siemens 840D User Manual

SINUMERIK 840D/810D SIMODRIVE 611 digital

Start-Up Guide

Valid for
Control	Version
SINUMERIK 840D/810D powerline		6
SINUMERIK 840DE/810DE powerline
	(export variant)	6
Drive	Version
SIMODRIVE 611 digital		5

03/2006 Edition

General preparation

Structure

Settings, MPI/BTSS

EMC/ESD measures

Power-On and Power-Up

Programming the control

PLC description

Alarm and message texts

Axis/spindle test run

Drive optimization

Data back-up

Replacing software and hardware

HMI

Miscellaneous

Abbreviations

Index

1

2

3

4

5

6

7

8

9

10

11

12

13

14

A

3ls	SINUMERIK→ documentation

Key to editions

The editions listed below have appeared before this edition.

The letters in the “Note” column indicate which status the previously published editions have.

Identification of the status in the “Notes” column:

A . . . . . New documentation.

B . . . . . Unchanged reprint with new order number.

C . . . . . Revised version with new edition number.

Edition	Order no.	Notes
03/2006	6FC5 297-6AB20-0BP0	A

Trademarks	→ are registered trademarks of Siemens AG. The other
All designations identified with the trademark note

designations in this publications may be trademarks, the use of which by third parties for their own purposes may infringe the rights of the owner.

Exclusion of liability

We have checked the content of the document to ensure that it conforms to the described hardware and software. Nevertheless, the possibility of differences cannot be totally excluded, so we are unable to guarantee that it conforms totally. However, the information in this document is checked regularly and necessary corrections are included in the subsequent editions.

Copyright E Siemens AG 2006

Order no: 6FC5297-6AB20-0BP0

Siemens AG 2006

Subject to technical modifications.

Preface

Structure of the documentation

Target group

Benefits

Standard scope

The SINUMERIK documentation is divided into three levels:

SGeneral documentation

SUser documentation

SManufacturer/service documentation

A monthly updated list of publications with the available language versions can be found on the Internet at:

http://www.siemens.com/motioncontrol

Follow the menu options “Support” → “Technical Documentation” → “List of Publications”.

The Internet edition of the DOConCD – the DOConWEB – can be found at: http://www.automation.siemens.com/doconweb

Information about training courses and FAQs (frequently-asked questions) can be found on the Internet at:

http://www.siemens.com/motioncontrol , select the “Support” option.

This documentation is intended for use by start-up engineers.

The Start-Up Guide will enable the intended target group to test the product/ system or plant and to bring it into service correctly and safely.

This Start-Up Guide describes the functionality of the standard scope. Additions or modifications made by the machine manufacturer will be documented by the machine manufacturer.

Other functions not explained in this document may also run on the control. However, no claims to these functions exist in the event of replacement and/or maintenance.

For the sake of clarity, this documentation does not contain all the detailed information about all types of the product, and also cannot take account of every possible situation for installation, operation and maintenance.

♥ Siemens AG 2006 All Rights Reserved	iii
SINUMERIK 840D/810D Start-Up Guide (IADC) – 03/2006 Edition

Preface

03/2006

Technical Support If you have any questions, please contact the following hotline:

Europe and Africa time zones:

A&D Technical Support

Tel.: +49 (0) 180 / 5050 – 222

Fax: +49 (0) 180 / 5050 – 223

Internet: http://www.siemens.com/automation/support-request

E-Mail: mailto:[e-mail]

Asia and Australia time zones:

A&D Technical Support

Tel.: [phone]

Fax: [phone]

Internet: http://www.siemens.com/automation/support-request

E-Mail: mailto:[e-mail]

America time zone:

A&D Technical Support

Tel.: [phone]

Fax: [phone]

Internet: http://www.siemens.com/automation/support-request

E-Mail: mailto:[e-mail]

Note

Questions about this Guide

Country-specific telephone numbers for technical advice can be found on the Internet:

http://www.siemens.com/automation/service&support

If you have any questions about the documentation (suggestions or corrections), please send a fax or e-mail to the following address:

Fax: [phone] / 98 – 63315

E-Mail: mailto:[e-mail]

Fax form: see Feedback sheet at the end of this document.

SINUMERIK	http://www.siemens.com/sinumerik
web site
EU Declaration of	The EU Declaration of Conformity about the EMC Directive can be found/
Conformity	obtained
	S on the Internet:
	http://www.ad.siemens.com/csinfo
	under product/order number 15257461
	S from the responsible branch of the A&D MC Division of Siemens AG
Object of the book	The publication illustrates the structure of the control system and the interfaces
	to the individual components. It also describes the procedure for starting up
	SINUMERIK 810D, and lists all the data, signals and PLC modules.

iv	♥ Siemens AG 2006 All Rights Reserved
	SINUMERIK 840D/810D Start-Up Guide (IADC) – 03/2006 Edition

03/2006

Preface

User-oriented activities such as the creation of part programs and control operation procedures are described in detail in separate documents.

