6FC5203-0AB20-1AA3 - Siemens

SINUMERIK 840D/

SIMODRIVE 611 digital

Installation and Start-Up Guide 04.2000 Edition

Manufacturer/Service Documentation

SINUMERIK

840D/810D/

FM-NC

SINUMERIK

Overview of SINUMERIK 840D/840Di/810D/FM-NC Documentation (04.00)

Brochure Catalog

Ordering Info

NC 60.1 *)

Technical Info.

NC 60.2

Description of

Functions

Drive Functions *)

Description of

Functions

– Basic Machine *)

– Extended Functions

– Special Functions

SINUMERIK

611D

840D/810D

SINUMERIK

840D/840Di/

810D/

FM-NC

840D/840Di/

810D/

FM-NC/611

Accessories

Catalog

Accessories NC-Z

SINUMERIK

SIROTEC

SIMODRIVE

840D/840Di/

810D

FM-NC

611D

Lists *)

Installation &

Start-up Guide *)

– FM-NC

– 810D

– 840D/611D

– MMC

SINUMERIK

840D

Description of

Functions

Digitizing

SINUMERIK

840D/810D/

FM-NC

Configuring Kit

MMC100/101

– Configuring

Syntax

– Development Kit

SINUMERIK

840D/810D/

FM-NC

Screen Kit

MMC100/101

SW Update and

Configuration

SINUMERIK

840D/840Di/

810D/

FM-NC

SINUMERIK

840D/840Di/

810D

Operator

Components

(HW) *)

840D/840Di/

810D/

FM-NC

Description of

Functions

SINUMERIK

Safety Integrated

SINUMERIK

SIMODRIVE

SINUMERIK

840D/810D/

FM-NC

611,

Motors

SIMODRIVE

DOC ON CD *)

The SINUMERIK System

General Documentation

Electronic Documentation

Manufacturer / Service Documentation

SINUMERIK

840D/810D/

FM-NC

SINUMERIK

840D/810D

User Documentation

Diagnostics

Guide *)

Operator’s Guide

–Unit

Operator Panel

–HPU

–HT 6

AutoTurn

– Short Guide

– Programming (1)

– Setup (2)

SINUMERIK

840D/840Di/

810D/

FM-NC

Program. Guide

– Short Guide

– Fundamentals *)

– Advanced *)

– Cycles

– Measuring Cycles

Description of

Functions

–ManualTurn

–ShopMill

Description of

Functions

Synchronized

Actions

Wood, Glass,

Ceramics

840D/810D

SINUMERIK

Operator’s Guide

–ManualTurn

– Short Guide ManualTurn

–ShopMill

– Short Guide ShopMill

840D/810D

Manufacturer / Service Documentation

SINUMERIK

840D/810D

Descr. of Functions

–Computer Link

–Tool Data

Information

System

*) These documents are a minimum requirement for the control

Operator’sGuide

– Short Guide

– Operator’s

Guide *)

SINUMERIK

840D/810D/

FM-NC

Configuring

(HW) *)

– FM-NC

– 810D

– 840D

SINUMERIK

840D/810D

SINUMERIK

840D/810D/

FM-NC

Description of

Functions

Operator Interface

OP 030

Description of

Functions

Tool Manage-

ment

SINUMERIK

SIMODRIVE SINUMERIK

SIMODRIVE

SINUMERIK

SIMODRIVE

SINUMERIK

SIMODRIVE SINUMERIK

SIMODRIVE

840D

611D 840D

611D

Description of

Functions

Linear Motor

SINUMERIK

SIMODRIVE

SIROTEC

EMC

Guidelines

Description of

Functions

– Hydraulics

Module

– Analog Module

User Documentation

SINUMERIK

System Overview

840Di

Manufacturer/Service Documentation

SINUMERIK

Descr. of Functions

ISO Dialects for

SINUMERIK

840D/810D SINUMERIK

Descr. of Functions

CAM Integration

DNC NT–2000

SINUMERIK

Manual

(HW + Installation

and Start-up)

