23
Alarm and message texts, 493
Switching over, 23
MBDDE.INI configuration file, 493
Commissioning
Standard text files, 494
611U, 346
User text files, 494
First, PLC, 157
Alarm numbers, 497
MCP, 270
Alarm text files
MCP 310, 253
Syntax, 497
MCP 483C IE, 191, 201, 222
Alarm texts, 493
NC with HMI Advanced, 355
Assembly
Communications processor (CP)
MCI board extension internal, 56
Parameterization of, 170, 172
MCI board for 840Di sl, 47
Comparison, 247
Automatic controller setting, 538
Compile cycle
Axes, 385
SW version, 481
Axis
Compile cycles, 478
Monitoring, 423
Constraints, 481
Parameter sets, 411
Reloading, 479
Reference point approach, 431
Configuration
Velocity matching, 421
load (PLC -> STEP 7), 185
Axis configuration, 385
Load (STEP 7 -> PLC), 179
Axis names, 388
Configuration
Loading into the PLC, 249
Consistency check, 248
Ｂ
CP
Backup battery, 488 Parameterization of, 170, 172
Basic commissioning of PLC, 126 CPU time share, 376
BATF, 488 Creating
BATL, 488 Drive project SINAMICS manual, 310

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Index

Current control loop Dynamic monitoring functions

Measurement, 513 Velocity monitoring, 428
Current version, 141 Dynamic Servo Control, 405
Cycle times, 375
Cyclic operation
PLC, 182 Ｅ
EMC measures, 119
Equidistant DP cycle, 244
Ｄ
Setting, 165
Data backup, 541 Equidistant master cycl. Proportion, 243
PLC data, 547 ESD measures, 120
Times, 541 ET 200, 45
Various components, 541 Ethernet, 170, 172
Data Exchange Time, 233 Communication data, 188
Detailed view, 163 Communications link, 188
Diagnostics Connections PCU 50.3, 187
NC, 486 Ethernet communication, 187
PLC, 486 Evaluation of internal drive variables, 589
PROFIBUS, 249 EXCHANGE
Differential handwheels, 62 LED: PP72/48, 99
DP cycle, 245 Expanded message frame configuration, 288, 298, 589
Setting, 165 Export version, 36
DP cycle time, 233 External power supply
DP slave 611U PP72/48, 93
Consistency, 288, 293, 298, 302
Inserting into an S7 project, 287, 297
Parameterization of, 288, 298 Ｆ
PROFIBUS DP Communication, 303
Factory settings, 560
PROFIBUS parameters, 288, 298
Failure safety, 25
Set the message frame type, 299
Fatal exception error, 25
Setting the I/O addresses, 292, 301
System information, 138
Setting the PROFIBUS address, 288, 298
FC 26
DP slave PP72/48
HPU_MCP, 208
Paste, 250
Final parameterization
PROFIBUS parameters, 251
DP slaves gen., 242
Setting the I/O addresses, 252
First commissioning
DP slave S120
611U, 346
PROFIBUS DP Communication, 294
recommended sequence, 122
Drift compensation, 420
FORCE, 488
Drive commissioning (requirements), 307, 345
Frequency response measurements, 512
Drive configuration, 389
FXST, 604
Drive Optimization, 407
Drive Optimization with HMI Advanced, 507
Drive variables
Ｇ
Evaluation, internal, 589
Drives GC, 233
Analog, 20 General information, 17
Digital, 20 Ghost Explorer, 136
General information, 20 Global control message frame, 233
SIMODRIVE, 45, 46 Graphic display
DSC, 405 Drive Optimization, 522
Dx, 233 Grounding

