HBI 0603 en

Manual 06/2003 Edition
SINUMERIK 840Di
General 1
Hardware Descriptions 2
Design 3
EMC and ESD Measures 4
SINUMERIK 840Di MPI Communication 5
Turning On and Ramp Up 6

Manual PROFIBUS DP
Communication 7
PLC Start-Up 8
Drive Start-Up
(Preconditions) 9
NC Start-Up with
HMI Advanced 10
Alarm and Message Texts 11
Dry Run of Axis and

Spindle 12
Drive Optimization using

HMI Advanced 13
User Data Backup/

Valid for Series Machine Start-Up 14
Control Software version SW Installation/Update

SINUMERIK 840DiE/840Di 1.1 and Data Backup 15
SINUMERIK 840DiE/840Di 2.1
840Di-Specific Data and
Functions 16
Abbreviations A
References B
EC Declaration of
Conformity C
06.2003 Edition Index D

SINUMERIK Documentation
3ls
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the “Remarks” column.
Status code in the “Remarks” column:
A . . . . . New documentation.
B . . . . . Unrevised reprint with new order no.
C . . . . . Revised edition with new status.
If factual changes have been made on the page since the last edition,
this is indicated by a new edition coding in the header on that page.
Edition Order No. Remarks

07.00 6FC5 297-5AE60-0BP1 A
09.01 6FC5 297-6AE60-0BP0 C
09.02 6FC5 297-6AE60-0BP1 C
06.03 6FC5 297-6AE60-0BP2 C
This manual is included in the documentation available on CD-ROM (DOCONCD)

Edition Order No. Remarks
11.03 6FC5 298-6CA00-0BG4 C
Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr and SIMODRIVEr are Siemens
trademarks. The other designations in this publication may also be trade marks, the use of which by third
parties may constitute copyright violation.
Further information is available on the Internet under: Other functions not described in this documentation might be
http://www.ad.siemens.de/sinumerik executable in the control. This does not, however, represent an
obligation to supply such functions with a new control or when
servicing.
This publication was produced with Interleaf V7.
We have checked that the contents of this document correspond to
The reproduction, transmission or use of this document or its the hardware and software described. Nonetheless, differences might
contents is not permitted without express written authority. Offenders exist. The information contained in this document is, however,
will be liable for damages. All rights, including rights created by patent reviewed regularly and any necessary changes will be included in the
grant or registration of a utility model or design, are reserved. following edition. We welcome suggestions for improvement.
 Siemens AG, 2003. All rights reserved Subject to technical changes without prior notice
Order No. 6FC5 297-6AE60-0BP2 Siemens Aktiengesellschaft

Printed in Germany
06.03 SINUMERIK 840Di Manual
Preface
PREFACE
Notes for the The SINUMERIK documentation is divided into three levels:
Reader
S General documentation
S User Documentation
S Manufacturer/Service Documentation.
For more information about the SINUMERIK 840D/810D/FM-NC documentation
as well as documentation for all SINUMERIK controls, please contact your local
SIEMENS office.
Hotline If you have any questions about the control, please contact the hotline:
A&D Technical Support Phone: +49–180–5050–222

Fax: +49–180–5050–223
E-mail: adsupport@siemens.com
Please send any questions about the documentation (suggestions forimprove-

ment, corrections) to the following fax number:
Fax: +49 (9131) 98–2176
Fax form: see reply at the end of the manual
Internet address http://www.ad.siemens.de/sinumerik

SINUMERIK
SW version The SW versions stated in the documentation apply for the SINUMERIK 840Di
control.
Target readers S Configuring engineers,

S Electricians and start-up specialists
S Service and operating personnel.
Objective This manual provides detailed information on the specific hardware and start-
up/installation of a SINUMERIK 840Di system.
This manual provides information about the control system design and the
interfaces of the individual components. Furthermore, the procedure for starting
up the SINUMERIK 840Di with PROFIBUS DP drives (in particular SIMODRIVE
611 universal) is described.
For detailed information about individual functions, function assignment and
performance data of individual components, please refer to the appropriate
document for the subject concerned (e.g. manuals, function descriptions etc.).
User-oriented activities such as the creation of parts programs and control
operating procedures are described in detail in separate documentations
(Programming Guide, Operator’s Guide, etc.).
 Siemens AG, 2003. All rights reserved

SINUMERIK 840Di Manual (HBI) – 06.03 Edition v
SINUMERIK 840Di Manual 06.03
Preface
Separate descriptions are likewise provided of the tasks to be performed by the

tool manufacturer such as configuring, design and PLC programming.
Definition: For the purpose of this manual and product labels, a “qualified person” is one
Who are who is familiar with the installation, mounting, start–up and operation of the
qualified equipment and the hazards involved.
personnel? S Training and education i.e. authority to switch on and off, to earth and tolabel
circuits and devices according to safety technology standards.
S Training and education in maintenance and use of adequate safety equip-
ment according to safety technology standards.
S First aid training.

vi SINUMERIK 840Di Manual (HBI) – 06.03 Edition
Preface
Warning notes The following warning notes with graded degrees of importance are used in this
documentation: Explanation of symbols
Danger
! Indicates an imminently hazardous situation which, if not avoided will result in
death or serious injury or in substantial property damage.
Warning
! Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury or in substantial property damage.
Caution
! Used with the safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury or in propertyda-
mage.
Caution
Used without safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
Notice
Used without the safety alert symbol indicates a potential situation which, if not
avoided, may result in an undesirable result or state.
Further notes Explanation of symbols
Important
! Important indicates an important or especially relevant item of information.
Notice
Notice refers to an important item of information about the product, handling of
the product or part of the documentation which is particularly relevant in the
current context.
Machine manufacturer
This symbol appears in this documentation whenever the machine manufac-
turer can influence or modify the described functional behavior. Please ob-
serve the information provided by the machine manufacturer!

SINUMERIK 840Di Manual (HBI) – 06.03 Edition vii
Preface
Warnings and To safeguard your own personal safety as well as protect the product described
safety information and all connected equipment and machines against damage, please read and
observe the following warnings and safety information.
Warning
! Operational electrical equipment has parts and components which are athazar-
dous voltage levels.
Allowing unqualified persons access to the equipment/system or failure to

heed the safety information could result in serious physical injury or substantial
property damage. Only properly qualified personnel who have been trained to
erect, install, start up or operate the product should be allowed to work on
theequipment/system.
Should it be necessary to test or take measurements on live equipment, then

the specifications and procedures defined in Accident Prevention Regulation-
VBG 4.0 must be adhered to, in particular § 8 “Permissible deviations when
working on live components”. Suitable electric tools must be used.
Warning
! S Repairs to equipment supplied by Siemens must always be carried out by
SIEMENS after-sales service personnel or by repair centers authorized
by SIEMENS. Parts or components must always be replaced by parts or
components specified in the spare parts list.
S Always disconnect the power supply before you open the unit.
S EMERGENCY STOP devices in compliance with EN 60204 IEC 204 (VDE
0113) must remain operative in all operating modes of the automationde-
vice. Resetting the EMERGENCY STOP device must not result in any un-
controlled or undefined system restart.
S Wherever faults in the automation device have the potential to cause sub-
stantial material damage or even human injury, i.e. they can present adan-
ger, additional external precautions must be taken or devices provided
which will guarantee or enforce a safe operating state in the event of a fault
(e.g. through independent limit value switches, mech. interlocks, etc.).
Caution
! S Connecting and signal leads must be installed such that inductive and ca-
pacitive interference cannot impair automation functions.

viii SINUMERIK 840Di Manual (HBI) – 06.03 Edition
Preface
ESD instructions Components that can be destroyed by Electrostatic Sensitive

Devices
Important
! Handling of ESD modules:
S When you are handling ESD-sensitive devices, make sure that you, your
workplace and the device packaging are grounded well.
S As a general rule, electronic boards should only be touched when absolu-

tely necessary. Never hold PCBs in such a way that you touch the module
pins or printed conductors.
S Do not touch ESD-sensitive components unless

– you are grounded by means of an antistatic wristband,
– you wear antistatic footwear or ground straps when walking on an anti-
static floor.
S Place sensitive modules only on high-resistance, conductive surfaces (table

with antistatic surface, conductive antistatic foam or antistatic packaging).
S Do not bring ESD-sensitive modules into the vicinity of visual display units,
monitors or TV sets (minimum distance to the screen > 10 cm).
S Do not bring ESD-sensitive modules into contact with chargeable and

highly-insulating materials, such as plastic, insulating table tops or clothing
made of synthetic materials.
S Measurements on ESD-sensitive modules may only be carried out if

– the measuring equipment is grounded (e.g. via the protective conductor)
or
– in the case of floating measuring instruments, the probe is briefly dis-
charged before a measurement is taken (e.g. through contact with bare
control housing).
Proper use The unit may be used only for the applications described in the catalog, and
only in combination with the equipment and components recommended and
approved by SIEMENS (e.g. SINUMERIK 840D/FM-NC).

SINUMERIK 840Di Manual (HBI) – 06.03 Edition ix
Preface
Notes

x SINUMERIK 840Di Manual (HBI) – 06.03 Edition
Contents
1 General on the SINUMERIK 840Di . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

1.1 Overview of SINUMERIK 840Di . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.1.1 System software packages and options (SW 2.1 and higher) . . . . . . 1-20
1.1.2 Hardware components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.1.3 Software components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.1.4 Real-time properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.1.5 System integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.1.6 Failure safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.1.7 Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1.1.8 Uninterruptible power system (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.2 Overview of software components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.3 Notes on start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.4 Standard/export version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.5 840Di start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.5.1 Menu command: Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
2 Hardware Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.1 Overview of hardware components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.2 MCI board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.2.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.2.2 Interface description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.2.3 Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2.2.4 Module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.2.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
2.3 MCI board extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2.3.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2.3.2 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
2.3.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
2.4 MCI board extension slot variation (SW 11.00 and higher) . . . . . . . . . 2-62
2.4.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
2.4.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
2.5 MCI board extension external variation (SW 02.01 and higher) . . . . . 2-70
2.5.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
2.5.3 Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
2.5.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

SINUMERIK 840Di Manual (HBI) – 06.03 Edition xi
Contents
2.6 Cable distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

2.7 SINUMERIK Industrial PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
2.7.1 SINUMERIK PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
2.7.2 SINUMERIK PCU 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
2.8 SINUMERIK operator panel fronts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
2.8.1 Operator panel front OP 012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
2.9 Floppy disk drive 3.5’’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
2.10 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
2.10.1 SITOP POWER Standard 24V/10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
2.11 Uninterruptible power supply (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
2.11.1 SITOP POWER DC UPS module 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
2.11.2 SITOP POWER storage battery module 24VDC/10A/3.2AH . . . . . . . 2-92
2.12 I/O Module PP72/48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
2.12.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
2.12.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
2.12.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
2.12.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
2.13 ADI4 (analog drive interface for 4 axes) (SW 09.01 and higher) . . . . 2-105
2.13.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
2.13.3 Cabinet mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119
2.13.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119
2.13.5 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
2.13.6 Connection overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
2.13.8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124
3 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3.1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3.2 Electrical design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
3.2.1 MCI board and PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
3.2.2 MCI board and MPI bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.2.3 MCI board extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.2.4 PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
3.2.5 PCU 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
3.3 Connection overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
3.3.1 PCU 50, MCI board and MCI board extension . . . . . . . . . . . . . . . . . . . 3-131
4 EMC and ESD Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135
4.1 Interference suppression measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135
4.2 ESD measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
5 MPI Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5.2 Network rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137

xii SINUMERIK 840Di Manual (HBI) – 06.03 Edition
Contents
5.3 Default address assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139

5.4 Machine control panel (MCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
5.4.1 Prerequisites for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
5.4.2 Parameterization of the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
5.4.3 Parameterization of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
5.4.4 Example: Connecting an MCP to SINUMERIK 840Di . . . . . . . . . . . . . 5-146
5.5 MPI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
5.5.1 Parameterization of the MPI interface . . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
5.6 Handheld unit (HHU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
5.6.2 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-153
5.6.3 MPI parameterization of the HHU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-154
5.6.4 MPI parameterization of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
5.6.5 GD circle parameterization of the HHU . . . . . . . . . . . . . . . . . . . . . . . . . 5-157
5.6.6 GD circle parameterization of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . 5-158
5.6.7 Example: Connecting a HHU to SINUMERIK 840Di . . . . . . . . . . . . . . 5-159
5.7 Handheld terminal HT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-161
5.7.2 Parameterization of the HT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-163
5.7.3 Parameterization of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-164
5.7.4 Example: Connecting an HT 6 to SINUMERIK 840Di . . . . . . . . . . . . . 5-166
5.7.5 Connecting and disconnecting an HT 6 during running operation . . . 5-167
5.8 External operator panel (PCU with HMI Advanced) . . . . . . . . . . . . . . . 5-168
5.8.1 General settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-168
5.8.2 Language default setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-169
6 Turning On and Ramp Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-173
6.1 Preparing for ramp-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-173
6.1.1 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-173
6.1.2 Recommended order when commissioning . . . . . . . . . . . . . . . . . . . . . . 6-174
6.2 First ramp-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-175
6.2.1 Basic ramp-up of the system software (SW 2.2 and higher) . . . . . . . . 6-175
6.2.2 Basic start-up of the system software (SW 2.1 and lower) . . . . . . . . . 6-177
6.2.3 Basic start-up of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-179
6.2.4 Ramp-up of the machine control panel (MCP) . . . . . . . . . . . . . . . . . . . 6-180
6.2.5 Ramp-up of the SIMODRIVE 611 universal drives . . . . . . . . . . . . . . . . 6-180
6.3 Ramp-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-181
6.3.1 Boot manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-181
6.3.2 SRAM handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-181
6.3.3 Ramp-up after battery replacement (backup battery of the MCI board) 6-183
6.3.4 Ramp-up after replacement of the MCI board . . . . . . . . . . . . . . . . . . . . 6-183
6.3.5 Ramp-up after replacement of the PCU (new) or reinstallation/
update of the 840Di software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-185
6.3.6 Ramp-up after replacement of the PCU or the MCI board . . . . . . . . . 6-186
6.3.7 Ramp-up after importing a backup copy . . . . . . . . . . . . . . . . . . . . . . . . . 6-186
6.3.8 Ramp-up after power failure (Power Fail) . . . . . . . . . . . . . . . . . . . . . . . 6-186
6.3.9 Ramp-up with shutdown signal (SW 2.3 and higher) . . . . . . . . . . . . . . 6-187
6.4 SINUMERIK desktop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-188
6.4.1 Network operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-188

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6.4.2 Software installation/update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-189

6.4.3 Setting the SINUMERIK HMI environment . . . . . . . . . . . . . . . . . . . . . . 6-189
6.4.4 Authorizing SIMATIC STEP7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190
6.4.5 Serial mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190
6.4.6 Fault analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-191
6.4.7 OEM configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-191
6.4.8 Replacing the SINUMERIK background image . . . . . . . . . . . . . . . . . . . 6-192
6.4.9 Information and constraints concerning the basic software . . . . . . . . . 6-192
6.5 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-193
6.5.1 Install/Update SINUMERIK System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-194
6.5.2 SINUMERIK Tools and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-194
6.5.3 DOS Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-195
6.5.4 Start Windows NT (Service Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-195
6.5.5 SINUMERIK System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-196
6.5.6 Backup/Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-197
6.5.7 840Di services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-197
6.6 Configuring PTP link on an external computer (PG/PC) . . . . . . . . . . . 6-199
6.6.1 Ext. computer with Windows 9x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-199
6.7 Subsequent installation of Windows NT components . . . . . . . . . . . . . 6-201
6.8 License management (SW 2.1 and higher) . . . . . . . . . . . . . . . . . . . . . . 6-201
7 PROFIBUS DP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-203
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-203
7.1.1 Message frame structure for cyclic DP communication . . . . . . . . . . . . 7-204
7.1.2 Description of a DP cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-205
7.1.3 SINUMERIK 840Di with PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . 7-206
7.2 Network rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-210
7.3 SIMATIC S7 project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-211
7.3.1 Creating an S7 Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-211
7.3.2 HW Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-212
7.3.3 840Di Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-212
7.3.4 SIMATIC S7 I/O devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-216
7.3.5 I/O module PP72/48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-217
7.3.6 ADI4 (SW 2.1 and higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-220
7.3.7 SIMODRIVE drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-231
7.3.8 Final parameterization of the equidistant DP slaves . . . . . . . . . . . . . . . 7-238
7.3.9 Loading a configuration into the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-244
8 PLC Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-249
8.1 Start-up prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-249
8.1.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-249
8.2 PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-251
8.2.1 Performance data of the PLC315-2DP . . . . . . . . . . . . . . . . . . . . . . . . . . 8-251
8.2.2 Installing the basic PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-251
8.2.3 PLC user program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-253
8.3 Loading the PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-255
8.3.1 S7 project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-255
8.3.2 Series machine start-up file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-257
8.4 Testing the PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-258

xiv SINUMERIK 840Di Manual (HBI) – 06.03 Edition
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8.4.1 Start-up behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-258

8.4.2 Cyclic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-259
8.4.3 Monitor/control using the SIMATIC Manager STEP7 . . . . . . . . . . . . . . 8-260
8.4.4 Monitor/control using HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-261
9 Drive Start-Up (Preconditions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-263
9.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI . . . . . . . . . . . . 9-263
9.1.1 Start-up variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-263
9.1.2 Preconditions for an online connection . . . . . . . . . . . . . . . . . . . . . . . . . . 9-265
9.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal/E) . . . . . . 9-265
9.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA) . . . . 9-267
9.1.5 Setting the MPI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-268
9.1.6 Setting the routing information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-269
9.1.7 Starting online operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-270
9.2 Installing SimoCom U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-271
10 NC Start-Up with HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-273
10.1 General procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-273
10.2 Machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-273
10.2.1 Display and input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-275
10.2.2 Protection levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-276
10.2.3 Machine data display filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-279
10.3 System data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-281
10.3.1 Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-281
10.3.2 Normalization of phys. quantities of Machine and Setting data . . . . . 10-283
10.3.3 Changing scaling machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-285
10.3.4 Loading default machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-286
10.3.5 Switching over the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . 10-287
10.3.6 Traversing ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-289
10.3.7 Positioning accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-289
10.3.8 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-290
10.3.9 Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-294
10.4 Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-296
10.4.1 DRAM memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-297
10.4.2 SRAM memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-298
10.4.3 Virtual SRAM (SW 2.3 and higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-300
10.4.4 DRAM file system (SW 2.2 and higher) . . . . . . . . . . . . . . . . . . . . . . . . . 10-305
10.5 Axes and spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-308
10.5.1 Axis configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-308
10.5.2 Axis names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-311
10.5.3 Drive configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-313
10.5.4 Setpoint/actual value channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-315
10.5.5 Parameterization of incremental measuring systems . . . . . . . . . . . . . . 10-317
10.5.6 Parameterization of absolute measuring systems . . . . . . . . . . . . . . . . 10-320
10.5.7 Parameterization of a 2nd measuring systems with ADI4 . . . . . . . . . . 10-322
10.5.8 DSC (Dynamic Servo Control) (SW 2.1 and higher) . . . . . . . . . . . . . . 10-325
10.5.9 Drive Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-326
10.5.10 Rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-326
10.5.11 Positioning axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-328
10.5.12 Indexing axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-329
10.5.13 Parameter sets of axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-330

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10.5.14 Position controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332

10.5.15 Speed setpoint matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-336
10.5.16 Drift compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-339
10.5.17 Velocity adaptation of axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-340
10.5.18 Monitoring functions of axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-343
10.5.19 Referencing an axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-351
10.5.20 Spindle basic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-362
10.5.21 Setpoint/actual-value channels of spindle . . . . . . . . . . . . . . . . . . . . . . . 10-365
10.5.22 Gear stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-365
10.5.23 Measuring systems of spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
10.5.24 Speeds and setpoint adjustment for spindle . . . . . . . . . . . . . . . . . . . . . 10-368
10.5.25 Positioning the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-370
10.5.26 Synchronizing the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371
10.5.27 Monitoring functions of the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-373
10.5.28 Spindle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-376
10.6 Digital and analog I/O devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-379
10.6.1 Setting parameters for the number of inputs/outputs in use . . . . . . . . 10-379
10.6.2 Assignment of the inputs/outputs to the signal modules . . . . . . . . . . . 10-380
10.6.3 System variable $A_...[n] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-381
10.6.4 Digital I/O bytes and system variables . . . . . . . . . . . . . . . . . . . . . . . . . . 10-382
10.6.5 Time behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-383
10.6.6 Configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-384
10.7 Loadable compile cycles (SW 2.2 and higher) . . . . . . . . . . . . . . . . . . . 10-389
10.7.1 Loading compile cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-390
10.7.2 Boundary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-391
10.7.3 Activating and licensing the technological functions . . . . . . . . . . . . . . . 10-391
10.7.4 Data descriptions (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-392
10.8 PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-393
10.8.1 Setting the parameters for the shut-down behavior . . . . . . . . . . . . . . . 10-393
10.8.2 Data descriptions (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-393
10.9 Initial settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-394
10.10 NC/PLC diagnosis (840Di SW 2.3 and higher) . . . . . . . . . . . . . . . . . . . 10-395
10.10.1 Menu: Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-395
10.10.2 Menu: Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-399
11 Alarm and Message Texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-403
11.1 Alarm and message texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-403
11.1.1 Configuration file MBDDE.INI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-403
11.1.2 Standard text files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-404
11.1.3 User text files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-404
11.1.4 Syntax for alarm text files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-406
11.1.5 Setting the alarm log properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-408
12 Dry Run of Axis and Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-411
12.1 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-411
12.2 Dry run of axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-413
12.3 Dry run of spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-415
13 Drive Optimization using HMI Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-417
13.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-417

xvi SINUMERIK 840Di Manual (HBI) – 06.03 Edition
Contents
13.2 Measuring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-419

13.3 Additional functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-421
13.4 Frequency response measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-423
13.4.1 Measurement of the torque control loop . . . . . . . . . . . . . . . . . . . . . . . . . 13-423
13.4.2 Speed control loop measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-423
13.4.3 Position control loop measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-427
13.5 Graphic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-431
13.6 Trace function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-434
13.6.1 Trace function properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-434
13.6.2 Main menu and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-435
13.6.3 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-436
13.6.4 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-438
13.6.5 Display function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-439
13.7 File function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-442
13.8 Print graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-444
13.9 Automatic controller setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-447
14 User Data Backup/Series Machine Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-449
14.1 Explanations on data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-449
14.2 Creating a series machine start-up file using HMI Advanced . . . . . . . 14-451
14.3 Considerations when saving PLC data . . . . . . . . . . . . . . . . . . . . . . . . . . 14-453
14.4 Reading in a series machine start-up file with HMI Advanced . . . . . . 14-454
15 SW Installation/Update and Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-455
15.1 General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-455
15.1.1 PCU basic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-455
15.1.2 Partitioning of the hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-456
15.1.3 Boot manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-457
15.1.4 Setting/determining the network parameters of an external
computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-458
15.2 Software installation/update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-460
15.2.1 Software installation//updating SINUMERIK 840Di system software . 15-460
15.2.2 Parallel link and external FAT16 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-460
15.2.3 Parallel link and external FAT32 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-463
15.2.4 Network link (Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-466
15.3 Data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-471
15.3.1 Hard disk backup using a parallel link . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-471
15.3.2 Restoring the hard disk backup using parallel link . . . . . . . . . . . . . . . . 15-475
15.3.3 Saving the hard disk using a network link (Ethernet) . . . . . . . . . . . . . . 15-480
15.3.4 Restoring the hard disk backup using a network link (Ethernet) . . . . . 15-486
15.3.5 Display connected drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-492
15.3.6 Disconnecting connected drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-492
15.3.7 Saving partitions (local) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-493
15.3.8 Changing the number of partition backups . . . . . . . . . . . . . . . . . . . . . . . 15-495
15.3.9 Deleting partition backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-496
15.3.10 Restoring a partition backup (local) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-497

SINUMERIK 840Di Manual (HBI) – 06.03 Edition xvii
Contents
16 840Di Specific Data and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-499

16.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-499
16.1.1 840Di-specific interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-499
16.1.2 Interface signals not supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-499
16.2 Expanded message frame configuration (SW 2.2 and higher) . . . . . . 16-501
16.2.1 Description of Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-501
16.2.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-503
16.2.3 Configuring SIMODRIVE drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-504
16.2.5 Data descriptions (MD, system variable) . . . . . . . . . . . . . . . . . . . . . . . . 16-509
16.2.6 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-510
16.3 Travel to fixed stop with high-resolution torque reduction
(SW 2.2 and higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-511
16.3.1 Description of Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-511
16.3.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-511
16.3.3 Setting parameters for SIMODRIVE drives . . . . . . . . . . . . . . . . . . . . . . 16-512
16.3.4 Setting parameters for the SINUMERIK 840Di NC . . . . . . . . . . . . . . . . 16-512
16.3.6 Data description (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-515
16.3.7 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-515
A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-517
B References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-523
C EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-537
D Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-539

xviii SINUMERIK 840Di Manual (HBI) – 06.03 Edition
General on the SINUMERIK 840Di 1
1.1 Overview of SINUMERIK 840Di
With the SINUMERIK 840Di, Siemens can provide a complete PC-integrated
control that controls the drive units and I/Os through the standard field bus
PROFIBUS DP with Motion Control functionality and therefore permits a distrib-
uted design of the overall system.
It therefore constitutes the basis for PC-based automation solutions and is gen-
erally especially designed for applications
S where decentralized automation solutions are required in the fields of PLC

I/Os and drives
and/or
S a complete PC-integrated control system is preferred, since this solution

better fits into the intended or existing automation environment.
Networking SIEMENS A&D Operator Panels

Industrial PC
e.g. TCP/IP (PCU) OEM Operator Panels
MCI board extension PC monitor and MF2 keyboard
(option)
Measuring pulses
Fast dig. I/Os

Handwheel
MCI board
SIMATIC DP
ET 200
I/O devices
Ext. HHU/
611 universal
SIMODRIVE
SIMODRIVE
progr. MCP
Third-party
HT 6
device
POSMO
drives
Fig. 1-1 SINUMERIK 840Di System Overview

SINUMERIK 840Di Manual (HBI) – 06.03 Edition 1-19
1 General on the SINUMERIK 840Di 06.03
1.1.1 System software packages and options (SW 2.1 and higher)
System software For optimum adaptation of the SINUMERIK 840Di to the automation task, Sie-
packages mens can provide various system software packages:
S System software Basic

S System software Universal
S System software Plus (requires PCU variant with CPU q500MHz).
The system software packages are each designed for the following quantities:
Basic Universal Plus

Basic Max. Basic Max. Basic Max.
Axes 5 6 5 10 5 18
Channels 1 2 1 2 1 1)
Mode groups 1 2 1 2 1 1)
Channels per 1 2 1 1 1)
2
mode group
Basic: Number of components available in the basic version
Max.: Maximum possible number of components with additional options
1. SW 2.1 and higher: 4
SW 2.2 and higher: 6
Performance In addition to the system software packages, the SINUMERIK 840Di can be
options adapted to requirements using various Performance options:
S Option: Advanced Processing 1

S Option: Advanced Processing 2.
IIPO cycles The following minimum IPO cycle times can be set with various system software
packages or using the performance options:
Basic Universal Plus 2)

Basic version 8ms 8ms 8ms
Adv. Processing 1 1) 4ms 4ms
Adv. Processing 2 1) 1) 2ms
1) Option not available
2) Requires PCU variant with CPU q500MHz
Position controller The position controller cycle times are not subject to any restrictions concerning
cycles system software packages or performance options.

1-20 SINUMERIK 840Di Manual (HBI) – 06.03 Edition
06.03 1 General on the SINUMERIK 840Di
1.1.2 Hardware components
The hardware basis for the SINUMERIK 840Di is an industrial PC (further re-
ferred to as PCU (PC Unit) from Siemens A&D in conjunction with the MCI
board (Motion Control Interface).
PCU The SINUMERIK 840Di is available with the following PCU variants, each with
24V power supply:
S PCU 50
– Pentium II 333MHz, 128MB SDRAM, 2 expansion slots
– Pentium III 500MHz, 128MB SDRAM, 2 expansion slots
– Celeron 566MHz, 128MB SDRAM, 2 expansion slots
– Celeron 1.2GHz, 256MB SDRAM, 2 expansion slots
S PCU 70
– Pentium III 500MHz, 128MB SDRAM, 4 expansion slots.
PCU Interfaces The PCU features interfaces to connect the new SINUMERIK front panels (OP
0xx) as well as standard PC interfaces for connecting e.g. monitor, keyboard,
mouse and Ethernet connection.
PCU expansion The PCU has the following expansion slots:

slots
– PCU 50 and PCU 70
1x shared ISA/PCI (length: max. 175mm, occupied with option MCI
board extension and MCI board extension slot variant)
– PCU 50
1x PCI (length: max. 265mm, occupied by the MCI board)
– PCU 70
3x PCI (length: max. 265mm, one occupied by the MCI board).
MCI board The MCI board is a 2/3 long PCI plug-in card (265mm) with integrated SIMATIC
S7-compatible PLC315-2DP as a routing-capable DP master. In addition, it has
interfaces for:
– PROFIBUS DP with Motion Control Functionality
– MPI (Multi Point Interface)
– MCI board extension (option).
PROFIBUS DP Drives and external I/Os are connected to the SINUMERIK 840Di in a distrib-
interface uted system by means of the PROFIBUS DP interface with Motion Control ca-
pability (synchronous and equidistant data exchange between DP master and
DP slaves).
MPI interface Machine control panel, handheld operator and programming units (e.g. PG 740)
are connected through the MPI interface.
MCI board A maximum of four fast digital I/Os, two sensing probes and two handwheels
extension each can be connected using the optional MCI board extension.
(option)

The MCI board extension occupies mechanically one slot in the PCU. The elec-
trical connection, however, is exclusively made using a ribbon cable connected
to both sides.
MCI board extension The MCI board extension slot variation is an electrically compatible successor
slot variation version to the MCI board extension module described above. It was extended
(option as by the option of operating differential handwheels or TTL handwheels.
from 11.00)
MCI board extension The MCI board extension external variation is a module that is electrically identi-
external variation cal with the MCI board extension internally. To free the PCI slot of the PCU,
(option as which is normally already taken up, for other purposes, in this variation mechan-
from 02.01) ical fixture is implemented in a modified housing cover of the PCU.
Drives For interpolating traversing of axes on the PROFIBUS, the SINUMERIK 840Di
uses the functionality defined in the PROFIDrive profile drive technology (Ver-
sion 1.4.2, 01. Sept. 00) “Motion Control with PROFIBUS DP”.
To this aim, Siemens offers the following drives:
– SIMODRIVE 611 universal
with option module MotionControl with PROFIBUS DP
– SIMODRIVE 611 universal E
– SIMODRIVE POSMO CD/CA
– SIMODRIVE POSMO SI.
In addition to traversing axes with interpolation, it is also possible to have the
drives positioned at PROFIBUS automatically and independently of other drives
(operating mode: Positioning).
To this aim, Siemens offers the following drives:
– SIMODRIVE 611 universal E
– SIMODRIVE POSMO SI
– SIMODRIVE POSMO A.
To operate drives with an analog setpoint interface, the following PROFIBUS
module is available:
– ADI4 (Analog Drives Interface for 4 Axis).
I/Os For use as distributed I/Os, the module range SIMATIC DP ET 200 (for the con-
nection conditions, see SIMATIC Documentation) and the low-cost I/O Module
PP 72/48 are available.
Operator panel Choose one of the new operator panel fronts from the SINUMERIK range (OP
front 010, OP 010C, OP 010S, OP 012, OP 015) as an operator component.

1.1.3 Software components
The software basis of the SINUMERIK 840Di consists of the components listed
below.
Note
For a detailed list of the installed software components or the ones required to
prepare for installation, please refer to Section 1.2, Page 1-32.
Windows NT The operating system basis of the SINUMERIK 840Di is Windows NT 4.0.
Windows NT is the platform on which all applications, such as the individual
user interfaces of the HMI modular system and the start-up tools run.
Since Windows NT, however, is only conditionally real-time capable, as known
(in this context, the term “soft real time” is used), SIEMENS has developed a
method that allows the operation of the NC system software in hard real time,
without modifying Windows NT.
NC The NC system software mostly has the same functionality as the SINUMERIK
system software 840D.
It comprises both simple Motion Control processes (positioning and linear inter-
polation) and complex automation tasks as they occur in conjunction with ma-
chining centers, handling and mounting, up to machine tools and machine tool-
related applications.
NCK The NCK (Numerik Control Kernel) is part of the NC system software that real-
izes the real-time capability of the SINUMERIK 840Di.
The NCK is characterized by the following features:
– The NCK is automatically started when Windows NT powers up.
– The NCK cyclically runs in the background.
– The current status of the NCK is displayed on the SINUMERIK 840Di
standard user interface 840Di start-up:
Menu command Window > Diagnostics > NC/PLC.
– The NCK is automatically quitted when Windows NT is quitted.
– When the NCK is quitted, it will write the SRAM data from NC and PLC to
the hard disk of the PCU as a backup copy.
– The maximum portion of NCK computation can be specified using an NC
machine data unselect.
Distribution of Windows NT and the NCK share the available processor power. The CPU time
computation time share used by the NCK (standard 65%) can be altered in the machine data. See
Subsection 10.3.8, Page 10-290 “Cycle times”.
PLC The PLC system software, like the NC system software, largely has the same
system software functionality as the SINUMERIK 840D.

SinuCom NC SinuCom NC is a Windows-based tool for starting up the SINUMERIK 840Di NC

using the possibilities for the:
– interactive parameterization of the NC
– option management and license management
– management of series machine start-up files.
840Di start-up The Windows-based user interface 840Di start-up (see Section 1.5, page 1-38)
has the basic operation functionality to allow the operator to become familiar
with the SINUMERIK 840Di.
840Di start-up is part of the scope of supply of a SINUMERIK 840Di and is al-
ready installed on the hard disk of the PCU.
Optional HMI com- The following components of the SINUMERIK HMI modular system can be used
ponents optionally:
S SINUMERIK HMI Advanced (option)

HMI Advanced is the SINUMERIK standard user interface intended espe-
cially for machine tools.
S SIMATIC Protool/Pro and Protool/Pro Option SINUMERIK

SIMATIC Protool/Pro and Protool/Pro Option SINUMERIK are configuring
packages for creating technology-specific user interfaces.
An operator interface configured in this way can only be run if the ProTool/
ProRuntime System is installed.
S 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
provides maximum flexibility for creating operator interfaces using standard
development tools (such as Visual C++).
The HMI Programming Package comprises mainly the description of the

interfaces and appropriate sample applications. Detailed information on the
OPC interface can be called from the Internet at the address of OPC
Foundation (http://www.opcfoundation.org.) .
1.1.4 Real-time properties
As already mentioned, Windows NT is not an operating system designed for

hard real-time requirements. Hard real-time requirements mean the operating
system will respond to an external event within a defined time frame of a few
µseconds.
The NC system software is therefore integrated in Windows NT as a so-called
Kernel mode driver and thus has its own integrated real-time system that paral-
lel to Windows NT provides for the appropriate real-time prerequisites.

Real-time Real-time violations occur when unsuitable PC components interrupt process-

violations ing 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 a
negative influence on the real-time behavior due to too long interrupt disable
times or PCI bus disables in conjunction with PCI bus mastering.
With real-time violations exceeding 200µsec, we cannot guarantee that the NC
system software will operate correctly. Depending on the size of the real-time
violation, an appropriate system reaction will occur:
– Display of an error message
– Alarm with axis stop from the NC
– Alarm and drive-independent axis stop.
The real-time behavior can be monitored using the system diagnosis included in
840Di start-up. (see Section 1.5, Page 1-38) or the NC/PLC diagnosis of the
HMI Advanced (see Section 10.10, Page 10-395).
Screen resolution The following points must be taken into account for screen resolution and depth
and depth of color of color settings on the PCU.
S Screen resolution
The standard screen resolution setting depends on the optimized value that
was set for the operator panel. This value was defined for technical reasons
and should be adhered to. Screen resolutions greater than 1024*768 pixels
are not supported.
S Color depth
The default color depth setting is 256 colors. Higher values can, in certain
circumstances, increase the amount of processor time used by Windows NT
and sporadically also by the real-time operating system.
For safe operation in all real-time operating modes, the permissible color
depth is restricted to 65536 colors.
In unfavorable situations, e.g. if the software causes a high load on the CPU
(e.g. due to a large number of axes or short interpolation cycles), sporadic
real-time violations or a time-out on the interpolation level of the NCK can
occur.
Testing or If it is necessary to test the screen resolution or switch to a different resolution

switchover and/or color depth, the NCK must be terminated first from the Windows NT Con-
trol Panel. Otherwise a malfunction may occur in the real-time response.
Terminating the The NCK is integrated in Windows NT as a “LogB Service”. To exit or start the
NCK function, go to:
Windows NT start bar: Start > Settings > Control Panel > Services > “LogB
Service” > Exit or Start

Warning
! Please pay attention to the following points with regard to the screen resolution
and depth of color of the PCU.
S The maximum color depth is restricted to 65536 colors and the maximum
screen resolution is restricted to 1024*768 pixels. Otherwise, in unfavorable
situations, e.g. if the NC software causes a high load on the CPU, sporadic
real-time violations or a time-out on the interpolation level of the NCK can
occur.
S Changing the screen resolution and/or depth of color

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 NT service “LogB Service” in the control
panel. Otherwise a malfunction may occur in the real-time response.
1.1.5 System integrity
In order to offer high quality and wide functionality of the entire system, SINUM-
ERIK 840Di comes completely configured and ready to operate.
To this aim, the system components used are subject to a certification proce-
dure with Siemens as the system manufacturer. This is to certify and document
the compliance with the real-time capability of the whole configuration in impor-
tant operating modes.
In the case of any modifications to or expansions of PC components (hardware
or software), no binding statements can be made regarding compliance with the
product features if any amendments are made by third persons. These are the
sole responsibility of the OEMs or the user who has made the modifications.
Certification of A PC generally constitutes an open system, and expansions of and/or modifica-

expansions tions to the software and hardware to achieve a certain functionality are in some
cases inevitable.
SIEMENS therefore offers testing and documentation of the real-time response
of system configurations for systems deviating from the factory settings as a
service.
Please contact your local SIEMENS sales representative.
1.1.6 Failure safety
Fatal exceptional If Windows NT detects a fatal exceptional error during the operation of the NC
error system software, the following steps are carried out:
(Blue Screen)
S Windows NT will stop.
S An error message will appear on the screen.
S NC and PLC will continue to operate as normally.

S The NC will signal the detected fatal exceptional error to the PLC by means
of the interface signal “PC OS fault”.
Depending on the current machining situation, the PLC user program can either
continue the machining or end it.
After completion of the machining, the PLC user program can request a shut-
down of the PC by sending the interface signal “PC shutdown” to the NC.
Due to the interface signal “PC shutdown”:
– the retentive NC and PLC data are stored
– NC and PLC ended.
Note
For a brief description of the interface signals “PC OS fault” and “PC shut-
down”, please refer to Subsection 16.1.1, Page 16-499.
The further sequence is as defined in the Windows NT configuration (settable in

the System Properties, tab: Start/shutdown):
– Stop (Blue Screen) (default)
– Automatic restart (reboot).
Notice
The interface signal “PC shutdown” must be reset in the organization block
OB100 (cold restart) of the PLC.
Loss of voltage A loss of voltage lasting more than five msecs is detected by the POWER FAIL
functionality of the SINUMERIK 840Di as a fault scenario and the following ac-
tions are initiated:
– The background lighting of the operator panel display is switched off
– The NC and PLC are shut down correctly
– The NC and PLC user data are saved in the SRAM of the MCI board.
With the next power-up of the SINUMERIK 840Di, the battery-backed user data
are available again. The SINUMERIK 840Di is thus immediately ready again
without data loss.
If the power supply is recovered before final shutdown of the PCU, the following
message box will be displayed:
SINUMERIK 840Di NCK/PLC
Alarm: Power-Fail detected, NCK/PLC restart with OK.

Notice
1. Data consistency after a loss of voltage can only be ensured if the power
supply of the PCU is at least 24V.
2. In the remaining time left by the internal power backup, Windows NT can no
longer be ended correctly. This implies the risk that the Windows NT instal-
lation can be damaged so that the SINUMERIK 840Di can no longer be run.
It is therefore urgently recommended to use an uninterruptible power sys-
tem (UPS) (see Subsection 1.1.8, page 1-29).
3. If the MCI board or its battery is replaced after a loss of voltage, this will
result in a data loss of the user data battery-backed on the SRAM of the
MCI board. How to proceed further: see Subsection 6.3.4, page 6-183.
Overtemperature With the SINUMERIK 840Di, three different temperatures are monitored for
reaching their appropriate threshold values:
1. Housing temperature
2. CPU module temperature
3. CPU temperature.
Error response
S Alarm: “2110 NCK temperature alarm”

S Logbook entry: “Alarm: Critical temperature values: Case <Temp.>°C, CPU
module <Temp.>°C, CPU <Temp.>°C”
When a temperature alarm is issued, the temperature measured for the fol-
lowing components is displayed in the logbook entry: case, CPU module
and CPU.
Error causes/remedy
One of the three monitored temperatures has reached or exceeded its threshold
value. The temperature must be reduced below the threshold value by at least
7°C before the alarm is reset.
If the temperature alarm occurs, the user and/or the machine manufacturer
(PLC program) must decide whether he interrupts the machining and quits or
turns off the SINUMERIK 840Di.
1.1.7 Power OFF
Windows NT To guarantee safe operation of the SINUMERIK 840Di, WINDOWS NT must be

shut down correctly before the PCU is switched off.
Note
Windows NT is shut down correctly as follows:
– Windows NT start bar: Start > Shutdown
– PLC interface signal: “PC shutdown”, see Subsection 16.1.1,
page 16-499.

If Windows NT is shut down not correctly, the Windows NT installation can be

damaged so that the SINUMERIK 840Di can no longer be operated.
NC and PLC On correct shutdown of Windows NT the following occurs:

– The SINUMERIK 840Di components NC and PLC are terminated cor-
rectly
– The NC and PLC user data in the SRAM of the MCI board and on the
hard disk of the PCU are backed up.
If the PCU is switched off without Windows NT having been correctly shut down,
with the POWER FAIL functionality or the SINUMERIK 840Di:
– end NC and PLC correctly
– save 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 NT,
please observe the following:
1. Data consistency of the NC and PLC user data can only be ensured if the
power supply of the PCU is at least 24V.
References /BH/ Operator Components, Manual
Chapter: PCU 50
2. In the remaining time left by the internal power backup, Windows NT can no
longer be ended correctly. This implies the risk that the Windows NT instal-
lation can be damaged so that the SINUMERIK 840Di can no longer be run.
It is therefore urgently recommended to use an uninterruptible power sys-
tem (UPS) (see Subsection 1.1.8, page 1-29).
3. If the MCI board or its backup battery is replaced after the PCU has been
switched off, this will result in a data loss of the user data battery-backed on
the SRAM of the MCI board. How to proceed further: see Subsection 6.3.4,
page 6-183.
1.1.8 Uninterruptible power system (UPS)
Physical SRAM The PCU has POWER FAIL detection that, in conjunction with the NC system
software, ensures that on a loss of voltage or power-off of the PCU without Win-
dows NT first having been shut down correctly the NC and PLC user data are
backed up in the SRAM of the MCI board.
However, in the remaining time left by the internal power backup, Windows NT
can no longer be ended correctly.

This can be avoided by using a UPS, e.g. SITOP POWER DC UPS MODULE
15 (see Section 2.11, page 2-90). 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.
During this time, the user can correctly shut down Windows NT manually, or
automatically by means of a status message from the UPS to the PLC, which
then passes the interface signal “PC shutdown” to the NC.
Virtual SRAM In conjunction with the virtual SRAM (see Subsection 10.4.3, Page 10-300), it is
absolutely necessary to use a UPS system. Furthermore, when parameterizing
the time for which the UPS is to maintain the voltage supply, the time required
by Windows NT to produce the memory dump to the hard disk of the PCU after
detecting a serious exception (Blue Screen) should be considered.
Connection The stated UPS has the following options for connections to signal the current
options status to the SINUMERIK 840Di:
Table 1-1 Connection option of the UPS
Connection Message to Comment

1) RS232-interface of Windows NT Configuration of the UPS functionality is per-
the UPS –> serial inter- formed using the Windows NT standard func-
face of the PCU tion UPS Windows NT task bar:
(COMx) Start > Settings > Control panel > UPS
Advantage:
Also works if the PLC application program is
not active.
Disadvantage:
Does not work in the event of serious excep-
tions from Windows NT (BlueScreen)
2) Message terminals PLC The UPS functionality is configured using the
via free wiring –> S7 PLC user program.
I/O inputs Advantage:
Also works in the event of serious exceptions
from Windows NT (BlueScreen)
Disadvantage:
PLC user program must be active
3) Message terminals NC The UPS functionality is configured using the
via free wiring –> MCI (SW 2.3 and menu. Settings in HMI Advanced (see Subsec-
board extension inputs higher) tion 10.10.2, Page 10-399).
Advantage:
Also works in the event of serious exceptions
from Windows NT (BlueScreen) and not if the
PLC application program is active.
Prerequisite: MCI board extension (option)
Notes
Re.: 3) For details of the start/up behavior of SINUMERIK 840Di with shutdown
signal present, refer to Subsection 6.3.9, Page 6-187.
Notice
One of the follwoing connection variants must be used for full back-up protec-
tion:
– Variant 1: Connection 1) and 2)
or
– Variant 2: Connection 3)

Power infeed SITOP POWER SITOP POWER DC UPS module 15 with

110/220VAC, 60/50Hz Standard 24V/10A SITOP POWER ACCU MODULE
SIEMENS
2) Free wiring
ET 200 I/Os
SINUMERIK 840Di
1) Serial connection
3) Free wiring
(RS232)
PROFIBUS DP
Fig. 1-2 Connection options: UPS

1.2 Overview of software components
SINUMERIK 840Di A range of different system software packages are available for the SINUMERIK
System software 840Di system:
S Basic system software

maximum of 6 axes
Order No.: see Table 1-2
S Universal system software

maximum of 10 axes
S Plus system software
maximum of 18 axes
Table 1-2 Order numbers for the SINUMERIK 840Di system software
PCU hardware
System software Order No. PCU 50 PCU 50 PCU 50 PCU 50 PCU 70
333MHz 500MHz 566MHz 1.2GHz 500MHz
Standard 840Di 6FC5 258-jAX10-jAjj n n n n n
Basic
Export 840DiE 6FC5 258-jAY10-jAjj n n n n n
Standard 840Di 6FC5 258-jAX20-jAjj n n n n n
Universal
Export 840DiE 6FC5 258-jAY20-jAjj n n n n n
Standard 840Di 6FC5 258-jAX30-jAjj – n n n n
Plus
Export 840DiE 6FC5 258-jAY30-jAjj – n n n n
j 6FC5 258-0 . . .-0AF0, current software version on the hard disk
6FC5 258-X . . .-YAF0, specific software version on the hard disk
6FC5 258-0 . . .-0AG2, software maintenance/update service on CD-ROM
6FC5 258-X . . .-YAG3, update when order placed, specific software version, on CD-ROM
specific software version: e.g. 2.1: X = 2, Y = 1
for more detailed information, please refer to: Ordering information Catalog NC 60
n possible
– not possible
Additional soft- The following software components are included in the scope of delivery of the
ware components SINUMERIK 840Di system and are either installed on the PCU hard disk or pro-
vided on CD for installation:
Basic software The basic SINUMERIK 840Di software encompasses the following compo-
nents:
– Basic PCU software
– Windows NT 4.0
– Service menu
– PCU-specific drivers
(installed)
– Basic 840Di software
– 840Di start-up
– NCK-specific real-time drivers

– 840Di-specific MPI drivers

(installed)
– Basic HMI software
– HMI-specific display and communications drivers
(installed)
Engineering Tools The Engineering Tools include applications for start-up of the
SINUMERIK 840Di-NC and SIMODRIVE drives:
– SinuCom NC
Start-up tool for SINUMERIK 840Di NC
(installed)
– SIMODRIVE 611 universal tool box
Contents:
– SimoCom U
Start-up tool for SIMODRIVE 611 universal / E and SIMODRIVE
POSMO SI, CD/CA drives
(installed/must still be installed: F:\SimoComU\<version>\
Setup.exe)
– SIMODRIVE 611 universal drive firmware
(firmware file: F:\Sys611U\<version>\611u.ufw)
– SIMODRIVE 611 universal option module: “Motion Control with PRO-
FIBUS DP” firmware
(firmware file: F:\611UToolbox\dpc31\<version>\v1sl.ufw)
– SIMODRIVE POSMO SI, CD/CA drive firmware
(firmware file: F:\SysPosmo\<version>\posmo.ufw)
SIMATIC S7 The SIMATIC S7 AddOn software contains sample programs and sample ap-
AddOn software plications:
S SIMATIC S7-AddOn software

– PLC Toolbox
Contents:
– Basic PLC program
– NC variable selector
– PLC sample programs
(installation software: F:\840DiTools\plcToolbox\<version>\Setup.exe)
– DriveOM and SlaveOM for SINUMERIK 840Di
Object Manager for the dialog-based configuration of PROFIBUS DP
drives using SIMATIC Manager STEP7 especially for SINUMERIK
840Di.
(DriveOM installation software: F:\840DiTools\support\DriveOM\setup.exe)
(SlaveOM installation software: F:\840DiTools\support\slaveom\setup.exe)
– DMF file for I/O module PP72/48
Device master file with the required information in the ASCII format for
integration of the I/O module PP72/48 into a SIMATIC S7 project as DP
slave.
(DMF file: F:\840DiTools\siem80a2.gsd)

– Sample PLC application

Sample application of a SIMATIC S7 project for SINUMERIK 840Di with
SIMODRIVE 611 universal drives and SIMATIC ET200 I/Os
(ZIP file: F:\840DiTools\support\840dibsp\840dibsp.zip)
Note
The components supplied as SIMATIC S7 add-on software
– DriveOM
– SlaveOM
must be installed on the computer (PG/PC) on which the S7 software (e.g. SI-
MATIC Manager S7) is installed for creating the S7 project for the SINUMERIK
840Di.
Note
Before installing the software, please read the information (*.txt, *.rtf, *.wri) con-
tained in the directory of the respective application.

1.3 Notes on start-up

The present SINUMERIK 840Di manual describes the start-up of the following
components:
S SINUMERIK 840Di NC and PLC

S MPI Bus
S PROFIBUS DP
For the start-up of the components used in conjunction with the SINUMERIK
840Di, such as:
S operator panel fronts (e.g. SINUMERIK OP 012)

S PROFIBUS DP drives (e.g. SIMODRIVE 611 universal),
please refer to the relevant documentation.
Notice
It is recommended to carry out the start-up of the SINUMERIK 840Di in the
order of the sections of the present Manual.
Software To start up the SINUMERIK 840Di, the following software is needed, which is
part of a SINUMERIK 840Di:
S To start up the SINUMERIK 840Di NC:

– 840Di start-up
– SinuCom NC
S To start up PLC, MPI and PROFIBUS DP communication:

– DriveOM
– SlaveOM
S To start up SIMODRIVE 611 universal drives

– SinuCom U.
Additional soft- To start up the SINUMERIK 840Di, the following software is needed, which is
ware not part of a SINUMERIK 840Di:
S To start up PLC, MPI and PROFIBUS DP communication:

– SIMATIC Manager STEP7: Version 5, Service Packs 1 and 2.
Additional hard- To start up the SINUMERIK 840Di, the following hardware components are ad-
ware ditionally needed:
S a programming device with MPI interface, e.g. PG740:

– for creating a SIMATIC S7 project to start up the SINUMERIK 840Di-

PLC, the MPI and PROFIBUS DP communication
– for installing additional software on the PCU.
S an MPI cable for connecting the PCU to the programming unit
Note
A programming device is not needed if:
– the SIMATIC Manager STEP7 is installed on the PCU of the SINUMERIK
840Di
– an existing PC is used to install additional software.
For installing software on the PCU, see Chapter 15, Page 15-455.
Documentation The following documentation is required for start-up:
S /BH/ Operator Components Manual

– SINUMERIK Operator Panels
– SINUMERIK Industrial PCs
– Machine Control Panels
– Handheld Operator and Programming Units.
Depending on the NC and PLC functions used, the relevant Descriptions of

Functions.
S /FB/ Description of Functions – Basic Machine

S /FB/ Description of Functions – Extended Functions
S /FB/ Description of Functions – Special Functions
The list of references in the Appendix provides an overview of the contents of
the individual Descriptions of Functions.
S /LIS/ Lists
– Overview of Functions
– Machine, Setting Data and Variables
– Interface Signals and PLC Blocks.
S /DA/ Diagnostics Guide, Contents:

– Alarms.

1.4 Standard/export version
1.4 Standard/export version
Duty to obtain an Since certain control functions require an export approval acc. to the German
export approval Export List, the SINUMERIK 840Di is offered in two variations.
The standard version (SINUMERIK 840Di) can contain the full scope of
functions of the control but this does mean that it requires export approval with
regard to its type.
In the export version SINUMERIK 840DiE, e.g. the following options are not
available:
S Interpolation with more than four axes

S 5-axis machining package
S Helix interpolation 2D + n (n greater than 2)
S OEM package
The following restrictions apply to useable options:
S The sag compensation is limited to traversing a maximum distance of

10 mm.
Note
For a complete overview of the options not available with the export version,
please refer the SINUMERIK Order Catalog NC 60.
Although the relevant option bits can be set, they are not effective (alarm when
programming these functions). With regard to its type, the export version does
not require an export approval.
(This does not pertain to an export approval that may result from the intended
purpose of application, and this can additionally result.)
The configuration of the control system is determined by the system software
that is offered in two versions (standard and export), i.e. the duty to obtain an
approval for the system software (for the relevant information, see delivery note
and/or invoice) is transferred to the control system with the particular
installation.
This must also be observed, in particular, in the case of updates/upgrades of
the system software, since this may have an influence on the duty to obtain an
export approval.
Identification of In addition to the information provided on the delivery note and invoice, the
the control hardware components supplied with the system software are also clearly
identified by adhesive labels as standard or export versions.
Note
The adhesive labels supplied additionally in the packaging are intended to
identify the control after installation and start-up and they must be stuck into the
control logbook. In the case of license orders, an appropriate number of
adhesive labels is supplied, which must be handled in the same manner.

1.5 840Di start-up
When the control has been booted, the export version can be identified by the
additional character ’E’ in the Service screen of the NCU version.
S HMI Advanced (option): Diagnostics operating area > Service displays >
Version > Version NCU
The identification of the control variation obtained by these measures is
important for service personnel and can also be helpful in providing evidence of
conformance for exports, in particular when making use of the negative
certificates that are provided for the export version.
1.5 840Di start-up

The user interface 840Di start-up included in the scope of supply of the SINUM-
ERIK 840Di is intended as a first introduction to the SINUMERIK 840Di function-
ality.
Overview of The user interface comprises the following functions:

functions
S Display of main screens
S Display of alarms and messages
S Management of parts programs
S ASCII editor
S NC, PLC and PROFIBUS diagnoses
S Log Book.
Menu bar The menu bar comprises the following menu commands:
S File
S Edit
S Window
S Display.
Context-sensitive The functions that can be called using the menu commands File and Edit are
menu functions context-sensitive, i.e. in all cases, only the functions are offered which are pos-
sible, depending on the window currently active.
Example:
S The parts program management window is selected. The menu command

Edit provides the following functions:
– Copy
– Insert
– Paste ...
– Load
– Unload.
S The window for display of the axis actual values is selected. The menu com-
mand Edit provides no further functions.

1.5 840Di start-up
1.5.1 Menu command: Window
The menu command Window provides the following functions:
Menu command Functionality

Window
Main screen
General data Display of:
– Channel state
– Program state
Axis actual values Display of:
– Axis names
– Axis positions in the selected coordinate
system
– Distance to go
– Feed
– Override
Switchover of the position display between:
– MCS
– WCS
Current block display Display of:
– Parts programs and up to 3 blocks
Program control Selection of:
– Machine function SBL1
– SBL2 after each block
– Program test
G functions/H functions Display of:
– Current G functions
– Current H functions
Program pointer Display of:
– Program name of the selected parts pro-
gram
– Number of passes P
– Block number
– Program levels: Main program and 3
subroutine levels
Alarm Display of current alarms and messages
Alarm log Display of all alarms and messages as they
occurred in time order

1.5 840Di start-up

Parts programs S Management of parts programs
Menu command File

– New ...
– Open
– Delete
– Exit
Menu command Edit
– Copy
– Insert
– Load
– Unload.
– Select
S Editing parts programs:

– Menu command File > Open
– Double-click with the left mouse
button on the file
Editor Editing files
Start the editor with:
– Menu command File > Open
– Double-click with the left mouse
button on the file
Menu command File
– Open
– Close
– Cut
– Exit
Menu command Edit
– Copy
– Insert
– Load
– Unload.
– Select
Diagnostics
PROFIBUS
Bus Display of bus configuration:
– Baud rate
– Cycle time
– Synchr. portion (TDX)
Display of status:
– Configuration
– Bus status
Slaves Display of:
– Slave no. (DP address)
– Assignment
– Active at the bus
– Synchr. with NC
– Number of slots
– Details

1.5 840Di start-up

NC/PLC S NC
– Display of NC status
– “NC Reset”
– “Clear NC memory”
S PLC
– Display of PLC status
– “RUN-P”
– “RUN”
– “STOP”
– “MRES”
S Latency display
– Current value
– Maximum value
– Number of violations
– Oscilloscope
Log Book Display of SINUMERIK 840Di system mes-
sages

1.5 840Di start-up
Notes

Hardware Descriptions 2
2.1 Overview of hardware components
SINUMERIK 840Di: A SINUMERIK 840Di control system can only be ordered as a complete system
Complete system (PCU and MCI board).
S SINUMERIK 840Di
PCU 50 with Pentium II 333MHz, 128MB RAM and MCI board, 24V power
supply
Order No.: 6FC5 220-0AA00-1AA0
S SINUMERIK 840Di
PCU 50 with Pentium III 500MHz, 128MB RAM and MCI board, 24V power
supply
S SINUMERIK 840Di
PCU 50 with Celeron 566MHz, 128MB RAM and MCI board,
24V power supply
S SINUMERIK 840Di
PCU 50 with Celeron 1.2GHz, 256MB RAM and MCI board,
24V power supply
S SINUMERIK 840Di
PCU 70 with Pentium III 500MHz, 128MB RAM and MCI board,
24V power supply
SINUMERIK 840Di: The following hardware components are available as spare parts:
Spare parts
S SINUMERIK PCU 50
Pentium II 333MHz, 128MB RAM and Windows NT 4.0 US,
24V power supply
Spare part Order No.: 6FC5 210-0DF01-0AA0
S SINUMERIK PCU 50
Pentium III 500MHz, 128MB RAM and Windows NT 4.0 US,
24V power supply
S SINUMERIK PCU 50
Celeron 566MHz, 128MB RAM and Windows NT 4.0 US,
24V power supply
S SINUMERIK PCU 50
Celeron 1.2GHz, 256MB RAM and Windows NT 4.0 US,
24V power supply

2 Hardware Descriptions 06.03
S SINUMERIK PCU 70
Pentium III 500MHz, 128MB SDRAM and Windows NT 4.0 US,
24V power supply
S MCI board
Spare part Order No.: 6FC5 222-0AA00-1AA0
S Backup battery for MCI board

Spare part Order No.: 6FC5 247-0AA18-0AA0
Optional The following hardware components can be ordered as options:

components
Expansion of the
Motion Control S SINUMERIK 840Di MCI Board Extension
Interface Order number: 6FC5 222-0AA00-0AA0
S SINUMERIK 840Di MCI Board Extension Slot Variation

Order number: 6FC5 222-0AA00-0AA1
S SINUMERIK 840Di MCI Board Extension External Variation

Operation and
display S SINUMERIK operator panel fronts
– OP 010
Order number: 6FC5 203-0AF00-0AA0
– OP 010C
– OP 010S
– OP 012
– OP 015
External
memory medium S Floppy Disk Drive 3.5’’ incl. 0.5m interconnecting cable
Power supply of
the PCU S SITOP POWER standard 24V/10A
Order No.: 6EP1 334-1SH01
Uninterruptible
power supply (UPS) S SITOP POWER DC UPS module 15
Order No.: 6EP1 931-2EC11
S SITOP POWER ACCUMODULE 24VDC/10A/3,2AH

Order No.: 6EP1 935-6MD11

06.03 2 Hardware Descriptions
PROFIBUS DP S7 I/O modules

Modules S SIMATIC ET 200 (distributed I/O system)
You will find detailed ordering information:
References: /ST7/ SIMATIC S7 Programmable Logic Controllers
Catalog ST 70
S I/O Modules PP72/48

Order number: 6FC5 611-0CA01-0AA0
Interface modules
S ADI4 (Analog Drive Interface for 4 Axes)

Order number: 6FC5 211-0BA01-0AA1
Drives
S SIMODRIVE 611 universal
S SIMODRIVE 611 universal E

S SIMODRIVE POSMO CD/CA

S SIMODRIVE POSMO SI
S SIMODRIVE POSMO A
For detailed ordering information on various drives, see:

References: /BU/ SINUMERIK & SIMODRIVE
Ordering information
Catalog NC 60.2002

2.2 MCI board
2.2 MCI board
2.2.1 Module
X2: MCI board extension
X111: MPI
Bus connector for MPI
X3: Backup battery
X11: PCI bus
Bus connector for X101: PROFIBUS DP

PROFIBUS DP
*) locking screws
Internal thread: UNC 4-40
Fig. 2-1 MCI board with bus connector
Order No.:
MCI board Designation Order No. (MLFB)
MCI board (as a spare part) 6FC5 222-0AA00-1AA0
Caution
Some parts of the MCI board are always alive due to the backup battery. To
avoid short circuits, do not place the MCI board on electrically conductive mate-
rials.

2.2 MCI board
Order No.:
bus connector Designation Order No. (MLFB)
Bus connector RS-485 for PROFIBUS DP and MPI
180° cable outlet 6GK1 500-0EA02

35° cable outlet, without PG connection socket 6ES7 972-0BA40-0XA0
35° cable outlet, with PG connection socket 6ES7 972-0BB40-0XA0
90° cable outlet, without PG connection socket 6ES7 972-0BA11-0XA0
90° cable outlet, with PG connection socket 6ES7 972-0BB11-0XA0
Order No.:
Backup battery Designation Order No. (MLFB)
Backup battery 6FC5 247-0AA18-0AA0
Notice
For MPI connection on the MCI board, you must use a connector with straight
cable outlet (180°).

2.2 MCI board
2.2.2 Interface description
Interface overview Interfaces of the MCI board module
Table 2-1 Interface overview: MCI board
Interface Designation Type

PROFIBUS DP X101 Socket connector
MPI X111 Socket connector
MCI board extension X2 Plug connector
Backup battery X3 Plug connector
PCI bus X11 Direct connector
Battery connection Interface description of the battery connection (X3):

(X3)
S Connection: 2-pin plug connector
S Pin assignment.
Table 2-2 Pin assignment: Battery connection (X3)
Pin Designation Type 1) Function

1 BATT– VI Minus pole of the battery
2 BATT+ VI Plus pole of the battery
1. VI Voltage Input
PROFIBUS DP Interface description PROFIBUS DP interface (X101):

interface
(X101)
S Connection: 9-pin SUB-D socket connector
S Pin assignment.
Table 2-3 Pin assignment: PROFIBUS DP interface (X101)

1 Not assigned – –
3 RS-DP B RS-485 differential signals
4 RTS O Request to Send
5 GNDext VO External ground 2)
6 P5ext VO Ext. 5V power supply 2)
8 XRS DP B RS-485 differential signals
1st VO Voltage Output
O Output
B Bidirectional
2) Pins 5 and 6 are only allowed to be used to supply power to the bus terminators
S Connection cable
see Subsection 3.3.1, Page 3-131.

2.2 MCI board
MPI interface Interface description MPI interface (X111):

(X111)
S Pin assignment.
Table 2-4 Pin assignment: MPI interface (X111)

3 RS-MPI B RS-485 differential signals
5 GNDext VO External ground 2)
6 P5ext VO Ext. 5V power supply 2)
8 XRS-MPI B RS-485 differential signals
1) VO Voltage Output
O Output
B Bidirectional
2) Pins 5 and 6 are only allowed to be used to supply power to the bus terminators
S Connection cable
see Subsection 3.3.1, Page 3-131.
Notice
The MPI and PROFIBUS DP interfaces are isolated both to one another and
with regard to the PCU.

2.2 MCI board
2.2.3 Changing the battery
Battery type 3V lithium battery
Order No.
Designation Order No. (MLFB)
Backup battery 6FC5 247-0AA18-0AA0
Service life Typical battery service life: > 3 years
General rules Please observe the following general rules when handling batteries:
for handling
S Do not charge them!
S Do not heat or burn them!
S Do not drill or squeeze them!
S Do not manipulate them in any other fashion neither mechanically, nor
electrically!
Caution
! Improper handling of backup batteries results in the hazard of inflammation,
burning or explosion.
Criteria for The 3V lithium battery to back up the SRAMs and the clock module is monitored
changing the in stages:
battery
Battery voltage Message
2.7 ... 2.9V Alarm: “2100 NCK battery warning threshold reached”
2.4 ... 2.6V Alarm: “2101 NCK battery alarm”
Alarm: “2102 NCK battery alarm”
The alarm “2101 NCK battery alarm” is output if battery low voltage is detected
in cyclic operation.
The alarm “2102 NCK battery alarm” is output if battery low voltage is detected
during power-up.

2.2 MCI board
Changing the To avoid data loss, the battery on the MCI board should be changed at the lat-
battery est if the alarm “2100 NCK battery warning threshold reached” has occurred for
the first time.
Warning
! When operating electrical devices, certain parts of these devices are inevitably
under hazardous voltage.
Improper handling of these devices may therefore result in loss of life, severe
personal injury or substantial material damage.
When servicing these devices, you should therefore observe all notices pro-
vided in this Section and attached to the product itself.
– This device may only be serviced by accordingly qualified personnel.
– Before starting any maintenance and service work, disconnect the device
from mains.
– Use only spare parts approved by the manufacturer.
– Strictly observe the prescribed maintenance intervals, as well as the in-
structions for repair and replacement.
Notice
The module contains electrostatically sensitive devices.
Electrostatically discharge your own body before touching the module. To do
so, touch an earthed, conductive object (e.g. blank cubicle parts, socket protec-
tion contact) immediately before starting work on the module.
In order to change the battery, proceed as follows:

1. Due to the battery change (SRAM is not backed up during this time), data
loss might occur in the SRAM of the MCI board. To avoid an expensive new
start-up, make sure prior to the battery change that an appropriate series
machine start-up file (NC and PLC) exists.
For information on how to create a series machine start-up file, please refer
to Chapter 14, Page 14-449.
2. Shut down the SINUMERIK 840Di and Windows NT correctly.
To do so, use one of the following possibilities:
S Windows NT taskbar: Start > Shut Down

S Interface signal: “PC shutdown”; see Subsection 16.1.1, page 16-499
3. Disconnect your PC from mains.

2.2 MCI board
4. Remove the screws from the cover of the housing (Fig. 2-2) and open the
housing of your PC, observing the relevant safety regulations.
Screws of the cover of the housing
Fig. 2-2 Cover of the housing of the PCU 50
5. Optional:
Remove interconnecting cable to the MCI board extension module, interface
X2.
6. Remove the fastening screw of the module holding-down device (Fig. 2-3)
and remove the module holding-down device.
Fastening
screws for
the module
holding-down
device
Module
holding-down
device
Guide rail
Plastic
holder
Fig. 2-3 Mounting of the module
7. Remove the fastening screw of the cover plate of the module.

8. Remove the module, observing the ESD measures.
9. Remove the battery receptacle using an appropriate screw driver
(see Fig. 2-4).

2.2 MCI board
Fig. 2-4 Remove the battery receptacle
10. Remove the cable connection X3 (battery connector) from the module.
11. Remove the used battery and dispose of it acc. to the relevant standards.
12. Install the new battery and plug the battery connector onto the connection
contacts without applying force (X3).
Marking of the
battery connector
Fig. 2-5 Battery connector

2.2 MCI board
13. Locate the battery on the module using the battery receptacle.
Note:
The clamps must lock into place audibly.
14. Insert the module into the appropriate slot on the mother board and fasten it
using the fastening screw on the cover plate.
15. Mount the module holding-down device.
16. Close the cover plate of the housing of your PC and fasten it using the two
housing screws.
17. Connect your PC to mains again and start it.
2.2.4 Module replacement

For module replacement, a module is installed and removed in an analogous
way to changing the battery (see Subsection 2.2.3, page 2-50).

2.2 MCI board
2.2.5 Technical Data

Safety
Degree of protection IP 20
Class of protection Class of protection I, acc. to VDE 0106 P1:
1982 (IEC 536)
Safety regulations EN61131-1
Certifications CE, UL, CSA
Power consumption 5V 3.3V
Typically 4.7W 50mW
Max. 6W 200mW
Mechanical data
Dimensions PCI card, 2/3 length
Weight 198g
Climatic environmental conditions
Heat dissipation Open-circuit cooling
Temperature limit values Operation Storage/transportation
– MCI board alone – –40 ... 70°C
– MCI board in PCU 50 5 ... 55°C –20 ... 60°C
Tested to DIN IEC 68-2-1, DIN IEC 68-2-2
(DIN EN 60068-2-2), DIN IEC 68-2-14
Limit values of rel. humidity 5 ... .80% 5 ... .95%
Tested to DIN IEC 68-2-30
per min. per hour
Temperature change max. 1K max. 10K
Condensation not admissible
Quality assurance acc. to ISO 9001
Vibrational load during operation
Class 3M4
Frequency range 10 ... 58Hz/58... 200Hz
Const. excursion/acceleration 0.075mm / 1g
Tested to DIN EN 60068-2-6
– module in PCU 50
Shock load during operation
Acceleration 50m/sec2
Duration of nominal shock 30msecs
Notice
The specified safety regulations, certifications, degree of protection and class
of protection only apply for the case that the module is plugged in a
SINUMERIK PCU 50.

2.3 MCI board extension
2.3.1 Module
The MCI board extension provides the following functions as an optional
expansion board of the MCI board:
– Four binary inputs (isolated)
– Four binary outputs (isolated)
– Two measuring inputs (isolated)
– Two handwheels (non-isolated).
*)
X121: Cable distributor

*)
PCI bus (mechanical)
*) locking screws
Fig. 2-6 MCI board extension
Order number:
MCI board extension (option) 6FC5 222-0AA00-0AA0
Caution
Never plug or remove the cable distributor at the X121 interface of the mod-
ule under voltage.
Before you plug or remove the cable connector, switch off the PCU (shut down
Windows NT correctly!). Otherwise, short circuits might occur on the module, as
a result of which the module could be destroyed.

2.3.2 Installation instructions
The connecting cable with the MCI board is part of the scope of supply and is
already plugged into the MCI board extension slot variation.
Installation To install the module, proceed in the sequence described below.
Warning
from mains.
Notice



4. Remove the fastening screw of the module holding-down device (Fig. 2-8) of
the MCI board and remove the module holding-down device.
Fastening
screws for
the module
holding-down
device
Module
holding-down
device
Guide rail
Plastic
holder
Fig. 2-8 Fixing the MCI board
5. Remove the blanking plate of the free PCI slot.

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

Interface overview
Table 2-5 Interfaces of the MCI board
Interface description Connector Connector type

designation
Cable distributor X121 37-pin Sub-D connector
MCI board extension X4 26-pin plug connector
Pin assignment: X121 Cable distributor

Maximum cable length: 25m for all functions
Special features: Four binary inputs (isolated)
Four binary outputs (isolated)
Two measuring inputs (isolated)
Two handwheels (non-isolated)
Table 2-6 Pin assignment of connector X121
Pin Signal designation Signal Pin Signal designation Signal

type type
1 M24EXT VI 20 P24EXT VI
2 M24EXT VI 21 P24EXT VI
3 OUTPUT 1 O 22 OUTPUT 3 O
4 OUTPUT 0 O 23 OUTPUT 2 O
5 INPUT 3 I 24 MEXT VI
9 MEPUS 0 I 28 MEPUS 1 I
10 MEPUC 0 I 29 MEPUC 1 I
11 MPG1 XA I 30 MPG1 A I
12 MPG1 5V VO 31 MPG1 0V VO
14 MPG1 XB I 33 MPG1 B I
15 MPG0 XA I 34 MPG0 A I
18 MPG0 XB I 37 MPG0 B I
19 Not assigned

Signal designations
MPGs 0, 1 5V Supply voltage 1 / 2nd Handwheel 0, 5V
MPG 0, 1 0V Supply voltage 1 / 2nd Handwheel 0 V
MPG 0, 1 A, XA 1st / 2nd Differential handwheel input, A, XA
MPG 0, 1 B, XB 1st / 2nd Differential handwheel input, B, XB
MEPUS 0, 1 1. / 2nd Sensor probe input (signal: 24V)
MEPUC 0, 1 1st / 2nd Sensor probe input, (reference: 0V)
INPUT [0...3] 1st to 4th Binary NC input ...
GNDEXT External ground (reference ground for binary NC inputs)
OUTPUT [0...3] 1st to 4th Binary NC output
M24EXT External 24V supply (–) for binary NC outputs
P24EXT External 24V supply (+) for binary NC outputs
Signal type
O Output
VO Voltage Output
I Input
VI Voltage Input
Notice
The maximum current carrying capacity of the handwheel interface of the MCI
board extension module is 1A for both handwheels. 500mA per handwheel.

Table 2-7 Technical data for MCI board extension

Safety
1982 (IEC 536)
Electrical data
Max. typical
Power consumption without 500mW 350mW
I/Os
Power consumption with I/Os 2.1W 85 0mW
both handwheels per handwheel
Max. current-carrying capacity 1A 500mA
of the 5V power supply
Mechanical data
Dimensions Short PCI card
Weight 110g
Operation Storage/transportation
Temperature limit values 5 ... 55°C –40 ... 70°C
(DIN EN 60068-2-2), DIN IEC 68-2-14
per min. per hour
Temperature change max. 1K max. 10K
Class 3M4
Const. excursion/acceleration 0.075mm / 1g
Notice
of protection only apply for the case that the module is plugged in a SINUM-
ERIK PCU 50.

2.4 MCI board extension slot variation (SW 11.00 and higher)
The MCI board extension slot variation is an electrically compatible successor
version of the MCI board extension module described in Section 2.3, page 2-56.
The module has been extended by the option of operating differential hand-
wheels or TTL handwheels.
2.4.1 Module
Switch S1
X121: Cable
distributor
PCI bus (mechanical)
*) locking screws
Fig. 2-9 MCI board extension slot variation
Order number:
MCI board extension slot variation (option) 6FC5 222-0AA00-0AA1
Caution
ule under voltage.

Switch S1 With switch S1 you can select the type of handwheel that is to be operated on
the module:
– Differential handwheels:
Switch S1 closed (as-delivered state)
– TTL handwheel:
Switch S1 open.
Differential or TTL handwheels can only be operated alternately.
Switch S1:
Switch position open
Fig. 2-10 Switch S1 switch position open (TTL handwheels)
Notice
You select between differential and TTL handwheels on the module using
switch S1 before installing the module.

The connecting cable with the MCI board is part of the scope of supply and is
already plugged into the MCI board extension slot variation.
Installation To install the module, proceed in the sequence described below.
Warning
from mains.
Notice



4. Remove the fastening screw of the module holding-down device (Fig. 2-12)
of the MCI board and remove the module holding-down device.
Fastening
screws for
the module
holding-down
device
Module
holding-down
device
Guide rail
Plastic
holder
Fig. 2-12 Fixing the MCI board
5. Remove the blanking plate of the free PCI slot.

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

Interface overview Interfaces of the MCI board extension slot variation
Table 2-8 Interfaces of the MCI board extension slot variation

Cable distributor X121 Connector
MCI board extension X4 Plug connector
Cable distributor Interface description of the cable distributor interface (X121):

(X121)
S Connector: 37-way Sub D connector
(see cable distributor Section 2.6, page 2-76)
S Pin assignment:
Table 2-9 Pin assignment: Interface X121

1 M24EXT VI/VO 24V ground, 24V output ground
2 M24EXT VI/VO 24V ground, 24V output ground
3 DOUT_CON(1) O 2nd 24V output
4 DOUT_CON(0) O 1st 24V output
5 DIN_CON(3) I 4th 24V input
6 DIN_CON(2) I 3rd 24V input
7 DIN_CON(1) I 2nd 24V input
8 DIN_CON(0) I 1st 24V input
9 MEPU0_S I 1st Sensor probe input (signal: 24V)
10 MEPU0_C I 1st Sensor probe input (reference: 0V)
11 MPG1_XA I input 2nd handwheel, track A
12 P5 VO Optional 5V handwheel power supply
14 MPG1_XB I input 2nd Input handwheel, track B
15 MPG0_XA I input 1st Input handwheel, track A
18 MPG0_XB I input 1st Input handwheel, track B
20 P24EXT VI 24V output load power supply
21 P24EXT VI 24V output load power supply
22 DOUT_CON(3) O 4th 24V output
23 DOUT_CON(2) O 3rd 24V output
24 MEXT VO 24V input ground
28 MEPU1_S I 2nd Sensor probe input (signal:
29 MEPU1_C I 2nd Sensor probe input (0V)

Table 2-9 Pin assignment: Interface X121

30 MPG1_A I input 2nd Input handwheel, track A
31 M VO Hand wheel PS ground, TTL handwh. ground
33 MPG1_B I input 2nd Input handwheel, track B
34 MPG0_A I input 1st Input handwheel, track A
37 MPG0_B I input 1st Input handwheel, track B
1) VI/VO Voltage Input/Voltage Output
VI Voltage Input
VO Voltage Input
I Input
O Output
Power supply of the digital inputs

Ext. power supply
X121
+24V stabilized
MCI board Pin number:
extension +24V 0V
Optocoupler
5...8
24...27
Power supply of the digital outputs

Ext. power supply
X121 +24V stabilized
MCI board Pin number:
+24V 0V
extension
20,21
Optocoupler
3,4,22,23
Relays
Driver
1,2
S The maximum cable length is 25m for all functions.

Digital inputs Please note the following points about the digital inputs:
– Isolated from the board electronics
– Connected to the same ground (GNDEXT)
Digital outputs Please note the following points about the digital outputs:
– Isolated from the board electronics
– Connected to the same ground (GND24EXT), as is their the external
24V power supply
Handwheels The handwheels are not isolated from the board electronics.
S In the case of differential handwheels, the following signals are used:

– MPGx_A
– MPGx_B
– MPGx_XA
– MPGx_XB
S In the case of TTL handwheels, the following signals are used:

– MPGx_A
– MPGx_B
– M
Notice
The optional power supply of the handwheels (P5) is electronically protected
with 2A. The maximum continuous load is 1A. Per handwheel 500mA.
Sensor probes Please note the following points about sensor probes:
– The sensor probes are isolated among themselves and from all other
potential areas (board electronics, dig. inputs, dig. outputs, and
handwheels).
Sensor probes The sensor probes are isolated among themselves and from the board electron-
ics.

Table 2-10 Technical data for MCI board extension, slot version
Safety
1982 (IEC 536)
Electrical data
Max. typical
Power consumption without 500mW 350mW
I/Os
Power consumption with I/Os 2.1W 850mW
both handwheels per handwheel
Max. current-carrying capacity 1A 500mA
of the 5V power supply
Mechanical data
Dimensions Short PCI card
Weight 110g
Temperature limit values 5 ... 55°C –40 ... 70°C
(DIN EN 60068-2-2), DIN IEC 68-2-14
per min. per hour
Temperature change Max. 1K Max. 10K
Class 3M4
Const. excursion/acceleration 0.075mm/1g
Notice
of protection only apply for the case that the module is plugged in a SINUM-
ERIK PCU 50.

2.5 MCI board extension external variation (SW 02.01 and higher)
2.5 MCI board extension external variation (SW 02.01 and

higher)
The MCI board extension external variation, like the slot variation, is an electri-
cally compatible successor version of the MCI board extension described in
Section 2.3, page 2-56. The module has been extended by the option of operat-
ing differential handwheels or TTL handwheels.
To free the PCI slot of the PCU, in this MCI board extension variation mechani-
cal fixture is implemented in a modified housing cover of the PCU.
2.5.1 Module
X121: Cable distributor Switch S1
Fig. 2-13 Module with a modified housing cover
Order number:
MCI board extension external variation (option) 6FC5 222-0AA01-0AA0
Caution
ule under voltage.

Switch S1 With switch S1 you can select the type of handwheel that is to be operated on
the module:
– Differential handwheels:
Switch S1 closed (as-delivered state)
– TTL handwheel:
Switch S1 open.
Differential or TTL handwheels can only be operated alternately.
Switch S1:
Switch position open
Fig. 2-14 Switch S1 switch position open (TTL handwheels)
Notice
You select between differential and TTL handwheels on the module using
switch S1 before installing the module.

Performing The MCI board extension external variation is already supplied in the modified
installation housing cover. The connecting cable with the MCI board is part of the scope of
supply and is already plugged into the MCI board extension external variation.
Before you can operate the MCI board extension external variation, you must
remove any internal MCI board extension module and replace the housing
cover.
To install the module, proceed in the sequence described below.
Warning
from mains.
Notice



4. Optional: If there is an internal MCI board extension module

– Remove interconnecting cable to the internal MCI board extension mod-
ule, interface X2.
– Remove the fastening screw of the module holding-down device and
remove the module holding-down device.
– Unscrew the fixing screw of the end plate of the internal MCI board ex-
tension module and remove the module, observing ESD precautions.
– Mount the module holding-down device again.
5. Insert the modified housing cover into the guide slot of the PCU and close
the housing to the extent that the connecting cable can be plugged into the
MCI board extension interface (X2).

Fig. 2-16 Modified housing cover with MCI board extension external variation
6. Make sure that the latches of the connectors have securely engaged on
both modules.
7. Close the housing completely and fix it again with the two housing screws.
8. Connect your PC to mains again and start it.
Fig. 2-17 PCU 50 with MCI board extension external variation

2.5.3 Dimension drawing
159 105
30
133
30
Fig. 2-18 PCU 50 with MCI board extension external variation

The interfaces of the MCI board extension external variation are identical with
those of the MCI board extension slot variation. See Subsection 2.4.3,
page 2-66.
2.5.5 Technical data

The technical data of the MCI board extension external variation are identical
with those of the MCI board extension slot variation. See Subsection 2.4.4,
page 2-69.