840Di

Valid for

Control Software Version

SINUMERIK 840D 5

SINUMERIK 840DE (export version) 5

Drive

SIMODRIVE 611D 4

04.00 Edition

SINUMERIK 840D

SIMODRIVE 611D

Installation and Start-Up Guide

General Preparations 1

Configuration 2

Settings, MPI/OPI 3

EMC/ESD Measures 4

Power On and Power Up 5

Parameterization of

Control

PLC Program 6

PLC Start-Up 7

Alarm and Message Texts 8

Axis/Spindle Dry Run 9

Drive Optimization 10

Data Backup 11

SW/HW Replacement 12

MMC 13

Miscellaneous 14

Abbreviations A

References B

Index

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

06.94 6FC5 297–0AB10–0BP0 A

08.94 6FC5 297–0AB10–0BP1 C

02.95 6FC5 297–2AB10–0BP0 C

04.95 6FC5 297–2AB10–0BP1 C

09.95 6FC5 297–3AB10–0BP0 C

03.96 6FC5 297–3AB10–0BP1 C

08.97 6FC5 297–4AB10–0BP0 C

12.97 6FC5 297–4AB10–0BP1 C

12.98 6FC5 297–5AB10–0BP0 C

08.99 6FC5 297–5AB10–0BP1 C

04.00 6FC5 297–5AB10–0BP2 C

This manual is included in the documentation available on CD-ROM (DOCONCD)

Edition Order No. Remarks

04.00 6FC5 298–5CA00–0BG2 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:

http://www.ad.siemens.de/sinumerik

This publication was produced with Interleaf V 7.

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.

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

edition. We welcome suggestions for improvement.

Subject to technical changes without prior notice.

Siemens–AktiengesellschaftOrder No. 6FC5 297–5AB10–0BP2

Printed in the Federal Republic of German

3ls

03.96

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

PREFACE

The SINUMERIK documentation is divided into 3 different levels:

SGeneral documentation

SUser Documentation

SManufacturer/Service Documentation

This document is intended for the manufacturers of machine tools incorporating

SINUMERIK 840D and SIMODRIVE 611D systems.

The Installation and Start-Up Guide provides all the relevant information

required for start-up, installation and servicing.

This document provides information about the control system design and the

interfaces of the individual components. It also describes the start-up and

installation procedure for SINUMERIK 840D with SIMODRIVE 611D including a

list of all data, signals and PLC blocks.

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 part programs and control

operating procedures are described in detail in separate documents.

Separate descriptions are likewise provided of the tasks to be performed by the

tool manufacturer such as configuring, design and PLC programming.

In addition to the table of contents and indexes of figures and tables, we have

provided the following information in the appendix for your assistance:

1. Index of abbreviations

2. List of references

3. Index

For a complete list and description of SINUMERIK 840D alarms, please refer to

References: /DA/, Diagnostics Guide

For further useful information on start-up and troubleshooting, please refer to

References: /FB/, D1, “Diagnostics Tools”

Structure of

documentation

Target group

Objective

Standard scope

Searching aids

SINUMERIK 840D Installation and Start-Up Guide

Preface

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SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

The following symbols with special significance are used in the documentation:

Note

This symbol appears in this document to draw your attention to information

relevant to the subject in hand.

!Important

This symbol appears in this document to draw your attention to an important

item of information.

Order data option

In this document, you will encounter the symbol shown on the left with a

reference to an ordering data option. Please note that the function described

can operate only if the specified option is installed in the control system.

The following warnings with varying levels of severity are used in this document:

!Danger

This symbol indicates that death, grievous injury or substantial property dam-

age will occur if the appropriate precautions are not taken.

!Caution

This symbol indicates minor injuries or property damage may occur if the ap-

propriate precautions are not taken.

!Warning

This symbol indicates that death, grievous injury or substantial property dam-

age may occur if the appropriate precautions are not taken.

Symbols

Warnings

SINUMERIK 840D Installation and Start-Up Guide

Preface

03.96

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SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Technical information

IBM is a registered trademark of the International Business Corporation.

MS–DOS and WINDOWST are registered trademarks of the Microsoft

Corporation.

The following notation and abbreviations are used in this document:

SPLC interface signals –> IS “Signal name” (signal data)

Examples:

–IS “MMC–CPU1 ready” (DB10, DBX108.2), i.e. the signal is stored in

data block 10, data byte 108, bit 2.

–IS “Feedrate/spindle override” (DB31–48, DBB0), i.e. the signals are

stored for specific spindles/axes in data blocks 31 to 48, data block

byte 0.

SMachine data –> MD: MD_NAME (English designation)

SSetting data –> SD: SD_NAME (English designation)

SThe character “” means “corresponds to”.

After data (e.g. machine data) have been changed, it must also be noted when

the change will become effective (e.g. after power ON or immediately). This in-

formation is therefore always provided.

Trademarks

Notation

Effectiveness of

changes

SINUMERIK 840D Installation and Start-Up Guide

Preface

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SINUMERIK 840D Installation and Start-Up Guide

Preface

Notes

04.00

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Contents

1 General Preparations 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Preconditions 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Standard/export version 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Configuration 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Mechanical configuration 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Overview 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Mains infeed module 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 NCU 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.4 General configuration of SINUMERIK 840D system 2-23. . . . . . . . . . . . . .