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 Index

PP72/48, 101 Basic software, 31

GSD file Engineering tools, 31
General information, 237 SIMATIC S7-AddOn-Software(SIMATICS7 add-on
I/O module PP72/48, 33 software), 33
Interface description
MCI board, 48
Ｈ MCI board extension, 60
PP72/48, 92
Handwheel connection
Interface overview
Cable distributor, 460
ADI4, 60
Ethernet, 464
MCI board, 48
PROFIBUS, 461
Interface signal
Handwheels, 460
PC OS fault, 25
Handwheels
PC shutdown, 25
Differential, 62
Interface version, 479
TTL, 63
Interface versions
Hard disk image, 136
dependencies, 480
Hardware Components, 43
Interfaces
MCI board extension slot variation, 43
MPI interface, 192, 202, 255, 272
Operator panel fronts, 44
IP address
Spare parts, 43
MCP 483C IE, 194
HMI Advanced
PROFIBUS diagnosis, 249
Series machine startup, 545
Ｌ
HMI Analyzer, 136
HMI configuring package, 22 LAN, 145
HMI Explorer, 136, 140 Language-specific nature of alarm texts, 495
HMI modular system, 22 LED
HT 8 Status code: PP72/48, 99
Thin Client, 80 License management, 146
HW Config, 163 Limit switches, 503
Loadable compile cycles, 478

Ｉ
Ｍ
I/O
Assignment to hardware, 469 Machine data
Digital/analog, 467 Changing scaling, 370
I/O modules, 20 Display filter, 363
Max. number of inputs/outputs, 468 Loading of default data, 371
System variable, 470 Normalization of physical quantities, 367
I/O Module PP72/48 Master application cycle, 233, 246
See also: DP slave PP72/48, 250 Master Time, 233
Identification of the control, 37 MCI board, 19
Incremental measuring systems Cable outlet, 48
Parameter assignment, 396 MCI board extension
Indexing axes, 410 Internal, 56
Initial settings, 485 Slot variation, 43
Input time, 233 MCI board extension internal, 20
installation, 124, 141 MCI2 board for 840Di sl, 47
MCI board extension slot variation, 58 MCP 310
Installation directory, 141 See also: DP slave MCP 310, 253
installed components MCP 483, 253

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Index

MD13070, 605 General information, 21

MD34210, 402 Operator panel fronts, 44
MD37620, 604, 605, 606, 607, 608 Optional HMI components, 22
Measurement of speed control loop, 514 Order Number
Measuring functions, 507, 508 SITOP POWER ACCUMODULE 24 V DC/10 A/3.2
Cancel, 509 AH, 45
starting, 509 SITOP POWER DC UPS module 15, 45
Measuring inputs, 63 SITOP POWER standard 24V/10A, 45
Memory Order Number
DRAM, 382 3.5" disk drive, USB, 45
SRAM, 383 Handheld Terminal HT 2, 44
Memory configuration, 381 Handheld Terminal HT 8, with handwheel, 44
Message frame configuration Handheld Terminal HT 8, without handwheel, 44
Extended, 589 Hard disk (spare part), 43
Message texts, 493 MCI board extension slot variation, 44
Module replacement MCI2 board (spare-part), 43
MCI board, 50 OP 010, 44
Monitor/control OP 010C, 44
Using HMI Advanced, 183 OP 010S, 44
Using the SIMATIC Manager STEP7, 182 OP 012, 44
MPI OP 012T, 44
Interface, 20 OP 015, 44
Interface signal, 587 SINUMERIK 840Di sl, 43
Parameterization of, 167, 169 TCU, 44
Setting, 350 TP 012, 44
TP 015A, 44
Order Number
Ｎ MCI board extension, 57
Order Number
Name of computer, 553, 556
PCU 50, 71
NC
Output time, 233
Default data, 487
Overview, 17
Reset, 487
OVTEMP
NC general reset, 487
LED: PP72/48, 99
NC status, 486
NC system clock cycle
Setting, 165
Ｐ
NC system software, 21
NCK P0881, 606
General information, 21 p1544, 605
Network connection, 145 Packages
Networking rules, 234 System Software, 18
Parameter assignment
MCP, 255, 272
Ｏ MCP 483C IE, 192, 202
Partition image, 136
OEM configuration, 138
PC OS fault
OEM directories, 138
Interface signal, 587
Online connection
PC shutdown
611U, 347
Interface signal, 587
Online operation
PCU, 19
Starting, 353
Interfaces, 19
Operator panel front, 75
Slots, 19