2.6 Cable distributor
Order No.
Cable distributor 6FX2 006-1BA02
Cable connection The cable distributor consists of a connector jacket for a 37-pin Sub-D
connector with enlarged interior. The cable distributor is used to split the I/O
electronic handwheel extension interface (X121) to a maximum of 7 single
cables. These must be connected in the order shown in Table 2-12, page 2-78.
To supply the digital outputs, an external 24V supply is possible at the cable
distributor.
Cable
6FX2002-4AA21-0jjj
Cable
6FX2002-4AA41-0jjj
90
Fig. 2-19 Cable distributor
Plug the appropriate single cable into the opened cable distributor and connect
it to the associated connector X1 to X10. When doing so, place the cable into
the appropriate cable entry.
Make sure that the shield jackets that became free have a large conductive
connection to the metallic contact areas of the cable distributor. See Fig. 2-20,
Page 2-77. Install the upper terminal clamp such that its “teeth” point towards

the “teeth” of the lower terminal clamp and then fasten the upper part of the
housing.
This will reliably press the cable shields between the contact areas of the
contact springs and contact them safely. The shield potential is reliably routed to
the housing of the PCU using the contact springs of the cable distributor on the
front panel of the PCU.
Position of the
interfaces
Cable guides
Terminal clamp
Contact areas
X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 Connectors X1...X10
S2 S5 S1
S4 S6 S3
S1 to S6:
closed
X11
open
Sub-D socket connector
Fig. 2-20 Position of the interfaces of the cable distributor
DIP-FIX switches The DIP-FIX switches in the interior of the cable distributor must be set as
follows:
Table 2-11 Setting the DIP-FIX switches in the cable distributor
Switch S1 S2 S3 S4 S5 S6
open X X X X
closed X X

Connector
assignment Table 2-12 Connector assignment
Connector No. Cable No. I/O

X1 1
1 handwheel
1.
X2 (top)
X3
2 2nd handwheel
X4
X5 3 2nd probe
X6
4 4 binary inputs
X7
X8 5 4 binary outputs
X9 6 Supply for 4 binary outputs
7
X10 1. probe
(bottom)
Notice
When assembling the cable distributor, make absolutely sure that the supplied
washer is installed correctly and the coding pins are installed.
Mounting The cable distributor is fastened using the two supplied adapter plates at the
X121 cable distributor interface of the MCI board extension module using
screws.
Cable distributor: Top view Cable distributor: Side view
Adapter plate
Fig. 2-21 Mounting the cable distributor

Connector pin Connector designation: X1...X10

assignment Connector type: DU-BOX plug connectors
Table 2-13 Connector pin assignment of the cable distributor

Pin no. DU-BOX Cable Cable order no.
37-pin connector no. 6FX2002-4AA....
Signal name Core color I/O device Terminal
connec- no./pin
tor
– X10/2 RD
9 MEPUS 0 X10/1 OG First probe Signal +24V
– X10/4 7 41–0jjj BN
10 MEPUC 0 X10/3 BK 1. probe Reference
Shield 0V
1 M24EXT X9/2 RD Ground
Supply of the
20 P24EXT X9/1 OG 24V
4 binary outputs
2 M24EXT X9/4 6 41–0jjj BN Ground
of the MPI
21 P24EXT X9/3 BK 24V
connector
Shield
3 OUTPUT 1 X8/2 RD 2nd output
22 OUTPUT 3 X8/1 OG 4th output
4 binary
4 OUTPUT 0 X8/4 5 41–0jjj BN 1st output
outputs
23 OUTPUT 2 X8/3 BK 3rd output
Shield
5 INPUT 3 X7/2 RD 4th input
24 GNDEXT X7/1 OG ground
6 INPUT 2 X7/4 BN 3rd input
25 GNDEXT X7/3 BK ground
4 binary
7 INPUT 1 X6/2 4 21–0jjj GN 2nd input
inputs
26 GNDEXT X6/1 YE ground
8 INPUT 0 X6/4 VT 1st input
27 GNDEXT X6/3 BU ground
Shield
– X5/2 RD
28 MEPUS 1 X5/1 OG 2nd probe Signal +24V
– X5/4 3 41–0jjj BN
29 MEPUC 1 X5/3 BK 2nd probe Reference
Shield 0V
11 MPG1 XA X4/2 RD XA
30 MPG1A X4/1 OG A
12 MPG1 5V X4/4 BN 5V
31 MPG1 0V X4/3 BK 2nd handwheel 0V
13 MPG1 5V X3/2 2 21–0jjj GN 5V
32 MPG1 0V X3/1 YE 6FC9320-5DB 0V
14 MPG1 XB X3/4 VT XB
33 MPG1 B X3/3 BU B
Shield
15 MPG0 XA X2/2 RD XA
34 MPG0 A X2/1 OG A
16 MPG0 5V X2/4 BN 5V
35 MPG0 0V X2/3 BK 1st handwheel 0V
17 MPG0 5V X1/2 1 21–0jjj GN 5V
36 X1/1 YE 6FC9320-5DB 0V
MPG0 0V
18 X1/4 VT XB
MPG0 XB
37 X1/3 BU B
MPG0 B
Shield

Signal names
MPG0, 1 5V Supply voltage 1 / 2nd handwheel 0, 1 5V
MPG0, 1 0 V Supply voltage 1 / 2nd handwheel 0,V
MPG0, 1 A, XA 1. / 2nd Differential handwheel input, A, XA
MPG0, 1 B, XB 1. / 2nd Differential handwheel input, B, XB
MEPUS 0, 1 1. / 2nd Measuring pulse signal
MEPUC 0, 1 1. / 2nd Measuring pulse Common (reference ground)
INPUT [0...3] 1. to 4th Binary NC input
MEXT External ground (reference ground for binary NC inputs)
OUTPUT [0...3] 1. to 4th Binary NC output
M24EXT External 24V supply (–) for binary NC outputs
P24EXT External 24V supply (+) for binary NC outputs
Notice
The maximum current carrying capacity of the handwheel interface is 1A for
both handwheels. 500mA per handwheel.
Colors
RD red
OG orange
BN brown
BK black
GN green
YE yellow
VT violet
BU blue

2.7 SINUMERIK Industrial PC
2.7.1 SINUMERIK PCU 50
**)
top *)
**)
*) orientation with reference

to operation with OP 012
**) Fixing screws
Housing cover
Fig. 2-22 PCU 50: Perspective view with installed hard disk drive
Order number
PCU 50 as spare part with Windows NT 4.0 US, with-
out MCI board:
PCU 50 333MHz, 128MB 6FC5 210-0DF01-0AA0
PCU 50 500MHz, 128MB 6FC5 210-0DF05-0AA0
PCU 50 566MHz, 128MB 6FC5 210-0DF20-0AA0
PCU 50 1.2GHz, 256MB 6FC5 210-0DF22-0AA0
Features Together with the MCI board, the SINUMERIK industrial PC “PCU 50” serves as
the basis for the SINUMERIK 840Di control system. The key features of the
PCU 50 are as follows:
S Processor versions:
– Pentium II 333MHz, 128MB SDRAM
– Pentium III 500MHz, 128MB SDRAM
– Celeron 566MHz, 128MB SDRAM
– Celeron 1.2GHz, 256MB SDRAM
S Hard disk min. 4.8GB (replaceable)
S Windows NT 4.0 operating system US version

S Robust design (continuous operation, high noise immunity)

S Space-saving installation thanks to compact dimensions (LxWxH):
296x267x100mm
S Easy installation with four screws on the rear of the operator panel front
S Mounting position and location to a large degree variable
S Screen resolution 640x480 (VGA), up to 1024x768 (XGA)
S Power supply: 24VDC
S Interfaces:
– Parallel interface LPT1
– Serial interfaces 1 x RS-232-C (25–pole), 1 x RS–232–C (9–pole)
– PS/2 keyboard interface
– PS/2 mouse interface
– MPI/PROFIBUS DP (max. 12 Mbaud)
– VGA interface for external monitor
– Ethernet connection 10/100 Mbaud
– Interfaces to the operator panel:
LVDS interface for SINUMERIK-OP,
USB interface for SINUMERIK-OP (internal)
– USB interfaces:
with Pentium II/III 366/500MHz: 1 x USB interface
with Celeron 566MHz/1.2GHz: 2 x USB interfaces
S Expansion slots
– 1 PCI expansion slot (length: max. 265mm, occupied by the MCI board)
– 1 x shared ISA/PCI expansion slot (length: max. 175mm, occupied with
option MCI board extension and MCI board extension slot variant).
Options The following options are offered:

S External floppy disk drive
S Memory extension up to max. 512MB.
References The complete documentation on the PCU 50 is to be found in:

References: /BH/ Operator Components Manual
Component PCU 50.
(SW 2.2 and In SW 2.2 and higher, distributed connection of PCU and operator panel is pos-
higher) sible via Videolink (option).
Distributed configuration

2.7.2 SINUMERIK PCU 70
top *)
**)
*) Orientation with reference

to operation with OP 012
**) Fastening screws
Housing cover
Fig. 2-23 PCU 70: Perspective view with installed hard disk drive
Order No.
PCU 70 as spare part with Windows NT 4.0 US, with-
out MCI board:
PCU 70 500MHz, 128MB 6FC5210-0DF04-0AA0
Features The PCU 70 is essentially a PCU 50 with two extra expansion slots (PCI). It has
the following features:
S Processor min. Pentium III, 500MHz
S User memory (RAM) max. 512MB
S Hard disk min. 10.4GB (swappable)
S Windows NT 4.0 operating system US version
S Robust design (continuous operation, high noise immunity)
S Dimensions (W x H x D): 297x267x122mm
S Easy-to-service design
S Screen resolution 640x480 (VGA), up to 1024x768 (XGA)
S Power supply: 24VDC
S Interfaces:
– Parallel interface LPT1

– 2 x RS-232 serial interfaces

– PS/2 keyboard interface
– PS/2 mouse interface
– MPI/DP (max. 12 MBaud)
– VGA interface for external monitor
– Ethernet connection 10/100 Mbaud
– PC card slot
– Interfaces to the operator panel:
LVDS interface for SINUMERIK-OP,
USB interface for SINUMERIK-OP (internal)
– USB interface
S Expansion slots
– Three PCI expansion slots (length: max. 265mm); 1 expansion slot occu-
pied by the MCI board)
– 1 x shared ISA/PCI expansion slot (length: max. 175mm, occupied with
option MCI board extension and MCI board extension slot variant).
Options The following options are offered:
S External floppy disk drive

S Memory extension up to max. 512MB.
References The complete documentation on the PCU 70 is to be found in:

Component PCU 70.
(SW 2.2 and In SW 2.2 and higher, distributed connection of PCU and operator panel is pos-
higher) sible via Videolink (option).
Distributed configuration

2.8 SINUMERIK operator panel fronts
Overview The individual SINUMERIK operator panel fronts can be connected using the
PCU interfaces for TFT and STN displays:
– OP 010
– OP 010C
– OP 010S
– OP 012
– OP 015.
In the following section, the OP 012 operator front is described as an example in

detail.
2.8.1 Operator panel front OP 012
Alpha key
Soft keys and direct keys
Soft keys and direct keys
group
Numerical
key group
Cursor
key group
Control
key group
USB
front
Soft keys interface
Recall Machine area “ETC” key Area switchover Mouse
Fig. 2-24 View of OP 012 operator panel front
Order No.
SINUMERIK OP 012 6FC5 203-0AF02-0AA0

Features The OP 012 operator front provides the following features:
S 12.1” TFT flat screen (color); resolution: 800x600

S Membrane keyboard with alpha, numeric, cursor and control key groups
S Soft keys/direct keys:
– 2x8 horizontal key rows with soft key functions
– 2x8 vertical key rows with soft key and direct key functions
– Direct keys connectable using PP031-MC or directly to the I/Os
S Shift key for switchover to the second key level (not for switching over the
letters, since uppercase letters only)
S Integrated mouse
S Status LEDs for power supply and overtemperature
S Front USB interface
S Degree of protection IP65
S Can be combined with the component PCU 50
S External floppy disk drive can be connected.
References A complete documentation of the OP 012 operator panel front is to be found in:
OP 012 operator panel front.

2.9 Floppy disk drive 3.5’’
2.9 Floppy disk drive 3.5’’
Fig. 2-25 External floppy disk drive 3.5’’
Order No.
Floppy disk drive 3.5’’ incl. 0.5m cable 6FC5 235-0AA05-0AA1
Accessories:
Cover of floppy disk drive with shutter, cover and bear- 6FC5 247-0AA20-0AA0
ing block
Features The AT-compatible floppy disk drive serves to archive data and programs on
3.5’’ diskettes. It can be installed, e.g. in the front panel of the control cubicle.
S Input voltage 24VDC
S Power consumption, max. 5W
S Degree of protection to DIN EN 60529 IP 54 (front)

(IEC 60529) IP 00 (rear)
S Humidity classification acc. to Term. 3K5 condensation and

DIN EN 60721-3-3 formation of ice excluded
Lowest air temperature 0°C.
References For a complete description of the external 3.5’’ floppy disk drive, please refer to:
floppy disk drive 3.5’’

2.10 Power supply
2.10 Power supply
2.10.1 SITOP POWER Standard 24V/10A
Fig. 2-26 View: SITOP POWER Standard 24V/10A
Order No.
SITOP POWER Standard 24V/10A 6EP1 334-1SH01
Features The SITOP POWER Standard 24V/10A power supply mode provides the follow-
ing features:
S Input voltage nominal value 120/230VAC
S Input voltage range 93 ... 132V/187 ... 264V
S Mains buffering > 20msecs
S Mains frequency nominal value 50/60Hz

S Mains frequency range 47 ... 63Hz
S Input current nominal value 3.5/1.7A
S Inrush current (25° C) 55A
S Output voltage nominal value 24VDC
S Output voltage tolerance ± 3%
S Efficiency > 87%

2.10 Power supply
S Output current nominal value 10A
S Electron. short-circuit protection with automatic restart

S Galvanic isolation (SELV acc. to EN 60950)
S Class of protection (IEC 536; VDE 1006 T1) class I
S Degree of protection (VDE 0470, IEC 529) IP 20
S Radio interference level (EN 55011) class A

2.11 Uninterruptible power supply (UPS)
2.11.1 SITOP POWER DC UPS module 15
Fig. 2-27 View: SITOP POWER, DC-UPS MODULE 10
Order number
SITOP POWER DC UPS module 15 6EP1 931-2EC11
Features The SITOP POWER DC UPS Module 15 provides the following features:
S Compact design
S Input voltage 24VDC
S Nominal output power 240W
S High efficiency approx. 96%
S Class of protection (IEC 536; VDE 1006 T1) Class III
S Degree of protection (VDE 0470, IEC 529) IP 20
S Absolutely uninterruptible mains buffering

S Immediate electronic connection of the accumulator once the load voltage or
the voltage present between the connections L+/M of the DC-UPS module
falls below the value of the connection threshold (18 to 26V).

S Settable buffer time by DIP switches in the range between 5 to 315 sec. or
up to enforced shutdown by deep discharging.
S In case of increased load current requirements (e.g. when connecting incan-

descent lamps, contactor relays with DC autotransformer winding, DC mo-
tors, DC/DC converters, electronic modules with high input capacity), high,
electronically limited peak currents are delivered automatically.
S After a power failure, the battery module is automatically electronically dis-

connected from the loads and quickly recharged with a constant current of
0.7A (U/I characteristic with 27V end-of-charge voltage).
S Exhaustive discharge protection

S ON/OFF control circuit
S Signaling
S LED green/LED yellow and floating changer for mains/battery operation
S LED red and floating changer for readiness for backup existing (LED OFF)/
alarm (LED ON).
S RS-232 interface (serial interface) for the additional output of all signals to a
PC.
Serial interface The connection from the SITOP POWER DC-UPS module 15 to the serial inter-
face of the PC is made using a 9-pin SUB-D interconnecting cable:
S Design connector/socket connector

S The individual cables are connected 1:1 to the appropriate pins.
Table 2-14 Pin assignment of the 9-pin SUB-D connectors
Pin Signal Designation

2 RxD Data cable
3 TxD Negative supply voltage
7 RTS Positive supply voltage

2.11.2 SITOP POWER storage battery module 24VDC/10A/3.2AH
Fig. 2-28 View: SITOP POWER lead-acid battery module
Order number
SITOP POWER storage battery module 6EP1 935-6MD11
24VDC/10A/3.2AH
Features The SITOP POWER LEAD-ACID MODULE 24VDC/10A/3.2AH provides the

following features:
S It has two maintenance-free, closed lead-acid batteries from the same lot,
which are installed in a holder and connected in series
S Complete with battery retainer and terminals

S Low self-discharge rate of approx. 3% per month (at +20°C)
S Short circuit protection (battery fuse 15A/32V)
S Class of protection (IEC 536; VDE 1006 T1) Class III
S Degree of protection (EN 60 529; VDE 0470 T1) IP 00

2.12 I/O Module PP72/48
2.12.1 Module
S1: DIL switch for setting the

PROFIBUS address
LED: POWER LED: OVTEMP LED: READY LED: EXCHANGE
X2: PROFIBUS
1 8
X1: Power supply ON
OFF
X333 X222 X111
Dig. input/outputs
(50-pin ribbon cable connector)
Fig. 2-29 I/O Module PP72/48
Order number
I/O Module PP72/48 6FC5 611-0CA01-0AA0
Features The I/O module PP72/48 is a simple and low-cost module (without a separate
housing) for connecting digital input/outputs as part of an automation system
based on PROFIBUS DP.
The module has the following important features:
S PROFIBUS DP connection (max. 12 Mbaud), specified by:

PROFIDrive profile drive technology version 3,
Draft V1.4.2, 01. September 00
S 72 digital inputs and 48 digital outputs

S On-board status display by means of four diagnostic LEDs
To power the module and the digital outputs, an external power supply source
(+24VDC) is required.

Interface overview Interfaces of the I/O modules PP72/48
Table 2-15 Interfaces of the I/O Module PP72/48

Power supply connection X1 Screw-terminal block
PROFIBUS DP address S1 DIL switch
Digital input/outputs 1 X111 Ribbon cable connector
External power Interface description of the external power supply (X1):

supply
(X1)
S Screw-terminal block MSTBVA 2,5/3-G-5,08, Phoenix
S Pin assignment.
Table 2-16 Pin assignment: Ext. power supply (X1)
Pin Designation Type Function

1)
1 P24 VI External power supply of the module (+24V)

2 M24 VI Reference for external power supply
3 PE VI Protective conductor of the external power sup-
ply
1. VI Voltage Input
S Connecting cable
The required connecting cables must be provided by the user:
– Wire, conductor cross-section: 1.0–1.5mm2 (AWG17–AWG16)
S Power supply
For data concerning the power supply, see Subsection 2.12.3, page 2-101.

PROFIBUS DP Interface description of the PROFIBUS DP interface (X2):

(X2) S Connection: 9-pin SUB-D socket connector
S Pin assignment.
Table 2-17 Pin assignment: PROFIBUS DP (X2)
Pin Designation Type Function

1)
1 – – –
2 – – –
3 RxD/TxD-P B Receive/transmit data P (B line)
5 DGND VO Data reference potential (M5V)
6 VP VO Power supply voltage plus (P5V)
7 – – –
8 RxD/TxD-N B Receive/transmit data N (A line)
9 – – –
O Output
B Bi-directional
S Connector
– 6ES7972-0BA40-0XA0; cable outlet 350, without PG socket connector
– 6ES7972-0BB40-0XA0; cable outlet 350, with PG socket connector
– 6ES7972-0BA11-0XA0; cable outlet 900, without PG socket connector
– 6ES7972-0BB11-0XA0; cable outlet 900, with PG socket connector
S Cables:
– 6XV1830-0EH10; by the meter, non-trailable
– 6XV1830-3BH10; by the meter, trailable
S Further technical data

Maximum possible data transmission rate: 12 Mbit/sec.
PROFIBUS The PROFIBUS address of the ADI4 can be set in the range 1 to 127 using
address (S1) switch S1.
Table 2-18 Meaning of switch S1
Switch Meaning
1 PROFIBUS address: 20 = 1
8 not used
Notice
A newly set PROFIBUS address will only come into effect after power ON.

Digital input/out- Interface description of the digital input/output interfaces (X111/X222/X333):

puts S Connector: 50-pin ribbon cable connector
(X111/X222/X333)
S Pin assignment on each connector.
Table 2-19 Pin assignment (X111/X222/X333)
Pin Signal designation Type 1) Pin Signal designation Type 1)

1 M VO 26 Input 2.7 I
2 P24OUT VO 27 – –
3 Input 0.0 I 28 – –
4 Input 0.1 I 29 – –
5 Input 0.2 I 30 – –
6 Input 0.3 I 31 Output 0.0 O
22 Input 2.3 I 47 DOCOMx VI
1) VI Voltage Input
VO Voltage Output
I Signal Input
O Signal Output
x with x = 1,2,3

Digital inputs
S Terminal assignment for the digital inputs

The following figure shows an example of the terminal assignment for the
digital inputs on connector X111. Connectors X222 and X333 are assigned
analogously.
X111
PP72/48 P24OUT Pin number:
(+24VDC)
1
2
3
Receiver
4
Receiver
: :
: :
: :
: :
26
Receiver
ext. power supply

+24V
+24V stabilized
P24OUText
2
1
0V
Fig. 2-30 Terminal assignment for the digital inputs
1 If you are using the internal power supply P24OUT
2 If you are using an external power supply P24OUText
S Internal power supply (P24OUT)

The internal power supply for the digital inputs (X111, X222, X333: Pin 2) is
derived from the general power supply of module X1, pin 2 (P24). Specifica-
tion: See Subsection 2.12.3, page 2-101.
Caution
A max. current of Iout = 0.5A on X111, X222, X333: Pin 2 must not be ex-
ceeded. An exceeding of the maximum current might destroy the module.
S External power supply (P24OUText)

If an external power supply Is used for the digital inputs, its reference ground
must be connected with X111, X222, X333: Pin 1 (GND).
X111, X222, X333: Pin 1 (P24OUT) then remains open.

For specification of the external power supply, see Subsection 2.12.3,

page 2-101.
S Connecting cable: The required connecting cables (ribbon cables) must be
provided by the user
S Electrical specification of the digital inputs:

Table 2-20 Electrical specification of the digital inputs
Digital outputs min. typical max. nominal

Voltage at high level (Vhi) 15V 1) 30V 24V
Input current IIN at VUhi 2mA – 15mA –
Voltage at low level (Vlo) –30V – +5V 0V
Signal delay time TPHL 2) 0.5msec – 3msec –
S Power supply of the digital inputs
1) typical output voltage: VCC – IOUT<RON
VCC: Current operating voltage (P24OUT) at X111,
X222, X333: Pin 2
Max. output current IOUT: 500mA per pin
Max. short-circuit current: 4A (max. 100msec, VCC = 24V)
Internal resistance RON: 0.4W
S 2)
Moreover, the PROFIBUS communication time and the application cycle time must
be taken into account.
S Polarity reversal causes neither high level nor destruction of the inputs.

Digital outputs
S Terminal assignment for the digital outputs

The following figure shows an example of the terminal assignment for the
digital outputs on connector X111. Connectors X222 and X333 are assigned
analogously.
Ext. power supply

PP72/48 +24V stabilized
X111
+24V 0V
Pin number:
47,48,49,50
(DOCOM1)
31
Relays
Driver
Driver 32
: :
: :
: :
: :
Driver 46
1 (M)
Fig. 2-31 Terminal assignment for the digital outputs
S Connecting cable: The required connecting cables (ribbon cables) must be

provided by the user.
S Supply voltage
To power the digital outputs, an external 24VDC power supply source must
be connected to DOCOMx (X111, X222, X333: Pins 47, 48, 49, 50).
The reference ground of the external power supply source must be con-
nected to X111, X222, X333: Pin 1 (GND).
For further data, see Subsection 2.12.3, page 2-101.
Caution
At the user end, it must be ensured that the maximum current drawn per
DOCOMx Pin (X111, X222, X333: Pins 47, 48, 49, 50) does not exceed 1A.
The power supply (+24VDC) for the digital outputs must therefore be con-
nected to all 4 pins (X111, X222, X333: Pin 47, 48, 49, 50) for each DOCOMx.

S Electrical specification of the digital outputs:

Table 2-21 Electrical specification of the digital outputs

Voltage at high level (Vhi) VCC – 3V 1) VCC 24V
Output current IOUT – – 500mA –
Voltage at low level (Vlo) – – – Output
open
Leakage current at low level – 50mA 400mA –
Signal delay time TPHL 2) – 0.5msec – –
Max. switching frequency 2)
Ohmic load 100Hz – – –

Inductive load 2Hz – – –
Lamp 11Hz – – –
S Power supply of the digital outputs
1) typical output voltage: VCC – IOUT<RON
VCC: Current operating voltage
Max. output current IOUT: 250mA for a simultaneity factor of 100%
500mA for a simultaneity factor of 50%
S 2)
Moreover, the PROFIBUS communication time and the application cycle time must
be taken into account.
S Incorrect polarization causes neither high level nor destruction of the outputs.
S General electrical properties

– Galvanic isolation using optocouplers
– Current limitation to max. 500mA
– Protection from: short-circuit, overtemperature, and loss of ground
– Autom. shutdown on undervoltage.

LED: Status display The module has three LEDs through which the module status is displayed.
Table 2-22 LED: Status display
Designation Color Description

POWER green Supply voltage
OVTEMP red Overtemperature display
EXCHANGE green Cyclic data exchange with DP master in prog-
ress
READY red Ready for cyclic data exchange with DP mas-
ter
2.12.3 Power supply

The supply voltage (24VDC) of the I/O module PP72/48 is connected to the
screw terminal block X1. See Subsection 2.12.2, page 2-94.
ADI4 module To power the ADI4 module (+24VDC), an external power supply source is
required. The power supply is connected through the screw terminal block X1.
Digital outputs To power the digital outputs (+24VDC), an external power supply source is
required. The power supply is connected through terminals X111, X222, X333,
pins 47, 48, 49, 50 (DOCOMx).
Digital inputs If the internal power supply from X111, X222, X333, Pin 2 (P24OUT) is not used
to power the digital inputs, it can be replaced by an external power supply
source (+24VDC) as an option.
The reference ground of the power supply source must be connected with X111,
X222, X333, Pin 1 (GND). X111, X222, X333, Pin 2 (P24OUT) then remains
open.
Specification of The external power supply voltages must be generated as functional extra-low
the power supply voltages with safe electrical isolation (according to IEC 204-1, Section 6.4,
voltages (+24VDC) PELV) and must be grounded centrally by the user.
The reference ground of the terminals X111, X222, X333. pin 1 (GND) must be
connected to a common grounding point with the reference ground of the power
supply of the I/O module PP27/48.
Caution
The external power supply voltages must be generated as function extra-low
voltages with safe electrical isolation (IEC 204-1, Section 6.4, PELV) and must
be grounded centrally by the user.

Moreover, the external power supply voltages for the I/O modules PP72/48, the
digital outputs, and optionally the digital inputs must meet the specifications
according to Table 2-23.
Table 2-23 Specification of the power supply voltage P24OUT,
Voltage
minimum 20.4V
nominal 24V
max. 28.8V
minimum (dynamic) 18.5V
maximum (dynamic) 30.2V
Non-cyclic overvoltage
max. (absolute, transient) 35V
max. duration 500msecs
min. recovery time 50secs
max. events per h 10
Voltage failure for min. power supply voltage
max. duration 1) 50msecs
min. recovery time 1s
max. events per h 10
Power consumption
max. approx. 40W
On the module side the power supplies must be protected against:
S Polarity reversal
S Short-circuit (elec. current limitation of the outputs)
S Overload (fuse protection).
2.12.4 Grounding
The installation of the module must be performed acc. to EN 60204.
If a large-area, permanent metallic connection with the central ground point
through the rear panel is not possible, the mounting plate must be connected to
the grounding by means of a line (cross section >10mm2).
Caution
! A protective conductor must be connected.

194
10.5
6.5
325
306
10 10 170
35
35
Fig. 2-32 Dimension drawing: I/O Module PP72/48

Technical data of the I/O modules PP72/48
Safety
1982 (IEC 536);
Protection against ingress of solid foreign bodies and
water to IEC 529
Certifications CE/CSA, CE
Power consumption
At nominal load 11W
Mechanical data
Dimensions WxHxD [mm] 194x325x35
Weight approx. 0.3kg approx. 1.2kg
without mounting plate with mounting plate
Temperature limit values 0 ... 50°C –20 ... 55°C/–40 ... 70°C
Limit values of rel. humidity 5 ... 95% 5 ... 95%
not condensing not condensing
Atmospheric pressure 700 ... 1060 hPa 700 ... 1060 hPa
Transportation height – –1000 ... 3000m
Shock loading during transportation
Free fall in transport package v1000mm

2.13 ADI4 (analog drive interface for 4 axes) (SW 09.01 and higher)
2.13 ADI4 (analog drive interface for 4 axes) (SW 09.01 and
higher)
2.13.1 Module
X1: External power supply

24VDC
OFF
ON
X2: PROFIBUS connection

1
PROFIBUS address:
equivalent to
AH = 10D
S2: DIL switch for setting the

PROFIBUS address
8
X3: Analog setpoint outputs

$10V DC, axis 1–4
X4–2: Encoder connection X4-1: Encoder connection

for axis 2 for axis 1
X5-2: Encoder connection X5-1: Encoder connection

for axis 4 for axis 3
X6-2: Connection for digital X6-1: Connection for digital

input signals output signals
Diagnostic LEDs
H1: PW TMP
H2: EXCH RDY Connection for protective ground
screw M6
Fig. 2-33 Connection overview ADI4

Order No.
ADI4 6FC5 211-0BA01-0AA1
Features The interface module ADI4 is suitable for operating up to four drives with an
analog setpoint interface on the PROFIBUS DP.
The module has the following important features:
S PROFIBUS DP connection (max. 12 Mbit/s), in accordance with:

PROFIDrive profile drive technology version 3,
S Four servo interfaces each with one:

– Input: TTL/SSI encoder for incremental and absolute measuring systems
– Output $10V analog
S General and drive-specific digital input/output signals

S On-board status display by means of four diagnostic LEDs
To power the module and the digital outputs, an external power supply source
(+24VDC) is required.
Notice
Please observe the following framework conditions for operating the ADI4 DP
slave:
S An ADI4 DP slave can only be operated on an equidistant PROFIBUS DP

(see Subsection 7.3.6, page 7-220).
S An ADI4 DP slave is not a DP standard slave certified as compliant with the

PROFIDrive profile, e.g. the ADI4 DP slave does not support acyclic com-
munication.

Interface overview Interfaces of the ADI4 module
Table 2-24 Interface overview: ADI4

External power supply +24V X1 Connector
PROFIBUS DP address S2 DIL switch
Analog setpoint interface X3 Connector
Encoder connection for axis 1 X4-1 Socket connector
Digital outputs X6-1 Connector
Digital inputs X6-2 Connector
Module status H1/H2 LEDs
External power Interface description of the external power supply (X1):

supply
(X1)
S Connector: Three-way connector MSTB 2.5/3-ST-5.08, Phoenix
S Pin assignment.
Table 2-25 Pin assignment: Ext. power supply (X1)

1 P24EXT1 VI External power supply of the module (+24V)
2 M24EXT1 VI Reference for external power supply
3 PE VI Protective conductor of the external power supply
1) VI Voltage Input
S Connecting cable
The required connecting cables must be provided by the user:
– Wire, conductor cross-section: 1.0–1.5mm2 (AWG17–AWG16)
S Supply voltage
For specification of the supply voltage, see Subsection 2.13.4, page 2-119.

PROFIBUS DP Interface description of the PROFIBUS DP interface (X2)

(X2) S Connection: 9-pin SUB-D socket connector
S Pin assignment.
Table 2-26 Pin assignment: PROFIBUS DP (X2)

1 – – –
2 – – –
3 RxD/TxD-P B Receive/transmit data P (B line)
5 DGND VO Data reference potential (M5V)
6 VP VO Power supply voltage plus (P5V)
7 – – –
8 RxD/TxD-N B Receive/transmit data N (A line)
9 – – –
O Output
B Bi-directional
S Connector
– 6ES7 972-0BA41-0XA0; 350 angle for cable outlet, without PG connec-
tion socket
– 6ES7 972-0BB41-0XA0; 350 angle for cable outlet, with PG connection
socket
– 6ES7 972-0BA12-0XA0; 900 angle for cable outlet, without PG connec-
tion socket
– 6ES7 972-0BB12-0XA0; 900 angle for cable outlet, with PG connection
socket
S Cables:
– 6XV1 830–0EH10; by the meter, non-trailable
– 6XV1 830–3EH10; by the meter, trailable
S Further technical data

Maximum possible data transmission rate: 12 Mbps.
PROFIBUS The PROFIBUS address of the ADI4 can be set in the range 1 to 127 using
address (S2) switch S2.
Table 2-27 Meaning of switch S2
Switch Meaning
8 not used

Notice
A newly set PROFIBUS address will only come into effect after power ON.
Analog setpoint Interface description of the analog setpoint interface (X3):

interface
(X3)
S Connection: 50-way SUB D connector
S Pin assignment.
Table 2-28 Pin assignment: Analog setpoint interface (X3)

1 SW1 VO Setpoint axis 1 ($10V)
2 BS2 VO Reference for setpoint axis 2
5–13 – – –
14 RF1_1 K 2) “Drive enable” axis 1, relay contact 1
18–33 – – –
38–46 – – –
K Relay contact
2) Max. current carry capacity: 2A with 150VDC or 125VAC
ADI4
X3
Pin number:
Relays
Signal: 14 ... 17
“Drive enable”
Axis 1 ... 4 47 ... 50
S Preassembled cables
– Order No. (MLFB) 6FX2 002-3AD01-1jj0
Cable length: v35m
Data about the length codes are to be found in:
References: /Z/ Catalog NC Z.

Encoder interface Interface description of the encoder interfaces (X4-1/X4-2/X5-1/X5-2):

(X4-1/X4-2)
(X5-1/X5-2)
S Pin assignment of the encoder interfaces:
Table 2-29 Pin assignment: Encoder interface axes 1 – 4 (X4-1/X4-2/X5-1/X5-2) for
incremental encoder (TTL) and absolute encoder (SSI)
Pin Designation1) yp 2)
Type Function
incremental absolute (SSI)
2 – CLSx O SSI shift cycles
3 – CLSx_N O SSI shift cycles negated
4 P5MS VO Power supply voltage 5VDC
5 P24SSI VO Power supply voltage 24VDC
6 P5MS VO Power supply voltage 5VDC
7 GNDEXT VO Reference for power supply
9 GNDEXT VO Reference for power supply
10 Rx_S – I Zero mark signal
11 XRx_S – I Zero mark signal negated
12 XBx_S – I Encoder signal track B negated
13 Bx_S – I Encoder signal track B
14 XAx_S – I Encoder signal track A negated
– DATAx_N I SSI data inverted
15 Ax_S – I Encoder signal track A
– DATAx I SSI data
1) X Number of the encoder interface with X4-1=1, X4-2=2, X5-1=3, X5-2=4
I Signal Input
O Signal Output
S Preassembled cables with use of:

– Incremental encoder (TTL) with RS422 (5V or 24V) 6FX2 001–2...
Order No.: 6FX8 002-2CD01-1jj0 (5V)
Order No. (MLFB): 6FX5 002-2CD24-1jj0 (24V)
Cable length: See below “Maximum cable lengths”.
– Absolute value encoder with SSI 6FX2 001-5...
Order No. (MLFB): 6FX8 002-2CC11-jjj0
– 1FT5 motor with installed ROD320 encoder
Order No. (MLFB): 6FX8 002-2CE02-1jj0
Data about the length codes are to be found in:
References: /Z/ Catalog NC Z.

S Maximum cable lengths

The max. cable length depends on the following parameters:
1st encoder power supply
Supply voltage 5VDC

Tolerance Power Max. cable length
consumption
4.75V – 5.25V x300 mA 25m
4.75V – 5.25V x220 mA 35m
Supply voltage 24VDC
Tolerance Power Max. cable length
consumption
20.4V – 28.8V x300 mA 100m
11V – 30V x300 mA 300m
2nd transmission frequency

Encoder type Supply voltage Frequency Max. cable length
incremental (TTL)
( ) 5V 1MHz 10m
500kHz 35m
24V 500kHz 150m
absolute (SSI)
( ) 24V 1.5 Mbps 10m
187.5 Kbps 250m
Note
If cable lengths longer than 25m or 35m are required with incremental encod-
ers, you can use encoder types with a supply voltage of +24VDC instead.
Caution
To ensure error-free transmission of encoder data, do not exceed the max.
cable lengths shown in the table.
S Specification of the encoder supply voltages:

Table 2-30 Specification of the encoder supply voltages
Supply voltage 1)
P5MS P24SSI
Voltage
minimum 5.1V 20.4V
nominal 5V 24V
max. 5.3V 28.8V
Ripple
max. 3.6Vpp
Current load
per encoder connection 0.3A
max. 1.35A 1A
1) P5MS: Supply voltage for encoders (+5VDC)
P24SSI: Supply voltage for encoders (+24VDC)

S Connectable measuring systems:

Incremental encoders (TTL)
– Differential transmission with RS-422 (5V or 24V):
Track A as a true and negated signal (Ua1, Ua1)
Track B as a true and negated signal (Ua2, Ua2)
Zero signal N as a true and negated signal (Ua0, Ua0)
– Max. output frequency: 1.5MHz
– Phase shift of track A to B: 90_"30_
– Power consumption: max. 300mA
Absolute encoder (SSI)
– Transmission procedure: Synchronous-serial interface (SSI) with 5V
Differential signal transmission (RS-422 standard):
Output signal: Data as a true and negated signal
Input signal: Shift cycles as a true and negated signal
– Resolution: max. 25 bits
– Max. transmission frequency: 1 Mbps
– Power consumption: max. 300mA
Notice
Only SSI Multiturn encoders can be used as absolute measuring systems.
Further measuring systems:

– Encoders with SINE/COSINE signals (e.g. 1Vpp) can be connected
through external pulse shaper electronics (EXE) that convert the signals
to 5V TTL levels.

Digital outputs Interface description of the digital output interface (X6-1):

(X6-1)
S Connector: two 12-way connector FK-MCP 1,5/15-ST-3.81, Phoenix (to-
gether with X6–2)
S Pin assignment:
Table 2-31 Pin assignment: Digital output interface (X6-1)

1 P24EXT2 VI Ext. Power supply voltage 24VDC
2 Q0 DO 1. Digital output signal
3 Q1 DO 2nd Digital output signal
4 Q2 DO 3rd Digital output signal
5 Q3 DO 4th Digital output signal
6 DIR1 DO 5th Digital output signal or
axis-specific direction signal axis 1 3)
7 DIR2 DO 6. Digital output signal or
10 RDY1 K 2) Ready signal “Ready” relay contact 1
11 RDY2 K 2) Ready signal “Ready” relay contact 2
12 MEXT2 VI Reference of ext. Supply voltage
1) VI Voltage Input
DO Digital Output (24V) Pin 1
K Relay contact
2) Max. current carry capacity: 2A for
150VDC or 125VAC
3) in the case of function “unipolar
spindle”
Ext. power supply

+24V stabilized
ADI4 X6-1
Pin number: +24V 0V
1 (P24EXT2)
Optocoupler
2
Relays
Driver
Driver 3
: :
: :
: :
: :
Driver 9
Relays
10
Signal:
“Ready”
11
12 (MEXT2)

S Supply voltage:
An external power supply source 24VDC must be connected to the power
supply of the digital outputs at X6-1, pin 1 (P24EXT2).
The reference ground of the external power supply source must be con-
nected with X6-1, pin 12 (MEXT2).
For further data, see Subsection 2.13.8, page 2-124.
S Electrical specification of the digital outputs:

Table 2-32 Electrical specification of the digital outputs

Voltage at high level (Vhi) VCC – 3V 1) VCC 24V
Output current IOUT – – 500mA –
Voltage at low level (Vlo) – – – 0V
Leakage current at low level – 50mA 400mA –
Signal delay TPHL and TPLH 2) – 0.5msec – –
S Power supply of the digital outputs

1) typical output voltage: VCC – IOUT<RON – 0.65V
VCC: Current operating voltage P24EXT2
Max. output current IOUT: 500mA
S 2) The PROFIBUS communication time and the application cycle
time must also be taken into account.
S Incorrect polarization causes neither high level nor destruction of the outputs.

– Current limitation to max. 500mA
– Protection from: short-circuit, overtemperature, and loss of ground
– Automatic shutdown on undervoltage.
S Relay contact Ready signal “Ready”

The relay contact remains open/is opened if one of the follwoing states is
present in the module:
– Initialization after Power On
– Power Failure or NMI
– No cyclic communication to DP master
– PLL error
– Synchronization error
– Overtemperature
The relay contact is closed when the following conditions are satisfied:
– Module status “Ready”
– Cyclic communication with the DP master

S Connecting cable: The required connecting cables must be provided by the

user.
– Power supply voltage X6-1, pins 1 and 12 (P24EXT2):
Wire, conductor cross-section 1.5mm2 (AWG16)
– Digital outputs X6-1, pins 2–9:
Wire, conductor cross-section 0.5–1.5mm2 (AWG20–AWG16)
– NC Ready X6-2, pins 10 and 11:
Notice
The lengths of the digital signal lines must not exceed 30m.

Digital inputs Interface description of the digital input interface (X6-2):

(X6-2)
S Connector: 2x12-way connector FK-MCP 1.5/15-ST-3.81, Phoenix (together
with X6-1)
S Pin assignment:
Table 2-33 Pin assignment: Digital input interface (X6-2)

1 P24OUT VI Power supply voltage 24VDC
2 BERO1 DI Input signal BERO1
6 MEPU1 DI Measuring signal 1st sensor probe
7 MEPU2 DI Measuring signal 2nd sensor probe
8 DRV1_RDY DI Ready signal “Drive Ready” axis 1
12 MOUT VI Reference of the power supply
1) VI Voltage Input
DI Digital Input (24V) Pin 1
X6-2
ADI4 P24OUT Pin number:
(+24VDC) 1
1
Optocoupler
2
: :
: :
: :
: :
11
0V +24V
12 P24OUText
ext. power supply
M +24V stabilized
1 Connection if the internal power supply voltage P24OUT is used;

the connection to 2 is then no longer necessary.

2 Connection if an external power supply is used

P24OUText; the connection to 1 is then no longer necessary.
S Internal power supply P24OUT

The power supply available for digital inputs at X6-2, pin 1 is specified as
follows:
Table 2-34 Specification of the power supply voltage P24OUT
Voltage
minimum 20.4V
nominal 24V
max. 28.8V
Ripple
max. 3.6Vpp
Current load
typical 0.1A
max. 1A
Power consumption
typical 3.02W
max. 30.2W
Insulation class A, acc. to DIN 57110b
S Typical output voltage: VCC – IOUT<RON – 0.65V

VCC: Current P24OUT operating voltage
max. output current IOUT: 1A
Internal resistor RON: 0.4W
S The power supply P24OUT is short-circuit-proof
S External power supply P24OUText

If an external power supply Is used for the digital inputs, its reference ground
must be connected to X6-2, pin 12 (GND).
X6-2, pin 1 (P24OUT) then remains open.
S Electrical specification of the digital inputs

Table 2-35 Electrical specification of the digital inputs
Digital inputs min. typical max. nominal

Voltage at high level (Vhi) 15V 1) 30V 24V
Input current IIN at VUhi 3.7mA – 7.5mA –
Voltage at low level (Vlo) –30V – +5V 0V
Signal delay TPHL and TPLH 2) – 3msecs – –
S 1) see Table 2-34, page 2-117
S 2) The PROFIBUS communication time and the application cycle
time must also be taken into account.
S Polarity reversal causes neither high level nor destruction of the inputs.
S Connecting cable: The required connecting cables must be provided by the

user.

– Power supply X6-2, pin 1 (P24OUT), external power supply P24OUText:

Wire, conductor cross-section 1.5mm2 (AWG16)
– Digital inputs X6-2, pins 2–11:

– Active current limitation of the inputs
– Protection from negative input voltage.
Module status The module status is displayed on 4 diagnostic LEDs on the front of the module.
(H1/H2)
Table 2-36 Diagnostic LEDs (H1/H2)
Designation Color Description

H1 POWER green Supply voltage
OVTEMP red Overtemperature display
H2 EXCHANGE green Cyclic data exchange with DP master in progress
READY red Ready for cyclic data exchange with DP master

2.13.3 Cabinet mounting
Mounting The housing of the ADI4 module must be connected with the back wall of the
cabinet and this, in turn, to the motors/machine through a low-resistance contact
for high-frequency interference currents. The ideal way of mounting the module
is on an unpainted mounting wall. The mounting wall must be connected to the
motors/machine by a large-area and conductive contact. Painted cabinet walls
and DIN rails, or similar mounting accessories with a small contact area do not
fulfill this requirement.
Cable routing Power and signal cables must always be laid apart. All signal cables of the I/O
interfaces (X6-1/X6-2) must be routed together. Single cores whose signals are
related must be twisted. Signal cables and encoder cables must ideally be laid
separately.
All cables within the cabinet must be routed as close as possible to the cabinet
walls, long routing through the open space can cause interference (antenna
effect). The vicinity of sources of interference (contactors, transformators, etc.)
must be avoided, placing a shield plate between the cable and the source of
interference, if necessary. Cable extension through terminals, etc. must be
avoided. To protect interference from external sources, signal cables must be
shielded.
Warning
! The ADI4 is designed for operation in an enclosed cabinet. Operation outside
an enclosed cabinet is not permissible.
2.13.4 Power supply
ADI4 module To power the ADI4 module (+24VDC), an external power supply source is
required. The power supply source is connected through terminal X1
(P24EXT1) on the front panel of the ADI4 module. See Subsection 2.13.2,
page 2-107.
Digital outputs To power the digital outputs (+24VDC), an external power supply source is
required. The power supply is connected through terminal X6-1, pin 1
(P24EXT2). See Subsection 2.13.2, page 2-107.
Digital inputs If the internal power supply from X6-2, Pin 1 (P24OUT) is not used to power the
digital inputs, it can be replaced by an external power supply source (+24VDC,
max. 1A) as an option.
The reference ground (GND) of the external power supply source must be con-
nected with X6-2, pin 12. X6-2, pin 1 (P24OUT) remains open.

Specification of The external power supplies for the ADI4 module, the digital outputs, and op-
the power supplies tionally the digital inputs must meet the specifications in Table 2-30.
(+24VDC)
Table 2-37 Specification of the external power supplies
Supply voltage 1)
P24EXT1 P24EXT2 P24OUText
Voltage
minimum 18.5V
nominal 24V
max. 30.2V
Ripple
max. 3.6Vpp
Current load
typical 0.5A – 0.1A
max. 1A 8A 1A
Power consumption
typical 12W – 3.02W
max. 30.2W 241.6W 30.2W
1) P24EXT1: Supply voltage of the ADI4 module
P24EXT2: Supply voltage for the digital outputs
P24OUText: Optional supply voltage for the digital inputs
Caution
The external power supply voltages must be generated as functional extra-low
voltages with safe electrical isolation (DIN EN 60204-1, Section 6.4, PELV).
On the module side, power supplies P24EXT1 and P24EXT2 must be protected
against:
S Overvoltage
S Short-circuit (elec. current limitation of the outputs)
S Polarity reversal
S Overload
– P24EXT1: Fuse 2.5A/250V
– P24EXT2: Fuse 8A/125V.

2.13.5 Grounding
The installation of the module must be performed acc. to EN 60204.
The user must ground the power supply voltages. From terminal X1, pin 2
(MEXT1) or X6-1, pin 12 (MEXT2) it is necessary to establish a link with a
central grounding point of the system.
If a large-area, permanent metallic connection with the central ground point
through the rear panel is not possible, the module must be connected to the
grounding rail by means of a line (cross section >10mm2).
Caution
! A protective conductor must be connected.
The housing front has an M6 screw bottom right for connecting the protective
conductor. See Subsection 2.13.1, page 2-105.

2.13.6 Connection overview
Order No.
ADI4 Preassembled cable
Connector:
MSTB 2.5/3-ST-5.08, Phoenix Ext. power supply
X1 Cable:
Ext. power supply 24VDC
Wire (1.0 to 2.5mm2)
24VDC
Connector:
6ES7 972-0BA41-0XA0
6ES7 972-0BB41-0XA0
6ES7 972-0BA12-0XA0
X2 6ES7 972-0BB12-0XA0 SINUMERIK 840Di
Cable:
PROFIBUS DP
6XV1 830-0EH10
6XV1 830-3EH10
6FX2 002-3AD01-1jj0 SIMODRIVE 611 analog

X3 v35m
Analog output 4 setpoints
axis 1 – 4
X4-1
Incremental encoder with
6FX8 002-2CD01-1jj0 (5V) RS422 (TTL) (5V or 24V)
Connections for encoders 1 – 4
6FX5 002-2CD24-1jj0 (24V)

1) 6FX2001-2...
X4-2
Absolute value encoder
6FX8 002-2CC11-1jj0 with SSI
1) 6FX2001-5...
X5-1
Pulse encoder
6FX8 002-2CE02-1jj0 ROD320
v 35m in the 1FT5 motor
X5-2
Ext. power supply

24VDC
X6-1
Dig. outputs Connector:
FK-MCP 1,5/15-ST-3.81, Phoenix
Cables: Sensors 1–n
Wire (0.14 to 2.5mm2)
X6-2
Dig. inputs Actuators 1–n
1) Max. cable lengths: See Subsection 2.13.2, page 2-107
Fig. 2-34 ADI4 connection overview

23.25
Ğ13 6.5
80 1)
3.2
374
360
1)
Necessary clearance for adequate
ventilation
80 1)
163.6
6.5
48.5
Max. tightening torque for all screws: 0.8Nm
Fig. 2-35 Dimension drawing: ADI4

Table 2-38 Technical data of the ADI4 module

Safety
Degree of protection IP20
1982 (IEC 536);
Protection against ingress of solid foreign bodies and
water to IEC 529
Certifications CE/CSA, CE
Power consumption
Nominal load 12W
Max. 30.2W
Mechanical data
Dimensions WxHxD [mm] 154.4x325x48.5
Weight approx. 1.5kg
Temperature limit values 0 ... 55°C –20 ... 55°C/–40 ... 70°C
Limit values of rel. humidity 5 ... 95% 5 ... 95%
not condensing not condensing
per min. per hour
Atmospheric pressure 700 ... 1060hPa 700 ... 1060hPa
Transportation height – –1000 ... 3000m
Shock loading during transportation
Free fall in transport package v1000mm

Design 3
3.1 System overview
OP 010 OP 010S OP 010C OP 012 OP 015

MCI board extension
MCI board slot variation
Industrial PC: PCU 50

PROFIBUS DP with MotionControl
MPI bus
SIMODRIVE
POSMO A
Decentr. I/O system SIMATIC

SIMODRIVE 611 universal ADI4 SIMODRIVE ET 200
option module: MotionControl POSMO SI
with PROFIBUS DP
Mini HHU
SIMODRIVE
POSMO CD/CA
I/O Module PP72/48 Handheld unit
type B-MPI
ÄÄ
ÄÄ
Handheld
Machine control panel PC/PG e.g. PG740 Terminal HT 6
Distributor box Distributor

or box
Fig. 3-1 SINUMERIK 840Di system overview: PROFIBUS DP and MPI (as a diagram)

3 Design 06.03
3.1 System overview
Operator panel front: OP 012
PS/2 mouse CD-ROM Diskette PS/2 keyboard

drive drive 3.5’’
Industrial PC: PCU 50
PC/programming SITOP POWER SITOP DC-UPS Module 15 with

device, e.g. PG740 VGA monitor Standard 24V/10A SITOP POWER lead-acid module
SIEMENS
SIEMENS
Optional
Fig. 3-2 System overview: PCU components (as a diagram)

06.03 3 Design
3.2 Electrical design
Note
For details on general accessories, such cables, connectors and prefabricated
cables, please refer to in:
References: /Z/ Catalog NC Z, Accessories and Equipment
3.2.1 MCI board and PROFIBUS DP
X2/X5
X111
X2 SIMATIC DP ET200
X2
X101
X2
I/O Module PP72/48

MCI board SIMODRIVE 611 universal
option module: MotionControl
with PROFIBUS DP
X2
*)
SIMODRIVE
POSMO A
ADI4
*) *)
SIMODRIVE SIMODRIVE
POSMO SI POSMO CD/CA
*)
PROFIBUS DP connection conditions:
References /POS1/ SIMODRIVE POSMO A User Manual
/POS3/ SIMODRIVE POSMO SI/CD/CA User Manual
Fig. 3-3 SINUMERIK 840Di MCI board and PROFIBUS DP components

3 Design 06.03
3.2.2 MCI board and MPI bus
X2/X5 Machine control panel Handheld unit

type B-MPI
(rear view)
ÄÄ
X5
X20
X111
X4
Distributor box
X101
X5 or Handheld
Terminal HT 6
X4
MCI board
Distributor box
PC/PG e.g. PG740 (4-core
confirmation technique)
Fig. 3-4 SINUMERIK 840Di MCI board and MPI bus components
3.2.3 MCI board extension
X4
Cable distributor
X121
2x probes 2x handwheels 4x digital inputs

4x digital output
MCI board extension
Fig. 3-5 SINUMERIK 840Di MCI board extension

06.03 3 Design
3.2.4 PCU 50
Connection for an exter-

nal floppy disk drive
(32-pin plug connector)
RESET
Fan Reset pushbutton switch
External floppy disk drive 3.5’’
Fig. 3-6 SINUMERIK 840Di PCU 50, left housing side
SITOP DC UPS module 10 with

SITOP POWER 10 SITOP POWER lead-acid module
SIEMENS
SIEMENS
MCI board
Power supply
X101 X111
for 24 VDC
PS2 mouse
PS/2 mouse COM1 COM2
USB
LPT1 VGA MPI/L2-DP Ethernet
PC card slot
PS/2 keyboard
1:
X121
MCI board extension
(option)
PS2 keyboard (QWERTY) Ext. CD-ROM VGA Monitor

drive
1) Only mouse and keyboard can be connected PC/programming

through the USB interface. device, e.g. PG740
Fig. 3-7 SINUMERIK 840Di PCU 50 (right housing side)

3 Design 06.03
3.2.5 PCU 70
Slot 3 (slave)
Slot 4 (slave)
X101 X111
1)
24V
X121
power supply
PS/2 mouse
2)
COM1 COM2
LPT1 VGA PC card slot
PS/2 keyboard USB MPI/L2-DP Ethernet
Expansion slots
1) Slot 1 (Master/slave)
Connections Note
Assignment as with PCU 50 The MCI board must only be run in slot 1
2) Slot 2 (master/slave)
MCI board extension (option)
Fig. 3-8 SINUMERIK 840Di PCU 70 (right housing side)
Note
The connections of the PCU 70 correspond to those of the PCU 50.

06.03 3 Design
3.3 Connection overview
3.3.1 PCU 50, MCI board and MCI board extension
SINUMERIK 840Di A maximum of

2 handwheels can be con-
PCU 50 nected in total
Dig. I/O
(max. of 4 each)
Cables:
6FX2002-4AA41-1jj0 Probe (max. of 2)
MCI board extension
6FX2006-1BA01
Cable distributor
X121
Cables: Electronic
6FX2002-4AA21-1jj0 handwheel
(optional)
v25m (max. of 2)
Cables: Distributor 4)
6FX2002-4AA21-1jj0 6FX2006-1BG00 Mini HHU
v25m, for handwheel signals
Cables:
X4 6FX2002-4AA21-1jj0
Distributor
1) 4) HHU
v25m, for handwheel 6FX2006-1BC01
type B-MPI
signals 6FX2006-1BF00
The following is included in
the scope of supply of the
1) 6)
Distributor for 4-core Cables: Handheld
confirmation
MCI board extension
6FX2002-1AA23-1jj0 terminal HT 6
6FX2006-1BH01 v40m
1)
Programming device
200m, 1.5 Mbaud
e.g. PG740
1) 7)
Machine control panel
PROFIBUS DP drive
1) e.g. SIMODRIVE 611
2) 7) universal
X2
X111 PP 031-MC or
MPI SIMODRIVE POSMO
MCI board
1)
3) 100m, 12 MBaud
X101
(PROFIBUS DP)
1) 1) 1)
SIMATIC DP ET200 8)
I/O module PP72/48 Interf. modules ADI4
Standard PC e.g. ET200M
interfaces 5)
Fig. 3-9 Connection overview PCU 50, MCI board and MCI board extension

3 Design 06.03
1) Connector:
6ES7972-0BA40-0XA0; cable outlet 350, without socket connector for pro-
gramming device
6ES7972-0BB40-0XA0; cable outlet 350, with socket connector for pro-
gramming device
6ES7972-0BA11-0XA0; cable outlet 900, without socket connector for pro-
gramming device
gramming device
Cable:
6XV1830-0EH10; yard ware, non-trailable
6XV1830-3BH10; yard ware, trailable
2) Connector:
6GK1500-0EA02; cable outlet 1800, without socket connector for program-
ming device
Cable:
3) Connector:
gramming device
gramming device
Cable:
4) The cable is included in the scope of supply of the HHU or the mini HHU.
5) For an overview of the standard PC interfaces, see Fig. 3-6, page 3-129
and Fig. 3-7, page 3-129.
Component PCU 50.
6) – HT 6 always plugged: Max. of 200m from connector X111 to HT 6
– HT 6 not always plugged: Max. of 200m from connector X111 to HT 6
With repeater only:
RS485 (6ES7972-0AA01-1XA0)
Otherwise, total length of MPI from connector
X111 to distributor v5m
– The line -4EA04 is not permitted.
Always connect the HT 6 at an end of the MPI path (integrated bus ter-
mination).
Note
The HT 6 can also be connected to a distributor with 3-core confirmation.
– Distributor: 6FX2006-1BC01
– Cable: 6FX2002-1AA83-1jj0

06.03 3 Design
7) Machine control panel and PP 031-MC can be operated together.Subsec-

tion3.3.1
8) For a more detailed connection overview of the ADI4, please refer to Sub-
section 2.13.6, page 2-122.
Note
The length codes for preassembled cables 6FXj002–... can be found in:
References: /BU/ SINUMERIK 840D/840Di/810D/FM-NC
Ordering information
Catalog NC 60@2000/2001
For supplementary conditions (if any) applicable to the individual accessories,
please refer to:
References: /Z/ SINUMERIK, SIROTEC, SIMODRIVE
Accessories and Equipment for Special-Purpose
Machines
Catalog NC Z.

3 Design 06.03
Notes

EMC and ESD Measures 4
4.1 Interference suppression measures
Shielded Only use the cables specified in the individual diagrams to ensure safe
signal cables interference-free operation of the system. Generally, the shield must be
conductively connected to the housings on both ends.
Exception:
S If third-party devices are connected (printer, programming devices etc.), it is

also possible to use standard shield cables connected to the housing to one
end only.
These devices, however, may not be connected to the control system during
normal operation. If the operation of third-party devices is inevitable, the
shields must be connected to both ends. In addition, the third-party device
must be connected to the control system using an equipotential bonding
conductor.
Installation rules In order to achieve maximum noise immunity of the whole system (control
system, power section, machine), observe the following EMC measures:
S Observe maximum clearance between signal and load cables.

S Use only the cables offered by SIEMENS as the signal lines from and to the
NC or PLC.
S Make sure that the signal lines have a sufficient clearance from strong
magnetic fields (e.g. motors and transformers).
S Pulse-loaded high-current/high-voltage cables must always be routed

completely separated from any other cables.
S If a sufficient clearance is not possible, signal lines must be routed in

shielding cable channels (metal).
S Make sure that the distance (interference injection area) between the cables
listed below is as low as possible:
– Signal line and signal line
– Signal line and appropriate equipotential bonding conductor
– Equipotential bonding conductor and appropriate protective conductor.
Important
! For further notes on interference suppression measures and the connection of
shielded cables, please refer to
References: /EMV/ EMC Installation Guide.

4 EMC and ESD Measures 06.03
4.2 ESD measures
4.2 ESD measures
Notice
Handling of ESD modules:
S When you are handling ESD-sensitive devices, make sure that you, your
workplace and the device packaging are grounded well.
S Do not touch electronic modules unless it is absolutely essential for the

work to do on it. When handling p.c. boards, never touch the module pins or
printed conductors.
S Do not touch ESD-sensitive components unless

– you are grounded by means of an antistatic wristband,
– you wear antistatic footwear or ground straps when walking on an anti-
static floor.
S Place sensitive modules only on high-resistance, conductive surfaces (table

with antistatic surface, conductive antistatic foam or antistatic packaging).
Notice
An exception are modules with their own power supplies (e.g. battery).
These may not be placed on conductive surfaces, as this might result in
short circuits and thus destroy the component on the module.
S Do not bring ESD-sensitive modules into the vicinity of visual display units,
monitors or TV sets (minimum distance to the screen > 10 cm).
S Do not bring ESD-sensitive modules into contact with chargeable and

highly-insulating materials, such as plastic, insulating table tops or clothing
made of synthetic materials.
S Measurements on ESD-sensitive modules may only be carried out if

– the measuring instrument is grounded (e.g. using a protective conduc-
tor) or
– the measuring head is discharged for a short time prior to the measure-
ment (e.g. by touching a bright control housing).

MPI Communication 5
5.1 General
Notice
On the SINUMERIK 840Di, nodes must not be plugged in or removed during
operation on the MPI bus.
MPI bus addresses Each node at the MPI bus must have a bus address in the range (0...31).
Data transfer rate

Notice
The data transfer rate at the MPI bus of the SINUMERIK 840Di must be set
to 1.5 Mbaud.
Communication If no communication can be established as a whole or with individual nodes at

does not start the MPI bus, check the following:
S Is the data transfer rate of all nodes whose data transfer rate is set manually
(DIP switches) set to 1.5 Mbaud?
S Are there any loosen cable connections?

S Are all bus segments terminated correctly?
With the MPI bus operating at 1.5 Mbaud, bus segments not terminated cor-
rectly will certainly result in disturbances of communication.
Notice
In some components (e.g. HHU and HT 6), the terminating resistor is installed
fixed.
5.2 Network rules

Observe the following rules when installing an MPI network:
1. An MPI bus line must be terminated on both ends. To this aim, enable the
terminating resistor in the MPI connector of the first and last nodes and dis-
able the remaining terminating resistors.

5 MPI Communication 06.03
5.2 Network rules
Notice
S The Handheld Unit (HHU) and the Handheld Terminal 6 (HT 6) have inte-
grated terminating resistors.
2. At least one termination must be supplied with a 5V voltage.

To this aim, an MPI connector with the terminating resistor enabled must be
connected to an enabled device. To this aim, the MPI connection on the MPI
board of the SINUMERIK 840Di can be used.
3. Stubs (feeding cable from the bus segment to the node) should be as short
as possible, i.e. < 5m. Stubs not used should be removed if possible.
Notice
If possible do not use stubs at all.
4. Each MPI node must be connected first to the bus and then be enabled.
When disconnecting the node, first disable the node. Then you can discon-
nect the node from the bus.
5. A maximum of 2 of the following components can be connected per bus
segment:
– Machine control panel (MCP)
– Handheld unit (HHU)
– Handheld Terminal 6 (HT 6)
6. Do not enable the bus terminating resistors at the distributor boxes of an
HHU or HT 6, since they are already integrated in the appropriate device.
7. Maximum cable lengths:
S 200m per bus segment

S 2,000m overall length with RS-485 repeater.
Example
PCU 50
HT 6 with OP 012 and
MCP
ON HMI Advanced
OFF OFF
Distributor
box SINUMERIK 840Di
OFF
MPI bus PCU 50
ON
Terminating resistor MCI board
ON
in the connector enabled
ON
Terminating resistor
integrated
Fig. 5-1 MPI network with terminating resistor

06.03 5 MPI Communication
5.3 Default address assignment
5.3 Default address assignment
Standard MPI The following figure 5-2 shows a SINUMERIK 840Di with the user interface run-
addresses ning on the PCU:
S 840Di start-up or HMI Advanced

and the further components connected on the MPI bus:
S Machine control panel (MCP) or interface customer operator panel

S Handheld terminal (HT 6)
S SIMATIC programming device PG 740
with standard assignment of the MPI addresses.
MCP/interface
PG 740 customer operator HT 6
panel
0 6 14
2 SINUMERIK 840Di
MPI bus PLC (PCU with MCI board)
1
840Di-start-up/
HMI Advanced
NC
3
X Address at MPI bus
Fig. 5-2 Default addresses at the MPI bus with SINUMERIK 840Di

5.4 Machine control panel (MCP)
+Y +X +C
[.] 1 –Z +Z
10 100 –C –X –Y % %
1000 10000
Fig. 5-3 Machine control panel front side; example: Version T (turning machine)
5.4.1 Prerequisites for start-up
Hardware In order to start up an MCP, the following hardware is required:

MPI bus cable
The MCP is connected to the SINUMERIK 840Di through the MPI bus. A termi-
nating resistor for the MPI bus is not integrated in the MCP.
Programming device (e.g. PG740)
A programming device is required for the SIMATIC Manager STEP7 as the plat-
form in order to match the basic PLC or PLC user program to the requirements
of the appropriate automation system with regard to the operation of an MCP
and to load it then into the PLC.
Note
A programming device is not required if the SIMATIC Manager STEP7 is
installed on the SINUMERIK 840Di.
How to install additional software is described in Chapter 15, page 15-455.
Software In order to start up an MCP, the following software is required:

MCP firmware
At least MCP firmware version 4.1.5 is required. The version number can be
checked when the MCP powers up.
Basic PLC program
The MCP relevant modules of the basic PLC program are FB 1 (MCP commu-
nication parameters), FC 19 (interface parameter assignment version: milling)
and FC 25 (interface parameter assignment, version: turning).

The basic PLC program is part of the SINUMERIK 840Di installation.

The installation of the basic PLC program as a SIMATIC S7 library is described
in Subsection 8.2.2 (page 8-251) in detail.
SIMATIC Manager STEP7
SIMATIC Manager S7 is used for adapting the basic PLC and user programs
(e.g. call of FC 25).
References The following manuals are required to start up an MCP:

/FB1/ Description of Functions, Basic Machine: P3, Basic PLC Program
Description of the program structure and modules of the basic PLC program.
/BH/ Operator Components, Manual
Description of MCP (interfaces, electrical connection, etc.)
/Z/ Catalog NC Z
Components required for connection: Cables, connectors, etc.
Automation To start up the MCP, the automation system must be electrically and mechani-
system cally connected completely with respect to NCK, PLC and MCP.
The drives must be secured against accidental moving.
5.4.2 Parameterization of the MCP
Electrical The MCP’s electrical connections and connections for MPI communication are
connection made using the interfaces on the rear side of the MCP.
Connection for equipotential bonding conductor LEDs1...4
1 2 3 4
3 1
X20
S3
4 2
X10
Power supply interface
MPI interface EMERGENCY

S3 DIP switch STOP button
connections
1 2 3
SHIELD M24 P24
Fig. 5-4 Position of interfaces on rear panel of MCP

For a detailed description of the electrical and mechanical design and of the
MCP interfaces, please refer to:
References: /BH/ Operator Components, Manual
Section: Machine control panel (MCP)
Display of After the MCP has been electrically connected, all LEDs on the front side of the
software version MCP flash until no communication takes place between MCP and PLC.
Simultaneously pressing the two keys “Feed stop” and “Feed enable” (in the
bottom right corner) displays the version number of the current software version
using the LEDs now lighting continuously.
Version number = V “Number of lighting LEDs in the left LED group”
“Number of lighting LEDs in the middle LED group”
“Number of lighting LEDs in the right LED group”
Version number V4.1.5 is displayed in the example (Fig. 5-5).
+Y +X +C
[.] 1 –Z +Z
10 100 –C –X –Y % %
1000 10000
Left key/LED group Right key/LED group Enable software version display
(both keys simultaneously)
Middle key/LED group
LED ON LED OFF
Fig. 5-5 MCP software version display
Data transfer rate The data transfer rate is set using switch S3 on the rear side of the MPI module.
It is 1.5 Mbaud on the MPI bus of the SINUMERIK 840Di.
Setting on S3: see Table 5-1, page 5-143.
MPI address The factory-set MPI address of the MCP is 6D (D = decimal).

The MPI address of the MCP can be set using switch S3 on the rear side of the
MCP.

S3 switch The parameters are set using switch S3 on the rear side of the MCP.
S Data transfer rate

S Transmission time and receive monitoring
S MPI address
S Operator component type.
Table 5-1 Meaning of the S3 switch
1 2 3 4 5 6 7 8 Meaning:
ON Data transfer rate = 1.5 Mbaud
OFF Data transfer rate = 187.5 kbaud
ON OFF 200msecscycle transmit pattern/2400msecs receive monitoring
OFF ON 100msecscycle transmit pattern/1200msecs receive monitoring
OFF OFF 50msecscycle transmit pattern/ 600msecs receive monitoring
ON ON ON ON MPI address: 15
ON ON ON OFF 14
ON ON OFF ON 13
ON ON OFF OFF 12
ON OFF ON ON 11
ON OFF ON OFF 10
ON OFF OFF ON 9
ON OFF OFF OFF 8
OFF ON ON ON 7
OFF ON ON OFF 6 (default setting)
OFF ON OFF ON 5
OFF ON OFF OFF 4
OFF OFF ON ON 3
OFF OFF ON OFF 2
OFF OFF OFF ON 1
OFF OFF OFF OFF 0
ON Type = interface to customer operator panel
OFF Type = MCP
ON OFF ON OFF ON ON OFF OFF Default setting
ON OFF ON OFF ON ON OFF OFF Default setting for 840Di
Data transfer rate: 1.5 Mbaud
Cyclical transmit pattern: 100msecs
MPI address: 6
Type: MCP
5.4.3 Parameterization of the PLC
Program structure The PLC program has a modular structure. It consists of the following function
blocks:
S Runup and synchronization (OB 100)

S Cyclic operation (OB 1)
S Process alarm processing (OB 40).

The user (machine manufacturer) must call the relevant part of the basic
program
in the OBs 1, 40 and 100, as shown in Fig. 5-6.
ÎÎÎ
OB 100 FB 1
ÎÎÎ
Start:
Restart e.g. MCP parameters
User program
ÎÎÎ
OB 1
FC 2 NCK
ÎÎÎÎ
ÎÎÎ
Cyclic Mode grp.
processing GP-OB 1 Channel
Axis
Spindle
FC 14
MCP,
HHU
FC 6
TOOLMAN
FC 19/25/26
MCP:
MCP_IFM
User FC (9/15/16/18)
MCP_IFT
program HPU_MCP
ASUB,
con. axes/
FC 7/8/22 spindles
TM:
TM_Trans FB 2/3/4
TM_Dir
Read/ write
var., PI
FC 17 services
Star/delta
FC 10
Error and FC 13
operational
messages HHU:
Display control
ÎÎÎÎÎ
OB 40 FC 3
ÎÎÎÎÎ
G group
Process alarm GP_PRAL
distributor
User
program
Fig. 5-6 Structure of PLC program
Setting the The MCP communication parameters are designated in function block FB1 with
communication MCPx... (with x = 1 or 2).
parameters (FB1) In addition to a first MCP, a second MCP or an HT 6 (for HT 6, see Section 5.7,
page 5-161) can be active as another operator component at the same time.

In order to synchronize several operator components, the PLC program must be

adapted accordingly. This is the user’s (machine manufacturer’s) responsibility.
MCPNum: INT:= 1; // number of active operator components
// MCP/HT 6 (default = 1; max. = 2)
MCP1In: POINTER; // address of MCP 1 input signals

MCP1Out: POINTER; // address of MCP 1 output signals
MCP1StatSend: POINTER; // Addr. of the MCP1 send status data

MCP1StatRec: POINTER; // Addr. of the MCP1 receive status data
MCP1BusAdr: INT:= 6; // default MPI address of the MCP
MCP1Timeout: S5TIME:= S5T#700MS; // should be kept

MCP1Cycl: S5TIME:= S5T#200MS; // should be kept
MCPMPI: BOOL:= FALSE; // MCP/HT 6 is operated at the “extended”

// MPI bus
The MCP2... parameters are only needed if in addition to the 1st MCP, a 2nd
MCP or HT 6 is used:
MCP2In: POINTER; // address of the MCP/HT 6 2 input signals
MCP2Out: POINTER; // address of the MCP/HT 6 2 output signals
MCP2StatSend: POINTER; // Addr. of the send status data MCP/HT 6 2

MCP2StatRec: POINTER; // Addr. of the MCP1 receive status data MCP/
// HT 6 2
MCP2BusAdr: INT; // MPI address

The parameters listed below serve to synchronize two operator components:

MCP1Stop: BOOL:= FALSE; // transfer of the relevant operator component:
MCP2Stop: BOOL:= FALSE; // FALSE = start; TRUE = stop
MCP1NotSend: BOOL:= FALSE; // Send and receive mode of the corresponding

MCP2NotSend: BOOL:= FALSE; // Operator component:
// FALSE = send and receive is active
// TRUE = only receive is active
Notice
A maximum of two MCP/HT 6 can be operated on an MPI line. To be able to
use MCP and HT 6 on an automation system alternately or simultaneously, the
user (machine manufacturer) has to adapt the PLC program accordingly.
References For a detailed description of the basic PLC program or of function block FB 1,
please refer to:
Section: FB 1: RUN_UP Basic program, start-up section
NC interface FC 19 (for version “M” MCP, milling) or FC 25 (for version “T” MCP, turning)
parameter transfers the signals of the MCP to the NC through the interface.
assignment

Notice
Block FC 19 or FC 25 is part of the basic PLC program. It is the user’s (ma-
chine manufacturer’s) responsibility to call the block correctly and/or assign the
interface the appropriate parameters.
References For a detailed description of FC 19 and FC 25, please refer to:

Section: FC 19: MCP_IFM Transmission of MCP signals tointerface
Section: FC 25: MCP_IFT Transfer of MCP/OP signals tointerface
5.4.4 Example: Connecting an MCP to SINUMERIK 840Di
1. Connect the MCP electrically.
Use the terminating resistor integrated in the MPI connector according to the
general rules for connecting components to the MPI bus.
Since function block FB1 is not yet parameterized in the basic PLC program,
communication with the PLC does not yet take place and all LEDs on the
MCP front panel flash.
2. Checking the software version
Simultaneously pressing the keys “Feed stop” and “Feed enable” displays
the software version using the LEDs located on the front side.
3. Parameterizing function block FB 1 (editing the FB 1 parameters in OB 100
using the SIMATIC Manager STEP7)
The MCP will be parameterized as the first and only MCP as an example:
MCPNum: INT:= 1; // one MCP is connected
// P# = pointer to
MCP1In: P#E 0.0; // address of input data (8 bytes)
MCP1Out: P#A A 0.0; // address of input data (8 bytes)
MCP1StatSend: P#A 8.0; // address of the send status data (4 bytes)

MCP1StatRec: P#A 12.0; // address of receive status data (4 bytes)
MCP1BusAdr: INT:= 6; // default address


// MPI bus
MCP1Stop: BOOL:= FALSE;
MCP1NotSend: BOOL:= FALSE;
4. Insert block FC 19 or FC 25 into the cyclic part of the PLC program

(see Fig. 5-6).

5. Load the modified blocks into the PLC and then restart the PLC.
6. After communication with the PLC has been established, the LEDs on the
MCP front stop flashing.
The LED of the basic settings for:
S Mode: Referencing
S Spindle Stop
S Feed hold
light up continuously.

5.5 MPI interface
5.5 MPI interface
Use The MPI (multi-point interface) is a module for connecting custom made opera-
tor panels to a SINUMERIK 840Di.
To this aim, the module provides 3 I/O interfaces with a total of 64 digital outputs
with C-MOS level (5V).
Start-up Start-up of an Interface MPI module is to a large degree identical to start-up of a

machine control panel (MCP), Section 5.4, page 5-140.
Therefore, only the differences from an MCP start-up are explained below.
5.5.1 Parameterization of the MPI interface
Electrical The MPI module’s electrical connections and connections for MPI communica-
connection tion are made using the interfaces on the rear side of the module.
MPI interface Connection I/O interfaces

for equipotential
bonding conductor
X20 X211 X221

X231
SW version
x.x H3
H1
X10 H4
S3 H2
Power supply interface
S3 DIP switch LEDs1...4

3 2 1
SW
P24 M24 SHIELD
Fig. 5-7 Position of the interfaces on the rear side of the MPI module
For a detailed description of the electrical and mechanical design, as well as for
the interfaces of the MPI module, please refer to:

5.5 MPI interface

Section: Multi-point interface (MPI) for the customer
operator panel.
Display of soft- A label indicating the current software version is to be found on the firmware
ware version EPROM (see Fig. 5-7).
Data transfer rate The data transfer rate is set using switch S3 on the rear side of the MPI module.
It is 1.5 Mbaud on the MPI bus of the SINUMERIK 840Di.
MPI address The factory-set MPI address of the MCP is 6D (D = decimal).

The MPI address of the MCP can be set using switch S3 on the rear side of the
MCP.
Switch S3 The data transfer rate is set using switch S3 on the rear side of the MPI module.

S Transmission time and receive monitoring
S MPI address
S Operator component type.
Table 5-2 Meaning of S3 switch
1 2 3 4 5 6 7 8 Meaning:
ON Data transfer rate = 1.5 Mbaud
OFF Data transfer rate = 187.5 kbaud
ON OFF 200msecs cycle transmit pattern/ 2400msecs receive monitoring
OFF ON 100msecs cycle transmit pattern/ 1200msecs receive monitoring
OFF OFF 50msecs cycle transmit pattern/ 600msecs receive monitoring
ON ON ON ON MPI address: 15
ON ON ON OFF 14
ON ON OFF ON 13
ON ON OFF OFF 12
ON OFF ON ON 11
ON OFF ON OFF 10
ON OFF OFF ON 9
ON OFF OFF OFF 8
OFF ON ON ON 7
OFF ON ON OFF 6 (default setting)
OFF ON OFF ON 5
OFF ON OFF OFF 4
OFF OFF ON ON 3
OFF OFF ON OFF 2
OFF OFF OFF ON 1
OFF OFF OFF OFF 0
ON Type = MPI module
OFF Type = MCP

5.5 MPI interface
Table 5-2 Meaning of S3 switch
1 2 3 4 5 6 7 8 Meaning:
ON OFF ON OFF ON ON OFF ON Default setting
ON OFF ON OFF ON ON OFF ON Default setting for 840Di
Data transfer rate: 1.5 Mbaud
Cyclical transmit pattern: 100msecs
MPI address: 6
Type: MPI module

5.6 Handheld unit (HHU)
SIEMENS
%
405060
30 70
20 80
10 90
100
0 110
Fig. 5-8 Handheld unit (HHU), front
Hardware The following hardware components are required to start up the HHU:
Distributor box
The distributor box incorporates the MPI module interface, the HHU interface,
as well as a terminal block for connecting EMERGENCY STOP, enable keys,
handwheel and 24V power supply.
HHU connection cable
The HHU is connected to the distributor box using the HHU cable.
MPI bus cable
Under no circumstances may the MPI connector for connecting the HHU con-
tain an integrated bus terminating resistor, since a bus terminating resistor is
already integrated in the HHU.


A programming device is required for the SIMATIC Manager STEP7 as the plat-
form in order to match the basic PLC or PLC user program to the requirements
of the appropriate automation system with regard to the operation of an MCP
and to load it then into the PLC.
Note
A programming device is not required if the SIMATIC Manager STEP7 is
How to install additional software is described in Chapter 15, page 15-455.
Software The following software components are required to start up the HHU:
Basic PLC program
The basic PLC is included on the SINUMERIK 840Di installation CD. (Start se-
tup.exe; Products –> Basic PLC Program.)
HHU-related blocks of the basic PLC program are FB1 (HHU parameter) and
FC13 (display control).
SIMATIC Manager S7 is used for adapting the basic PLC and user programs
(e.g. call of FC 13).
References The following manuals are required to start up the HHU:

/BH/ Operator Components Manual
Description of HHU (interfaces, electrical connection, etc.)
Description of the program structure and modules of the basic PLC program.
/Z/ Catalog NC Z
Components required for connection: Cables, connectors, etc.
Automation In order to start up the HHU, the automation system must be electrically and
system mechanically connected completely with respect to NC, PLC and MCP.

5.6.2 Electrical connection
Connecting the In order to connect HHU electrically and for communication along the MPI bus,
HHU electrically a distributor box is used.
The distributor box has an interface to the MPI bus, as well as a terminal block
for connecting EMERGENCY STOP, enable keys, handwheel and 24V power
supply.
Connecting If you wish to connect more than two HHUs to a bus segment or if the HHU can-
several HHUs not be connected at the bus end, it is generally recommended to use a PROFI-
BUS repeater for connecting the HHUs.
MCP
OFF
SINUMERIK ON OFF
MPI
840Di
ON
Distributor box
HHU HHU
Repeater RS-485
OFF ON ON
Open terminating resistor
ON Closed terminating resistor
Fig. 5-9 Connecting using a repeater
Note
If a HHU is connected to the bus ends, no repeater is required.
For a detailed description of the electrical and mechanical design, as well as for
the interfaces of the HHU module, please refer to:
Section: Handheld Unit and Distributor Box.

5.6.3 MPI parameterization of the HHU
Setting the MPI The relevant parameters for the MPI communication of the HHU:
parameters
S MPI address
S IDLE time
are set using DIP switches. The relevant DIP switches S1 and S2 are integrated
in the HHU.
To check or modify the parameters, disconnect the HHU from mains. After loos-
ening the fastening screws, you can remove the HHU front plate.
ON OFF
Reserved
4
1.5 Mbaud
3
S1
2 IDLE time
100msecs
1
ON OFF
S1 4
S2 Default MPI
3
S2 address 15D
2
Fig. 5-10 Settings required on the HHU for SINUMERIK 840Di
Data transfer rate The data transfer default setting must be changed from 187.5 kbaud to
1.5 Mbaud. To do so, set switch 3 of DIP switch S1 to ON.
Notice
To run the HHU on the MPI bus of the SINUMERIK 840Di, the data transfer rate
has to be set to 1.5 Mbaud.

MPI address The MPI address is set to FH = 15D by default. This address can normally be
kept.
Table 5-3 MPI addresses that can be set using S2
S2 MPI address
1 2 3 4
ON ON ON ON FH = 15D (default address)
ON ON ON OFF EH = 14D
ON ON OFF ON DH = 13D
ON ON OFF OFF CH = 12D
ON OFF ON ON BH = 11D
ON OFF ON OFF AH = 10D
ON OFF OFF ON 9
ON OFF OFF OFF 8
OFF ON ON ON 7
OFF ON ON OFF 6
OFF ON OFF ON 5
OFF ON OFF OFF 4
OFF OFF ON ON 3
OFF OFF ON OFF 2
OFF OFF OFF ON 1
OFF OFF OFF OFF 0
Display of soft- After the HHU has been electrically connected, the message: “Waiting for PLC”,
ware version and the software version and the MPI address are displayed on the screen until no
MPI address communication between HHU and PLC takes place.
SIEMENS
Waiting for PLC

V04.01.01 F
Software Version: Version 4.1.1 MPI Address: FH = 15D
Fig. 5-11 Software version and MPI address
5.6.4 MPI parameterization of the PLC
blocks:

program in the OBs 1, 40 and 100, as shown in Fig. 5-12.

FB 1
ÎÎÎ
OB 100
Start:
Restart e.g. HHU parameters
User program
ÎÎÎ
OB 1
ÎÎÎ
ÎÎÎÎ
FC 2 NCK
Cyclic Mode grp.
Axis
Spindle
FC 14
MCP,
HHU
FC 6
TOOLMAN
FC 19/25/26
MCP:
MCP_IFM
User FC (9/15/16/18)
MCP_IFT
program HPU_MCP
ASUB,
con. axes/
FC 7/8/22 spindles
TM:
TM_Trans FB 2/3/4
TM_Dir
Read/ write
var., PI
FC 17 services
Star/delta
FC 10
Error and FC 13
operational
messages HHU:
Display control
FC 3
ÎÎÎÎÎ
OB 40
G group
distributor
User
program
Setting the MPI The MPI parameters are set on the PLC side in function block FB 1. Since the
parameters data transfer rate of the MPI bus with SINUMERIK 840Di is 1.5 Mbaud, the pa-
(FB 1) rameters have to be set as follows:
HHU: INT:= 2; // the HHU is operated on an MPI bus
HHU MPI BOOL:= FALSE // at 1.5 Mbaud
Notice
To be able to use HHU on an automation system alternately or simultaneously
together with MCP/HT 6, the user (machine manufacturer) has to adapt the
PLC program accordingly.

