Siemens SINUMERIK 840Di Installation guide

SINUMERIK 840Di
System Overview 02.2001 Edition

Introduction 1
System Overview 2
Hardware 3
Software 4
Start-up, Service and
Maintenance 5
Services 6
Information and
Training 7
SINUMERIK 840Di
System Overview
Applies to
Control system Software version
SINUMERIK 840Di 1.0
SINUMERIK 840DiE (export variant) 1.0
SINUMERIK 840Di 1.1
SINUMERIK 840DiE (export variant) 1.1
SINUMERIK 840Di 1.2
SINUMERIK 840DiE (export variant) 1.2
02.2001 Edition

SINUMERIK® documentation
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© Siemens AG 2001. All Rights Reserved.
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02.2001 Contents
© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition v
Contents
Introduction ............................................................................................................................1-7
System Overview....................................................................................................................2-9
2.1 The SINUMERIK 840Di................................................................................2-10
2.2 Fields of application .....................................................................................2-11
2.3 System hardware.........................................................................................2-12
2.4 System software...........................................................................................2-14
2.5 System advantages......................................................................................2-16
Hardware.................................................................................................................................3-19
3.1 SIEMENS industrial PCs .............................................................................3-20
3.2 MCI Board....................................................................................................3-21
3.3 MCI Board Extension...................................................................................3-23
3.4 Operator panel fronts...................................................................................3-24
3.5 Handheld operator and programming units..................................................3-25
3.6 Machine control panels................................................................................3-25
3.7 Drives...........................................................................................................3-26
3.8 I/Os ..............................................................................................................3-29
3.9 Uninterruptible power supply (UPS).............................................................3-30
Software..................................................................................................................................4-31
4.1 Windows NT.................................................................................................4-32
4.2 NC software .................................................................................................4-32
4.3 HMI software................................................................................................4-33
4.4 Power OFF and behavior in case of power failure .......................................4-39
4.5 Supplementary conditions regards software and hardware..........................4-40

Contents 02.2001
© Siemens AG 2001 All Rights Reserved
vi SINUMERIK 840Di System Overview (SYI) - 02.2001
Start-up, Service and Maintenance.......................................................................................5-41
5.1 Starting up the SINUMERIK 840Di...............................................................5-42
5.2 Starting up the drives...................................................................................5-43
5.3 Service information ......................................................................................5-46
5.4 Data backup.................................................................................................5-46
5.5 Remote diagnosis ........................................................................................5-47
Services ..................................................................................................................................6-49
6.1 Services offered by Siemens........................................................................6-50
Information and Training.......................................................................................................7-51
7.1 Documentation.............................................................................................7-52
7.2 Internet.........................................................................................................7-53
7.3 Training........................................................................................................7-53
■

© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition 1-7
Introduction
Control systems based on industrial PC are used in many fields of automation
technology. Moreover, the trend towards control systems completely based on PC
is to be found in many areas, such as woodworking, packaging, handling, bending,
spark erosion, as well as in the field of machine tools and other production
machines. The application and acceptance of control systems in the individual
automation sectors and regions is developed to a different degree, but it is
expected to increase further in future.
Integration
Siemens has taken the first step towards PC based control systems in the area of
the operation with the CNCs SINUMERIK 840C and SINUMERIK 810D/840D. The
new control system SINUMERIK 840Di now represents the consistent continuation
of the SINUMERIK 810D/840D. In addition to the operating functionality, the CNC
functionality is also integrated in the PC.
Decentralization
Another trend in the world of automation is decentralization. More and more
components are relocated from the control cubicle to the system/installation, thus
being as much as possible near the machine. As a result, this provides, on the one
hand, reduced wiring expenditure and, on the other hand, increased flexibility and
reliability. This pertains not only to the I/O modules for input/output signals, but to
an increasing degree also to the drive units.
With the SINUMERIK 840Di, SIEMENS now offers a completely PC integrated
control system that uniformly controls the drive units and I/Os via the standard
PROFIBUS DP with Motion Control functionality, facilitating a distributed design of
the whole system.
The most important features of the SINUMERIK 840Di and the provided
automation components are described in the following Sections.
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1

1 Introduction 02.2001 Edition
© Siemens AG 2001 All Rights Reserved
1-8 SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition

© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition 2-9
System Overview
2.1 The SINUMERIK 840Di .......................................................................2-10
2.2 Fields of application............................................................................. 2-11
2.3 System hardware................................................................................. 2-12
2.4 System software .................................................................................. 2-14
2.5 System advantages ............................................................................. 2-16
2