Separate descriptions are likewise provided for the tasks to be performed by the tool manufacturer such as configuring, installation and PLC programming.

Safety instructions This manual contains instructions that you must follow to ensure your own personal safety and to avoid damage to property. The instructions that concern your personal safety are indicated by a warning triangle. Instructions that concern only damage to property have no warning triangle. The warnings labels are illustrated in descending order according to the level of risk.

Danger

!means that death or severe injury will occur if the specified precautionary measures are not taken.

Warning

!means that death or severe injury may occur if the specified precautionary measures are not taken.

Caution

!with warning triangle means that slight injury may occur if the specified precautionary measures are not taken.

Caution

without a warning triangle means that damage to property may occur if the specified precautionary measures are not taken.

Notice

means that an unwanted result or state may occur if the specified instructions are not followed.

If several levels of risk apply, the warning instructions always indicate the highest level. If a warning of personal injury is given in a warning notice with the warning triangle, there may also be a warning about damage to property in the same warning notice.

♥ Siemens AG 2006 All Rights Reserved	v
SINUMERIK 840D/810D Start-Up Guide (IADC) – 03/2006 Edition

Preface

03/2006

Qualified	The associated device/system must only be set up and operated in conjunction
personnel	with this documentation. A device/system must only be brought into service and
	operated by qualified personnel. Qualified personnel as specified in the safety
	instructions in this documentation are people who are authorized to bring into
	service, earth and identify devices, systems and power circuits in accordance
	with the recognized safety standards.
Use as prescribed	Please note the following points:

Warning

!The device must only be used for the purposes described in the catalog and in the technical description, and then only in conjunction with non-Siemens devices and components that are recommended or approved by Siemens. Correct and safe operation of the product requires it to have been transported, stored, installed and assembled correctly and carefully operated and maintained.

Further notes

Note

The “Note” symbol is displayed in this document to draw your attention to information relevant to the subject.

Technical information

Notations	The following notations and abbreviations are used in this documentation:
	S PLC interface signals –> NST “signal name” (signal data)
	Examples:
	– IS “MMC CPU1 ready” (DB10, DBX108.2), i.e. the signal is stored in data
	block 10, data byte 108, bit 2.
	– IS “Feedrate override” (DB31, ... DBB0), i.e. the signals are stored in
	data blocks 31 to 38, data block byte 0.
	S Machine data –> MD: NUMMER, MD_NAME (German designation)
	S Setting data –> SD: NUMMER, SD_NAME (German designation)
	S The character “8” means “corresponds to”.
	J

vi	♥ Siemens AG 2006 All Rights Reserved
	SINUMERIK 840D/810D Start-Up Guide (IADC) – 03/2006 Edition

Contents

1	General preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1-13
	1.1	Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-13
	1.2	Standard/export variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-14
2	Structure	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-17
3	Settings, MPI/BTSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3-19
	3.1	MPI network rules for SINUMERIK 840D . . . . . . . . . . . . . . . . . . . . . . . .	3-19
	3.1.1	Communication equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-21
	3.2	MPI network rules for SINUMERIK 810D . . . . . . . . . . . . . . . . . . . . . . . .	3-24
	3.3	MPI default configuration for SINUMERIK 840D . . . . . . . . . . . . . . . . . .	3-26
	3.4	MPI default configuration for SINUMERIK 810D . . . . . . . . . . . . . . . . . .	3-28
	3.5	Deviation from standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . .	3-30
	3.6	MPI interface for customer’s operating panel . . . . . . . . . . . . . . . . . . . .	3-31
	3.7	2nd machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-32
	3.8	PCU 20/50/50.3/70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-33
	3.8.1	Settings with HMI Embedded/HMI Advanced for SINUMERIK 840D	3-33
	3.8.2	Settings with HMI Embedded/HMI Advanced for SINUMERIK 810D	3-34
4	EMC and ESD Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4-35
	4.1	RI suppression measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-35
	4.2	ESD measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-36
	4.3	Heat dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-36
5	Power-On and Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		5-37
	5.1	Start-up order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-37
	5.2	NCU controls and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-38
	5.3	CCU controls and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-39
	5.4	Power-On and Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-40
	5.4.1	Power-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-40
	5.4.2	Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-41
	5.4.3	PCU power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-44
	5.4.4	Error while Control power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-45
	5.4.5	Power-up of machine control panel (MSTT) . . . . . . . . . . . . . . . . . . . . .	5-46
	5.4.6	Powering up the drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-46
	5.4.7	PCU/HMI Advanced BIOS setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-47