References For a detailed description of the basic PLC program or of function block FB 1,
please refer to:
Section: FC 13: BHGDisp Display control for handheld unit.
5.6.5 GD circle parameterization of the HHU
Global data GD stands for global data. Global data serve to exchange smaller volumes of
data between two or several automation components.
The data exchange is carried out by the operating systems of the automation
components involved. This has the advantage that no further programming is
required with respect to this communication.
GD circle Communication using global data is arranged by so-called GD circles. A GD

circle is unambiguously marked by its GD circle number.
GD circle parameters The GD circle parameters of a node (here: HHU) must be set for SEND and
RECEIVE separately.
S GD circle number
S GBZ number
S Object number.
Default setting The GD circle parameters of the HHU are assigned default values. Normally,
these default values can be kept.
Table 5-4 Default values and range of values of GD circle

parameters
HHU Default Value

Designation display value range
GD circle No. Rec-GD-No: 2 1–16
Receive GBZ No. Rec-GBZ-No: 1 1–255
Object No. Rec-Obj-No: 1 1–255
GD circle No. Send-GD-No: 2 1–16
Send GBZ No. Send-GBZ-No: 2 1–255
Object No. Send-Obj-No: 1 1–255

Setting the GD The current values of the GD circle parameters of the HHU can be set and/or
circle parameters checked on the HHU display (see Fig. 5-13).
Activate display
While the message “Waiting for PLC” is displayed on the HHU display, the up-
permost right and left keys must be pressed simultaneously (see Fig. 5-13).
Then the first GD circle parameter is displayed.
Modify value
The value of a GD circle parameter can be modified within its admissible range
of values using the + or – keys (see Fig. 5-13).
Display next parameter
Use the 2nd key from the left in the uppermost key row (see Fig. 5-13) to ad-
vance to the next parameter. After the last GD circle parameter has been
reached, the set values will be automatically saved in the HHU (flash EPROM).
Activate display
(press simultaneously)
Display
next parameter
Current value + 1
Current value – 1
Fig. 5-13 Displaying and modifying GD circle parameters
5.6.6 GD circle parameterization of the PLC
Setting the GD The GD circle parameters on the side of the PLC are set side in function block
circle parameters FB 1. For editing FB1, it has to be loaded into SIMATIC Manager STEP7.
(FB 1) The HHU GD circle parameters of FB1 must comply with the GD circle parame-
ters set in the HHU.
In this context, you should note that the GD circle parameters for sending and
receiving HHU and PLC (FB1) must be identical one across the other, i.e. the
send parameters of the HHU are the receive parameters of the PLC and the
receive parameters of the HHU are the send parameters of the PLC.

HHU PLC (FB 1)

GD circle parameters GD circle parameters
Send-GD-No HHUSendGDNo
Send-GBZ-No HHUSendGBZNo
Send-Obj-No HHUSendObjNo
Rec-GD-No HHURecGDNo
Rec-GBZ-No HHURecGBZNo
Rec-Obj-No HHURecObjNo
Fig. 5-14 Crosswise coincidence of GD circle parameters
Notice
The GD circle parameters of sender and receiver must be identical crosswise.
5.6.7 Example: Connecting a HHU to SINUMERIK 840Di
1. Checking the HHU for MPI bus capability:

“B-MPI” must be indicated on the rating plate attached to the HHU’s rear.
2. Open the HHU to check and set (as necessary) the DIP switches S1 and S2
in the HHU:
– Data transfer rate = 1.5 Mbaud
– IDLE time = 100msecs
– MPI address = 15D
3. The terminating resistor in the MPI bus connector on the distributor box for
connecting the HHU must be disabled. (The HHU has an integrated MPI bus
terminator).
4. Make the electrical connections on the distribution box and HHU.
Once the HHU is connected to the power, the following message is dis-
played:
Waiting for PLC
V04.01.01 F
5. Check the HHU GD circle parameters (see: Fig. 5-13, page 5-158).
(The GD circle parameters displayed here must be imported to FB1 (see
Point 6.). The example uses default values).
6. Parameterizing function block FB1 (loading and editing in SIMATIC Manager
STEP7):

HHU:= 2 // (the HHU is operated on an MPI bus

HHUMPI:= FALSE // with 1.5 Mbaud)
HHUIn P#E 0.0 // address of input data

HHUOut: P#A 8.0 // address of input data
// (Notice! see below: Note)
BHGInLen:= B#16#6 // length of input data (6 bytes)
BHGOutLen:= B#16#14 // length of output data (20 bytes)
BHGStatSend P#A 28.0 // Addr. of send status data (4 bytes)

HHUStatRec P#A 32.0 // Addr. of receive status data (4 bytes)
BHGTimeout:= S5T#700MS
BHGCycl:= S5T#400MS
BHGRecGDNo:= 2 // acc. to the GD circle parameters

BHGRecGBZNo:= 2 // of the HHU for sending
BHGRecObjNo:= 1
BHGSendGDNo:= 2 // acc. to the GD circle parameters

HHUSendGBZNo:= 1 // of the HHU for receiving
BHGSendObjNo:= 1
Notice
BIT7 in the 1st output byte (parameter: HHUOut; in the example, A 8.7), must
be set to fixed value 1.
7. Load the modified function block into the PLC and then restart the PLC.
8. After communication with the PLC has been established, the message
“Waiting for PLC ...” will disappear from the HHU display.
Now, the display set by way of the block FC13 will appear on the display.
References: /FB1/ Description of Functions, Basic Machine: P3,
Basic PLC Program
Section: FC 13: HHUDisp Display control for
handheld unit

5.7 Handheld terminal HT 6

The HT 6 (Handheld Terminal with 6” screen diagonal) is a compact operator
component consisting of an HMI and a machine control panel component.
EMERGENCY Override
STOP
Fig. 5-15 Handheld terminal HT 6 front side
Hardware The following hardware components are required to start up the HT 6:

Distributor box
The distributor box incorporates the MPI module interface, the HT 6 interface,
as well as a terminal block for connecting EMERGENCY STOP, enable keys,
handwheel and 24V power supply. For the distributor box, see Section 3.3,
page 3-131.
HT 6 connection cable
The HT 6 is connected to the distributor box using the HT 6 cable. For the HT 6
connection cable, see Section 3.3, page 3-131.
MPI bus cable
Under no circumstances may the MPI bus cable contain an integrated bus ter-
minating resistor, since a bus terminating resistor is already integrated in the HT
6. For the MPI cable, see Section 3.3, page 3-131.


A programming device/PC is required for the SIMATIC Manager STEP7 as the
platform in order to match the basic PLC or PLC user program to the require-
ments of the appropriate automation system with regard to the operation of an
HT 6 and to load it then into the PLC. For adapting the basic PLC or PLC user
program, see Chapter 8, page 8-249.
Note
A programming device/PC is not required if the SIMATIC Manager STEP7 is
The installation of additional software on the SINUMERIK 840Di is described in
Chapter 15, page 15-455.
A PC/programming device is also required if the HT 6 user interface or the MPI

address is modified using the HT 6 system software and the whole modified
software is then to be loaded into the HT 6.
Software The following software components are required to start up the HT 6:

Basic PLC program
The basic PLC program is included on the SINUMERIK 840Di installation CD.
HT 6-relevant modules of the basic PLC program are FB 1 (HT 6/PLC commu-
nication) and FC 26 (NC/PLC communication).
For the archiving location of the basic PLC program, please refer to Section 1.2,
page 1-32.
For the use of the basic PLC program, please refer to Chapter 8, page 8-249.
SIMATIC Manager S7 is used for adapting the basic PLC user program (e.g.
parameterization of FB 1).
HT 6 system software (optional)
The HT 6 system software (CD-ROM) provides the following possibilities:
– Language selection for the 1st and 2nd Language
– Creation of the user’s alarm texts
– Modification of the MPI address
Order No. (MLFB): 6FK5 453-jAX10-jAG0 (version-dependent)
References The following manuals are required to start up the HT 6:

Description of the HT 6 interfaces, electrical connection at the distributor, inter-
face signals etc.
/Z/ Catalog NC Z
Connection components: Cables, connectors, etc.

Further references on the HT 6

/FBPH/ Description of Functions HT 6
Configuring the HT 6 user interface
/IAM BE1/ Description of Functions HT 6
Completing the user interface
Automation In order to start up the HT 6, the automation system must be electrically and
system mechanically connected completely with respect to NC, PLC and HT 6.
5.7.2 Parameterization of the HT 6
Electrical In order to connect HT 6 electrically and for the MPI communication, a distribu-
connection tor box is used.
Notice
Under no circumstances may the MPI connector for connecting the HT 6 be
enabled, since the HT 6 already contains an integrated bus terminator.
Please observe the warning notices with respect to the MPI cables and the
EMERGENCY STOP jumper. (For a detailed description, please refer to the
relevant references).
For a detailed description of the electrical and mechanical design of the distribu-
tor box, as well as for the electrical and data interfaces of the HT 6, please refer
to:
Section: Handheld Terminal HT 6
Data transfer rate The HT 6 detects the data transfer rate at the MPI bus automatically. With the
SINUMERIK 840Di, it is 1.5 Mbaud.
MPI address The factory-set MPI address of the HT 6 is 14 by 14D (D = decimal). The default
address can only be modified using the HT 6 system software.
Display of the The current software version of the HT 6 is displayed in a menu of the user in-
software version terface. After power-up of the HT 6, you will get to this menu using the following
sequence of operations:
1. Key MENU SELECT
2. Soft keys Diagnosis > Service display > Version > Vers. MMC.

5.7.3 Parameterization of the PLC
blocks:

program in the OBs 1, 40 and 100, as shown in Fig. 5-16.
OB 100 FB 1
ÎÎÎ
Start:
Restart e.g. HHU parameters
User program
ÎÎÎOB 1 FC 2
ÎÎÎÎ
ÎÎÎ
NCK
Cyclic Mode grp.
Axis
Spindle
FC 14
MCP,
HHU
FC 6
TOOLMAN
FC 19/25/26
MCP:
MCP_IFM
User FC (9/15/16/18)
MCP_IFT
program HPU_MCP
ASUB,
con. axes/
FC 7/8/22 spindles
TM:
TM_Trans FB 2/3/4
TM_Dir
Read/ write
var., PI
FC 17 services
Star/delta
FC 10
Error and FC 13
operational
messages HHU:
Display control
ÎÎÎÎÎ
OB 40 FC 3
ÎÎÎÎÎ
User
G group
distributor
program

Setting the The HT 6 is parameterized as a machine control panel (MCP) in organization

communication block OB 100 in the call parameters of function block FB 1.
parameters (FB 1) The HT 6 can be operated either as an MCP substitute or, in addition to an
MCP, as a 2nd operator component.
In order to synchronize several operator components, the PLC program must be
adapted accordingly. This is the user’s (machine manufacturer’s) responsibility.
MCPNum: INT:= 1; // 1: 1 operator component MCP/HT 6 (default)
// 2: Two operator components MCP/HT 6


// HT 6 1
MCP1BusAdr: INT:= 14; // default MPI address of the HT 6


// MPI bus
The MCP2... parameters are only needed if in addition to the 1st MCP/HT 6 a
HT 6 is additionally used:

// HT 6 2
MCP2BusAdr: INT; // MPI address

The parameters listed below serve to synchronize two operator components:

MCP1Stop: BOOL:= FALSE; // 0: Start transfer of the MCP/HT 6 signals
MCP2Stop: BOOL:= FALSE; // 1: Start transfer of the MCP/HT 6 signals
MCP1NotSend: BOOL:= FALSE; // 0: Send and receive mode is active

MCP2NotSend: BOOL:= FALSE; // 1: Only reception of the MCP/HT 6 signals
Notice
A maximum of two MCP/HT 6 can be operated on an MPI line. To be able to
use MCP and HT 6 on an automation system alternately or simultaneously, the
user (machine manufacturer) has to adapt the PLC program accordingly.
References For a detailed description of the basic PLC program or of function block FB1,
please refer to:

Parameter The FC 26 transfers the signals of the HT 6 with regard to:

assignment of
the NC interface
S Operating modes
(FC 26) S WCS/MCS switchover
S Traversing keys
S Override
to the NC through the PLC interface.
Notice
Block FC 26 or FC is part of the basic PLC program. It is the user’s (machine
manufacturer’s) responsibility to call the block correctly and/or assign the inter-
face the appropriate parameters.
References For a detailed description of FC 26 and FC, please refer to:

Section: FC 26 HPU_MCP Transfer of HPU signals tointerface
5.7.4 Example: Connecting an HT 6 to SINUMERIK 840Di
1. Make the electrical connections on the distribution box and HT 6.
The terminating resistor in the MPI bus connector on the distributor box for
connecting the HHU must be disabled. (The HT 6 has an integrated MPI bus
terminating resistor).
Once power is present on the HT 6, the start screen for communication with
the HT 6 system software is displayed for some seconds. (Use key “6” be-
neath the key labeling “PARAM” to get to the data transfer rate selection
menu of the serial interface of the HT 6).
After the waiting time has expired or pressing a key, the message:
Waiting for PLC
V04.01.01 date time
is displayed.
Since function block FB 1 in the basic PLC program is not yet parameter-
ized, communication with the PLC does not yet take place.
2. Parameterizing function block FB 1 (editing FB 1 in SIMATIC Manager
STEP7).
The HT 6 is parameterized as the first and only MCP as an example:

MCPNum: INT:= 1; // one HT 6 exists
// P# = pointer to
MCP1In: P#E 0.0; // address of input data (8 bytes)
MCP1Out: P#A A 0.0; // address of input data (8 bytes)
MCP1StatSend: P#A 8.0; // address of the send status data (4 bytes)

MCP1StatRec: P#A 12.0; // address of receive status data (4 bytes)
MCP1BusAdr: INT:= 14; // default MPI address of the HT 6

MCPMPI: BOOL:= FALSE; // the HT 6 is operated at the “extended”

// MPI bus
MCP1Stop: BOOL:= FALSE;
MCP1NotSend: BOOL:= FALSE;
3. Insert block FC 26 into the cyclic part of the PLC program (see Fig. 5-16).
4. Load the modified blocks into the PLC and then restart the PLC.
5. After communication with the PLC has been established, the message
“Waiting for PLC ...” will disappear from the HT 6 main screen.
The MMC user interface is displayed.
5.7.5 Connecting and disconnecting an HT 6 during running operation
To be able to connect an HT 6 to or disconnect from an automation system with-

out any trouble during operation, make the following arrangements:
S The EMERGENCY STOP of the HT 6 must be enabled or jumpered,

S The HT 6 must be connected to the MPI bus through a PROFIBUS repeater.
References For a detailed description of the actions to be taken and the devices required,
please refer to:
Section: Handheld Terminal HT 6
Connecting and disconnecting the HT 6 during operation.

5.8 External operator panel (PCU with HMI Advanced)
5.8.1 General settings
Data transfer rate With the SINUMERIK 840Di, the data transfer rate at the MPI bus is 1.5 Mbaud.
S HMI Advanced
With HMI Advanced, the data transfer rate must be set to 1.5 Mbaud in the
menu “Start-up/MMC/operator panel”.
Screen MD 9000: LCD_CONTRAST (contrast)

The contrast setting can be entered directly in the machine data or selected by
means of the “LCD brighter” or “LCD darker” soft key in the “Diagnosis” menu.
MD 9001: DISPLAY_TYPE (monitor type)
The monitor type (e.g. LCD monochrome, LCD color) is entered in this machine
data (for MMC 100).
Language MD 9003: FIRST_LANGUAGE (foreground language for MMC 100)
S HMI Advanced
HMI Advanced is always supplied with several languages; default language
is English.
Display resolution MD 9004: DISPLAY_RESOLUTION

The display resolution for position values on the screen is entered in this ma-
chine data. The maximum number of digits on the screen is 10, before or after
the decimal point (e.g.: 4 places after decimal point, max. display =
+/– 999999.9999).
Protection levels The protection levels for the user data are set in the machine data 9200 to
User data 9299.
RS-232 interfaces The RS-232 interface settings are stored from MD 9300 onwards. The settings
for three different devices are made in the “Services” menu using an input dis-
play.

5.8.2 Language default setting
Language To be able to switch between the two configured languages even when the op-
switchover erator is not familiar with the selected language, the switchover between the
languages must be performed “blindfolded”:
1. Select menu bar.
2. Select “Start-up” (3rd horizontal soft key from right).
3. Switch to the highest level with RECALL.
4. Select “Change language” (3rd vertical soft key from top).
HMI Advanced HMI Advanced offers several possibilities to switch over the language during
operation:
S Switchover between two preset languages.

S Online change of the second language.
Language The selectable languages are set and managed in a file. When the language is
switchover switched in online operation, the first language remains as originally set and
concept only the second language can be changed.
Switchover The vertical soft key labeled “Change language” in the “Start-up” display is used
between two to switch between two languages. The switchover takes effect immediately. This
languages key can only be used to switch between two predefined languages.
Online change of Different languages are selected in the “Start-up/MMC/Languages” display (pro-
the 2nd language vided that languages are loaded).
This screen displays a list from which the user can choose the desired lan-
guage(s). The user selects the desired language and acknowledges his/her
selection with “OK”. The user can then change over between the first language
and the language just set by selecting the “Change language” soft key in the
“Start-up” display. The 2nd language can always be changed in online mode.
Installing HMI Advanced contains the languages German and English as default lan-
language guages. The two supplementary packages (1 and 2) are also available.
packages Supplementary package 1: European languages:
GR German (standard)
SP Spanish
FR French
UK English (standard)
IT Italian
Supplementary package 2: Asian languages:
KO Korean (Korea) pictographic language
TW Chinese (Taiwan) pictographic language
CH Chinese (Mandarin) pictographic language

Defining useable In the file c:<installation path>\mmc2\mmc.ini, the languages that can be
languages used in the MMC are configured. Any modifications to the file described in the
following can be made using the editor provided to the user under Start-up/
MMC.
Default setting Two languages can be configured from the languages listed below:
without activating GR German (standard)
pictographic SP Spanish
languages FR French
IT Italian
Example:
First language German, second language English
File MMC.INI must be altered as shown below:
Excerpt from mmc.ini:
...
[LANGUAGE]
Language=GR
LanguageFont=Europe
Language2=UK
LanguageFont2=Europe
...
Notice
When editing file MMC.INI, take care to ensure that you change only the high-
lighted (bold print) texts. Make sure that your entries are spelled correctly.
Default setting Two languages can be configured from the languages listed below:
with pictographic GR German (standard)
languages SP Spanish
FR French
IT Italian
TW Chinese (Taiwan) pictographic language
CH Chinese (Mandarin) pictographic language
Example:
First language German, second language Chinese
File MMC.INI must be altered as shown below:

Excerpt from mmc.ini:

...
[LANGUAGE]
Language=GR
LanguageFont=Europe
Language2=CH
LanguageFont2=China
;LanguageList=GR, SP, FR, UK, IT

;FontList=Europe, Europe, Europe, Europe, Europe
;LBList=espanol, francais, english, italiano
LanguageList=GR, CH, TW, SP, FR, UK, IT

FontList=Europe, China, China, Europe, Europe, Europe, Europe
LBList=chinese, taiwan, espanol, francais, english, italiano
AddOnProd=c:\cstar20\cstar20.exe
...
AddOn products To be able to operate the control with pictographic languages, the appropriate
AddOn product must be installed for each selectable language. Languages
based on different AddOn products cannot be configured at the same time.
Notice
When you change the “LanguageList”, “FontList”, “LBList” and “AddOnProd”
lines, make sure that you only manipulate (shift, delete) the “;” character repre-
senting the comment.
When editing file MMC.INI, take care to ensure that you change only the high-
lighted (bold print) texts. Make sure that your entries are spelled correctly.

Notes

Turning On and Ramp Up 6
6.1 Preparing for ramp-up
6.1.1 Checklist
SINUMERIK 840 Di The following checklist will help you to start up the supplied components without
undue problems and to guarantee high availability on your product:
S When handling the components, all ESD measures are observed.

S All screws are tightened with their prescribed torque.
S All connectors are plugged correctly and locked/screwed.
S All components are grounded and connected to shields.
S The load capacity of the central power supply is taken into account.
SIMODRIVE 611 With regard to the SIMODRIVE 611 universal inverter systems, some additional
universal points must be observed. For more detailed information, please refer to the fol-
lowing references:
References: /FBU/ Description of Functions, SIMODRIVE 611 universal.
Limit values All components are dimensioned for defined mechanical, climatic and electrical
environmental conditions. No limit value may be exceeded, neither during op-
eration, nor during transport.
In particular, the following must be observed:
– Mains conditions
– Pollution burden
– Hazardous gases
– Climatic environmental conditions
– Storage/transportation
– Shock load
– Vibratory load
– Ambient temperature.

6 Turning On and Ramp Up 06.03
6.1 Preparing for ramp-up
6.1.2 Recommended order when commissioning
The individual steps for a commissioning are listed below in the recommended
order.
1. The whole plant is mechanically and electrically connected and tested acc.
to the checklist (see above) for errors.
– SINUMERIK 840Di
– SIMODRIVE 611 universal inverter system
– Motors
– SIMATIC S7 I/O components
– HMI user interfaces.
2. The order numbers (MLFB) of the SIMODRIVE 611 universal drives and
SIMATIC S7-I/O components should be available.
When creating the SIMATIC S7 project, they are used to check whether the
component chosen from the hardware catalog by “HW Config” corresponds
to the component used on the plant.
3. Configure the SINUMERIK 840Di completely on first booting
(Section 6.2, page 6-175).
4. Create the PLC default program (basic PLC program, PLC user program
and configuration) supplied for the PLC or your own SIMATIC S7 project and
load it into the PLC (Chapter 7, page 7-203).
5. Prepare the SIMODRIVE 611 universal drives for communication on PROFI-
BUS DP (Chapter 9, page 9-263).
6. Carry out ramp-up of the NC (channels, axes and spindles, etc.)
(Section 10.5, page 10-308)
7. Setting up the alarm texts (Chapter 11, page 11-403).
8. Carry out ramp-up of the SIMODRIVE 611 universal drives through PROFI-
BUS DP using SimoCom U.
References: /FBU/ Description of Functions, SIMODRIVE 611 universal.
9. Carry out a dry run for all axes and for the spindle
(Chapter 12, page 12-411).
10. Carry out the drive optimization of the SIMODRIVE 611 universal drives us-
ing HMI Advanced (Chapter 13, page 13-417) and/or SimoCom U
11. Carry out a user data backup (series machine ramp-up file)
(Chapter 14, page 14-449).
12. If necessary carry out also a complete data backup (partition and/or hard
disk image) (Section 15.3, page 15-471).

06.03 6 Turning On and Ramp Up
6.2 First ramp-up
6.2 First ramp-up
6.2.1 Basic ramp-up of the system software (SW 2.2 and higher)
Objective of basic After a basic start-up described in the following, the following prerequisites must
ramp-up be provided:
S SINUMERIK 840Di-NC and PLC are operated in cyclic operation

S If a machine control panel is connected, no alarms or messages should be
present
S The displayed axes of the NC can be traversed by simulation.
Delivery state At delivery, the hard disk of the PCU is already partitioned for running SINUM-
ERIK 840Di and any other SINUMERIK applications. The software applications
included in the delivery are ready for installation and are located on the hard
disk under D:\Setup\Apps\<Application1> . . . <Application n>.
active
C: FAT16 D: FAT16 E: NTFS F: NTFS
Name: DOS Name: Install Name: WinNT Name: 840Di system

Contents: DOS 6.2 Contents: Images, Contents: WinNT 4.0 Contents: empty
Tools Setups,
Updates
Primary partition Extended partition Primary partition Primary partition

with logic drive
Fig. 6-1 Partitioning of the harddisk
Installing the When the PCU is first booted, the following menu is displayed:
software
Welcome to SINUMERIK !
These SINUMERIK products will be installed now:
<Application 1> <Version>

: :
: :
<Application n> <Version>
Install NOW
Install at NEXT REBOOT
CANCEL installing

6.2 First ramp-up
Menu commands:
S Install NOW
All the applications displayed will be installed in the listed order. During the
installation procedure follow the instructions that appear on the screen.
Notice
You must not switch off the PCU during the entire installation procedure. Loss
of data!
S Install at NEXT REBOOT

None of the listed applications are installed and you go to the NT Desktop.
The installation menu is displayed again the next time the PCU is booted.
S CANCEL installing
None of the listed applications are installed.
Notice! It is not possible to repeat the installation process at a later time.
Notice
The installation menu is not displayed the next time the PCU is booted. It is
not possible to repeat the installation process.
Completion Once the PCU has powered up again, you can continue with the basic start-up
procedure of the PLC (Subsection 6.2.3, page 6-179).

6.2 First ramp-up
6.2.2 Basic start-up of the system software (SW 2.1 and lower)
Objective of basic After a basic start-up described in the following, the following prerequisites must
start-up be provided:
S SINUMERIK 840Di-NC and PLC are operated in cyclic operation
S If a machine control panel is connected, no alarms or messages should be
present
S The displayed axes of the NC can be traversed by simulation.
Loading the The first step of basic start-up is to copy the SINUMERIK 840Di system soft-
system software ware and Windows NT to the PCU hard disk.
On delivery, the hard disk of the PCU is already partitioned for operation of the
SINUMERIK 840Di and any further SINUMERIK applications, and the software
required for basic start-up is installed:
– The boot software and further software required for start-up is to be
found at C:
– The disk image with the SINUMERIK 840Di system software and Win-
dows NT are to be found at D:\Images
The drives E: and F: are empty.
active
Name: DOS Name: TMP Name: WinNT Name: 840Di system

Contents: Ramp- Contents: Images, Contents: empty Contents: empty
up Install,
tools Updates

with logic drive
Fig. 6-2 Partitioning of the harddisk
Selecting the When the PCU is booted for the first time, the following menu appears:
version
Please Select SINUMERIK HMI Version to install:
1 SINUMERIK 840Di Software <version>
9 Service menu
Your Choice [1,9]?
Use the appropriate key “1” ... “8” to select the version you want to install and
then press “Y” to confirm.
After your confirmation, the appropriate disk image is copied to the hard disk
(drives C:, E: and F:) .
The contents of the hard disk will then be as follows:
1st partition/drive C:
The drive C: contains:
– MS DOS 6.2

6.2 First ramp-up
– Service menu software

– Norton Ghost
– Norton Ghost Walker
2nd partition/drive D:
The Images directory contains both the supplied image files and the image
files you have created for yourself.
The Install directory contains for example Windows NT drivers that can be
installed later or for updating.
3rd partition/drive E:
Drive E: is exclusively intended for the Windows NT system software.
4th partition/drive F:
Drive F: is intended for Windows NT applications, such as
– SINUMERIK 840Di
– SINUMERIK HMI Advanced.
Service menu Use the key “9” to call the service menu.
Service menu <version>
Please select:
3 DOS Shell
5 SINUMERIK System Check
6 Reboot System (warm restart)
7 Backup/Restore
8 Start PC Link
9 Exit
Your Choice [3,5,6,7,8,9] ?
SINUMERIK The menu item 5 SINUMERIK System Check will grant you access to a follow-
System Check ing menu to choose the error checks:
– Logic check of the directory/file system
– Physical check of the hard disk.
Backup/Restore Using the menu item 7 Backup/Restore to:
S Backup
create ghost images of individual partitions or of the entire hard disk and to
save them locally under D:\Images or to transfer them to an external com-
puter using a parallel or network connection.
S Restore
load ghost images from an external computer using a parallel or network
connection.
The backup/restore process is described in detail in Section 15.3, page 15-471.

6.2 First ramp-up
6.2.3 Basic start-up of the PLC
Starting the After installing the system software (SW 2.1 and lower)/completing the installa-
SINUMERIK tion procedure (SW 2.2 and higher), a the system is automatically rebooted. The
Desktop PCU will then power up and the default menu of the boot manager is displayed:
SINUMERIK
Service menu (hidden)
To start the SINUMERIK desktop (Windows NT), press the input key to confirm
or wait the preset time until the boot process is started automatically.
Carrying out After the SINUMERIK desktop (Windows NT) has appeared, only the supplied
basic start-up PLC series machine start-up must be loaded into the PLC for basic start-up.
To do so, proceed as follows:
1. Start the “SinuCom NC” start-up tool from the Windows NT taskbar:
Start > Programs > SinuCom NC > SinuCom NC
2. Use SinuCom NC to load the supplied series machine start-up file
PLC_BSP.ARC into the PLC.
Menu command: File > SeriesStart-up archive > ReadIn
Dialog: Read-in archive
– Optional field: Data management
– Button: “NEXT”
– Select the file PLC_BSP.ARC from the Archive folder.
– Button: “FINISH”.
Basic start-up has then been completed. NC and PLC run in cyclic mode.
If a machine control panel is connected, the LEDs of the machine control panel
should now no longer flash and no more alarms should be present on the NC.

6.2 First ramp-up
6.2.4 Ramp-up of the machine control panel (MCP)
Testing the When you press the keys “Feed Start” and “Feed Stop” when the machine con-
system software trol panel powers up (all LEDs flash), the software version of the machine con-
trol panel is displayed.
This means that the system software of the machine control panel has booted
correctly and waits until the cyclic communication is established by the PLC.
Check the MPI Whether the machine control panel on the MPI bus is detected, can be checked
communication as follows:
S HMI Advanced
With HMI Advanced, the active nodes at the MPI bus are displayed with
operating area Start-up > MMC > Operator panel > Bus node.
S SIMATIC Manager STEP7

The active nodes at the MPI bus are displayed using the SIMATIC Manager
STEP7 by menu command Target system > Display accessible nodes.
MPI default The MPI default addresses of the individual components are:
addresses
– PLC = 2
– NC = 3
– Machine control panel = 6.
If the machine control panel is displayed as an MPI node with address 6, it has
been detected correctly.
Error note If the machine control panel continues to flash, check the parameterization of
the PLC block FB1, Subsection 5.4.3, page 5-143.
6.2.5 Ramp-up of the SIMODRIVE 611 universal drives
For detailed information on the ramp–up of SIMODRIVE 611 universal drives,

please refer to:
References: /FBU/ SIMODRIVE 611 Universal, Description of Functions

6.3 Ramp-up
6.3 Ramp-up
6.3.1 Boot manager
The PCU powers up and the menu of the boot manager is displayed:
OS Loader ...
Please select the operating system to start:
SINUMERIK
Service menu (not visible)
Use " and # to move the highlight to your choice.

Press Enter to choose.
With the menu you can choose between:
S SINUMERIK desktop (normal case)

See Section 6.4, page 6-188.
S Service menu (password protected)

See Section 6.5, page 6-193.
6.3.2 SRAM handling
The user data of the NC (machine data, setting data, user variables, parts pro-
grams, cycles, etc.), as well as the retentive data of the PLC are battery-backed
in the static memory area (SRAM) of the MCI board.
With each “NCK power ON RESET” (warm restart) or shutting down Windows
NT correctly, the contents of the SRAM is saved to the hard disk of the PCU as
an SRAM image. In this case, the SRAM image valid until then also be saved to
the hard disk of the PCU as an SRAM backup.
In certain error or service cases, it is also possible to use the SRAM image or
backup to be able to continue work immediately without recommissioning the
SINUMERIK 840Di.

6.3 Ramp-up
Table 6-1 SRAM handling
Serial No. SRAM SRAM image SRAM backup Used user data / remark
MCI board MCI board (hard disk) (hard disk)
OK OK OK
Known yes not applicable not applicable MCI / normal ramp-up
Known no yes not applicable IMAGE / no message box or alarms;
see Subsection 6.3.4; case 1
Known no no yes BACKUP / message box and alarm;
Known no no no Start-up / Restart-up required
Unknown yes yes not applicable MCI or IMAGE / Request carried out;
see Subsection 6.3.6
Unknown yes not applicable not applicable MCI / message box;
(SW update) see Subsection 6.3.5
Unknown yes no yes MCI or BACKUP / Request carried out; if BACKUP
is selected, message box and alarm will occur;
Unknown yes no no MCI / message box;
see Subsection 6.3.5
Unknown no yes not applicable IMAGE / MessageBox;
Unknown no no yes BACKUP / message box and alarm;
Unknown no no no Start-up / Restart-up required
Serial no. of MCI board

Known: The serial no. of the MCI board complies with the serial number last stored on
the PCU.
Unknown: The serial no. of the MCI board does not comply with the serial number last
stored on the PCU.
Unknown: Provided that the SRAM of the MCI board is OK, the system does not request
(SW update) which SRAM (MCI or IMAGE) is to be used when it runs up for the first time
after performing a SW update. The SRAM of the MCI board is always used.
SRAM image or SRAM backup (hard disk) “OK”

Yes: The following criteria must be fulfilled:
1. NC and PLC software version of SRAM image or backup must comply
with the installed software version.
2. Windows NT must be shut down correctly (to do so, the POWER FAIL
mechanism of the SINUMERIK 840Di is also sufficient)
3. The checksum test using the SRAM image or backup must be successful.
4. The battery status at the time of saving of the SRAM image must be O.K.
Used user data

MCI: The battery-backed user data in the SRAM of the MCI board will be used.
IMAGE: The user data battery-backed in the SRAM image on the hard disk of the
PCU will be used.
BACKUP: The user data battery-backed in the SRAM backup on the hard disk of the
PCU will be used.
Start-up The user data of the NC will be deleted and default machine data
will be loaded.

6.3 Ramp-up
6.3.3 Ramp-up after battery replacement (backup battery of the MCI

board)
Correct Before you change the backup battery of the MCI board, the SINUMERIK 840Di
shutting down or Windows NT must be shut down correctly.
For shutting down, use one of the following options:

S Interface signal: “PC shutdown”; see Subsection 16.1.1, page 16-499.
Inverting SRAM If SRAM memory cells are inverted when changing the battery, this will be de-
memory cells tected during ramp-up. In this case, the SRAM image will be written back to the
SRAM of the MCI board and the SINUMERIK 840Di is thus ready immediately.
Reactions
None.
Notice
If Windows NT is shut down not correctly before changing the backup battery,
an inversion of the SRAM memory cells during the battery change cannot reli-
ably be detected.
The SINUMERIK 840Di must then be restarted.
6.3.4 Ramp-up after replacement of the MCI board
After the MCI board has been changed, the further procedure depends on the
past history. The following cases are distinguished:
1. An up-to-date SRAM image exists.
2. An up-to-date SRAM image does not exist.
Case 1: Before the MCI board has been changed, Windows NT could not be shut down
An up-to-date SRAM correctly. An up-to-date SRAM image is thus provided.
image exists During ramp-up, the MCI board is detected as a new one using the serial num-
ber. The SRAM image will then be written back to the SRAM of the MCI board.
The SINUMERIK 840Di is thus ready again immediately.
Reactions
A note will appear in a message box, which must be acknowledged with “OK”:

6.3 Ramp-up
Note: User data loaded into MCI card.
Notice
1. If the MCI board is detected defective during the ramp-up of the SINUM-
ERIK 840Di, the last SRAM image is kept when shutting down Windows NT.
After the MCI board has been changed, proceed as described above.
2. If the MCI board is changed due to a supposed or an actual error (in the
case of suspected errors, sporadic errors, etc.), it is recommended to restart
up the SINUMERIK 840Di-NC and PLC; otherwise, data errors could be
taken over from the SRAM image.
Case 2: A defect of the MCI board has occurred during operation of the SINUMERIK
An up-to-date SRAM 840Di. Windows NT has possibly been shut down correctly, but no SRAM
image does not exist image could be created.
After the MCI board has been changed, it will be identified as “unknown” using
the serial number. Since no up-to-date SRAM image exists, the SRAM backup
is written back into the SRAM of the MCI board. The SINUMERIK 840Di is thus
ready again immediately.
The user data or the operating state of the SINUMERIK 840Di must be checked
to see whether they are suitable to be worked with in the future. It might be nec-
essary to perform commissioning of the SINUMERIK 840Di NC and PLC again.
Reactions
A note will appear in a message box, which must be acknowledged with “OK”.
Alarm: Old backup of user data loaded into MCI card.

The user data were saved at 07.07.2000 10:30

6.3 Ramp-up
In addition, an NC alarm is output, which is displayed on the appropriate user

interface of the SINUMERIK 840Di (840Di start-up, HMI Advanced, etc.):
S Alarm: “4065 Battery-backed memory has been restored from the hard
disk (possible data loss)”
For safety reasons, the alarm must be acknowledged explicitly by the operator
before performing the necessary NCK power ON reset.
See Subsection 10.10.1, page 10-395.
6.3.5 Ramp-up after replacement of the PCU (new) or reinstallation/

update of the 840Di software
If an MCI board used in a new PCU once is further used or if the 840Di software
is reinstalled on a SINUMERIK 840Di that is already started up, then the bat-
tery-backed user data in the SRAM of the MCI board are kept.
To achieve this, it is essential that the current NC and PLC software version of
the SINUMERIK 840Di complies with the software version with which the bat-
tery-backed user data of the SRAM have been created.
Reactions
A note will appear in a message box, which must be acknowledged with “OK”:
Note: User data from MCI card used.
Notice
If you do not wish to use the battery-backed user data further, you must repeat
ramp-up of the SINUMERIK 840Di.

6.3 Ramp-up
6.3.6 Ramp-up after replacement of the PCU or the MCI board
If it is detected during the ramp-up that both the SRAM image on the hard disk
of the PCU and the SRAM of the MCI board have battery-backed valid, but dif-
ferent user data (both components were already used in a SINUMERIK 840Di),
it is not possible to make an automatic selection.
Reactions
The following message box is displayed with which the user has to decide
which user data have to be used further.
New MCI card detected. Valid user data are found:

– on MCI card
– on harddisk
If you want to use the user data from MCI card press “Yes”
If you want to use the user data from the hard disk press “No”
Yes No
6.3.7 Ramp-up after importing a backup copy
If a backup copy (ghost image) of a SINUMERIK 840Di already started up is

loaded into the PCU again, the battery-backed user data in the SRAM of the
MCI board will be used further.
6.3.8 Ramp-up after power failure (Power Fail)
Case 1: In case of a power failure, the SINUMERIK 840Di will save the user data in the
SRAM saved SRAM of the MCI board thanks to the Power Fail detection integrated in the
PCU. An SRAM image, however, cannot be created any more in this case.
When the power returns or with the next ramp-up, the data will be available
again.

6.3 Ramp-up
Notice
Saving of the user data in the SRAM of the MCI board in case of power failure
is only guaranteed if the PCU is operated within its defined specifications.
References /BH/ Operator Components Manual
Section: Component PCU 50
Case 2: If the SINUMERIK 840Di has been operated outside its defined specifications, it
SRAM not is under certain circumstances possible that the user data could not be saved in
saved the SRAM. Therefore, proceed as described in Subsection 6.3.4, page 6-183
case 2.
6.3.9 Ramp-up with shutdown signal (SW 2.3 and higher)
If the SINUMERIK 840Di is operated with a UPS system, the shutdown system
must be configured appropriately. See Subsection 10.10.2, page 10-399. When
the shutdown signal is present, the NC and PLC are terminated first and Win-
dows NT then shut down correctly.
1. Ramp-up If ramp-up takes place while the shutdown signal is present, Windows NT is
shutdown again straight away.
as of 2nd. ramp-up As of 2nd ramp-up with shutdown signal present produces the following system
behavior:
– Windows NT is not shut down correctly again
– NC and PLC are not started
– The following message box appears:
Alarm: NCK started while Power Failure, shutdown with OK
OK
The circuit on the MCI board extension module and the configuration of
the shutdown signal (see Subsection 10.10.2, Page 10-399) can be
checked and modified if necessary.
If the shutdown signal is no longer present after acknowledging the mes-
sage box, the NC and PLC are started. Otherwise, Windows NT is shut
down correctly.

6.4 SINUMERIK desktop

The SINUMERIK desktop is intended for service and provides the following
functionality on the Windows NT level:
S Network operation for installing/updating system software

S Setting the system environment
S Authorization of the SIMATIC STEP7 software
S Test functions for system components.
6.4.1 Network operation
The PCU contains a network connection by default.

In order to operate the PCU in a network (Internet, Intranet), in addition to con-
nect the Ethernet cable to the PCU, the following settings are required:
– Computer Name
– Network protocol
– IP address.
Note
To obtain the required specifications required for network operation, please
contact the appropriate network administration.
Computer name In order to set the computer name of the PCU, open the control panel using the
Windows NT task bar Start > Settings > Control Panel.
In the control panel, open Network and type the name of the new computer.
Dialog Dialog: Network

Register: Identification
Computer Name: <COMPUTER NAME>
OK
TCP/IP In order to establish a network connection using the TCP/IP protocol, the PCU
must be assigned an unambiguous IP address in the network.
To do so, choose: Start > Settings > Control Panel.
In the “Control Panel”, open Network. From the register: “Protocols” select the
TCP/IP protocol and click the button: “Properties” to call the Properties dialog:
S If a DHCP server exists in the network, select:

“Obtain an IP address form a DHCP server”
S If no DHCP server exists in the network, select:

“Specify an IP address”
and enter the appropriate specifications (see above: Note).

6.4.2 Software installation/update
The SINUMERIK desktop provides various ways of installing and updating soft-
ware:
S Installation/updating is started directly from the SINUMERIK desktop by exe-

cuting the appropriate file (usually install.exe).
S The installation/update package is copied into the D:\INSTALL directory. The

next time the PCU is started up, installation/updating is started automatically.
After installation/updating has been completed, the system software can be
started immediately.
Note
This function can be also be run from the service menu (Chapter 15, page
15-455).
6.4.3 Setting the SINUMERIK HMI environment
The SINUMERIK desktop provides the functions

S Original SINUMERIK HMI Environ
S Current SINUMERIK HMI Environ
as script files for setting the required HMI system environment.
Original Before starting SINUMERIK HMI, the HMI-spec. system environment is put in
HMI environment the as-delivered state. For that purpose, the content of directories
– F:\ADD_ON
– F:\USER
– F:\OEM
– C:\RUNOEM
is backed up and then the directories are cleared.
Current Before SINUMERIK HMI is started, the backed up files from the above directo-
HMI environment ries are loaded.
Note
This function can be executed through the service menu (Subsection 6.5.4,
page 6-195).

6.4.4 Authorizing SIMATIC STEP7
For authorizing the SIMATIC STEP7 software previously installed on the PCU,
you can use the function
S STEP7 authorizing
in the form of a script file.
Note
page 6-194).
6.4.5 Serial mouse
The two COM interfaces of the PCU are by default set in such a way that serial
devices (except for a serial mouse) can be used connected to them.
Activating The following settings are required to operate a mouse:

serial mouse S Alter file boot.ini:
– Open the following file with a Windows NT standard editor (e.g. Start >
Programs > Accessories > Notepad): C:\boot.ini
– Remove section: [operating systems]
option: /NoSerialMice
– Save and close the changed file.
S Adjust the system setting to serial mouse:
– Select the serial mouse used in the Mouse Properties dialog box from
the Control Panel: Start > Settings > Control > Mouse
Dialog Dialog: Mouse Properties

Tab: General
Button: “Change...”
Dialog: Select Device
Optional field: “Show all devices”
Select the corresponding serial mouse
OK
OK
Note
After you have activated the serial mouse, a PS/2 mouse that you were pre-
viously using will no longer work.

6.4.6 Fault analysis
Testing system The following function is available for testing system components
components S Check SINUMERIK System
in the form of a script file. The function tests the following system components:
S Hard disk of the PCU

Partitions C:, D:, E: and F: are tested.
Note
page 6-196).
System If a “serious exception” (blue screen) occurs, system information is written to the
information following file:
S D:\Memory.dmp.
Basic software Version information about:

version S System components of the service menu
S Windows NT
are contained in the file:
S C:\BaseVers.txt.
HMI system Versions information about:

software S HMI system software packages
version
S Windows NT
are obtained using the Windows program
S HMI Explorer
It is also (in some cases) possible to run and uninstall HMI applications.
6.4.7 OEM configuration
OEM OEM configuration provides the possibility of running Windows programs before
directories starting the SINUMERIK System Software. The appropriate Windows programs
or links must be routed to special directories.
1. C:\RunOEM\SeqOnce
Programs stored here are run once and sequentially1).

2. C:\RunOEM\Seq
Programs stored here are run on each ramp-up and sequentially1).
1) Sequentially means that a program is not launched until the previous pro-
gram has been closed.
3. C:\RunOEM\ParOnce
Programs stored here are run once. They run parallel with the HMI system
software.
4. C:\RunOEM\Par
Programs stored here are run on each ramp-up . They run parallel with the
HMI system software.
Order of execution
S Subdirectories
The subdirectories are executed in the order listed above.
S Programs
The programs within a subdirectory are started in the order in which they
have been placed in the subdirectory chronologically.
Data files In addition to executable programs, you can also place data files in the subdi-
rectories. They will be opened in the application with which their file type is as-
sociated:
S File type: “.txt” –> Notepad
S File type: “.htm” –> Internet Explorer
6.4.8 Replacing the SINUMERIK background image
During ramp-up of the PCU, a SINUMERIK background image is displayed until

the HMI software starts. The SINUMERIK background image is stored in the
following file:
S Alter file E:\WINNT.40\System32\MMC840D.bmp

Format: 800x600 pixels
6.4.9 Information and constraints concerning the basic software
You will find information and constraints on the current basic software on the
SINUMERIK desktop in files:
S SIEMENSD (German)
S SIEMENSE (English)

6.5 Service menu
6.5 Service menu
PLEASE SELECT
1 Install/Update SINUMERIK System
2 SINUMERIK Tools and Options
3 DOS Shell
4 Start Windows NT (Service Mode)
7 Backup/Restore
8 Start PC Link
9 Reboot (warm restart)
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
Functions The service menu provides the following functions at DOS level:
S Install/Update SINUMERIK System

Installation and addition or updating of the SINUMERIK system
S SINUMERIK Tools and Options
Loading additional tools and enabling options
S DOS Shell
The DOS command interpreter is started
S Start Windows NT
WinNT is started
S SINUMERIK System Check
Consistency test and, if necessary, recovery (SCANDISK) of the file system
S Backup/Restore
Hard disk backup/restore with Norton Ghostt
S Start PC Link
Installation of PC link software (Interlink/Interserve) using CD-ROM
S Reboot
Restart of the system
S 840Di services
Activating 840Di-specific functions
The service menu is started with the operating sequence “Cursor down” and
“Enter”.
Activation The service menu is started from the boot manager with the operating se-
quence “Cursor down” and “Enter”.
A password of protection levels 0–2 is required to execute the service menu:
– System
– Manufacturer
– Service.

6.5 Service menu
6.5.1 Install/Update SINUMERIK System
A detailed description of the software installation/update is to be found in Sec-

tion 15.2, page 15-460.
6.5.2 SINUMERIK Tools and Options
PLEASE SELECT
2 SINUMERIK tools and options
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
Under menu item: Two SINUMERIK Tools and Options, you can execute the
following actions:
S Authorizing SIMATIC STEP7.
Authorizing SIMATIC STEP7
Requirements The following requirement must be fulfilled:
S The SIMATIC STEP7 software has already been installed on the PCU.
Operator action Select SINUMERIK Tools and Options with key “2”.
Following menu:
PLEASE SELECT
1 Activate Step7 for PCU
9 Return to Main Menu
Your Choice [1, 9] ?
To request authorization press key “1”.

Actual authorization is performed automatically during ensuring ramp-up of the
PCU under Windows NT.
Note
Authorization can also be performed on the SINUMERIK desktop by starting
the function “STEP7 Authorizing”.

6.5 Service menu
6.5.3 DOS Shell

PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
Operator action Select DOS Shell with key “3”.

The DOS command interpreter is started.
To leave the DOS Shell enter “exit” and conclude the command with the “Re-
turn” key.
Version display: The version of the basic software is displayed with the command:
Basic software S C:\BaseVers.txt.
6.5.4 Start Windows NT (Service Mode)

PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
Under menu item: 4 Start Windows NT (Service Mode), you can perform the
following actions:
S Standard Windows NT (without starting SINUMERIK HMI)

After the PCU has started up, Windows NT is started without any
SINUMERIK HMI
S Original SINUMERIK HMI environment

SINUMERIK HMI is started in the as-delivered state, i.e. the content of the
directories:
– F:\ADD_ON
– F:\USER
– F:\OEM
– C:\RUNOEM
has been backed up and the directories then cleared.

6.5 Service menu
S Current SINUMERIK HMI environment

Before you start SINUMERIK HMI, the backed up files of the above directo-
ries are loaded.
Operator action Select Start Windows NT (ServiceMode) with key “4”.

Following menu:
PLEASE SELECT
1 Standard Windows NT (without starting SINUMERIK HMI)
4 Original SINUMERIK HMI environment
5 Current SINUMERIK HMI environment
Your Choice [1,4,5,9] ?
After you have selected the function, the system is rebooted. The function is
actually executed during the ensuing ramp-up of Windows NT before the HMI
system software is started.
Note
S The SINUMERIK desktop can also be started if you press key “3” while SI-
NUMERIK background image is being displayed during ramp-up of the
PCU (time range: 3 sec).
S The HMI environment can also be set on the SINUMERIK desktop by start-
ing the functions:
– Original SINUMERIK HMI Environ
– Current SINUMERIK HMI Environ.
6.5.5 SINUMERIK System Check

PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
Under menu item: SINUMERIK System CHECK, the following system compo-
nents are checked:
S Hard disk of the PCU

Partitions C:, D:, E: and F: are tested.
Operator action Select SINUMERIK System CHECK with key “5”.

6.5 Service menu
After you have selected the function, the system is rebooted. The function is
actually executed during the ensuing start-up of Windows NT before the HMI
system software is started.
Note
You can also starting testing of the system components from the SINUMERIK
desktop by starting the function “Check SINUMERIK System”.
6.5.6 Backup/Restore
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
You will find a detailed description of the backup/restore functions (data backup)
in Section 15.3, page15-471.
6.5.7 840Di services

PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di services
Your Choice [1,2,3,4,5,7,8,9,P] ?
Under menu item: 840Di Services, 840Di-spec. functions are requested that are
then executed during the ensuing ramp-up of the SINUMERIK 840Di NC or
PLC.
PLC functions:
S Set PLC Mode to STOP
S Set PLC Mode to RUN
S Set PLC Mode to RUNP
S Set PLC Mode to MRES
Notice! This function deletes all PLC data.

6.5 Service menu
Operator action Select 840Di Services with key “P”.

Following menu:
PLEASE SELECT
1 Set PLC-Mode to STOP
2 Set PLC-Mode to RUN
3 Set PLC-Mode to RUNP
Your Choice [1,2,3,4,9] ?
After you have selected the function, the system is rebooted. While the PCU is
started up, the following message box is displayed indicating execution of an
840Di Service:
Alarm: System order executed.
The message box must be acknowledged with “OK”.

The selected function is executed after ramp-up of the corresponding SINUM-
ERIK 840Di component.

6.6 Configuring PTP link on an external computer (PG/PC)

6.6.1 Ext. computer with Windows 9x
In order to establish a PTP (point-to-point) connection between a PCU 50 and

an external computer (PG/PC) under Win9x, the following preconditions must
be fulfilled with regard to the external computer:
1. The Ethernet cable is connected to the Ethernet interface of the external
computer and the PCU
– Point-to-point connections require an Ethernet cable of the type “Twisted
Pair Crossed 10baseT/100baseTX Ethernet Cable”.
Notice
A point-to-point connection between PCU 50 and an external computer
(PG/PC) requires an Ethernet cable of the type “Twisted Pair Crossed 10ba-
seT/100baseTX Ethernet Cable”.
2. The network protocol NetBEUI is installed on the external computer.

3. I want to be able to give others access to my files.
4. The computer name of the external computer is known.
5. Access to the drive/folder of the external computer you want to access must
be shared by the PCU, and the sharing name must be known.
Network protocol: In order to check whether the network protocol NetBEUI is installed, open con-
NetBEUI trol panel using the Windows 9x task bar Start > Settings > Control Panel on
the external computer.
Open Network in the control panel. The network components installed are dis-
played in the “Configuration” tab. If the network protocol NetBEUI is not dis-
played between them, it must now be installed.
Dialog: Dialog: Network
Start Tab: Configuration
Button: “Add...”
Dialog: Select network component type
Choose from the list: Protocol
Dialog: Select Network Protocol
Choose from the “Manufacturers” list: Microsoft
Choose from the “Network protocols” list: NetBEUI
OK
Sharing file access In order to check or share access to files for other users, select the: Configura-
tion tab and click there the button: “File and Print Sharing...”

Dialog: Tab: Configuration

cont’d. Button: “File and Print Sharing...”:
Dialog: “File and Print Sharing...”
I want to be able to give others access to my files.
OK
Computer name In the case of a point-to-point connection, the computer name and the designa-
and tion of the workgroup of the external computer is random.
workgroup To determine or set the computer name and the workgroup, select the tab:
“Identification”:
Dialog: Tab: Identification
End Computer name: <COMPUTER NAME>
Workgroup: <WORKGROUP>
OK
Sharing access to In order to share access to the drive/directory or determine the sharing name,
the drive/directory start the Windows Explorer on the external computer and select the drive/direc-
or determining tory to be released for shared access for the PCU.
sharing names
Note
The access control is set in the Windows Explorer in the tab: “Access control”
of the Properties dialog of a drive/directory. If the tab: “Access control” is not
displayed, the computer is or was part of a Domain network and the system
administration has switched off the tab display for safety reasons.
In order to be able to make the settings required for the point-to-point connec-
tion, the tab must be unhidden. This can be done using the program “pole-
dit.exe”. Poledit.exe is to be found on the Win9x CD under: admin\app-
tools\poledit or available for free download under http://www.microsoft.com/win-
dows95/downloads.
Open the Properties dialog (right mouse button > Properties) of the drive/di-
rectory and define the sharing name and the access rights.
Dialog Dialog: Properties of <drive>/<directory>
Tab: Share access
Optional field: Choose “Shared As:”
Sharing name: <SHARED AS>
Button: “Rights...”
Dialog: Access by share access rights
Dialog: Add users and groups
Names: Choose a name from the list
e.g. “User” or “Everybody”
Button: “Add”
OK
Access type: <Read>
OK
OK

6.7 Subsequent installation of Windows NT components
6.7 Subsequent installation of Windows NT components

The directory D:\Updates\WinNT\I386 of the PCU hard disk contains the subdi-
rectory I386 of the Windows NT installation CD.
This subdirectory can be used to additionally install, e.g. Windows NT drivers.
6.8 License management (SW 2.1 and higher)

With SW 2.1 and higher, before using the SINUMERIK 840Di system software
and the activated options, you need to assign the corresponding software li-
censes to the SINUMERIK 840Di hardware. During the assignment procedure,
you will be given a license key which electronically links the software to the SI-
NUMERIK 840Di hardware. This assignment is performed over the Internet.
You can also activate options without the license keys and use them for test
purposes. The control will then cyclically display a reminder/alarm that a license
has not yet been registered for the option.
Option selection up to entering the license key is performed as follows:
1. Select the required options; order and obtain the corresponding license
packages and/or single-user licences:
Order catalog: NC 60.2002
2. Activate the options
SinuCom NC at the SINUMERIK 840Di in question
3. Obtain the license key for the required control.
Web License Manager through the Internet on the SINUMERIK 840Di or
external PC under: www.siemens.com/automation/license
4. Complete the entry procedure for the license key:
SinuCom NC at the SINUMERIK 840Di in question
SinuCom NC Control-spec. administration of the options and licenses is performed exclu-

sively through SinuCom NC on the SINUMERIK 840Di in question.
Start SinuCom NC from the Windows NT taskbar: Start >
Programs > SinuCom NC > SinuCom NC
Option menu To license the options you can with the SINUMERIK 840Di you can access the
machine data block by double-clicking with the left mouse button as soon as
SinuCom NC has established the online link (Fig. 6-3).

6.8 License management (SW 2.1 and higher)
SinuCom NC – [[Online]SinuCom_NC_Project]
Machine data
block
Sinumerik – Project objects
Sinumerik 840Di(1) [connected]
Machine data MD block1
Fig. 6-3 SinuCom NC: Basic menu
License key The option menu allows setting of new and additional options in the appropriate
input fields (Fig. 6-4).
The procedure described above (Items 1. to 4.) is triggered with button “Get a
new License Key” (Fig. 6-4). The follow further instructions in the following dia-
log boxes.
SinuCom NC – [[Online]SinuCom_NC_Project : MD block1]
MD-block1 Options: /MD-block1

Options
Show all Show not licensed only
Channel Mode gro
PROFIBUS assign Option Set Licensed
Axis configuration System software UNIVERSAL
AX1:X1 6FC5251-
AX2:Y1
AX4:A1 Mode group (BAG), additional
Input fields:
3 0
AX3:Z1 6FC5251-0AD00-0AA0
Options
Functions
Processing channel, additional 3 0
6FC5251-0AA07-0AA0
Cycles in DRAM
Current License Key is not sufficient
Get a new License Key
Button: License Key
Fig. 6-4 SinuCom NC: Option menu

PROFIBUS DP Communication 7
7.1 General
PROFIBUS DP PROFIBUS DP is an international, open field bus standard laid down in the Eu-
ropean field bus standard EN 50170 Part 2. PROFIBUS DP is optimized for fast,
time-critical data communication on the field level.
The components communicating on PROFIBUS DP are subdivided into master
and slave components.
1. Master (active node)
Components operating on the bus as master determine the data exchange
on the bus and are therefore also designated active nodes.
Masters divide into two classes:
S DP master, class 1 (DPMC1):

This is the designation for central master devices exchanging informa-
tion with the slaves within defined message cycles.
Examples: SIMATIC S5, SIMATIC S7, etc.
S DP master, class 2 (DPMC2):

These are devices for configuring, starting up, operating and watching
during running bus operation.
Examples: Programming devices, operator control and monitoring de-
vices
2. Slaves (passive nodes)
These devices may only receive messages, acknowledge them and transfer
message to the master on its request.
Examples: Drives, I/O modules.
PROFIBUS DP with Communication between SINUMERIK 840Di (NC and PLC), as the master, and
Motion Control the slave components on PROFIBUS DP is based on PROFIBUS DP with the
extension MotionControl extension.
The MotionControl extension is characterized by:
S Configurable equidistant DP cycle

S Synchronization of the DP slaves by the DP master using a GlobalControl
message frame in every DP clock
S Automatic maintenance of the equidistant clock by the DP slaves during a

short communication failure.
References: /PPA/ PROFIDrive Profile Drive Technology Version 3,


7 PROFIBUS DP Communication 06.03
7.1 General
7.1.1 Message frame structure for cyclic DP communication
This is the message frame structure for cyclic DP communication using the
drive “SIMODRIVE 611 universal”.
Message frame The message frames for cycle data transmission have the following basic struc-
structure ture:
Drive A Drive B
Protocol Useful data (PPO) Useful data (PPO) Protocol

frame Parameter Process Parameter Process frame
identifier data identifier data
(header) (trailer)
value (PDA) value (PDA)
(PIV) (PIV)
Note:
The useful data for drive B are only transmitted when “DP slave 611U” is
operated as a double-axis module.
Fig. 7-1 Message frame structure for cyclic data transmission
Useful data The useful data for cyclic operation are termed parameter process data objects
structure (PPO). The are subdivided into two areas within the message frame:
S Parameter area (PIV, parameter identifier value)
This part of the message frame is for reading and/or writing parameters and
for reading out faults.
S Process data area (PDA, process data)
This area contains the control words, setpoints, or additional information and
actual values.
The following data are transmitted with the process data:
– Control words and setpoints (requests: master ––> drive) or
– status words and actual values (responses: drive ––> master).

06.03 7 PROFIBUS DP Communication
7.1 General
7.1.2 Description of a DP cycle
Actual values At the time TI, all equidistant drives (DP slaves) read in the current actual posi-
tion values. In the next DP cycle, at time TDX, the actual values are transferred
to the DP master.
Position controller At the time TM, with TM > TDX, the NC position controller is started, calculating
the new speed setpoints using the actual position values transferred.
Setpoints At the beginning of the next DP cycle at time TDX, the speed setpoints are trans-
ferred from DP master to the DP slaves (drives).
At the time TO, the speed setpoints are accepted by all servo drive controls as
the new default.
TMAPC = TDP
NC:
Master or position TM
controller R
TDX TDX
1 2
PROFIBUS DP
DPV1 RGT GC Dx Dx Dx DPV1 RGT GC Dx Dx Dx
communication
Speed
controller cycle
Drives:
R R R R R R R R R R R R R R R R
DP slave: 1 to 3
T TI
O
TI TO
Fig. 7-2 Example: Optimized DP cycle with 3 DP slaves 611U
Explanations regarding Fig. 7-2:

TMAPC Master Application Cycle: NC position controller cycle
With SINUMERIK 840Di, the following applies in all cases: TMAPC = TDP
TDP DP cycle time: DP cycle time
TDX Data Exchange Time: Total of transfer times of all

DP slaves

7.1 General
TM Master Time: Shift of starting time of the NC position control
TI Input Time: Time of actual-value sensing The actual values are

transferred to the DP master in the next DP cycle.
TO Output Time: Time of setpoint acceptance. The setpoints were created

by the DP master application in the previous DP cycle.
GC Global Control Message Frame Type (Broadcast Message Frame) for

cyclic synchronization of the isosynchronism between DP Master and
DP slaves
R Computing time of speed and/or position controller
Dx User data exchange between DP master and DP slaves
DPV1 After cyclic communication an acyclic service is sent, if the token holding
time TTH was not exceeded. TTH is calculated by the configuring system.
GAP An attempt is made during GAP to accept new active stations.
TOKEN Token passing is either performed from the station to itself or to other
masters.
RES The reserve is used as an “active pause” for the station to send the token
to itself until the equidistant cycle is terminated.
1
The actual values for the current DP cycle/position controller cycle are
transferred from the DP slave drives to the NC position controller.
2
The setpoints calculated by the NC position controller are transferred to
the DP slave drives.
7.1.3 SINUMERIK 840Di with PROFIBUS DP
PROFIBUS DP and The configuration of PROFIBUS DP is carried out within the framework of a
SIMATIC S7 SIMATIC S7 project (further referred to as S7 project).
To create an S7 project for a SINUMERIK 840Di, the following components are
needed:
S SIMATIC Manager STEP7

S SINUMERIK 840Di
S Programming device/PC with MPI connection (e.g. PG740) and MPI cable
(not required if the SIMATIC Manager is installed on the SINUMERIK 840Di)
S Basic PLC program

S 840Di rack
(a SIMATIC S7-300 station preconfigured for SINUMERIK 840Di)
S DriveOM/SlaveOM.

7.1 General
Programming The SIMATIC Manager STEP7 required to create the S7 project can be installed
device (PG)/PC on any PG/PC with MPI connection, which fulfills the following requirements:
S CD-ROM drive
S MPI connection with 1.5 Mbaud.
To transfer the S7 project to the PLC of the SINUMERIK 840Di, the PG/PC must
be linked with the MPI interface of the MCI board.
SINUMERIK 840Di The SIMATIC Manager STEP7 required to create the S7 project can also be
(The installation of additional software on the SINUMERIK 840Di is described in
detail in Chapter 15, page 15-455).
Windows applications executed on the SINUMERIK 840Di have direct access
to the PLC through the internal MPI interface of the MCI board. To transfer the
S7 project into the PLC of the SINUMERIK 840Di, no additional MPI cable is
therefore needed.
SIMATIC Manager For creating the S7 project for the SINUMERIK 840Di, a SIMATIC Manager
STEP7 STEP7 is required:
S SIMATIC Manager STEP7 Version 5.1 and higher, Service Pack 3.
Notice
The SIMATIC Manager STEP7 is not included in the scope of supply of the
SINUMERIK 840Di.
840Di Rack The 840Di Rack is a SIMATIC-300 station preconfigured for the requirements of
the SINUMERIK 840Di. The following versions are available in the hardware
catalog of HW config.:
S 840Di with PLC 315-2DP 2AF03

– SINUMERIK 840Di PLC
standard designation: PLC315-2DP M/S 2AF03
– PROFIBUS DP Master
standard designation: DP master
– SINUMERIK 840Di NC
standard designation: S7 FM NCU.
The 840Di Rack is part of the PLC Toolbox and is automatically installed in the
SIMATIC Manager STEP7 when installing the basic PLC program also included
in the PLC Toolbox.

7.1 General
Notice
The basic PLC program must be installed on that computer on which the SI-
MATIC Manager STEP7 required to install the S7 project is already installed.
For installing the basic PLC program, please observe the appropriate notes in
the file:
– <installation path>\readme.txt.
After the basic PLC program has been successfully installed, the 840Di Rack is
already available in the hardware catalog of “HW Config” (configuration tool in
the SIMATIC Manager STEP7) in order to be integrated into the S7 project:
S “HW Config” hardware catalog:

Profile: Standard
SIMATIC 300 > SINUMERIK > 840Di > 840Di with PLC315-2AF03
or (SW 2.1 and higher)
. . . > 840Di with PLC315-2AF03, P/C bus
DriveOM/ The SlaveOM (Slave Object Manager) for SINUMERIK 840Di allows dialog-
SlaveOM based configuration of the following drives in conjunction with a SINUMERIK
840Di:
– SIMODRIVE 611 universal or universal E
– SIMODRIVE POSMO A
– ADI4 (Analog Drive Interface for Four Axes).
Notice
If the SlaveOM is used in conjunction with other PLC-CPUs, a consistency er-
ror is signaled when compiling the configuration and no system data blocks are
generated.
The two Object Managers DriveOM and SlaveOM are part of the SINUMERIK
840Di installation. Before using the SlaveOM, first both Object Managers must
be installed in the defined order.
1. Install the DriveOM
2. Install the SlaveOM.
Notice
The Object Managers DriveOM and SlaveOM must be installed on that com-
puter on which the SIMATIC Manager STEP7 for creating the S7 project is al-
ready installed.
To install the Object Managers, please refer to the appropriate notes in the file:

7.1 General
After the SlaveOM has been installed, the following DP slave drives are avail-
able in the hardware catalog of “HW Config” (hardware configuration tool within
the SIMATIC Manager) for being inserted into the S7 project:

Profile: Default
– PROFIBUS DP > SIMODRIVE > SIMODRIVE 611 universal
– SIMODRIVE POSMO CD
– SIMODRIVE POSMO CA
– SIMODRIVE POSMO A
– PROFIBUS DP > SINUMERIK > ADI4
DMF file All properties of a DP slave are stored in a DMF file (device master file) in ASCII
format. STEP7 requires one DMF file each for each DP slave so that the DP
slave can be selected from the hardware catalog.
If a DP slave is not displayed in the hardware catalog, its specific DMF file must
be installed in “HW Config” using the menu command Tools > Install new DMF
file.
After the DMF file has been installed, the DP slave is available in the hardware
catalog of “HW Config” for being inserted into the S7 project:

Profile: Standard
PROFIBUS DP > further field units > ...
Notice
The DMF files must be installed on that computer on which the SIMATIC Man-
ager STEP7 required to install the S7 project is already installed.
To install a DMF file, please refer to the appropriate notes in the file:

7.2 Network rules
7.2 Network rules
The following basic rules must be observed:

1. The bus line must be terminated on both ends. To this aim, enable the ter-
minator in the PROFIBUS DP connector of the first and of the last nodes
and disable the remaining terminators.
Notice
Only two enabled terminating resistors are permitted per bus line.
2. At least 1 terminator must be supplied with 5V voltage.

For this, the PROFIBUS DP connector with inserted terminating resistor
must be connected to a powered device.
3. No tap lines may be routed along PROFIBUS DP.
4. Each PROFIBUS node must first be connected and then enabled.
When disconnecting a node, first disable the connection, then remove the
connector.
5. The cable length of a PROFIBUS DP bus segment may be max. 100m.
Example:
PROFIBUS DP
network Field device Field device
SIMATIC ET200 SIMATIC ET200
installation
OFF ON
SINUMERIK 840Di
PROFIBUS DP
PCU
MCI board
(max. of 100m) ON
PROFIBUS DP
OFF OFF
ON
Terminating resistor in
Drive Drive the connector enabled
SIMODRIVE 611 SIMODRIVE 611
universal universal Terminating resistor in
OFF
the connector not en-
abled
Fig. 7-3 Example of a PROFIBUS DP network installation

7.3 SIMATIC S7 project

The instructions regarding the configuration of PROFIBUS DP, which are pro-
vided in the following, are mainly limited to the special features with respect to
SINUMERIK 840Di.
Note
For details regarding the creation and editing of SIMATIC S7 projects, please
refer to the Documentation on SIMATIC Manager STEP7 or the corresponding
online help.
7.3.1 Creating an S7 Project
To configure PROFIBUS DP for equidistant communication between master and

slaves, an S7 project must be created.
The following definitions are made within the framework of this S7 project:
S Hardware configuration
S PROFIBUS addresses: DP master and DP slaves
S Equidistant PROFIBUS DP cycle
S Equidistant time.
Creating an A new S7 project is created in the SIMATIC Manager using the menu command
S7 project File > New Project.
Type a name you want to assign the project and click OK to confirm the dialog.
The Project window will appear where the structure of the S7 project is dis-
played.
Inserting a To insert the hardware into the S7 project, first a SIMATIC 300 station must be
300 station chosen and pasted to the project:
1. Possibility
– Position the cursor on the Project window
– Right mouse button Insert New Object > SIMATIC Station-300
2. Possibility
Menu command Insert > Station > SIMATIC Station-300.
Open the station and start “HW Config” by double-clicking the hardware icon.

7.3.2 HW Config
Hardware catalog The user interface of “HW Config” mainly contains:

– Menu bar
– Station window
– Hardware catalog.
If the hardware catalog is not displayed, open it using the menu command
View > Catalog.
Station window The station window is split. The upper part displays the structure of the station
graphically, and the lower part provides a detailed view of the selected module.
Note
To check whether a module selected from the hardware catalog complies with
the module in the automation system, the following procedure is recom-
mended:
1. Put down the MLFB numbers of all modules used in the automation system.
2. Select the appropriate module from the hardware catalog and compare the
order number (MLFB) with the MLFB number of the module displayed in the
hardware catalog. Both MLFB numbers must be the same.
7.3.3 840Di Rack
840Di Rack contains the already partially preset modules:
S SINUMERIK 840Di PLC

standard designation: PLC315-2DP M/S 2AF03
S PROFIBUS DP Master
standard designation: DP master
S SINUMERIK 840Di NC
standard designation: S7 FM NCU.
Inserting The 840Di rack is to be found in the hardware catalog under:

Profile: Standard
SIMATIC 300 > SINUMERIK > 840Di > 840Di with PLC315-2AF03
Use the right mouse button to select 840Di Rack and drag it to the Station win-
dow, holding down the mouse button. When you release the mouse button,
840Di Rack will be inserted in the S7 project.

Configuring the After 840Di Rack has been inserted, the dialog box for configuring DP master
DP master opens automatically.
Use the Properties dialog box of DP master to make the following settings:
S PROFIBUS address of DP master

The default setting of the PROFIBUS address is 2. It is recommended to
keep this setting.
S Subnetwork
S Equidistant DP cycle
S Equidistant time.
Equidistant time The SINUMERIK 840Di will accept the set equidistant DP cycle as the NC
system clock cycle and position controller cycle.
position controller cycle = NC system clock cycle = equidistant DP
cycle
The time that can be set for the equidistant DP cycle depends on:
1. The cyclic communication load by the drives and field devices on PROFI-
BUS DP.
2. The capacity utilization of the cyclic position controller level of the NC by the
number of position-controlled machine axes and the active functions.
Dialog Dialog: Properties – PROFIBUS Interface DP Master

Tab: Parameters
Address: 2
Subnetwork:
Button: “New...”
Dialog: Properties – New PROFIBUS Subnetwork
Tab: General
S7 subnetwork ID: <Subnetwork ID> (see below: Note)
Tab: Network settings
Data transfer rate: 12 Mbps
Profile: DP
Button: “Options...”
Dialog: Options
Tab “Isosynchronism”
Enabling the equidistant bus cycle:
Equidistant DP cycle: <Isosynchronous time>
OK
OK
OK
Note
It is recommended to put down the S7 subnetwork ID, since it will be needed
later to parameterize the routing settings of the axis start-up tool SimoCom U.
See Subsection 9.1.6, page 9-269.

Configuring the After DP master has been configured, 840Di Rack with PROFIBUS DP is now
PLC displayed in the Station window.
Parameterizing the You can use the axis start-up tool SimoCom U to start up all DP slaves 611U
MPI interface connected to PROFIBUS from a SINUMERIK 840Di. To allow this, the PLC
must route SimoCom U to PROFIBUS. This requires that the MPI interface of
the PLC is networked.
To do so, open the Properties dialog box by double-clicking on the PLC in 840Di
Rack.
The following settings are made in the dialog box:
S Interface type
S Address
S Data transfer rate.
Dialog Dialog: Properties of PLC315-2DP M/S 2AF03

Tab: General
Group: Interface
Button: “Properties...”
Dialog: Properties – MPI Interface PLC315-2DP M/S 2AF03
Tab: Parameters
Address: 2 (see Note)
Subnetwork: MPI
Dialog: Properties – MPI
Tab “Network Settings”
Data transfer rate: 1.5 Mbps
OK
OK
OK
Notice
With SINUMERIK 840Di, the MPI address of the PLC must always be set to “2”.

Configuring the The NC installed in the 840Di Rack is called S7 FM NCU. To allow communica-
NC tion between NC and PLC, the following setting are required:
S MPI address of the NC: PLC address + 1

S Input address and output address: 256
S Length of data: 2 (preset, no input possible).
To this aim, open the Properties dialog by double-clicking on the NC in 840Di
Rack.
Dialog Dialog: Properties – S7 FM-NCU

Tab: General
Group: Backplane connection
MPI address: 3 (see Note)
Tab: Addresses
Group: Inputs
Start: 256
Length: 2
Group: Outputs
Start: 256
Length: 2
OK
Notice
The MPI address of NC and PLC are tightly connected one to another.
MPI addr. of NC = (MPI addr. of PLC) + 1
Notice
The input/output address of the NC must be set to 256.
In the case of values other than 256, auxiliary functions provided from the PLC
will no longer be acknowledged to the NC and the parts program execution is
thus no longer continued.

7.3.4 SIMATIC S7 I/O devices
The SIMATIC I/O devices of the series ET200, e.g. ET200M, are integrated into
the S7 project as usual and configured.
Note
To simplify parameterization of the equidistant communication on the PROFI-
BUS DP, you must first insert all the SIMATIC S7 I/Os you require into the con-
figuration before parameterization of the DP drives (e.g. DP slave 611U or
ADI4).
Note
To check whether a module selected from the hardware catalog complies with
the module in the automation system, the following procedure is recom-
mended:
1. Put down the MLFB numbers of all modules used in the automation system.
2. Select the appropriate module from the hardware catalog and compare the
order number (MLFB) with the MLFB number of the module displayed in the
hardware catalog. Both MLFB numbers must be the same.

7.3.5 I/O module PP72/48
The configuration with regard to the I/O modules PP72/48 is carried out using
the DMF file SIEM80A2.DMF.
For installation of the DMF file, see Subsection 7.1.3., page 7-209 DMF files.
Note
To make parameterization of equidistant communication with PROFIBUS DP
easier, we recommend inserting all required DP slaves 611U into the configura-
tion before setting the times for equidistant communication.
Inserting To insert a DP slave PP72/48 into the configuration, open the hardware catalog
using menu command View > Catalog.
The DP slave PP72/48 is to be found at:
S Profile: Standard
PROFIBUS DP > further field units > IO > PP input/output module
Click with the left mouse button on the DP slave PP72/48 in the hardware cata-
log (see Note) and drag it onto the DP master system in the station window,
holding down the left mouse button.
Note
As DP slave PP72/48, the directory symbol with the designation “PP input/
output module” and not the module symbol beneath with the designation “uni-
versal module” must be selected.
Make sure that the cursor that appears as a crossed-out circle when dragging
the DP slave is positioned exactly on the DP master system so that it can be
inserted into the configuration.
The DP master system is displayed in the station window with the following
symbol:
When you release the left mouse button, the DP slave PP72/48 is inserted into
the configuration.

Selecting the When inserting DP slave PP72/48 into the configuration, the set configuration of
set configuration the module must be selected with regard to the I/O addresses.
The dialog offers the following configurations to choose from:
1. I/O 6/9 O222 I212121
2. I/O 6/9 O411 I212121
3. I/O 6/9 O42 I41
For DP slave PP72/48, select the 1st configuration and click OK to confirm the
dialog.
PROFIBUS After the dialog to choose the set configuration, the dialog “PROFIBUS proper-
Parameters ties Interface PP input/output” is displayed.
The following PROFIBUS parameters must either be set or verified:
– PROFIBUS address
– Data transfer rate
– Profile.
Notice
The PROFIBUS address of DP slave PP72/48 set in the S7 project must match
with the PROFIBUS address set on the module using switch S1 (see Section
2.12, page 2-93).
No automatic adjustment takes place!
The following data must be identical.
1. SIMATIC S7 configuration of DP slave PP72/48
PROFIBUS address
2. I/O module PP72/48
PROFIBUS address (switch S1)
Dialog Dialog: PROFIBUS properties Interface PP input/output

Register: Parameters
Address: <PROFIBUS–Adresse>
Dialog: Properties – PROFIBUS
Data transfer rate: 12 Mbps
Profile: DP
OK
OK

Setting the After the dialog has been quitted, the DP slave PP72/48 is inserted into the DP
I/O addresses master system. Inserting of the detail view makes visible DP slave PP72/48 in
the station window.
The I/O addresses are assigned by “HW Config” automatically. These I/O ad-
dresses should be modified in view of the following supplementary conditions:
S I/O address range of the NC

S Selective access to the input/outputs by the PLC.
I/O address range For compatibility reasons and for future system expansions, the I/O addresses
of the NC 256–271 should not be assigned.
Selective access In the case of I/O addresses > 256, the PLC cannot access the individual input/
outputs. The input/output data must first be copied to internal flags of the PLC.
To this aim, use the system functions SFC14 and 15.
For the reasons above, it is recommended to assign the I/O addresses to the
range between 0 and 255.

7.3.6 ADI4 (SW 2.1 and higher)
Notice
The ADI4 DP slave can only be operated on an equidistant PROFIBUS DP.
SlaveOM Parameterization of the configuration with regard to the ADI4 modules, called
DP slave ADI4 here, is performed with the SlaveOM for SINUMERIK 840Di.
For installing the SlaveOM, see Section 7.1, page 7-203f: DriveOM / SlaveOM
Note
BUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.)
you require into the configuration before parameterization of the DP drives,
before you set the times for equidistant communication.
ADI4 DP slave To insert an DP slave in the configuration, open the hardware catalog via the
Insertion menu command View > Catalog.
The DP slave ADI4 is to be found at:
S Profile: Default
PROFIBUS DP > SINUMERIK > ADI4.
Select DP slave ADI4 by clicking with the left mouse button on it and drag it to
the DP master system in the Station window while holding down the mouse but-
ton.
symbol:
When you release the left mouse button, the DP slave ADI4 is inserted into the
configuration.
Note
Make sure that the cursor, which appears as a crossed-out circle when drag-
ging the DP slave, is positioned exactly on the DP master system so that the
DP slave is inserted into the configuration.
Parameterizing Parameterization of DP slave ADI4 is divided into 2 main steps:

DP slave ADI4
Step 1: Start Step 1 includes the DP slave ADI4-specific parameterization of:
S PROFIBUS parameters
– PROFIBUS address

– Number of axes and encoders (message frame type)

– I/O addresses
S Function parameters
– Encoder type
– Unipolar spindle
– Shutdown ramp
– Shutdown delay time.
Step 1 should first be carried out for all DP slaves ADI4 required for the configu-
ration.
Step 2 Step 2 includes parameterization of the times for equidistant cyclic communica-
tion. Step 2 should be carried out finally, for any DP slave ADI4.
The settings made during the operational sequence above can be transferred to
all of the remaining DP slaves ADI4 using the matching function of SlaveOM.
PROFIBUS parameters
PROFIBUS On insertion of a DP slave ADI4 into the configuration, the dialog: Properties –
address PROFIBUS Interface ADI4 opens.
SlaveOM has set the PROFIBUS address to the next free PROFIBUS address.
Any PROFIBUS address is possible but it must match the address set on the
ADI4 using DIP switch S2.
Notice
The PROFIBUS address of DP slave ADI4, which is set on the SlaveOM, must
match with the PROFIBUS address set in the drive:
1. SIMATIC S7 configuration of DP slave ADI4
PROFIBUS address
2. ADI4 module DIP switch S2
PROFIBUS address
Dialog Dialog: Properties – PROFIBUS interface ADI4

Tab card: Parameters
Address: PROFIBUS address
OK
After you have confirmed this dialog using the button: “OK”, the dialog:
“DP Slave properties” opened.

Message frame The ADI4 DP slave is operated with the specific message frame type: Four axes
type each with an encoder (standard message frame 3) and I/O data:
Message frame type Description

4 axes each with an encoder, standard mes- 4 x standard message frame 3 and 1 PDA
sage frame 3 + IO, PDA-5/9 O/I 1/1 word each for digital I/O data
PDA x/y number of process data words, x: Setpoint, y: Actual value
ADI4 message frame structure

Axis1 Axis2 Axis3 Axis4 I/O
STD 3 STD 3 STD 3 STD 3 O word Setpoints (master –> slave)
Low Axis1 Axis2 Axis3 Axis4 I/O High
STD 3 STD 3 STD 3 STD 3 I word Actual values

(slave –> master)
STD 3: Standard message frame 3 acc. to PROFIDrive specification V3.0
O word: Digital output data (16 bits)
I word: Digital input data (16 bits)
Standard message frame 3: Speed setpoint interface 32 bits with 1 encoder

PDA1 PDA2 PDA3 PDA4 PDA5
STW1 NSOLL_B STW2 G1_STW Setpoint (master –> slave)
Low High
PDA1 PDA2 PDA3 PDA4 PDA5 PDA6 PDA7
ZSW1 NIST_B ZSW2 G1_ZSW G1_XIST1
PDA8 PDA9
G1_XIST2 Actual value
(slave –> master)
O word (dig. output data 16 bits) 1)

High byte Low byte
15 12 11 8 7 4 3 0
Zero mark / BERO as a reference
signal 1–4 in 611U conformant mode
not used
Dig. output 1–4
–> X6–1: Pins 2–5
Dig. outputs 5–8 / direction signal
1–4 for unip. spindle
–> X6–1: Pins 6–9
I word (dig. input data 16 bits) 1)

High byte Low byte
1514 1312 11 87 2 1 0
Dig. inputs 9–10 / Drv_Rdy 3–4
–> X6–2: Pins 10–11
not used
Dig. input 1–4 / BERO 1–4
–> X6–2: Pins 2–5
Dig. inputs 5–6 / probes 1–2
–> X6–2: Pins 6–7
Dig. inputs 7–8 / Drv_Rdy 1–2
–> X6–2: Pins 8–9
1) Note:
To use the I/O words within the NC: See Section 10.6, page 10-379

Notice
The message frame type of DP slave ADI4, which is set on the SlaveOM, must
match with the PROFIBUS address set on the NC.
1. SIMATIC S7 configuration DP slave ADI4
Message frame type (3)
2. SINUMERIK 840Di–NC
MD13060 DRIVE_TELEGRAM_TYP (3)
Dialog Dialog: DP Slave Properties

Tab: Configuration
Default: <Message Frame Type>
OK
I/O addresses A communication between NC and the individual axes of the DP slaves ADI4 in
the SINUMERIK 840Di can only take place if the I/O addresses for setpoint and
actual value of an axis are the same.
This prerequisite is taken into account by SlaveOM automatically when inserting
a DP slave ADI4 into a configuration.
The standard default of the NC machine data:
S MD13050 DRIVE-LOGIC_ADDRESS[n], (logical drive address)

is described in Subsection 10.5.1, page 10-308.

Tab: Configuration
PROFIBUS partner, I/O addr.: <I/O address>
OK
Notice
S The I/O addresses for set and actual values of an axis must be the same.
I/O address actual value = I/O address setpoint
If a DP slave ADI4 is inserted into an S7 project due to a copying process
(e.g. from another S7 project), the I/O addresses are assigned exclusively
under the control of “HW Config”.
This may have the consequence that one axis are assigned different I/O
addresses for set and actual values. In this case, the I/O addresses must
be corrected manually.
S To avoid access conflicts between PROFIBUS DP drives and I/O modules,
you need to set values w272 for ADI4 DP slave I/O addresses.