2 System Overview 02.2001
© Siemens AG 2001 All Rights Reserved
2-10 SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition
2.1 The SINUMERIK 840Di
Industrial PC (PCU)
Software
WINDOWS-NT
NC SW Start-up/
Installation Operation OEM/
End User
PC SW MCI
Board OEM/
End User
PC Board
Boards
I/O
Modules
PROFIBUS DP (12 MBaud)
Drive
Units
Fig.2-1 Overview of the SINUMERIK 840Di
Hardware basis
The hardware basis of the SINUMERIK 840Di is a SIEMENS industrial PC in
conjunction with a PCI plug-in board, the so-called MCI Board (Motion Control
Interface), which has been developed by Siemens. Depending on the variant of the
industrial PC used, a different number of OEM or end user PC boards (PCI or ISA)
can be plugged optionally.
Drive units and I/Os can be connected to the SINUMERIK 840DI via PROFIBUS
DP with Motion Control functionality (both clocked and in equidistant mode) both
centrally and decentralized.
Software basis
The software basis is the WINDOWS NT standard operating system. In addition, a
software method developed by Siemens allows the operation of the NC software in
real time mode parallel to WINDOWS NT. NC and PLC software, as well as
installation/start-up and operation are already integrated in the system software.
In addition, the open concept allows specific extensions by the OEM or end user
PC software (see also Section "Certification").

02.2001 2 System Overview
© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition 2-11
2.2 Fields of application
The SINUMERIK 840Di supplements the product spectrum of the SINUMERIK
control systems. Generally, it is suited, in particular for applications
•for which decentralized automation solutions in the field of PLC and the drives
are required
•or a completely PC-integrated control system is given preference (e.g. if a PC
is anyway needed for tasks, such as visualization or networking).
Technological area of application
The technological area of application of the SINUMERIK 840Di ranges from simple
Motion Control tasks (positioning and linear interpolation) via applications, such as
woodworking centers, handling, installation/mounting - also in the field of
packaging - up to machine tools and machine tool-related applications.
Experience has shown that the SINUMERIK 840Di is of special importance for
those who produce their control systems themselves. For lack of suitable standard
control systems, these people have already been accustomed to use the openness
of the PC technology in hardware and software for their automation systems for a
long time. Nowadays, in view of a generation change in the control technology,
anyone designing and producing the control system himself is provided with a
comprehensive basic system in the form of the SINUMERIK 840Di:
•Thanks to this openness, he can implement his technology with a minimum of
his own, additional engineering (time, costs).
•In the terms of an operational optimum, he can thus fully concentrate on his
technological core competencies.
•He will reduce the logistic expenditure for the PC technology as such
(procurement, qualification).
•He will benefit from the advantage that Siemens is well known and spread all
over the world (sales/marketing and service).
Consistency to the SINUMERIK 840D
A special feature of the SINUMERIK 840Di is the consistency to the SINUMERIK
840D. This pertains, in particular, to:
•the compatibility of the NC and PLC programs,
•the various possibilities of the openness and
•the usability of the same components, such as PCU, operator panel fronts,
SIMATIC I/Os, motors and various accessories.
This consistency provides the user with more flexibility when choosing the control
system meeting his specific requirements optimally.

2 System Overview 02.2001
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2-12 SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition
2.3 System hardware
Industrial PC
(
PCU
)
Networking
(e.g. TCP/IP)
PROFIBUS-DP (12 MBaud)
•=Siemens A&D Operator Panels
•=OEM Operator Panels
•=PC Monitor and MF2 Keyboard
MCI-Board Extension
(Option)
Fast Dig. I/Os
Measuring Pulses
Handwheels
Prog. Dev's
(e.g. PG 740) MCP Operator Units (HHU/HT6)
MCI Board
SIMODRIVE POSMO SI, CD, C
A
SIMODRIVE 611 universal Non-Siemens Drives
Analog Drives
ADI4
SIMATIC DP ET 200
MPI (1.5 MBaud)
Fig.2-2 The SINUMERIK 840Di hardware (system overview)
Hardware basic variant
The basic variant of the SINUMERIK 840Di is a compact SIEMENS industrial PC
and a PCI plug-in board, the so-called MCI Board (Motion Control Interface), which
has been developed by Siemens.
PCU (industrial PC)
In view of different cases of applications, PC variants with a differentiated scope of
performance and expandability are planned. The first product stage envisages the
PCU 50 (PC Unit), a built-in industrial PC with a free ISA/PCI slot for hardware
expansions in two variants (Pentium II/III at 333MHz/500MHZ) for the SINUMERIK
840Di.
A PCU variant with additional free PCI slots is available soon.