♥ Siemens AG 2006 All Rights Reserved	vii
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Contents

03/2006

6	Programming the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		6-49
	6.1	Machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-49
	6.2	Handling machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-52
	6.3	Protection level concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-53
	6.3.1	Protection levels for NC language commands (REDEF) . . . . . . . . . . .	6-55
	6.3.2	Configurable parameter areas for GUD blocks . . . . . . . . . . . . . . . . . . .	6-57
	6.4	Display filter for machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-61
	6.4.1	Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-61
	6.4.2	Selecting and setting the display filter . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-61
	6.5	Example of a start-up concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-64
	6.6	System data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-67
	6.6.1	Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-67
	6.7	Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-71
	6.7.1	Dynamic RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-73
	6.7.2	Static RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-73
	6.8	Scaling machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-76
	6.9	Axes and spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-78
	6.9.1	Description of the axis configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-78
	6.9.2	Drive configuration (VSA, SLM, HSA) . . . . . . . . . . . . . . . . . . . . . . . . . .	6-82
	6.9.3	Programming axis-specific setpoint/actual values . . . . . . . . . . . . . . . .	6-85
	6.9.4	Setting drive parameters (FDD, MSD) . . . . . . . . . . . . . . . . . . . . . . . . . .	6-87
	6.9.5	Parameter settings for incremental measuring systems . . . . . . . . . . .	6-89
	6.9.6	Parameter settings for absolute measuring systems (EnDat interface)	6-92
	6.9.7	Overview of the drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-95
	6.9.8	Axis data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-99
	6.9.9	Axis velocity matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-102
	6.9.10	Axis position control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-103
	6.9.11	Monitoring for axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-108
	6.9.12	Referencing an axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-113
	6.9.13	Spindle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-115
	6.9.14	Spindle configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-117
	6.9.15	Spindle encoder matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-118
	6.9.16	Velocities and setpoint matching for spindles . . . . . . . . . . . . . . . . . . . .	6-120
	6.9.17	Spindle positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-122
	6.9.18	Spindle synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-123
	6.9.19	Spindle monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-125
	6.9.20	Example: Starting up NCK I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-127
	6.10	Linear motors (1FN1 and 1FN3 motors) . . . . . . . . . . . . . . . . . . . . . . . . .	6-129
	6.10.1	General information for starting up linear motors . . . . . . . . . . . . . . . . .	6-129
	6.10.2	Start-up: linear motor with a primary section . . . . . . . . . . . . . . . . . . . . .	6-131
	6.10.3	Start-up: linear motors with 2 identical primary sections . . . . . . . . . . .	6-141
	6.10.4	Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-143
	6.10.5	Temperature sensors for 1FN1 and 1FN3 motors . . . . . . . . . . . . . . . .	6-144
	6.10.6	Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-147
	6.10.7	Parallel connection of linear motors . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-150
	6.10.8	Test measurements on linear motors . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-152

viii	♥ Siemens AG 2006 All Rights Reserved
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Contents

	6.11	AM/U/F function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-154
	6.12	System settings for power-up, RESET and starting part programs . .	6-155
7	PLC Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		7-159
	7.1	PLC start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-159
	7.2	Overview of the organizational blocks, function blocks, DBs . . . . . . .	7-162
8	Alarm and message texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		8-163
	8.1	Alarm text files for HMI Embedded . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8-163
	8.2	Alarm text files for HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8-164
	8.3	Syntax for alarm text files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8-167
	8.3.1	Alarm list properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8-169
9	Axis/Spindle Dry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		9-171
	9.1	Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9-171
	9.2	Axis dry run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9-173
	9.3	Test of the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9-175
10	Drive Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		10-177
	10.1	Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-177
	10.2	Measuring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-179
	10.3	Interface signals: Drive test travel request and Travel enable . . . . . .	10-182
	10.4	Frequency response measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-183
	10.4.1	Scanning the torque control loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-183
	10.4.2	Scanning the speed control loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-184
	10.4.3	Scanning position control loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-188
	10.5	Measuring function for coupled axes . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-191
	10.5.1	Interconnected gantry axes only or master–slave couplings . . . . . . . .	10-191
	10.5.2	Mixed couplings of master/slave and gantry axes . . . . . . . . . . . . . . . .	10-193
	10.6	Graphical display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-194
	10.6.1	Associated conditions for gantry axes . . . . . . . . . . . . . . . . . . . . . . . . . .	10-195
	10.7	Trace function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-196
	10.7.1	Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-198
	10.7.2	Programming and activating measurements . . . . . . . . . . . . . . . . . . . . .	10-198
	10.7.3	Display function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-202
	10.7.4	Display bit graph for SI signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-205
	10.7.5	File functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-213
	10.7.6	Print graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-215
	10.8	Analog output (DAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-216
	10.9	Automatic controller settings ( HMI Advanced only) . . . . . . . . . . . . . . .	10-217
	10.9.1	Flowchart for self-optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10-219
	10.9.2	Input possibilities for self-optimization . . . . . . . . . . . . . . . . . . . . . . . . . .	10-223