Consistency The default setting with regard to the consistency of the I/O data is whole
length.
This setting results in:
S Direct accesses from the PLC user program (e.g. byte, word or double word)
to this address range are not admitted by the PLC operating system.
S Accesses to this address range must be carried out using the system func-
tions SFC 14 and SFC 15.
S The system functions SFC 14 and SFC 15 guarantee consistent reading/

writing of the data of an axis.
Note
The terms isochronous, clock-synchronous, and equidistant (same length) are
used as synonyms in various documents.
Function parameters
In dialog box: DP slave properties –> Encoder tab, the function parameters are
entered (see Fig. 7-4 with sample values for the individual parameters).
DP slave properties
General Configuration Clock synchronization Encoder

Encoder 1 Encoder 2 Encoder 3 Encoder 4
Encoder type: Encoder type: Encoder type: Encoder type:
TTL TTL SSI SSI
Parity Parity
Resolution: 6000 Resolution: 6000 Resolution: 2048 Resolution: 2048
MsgLength: 21 MsgLength: 21
Encoding: Encoding
Binary Gray
Baudrate: Baudrate:
187.5 kbps 187.5 kbps
Unipolar spindle
1st Axis 2nd Axis 3rd Axis 4th Axis
Shutdown ramp [ms]: 1 Tolerable sign-of-life errors: 5
Shutdown delay [s]: 0 Reserved bits for fine resolution: 11
611U conformant mode
OK Cancel Help
Fig. 7-4 Dialog: DP slave properties, tab card: Encoder

Encoder The encoder parameters depend on the encoder type.
Encoder type: Encoder type “does not exist” for encoder x means that axis x does not exist or
Does not exist must not be used. In the PROFIBUS message frame, empty useful data are
transmitted for this axis.
Encoder type: Encoder parameters:

TTL S Resolution
Number of encoder lines [encoder lines/revolution]
Note
Both rotary and linear incremental measuring systems can be used, as the spe-
cific parameters of the measuring system are set in den NC machine data (see
Subsection 10.5.5, page 10-317ff).
Encoder type: Encoder parameters:

SSI S Parity
Select this radio button if the encoder data are to be transmitted from the
encoder to the ADI4 with a parity bit.
S Resolution
Number of encoder lines [encoder lines/revolution]
S MsgLength
Number of useful data bits transmitted by the encoder
S Encoding
The following encoder codes are supported:
– Binary
– Gray
S Baudrate
The following baudrates are supported:
– 187.5 kbps
– 375 kbps
– 750 kbps
Notice
The baudrate must be set identically for all SSI encoders. If different baudrates
are set, the baudrate of the SSI encoder with the highest encoder number is
used.

Encoder control Description of the encoder control word (extract) with regard to:
word S Reference mark search
G1_STW
S In-process measurement.
Bit Name Signal state, description

Bit 7 = 0 => Request: Reference mark search
Bit Meaning
0 Function 1: Referencing using a zero mark
0 (except for “611U conformant mode”)
1 Function 2: Referencing using a rising edge of the associated BERO
2 Function 3: Referencing using a falling edge of the associated BERO
3 Function 4: not used
Bit 7 = 1 => Request: In-process measurement.
Bit Meaning
0 Function 1: Sensor 1 rising edge
1
1 Function 2: Sensor 1 falling edge
2 Function 3: Sensor 2 rising edge
3 Function 4: Sensor 2 falling edge
Func-
tions Tip:
Reference
mark S Bit x = 1 Function requested
search Bit x = 0 Function not requested
2
or S If more than one function is activated, then:
In-process The values for all functions can only be read when each activated function has
measure- been terminated and this has been confirmed with the corresponding status bit
ment. (G1_ZS Bit0 / 3 “0” signal again).
S In-process measurement.
3
A rising and falling edge can be activated simultaneously.
The sensor signal is detected depending on the direction. The values are read out
one after the other.
4 Bit 6, 5, 4 Meaning
000 Basic setting
5 Com- 001 Activate function x
mand
010 Read value x
6 011 Cancel function x
0 Reference mark search (zero mark or BERO)

7 Mode
1 In-process measurement.

Unipolar spindle With radio button “Unipolar spindle” the voltage range of the analog output volt-
age is switched over:
S Radio button “Unipolar spindle” not selected:

Output voltage: –10V to +10V
S Radio button “Unipolar spindle” selected:

Output voltage: 0V to +10V
If the function: “Unipolar spindle” of the ADI4 is activated, the direction of
rotation is output through a digital output and depends on the current speed
setpoint:
– Direction of rotation signal for axis 1 –> digital output X6-1, Pin 6
– Direction of rotation signal for axis 4 –> digital output X6-1, Pin 9.
Shutdown ramp You can set a linear time function in parameter “Shutdown ramp”. When this
time period is exceeded, if an error is detected in ADI4, all drives of ADI4 are
decelerated to setpoint 0.
If you set the parameter to 0, the drives coast to standstill.
S Unit: [msec]
Max. setpoint
current setpoint
0 t [msec]
Parameter value:
Shutdown ramp
Fig. 7-5 Parameter: Shutdown ramp
Shutdown In the “Shutdown delay time” parameter you can set a time delay after which all
delay time drives of ADI4 are decelerated to setpoint 0 if a temperature alarm occurs.
After the “Shutdown delay time” has elapsed the “Shutdown ramp” parameter is
taken into account.
S Unit: [sec]
Tolerable Parameter “Tolerable sign-of-life failures” states the number of tolerable sign-of-
sign-of-life failures life failures of the DP master. If the parameterized number is exceeded, the set-
point interfaces of all drives are shut down to value 0 using the “Shutdown
ramp”.
Reserved bits for Via the parameter “Additional substitute bits for fine resolution”, you can specify
fine resolution the desired pulse multiplication of the encoder increments currently read in the
encoder increments and transferred in the encoder actual value G1_XIST1.

In conjunction with SINUMERIK 840Di, the number of additional bits for fine
resolution should currently be set to the value 11. This corresponds to a pulse
multiplication of: 211 = 2048.
Transferred encoder actual value G1_XIST1

31 10 0
current encoder
Overflows Reserved bits for fine resolution:
increments
Notice
S Parameter “Additional substitute bits for fine resolution” must currently al-
ways be set to 11.
S In accordance with the parameter “Additional substitute bits for fine resolu-
tion,
– MD30260: ABS_INC_RATIO (ratio of absolute resolution to incremental
resolution)
the value: 2“Additional substitute bits for fine resolution” = 211 = 2048 must be en-
tered in the machine data.
611U conformant With parameter “611U conformant mode” is used for selection of the signal
mode source conformant with SIMODRIVE 611 universal for referencing the axis.
In 611U conformant mode, the signal source for referencing the axes (zero mark
or BERO) is no longer set in the standard message frame (encoder control word
G1_STW, page 7-226), but with the digital output word.
S Digital output word, bits 8–11 (see O word, page 7-222)

Referencing the axis:
– Bit 8 = 0 –> axis 1 with zero mark of encoder 1 (X4–1)
– Bit 8 = 1 –> axis 1 with rising edge of BERO 1 (X6–2, Pin 2)
– Bit 11 = 1 –> axis 4 with rising edge of BERO 4 (X6–2, Pin 5).
Step 1: End When you terminate the dialog box “DP slave properties” with the button: “OK”,
the data are transferred and the dialog box is closed. Step 1 of parameterization
of DP slave 611U is then complete.

Setting the final Once the components (drives, ADI4, I/O devices, etc.) have been inserted in the
parameters for configuration and parameterized, the parameters are set for the equidistant DP
ADI4 cycle while taking the framework conditions listed below into consideration, (see
Subsection 7.3.8, page 7-238).
Boundary When setting the parameters for the equidistant DP cycle, with ADI4 it is neces-
conditions sary to take the following framework conditions into account:
(SW 2.1 and
higher) DP slave properties
General Configuration Clock synchronization
Synchronize drive to equidistant DP cycle
Network settings in msec:
Equidistant bus cycle activated
Equidistant DP cycle: 2.000 Cyclic portion of equidistant master 0.872
TDP TDX
Factor
Basic time [msec]
Master application cycle 2.000 = 1 2.000
x
[msec]:
Factor
Basic time [msec]
DP cycle [msec]: 2.000 = 16 x 0.125
TI Factor
Basic time [msec]
Actual-value sensing 0.250 = 2 x 0.125
[msec]:
TO Factor
Basic time [msec]
Setpoint acceptance x
1.000 = 8 0.125
[msec]:
Fig. 7-6 Dialog: DP slave properties (cutout)
1. Equidistant DP cycle (TDP)

TDP = 2* n * 125msec; where n w 4 ( => minimum TDP = 1 msec)
2. Setpoint acceptance (To)
(TDX + 125msec) v TO t TDP; where TDX = TDX, rounded up to an
integral multiple of 125msec
3. Actual-value sensing (Ti)
250msec v TI v TDP
4. TI and TO must not be in the same 125msec cycle
DT , 0; where DT = TDP – TI – TO
5. If TO == (TDP – 125msec)
Then the following must be valid for TI: TI u 3 * 125msec
6. If TO == (TDX + 125msec)
Then the following must be valid for (TI + TO): (TI + TO) , (TDP + 125msec)
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
DT 0
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÇÇÇÇÇÇÇÇÇÇ
Max.: TDP
TDX
TO
Min.: 2*125msec
Min.: TDX+125msec
TI
Max.: TDP
TDP
1*125msec 2*125msec 3*125msec 4*125msec 5*125msec 6*125msec 7*125msec 8*125msec
Fig. 7-7 Graphical illustration of the boundary conditions

For a description of a full DP cycle, refer to Subsection 7.1.2, Page 7-205.
Typical values Typical parameter values are as follows:

– Equidistant DP cycle (TDP): 2,000 msecs
– Actual-value sensing (Ti) 0.250 msecs
– Setpoint acceptance (To) 1,000 msecs
Notice
DP slaves ADI4:
– Order No.: 6FC5 211–0BA01–0AA0
– Order No.: 6FC5 211–0BA01–0AA1
exhibit different behavior with respect to parameterization of the actual value
recording (Ti) and setpoint acceptance (To) that deviates from one of the
above–mentioned boundary conditions.
S DP slave ADI4 with MLFB ...–0AA0

A parameterization that deviates from one of the above mentioned bound-
ary conditions is ignored by this DP slave ADI4, since the parameters are
set permantenly internally. The DP slave ADI4 starts communication with
the DP master using the values that deviate from he parameterized values
without issuing an error message.
S DP slave ADI4 with MLFB ...–0AA1

If a configuration that deviates from the above/mentioned boundary condi-
tions is loaded to this DP slave ADI4, the DP slave ADI4 does not start cy-
clic communication with the DP master.

7.3.7 SIMODRIVE drives
Parameterization of the configuration with regards to the SIMODRIVE drives:

– SIMODRIVE 611 universal and universal E
is exemplified here by parameterization of the SIMODRIVE 611 universal.
SlaveOM The drives are parameterized using the SlaveOM for SINUMERIK 840Di (for
installation of the SlaveOM, see Section 7.1, page 7-203: DriveOM / SlaveOM).
Note
BUS DP, you must first insert all the DP slaves (drives, ADI4, I/O modules, etc.)
you require into the configuration before parameterization of the DP drives,
before you set the times for equidistant DP communication.
Inserting In order to insert a DP slave 611U into the configuration, open the hardware
DP slave 611U catalog using the menu command View > Catalog.
The DP slave 611U is to be found at:
S Profile: Default
PROFIBUS DP > SIMODRIVE > SIMODRIVE 611 universal, PROFI–
BUS DP, MC
Select DP slave 611U by clicking with the left mouse button on it and drag it to
the DP master system in the Station window while holding down the mouse but-
ton.
symbol:
When you release the left mouse button, the DP slave 611U is inserted into the
configuration.
Note
Make sure that the cursor, which appears as a crossed-out circle when drag-
ging the DP slave, is positioned exactly on the DP master system so that the
DP slave is inserted into the configuration.
Expanded In SW 2.2 and higher, “expanded message frame configuration” has been pro-
message frame vided to transfer drive data to the NC in the cyclic PROFIBUS message frame in
configuration addition to the process data for the selected standard message frame type (102
(SW 2.2 and to 107).
higher) The expanded message frame configuration is described in Section 16.2,
page 16-501.

DP slave 611U Parameterization of the DP slave 611U is divided into 2 steps:

Parameterization
Step 1 In Step 1, DP slave 611U-specific parameter settings are made for:
S PROFIBUS address
S Number of axes and encoders (message frame type)
S I/O addresses
S Expanded message frame configuration (SW 2.2 and higher).
Step 1 should first be carried out for all DP slaves 611U required for the configu-
ration.
Step 2 Step 2 includes parameterization of equidistant DP communication. Step 2 can

be carried out finally, for any DP slave 611U.
The settings made during the operational sequence above can be transferred to
all of the remaining DP slaves 611U using the matching function of SlaveOM.
PROFIBUS Inserting a DP slave 611U into the configuration will open the dialog for parame-
address terizing the PROFIBUS DP properties.
SlaveOM sets the PROFIBUS address to the next free PROFIBUS address
automatically.
The PROFIBUS address can generally be freely selected. It must, however,
match the PROFIBUS address set in the drive (e.g. with SimoCom U) (parame-
ter P0918).
Notice
The PROFIBUS address of DP slave 611U, which is set on the SlaveOM, must
match with the PROFIBUS address set in the drive:
1. SIMATIC S7 configuration of DP slave 611U
PROFIBUS address
2. SIMODRIVE 611 universal
Parameter P0918 (PROFIBUS node address.)
Dialog Dialog: Properties – PROFIBUS Interface SIMODRIVE 611U DP2, DP3

Tab: Parameters
Address: PROFIBUS address
OK

Message frame After this dialog has been confirmed using the button: “OK”, the dialog: “DP
type Slave properties” opened.
Depending on the drive functionality to be used, you must select the correct
message frame type from the listbox: default. The selected message frame type
only defines the number of cyclically transferred process data units within the
cyclic message frames.
The number of cyclically transferred process data units depends on:
– The number of axes per drive module
– The number of encoders used per axis
– The drive functionality used.
The following message frame types are predefined for parameterization of the
DP slave 611U:
Table 7-1 Message frame types
Message frame type Description

1 axis, Message frame type 102, nset interface with encoder 1
PDA 6/10
2 axes, Message frame type 102, nset interface with encoder 1
PDA 6/10
1 axis, Message frame type 103/104, nset interface with encoders 1 and 2 (103)
PDA 7/15 or encoders 1 and 3 (104)
2 axes, Massage frame type 104, nset interface with encoders 1 and 3
PDA 7/15
1 axis, Message frame type 105, nset interface with DSC and encoder
PDA 10/10
2 axes, Message frame type 105, nset interface with DSC and encoders 1
PDA 10/10 and 2
1 axis, Message frame type 106/107, nset interface with DSC and encoders 1
PDA 7/15 and 2 (106) or encoders 1 and 3 (107)
2 axes, Message frame type 106/107, nset interface with DSC and encoders 1
PDA 7/15 and 2 (106) or encoders 1 and 3 (107)
PDA x/y number of process data words, x: setpoints, y: actual values
DSC Functionality “Dynamic Servo Control”
Encoder 1 Encoder 2 Encoder 1 Encoder 2
Encoder 3
SIMODRIVE 611 universal SIMODRIVE 611 universal E

Tab: Configuration
OK

Notice
The message frame type of DP slave 611U, which is set on the SlaveOM, must
match with the PROFIBUS address set on the NC and the drive:
1. SIMATIC S7 configuration DP slave 611U
Message frame type
2. SINUMERIK 840Di-NC
MD13060 DRIVE_TELEGRAM_TYP
3. SIMODRIVE 611 universal
Parameter P0922 (PROFIBUS message frame type selection).
For a detailed description of the different message frame types, please see:
S SIMODRIVE 611 universal and universal E:

References: /FBU/ SIMODRIVE 611 universal, Description of Functions
S SIMODRIVE POSMO SI/CD/CA

References: /POS3/ User Manual SIMODRIVE POSMO SI/CD/CA
in each case in Section: Communication on PROFIBUS DP.
I/O addresses A communication between NC and the individual axes of the DP slaves 611U in
the SINUMERIK 840Di can only take place if the I/O addresses for setpoint and
actual value of an axis are the same.
This prerequisite is taken into account by SlaveOM automatically when inserting
a DP slave 611U into a configuration.
Notice
S The I/O addresses for set and actual values of an axis must be the same.
I/O address actual value = = I/O address setpoint
If a DP slave 611U is inserted into an S7 project due to a copying process
(e.g. from another S7 project), the I/O addresses are assigned exclusively
under the control of “HW Config”.
This may have the consequence that one axis are assigned different I/O
addresses for set and actual values. In this case, the I/O addresses must
be corrected manually.
S To avoid access conflicts between PROFIBUS DP drives and I/O modules,
you need to set values w272 for ADI4 DP slave 611U I/O addresses.

Notice
The I/O address set by the SlaveOM for an axis must match the I/O address
set in the NC.
I/O address
2. SINUMERIK 840Di-NC
MD13060 DRIVE_LOGIC_ADDRESS[n], (logical drive address).
Note
To avoid any modifications to the I/O addresses in NC machine data:
S MD 13050 DRIVE_LOGIC_ADDRESS[n].
it is recommended to use the default values of the machine data when config-
uring the I/O addresses within the configuration:
1. Axis: Default I/O address = 272
mth Axis: Default I/O address = 272 + (m-1)*20
The default setting for the machine data is described in Subsection 10.5.1,
page 10-308.

Tab: Configuration
Table entry: PROFIBUS partner, I/O addr.: <I/O address>
OK
After you have confirmed this dialog using the button: “OK”, the dialog:
“DP slave properties” closed. Step 1 of parameterization of DP slave 611U is
then complete.
Consistency The default setting with regard to the consistency of the I/O data is whole
length.
This setting results in:
S Direct accesses from the PLC user program (e.g. byte, word or double word)
to this address range are not admitted by the PLC operating system.
S Accesses to this address range must be carried out using the system func-
tions SFC 14 and SFC 15.
S The system functions SFC 14 and SFC 15 guarantee consistent reading/

writing of the data of an axis, e.g.:
– Message frame type 102: 6 words for the set value or 10 words for the
actual value

S Because DP slaves 611U can be assigned both to the NC and to the PLC,
check system functions SFC 14 and SFC 15 when writing data to see
whether the drive belongs to the writing component. If this is not the case,
the data access is denied.
Dependencies: The overview example shows the interrelations or interdependencies when con-
PROFIBUS DP figuring the PROFIBUS DP communication between the components:
communication S NC
S DP master
S DP Slave 611U
NC DP master
I/O address, message frame type PROFIBUS address, slot and I/O address
MD13050: DRIVE_LOGIC_ADDRESS[ n ] (message frame type)
1. machine axis: 272 PROFIBUS address: 10
2. machine axis: 292 Axis 1: Slot 5/6, I/O addr. 272
Check MD 13060: DRIVE_TELE- Axis 2: Slot 9/10, I/O addr. 292
GRAM_TYP[ n ] (Message frame type: 102)
1. machine axis: 102
2. machine axis: 102
PROFIBUS DP 2
Cyclic message frame: 102

PIV/PDA PIV/PDA
Header Axis 1/ Axis 2/ Trailer
drive A drive B
DP save 611U
PROFIBUS address, message frame type
PROFIBUS address: 10
Message frame type: 102
Axis 1 / Drive A
Axis 2 / Drive B
Fig. 7-8 Dependencies: NC, PLC/DP master and DP slave (SIMODRIVE 611 universal)

1 NC
Due to the I/O address and the message frame type of the machine axis, which
are entered in the machine data:
S MD13050: DRIVE_LOGIC_ADDRESS[n]
S MD13060: DRIVE_TELEGRAM_TYP[ n ]
the NC reads and writes the axis data from/into the appropriate I/O range of the
PLC/DP master:
1st machine axis: I/O address 272
Message frame type 102
2nd machine axis: I/O address 292
For configuring the drive within the framework of the NC start-up, please refer to
Subsection 10.5.3, page 10-313.
2 DP master
The information regarding the individual DP slaves are known to the DP mas-
ters from the PROFIBUS SDB generated from the configuration.
DP master equidistantly transfers the data to/from the DP slaves cyclically using
the following information:
PROFIBUS addr. 10: Setpoint: Slot 5, I/O address 272
Actual value: Slot 6, I/O address 272
Setpoint: Slot 9, I/O address 292
Actual value: Slot 10, I/O address 292
For a 2 axis-closed-loop control module of a SIMODRIVE 611 universal, the
following assignment applies:
S Slots 5/6 => Axis 1 or drive A
S Slots 9/10 => Axis 2 or drive B
3 DP save 611U
DP slave interprets the message frames received from the DP master because
of the drive parameters
S Parameter P0922 (message frame selection PROFIBUS)

Message frame type set:
Final After all PROFIBUS components (drives, ADI4, I/O devices, etc.) have been
parameterization inserted into the configuration and parameterized, the equidistant DP cycle is
parameterized in the final step.

7.3.8 Final parameterization of the equidistant DP slaves
After all the planned DP slaves have been inserted into the configuration and
parameterized individually, the following parameters of the equidistant DP
slaves are set in two separate steps for final parameterization of the equidistant
DP communication:
Step1:
S Enabling of the equidistant DP cycle

S Master cyclic portion TDX.
Step2:
S Equidistant DP cycle TDP

S Master application cycle TMAPC
S Actual-value sensing TI
S Setpoint acceptance TO.
An overview of the various times of a DP cycle is shown in Fig. 7-2, page 7-205.
Note
The procedure of final parameterization of equidistant DP communication is
exemplified by one DP slave 611U. For other equidistant DP slaves, e.g. SIMO-
DRIVE POSMO SI, CD/CA; ADI4; etc., proceed analogously.
Notice
If a project you want to perform final parameterization on contains DP slave
ADI4 interfaces, please observe the boundary conditions for the following pa-
rameters:
S Master cyclic portion TDX.
See also: ADI4-specific boundary conditions, page 7-229.

Activation of the If you double-click on a DP slave 611U in the station window, the dialog box:
equidistant “DP slave properties” opens.
DP cycle We recommend activating the equidistant DP cycle for all DP slaves 611U by
activating the equidistant DP cycle within the selected DP slave 611U and finally
adjusting.
During the adjustment, all:
S DP slave properties
displayed in the tab: Clock Synchronization
are transferred to all DP slaves of the same type in the configuration, here DP
slave 611U.
Dialog: Dialog: DP Slave Properties

Start Tab: Clock synchronization
Optional field: “Synchronize drive to equidistant DP cycle”
Button: “Adjust”
DP slave properties
Factor Basic time [msec]

Master application cycle 1.000
[msec]: = 1 x 1.000

DP cycle [msec]: 1.000 = 8 x 0.125

Actual-value sensing [msec]: 0.125 = 1 x 0.125

Setpoint acceptance [msec]: 0.500 = 4 x 0.125
Adjust
OK Cancel Help
Fig. 7-9 Enabled equidistant DP cycle
Notice
If there are different types of equidistant DP slaves in a S7 project, e.g. different
SIMODRIVE drives, ADI4, etc., the following steps:
1. Synchronize drive to equidistant DP cycle
2. Adjust
must be performed for each type of DP slave first before you can go on to set
the other parameters.

Equidistant master After synchronization to the equidistant DP cycle has been activated for all DP
cyclic portion slaves, the timer requirement of the cyclic portion of DP communication must be
TDX calculated.
Calculation is performed by the DP master on activation of the equidistant bus
cycle.
Dialog: Tab: General

cont’d. Group: Node
Button: “PROFIBUS...”
Dialog: Properties – PROFIBUS Interface SIMODRIVE ...
Tab: Parameters
Dialog: Properties PROFIBUS
Button: “Options...”
Dialog: Options
1st Optional field: Enable equidistant bus cycle
2nd Optional field: Enable equidistant bus cycle
Equidistant DP When calculating the cyclic portion of the PROFIBUS communication, the time
cycle TDP for the equidistant DP cycle is automatically changed to the time required as the
minimum. This change must be undone by reentering the time intended for the
equidistant DP cycle.
Dialog: Group: Equidistant time in msec

cont’d. Equidistant DP cycle: Equidistant time
OK
OK
OK
Options
Isosynchronism Node Cables
Activate equidistant bus cycle / recalculate equidistant time
Number of PGs/OPs/TDs on the PROFIBUS
Configured: 0 Total: 0
Equidistant time in msec
Equidistant DP cycle 2.000 ( 1.451 minimum)
Details ...
OK Cancel Help
Fig. 7-10 Dialog: Options

On tab card “Clock synchronization” the following parameters are now set for
each type of DP slave:

DP slave properties

Master application cycle 2.000
[msec]: = 1 x 2.000

DP cycle [msec]: 2.000 = 16 x 0.125

Actual-value sensing [msec]: 0.125 = 1 x 0.125

Setpoint acceptance [msec]: 1.500 = 12 x 0.125
Adjust
OK Cancel Help
Fig. 7-11 Dialog: DP slave properties
DP cycle The DP cycle time of the DP slave 611U must be set to the cycle time of the DP
TDP master displayed under “equidistant DP cycle”.
Notice
For DP cycle time TDP the following condition must be fulfilled:
DP cycle = isosynch. DP cycle
Master application The parameter: Master Application Cycle TMAPC defines the integer ration be-
cycle TMAPC tween the master application (NC position controller) and the equidistant DP
cycle.
Using ratios other then 1:1, the dead times of the position controller can be re-
duced if NC hardware of the lower performance range is used.

Notice
On a DP slave 611U used with SINUMERIK 840Di, the ratio between the mas-
ter application cycle TMAC and DP cycle time TDP must be 1:1.
Master application cycle = DP cycle
Dialog: Tab: Clock synchronization

cont’d. Master application cycle [msec]:
Factor: 1
Actual-value The parameter: Actual-value sensing Ti defines the time at which the actual
sensing value (actual position value) can be read in from a DP slave 611U.
TI It is recommended to use the same value for the time of actual-value sensing Ti
for all DP slaves 611U, in particular, if the axes interpolate.
Notice
The following condition must be observed for the time of actual-value
sensing TI:
DP cycle >= actual value acquisition >= basic time

cont’d. Actual-value sensing [msec]:
Factor: Factor
Setpoint The parameter: Setpoint Acceptance To defines the time when the speed set-
acceptance point of the NC position controller is accepted by a DP slave 611U.
TO It is recommended to use the same value for the time of setpoint acceptance To
for all DP slaves 611U, in particular, if the axes interpolate.
Notice
The following condition must be observed for the time of setpoint
acceptance TO:
DP cycle >= setpoint acceptance >= equidistant master cycl. portion +
basic time

cont’d. Setpoint acceptance [msec]:
Factor: Factor

Adjustment Press the button: Adjust, to transfer the values shown on tab card: “Clock Syn-
chronization” of the current DP slave 611U to the other DP slaves 611U of the
configuration.
This adjustment must be carried out at the end, and the dialog must then be
confirmed with OK.

End Button: Adjust
OK
Notice
If there are different types of equidistant DP slaves in a S7 project, e.g. different
SIMODRIVE drives, ADI4, etc., the following parameters:
must be set for each type of DP slave as described above and adjustment
must be performed.
By adjustment, the values displayed on tab card: “Clock Synchronization” are
only transmitted to the DP slave of the same type.

7.3.9 Loading a configuration into the PLC
Prerequisites for For loading the configuration into the PLC, the following prerequisites must be
loading fulfilled:
S “HW Config” is active

S Current system data blocks are available
S An MPI connection is established between “HW Config” and the PLC
S SINUMERIK 840Di is active, i.e. the NC is in cyclic operation and the PLC in
either of the states RUN or STOP.
Generating system The system data blocks (SDB) are generated by compiling the current configu-
data blocks ration using “HW Config”. They contain the relevant information required for
communication of the module with the entire system.
Consistency check Before saving and compiling the current configuration, it is recommended to
check the consistency of the configuration using the menu command Station >
Check Consistency.
If “HW Config” finds any inconsistencies within the configuration, an error dialog
box appears, which displays the appropriate error messages and possible rem-
edies.
Save and The menu command Station > Save and Compile saves the current configura-
Compile tion in S7 as an object: Station and is then compiled. The compilation includes
a consistency check of the parameterized settings.
System data If no inconsistencies are contained within the current configuration, the system
blocks data blocks are generated and stored in the folder Blocks of the corresponding
module.
The system data blocks for the created configuration are to be found at:
S PLC315-2DP M/S 2AF0

S7 program
Sources
Blocks –> System Data
Display of current system data blocks:
S Double-click with the left mouse button on “System Data”:

Dialog: System Data Blocks
Note
System data blocks cannot be edited separately, but always only in its entity as
a configuration.

Making the Before loading the configuration (system data blocks) into the PLC, first the re-
MPI connection quired MPI connection must be established.
HW Config on an If the configuration is transferred from an external PG/PC (e.g. PG740), the fol-
external PG/PC lowing requirements must be fulfilled:
S An MPI card exists (e.g. CP5611)

S The MPI drivers are installed
S Current interface parameterization: CP5611(MPI)
S Data transfer rate: 1.5 Mbps
S The MPI interface of the PG/PC is linked with the MPI interface of the MPI
board (X111) using an MPI cable.
HW Config on a If the configuration is transferred from the PC in which the MCI board is installed
local PC (e.g. SINUMERIK 840Di with PCU50), the following requirements must be ful-
filled:

S Current interface parameterization: SINUMERIK MCI board (MPI)
Parameterizing the Parameterization of the MPI interface is carried out with the SIMATIC Manager
MPI interface using menu command Tools > Set PG/PC Interface.
Dialog Dialog: Setting the PG/PC Interface

Register: Access Path
Interface parameter set used:
with ext. PG/PC: CP5611(MPI)
or
with local PC: SINUMERIK MCI board (MPI)
Button: “Properties”
Dialog: Properties
Group: Network Parameters
Transmission rate: 1.5 Mbps
OK
OK
Note
Parameterization of the MPI interface can be effected or changed from the
SIMATIC Manager at any time.
Checking The PLC status and thus also the MPI connection to the PLC can be checked
PLC status from “HW Config” using the menu command Target System > Status.
and
MPI interface

If the current operating status of the PLC is displayed, the MPI connection oper-
ates correctly.
If the current status of the PLC is not displayed, first check the MPI interface for
correct parameterization. If no connection is established to the PLC despite cor-
rectly set MPI interface, an overall reset of the PLC must be carried out.
General PLC reset General reset of the PLC can be performed using 840Di Start-up or HMI Ad-
vanced (option):
S 840Di start-up
– Start 840Di start-up: Windows NT taskbar > Start > Programs >
SINUMERIK 840Di > 840Di start-up.
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC.
S HMI Advanced (840Di SW 2.2 and higher and HMI Advanced SW 6.2)
– Open the dialog box: Operating area switchover > Start-up > NC/PLC
Diagnosis
S To initiate a general PLC reset, activate the button: “MRES”.

At completion of this general reset, the PLC is in the RUN state (RUN LED lights
in green).
Loading the The configuration is loaded in “HW Config” using the menu command Target
configuration system > Load into module.
For loading a configuration, the PLC must be in the STOP state. If “HW Config”
detects on loading that the PLC is still in the RUN state, a dialog box will appear
where you can set the PLC to the STOP state.
From the dialog box “Choose Target Module”, choose the module into which
you want to load the current configuration. In this case: PLC315-2DP M/S
2AF03.
Dialog Dialog: Choose Target Module

Target modules:
Module: PLC315-2DP M/S 2AF03
OK
Operating a PLC To load the configuration, put the PLC in the STOP condition. The STOP condi-
with a new tion of the PLC is interpreted by the NC as a failure of the PLC, and an appropri-
configuration ate alarm response is output.
(RUN) After the configuration has been loaded into the PLC successfully, for resyn-
chronization of NC and PLC, NC reset must be initiated, e.g. using 840Di
start-up:
S Start 840Di start-up

– Windows NT taskbar: Start > Programs > SINUMERIK 840Di > 840Di
Start-up
S Carry out NC reset

– Menu command: Window > Diagnostics > NC/PLC

– Dialog: NC/PLC Diagnosis

Group NC
Button: “NC Reset”
J

Notes

PLC Start-Up 8
PLC module The PLC integrated on the MCI board of the SINUMERIK 840Di is compatible
with the SIMATIC S7-PLC: AS315-2 DP.
8.1 Start-up prerequisites

Start-up of the PLC differs, depending on whether start-up has already been
carried out and on whether the PLC program is to be loaded as an S7 project
using the SIMATIC Manager STEP7 or as a series machine start-up file.
In order to start up the PLC, generally, the following prerequisites have to be
fulfilled:
1. SINUMERIK 840Di is turned on and booted
2. NC in cyclic mode
3. PLC is in the RUN condition
4. The PLC program to be loaded is available either as an S7 project or as a
series machine start-up file.
8.1.1 Commissioning
When commissioning the PLC, first a general reset of the PLC has to be carried
out after the SINUMERIK 840Di has been turned on and booted.
In order to obtain a defined initial state of the whole system (NC and PLC), it is
recommended also to delete the NC data when commissioning the PLC.
General PLC reset General reset brings the PLC to a defined initial state by deleting and initializing
all system and user data.
Deleting NC data After a request to delete NC data, all user data (zero offsets, tool offsets, etc.)
are deleted and the system data (machine data) are reinitialized with the next
ramp-up of the NC.

8 PLC Start-Up 06.03
8.1 Start-up prerequisites
General reset of General reset of the PLC and deletion of NC data can be performed using
PLC and 840Di Start-up or HMI Advanced.
deleting NC data
S 840Di start-up
– Start: Windows NT taskbar: Start > Programs > SINUMERIK 840Di >
840Di Start-up
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC
S HMI Advanced (840Di SW 2.2 and higher and HMI Advanced SW 6.2)
Diagnosis.
Dialog Proceed as follows in the dialog boxes:

1. General PLC reset
PLC group
Button: “MRES”
Notice
The following parameters are reset by the general PLC reset:
– MPI address of the PLC = 2
– MPI data transfer rate = 1.5 Mbit/s
2. Delete NC data
NC group
Button: “General NCK reset”
3. Trigger NC reset
In order to start cyclic operation or NC/PLC communication, NC reset (but-
ton: “NCK Reset”) must be initiated:
The subsequent power up of the SINUMERIK 840Di is successfully completed
if the following display appears in the dialog:
S NC status:
NC group
6 NCs in cyclic operation
S PLC status:
PLC group
LED RUN lights continuously.
Note
Since no PLC program is executed after general PLC reset, the following
alarms are displayed:
S Alarm: “120201 Communication failed”
S Alarm: “380040 PROFIBUS DP: Configuring error 3, parameter”
S Alarm: “2001 PLC not booted”.
These alarms have no influence on how to continue.

06.03 8 PLC Start-Up
8.2 PLC program
8.2 PLC program
PLC program The PLC program has a modular structure and is differed by:
– Basic program
– User program.
Basic PLC The basic PLC program provides the data and function blocks for the basic
program communication between PLC and NC.
The modules of the basic PLC program are part of a SIMATIC S7 library sup-
plied with SINUMERIK 840Di. Before you can use it in an S7 project, the library
must be installed in the SIMATIC Manager STEP7.
PLC user program The PLC user program is the user-specific part of the PLC program by which
the basic PLC program has been added or extended.
User memory The user memory provided for basic PLC and user programs of the PLC inte-
grated on the MCI board: AS315-2 DP, amounts to 64KB by default.
Optionally, a user memory of up to 288KB is possible.
8.2.1 Performance data of the PLC315-2DP
The PLC315-2DP complies with the following performance data regarding the
max. number of blocks and their max. length:
Table 8-1 Block performance data of the PLC315-2DP
Block type Max. no. Max. length per block

FC 192 16420 bytes
FB 192 16420 bytes
DB 255 16420 bytes
8.2.2 Installing the basic PLC program
Installation The basic PLC program is part of the PLC toolbox supplied with SINUMERIK
840Di. To be able to use the blocks of the basic PLC program in a SIMATIC S7
project, the library has to be installed in SIMATIC Manager STEP7 first.

8.2 PLC program
Notice
The basic PLC program must be installed on that computer on which the SI-
MATIC Manager STEP7 required to install the S7 project is already installed.
For installing the basic PLC program, please observe the appropriate notes in
the file:
Using basic PLC In order to be able to use the blocks of the basic PLC program in your own S7
program modules project, these have to be copied from the supplied library into the folder: Blocks
of the corresponding module.
Note
The example project mentioned in the following refers to the S7 project created
within the framework of the PROFIBUS DP configuration, Section 7.3, page
7-211.

1. Start the SIMATIC Manager STEP7.
2. Open the S7 project.
3. Open the station (in the example project: SIMATIC 300)
4. Open the module (in the example project: PLC315-2DP M/S 2AF03)
5. Open the folder: S7 Program > Blocks
6. Open the installed library: gp8x0<language><version>
e.g.: gp8x0d53
SIMATIC Manager: Menu command File > Open File
Dialog Dialog: Open
Optional field: Select libraries
Library: gp8x0d52 select
OK
7. The library is displayed in a new window.
To copy the required block of the basic PLC program, open the Blocks
folder, e.g. pg8x0d53 > gp8x0d > blocks
8. Choose the required blocks of the basic PLC program and copy them into
the S7 project to Station (in the example project: SIMATIC 300) > Module
(in the example project: PLC315-2DP M/S 2AF03) > S7 Program > Blocks
Description of For a complete description of the basic PLC program, its structure and all mod-
the basic PLC ules including their call parameters, please refer to:
program References: /FB1/ Description of Functions, Basic Machine
Section: P3, Basic PLC Program

8.2 PLC program
8.2.3 PLC user program
The organization blocks:
S OB100 (cold restart)

S OB1 (cyclic processing)
S OB40 (process alarm)
contain the entry points for the appropriate parts of the PLC user program.
OB 100 FB 1
Start
Restart
User
program
OB 1 NCK
FC 2 Mode grp.
Cyclic Channel
processing GP–OB 1 Axis
Spindle
FC 14
MCP,
HHU
FC 6
TOOLMAN
(not FMNC)
FC 19/25
MCP:
User MCP_IFM
program FC (9/15/16/18)
MCP_IFT
ASUB,
con. axes/
FC 7/8/22 spindles
TM:
TM_Trans FB 2/3/4
TM_Dir
Read/ write
var., PI
FC 17 services
Star/delta FC 13
HHU:
FC 10 Display
Error and control
operational
messages
OB 40 FC 3
GP_PRAL G group
Process alarm
distributor
User
program

8.2 PLC program
Processing The individual blocks in the basic PLC program can be processed in the SI-
modules MATIC Manager STEP7:
S Select the appropriate block, e.g. OB 100 in the folder Blocks of the corre-
sponding Module.
S Use the menu command Edit > Open Object to open the block or double-
click with the left mouse button on the block.
S Edit the block using the LAD/STL/CSF editor

Switch over the block display using the menu command View > LAD or STL
or CSF.

8.3 Loading the PLC program

8.3.1 S7 project
Prerequisites for For loading the PLC program into the PLC, the following prerequisites must be
loading fulfilled:
S SIMATIC Manager STEP7 is active

S The current PLC program is present.
S An MPI connection is established between SIMATIC Manager and PLC.
S SINUMERIK 840Di is active, i.e. the NC is in cyclic operation and the PLC in
either of the states RUN or STOP.
Making the Before loading the configuration (system data blocks) into the PLC, first the re-
MPI connection quired MPI connection must be established.
SIMATIC Manager If the configuration is transferred from an external PG/PC (e.g. PG740), the fol-
STEP7 on an lowing prerequisites must be fulfilled:
external PG/PC
S An MPI card exists (e.g. CP5611)
S Current interface parameterization: CP5611(MPI)
S The MPI interface of the PG/PC is linked with the MPI interface of the MPI
board (X111) using an MPI cable.
SIMATIC Manager If the configuration is transferred from the SINUMERIK 840Di, the following re-
STEP7 on quirements must be fulfilled:
SINUMERIK 840Di
S Current interface parameterization: SINUMERIK MCI board (MPI)
Parameterizing the Parameterization of the MPI interface is carried out with the SIMATIC Manager
MPI interface STEP7 using menu command Tools > Set PG/PC Interface.
Dialog Dialog: Setting the PG/PC Interface

Register: Access Path
with ext. PG/PC: CP5611(MPI)
or
with local PC: SINUMERIK MCI board (MPI)
Button: “Properties”

Dialog: Properties
Group: Network Parameters
Transmission rate: 1.5 Mbps
OK
OK
Note
Parameterization of the MPI interface can be effected or changed from the
SIMATIC Manager STEP7 at any time.
Operating status: When the PLC program is loaded in the RUN operating status, each block
STOP loaded becomes active immediately. This can result in inconsistencies when
executing the active PLC program.
To load the PLC program, it is therefore recommended to set the PLC to the
STOP operating status.
To this aim, choose the module (in the example project: PLC315-2DP
M/S 2AF03) from the SIMATIC manager. Using the menu command Target
System > Operating Status, the dialog box Operating Status opens. Use the
button “STOP” to bring the PLC to the required operating status.
Dialog Dialog: Operating Status

Button: “STOP”
OK
Loading the PLC To load the entire PLC program, choose the folder Blocks of the corresponding
program module from the SIMATIC Manager using the left mouse button.
Use the menu command Target System > Load to load the PLC program into
the corresponding module.
If the folder “Blocks” of the appropriate module contains system data blocks,
you will be asked at the end of the loading process whether you want to load
them, too.
– No: The loaded configuration remains stored.
– Yes: The new configuration is loaded.
Operating status: After the PLC program has been loaded, the PLC has to be brought to the RUN
RUN operating status again.
To this aim, choose the module (in the example project: PLC315-2DP
M/S 2AF03) from the SIMATIC manager. Using the menu command Target
System > Operating Status, the dialog box Operating Status opens. Use the
button “RUN” to bring the PLC to the required operating status.
Dialog Dialog: Operating Status

Button: “RUN”
OK

Triggering The STOP condition of the PLC which is taken by the PLC for a short time on
NC reset loading is interpreted by the NC as a PLC failure with an appropriate alarm re-
sponse.
After the PLC program has been loaded successfully, for re-synchronization of
NC and PLC, NC reset must be initiated, e.g. using 840Di start-up:
S 840Di start-up
Dialog: NC/PLC Diagnosis
Group NC
Button: “NC-Reset”
8.3.2 Series machine start-up file
The creation and loading of a series machine start-up file within the framework
of data backup can be carried out using
– SinuCom NC (part of the SINUMERIK 840Di installation)
or
– HMI Advanced (option).
For detailed information on data backup, please refer to:

References: SinuCom NC
Online Help
HMI Advanced:
/IAM/ MMC/HMI Installation and Start-Up Guide

8.4 Testing the PLC program

8.4.1 Start-up behavior
The start-up behavior of a SIMATIC-CPU module can be set for the following
start-up modes:
S Restart
S Cold restart (warm restart)
S Cold start.
The start-up mode of a module is set using the dialog Properties, Register
Start-up of module.
Notice
The menu command Edit > Object Properties in the SIMATIC STEP7 Man-
ager can only be used for reading access to the module properties.
To modify the properties, open the dialog in “HW Config” after you have se-
lected the module using the menu command Edit > Object Properties or by
double-clicking on the module.
SINUMERIK 840Di The start-up mode of the PLC with SINUMERIK 840Di is fixed to COLD RE-
PLC START. This setting cannot be modified.
Boot type: In the case of COLD RESTART, OB 100 is passed prior to the cyclic processing
COLD RESTART (OB 1). Then the cyclic operation starts with calling OB 1.
The following data are kept in the case of COLD RESTART:
S All data blocks and their contents

S Retentive timers, counters and flags.
Retentive ranges The ranges of the timers, counters and flags that are to be retentive must be set
using the dialog Properties, register Retention of the PLC-CPU module.
Notice
The retention of the data areas can only be achieved with the backup supply
(backup battery) active. If the battery backup is empty, the PLC will not restart.
The following operations are performed during a restart:
S UStack, BStack and non-retentive flags, timers and counters will be deleted

S The process output image (POI) will be deleted

S Process and diagnostics alarms will be canceled
S The system status list will be updated
S Parameterization objects of modules (from SD100 onwards) will be evalu-
ated or defaults parameters will be output to all modules in single-processor
mode
S OB100 (cold restart) is executed

S The process input image (PII) is read in
S The command output disable (COD) is canceled.
8.4.2 Cyclic operation
In cyclic operation, communication or exchange of data and signals is carried

out between the PLC and the components NC, HMI (e.g. HMI Advanced) and
MCP (machine control panel).
The execution of the PLC program is carried out such that – with regard to time
– the basic PLC user program is executed prior to the PLC user program.
NC communication Communication of the PLC with the NC is carried out using the NC/PLC inter-
face. The interface is divided into the following areas:
S Mode groups
S Channels
S Axes/spindles
S General NC data.
Data exchange through the NC/PLC interface is carried out in the basic PLC
program at the beginning of OB 1. This ensures that the data for the PLC re-
main constant over the entire PLC cycle.
The current G functions of the NC channels are transferred to the PLC (pro-
vided function is activated) on the process alarm level (OB 40).
Sign-of-life A cyclic, mutual sign-of-life monitoring function is activated between PLC and
monitoring NCK once ramp-up and the first OB1 cycle have been completed.
In case of failure of the PLC or in case of STOP of the PLC program execution,
the following alarm is displayed:
S Alarm: “2000 sign-of-life monitoring for PLC”.

8.4.3 Monitor/control using the SIMATIC Manager STEP7
The SIMATIC Manager STEP7 provides an extensive functionality for testing

the PLC program or the module.
Monitoring and The menu command Target System > Monitor/Control Variable is used to
controlling the start the tool “Monitor/control variable”.
variable “Monitor and control variable” can be used to:
S Display the current values of individual variables of the PLC user program or
the CPU module: Monitor variables.
S Assign individual variables of the PLC user program or the CPU module
fixed values: Control variables.
S Assign individual I/O outputs of the PLC user program or the CPU module
fixed values in the STOP operating status: Enable PO and activate control
values.
S Assign individual variables of the PLC user program or the CPU module
fixed values which cannot be overwritten by the PLC user program: Force
variables.
Variable types You can specify or display values of the following variable types:
S Inputs, outputs, flags, timers and counters

S Contents of data blocks
S I/O.
Summarize the variables you want to display or control in variable tables.
When and how often variables are monitored or overwritten with values, is de-
fined by Triggering Point and Trigger Condition.
Further test The menu command Target System > ... provides the following further test
functions functions:
S Display accessible nodes

S CPU messages ...
S Display force values
S Diagnose hardware
S Module status ...
S Operating status ...

8.4.4 Monitor/control using HMI Advanced
PLC status Use the soft keys Operating Area Switchover > Diagnosis > PLC Status to
display call the dialog box PLC Status Display.
The dialog PLC Status Display serves to monitor and control variables of:
S Inputs, outputs, flags, timers and counters

S Contents of data blocks
Input syntax: The following two tables show the input syntax of the fields: Operand and
– Operand Format of the PLC status display.
– Format
Table 8-2 Input field: Operand
Syntax Meaning
En.x Input byte n, bit x
IBn Input byte n
IBn Input word n
IBn Input double-word n
DBn.DBXm.x Data block n, byte m, bit x
DBn.DBBm Data block n, byte m
DBn.DBWm Data block n, word m
DBn.DBDm Data block n, double word m
On Output n
Fn Flag n
Tn Timer n
Cn Counter n
Table 8-3 Input field: Format
Syntax Meaning
H Hexadecimal
D Decimal
B Binary
F Floating point (only in conjunction with
double word)
Monitoring After the variable to be displayed has been input in the field Operand using the
syntax described above, the current value of the variable is displayed in the
format you have set.
Controlling: Start Use the soft key Change to switch over to the Control mode. Now you can use
the field Value to specifynew values for the displayed variables.
The entered value must be within the definition range of the set format.

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

Drive Start-Up (Preconditions) 9
Section “Drive start-up (requirements)” describes the Requirements of the SI-
NUMERIK 840Di for optimum start-up of the drives as regards material and
cost.
It is not the section’s objective to explain in detail how a drive is started up. For
start-up of the drive, please refer to the relevant drive documentation.
9.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI
9.1.1 Start-up variations
The following distinction is made between start-up of the above SIMODRIVE

drives:
S First start-up
S Series start-up.
First start-up A first start-up must only be carried out if no matching parameter record is avail-
able for the drive in the form of the parameter file.
Series machine A series machine start-up must only be carried out if no matching parameter
start-up record is available for the drive in the form of the parameter file.
The parameter file is then loaded into the drive to be started up using SimoCom
U in online mode (for online mode, see: Subsection 9.1.2, page 9-265).
Possible ways The possible ways of starting up a drive are:

of proceeding
S Using a display and operator unit directly on the drive (611U/E only)
S Using SimoCom U:
1. SimoCom U is installed on any PG/PC with a serial interface and is direct
connected to the corresponding drive using a RS-232 cable.
2. SimoCom U is installed on any PG/PC with a PROFIBUS DP interface
and connected to all drives using a PROFIBUS cable:
– PG 740 or PCU 50 with integrated PROFIBUS DP interface
– Standard PC with CPU module, e.g. CP 5611

9 Drive Start-Up (Preconditions) 06.03
3. SimoCom U is installed on the SINUMERIK 840Di and is routed from the

PLC to the PROFIBUS. Via the PROFIBUS DP interface of the MCI
board, SimoCom U is connected to all drives using a PROFIBUS cable.
Recommended Within the framework of SINUMERIK 840Di, the procedure described above
procedure (Point 3.) is recommended:
The advantages of this procedure are:
S SimoCom U is always available for:

– start-up
– diagnosis
– controller optimization
– software upgrade of drive firmware
– software upgrade of option module firmware
S no additional PG/PC required

S no additional cables required.

06.03 9 Drive Start-Up (Preconditions)
9.1.2 Preconditions for an online connection
In order to be able to establish an online connection between SimoCom U and

the SIMODRIVE 611 universal drives connected using PROFIBUS DP, the fol-
lowing preconditions must be fulfilled:
S SimoCom U must be installed
– For installing SimoCom U, see Section 9.2, page 9-271
S A PROFIBUS connection must exist from the PROFIBUS interface of the
MCI board to all drives
– For network rules, see Section 7.2, page 7-210
S With all drives, the PROFIBUS address must be set
– For SIMODRIVE 611 universal/E see Subsection 9.1.3, page 9-265
– For SIMODRIVE POSMO CD/CA and SI see Subsection 9.1.4, page
9-267
S The SINUMERIK 840Di PLC must be networked using MPI
– For networking the PLC, see Subsection 7.3.2, page 7-212
S The configuration must be loaded into the PLC
– For creating an S7 project, see Section 7.3, page 7-211
– For loading the PLC, see Subsection 7.3.8, page 7-238
S The MPI interface must be set on the “SINUMERIK MCI Card (MPI)”
– For setting the MPI interface, see Subsection 9.1.5, page 9-268
S The routing information must be set
– For setting the routing Information, see Subsection 9.1.6, page 9-269.
9.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal/E)
For SimoCom U to be able to enter online operation with the SIMODRIVE drives
connected to the PROFIBUS, the PROFIBUS address specified in the S7 proj-
ect (see Section 7.3, page 7-211f) must be set on DP slave 611U or UE in ques-
tion using the display and operator unit.
Display
+ P – Control unit
Fig. 9-1 Display and control unit

Preconditions The precondition for setting the PROFIBUS address on the control unit is that
no faults or warnings are displayed.
If faults or warnings are displayed (display: E_xxxx), press the “–” key to switch
from the alarm mode to parameterization mode.
Sequence of To set the PROFIBUS address, proceed as follows:

operations
1. Setting the PROFIBUS address (parameter P0918)
– Hold down the “P” key longer than 3 seconds.
=> The current value of the parameter P0918 (PROFIBUS address) is
displayed.
– Use the keys “+” and “–” to set the desired PROFIBUS address.
– Press the “P” again to quit the input mode.
2. Saving the PROFIBUS node address in the FEPROM
– Press the “+” or “–” key
=> The parameter P0652 (acceptance into FEPROM) is displayed.
– Press the “P” again to call the input mode.
– Use the “+” key to change the value to 1 (start writing)
and wait until the write process is acknowledged with 0 on the display.
3. Carrying out POWER ON Reset
– Push the “POWER ON RESET” button on the front panel of the drive
module.
=> After power-up, the set PROFIBUS address is active.
References For detailed information on start-up of SIMODRIVE 611 universal drives, refer
to:
/FBU/ SIMODRIVE 611 universal, Description of Functions
Section: Parameterizing the board
Parameterization using the display and operator unit
and
Section: PROFIBUS DP master settings
Start-up.

9.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA)
For SimoCom U to be able to enter online operation with the SIMODRIVE drives
connected to the PROFIBUS, the PROFIBUS address specified in the S7 proj-
ect (see Section 7.3, page 7-211f) must be set on DP slave POSMO SI/CD/CA
in question using the DIL switches of the PROFIBUS unit in question.
Switch position
OFF=0
12 34 1 2345 678
ON=1
Terminating resistor active PROFIBUS address
ÏÏ ÏÏ
ÏÏÏÏÏ
1
Ï 2 3 4
ON
ÏÏ
ÏÏ
ÏÏ1
ÏÏ
ÏÏ
ÏÏÏÏ ÏÏÏ Ï
ÏÏÏÏÏÏÏ
2
Ï
3 4 5 6 7 8
ON
20 21 22 23 24 25 26 (reserved)
Terminating resistor (1) (2) (4) (8) (16) (32) (64)
inactive = OFF Example: PROFIBUS address = 37
ON ON
1 2 3 4 1 2 3 4 5 6 7 8
Note: 1 + 4 + 32 = 37
S The valid settable address are: 3 to 126
S The set address is read by POSMO SI/CD/CA and displayed using

P0918 (PROFIBUS node address).
Fig. 9-2 Setting the PROFIBUS address and terminating resistor
Notice
To set the PROFIBUS address and terminating resistor it is necessary to re-
move the PROFIBUS unit.
References For detailed information on start-up of SIMODRIVE POSMO CD/CA and SI uni-
versal drives, refer to:
/POS3/ SIMODRIVE POSMO SI/CD/CA User Manual
Section: Connecting the PROFIBUS unit.

9.1.5 Setting the MPI interface
The MPI interface through which SimoCom U accesses the drives connected to
PROFIBUS by means of routing, must be parameterized as follows:
– Access point of application
S7ONLINE STEP7 ––> SINUMERIK MCI board (MPI)
– Interface parameterization
SINUMERIK MCI board (MPI).
The MPI interface can be parameterized direct from SimoCom U. To do so, pro-
ceed as follows:
1. Start SimoCom U from the WINDOWS NT taskbar:
Start > Programs > SimoComU > SimoComU
2. In SimoCom U, open the interface dialog using the menu command:
Tools > Communication.
SimoCom U dialog: Dialog: Interface

Start Option field: “Route through S7 CPU”
Button: “Set PG/PC Interface...”
PG/PC Dialog: Setting the PG/PC Interface

interface dialog: Register: Access Path
Start Access point of application:
S7ONLINE STEP7 ––> SINUMERIK MCI board (MPI)
SINUMERIK MCI board (MPI).
If “SINUMERIK MCI board (MPI)” cannot be selected for the interface parame-
terization, the interface has to be installed first.
PG/PC Button: “Install...”

interface dialog:
End Dialog: Install / Remove Interface
Selection: SINUMERIK MCI Board (MPI)
Button: “Install––>“
Close
OK.
Finally, the routing information must be set in the interface dialog of Simo-
Com U.

9.1.6 Setting the routing information
Setting the routing information:

– MPI address of the PLC
– PROFIBUS subnetwork ID.
The easiest method to do so is the expert mode after resetting the routing infor-
mation.
Notice
To use the PLC as a router between MPI and PROFIBUS DP, the MPI network-
ing of the PLC must be parameterized in the S7 project.For network rules, see
SimoCom U dialog: Button: “Reset routing information...”

End Radio button: Expert mode
MPI No: 2 (see Note)
PROFIBUS: <Subnetwork ID> (see below)
OK or Go online.
Notice
With SINUMERIK 840Di, the routing of the MPI interface to the PROFIBUS DP
is provided the PLC. Therefore, the MPI address of the PLC must be specified
as the “MPI No”.
With SINUMERIK 840Di, the PLC always has the MPI address 2.
Entering the Enter the 8-digit PROFIBUS S7 subnetwork ID of DP master (S7 project) in the
PROFIBUS S7 12-digit input screen form of the SimoCom U dialog as follows:
subnetwork ID Example:
S7 project: 8-digit S7 subnetwork ID:
0010 – 0005
SimoCom U: 12-digit S7 subnetwork ID:

00 10 00 00 00 05
Determining If you do not have the PROFIBUS S7 subnetwork ID, you can call it using the
PROFIBUS S7 SIMATIC Manager STEP7
subnetwork ID To do so, proceed as follows:
S Open the appropriate S7 project in the SIMATIC Manager S7.

S Select the appropriate station (in the example project: SIMATIC 300)

S Open the hardware configuration of the station (double-click with left mouse
button on: Hardware; “HW Config” will be started)
S Open DP master (in the example project: DP master) (double-click with left
mouse button on DP master)
S You will find the subnetwork ID as follows using the property dialog of DP
master:
Dialog Dialog: Properties – DP Master

Tab: General
Group: Interface
Type: PROFIBUS
Address: 2
Dialog: Properties – PROFIBUS Interface DP Master
Tab: Parameters
Subnetwork: PROFIBUS
Dialog: Properties PROFIBUS
Tab: General
S7 subnetwork ID: 0010 – 0005 (example)
Cancel
Cancel
Cancel.
The online operation with the drives connected to PROFIBUS can now be
started.
9.1.7 Starting online operation
After parameterization of the MPI interface and entry of the routing information,
SimoCom U can enter online operation with the SIMODRIVE drives.
Start search To start the search for any drives connected,

– quit the above mentioned dialog for setting the MPI interface using the
button: “Go online”
or
– use the menu command Start-up > Search for online drives.
Display of the The SIMODRIVE drives with which SimoCom U could start the online operation
drives are displayed in the SimoCom U main screen:
– Drive and dialog browser (left window)
– Status overview (upper status bar).

9.2 Installing SimoCom U
Installation SimoCom U is part of the 611U toolbox supplied with the SINUMERIK 840Di in
directory:
S <Installationspfad>\siemens\611UToolbox\SimoComU
To instal SimoCom U on the PCU, start file setup.exe and follow the further
installation instructions.
Note
Before installing SimoCom U, please observe the appropriate notes in the file:
<installation path>\readme.txt.
Scope of available SimoCom U provides the following functions:

functions
– Make an online connection to the drives
– Upgrade the firmware
– Optimize the control parameters
– Traverse the axes
– Diagnose the drive status.
Online help After installation, the documentation for SimoCom U is available electronically.
Use the menu command Help in SimoCom U to call information on the topics:
– Short introduction...
– How to Use WINDOWS Help...
– Help Topics...
– Key Operation...
– Wiring...
– About SimoCom U...
References In addition, for a detailed description on SimoCom U, please refer to:
/FBU/ SIMODRIVE 611 Universal, Description of Functions

J

Notes

NC Start-Up with HMI Advanced 10
10.1 General procedure
The NC is parameterized with respect to the connected machine is by setting

system variables.
These system variables are called:
S Machine data (MD)

S Setting data (SD).
10.2 Machine and setting data
Machine data Machine data are system variables used to adapt the NC to the machine.
Identifier The identifier of a machine data is subject to the scheme:

$ M k _IdentifierString
The letters/characters have the following meaning:
S $ System variable
S M Machine data
S k Component
k identifies the components of the NC parameterizing the appropriate machine
data:
S N NC
S C Channel
S A Axis
S D Drive
S M MMC.

10 NC Start-Up with HMI Advanced 06.03
Activation The activation with respect to a machine data specifies in which status of the
NC a change of a machine data becomes active.
Activation categories are:
S Power ON
S Reconfiguration
S Reset
S Effective immediately.
Setting data Setting data are system variables telling the NC the current machine properties.
Identifier The identifier of a setting data is subject to the scheme:

$ S k _IdentifierString
The letters/characters have the following meaning:
S $ System variable
S S Setting data
S k Component
k identifies the components of the NC parameterizing the appropriate machine
data:
S N NC
S C Channel
S A Axis
Activation In contrast to machine data, changes of setting data always come immediately
into effect.
Overview The machine data are divided into the following areas:
of machine data Table 10-1 Overview of machine data
Area Designation
from 1000 to 1799 Machine data for drives ($MD_....)
from 9000 to 9999 Machine data for operator panel ($MM_....)
from 10000 to 18999 NC-specific machine data ($MN_....)
from 19000 to 19999 Reserved
from 20000 to 28999 Channel-specific machine data ($MC_....)
from 30000 to 38999 Axis-specific machine data ($MA_....)
from 51000 to 61999 General machine data for compile cycles
from 62000 to 62999 Channel-specific machine data for compile cycles
from 63000 to 63999 Axis-specific machine data for compile cycles

06.03 10 NC Start-Up with HMI Advanced
Overview of The setting data are divided into the following areas:
setting data Table 10-2 Overview of setting data
Area Designation
from 41000 to 41999 General setting data ($SN_....)
from 42000 to 42999 Channel-specific setting data ($SC_....)
from 43000 to 43999 Axis-specific setting data ($SA_....)
Data description For a detailed description of the machine or setting data, please refer to the de-
scription of the function that uses the machine data in question, e.g.:
References: /FB/ Description of Functions – Basic Machine
/FB/ Description of Functions – Extended Functions
/FB/ Description of Functions – Special Functions
A brief table of all machine and setting data is to be found in:

References: /LIS/ Lists
Machine and setting data.
Note
To search for information regarding machine and setting data, it is recom-
mended to use the search functions in the electronic documentation:
SINUMERIK DOConCD.
10.2.1 Display and input
Machine data To display and input machine data, appropriate screen forms are provided.
screen forms
The screen forms are found on the HMI Advanced user interface at:
Area Switchover –> Start-up –> Machine Data.
Notice
To input machine data, at least the password of protection level 2 (default:
“EVENING”) must be set.
Bit editor To facilitate the input of machine data in the bit format (HEX), a bit editor is pro-
vided.
If the input cursor is on a machine data in HEX format in the MD list, you can
call up the editor by pressing the toggle key (in the middle of the cursor keys).

Fig. 10-1 Input screen form of the bit editor for HEX machine data
You can set or reset single bits by clicking them with the mouse or by selecting
them with the cursor keys by pressing the toggle key.
S With the soft key OK, you can terminate the bit editor and accept the value
set.
S With the soft key Abort, you can quit the bit editor and discard the value set.
The previous setting is then valid again.
10.2.2 Protection levels
Access rights The access to programs, data and functions is protected user-oriented using
eight hierarchical protection levels. These are divided into
(see Table 10-3):
S Four password levels for SIEMENS, machine manufacturers and final users
S Four keyswitch positions for end users.
This provides a multi-stage safety concept to manage the access rights.

Table 10-3 Protection levels
Protection Type User Access to (examples)

level
0 Pass– SIEMENS All functions, programs and data
word
1 Pass– Machine manufacturer: Defined functions, programs and data;

word Development e.g.: Enter options
2 Pass– Machine manufacturer: Defined functions, programs and data;

word System start-up engineer e.g.: Majority of machine data
3 Pass– Final user: Assigned functions, programs and data;

word Service
4 Key– Final user: Less than protection levels 0 to 3;

switch Programmer defined either by machine manufacturer or
pos. 3 setter end user
5 Key– Final user: Less than protection levels 0 to 3;

switch Qualified operator defined by the end user
pos. 2 who will not program Descending
access rights
6 Key– Final user: Example:
switch Trained operator Only program selection, input of tool wear
pos. 1 who will not program and zero offsets
7 Key– Final user: Example:

switch Semiskilled operator No inputs, no program selection
pos. 0 only possible if the machine control panel can be
operated
Setting the For the four possible password levels with their access permissions, the pass-
password words can be entered in the control area DIAGNOSIS by actuating the soft key
SET PASSWORD.
References: /BA/ Operator’s Guide
Resetting Please note that a password remains valid until access authorization is reset
the password with the soft key DELETE PASSWORD.
Access rights are thus not automatically deleted by power ON!
Possible Up to eight characters are possible for a password. When choosing the pass-
characters word, it is recommended to limit yourself to the character set of the operator
panel. If the character has less than 8 characters, the remaining characters are
interpreted as a blank.

Default The following default passwords are defined for the protection levels 1 though 3:
passwords Protection level 1 SUNRISE
Protection level 2 EVENING
Protection level 3 CUSTOMER
Notice
A system power-up with loading the default machine data (after “Delete NCK
data”, e.g. using 840Di Start-up) will reset the passwords to the default values.
In order to provide safe access protection, the default passwords should be
modified.
Redefining The protection levels of machine and/or setting data can be modified both with
protection levels respect to complete machine or setting data ranges and for single data.
Data areas
Table 10-4 Protection levels: Machine data
Number Identifier Name Ref.

MMC machine data ($MM_....)
9200 USER_CLASS_READ_TOA Protection level “Read tool offsets”
9201 USER_CLASS_WRITE_TOA_GEO Protection level “Write tool geometry”
9202 USER_CLASS_WRITE_TOA_WEAR Protection level “Write tool wear data”
9203 USER_CLASS_WRITE_FINE Protection level “Write fine”
9204 USER_CLASS_WRITE_TOA_SC Protection level “Change additive tool offsets”
9205 USER_CLASS_WRITE_TOA_EC Protection level “Change tool setup offsets”
9206 USER_CLASS_WRITE_TOA_SUPVIS Protection level “Change tool monitoring limit
values”
9207 USER_CLASS_WRITE_TOA_ASSDNO Change assigned D-No. of a tool edge
9208 USER_CLASS_WRITE_MAG_WGROUP Change wear group magazine location/mag.
9209 USER_CLASS_WRITE_TOA_ADAPT Protection level “Tool adapter data”
9210 USER_CLASS_WRITE_ZOA Protection level “Write settable zero offset”
9213 USER_CLASS_OVERSTORE_HIGH Protection level “Extended overstore”
9214 USER_CLASS_WRITE_PRG_CONDIT Protection level “Program control”
9215 USER_CLASS_WRITE_SEA Protection level “Write setting data”
9218 USER_CLASS_SELECT_PROGRAM Protection level “Program selection”
9219 USER_CLASS_TEACH_IN Protection level “TEACH IN”
9220 USER_CLASS_PRESET Protection level “PRESET”
9221 USER_CLASS_CLEAR_RPA Protection level “Delete R parameters”
9222 USER_CLASS_WRITE_RPA Protection level “Write R parameters”
9231 USER_CLASS_WRITE_RPA_1 Protection level for the first RPA area
9232 USER_BEGIN_WRITE_RPA_1 Start of the first RPA area
9233 USER_END_WRITE_RPA_1 End of the first RPA area
9234 USER_CLASS_WRITE_RPA_2 Protection level for the second RPA area


9235 USER_BEGIN_WRITE_RPA_2 Start of the second RPA area
9236 USER_END_WRITE_RPA_2 End of the second RPA area
9237 USER_CLASS_WRITE_RPA_3 Protection level for the third RPA area
9238 USER_BEGIN_WRITE_RPA_3 Start of the third RPA area
9239 USER_END_WRITE_RPA_3 End of the third RPA area
9240 USER_CLASS_WRITE_TOA_NAME Change tool name and duplo
9241 USER_CLASS_WRITE_TOA_TYPE Change tool type
9247 USER_CLASS_BASE_ZERO_OFF_PA IAM, IM1 availability of the basic offset in the Pa-
rameter operating area
9248 USER_CLASS_BASE_ZERO_OFF_MA IAM, IM1 availability of the basic offset in the Ma-
chine operating area
References: /FB/ Description of Functions – Basic Machine:

A2, Various Interface Signals
Section: MMC machine data for protection levels
Single data The protection level of individual machine and/or setting data can be modified in
the file SGUD.DEF.
Example:
The axial machine data item CTRLOUT_SEGMENT_NR requires protection
level 3 for reading and protection level 2 for writing.
Syntax:
REDEF $machine data string APR n APW m
APR n: Defining the protection level for reading (Read) the data
APW m: Defining the protection level for writing (Write) the data
File SGUD.DEF:
%_N_UGUD_DEF
;$PATH=/_N_DEF_DIR
REDEF $MA_CTRLOUT_SEGMENT_NR APR 3 APW 2
M30
References: /PGA/ Programming Guide Advanced

Section: File and Program Management
Defining protection levels for user data (GUD)
10.2.3 Machine data display filter
Through the use of the machine data display filter, it is possible to reduce the
number of displayed machine data of a certain area, e.g. general machine data
or channel machine data, for special purposes.
Machine data Display filters are provided for the following machine data areas:
areas
S General machine data

S Channel-specific machine data

S Axis-specific machine data
S Drive machine data.
Display filter To parameterize the display filter of a machine data area, use the vertical soft
key Display Options... in the appropriate machine data area.
Example:
Display filter for channel machine data
Operating area: Start-up –> Machine Data –> Channel MD –> Display Options...
Note
The parameter: Display Filter of the corresponding machine data description
indicates to which display group a machine data item belongs to.
References: /LIS/ Lists
Display groups A display group contains machine data within a machine data area which be-
long to the same topic.
By selecting/deselecting the display groups, the number of displayed machine
data of the current machine data area increases or decreases.
Expert mode If the Expert mode display filter is disabled, only the machine data of a machine
data range are displayed which are required for the basic functionality of the
NC.
Index from The index filter refers to the machine data fields. On the display, these machine
to data can be identified by the field index attached to the machine data string.
Example: 10000 AXCONF_MACHAX_NAME_TAB[index]
If the index filter is activated, machine data fields are only displayed in the
specified index area.

10.3 System data
10.3 System data
10.3.1 Resolutions
The resolutions of linear and angle positions, velocities, accelerations and jerk
differ by:
S the input resolution, i.e. the input of data from the user interface or using
the parts programs
S the display resolution, i.e. the display of data on the user interface
S the computational resolution, i.e. the internal representation of the data
input through the user interface or the parts program.
Input and display The input and display resolution is determined by the control unit used whereby
resolution the display resolution for position values can be modified using the MD 9004:
DISPLAY_RESOLUTION (display resolution).
MD 9011: DISPLAY_RESOLUTION_INCH (INCH unit system display resolu-
tion) can be used to configure the display resolution for position values with inch
setting. With inch setting, it is thus possible to display up to six digits after the
comma.
For programming in parts programs, the input resolutions indicated in the Pro-
gramming guide.
Computational The computational resolution defines the maximum number of effective decimal
resolution places for all data the physical unit of which is referred to a length or an angle,
e.g. position values, velocities, tool offsets, zero offsets, etc.
The desired computational resolution is defined using the machine data
S Check MD 10200: INT_INCR_PER_MM (computational resolution for linear

positions)
S Check MD 10210: INT_INCR_PER_DEG (computational resolution for

angle positions).
The default assignment is:
S 1,000 increments/mm
S 1,000 increments/degree.
The computational resolution thus also determines the maximum achievable
accuracy for positions and selected offsets. However, it is essential that the
measuring system is adapted to this degree of accuracy.
Tip Although the computational resolution is generally independent of the input/dis-

play resolution, it should have at least the same resolution.
Rounding The accuracy of angle and linear positions is limited to the computational reso-
lution by rounding the product of the programmed value with the computational
resolution to an integer number.
Example of rounding:

10.3 System data
Computational resolution: 1,000 increments/mm

Programmed path: 97.3786mm
Effective value = 97.379mm
Tip To keep the executed rounding more traceable, it is reasonable to use powers
to the 10th for the computational resolution (100, 1000, 10.000).
Display resolution In MD 9004: DISPLAY_RESOLUTION, you can set the number of decimal
places after the decimal point for the position values on the operator panel.
Limit values for The limitation of the input limits depends on the display and input possibilities on
input and the operator panel.
display This limit is reached at 10 digit positions plus decimal point plus sign.
Examples of programming in the 1/10mm-range:

Supposed all linear axes of a machine will be programmed and traversed within
the range of values 0.1 ... 1,000mm.
To position exactly to 0.1mm, the computational resolution must be set to
104 incr. /mm.
Check MD 10200: INT_INCR_PER_MM = 10,000 [incr. /mm]:
Example of related parts program:
N20 G0 X 1.0000 Y 1.0000 ; Axes move to position
X=1.0000mm, Y=1.0000mm;
N25 G0 X 5.0002 Y 2.0003 ; Axes move to position
X=5.0002mm, Y=2.0003mm
Machine data
Table 10-5 Resolutions: Machine data
Number Identifier Name/remarks Ref.

General ($MN_ ...)
9004 DISPLAY_RESOLUTION Display resolution G2
9011 DISPLAY_RESOLUTION_INCH Display resolution for INCH unit system G2
10200 INT_INCR_PER_MM Computational resolution for linear positions G2
10210 INT_INCR_PER_DEG Computational resolution for angular positions G2
References /FB/ Description of Functions – Basic Machine

G2 Velocities, Traversing Ranges, Accuracies,
Section: Input/display resolution, calculation resolution

10.3 System data
10.3.2 Normalization of phys. quantities of Machine and Setting data
Default Machine and setting data having a physical unit are interpreted in the input/out-
put units listed in Table 10-6 by default, depending on the scaling system (met-
ric/inch).
The internally used units which the NC uses are independent and fixed.
Table 10-6 Normalization of phys. units of machine data and setting data
Physical quantity Input/output units for the Internally used

default scaling system Unit
Metric Inch
Linear position 1 mm 1 inch 1 mm
Angular position 1 degree 1 degree 1 degree
Linear velocity 1 mm/min 1 inch/min 1 mm/sec
Angular velocity 1 rpm 1 rpm 1 degree/sec
Linear acceleration 1 m/sec2 1 inch/sec2 1 mm/sec2
Angular acceleration 1 rev./sec2 1 rev./sec2 1 degree/sec2
Linear jerk 1 m/sec3 1 inch/sec3 1 mm/sec3
Angular jerk 1 rev./sec3 1 rev./sec3 1 degree/sec3
Time 1 sec 1 sec 1 sec
Position controller loop gain 1 sec–1 1 sec–1 1 sec–1
Rotational feedrate 1 mm/rev. 1 inch/rev. 1 mm/degree
Compensation value of linear position 1 mm 1 inch 1 mm
Compensation value of angle position 1 degree 1 degree 1 degree
User-defined The user can define different input/output units for machine and setting data.
To this aim, an adaptation between newly selected input/output units and the
internal units must be made in
S MD 10220: SCALING_USER_DEF_MASK (activation of scaling factors) and

S MD 10230: SCALING_FACTORS_USER_DEF[n] (scaling factors of physi-
cal quantities)
.
Input values for machine data
MD 10220 no
Scaling factor Internal scaling
activated?
Yes
MD 10230 Scaling factor
Internal physical quantity

10.3 System data
The following applies:
Selected inputoutput unit
MD : SCALING_FACTORS_USER_DEF[n] * internal unit
Enter the selected input/output unit expressed in the internal units 1mm,
1 degree and 1 sec in MD 10230: SCALING_FACTORS_USER_DEF[n].
Table 10-7 Bit number and index for user definition
Physical quantity MD 10220: MD 10230:

Bit number Index n
Linear position 0 0
Angular position 1 1
Linear velocity 2 2
Angular velocity 3 3
Linear acceleration 4 4
Angular acceleration 5 5
Linear jerk 6 6
Angular jerk 7 7
Timer 8 8
KV factor 9 9
Rotational feedrate 10 10
Compensation value of linear position 11 11
Compensation value of angle position 12 12
Example 1:
The machine data input/output of linear velocities is to be carried out in m/min,
instead of mm/min (default). The internal unit is mm/sec.
Via MD 10220: SCALING_USER_DEF_MASK Bit2 = 1 is used to enter the
scaling factor for linear velocities as a user-defined value.
The scaling factor is calculated using the following formula:
Selected inputoutput unit

MD : SCALING_FACTORS_USER_DEF[n]
internal unit
m 1000mm
1 min
MD : SCALING_FACTORS_USER_DEF[n] mm 60secs
mm 1000 16, 667;
1 secs 1 secs 60
MD : SCALING_FACTORS_USER_DEF[2] 16, 667
Index 2 specifies the “linear velocity” (see above).
Example 2:
In addition to the change of example 1, the machine data input/output of linear
accelerations, is to be performed in ft/sec2, instead of m/sec2 (default).
(The internal unit is mm/sec2.)

10.3 System data
MD : SCALING_USER_DEF_MASK H14; (bit No. 4 and bit No. 2

of example 1 as hex value)
ft mm
1 12 * 25, 4
secs 2 secs 2
MD : SCALING_FACTORS_USER_DEF[n] 304, 8;
1 mm2 1 mm
secs secs 2
MD : SCALING_FACTORS_USER_DEF[4] 304, 8
Index 4 specifies the “linear acceleration” (see above).
Machine data
Table 10-8 Normalization of phys. units of machine data and setting data: Machine data

General ($MN_ ...)
10220 SCALING_USER_DEF_MASK Activating the scaling factors
10230 SCALING_FACTORS_USER_DEF[n] Scaling factors of the physical units
10240 SCALING_SYSTEM_IS_METRIC Metric scaling system
10250 SCALING_VALUE_INCH Conversion factor for switchover to the inch sys-
tem
10260 CONVERT_SCALING_SYSTEM Basic system switch active
10270 POS_TAB_SCALING_SYSTEM Unit system of position tables T1
10290 CC_TDA_PARAM_UNIT Physical units of tool data for CC
10292 CC_TDA_PARAM_UNIT Physical units of cutting edge data for CC
10.3.3 Changing scaling machine data
The scaling of machine data having physical units is defined by the following
machine data:
S MD 10220: SCALING_USER_DEF_MASK (activation of scaling factors)

S MD 10230: SCALING_FACTORS_USER_DEF (scaling factors of physical
quantities)
S MD 10240: SCALING_SYSTEM_IS_METRIC (basic system metric)

S MD 10250: SCALING_VALUE_INCH (conversion factor for switchover to
INCH system)
S MD 30300: IS_ROT_AX (rotary axis)

When scaling machine data are modified, all machine data affected by this mod-
ification due to their physical unit are converted with the next NCK reset.
Example: Redefining an A1 axis from linear to rotary axis.

10.3 System data
The control has been started up with default values. Axis A1 is declared as a
linear axis.
S MD 30300: IS_ROT_AX[A1] = 0 (no rotary axis)

S MD32000: MAX_AX_VELO [A1] = 1000 [mm/min] (max. axis velocity).
Axis A1 is now declared as a rotary axis containing the following machine data:
S MD 30300: IS_ROT_AX = 1 (rotary axis)

S MD32000: MAX_AX_VELO [A1] = 1000 [mm/min] (max. axis velocity).
With the next NCK reset, the control system recognizes that axis A1 is defined
as a rotary axis and rescales MD32000: MAX_AX_VELO to [rev./min] with refer-
ence to a rotary axis.
S MD 30300: IS_ROT_AX = 1 (rotary axis)

S MD32000: MAX_AX_VELO [A1]= 2.778 [rev./min].
Note
If a scaling machine data item is altered, then the control outputs alarm
“4070 Scaling data changed”.
Modifying The following procedure is recommended when modifying scaling machine data
manually manually:
1. Set all scaling machine data
2. Carry out NCK reset
3. Set all dependent machine data after the NC has powered up.
10.3.4 Loading default machine data
The default machine data can be loaded in different ways.
840Di start-up Via the SINUMERIK 840Di standard user interface 840Di start-up:
Menu command Window > Diagnosis > NC/PLC
S Button: “Delete NCK Data”

S Button: “NCK RESET”
Notice
With deleting the NCK data, all user data are lost.
To avoid data loss, a series machine start-up file should be created before the
NCK data are deleted. How to create a series machine start-up file is described
in Section 14.2, page 14-451.

10.3 System data
MD11200: INIT_MD The input values in MD11200: INIT_MD (loading the default machine data with
the next NC boot), which are listed below, various data areas can be loaded
when the NC boots next time.
After setting the machine data, NCK reset must be carried out twice:
1. NCK RESET: The machine data is activated.
2. NCK RESET: Depending on the input value, the appropriate machine data
are set to their default values and MD11200: INIT_MD is reset again to the
value “0”.
Input values MD11200: INIT_MD = 1

On the next NC power-up, all machine data (with the exception of the memory
configuring data) are overwritten with default values.
MD11200: INIT_MD = 2
On the next NC power-up, all memory-configuring machine data are overwritten
with default values.
10.3.5 Switching over the measuring system
The unit system is switched over for the entire machine using a soft key in the
HMI Advanced operating area “MACHINE”. The switch will only be accepted if:
S MD10260: CONVERT_SCALING_SYSTEM=1
S Bit 0 of MD20110: RESET_MODE_MASK is set in each channel
S all channels are reset
S the axes are not traversed with JOG, DRF or the PLC
S constant grinding wheel peripheral speed (GWPS) is not active.
For the duration of the switching, actions, such as parts program start or mode
change, are blocked.
If the switch cannot be carried out, this is indicated by an appropriate message
on the operator interface. This definition ensures that the program currently exe-
cuted always finds a consistent data record with reference to the unit system.
The switch to the unit system itself is internally carried out by writing of all ma-
chine data required and then activating them by RESET.
MD10240: SCALING_SYSTEM_IS_METRIC and the corresponding settings
G70/G71/G700/G710 in MD20150: GCODE_RESET_VALUES are switched for
all channels configured automatically.
During this process, the value specified in MD20150: GCODE_RE-
SET_VALUES[12] changes between G700 and G710.
This process is carried out irrespective of the protection level currently set.

10.3 System data
System data When switching over the unit system, from the view of the user, all length-re-
lated specifications are converted to the new unit system automatically. These
data include:
S Positions
S Feedrates
S Accelerations
S Jerk
S Tool offsets
S Programmable, settable and external zero offsets, DRF offsets
S Compensation values
S Protection zones
S Machine data
S Jog and handwheel weightings.
After switching, all above mentioned data are available in the physical quantities
as specified in Subsection 10.3.2 (page 10-283).
Data for which no unambiguous physical quantities are defined, such as:
S R parameters
S GUDs (Global User Data)
S LUDs (Global User Data)
S PUDs (Program global User Data)
S Analog input/outputs
S Data exchange through the FC21
will not be subject to automatic conversion. It is the user’s task to take into ac-
count the unit system currently active (MD 10240: SCALING_SYS-
TEM_IS_METRIC).
The unit system setting currently active can be read from the PLC interface us-
ing the signal “Inch unit system” DB10.DBX107.7. The unit system change
counter can be read in DB10.DBB71.
Machine data
Table 10-9 Switching over the unit system: Machine data

General ($MN_ ...)
10240 SCALING_SYSTEM_IS_METRIC Metric scaling system
10250 SCALING_VALUE_INCH Conversion factor for switchover to the inch
system
10260 CONVERT_SCALING_SYSTEM Basic system switch active
Axis-specific ($MA_ ...)
32711 CEC_SCALING_SYSTEM_METRIC Unit system of sag compensation G2
References /FB/ Description of Functions, Basic Machine,

G2 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control,
Section: Metric/inch measuring system

10.3 System data
10.3.6 Traversing ranges
Computational The range of values of the traversing ranges directly depends on the selected
resolution and computational resolution (see Subsection 10.3.1, page 10-281).
traversing ranges With the default assignment of the machine data for the computational
resolution
S 1,000 increments/mm
S 1,000 incr/degr.
the following traversing ranges result:
Table 10-10 Traversing ranges
Traversing range in the metric system Traversing range in the inch system
Linear axes 999,999.999 [mm; degrees] 399,999.999 [Inch; degrees]
Rotary axes 999,999.999 [mm; degrees] 999,999.999 [inch; degrees]
Interpolation parameters I, J, K 999,999.999 [mm; degrees] 399,999.999 [Inch; degrees]
10.3.7 Positioning accuracy
Computational The positioning accuracy depends on:

accuracy and
S the computational accuracy (internal increments/(mm or degrees))
traversing ranges
S the actual-value resolution (encoder increments/(mm or degrees)).
The rougher resolution of both determines the positioning accuracy of the NC.
The input resolution, the position control and interpolation clock do not affect the
accuracy.
Machine data
Table 10-11 Positioning accuracy: Machine data

General ($MN_ ...)
10200 INT_INCR_PER_MM Computational resolution for linear positions G2
31020 ENC_RESOL[n] Encoder lines per revolution

10.3 System data
10.3.8 Cycle times
On the SINUMERIK 840Di the system clock cycle, the position controller cycle,
and the interpolation cycle of the NC are based on the DP cycle time configured
in STEP7 “HW Config”. See Section 7.3, page 7-211f.
System clock cycle The system clock cycle is set fixed to the ratio of 1:1 with regard to the DP cycle
time. In the machine data, the active value is displayed. This setting cannot be
modified.
S MD10050: SYSCLOCK_CYCLE_TIME (system clock cycle).
Position controller The position controller cycle is set fixed to the ratio of 1:1 with regard to the sys-
cycle tem clock cycle. This setting cannot be modified.
Position controller The position controller cycle offset (TM) must be set such that the following con-
cycle offset ditions are fulfilled within a PROFIBUS DP/system clock cycle:
– The cyclic communication with the DP slaves (drives) must be com-
pleted before the position controller is started.
Condition: TM > TDX
– The position controller must be completed before the DP cycle/system
clock is completed.
Condition: TM + TPos < TDP
TDP
TM TPos
NC:
R R R
Position controller
TDX
PROFIBUS DP MSG RES GC Dx Dx Dx MSG RES GC Dx Dx Dx

communication
DP slaves: R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R R
R R
R
R
Drives
Fig. 10-2 Position controller cycle offset to the PROFIBUS DP cycle

10.3 System data
Explanations regarding Fig.10-2:

TPos Computational time required by the position controller
TDX Data exchange time: Total of transfer times of all

DP slaves
TM Master time: Shift of starting time of the NC

position control
GC Global Control: Broadcast message frame for cyclic

synchronization of the isosynchronism between DP master
and DP slaves
R Computational time
MSG Acyclic services (e.g. DP/V1, token transfer)
RES Reserve: “active break” until the equidistant cycle has elapsed
S MD10062 POSCTRL_CYCLE_DELAY (position control cycle offset)

The following setting is recommended as the orientation value for the position
control cycle offset:
TM = TDP – 3*Tpos max
– TDP
The DP cycle time is equivalent to position controller cycle of the SINUMERIK
840Di
– Tpos max
Display using HMI Advanced (Option):
Operating area switchover > Diagnosis > Service displays >
System resources
Error response
S Alarm: “380005 PROFIBUS DP: Bus access conflict, type t, counter z”

Error causes/remedy
S t=1
The position controller cycle offset has been chosen too small. The cyclic
PROFIBUS DP communication with the drives was not yet completed with
the start of the position controller.
Remedy: Increasing the position controller cycle offset.
S t=2
The position controller cycle offset has been chosen too large. The cyclic
PROFIBUS DP communication with the drives started before the position
controller was completed. The position controller requires more
computational time than available within the DP cycle.
– Remedy: Reducing the position controller cycle offset
or
– Remedy: increasing the DP cycle time.
The DP cycle time is set using STEP7 “HW Config”. See Section 7.3,
page 7-211f.