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© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition 2-13
MCI Board
Together with the PCU, the MCI Board constitutes the hardware basis for the
SINUMERIK 840Di. The most important components installed on the MCI Board
are:
•PLC: SIMATIC S7 CPU 315-2DP
•SRAM for retentive NC and PLC data
•an MPI interface (Multi-Point Interface) (1.5 MBaud)
•a PROFIBUS-DP interface (12 MBaud, electrical)
•an MCI-Board Extension interface
PROFIBUS DP
The PROFIBUS-DP interface of the MCI Board is used to connect the SINUMERIK
840Di to the drives and the I/Os.
•Drive systems
Either the modular converter system SIMODRIVE 611 or the distributed drive
system POSMO A, SI, CD/CA can be used as the drive system. Drives with an
analog setpoint interface can also be connected to PROFIBUS DP via the
interface module ADI4 (Analog Drive Interface for 4 Axes) (available soon).
•I/Os
Either the range of the SIMATIC DP ET 200 modules (for the connected loads,
see SIMATIC Documentation) or the I/O module PP 72/48 (3x24 dig. inputs,
3x16 dig. outputs) can be used as I/Os.
MPI
The MPI interface of the MCI Board serves for optional connection of additional
operator components, such as of a machine control panel, a handheld unit
(handheld operator or programming unit) or of an external programming device
(PG) for programming or diagnosing the PLC.
MCI Board Extension
An MCI-Board Extension Board is offered as an option. Using this expansion board
for the MCI Board, sensing probes, handwheels and fast digital I/Os can be
connected via a SINUMERIK cable distributor.
Operator components
As operator components, the new operator panel fronts from the SINUMERIK
family (OP 010, OP 010C, OP 010S, OP 012, OP 015) are available optionally.
Further components that can be connected optionally are PS/2 mouse, PS/2
standard or CNC full keyboard. It is also possible to connect a standard PC monitor
via the VGA interface.

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2-14 SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition
2.4 System software
Operating system
The operating system installed is Windows NT 4.0 (US version).
NC software
The NC software runs on the PC in real time mode parallel to Windows NT. To
achieve this, a solution has been developed which ensures the processing of real
time tasks at a high reliability, allowing Windows NT applications to run without
influencing any other applications.
HMI software (Human Machine Interface)
Scope of supply
To start-up, program and operate the SINUMERIK 840Di, the following Windows
NT applications are already included in the scope of supply:
•SINUMERIK 840Di-StartUp, a straightforward user interface for visualizing the
control states, as well for creating, loading and managing part programs
•SinuCom NC, the NC start-up tool of the SINUMERIK 840Di
•SimoCom U, the drive start-up tool for SIMODRIVE 611 and SIMODRIVE
POSMO drive systems
Options
For the user-specific programming and configuration of user interfaces, the
following software packages are offered as options:
•HMI Programming Package (option and OEM agreement required)
Using the standard development tool Microsoft Visual Studio 6 and the HMI
basic software, you can use the HMI Programming Package to implement your
own operating philosophies and concepts.
•HMI Configuring Package (option and OEM agreement required)
With the HMI Configuring Package and based on ProTool/Pro with the
SINUMERIK option, you can configure simple screenforms quickly.
For machine tools, a comprehensive standard user interface is provided with HMI
Advanced (option):
•HMI Advanced (option)
HMI Advanced is a user interface running under Windows NT, which has been
designed especially for machine tools, regardless of the technology. It offers a
user-friendly and complete window-oriented operation of the machine.

02.2001 2 System Overview
© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition 2-15
PLC software
To create the PLC user program and to configure the PLC integrated in the MCI
Board, STEP 7, the standard tool for all SIMATIC S7 based automation systems is
used.
The STEP 7 software can run either, as usual, run on SIMATIC programming
devices PG 720, PG 740 or PG 760, or also directly on the PCU of the
SINUMERIK 840Di.
As the programming language, STEP 7 offers the following, tried and tested, non-
conforming PLC programming languages:
•Statement list (STL)
•Ladder diagram (LAD)
•Control system flowchart (CSF)

2 System Overview 02.2001
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2-16 SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition
2.5 System advantages
The SINUMERIK 840Di has an open software and hardware architecture and
stands out by the following features:
A ready-to-use configured and tested system from a single source
The ready-to-use configured and tested system equipped with Siemens-certified
components is free of the risk of system integration and helps save you your own
engineering overhead. With the open NC software of the SINUMERIK 840Di, a
comprehensive, expandable functionality compatible with the A&D world is also
offered for everyone who today makes his own NCs.
In addition, SINUMERIK 840Di as part of the known automation systems from
SIEMENS (SINUMERIK, SIMODRIVE and SIMATIC) also offers the advantage
that already existing know-how can be used in many places, resulting in a
reduction of the costs required for training and qualification of staff.
Distribution with PROFIBUS DP
Drives and I/Os are controlled consistently via the PROFIBUS DP with Motion
Control functionality. Both the drive and the I/Os can thus be arranged either
centralized or distributed.
The following components are provided for connection to PROFIBUS DP:
Drives
•the highly dynamic modular converter system SIMODRIVE 611 with digital
closed-loop control modules SIMODRIVE 611 universal and the option module
PROFIBUS DP with Motion Control;
•the completely distributed drive system SIMODRIVE POSMO CD/CA
(with/without its own mains infeed) with integrated converter and control unit for
high-performance servo applications;
•the distributed 1-axis servo drive SIMODRIVE POSMO SI as a separate, fully
functional Mechatronic unit with centralized mains infeed;
•the intelligent distributed positioning motor SIMODRIVE POSMO A as a simple
and compact drive unit.
•the ADI4 interface module (Analog Drive Interface for 4 Axes, available soon)
for connecting drives with analog setpoint interface.
I/O modules
•the known SIMATIC I/O modules of the ET 200 series;
•the low-cost I/O module PP72/48 with 72 digital inputs and 48 digital outputs.

