Siemens SINUMERIK 840Di User manual

Manual 06/2003 Edition
SINUMERIK 840Di

Valid for
Control Software version
SINUMERIK 840DiE/840Di 1.1
SINUMERIK 840DiE/840Di 2.1
SINUMERIK 840DiE/840Di 2.2
SINUMERIK 840DiE/840Di 2.3
06.2003 Edition
SINUMERIK 840Di
Manual
General 1
Hardware Descriptions 2
Design 3
EMC and ESD Measures 4
MPI Communication 5
Turning On and Ramp Up 6
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/
Series Machine Start-Up 14
SW Installation/Update
and Data Backup 15
840Di-Specific Data and
Functions 16
Abbreviations A
References B
EC Declaration of
Conformity C
Index D

SINUMERIKDocumentation
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:
ANew documentation.. . . . .
BUnrevised reprint with new order no.. . . . .
CRevised 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
11.036FC5 298-6CA00-0BG4C
Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKrand SIMODRIVErare 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:
http://www.ad.siemens.de/sinumerik
This publication was produced with Interleaf V7.
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority. Offenders
will be liable for damages. All rights, including rights created by patent
grant or registration of a utility model or design, are reserved.
Siemens AG, 2003. All rights reserved
Other functions not described in this documentation might be
executable in the control. This does not, however, represent an
obligation to supply such functions with a new control or when
servicing.
We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences might
exist. The information contained in this document is, however,
reviewed regularly and any necessary changes will be included in the
following edition. We welcome suggestions for improvement.
Subject to technical changes without prior notice
Siemens AktiengesellschaftOrder No. 6FC5 297-6AE60-0BP2
Printed in German
y
3ls

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SINUMERIK 840Di Manual (HBI) – 06.03 Edition
PREFACE
The SINUMERIK documentation is divided into three levels:
SGeneral documentation
SUser Documentation
SManufacturer/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.
If you have any questions about the control, please contact the hotline:
A&D Technical Support Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Please send any questions about the documentation (suggestions forimprove-
ment, corrections) to the following fax number:
Fax: [phone]
Fax form: see reply at the end of the manual
http://www.ad.siemens.de/sinumerik
The SW versions stated in the documentation apply for the SINUMERIK 840Di
control.
SConfiguring engineers,
SElectricians and start-up specialists
SService and operating personnel.
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.).
Notes for the
Reader
Hotline
Internet address
SINUMERIK
SW version
Target readers
Objective
SINUMERIK 840Di Manual
Preface

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

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SINUMERIK 840Di Manual (HBI) – 06.03 Edition
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.
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!
Warning notes
Further notes
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Preface

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To safeguard your own personal safety as well as protect the product described
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
SRepairs 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.
SAlways disconnect the power supply before you open the unit.
SEMERGENCY 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.
SWherever 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
SConnecting and signal leads must be installed such that inductive and ca-
pacitive interference cannot impair automation functions.
Warnings and
safety information
SINUMERIK 840Di Manual
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SINUMERIK 840Di Manual (HBI) – 06.03 Edition
Components that can be destroyed by Electrostatic Sensitive
Devices
!Important
Handling of ESD modules:
SWhen you are handling ESD-sensitive devices, make sure that you, your
workplace and the device packaging are grounded well.
SAs 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.
SDo 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.
SPlace sensitive modules only on high-resistance, conductive surfaces (table
with antistatic surface, conductive antistatic foam or antistatic packaging).
SDo not bring ESD-sensitive modules into the vicinity of visual display units,
monitors or TV sets (minimum distance to the screen > 10 cm).
SDo 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.
SMeasurements 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).
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).
ESD instructions
Proper use
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Preface
Notes

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Interface description 2-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Installation instructions 2-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Interface description 2-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2 Installation instructions 2-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3 Dimension drawing 2-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.4 Interface description 2-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.5 Technical data 2-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.2 Interface description 2-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.3 Power supply 2-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.4 Grounding 2-102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.5 Dimension drawing 2-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13.2 Interface description 2-107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13.7 Dimension drawing 2-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1 Prerequisites for start-up 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.1 Prerequisites for start-up 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.10NC/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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SINUMERIK 840Di Manual (HBI) – 06.03 Edition
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.2.4 Boundary conditions 16-508. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . .
16.3.5 Boundary conditions 16-514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3.6 Data description (MD) 16-515. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3.7 Alarms 16-515. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Abbreviations A-517. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B References B-523. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEC Declaration of Conformity C-537. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIndex Index-539. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SINUMERIK 840Di Manual
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Siemens AG, 2003. All rights reserved
SINUMERIK 840Di Manual (HBI) – 06.03 Edition
General on the SINUMERIK 840Di
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
Swhere decentralized automation solutions are required in the fields of PLC
I/Os and drives
and/or
Sa complete PC-integrated control system is preferred, since this solution
better fits into the intended or existing automation environment.
Networking
e.g. TCP/IP Industrial PC
(PCU)
MCI board extension
(option)
MCI board
SIEMENS A&D Operator Panels
OEM Operator Panels
PC monitor and MF2 keyboard
Handwheel Measuring pulses Fast dig. I/Os
Ext.
progr.
device MCP HHU/
HT 6
SIMATIC DP ET 200
I/O devices
SIMODRIVE 611 universal
SIMODRIVE POSMO
Third-party drives
Fig. 1-1 SINUMERIK 840Di System Overview
1

06.03
1.1 Overview of SINUMERIK 840Di
1-20 Siemens AG, 2003. All rights reserved
SINUMERIK 840Di Manual (HBI) – 06.03 Edition
1.1.1 System software packages and options (SW 2.1 and higher)
For optimum adaptation of the SINUMERIK 840Di to the automation task, Sie-
mens can provide various system software packages:
SSystem software Basic
SSystem software Universal
SSystem 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)
Modegroups 121211)
Channels per
mode group 121211)
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
In addition to the system software packages, the SINUMERIK 840Di can be
adapted to requirements using various Performance options:
SOption: Advanced Processing 1
SOption: Advanced Processing 2.
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
The position controller cycle times are not subject to any restrictions concerning
system software packages or performance options.
System software
packages
Performance
options
IIPO cycles
Position controller
cycles
1 General on the SINUMERIK 840Di