10.3 System data
Interpolation cycle The interpolation cycle can be freely selected in integer multiples of the position
controller cycle.
S MD10070 IPO_SYSCLOCK_TIME_RATIO (factor for the interpolation cycle)
NCK CPU time The processor power of the PCU must be shared between the NC and Win-
share dows NT. By default, the NC is assigned 65%.
The value for the CPU time share of the NC is the maximum value that the NC
will only use in the worst case. If the NCK requires less computation time, it will
cede it dynamically to Windows NT.
TDP
TM
ÉÉÉÉ ÉÉÉÉÉ
NC NC
Part 1 Part 2
ÉÉÉÉ ÉÉÉÉÉ
Windows NT (general) Windows NT (position controller
ÉÉÉÉ ÉÉÉÉÉ
Part 1 Part 2 and
interpolator)

position control
Fig. 10-3 CPU time sharing between Windows NT and NC
Default value In NC machine data
S MD10185: NCK_PCOS_TIME_RATIO (NCK computation time portion)

the maximum CPU time share of the NC is set with reference to a DP cycle. The
default value is 65%.
Individual setting An individual setting can only be made by the following formula:
MD10185 >= 300 * (Tpos max * MD10070 + TIPO max + 0.2msecs) / MD10071
with:
– Tpos max [ms] and TIPO max [ms]: maximum netruntimes of the position controller or
interpolator.
Display on HMI Advanced (optional):
Operating area switchover > Diagnosis > Service displays >
System resources
– MD10070: IPO_SYSCLOCK_TIME_RATIO (factor for interpolation clock pulse)
– MD10071: IPO_CYCLE_TIME (interpolator clock pulse) [ms].

10.3 System data
Note
S The values displayed in menu: System resources of HMI Advanced refer to
the total power of the CPU, not to the CPU time share of the NCK set in MD
10185: NCK_PCOS_TIME_RATIO.
S The values for Tpos max and TIPO max are considerably influenced by ap-
plications active under Windows NT due to cache effects of the PCU proc-
essor. To calculate these value, it is therefore necessary to activate Win-
dows NT applications demanding a lot of CPU time in parallel with execu-
tion of NC parts programs.
When the maximum values for Tpos and TIPO displayed as you proceed as
described above no longer change, you can calculate the above formula
with a value of 200 instead of 300.
The maximum value for the NCK CPU time share of 75% must not be ex-
ceeded. A value greater than 75% can lead to significant impairment (slow-
ing down) of Windows NT applications. If necessary, the values must be
adapted to the system clock cycle/position controller cycle (DP cycle time)
and/or interpolation cycle.
Error response
S Alarm: “4240 CPU time overflow on the IPO or position controller level”
Error causes/remedy
The DP cycle time/position controller cycle, the interpolation cycle, or the NC
CPU time share is set in such a way that not enough CPU time is available for
one of the two cyclic levels of the NC (position controller or interpolator).
Remedy:
Calculate the maximum values for Tpos max and TIPO max (see above) and adjust
the following machine data:
S MD10185: NCK_PCOS_TIME_RATIO (NCK computation time portion)

S MD10070: IPO_SYSCLOCK_TIME_RATIO (factor for interpolation cycle)
S MD10050: SYSCLOCK_CYCLE_TIME (system clock cycle).
Note
You must adjust the system clock cycle by changing the DP cycle time using
STEP7 “HW Config”. To do that, proceed as you would for final parameteriza-
tion of a DP slave 611U. See Subsection 7.3.7, page 7-231f.
References /FB/ Description of Functions, Special Functions

G3 Cycle Times

10.3 System data
Machine data
Table 10-12 Cycle times: Machine data

General ($MN_ ...)
10050 SYSCLOCK_CYCLE_TIME System clock cycle/only display data; is always
equal to the equidistant PROFIBUS DP cycle.
Note: with 840Di, only for display!
10060 POSCTRL_SYSCLOCK_TIME_RATIO Factor for the position control cycle/is set fixed to
the factor 1.
Note: is not displayed with the 840Di
10062 POSCTRL_CYCLE_DELAY Position control cycle offset
10070 IPO_SYSCLOCK_TIME_RATIO Factor for the interpolator cycle/can be freely se-
lected in integer multiples.
Caution
! If you have changed the time cycles, check that the operating response of the
control is correct in all operating modes before ending the start-up process.
Note
The smaller the cycle times (PROFIBUS DP cycle) are selected, the higher is
the control quality of the drive and the surface finish of the workpiece.
10.3.9 Velocities
Max. axis velocity The maximum possible axis velocities and spindle speeds depend on the ma-
or spindle speed chine design, drive dynamics and the encoder limit frequency of the individual
drives.
Max. progr. The maximum programmable tool path velocity results from the maximum axis
tool path velocity velocities of the axes involved in the path programmed.
Max. tool path The maximum tool path velocity at which traversing is possible within a parts
velocity program block results as follows:
progr. path length in parts program [mm or degrees]
Vmax
IPO cycle [secs]
Upper limit To guarantee that parts program blocks are executed continuously (control mar-
gin), the NC limits the tool path velocity within a parts program block to 90% of
the max. possible tool path velocity as follows:

10.3 System data
progr. path length in parts program [mm or degrees]

Vmax * 0, 9
IPO cycle [secs]
For example, in the case of parts programs generated by means of CAD sys-
tem, which contain extremely short blocks, this limiting of the path velocity can
result in a strong reduction of the path velocity over several parts program
blocks.
The function “Online compressor” can help to avoid such sudden velocity dips.
References: /PGA/ Programming Guide Advanced
Section: Compressor COMPON/COMPCURVE
Lower limit The minimum tool path or axis velocity at which traversing is possible results
from:
Vmin 10 3
Computational resolution[mm orIncr.
degrees
] * IPO cycle [secs]
(for the computational resolution, see: Subsection 10.3.1,

page 10-281)
If Vmin is not reached, no traversing movement is carried out.
References /FB/ Description of Functions, Basic Machine

G2 Velocities, Traversing Ranges, Accuracies,
Section: Velocities

10.4 Memory configuration
Hardware The dynamic (DRAM) or static (SRAM) memory available in each case depends
configuration on the hardware configuration of the components used (PCU and MCI board)
and the memory available for SINUMERIK 840Di.
DRAM DRAM for SRAM SRAM

max. 840Di 1) physical virtual 2)
PCU 50 256MB Approx. 16MB – 3MB
MCI board – – 1MB –
1) DRAM component (main memory) occupied by SINUMERIK 840Di and thus no longer
available for Windows NT.
2) Virtual SRAM resides in main memory (DRAM) during operation of the

SINUMERIK 840Di and retentive on the hard disk of the PCU.
User data The memory areas of the user data are preset to expedient values during gen-
eral reset of the NC. The size of the individual areas can be set for optimized
utilization of the user memory, e.g. for:
S Parts programs
S Tool management
S Tool offset
S User variables
S R parameters
S Compensation
S Protection zones
S Frames.
(see Subsection 10.4.2, Page 10-298):
Memory allocation must take place before actual commissioning of the NC,
since all user data are lost when changes to the memory allocation are made
(e.g. parts programs, tool offsets)!
Machine data, setting data and option data are retained after a memory
reorganization.
Activation The MDs for the memory configuration are activated by power ON.
References: /FB/ Description of Functions
S7 Memory Configuration

10.4.1 DRAM memory
Free memory The free DRAM memory is displayed in machine data

S MD18050: INFO_FREE_MEM_DYNAMIC (free dynamic memory).
The free DRAM should not be less than 15,000 bytes.
Caution
Before you enlarge DRAM areas, you should first check whether the free
memory is sufficient:
S MD18050: INFO_FREE_MEM_DYNAMIC (free dynamic memory).

If more dynamic memory is requested than is available, the SRAM and
therefore all user data will be cleared without prior warning on the next NCK
start-up!
Machine data
Table 10-13 Machine data required to configure the DRAM

General ($MN_ ...)
18050 INFO_FREE_MEM_DYNAMIC Display data of the free dynamic memory
18170 MM_NUM_MAX_FUNC_NAMES Number of miscellaneous functions
18180 MM_NUM_MAX_FUNC_PARAM Number of additional parameters
18210 MM_USER_MEM_DYNAMIC User memory in DRAM
18240 MM_LUD_HASH_TABLE_SIZE Hash table size for user variables
18242 MM_MAX_SIZE_OF_LUD_VALUE Maximum field size of the LUD variables
18250 MM_CHAN_HASH_TABLE_SIZE Hash table size for channel-specific data
18260 MM_NCK_HASH_TABLE_SIZE Hash table size for global data
18340 MM_NUM_CEC_NAMES Number of LEC tables
18342 MM_CEC_MAX_POINTS Max. table size for sag compensation
18500 MM_EXTCOM_TASK_STACK_SIZE Stack size for external communication task
18510 MM_SERVO_TASK_STACK_SIZE Stack size of servo task
18520 MM_DRIVE_TASK_STACK_SIZE Stack size of drive task
Channel-specific ($MC_ ...)
20096 T_M_ADDRESS_EXIT_SPINO Spindle number as an address extension /FBW/,
W1
27900 REORG_LOG_LIMIT Percentage of IPO buffer for enabling the log file
28000 MM_REORG_LOG_FILE_MEM Memory size for REORG /FB/, K1
28010 MM_NUM_REORG_LUD_MODULES Number of modules for local user variables with
REORG
28020 MM_NUM_LUD_NAMES_TOTAL Number of local user variables
28040 MM_LUD_VALUES_MEM Memory size for local user variables
28060 MM_IPO_BUFFER_SIZE Number of NC blocks in the IPO buffer
28070 MM_NUM_BLOCKS_IN_PREP Number of blocks for block preparation


28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for Compile cycles
28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for Compile cycles
28105 MM_NUM_CC_HEAP_MEM Heap memory for compile cycle applications
28210 MM_NUM_PROTECT_AREA_ACTIVE Number of simultaneously active protection zones /FB/, A3
28500 MM_PREP_TASK_STACK_SIZE Stack size of preparation task
28510 MM_IPO_TASK_STACK_SIZE Stack size of IPO task
28550 MM_PRSATZ_MEM_SIZE Available memory for internal blocks
38010 MM_QEC_MAX_POINTS Number of values for quadrant error /FB/, K3
compensation /IAD/
10.4.2 SRAM memory
Free memory The free SRAM memory is displayed in machine data

S MD18060: INFO_FREE_MEM_DYNAMIC (free static memory).
The free SRAM should not be less than 15,000 bytes to ensure that data (e.g.
tool offsets) can be read in at all times.
Reconfiguration of Modifying the machine data listed in Table 10-14 results in a reconfiguration of
the SRAM the SRAM with a loss of all user data. Before the change comes into effect in
the NC, the following alarm message is output:
S Alarm: “4400 MD change results in reorganization of the non–volatile

memory (loss of data!)”
Notice
When reconfiguring the SRAM memory, all user data are lost. To prevent data
loss, a series machine start-up file should be created prior to reconfiguration
(see Section 14.2, Page 14-451).
Machine data
Table 10-14 Machine data required to configure the SRAM

General ($MN_ ...)
18060 INFO_FREE_MEM_STATIC Display data of the free static memory
18080 MM_TOOL_MANAGEMENT_MASK Screen form for reserving memory for the tool /FBW/
management
18082 MM_NUM_TOOL Number of tools managed by NCK
18084 MM_NUM_MAGAZINE Number of magazines managed by NCK /FBW/
18086 MM_NUM_MAGAZINE_LOCATION Number of magazine locations /FBW/
18090 MM_NUM_CC_MAGAZINE_PARAM Compile cycles of tool management: Number of /FBW/
magazine data

General ($MN_ ...)

18092 MM_NUM_CC_MAGLOC_PARAM Compile cycles of tool management: Number of /FBW/
magazine location data
18094 MM_NUM_CC_TDA_PARAM Compile cycles of tool management: Number of /FBW/
TDA data
18096 MM_NUM_CC_TOA_PARAM Compile cycles of tool management: Number of /FBW/
TOA data
18098 MM_NUM_CC_MON_PARAM Compile cycles of tool management: Number of /FBW/
monitor data
18100 MM_NUM_CUTTING_EDGES_IN_TOA Number of tool offsets in NCK
18118 MM_NUM_GUD_MODULES Number of GUD modules
18120 MM_NUM_GUD_NAMES_NCK Number of global user variables
18130 MM_NUM_GUD_NAMES_CHAN Number of channel-specific user variables
18140 MM_NUM_GUD_NAMES_AXIS Number of axis-specific user variables
18150 MM_GUD_VALUES_MEM Memory reserved for global user variables
18160 MM_NUM_USER_MACROS Number of macros
18190 MM_NUM_PROTECT_AREA_NCK Number of protection zones in NCK /FB/, A3
18230 MM_USER_MEM_BUFFERED User memory in SRAM
18270 MM_NUM_SUBDIR_PER_DIR Number of subdirectories
18280 MM_NUM_FILES_PER_DIR Number of files per directory
18290 MM_FILE_HASH_TABLE_SIZE Hash table size for files in a directory
18300 MM_DIR_HASH_TABLE_SIZE Hash table size for subdirectories
18310 MM_NUM_DIR_IN_FILESYSTEM Number of directories in passive file system
18320 MM_NUM_FILES_IN_FILESYSTEM Number of files in passive file system
18330 MM_CHAR_LENGTH_OF_BLOCK Max. length of an NC block
18350 MM_USER_FILE_MEM_MINIMUM Minimum parts program memory
28050 MM_NUM_R_PARAM Number of channel-specific R parameters
28080 MM_NUM_USER_FRAMES Number of settable frames
28085 MM_LINK_TOA_UNIT Allocation of a TO unit to a channel /FBW/,
W1
28200 MM_NUM_PROTECT_AREA_CHAN Number of modules for channel-specific /FB/, A3
protection zones
38000 MM_ENC_COMP_MAX_POINTS Number of intermediate points with interpolatory /FB/, K3
compensation

10.4.3 Virtual SRAM (SW 2.3 and higher)
Virtual SRAM If more user memory is required than is available via the SRAM of the MCI
board, the function “Virtual SRAM” can be used with SW 2.3 and higher.
The “Virtual SRAM” function is activated via HMI Advanced (option) (see Sub-
section 10.10.2, Page 10-399).
Mode of During operation of the NCK, the memory area of the virtual SRAM is physically
functioning located in the main memory (DRAM) of the PCU. When Windows NT is shut
down correctly, this memory area is written to the hard disk of the PCU as reten-
tive memory.
During start–up of the NCK, the “SRAM” data are loaded from the hard disk of
the PCU to the main memory (DRAM) of the PCU and made available to the
NCK again as virtual SRAM. The status of the “SRAM” corresponds to the sta-
tus at the time of last proper shutdown.
Notice
On loss of voltage or on deactivation of the PCU without proper shutdown of
Windows NT beforehand, all user data stored in the virtual SRAM will be lost. A
UPS system (see Subsection 1.1.8, Page 1-29) is therefore absolutely neces-
sary in conjunction with the virtual SRAM.
System security The Windows NT system settings stated below can generally prevent loss of
data in the event of a serious exception (Blue Screen) detected by Windows
NT.
The necessary Windows NT system settings are check during start/up of the
SINUMERIK 840Di. If setting are incorrect, a message box appears with the
appropriate text.
The necessary Windows NT system settings have already been made for all
new SINUMERIK 840Di systems delivered. The following systems are excep-
tions:
– PCU50 333MHz / 500MHz with more than 128MB main memory
– PCU50 566MHz / 1,2GHz with more than 256MB main memory
With these systems, the relevant Windows NT system settings must be made
manually during the commissioning phase.

Windows NT The following Windows NT system settings are required:

system settings
1. Startup / Shutdown
Windows NT start bar: Start > Settings > Control Panel > System > Tab:
Startup/Shutdown
System Properties
General Performance Environment

Startup/Shutdown Hardware Profiles User Profiles
System Startup
Startup: ”SINUMERIK” /NoSerialMice
Show list for: 3
Recovery
When a STOP error occurs, do the following:
Write an event to the system log
Send an administrative alert

Write debugging information to:
D:\Memory.dmp.
Overwrite any existing file
Automatically reboot
OK Cancel
Fig. 10-4 Dialog: Windows NT system settings
The following settings must be made:

– Option: “Write debugging information to:” selected
– Drive and file specified.
The file should preferably reside on drive D: to prevent it being stored in
a ghost image, and the file name must be valid according to Windows
NT file name conventions.
– Option: “Overwrite any existing file” selected
If settings are incorrect, the following message box appears:
Alarm: Wrong Windows ”System Properties” settings for Recovery.
OK

2. Virtual Memory
Windows NT start bar: Start > Settings > Control Panel > System > Per-
formance > Virtual Memory

System Properties
Drive: [Volume Label] Paging File Size [MB] OK
C: [DOS]
D: [TMP] Cancel
E: [WinNT] 135 – 200
F: [840DSystem]
Help
Paging File Size for Selected Drives
Drive: E: [WinNT]
Space Available: 560 MB
Initial Size [MB]: 135 MB
Maximum Size [MB]: 200 MB Set
Total Paging File Size for All Drives

Minimum Allowed: 2 MB
Recommended: 75 MB
Currently Allocated: 135 MB
Registry Size
Current Registry Size: 10 MB

Maximum Registry Size [MB]: 13
Fig. 10-5 Dialog: Windows NT system settings
The following setting must be made:

– The size of the Paging Files set (“Paging File Size [MB]”) on the Win-
dows NT drive ( E: [WinNT] )must correspond at least (“Initial Size [MB]”)
to the size of the main memory of the PCU.
If settings are incorrect, the following message box appears:
Alarm: Increase “Initial Size” of pagefile to at least 128 MB.
OK

3. Hard disk storage space

There must be sufficient free space on the hard disk of the PCU to save the
file (D:\Memory.dmp) specified at 1.. If free space is insufficient, the following
message box appears:
Alarm: Not enough disk space for dumpfile on partition D:\.
OK
Note
To ensure that there is also sufficient storage space o n the hard disk of the
PCU in the event of an error, the storage space required for the function “Virtual
SRAM” is reserved immediately on selection of the function
(see Subsection 10.10.2, Page 10-399).
Notice
After acknowledging the relevant message box, start–up of the SINUMERIK
840Di is continued. Following start–up, the control operates normally, even if
the settings that caused the alarm are not corrected.
The user data will then be lost however if a subsequent serious exception Win-
dows NT (Blue Screen) then occurs. In the start–up of the SINUMERIK 840Di
that follows, the last valid version on the user data are loaded to the virtual
SRAM and the follwoing alarm issued (also refer to Loss of data, Page
10-304):
S Alarm: “4065 non–volatile memory restored from hard disk
(data loss possible)”
Serious exception If a serious exception (Blue Screen) occurs, an appropriate message box ap-
(Blue Screen) pears. SINUIMERIK 840Di NCK and PLC continue to operate normally. To pre-
vent loss of user data, Windows NT must be terminated by one of the following
means:
S Interface signal: “PC shutdown” (see Subsection 16.1.1, Page 16-499)

S UPS signal: “Shutdown” (see Subsection 10.10.2, Page 10-399ff)
The SINUMERIK 840Di must not be deactivated until the all the required data
have been saved on the hard disk of the PCU.
The following sequence of operations must be observed:
1. After the occurence of a serious exception (Blue Screen), the user has un-
limited time to switch off the SINUMERIK 840Di
(the serious exception and further processing of the SINUMERIK 840Di
NCK and PLC are displayed to the user via a message on screen).

2. At the time when the user switches off the system, the UPS takes charge of
the supply voltage for the SINUMERIK 840Di. Correct termination of Win-
dows NT must now be requested via one of the shutdown signals described
above.
3. After request for correct shutdown of Windows NT by the shutdown signal,
the standard Windows NT Blue Screen appears with a message to indicate
that the memory dump has been started:
– Beginning dump of physical memory
– Dumping physical memory to disk:
4. On completion of the memory dump, Windows NT issues the following mes-
sage:
– Physical memory dump complete
– Contact your system administrator or technical support group
5. The UPS can now switch off the power to the SINUMERK 840Di.
The next start–up of the SINUMERIK 840Di takes considerably longer due to
the necessary restoring activities. The following message box appears to inform
the user:
Alarm: Restoring NCK user data after BlueScreen,

this may take a while.
OK
Notice
The control must not be switched off / terminated until start–up of the SINUM-
ERIK 840Di is complete. Otherwise, all user data will be lost (requiring re/com-
missioning of the SINUMERIK 840Di–NCK and PLC).
Data loss If the memory area of the virtual SRAM could not be written to the hard disk of
the PCU, e.g. because the control was switched off without correctly terminating
Windows NT, the current user data are lost.
During the next start–up of the SINUMERIK 840Di that follows, the last valid
version on the user data are loaded to the virtual SRAM. The SINUMERIK
840Di is thus ready again immediately.
The user data or the operating state of the SINUMERIK 840Di must be checked
to see whether they are suitable to be worked with in the future. It might be nec-
essary to perform commissioning of the SINUMERIK 840Di NC and PLC again.
The following alarm is displayed:
S Alarm: “4065 Battery-backed memory has been restored from the hard
disk (possible data loss)”
For safety reasons, the alarm must be acknowledged explicitly by the operator
before performing the necessary NCK POWER ON reset.
See Subsection 10.10.1, Page 10-395ff.

10.4.4 DRAM file system (SW 2.2 and higher)
Function For historical reasons, the passive file system of the NCK in which the user
data, such as parts programs, user cycles, etc. are located is in the SRAM area
of the NCK.
The SINUMERIK 840Di has retained this system architecture, among other rea-
sons, because of the increased data security:
– Data retention also in case of a power fail event
– Protection from overwriting because no access to this memory area is
possible by Windows NT applications.
The function DRAM file system permits relocation of data areas are in the
SRAM area of the NCK by default into the DRAM file system by activating a
machine data. The memory that that releases in the SRAM can be used, for
example, for more or larger parts programs.
Retentive back- Because when you switch off the NCK, the memory content of the DRAM is lost,
ground memory the DRAM file system requires a retentive background memory. The DRAM file
system is reloaded from this retentive background memory every time the NCK
is booted. On the SINUMERIK 840Di, the hard disk of the PCU is used as the
background memory.
Clearing the To ensure data consistency, not only the entire SRAM but also the retentive
NC memory background memory of the DRAM file system is cleared with the function “Clear
NC data”, for example, before restart-up of the NCK.
Machine data The maximum size of the DRAM file system in Kbytes can be set in the ma-
chine data:
S MD18351: MM_DRAM_FILE_SIZE (size of DRAM file system).
To ensure system compatibility with the SINUMERIK 840D, the DRAM file sys-
tem of the SINUMERIK 840Di requires configuration of a flash file system (FFS).
The size of the FFS in Kbytes can be set in the machine data:
S MD18332: MM_FLASH_FILE_SYSTEM_MEM_SIZE (size of the FFS)
Notice
The size of the DRAM file system and the FFS should currently be set to be
equal, but in any case, the FFS must be greater than or equal to the DRAM file
system.
The max. size per file system is 4MB.
Cycles In SW 2.2 and higher, Siemens, machine manufacturer and user cycles can be
swapped to the DRAM file system. This swapping has no effect on the use of
the cycles.

Option Relocation of cycles into the DRAM file system is an option:

“Cycle storage separate from the CNC user memory”
Relocation of cycles The cycle areas that are to be relocated into the DRAM file system are selected
in the machine data:
S MD11290: DRAM_FILESYSTEM_MASK (selection of directories in the
DRAM)
– Bit 0 = 1: Siemens cycles (CST)
– Bit 1 = 1: Machine manufacturer cycles (CMA)
– Bit 2 = 1: User cycles (CUS)
Saving cycles Selection of the cycle areas to be saved to retentive background memory on a
NCK power ON reset (reboot) or correct termination of Windows–NT is carried
out per machine data:
S MD11291: DRAM_FILESYST_SAVE_MASK (select directory backup to
DRAM)
– Bit 0 = 1: Siemens cycles (CST)
– Bit 1 = 1: Machine manufacturer cycles (CMA)
– Bit 2 = 1: User cycles (CUS)
On account of the preset value of the machine data, all cycle areas are saved in
the retentive background memory per default.
Loading cycles On loading a series machine start-up file or one of the individual cycles to the
NCK, the cycles are first written to the retentive background memory and then
load to the DRAM file system when the function is selected.
Changing relocated Cycles relocated into the DRAM file system can be changed (edited). The
cycles changes take effect immediately. Retentive storage of the changes in the back-
ground memory is not effected until the next:
– “NCK power ON reset” (warm start)
– Proper shutdown of Windows NT.
Notice
If the SINUMERIK 840Di is switched off or if a “serious exception” (blue screen)
has occurred although
– “NCK power ON reset” (warm start)
– Proper shutdown of Windows NT
has not been performed, all changes to the cycles made until that time will be
lost.
Alarms The following error status can occur in connection with relocation of cycles into
the DRAM file system:
S Too little memory available in the DRAM file system

During start-up of the NCK, the cycles are loaded from the background
memory into the DRAM file system. If the configured memory is no longer
sufficient during loading, from this time on cycles still to be loaded will be
loaded into the SRAM file system. If there is insufficient space in the SRAM,
too, loading is stopped and the following alarm is output:
– Alarm: “6690 cycles from the NC card cannot be copied into the passive
file system”
Remedy:
Adaptation of the DRAM file system size in the machine data:
– MD18351: MM_DRAM_FILE_MEM_SIZE (size of DRAM file system)
S Too little memory available in the FFS

When a cycle is stored in the DRAM file system, it is also stored in the FFS.
If there is not enough free space in the FFS, the following alarm is output:
– Alarm: “6691 cycles in the passive file system cannot be saved on the
NC card”
Remedy:
Adaptation of the FFS size in the machine data:
– MD18332: MM_FLASH_FILE_SYSTEM_SIZE (size of the FFS)
or deletion of cycles from the DRAM file system (the cycles are also deleted
from the FFS).
11290: DRAM_FILESYSTEM_MASK (selection of directories in the DRAM)
S Changed cycles cannot be saved in the background memory.

If the control is switched off although the cycles have not been saved in the
background memory, the following alarm is output the next time the NC
starts up:
– Alarm: “6692 cycle has been lost”.
Machine data
Table 10-15 Machine data required to configure the FFS

General ($MN_ ...)
11290 DRAM_FILESYSTEM_MASK Select directories in DRAM
($MM_ ... )
18332 FLASH_FILE_SYSTEM_SIZE Size of the Flash File System (FFS)
18351 DRAM_FILE_MEM_SIZE Size of the DRAM file system

10.5 Axes and spindles
10.5.1 Axis configuration
Definition The term “axis” is often used either as a single term in conjunction with SINUM-
ERIK 840Di or as a compound, e.g. machine axis, channel axis, etc. To provide
an overview of the philosophy used as the basis, this term will be explained
here in brief.
Generally, 3 types of axes are distinguished:
1. Coordinate axes
2. Machine axes
3. Geometry and special axes.
Coordinate Coordinate axes (abscissa, ordinate, applicate) are the axes of a Cartesian
axes coordinate system.
Machine axes Machine axes are the motion units existing on a machine, which can also be
designated as linear or rotary axes, depending on their useable movement.
Geometry and The geometry and special axes serve to program traversing movements in
special axes parts programs.
Channel axes The total of all machine, geometry and special axes assigned to a channel is
designated as channel axes.
In this context, the geometry and special axes constitute the program-techno-
logical part of the machining process, i.e. they are used for programming in the
parts program.
The machine axes constitute the physical part of the machining process, i.e.
they carry out the programmed traversing movements on the machine.
Geometry axes The geometry axes constitute the rectangular Cartesian basic coordinate sys-
tem of a channel.
Generally, (Cartesian arrangement of the machine axes) direct imaging of the
geometry axes to the machine axes is possible. If the arrangement of the ma-
chine axes, however, is not Cartesian at right angles, the imaging is performed
using a kinematic transformation.
Additional axes Additional axes are all other channel axes that are not geometry axes. Unlike
for geometry axes (Cartesian coordinate system), for additionalaxes, no geo-
metrical relation is defined, neither between special axes, nor with respect to the
geometry axes.

The assignment of drives, machine axes, channel axes and geometry axes
using the corresponding machine data is shown in the illustration below.
List of all channel axes

3 of the channel
List of all geometry axes
4
of the channel MD20070: AXCONF_MACHAX_USED[n]
MD20050: AXCONF_GEOAX_ASSIGN_TAB[n] Channel 1
Channel 1 [0] = 1
[0] = 1 [1] = 2
[1] = 2 [2] = 3
[2] = 3 [3] = 4
Special axes
[4] = 5
2 Machine axes of the NC
MD30110: CTRLOUT_MODULE_NR[0]
MD30220: ENC_MODULE_NR[0]
Machine axis 1
[0] = 1
Machine axis 2 List of all drives

[0] = 2 1
of the NC
MD13050: DRIVE_LOGIC_ADDRESS[n]
Machine axis 3
[0] = 3 NC
[0] = I/O address of drive
. [1] = I/O address of drive
. [0] = 4 [2] = I/O address of drive
[0] = 5 [5] = I/O address of drive
.
[7] = I/O address of drive
.
[0] = 6
.
.
[0] = 7
.
.
[0] = 8
Fig. 10-6 Axis assignment

1 The machine data
MD13050: DRIVE_LOGIC_ADDRESS[n] (I/O address of the drive)

tells the NC the I/O addresses of the drives defined in the S7 project using “HW
Config”.
The machine data index (n+1) constitutes the logical drive number for the NC.
2
The machine data
MD 30110: #MODULE_NR[0] (setpoint assignment)

MD 30220: ENC_MODULE_NR[0] (actual-value assignment)
are used to assign each individual machine axis to a drive.
The logical drive number m to be entered in the two machine data refers to the
entry with the index n=(m–1) in the list described under Point 1 MD13050:
DRIVE_LOGIC_ADDRESS[n].
3 The machine data
MD 20070: AXCONF_MACHAX_USED[n] (machine axis number valid in

channel)
defines explicitly which channel axis and which machine axis is used and de-
fines implicitly how many channel axes exist in the channel.
The machine axis number m to be entered in the machine data (with m=1,2,3...)
is referred to the appropriate machine axis m.
4
The machine data
MD 20050: AXCONF_GEOAX_ASSIGN_TAB[n] (assignment geometry axis

– channel axis) (n = 0...2)
defines explicitly which channel axis is a geometry axis and defines implicitly
how many geometry axes exist in the channel.
The channel axis number k to be entered in the machine data (k=1,2,3...) is
referred to the entry with the index n (n=(k–1)=0,1,2...) in the list of the channel
axes MD20070: AXCONFIG_MACHAX_USED[n] (see Point 3).

Machine data
Table 10-16 Axis configuration: Machine data

General ($MN_ ...)
13050 DRIVE_LOGIC_ADDRESS I/O address of drive
20050 AXCONF_GEOAX_ASSIGN_TAB Assignment of geometry axis to channel axis
20070 AXCONF_MACHAX_USED Machine axis number valid in channel
30110 CTRLOUT_MODULE_NR Setpoint assignment
30220 ENC_MODULE_NR Actual-value assignment

K2 Axes, Coordinate Systems, Frames, Actual-Value System for
Workpiece IWS, Section: Axes
10.5.2 Axis names
Each machine, channel and geometry axis can/must be assigned an individual

name unambiguously identifying it in its name range.
Machine axes The machine data
MD10000: AXCONF_MACHAX_NAME_TAB [n] (machine axis name)

is used to define the machine axis names.
Machine axis names must be unambiguous for the entire NC.
The names and the corresponding index defined in the machine data above is
used for
accessing axis-specific machine data (loading, saving, displaying)

reference point approach from the parts program G74
measuring
test point traversing from the parts program G75
traversing the machine axis from PLC
display of axis-specific alarms
display in the actual-value system (machine-related)
DRF handwheel function.

Channel axes The machine data
MD 20080: AXCONF_CHANAX_NAME_TAB[n] (name of the channel axis

in the channel)
is used to define the channel axis names.
Channel axis names must be unambiguous for the entire channel.
Geometry axes The machine data
MD 20060: AXCONF_GEOAX_NAME_TAB[n] (name of the geometry axis

in the channel)
is used to define the geometry axis names.
Geometry axis names must be unambiguous for the entire channel.
The axis names for channel and geometry axes are used in the parts program
for programming general traversing movements or to describe the workpiece
contour. The axis names are used for
path axes
synchronized axes
positioning axes
command axes
spindles
gantry axes
coupled-motion axes
master value coupling axes.
Machine data
Table 10-17 Axis names: Machine data

General ($MN_ ...)
10000 AXCONF_MACHAX_NAME_TAB[n] Machine axis name
20060 AXCONF_GEOAX_NAME_TAB Geometry axis in the channel
20080 AXCONF_CHANAX_NAME_TAB Name of channel axis/special axis in the channel

Workpiece IWS,
Section: Axes

10.5.3 Drive configuration
I/O addresses TIn order to allow the NC to communicate with the drives connected to PROFI-
BUS DP, it must know the I/O addresses of setpoint and actual value of the
axes.
The I/O addresses of the axes set in the SIMATIC S7 project are entered in
MD13050: DRIVE_LOGIC_ADDRESS[n] (logical I/O address)
For parameterizing the drives with regard to PROFIBUS DP, see

Default values The default values of the machine data are dimensioned such that they leave
sufficient distance per axis with one measuring circuit each, beginning from I/O
address 272 (the I/O addresses from 256 plus 16 bytes for the PLC are re-
served for the PROFIBUS drives):
Default values
MD13050: DRIVE_LOGIC_ADDRESS[n] = 272 + n*20
Notice
Any changes in the I/O addresses must be carried out consistently:
DP slave 611U (SIMATIC S7 project, HW Config): I/O address for set-

point and actual value
NC: MD13050: DRIVE_LOGIC_ADDRESS[n]

Message The message frame type describes the data volume and the data structure of
frame type the message frames exchanged between NC and drive on PROFIBUS DP dur-
ing the cyclic communication.
For parameterizing the message frame type, see Section 7.3, page 7-211.
Note
You will find a detailed description of the message frame structure of each mes-
sage frame type in the following documents, in each case in Section: Commu-
nication on PROFIBUS DP:
SIMODRIVE 611 universal and universal E:
SIMODRIVE POSMO A
References: /POS1/ User Manual SIMODRIVE POSMO A
SIMODRIVE POSMO SI/CD/CA
ADI4
References: /Subsection 7.3.6; page 7-220.

The message frame type defined in the S7 project is entered in machine data
MD13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)
Default values The default values of the machine data refer to the default message frame type
of SIMODRIVE 611 universal with 1 or 2 axes per drive module and 1 motor
encoder per axis.
Notice
A change of the message frame type has to be carried out consistently:
DP slave 611U (SIMATIC S7 project, HW Config): Message frame type

NC: MD13060: DRIVE_TELEGRAM_TYPE[n].
SIMODRIVE 611 universal: Parameter P0922 message frame selection
PROFIBUS
Notice
The order of the drives to which reference is made in the machine data
MD13050: DRIVE_LOGIC_ADDRESS[n]
MD13060: DRIVE_TELEGRAM_TYPE[n].
must be identical in both machine data.
ADI4 With an ADI4 module you can operate up to 4 drives with analog setpoint inter-
face on an isochronous PROFIBUS.
In addition to performing the above mentioned drive configuration, for these
drives you also need to deactivate all the SIMODRIVE 611U-specific DP func-
tions that are active by default. In the drive-specific machine data:
MD13070: DRIVE_FUNCTION_MASK (DP functions being used)

you must enter the hexadecimal value 0FH for each drive operated via ADI4.
Machine data
Table 10-18 Drive configuration: Machine data

General ($MN_ ...)
13050 DRIVE_LOGIC_ADDRESS[n] Logical I/O address of drive G2
13060 DRIVE_TELEGRAM_TYPE[n]. Drive message frame type for the drives con- G2
nected to PROFIBUS DP
13070 DRIVE_FUNCTION_MASK[n] 611U-specific DP functions in use

10.5.4 Setpoint/actual value channels
Note
In order to guarantee that the control runs up reliably, all machine axes are de-
clared as simulation axes (without hardware).
MD 30130: CTRLOUT_TYPE (setpoint output type) = 0

MD 30240: ENC_TYPE (actual-value acquisition mode) = 0
Traversing of the axes in servo mode is simulated without speed setpoint out-
put, and no hardware-specific alarms are output.
The machine data
MD 30350: SIMU_AX_VDI_OUTPUT (output of axis signals with simula-

tion axes)
can be used to select whether the interface signals of a simulation axis are
output at the PLC interface (e.g. during program test, if there is no drive hard-
ware).
Assignment of the For each machine axis that a drive is to be assigned,

setpoint/actual-
value channels
a setpoint channel and
at least one actual-value channel
must be parameterized.
A second actual-value channel can be set up as an option.
Notice
The motor measuring system is always used for the speed control function.
Motor and motor measuring system must therefore always be connected to the
same drive module.
In the two axis-specific machine data:
MD 30110: CTRLOUT_MODULE_NR[0] (setpoint assignment: logic drive

number)
MD 30220: ENC_MODUL_NR[n] (actual-value assignment: logic drive num-

ber)
must always be entered the same logic drive number m of the drive represent-
ing the machine axis.
The entered value m refers to the drive whose I/O address is defined under the
index n = (m–1) in MD13050: DRIVE_LOGIC_ADDRESS[n] (see Subsection
10.5.3, page 10-313).
NCK reset Once the drive configuration and setpoint/actual value assignment have been
parameterized, an NCK reset must be executed to initiate a warm restart. After
the NC has powered up, the set configuration is effective.

Measuring system The interface signals

switchover
DB31, ... DBX1.5 (position measuring system 1 selected)
DB31, ... DBX1.6 (position measuring system 2 selected)
can be used to switch from the PLC between the two position measuring
systems of a machine axis.
References: /FB/ Description of Functions, Basic Machine
A2, Various Interface Signals
Machine data
Table 10-19 Setpoint/actual-value channels: Machine data

30100 CTRLOUT_SEGMENT_NR Setpoint assignment: Drive type
5 = PROFIBUS DP
30110 CTRLOUT_MODULE_NR Setpoint assignment: Logical drive number
30130 CTRLOUT_TYPE Setpoint output type
0 = simulation
1 = speed setpoint output
30200 NUM_ENCS Number of measuring channels
1 = one position measuring system installed
2 = two position measuring systems installed
30210 ENC_SEGMENT_NR[0] Actual-value assignment: Drive type
5 = PROFIBUS DP
30220 ENC_MODULE_NR[0] Actual-value assignment: Logic drive number for
position measuring system 1
30230 ENC_INPUT_NR[0] Actual-value assignment: Position encoder 1
1 = motor measuring system
2 = direct measuring system
30230 ENC_INPUT_NR[1] Actual-value assignment: Position measuring sys-
tem 2
1 = motor measuring system
2 = direct measuring system
30240 ENC_TYPE[0] Actual-value acquisition modes
0 = simulation
1 = incremental encoder
4 = absolute encoder with EnDat interface
Interface signals
Table 10-20 Switching over the position measuring system: Interface signals
DB Bit, Byte Name Ref.
Number
Axis/spindle-specific Signals from PLC to axis/spindle
31, ... 1.5 Position measuring system 1
References /FB/ Description of Functions, Basic Machine

G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control
Section: Setpoint/actual-value system

/FB/ Description of Functions, Basic Machine

A2 Various Interface Signals
Section: Interface signals to axis/spindle
10.5.5 Parameterization of incremental measuring systems
Rotary measuring The diagrams below show the general possibilities of arranging a rotary
system incremental measuring system with regard to motor and load, as well as the
resulting values for the appropriate machine data.
Linear axis with

rotary encoder ENC_IS_LINEAR_=0 IS_ROT_AX=0
on the motor n
Encoder ENC_IS_DIRECT=0
Meas. Load
ÍÍÍÍÍ
gearbox gearbox Table
F M Ball screw
nSpindle LEADSCREW_PITCH
nMotor
ENC_RESOL
DRIVE_AX_RATIO_NUMERA Motor revs

=
DRIVE_AX_RATIO_DENOM Spindle revs
DRIVE_ENC_RATIO_NUMERA Motor revs

DRIVE_ENC_RATIO_DENOM Encoder revs
Fig. 10-7 Linear axis with motor-mounted rotary encoder
Linear axis with

rotary encoder DRIVE_AX_RATIO_NUMERA Motor revs
on the machine =
ENC_IS_DIRECT=1
ÍÍÍÍÍ
IS_ROT_AX=0
Meas. ENC_IS_LINEAR_=0
ÍÍÍÍÍ
Table gearbox
M F
Leadscrew ENC_RESOL
Load
gearbox LEADSCREW_PITCH
ENC_TYPE=1
n n n ENC_IS_LINEAR=0
Motor Spindle Spindle n
Encoder
ENC_RESOL
Motor revs DRIVE_ENC_RATIO_NUMERA

=
Encoder revs DRIVE_ENC_RATIO_DENOM
Fig. 10-8 Linear axis with machine-mounted rotary encoder

Rotary axis with

motor-mounted
n
rotary encoder ENC_IS_DIRECT=0
Load
n
Encoder
Meas. Load IS_ROT_AX=1 Rotary table
gearbox gearbox
F M L
n DRIVE_AX_RATIO_NUMERA Motor revs

Motor =
DRIVE_AX_RATIO_DENOM Encoder revs
ENC_TYPE=1
ENC_IS_LINEAR=0 DRIVE_ENC_RATIO_NUMERA Motor revs
=
ENC_RESOL DRIVE_ENC_RATIO_DENOM Encoder revs
ENC_IS_DIRECT=0
Fig. 10-9 Rotary axis with motor-mounted rotary encoder
Rotary axis with

machine-mounted ENC_TYPE=1
rotary encoder ENC_IS_LINEAR=0
n ENC_IS_DIRECT=1
ENC_RESOL
Motor
n Load ENC_IS_DIRECT=1
n
Load Meas. Encoder
gearbox gearbox
M L F
DRIVE_ENC_RATIO_NUMERA Encoder revs

=
IS_ROT_AX=1

=
Fig. 10-10 Rotary axis with machine-mounted rotary encoder
Machine data
Table 10-21 Incremental measuring systems: Machine data

30240 ENC_TYPE[n] Actual-value acquisition modes
1 = incremental signal generator
30242 ENC_IS_INDEPENDENT[n] Encoder is independent
30300 IS_ROT_AX Rotary axis R2
31000 ENC_IS_LINEAR[n] Direct measuring system (linear scale)
31020 ENC_RESOL[n] Encoder lines per revolution
31030 LEADSCREW_PITCH Leadscrew pitch
31040 ENC_IS_DIRECT[n] Encoder is directly mounted on the machine
31050 DRIVE_AX_RATIO_DENOM[n] Load gear denominator
31060 DRIVE_AX_RATIO_NUMERA[n] Load gear numerator
31070 DRIVE_ENC_RATIO_DENOM[n] Denominator of resolver gearbox
31080 DRIVE_ENC_RATIO_NUMERA[n] Numerator of resolver gearbox

Linear measuring The diagrams below show the general possibilities of arranging a rotary
system incremental measuring system with regard to motor and load, as well as the
resulting values for the appropriate machine data.
Linear axis with

linear scale
=
DRIVE_AX_RATIO_DENOM spindle revs
IS_ROT_AX=0
ÍÍÍÍÍÍ
Table
Leadscrew
M
LEADSCREW_PITCH
Load gearbox
Linear scale
ENC_IS_LINEAR=1
ENC_IS_DIRECT=1
ENC_GRID_POINT_DIST
ENC_FEEDBACK_POL= [1 or -1]
Fig. 10-11 Linear axis with linear scale
Machine data
Table 10-22 Linear measuring system: Machine data

1 = incremental signal generator
31010 ENC_GRID_POINT_DIST[n] Pitch period for linear scales
32110 ENC_FEEDBACK_POL[n] Sign of actual value (control direction)

10.5.6 Parameterization of absolute measuring systems
Encoder types SINUMERIK 840Di currently supports the following absolute encoders:
EQN 1325
EQN 1325 Manufacturer of the absolute encoder EQN 1325 is Heidenhain. It is also pos-
sible to use compatible encoders of other manufacturers.
The absolute encoder EQN 1325 has the following properties:
Voltage signals sin/cos 1Vpp

EnDat interface
2,048 pulses/revolution
4,096 revolutions.
Measuring An absolute encoder can currently exclusively be used as a motor encoder (in-
systems direct measuring system).
Linear axis with

motor-mounted DRIVE_ENC_RATIO_NUMERA Motor revs
rotary absolute ENC_IS_LINEAR=0
ENC_IS_DIRECT=0 IS_ROT_AX=0
encoder
n
Encoder
ÍÍÍÍÍÍ
Load
gearbox
ÍÍÍÍÍÍ
Table
F M Ball screw
Meas.
gearbox nSpindle LEADSCREW_PITCH
nMotor
ENC_TYPE=4
ENC_ABS_TURNS_MODULO=4096
ENC_REFP_MODE=2 =
Fig. 10-12 Linear axis with motor-mounted rotary absolute encoder

Rotary axis with

motor-mounted DRIVE_ENC_RATIO_NUMERA Motor revs
=
rotary absolute DRIVE_ENC_RATIO_DENOM Encoder revs
ENC_IS_LINEAR=0
encoder
ENC_IS_DIRECT=0 n
Load
n
Encoder
Load IS_ROT_AX=1 Rotary table
gearbox
F M L
Meas.
gearbox
n DRIVE_AX_RATIO_NUMERA Motor revs
ENC_TYPE=4 Motor =
ENC_ABS_TURNS_MODULO=4096
ENC_REFP_MODE=2
Fig. 10-13 Rotary axis with motor-mounted rotary absolute encoder
Machine data
Table 10-23 Incremental measuring systems: Machine data

4 = absolute encoder with EnDat interface
0=motor-mounted encoder
31070 DRIVE_ENC_RATIO_DENOM[n] Resolver gearbox denominator
31080 DRIVE_ENC_RATIO_NUMERA[n] Resolver gearbox numerator
34200 ENC_REFP_MODE[n] Referencing mode
2=absolute encoder
34210 ENC_REFP_STATE[n] State of absolute encoder
0 = encoder not adjusted (default setting)
1 = encoder adjustment enabled; encoder not yet
adjusted
2 = encoder adjusted
34200 ENC_ABS_TURNS_MODULO[n] Range of absolute encoder with rotary encoders R2

10.5.7 Parameterization of a 2nd measuring systems with ADI4
A maximum of 2 measuring systems can be configured for one machine axis. If

direct connection of the 2nd measuring system to the associated drive module
is not possible, an ADI4 module can be used for this purpose.
Note
For detailed information on measuring systems that can be connected to the
ADI4, please refer to:
References: /ADI4/ Analog Drive Interface for 4 Axes
Section: Hardware Description
Sample The sample configuration below illustrates the general procedure for configuring
configuration the NC for a 2nd measuring system of a machine axis connected via ADI4. The
following assumptions are made:
NC
2 measuring systems should be parameterized for the 1st machine axis.
– 1st measuring system: Motor measuring system of drive
– 2nd measuring system: Direct measuring system
Drive
A SIMODRIVE 611U 1 axis module with connection option for a measuring
system (motor sensor) is used as a drive.
ADI4
The 2nd measuring system is connected via the sensor interface of the 1st
axis of an ADI4 module (generally, connection is possible to any axis of the
ADI4 module)
Configuration The associated configuration is shown in Fig. 10-14.
840Di (configuration) –– 611U_ADI4

PROFIBUS(1): DP master system (1)
(0) 840Di
2 PLC315–2DP (10) SIMOD (15) ADI4
X2 DP Master
4 S7 FM NCU.
Fig. 10-14 Configuration Axis with 2nd measuring systems on ADI4

I/O addresses and The I/O addresses and messages frame types for the drive and ADI4 axis are
message frame set to the following values during configuration:
types Drive
– I/O address: 258
– Message frame type: Message frame 102
DP slave properties
General Configuration Clock synchroniza- Encoder

tion
1 axis, Messsage frame 102, PZD-6/10
Slot Drive PROFIBUS Partner

Type Adre... Type PR... I/O ad- Length Unit Consis-
4 No PDA dress tency
5 Actual value PDA1 Input 2 258 10 Word Overall length
6 Setpoint PDA1 output 2 258 6 Word Overall length
Fig. 10-15 DP slave properties: SIMODRIVE 611U
ADI4
– I/O address: 472
– Message frame type Standard message frame 3
DP slave properties
General Configuration Clock synchroniza- Encoder

tion
4 axes each with an encoder, standard message frame 3 + IO, PDA-5/9 A
Slot Drive PROFIBUS Partner

Type Address.Type PR... I/O ad- Length Unit Consis-
4 No PKW dress tency
5 Actual value PDA1 Input 2 472 9 Word Overall length
6 Setpoint PDA1 output 2 472 5 Word Overall length
Fig. 10-16 DP slave properties: ADI4
NC machine data The general and axis–specific NC machine data must then be set as follows:
Drive assignment
The axis of the SIMODRIVE 611U drive module is assigned to the NC as 1st
machine axis. This is done by entering its I/O address and the message frame
type under Index 0:
MD13050: DRIVE_LOGIC_ADRESS[0] = 258
MD13060: DRIVE_TELEGRAM_TYPE[0] = 102
The I/O address and the message frame type of the 1st axis of the ADI4 module
is entered in the next free machine data (e.g. Index 3):
MD13050: DRIVE_LOGIC_ADRESS[3] = 472
MD13060: DRIVE_TELEGRAM_TYPE[3] = 3

Assigning the actual value channels

The 1st measuring system (Index 0) of the machine axis on the measuring input
of the SIMODRIVE 611U drive module is assigned via the axis–specifiec ma-
chine data:
MD 30220: ENC_MODUL_NR[0] = 1
where 1 = (Index 0 of the relevant MD13050 + 1)
The 2nd measuring system (Index 1) of the machine axis on the measuring cir-
cuit input of the ADI4 module is assigned via the axis–specific machine data:
MD 30220: ENC_MODUL_NR[1] = 4
where 4 = (Index 3 of the relevant MD13050 + 1)
Also refer to Subsection 10.5.4, Page 10-315.
Machine data
Table 10-24 Drive configuration: Machine data

General ($MN_ ...)
13050 DRIVE_LOGIC_ADDRESS[n] Logical I/O address of drive G2
13060 DRIVE_TELEGRAM_TYPE[n]. Drive message frame type for the drives con- G2
nected to PROFIBUS DP
Interface signals
Table 10-25 Switching over the position measuring system: Interface signals
DB Bit, Byte Name Ref.
Number

10.5.8 DSC (Dynamic Servo Control) (SW 2.1 and higher)
The DSC function eliminates the deadtime that necessarily exist at the speed
setpoint interface normally used between the NC and drive due to relocation of
the position controller into the drive.
That results in the following advantages for an axis operated with DSC:
Considerably improved fault response/stability of the position control loop

Improved control behavior (contour precision) if the higher servo gain
(KV factor) that can be set in conjunction with DSC is used.
A reduction of the cyclic communication load on the PROFIBUS, if the posi-

tion controller cycle/PROFIBUS cycle is reduced by adjusting the above
parameters even if the control loop performance is the same.
Note
The speed feedforward control can be used in conjunction with DSC.
Prerequisites Before you can activate DSC mode, the following preconditions must be fulfilled:
DSC-capable drive, e.g.:

A DSC-capable message frame type has been parameterized in the S7 proj-

ect for the drive (see Subsection 7.3.7, page 7-233).
Switch ON/OFF The DSC function is switched ON in the axis-spec. NC machine data
MD32640: STIFFNESS_CONTROL_ENABLE (dyn. stiffness control)
If DSC operation is switched ON or OFF, it might be necessary to adjust the

following machine data:
MD32200: POSCRTL_GAIN (KV factor)

MD32610: VELO_FFW_WEIGHT (feedforward control factor)
MD32810: EQUIV_SPEEDCTRL_TIME (substitute time const. of the closed
speed control loop).
Notice
Before you can switch off DSC operation you might have to adapt (reduce) the
KV factor of the axis. Otherwise, instability of the position control loop might
result.

Speed setpoint If you use DSC, a speed setpoint filter for rounding the speed setpoint steps is
filter no longer necessary. The speed setpoint filter is then only of any use with differ-
ence injection to support the position controller, for example, to suppress reso-
nance.
Measuring system DSC is only possible in conjunction with the motor measuring system.
Machine data
Table 10-26 DSC: Machine data

32640 STIFFNESS_CONTROL_ENABLE dyn. stiffness control DD2
32200 POSCRTL_GAIN KV factor G2
10.5.9 Drive Optimization
Optimization of the control loop (current, speed, and position control loop) of the
drives can be performed with:
HMI Advanced (see Chapter 13, page 13-417)

– All drives
Start-up tool SimoCom U

– SIMODRIVE 611 universal/E
Note
You will find detailed information about frequency measurement and optimiza-
tion of the SIMODRIVE 611 universal/E, POSMO CD/CA and SI drives in the
online help of the start-up tool SimoCom U under:
Menu command: Help > Help topics > Index
– Measuring function
– Optimization of speed control loop.
10.5.10 Rotary axes
Rotary axes A machine axis is parameterized as a rotary axis in
MD 30300: IS_ROT_AX = 1 (rotary axis)

The machine data is a scaling machine data. A change results in a conversion
of all machine data of the machine axis with length-related units.

For the recommended procedure with respect to scaling machine data, please
refer to Subsection 10.3.3, page 10-285.
Modulo display The machine data
MD30300: DISPLAY_IS_MODULO (modulo 360 degrees display for rotary

axes)
is used to display the rotary axis position modulo 360 degrees.
Endlessly rotating The machine data

rotary axis
MD 30310: ROT_IS_MODULO (modulo conversion for rotary axis)
is used to traverse the rotary axis modulo 360 degrees. The limit switches are
not monitored during this process. The rotary axis can thus rotate endlessly.
Machine data
Table 10-27 Rotary axes: Machine data

General ($MN_ ...)
30300 IS_ROT_AX Axis is rotary axis
30310 ROT_IS_MODULO Modulo conversion for rotary axis
30320 DISPLAY_IS_MODULO Actual-value display modulo
36100 POS_LIMIT_MINUS Software limit switch minus A3
36110 POS_LIMIT_PLUS Software limit switch plus A3
Setting data
Table 10-28 Rotary axes: Setting data

General ($SN_ ...)
41130 JOG_ROT_AX_SET_VELO JOG speed for rotary axes H1
Axis-specific ($SA_...)
43430 WORKAREA_LIMIT_MINUS Work area limiting minus A3
43420 WORKAREA_LIMIT_PLUS Work area limiting plus A3
References /FB/ Description of Functions, Extended Functions

R2 Rotary Axes

10.5.11 Positioning axes
Positioning axes are channel axes traversing parallel to the path axes without
interpolating with them.
Positioning axes can be traversed either from the parts program or from the
PLC.
Concurring The machine data

positioning axes
MD30450: IS_CONCURRENT_POS_AX (concurr. positioning axis) = 1
is used to assign the PLC a channel axis by default. To traverse it from the parts
program later, it must be requested explicitly using a parts program statement
(GET).
Positioning axis If a positioning axis is programmed in the parts program without specifying an
feedrate axis-specific feedrate, the feedrate entered in
MD32060: POS_AX_VELO (initial setting for positioning axis velocity

will apply to this axis automatically.
This feedrate will apply until an axis-specific feedrate is programmed in the
parts program for this axis.
Machine data
Table 10-29 Positioning axes: Machine data

22240 AUXFU_F_SYNC_TYPE Output time for F functions H2
30450 IS_CONCURRENT_POS_AX Concurring positioning axis
32060 POS_AX_VELO Feedrate for positioning axis
Interface signals
Table 10-30 Positioning axes: Interface signals
DB number Bit, Byte Name Ref.

31,... 0 Feedrate override, axis-specific
31,... 2.2 Delete distance-to-go, axis-specific
Signals from axis/spindle to PLC
31,... 74.5 Positioning axis
31,... 78–81 F function (feedrate) for positioning axis
References /FB/ Description of Functions, Extended Functions,

P2 Positioning axes

10.5.12 Indexing axes
Indexing axis are rotary or linear axes that may only be traversed within their
traversing range to defined positions, the indexing positions.
Traversing to indexing positions using the parts program or manually is only
effective if the corresponding machine axis has been successfully referenced.
The indexing positions are stored in tables.
Indexing axis The machine data
MD 30500: INDEX_AX_ASSIGN_POS_TAB[n] (axis is indexing axis)

assigns the machine axis the relevant table of indexing positions and also
defines the machine axis as an indexing axis.
Indexing position The indexing positions are stored in one of 2 possible tables.
tables
MD10900: INDEX_AX_LENGTH_POS_TAB_1 (number of positions of in-
dexing table 1)
MD10910: INDEX_AX_POS_TAB_1[n] (indexing position table 1)
MD10920: INDEX_AX_LENGTH_POS_TAB_2 (number of positions of in-

dexing table 2)
MD10930: INDEX_AX_POS_TAB_2[n] (indexing position table 2)
Machine data
Table 10-31 Indexing axes: Machine data

General ($MN_ ...)
10260 CONVERT_SCALING_SYSTEM Basic system switch active G2
10270 POS_TAB_SCALING_SYSTEM Unit system of position tables
10900 INDEX_AX_LENGTH_POS_TAB_1 Number of indexing positions used in Table 1
10910 INDEX_AX_POS_TAB_1[n] Indexing position table 1
10920 INDEX_AX_LENGTH_POS_TAB_2 Number of indexing positions used in Table 2
10930 INDEX_AX_POS_TAB_2[n] Indexing position table 2
Axis/spindle-specific ($MA_ ...)
30310 ROT_IS_MODULO Modulo conversion for rotary axis R2
30320 DISPLAY_IS_MODULO Position display “Modulo 360°” R2
30500 INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis
30501 INDEX_AX_NUMERATOR Counter for indexing axes with equidistant positions

Interface signals
Table 10-32 Indexing axes: Interface signals

Axis/spindle-specific Signals from axis/spindle to PLC
31,... 60.4, 60.5 Referenced/synchronized 1, referenced/synchronized 2 R1
31,... 76.6 Indexing axis in position

T1 Indexing Axes
10.5.13 Parameter sets of axis/spindle
Per machine axis, 6 parameter sets are available. They are used as follows:
with one axis:

for accommodation of the own dynamic response to another machine axis,
e.g. when tapping or thread cutting.
with a spindle:
quick accommodation of the position controller to modified properties of the
machine during operation, e.g. when switching the gearbox.
Tapping, thread The following applies to axes:

cutting
For a machine axis that is not involved in tapping or thread cutting, the 1st
set of parameters (index=0) is active in all cases.
All further sets of parameters need not be taken into account.
For machine axes involved in tapping or thread cutting, the parameter sets
corresponding to the current gear stage of the spindle becomes active.
All sets of parameters corresponding to the gear stages of the spindle have
to be parameterized.
The following applies to spindles:
With spindles, each gear stage is assigned a parameter set of its own. The
parameter set is selected from the PLC using the interface signal DB31, ...
DBX16.0 – 16.2 (actual gear stage).
All sets of parameters corresponding to the gear stages of the spindle have
to be parameterized.
For example, in HMI Advanced, the active parameter set of a machine axis is
displayed in the control area “DIAGNOSIS” in the screen form “Service Axis”.

Spindle gear
Parameter set no. Axis Spindle stage
Default Axis mode As specified by

0 manufacturer
Axis interpolates
1 Spindle mode 1.
with spindle (G33)
Axis interpolates Spindle mode 2nd
2 with spindle (G33)
Axis interpolates Spindle mode 3rd
3 with spindle (G33)
Axis interpolates
4 Spindle mode 4th
with spindle (G33)
Axis interpolates
5 Spindle mode 5th
with spindle (G33)
Fig. 10-17 Validity of parameter sets in axis and spindle modes
Machine data The following machine data of a machine axis depend on the parameter set:
n = parameter set number (0 ... 5)
Table 10-33 Parameter set-dependent machine data

Axis/spindle-specific ($MA_ ...)
32200 POSCTRL_GAIN[n] Kv factor
32810 EQUIV_SPEEDCTRL_TIME[n] Equivalent time constant of speed control loop for feed-
forward control
32910 DYN_MATCH_TIME[n] Time constant of dynamic adaptation
35110 GEAR_STEP_MAX_VELO[n] Max. speed for gear stage change
35120 GEAR_STEP_MIN_VELO[n] Min. speed for gear stage change
35130 GEAR_STEP_MAX_VELO_LIMIT[n] Max. speed of gear stage
35140 GEAR_STEP_MIN_VELO_LIMIT[n] Min. speed of gear stage
35200 GEAR_STEP_SPEEDCTRL_AC- Acceleration in speed control mode
CEL[n]
35210 GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode
36200 AX_VELO_LIMIT[n] Threshold value for velocity monitoring

10.5.14 Position controller
Closed-loop The closed-loop control of a machine consists of the cascaded closed-loop

control circuits control circuits of current controller, speed controller and position controller.
SINUMERIK 840Di PROFIBUS DP drive
Setpoint position
from
Position Speed Current
interpolator nset iset
controller controller controller Encoder
Motor
nact iact
Actual current value
Actual speed value
Actual position
Fig. 10-18 Closed-loop control circuits
Traversing If the axis does not traverse into the desired direction, the appropriate
direction adaptation is made in
MD32100: AX_MOTION_DIR (traversing direction).

The value “–1” reverses the direction of motion.
Control direction If the control direction of the position measuring system is incorrect, it can be
adjusted with
MD32110: ENC_FEEDBACK_POL (sign of actual value).
Loop gain In order to obtain high contour accuracy, a high loop gain (KV factor) of the
position controller is required. However, an excessively high KV factor causes
overshoot, instability and impermissibly high machine loads.
The maximum permissible KV factor is dependent on the dynamic response of
the drive and the mechanical system of the machine.
If “0” is entered for the loop gain factor, the position controller will be discon-
nected.

Definition of the The servo gain factor is defined as the ratio of velocity in m/min and the
KV factor resulting following error in mm
Velocity [m/min]
KV =
Following error [mm]
i.e. with a Kv factor of 1 and a velocity of 1 m/min, the following error will be
1 mm.
MD32200: POSCTRL_GAIN[n] (loop gain)

is used to specify the Kv factor of the machine axis.
Note
To adapt the input/output unit of the Kv factor selected by default to the internal
unit [1/sec], the following machine data are assigned by default:
MD 10230: SCALING_FACTORS_USER_DEF[9] = 16.666667

MD 10220: SCALING_USER_DEF_MASK = ’H200’; (bit no. 9 as a hex-
adecimal value)
When entering the servo gain factor, take into account that the amplification
factor of the entire position control loop is also dependent on other parameters
of the controlled system.
These factors are:
MD32260: RATED_VELO
MD32250: RATED_OUTVAL
Tacho adjustment on the speed controller
Tacho generator on drive.
Notice
Machine axis that interpolate one with another must have the same following
error at the same velocities.
This can be achieved by setting the same KV factor or dynamic response
adaptation in:
MD32900: DYN_MATCH_ENABLE
MD32910: DYN_MATCH_TIME.
The real servo gain factor can be checked with the following error in the service
display.
e.g. HMI Advanced: Operating area “DIAGNOSIS” > Service displays >
Service axis.

Checking the If a KV factor is already known for the machine in question, this can be set and
servo gain checked. For checking, reduce the acceleration of the axis in
MD32300: MAX_AX_ACCEL (axis acceleration)

to make sure that the drive does not reach its current limit when accelerating
and decelerating.
The KV factor must also be checked for high speeds of the rotary axis and
spindle (e.g. for spindle positioning, tapping).
The approach behavior at various speeds can be checked by means of a
storage oscilloscope or the HMI Advanced servo trace software. The check is
made on the basis of the speed setpoint.
nset nset
[V] [V]
“Poor” “Good”
Selected Kv factor Selected Kv factor
t [msec] t [msec]
Fig. 10-19 Speed setpoint curve
No overshoots may occur while the drive is approaching the static statuses; this
applies to all speed ranges.
Overshoot in the The reasons for an overshoot in the control loop can be:
control loop Acceleration too high (current limit is reached)
Error in speed controller (reoptimization necessary)
Mechanical backlash
Mechanical components canted.
For safety reasons set the KV factor to a little less than the maximum possible
value.
The real KV factor must precisely match that set because monitoring functions
are derived from the KV factor that would otherwise respond (e.g. contour
monitoring).
Acceleration The machine axes are accelerated and decelerated at the acceleration entered
in
MD 32300: MAX_AX_ACCEL (axis acceleration)
This value should allow the axes to be accelerated and positioned rapidly and
accurately while ensuring that the machine is not unduly loaded.
Default values The default values of the acceleration are in the range from 0.5 m/sec2 to 2 m/
sec2

Checking the The sign of a properly adjusted acceleration of a machine axis is acceleration
acceleration and positioning free from overshoot at rapid traverse rate and maximum load
(heavy workpiece).
After the acceleration has been entered, the axis is traversed rapidly and the
actual current values and current setpoint are recorded.
Note
With SIMODRIVE 611 universal drives, the current actual value and the current
setpoint can be recorded using the SimoCom U start-up tool (trace function).
For further information, please refer to the online help of SimoCom U.
This recording shows whether the drive reaches the current limit. During this,
the current limit can be reached for a short time.
However, the current must be well below the current limit before the rapid tra-
verse velocity or the final position is reached.
Slight load changes during machining must not cause the current limit to be
reached. Excessive current during machining causes falsification of the contour.
For this reason, the acceleration value should be a little bit less than the maxi-
mum acceleration value.
Machine axes can have different acceleration values, even if they interpolate
with each other.
Machine data
Table 10-34 Position control: Machine data

32100 AX_MOTION_DIR[n] Traversing direction
32110 ENC_FEEDBACK_POL[n] Sign of actual value
32200 POSCTRL_GAIN[n] Servo gain
32300 MAX_AX_ACCEL[n] Axis acceleration
32900 DYN_MATCH_ENABLE[n] Dynamic adaptation
32910 DYN_MATCH_TIME[n] Time constant of dynamic adaptation

G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control,
Section: Closed loop control

10.5.15 Speed setpoint matching
In speed setpoint matching the NC is informed for parameterization of the axial

control and monitoring which motor speed in the drive corresponds to which
speed setpoint. Speed setpoint matching can be performed automatically or
manually.
Automatic It is possible to perform automatic speed setpoint matching if the drive supports
matching acyclic services on the PROFIBUS DP
Acyclic services on the PROFIBUS DP are supported by the following
SIMODRIVE drives:
– SIMODRIVE 611 universal/E
and the value 0 must be entered in machine data:
MD32250: RATED_OUTVAL (rated output voltage) [ % ]
During start-up of the NC, speed setpoint matching between the NC and the
drive is then performed automatically.
Note
If automatic speed setpoint matching fails for one axis, the following message
is output on a traverse request for his axis:
Message “Wait, axis enable missing”
This axis and any axes that interpolate with it are not traversed.
Manual If a value not equal to 0 is entered in machine data

matching
the NC assumes that speed setpoint matching will be performed manually.
SIMODRIVE The rated motor speed entered in axis-specific matching data:

611 universal/E
MD32260: RATED_VELO (rated motor speed) [ rev/min ]
POSMO CD/CA
POSMO SI with reference to 100% must be equal to the speed evaluation entered in the
drive (P880):
P880: Speed evaluation PROFIBUS [rpm] (ARM/SRM) or

[ m/min ] (SLM)
SINUMERIK 840Di-NC SIMODRIVE 611 universal.

MD32260: RATED_VELO
* 100 = P880

ADI4 Because ADI4 does not support acyclic services on the PROFIBUS DP, manual
speed setpoint matching must be performed.
In the two axis-specific NC machine data:
MD32260: RATED_VELO (rated motor speed) [ rev/min ]

the reference between the speed setpoint set by the NC and the associated
output voltage at the setpoint output of the ADI4 is established (reference volt-
age = 10V).
SINUMERIK 840Di-NC ADI4

MD32260: RATED_VELO 2 10V *
100
Note
The max. upper limit for the speed setpoint is set in machine data
MD 36210: CTRLOUT_LIMIT (max. speed setpoint) [ % ]
Values greater than 100% make sense in connection with ADI4 because the
DACs of the ADI4 limit the output voltage to 10V.
Calculation of the If the motor speed required for speed setpoint matching is not known directly, it
motor speed can be calculated as follows with reference to the required axis velocity (linear
axis) or load speed (rotary axis/spindle):
Motor speed for linear axis

MD 31060: DRIVE_RATIO_NUMERA
vAxis *
MD31050: DRIVE_RATIO_DENOM
=
nMotor
MD31030: LEADSCREW_PITCH
Motor speed for rotary axis/spindle

MD 31060: DRIVE_RATIO_NUMERA
nMotor = nLoad *
MD31050: DRIVE_RATIO_DENOM
– vAxis [ mm/min ]
– MD31060: DRIVE_RATIO_NUMERA (numerator load gearbox)
– MD31050: DRIVE_RATIO_DENOM (denominator load gearbox)
– MD31030: LEADSCREW_PITCH (pitch of the ball screw) [ mm/rev ]
– nMotor [ rpm ]
– nLoad [ rpm ]

Checking Incorrect speed setpoint matching has a negative impact on the real servo gain
matching of the axis.
To check speed setpoint matching it is necessary for a defined traverse velocity
to compare the actual following error with the desired following error that should
be set if speed setpoint matching is correct.
Traversing velocity
Desired following error =
MD32200: POSCTRL_GAIN
– Desired following error [ mm ]
– Traversing velocity [ m/min ]
– MD32200: POSCTRL_GAIN (KV factor) [ (m/min)/mm ]
The actual following error is displayed in the axis-specific service data:

HMI Advanced:
Operating area switchover > Diagnosis > Service displays > Service
axis/spindle
Machine data
Table 10-35 Speed setpoint matching: Machine data

32250 RATED_OUTVAL Rated output voltage G2
32260 RATED_VELO[n] Rated motor speed G2

Section: Velocities, traversing Ranges, accuracies

10.5.16 Drift compensation
Digital drives Digital drives are not subject to drift or compensate for it automatically.
ADI4 Because ADI4 does not support acyclic services on the PROFIBUS DP, drift
compensation must be performed manually by entering the appropriate
compensation value in the axial machine data
MD36720 DRIFT_VALUE (basic drive value)
Manual Manual drift compensation is performed with the axis at zero speed as follows:
drift compensation
Requirements
– Zero speed of the axis
– Axis enables pending
Speed-controlled axis
The drift causes constant traversing of the axis. To compensate for the drift,
the compensation value is incremented/decremented step by step depend-
ing on the direction of the drift until the axis reaches zero speed.
Position-controlled axis
The drift causes a constant following error or position setpoint , 0. To com-
pensate for the drift, the compensation value is incremented/decremented
step by step depending on the direction of the drift until following error or
position setpoint = 0 is displayed.
HMI Advanced:
Operating area switchover > Diagnosis > Service displays > Service
axis/spindle
Warning
! If an axis is used for the function DSC (Direct Servo Control)
MD32640: STIFFNESS_CONTROL_ENABLE (dyn. stiffness control) = 1

drift compensation must not be enabled for that axis.
Drift compensation causes extreme speed fluctuations during switch-on/off of
the DSC function.
Machine data
Table 10-36 Drift compensation: Machine data

36720 DRIFT_VALUE Basic drift value G2

10.5.17 Velocity adaptation of axis
Max. axis velocity The value entered in machine data
MD32000: MAX_AX_VELO[n] (max. axis velocity)

is the limit velocity up to which a machine axis can accelerate (rapid traverse
limiting). It depends on the machine and drive dynamics and the limit frequency
of actual-value acquisition.
The max. axis velocity is used for traversing in the parts program when rapid
traverse (G00) is programmed.
Depending on MD30300: IS_ROT_AX[n], the maximum linear and rotary axis
velocity must be entered in the machine data.
Rapid traverse in The value entered in machine data

JOG mode
MD 32010: JOG_VELO_RAPID[n] (rapid traverse in JOG mode) or
MD32040: JOG_REV_VELO_RAPID[n] (revolutional feedrate in JOG mode
with rapid traverse override)
is the velocity at which the machine axis traverses in JOG mode with the rapid
traverse override key actuated and with an axial feedrate override of 100%.
The entered value may not exceed the max. permissible axis velocity.
This machine data will not be used for the programmed rapid traverse G00.
Axis velocity in The value entered in machine data

JOG mode
MD32020: JOG_VELO[n] (axis velocity in JOG mode) or
MD32050: JOG_REV_VELO[n] (revolutional feedrate in JOG mode)
is the velocity at which the machine axis traverses in JOG mode with an axial
feedrate override of 100%.
The velocity defined in MD32020: JOG_VELO[n] or MD32050:
JOG_REV_VELO[n] will only be used if
for linear axes: SD41110: JOG_SET_VELO = 0
for rotary axes: SD41130: JOG_ROT_AX_SET_VELO = 0

or
at revolutional feed: SD41120: JOG_REV_SET_VELO = 0.

If the above mentioned setting data are unequal to 0, the JOG velocity results
as follows:
1. SD: JOG_REV_IS_ACTIVE (revolutional feedrate in JOG mode) = 0
=> linear feed (G94)
Linear axes:
JOG speed = SD41110: JOG_SET_VELO (JOG velocity for G94)
Rotary axes:
JOG speed = SD41130: JOG_ROT_AX_SET_VELO (JOG velocity for
rotary axes)
2. SD: JOG_REV_IS_ACTIVE (revolutional feedrate in JOG mode) = 1
JOG speed SD41120: JOG_REV_SET_VELO (JOG speed with G95)

The entered value may not exceed the max. permissible axis velocity.
Notice
Depending on MD30300: IS_ROT_AX[n], the velocities have to be entered

in mm/min, inch/min, or rpm.
If the velocities change, MD 36200: AX_VELO_LIMIT[n] (threshold value for

velocity monitoring) must be adapted accordingly.

Machine data
Table 10-37 Velocities: Machine data

30300 IS_ROT_AX[n] Rotary axis
32000 MAX_AX_VELO[n] Maximum axis velocity G2
32010 JOG_VELO_RAPID[n] Conventional rapid traverse
32020 JOG_VELO[n] Conventional axis velocity
32040 JOG_REV_VELO_RAPID[n] Revolutions feedrate in JOG mode with rapid tra-
verse override
32050 JOG_REV_VELO[n] Revolutional feedrate in JOG mode
32060 POS_AX_VELO Reset position for positioning axis velocity P2
32250 RATED_OUTVAL Rated output voltage
32260 RATED_VELO[n] Rated motor speed
Setting data
Table 10-38 Velocities: Setting data

General ($SN_ ...)
41100 JOG_REV_IS_ACTIVE Revolutional feedrate in JOG mode active
41110 JOG_SET_VELO JOG velocity for linear axes (for G94)
41120 JOG_REV_SET_VELO JOG velocity (for G95)
41130 JOG_ROT_AX_SET_VELO JOG speed for rotary axes
41200 JOG_SPIND_SET_VELO JOG velocity for the spindle

Section: Velocities, traversing Ranges, accuracies
/FB/ Description of Functions – Extended Functions,

H1JOG with/without handwheel

10.5.18 Monitoring functions of axis
Static monitoring The static monitoring functions with reference to a machine axis are:
functions
Exact stop coarse Window around the setpoint position within which exact stop coarse is detected.
MD36000: STOP_LIMIT_COARSE (exact stop coarse)

IS: DB31,... DBX60.6 (position reached with exact stop coarse).
Exact stop fine Window around the setpoint position within which exact stop fine is detected.
MD 36010: STOP_LIMIT_FINE (exact stop fine)

IS: DB31,... DBX60.7 (position reached with exact stop coarse).
Delay time Delay time after which the actual value must have reached the tolerance
Exact stop fine window “Exact stop fine” when the setpoint position is reached.
MD 36020: POSITIONING_TIME (exact stop fine delay time)

Alarm: “25080 Positioning monitoring” and follow-up mode”.
Standstill position Position tolerance which a standing machine axis may not leave.
tolerance
MD36030: STANDSTILL_POS_TOL (standstill position tolerance)
Alarm: “25040 Zero speed control” and follow-up mode”.
Delay time Delay time after which the actual value must have reached the tolerance
Zero speed control window “Standstill position tolerance” when the setpoint position is reached.
MD36040: STANDSTILL_DELAY_TIME (zero speed control delay time)

Alarm: “25040 Zero speed control” and follow-up mode”.
Clamping tolerance Tolerance window for a standing machine axis while the signal “Clamping
process running” is present at the PLC interface.
MD36050: CLAMP_POS_TOL (clamping tolerance)

IS: DB31,... DBX2.3 (clamping process running)
Alarm: “26000 Clamping monitoring”.

S IS: “Exact stop coarse”
IS: “Exact stop fine”

Actual value
IS “Clamping process
running”
CLAMP_POS_TOL
Setpoint
STANDSTILL_POS_TOL
STOP_LIMIT_COARSE
STOP_LIMIT_FINE
Time t
STANDSTILL_
DELAY_TIME
POSITIONING_TIME
Fig. 10-20 Static monitoring functions
Working area The permissible working area of the machine axes can be adapted to the partic-
limitation ular machining situation using the “dynamic” working area limitation.
SD43400: WORKAREA_PLUS_ENABLE (working area limitation active in

the positive direction)
SD43410: WORKAREA_PLUS_ENABLE (working area limitation active in

the negative direction)
SD43420: WORKAREA_LIMIT_PLUS (working area limitation plus)

SD43430: WORKAREA_LIMIT_MINUS (working area limitation minus)
Alarm: “10630 Axis reaching operating range limit +/–”
Alarm: “10631 Axis is at operating range limit +/– (JOG)”
Alarm: “10730 Progr. end point is behind operating range limit +/–”.
Software Two software limit switch pairs are provided per machine axis. The active soft-
limit switches ware limit switch pair is selected in the PLC.
MD36100: POS_LIMIT_MINUS (1st software limit switch minus)

MD36110: POS_LIMIT_PLUS (1st software limit switch plus)
MD36120: POS_LIMIT_MINUS (2nd software limit switch minus)

MD36130: POS_LIMIT_PLUS (2nd software limit switch plus)

IS: DB31,... DBX12.2 (2nd software limit switch minus)
IS: DB31,... DBX12.3 (2nd software limit switch plus)
Alarm: “10620 Axis reaching software limit switch +/–”
Alarm: “10621 Axis is at software limit switch +/– (JOG)”
Alarm: “10720 Progr. end point is behind software limit switch +/–”.
Notice
All position monitoring functions are only active with valid reference point of the
corresponding reference point of the machine axis.
Hardware If the PLC signals that a hardware limit switch has been reached, the machine
limit switches axis is stopped with the parameterized brake response.
IS: DB31, ... DBX12.1 (hardware limit switch plus)

IS: DB31, ... DBX12.0 (hardware limit switch minus)
MD 36600: BRAKE_MODE_CHOICE (brake response at the hardware limit
switches)
0 = brake characteristic is observed
1 = rapid deceleration with setpoint “0”
Alarm: “21614 hardware limit switch [+/–]”.
EMERGENCY
STOP
Working 2nd software 1. software Hardware

area limit switch limit switch limit switch
limitation plus plus plus
plus (activated in PLC) Mechanical
traversing end
plus
Fig. 10-21 Overview of end limitations
Dynamic The dynamic monitoring functions with reference to a machine axis are:
monitoring
functions
Speed setpoint The speed setpoint monitoring prevents that the max. admissible motor speed
monitoring is exceeded.
It must be set such that the max. speed (rapid traverse) can be reached and, in
addition, a certain control margin remains.

MD36210: CTRLOUT_LIMIT[n] (maximum speed setpoint in %)
SIMODRIVE 611 The max. permissible motor speed is specified in P1401:0 “Speed for max.
universal useful motor speed” of the SIMODRIVE 611 universal assigned to the machine
axis.
SIMODRIVE 611 MD36210: CTRLOUT_LIMIT[n] corresponds to P1405:0 “Monitoring speed of

universal motor” of the SIMODRIVE 611 universal assigned to the machine axis.
Speed setpoint [ %]
100% MD 36210: CTRLOUT_LIMIT[n]
e.g. MD 36210: CTRLOUT_LIMIT[n+1]

80% (for test mode)
Fig. 10-22 Speed setpoint limiting
MD 36220: CTRLOUT_LIMIT_TIME[n] (delay time for speed setpoint

monitoring)
defines how long the speed setpoint may remain within the limits before the
speed setpoint monitoring responses.
Error response
ALARM: “25060 Speed setpoint limiting”

and stopping the machine axis using a speed setpoint ramp whose
characteristic is set in
MD36610: AX_EMERGENCY_STOP_TIME (time of brake ramp in case of

error conditions).
Error causes/remedy
A control loop or drive error is present.

Too high setpoint specifications (accelerations, velocities, reducing factors)
Obstacle in work area (e.g. positioning on a working table)
=> Remove obstacle.
The speed setpoint consists of the speed setpoint of the position controller and
the feedforward control parameter (if feedforward control is active).

Feedforward control value
+ to speed
Kv controller
Following
error
Speed
setpoint
Position controller monitoring
Fig. 10-23 Speed setpoint calculation
Notice
The limitation of the speed setpoint will turn the control loop into a nonlinear
control loop.
Generally, this will result in deviations from the contour and longer dwelling of
the machine axis within the speed setpoint limitation.
Actual velocity Monitoring due to the actual velocity of the machine axis determined based on
monitoring the encoder values
MD 36020: AX_VELO_LIMIT (threshold value for speed monitoring)

Error response
Alarm: “25030 Alarm limit of actual velocity”


error conditions).
Error causes/remedy
Check speed setpoint cable

Check actual values
Check direction of position control
Threshold value for velocity monitoring is possibly too low.
Contour Monitoring of the difference between following error measured and following
monitoring error calculated from the position setpoint.
MD36400: CONTOUR_TOL (contour monitoring tolerance band)

Error response
Alarm: “25050 Contour monitoring”


error conditions).
Error causes/remedy
Contour errors are due to signal distortions in the position-control loop.
Remedy:
Enlarge tolerance band

Check the Kv factor.
The real servo gain must correspond to the desired servo gain set by MD
32200: POSCTRL_GAIN[n].
HMI Advanced
Operating area: DIAGNOSIS > Service displays > Service of axis
Check optimization of speed controller

Check easy movement of axes
Check machine data for traversing movements
(feed override, acceleration, max. speeds, ...)
When operating with feedforward control:

MD 32810: EQUIV_SPEEDCTRL_TIME (equivalent time constant of speed
control loop for feedforward control)
If the machines are set too inexactly, MD 36400: CONTOUR_TOL must be
increased.
Encoder Monitoring of the cut-off frequency of the encoder of a machine axis.

cut-off frequency
monitoring
MD 36300: ENC_FREQ_LIMIT (encoder cut-off frequency)
Error response
Alarm: “21610 Encoder frequency exceeded”

IS: DB31, ... DBX60.2 “Encoder cut-off frequency exceeded 1”
IS: DB31, ... DBX60.3 “Encoder cut-off frequency exceeded 2”

error conditions).
Error causes/remedy
The position control resumes automatically after the axes have stopped.
Notice
The axis concerned must be re-referenced.