02.2001 2 System Overview
© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition 2-17
Higher reliability through industrial quality (referred to standard PCs)
•Higher ambient temperature (between 5° and 55°C)
•Higher mechanical stressability (e.g. special hard disk suspension)
•EMC in line with the industrial requirements
•Developed acc. to stringent SIMATIC and SINUMERIK boundary conditions
•Qualified components from renowned manufacturers
•In-house series production
•DIN ISO 9001 certification
•Standardized type tests
•48-hrs. run-in test at 40°C
This results in safe operation in industrial environments without cost-intensive
additional measures and ensures high availability of the SINUMERIK 840Di.
Investment reliability through PC models available in the longer run (referred to
standard PCs)
•Use of units and components with high MTBF
•Product updates in line with the relevant technology standard at regular
intervals
•Long-term availability with function compatibility
•Long-term spare parts supply (5 years function-compatible spare parts)
These aspects secure investments in the long run and reduce the operating costs
of a machine or installation.
Worldwide support
•Worldwide marketing network
•Regional service departments all over the world
•Spare parts logistic infrastructure
•Engineering
•Software application
•Support for machine availability

2 System Overview 02.2001
© Siemens AG 2001 All Rights Reserved
2-18 SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition
Siemens' worldwide support for machine and system manufacturers improves the
chances on the world market and offers the end user more safety through
competent local support.
•We adapt control system and drive for your particular technological task,
reduce planning times for new machines and eliminate potential error sources
in advance.
•We create user-specific programs and user interfaces, and we also create the
control functionality aimed at differentiation in competition and technology
adaptation.
In addition, effective service and maintenance agreements after expiration of the
warranty ensure that all automation systems - from the individual machine to
interlinked systems throughout the world - operate efficiently. Service and response
times can be adapted to the specific requirements in a flexible manner.


© Siemens AG 2001 All Rights Reserved
SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition 3-19
Hardware
3.1 SIEMENS industrial PCs...................................................................... 3-20
3.2 MCI Board............................................................................................ 3-21
3.3 MCI Board Extension........................................................................... 3-23
3.4 Operator panel fronts........................................................................... 3-24
3.5 Handheld operator and programming units.......................................... 3-25
3.6 Machine control panels........................................................................ 3-25
3.7 Drives................................................................................................... 3-26
3.8 I/Os...................................................................................................... 3-29
3.9 Uninterruptible power supply (UPS)..................................................... 3-30
3

3 Hardware 02.2001
© Siemens AG 2001 All Rights Reserved
3-20 SINUMERIK 840Di System Overview (SYI) - 02.2001 Edition
3.1 SIEMENS industrial PCs
The SINUMERIK 840Di consists of a compact
SIEMENS industrial PC with a plug-in board (MCI
Board) as an interface board for the Motion Control
and PLC tasks, which has been developed by
Siemens.
Features
The current PC variant named PCU 50 is offered
in 2 different performance classes and provides
the following features:
•Mobile Intel Pentium-II processor
at 333 MHz or
Mobile Intel Pentium-III processor
at 500MHz
•Hard disk (min. 4.8 GB) with dampened suspen-
sion suitable for use in industry
•128 MB SDRAM (max. 256 MB)
•1 expansion slot with PCI interface (occupied by
the MCI board)
•1 shared ISA/PCI expansion slot (max. 175 mm
long)
-occupied by the MCI Board Extension option slot variant
-free, with MCI Board Extension option external variant
•Robust design (continuous operation, high noise immunity)
•Space-saving installation thanks to compact dimensions (LxWxH):
296x267x100 mm
•Easy-to-service design
•Easy to install by means of four screws on the rear side of the operator panel
front
•Mounting location and position to a large degree variable
•Comprehensive fire protection (to EN60950)
•Steel sheet built-in housing with vacuum ventilation (suck-off type)
Interfaces
The following interfaces are provided:
•Parallel interface LPT1
•Serial interfaces 1 x V.24, 1 x V.24/TTY
•PS/2 keyboard interface
•PS/2 mouse interface
Fig 3-1 PC PCU 50