siemens 840Disl User Manual

SINUMERIK 840Di sl

Manual

Commissioning Manual

Valid for

SINUMERIK 840Di sl/840DiE sl control

Software	Version
System software for 840Di sl/DiE sl	1.4

05/2008

6FC5397–4CP10–4BA0

Foreword

	General Information on the
		1
	SINUMERIK 840Di sl
	Hardware Descriptions	2
	Configuration	3
	EMC and ESD Measures	4
	Power-On and Power-Up	5
	PLC commissioning	6
	Ethernet communication	7
	PROFIBUS DP
		8
	Communication
	Drive commissioning
		9
	(SINAMICS)
	Drive commissioning
		10
	(SIMODRIVE)
	NC Commissioning with HMI
		11
	Advanced
	Alarm and message texts	12
	Axis and Spindle Test Run	13
	Drive Optimization with HMI
		14
	Advanced
	User data backup/Series
		15
	commissioning
	Software installation/update
		16
	and data backup
	License management	17
	840Di-specific data and
		18
	functions
	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	[phone]
Fax	[phone]
Internet	http://www.siemens.com/automation/support-request
	America
Phone	[phone]
Fax	[phone]
Email	mailto:[e-mail]
	Asia/Pacific
Phone	[phone]
Fax	[phone]
Email	mailto:[e-mail]

Note

Country-specific telephone numbers for technical support are provided under the following Internet address:

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

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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	[phone]
Email	mailto:[e-mail]

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 linkbar 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. Nonobservance 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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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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General Information on the SINUMERIK 840Di sl

1

1.1Overview 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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1.1.1System 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.

1.1.2System 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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1.1.3Hardware 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 ControlInterface).

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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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 MPIcommunication 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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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.

1.1.4Software 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 realtime 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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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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1.1.5Real-time properties

Windows XP is not an operating system designed for hard real-time requirements. Hard realtime 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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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 > "SINUMERIKNC"

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.

1.1.6System 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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1.1.7Failure 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 MCIBoards" (Page 129).

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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.

1.1.8Switch 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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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 MCIBoards" (Page 129).

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1.1.9UPS 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
1) UPS -> PCU:	Windows XP
USB connection

2) Signal terminals via free	PLC
interconnection -> S7 I/O
inputs
3) Signal terminals via free	NC
interconnection -> MCI
board extension inputs

Note:

For 3)

Comment

The UPS functionality is configured: see Configuration 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)

The UPS functionality is configured using the PLC user program.

Advantage: Also works in the event of a fatal exception error of Windows XP (BlueScreen)

Disadvantage: PLC user program must be active

The UPS functionality is configured using the menu: Settings in HMI Advanced (see Subsection "Menu: 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)

For information on the boot response of the SINUMERIK 840Di sl with pending shutdown signal see Subsection "Power-up with shutdown signal" (Page 133).

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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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Figure 1-2 Possible connections: USV

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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