Encoder The zero mark monitoring of the encoder of a machine axis checks whether
zero mark pulses were lost between two zero mark passes.
monitoring
MD 36310: ENC_ZERO_MONITORING (zero mark monitoring)
is used to enter the number of detected zero mark errors at which the
monitoring is to respond.
Special feature:
A value of 100 will additionally disable the hardware monitoring of the encoder.
Error response
Alarm: 25020 Zero mark monitoring”

and stopping the machine axes using a speed setpoint ramp whose

error conditions).
Error causes/remedy
MD36300: ENC_FREQ_LIMIT [n] (encoder limit frequency) set too high

Encoder cable damaged
Encoder or encoder electronics defective.
Position tolerance It is possible to switch over between the two possible encoders or position
when switching over measuring systems of a machine axis at any time. The permissible position
the encoder difference between the two position measuring systems is monitored.
MD 36500 ENC_CHANGE_TOL (maximum tolerance when switching over

the actual position value)
Error response
Alarm: “25100 Measuring system cannot be switched over”

The requested switchover to another encoder is not carried out.
Error causes/remedy
The specified permissible tolerance is too small

The position measuring system to which you will switch over is not
referenced.
Cycl. monitoring of The position difference between the two encoder or position measuring systems
encoder of a machine axis is monitored with
position tolerance
MD36510 ENC_DIFF_TOL (measuring system synchronism tolerance)
Error response
Alarm: “25105 Measuring systems are not synchronous”

and stopping the machine axes using a speed setpoint ramp whose

error conditions).

AX_EMERGENCY_STOP_TIME
Setpoints from Braking

Setpoint Position ramp Speed set-
interpolator processing controller point
CTRLOUT_LIMIT
Control loop
model
PROFIBUS DP
drive
ENC_CHANGE_TOL
CONTOUR_TOL ENC_DIFF_TOL ENC_ZERO_MONITORING
ENC_FREQ_LIMIT
Following error Actual-value
STSTILL_VELO_TOL processing 1
STOP_LIMIT_COURSE
STOP_LIMIT_FINE AX_VELO_LIMIT Actual-value
POSITIONING_TIME processing 2
STANDSTILL_DELAY_TIME
STANDSTILL_POS_TOL IS “Position measuring system 1/2 active”
CLAMP_POS_TOL
Fig. 10-24 Monitoring functions with SINUMERIK 840Di
Notice
MD 36620: SERVO_DISABLE_DELAY_TIME (servo enable cutout delay)

must always be selected greater than
MD 36610: AX_EMERGENCY_STOP_TIME (time of brake ramp in case of

error conditions).
If this is not the case, the braking ramp cannot be kept.

A3 Axis Monitoring, Protection Zones

10.5.19 Referencing an axis
Referencing When referencing a machine axis, the actual position value system of the ma-
chine axis is synchronized with the machine geometry.
Depending on the encoder type used, the machine axis is referenced with or
without traversing movements.
Reference point For all machine axes which are not equipped with an encoder providing an ab-
approach solute actual position value, referencing is carried out by traversing the machine
axis, the so-called reference point approach.
The reference point approach can be carried out either manually in JOG mode,
submode REF, or using a parts program. Reference point approach is started
using traversing keys PLUS or MINUS (depending on the parameterized refer-
ence point approach direction).
Incremental With incremental measuring systems, referencing is carried out using a

measuring reference point approach divided into 3 phases:
systems 1. Traversing to the reference cam
2. Synchronizing to the encoder zero marker
3. Approach reference point.
Phase-independent The following machine data and interface signals are independent with re-
data spect to the individual phases of reference point approach:
MD11300: JOG_INC_MODE_LEVELTRIGGRD (INC/REF in jog mode)

MD34000: REFP_CAM_IS_ACTIVE (axis with reference cam)
MD34110: REFP_CYCLE_NR (axis sequence with channel-specific refer-
ence point approach)
MD 30240: ENC_TYPE (encoder type)

Set MD 34200: ENC_REFP_MODE (referencing mode)
IS: DB21, ... DBX1.0 (“Activate referencing”)
IS: DB21, ... DBX33.0 (“Referencing active”).

IS “Reference point approach delay”

(DB31, ... DBX12.7)
IS “Traversing command plus”

(DB31, ... DBX64.7)
IS “Traversing command minus”

(DB31, ... DBX64.6)
IS “Traversing key plus/minus”

(DB31, ... DBX4.7 and 4.6)
IS “Referenced/synchronized”
(DB31, ... DBX60.4 and 60.5)
Zero marker of position
measuring system
Velocity
MD 34020: REFP_VELO_SEARCH_CAM
Reference-point approach velocity
MD 34070: REFP_VELO_POS
Reference-point positioning velocity
MD 34040: REFP_VELO_SEARCH_MARKER
Reference-point shutdown velocity
t
Phase 1 Phase 2 Phase 3
Fig. 10-25 Referencing sequence with incremental measuring system (example)
Phase 1: The following machine data and interface signals are important:
Traversing to the
reference cam
MD34010: REFP_VELO_SEARCH_CAM (reference cam approach in the
negative direction)
MD34020: REFP_VELO_SEARCH_CAM (reference cam approach velocity)

MD34030: REFP_MAX_MARKER_DIST
(maximum distance to reference cam)
MD 34092: REFP_CAM_SHIFT (electr. cam offset, incremental measuring

systems with equidistant zero markers)
IS: DB21, ... DBX36.2 (“All axes to be referenced are referenced”

IS: DB31, ... DBX4.7/DBX4.6 (“Traversing keys plus/minus”)
IS: DB31, ... DBX12.7 (“Reference point approach delay”)
IS: DB31, ... DBX60.4, DBX60.5 (“Referenced/synchronized 1, 2”).

Properties of phase 1:
The feed override (the feed override switch) is active
The feed stop (channel-specific and axis-specific) is active
The machine axis can be stopped and started again using NC Stop/NC Start
If the machine axis traverses a distance defined in
MD 34030: REFP_MAX_CAM_DIST
(max. distance to the reference cam)
without reaching the reference cam
– IS: DB31, ... DBX12.7 (“Reference point approach delayed”) = 0
the axis stops, and
– alarm 20000 “Reference cam not reached”
is output.
Warning
! If the reference cam is not adjusted exactly, it is possible that a wrong zero
marker is evaluated after the reference cam has been left. As a result, the
control system will take a wrong machine zero.
Software limit switches, protection areas and work area limits will thus also be
active for the wrong positions. The difference corresponds to " one encoder
revolution.
Danger for man and machine exists.
Synchronizing to the
encoder zero marker
MD 34040: REFP_VELO_SEARCH_MARKER (shutdown speed)
MD 34050: REFP_SEARCH_MARKER_REVERSE
(direction reversal to reference cam)
MD 34060: REFP_MAX_MARKER_DIST
(maximum path from cam to reference mark).
Feed override (the feed override switch) is not active.
100% is fixed, an abortion is carried out at 0%
Feed stop (channel-specific and axis-specific) is active. On feed stop the

axis stops and
– Alarm 20005 “Reference point approach canceled”
is output
The machine axis cannot be stopped or restarted using NC Stop/NC Start

If the machine axis travels a distance defined in MD 34060:
DB31, ... DBX12.7 (“Reference point approach delayed”) = 0
– MD 34060: REFP_MAX_MARKER_DIST (max. distance to the

reference mark)
and the zero mark is not detected, the machine axis stops and

– Alarm 20002 “Zero mark missing”

is output.
Traversing to the
reference point
MD34070: REFP_VELO_POS (reference-point positioning velocity)
MD34080: REFP_MOVE_DIST (reference point distance to the zero mark)
MD34090: REFP_MOVE_DIST_CORR (reference-point offset additive)
MD34100: REFP_SET_POS (reference point value).
IS: DB31, ... DBX2.4, 2.5, 2.6, 2.7 (“Reference point values 1...4”)
Feed override (the feed override switch) is active.
Feed stop (channel-specific and axis-specific) is active.
The machine axis can be stopped and started again using NC Stop/NC
Start.
References /FB1/ Description of Functions, Basic Machine,

R1 Reference Point Approach
Section: Referencing with incremental measurement systems

Clearance-coded When clearance-coded reference marks are used, referencing is divided into 2
reference marks phases:
1. Synchronizing by overtraveling 2 reference marks
2. Traversing to target point
IS “Reference point approach delay”

(DB31, ... DBX12.7)
IS “Traversing command minus”

(DB31, ... DBX64.6)
IS “Traversing key plus/minus”

(DB31, ... DBX4.7 and 4.6)
IS “Referenced/synchronized”
(DB31, ... DBX60.4 and 60.5)
Reference marks of length measuring

system
Velocity
MD 34070: REFP_VELO_POS
(Reference-point positioning velocity)
MD 34040:
REFP_VELO_SEARCH_MARKER
(Reference-point shutdown velocity) t
Phase 1 Phase 2
Fig. 10-26 Clearance-coded reference marks
Phase-independent The following machine data and interface signals are independent with re-
data spect to the individual phases of reference point approach:
MD11300: JOG_INC_MODE_LEVELTRIGGRD (INC/REF in jog mode)

MD34000: REFP_CAM_IS_ACTIVE (axis with reference cam)
MD34110: REFP_CYCLE_NR (axis sequence with channel-specific refer-
ence point approach)
MD 30240: ENC_TYPE (encoder type)

Set MD 34200: ENC_REFP_MODE (referencing mode)
MD 34310: ENC_MARKER_INC (interval between two reference marks)
MD 34320: ENC_INVERS (inverse measuring system)
IS: DB21, ... DBX1.0 (“Activate referencing”)
IS: DB21, ... DBX33.0 (“Referencing active”).
Synchronizing by
overtraveling 2
MD34010: REFP_VELO_SEARCH_CAM (reference cam approach in the
negative direction)
reference marks

MD 34040: REFP_VELO_SEARCH_MARKER (referencing speed)

MD34060: REFP_MAX_MARKER_DIST
(maximum path between two reference marks)
MD34300: ENC_REFP_MARKER_DIST
(distance between reference marks)
IS: DB21 ...30, DBX36.2 (“All axes to be referenced are referenced”

IS: DB31, ... DBX4.7/DBX4.6 (“Traversing keys plus/minus”)
IS: DB31, ... DBX12.7 (“Reference point approach delay”)
Properties of phase 1
If the machine axis traverses a distance defined in MD

34300: REFP_MARKER_DIST
(max. distance to the reference mark)
without overtraveling the two reference marks, the machine axis stops
and
– alarm 20004 “Reference mark missing”
is output.
Traversing to the
target point
MD 34070: REFP_VELO_POS (target point positioning velocity)
MD 34090: REFP_MOVE_DIST_CORR (absolute offset)
Set MD 34100: REFP_SET_POS (target point)
MD 34330: REFP_STOP_AT_ABS_MARKER (with/without target point)
Properties of phase 2
The feed override (the feed override switch) is active.
The feed stop (channel-specific and axis-specific) is active.
The machine axis can be stopped and started again using NC Stop/NC
Start.
Determining the To determine the absolute offset between the measuring system zero point and
absolute off-set the machine zero, the following procedure is proposed:
1. Determine the actual position of the measuring system
After two reference marks following one after the other (synchronized) have
been overtraveled, the actual position of the length measuring system can be
read on the user interface at “Actual position”.
MD 34090: REFP_MOVE_DIST_CORR (reference point/absolute offset) must
be zero at this time.
2. Determine the absolute machine actual position
Traverse the machine axis to a position at which the actual machine position
can be exactly measured with reference to machine zero, e.g. using a laser
interferometer.
3. Calculate the absolute offset.

– length measurement system equidirectional to the machine system:

Absolute offset = machine actual position + actual position of
the measuring system
– length measurement system opposite to the machine system:
Absolute offset = machine actual position – actual position of
the measuring system
MD34090: REFP_MOVE_DIST_CORR (reference point/absolute offset)
Warning
! After you have determined the absolute offset and made an entry in
MD34090: REFP_MOVE_DIST_CORR (reference point/absolute offset)

the position measuring system must be re-referenced.

Section: Referencing with linear measurement systems
with distance-coded reference marks
Absolute encoder Referencing of an axis with absolute encoders is carried out automatically when
the NC powers up if the corresponding axis is detected adjusted.
The following two requirements must be fulfilled:
The absolute encoder is adjusted.

Sign: MD 34210: ENC_REFP_STATE[n] = 2
The measuring system of the machine axis, which is active when the NC
powers up, uses the absolute encoder.
The acceptance of the absolute encoder is carried out without axis movement.
Adjustment In the case machine axes are equipped with absolute encoders, the measuring
system is not synchronized by approaching a reference point, but it is adjusted.
When adjusting the axis, the actual value of the absolute encoder is matched
with the machine zero once during the start-up and then enabled.
The adjustment can be carried out in three different ways:
Operator-assisted adjustment
Automatic adjustment with probe
Adjustment with BERO.
Any other kinds of referencing with absolute encoders will not be supported.

The “operator-assisted adjustment” will be described in the following. For the

other two kinds of adjustment, see:
References: /FB/, Description of Functions, Basic Machine
R1, Reference Point Approach
Section: Automatic calibration with probe
Adjustment with BERO.
Operator-assisted The machine axis to be adjusted is moved to a defined machine position, and
adjustment then the appropriate actual value is set in the NC.
Chronological sequence
1. Parameterize the referencing mode to “No reference point approach; accep-
tance of MD34100: REFP_SET_POS” by setting value “0” in:
MD34200: ENC_REFP_MODE[n] (referencing mode)
2. Approach a known machine position
Traverse the machine axis in JOG mode to a known position.
The direction in which the position is approached must correspond to the
direction set in
MD34010: REFP_CAM_DIR_IS_MINUS (ref. point approach in
the minus direction)
(0 = positive direction, 1 = negative direction).
Notice
This known position must be approached at slow velocity and always from the
same direction to make sure that the actual value is not invalidated by the
backlash in the drive system.
3. Enter the approached machine position in the machine data:

MD34100: REFP_SET_POS[n] (ref. point value) = machine position
(This value can be a value specified from the design (e.g. fixed stop) or be
determined using a measuring instrument)
4. Enable “adjustment” in the NC by entering the value 1 (“enable encoder ad-
justment”) in:
MD34210: ENC_REFP_STATE[n] (status of absolute encoder)
5. Carry out “NCK RSET” to enable the changed machine data.
6. After the NC has powered up, switch over to JOG/REF mode and select
there the appropriate machine axis.
7. Calculation of the reference point offset
Press the traversing key already used in Step 2 to calculate the offset be-
tween the actual machine position and the actual encoder position and enter
itin
MD34090: REFP_MOVE_DIST_CORR[n] (reference point offset).
The machine axis is marked adjusted by the NC by the change of the dis-
played value in the axis-specific machine data:
from 1 = “Encoder adjustment enabled” to 2 = “Encoder is adjusted”.

Notice
The axis will not move if the traversing key is pressed!
The value entered in MD34100: REFP_SET_POS[n] (ref. point value) is dis-
played on the actual-value display of the appropriate traversing key.
8. The adjustment of the absolute encoder of this machine axis is thus com-
pleted.
Adjusting several For time-optimized adjustment of several machine axes, the following procedure
axes is recommended:
1. Traverse all or several machine axes (as far as permitted by the machine
design) to the adjustment point (see above, Points 1 – 5).
2. Switch over to: JOG/REF mode (Point 6).
3. Carry out the adjustment for each machine axis (Point 7).
Readjustment A readjustment of the absolute encoder is required:
after dismantling/installing the encoder or the motor with absolute encoder

or,
if data are lost in the NC SRAM, battery voltage failure, PRESET,

in the case of gear change between load and absolute encoder.
Notice
The status in
is only reset by the NC automatically in the case of gear change.
In all the other cases, the user must reset the status to 0 = “Encoder not ad-
justed” by himself/herself and provide for readjustment.
Interface signals
Table 10-39 Referencing: Interface signals

Mode group-specific Signals from PLC to mode group
11, ... 0.7 Mode group reset K1
11, ... 1.2 Machine function REF K1
Mode group-specific Signals from mode group to PLC
11, ... 5.2 Active machine function REF K1
Channel-specific Signals from PLC to channel
21,... 1.0 Activate referencing
Channel-specific Signals from channel to PLC
21,... 28.7 (MMC –––> PLC) REF K1
21,... 33.0 Referencing active
21,... 35.7 Reset K1
21,... 36.2 All axes to be referenced are referenced.

Axis-specific Signals from PLC to axis/spindle

31, ... 1.5/1.6 Position measuring system 1/position measuring system 2 A2
31, ... 2.4–2.7 Reference point values 1 to 4
31, ... 4.6/4.7 Traversing keys minus/plus H1
31, ... 12.7 Delayed reference-point approach
Axis-specific Signals from axis/spindle to PLC
31, ... 60.4 / 60.5 Referenced, synchronized 1/referenced, synchronized 2
31, ... 64.6/64.7 Traversing command minus/plus H1
Machine data
Table 10-40 Referencing: Machine data

General ($MN_ ...)
11300 JOG_INC_MODE_LEVELTRIGGRD INC/REF in inching mode/continuous mode H1
20700 REFP_NC_START_LOCK NC start lock without reference point
30200 NUM_ENCS Number of encoders G2
30240 ENC_TYP Actual-value encoder type
30242 ENC_IS_INDEPENDENT Encoder is independent G2
31122 BERO_DELAY_TIME_PLUS BERO delay time in plus direction S1
31123 BERO_DELAY_TIME_MINUS BERO delay time in minus direction S1
34000 REFP_CAM_IS_ACTIVE Axis with reference cam
34010 REFP_CAM_DIR_IS_MINUS Reference-point approach in minus direction
34020 REFP_VELO_SEARCH_CAM Reference point approach velocity
34030 REFP_MAX_CAM_DIST Max. distance to be traversed to the reference
cam
34040 REFP_VELO_SEARCH_MARKER[n] Reference point creep speed
[encoder number]
34050 REFP_SEARCH_MARKER_REVERSE[n] Direction reversal at reference cam
[encoder number]
34060 REFP_MAX_MARKER_DIST[n] Max. distance to be traversed to the reference
cam; max. distance to 2 reference marks with
distance-coded measurements [encoder num-
ber]
34070 REFP_VELO_POS Reference point positioning velocity
34080 REFP_MOVE_DIST[n] Reference point distance/target point with dis-
tance-coded system [encoder number]
34090 REFP_MOVE_DIST_CORR[n] Distance-coded reference point/absolute offset
[encoder number]
34092 REFP_CAM_SHIFT Electronic reference cam offset for incremental
measuring systems with equidistant zero marks
34100 REFP_SET_POS[n] Reference point value [reference point number]
34102 REFP_SYNC_ENCS Actual-value adjustment to the referencing
measuring system
34110 REFP_CYCLE_NR Axis order on channel-specific referencing
34120 REFP_BERO_LOW_ACTIVE Polarity change of BERO
34200 ENC_REFP_MODE[n] Referencing mode [encoder number]
34210 ENC_REFP_STATE[n] Status of absolute encoder [encoder number]


34220 ENC_ABS_TURNS_MODULO Range of absolute encoder with rotary encod- R2
ers
34300 ENC_REFP_MARKER_DIST[n] Reference marker distance with distance-coded
measurements [encoder number]
34310 ENC_MARKER_INC[n] Interval between two reference marks with dis-
tance-coded measurements[encoder no.]
34320 ENC_INVERS[encoder] Linear measuring system inverse to the ma-
chine system [encoder number]
34330 REFP_STOP_AT_ABS_MARKER[n] Distance-coded linear measuring system with-
out target point [encoder number]
35150 SPIND_DES_VELO_TOL Spindle speed tolerance S1
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency for re-synchronization
36310 ENC_ZERO_MONITORING Zero mark monitoring
30250 ACT_POS_ABS Absolute encoder position on switching off


10.5.20 Spindle basic data
The spindle mode of a machine axis is a subset of the general axis functionality.
For this reason, the machine data required to start up an axis have also to be
set for a spindle.
The machine data to parameterize a spindle are therefore to be found under the
axis-specific machine data (from MD 35000 onwards).
Notice
After the default machine data have been loaded, no spindle is defined.
Spindle definition By setting the machine data
MD 30300: IS_ROT_AX (rotary axis/spindle)

MD 30310: ROT_IS_MODULO (modulo conversion for rotary axis/spindle)
MD 30320: DISPLAY_IS_MODULO (modulo 360 degrees display for rotary
axis/spindle)
a machine axis is declared to be an endlessly rotating rotary axis whose pro-
gramming and display is carried out modulo 360 degrees.
The machine axis is converted to a spindle by defining the spindle number x
(with x = 1, 2, ...max. number of channel axes) in machine data
MD 35000: SPIND_ASSIGN_TO_MACHAX (spindle number)

The spindle number must be unambiguous within the channel axes of the
channel to which the spindle is assigned, i.e. several spindles can be defined
with spindle number 1 provided they are assigned different channels (for
assigning machine axes to channels, please refer to Subsection 10.5.1,
page 10-308).
Spindle modes The diagram below illustrates the spindle modes and possible transitions
between them.
Oscillation mode Synchronous mode
gearbox gearbox
gearbox changed COUPON COUPOF
SPOS and SPOSA
Control mode Positioning mode

SPCOF
M3, M4, M5
M41–45
M70 SPOS
SPOSA
SPCOF
M3, M4, M5 Axis mode Axis name
M41–45
G332 G331
Rigid tapping
Fig. 10-27 Spindle modes

Default The machine data

mode
MD 35020: SPIND_DEFAULT_MODE (spindle park position)
MD35030: SPIND_DEFAULT_ACT_MASK (effective time of spindle park
position)
can be used to define the default mode of a spindle at a defined time:
MD 35030: SPIND_DEFAULT_ACT_MASK
RESET 2
NC START 1
Power ON 0
0 1 2 3
Axis mode
Positioning mode
Speed mode without
Speed mode with

position control
position control
Standard adjustment
MD 35020: SPIND_DEFAULT_MODE
Fig. 10-28 Default setting of spindle mode
Axis mode It is possible to switch directly from spindle mode to axis mode provided the
same drive is used for both modes.
1. Transition to axis mode by programming the spindles using their axis names
or by M70.
2. If the axis is not synchronized, e.g. position control enabled with M70, the
axis has to be referenced with G74 first. Only then the mechanical position
will coincide with the programmed position.
3. It is switched over to the current feedforward control mode marked by the
machine data and commands FFWON and FFWOF.
Special features The following characteristics apply to the axis mode of a spindle:
1. The feed override switch is valid.
2. The IS “Reset” (DB21, ... DBX7.7) does not end axis mode by default.
3. The interface signals DBB16 to DBB19 and DBB82 to DBB91 in DB31, ...
are not important if the IS “Axis/no spindle” (DB31, ... DBX60.0) is set to
zero.
4. The axis mode can be enabled in any gear stage. If the positional actual-
value encoder is mounted on the motor (indirect measuring system), differ-
ent positioning and contour accuracies may result between the gear stages.

5. If axis mode is active, it is not possible to switch over the gear stage. To this
aim, it is necessary to switch over to control mode using M41 to M45.
6. In axis mode, the machine data of the 1st parameter record (index zero) will
apply to be able to make adaptations.
Master spindle To be able to use various spindle functions in a channel, such as
Revolutional feed (G95)

Tapping with compensation chuck (G63)
Thread cutting (G33)
Dwell time in spindle revolutions (G4 S...)
a master spindle has to be defined in the corresponding channel:
MD20090: SPIND_DEF_MASTER_SPIND (master spindle initial setting in

channel)
In machine data
MD 35000: SPIND_ASSIGN_TO_MACHAX (spindle number)

the defined spindle number of the spindle of the channel is entered, which will
be the master spindle.
Spindle reset The machine data
MD 35040: SPIND_ACTIVE_AFTER_RESET (spindle active with reset)

defines whether the spindle is to remain active beyond
reset (IS: DB21,... DBX7.7)

end of program (M02/M30).
To cancel spindle movements, an independent spindle reset is required:
IS: DB31,... DBX2.2 (spindle reset).

S1 Spindles

10.5.21 Setpoint/actual-value channels of spindle
Parameterization of the setpoint/actual-value channels of a spindle is identical

to parameterization of the setpoint and actual-value channels of an axis. See
above, Subsection 10.5.4, page 10-315.
10.5.22 Gear stages
Enabling The gear stage change is generally carried out in

Gear stage change
MD35010: GEAR_STEP_CHANGE_ENABLE (gear stage change possible),
spindle has several gear stages).
If this machine data is not set, the system assumes that the spindle has no gear
stages.
Parameter sets In Spindle mode of a spindle, the NC will select the parameter set that suits the
current gear stage best.
Gear stage x => parameter set (x+1) => index [x]
In axis mode of a spindle, the NC always selects the 1st parameter set (index
[0], independent of the current gear stage.
The machine data listed in the following are gear stage-dependent machine
data of a spindle:
MD35110: GEAR_STEP_MAX_VELO[n] (nmax for gear stage change)

MD35120: GEAR_STEP_MIN_VELO[n] (nmin for gear stage change)
MD35130: GEAR_STEP_MAX_VELO_LIMIT[n] (nmax for gear stage)
MD35140: GEAR_STEP_MIN_VELO_LIMIT[n] (nmin for gear stage)
MD35200: GEAR_STEP_SPEEDCTRL_ACCEL[n]
(acceleration in speed-control mode)
MD35210: GEAR_STEP_POSCTRL_ACCEL[n] (acceleration in position

control mode).
For further information with respect to parameter records, see above,

S1 Spindles
Section: Gear stage change

10.5.23 Measuring systems of spindle
Adapting the When parameterizing the measuring systems of spindles, the same conditions
encoder apply as for parameterization of the measuring systems of rotary axes. This
multiple is 2048.
For incremental measuring systems, see above, Subsection 10.5.5,
page 10-317.
For absolute measuring systems, see above, Subsection 10.5.6, page 10-320.
Notice
If the motor encoder is used for actual-value sensing, the encoder matching
data must be entered in the machine data for each individual gear stage if
several gear stages are present.
Pulse The maximum multiplication of the appropriate drive is always used as the
multiplication multiplication of the increments.
SIMODRIVE 611 The pulse multiplication with SIMODRIVE 611 universal is 128.
universal
Examples of encoder adaptation
Example A: Supposed the following conditions are provided:

Spindle-mounted
encoder
The incremental encoder is mounted on the spindle.
Encoder pulses = 500 [pulses/rev.]
Pulse multiplication = 128
Internal precision = 1000 [increment/degree]
Encoder gear stage = 1:1
Load gear stage = 1:1
The machine data are set acc. to the values above:
MD10210: INT_INC_PER_DEG (computational resolution) = 1,000 [incr./de-

gree]
MD31020: ENC_RESOL (encoder resolution) = 500 [pulses/rev.]

MD31050: DRIVE_AX_RATION_DENOM (load rev. denominator) = 1
MD 31060: DRIVE_AX_RATION_NUMERA (load rev. numerator) = 1
MD31070: DRIVE_ENC_RATION_DENOM (load rev. denominator) = 1
MD31080: DRIVE_ENC_RATION_NUMERA (load rev. numerator) = 1

Internal 360 degrees MD 31080 MD 31050

resolution = * * * MD10210
MD31020 * pulse rev. MD 31070 MD 31060
Internal
360 1 1 int. increments
resolution = * * * 1000 = 5.625
500 * 128 1 1 Encoder pulse
The encoder increment corresponds to 5.625 internal increments.

An encoder increment corresponds to 0.005625 degrees (highest possible
positioning resolution).
Example B: Supposed the following conditions are provided:

Motor-mounted
encoder
The incremental encoder is mounted on the motor.
Encoder pulses = 2048 [pulses/rev.]
Pulse multiplication = 128
Internal precision = 1000 [increment/degree]
Encoder gear stage = 1:1
Load gear stage 1= 2.5:1 [motor rev./spindle rev.]
Load gear stage 2= 1:1 [motor rev./spindle rev.]
Gear stage 1
Internal 360 degrees MD 31080 MD 31050

resolution = * * * MD10210
MD 31020 * pulse rev. MD 31070 MD 31060

Internal =
resolution
* * * 1000 = 0.54932
2048 * 128 1 2.5 Encoder pulse
One encoder increment corresponds to 0.54932 internal increments.

Gear stage 2

Internal =
* * * 1000 = 1.3733
resolution 2048 * 128 1 1 Encoder pulse
One encoder increment corresponds to 1.3733 internal increments.


10.5.24 Speeds and setpoint adjustment for spindle
Speeds, gear In SINUMERIK 840Di, data for five gear stages are implemented. These stages
stages are defined by a minimum and maximum speed for the stage itself and by a
minimum and maximum sped for the automatic gear stage changeover.
A new gear stage is output only if the newly programmed speed setpoint cannot
be traversed in the present gear stage. For the sake of simplification, the oscilla-
tion times for gear stage changeovers can be specified directly in the NC; the
oscillation function must otherwise be implemented in the PLC. The oscillation
function is initiated in the PLC.
Speed
(rev./min)
ÉÉÉ
Max. spindle speed
Max. speed of gear stage 2
Max. speed for gear stage 2 changeover
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
Max. speed of gear stage 1
Max. speed for gear stage 1 changeover
ÉÉÉ
ÉÉÉ
Min. speed for gear stage 2 changeover ÉÉÉ
ÉÉÉ
ÉÉÉ
Min. speed of gear stage 2
Min. speed for gear stage 1 changeover
Min. speed of gear stage 1
ÉÉÉ
Min. spindle speed
0
1 2 gear stage
Fig. 10-29 Example of speed ranges with automatic gear stage selection (M40)
Velocities for The speeds of the spindle in conventional mode are entered in the machine
conventional data:
operation
MD 32010: JOG_VELO_RAPID (conventional rapid traverse) or
MD32020: JOG_VELO (conventional axis velocity).
The direction of rotation is specified using the appropriate directional keys for
the spindle on the MCP.
Direction of The direction of rotation of a spindle corresponds to the traversing direction of

rotation an axis.
Setpoint The speeds for drive control must be transferred to the drive as scaled values.
adjustment The values are scaled in the NC using the selected load gear and the appropri-
ate drive parameter.

SIMODRIVE 611 Drive parameter P0880: PROFIBUS speed evaluation

universal
Speed n
Normalization value
P0880
4000H speed setpoint (low resolution)

4000 0000H speed setpoint (high resolution)
Fig. 10-30 Speed setpoint normalization
The desired speed on the spindle is obtained using a mechanical gear stage.
Machine data
Table 10-41 Speeds and setpoint adjustment for spindle: Machine data
31050 DRIVE_AX_RATIO_DENOM Load gear denominator G2
31060 DRIVE_AX_RATIO_NUMERA Load gear numerator G2
32010 JOG_VELO_RAPID Conventional rapid traverse
32020 JOG_VELO Conventional axis velocity
35010 GEAR_STEP_CHANGE_ENABLE Gear stage change possible
35020 SPIND_DEFAULT_MODE Spindle park position
35030 SPIND_DEFAULT_ACT_MASK Activate spindle park position
35040 SPIND_ACTIVE_AFTER_RESET Spindle activated by reset
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode
35220 ACCEL_REDUCTION_SPEED_POINT Speed limit for reduced acceleration
35230 ACCEL_REDUCTION_FACTOR Reduced acceleration
35400 SPIND_OSCILL_DES_VELO Oscillation speed
35410 SPIND_OSCILL_ACCEL Acceleration on oscillation
35430 SPIND_OSCILL_START_DIR Start direction on oscillation
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction
Interface signals
Table 10-42 Speeds and setpoint adjustment for spindle: Interface signals
31, ... 4.6 Traversing keys minus
31, ... 4.7 Traversing keys plus


31, ... 16.2–16.0 Actual gear stage
31, ... 16.3 Gear switched
31, ... 16.6 No speed monitoring when changing the gear
31, ... 18.4 Oscillation by the PLC
31, ... 18.5 Oscillation speed
31, ... 82.2–82.0 Set gear stage
31, ... 82.3 Switch gear
31, ... 84.7 Active spindle mode “Control mode”
31, ... 84.6 Active spindle mode “Oscillation mode”
10.5.25 Positioning the spindle
The NC provides an “oriented spindle stop” function with which the spindle can
be moved into a certain position and held there (e.g. for tool changing pur-
poses). Several programming commands are available for this function which
define the approach and program processing.
References: /PA/ Programming Guide
S1 Spindles
Functionality
To absolute position (0 – 360 degrees)
Incremental position (+/– 999999.99 degrees)
Block change when position reached
Block change on block end criterion.
The control brakes the spindle down to creep speed at the acceleration rate for
speed operation.
If the creep speed has been reached (INT “Spindle in setpoint range”), the con-
trol branches into position control mode and the acceleration rate for position
control mode and the KV factor become active.
The interface signal “Fine exact stop” is output to indicate that the programmed
position has been reached (block change when position reached).
The acceleration rate for position control mode must be set such that the current
limit is not reached. The acceleration rate must be entered separately for each
gear stage.
If the spindle is positioned from zero speed, it is accelerated up to a maximum
speed corresponding to creep speed; the direction is defined in machine data.
The contour monitoring function is activated as soon as the control mode
switches to position control.
Machine data
Table 10-43 Spindle positioning: Machine data

35300 SPIND_POSCTRL_VELO Creep speed
35350 SPIND_POSITIONING_DIR Direction of rotation when positioning from the
standstill
35210 GEAR_STEP_POSCTRL_ACCEL Acceleration in position control mode


36000 STOP_LIMIT_COARSE Exact stop coarse
36010 STOP_LIMIT_FINE Exact stop fine
32200 POSCTRL_GAIN KV factor
36400 CONTOUR_TOL Contour monitoring
Interface signals
Table 10-44 Spindle positioning: Interface signals

31, ... 60.6 Position reached with exact stop fine
31, ... 60.7 Position reached with exact stop coarse
31, ... 84.5 Positioning mode
10.5.26 Synchronizing the spindle
To allow the spindle to be positioned from the NC, its position has to be adjusted
using the measuring system. This operation is called “synchronization”.
As a rule, synchronizing is done to the zero mark of the connected encoder or
to a BERO as zero mark substitute.
The machine data
Set MD 34100: REFP_SET_POS (reference point value).

defines the actual position of the spindle at the zero mark position.
The machine data
MD34090: REFP_MOVE_DIST_CORR (reference-point offset)

is used to enter the zero mark offset.
The machine data
MD 34200 ENC_REFP_MODE (referencing mode)

specifies which signal is used for synchronization:
1 = encoder zero mark
2 = BERO.
SIMODRIVE 611 The drive SIMODRIVE 611 universal supports the connection of a BERO as a
universal zero mark substitute for synchronizing the spindle.
For the exact procedure of operating a BERO on SIMODRIVE 611 universal,
see:
Section:Motion Control with PROFIBUS DP
(from SW 3.1)
Zero mark substitute on PROFIBUS

Chuck
BERO
gearbox Motor Motor
encoder
Power Motor en-

connection coder cable
Toothed belt SIMODRIVE 611 universal
Fig. 10-31 Synchronization using BERO
When is The spindle will be synchronized:

synchronization after the NC has powered up when the spindle is moved using a
necessary? programming command
after request for resynchronizing from the PLC
IS DB31,... DBX16.4 (resynchronize spindle 1)
IS DB31,... DBX16.5 (resynchronize spindle 2)
after each gear stage change when an indirect measuring system is used
MD 31040: ENC_IS_DIRECT (direct measuring system) = 0
when the encoder cut-off frequency falls below the programmed value after
a speed has been programmed which is above the encoder cut-off fre-
quency.
Notice
To synchronize the spindle, it must always be rotated using a programming

command (e.g. M3, M4, SPOS). The specification of a spindle speed using
the direction keys of the machine control panel is not sufficient.
If the spindle encoder is not mounted directly on the spindle and there are
speed-transforming gears between the encoder and spindle (e.g.
motor-mounted encoder), then a BERO signal connected to the drive
module must be used for synchronization.
The control then automatically resynchronizes the spindle after each gear
change. No manual intervention is required on the part of the user.
In general, backlash, gearbox elasticity and proximity switch hysteresis re-

duce the accuracy achievable during synchronization.
Machine data
Table 10-45 Synchronizing spindle: Machine data

34100 REFP_SET_POS Reference point value
34090 REFP_MOVE_DIST_CORR Reference point offset
34200 REFP_MODE Referencing mode

Interface signals
Table 10-46 Synchronizing spindle: Interface signals

31, ... 16.4 Synchronize spindle 1
31, ... 16.5 Synchronize spindle 2
31, ... 60.4 Referenced/synchronized 1
31, ... 60.5 Referenced/synchronized 2
10.5.27 Monitoring functions of the spindle
Axis/spindle at a If the actual speed entered in machine data

standstill
MD36060: STANDSTILL_VELO_TOL (maximum velocity/speed for “axis/
spindle stopped”)
falls below the programmed velocity/speed, the interface signal
IS DB31,... DBX61.4 (axis/spindle stopped)

is set. If
MD 35110: SPIND_STOPPED_AT_IPO_START (feed enable for “Spindle

stopped”) is set,
the path feed is enabled.
Spindle in If the spindle reaches the tolerance range specified in machine data
setpoint range
MD35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
the interface signal
IS DB31,... DBX83.5 (spindle in setpoint range)

is set. If
MD 35110: SPIND_STOPPED_AT_IPO_START (feed enable for “Spindle

stopped”) is set,
the path feed is enabled.
Max. spindle The maximum spindle speed is entered in machine data

speed
MD35100: SPIND_VELO_LIMIT (maximum spindle speed).
The NC limits the spindle speed to this value.

Error response
If the speed is nevertheless exceeded by the speed tolerance (drive error), the
following signal is output:
IS DB31,... DBX83.0 (speed limit exceeded) = 1

Alarm “22150 Maximum number of chucks exceeded”

The machine data
MD36200: AX_VELO_LIMIT (threshold value for speed monitoring)

also limits the speed of the spindle. When the speed is exceeded, an alarm is
generated.
In position-controlled mode (e.g. SPCON), the NC limits the specified maximum
speed specified in machine or setting data to 90% of the maximum value (con-
trol reserve).
Gear stage speed The max./min. gear stage speed is entered in:
min./max.
MD35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)
MD35140: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)
The speed cannot leave this range when the appropriate gear stage is en-
gaged.
Progr. spindle The functions

speed limitations
G25 S... (min. spindle speed)
G26 S... (max. spindle speed)
can be used to specify a spindle speed limitation in a parts program. The limita-
tion is active in all operating modes.
The function LIMS=...
LIMS=... (spindle speed limitation (G96))

can be used to specify a spindle speed limit for G96 (constant cutting rate). This
limitation is operative only when G96 is active.
Encoder cut-off If the encoder cut-off frequency

frequency
MD36300: ENC_FREQ_LIMIT (encoder cut-off frequency)
is exceeded, the synchronization of the spindle is lost and the spindle function-
ality reduced (thread, G95, G96).
The spindle will be resynchronized once the encoder frequency falls below the
value defined in machine data
MD36302: ENC_FREQ_LIMIT_LOW (encoder cut-off frequency at which the

encoder is turned on again).
The encoder limit frequency value must be such that the mechanical encoder
speed limit is not exceeded or else the synchronization from high speeds will be
incorrect.

Speed
Max. encoder limit frequency
Max. spindle speed
Max. spindle speed of current gear stage
Programmable spindle speed limitation G26
Programmable spindle speed limiting LIMS
Programmable minimum spindle speed G25
Min. spindle speed of current gear stage
Max. velocity/speed “Axis/spindle stopped”
with constant cutting rate G96 and G97

0
Speed range of current gear stage


IS: Axis/spindle stopped (n<nmin)
IS: Referenced/synchronized
limited by G25 and G26
Speed range of spindle
or spindle chuck
Fig. 10-32 Ranges of spindle monitoring functions/speeds

S1 Spindles
Section: Spindle monitoring

10.5.28 Spindle data
Machine data
Table 10-47 Spindle: Machine data

General ($MN_ ...)
12060 OVR_SPIND_IS_GRAY_CODE Spindle override, Gray-coded V1
12070 OVR_FACTOR_SPIND_SPEED Evaluation of the spindle speed override switch V1
12080 OVR_REFERENCE_IS_PROG_FEED Override reference speed V1
20090 SPIND_DEF_MASTER_SPIND Initial setting of master spindle in the channel
20092 SPIND_ASSIGN_TAB_ENABLE Enable/disable spindle converter
20118 GEOAX_CHANGE_RESET Permit automatic geometry axis change
22400 S_VALUES_ACTIVE_AFTER_RESET S function effective with RESET
30310 ROT_IS_MODULO Modulo conversion R2
30320 DISPLAY_IS_MODULO Position display R2
31050 DRIVE_AX_RATIO_DENOM Load gear denominator G2
31060 DRIVE_AX_RATIO_NUMERA Load gear numerator G2
31122 BERO_DELAY_TIME_PLUS BERO delay time in plus direction
31123 BERO_DELAY_TIME_MINUS BERO delay time in minus direction
32200 POSCTRL_GAIN KV factor G2
32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant of speed control loop K3
for feedforward control
32910 DYN_MATCH_TIME. Time constant of dynamic adaptation G2
34040 REFP_VELO_SEARCH_MARKER Reference shutdown speed R1
34060 REFP_MAX_MARKER_DIST Monitoring of zero reference mark distance R1
34080 REFP_MOVE_DIST Reference point distance/target position with R1
clearance-coded system
34090 REFP_MOVE_DIST_CORR Reference point offset/absolute offset R1
clearance-coded
34100 REFP_SET_POS Reference point value R1
34200 ENC_REFP_MODE Referencing mode R1
35000 SPIND_ASSIGN_TO_MACHAX Assignment of spindle to machine axis
35010 GEAR_STEP_CHANGE_ENABLE Gear stage change possible
35012 GEAR_STEP_CHANGE_POSITION Gear stage change position
35020 SPIND_DEFAULT_MODE Spindle park position
35030 SPIND_DEFAULT_ACT_MASK Activate spindle park position
35040 SPIND_ACTIVE_AFTER_RESET Spindle activated by reset
35100 SPIND_VELO_LIMIT Max. spindle speed
35110 GEAR_STEP_MAX_VELO[n] Max. speed for gear stage change
35120 GEAR_STEP_MIN_VELO[n] Min. speed for gear stage change
35130 GEAR_STEP_MAX_VELO_LIMIT[n] Max. speed of gear stage
35140 GEAR_STEP_MIN_VELO_LIMIT[n] Min. speed of gear stage
35150 SPIND_DES_VELO_TOL Spindle speed tolerance
35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limiting from PLC
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode


35210 GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode
35220 ACCEL_REDUCTION_SPEED_POINT Speed limit for reduced acceleration
35230 ACCEL_REDUCTION_FACTOR Reduced acceleration
35300 SPIND_POSCTRL_VELO Position control threshold speed
35350 SPIND_POSITIONING_DIR Direction of rotation when positioning with the
spindle not synchronized
35400 SPIND_OSCILL_DES_VELO Oscillation speed
35410 SPIND_OSCILL_ACCEL Acceleration on oscillation
35430 SPIND_OSCILL_START_DIR Start direction on oscillation
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction
35500 SPIND_ON_SPEED_AT_IPO_START Feedrate enable for spindle in setpoint range
35510 SPIND_STOPPED_AT_IPO_START Feed enable with the spindle stopped
35590 PARAMSET_CHANGE_ENABLE Parameter set specification possible from PLC A2
36060 STANDSTILL_VELO_TOL Threshold speed “Axis/spindle stopped” A3
36200 AX_VELO_LIMIT Threshold value for velocity monitoring A3
Setting data
Table 10-48 Spindle: Setting data

Spindle-specific ($SA_ ...)
42600 JOG_FEED_PER_REF_SOURCE Revolutional feedrate control in JOG mode V1
42800 SPIND_ASSIGN_TAB Spindle number converter
42900 MIRROR_TOOL_LENGTH Mirror tool length compensation W1
42910 MIRROR_TOOL_WEAR Mirror wear data of tool length compensation W1
42920 WEAR_SIGN_CUTPOS Mirror wear data of processing level W1
42930 WEAR_SIGN Invert signs of all wear data W1
42940 TOOL_LENGTH_CONST Keep the assignment of the tool length compo- W1
nents when changing the processing level
(G17 to G19).
43210 SPIND_MIN_VELO_G25 Programmable spindle speed limiting G25
43220 SPIND_MAX_VELO_G26 Programmable spindle speed limiting G26
43230 SPIND_MAX_VELO_LIMS Programmable spindle speed limiting G96
43300 ASSIGN_FEED_PER_REF_SOURCE Revolutional feedrate for positioning V1, P2
axes/spindles
Interface signals
Table 10-49 Spindle: Interface signals

31, ... 0 Feed override V1
31, ... 1.7 Override active V1


31, ... 1.6 Position measuring system 2 A2
31, ... 1.5 Position measuring system 1 A2
31, ... 1.4 Follow-up mode A2
31, ... 1.3 Axis/spindle disable A2
31, ... 2.2 Spindle reset/delete distance-to-go A2
31, ... 2.1 Controller enabling command A2
31, ... 3.6 Velocity/spindle speed limiting A3
31, ... 16.7 Delete S value
31, ... 16.5 Resynchronize spindle 2
31, ... 16.4 Resynchronize spindle 1
31, ... 16.3 Gear switched
31, ... 16.2–16.0 Actual gear stages A to C
31, ... 17.6 Invert M3/M4
31, ... 17.5 Resynchronize spindle when positioning 2
31, ... 17.4 Resynchronize spindle when positioning 1
31, ... 18.7 Set direction of rotation CCW
31, ... 18.6 Set direction of rotation CCW
31, ... 18.5 Oscillation speed
31, ... 18.4 Oscillation by the PLC
31, ... 19.7–19.0 Spindle override H – A V1
31, ... 60.7 Position reached with exact stop fine B1
31, ... 60.6 Position reached with exact stop coarse B1
31, ... 60.5 Referenced/synchronized 2 R1
31, ... 60.4 Referenced/synchronized 1 R1
31, ... 60.3 Encoder limit frequency exceeded 2 A3
31, ... 60.2 Encoder limit frequency exceeded 1 A3
31, ... 60.0 Axis/no spindle
31, ... 61.7 Current controller active A2
31, ... 61.6 Speed controller active A2
31, ... 61.5 Position controller active A2
31, ... 61.4 Axis/spindle stopped (n < nmin) A2
31, ... 82.3 Switch gear
31, ... 82.2–82.0 Set gear stage A–C
31, ... 83.7 Actual direction of rotation CW
31, ... 83.5 Spindle within set range
31, ... 83.2 Set speed increased
31, ... 83.1 Set speed limited
31, ... 83.0 Speed limit exceeded
31, ... 84.7 Active spindle mode “Control mode”
31, ... 84.6 Active spindle mode “Oscillation mode”
31, ... 84.5 Active spindle mode “Positioning mode”
31, ... 84.3 Tapping without compensating chuck active
31, ... 86 and 87 M function for spindle
31, ... 88–91 S function for spindle

10.6 Digital and analog I/O devices

The following digital and analog signal modules are available:
Digital I/O modules
– MCI board extension module (option)
On the MCI board extension module (option) there are 4 digital inputs/
outputs (Section 2.4, page 2-62).
– PP 72/48
The I/O module PP 72/48 has 72 digital inputs and 48 digital outputs
– ADI4
The ADI4 has two digital input and output bytes that are used for
ADI4-internal functions and as I/O signals at the interfaces of the module
– SIMATIC S7: ET200 modules
Via the PROFIBUS DP it is possible to connect all subtypes of SIMATIC-
S7 I/O modules of type ET200 (e.g. ET200M) as long as they support a
data transmission rate of 12 Mbaud.
Analog I/O modules
– SIMATIC S7: ET200 modules
See above.
Notice
The digital and analog input/outputs connected on PROFIBUS DP are provided
for both NC and PLC.
It is the sole responsibility of the user to avoid access conflicts:
On the side of the NC: Parts program/synchronized action
On the side of the PLC: PLC user program.

A4 Digital and Analog NCK I/Os
10.6.1 Setting parameters for the number of inputs/outputs in use
Max. number The maximum number of digital or analog input/outputs that can be used for the
NC is:
Total MCI board PROFIBUS
extension modules
Analog inputs 8 – 8
Analog outputs 8 – 8
Digital inputs 36 4 32
Digital outputs 36 4 32

Note
The first digital input and output byte is permanently assigned to the MCI board
extension module (option). Therefore you can connect a maximum of 4 addi-
tional input/output bytes to the PROFIBUS DP via signal modules. See config-
uration example Subsection 10.6.6, page 10-384.
Machine data The number of used analog and digital inputs/outputs is set in the following ma-
chine data parameters:
Analog input/outputs
MD10300: FASTIO_ANA_NUM_INPUTS (“Number of active analog NC in-
puts”)
MD10310: FASTIO_ANA_NUM_OUTPUTS (“Number of active analog NC
outputs”).
Digital input/outputs
MD10350: FASTIO_DIG_NUM_INPUTS (“Number of active digital NC input
bytes”).
MD10360: FASTIO_DIG_NUM_INPUTS (“Number of active digital NC out-
put bytes”)
10.6.2 Assignment of the inputs/outputs to the signal modules
On the NC side, the analog and digital inputs/outputs are assigned to the re-
spective signal modules on the PROFIBUS DP via the appropriate I/O ad-
dresses in the machine data:
Machine data Analog inputs/outputs

MD10362: HW_ASSIGN_ANA_FASTIN[n] (“hardware assignment of exter-
nal analog inputs”), per input where n = 0–7
MD10364: HW_ASSIGN_ANA_FASTOUT[n] (“hardware assignment of ex-
ternal analog outputs”), per output where n = 0–7.
MD10366: HW_ASSIGN_DIG_FASTIN[n] (“hardware assignment of external
digital inputs”), per input byte where n = 0–3
MD10368: HW_ASSIGN_DIG_FASTOUT[n] (“hardware assignment of ex-
ternal digital outputs”), per output byte where n = 0–3.
Input format
05 00 I/O high I/O low
S7 I/O address Low part
(hexadecimal)
S7 I/O address High part
(hexadecimal)
always 00
always 05 (identifier:
PROFIBUS I/Os)

Note
The first digital I/O bytes defined in each case via machine data:
MD10350: FASTIO_DIG_NUM_INPUTS
MD10360: FASTIO_DIG_NUM_OUTPUTS
always refer to the 4 digital input/outputs on the MCI board extension mod-
ule. Explicit assignment in machine data is not possible. Therefore, the ma-
chine data required to assign the digital and analog input/outputs refer ex-
clusively to the signal modules connected via the PROFIBUS DP.
The I/O address to be entered in the machine data hexadecimally is the

decimal I/O address of the slot of the signal module allocated by
“HW Config” or set manually.
10.6.3 System variable $A_...[n]

The digital and analog input/outputs are available in the NC (parts program,
ASUP, synchronized action, etc.) in the form of system variables.
$A_INA[n] (“Read analog input n, with n=1...8”)
$A_OUTA[n] (“Write analog output n, with n=1...8”)
$A_IN[n] (“Read digital input (Bit) n, with n=1...4 and 9...40”)
$A_OUT[n] (“Write digital output n, with n=1...4 and 9...40”)
Hardware assign machine data System variable

MD10362: HW_ASSIGN_ANA_FASTIN[ 0–7 ] $A_INA[ 1–8 ]
MD10364: HW_ASSIGN_ANA_FASTOUT[ 0–7 ] $A_OUTA[ 1–8 ]
MCI board extension: Digital inputs 1–4 $A_IN[ 1–4 ]
MD10366: HW_ASSIGN_DIG_FASTIN[ 0–3] $A_IN[ 9–40 ]
MCI board extension: Digital outputs 1–4 $A_OUT[ 1–4 ]
MD10368: HW_ASSIGN_DIG_FASTOUT[ 0–3] $A_OUT[ 9–40 ]
Note
The digital input/outputs are organized as follows:
Hardware assign machine data: Byte by byte
System variables: Bit by bit

10.6.4 Digital I/O bytes and system variables
Digital inputs The following example uses the configuration of 3 digital input bytes to illustrate
the connection between digital input bytes and system variables.
The following prerequisites apply for the sample configuration:
– MCI board extension module: 1 input byte.
– PROFIBUS–DP signal modules: 2 input bytes
The MCI board extension module always uses one digital input byte. Digital
input bytes from external signal modules must therefore always be counted as
additional input bytes:
MD10350: FASTIO_DIG_NUM_INPUTS = 1 + m,
where m = number of input bytes from external signal modules
Since the 1st input byte is internally permanently assigned to the MCI board
extension module, only the input bytes of the external signal modules need to
be explicitly assigned to the system variables.
MD10366: HW_ASSIGN_DIG_FASTIN[0] –> 1. external input byte
MD10366: HW_ASSIGN_DIG_FASTIN[1] –> 2. external input byte
MD10350: FASTIO_DIG_NUM_INPUTS = 3 = 1 + m
where: 1 –> 1. Dig. input byte of the MCI board extension module
(alwazs permanently 1, see text)
m=2 –> 2nd and 3rd dig. input byte via PROFIBUS I/O modules
(number of input bytes used by external signal modules)
MCI board extension Module System variable:

$A_IN[1] ... $A_IN[4]
MD10366: HW_ASSIGN_DIG_FASTIN [n]

05 00 I/O high I/O low 0 $A_IN[9] ... $A_IN[16]
05 00 I/O high I/O low 1 $A_IN[17] ... $A_IN[24]
:
:
Fig. 10-33 Sample configuration: 3 digital input bytes

If the optional MCI board extension module is not present, the assignment in the
machine data must still be carried out as specified, since the 1st input byte is
permanently assigned internally in this module. The system variables $A_IN[1]
bis $A_IN[4] then do not contaion any information.
Digital outputs The configuration of digital outputs is analogous to the example described
above for digital inputs.

10.6.5 Time behavior

After the system variables have been set, e.g. $A_OUT[8] for setting the 8th
digital output of the NC on a SIMATIC-S7 signal module connected on PROFI-
BUS DP, the system variable is transferred from DP master to the signal module
along PROFIBUS DP during the next position controller cycle.
The signal module will then provide the signal to the appropriate with the output
next output cycle. The PROFIBUS DP cycle and the cycle of the signal mod-
ule are not synchronized during this process.
The transmission cycle described is illustrated in Fig. 10-34, page 10-383.
The time properties when reading in a digital or analog input are analogously to
the properties described above.
TMAPC
1
TM
NC:
Position controller
RPos. RInterpol.
and interpolator
TDP TDX
PROFIBUS DP MSG RES GC Dx Dx Dx MSG RES GC Dx Dx Dx

communication
DP slave: 3
R R R R R R
Signal module
Fig. 10-34 Time behavior when outputting an output signal with optimized DP cycle
Explanations regarding Fig. 10-34:

TMAPC Master application cycle: NC position controller cycle
With SINUMERIK 840Di, the following applies in all cases: TMAPC = TDP
TDX Data exchange time: Total of transfer times of all

DP slaves

position control
GC Global Control: Broadcast message frame for cyclic

synchronization of the isosynchronism between DP master
and DP slaves

R Computational time of position controller and/or signal module
MSG Acyclic services (e.g. DP/V1, token transfer)
RES Reserve: “active break” until the equidistant cycle has elapsed
1
Set the system variables, e.g. $A_OUT[8] in the parts program or
synchronized action
2 Transmit the output signal to the signal module on
PROFIBUS DP
3
Connect the signal to the output of the module.
10.6.6 Configuration example

In the following configuration example the following input/outputs are available
to the NC:
ET200
– 24 digital inputs
– 16 digital outputs
ADI4
– 8 digital inputs
– 16 digital outputs
Note
The I/O addresses of the modules are assigned automatically by “HW Con-
fig”. (Manual adjustment is possible.)
Each I/O address refers to an input/output byte.
840Di (configuration) –– 840Di_ET200_ADI4

PROFIBUS(2): DP master system (2)
(5) IM 153 (6) ADI4

(0)840Di
(0) UR
2 PLC315-2DP M/S 2AF03
X2 DP Master
4 CP 342–5
Fig. 10-35 Example configuration: SINUMERIK 840Di with ET200 and ADI4

ET200 I/Os: IM 153

Slot Module I address O address Comment
4 SM 322 DO16xDC24V/0.5A – 128...129

5 SM 322 DO32xDC24V/0.5A – 130...133
6 SM 321 DI16xDC24V/0.5A 128...129 –
7 SM 321 DI32xDC24V/0.5A 130...133 –
ADI4
Slot Module I address O address Comment
4 Drive modules
5 Drive modules 258...275 1. Axis
6 Drive modules 258...267 1. Axis
7 Drive modules
8 Drive modules
9 Drive modules 332...349 2nd Axis
10 Drive modules 332...341 2nd Axis
11 Drive modules
12 Drive modules
13 Drive modules 350...367 3rd Axis
14 Drive modules 350...359 3rd Axis
15 Drive modules
16 Drive modules
17 Drive modules 312...329 4th Axis
18 Drive modules 312...321 4th Axis
19 Drive modules
20 Drive modules
21 Drive modules 330...331 I word
22 Drive modules 330...331 O word
Note:
The structure of the PROFIBUS message frame is described in Subsection 7.3.6,
page 7-220f.
Machine data Parameterization of the NC machine data is shown below:
Number of ET200
input bytes 3 input bytes
ADI4
1 input byte.
Note
Although only four input bytes are used, five must be declared. The 1st input
byte is always assigned to the MCI board extension module, even if it does not
exist:
– MD10350: FASTIO_DIG_NUM_INPUTS = 5

Number of ET200
output bytes 2 output bytes
ADI4
2 output bytes.
Note
Although only four output bytes are used, five must be declared. The 1st output
byte is always assigned to the MCI board extension module even if it is not
installed:
– MD10360: FASTIO_DIG_NUM_OUTPUTS = 5
Hardware The following input bytes are used by the NC:

assignment: ET200
input bytes Both input bytes of the input module (slot 6)
– MD10366: HW_ASSIGN_DIG_FASTIN[0] = H05000080 (128D)
The 4th of the 4 input bytes of the signal module (slot 7)
ADI4
The high byte of the input word (slot 21)
– MD10366: HW_ASSIGN_DIG_FASTIN[3] = H0500014B (331D)
Hardware The following output bytes are used by the NC:

assignment: ET200
output bytes The 1st output byte of the output modules (slots 4 and 5)
– MD10368: HW_ASSIGN_DIG_FASTOUT[0] = H05000080 (128D)
– MD10368: HW_ASSIGN_DIG_FASTOUT[1] = H05000082 (130D)
ADI4
Both output bytes of the output word (slot 22)
– MD10366: HW_ASSIGN_DIG_FASTOUT[2] = H0500014A (330D)
– MD10366: HW_ASSIGN_DIG_FASTOUT[3] = H0500014B (331D)

Machine data
Table 10-50 Digital and analog I/Os: Machine data

General ($MN_ ...)
10300 FASTIO_ANA_NUM_INPUTS Number of active analog NC inputs
10310 FASTIO_ANA_NUM_OUTPUTS Number of active analog NC outputs
10320 FASTIO_ANA_INPUT_WEIGHT Weighting factor for analog NC inputs
10330 FASTIO_ANA_OUTPUT_WEIGHT Weighting factor for analog NC outputs
10350 FASTIO_DIG_NUM_INPUTS Number of active digital NC input bytes
10360 FASTIO_DIG_NUM_OUTPUTS Number of active digital NC output bytes
10362 HW_ASSIGN_ANA_FASTIN Hardware assignment of the external analog NC
inputs
10364 HW_ASSIGN_ANA_FASTOUT Hardware assignment of the external analog NC
outputs
10366 HW_ASSIGN_DIG_FASTIN Hardware assignment of the external digital NC
inputs
10368 HW_ASSIGN_DIG_FASTOUT Hardware assignment of the external digital NC
outputs
10380 HW_UPDATE_RATE_FASTIO Update rate of the synchronous external NC I/Os
10382 HW_LEAD_TIME_FASTIO Lead time of the synchronous external NC I/Os
10384 HW_CLOCKED_MODULE_MASK Synchronous processing of the external NC I/Os
10394 PLCIO_NUM_BYTES_IN Number of directly readable input bytes of the PLC
I/Os
10395 PLCIO_LOGIC_ADDRESS_IN Start address of the directly readable input bytes of
the PLC I/Os
10396 PLCIO_NUM_BYTES_OUT Number of directly writeable output bytes of the
PLC I/Os
10397 PLCIO_LOGIC_ADDRESS_OUT Start address of the directly writeable
output bytes of the PLC I/Os
10530 COMPAR_ASSIGN_ANA_INPUT_1 Hardware assignment of the NC analog inputs for
comparator byte 1
10531 COMPAR_ASSIGN_ANA_INPUT_2 Hardware assignment of the NC analog inputs for
comparator byte 2
10540 COMPAR_TYPE_1 Parameterization for comparator byte 1
10541 COMPAR_TYPE_2 Parameterization for comparator byte 2
21220 MULTFEED_ASSIGN_FASTIN Assignment of the input bytes of the NC I/Os for V1
“Several feedrates in a block”
Setting data
Table 10-51 Digital and analog I/Os: Setting data

General ($SN_ ...)
41600 COMPAR_THRESHOLD_1 Threshold values for comparator byte 1
41601 COMPAR_THRESHOLD_2 Threshold values for comparator byte 2

Interface signals
Table 10-52 Digital and analog I/Os: Interface signals

DB num- Bit, Byte Name Ref.
ber
General Signals from PLC to NC
10 0, 122, 124, 126, 128 Disable digital NC inputs
10 1, 123, 125, 127, 129 Set digital NC inputs from the PLC
10 4, 130, 134, 138, 142 Disable digital NC outputs
10 5, 131, 135, 139, 143 Overwrite screen form of digital NC outputs
10 6, 132, 136, 140, 144 Setting value of digital NC outputs from PLC
10 7, 133, 137, 141, 145 Setting screen form of digital NC outputs
10 146 Disable analog NC inputs
10 147 Setting screen form of analog NC inputs
10 148–163 Setting value for analog NC inputs from PLC
10 166 Overwrite screen form of analog NC outputs
10 167 Setting screen form of analog NC outputs
10 168 Disable analog NC outputs
10 170–185 Setting value for analog NC outputs from PLC
Signals from NC to PLC
10 60, 186–189 Actual value of digital NC inputs
10 64, 190–193 Setpoint of digital NC outputs
10 194–209 Actual value of analog NC inputs
10 210–225 Setpoint of analog NC outputs

10.7 Loadable compile cycles (SW 2.2 and higher)

Brief description Compile cycles are functional expansions of the NCK system software that can
be created by the operator and/or by Siemens and then imported in the control
later.
As part of the open NCK system architecture, compile cycles have comprehen-
sive access to data and functions of the NCK system level via defined software
interfaces. Therefore, you can use compile cycles to expand the functionality of
the NCK as much as you require or redefine it as far as allowed by the inter-
faces.
Until now, integrating a compile cycle in the control required an additional gener-
ation process to bind the compile cycle to the NCK system software to achieve
a complete system.
With SW 2.2 and higher, the compile cycles are no longer integrated in the NCK
by means of an additional generation process; instead they can be loaded in
the control at any time.
Siemens The following technological functions are available from Siemens as loadable
compile cycles compile cycles:
– 1D/3D clearance control in position controller cycle
Order No.: 6FC5 251-0AC05-0AA0
References: /FB3/ Description of Functions Special Functions
Section clearance control (TE1)
– Continue Machining at the Contour (Retrace Support)
Order No.: 6FC5 251-0AE72-0AA0
Section Continue Machining-Retrace Support (TE7)
– Fast Laser Switching Signal
Order No.: 6FC5 251-0AE74-0AA0
Section Cycle-Independent Path-Synchronous Switching
Signal Output TE8
When you order one of the listed technological functions, you are given the cor-
responding software license number. To obtain the compile cycle itself as a
loadable file (extension .ELF for executable and linking format), please contact
your local Siemens sales representative.
Note
Compile cycles created by Siemens are options that require explicit activation
and licensing.
References: Ordering information Catalog NC 60.2002
User To create your own compile cycles, in addition to the necessary NCK-specific
compile cycles development environment, you need the SINUMERIK Open Architecture com-
ponent “OA package NCK”.
Note
To use the SINUMERIK Open Architecture component “OA package NCK”, you
need to conclude an OEM contract.

10.7.1 Loading compile cycles
Requirements: The following requirements must be met to enable loading a compile cycle to
Control the NCK:
1. A flash file system (FFS) of at least 512KB is set up on the NCK.
MD18332: MM_FLASH_FILE_SYSTEM_MEM_SIZE (size of the FFS).
2. To transfer the compile cycle to the control, you need one of the following
transfer media:
– Floppy disk drive (option)
– Network connection via the Ethernet interface of the PCU with the exter-
nal PC/PG containing the compile cycles file.
3. To copy the compile cycle to the FFS of the NCK, you need SinuCom NC
Version 6.2.12 or higher.
Transfer Proceed as follows to transfer a compile cycle to the NCK:

1. Exit any active HMI Advanced windows and activate the NT desktop.
2. Use the Windows NT Explorer to copy the compile cycle file (e.g. ccresu.elf)
from the diskette drive or external PC/PG to a directory of your choice on the
PCU hard disk, e.g. F:\techfunctions.
3. Copy the compile cycle file with SinuCom NC from the directory used in
Step 2 on the PCU hard disk to the NCK FFS.
SinuCom NC menu command: File > Load compile cycle
Load compile cycle
NC flash file system – Loaded compile cycles
Name Size Changed on

ccclc.elf 80,985 7/30/02 10:38
Free memory space (bytes): ,431,015 Delete
Hard disk – Load compile cycle
Look in: techfunctions
Name Size Type Modified Attribute

ccclc.elf 79KB 7/30/02 10:38 A
ccresu.elf 64KB 7/30/02 10:38 A
cchslc.elf 80KB 7/30/02 10:38 A
File name: ccresu.elf Load
Files of type: Compile cycles (*.elf) Abort
Fig. 10-36 SinuCom NC: Load compile cycle

After copying the compile to the FFS, you need to reset the NCK. The com-
pile cycle is loaded in the NCK system software the time the NCK is booted.

Note
Several compile cycles can be copied to the NCK FSS in succession; you don’t
need to perform an NCK reset after each copy procedure.
10.7.2 Boundary conditions

The following checks are performed for all loaded compile cycles when the NCK
boots:
Interface If the interface version of the compile cycle is incompatible with the interface
versions version of the NCK system software, the following alarm is issued:
Alarm “7200 Version_conflict_with_CCNCKInterfaceVersion”.
Dependencies If a compile cycle has a functional dependency on another one which is not
loaded to the NCK, the following alarm is issued:
Alarm “7200 CC<Identifier>_ELF Loader_problem_from_dFixup”.
System enables If the compile cycle is not enabled in conjunction with SINUMERIK
840Di/840DiE, the following alarm is issued:
Not enabled for SINUMERIK 840Di
Alarm “7200 CC<identifier>_ELF NO_840Di”
Not enabled for SINUMERIK 840DiE
Alarm “7200 CC<identifier>_ELF NO_EMBARGO”.
Notice
If after booting the NCK, alarm “7200 . . .” appears, then none of the loaded
compile cycles are active.
10.7.3 Activating and licensing the technological functions
Activating and To activate the technological function loaded with the compile cycle to the NCK,
licensing the you need to set and license the respective option.
option For information about how to activate and license options, please see Section
6.8, page 6-201.
Activating the Each loaded compile cycle generates a technological function-specific global
technological machine data:
function
$MN_CC_ACTIVE_IN_CHAN_<identifier>[n], with n = 0, 1
in the machine data number range 60900 to 60999.

You can activate the entire technological function in the individual NC channels
or individual subfunctions via the above mentioned general NCK machine date.
For a description of the machine data, please see Subsection 10.7.4, page
10-392.
References The individual technological functions are described in:

/FB3/ Description of Functions Special Functions
Sections TE1 to TE8
Version display: The compile cycles loaded in the FSS NCK are displayed together with the re-
HMI Advanced spective version of HMI Advanced (option) in the following menu:
(option) Operating area switchover > Service > Version > Compile cycles
10.7.4 Data descriptions (MD)
General
machine data
60900 + i CC_ACTIV_IN_CHAN_XXXX[n]
with i = 0. 1. 2nd 3 ... with: XXXX = function identifier, n = 0 or 1
MD number n = 0: Activation of the technological function in the NC channels
n = 1: Additional functions within the technological function
Default settings: 0 min. input limit: 0 max. input limit: FFFF
Changes valid after RESET Protection level: 2 / 7 Unit: –
Data type: UINT16 valid from SW: 2.2
Meaning: Activation of the technological function in the NC channels
The technological function is activated in the NC channels via the MD with the index n = 0.
Bit 0 = 1: Technological function activated in NC channel 1
Bit n = 1: Technological function activated in NC channel n+1
For more details about which NC channels a technological function can be activated,
please refer to the manuals below.
Additional functions within the technological function:
Additional functions within the individual technological function can be activated via the MD
with the index n = 1. See References below.
References: /FB3/ Description of Functions Special Functions TE1 – TE8.

10.8 PROFIBUS DP
10.8 PROFIBUS DP
10.8.1 Setting the parameters for the shut-down behavior

If specific DP slaves react to an abrupt shut-down of PROFIBUS DP commu-
nication with error states, e.g. in response to on a power ON NC reset (warm
restart), machine data:
MD11250 PROFIBUS_SHUTDOWN_TYPE (PROFIBUS shutdown han-

dling)
can be used to configure the staged shut-down of PROFIBUS DP communica-
tion.
Note
The drives available for SINUMERIK 840Di:
– SIMODRIVE 611U / UE
– SIMODRIVE POSMO SI / CD / CA
can be operated by default with mode 0 (abrupt shut-down of PROFIBUS DP
communication). This corresponds to the initialized default setting of the ma-
chine data (see Subsection 10.8.2, page 10-393).
10.8.2 Data descriptions (MD)
General
machine data
11250 PROFIBUS_SHUTDOWN_TYPE
MD number PROFIBUS shutdown handling
Default settings: 0 min. input limit: 0 max. input limit: 2
Changes valid after RESET Protection level: 2 / 7 Unit: –
Data type: UINT8 valid from SW: 2.2
Meaning: Shut-down modes of PROFIBUS DP communication:
0= PROFIBUS DP communication is shut down at the DP master end without any
warning.
1= PROFIBUS DP is switched to CLEAR mode for at least 20 clock cycles.
PROFIBUS DP communication is then shut down.
If it is not possible to switch the PROFIBUS DP to CLEAR mode, the
procedure described in step 2 is followed.
To be used for: SINUMERIK 840D with DP-Link module.
2= Null vales are transmitted for at least 20 clock cycles for all DP slave drives
connected to PROFIBUS DP for the following frame data:
– Control word 1
– Control word 2
PROFIBUS DP communication is then shut down.
To be used for: SINUMERIK 840Di with PLC 315-2DP, 314-2C, 317-2DP.

10.9 Initial settings
10.9 Initial settings

Concept The status of an NC function, e.g. G codes, tool length compensation, trans-
formation, coupled motion (of an axis) etc., which is taken in a certain status of a
channel is a default setting.
Channel states for which default settings can be parameterized are:
1. Power up (NCK reset), reset (channel or mode group reset) and end of parts
program
and
2. Parts program start.
The default setting of an NC function remains stored until it is explicitly changed
by operation or programming.
Parameterizing The machine data:

default settings
MD20110: RESET_MODE_MASK (“Definition of the control default settings
in case of reset”)
MD 20112: START_MODE_MASK (“Definition of the control default settings

in case of NC start”)
MD20150: GCODE_RESET_VALUES (“Reset position of the G groups”)

MD20152: GCODE_RESET_MODE (“G code initial setting in case of reset”)
are used to define the relevant default settings.
Table 10-53 Default settings that can be parameterized through MD
State parameterizable through MD

Power up (power ON) MD20110: RESET_MODE_MASK
MD20150: GCODE_RESET_VALUES
RESET/parts program end MD20110: RESET_MODE_MASK
MD20150: GCODE_RESET_VALUES
MD20152: GCODE_RESET_MODcE
Parts program start. MD20112: START_MODE_MASK
MD20110: RESET_MODE_MASK

Workpiece IWS
Section: Workpiece-related actual value system/reset behavior

10.10 NC/PLC diagnosis (840Di SW 2.3 and higher)
10.10.1 Menu: Diagnostics
Operating path The menu for NC/PLC diagnosis is located under the follwoing operating path:
S Operating area switchover > Diagnosis > NC/PLC Diagnosis > Diagnosis
Start-up CHAN1 AUTO MPF0

Channel RESET Program aborted PLC
ROV RUN–P
PLC
NCK PLC RUN
6 Running
SF PLC
NCK reset RUN–P STOP
Acknowledge BATL
alarm 4065
General NCK reset BATF RUN PLC
MRES
FORCE STOP
NCK latency times
RUN General
200
STOP PLC reset

PLC MRES
SF–DP
General PLC reset NCK
ms
BUSF Reset
General
0 NCK reset
0 Time (sec) 73
>>
Diagnostics Settings
Fig. 10-37 Menu: NC/PLC diagnosis
Group: NCK The NCK group combines the following functions:
S NCK status
The output field displays the current status of the NCK:
– 0 not started
– 1 started
– 2 Initialize data
– 3 Initialize data
– 4 Start–up
– 5 Wait for PLC
– 6 Running
– F NCK error

S NCK reset
The “NCK Reset” button initiates an NCK POWER ON reset.
On NCK POWER ON reset, all machining activities are aborted. Maximum
deceleration for drives in motion does not take place at the acceleration
characteristic but at the current limit.
After start–up, the NC status is Reset. Machine and user data are not
changed.
S General NCK reset

The “General NCK reset” button initiates a NCK–POWER ON reset followed
by ageneral NCK reset.
All active machining processes are aborted as described for “NCK reset”.
After start–up, the NC status is Reset. All machine and user data have been
deleted and the standard machine data loaded.
Notice
After “General NCK resetart”, it is necessary to recommission the NC or load a
series start–up file (see Section 14, Page 14-449).
S Acknowledging Alarm 4065

The “Acknowledge Alarm 4065” acknowledges alarm:
S Alarm: “4065 Battery-backed memory has been restored from the

backup copy disk (possible data loss)”
and triggers a NCK–POWER ON reset.
To acknowledge the alarm per soft key, it is necessary to switch to the next
soft key bar per ETC.
Note
Alarm 4065 can also be acknowledged with a NCK–POWER ON reset per
“General NCK reset”. Then, the NC must be recommissioned or a series ma-
chine start-up file (see Chapter 14, Page 14-449) loaded.
Group: PLC The PLC group combines the following functions:
S PLC RUN–P
Use the button PLC “RUN–P” to bring the PLC to the status ”RUN–PRO-
GRAMMING”. In this state, it is possible to modify the PLC user program
without activating the password.
S PLC RUN.
Use the button “PLC RUN” to bring the PLC to the ”RUN” status. Only read
access via a programming unit is possible in this operating state. Changes
cannot be made to the PLC user program until the password has been set.

S PLC STOP
Use the button “PLC STOP” to bring the PLC to the status ”STOP”. Process-
ing of the PLC program is halted and all outputs are set to alternative values.
S PLC MRES
Use the button “PLC MRES” to bring the PLC to the “STOP” state and then
perform a general PLC reset. The follwoing actions are carried out by the
PLC:
1. The PLC deactivates all existing connections.
2. The user data are deleted (data and program blocks)
3. The system data blocks (SDB) are deleted.
4. Non–volatile data are copied to RAM again by the PLC after the general
reset.
5. The diagnosis buffer, MPI parameters, time and operating hour counter
are not reset.
S General PLC reset

Use the button “General PLC reset” to bring the PLC to the “STOP” state
and then perform an extended general PLC reset. The actions stated above
at 1. – 4. are performed and the parameters stated at 5. also reset.
S Status displays
The states displayed by the LEDs proivde the following information:
S SF (System Fault)
Lights up on PLC system fault, e.g. hardware, programming, parameter-
ization, computation, timing, battery and communication faults.
S BATL (Battery Low)

Lights up if the 5 V supply voltage (buffer battery) falls below it minimum
permissible value.
S BATF (Battery Fault)

Lights up if the 5 V supply voltage fails (buffer battery).
S FORCE
Lights up when the FORCE function is active.
Use the FORCE function to set user variable to fixed values that the user
program must not exceed. Detailed information is provided in the online
help of the SIMATIC Manager STEP 7.
S RUN: see Table 10-54 below.

S STOP: see Table 10-54 below.
S SF–DP (Groupfault–Distributed I/Os)
Lights up if one of the distributed I/Os signals a fault.
S BUSF (Bus fault)

Lights up in connection with PROFIBUS–DP, e.g.:
– Bus fault (e.g. short/circuit or interruption)
– Interface error (e.g. error in S7 configuration)

Table 10-54 PLC operating state display per RUN/STOP evaluation
RUN STOP PLC operating state

lit off RUN The PLC program is running.
off lit STOP: The PLC program is not running. STOP
can be triggered by the PLC program, by an er-
ror or per user operation.
Flashes at 0.5 Hz lit HOLD: The PLC user program was halted (trig-
gered by a test function).
Flashes at 2 Hz lit RESTART: A PLC start–up is performed (transi-
tion from STOP to RUN). If the action is aborted,
a transition to STOP take place.
off – lit General reset: General reset requested.
– off for 3 secs
– lit
off – lit General reset: General reset active
– flashes at 2Hz
for at least. 3
secs
– lit
Group: NCK The NCK latency time group combines the following information:
latency time S NCK latency time
The foundation for the SINUMERIK 840Di Real–time property is the cyclic
activation of the NC system software at defined intervals.
Since the NC and Windows NT share the available processor resources of
the PLC, there can be delays (latency times) when calling the NCK. Latency
times greater than 200µsecs are Real–time violations, for which the func-
tional integrity of the NC is not longer guaranteed.
The latency time display of the NCK can be used to continuously monitor
the latency behavior of the NCK over a period of 50 seconds. Following re-
placement of extension of the HW and/or SW components, it is thus pos-
sible to determine whether, and if so to what extent, these have an effect on
the real–time behavior of the NCK.
Note
For details of real–time properties of the SINUMERIK 840Di, refer to Subsec-
tion 1.1.4, Page 1-24.

10.10.2 Menu: Settings
Operating path The menu for the SINUMERIK 840Di–specific settings is located under the foll-
woing operating path:
S Operating area switchover > Diagnosis > NC/PLC Diagnosis > Settings

Channel RESET Program aborted
ROV
Settings
non–volatile user memory 2560 KB RAM / HD non–volatilet
Signal input for shutdown behavior

Signal source deactivated
Signal level –
Modify
Fig. 10-38 Menu: Settings
Modifying data On switchover to the menu, the data displayed are read–only. To modify the
data, first press the soft key: Modify.
Group: Settings The Settings group combines the following functions:
S Non–volatile user memory

Use the list box to select the size of the non–volatile user memory:
Note
The siye of the SRAM memory area is displayed in the following machine data:
S MD 18060: INFO_FREE_MEM_DYNAMIC (free static memory).

S 512KB SRAM
This selection option assigns the 1 MB physical SRAM SRAM of the
MCI boards to the NCK for storing retentive data. Approx. 512KB, de-
pending on the configuration of the NCK (number of channels, number of
axes, etc.) are available to the user as user memory.
S 2560KB RAM / HD non–volatile

This selection option assigns 3MB of virtual SRAM (see Subsection
10.4.3, Page 10-300) to the NCK for storing retentive data. Approx.
2560KB, depending on the configuration of the NCK (number of chan-
nels, number of axes, etc.) are available to the user as user memory.
Notice
On loss of voltage or if the PCU is deactivated without terminating Window NT
correctly, all user data are lost. A UPS system (see Subsection 1.1.8, Page
1-29) is therefore absolutely necessary in conjunction with the virtual SRAM.
S Signal input for Shutdown behavior: Signal source

Use the list box to configure the digital input used for the shutdown signal of
the UPS:
S deactivated
No input signal present
S NCK inputs 0...3

The shutdown signal of the UPS is connected to the digital input of the
MCI board extension module (see Subsection 2.4.3, Page 2-66).
S Signal input for shutdown behavior: Signal level

Use the list boc to configure the level of the shutdown signal of the UPS:
S Low active
On detection of the low level (0) at the configured input,
SINUMERIK 840Di NCK / PLC and then Windows NT are terminated
S High active
On detection of the high level (1) at the configured input,
SINUMERIK 840Di NCK / PLC and then Windows NT are terminated.

Accept changes To accept the changes made press the soft key: Accept. The message box that
appears must also be confirmed by pressing the soft key: Accept.
Use the soft key: Abort to discard all changes and display the original settings
again.

Channel RESET Program aborted
ROV
Settings
Accepting user
non–volatile the changes
memorycan result in the loss of2560
NC user data. / HD non–volatile
KB RAM
Ensure that these data have been stored in a series machine start-up file.
1. Memory
Signal setting
input for have been
shutdown changed.
behavior
Changes do not become effective until after a full system reboot.
Signal source deactivated
2. The shutdown behavior has been modified.
Signal level – of voltage.
Wrong configuration results in data loss on loss
Do you really want to make the changes now?
Cancel
Accept
Fig. 10-39 Accepting settings
Notice
It is strongly recommended that you create a series machine start-up file as
described above prior to making any changes. See Chapter 14, page 14-449.

Notes

Alarm and Message Texts 11
11.1 Alarm and message texts
In order to be able to easily adapt alarm and message texts to the specific re-
quirements of an automation system, the alarm and message texts are stored in
freely accessible ASCII text files.
The alarm and message texts contained in the text files are used commonly by
all SINUMERIK user interfaces:
S SinuCom NC
S 840Di start-up
S HMI Advanced.
By changing/modifying the texts or files or by creating new texts/files, a flexible
adaptation to the current requirements is possible.
Storage of the Files containing the alarm and message texts are stored on the hard disk in
text files directory <installation path>\dh\mb.dir\.
11.1.1 Configuration file MBDDE.INI
Structure of the The alarm and message texts to be used are set in the file <installation
file MBDDE.INI path>\mmc2\mbdde.ini. To this aim, the appropriate paths to the application-
specific standard and user files must be stored in the section [Textfiles] of the
file MBDDE.INI.
Extract of the file “MBDDE.INI”:
...
[Textfiles]
MMC= <installation path>\dh\mb.dir\alm_
NCK= <installation path>\dh\mb.dir\aln_
PLC= <installation path>\dh\mb.dir\plc_
ZYK= <installation path>\dh\mb.dir\alz_
CZYK= <installation path>\dh\mb.dir\alc_
UserMMC=
UserNCK=
UserPLC= <installation path>\dh\mb.dir\myplc_
UserZyk=
UserCZyk=
...

11 Alarm and Message Texts 06.03
11.1.2 Standard text files
Standard The standard alarm and message texts in ASCII format are stored in the
text files following files on the hard disk:
– MMC : <installation path>\dh\mb.dir\alm_XX.com
– NCK : <installation path>\dh\mb.dir\aln_XX.com
– PLC : <installation path>\dh\mb.dir\alp_XX.com
– ZYK : <installation path>\dh\mb.dir\alz_XX.com
– CZYK : <installation path>\dh\mb.dir\alc_XX.com
“XX” stands for the abbreviation of the appropriate language (see Table 11-1,
page 11-405).
The standard text files should not be modified for adaptation of the alarm and
message texts. In the case of a software update, the inserted or modified user-
specific texts would be lost by overwriting the existing data. It is therefore ur-
gently recommended to store user-specific alarm and message texts in sepa-
rate user text files.
11.1.3 User text files
User You can replace the alarm and message texts stored in the standard text files
text files by your own user-specific text files or extend them.
Note
To edit the text files, any ASCII editor can be used.
When editing the text files with a different editor, make sure that they are then
stored in ASCII format.
The alarm and message texts from the user files replace the standard texts with
the same alarm and message numbers.
Texts for alarm or message numbers not contained in the standard texts are
additionally provided.
Notice
The maximum length of an alarm or message text displayed over two lines is
110 characters.
Storage path The user-specific text files must be copied with operating area:
Services into the directory:
<installation path> \dh\mb.dir.