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Contents

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11	Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		11-227
	11.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-227
	11.2	Data back-up via HMI Embedded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-229
	11.3	Data back-up via HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-229
	11.4	Data back-up via PG/PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-229
	11.5	Data back-up via machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-231
	11.5.1	Standard system start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-233
	11.6	Data back-up via V24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-236
	11.7	Data output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-239
	11.7.1	Outputting the drive data via V24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-239
	11.7.2	Outputting the NC data via V24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-240
	11.7.3	Outputting the PLC data via V24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-242
	11.7.4	Outputting the HMI data via V24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-243
	11.7.5	Outputting the standard system start-up file via V24 . . . . . . . . . . . . . .	11-244
	11.8	Backing up the hard disk with Norton GhostR . . . . . . . . . . . . . . . . . . . .	11-245
	11.8.1	Hard disk backup/restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-245
	11.8.2	Saving user data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-247
	11.8.3	Backing up the hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-247
	11.8.4	Copy data to hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-249
	11.9	Backing up the current image of the latest software . . . . . . . . . . . . . . .	11-251
	11.10	Installing a replacement hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-253
	11.11	Data back-up with VALITEK streamer with the PCU 50 . . . . . . . . . . .	11-255
	11.12	Line checksums and MD numbers in MD files . . . . . . . . . . . . . . . . . . .	11-260
	11.12.1	Line checksums (MD 11230 MD_FILE_STYLE) . . . . . . . . . . . . . . . . . .	11-260
	11.12.2	Machine data numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-261
	11.12.3	Response to canceling while reading in machine data . . . . . . . . . . . . .	11-261
	11.13	Machine/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-263
	11.14	Back up PLC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11-264
12	Replacing software and hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		12-265
	12.1	Software update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12-265
	12.1.1	Standard upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12-266
	12.2	Software upgrade for HMI Embedded . . . . . . . . . . . . . . . . . . . . . . . . . .	12-267
	12.3	Software upgrade for HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . .	12-267
	12.4	Standard system start-up via NC card . . . . . . . . . . . . . . . . . . . . . . . . . .	12-267
	12.4.1	DRAM for storing cycles and programs . . . . . . . . . . . . . . . . . . . . . . . . .	12-269
	12.4.2	SINUCOPY-FFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12-272
	12.4.3	Associated conditions for replacing software . . . . . . . . . . . . . . . . . . . . .	12-276
	12.5	Hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12-277
	12.6	Replacing batteries and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12-277

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Contents

13 HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-279

14 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-281

	14.1	Tool box software package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14-281
	14.1.1	Contents of the tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14-281
	14.1.2	Application of the Tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14-281
	14.2	Machine data access via part program . . . . . . . . . . . . . . . . . . . . . . . . . .	14-282
A	Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		A-285
B	Index . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	Index-291
			J

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Notes

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General preparation

1.1Preconditions

1

1

Introduction	This Installation and Start-Up Guide describes the procedure for starting up the
	basic control functions including drive-related functions. Further reference mate-
	rial on special NCK, HMI, PLC or drive functions can be found in the Function
	Descriptions/Manuals (see “Documentation required”).
Software required	You will need the following software for starting up the SINUMERIK 840D:
	1. SinuComNC start-up/service tools
	Supplied on CD-ROM with:
	–	SinuCom NC
	–	SinuCom FFS
	–	SinuCom ARC
	–	SinuCom PCIN
	– Start-up tool
	2. SIMATIC Step7
	3. Tool-Box for SINUMERIK powerline with:
	–	Basic PLC program
	–	NC variable selector
	–	Sample programs

Required devices and accessories

4.For HMI Embedded, application diskette or CompactFlash card for creating PLC alarm texts and transferring them to the PCU (supplied with the HMI system software).