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 Index

PCU 50.3 Power-up

Ethernet connections, 187 After PCU/MCI board replacement, 132
PDA area, 231 Power-up
Pin assignments After importing a backup copy, 132
Cable distributor, 68 Power-up
PIV area, 231 After power failure, 133
PLC PP72/48
Basic program installation, 151 Setting the PROFIBUS address, 251
Default data, 488 PP72/48 I/O module, 45
Delete program, 488 Preparing for commissioning, 121
Memory reset, 488 PRESETON, 438
Performance Data, 149 PROFIBUS address
Program, 150 Setting using an operator unit, 348
RUN, 488 Setting using the PROFIBUS unit, 349
RUN-P, 487 SIMODRIVE POSMO SI/CD/CA, 349
STOP, 488 PROFIBUS communication
PLC commissioning, 149 Parameterization of, 165
PLC operating state, 489 PROFIBUS DP, 484
PLC program, 150 General, 229
Load, 177 Interface, 19
load (PLC -> STEP 7), 185 PROFIBUS DP Communication, 229
Load (STEP 7 -> PLC), 179 PROFIBUS S7 subnet ID,, 351
PLC system errors, 488 determining, 352
PLC system software, 22 Proper shutdown, 29
PLC Toolbox, 33 Protection levels, 360
PLC user program, 153 Protool/Pro, 22
Position control loop
Measurement, 518
Reference frequency response, 519 Ｑ
Setpoint step change, 520
Quantity framework, 18
Step height, 521
Position controller, 413
Position controller cycle
Ｒ
Setting, 165
Positioning accuracy of the control system, 374 READY
Positioning axes, 409 LED: PP72/48, 99
POWER Real-time properties, 23
LED: PP72/48, 99 Real-time property, 489
Power down, 26 Realtime response, 489
Power supply Real-time violations, 489
PP72/48, 100 Real-time violations, 23
Power-On and Power-Up, 121 Reference point approach, 431
Power-up, 127 Requirements
first-time, 124 Commissioning, PLC, 155
Power-up Resolutions, 365
after battery replacement, 129 Restoring, 560
Power-up RI suppression measures, 119
After replacement of the MCI board, 129 Rotary axes
Power-up Drive Optimization, 407
After reinstallation/update, 131 Routing information
Power-up Setting, 351
After PCU replacement, 131 Rules for routing cables