06.03 11 Alarm and Message Texts
Language The language assignment of the user-specific alarm texts is done using the
dependency of name of the text file. The appropriate code and the file extension .com are
the alarm texts added to the user file name entered in MBDDE.INI:
Table 11-1 Language codes
Language Abbreviation
German gr
English uk
French fr
Italian it
Spanish sp
Announcement in The user-specific text files that are now in the directory: <installation path>
the system \dh\mb.dir are announced to the system using an appropriate entry in the file
MBDDE.INI.
Note
To make sure that the modified file MBDDE.INI is not overwritten in the case of
a software update, it is strictly recommended to store it in the intended
USER path (<installation path>\user\mbdde.ini).
Example Example of adding an additional text file MYPLC_GR.COM:
Note
If the text file MYPLC_GR.COM is created on an external PC and then read in
through the serial interface (e.g. with PCIN), the following lines must be con-
tained at the beginning of the file:
%_N_MYPLC_GR_COM
;$Path=/_N_MB_DIR
MYPLC_GR.COM: User-specific file for user-specific, German PLC alarm texts

%_N_MYPLC_GR_COM
;$Path=/_N_MB_DIR
700000 0 0 “DB2.DBX180.0 set”
700001 0 0 “Lubrication pressure missing”
....
MBDDE.INI:
[Textfiles]
UserPLC= <installation path>\dh\mb.dir\myplc_
Notice
Any modifications to alarm texts come only into effect after the appropriate user
interface has been rebooted.
When creating text files, make sure that the date and time are correctly set on
the PCU. Otherwise the user texts might not be displayed on the screen cor-
rectly.

11.1.4 Syntax for alarm text files
Alarm numbers The following alarm numbers are available for alarms relating to cycles, compile
cycles and the PLC:
Table 11-2 Alarm numbers for cycle, compile cycle and PLC alarms
Number range Designation Effect Delete

60000–60999 Cycle
y alarms Display, NC start disable Reset
61000–61999 (Si
(Siemens) ) Display, NC start disable, Reset
axis/spindle standstill
62000–62999 Display Cancel
63000–64999 Reserved
65000–65999 Cycle
y alarms Display, NC start disable Reset
66000–66999 (
(user)
) Display, NC start disable, Reset
axis/spindle standstill
67000–67999 Display Cancel
68000–69000 Reserved
70000–79999 Compile cycle alarms
400000–499999 PLC alarms, general
500000–599999 PLC alarms for channel
600000–699999 PLC alarms for axis and
spindle
700000–799999 PLC alarms for user
800000–899999 PLC alarms for sequential
controllers/graphs
Format of the The text file for cycle and compile cycle alarms has the following structure:
text file for Table 11-3 Structure of text file for cycle alarm texts
cycle alarm texts
Alarm number Display Help ID Text or alarm number
60100 1 0 “No D number %1 programmed”
60101 1 0 60100
... ... ... ...
65202 0 1 “Axis %2 in channel %1 is still moving”
// Alarm text file for cycles in German

P3 Basic PLC Program
Section: Lists
Alarm number Alarm number list
Display This number defines the alarm display type:

0: Display in alarm line
1: Display in a dialog box

Help ID The default setting “0” means:

The help file supplied by Siemens provides a detailed description of the alarm.
A value between 1 and 9 uses an assignment entry in the MBDDE.INI file to
refer to a help file created by the user. See also Subsection 11.1.5,
page 11-408, section: HelpContext.
Text or The associated text is given in inverted commas with the position parameters.
alarm number
S The characters ” and # must not be used in alarm texts.
The character % is reserved for displaying parameters.
S If the user wishes to use an existing text, he can insert a reference to the
appropriate alarm text. 5-digit alarm number instead of “text”.
S The alarm text file may contain comment lines which must start with “//”. The
maximum length of the alarm text is 110 characters for a 2-line display. If the
text is too long, it is cut off and the symbol “*” added to indicate missing text.
S Parameter “%1”: Channel number

Parameter “%2”: Block number.
Format of the The ASCII file for PLC alarm texts has the following structure:
text file for
PLC alarm texts Table 11-4 Structure of text file for PLC alarm texts
Alarm Display Help ID Text Text on MMC

no.
510000 1 0 “Channel %K FDDIS all” Channel 1 FDDIS all
600124 1 0 “Feed disable axis %A” Feed disable axis 1
600224 1 0 600124 Feed disable axis 2
600324 1 0 600224 Feed disable axis 3
703210 1 1 “User text” User text
...
703211 1 1 “User text%A ...” User text
Axis 1 ...
// Alarm text file for PLC alarms

P3, Basic PLC Program
Display This number defines the alarm display type:

0: Display in alarm line
1: Display in a dialog box
Help ID The default setting “0” means:

The help file supplied by Siemens provides a detailed description of the alarm.
A value between 1 and 9 uses an assignment entry in the MBDDE.INI file to
refer to a help file created by the user. See also Subsection 11.1.5,
page 11-408, section: HelpContext.

Text or The associated text is given in inverted commas with the position parameters.
alarm number
S The characters ” and # must not be used in alarm texts.
The character % is reserved for displaying parameters.
S If the user wishes to use an existing text, he can insert a reference to the
appropriate alarm text. 6-digit alarm number instead of “text”.
S The alarm text file may contain comment lines which must start with “//”. The
maximum length of the alarm text is 110 characters for a 2-line display. If the
text is too long, it is cut off and the symbol “*” added to indicate missing text.
S Parameter “%K”: Channel number (2nd digit of alarm number)

Parameter “%A”: The parameter is replaced by the signal group no.
(e.g. axis no., user area no., sequential controller no.)
Parameter “%N”: Signal number
Parameter “%Z”: Status number.
11.1.5 Setting the alarm log properties
In addition to the current alarms, an alarm log showing the alarms occurred hith-
erto is displayed on the user interface in the form of a list. The properties of the
alarm list can be changed in the MBDDE.INI file.
Table 11-5 Section of the file MBDDE.INI
Section Meaning
Alarms General information on the alarm list:
e.g. time/date format of the messages
TextFiles Path/file specification of the alarm/text files:
e.g. UserPLC = <installation path>\dh\mb.dir\myplc_
HelpContext Names and paths of the help files: e.g. File0=hlp\alarm_
DEFAULTPRIO Priorities of the various alarm types: e.g. POWERON=100
PROTOCOL Log properties:
e.g. file=.\proto.txt <name and path of log file>)
KEYS Information on keys that can be used to delete alarms:
e.g. Cancel = +F10 <Use key combination Shift+F10 to delete an
alarm>
You will find further details of file entries in:

References: /BN/ User’s Guide: OEM package for MMC

Section: [Alarms] The settings in this section define the following properties of the alarm list:
S TimeFormat
Here, the pattern is entered which is to be used for output of date and time.
It is the same as the CTime: Format of the Microsoft Foundation Classes.
S MaxNo
defines the maximum size of the alarm list.
S ORDER
defines the order in which the alarms are included in the alarm list:
FIRST puts more recent alarms at the head of the list,

LAST puts more recent alarms at the end of the list.
Example Example for the section: [Alarms]

– Time format: day.month.year hour:minute:second
– Maximum size of alarm list: 50
– Order: New alarms are to be put at the end of the list
[Alarms]
TimeFormat=%d.%m.%y %H:%M:%S
MaxNo=50
ORDER=FIRST
J

Notes

Dry Run of Axis and Spindle 12
12.1 Preconditions
Axis To allow an axis to be traversed from the control system, it is necessary to

enabling supply enabling terminals on the drive and to set enabling bits on the interface.
DBxx The data block designated DBxx depends on the maximum configuration of the
machine axes currently validated for SINUMERIK 840Di.
Enables on
the drive
112 Setting-up mode
9 +24V
63 Pulse enable
9 +24V
64 Drive enable
9 +24V Mains supply module
48 DC link start
9 +24V
663 Pulse enable

Drive module
9 +24V
Enabling through The following signals must be made available at the PLC interface for axis or
PLC interface spindle:
IS “Servo enable” (DB31-DBxx, DBX2.1)
IS “Pulse enable” (DB31-DBxx, DBX21.7)
IS “Position measuring system 1 or 2” (DB31-DBxx, DBX1.5, DBX 1.6)
The following signals on the interface must not be set or else the axis/spindle
motion will be disabled:
IS “Feed/spindle override switch” (DB31-DBxx, DBB0) not at 0%
IS “Axis/spindle lock” (DB31-DBxx, DBX1.3)
IS “Follow-up mode” (DB31-DBxx, DBX1.4)
IS “Distance to go/spindle reset” (DB31-DBxx, DBX2.2)
IS “Feed stop/Spindle stop” (DB31-DBxx, DBX4.3)
IS “Traversing key lock” (DB31-DBxx, DBX4.4)
IS “Ramp-function generator lock” (DB31-DBxx, DBX20.1)

12 Dry Run of Axis and Spindle 06.03
12.1 Preconditions
References: /FB/ Description of Functions, Basic Machine

A2, Various Interface Signals and Functions
Limit switches Setting the limit switches and checking the interface signals:
S Hardware limit switch PLUS DB31-DBxx.DBX12.1
S Hardware limit switch MINUS DB31-DBxx.DBX12.0.

06.03 12 Dry Run of Axis and Spindle
12.2 Dry run of axis
Check enabling signals on drive

I/RF module: Terminal 63 (pulse enable)
64 (drive enable)
48 (DC link start)
FDD module: 663 (pulse enable)
Check interface signals (DB 31–48)
DBB0 Feedrate override switch
DBX1.7 Compensation active
DBX1.5/1.6 Position measuring system 1/2
DBX1.4 Follow-up mode
– Select JOG mode DBX1.3 Axis disable
– Traverse axis using direction key DBX2.2 Delete distance to go
DBX2.1 Controller enable
DBX4.3 Feed stop/spindle stop
DBX5.0-5.5 JOG-INC
DBX4.6/4.7 Traversing keys
DBX20.1 HLGSS (Drive)
DBX21.7 Pulse enable (611D)
Check machine data
no
Does the MD32000–32050 Velocities
axis move? MD36000–36620 Monitoring functions
MD32110 Sign actual value
MD32250 Nominal output voltage 1)
MD32260 Nominal output speed
yes Service display
Traversing
direction no Check:
OK? MD32100: AX_MOTION_DIR
yes
Set path 10mm
Is path no
evaluation Check:
O.K.? MD31000–31080: (encoder matching)
yes
1) Speed setpoint matching
1 – ADI4: –> MD32250 00
– SIMODRIVE 611 universal / E; POSMO CD/CA, SI
–> MD32250 = 0

Traverse with
1. Feedrate 1000 mm/min
2. Rapid traverse
yes 1. Interpret alarm

Alarm? 2. Check:
MD of velocity adaptation
no
Check machine data

MD32200 KV factor
MD32410 Time constant for jerk limitation
Following no MD32910 Dynamic response adaptation
error OK? MD31050/31060 Load gearing
MD32610 Feedforward control
MD of the velocity matching
Check the drive parameters
yes P880 PROFIBUS speed evaluation
End

06.03 12 Dry Run of Axis and Spindle
12.3 Dry run of spindle
Check enabling signals on drive

I/RF module 63 pulse enable
64 drive enable
48 DC link start
Drive module 663 pulse enable
Check interface signals (DB31–48)
DBB0 Spindle speed override
DBX1.7 Compensation active
DBX1.5/DBX1.6 Position measuring system 1/2
DBX1.3 Axis/spindle disable
Enable spindle DBX2.1 Controller enable
(controller enable NC, DBX16.7 Delete S value
enable on drive) DBX3.6 Velocity/spindle speed limi-
tation and MD 35160
Define speed DBX4.3 Feed stop/spindle stop
DBX20.1 HLGSS
DBX2.2 Spindle reset when MD 35050=1
DBX21.7 Pulse enable
Check machine and setting data
MD32250 Nominal output voltage 1)
MD32260 Nominal output speed
Does the no MD 35100–35150 Spindle speed limitation
spindle ro- MD 36200 AX_VELO_LIMIT
tate? SD 41200 JOG_SPIND_SET_VELO
SD 43220 SPIND_MAX_VELO_G26
SD 43210 SPIND_MIN_VELO_G25
yes Service display
Is
rotational no Check:
direction MD32100: AX_MOTION_DIR
OK
yes
Specified speed 100rpm
Actual
speed no
= Check:
Set MD31000–31080: (encoder matching)
speed?
yes
1
1) Speed setpoint matching
– ADI4: –> MD32250 00
– SIMODRIVE 611 universal / E; POSMO CD/CA, SI
–> MD32250 = 0

IS Check machine data and interface signals

“Spindle in MD 35110–35140 Speeds for gear stages
no
setpoint range” MD 35150 Spindle speed tolerance
(DB31–DBxx, IS “Actual gear stage” (DB31-DBxx, DBB16)
DBX83.5)? IS “Select drive parameter set” (DB31-DBxx, DBB21)
IS “Setpoint gear stage” (DB31-DBxx, DBB82)
IS “Active drive parameter set” (DB31-DBxx, DBB93)
Change over
gear stage yes
no All gear
stages tested?
yes
Position no
spindle? End
yes
Check machine data

Position MD 36000 Coarse exact stop
reached off: no MD 36010 Fine exact stop
1. Higher speed MD 32200 KV factor
2. Zero speed MD 35210 Acceleration in position control range
Change over MD 35300 Creep speed
gear stage MD 36300 Encoder limit frequency
MD34200 Spindle synchronization
yes MD of encoder matching
no All gear
stages tested?
yes
End

Drive Optimization using HMI Advanced 13
13.1 Overview
Start-up: In the operating area Start-up of HMI Advanced, the following functions can be
drive/servo chosen from the menu item Drives/Servo for analyzing speed and position con-
troller of a drive, as well as individual drive/servo data:
S Frequency response measurement of speed control loop

S Frequency response measurement of position control loop
S Function generator
S Circularity test
S Servo trace.
Notice
A measurement of the torque control loop with HMI Advanced is not possible
within the framework of SINUMERIK 840Di.
Measuring The measuring functions make it possible to evaluate the most important speed
functions and position control loop quantities in the time and frequency range of a drive
without any external measuring instruments.
Integrated FFT The integrated FFT analysis (Fast Fourier Transformation) provides a powerful
analysis means to assess the control loop quality and, in addition, also to analyze the
given mechanical properties.
The FFT analysis should be used whenever:
– unsteady speed or position signal curves indicate problems with stability
– only long rise times can be obtained in the speed loop.
Circularity test The circularity test serves to analyze the contour accuracy on the quadrant tran-
sitions of circular contours achieved by means of friction compensation (con-
ventional or neural quadrant error compensation).
References: /FB/, Description of Functions, Extended Functions
K3, Compensations
Section: Circularity test

13 Drive Optimization using HMI Advanced 06.03
13.1 Overview
Servo trace Servo trace provides a graphically assisted analysis of the time response of
servo and drive data. For example:
S Actual position
S Setpoint position
S Following error
S Contour deviation.
Saving The diagrams determined can be archived using file functions. Thus, they can
measurement be used both for documenting the machine settings and to facilitate remote
results diagnosis.

06.03 13 Drive Optimization using HMI Advanced
13.2 Measuring functions
Explanation Several measuring functions are provided to display the time and/or frequency
response of drives and closed-loop controls in graphic form on the screen. For
this purpose, test signals with an adjustable interval are connected to the drives.
Measurement/ The test setpoints are adapted to the application in question by means of mea-
signal parameters surement or signal parameters, the units of which are determined by the rele-
vant measuring function or operating mode. The measurement or signal param-
eter units are subject to the following conditions:
Table 13-1 Quantities and units of measurement and signal parameters
Size Unit
Velocity Metric system:
Specified in mm/min or rev/min for translatory or rotary motions
Inch system:
Specified in inch/min or rev/min for translatory or rotary motions
Distance Metric system:
Specified in mm or degrees for translatory or rotary motions
Inch system:
Specified in inches or degrees for translatory or rotary motions
Time Specified in msec
Frequency Specified in Hz
Note
The default setting for all parameters is 0.
Prerequisites for To ensure that no erroneous traversing movements due to parts programs can
starting measuring be carried out, the measuring functions have to be started in JOG mode.
functions
Caution
! When traversing movements are carried out within the framework of measuring
functions, no software limit switches and working area limitations are moni-
tored, since these are carried out in follow-up mode.
Prior to starting traversing motions, the user must therefore ensure that the
axes are positioned such that the traversing limits specified within the frame-
work of the measuring functions are sufficient to prevent collision with the ma-
chine.

Starting measuring Measuring functions initiating a traversing movement are only selected using
functions the specific soft key. The actual start of the measuring function and thus of the
traversing movement is always carried out with NC START on the machine con-
trol panel.
If the main screen of the measuring function is quitted without the traversing
motion being initiated, the selection of the traversing function is canceled.
Once the traversing function has been started, the main screen can be quitted
without any affect on the traversing motion.
Note
JOG mode must be selected when measuring functions are started.
Further safety The user must ensure that when the measuring functions are used:
notices
– the EMERGENCY STOP button is always within the reach;
– no obstacles are in the traversing range.
Canceling The following events will cancel active measuring functions:

measuring
– Hardware limit switch reached
functions
– Traversing range limits exceeded
– EMERGENCY STOP
– RESET (mode group, channel)
– NC stop
– No controller enabling command
– Canceling drive enable
– Canceling traversing enable
– Selection of parking (in position-controlled operation)
– Feed override = 0%
– Spindle override = 50%
– Change in operating mode (JOG) or operating mode JOG not selected
– Actuation of traversing keys
– Actuation of handwheel
– Alarms leading to axis shutdown.

13.3 Additional functions
Interface signals: In conjunction with the measuring functions, another 2 axis-specific interface
Drive test signals are provided:
Traversing
S DB31-DBx, DBX61.0 “Drive test traversing request”
request,
Traversing enable S DB31-DBx, DBX1.0 “Drive test traversing enable”
In the PLC user program, this can be used in conjunction with measuring func-
tions to realize an additional axis-specific traversing enable.
Activation The interface signals are activated from the main menu of the appropriate mea-
suring function in the group “Drive test traversing enable”. See Fig. 10-37,
page 10-395.
Fig. 13-1 Main menu: Position control loop measurement
Choose the type of traversing enable from the selection list either by using the
Toggle key or by clicking with the right mouse button on the desired enable
type:
– Without PLC
Traversing of the axis to be measured is enabled depending on the
interface signals typical for JOG mode (servo enable, pulse enable, etc.).

– With PLC
Traversing of the axis to be measured is enabled in addition to the
interface signals typical for JOG mode depending on the interface signal.
“Drive test traversing enable”.
Toggle key
Traversing range The measuring functions have their own traversing range monitoring. This tra-
monitoring versing range monitoring can be used to limit or monitor the traversing range of
an axis to be measured without referencing this axis.
The basis is the absolute axis position displayed in the “Status” group at the
time of measurement.
Activation The traversing range monitoring is activated from the main menu of the ap-
propriate measuring function in the group “Traversing range”. See Fig. 10-37,
page 10-395.
Choose the type of traversing range monitoring from the selection list “Monitor-
ing” either using the Toggle key or by clicking with the right mouse button on
the desired type of traversing range monitoring:
– Inactive
The axis is traversed without monitoring of the traversing range.
– Active
The axis is traversed with monitoring of the traversing range, depending
on the traversing range limits set:
– Upper limit
– Lower limit.

13.4 Frequency response measurement

You can measure both digital and analog drives. However, the bandwidth avail-
able for measuring is limited by the position controller or PROFIBUS cycles.
Note
You will find detailed information about frequency measurement and optimiza-
tion of the torque/current and speed control loop of the SIMODRIVE 611 univer-
sal/E, POSMO CD/CA and SI drives in the online help of the start-up tool Simo-
Com U:
Menu command: Help > Help topics > Index
– Measuring function
– Optimization of speed control loop.
13.4.1 Measurement of the torque control loop
A measurement of the torque control loop with HMI Advanced is not possible
within the framework of SINUMERIK 840Di.
13.4.2 Speed control loop measurement
Note
You will find information about optimization of the torque/current and speed
control loop of the SIMODRIVE 611 universal/E, POSMO CD/CA and SI drives
in the online help of the start-up tool SimoCom U, Index: Optimization of speed
control loop.
Functionality This measurement function basically analyses the response to the motor mea-
suring system. Depending on which basic measurement setting has been se-
lected, various measurement parameters lists as described below are made
available.
Procedure The traversing range monitoring function is set and the enabling logic (external/
internal) selected in the speed control loop measurement main screen.
1. Set the traversing range monitoring function and enabling logic in the main
menu.
Four different types of measurement are available for testing the speed con-
trol loop:
– Reference frequency response
– Setpoint step change
– Interference frequency response
– Disturbance step change
– Speed controller system

2. Set the required parameters in the measurement parameter screen.

3. Display of the measurement result on the screen with the soft key Display.
Measurement: The reference frequency response measurement determines the transmission

Reference fre- response of the speed controller.
quency response The response range should be as wide as possible and without resonance. It
may be necessary to install stop or low-pass filters. Particular care must be
taken to prevent resonance within the speed controller limit frequency range
(stability limit approx. 200–500Hz).
Fig. 13-2 Example: Measurement results of a reference frequency response measurement
Measurement: Alternatively, the interference frequency response can be recorded in order to

Interference fre- assess how well the control suppresses interference.
quency response
Measurement Amplitude
parameters: This parameter determines the height of the test signal amplitude. This should
Reference and give rise to only a very low speed of a few (approximately 1 to 2) revs/min at the
interference motor end.
frequency
response

Bandwidth
The bandwidth parameter is used to set the analyzed frequency range. The
larger this value, the finer the frequency resolution and the longer the measure-
ment time. The maximum value is given by the position control cycle (Tposition
controller).
Bandwidthmax [ Hz ] = 1 / (2 * Tposition controller [ sec ])

Example: Position controller cycle: 2msec
Bandwidthmax = 1 / (2 * 2*10–3) = 250Hz
Averaging
The accuracy of the measurement, but the measurement duration, too, will in-
crease with this value. A value of 20 is normally suitable.
Settling time
This value represents the delay between recording of the measured data and
injection of the test setpoint and offset. A value of between 0.2 and 1sec is rec-
ommended. Do not set too low a value for the settling times or the frequency
response and phase diagrams will be distorted.
Offset
The measurement requires a slight speed offset of a few motor revolutions per
minute. The offset must be set to a higher value than the amplitude.
S The Offset is run up using an acceleration ramp.
S The acceleration value is defined for one
axis: check MD 32300: MAX_AX_ACCEL
spindle: check MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL
MD 35210: GEAR_STEP_POSCTRL_ACCEL
S The following applies: Acceleration value = 0, no ramp

Acceleration value > 0, ramp active
S The actual measuring function becomes active only when the offset value is
reached.
Measurement The transient response (command behavior or disturbance characteristic) of the

parameters: speed control in the time range can be assessed using the step excitation. The
Setpoint and test signal is connected to the speed controller output for recording of the re-
disturbance sponse to disturbances.
setpoint change Amplitude
This parameter determines the height of the preset setpoint step change or dis-
turbance change.
Measuring time
This parameter determines the recorded time range (maximum 2048 x speed
controller cycles).

Offset
A low offset of a fed motor revolutions per minute can be selected to rule out an
influence of the static friction.
S The Offset is run up using an acceleration ramp.
S The acceleration value is defined for one
axis: check MD 32300: MAX_AX_ACCEL
spindle: check MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL
MD 35210: GEAR_STEP_POSCTRL_ACCEL
S The following applies: Acceleration value = 0, no ramp

Acceleration value > 0, ramp active
S The actual measuring function becomes active only when the offset value is
reached.
Settling time
This value represents the delay between measured data recording/test setpoint
output and the injection of the offset.
Speed
setpoint
Amplitude
Offset
Time
0 Settling time Measuring period
Position
characteristic
Time
0
Fig. 13-3 Setpoint signal with measuring function speed control loop – step
response
Additional The measurement parameters and the measurement results (diagrams) can be
information loaded and/or saved using the soft key File functions.

13.4.3 Position control loop measurement
Functionality This measurement function basically analyses the response to the motor posi-
tion measuring system. If the function is activated for a spindle without position
measuring system, the NCK will generate an error message. Depending on
which basic measurement setting has been selected, various measurement
parameters lists as described below are made available.
Procedure
1. Set the traversing range monitoring function and enabling logic in the main
menu.
One of three different types of measurement can be selected:
S Reference frequency response

S Setpoint step change
S Setpoint ramp
2. Set the required parameters in the measurement parameter screen.
3. Display of the measurement result on the screen with the soft key Display.
Measurement: The reference frequency response determines the transmission response of the
Reference position controller in the frequency (active position measuring system). The set-
frequency point filters, Kv value and feedforward control must be parameterized such that
response resonance is avoided wherever possible over the entire frequency range. In the
case of dips in the frequency response, the setting of the feedforward control
balancing filters should be checked. Excessive resonance requires:
1. Decrease of the Kv value
2. Decrease of the feedforward control value
3. Use of setpoint filters.
The effects of these measures can also be checked in the time range.

Fig. 13-4 Example: Measurement results of a reference frequency response measurement
Measurement Amplitude
parameters: This parameter determines the height of the test signal amplitude. It should be
Reference set to the smallest possible value (e.g. 0.01mm).
frequency Bandwidth
response The bandwidth parameter is used to set the analyzed frequency range. The
larger this value, the finer the frequency resolution and the longer the measure-
ment time. The maximum value is given by the position control cycle (Tposition
controller).
Bandwidthmax [ Hz ] = 1 / (2 * Tposition controller [ sec ])

Example: Position controller cycle: 2msec
Bandwidthmax = 1 / (2 * 2*10–3) = 250Hz
Averaging
The accuracy of the measurement, but the measurement duration, too, will in-
crease with this value. A value of 20 is normally suitable.
Settling time
This value represents the delay between recording of the measured data and
injection of the test setpoint and offset. A value of between 0.2 and 1sec is rec-
ommended. Do not set too low a value for the settling times or the frequency
response and phase diagrams will be distorted.

Offset
The measurement requires a slight speed offset of a few motor revolutions per
minute. The offset must be set such that no speed zero crossings occur at the
set amplitude.
Measurement The transient response and positioning response of the servo loop in the time
parameters: range, in particular, the effect of setpoint filters, can be assessed using the step
Setpoint step excitation and the ramp excitation.
change and If an offset value other than zero is input, the step change is stimulated during
setpoint ramp traversal. For the sake of clarity, the displayed position actual value does not
include this speed offset. The following measurement quantities are possible:
– Actual position value (active position measuring system)
– Control deviation (following error)
Amplitude
This parameter determines the height of the preset setpoint step change or
ramp.
Measurement time
This parameter determines the period of time to be recorded (maximum value:
2048 position controller cycles).
Settling time
This value represents the delay between measured data recording/test setpoint
output and the injection of the offset.
Ramp duration
In basic setting Setpoint ramp the position setpoint is preset according to the
set ramp duration. In this case, the acceleration limits which currently apply to
the axis or spindle are effective.
A jerk-controlled motion can be set axis-specifically using
S MD 32400 AX_JERK_ENABLE (axial jerk limitation) =1

S MD34210 AX_JERK_TIME (time constant for the axial jerk filter).
The position setpoint and the actual value of the active measuring system are
recorded.
Offset
The step is stimulated from standstill or starting from the constant traverse
speed set in this parameter.

Position
Amplitude
t
0
Settling time Ramp Measuring period
Speed time
Offset
t
0
Fig. 13-5 Signal curve with measuring function position setpoint/ramp
At maximum axis velocity, there is a (virtual) step change in the velocity (contin-
uous line).
The curves represented by the dashed line correspond to a realistic, finite
value. The offset component is excluded from the display graphic in order to
emphasize the transient processes.
Step height In order to avoid damage to the machine, the step height for the setpoint step
change is limited to the value specified in
S MD 32000 MAX_AX_VELO (maximum axis velocity).

This can lead to not achieving the desired step height.
Just as well, the
S MD 32000 MAX_AX_VELO (maximum axis velocity)

S MD 32300 MAX_AX_ACCEL (max. axis acceleration)
are effective with the setpoint ramp in the range of the ramp. The max. axis ve-
locity limits the ramp rate of rise (velocity limitation) whereby the drive does not
reach the programmed end position (amplitude).
The acceleration limitation caused by the max. acceleration “rounds” the transi-
tion at the beginning and end of the ramp.
Caution
Changing:
S MD 32000 MAX_AX_VELO (maximum axis velocity).

S MD 32300 MAX_AX_ACCEL (max. axis acceleration)
may only be carried out with utmost care, e.g. by a certain step height. These
machine data are exactly matched with the machine!

13.5 Graphic display
Display of You can have the measurement results displayed by pressing soft key Display
measurement in the relevant main menu of the measuring function after completion of mea-
results surement.
Fig. 13-6 Menu: Display of measurement with marker X = ON
Soft keys: When the soft keys X marker ON and Y marker ON are pressed, a vertical or
X marker ON horizontal line with a circle is displayed on the measurement curve.
Y marker ON The corresponding values, e.g. for damping, frequency, degrees, etc. are dis-
played in the appropriate diagram.
Use the cursor keys to move the markers:
– slowly: Cursor key

– fast: Shift key + cursor key

Soft keys: If a marker is active, pressing the soft key 2nd marker will display a 2nd line in
2nd marker, the diagram. These two lines define the range that you can then have displayed
zoom, over the entire display range by pressing soft key Zoom.
fullscreen The process of zooming a range (marker ON, 2nd marker, zoom) can be re-
peated as often as desired until the maximum size of representation is reached.
Use the soft key Fullscreen to switch the display of the diagrams back to their
original size.
Note
X and Y markers can be active at a time.
Soft key: Use the soft key Scale to change the scaling of the traces and of the marker
Scale ranges in the two graphs.
The scaling can be switched over between auto (default setting) and fixed. The
Y range (Y min/max) to be displayed can only be changed in fixed mode.
Fig. 13-7 Menu: Scaling of graphics

Soft keys: Use the Graphics ... soft key shown in Fig. 13-6, page 13-431 to call the follow-
Graphics ... ing functions:
– Switching over the display from double to single graphics and vice versa
(this function also exists in the scaling menu Fig. 13-7, page 13-432)
– Printing graphics
Printing the graphics into a file (bitmap) or output to a connected printer.
– Printer selection
Selecting the output of the graphics to a bitmap file or to a connected
printer.

13.6 Trace function
13.6 Trace function
13.6.1 Trace function properties
The trace function with a graphical user interface serves to record the time
change of data (values, signals, states, etc.) in the servo range and partially in
the range of the drives, too.
You can select measuring signals and set the measuring parameters with soft
keys and drop-down lists.
The function is operated using the mouse or keyboard.
Function Individual functions of the trace function

overview
S Four trace buffers with up to 2,048 values each
S Selection of SERVO and drive signals (in position control cycle)
S Trace/trigger signals can be set using absolute address and value masking
S Different trigger conditions to start recording
(triggering always on Trace 1)
S Pretriggering and posttriggering possible

S Measuring signal display
S Fixed Y-scaling selectable for each trace
S Marker function selectable for each trace
S Expand function in the time axis
S Selective loading and saving of the measurement parameters and traces.

13.6 Trace function
13.6.2 Main menu and operation
Main menu You can access the main screen of this trace function using the soft keys Area
Servo trace switchover > Start-up > Drives/servo > Servo trace.
Fig. 13-8 Main menu: Servo trace
If the cursor is placed on a The cursor is controlled Toggle key

list box, press the insert key using the arrow keys
to open the list box. on the operator panel
or with the mouse.
You page in the list

using the arrow keys.
You accept a
value using the
input key.
Fig. 13-9 Cursor control

13.6 Trace function
13.6.3 Parameterization
Parameterization In the main menu you can select

in the main menu
– the axis/spindle to be measured
– the signal to be measured
– the measuring period
– the triggering time
– the type of triggering
– the triggering threshold.
Signal selection
Input field: The cursor must be positioned on the “Axis/spindle name” list box of the trace
Axis/spindle name concerned. You can select it with the soft keys Axis+ and Axis– or by accepting
a value from the drop-down list.
Input field: The cursor must be positioned on the “Signal selection” list box of the trace
Signal selection concerned. You can select a value by accepting it from the drop-down list.
Measurement
parameters
Input field: The measuring time is written directly into the “Measuring duration” input field.
Measuring duration
Input field: Direct input of pretriggering and posttriggering.
Triggering time With negative input values (sign minus –) recording starts in advance of the
triggering event by the time set.
With positive input values (without sign) recording starts
the time set after the triggering event.
Boundary condition: Trigger time + measurement duration y 0.
Input field: The trigger type is chosen from the drop-down list Trigger.
Trigger The trigger always refers to trace 1. Once the triggering conditions are fulfilled
traces 2 to 4 are started simultaneously.
Settable triggering conditions:
S No trigger, i.e. measurement starts when you operate the soft key Start (all
traces are started in synchronism).
S Positive edge
S Negative edge.
Input field: Direct input of the triggering threshold.

Threshold
The threshold is only active with the types of triggering “Positive edge” and
“Negative edge”.
The unit refers to the signal selected.

13.6 Trace function
Soft key: Selection of axis/spindle when the cursor is positioned on the appropriate list
Axis + field “Axis/spindle name”.
Axis – You can also select the axis/spindle directly in the list box from the drop-down
list using the cursor.
Soft key: The soft key Start starts recording of the trace function.
Start
With the Stop or RESET soft key, you can cancel a running measurement.
Stop
Soft key: Within the framework of the trace function, it is also possible to select data using
Physical its physical address.
address
Fig. 13-10 Menu: Physical address for trace x

– Choose the signal type “Physical address” from the desired trace.
– Press the soft key Physical address.
– Enter the desired values in the input screen form.
– Press the soft keys OK to complete your input.
Notice
This function is only required in exceptional cases, for example, if the informa-
tion provided by the known signals (see “Signal selection” list field) is not
adequate.
Before using this function, you should contact the SINUMERIK hotline.
The input of all parameters is carried out in the hexadecimal number format.
Input field: This screen form is used to select the data format to be evaluated when record-
Screen form ing.
– Byte: 0000 00FF
– Word: 0000 FFFF
– Double word: FFFF FFFF

13.6 Trace function
– Individual bits: xxxx xxxx

– 1: selected
– 0: not selected.
By default, all bits are selected.
Input field: The input field “Threshold” is only used to enter the triggering threshold for the
Threshold physical address of trace 1. If you exit the input screen form with the Ok soft
key, this hex value is then entered in the field “Threshold” of the main screen
of the trace function.
13.6.4 Measuring
Soft key: After parameterization has been completed, you then enable measurement by
Start pressing soft key Start.
The measurement is carried out once the set trigger condition of trace 1 is ful-
filled.
End of The measurement is completed after the set measurement duration is expired.
measurement
With the end of the measurement, the graphics are prepared automatically. Use
the “Display” soft key to call the display functions of the graphics (see next Sec-
tion).
Soft key: With the Stop soft key, you can cancel a running measurement at any time. A
Stop canceled measurement cannot be displayed.

13.6 Trace function
13.6.5 Display function
If you press the Display soft key after the set measurement time has expired
and the measurement results have been prepared automatically, you can call
the graphical display function of the measurement results.
Fig. 13-11 Measurement results: Trace function
Soft keys: When the soft keys X marker ON and Y marker ON are pressed, a vertical or
X marker ON horizontal line with a circle is displayed on the measurement curve.
Y marker ON The corresponding values, e.g. for damping, frequency, degrees, etc. are dis-
played in the appropriate diagram.
Use the cursor keys to move the markers:
– slowly: Cursor key

– fast: Shift key + cursor key

13.6 Trace function
Soft keys: If a marker is active, pressing the soft key 2nd marker will display a 2nd line in
2nd marker, the diagram. These two lines define the range that you can then have displayed
zoom, over the entire display range by pressing soft key Zoom.
fullscreen The process of zooming a range (marker ON, 2nd marker, zoom) can be re-
peated as often as desired until the maximum size of representation is reached.
Use the soft key Fullscreen to switch the display of the diagrams back to their
original size.
Note
X and Y markers can be active at a time.
Soft key: Use the soft key Scale to change the scaling of the traces and of the marker
Scale ranges in the two graphs.
The scaling can be switched over between auto (default setting) and fixed. The
Y range (Y min/max) to be displayed can only be changed in fixed mode.
Fig. 13-12 Menu: Scaling of graphics

13.6 Trace function
Soft keys: Use the Graphics ... soft key shown in Fig. 13-11, page 13-439 to call the fol-
Graphics ... lowing functions:
– Switching over the display from double to single graphics and vice versa
(this function also exists in the scaling menu Fig. 13-12, page 13-440)
– Printing graphics
Printing the graphics into a file (bitmap) or output to a connected printer.
– Printer selection
Selecting the output of the graphics to a bitmap file or to a connected
printer.

13.7 File function
13.7 File function
Description Use the File functions soft key to call the appropriate screen form.
Here you can save, load and delete the parameters, axis-specific machine data
and measurement results set for the measurements.
The file functions are not intended as a replacement for a complete copy of the
system and user data, e.g. for archiving or series machine start-up, but only for
the simplified and flexible management of the specific measurement data.
Fig. 13-13 Menu: File functions
Assigning In the “File” group, you can select an existing file from the drop-down list or
file names enter one in the text field underneath.
Selecting the In the Directory group, you can select the directory where you want to save the
directory file. This can also be a directory in the Services operating area you have
created by yourself or the basic directory of the data management (list entry:
standard directory).
Selecting the In the Data group, you can select the data you want to save.
data type
You can only select one data type. Use either the mouse button or the cursor or
toggle key for selection.

13.7 File function
Creating If you do not wish the data of the trace function to be stored in the “default direc-
subdirectories tory”, you can create user-specific directories.
New directories are created in the operating area Operating area switchover >
Services > Manage data. New subdirectories can be created below the Diag-
nosis directory.
For the description of the operating area Services, please refer to:

13.8 Print graphics
13.8 Print graphics
Printer selection The soft key Graphics in the main screens of the measuring functions opens
the menu to select the printer and to print the graphics.
Fig. 13-14 Graphics soft keys
Soft key: Use the soft key Printer selection to open the appropriate menu, Fig. 13-15,
Printer selection page 13-445.
Choose the type of file output from the selection list of the menu “Select printer”
using either the Toggle key or by double-clicking with the right mouse button on
the desired file output type:
– Bitmap file
– Printer
Toggle key

13.8 Print graphics
Fig. 13-15 Menu: Printer selection
Output to Choose the printer to which you wish the file to be output from the list field using
printer either the Toggle key or by double-clicking with the right mouse button on the
desired printer.
Output as a The graphics is to be saved in a bitmap file (*.bmp):

bitmap file
S In the selection field for printer setting, set “Output to bitmap file”
S Press the soft key Print graphics
S Enter the desired file name.
You can enter a new file name or choose an existing file from the drop-down
list.

13.8 Print graphics
Soft key: Use the soft key Print graphics Fig. 13-14, page 13-444 to output the graphics
Print graphics to the set medium:
– Printer
– Bitmap file.
Printer The graphics is output directly to the selected printer.
Bitmap file If you wish the graphics to be output to a bitmap file, the following specifications
are still required in the submenu “File name for bitmap printout”:
– File names
– Directory.
Fig. 13-16 Menu: File name for bitmap printing
Assigning In the File name group, you can select an existing file from the drop-down list or
file names enter one in the text field underneath.
Selecting the In the Directory group, you can select the directory where you want to save the
directory file.
This can also be a directory in the operating area Services > Data you have
created by yourself or the basic directory of the data management (list entry:
standard directory).
For the description of the operating area Services, please refer to:
S The file is saved using the soft key OK.

S Use the soft key Abort to return to the current graphic display.

13.9 Automatic controller setting
An automatic controller adjustment with HMI Advanced is not possible within the
framework of SINUMERIK 840Di.
SIMODRIVE 611 For a description how to carry out an automatic controller adjustment of SIMO-
universal DRIVE 611 universal drives, please refer to:
References: /FBU/ SIMODRIVE 611 Universal, Descriptions of Function
Section:Description of Functions
Optimizing current and speed controllers
J

Notes

User Data Backup/Series Machine Start-Up 14
14.1 Explanations on data backup
User data User data are called all data or data areas that can be entered by the user to
achieve the specific functionality of the SINUMERIK 840Di or the
SIMODRIVE 611 universal drives.
In the case of a data backup, e.g. after start-up of the control system, the user
data selected through the user interface are written to a so-called series ma-
chine start-up file.
After the series machine start-up file has been read in, the control system is in
its original status again as it was at the time of data backup.
Times for The past has shown that the following times are recommended to carry out data
data backup backups:
S After start-up,
S After changing machine-specific settings,
S In service cases (e.g. after a hardware replacement, software upgrade, etc.),
to resume production without longer downtimes.
Before activating memory-configuring machine data (a warning appears), a data
backup must be carried out.
Data backup of A data backup can currently not yet be carried out uniformly for all components
various (SINUMERIK 840Di-NC, PLC, HMI Advanced (option) and SIMODRIVE 611
components universal).
A data backup must therefore be carried out separately for the following compo-
nents:
S NC, PLC and HMI Advanced (option)

S SIMODRIVE 611 universal.
NC, PLC, HMI The data backup with respect to the NC, PLC and HMI Advanced (option) user
user data data is carried out with
S SinuCom NC (part of the SINUMERIK 840Di installation)

S HMI Advanced (option).

14 User Data Backup/Series Machine Start-Up 06.03
14.1 Explanations on data backup
For detailed information regarding the data backup of the components men-
tioned above, please refer to:
References: SinuCom NC:
Online help
HMI Advanced:
/BAI/ Operator’s Guide – HMI Advanced
SIMODRIVE 611 A data backup with respect to SIMODRIVE 611 universal drives is carried out
universal using the start-up tool SimoCom U. When doing so, one parameter file each is
drive data saved per drive on the hard disk of the PCU.
SimoCom U is part of the SINUMERIK 840Di installation.
For detailed information on the data backup of SIMODRIVE 611 universal

drives, please refer to:
References: /FBU/ SIMODRIVE 611 Universal, Description of Functions
Section: Closed-loop control unit for rpm servo control
and positioning
and
SimoCom U: Online help

06.03 14 User Data Backup/Series Machine Start-Up
14.2 Creating a series machine start-up file using HMI Advanced
14.2 Creating a series machine start-up file using HMI

Advanced
The creation of a series machine start-up file is divided into the following steps:
1. Open the menu to create a series machine start-up file:
Operating area switchover > Services > key:up “>” > Series machine
start-up > Create start-up archive
2. Select the contents and assign the file name
3. Create the series machine start-up file by selecting the device to which you
wish the file to be output
Note
Because of its file extension “.arc”, the series machine start-up file is also called
archive.
Selecting contents A series machine start-up file can be created for the following components:
S NC with/without compensation data

S PLC
S HMI
When selecting, any combinations are possible.
However, it is recommended to save the individual components separately in
separate series machine start-up files. It is thus possible to reload them inde-
pendently of each other and with maximum flexibility.
Note
Compensation data must only be archived if the series machine start-up file is
to be reloaded into the same control system (backup).

14.2 Creating a series machine start-up file using HMI Advanced
NC The contents of a series machine start-up file created for the NC comprises
mainly the following data:
– Configuration data
– Option data
– Machine data
– Setting data
– Tool offset
– Workpieces
– Parts programs
– Cycle programs
– GUDs (Global User Data).
PLC The contents of a series machine start-up file created for the PLC comprise all
blocks loaded at the time when the data backup was made:
– OB (organization blocks)
– FB (function blocks)
– SFB (system function blocks)
– FC (functions)
– SFC (system functions)
– DB (data blocks)
– SDB (system data blocks).
HMI The contents of a series machine start-up file created for the HMI Advanced
comprise all data stored in the HMI database in the directory “dh” at the moment
when the data backup was made.
Creation and The creation and output of the series machine start-up file is started with select-
starting output ing the component to which the file is to be output.
Components that can be selected:
– RS-232-C
– PG (programming device, e.g. PG740)
– Floppy disk drive (option)
– Archive (HMI data management on the hard disk of the PCU)
– NC Card.

06.03 14 User Data Backup/Series Machine Start-Up
14.3 Considerations when saving PLC data
14.3 Considerations when saving PLC data
When creating a series machine start-up file that contains PLC data, the PLC
image that is saved during this process is dependent on the status of the PLC at
the time of creation.
Depending on the status of the PLC, the following PLC images result:
– Original image
– Instantaneous image
– Inconsistent image.
Original image The original image of the PLC is represented by the PLC data immediately after
loading the S7 project into the PLC.
Operating sequence:
1. Set the PLC to the operating status STOP
2. Load the appropriate S7 project into the PLC using the SIMATIC Manager
STEP7
3. Create a series machine start-up file with PLC data
4. Set the PLC to the operating status RUN.
Instantaneous If you cannot use the procedure described above, you can use the following
image alternative procedure to save an original image:
Operating sequence:
1. Set the PLC to the operating status STOP
2. Archive the PLC data
3. Set the PLC to the operating status RUN.
Inconsistent An inconsistent image results if a series machine start-up file with PLC data is
image created and the PLC is in the status RUN (cyclic operation).
The data blocks of the PLC are saved at different times with contents that under
certain circumstances may meanwhile have changed. This may result in a data
inconsistency that after copying the data backup back into the PLC may under
certain circumstances result in PLC stop in the user program.
Notice
The creation of a series machine start-up file with PLC data while the PLC is in
the RUN status (cyclic operation) may result in an inconsistent PLC image in
the series machine start-up archive.
After this series machine start-up file has been copied back, this data inconsis-
tency in the PLC user program may under certain circumstances result in the
stop of the PLC.

14.4 Reading in a series machine start-up file with HMI Advanced
Changing the PLC To change the PLC operating status, proceed as follows:
operating status
S With 840Di start-up:
– Start 840Di start-up Windows NT taskbar > Start > Programs > SI-
NUMERIK 840Di > 840Di start-up.
– Open the dialog box: Menu command Window > Diagnosis > NC/PLC.
S With HMI Advanced (840Di SW 2.2 and higher and HMI Advanced SW 6.2
and higher)
Diagnosis
S Change the PLC operating state: Group PLC, buttons: “STOP” and “RUN”.
S NC and PLC must then be resynchronized: Group PLC, buttons: “NC Re-
set”.
14.4 Reading in a series machine start-up file with HMI

Advanced
Reading in a series machine start-up file is divided into the following steps:
1. Open the menu to read in a series machine start-up file:
Operating area switchover > Services > key:up “>” > Series machine
start-up > Read in start-up archive
2. Select the series machine start-up file
3. Start read in: Start
Note
Because of the file extension “.arc” of the series machine start-up files, this is
also called archive.

SW Installation/Update and Data Backup 15
15.1 General requirements
Short description This section describes installation or updating of software applications and data
backup of the entire hard disk (disk images) or partitions (partition images) of
the PCU on the basis of preinstalled PCU basic software.
All actions described here are started from the Service Menu under MS DOS.
The Service menu is selected from the menu of the Boot Manager that is dis-
played when booting after turning on the PCU.
15.1.1 PCU basic software
Scope of basic The PCU basic software that is already preinstalled on the PCU hard disk when
software the SINUMERIK 840Di is supplied comprises:
S Windows NT 4.0, Service Pack 6, English version

S Internet Explorer 5, English version
S MS-DOS SW 6.21 and higher
S MPI driver SW 5 and higher
S Norton Ghostt Version 6 and higher
S Norton GhostWalkert Version 6 and higher.
Note
For information on the PCU basic software, please refer to the file
C:\Siemensd.rtf.
For the versions of the system components contained in the PCU basic soft-
ware, please refer to the file C:\BaseVers.txt.

15 SW Installation/Update and Data Backup 06.03
15.1.2 Partitioning of the hard disk
The PCU hard disk is divided into four partitions (three primary partitions and an
extended partition).
S For reasons of data security, the SINUMERIK 840Di system software, the
Windows NT system software and the Service software are installed in dif-
ferent partitions.
S A boot manager is provided so that you can boot the system either with Win-
dows NT (SINUMERIK 840Di user interface) or MS DOS (Service menu).
Partitions The diagram below shows the partitioning of the hard disk when the control sys-
tem is supplied:
active
Name: DOS Name: TMP Name: WinNT Name: 840D system

Contents: Tools Contents: Images, Contents: WinNT 4.0 Contents: 840Di system
Install, software,
Updates further appl.

with logic drive
Fig. 15-1 Partitioning of the hard disk
1st partition/drive C:
Drive C: contains MS DOS 6.2, tools (e.g. Norton Ghostt) and scripts
implemented by the service menu.
2nd partition/drive D:
Drive D: contains:
– The Images directory with the images preinstalled and created by
the user
– The Install directory into which the software to be installed is to be
copied first before the installation process itself is carried out under
Windows NT.
– The Update directory for later installation of Windows NT system
software.
3rd partition/drive E:
Drive E: is reserved for the Windows NT system software.
4th partition/drive F:
Drive F: contains the Windows NT applications, e.g. the SINUMERIK
840Di system software.
Further applications, such as HMI system software, HMI-OEM applica-
tions, SIMATIC Manager S7/M7 or customer-specific applications (e.g.
user interfaces created using Protool/Pro MC), will also be installed here.

06.03 15 SW Installation/Update and Data Backup
15.1.3 Boot manager
Boot manager When booting the PCU, the boot manager menu offers the following options to
menu choose from:
– SINUMERIK
– Service menu (hidden).
SINUMERIK Select the menu item SINUMERIK and you will get to the Windows NT desktop.
Under Windows NT you can:
S start the SINUMERIK 840Di user interface

S install system software using the network link (Ethernet) (e.g. the HMI soft-
ware)
S install optional software (e.g. additional languages)

S change INI files/hardware configuration (e.g. install drivers).
Note
With power-up under Windows NT, the NC system software is automatically
started in the background.
Service menu Select the hidden menu option Service menu (CursorDown key and Input
(hidden) key) to start the SINUMERIK service software.
In the Service menu under MS DOS, you can:
S establish the connection to an external computer (programming device/PC)

– through the parallel interface
– through the network connection (log: NetBEUI)
S install and update Windows NT applications

S make backup copies (GHOST images) of the entire hard disk or of individual
partitions and restore them.

15.1.4 Setting/determining the network parameters of an external

computer
In order to be able to establish a network connection to an external computer,

the following requirements must be fulfilled with respect to the external com-
puter:
1. The Ethernet cable is connected to the Ethernet interface of the external
computer and the PCU.
– Point-to-point connections require a “twisted” Ethernet cable (Converted
Twisted Pair).
Notice
Point-to-point connections require a “twisted” Ethernet cable (Converted
Twisted Pair).
2. The network protocol NetBEUI must be installed on the external computer.

3. The computer name of the external computer must be known.
4. Access to the drive/folder of the external computer you want to access must
be shared by the PCU, and the sharing name must be known.
Installing the net- To install the network protocol NetBEUI, open Control Panel using the Windows
work protocol 95/NT taskbar Start > Settings > Control Panel on the external computer.
NetBEUI Open Network in the Control Panel.
Register: Protocols
Dialog: Select Network Protocol
Network Protocol <NetBEUI protocol>
OK
OK
Determining the To determine the computer name, open the Windows 95/NT taskbar Start >
computer name Settings > Control Panel on the external computer.
In the “Control Panel”, open Network.
Register: Identification
Computer Name: <COMPUTER NAME>
OK
Notice
Various SINUMERIK OPs allow to enter uppercase letters. Therefore, to enter
the user name and the password of the external computer (PG/PC), either use
only uppercase letters or connect a standard PC keyboard to the PCU.

Sharing access to In order to share access to the drive/directory or determine the sharing name,
the drive/directory start the Windows Explorer on the external computer and select the drive/direc-
or determining tory to be released for shared access for the PCU.
sharing names Open the Properties dialog (right mouse button > Properties) of the drive/di-
rectory and define the sharing name and the access rights.
Dialog Dialog: Properties of <drive>/<directory>
Tab: Share access
Optional field: Choose “Shared As:”
Sharing name: <SHARED AS>
Button: “Rights...”
Dialog: Access by share access rights
Dialog: Add users and groups
Names: Choose a name from the list
e.g. “User” or “Everybody”
Button: “Add”
OK
Access type: <Read>
OK
OK

15.2 Software installation/update

15.2.1 Software installation//updating SINUMERIK 840Di system soft-
ware
Brief description The following describes the necessary operator actions to install/update SI-
NUMERIK 840Di system software on the PCU from an external computer
(PG/PC).
Operating actions
1. Backup the NC and PLC user data by creating a series machine start-up file.
See Chapter 14, page 14-449.
2. Install//update the SINUMERIK 840Di system software. According to your
requirements, please see:
– Parallel link and external FAT16 drive:
– Parallel link and external FAT32 drive:
– Network link (Ethernet):
3. Initialize the control by deleting NC data and performing a general PLC re-
set. See Subsection 8.1.1, page 8-249.
4. Read in the series machine start-up file created in Step 1. See Section 14.4,
page 14-454.
15.2.2 Parallel link and external FAT16 drive
Brief description The operator actions explained in the following will copy software from an exter-
nal computer (PG/PC) from a FAT16 drive into the installation directory
D:\INSTALL on the PCU by means of a parallel link.
When the control is booted for the next time under Windows NT, the software
(setup.exe) contained in the installation directory D:\INSTALL is installed auto-
matically.
Requirements The following requirements must be fulfilled:
S The software to be installed is to be found in a FAT16 drive called MMC102

directory of the external computer.
S The operating system of the external computer is either:

– Windows 95
– Windows 3.11
– DOS.

Notice
Before you copy the software into the D:\Install directory make sure that suffi-
cient free memory space is available.
Operating actions
1. Power OFF the PCU.
2. Use a parallel data transfer cable (PC-Link or LapLink cable) to link the par-
allel port of the external PC (LPT1) with the parallel port of the PCU (LPT1).
3. Copy the software to be installed on the PCU into the directory C:\MMC102
(create it if it does not yet exist) of the external computer (PG/PC).
If not enough space is available on drive C: or C: is not a FAT16 drive, you
can also use another local drive (e.g. D:) .
Note:
Direct installation from CD is not possible.
4. On an external computer (PG/PC), start the program intersrv.exe under DOS
or under Windows 95 from a DOS prompt. As the parameter, specify the
drive on which the software to be installed is found.
intersrv <drive> (e.g. C:)
The following menu will appear:
Microsoft Interlnk Server Version <version>

This Computer Other Computer
(Server) (Client)
C: <size>
Transfer | Port: Speed: | Alt + F4=Exit
Notice
The PCU must be switched OFF. If the PCU is switched ON, switch it OFF now.

5. Now switch on the PCU (again) and choose the menu item “Service menu”
(hidden) from the menu of the boot manager.
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
6. Choose Install/Update SINUMERIK System using the key “1”.

The system prompts you to enter a password:
7. Type one of the passwords of protection levels 0–2.
– System
– Manufacturer
– Service.
Following menu:
PLEASE SELECT MEDIUM:
1 Install from Floppy Disk
2 Install via Serial/Parallel Line
3 Install from Network Drive
5 REBOOT
8. From the following menu, choose the menu item Install via Serial/Parallel
Line using the key “2”.
The software to be installed is now transferred from the ext. computer
(PG/PC) to the PCU into the directory D:\INSTALL.
If the transfer is completed, a power-up of the PCU following the Windows
NT procedure is carried out and the software that is to be found under
D:\INSTALL is installed automatically.
9. Exit the Server mode on the external computer (PG/PC):
Key combination: Alt + F4

15.2.3 Parallel link and external FAT32 drive
nal computer (PG/PC) from a FAT32 drive to the installation directory
D:\INSTALL of the PCU using a parallel link using the tool: Interserve/Interlink.
matically.
S The software to be installed is on a FAT32 drive of the external computer

(PG/PC).
S The operating system of the external computer (PG/PC) is:

– Windows 95
– Windows 3.11
– DOS.
S To transfer the software to be installed on the PCU, the program interlnk.exe

must be installed on the external computer (PG/PC).
S The PCU is equipped with a full keyboard.
Notice
Operating actions
1. Make sure that the program interlnk.exe is installed on the ext. computer
(PG/PC).
Windows 95 / Windows 3.11
dir c:\windows\command\interlnk.exe
DOS
dir c:\dos\interlnk.exe.
If the program interlnk.exe is not installed, copy it (e.g. from the HMI102 di-
rectory of the HMI installation CD) into the appropriate directory.
Add the following line to the file CONFIG.SYS:
device=c:\windows\command\interlnk.exe /AUTO
Now, switch the ext. computer off.
2. Use a parallel data transfer cable (PC-Link or LapLink cable) to link the par-
allel port of the external PC (LPT1) with the parallel port of the PCU (LPT1).

3. Now, turn on the PCU and choose the menu option “Service menu” (hidden)
from the menu of the boot manager using the CursorDown key and then
press the Input key.
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
4. Select Start PC Link using the key “8”.

– System
– Manufacturer
– Service.

(Server) (Client)
C: <size>
D: <size>
LPT1:
6. Now, restart the ext. computer (PG/PC).

7. After the ext. computer (PG/PC) has been booted, the PCU automatically
reestablishes the connection to it.

(Server) (Client)
C: <size> F:
D: <size> G:
LPT1:

The drive display in the menu under “Client”, e.g. as G: means that drive D:
of the PCU can be addressed from the ext. computer (PG/PC) as drive G: .
8. Now copy the software to be installed from the ext. computer into the drive
D:\INSTALL of the PCU.
copy <path>\*.* G:\INSTALL\
9. If the copying process is complete, exit INTERSVR on the PCU (key com-
bination: Alt + F4).
(setup.exe) contained in the installation directory D:\INSTALL of the PCU is
installed automatically.

15.2.4 Network link (Ethernet)
nal computer (PG/PC) into the installation directory D:\INSTALL on the PCU
using a network link (Ethernet).
For data transfer, a local point-to-point connection between the external com-
puter and the PCU is established using the standard Ethernet cable of the type
“Twisted Pair Crossed 10baseT/100baseTX Ethernet Cable”.
matically.
S The operating system of the external computer is

– Windows NT 4.0
– Windows 95.
S The Ethernet cable is connected to the Ethernet interface of the external

Notice
S The network parameters of the external computer are set or known:

– Network Protocol NetBEUI
– Computer Name
– Shared As.
How to set or determine the network parameters of an external computer is
described in Subsection 15.1.4 (page 15-458).
S The drive/directory of the ext. computer (PG/PC) where the software you
wish to copy is to be found for sharing with the PCU.
Notice
Operating actions After the PCU has been turned on, the menu of the boot manager is displayed.
1. Select the menu option Service menu (hidden) using the CursorDown key
and then press the Input key.

PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
2. Choose Install/Update SINUMERIK System using the key “1”.

– System
– Manufacturer
– Service.
Following menu:
PLEASE SELECT MEDIUM:
1 Install from Floppy Disk
2 Install via Serial/Parallel Line
3 Install from Network Drive
5 REBOOT
4. Choose Install from Network Drive using the key “3”.

Following menu:
PLEASE SELECT:
1 Connect to Network Drive
2 Show Connected Network Drives
3 Disconnect from all Network Drives
4 Change install directory
5 Install from F:\INSTALL
9 Return to previous Menu
5. Choose Connect to Network Drive using the key “1”.

– Type the user name and the password you want to use for access to
the external computer.
Windows NT 4.0
User name and password of the local user of the PG/PC

Windows 95
Any user name; if a password is required, type the password you have
specified to share access to the directories.
– For later verification, you may be prompted to confirm saving of the

password.
– Specify the drive letter under which the external drive is to be accessed
from the PCU (e.g. “H”).
– DIRECTORY TO BE MOUNTED:
Please type a name of the computer and the access name of the drive/
directory of the external computer:
\\<COMPUTER NAME>\<SHARED AS>
e.g. \\r3344\MY_INSTALL
How to set or determine the network parameters of an external computer
is described in Subsection 15.1.4 (page 15-458).
The set network information is now displayed on the PCU.
Connected network drive (last) H: (\\R3344\MY_INSTALL)

Install Directory F:\INSTALL
6. The default setting of the directory where the software is to be installed on

the external computer (Install Directory) is F:\INSTALL.
If the software is in a different directory, what is normally the case, this set-
ting must be adapted accordingly.
PLEASE SELECT:
3 Disconnect form all Network Drives
4 Change Install Directory
5 Install from F:\INSTALL
To this aim, choose Change Install Directory using the key “4”.
In the input screen form that now appears, type the appropriate drive letter
(in the example: “H:”) and possibly any further path if the software is not
installed directly in the shared drive/directory (in the example:
R3344\MY_INSTALL), but in a subdirectory of MY_INSTALL.
Old Install Directory F:\INSTALL

New Install Directory H:\<PATH>
The complete network settings are displayed in the Service menu, and the
installation directory in the menu item Install from ..., (in the example:
H:<PATH>).

Connected Network Drive (last) H: (\\R3344\MY_INSTALL)

Install Directory H:\<PATH>
PLEASE SELECT:
5 Install from H:<PFAD>
7. To start the data transfer, choose Install from H:<PATH> using the key “5”.
– When the transmission is complete, the PCU will reboot.
matically.

SHOW connected Use the menu item Show connected Network Drives to display all network
network drives drives currently linked with the PCU.
PLEASE SELECT:
5 Install from H:<PATH>
Choose Show Connected Network Drives using the key “2”.
Status Local Name Remote Name

OK H: \\R3344\MY_INSTALL
DISCONNECT from Use the menu item Disconnect from all Network Drives to disconnect all links
all Network Drives to network drives.
PLEASE SELECT:
2 Show connected Network Drives
5 Install from H:<PATH>
Choose Disconnect form all Network Drives using the key “3”.
The network connections are then displayed in the Service menu as -none-.
Connected Network Drives (last): -none-

Install Directory: H:\<PATH>

15.3 Data backup
15.3 Data backup

15.3.1 Hard disk backup using a parallel link
Brief description The operating actions explained in the following are intended to make a backup
copy of the entire hard disk of the PCU (disk image) and to transfer it to an ex-
ternal computer (PG/PC) using a parallel link.
S The program Norton Ghostt (Version 6 or higher) is installed on the PCU

and on the ext. computer.

– DOS
– Windows 3.11
– Windows 95.
S A directory for the backup copy is installed on the external computer and
enough memory capacity is provided.
S In the BIOS of the PCU and of the external computer, the parallel interface is
set to EPP or ECP.
Notice
Before you transfer the backup copy (disk image), make sure that enough free
memory space is available on the ext. computer (PG/PC).
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?
2. Choose Backup/Restore using the key “7”.

15.3 Data backup

– System
– Manufacturer
– Service.
Following menu:
PLEASE SELECT
1 Hard disk Backup/Restore with GHOST
4 Partitions Backup/Restore with GHOST
9 Back to previous Menu
Your Choice [1,4,9]?
4. Choose the menu item Hard disk Backup/Restore with Ghost using the
key “1”.
Following menu:
PLEASE SELECT
1 Configure Ghost Parameters
2 Hard disk Backup to <PATH>, Mode...
3 Hard disk Backup from <PATH>, Mode...
5. Now select the menu option Configure GHOST parameters using the key
“1” to set the following parameters:
– Connection type (PARALLEL)
– Path or File name under which you wish the backup copy to be stored
on the external computer.
Following menu:
PLEASE SELECT
1 Set Connection Mode PARALLEL
2 Set Connection Mode LOCAL
3 Change Backup Image Filename
4 Change Restore Image Filename
5 Change Machine Name
6 Manage Network Drives
Your Choice [1,2,3,4,5,6,9]?
S To set the connection mode “Parallel link”, choose the menu item Set Con-
nection Mode PARALLEL using the key “1”.
S To set the path or the file name under which you wish the backup copy to be
stored on the external computer, select the menu option Change Backup
Image Filename using the key “3”.

15.3 Data backup
– Specify the complete path, e.g.:

C:\SIN840DI\PCU\
and the appropriate file name, e.g.:
SICHER01.GHO
under which the backup copy will be stored on the external computer.
Use the key “9” to return to the previous menu after you have confirmed the
modified GHOST parameters.
Following menu:
PLEASE SELECT
1 Configure GHOST Parameters
2 Hard disk Backup to <PATH>\SICHER01.GHO, Mode PARALLEL
3 Hard disk Backup from <PATH>\SICHER01.GHO, Mode PARALLEL
6. Choose the menu item Hard disk Backup to ... using the key “2”.
7. This item will only apply if local images exist. Otherwise, Point 8. is dis-
played immediately.
Following menu:
PLEASE SELECT
1 Backup WITHOUT Local Images
3 Backup WITH Local Images
If you do not wish to save the local backup copies of saved partitions avail-
able on the hard disk of the PCU, then choose:
– Backup WITHOUT Local Images using the key “1”.
Otherwise, choose:
– Backup WITH Local Images using the key “2”.
8. A message window appears:
– You will be prompted to check whether the connection between the PCU
and the external computer is established.
– The path and the file name under which the backup copy will be stored
on the external computer is displayed. In the example:
C:\SIN840DI\PCU\SICHER01.GHO
– Now start Norton Ghostt on the external computer (PG/PC) under DOS
or Windows 95/ 3.11 in a DOS prompt window with:
ghost –lps
– Then press the “Y” key to start the backup process.

15.3 Data backup
9. Norton Ghostt now initiates data transfer.

The following information is displayed in the Ghost message window:
– The progress of the data transfer is displayed.
– The paths are displayed.
– The volume of data to be transferred is displayed.
Size of backup copy with compressing: 4.8GB hard disk –> approx. 330MB file
Time for transfer: approx. 50min.

15.3 Data backup
15.3.2 Restoring the hard disk backup using parallel link
Brief description The operating actions explained in the following are intended to restore a
backup copy of the entire hard disk of the PCU (disk image) from an external
computer using a network link.
S The program Norton Ghostt (Version 6 or higher) is installed on the PCU

and on the ext. computer.
S The operating system of the external computer is:

– Windows 95
– Windows 3.11
– DOS.
S A directory for the backup copy is installed on the external computer and
enough memory capacity is provided.
S In the BIOS of the PCU and of the external computer, the parallel interface is
set to EPP or ECP.
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?

– System
– Manufacturer
– Service.

15.3 Data backup
Following menu:
PLEASE SELECT
key “1”.
Following menu:
PLEASE SELECT
– Connection type (PARALLEL)
Following menu:
PLEASE SELECT
Your Choice [1,2,3,4,5,6,9]?
S To set the connection mode “Network Connection”, choose the menu item
Set Connection Mode PARALLEL using the key “1”.
S To set the path or the file name of the backup copy to be restored, choose
the menu item Change Backup Image Filename using the key “4”.
– Specify the complete path, e.g.:
C:\SIN840DI\PCU\
and the appropriate file name, e.g.:
SICHER01.GHO
under which the backup copy will be stored on the external computer.
Use the key “9” to return to the previous menu after you have confirmed the
modified GHOST parameters.

15.3 Data backup
Following menu:
PLEASE SELECT
2 Hard disk Backup to <PFAD>\SICHER01.GHO, Mode PARALLEL
3 Hard disk Backup from <PATH>\SICHER01.GHO, Mode PARALLEL
6. Choose the menu item Hard disk Backup from... using the key “3”.
Following menu:
PLEASE SELECT
1 Windows NT
2 Win95
3 WfW3.11
4 DOS
Your Choice [1,2,3,4,9]?
7. Use this menu to choose the operating system used as the basis for the
backup copy. In the case of SINUMERIK 840Di, this is exclusively Windows
NT. Therefore, choose Windows NT using the key “1”.
Following menu:
What kind of disk partitioning do you want?
1 Standard Partitioning (default)
2 User-defined Partitioning
Your Choice [1,2]?
Standard partitioning (default)

The hard disk partitioning of the PCU is set to the initial state by auto-
matic parameterization by Norton Ghostt.
User-defined partitioning
You can adapt the sizes of the hard disk partitions on the PCU manually
in Norton Ghostt.
A message window appears during the choice:
– The path and the file name under which the backup copy will be stored
on the external computer is displayed. In the example:
C:\SIN840DI\PCU\SICHER01.GHO
– You will be prompted to check whether the backup copy exists on the
external computer.
– Now start Norton Ghostt on the external computer (PG/PC) under DOS
or Windows 95/ 3.11 in a DOS prompt window with:
ghost –lps

15.3 Data backup
– Then press the “Y” key to start the backup process.

8. The backup copy is now imported by Norton Ghostt. The following informa-
tion is displayed in the Ghost message window:
Size of backup copy with compressing: 4.8GB hard disk –> approx. 330MB file
Notice
If you abort the transfer, inconsistent data will be available on the PCU, and the
system can possibly no longer be booted.
To boot the PCU, you will need a boot diskette.
Norton Ghostt closes automatically when the import process is completed.

9. With restoring the backup copy to the PCU, the last valid computer name
with which the PCU has been identified on the network has been overwrit-
ten.
To make sure that the PCU is assigned a valid computer name again, you
must type a new name of the computer. The following menu will appear:
PLEASE SELECT
1 Input Machine Name MANUALLY
2 Input Machine Name RANDOMLY
9 Abort
S Input Machine Name MANUALLY

Type the new 10-digit computer name computer name into the input screen
form displayed. When you confirm the new name using the Input key, the
computer name is taken over into the system.
S Input Machine Name RANDOMLY

A random computer name is generated and taken over into the system.
S Abort
The computer name taken over with the image is kept.
Changes to the computer name and system ID are made using the program
Norton Ghost Walkert.

15.3 Data backup
Notice
The network settings can be later modified/determined under Windows NT.
Windows NT taskbar: Start > Settings > Control Panel: Network
10. After Norton Ghost Walkert has updated the computer name and system
ID, the following menu is displayed:
It seems, that Ghost Restore succeeded.
Hit any Key to reboot the System.
When the PCU is booted for the next time under Windows NT, the partitions E:
and F: will be checked by the diagnostic program CHKDISK in succession
whereby the PCU is rebooted automatically.
After completion of the check, the system with the restored backup copy is ac-
tive.

15.3 Data backup
15.3.3 Saving the hard disk using a network link (Ethernet)
copy of the entire hard disk of the PCU (disk image) and to transfer it to an ex-
ternal computer (PG/PC) using a network connection.

– Windows NT 4.0
– Windows 95.

Notice

– Computer Name
– Shared As.
How to set or determine the network parameters of an external computer is de-
scribed in Subsection 15.1.4 (page 15-458).
Notice
Before you transfer the backup copy (disk image), make sure that enough free
memory space is available on the ext. computer (PG/PC).

15.3 Data backup
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?

– System
– Manufacturer
– Service.
Following menu:
PLEASE SELECT
key “1”.
Following menu:
PLEASE SELECT
Fig. 15-2 Main menu for saving/restoring hard disks
– Connection type (LOCAL)
– Network parameters of the PCU

15.3 Data backup
Following menu:
PLEASE SELECT
Your Choice [1,2,3,4,5,6,9]?
Fig. 15-3 Main menu for configuring the Ghost parameters
Set Connection Mode LOCAL using the key “2”.
S To set the network parameters of the PCU, choose the menu item Manage
Network Drives using the key “6”.
Following menu:
PLEASE SELECT:
Choose Connect to Network Drive using the key “1”.

the external computer using the network connection.
Windows NT 4.0
Windows 95

password.
e.g. \\R3344\MY_BACKUP
The set network information is displayed.

15.3 Data backup
Connected network drive (last) H: (\\R3344\MY_BACKUP)
Use the key “9” to return to the “Main menu for configuring the Ghost param-
eters” Fig. 15-3 (page 15-482).
– Specify the network drive (in the example: “H:”) under which the backup
copy will be stored on the external computer.
If necessary you can enter an additional path specification that will be
added to the path specification of the network drive. In this way, you can
store the backup copy in a subdirectory, with reference to the shared
drive/directory of the external computer.
– Type the desired file name under which you wish to store the backup
copy: e.g. SICHER01.GHO
eters” Fig. 15-3 (page 15-482).
Use the key “9” to return to the “Main menu for saving/restoring hard disks” after
you have confirmed the confirmation warning regarding the modified GHOST
parameters.
Following menu:
PLEASE SELECT
2 Hard disk Backup to H:\<PATH>\SICHER01.GHO, Mode LOCAL
3 Hard disk Backup from H:\<PATH>\SICHER01.GHO, Mode LOCAL
6. To start the data transfer, choose the menu item Hard disk Backup to ...
using the key “2”.
Following menu:
PLEASE SELECT
1 Backup WITHOUT Local Images
3 Backup WITH Local Images

15.3 Data backup
7. If you do not wish to save the local backup copies of saved partitions (see
next section) available on the hard disk of the PCU, then choose:
– Backup WITHOUT Local Images using the key “1”.
Otherwise, choose:
– Backup WITH Local Images using the key “2”.
A message window appears:
– The destination path in which the backup copy will be stored on the ex-
ternal computer is displayed.
– Press “Y” to start the backup process.
The actual backup process is now carried out by Norton Ghostt.
The following information is displayed in the message window that opens:
Size of backup copy with compressing: 4.8GB hard disk –> approx. 330MB
image file.

15.3 Data backup
SHOW connected Use the menu item Show connected Network Drives to display all network
network drives drives currently linked with the PCU.
PLEASE SELECT:
Choose Show Connected Network Drives using the key “2”.

OK H: \\R3344\MY_BACKUP
DISCONNECT from Use the menu item Disconnect from all Network Drives to disconnect all links
all Network Drives to network drives.
PLEASE SELECT:
Choose Disconnect form all Network Drives using the key “3”.

15.3 Data backup
15.3.4 Restoring the hard disk backup using a network link (Ethernet)
copy of the entire hard disk of the PCU (disk image) and to restore it from an
external computer (PG/PC) using a network connection.

– Windows NT 4.0
– Windows 95.

Notice

– Computer Name
– Shared As.
How to set or determine the network parameters of an external computer is de-
scribed in Subsection 15.1.4 (page 15-458).
1. Choose the menu item Service Menu (hidden).

15.3 Data backup
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?

– System
– Manufacturer
– Service.
Following menu:
PLEASE SELECT
key “1”.
Following menu:
PLEASE SELECT
Fig. 15-4 Main menu for saving/restoring hard disks
– Connection type (LOCAL)
– Network parameters of the PCU

15.3 Data backup
Following menu:
PLEASE SELECT
Your Choice [1,2,3,4,5,6,9]?
Fig. 15-5 Main menu for configuring the Ghost parameters
Set Connection Mode LOCAL using the key “2”.
S To set the network parameters of the PCU, choose the menu item Manage
Network Drives using the key “6”.
Following menu:
PLEASE SELECT:
Choose Connect to Network Drive using the key “1”.

the external computer using the network connection.
Windows NT 4.0
Windows 95

password.
e.g. \\R3344\MY_BACKUP
The set network information is displayed.

15.3 Data backup
Connected network drive (last) H: (\\R3344\MY_BACKUP)
eters” Fig. 15-5 (page 15-488).
– Specify the network drive (in the example: “H”) under which the backup
copy will be stored on the external computer.
If necessary you can enter an additional path specification that will be
added to the path specification of the network drive. In this way, you can
restore the backup copy from a subdirectory, with reference to the
shared drive/directory of the external computer.
– Type the desired file name under which you wish to store the backup
copy: e.g. SICHER01.GHO
eters” Fig. 15-5 (page 15-488).
Use the key “9” to return to the “Main menu for saving/restoring hard disks” after
you have confirmed the confirmation warning regarding the modified GHOST
parameters.
Following menu:
PLEASE SELECT
2 Hard disk Backup to H:\<PFAD>\SICHER01.GHO, Mode LOCAL
3 Hard disk Backup from H:\<PATH>\SICHER01.GHO, Mode LOCAL
6. Choose the menu item Hard disk Backup from... using the key “3”.
Following menu:
PLEASE SELECT
1 Windows NT
2 Win95
3 WfW3.11
4 DOS
7. Use this menu to choose the operating system used as the basis for the
backup copy. In the case of SINUMERIK 840Di, this is exclusively Windows
NT. Therefore, choose Windows NT using the key “1”.

15.3 Data backup
Following menu:
What kind of disk partitioning do you want?
1 Standard Partitioning (default)
2 User-defined Partitioning
Your Choice [1,2]?
Standard partitioning (default)

The hard disk partitioning of the PCU is set to the initial state by auto-
matic parameterization by Norton Ghostt.
User-defined partitioning
You can adapt the sizes of the hard disk partitions on the PCU manually
in Norton Ghostt.
Answer the confirmation question with “Y” to start restoring.
Norton Ghostt is now started. The following information is displayed in the
message window that opens:
Size of backup copy with compressing: 4.8GB hard disk –> approx. 330MB
image file
Notice
If you abort the transfer, inconsistent data will be available on the PCU, and the
system can possibly no longer be booted.
To boot the PCU, you will need a boot diskette.
Norton Ghostt closes automatically when the import process is completed.
8. With restoring the backup copy to the PCU, the last valid computer name
with which the PCU has been identified on the network has been overwrit-
ten.
To make sure that the PCU is assigned a valid computer name again, you
must type a new name of the computer. The following menu will appear:
PLEASE SELECT
1 Input Machine Name MANUALLY
2 Input Machine Name RANDOMLY
9 Abort

15.3 Data backup
S Input Machine Name MANUALLY

Type the new 10-digit computer name computer name into the input screen
form displayed. When you confirm the new name using the Input key, the
computer name is taken over into the system.
S Input Machine Name RANDOMLY

A random computer name is generated and taken over into the system.
S Abort
The computer name taken over with the image is kept.
Changes to the computer name and system ID are made using the program
Norton Ghost Walkert.
Note
The network settings can be later modified/determined under Windows NT.
Windows NT taskbar: Start > Settings > Control Panel: Network
9. After Norton Ghost Walkert has updated the computer name and system
ID, the following menu is displayed:
After completion of the check, the system with the restored backup copy is ac-
tive.

15.3 Data backup
15.3.5 Display connected drives
From the menu displayed in the Subsection 15.3.4 under Point 5.

(page 15-487), select
PLEASE SELECT:
the menu option Show Connected Network Drives using the key “2”.
Following menu:
OK H: \\R3344\MY_BACKUP
All currently connected drives are displayed.
15.3.6 Disconnecting connected drives
From the menu displayed in the Subsection 15.3.4 under Point 5.

(page 15-487), select
PLEASE SELECT:
the menu option Disconnect form all Network Drives using the key “3”.

15.3 Data backup
15.3.7 Saving partitions (local)
What is to be The operating actions explained in the following are intended to make a backup
done? copy of the partitions C:, E: and F: of the PCU hard disk (partition image) and to
transfer it to D:\IMAGES.
S Sufficient free hard disk capacity must be available on drive D:

S The maximum number of possible partition backups may not yet be
reached.
1. Choose the menu item Service Menu (hidden).
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?

– System
– Manufacturer
– Service.
Following menu:
PLEASE SELECT
4. Choose the menu option Partitions Backup/Restore with Ghost using

key “4”.

15.3 Data backup
Following menu:
Ghost Connection Mode: LOCAL

Maximum Backup Images: <max. number>
Actual Backup Images: <act. number>
PLEASE SELECT
2 Partitions Backup, Mode LOCAL
3 Partitions Restore, Mode LOCAL
4 Delete Image
Make sure that the displayed max. number of possible partition backups is
not yet reached.
How to change the max. number, see Subsection 15.3.8 (page 15-495).
To delete partition backups, see Subsection 15.3.9 (page 15-496).
5. Choose the menu item Partitions Backup, Mode LOCAL using key “2”.
Following menu:
You must specify the image name (max. 7 characters long):
Image Name:
6. Type the name under which you wish the partition backup to be stored
(max. 7 characters). In the example: IBNZWST
If more than one partition backup is possible, the input option of a descrip-
tion is offered.
You can store a description text along with the image:
description [Local Backup]:
When you select a partition backup to restore it, this description is displayed
together with date and time to identify the partition backup.
To facilitate the identification of the partition backup, a clear description
should be used. In the example: Start-up intermediate version 1.
When you confirm the specifications above, the partition backup will be
started.
After the partition backup has been made, a check can then be carried out
using CRC Check.

15.3 Data backup
Storing a partition When saving a partition C:, E: and F: an independent image file with the name
backup of the partition backup in front of it is created under D:\IMAGES for each of the 3
saved partitions, e.g.:
– for partition C: IBNZWST.GH1
– for partition E: IBNZWST.GH3
– for partition F: IBNZWST.GH4
When restoring the partition backup, however, the 3 individual files will be ad-
dressed as one partition backup with the description entered under Point 6.
15.3.8 Changing the number of partition backups
From the menu displayed in the Subsection 15.3.7 under Point 4. (page
15-493), select

Maximum Backup Images: <max. Anzahl>
Actual Backup Images: <akt. Anzahl>
PLEASE SELECT
4 Delete Image
the menu option Configure GHOST Parameters using key “1”.

Following menu:
PLEASE SELECT
1 Change Maximum Backup Images
Your Choice [1,9]?
Choose the menu item Change Maximum Backup Images using key “1”.
Type the new number in the following menu and confirm the question: “Save
GHOST parameters” with “Yes”.

15.3 Data backup
15.3.9 Deleting partition backups
From the menu displayed in the Subsection 15.3.7 under Point 4. (page
15-493), select

Maximum Backup Images: <max. Anzahl>
Actual Backup Images: <akt. Anzahl>
PLEASE SELECT
4 Delete Image
Choose the menu item Delete Image using key “4”.
Choose the partition backup you want to delete from the next following menu
and confirm the warning questions with “Yes”.

15.3 Data backup
15.3.10 Restoring a partition backup (local)
Brief description Use the operator actions explained in the following to restore a partition backup
of the partitions C:, E: and F: of the PCU hard disk (partition image).
Requirements No special requirements need to be fulfilled.
PLEASE SELECT
3 DOS Shell
7 Backup/Restore
8 Start PC Link
P 840Di Services
Your Choice [1,2,3,4,5,7,8,9,P] ?

– System
– Manufacturer
– Service.
Following menu:
PLEASE SELECT
4. Choose the menu option Partitions Backup/Restore with Ghost using

key “4”.