You will need the following devices and accessories for starting up the SINUMERIK 840D:

1.PC/PG for SinuComNC start-up/service tools and SIMATIC Step7

2.MPI cable for PC/PG

3.V24 cable with 9-pin connector (socket)

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1 General Preparation

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1.2Standard/export variants

1	Documentation		You will need the following documentation for starting up the SINUMERIK 840D.
	required		A detailed description of the mechanical and electrical structure of the individual
			components can be found in:
			1.	/BU/ Catalog of automation systems for machine tools
			2.	/PHD/ Device Manual, NCU Configuration
				SINUMERIK 840D
			3.	/PHC/ Device Manual, CCU Configuration
				SINUMERIK 810D
			4.	/PJU/ Converter Configuration Manual
				SIMODRIVE 611 digital
			5.	/BH/ Device Manual, Operating Components
				SINUMERIK 840D/840Di/810D
			6.	/FB1/ Function Guide for Basic Machine
			7.	/FBA/ Function Guide for Drive Functions
			8.	/LIS1/ Lists
			9.	/PI/PCIN Description
			10.	/DA/ Diagnostic Instructions
			11.	/IAM/ HMI Start-up Guide
	1.2	Standard/export variants

Export permits required

2 variants of the SINUMERIK 840D/810D can be configured due to the requirement to obtain approval for certain control functions as listed in the German export list.

The standard variant (840D/810D) can contain the full range of functions of the control, but is therefore subject to the requirement to obtain approval.

With the export variant (840DE810DE), certain options are not available.

Current information about the type and scope of the options is contained in Reference material: /BU/ Catalog of automation systems for machine tools

(This shall not affect any requirement to obtain approval with respect to the intended usage which may also arise).

The specific version of the control is determined by the system software, which is thus available in two variants (standard and export). This means that the requirement to obtain approval for the system software (further information may be given on the delivery note or invoice) is ’inherited’ when it is installed on the control system. This point should be noted, particularly for conversions/ upgrades of the system software, since this may change the requirement to obtain export approval for the control.

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03/2006	1 General Preparation
1.2	Standard/export variants

Identification of the control

The hardware components supplied with system software are, in addition to any

information on the delivery note and invoice, clearly identified by as standard or 1 export variants by means of stickers.

Note

The additional stickers supplied in the packaging are intended to identify the control after start-up, and should be stuck into the control’s logbook. When licenses are ordered, a corresponding number of stickers is supplied. These should be used in the same way.

Once the control has powered up, the export variant can be identified by the additional letter ‘E’ on the Service screen (NCK information). It is important for Service to be able to identify the control variant in this way. It can also serve to provide the necessary verification for exports, particularly if existing negative certificates for the export variant are used.

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1.2Standard/export variants

1		Notes

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Structure

2 2

Reference material A detailed description of the mechanical and electrical structure can be found in the following documents:

S/PHD/ Device Manual, NCU Configuration SINUMERIK 840D

S/PHC/ Device Manual, CCU Configuration SINUMERIK 810D

S/PJU/ Converter Configuration Manual SIMODRIVE 611 digital

S/BH/ Device Manual, Operating Components SINUMERIK 840D/840Di/810D

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Notes

2

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Settings, MPI/BTSS

3

3

3.1MPI network rules for SINUMERIK 840D

The following basic rules should be followed when installing a network.

1.The bus line must be terminated at both ends. To do this, activate the terminating resistor in the MPI connector of the first and last node,and deactivate the remaining terminating resistors.

Note

SOnly two resistors are permissible.

SWith HHU, bus terminating resistors are hard-wired into the device.

2.There must be at least 1 termination at the supply voltage. This occurs automatically when the MPI connector with active terminating resistor is connected to a live device.

3.Spur lines (lead cables from the bus segment to the node) should be as short as possible.

Note

Any spur lines that are not assigned should be removed if possible.

4.Each MPI node must be connected before being activated. When an MPI node is disconnected, the connection must be deactivated before the connector can be pulled out.

5.One or two HHU may be connected per bus segment. No bus terminators may be connected to the distributor boxes of an HHU. If necessary, an intermediate repeater can be used to connect more than one HHU to a bus segment.

6.The following cable lengths for the standard MPI without repeater must not be exceeded:

MPI (187.5 kBaud): max. total cable length 1000 m

Note

Piggy-back connectors are not recommended for power connections.

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3 Settings, MPI/BTSS

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3.1MPI network rules for SINUMERIK 840D

Example A

3

Example B

HHU			on
			Terminating resistor
on			fitted in connector
Distributor		PCU	on
	MSTT
box			Terminating resistor
			hard-wired
	BTSS		on
			Control 840D
		MPI	on
		PG

Fig. 3-1 Network installation with two terminating resistors in

MPI: PG, control 840D

BTSS: HHU, control 840D

		on
		Terminating resistor
		fitted in connector
	OP030	PCU
		on
MSTT
		Terminating resistor
on
		hard-wired
		on
		BTSS
		Control 840D

Fig. 3-2 Network installation with two terminating resistors in BTSS:

MSTT, control 840D

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03/2006	3 Settings, MPI/BTSS
	3.1 MPI network rules for SINUMERIK 840D

3.1.1	Communication equipment
	The components involved in MPI and BTSS communication are PLC, NCK,
	COM and PCU/HMI. They allow communication between the active nodes.
	Communication between passive nodes, e.g. GD circuit communication, is not
	discussed here.
			3
	The aforementioned component perform the following tasks concerning MPI
	and BTSS communication:
	S	PLC and NCK
		PLC and NCK are both servers that provide communication links to client
		components and execute jobs via these client components upon request.
		The number of possible communication links from the server to the clients
		and the number of parallel function jobs (Read variables, Write variables,
		etc.) are limited.
	S	HMI
		An HMI component is a client that requests communication links from one or
		more servers and sends jobs to them.
	S	COM
		The COM component is a router that allows communication between va-
		rious component via different communication links (MPI, BTSS and Dual
		Port RAM).