2.2 Electrical configuration 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Component connections 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 Connection of mains infeed module (U/E, I/RF) 2-25. . . . . . . . . . . . . . . . . .

2.2.3 Motor connection 2-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.4 Encoder connection 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.5 Connection of MMC100 and MMC102/103 2-30. . . . . . . . . . . . . . . . . . . . . .

2.2.6 Configuration of components for digitizing 2-32. . . . . . . . . . . . . . . . . . . . . . .

3 Settings, MPI / OPI 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 MPI/OPI, network rules 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Standard configuration 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Standard configuration up to SW 3.1 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Standard configuration as from SW 3.2 3-40. . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Connection of a 2nd MCP/customer operator panel interface

and/or 1 HHU (up to SW 3.1) 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Connection to OPI bus 3-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Connection to MPI bus 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Example of a configuration of MCP and HHU via OPI 3-46. . . . . . . . . . . . .

3.3.4 Example of a configuration of HHU via MPI 3-47. . . . . . . . . . . . . . . . . . . . . .

3.4 Handheld unit 3-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Settings on the HHU up to software version 3.x 3-52. . . . . . . . . . . . . . . . . .

3.4.2 Settings on the HHU for software version 4.x and higher 3-53. . . . . . . . . .

3.4.3 Configuring the HHU, setting interface parameters 3-53. . . . . . . . . . . . . . .

3.4.4 Example: Connecting the HHU to the SINUMERIK 840D 3-55. . . . . . . . . .

3.5 Handheld programming unit 3-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1 Interface signals of the HPU 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2 Standard configuration of the HPU (without MCP) 3-58. . . . . . . . . . . . . . . .

3.5.3 Deviations from the standard HPU configuration

(up to SW 3.1) 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Machine control panel (MCP) 3-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Customer operator panel interface 3-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.8 Second machine control panel 3-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 MMC 100/MMC 102/103 operator panel 3-69. . . . . . . . . . . . . . . . . . . . . . . .

3.9.1 Settings on the MMC 3-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.2 Language default 3-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 EMC / ESD Measures 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Measures to suppress interference 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Measures to protect ESD-sensitive components 4-74. . . . . . . . . . . . . . . . .

5 Power On and Power-Up 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Startup sequence 5-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Power on and power-up 5-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Power on 5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Power-up 5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 MMC100 – MMC102/103 power-up 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.4 Error during control power-up (NC) 5-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.5 Machine control panel (MCP) power-up 5-84. . . . . . . . . . . . . . . . . . . . . . . . .

5.2.6 Drive system power-up 5-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.7 MMC102/103 BIOS setup 5-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Assigning Parameters to the Control and the PLC Program 6-85. . . . . . . . . . . . .

6.1 Machine and setting data 6-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Handling machine and setting data 6-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Protection level concept 6-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Machine data masking filter (SW 4.2 and higher) 6-92. . . . . . . . . . . . . . . . .

6.4.1 Function 6-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.2 Selecting and setting the machine data masking filters 6-92. . . . . . . . . . . .

6.4.3 Saving the filter settings 6-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Example of start-up design concept 6-96. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 System data 6-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 Basic settings 6-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Memory configuration 6-102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7.1 Dynamic RAM memory 6-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7.2 Static RAM memory 6-104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Scaling machine data 6-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 Axes and spindles 6-108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.1 Description of the axis configuration 6-108. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.2 Drive configuration (FDD, SLM, MSD) 6-111. . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.3 Setting the axis-specific setpoint/actual value parameters 6-114. . . . . . . . .

6.9.4 Drive parameterization (FDD, MSD) 6-116. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.5 Parameterization of incremental measuring systems 6-118. . . . . . . . . . . . . .

6.9.6 Parameterization of absolute measuring systems

(EnDat interface) 6-121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.7 Overview of optimization drive parameters 6-124. . . . . . . . . . . . . . . . . . . . . .

6.9.8 Axis data 6-127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.9 Velocity matching (axis) 6-129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.10 Position controller data (axis) 6-130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.11 Monitoring functions (axis) 6-133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.9.12 Reference point approach (axis) 6-138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.13 Spindle data 6-140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.14 Spindle configuration 6-142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.15 Encoder matching (spindle) 6-142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.16 Speeds and setpoint adjustment for spindle 6-144. . . . . . . . . . . . . . . . . . . . .