15.3 Data backup
Following menu:
PLEASE SELECT
4 Delete Image
5. Choose the menu item Partitions Backup, Mode LOCAL using key “3”.
Following menu:
PLEASE SELECT
1 PCU Basic Software V06.01.04 Win NT 4.0
[05.09.2000;05.30.32pm]
2 Start-up intermediate version 1
[05.10.2000; 04.03.15pm]
6. The descriptions that have been specified for the individual partition back-
ups are displayed. Choose the partition backup you want to restore.
In the example: “Start-up intermediate version 1” using the key “2”.
After confirmation, a warning is displayed:
CAUTION: All data will be overwritten!
If you confirm again, the partitions of the hard disk are restored.
Following menu:
After completion of the check, the system with the restored backup copy is
active.
J

840Di Specific Data and Functions 16
16.1 Interface signals
For detailed information on interface signals, please refer to the descriptions of functions:
S /FB1/ Description of Functions – Basic Machine
S /FB2/ Description of Functions – Extended Functions
S /FB3/ Description of Functions – Special Functions
S /FBSY/ Description of Functions – Synchronized Actions

For a complete list of all existing interface signals, please refer to:
S /LIS/ Lists, Section: Interface signals
16.1.1 840Di-specific interface signals

DB number Byte, bit Name Doc. Ref-
erence
Signals from NC to PLC
10 108.2 MMC ready, communication via MPI
10 108.3 MMC ready, communication via shared memory communication
10 109.4 PC OS fault
10 57.3 PC shutdown
16.1.2 Interface signals not supported

erence
31, ... 20.0 Ramp-function switch U/F mode
31, ... 20.2 Torque limit 2
Safety Integrated signals from PLC to axis/spindle
31, ... 22.0 Deselection of safe velocity and safe operational stop (SBH/SG de-
selection)
31, ... 22.1 Deselection of safe operational stop (SBH deselection)
31, ... 22.3 Velocity limit – bit value 0 (SG selection)
31, ... 22.4 Velocity limit – bit value 1
31, ... 23.0–23.2 Ratio selection – bit value 0 through bit value 2
31, ... 23.5 Enable limit position pair 2
31, ... 23.7 Enable test stop
Signals from axis/spindle to PLC
31, ... 92.0 Setup mode active
31, ... 92.2 Torque limit 2 active
Safety Integrated signals from axis/spindle to PLC

16 840Di Specific Data and Functions 06.03
16.1 Interface signals

erence
31, ... 108.0 Safe velocity or safe operational stop active (SBH/SG active)
31, ... 108.2 Delete status pulses
31, ... 108.7 Axis referenced reliably
31, ... 109.0–109.7 Cam signals of plus and minus cams (SN1+/1– through SN4+/4–)
31, ... 110.1 Safe operational stop active (SBH active)
31, ... 110.3–110.4 Safe velocity active – bit value 0 through bit value 1
31, ... 110.5 n < nx
31, ... 111.1 Safe operational stop active (SBH active)
31, ... 111.4–11.7 Stop A/B through Stop E active

06.03 16 840Di Specific Data and Functions
16.2 Expanded message frame configuration (SW 2.2 and higher)
16.2 Expanded message frame configuration (SW 2.2 and

higher)
16.2.1 Description of Functions
The PROFIdrive profile provides two different possibilities for defining the quan-
tity and meaning of message frame data transferred between the DP master
and DP slave drives within the framework of the cyclic PROFIBUS communica-
tion:
1. Select a predefined standard message frame
You can uniquely define the quantity and meaning of the transferred data by
selecting a standard message frame type in the associated components DP
slave drive, DP master and NC.
2. Customizable message frame configuration
With customizable message frame configuration, a user-specific frame type
is defined, in which you need to separately inform each associated compo-
nent – DP slave, DP master and NC – of the quantity and meaning of the
transferred data.
With SW 2.2 and higher, the SINUMERIK 840Di system offers expanded message frame configura-
tion which allows you to cyclically transfer drive data in addition to process data from the drive (DP
slave) to the NC (DP master) by combining standard message frames and customized message
frame configuration.
Message frame The drive data transferred in addition to the standard message frame process
configuration data must always be appended at the end of the standard message frame.
PDA for expanded message

frame
Process data: Standard Process data:
frame additional drive
data
PDA .... PDA PDAx+ .... PDAy
1 . x 1 .
Fig. 16-1 Standard message frame with additional process data (PDA)
NC According to the selected functionality, for each axis the additional drive data is
system variable available on the NC side in individual specified system variables or the entire
frame as an array of neutral data words via a general system variable. In both
cases, the system variables are read-only.
Select the required setting in the NC machine data:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] (acquisition of additional drive

actual values)
Specific The specific drive data listed below is transferred in individually specified sys-
system variables tem variables with the machine data setting:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] = 1

The drive data must be configured as additional process data on the drive with the exact meaning
in the exact order specified in Table 16-1.
Table 16-1 Specific drive data
Pro- Drive data System variable

cess
data
x+1 Load $AA_LOAD
x+2 Smoothed torque setpoint (Mset) $AA_TORQUE
x+3 Active power (Pact) $AA_POWER
x+4 Smoothed torque-producing current Iq $AA_CURR
(IqGl)
Note
Transfer of specific drive data can only take place if the following is applicable:
Standard message frame data + additional data v max. number process data.
Currently a message frame can contain up to 16 process data items (PDA1 to
PDA16).
General The entire message frame with standard process data and additional process
system variable data is transferred in a general system variable as an array of 16-bit integer
data words via:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] = 2
S System variable: $VA_DP_ACT_TEL[n, a]
with n = index: 0,2,...15
a = machine axis identifier.
Note
When using the system variable $VA_DP_ACT_TEL[n, a], it is only permissible
to use a constant as index n.
Application example for system variables in a synchronized action:

IDS=1 DO $AC_MARKER[0] = $VA_DP_ACT_TEL[12, X]
Data formats The user must take the following points into account with regard to the data for-
mats of the process data stored in the system variables:
S The process data are transferred in the message frame in the following for-
mat:
– unsigned 16-bit integer (UINT16)
They are stored in the system variables in the format
– signed 32-bit integer (INT32)
In the necessary format conversion, bit 15 of the unsigned 16-bit integer
PDA value is transferred to bits 16 to 31 of the signed 32-bit integer value in
the system variable.

For the physical unit as well as the drive-end weighting of the drive actual
values transferred in the additional PDA, please refer to the data description
of the specific drive documentation.
S Drive actual values composed of 2 PDAs (both 16-bit) e.g.

– Encoder 2 position actual value 1 (G2_XACT1)
– Encoder 2 position actual value 2 (G2_XACT2)
are mapped on two separate data items (both 32-bit) in the system variable
$VA_DP_ACT_TEL.
Fig. 16-2 shows how the process data of the message frame are mapped onto system variable
$VA_DP_ACT_TEL:
PDA for expanded message frame
Process data: Standard Process data: addi-

frame tional drive data
15 0 15 0 15 0 15 0
PDA1 ..... PDAx PDAx1 ..... PDAy
Bit 31...16 = bit 15 Bit 31...16 = bit 15 Bit 31...16 = bit 15 Bit 31...16 = bit 15
31 16 15 0 31 16 15 0 31 16 15 0 31 16 15 0
PDA1 ..... PDAx PDAx+1 ..... PDAy
Index n = 0 Index n = x Index n = x+1 Index n = y
System variable $VA_DP_ACT_TEL[n, a]
Fig. 16-2 Mapping principle: PDA on system variable $VA_DP_ACT_TEL
Notice
The responsibility for possibly necessary format conversions or correct inter-
pretation of the physical unit and significance of a system variable used in parts
programs or synchronized actions lies exclusively with the user. Due to system
restrictions, it is not possible for the NC to perform a consistency check.
16.2.2 Requirements
The following conditions must be met to configure an expanded message frame:
S Drive
The drive to be used for the expanded message frame configuration must
support customizable message frame configuration in addition to selection
of standard message frames.

S DP master / SIMATIC STEP 7

No additional requirements
S SINUMERIK 840Di NC
– SW 2.2 and higher
– Option: “Evaluation of internal drive variables”,
Order No.: 6FC5 251-0AB17-0BA0
– NC machine data for activating the data transfer for the additional PDA in
the system variables:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] (acquisition of additional
drive actual values)
16.2.3 Configuring SIMODRIVE drives

Expanded message frame configuration in relation to SIMODRIVE drives:
– SIMODRIVE 611 universal/universal E
is illustrated on the basis of an example using SIMODRIVE 611 universal (DP slave 611U). Please
adapt your procedure for the other SIMODRIVE drives.
Recommended We recommend proceeding in the following order to configure the components

configuration included in the expanded message frame configuration:
sequence 1. Configure the DP master with SIMATIC STEP 7
2. Configure the DP slave 611U with the start-up tool: SimoCom U
3. SINUMERIK 840Di NC with start-up tool: SinuCom NC or the user interface:
HMI Advanced (option).
Standard Before performing the expanded message frame configuration, please define
configuration the following:
– Which standard message frame the drive axis/axes is supposed to oper-
ate with.
– How many additional drive actual values/PDA are to be transferred.
Note
It is advisable to configure each component first with the appropriate standard
message frame and then expand the frame by the additional PDA.

Step 1: Before performing the expanded message frame configuration, you need to
Configuring the configure the DP slave 611U with the standard message frame required for this
DP master drive.
Standard For information on how to perform a standard configuration of the DP master,

configuration please see Subsection 7.3.7, page 7-231ff.
Expanded To transfer the additional process data, you need to change the configuration of
message frame the DP slave 611U as follows:
configuration 1. The length of the PDA which is already configured with the standard mes-
sage frame must been expanded by the length of the additional PDA.
2. As the I/O address of setpoint and the actual value of an axis must be the
same, change the I/O address of the setpoint to the I/O address of the ac-
tual value which is automatically adapted by the HW Config if necessary.

Tab: Configuration
Actual value > length: <Length standard PDA + length additional
PDA>
Setpoint > I/O address: <I/O address actual value> (see above 2.)
OK
Notice
S The I/O address for setpoint and actual values of an axis must be the same.
I/O address actual value = = I/O address setpoint
S The axis I/O address set via the SlaveOM must match the I/O address set
in the NC.
I/O address
2. SINUMERIK 840Di NC
MD13060: DRIVE_LOGIC_ADDRESS[n] (logical drive address)
Note
After increasing the length of the actual value PDA (dialog box: DP slave Prop-
erties > Configuration > Actual value > Length), when the Properties dialog box
is opened again, in message frame type:
Dialog: DP slave properties
Tab: Configuration
the message frame type that was originally selected is no longer displayed, but
the message frame that matches the modified PDA or no message frame type.

Step 2: Before performing expanded message frame configuration, you first need to
Configuring the perform the standard configuration or start-up of the drive.
DP slave 611U
Standard For the standard configuration/start-up of the drive, please see:
configuration
S Start-up (requirements)
– Subsection 8.1, page 8-249
S Standard configuration/start-up
– SIMODRIVE 611 universal and universal E:
References: /FBU/ SIMODRIVE 611 universal, Description of
Functions
– SIMODRIVE POSMO SI/CD/CA
– SimoCom U start-up tool
References: Online help for SimoCom U.
Expanded To configure the additional drive actual values, modify the standard configura-
message frame tion of the drive e.g. starting at standard message frame 102 as follows with the
configuration SimoCom U start-up tool:
Notice
Before configuring the additional drive actual values, please ensure that the
correct drive – and if using a multiple axis module, the correct axis – was
selected in the SimoCom U start-up tool.
S Activating the customizable message frame configuration.

To activate the customizable message frame configuration, replace the mes-
sage frame type of the selected standard message frame in the menu: PRO-
FIBUS Parameter Settings (menu command Start-up > Parameterization
Views > PROFIBUS Parameter Settings) with “0”.
SimoCom U 12A drive
File Edit Start-up Operation Diagnostics Tools Help
Online to drive 12A => data are modified directly in the drive!
Option module type 4 PROFIBUS station address 12

Configurati
Analog in Expected option module type 4 Message frame selection 0
Mechanic Received data PDA Sent data PDA
Limits
Digital in 1 Control word 1 (CTW1) 1 Status word 1 (STW1)
Digital out 2 Speed setpoint B (NSET_B) 2 Speed actual value B (NACT_B)
Analog out
Monitoring 3 Speed setpoint B (NSET_B) 3 Speed actual value B (NACT_B)
Controller 4 Control word 2 (CTW2) 4 Status word 2 (STW2)
Traversing bl
5 Torque reduction (TorRed) 5 Torque reduction (TorRed)
Shaft-angle
encoder int 6 Encoder 1 control word (G1_CTW) 6 Encoder 1 status word (G1_STW)
PROFIBUS
7 No signal (NIL) 7 Enc. 1 pos. act. val. 1 (G1_XACT1)
Spindle posi
Fig. 16-3 Activating the customizable message frame configuration

S Configuring the additional drive actual values

The drive utilization for PDA11 is configured via the selection list of the cor-
responding parameter (PROFIDrive parameter P0916[x]) in Fig. 16-4.
SimoCom U 12A drive

PROFIBUS OFF1 Control of clock-synchronized PROFIBUS
5 Torque reduction (TorRed) 5 Message word (MessW)
Configurati 6 Encoder 1 control word (G1_CTW) 6 Encoder 1 status word (G1_STW)

Analog in 7 No signal (NIL) 7 Encoder 1 position actual value 1 (G1_XACT1)
Mechanic
Limits 8 No signal (NIL) 8 Encoder 1 position actual value 1 (G1_XACT1)
Digital in
Digital out 9 No signal (NIL) 9 Encoder 1 position actual value 2 (G1_XACT2)
Analog out 10 Encoder 1 position actual value 2 (G1_XACT2)
10 No signal (NIL)
Monitoring
Controller 11 No signal (NIL) 11 Currently selected block (CurrBlo)
Traversing bl. Analog input T. 24.x/20 (ADC)
Shaft-angle 12 No signal (NIL) 12 Analog input T. 56.x/14 (ADC)
Load (Load)
encoder int
13 No signal (NIL) 13 Digital inputs (DIG_IN)
PROFIBUS Speed actual value A (NACT_A)
Spindle posi 14 No signal (NIL) 14 No signal (NIL)
15 No signal (NIL) 15 No signal (NIL)
16 No signal (NIL) 16 No signal (NIL)
Fig. 16-4 Configuring the additional drive actual values
Step 3: Before configuring the expanded message frames, you first need to perform the
Configuring the standard configuration on the NC for the drive.
NC
Standard How to proceed with the standard configuration of a drive is described in Sec-
configuration tion 10.5.3, page 10-313.
Expanded On the NC for the expanded message frame configuration, you only need to
message frame activate PDA transfer in the respective system variable.
configuration – Option: “Evaluation of internal drive variables”,
Order No.: 6FC5 251-0AB17-0BA0
– NC machine data for activating the data transfer in the system variables:
S MD 36730: DRIVE_SIGNAL_TRACKING[n] (acquisition of additional
drive actual values)
Note
After configuring the expanded message frames, the standard message frame
with which the axis is driven is only explicitly visible in the NC machine data:
S MD 13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)

Restrictions The following restrictions are applicable with regard to the “expanded message
frame configuration” function:
S Additional data can only be transferred from the drive to the SINUMERIK
840Di NC (actual value channel). You cannot transfer data in the other direc-
tion, i.e. from the NC to the DP slave drive (setpoint channel).
S You can only have read access to the drive data stored in the system vari-
ables.
Consistency check At SINUMERIK 840Di boot, the NC checks the consistency of the process data
configuration (PDA) of the parameters relevant to the cyclic PROFIBUS commu-
nication:
S NC
– MD 13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)
S DP master (configuration)
– DP Slave Properties > Configuration > Setpoint: Length
– DP Slave Properties > Configuration > Actual Value: Length
S Drive
– Parameter P0922 message frame selection
– Parameter P0915[x] PDA setpoint assignment
– Parameter P0916[x] PDA actual value assignment.
If the number of process data expected from the NC set in the message frame (telegram) type pa-
rameter in the NC machine data:
S MD 13060: DRIVE_TELEGRAM_TYPE[n] (drive message frame type)
is greater than the number of process data configured with STEP7: HW Config for the DP slave
drive:
S DP Slave Properties > Configuration > Setpoint: Length
S DP Slave Properties > Configuration > Actual Value: Length
or if the process data configuration determined at the drive-end from the drive parameters:
S P0922 message frame selection
S P0915[x] PDA setpoint assignment
S P0916[x] PDA actual value assignment
does not match the message frame type of the NC machine data, then the following alarm is issued:
S Alarm 26015 “Axis axis identifier machine data $MN_DRIVE_TELE-
GRAM_TYPE[index] value not permissible”.
No acyclic If acyclic communication is not supported by a drive, or if acyclic communication

communication was not explicitly deactivated for a drive via the axis-specific NC machine data:
possible
S MD 13070: DRIVE_FUNCTION_MASK[n] (used DP functions)
then responsibility lies solely with the start-up engineer to perform a consistency check on the above
data.

Warning
! For reasons relating to the system, the consistency check – which is performed
during SINUMERIK 840Di boot and based on acyclic communication with the
drive – runs parallel in time with the already active cyclic communication be-
tween NC and drive.
As setpoint and actual values are already being exchanged between the NC
position control and drive as part of the cyclic communication, uncontrolled
system states can occur on the drive side due to faulty process data configura-
tions which cannot be detected yet at this point in time.
The same applies if acyclic communication is not supported by a drive, or if
acyclic communication was deactivated for a drive via the axis-specific NC ma-
chine data:

and therefore it is not possible for the NC to perform a consistency check.
Therefore, the responsibility lies with the start-up engineer to implement suit-
able measures (e.g. connecting terminals 64/65A/65B/ 663) to avoid uncon-
trolled traversing of the drives during start-up, caused by inconsistencies in the
above mentioned data.
An error can present a risk of danger to person or machine.
16.2.5 Data descriptions (MD, system variable)
General machine
data
13070 DRIVE_FUNCTION_MASK
MD number Bit-coded screen for selecting the functional scope expected by the NCK with PROFIBUS
drives
Default settings: 0 min. input limit: 0 max. input limit: FFFF FFFF
Changes effective after power ON Protection level: 2/7 Unit: –
Data type: DWORD valid from SW: 2.1
Meaning: Meaning of set bits:
Bit 0: Deactivation of the 611U-specific drive alarm mapping
Bit 1: Deactivation of the 611U-specific drive type detection
Bit 2: Deactivation of the 611U-specific parameter accesses encoder drivers
Bit 3: Deactivation of the 611U-specific parameter accesses output drivers
Bit 4: Activation third-party drive: DSC bits (CTW1.12/STW1.12)
Bit 5: Deactivation of the 611U-specific drive parks (CTW2.7/STW2.7)
Bit 6: Deactivation of the 611U-specific travel to fixed stop (CTW2.8/STW2.8)
Bit 7: Deactivation of the 611U-specific motor changeover internal (STW2.9–11)
Bit 8: Deactivation of the 611U-specific ramp block (CTW1.13)
Bit 9: Deactivation of the 611U-specific function generator functions (CTW1.8/STW1.13)
Bit 14: Selection of non-cyclic DP communication: 0=DPT; 1=DPV1
Bit 15: Deactivation of consistency check for PROFIBUS message frame configuration
CTW: Control word (PDA word in the PROFIDrive message frame to DP slave)
STW: Status word (PDA word in the PROFIDrive message frame from DP slave)
PDA: Process data
MD irrelevant with ...... –––

Axis-specific
machine data
36730 DRIVE_SIGNAL_TRACKING
MD number Detection of additional drive actual values
Default settings: 0 min. input limit: 0 max. input limit: 4
Data type: BYTE valid from SW: 2.1
Meaning: MD: DRIVE_SIGNAL_TRACKING (acquisition of additional drive actual values) informs the
NC which additional drive actual values are transferred in the PROFIDrive message frame
and in which system variables they should be stored.
Coding:
0: No additional drive actual values
1: The following drive actual values are transferred and stored in system variables:
Actual value System variable
Load $AA_LOAD
Torque setpoint $AA_TORQUE
Active power $AA_POWER
Current actual value t$AA_CURR
2: The entire PROFIDrive message frame is stored in a system variable:
Actual value System variable
PROFIDrive message frame $VA_DP_ACT_TEL
System variable
Name $VA_DP_ACT_TEL[n, a]
Meaning Word by word mapping of the PROFIBUS message frame from the
DP slave
Data type INTEGER
Value range [0, 65535]
Indexes n: Array index Value range [0,20]
a: Machine axis Value range Machine axis identifier
Accesses Parts program Synchronized OPI
action
Read Read Read
Attributes Implicit preprocessing stop Cross-channel
Read Yes
16.2.6 Alarms
Detailed information on the individual alarms can be found in:
References: /DA/ Diagnostics Guide
For systems with HMI Advanced you can refer to the online help.

16.3 Travel to fixed stop with high-resolution torque reduction (SW 2.2 and higher)
16.3 Travel to fixed stop with high-resolution torque

reduction (SW 2.2 and higher)
The full description of functions for “Travel to fixed stop” can be found in:
References: /FB1/ Description of Functions, Basic Machine
Section: F1 Travel to fixed stop
16.3.1 Description of Functions

With travel to fixed stop, you specify the torque reduction of the drive torque effective in the drive
(terminal torque) via the parts program instruction FXST.
For PROFIBUS drives, up to now the torque reduction was at a resolution of 1% and could not be
changed. With SW 2.2 and higher, you can set the torque reduction in the range from 0.01% to 10%
providing the required NC and drive parameters have been set.
16.3.2 Requirements
Basic The following basic requirements must be met to set the parameters for torque
requirements reduction resolution:
– There must be a parameter in the drive via which the resolution for the
torque reduction can be set at the drive end.
– The drive is operating with a message frame type containing the control
word: TorRed (torque reduction) e.g. SIMODRIVE standard message
frame 102 to 107.
Automatic To simplify the start-up of torque reduction, the SINUMERIK 840Di NC carries
adjustment out an automatic matching procedure using the torque reduction resolution
parameterized in the drive. The following requirements must be met:
– The drive supports acyclic communication and it is enabled on the NC
side. For information on how to enable acyclic communication on the
NC, please see the description of NC machine data:
– Parameter P881 is present in the drive with the corresponding meaning
and a scaling of 16384 ¢ 1%.
During SINUMERIK 840Di boot and in the state: “Incoming station” of the DP slave 611U, the SI-
NUMERIK 840Di NC cyclically reads parameter P881 from the drive and transfers it to the appropri-
ate axis-specific NC machine data:
S MD 37620: PROFIBUS_TORQUE_RED_RESOL (torque reduction resolu-

tion on PROFIBUS (LSB weighting)).
Manual If the requirements are not met for automatic adjustment, then the parameters
adjustment can be set manually for the SINUMERIK 840Di NC if the resolution of the torque
reduction is parameterized in principle in the mappable range (0.01% to 10%).

16.3.3 Setting parameters for SIMODRIVE drives

The requirements for an automatic or manual adjustment of the following SIMODRIVE drives:
– SIMODRIVE 611 universal/universal E
are met with SW 4.1 and higher.
The following describes the function on the basis of a SIMODRIVE 611 universal (DP slave 611U)
drive. Please adapt your procedure for the other SIMODRIVE drives.
Note
If third-party drives are used, please read the manufacturer’s documentation to
see whether and how to set the parameters on the drive.
Parameter P0881 The resolution of the torque reduction is parameterized in the DP slave 611U in
parameter:
S P0881 Torque reduction evaluation
Scaling As standard, in the DP slave parameter P0881 is scaled to: 16384.00 ¢ 1%

Examples for other resolutions:
– 1638.40 ¢ 0.1%
– 163.84 ¢ 0.01%.
Setpoint torque Setpoint torque Tset of the drive is therefore calculated by:
Tset
P0881 * TorRed[%]
Tset = Tmax * ( 1 – )
16384 * 100%
Tmax:
Maximum possible drive torque from rated motor torque and parameter P1230 Torque limit value.
TorRed:
The percent specified via FXST for the reduced drive (control word in SIMODRIVE standard mes-
sage frame 102 to 107).
16.3.4 Setting parameters for the SINUMERIK 840Di NC

In the SINUMERIK 840Di NC system, the parameters for the resolution of the torque reduction are
set via the axis-specific machine data:


Automatic To simplify the start-up of torque reduction, as standard the NC tried to perform
parameterization an automatic matching procedure. The adjustment is carried out in the following
system states:
– SINUMERIK 840Di boot
– “Incoming station” of the DP slave 611U.
The NC reads the resolution set in the parameters on the drive via parameter P0881 using acyclic
communication and transforms the read value into the format of the above mentioned machine
data.
If the detected drive-end resolution is not equal to the resolution currently set in the parameters in
the NC machine data, the value determined by the drive is transferred to the NC machine data. The
resulting NC-end rescaling of the torque reduction for this machine axis is indicated in the following
alarm:
S Alarm 26024 “Axis axis identifier machine data $MA_PROFI-
BUS_TORQUE_RED_RESOL value adapted”.
If the value of parameter P0881 converted into NC format lies outside the admissible limit values,
the value set in the NC machine data is retained. An alarm is then not issued.
Note
You can disable automatic adjustment via:
S MD 13070: DRIVE_FUNCTION_MASK[n], bit 15 = 0
Manual If one of the requirements listed above for automatically adjusting the torque
parameterization reduction resolution is not met, it is possible to set the parameters manually to
achieve consistence if the torque reduction resolution was parameterized in the
mappable range (0.01% to 10%).
Example The following conditions apply:

– Machine axis X1 corresponds to drive 12A
– The torque reduction resolution is to be 0.1%.
Parameterizing the DP slave 611U
The value 1638.40 is entered in parameter P0881.
The parameters are set with the start-up tool SimoCom U: menu command Start-up > Additional
Parameters > Expert List > Number > 881
The parameter is immediately effective.
SimoCom U 12A drive

PROFIBUS OFF1 Control of clock-synchronized PROFIBUS

Number Text Value Unit Effective
881 Evaluation of torque/power reduction PRO 1638.40 % immediately
Fig. 16-5 Set parameter P0881

Setting parameters for the SINUMERIK 840Di NC

Enter value 0.1 in the axis-specific machine data of machine axis X1
The machine data is effective after NC reset (warm restart).
Notice
It is the start-up engineer’s responsibility to ensure that the parameter settings
are consistent in the SINUMERIK 840Di NC and all relevant drives for which
torque reduction is being performed.
The following data must be consistent in terms of values and meaning:
1. SINUMERIK 840Di NC machine data
MD 37620: PROFIBUS_TORQUE_RED_RESOL (torque reduction resolu-
tion on PROFIBUS (LSB weighting))
2. Drive
With automatic adjustment:
Parameter P0881 torque reduction evaluation
With manual adjustment:
The parameter corresponding in meaning to the DP slave 611U: pa-
rameter P0881.
Notice
If automatic adjustment cannot be performed by the SINUMERIK 840Di NC
due to requirements that are not met, of if the drive returns a value for parame-
ter P0881 that lies beyond the NC machine data limit values, or if the torque
reduction is not rescaled on the NC end, no alarm is issued. The machine data

tion on PROFIBUS (LSB weighting))
is effective in all cases independently.

16.3.6 Data description (MD)
General machine
data
13070 DRIVE_FUNCTION_MASK
MD number Bit-coded screen for selecting the functional scope expected by the NCK with PROFIBUS
drives
Default settings: 0 min. input limit: 0 max. input limit: FFFF FFFF
Data type: DWORD valid from SW: 2.1
Meaning: Meaning of set bits:
Bit 0: Deactivation of the 611U-specific drive alarm mapping
Bit 1: Deactivation of the 611U-specific drive type detection
Bit 2: Deactivation of the 611U-specific parameter accesses encoder drivers
Bit 3: Deactivation of the 611U-specific parameter accesses output drivers
Bit 4: Activation third-party drive: DSC bits (CTW1.12/STW1.12)
Bit 5: Deactivation of the 611U-specific drive parks (CTW2.7/STW2.7)
Bit 6: Deactivation of the 611U-specific travel to fixed stop (CTW2.8/STW2.8)
Bit 7: Deactivation of the 611U-specific motor changeover internal (STW2.9–11)
Bit 8: Deactivation of the 611U-specific ramp block (CTW1.13)
Bit 9: Deactivation of the 611U-specific function generator functions (CTW1.8/STW1.13)
Bit 14: Selection of non-cyclic DP communication: 0=DPT; 1=DPV1
Bit 15: Deactivation of consistency check for PROFIBUS message frame configuration
CTW: Control word (PDA word in the PROFIDrive message frame to DP slave)
STW: Status word (PDA word in the PROFIDrive message frame from DP slave)
PDA: Process data
Axis-specific
machine data
37620 PROFIBUS_TORQUE_RED_RESOL
MD number torque reduction resolution on PROFIBUS (LSB weighting)
Default settings: 1 min. input limit: 0.01 max. input limit: 10
Changes effective after NEWCONF Protection level: 2 / 7 Unit: %
Data type: DOUBLE valid from SW: 2.2
Meaning: For the drives connected via PROFIBUS, the MD defines the resolution of the torque re-
duction transferred in the cyclic SIMODRIVE standard message frames 102 to 107 (control
word: TorRed). The torque reduction is e.g. required as part of the function “Travel to fixed
stop” (FXST).
At automatic adjustment, the machine data must be set so that it is consistent with the
meaning of drive parameter P0881: “Torque reduction evaluation”; or with manual adjust-
ment with the drive-end interpretation of the control word: TorRed.
The default value of 1% corresponds to the resolution that was valid prior to SW 2.2.
16.3.7 Alarms
Detailed information on the individual alarms can be found in:
References: /DA/ Diagnostics Guide
For systems with HMI Advanced you can refer to the online help.
J

Notes

Abbreviations A
ADI4 Analog Drive Interface for 4 Axis
ARM Asynchronous Rotary Motor
ASCII American Standard Code for Information Interchange
ASUP Asynchronous subprogram
BA Operating Mode
BAG Operating mode group
BB Ready
BCD Binary Coded Decimals: Decimal numbers encoded in binary format
BP Basic program
COM Communication
CPU Central Processing Unit:
DAC Digital-Analog converter
DB Data Block
DBB Data Block Byte
DBX Data Block Bit
DHCP Dynamic Host Configuration Protocl: Protocol for automatical assignment of IP

addresses from a DHCP server to a client computer
DPR Dual-Port RAM
DRAM Dynamic memory (not non-volatile)
DRF Differential Resolver Function
DRY Dry Run: Probelaufvorschub
DSR Data Send Ready:

Message to indicate that serial data interfaces are ready
DW Data Word
EFP Simple I/O module (PLC I/O module)
EPROM Erasable Programmable Read-Only Memory
ETC ETC key > extension of soft key bar in the same menu

SINUMERIK 840Di Manual (HBI) – 06.03 Edition A-517
A Abbreviations 06.03
FC Function Call on the PLC
FDD Feed drive
FEPROM Flash EPROM: Readable and writable memory
FIFO First in First Out: Memory that operates without addresses where the data
are always read out in the same order in which they were stored.
FIPO Fine interpolator
FRK Milling radius correction
FST Feed Stop: Feed hold
GEO Geometry
GND Ground signal
HASH Software procedure for mapping a large quantity of identifiers onto a finite
memory area
HEX Hexadecimal number
HHU Handheld unit
HMI Human Machine Interface
HW Hardware
HW Config SIMATIC S7 Tool to configure and parameterize S7 hardware within an S7 proj-

ect
HW limit switch Hardware limit switch
INC Increment:
INI Initialization (Initializing Data)
INTV Internal multiplication
IS Interface signal
ISO Code Special punchtape code, number of punched holes per character always even
JOG Jogging: Setting-up mode
K1 Channel 1
KUE Transmission ratio
KV Servo gain factor
LED Light Emitting Diode:
LSB Last significant Bit
MCI Motion Control Interface
MCP Machine Control Panel
MCS Machine Coordinate System

A-518 SINUMERIK 840Di Manual (HBI) – 06.03 Edition
06.03 A Abbreviations
MD Machine data
MDA Manual Data Automatic: NC mode for entering and processing individual part
program blocks or block sequences.
MLFB Machine-readable product designation: Order No.
MMC Human Machine Communication: SINUMERIK operator interface for operating,

programming and simulation
MPF Main Program File: NC parts program (main program)
MPI Multi Point Interface:
MSD Main Spindle Drive
NC Numerical Control:
NCK Numerical Control Kernel: Numerical Control Kernel with block preparation,
travel range etc.
NCU Numerical Control Unit: NC-Modul
OB Organization Block: Block type of PLC basic or user program
PCMCIA Personal Computer Memory Card International Association
PCW Program control word
PD Process data: Process data part of a PPO
PG Programming unit
PID Parameter Identification: Part of a PIV
PIV Parameter Identification Value: Parameterizing part of a PPO
PLC Programmable Logic Controller
PMS1 Position measuring system 1
PMS2 Position measuring system 2
PNO PROFIBUS user organization
PO Power ON
POSMO A Positioning Motor Actuator
POSMO CA Positioning Motor Compact AC: Positioning Motor Compact AC: Complete drive
unit with integrated power and control modul as well as positioning unit and pro-
gram memory; AC infeed.
POSMO CD Positioning Motor Compact DC: as CA, however, with DC infeed
POSMO SI Positioning Motor Servo Integrated: Positioning motor, DC infeed
PPO Parameter Process data ObjectCyclic data message frame for PROFIBUS DP
transmissionand “Variable speed drives” profile
PROFIBUS Process Field Bus: Serial data bus

PRT Program test
RAM Random Access Memory in which data can be read and written
ROV Rapid Override
RPA R-Parameter Active: Identifier for R parameters
RS-232 Serial interface
RTS Request To Send: Control signal on serial data interfaces
SBL Single Block
SD Setting data
SEA Setting Data Active: Identifier for setting data
SK Soft key
SKP Skip: Skip block
SLM Synchronous Linear Motor
SPF Sub Program File
SRAM Static RAM (non-volatile)
SRM Synchronous Rotary Motor
SSFK Spindle pitch for error compensation
SSI Synchronous Serial Interface (interface type)
STW Status word
SW Software
SW limit switch Software limit switch
T Tool
TC Tool Change
TEA Testing Data Active: Identifier for machine data
TO Tool Offset
TOA Tool Offset Active: Identifier for tool offsets
TRC Tool Radius Offset
TTL Transistor-Transistor Logic (interface type)
VDI interface Data interface between NC and PLC
WCS Tool Coordinate System
ZOA Zero Offset Active: Identifiere for zero offset

06.03 A Abbreviations
ZV Zero Offset (work offset)
µC Microcontroller
J

Notes

References B
General Documentation
/BU/ SINUMERIK & SIMODRIVE, Automation Systems for Machine Tools

Catalog NC 60
Order No.: E86060-K4460-A101-A9-7600
/IKPI/ Industrial Communication and Field Devices

Catalog IK PI
Order No.: E86060-K6710-A101-B2-7600
/ST7/ SIMATIC
Products for Totally Integrated Automation and Micro Automation
Catalog ST 70
Order No.: E86060-K4670-A111-A8-7600
/Z/ MOTION-CONNECT
Cable, Connectors & System Components for SIMATIC, SINUMERIK,
Masterdrives and SIMOTION
Catalog NC Z
Order No.: E86060-K4490-A001-B1-7600
Electronic Documentation
/CD1/ The SINUMERIK System (11.02 Edition)

DOC ON CD
(includes all SINUMERIK 840D/840Di/810D/802D/802SC and SIMODRIVE
publications)
Order No.: 6FC5298-6CA00-0BG3

SINUMERIK 840Di Manual (HBI) – 06.03 Edition B-523
B References 06.03
User Documentation
/AUK/ SINUMERIK 840D/810D (09.99 Edition)

Short Guide AutoTurn Operation
Order No.: 6FC5298-4AA30-0BP2
/AUP/ SINUMERIK 840D/810D (02.02 Edition)

Operator’s Guide AutoTurn Graphic Programming System
Programming/Setup
/BA/ SINUMERIK 840D/810D (10.00 Edition)

Operator’s Guide MMC
/BAD/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Operator’s Guide HMI Advanced
Order No.: 6FC5298-6AF00-0BP2
/BAH/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Operator’s Guide HT 6
Order No.: 6FC5298-0AD60-0BP2
/BAK/ SINUMERIK 840D/840Di/810D (02.01 Edition)

Short Guide Operation
/BAM/ SINUMERIK 840D/810D (08.02 Edition)

Operation/Programming ManualTurn
/BAS/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Operation/Programming ShopMill
/BAT/ SINUMERIK 840D/810D (06.03 Edition)

Operation/Programming ShopTurn
/BEM/ SINUMERIK 840D/810D (11.02 Edition)

Operator’s Guide HMI Embedded
Order No.: 6FC5298-6AC00-0BP2

B-524 SINUMERIK 840Di Manual (HBI) – 06.03 Edition
06.03 B References
/BNM/ SINUMERIK 840D/840Di/810D (11.02 Edition)

User’s Guide Measuring Cycles
/BTDI/ SINUMERIK 840D/840Di/810D (04.03 Edition)

Motion Control Information System (MCIS)
User’s Guide Tool Data Information
Order No.: 6FC5297-6AE01-0BP0
/CAD/ SINUMERIK 840D/840Di/810D (03.02 Edition)

Operator’s Guide CAD Reader
Order No.: (included in online help)
/DA/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Diagnostics Guide
/KAM/ SINUMERIK 840D/810D (04.01 Edition)

Short Guide ManualTurn
/KAS/ SINUMERIK 840D/810D (04.01 Edition)

Short Guide ShopMill
/KAT/ SINUMERIK 840D/810D (07.01 Edition)

Short Guide ShopTurn
/PG/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Programming Guide Fundamentals
Order No.: 6FC5298-6AB00-0BP2
/PGA/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Programming Guide Advanced
/PGK/ SINUMERIK 840D/840Di/810D (10.00 Edition)

Short Guide Programming
/PGM/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Programming Guide ISO Milling

B References 06.03
/PGT/ SINUMERIK 840D/840Di/810D

Programming Guide ISO Turning (11.02 Edition)
/PGZ/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Programming Guide Cycles
/PI/ PCIN 4.4

Software for Data Transfer to/from MMC Module
Order No.: 6FX2060 4AA00-4XB0 (English, French, German)
Order from: WK Fürth
/SYI/ SINUMERIK 840Di (02.01 Edition)

System Overview
Manufacturer/Service Documentation
a) Lists
/LIS/ SINUMERIK 840D/840Di/810D (11.02 Edition)

SIMODRIVE 611D
Lists
b) Hardware
/ASAL/ SIMODRIVE (06.03 Edition)

Planning Guide General Information for Asynchronous Motors
Order No.: 6SN1197-0AC62-0BP0
/APH2/ SIMODRIVE (07.03 Edition)

Planning Guide 1PH2 Asynchronous Motors



06.03 B References
/APL6/ SIMODRIVE (07.03 Edition)

Planning Guide 1PL6 Asynchronous Motors
/BH/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Operator Components Manual (HW)
/BHA/ SIMODRIVE Sensor (03.03 Edition)

User’s Guide (HW) Absolute Position Sensor with Profibus-DP
Order No.: 6SN1197-0AB10-0YP2
/EMV/ SINUMERIK, SIROTEC, SIMODRIVE (06.99 Edition)

Planning Guide (HW) EMC Installation Guide
The current Declaration of Conformity is available under the

following Internet address:
http://www4.ad.siemens.de
Please enter the ID No.: 15257461 in the ’Search’ field (top right)
and click on ’go’.
/GHA/ SINUMERIK/SIMOTION
ADI4 – Analog Drive Interface for 4 Axes (02.03 Edition)
Manual
Order No.: 6FC5297-0BA01-0BP1
/PFK6/ SIMODRIVE (05.03 Edition)

Planning Guide 1FK6 Three-Phase AC Servomotors
Order No.: 6SN1197-0AD05-0BP0
/PFK7/ SIMODRIVE (01.03 Edition)

Planning Guide 1FK7 Three-Phase AC Servomotors
/PFS6/ MASTERDRIVES (07.03 Edition)

Planning Guide 1FS6 Three-Phase AC Servomotors
/PFT5/ SIMODRIVE (05.03 Edition)

Planning Guide 1FT5 Three-Phase AC Servomotors
/PFT6/ SIMODRIVE (05.03 Edition)

Planning Guide 1FT6 Three-Phase AC Servomotors

B References 06.03
/PHC/ SINUMERIK 810D

Configuring Manual CCU (HW) (11.02 Edition)
/PHD/ SINUMERIK 840D (09.03 Edition)

Configuring Manual NCU (HW)
/PJAL/ SIMODRIVE 611 / Masterdrives MC (01.03 Edition)

Planning Guide Three-Phase AC Servomotors
General Part
/PJAS/ SIMODRIVE (07.03 Edition)

Planning Guide Asynchronous Motors (Compendium)
/PJFE/ SIMODRIVE (02.03 Edition)

Planning Guide 1FE1 Built-In Synchronous Motors
Three-Phase AC Motors for Main Spindle Drives
/PJF1/ SIMODRIVE (12.02 Edition)

Installation Guide 1FE1 051.–1FE1 147. Built-In Synchronous Motors
Three-Phase AC Motors for Main Spindle Drives
Order No.: 610.43000.02
/PJLM/ SIMODRIVE (06.02 Edition)

Planning Guide 1FN1, 1FN3 Linear Motors
ALL General Information about Linear Motors
1FN1 1FN1 Three-Phase AC Linear Motor
1FN3 1FN3 Three-Phase AC Linear Motor
CON Connections
Order No.: 6SN1197-0AB70-0BP4
/PJM/ SIMODRIVE (11.00 Edition)

Planning Guide Motors
Three-Phase AC Servo Motors for Feed and Main Spindle Drives
/PJM2/ SIMODRIVE (07.03 Edition)

Planning Guide Servomotors
Three-Phase AC Motors for Feed and Main Spindle Drives
Order No.: 6SN1197-0AA20-0BP4

06.03 B References
/PJTM/ SIMODRIVE (05.03 Edition)

Planning Guide 1FW6 Integrated Torque Motors
/PJU/ SIMODRIVE 611 (02.03 Edition)

Planning Guide Inverters
/PKTM/ SIMODRIVE (09.03 Edition)

Planning Guide 1FW3 Complete Torque Motors
/PMH/ SIMODRIVE Sensor (07.02 Edition)

Configuring/Installation Guide (HW)
Hollow-Shaft Measuring System SIMAG H
/PMHS/ SIMODRIVE (12.00 Edition)

Installation Guide Measuring System for Main Spindle Drives
SIZAG2 Toothed-Wheel Encoder
Order No.: 6SN1197-0AB00-0YP3
/PMS/ SIMODRIVE (02.03 Edition)

Planning Guide ECO Motor Spindle for Main Spindle Drives
/PPH/ SIMODRIVE (12.01 Edition)

Planning Guide 1PH2, 1PH4, 1PH7 Motors
AC Induction Motors for Main Spindle Drives
/PPM/ SIMODRIVE (11.01 Edition)

Planning Guide Hollow-Shaft Motors
for 1PM4 and 1PM6 Main Spindle Drives
c) Software
/FB1/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Description of Functions Basic Machine (Part 1)
(the various sections are listed below)
A2 Various Interface Signals
A3 Axis Monitoring, Protection Zones
B1 Continuous Path Mode, Exact Stop and Look Ahead
B2 Acceleration
D1 Diagnostic Tools

B References 06.03
D2 Interactive Programming
F1 Travel to Fixed Stop
G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop
Control
H2 Output of Auxiliary Functions to PLC
K1 Mode Group, Channel, Program Operation Mode
Workpiece, External Zero Offset
K4 Communication
N2 EMERGENCY STOP
P1 Transverse Axes
P3 Basic PLC Program
S1 Spindles
V1 Feeds
W1 Tool Offset
/FB2/ SINUMERIK 840D/840Di/810D(CCU2) (11.02 Edition)

Description of Functions Extended Functions (Part 2)
including FM-NC: Turning, Stepper Motor
A4 Digital and Analog NCK I/Os
B3 Several Operator Panels and NCUs
B4 Operation via PG/PC
F3 Remote Diagnostics
H1 JOG with/without Handwheel
K3 Compensations
K5 Mode Groups, Channels, Axis Replacement
L1 FM-NC Local Bus
M1 Kinematic Transformation
M5 Measurement
N3 Software Cams, Position Switching Signals
N4 Punching and Nibbling
P2 Positioning Axes
P5 Oscillation
R2 Rotary Axes
S3 Synchronous Spindles
S5 Synchronized Actions (up to and including SW 3)
S6 Stepper Motor Control
S7 Memory Configuration
T1 Indexing Axes
W3 Tool Change
W4 Grinding
/FB3/ SINUMERIK 840D/840Di/810D(CCU2) (11.02 Edition)

Description of Functions Special Functions (Part 3)
F2 3-Axis to 5-Axis Transformation
G1 Gantry Axes
G3 Cycle Times
K6 Contour Tunnel Monitoring
M3 Coupled Motion and Leading Value Coupling
S8 Constant Workpiece Speed for Centerless Grinding
T3 Tangential Control

06.03 B References
TE0 Installation and Activation of Compile Cycles

TE1 Clearance Control
TE2 Analog Axis
TE3 Master-Slave for Drives
TE4 Transformation Package Handling
TE5 Setpoint Exchange
TE6 MCS Coupling
TE7 Retrace Support
TE8 Path-Synchronous Switch Signal
V2 Preprocessing
W5 3D Tool Radius Compensation
/FBA/ SIMODRIVE 611D/SINUMERIK 840D/810D (11.02 Edition)

Description of Functions Drive Functions
DB1 Operational Messages/Alarm Reactions
DD1 Diagnostic Functions
DD2 Speed Control Loop
DE1 Extended Drive Functions
DF1 Enable Commands
DG1 Encoder Parameterization
DL1 Linear Motor MD
DM1 Calculation of Motor/Power Section Parameters and
Controller Data
DS1 Current Control Loop
DÜ1 Monitors/Limitations
/FBAN/ SINUMERIK 840D/SIMODRIVE 611 digital (02.00 Edition)

Description of Functions ANA MODULE
/FBD/ SINUMERIK 840D (07.99 Edition)

Description of Functions Digitizing
DI1 Start-up
DI2 Scanning with Tactile Sensors (scancad scan)
DI3 Scanning with Lasers (scancad laser)
DI4 Milling Program Generation (scancad mill)
/FBDN/ SINUMERIK 840D/840Di/810D (03.03 Edition)

Description of Functions DNC NC Program Management
DN1 DNC Plant / DNC Cell
DN2 DNC IFC SINUMERIK, NC Data Transfer via Network
/FBFA/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Description of Functions ISO Dialects for SINUMERIK

B References 06.03
/FBFE/ SINUMERIK 840D/840Di/810D (04.03 Edition)

Description of Functions Remote Diagnosis
FE1 Remote Diagnosis ReachOut
FE3 Remote Diagnosis pcAnywhere
/FBH/ SINUMERIK 840D/840Di/810D (11.02 Edition)

HMI Configuring Package
Order No.: (supplied with the software)
Part 1 User’s Guide

Part 2 Description of Functions
/FBH1/ SINUMERIK 840D/840Di/810D (03.03 Edition)

HMI Configuring Package
ProTool/Pro Option SINUMERIK
Order No.: (supplied with the software)
/FBHL/ SINUMERIK 840D/SIMODRIVE 611 digital (11.02 Edition)

Description of Functions HLA Module
/FBIC/ SINUMERIK 840D/840Di/810D (06.03 Edition)

Description of Functions TDI Ident Connection
/FBMA/ SINUMERIK 840D/810D (08.02 Edition)

Description of Functions ManualTurn
/FBO/ SINUMERIK 840D/810D (09.01 Edition)

Description of Functions Configuring OP 030 Operator Interface
BA Operator’s Guide
EU Development Environment (Configuring Package)
PS Online only: Configuring Syntax (Configuring Package)
PSE Introduction to Configuring of Operator Interface
IK Screen Kit: Software Update and Configuration
/FBP/ SINUMERIK 840D (03.96 Edition)

Description of Functions C-PLC Programming

06.03 B References
/FBR/ SINUMERIK 840D/810D (09.01 Edition)

IT Solutions
Description of Functions Computer Link (SinCOM)
NFL Host Computer Interface
NPL PLC/NCK Interface
/FBSI/ SINUMERIK 840D / SIMODRIVE 611 digital (11.02 Edition)

Description of Functions SINUMERIK Safety Integrated
/FBSP/ SINUMERIK 840D/840Di/810D (08.03 Edition)

Description of Functions ShopMill
/FBST/ SIMATIC (01.01 Edition)

Description of Functions FM STEPDRIVE/SIMOSTEP
Order No.: 6SN1197-0AA70-0YP4
/FBSY/ SINUMERIK 840D/840Di/810D (10.02 Edition)

Description of Functions Synchronized Actions
/FBT/ SINUMERIK 840D/810D (06.03 Edition)

Description of Functions ShopTurn
/FBTC/ SINUMERIK 840D/810D (01.02 Edition)

IT Solutions
SINUMERIK Tool Data Communication SinTDC
Description of Functions
/FBTD/ SINUMERIK 840D/810D (02.01 Edition)

IT Solutions
Tool Information System (SinTDI) with Online Help
/FBTP/ SINUMERIK 840D/840Di/810D (01.03 Edition)

Description of Functions TPM Total Productive Maintenance, Version 3.0
Order No.: Document is supplied with the software

B References 06.03
/FBU/ SIMODRIVE 611 universal/universal E (07.03 Edition)

Closed-Loop Control Component for Speed Control and Positioning
/FBU2/ SIMODRIVE 611 universal (04.02 Edition)

Installation Guide (enclosed with SIMODRIVE 611 universal)
/FBW/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Description of Functions Tool Management
/HBA/ SINUMERIK 840D/840Di/810D (03.02 Edition)

Manual @Event
Order No.: 6AU1900-0CL20-0BA0
/HBI/ SINUMERIK 840Di (06.03 Edition)

Manual
/INC/ SINUMERIK 840D/840Di/810D (06.03 Edition)

System Description Commissioning Tool SINUMERIK SinuCOM NC
Order No.: (an integral part of the online help for the start-up tool)
/PJE/ SINUMERIK 840D/810D (08.01 Edition)

Description of Functions Configuring Package HMI Embedded
Software Update, Configuration Installation
Order No.: 6FC5297-6EA10-0BP0
(the document PS Configuring Syntax is supplied with the software
and available as a pdf file)
/POS1/ SIMODRIVE POSMO A (05.03 Edition)

User’s Guide Distributed Positioning Motor on PROFIBUS DP
/POS2/ SIMODRIVE POSMO A (04.02 Edition)

Installation Guide (enclosed with POSMO A)
/POS3/ SIMODRIVE POSMO SI/CD/CA (07.03 Edition)

User’s Guide Distributed Servo Drive Systems
/POS4/ SIMODRIVE POSMO SI (04.02 Edition)

Installation Guide (enclosed with POSMO SI)

06.03 B References
/POS5/ SIMODRIVE POSMO CD/CA (04.02 Edition)

Installation Guide (enclosed with POSMO CD/CA)
/S7H/ SIMATIC S7–300 (2002 Edition)

– Manual: CPU Data (Hardware)
– Reference Manual: Module Data
– Manual: Technological Functions
– Installation Manual
Order No.: 6ES7398-8FA10-8BA0
/S7HT/ SIMATIC S7–300 (03.97 Edition)

Manual: STEP 7, Fundamentals, V. 3.1
Order No.: 6ES7 10-4CA02-8BA0
/S7HR/ SIMATIC S7–300 (03.97 Edition)

Manual: STEP 7, Reference Manuals, V. 3.1
Order No.: 6ES7810-4CA02-8BR0
/S7S/ SIMATIC S7–300 (04.02 Edition)

FM 353 Positioning Module for Stepper Drive
Order together with configuring package
/S7L/ SIMATIC S7–300 (04.02 Edition)

FM 354 Positioning Module for Servo Drive
/S7M/ SIMATIC S7–300 (01.03 Edition)

FM 357-2 Multimodule for Servo and Stepper Drives
/SP/ SIMODRIVE 611–A/611–D

SimoPro 3.1
Program for Configuring Machine-Tool Drives
Order No.: 6SC6111-6PC00-0BAj, Order from: WK Fürth

B References 06.03
d) Installation and
Start-Up
/BS/ SIMODRIVE 611 analog (10.00 Edition)

Description Start-Up Software for Main Spindle and Asynchronous
Motor Modules
Version 3.20
/IAA/ SIMODRIVE 611A (10.00 Edition)

Installation and Start-Up Guide
/IAC/ SINUMERIK 810D (11.02 Edition)

(incl. description of SIMODRIVE 611D start-up software)
/IAD/ SINUMERIK 840D/SIMODRIVE 611 digital (11.02 Edition)

(incl. description of SIMODRIVE 611 digital start-up software)
/IAM/ SINUMERIK 840D/840Di/810D (11.02 Edition)

Installation and Start-Up Guide HMI/MMC
AE1 Updates/Supplements
BE1 Expanding the Operator Interface
HE1 Online Help
IM2 Starting up HMI Embedded
IM4 Starting up HMI Advanced
TX1 Creating Foreign Language Texts

EC Declaration of Conformity C
In order to provide the most recent version, the EC Declaration of Conformity is
no longer included as part of this manual.
The EC Declaration of Conformity is available in PDF format under Product ID
on Siemens A&D Product Information page: 15257461.
– Internet address: www.ad.siemens.de > Support > Service & Support >
Produkt Support > Search: 15257461 > Go
Support
Service & Support
Product Support
15257461

SINUMERIK 840Di Manual (HBI) – 06.03 Edition C-537
C EC Declaration of Conformity 06.03
Notes

C-538 SINUMERIK 840Di Manual (HBI) – 06.03 Edition
Index
Advanced Processing 2, 1-20
Alarm, 4065, 10-304, 10-396
Alarm and message texts, 11-403
MBDDE.INI configuration file, 11-403
Numbers Standard text files, 11-404
840Di Rack, 7-207, 7-212 User text files, 11-404
840Di rack, Inserting, 7-212 Alarm numbers, 11-406
840Di services, 6-197 Alarm text files, Syntax, 11-406
Assigning actual-value channels, 10-315
Assigning setpoint channels, 10-315
Authorizing SIMATIC STEP7 , 6-190
A Automatic controller setting, 13-447
Abbreviations, A-517 Axes, 10-308
Absolute encoder Axis
Adjusting several axes, 10-359 Monitoring functions, 10-343
Adjustment, 10-357 Parameter records, 10-330
Operator-assisted adjustment, 10-358 Reference point approach, 10-351
Readjustment, 10-359 Velocity adaptation, 10-340
Absolute encoders, 10-357 Axis assignment, 10-309
Absolute measuring systems, Axis configuration, 10-308
Parameterization, 10-320 Axis names, 10-311
Acceleration, 10-334 Channel axes, 10-312
Checking, 10-335 Geometry axes, 10-312
Access rights, 10-276 Machine axes, 10-311
ACCU, 2-92 Axis velocity in JOG mode, 10-340
Actual-value sensing , 7-242
Additional axes, 10-308
Address, 9-267
ADI4, 2-45, 2-105, 7-220
B
611U conformant mode, 7-228 Background image , 6-192
Drift compensation, 10-339 Backup battery
Drive configuration NC, 10-314 MCI board, 2-47
Encoder, 7-225 Monitoring, 2-50
Encoder control word G1_STW, 7-226 Basic, 1-20
Encoder type, 7-225 Basic PLC program, 8-251
Final parameter settings, 7-229 Description, 8-252
Function parameters, 7-224 Installing, 8-251
Properties, 7-224 Processing modules, 8-254
Reserved bits for fine resolution, 7-227 Using modules, 8-252
See also: ADI4 DP slave, 7-220 Basic software
Shutdown delay time, 7-227 Constraints, 6-192
Shutdown ramp, 7-227 Information, 6-192
Sign-of-life failures, 7-227 Basic start-up , 6-179
Speed setpoint matching, 10-337 BATF, 10-397
SSI encoder, 7-225 BATL, 10-397
TTL encoder, 7-225 Battery replacement, Performing, 2-51
Unipolar spindle, 7-227 Battery service life, 2-50
ADI4 DP slave Battery type, 2-50
Inserting, 7-220 Blue Screen, 1-26, 10-303
PROFIBUS parameters, 7-221 Boot manager, 6-181
Setting message frame type, 7-222 Boot type, cold restart, 8-258
Adjustment, 7-243 Buffer battery, 10-397
Advanced Processing 1, 1-20 Bus connector, PROFIBUS and MPI, 2-47

SINUMERIK 840Di Manual (HBI) – 06.03 Edition Index-539
Index 06.03
Bus fault, 10-397 D

BUSF, 10-397
Data backup, 14-449
611u, 14-450
PLC data, 14-453
C Time, 14-449
Cabinet mounting, ADI4, 2-119 Various components, 14-449
Cable distributor, 2-76 Data Exchange Time, 7-205
Connector assignment, 2-78 Data loss, 10-304
Cable outlet, 2-47 Data transfer rate
Cable routing, ADI4, 2-119 HHU, 5-154
Certification , expansions, 1-26 HT 6, 5-163
Changing the battery MCP, 5-142
Criteria for, 2-50 MPI interface, 5-149
MCI board, 2-50 PCU with HMI Advanced, 5-168
Channel axes, 10-308 Declaration of Conformity, C-535
Checklist, Preparing for start-up, 6-173 Default address assignment, 5-139
Circularity test, 13-417 Default password, 10-278
Clamping tolerance, 10-343 Deleting NC data, 8-250
Clearance-coded reference marks, 10-355 Detailed view, 7-212
Closed-loop control circuits, 10-332 Diagnosis
Color depth NC, 10-395
Setting, 1-25 PLC, 10-395
Switchover, 1-25 Differential handwheels, 2-68
Commissioning Dimension drawing
PLC, 8-249 ADI4, 2-123
Recommended order, 6-174 MCI board extension backpack, 2-75
Compile cycles, 10-389 PP72/48, 2-103
Boundary conditions, 10-391 Display resolution, 10-281, 10-282
Retrofitting, 10-390 PCU with Advanced, 5-168
Complete system, 2-43 Distributed I/Os, 10-397
Computational resolution, 10-281 DMF file
Computer name, 6-188, 6-200 General, 7-209
Configuration I/O module PP72/48, 1-33
Loading into the PLC, 7-244, 7-246 DOS Shell, 6-195
Operating a PLC with a new DP cycle, 7-205, 7-241
configuration, 7-246 Setting, 7-213
Connection overview DP cycle time, 7-205
ADI4, 2-122 DP master, 7-213
MCI board, 3-131 DP slave 611U
MCI board extension, 3-131 Consistency, 7-231, 7-235
PCU 50, 3-131 Inserting into an S7 project, 7-231
Contour monitoring, 10-347 PROFIBUS DP communication, 7-236
Control direction, 10-332 Setting the I/O addresses, 7-234
Coordinate axes, 10-308 Setting the message frame type, 7-233
Correct shutdown, 1-29 Setting the PROFIBUS address, 7-232
CPU time share, 10-292 DP slave 611u, PROFIBUS parameters, 7-232
Current control loop, Measurement, 13-423 DP slave ADI4
Current HMI–Environment, 6-189 Boundary conditions in SW 2.1 and
Customizable message frame configuration, higher, 7-229
16-501 Consistency, 7-224
Cycle times, 10-290 Setting the I/O addresses, 7-223
Cycles Setting the PROFIBUS address, 7-221
Changing, 10-306 DP slave PP72/48
Option, 10-306 Inserting, 7-217
Relocation, 10-306 PROFIBUS parameters, 7-218
Saving, 10-306 Selecting the set configuration, 7-218
Swapping, 10-306 Setting the I/O addresses, 7-219
Cyclic operation, PLC, 8-259 DP-Slave 611U, Parameterization, 7-232

Index-540 SINUMERIK 840Di Manual (HBI) – 06.03 Edition
06.03 Index
DRAM file system, 10-305 Exact stop fine, Delay time, 10-343
Drift compensation, 10-339 EXCHANGE
Drive configuration, 10-313 LED: ADI4, 2-118
ADI4, 10-314 LED: PP72/48, 2-101
I/O addresses, 10-313 Expanded message frame configuration, 7-231,
Message frame type, 10-313 16-501
Drive optimization, 10-326 Expert mode, 10-280
Drive Optimization using HMI Advanced, 13-417 Export version, 1-37
Drive start-up (preconditions), 9-263 External, floppy disk drive, 3-129
DriveOM, 1-33, 7-208 External operator panel (PCU with HMI
Drives, 2-45 Advanced), 5-168
General information, 1-22 External power supply, PP72/48, 2-94
Dry Run, axis, 12-413
Dry run
Axis and spindle, 12-411
Axis enabling, 12-411
F
Drive enable, 12-411 Failure safety, 1-26
Preconditions, 12-411 Fatal exceptional error, 1-26
Spindle, 12-415 Fault analysis, 6-191
DSC, 10-325 FB 1
Dx, 7-206 HPU, 5-165
Dynamic monitoring, 10-345 MCP, 5-144
Velocity monitoring, 10-347 FFT analysis, 13-417
Dynamic Servo Control, 10-325 Final parameterization, DP slaves gen., 7-238
Firmware, MCP, 5-140
First start-up, 611u, 9-263
Floppy disk drive , 2-44
E Floppy disk drive 3.5’’, 2-87
EC Declaration of Conformity, C-535 FORCE, 10-397
Electrical connection Frequency response measurement, 13-423
HHU, 5-153
HT 6, 5-163
MPI interface, 5-148
Electrical installation
G
MCI board and MPI bus, 3-128 GC, 7-206
MCI board and PROFIBUS DP, 3-127 GD circle parameterization
MCI board extension, 3-128 HHU, 5-157
PCU 50, 3-129, 3-130 PLC: BHG, 5-158
PCU 70, 3-130 Gear stage speed, 10-374
EMC measures, 4-135 General, 1-19
Encoder cut-off frequency, 10-374 General NCK reset, 10-396
Encoder monitoring General PLC reset, 7-246, 10-397
Cut-off frequency, 10-348 General reset of PLC, 8-250
Cyclic monitoring of position tolerance, 10-349 Geometry axes, 10-308
Position tolerance when switching over the Global Control Message Frame Type, 7-206
encoder, 10-349 Graphic display, drive optimization, 13-431
Zero mark monitoring, 10-349 Grounding
Encoder types, Absolute measuring system, ADI4, 2-121
10-320 PP72/48, 2-102
Endlessly rotating rotary axis, 10-327 Group fault, 10-397
EQN 1325, 10-320
Equidistant DP cycle, 7-240
Setting, 7-213
Equidistant master cyclic portion, 7-240
H
Equidistant time, 7-213 H1, Module status, ADI4, 2-118
ESD measures, 4-136 H2, Module status, ADI4, 2-118
ET 200, 2-45 Handheld terminal HT 6, 5-161
Exact stop Handheld unit (HHU), 5-151
Coarse, 10-343
Fine, 10-343

Index 06.03
Handwheels Interface signal

Differential, 2-68 PC OS fault, 1-27
TTL, 2-68 PC shutdown, 1-27, 10-303
Hardware catalog, 7-212 Interface signals
Hardware components, 2-43 840Di-specific, 16-499
Complete system, 2-43 Not supported, 16-499
MCI board extension, 2-44 Interference suppression measures, 4-135
MCI board extension backpack, 2-44 Interpolation cycle, 10-292
MCI board extension slot variation, 2-44
Operator panel fronts, 2-44
Spare parts, 2-43
Hardware limit switches, 10-345
L
Hazards, Backup battery, 2-50 Language default setting, 5-169
HMI Explorer, 6-191 Language dependency of the alarm texts, 11-405
HT 6, 5-161 Language switchover, 5-169
HW Config, 7-212 Latency time, 10-398
HW Config on a local PC, 7-245 LED
HW Config on an external PG/PC, 7-245 Diagnostics: ADI4, 2-118
Status display: PP72/48, 2-101
License key, 6-202
License management , 6-201
I Limit switches, 12-412
I/O, Assignment to hardware, 10-380 Linear axis
I/O addresses, Drive configuration, 10-313 With linear scale, 10-319
I/O Module PP72/48, 2-93 With motor-mounted rotary encoder, 10-320
I/O module PP72/48, See also: DP slave With rotary encoder on the motor, 10-317
PP72/48, 7-217 Linear measuring systems, 10-319
I/O modules PP 72/48, 2-45 Literatur, B-523
I/Os lithium battery, 2-50
Digital/analog, 10-379 Loading the system software, 6-177
I/O modules, 1-22 Loop gain, 10-332
Max. number of inputs/outputs, 10-379 Loss of voltage, 1-27
System variable, 10-381
Identification of the control, 1-37
Incremental measuring systems,
Parameterization, 10-317
M
Indexing axes, 10-329 Machine axes, 10-308
Indexing position tables, 10-329 Machine control panel (MCP), 5-140
Industrial PC, 2-81 Ramp-up, 6-180
Initial settings, 10-394 Machine data, 10-273
Input limits, 10-282 Activation, 10-274
Input resolution, 10-281 Bit editor, 10-275
Input Time, 7-206 Changing scaling, 10-285
Inserting a 300 station, 7-211 Display filter, 10-279
Installation, 6-175 Display/input screen forms, 10-275
MCI board extension backpack, 2-72 Identifier, 10-273
MCI board extension slot variation, 2-57, 2-64 Normalization of physical quantities, 10-283
Installation rules, EMC/ESD, 4-135 Overview, 10-274
Installed components, Basic software, 1-32 machine data, Loading default data, 10-286
installed components Making the MPI connection, 8-255
Engineering Tools, 1-33 Master Application Cycle, 7-205
SIMATIC S7 AddOn software, 1-33 Master application cycle, 7-241
Installing language packages, 5-169 Master Time, 7-206
Interface description Max. axis velocity, 10-340
ADI4, 2-107 MCI board, 1-21, 2-46
MCI board, 2-48 Cable outlet, 2-47
MCI board extension, 2-59, 2-66 MCI board extension, 1-21, 2-44, 2-56
MCI board extension backpack, 2-75 Backpack, 2-44
PP72/48, 2-94 Internal, 2-62, 2-70
Interface overview, ADI4, 2-48, 2-66, 2-107 Slot variation, 2-44

06.03 Index
MCI board extension internal, 1-22 Network rules, 5-137, 7-210

Switch S1, 2-62, 2-63, 2-70, 2-71 Node address, 9-267
MD, 18060, 10-399
Measuring functions, canceling, 13-420
Measuring functions, 13-417, 13-419
Starting, 13-420
O
Measuring system switchover, Interface OEM configuration, 6-191
signals, 10-316 OEM directories, 6-191
Memory Online connection, 611u, 9-265
DRAM, 10-297 Online operation, starting, 9-270
Free DRAM memory, 10-297 OP 012, 2-85
Free SRAM memory, 10-298 Operator panel front, 2-85
SRAM, 10-298 General, 1-22
SRAM reconfiguration, 10-298 Operator panel fronts, 2-44
Memory configuration, 10-296 Operator panel settings, RS-232 interfaces, 5-168
Hardware configuration, 10-296 Optional HMI components, 1-24
Message frame type, Drive configuration, 10-313 Options , Performance, 1-20
Message texts, 11-403 Order No.
Module ADI4, 2-106
ADI4, 2-105 Cable distributor, 2-76
MCI board, 2-46 MCI board, 2-46
MCI board extension, 2-56 OP 010, 2-44
MCI board extension internal, 2-62, 2-70 OP 010C, 2-44
PP72/48, 2-93 OP 010S, 2-44
Module replacement, MCI board, 2-54 OP 012, 2-85
Modulo display, 10-327 OP 015, 2-44
Monitor/control PCU 70, 2-83
Using HMI Advanced, 8-261 SITOP POWER 10, 2-87, 2-88
Using the SIMATIC Manager STEP7, 8-260 Order number
Mounting, ADI4, 2-119 Backup battery, 2-50
MPI, interface, 1-21 MCI board extension, 2-44, 2-56, 2-62, 2-70
MPI address MCI board extension backpack, 2-44
HHU, 5-155 MCI board extension slot variation, 2-44
HT 6, 5-163 PCU 50, 2-81
MCP, 5-142 PP72/48, 2-93
MPI interface, 5-149 SITOP POWER DC UPS MODULE 10, 2-90
MPI communication, 5-137 SITOP POWER lead-acid battery module
MPI interface, 5-148 24VDC/10A/3.2AH, 2-92
Parameterizing, 7-214, 7-245, 8-255 Original HMI–Environment, 6-189
Setting, 9-268 Output Time, 7-206
MPI parameterization of the PLC, HHU, 5-155 Overtemperature, 1-28
MPI parameters, HHU, 5-154 Overview, 1-19
OVTEMP
LED: ADI4, 2-118
LED: PP72/48, 2-101
N
NC system clock cycle, setting, 7-213
NCK
Distribution of computation time, 1-23
P
General, 1-23 Packages , System software, 1-20
Setting the CPU time share, 10-292 Paging File, 10-302
NCK CPU time share, 10-292 Parameter records of the position
NCK interface, HPU, 5-166 controller, 10-330
NCK interface parameter assignment, Parameterization
MCP, 5-145 HT 6, 5-163
NCK latency time, 10-398 MCP, 5-141
NCK reset, 10-396 MPI interface, 5-148
NCK status, 10-395 Parameterization of the PLC
NetBEUI, 6-199 HT 6, 5-164
Network operation, 6-188 MCP, 5-143

Index 06.03
Parameterizing axis-specific actual PROFIBUS address

values, 10-315 Setting using an operator unit, 9-265
Parameterizing axis-specific setpoints, 10-315 Setting using the PROFIBUS unit, 9-267
Password SIMODRIVE POSMO SI/CD/CA, 9-267
Resetting, 10-277 PROFIBUS DP, 10-393
Setting, 10-277 General, 7-203
PCU, 1-21 Interface, 1-21
Interfaces, 1-21 PROFIBUS DP communication, 7-203
Slots, 1-21 PROFIBUS S7 subnetwork ID, 9-269
PCU 50, 2-81 Determining, 9-269
PCU 70, 2-83 Programmable spindle speed limitations, 10-374
PDA area, 7-204 Proper shutdown, 10-306
Performance data, PLC315-2DP, 8-251 Protection levels, 10-276
Performance options, 1-20 PTP link, 6-199
PG/PC, 7-207 Pulse multiplication, 10-366
PHG, connecting/disconnecting during running
operation, 5-167
Pin assignment, cable distributor, 2-79
PIV area, 7-204
R
PLC module, 8-249 Ramp-up, 6-180, 6-181
PLC MRES, 10-397 After battery replacement, 6-183
PLC operating state, 10-398 First, 6-175
PLC program, 8-251 Ramp-up
Loading, 8-255, 8-256 After importing a backup copy, 6-186
PLC RUN, 10-396 After PCU/MCI board replacement, 6-186
PLC RUN–P, 10-396 After power failure, 6-186
PLC start-up, 8-249 After reinstallation/update, 6-185
PLC STOP, 10-397 After replacement of the MCI board, 6-183
PLC system fault, 10-397 Rapid traverse in JOG mode, 10-340
PLC Toolbox, 1-33 READY
PLC user program, 8-251, 8-253 LED: ADI4, 2-118
Plus, 1-20 LED: PP72/48, 2-101
Position control loop Real–time behavior , 10-398
Measurement, 13-427 Real–time property, 10-398
Overshoots, 10-334 Real–time violations, 10-398
Reference frequency response, 13-427 Real-time properties, 1-24
Step height, 13-430 Real-time violations , 1-25
Position controller, 10-332 Redefining protection levels, 10-278
Position controller cycle, 10-290 Reference point approach, 10-351
Setting, 7-213 Resolutions, 10-281
Position controller cycle offset, 10-290 Restart, 10-315
Positioning accuracy, 10-289 Retentive ranges, 8-258
Positioning axes, 10-328 Rotary axes, Drive optimization, 10-326
Concurring, 10-328 Rotary axis
Feedrate, 10-328 With machine-mounted rotary
POWER encoder, 10-318
LED: ADI4, 2-118 With motor-mounted rotary
LED: PP72/48, 2-101 encoder, 10-318, 10-321
Power OFF, 1-28 Rotary measuring system, 10-317
Power supply, 2-88 Routing information, setting, 9-269
ADI4, 2-119 RUN, 10-397
PP72/48, 2-101
PP72/48, 2-93
Setting the PROFIBUS address, 7-218
Preparing for start-up, 6-173
S
PROFIBUS S1
Modules, 2-45 Handwheel type, MCI board Ext., 2-63
Node address, 9-267 PROFIBUS address, PP72/48, 2-95

06.03 Index
S2, PROFIBUS address, ADI4, 2-108 SIMODRIVE 611 universal, 7-231, 9-263, 16-504,
S3 16-512
MCP, 5-141 BERO, 10-371
MPI interface, 5-149 Max. useful motor speed, 10-346
S7 project, 8-255 Motor monitoring speed, 10-346
Configuring the NC, 7-215 Pulse multiplication, 10-366
Configuring the PLC, 7-214 Speed evaluation PROFIBUS, 10-369
Creating, 7-211 Speed setpoint matching, manual, 10-336
Sample PLC application, 1-34 SIMODRIVE 611 universal E, 7-231, 16-504,
Saving measurement results, 13-418 16-512
Screen, PCU with HMI Advanced, 5-168 SIMODRIVE 611u, See also: DP slave 611u,
Screen resolution 7-231, 16-504, 16-512
Setting, 1-25 SIMODRIVE POSMO CD/CA, 7-231, 16-504,
Switchover, 1-25 16-512
Selecting a series machine start-up archive, se- Speed setpoint matching, manual, 10-336
lecting the contents, 14-451 SIMODRIVE POSMO SI, 7-231, 16-504, 16-512
Selecting the version, 6-177 Speed setpoint matching, manual, 10-336
Serial mouse, 6-190 SinuCom NC, General information, 1-24
Series Machine Start-Up, 14-449 SINUMERIK Desktop, 6-179
Series machine start-up, 611u, 9-263 SINUMERIK desktop, 6-188
Series machine start-up archive SITOP POWER 10, 2-88
Creation using HMI Advanced, 14-454 SITOP POWER ACCUMODULE
Creation using HMI Advanced, 14-451 24VDC/10A/3,2AH, 2-44
Series machine start-up file, creating a, 8-257 SITOP POWER DC UPS module 15, 2-44
Serious exception, 10-300, 10-303 SITOP POWER lead-acid battery module
Service menu, 6-193 24VDC/10A/3.2AH, 2-92
Service Mode, 6-195 SITOP POWER standard 24V/10A, 2-44
Services, 6-197 SlaveOM, 1-33, 7-208, 7-231
Servo gain, Checking the, 10-334 Software components, Overview, 1-32
Servo gain factor, Definition, 10-333 Software limit switches, 10-344
Servo loop, setpoint step change, 13-429 Software version
Servo trace, 13-418 HHU, 5-155
Setpoint acceptance, 7-242 HT 6, 5-163
Setting data, 10-274 MPI interface, 5-149
Activation, 10-274 Software version, MCP, 5-142
Identifier, 10-274 Spare parts, 2-43
Normalization physical quantities, 10-283 Speed control loop
Overview, 10-275 Interference frequency response, 13-424
Setting the HMI environment, 6-189 Reference frequency response, 13-424
Settings, 10-399 Setpoint and disturbance step change, 13-425
SF, 10-397 Speed control loop measurement, 13-423
SF–DP, 10-397 Speed setpoint matching, 10-336
Sharing names, 6-200 Automatic, 10-336
Shielded signal cables, 4-135 Speed setpoint monitoring, 10-345
Shutdown, 10-301
Shutdown behavior, 10-400
Shutting down correctly, 1-28
Sign-of-life monitoring, 8-259
Signal distortion, 10-348
SIMATIC ET 200, 2-45
SIMATIC Manager STEP7, 7-207
On an external PG/PC, 8-255
On SINUMERIK840Di, 8-255
SIMATIC S7 I/O devices, 7-216
SIMATIC S7 project, 7-211
SIMODRIVE drives, 7-231

Index 06.03
Spindle System integrity, 1-26

Adapting the encoder, 10-366 System overview, 3-125
Axis mode, 10-363 System software, 1-32
Basic data, 10-362 System software packages, 1-20
Definition in machine data, 10-362
Enabling gear stage change, 10-365
Gear stages, 10-365
Gear stages, 10-368
T
Master , 10-364 Tapping/thread, cutting, 10-330
Measuring systems, 10-366 TCP/IP, 6-188
Modes, 10-362 TDP, 7-205, 7-240, 7-241
Monitoring functions, 10-373 TDX, 7-205
Parameter records, 10-330 Technical data
Parameter sets, 10-365 ADI4, 2-124
Positioning, 10-370 MCI board, 2-55
Reset, 10-364 MCI board extension, 2-61, 2-69
Setpoint adjustment, 10-368 MCI board extension backpack, 2-75
Setpoint/actual-value channels, 10-365 PP72/48, 2-104
Speeds, 10-368 Technological functions
Synchronizing, 10-371 Activation, 10-391
Spindle at a standstill, 10-373 Licensing, 10-391
Spindle data, 10-376 Version display, 10-392
Spindle in setpoint range, 10-373 Temperature
Spindle speed, Maximum, 10-373 CPU, 1-28
Spindles, 10-308 CPU module, 1-28
SRAM Temperature , housing, 1-28
Physical, 1-29, 10-400 Terminating resistor, MCP, 5-140
Virtual, 1-30, 10-400 Testing the PLC program, 8-258
SRAM , Virtual, 10-300 Text file for cycle alarm texts, 11-406
SRAM handling, 6-181 Text file for PLC alarm texts, 11-407
Standard version, 1-37 TI, 7-206, 7-242
Standstill position tolerance, 10-343 TM, 7-206
Start-up, 1-38 TMAPC, 7-205, 7-241
611u, 9-263 TO, 7-206, 7-242
General information, 1-24 Torque control loop, Measurement, 13-423
HHU, 5-151 Torque reduction , 16-511
HT6, 5-161 Trace function
MCP, 5-140 Creating subdirectories, 13-443
Menu command: Window, 1-39 Display function, 13-439
NC with HMI Advanced, 10-273 Drive optimization, 13-434
Notices, 1-35 Main menu, 13-435
Start-up , After PCU replacement, 6-185 Measurement parameters, 13-436
Start-up behavior, PLC, 8-258 Measuring, 13-438
Starting the SINUMERIK Desktop, 6-179 Operation, 13-435
Startup , 10-301 Parameterization, 13-436
Static monitoring functions, 10-343 Printer selection, 13-444
Station window, 7-212 Signal selection, 13-436
Status displays, 10-397 Traversing direction, 10-332
STOP, 10-397 Traversing ranges, 10-289
PLC, 10-397 Triggering NC reset, 8-257
Storage of the text files, 11-403 TTL handwheels, 2-68
SUB-D, Socket connector, 2-48 Turning On and Ramp Up, 6-173
Subsequent installation , Windows NT compo-
nents, 6-201
Switching over the measuring system, 10-287
System Check, 6-196
U
System clock cycle, 10-290 Uninterruptible power system (UPS), 1-29
System data, 10-281 Universal, 1-20
System data blocks, 7-244 UPS, 2-90
System information, 6-191 SITOP POWER DC UPS module 15, 2-90

06.03 Index
User data, 10-296 X10, MCP, 5-141

User memory X101, PROFIBUS DP, MCI board, 2-48
Non–volatile, 10-399 X111
PLC, 8-251 Digital inputs/output, PP72/48, 2-96
MPI interface, MCI board, 2-49
X121
Cable distributor, MCI board Ext., 2-59
V I/O MPG extension, MCI board Ext., 2-66
Velocities, 10-294 X121: Cable distributor, 2-56
Lower limit, 10-295 X121: I/O MPG extension, 2-62, 2-70
Max. axis velocity, 10-294 X2
Max. spindle speed, 10-294 PROFIBUS DP, ADI4, 2-108
Max. tool path velocity, 10-294 PROFIBUS DP, PP72/48, 2-95
Upper limit, 10-294 X20, MCP, 5-141
Velocity monitoring, Actual, 10-347 X222, Digital input/outputs, PP72/48, 2-96
Version X3
Basic software, 6-191 Analog setpoint interface, ADI4, 2-109
HMI system software, 6-191 Battery connection, MCI board, 2-48
Version display, Basic software, 6-195 X333, Digital input/outputs, PP72/48, 2-96
Virtual Memory, 10-302 X4: MCI board extension, 2-56, 2-62, 2-70
X4-1, Encoder interface, ADI4, 2-110
W X5-2, Encoder interface, ADI4, 2-110
Windows NT, 2-83 X6-1, Digital outputs, ADI4, 2-113
General, 1-23 X6-2, Digital inputs, ADI4, 2-116
Workgroup, 6-200
Working area limitation, 10-344
Z
Zero speed control, Delay time, 10-343
X
X1
External power supply ADI4, 2-107
External power supply, PP72/48, 2-94

Index 06.03

To Suggestions
SIEMENS AG Corrrections
A&D MC BMS for publication:
P.O. Box 3180
SINUMERIK 840Di
D-91050 Erlangen/Germany
(Tel. ++49–(0)180 / 5050–222 [Hotline]
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email: motioncontrol.docu@erlf.siemens.de) Manufacturer/Service documentation
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Overview of SINUMERIK 840D/840Di/810D Documentation
General Documentation User Documentation
SINUMERIK
SIROTEC
SINUMERIK SINUMERIK SIMODRIVE SINUMERIK SINUMERIK SINUMERIK SINUMERIK
840D/810D 840D/840Di/ Accessories 840D/810D/ 840D/840Di/ 840D/840Di/ 840D/840Di/
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Brochure Catalog Catalog AutoTurn Operator’s Guide Diagnostics Operator’s Guide *)

Ordering Info. Accessories – Short Guide – HT 6 Guide *) – Short Guide
NC 60 *) NC-Z – Programming/ – HMI Embedded
Setup – HMI Advanced
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840D/840Di/ 840D/810D 840Di 840D/840Di/ 840D/810D 840D/840Di/
810D 810D 810D
Program. Guide Operator’s Guide System Overview Configuring Operator Description of Description of
– Short Guide – ManualTurn (HW) *) Components Functions Functions
– Fundamentals *) – Short Guide ManualTurn – 810D (HW) *) – ManualTurn Synchronized
– Advanced *) – ShopMill – 840D – ShopMill Actions
– Cycles – Short Guide ShopMill – ShopTurn
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611D 840D/840Di/ 840D/840Di/ 840D/810D 840D/810D 840D/840Di/
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Description of Description of Description of Configuring Kit Description of Motion Control Information System
Functions Functions Functions HMI Embedded Functions – Computer Link SinCom
Drive Functions *) – Basic Machine *) Tool Manage- Operator Interface – Tool Information System SinTDI
– Extended Functions ment OP 030 – DNC NC Program Management
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840D 840D/840Di 840D 840D
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Description of Description of Installation & Lists *) Description of Description of Functions EMC

Functions Functions Start-Up Guide *) Functions – Hydraulics Module Guidelines
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SIMODRIVE 840Di
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611, Motors
DOC ON CD *) Description of Manual Description of Manual

The SINUMERIK System Functions (HW + Installation Functions @ Event
ISO Dialects for and Start-Up) Remote Diagnosis
SINUMERIK
*) These documents are a minimum requirement
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Automation & Drives
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P.O. Box 3180, D-91050 Erlangen © Siemens AG, 2003
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Manual 06/2003 Edition

EMC and ESD Measures 4

SINUMERIK 840Di MPI Communication 5

Turning On and Ramp Up 6

Alarm and Message Texts 11

Dry Run of Axis and

Drive Optimization using

User Data Backup/

Control Software version SW Installation/Update

06.2003 Edition Index D

Status code in the “Remarks” column:

Edition Order No. Remarks

This manual is included in the documentation available on CD-ROM (DOCONCD)

Order No. 6FC5 297-6AE60-0BP2 Siemens Aktiengesellschaft

A&D Technical Support Phone: +49–180–5050–222

Please send any questions about the documentation (suggestions forimprove-

Fax form: see reply at the end of the manual

Internet address http://www.ad.siemens.de/sinumerik

Target readers S Configuring engineers,

 Siemens AG, 2003. All rights reserved

Separate descriptions are likewise provided of the tasks to be performed by the

 Siemens AG, 2003. All rights reserved

Further notes Explanation of symbols

 Siemens AG, 2003. All rights reserved

Allowing unqualified persons access to the equipment/system or failure to

Should it be necessary to test or take measurements on live equipment, then

 Siemens AG, 2003. All rights reserved

ESD instructions Components that can be destroyed by Electrostatic Sensitive

S As a general rule, electronic boards should only be touched when absolu-

S Do not touch ESD-sensitive components unless

S Place sensitive modules only on high-resistance, conductive surfaces (table

S Do not bring ESD-sensitive modules into contact with chargeable and

S Measurements on ESD-sensitive modules may only be carried out if

 Siemens AG, 2003. All rights reserved

 Siemens AG, 2003. All rights reserved

1 General on the SINUMERIK 840Di . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

 Siemens AG, 2003. All rights reserved

2.6 Cable distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

 Siemens AG, 2003. All rights reserved

5.3 Default address assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139

 Siemens AG, 2003. All rights reserved

6.4.2 Software installation/update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-189

 Siemens AG, 2003. All rights reserved

8.4.1 Start-up behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-258

 Siemens AG, 2003. All rights reserved

10.5.14 Position controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332

 Siemens AG, 2003. All rights reserved

13.2 Measuring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-419

 Siemens AG, 2003. All rights reserved

16 840Di Specific Data and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-499

 Siemens AG, 2003. All rights reserved

S where decentralized automation solutions are required in the fields of PLC

S a complete PC-integrated control system is preferred, since this solution

Networking SIEMENS A&D Operator Panels

Fast dig. I/Os

Fig. 1-1 SINUMERIK 840Di System Overview

 Siemens AG, 2003. All rights reserved

S System software Basic

Basic Universal Plus