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Index

EMC/ESD, 119 Commissioning, 307

RUN, 488 Configuration: Motors and encoders, 318
Configuring PROFIBUS message frames, 324
Control Unit: BICO interconnection, 325
Ｓ Control Unit: PROFIBUS message frame, 321
Drive: BICO interconnection, 330
S1
Entering component topology automatically, 316
Handwheel type, MCI board Ext., 57
Firmware upgrade, 342
MCP 483C IE, 194
Infeed: BICO interconnection, 326, 327, 328, 329
PROFIBUS address, PP72/48, 95
Infeed: PROFIBUS message frame, 321
S2
Running the motor, 331
MCP 483C IE, 195
Saving parameters, 331
safe operation, 6
Specific parameters, 332
Sample PLC application, 33, 126
SINAMICS drives, 287
Screen resolution
SINAMICS S120, 287, 605
Setting, 23
See also: DP slave S120, 287
Switching over, 23
SinuCom NC, 32, 34, 188
Series machine startup, 541
General information, 22
611U, 346
Series machine startup, 546
Selecting archive content, 543
SINUMERIK Desktop, 135
Series startup archive
Activate, 135, 136
Creation using HMI Advanced, 548
Setting the power-up response., 138
Series startup file
SlaveOM, 236, 287, 297
Creating, 180
Softbus
ServiceCenter, 136, 142
Interface signal, 587
840Di sl-specific, 143, 144
Software components
Activate, 142
Overview, 31
Servo trace, 507
Software version
Setpoint transfer, 247
MCP, 256, 272
Setting data
MCP 483C IE, 193
Normalization of physical quantities, 367
Spare parts, 43
Setting the axis-specific setpoint parameters, 393
Speed control loop
Setting the axis-specific setpoint/actual value
Interference frequency response, 516
parameters, 393
Reference frequency response, 516
settings, 490
Setpoint/disturbance step changes, 517
Settings System Network, 136
Speed setpoint matching, 417
SF, 488
Spindle
Shielded signal cables, 119
Basic Data, 441
Shutdown behavior, 491
Gear stages, 444
Signal distortion, 428
Measuring systems, 445
SIMATIC ET 200, 45
Monitoring, 453
SIMATIC Manager STEP 7, 235
Parameter sets, 411
SIMATIC S7 I/O devices, 249
Positioning, 450
SIMATIC S7 project, 160, 239
Setpoint/actual value channels, 444
SIMODRIVE drives, 297
Synchronization, 451
SIMODRIVE 611 universal, 297, 346, 595, 606
Spindle data, 456
SIMODRIVE 611 universal E, 297, 595, 606
Spindles, 385
SIMODRIVE 611u
SRAM
See also: DP slave 611u, 297, 595, 606
Physical, 29
SIMODRIVE POSMO CD/CA, 297, 595, 606
SRAM handling, 127
SIMODRIVE POSMO SI, 297, 595
Standard version, 36
SINAMICS
STARTER
Check configuration, 322

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 Index

ONLINE commissioning, 313 Requirements, 501

Startup, 38 Spindle, 505
General information, 22 Testing the PLC program, 181
Menu command: Windows, 39 Text file for cycle alarm texts, 497
Startup characteristics Text file for PLC alarm texts, 498
PLC, 181 Thin Client
Startup image, HMI HT 8, 80
User-specific, 139 TI, 233, 246
Status displays, 488 TM, 233
STOP, 488 TMAPC, 233, 246
PLC, 488 TO, 233, 247
Storing the text files, 493 Torque reduction, 605
SUB-D Torque reduction
Socket, 48 high-resolution, 604
SW version, 481 Touchware, 136
Switch off Trace function
PCU, 27 Creating subdirectories, 534
Switching over the measuring system, 372 Display function, 531
System components, 18 Drive Optimization, 525
System data, 365 Main screen, 526
System data blocks Measuring parameters, 527
Create, 248 Operation, 526
System integrity, 24 Parameter assignment, 527
System Software, 18 Performing the measurement, 530
System software packages, 18 Printer selection, 535
Signal selection, 527
Traversing ranges, 374
Ｔ TTL handwheels, 63
TCU
Commissioning, 78
Ｕ
Configuration, 78
General information, 21 Update, 141
TDP, 233, 244, 245 UPS system, 29
TDX, 233
Technical data
MCI board extension, 63 Ｖ
PP72/48, 103
Velocities, 379
Technology functions
Version display, 141
Activate, 482
Voltage failure, 26
Licensing, 482
Temperature
CPU, 27
Ｗ
CPU module, 27
Temperature WAN, 145
Enclosure, 27 Windows NT:
Temperature sensor, 27 General information, 21
Terminator Windows XP, 21
MCP 483, 253, 270 WinPE, 136
Test run Workgroup, 553, 556
Axis, 504
Axis and spindle, 501
Drive enable, 502

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Index

Ｘ I/O MPG extension, MCI board Ext., 60

X2
X1
PROFIBUS DP, PP72/48, 94
Ext. power supply, PP72/48, 93
X222
X101, 160, 165, 307
dig. inputs/outputs, PP72/48, 95
PROFIBUS DP, MCI board, 49
X3
X102, 160, 167, 169
Battery connection, MCI board, 50
MPI/DP interface, MCI board, 49
X333
X111
dig. inputs/outputs, PP72/48, 95
dig. inputs/outputs, PP72/48, 95
X121

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