HMI (client)

Machine control panel (passive GD circuit node)

1	6
	BTSS bus	(1.5 MBaud)
SIMATIC	HMI (client)
programming device

0

1

MPI bus (187 5 kBaud)

Default bus addresses

	SINUMERIK 840D
	COM (router)
X101		DPR
	Router
13
			NCK
		3	(server)
	PLC (server)
X122	2
	Router
		X102
	PROFIBUS DP (12 MBaud)

Fig. 3-3 Default application for SINUMERIK 840D

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3.1MPI network rules for SINUMERIK 840D

HMI communication: BTSS bus

3

HMI communication: MPI bus

Associated conditions for STEP 7

Logon IDs

Communication links

An HMI component logs on onto the NCK and PLC servers as a client via the COM module and is allocated communication resources by them as a result of logging on.

Jobs with a bus address/job ID for NCK are routed by the COM module directly to the NCK. Jobs with different bus addresses/job IDs are routed to the PLC. This response is implicit routing, and no special routing information is required in the COM module about other communication nodes on adjacent bus systems.

An HMI component logs onto the NCK server as a client indirectly via the COM module and directly at the server PLC is allocated communication resources by them as a result of logging on.

Jobs with a bus address/job ID for NCK are routed by the COM module directly to the NCK. Jobs with different bus addresses/job IDs are ignored by the COM module. This response is also implicit routing, and no special routing information is required in the COM module about other communication nodes on adjacent bus systems.

It is not possible to configure the entire communication setup illustrated in Fig. 3-3 in SIMATIC STEP7. Thus, STEP7 and any other engineering tools will

not provide all the possible communication links. In particular, the COM module that acts as the link between the MPI and BTSS buses cannot be configured.

When a connection is established, a client component logs onto the PLC with its logon ID. Typical logon IDs include programming device: “PG” and operator panel: “OP”. One communication link on the PLC is reserved for a component with the logon ID “PG” and one for the “OP” logon ID. For historical reasons, an HMI component with the logon ID: “PG” by default. For the “M to N” function, it logs on with the logon ID: “OP”.

The NCK, COM and PLC components allow the following maximum number of possible communication links:

Component		Number
NCK		5
COM
	from BTSS bus to NCK	3
	from BTSS bus to PLC	3
	from MPI bus to NCK	3
PLC 1)
	PLC 315-2DP (contained in: CCU3 and NCU*.3)	4
	PLC 314C-2DP (contained in NCU*.4)	12
	PLC 317-2DP (contained in NCU*.5)	32
	from MPI bus to PLC	2)

1) One communication link is reserved by default for connecting a programming device

(PG) e.g. for diagnostics with STEP7.

2) The number results from the maximum number of PLCs integrated into the NCU, minus the active PLC communication links on the BTSS bus.

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	3.1 MPI network rules for SINUMERIK 840D

Each client component requires the following communication links for communication with the NCK and PLC servers:

	Component		Number
	HMI Advanced or HMI Embedded
		To NCK	1
						3
		To PLC	1
	Shopmill/Shopturn on HMI Advanced or HMI Embedded
		To NCK 1)	+1
		To PLC 1)	+1
	STEP 7 on HMI
		To PLC 1)	+1
	1) In addition to the HMI communication link

Note

A Protool configuration does not need an additional communication link for

ProtoolPro with the “SINUMERIK” option.

Equipment	The following tables illustrate the communication equipment required for the
required	individual components: NCK, PLC and COM
Table 3-1	NCK equipment required
Resource unit			Machine data
Max. number of HMI resource units 1)		10	$MN_MM_NUM_MMC_UNITS

1) HMI Embedded and HMI Advanced require 2 resource units per communication link.

Table 3-2 PLC equipment required

PLC 314

PLC 315-2AF00

PLC 315-2AF01

PLC 315-2AF03

PLC 314C-2DP

							PLC 317-2DP
Communication links
max. possible number		4	4	4	4	12	32
Reserved for programming device		1	1	1	1	1	1
Available for HMI components		3	3	3	3	11	31
Table 3-3	COM equipment required
						PLC
							NCK
Links 1)
BTSS bus: max. possible number						3	3
MPI bus: max. possible number						1)	3

1) Note: The MPI links are not routed via the COM module. They go directly to the PLC.

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3 Settings, MPI/BTSS

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3.2MPI network rules for SINUMERIK 810D

3.2		MPI network rules for SINUMERIK 810D
		Please take the following basic rules into account when undertaking network
		installations:
3		1. The bus line must be terminated at both ends. To do this, activate the termi-
		nating resistor in the MPI connector of the first and last node, and deactivate

the remaining terminating resistors.

Note

SOnly two resistors are permissible.

SWith HHU, bus terminating resistors are hard-wired into the device.

2.It is necessary to apply 5 V voltage to at least 1 terminator. This occurs automatically when the MPI connector with active terminating resistor is connected to a live device.

3.Spur lines (lead cables from the bus segment to the node) should be as short as possible.

Note

Any spur lines that are not assigned should be removed if possible.

4.Each MPI node must be connected before being activated. When disconnecting an MPI node, the connection must be deactivated before the connector can be pulled out.

5.You can either connect one HHU and one HT6, or two HHUs or HT6s per bus segment. It is not permissible to connect bus terminators to the distributor boxes of an HHU or HT6.

If necessary, an intermediate repeater can be used to connect more than one HHU/HT6 to a bus segment.

6.The following cable lengths for the standard MPI without repeater must not be exceeded:

MPI (187.5 kBaud): max. total cable length 1000 m

Note

Piggy-back connectors are not recommended for power connections.

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	3.2 MPI network rules for SINUMERIK 810D

Example A

Example B

	HHU		on
			Terminating resistor
	on		fitted in connector
			PCU
	Distributor	MSTT	on
	box		Terminating resistor	3
			hard-wired in device
		MPI	on
			Control 810D

Fig. 3-4 Network installation with two terminating resistors in MPI:

BHG, control 810D

		on
		Terminating resistor
		fitted in connector
OP030	PCU	on
MSTT		Terminating resistor
on		hard-wired
MPI		on
		Control 810D

Fig. 3-5 Network installation with two terminating resistors in MPI:

MSTT, control 810D

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3.3MPI default configuration for SINUMERIK 840D

3.3MPI default configuration for SINUMERIK 840D

One or two machine control panels (interface for customer’s operating panels, PP 031) and/or HHU are connected by means of parameter settings in the PLC basic program (FB1). In this case, parameter settings using the STEP7 tool

3	“Communication Configuration” are no longer required.
	Reference material: /FB1/	P3 Pl, Function manual for basic machines,
		PLC basic program powerline
Standard	SINUMERIK 840D with one PCU and one machine control panel (MSTT) or
application	interface for customer’s operating panel on the BTSS.
Requirement for	At least firmware release V 03_01_01 for
the hardware	S MCP
	S interface for customer’s operating panel/PP 031
Bus addresses	Every node on the MPI/BTSS bus must have a bus address (0...31).

PCU
		Default bus addresses
	1		BTSS 1.5 MBaud
			6
		SINUMERIK 840D
	X101		MSTT/interface for
		13	customer’s operating panel
			NCK
		3
	0
PG/start-up	X122		PLC
tool		2
	MPI 187.5 kBaud

Fig. 3-6 Default application for SINUMERIK 840D

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03/2006	3 Settings, MPI/BTSS
	3.3 MPI default configuration for SINUMERIK 840D

Bus address and

GD circuit

Note

The parameter settings for the bus address (on the machine control panel) or the GD circuit parameters (on the HHU) in the PLC basic program are used for

the logical addressing of the components. The physical addressing on the 3 BTSS/MPI is always done via the GD circuits, however. Each machine control

panel, interface for customer’s operating panel, etc, must be addressed with a separate GD circuit.

In the control, the bus address in the associated GD circuit is converted via the PLC program.

On the machine control panel, the bus address, and thus the associated GD circuits, are set via the DIP-FIX switches.

On the MPI, the same GD circuits are set, however, for the machine control panel, interface for customer’s operating panel and PP031 components, even if the bus addresses are different. This should be noted if more than one machine control panel, etc, is used.

The following table illustrates the interaction.

Table 3-4	Interaction between bus address and GD circuit
Bus addresses on the MPI		GD circuit
	15, 14, 13	1
	12, 11	2
	10, 9	3
	8, 7	4
	6	8
	5, 4	5

Example:

2 machine control panels (MSTTs) are to be connected to the MPI on a control. The first MSTT can be connected to bus address 15 (GD circuit 1) and the second to bus address 12 (GD circuit 2).

MPI interface and

GD circuit

Note

If the “Communication Configuration” STEP7 tool is to be used to establish PLC-PLC cross-communication on the MPI, for example, and if one or more MSTTs are connected to the MPI, then the GD circuits assigned must be unique. The “Communication Configuration” STEP 7 tool assigns the GD circuits, starting with GD circuit 1 in ascending order. If the MSTTs are connected to the BTSS, then this has no effect on the PLC–PLC communication on the MPI.

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3 Settings, MPI/BTSS

03/2006

3.4MPI default configuration for SINUMERIK 810D

Example:

GD circuits 1 and 2 are assigned by “Communication Configuration” as a result of the PLC–PLC cross-communication. A first MSTT on the MPI can then be assigned to GD circuit 3 (bus address 9 or 10), and a second MSTT on the MPI to GD circuit 4 (bus address 7 or 8).

3

3.4MPI default configuration for SINUMERIK 810D

Standard	SINUMERIK 810D with PCU and one machine control panel (MSTT) or inter-
application	face for customer’s operating panel
Hardware	At least firmware release V 03_01_01 for
requirements	S MCP
	S interface for customer’s operating panel
STEP7	from version 2.x
MPI baud rate	All MPI bus nodes operate at 187.5 kbaud.
Bus addresses	Every node on the MPI bus must have a bus address (0...15).

PCU	PG/start-up tool
1	0		Bus addresses	MPI bus
				187.5 kbaud
				14
	SINUMERIK 810D
				MSTT/interface for
			PLC	customer’s operating panel
		2
	X122
		3	NCK

Fig. 3-7 Standard application for SINUMERIK 810D

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	SINUMERIK 840D/810D Start-Up Guide (IADC) – 03/2006 Edition

03/2006	3 Settings, MPI/BTSS
	3.4 MPI default configuration for SINUMERIK 810D

Communication parameters

Assigned inputs/ outputs in the PLC–CPU

Configuration via FB1

If the MSTT/interface for customer’s operating panel is set to MPI address 14 and with SDB210 from the basic program diskette, the communication starts when the PLC is restarted (LEDs stop flashing).

Note	3

The STEP7 project manager (S7 TOP) does not display the SDB as standard. To display the SDB, select “All blocks with SDBs” in menu View/Set filters.

The following bytes in the PLC CPU are then assigned to the MSTT or interface for customer’s operating panel:

SInput byte 0–7

SOutput byte 0–7

Communication does not start

SStatus bytes for error detection output bytes 12–15 (evaluated by basic program)

Parameterization on FB1 (basic program) for the MCP is already preset for the standard application.

If communication does not commence after a PLC reset (LEDs flashing), the following points should be checked:

SThe firmware release of the MSTT/interface for customer’s operating panel must be at least V03_01_01.

Scan:

The firmware version is displayed on the left, central and right LED block of the machine control panel if the keys “Feed start” and “Feed hold” are pressed simultaneously while the machine control panel is powering up.

SMPI cable and connector wiring

SDIP switch S3 (default setting)

SDB 210 must not be loaded.

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3.5Deviation from standard configuration

3.5Deviation from standard configuration

Required documentation

3

Example

Procedure

SIMATIC STEP7, version 2.1

The following additional publications are required:

Reference material: /BH/ Device Manual, Operating Components /FB/ P3, PLC basic program

/S7HT/ Manual, Application of Tools

A configuration may be non-standard owing to one of the following:

SChange of address assignment

for the input, output or status bytes, or for the flag area or data block

SAdditional connection of a handheld unit (HHU)

SConnection of a 2nd MSTT or handheld terminal (HT 6)

In such cases, you must adjust the communications parameters and possibly the switch settings (addresses) of the bus nodes.

A new configuration is entered via the Define global data soft key. The following description of how to proceed is based on the assumption that you already know how to use this menu.

1.Set up new project and CPU programs using the STEP7 tool. A separate CPU program should be set up for each component of the plant (PLC, MSTT, HHU, 2.MSTT, HT 6, ...).

2.Connect the MPI nodes, i.e. network CPU programs with MPI address.

3.Activate the “Global Data” menu command in the following soft key sequence File Manager/MPI Network/Extras/Global Data and enter the desired configuration.

4.Compile this configuration. A new SDB is generated for each CPU program.

5.Set the cyclical transmission grid. Once the configuration has been compiled successfully for the first time, the “Conversion factor” and “Status” can be activated and then input.

6.Now compile your configuration again.

7.Transfer the SDB (from the CPU program of the PLC) to the PLC.

8.You must parameterize call FB1, DB7 in OB 100 in the basic PLC program for all operator control components (MPI nodes).

9.You must configure the status pointer (double word) for every component in FB1 for monitoring purposes.

Note

For a description of the “Global data” menu and the application, see

Reference material: /S7HT/ SIMATIC Step7 Manual, Starting up MPI bus nodes

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