6.9.17 Spindle positioning 6-145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.18 Spindle synchronization 6-146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.19 Spindle monitoring 6-148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.20 Example: Start-up of NCK I/O devices 6-150. . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 Linear motors (1FN1 and 1FN3 motors) 6-152. . . . . . . . . . . . . . . . . . . . . . . . .

6.10.1 General information about starting up linear motors 6-152. . . . . . . . . . . . . . .

6.10.2 Start-up: Linear motor with one primary part 6-154. . . . . . . . . . . . . . . . . . . . .

6.10.3 Start-up: Linear motors with 2 identical primary parts 6-163. . . . . . . . . . . . .

6.10.4 Mounting dimensions 6-165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10.5 Temperature sensors for 1FN1 and 1FN3 motors 6-166. . . . . . . . . . . . . . . .

6.10.6 Measuring system 6-169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10.7 Parallel connection of linear motors 6-172. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10.8 Test measurements on linear motor 6-174. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 AM / U/F function 6-176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 System settings for power up, RESET and part program start 6-177. . . . . .

7 PLC Start-Up 7-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 PLC start-up 7-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Overview of organization blocks, function blocks and DBs 7-184. . . . . . . . .

8 Alarm and Message Texts 8-185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Alarm and message texts 8-186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Alarm text files for MMC 100 8-186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.2 Alarm text files for MMC 102/103 8-188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.3 Alarm text files for HPU 8-190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.4 Syntax for alarm text files 8-192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.5 Properties of alarm list 8-195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Axis and Spindle Dry Run 9-197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Preconditions 9-197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Axis test run 9-198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Testing the spindle 9-200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Drive Optimization with Start-Up Tool 10-203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 Instructions for use 10-204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.1 System requirements 10-205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.2 Installation 10-205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.3 Starting the program 10-206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.4 Terminating the program 10-206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Measuring functions 10-207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Interface signals Traverse request and Motion enable drive test 10-209. . . .

10.4 Aborting measuring functions 10-210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5 Frequency response measurement 10-211. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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10.5.1 Measurement of torque control loop 10-211. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5.2 Measurement of speed control loop 10-212. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5.3 Measurement of position control loop 10-216. . . . . . . . . . . . . . . . . . . . . . . . . . .

10.6 Graphic display 10-219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7 Gantry axes (SW 5.1 and later) 10-221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.1 Description 10-221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.2 Conditions 10-221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8 Trace function (SW 4.2 and higher) 10-222. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8.1 Description 10-222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8.2 Operation, basic display 10-223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8.3 Parameterization 10-224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8.4 Performing measurement 10-227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8.5 Display function 10-228. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8.6 File function 10-230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8.7 Print graph 10-231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.9 Analog output (DAC) 10-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.10 Automatic controller adjustment

(only MMC 103, SW 4.3 and higher) 10-234. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.10.1 Flow chart for self-optimization 10-236. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.10.2 Input options for self-optimization 10-240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Data Backup 11-245. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 General information 11-245. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 Data backup via MMC 100 11-248. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3 Data backup via MMC 102/103 11-254. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3.1 Data backup via V24 on the MMC 102/103 11-255. . . . . . . . . . . . . . . . . . . . . .

11.3.2 Output of drive data via V24 on MMC102/103 11-257. . . . . . . . . . . . . . . . . . .

11.3.3 Output of drive data via V24 on the MMC102/103 11-258. . . . . . . . . . . . . . . .

11.3.4 PLC data output via V24 on MMC102/103 11-262. . . . . . . . . . . . . . . . . . . . . . .

11.3.5 Output of MMC data via V24 on MMC102/103 11-262. . . . . . . . . . . . . . . . . . .

11.3.6 Output of the series start-up file via V24 on MMC102/103 11-263. . . . . . . . .

11.4 Back up hard disk via Norton GhostR (SW 4.4 and higher) 11-265. . . . . . . .

11.4.1 Back up hard disk / Import data backup 11-265. . . . . . . . . . . . . . . . . . . . . . . . .

11.4.2 Saving user data 11-268. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4.3 Back up hard disk 11-268. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4.4 Restore data to hard disk 11-270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.5 Several SW versions on one MMC 103 (SW 5.2 and higher) 11-272. . . . . . .

11.6 Installing a replacement hard disk (SW 4.4 and higher) 11-274. . . . . . . . . . .

11.7 Data backup with VALITEK streamer on the MMC101/102/103

(SW 5.3 and lower) 11-276. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.8 Line checksums and MD numbers in MD files

(software Version 3.2 and higher) 11-281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.8.1 Line checksums (MD 11230 MD_FILE_STYLE) 11-281. . . . . . . . . . . . . . . . . .

11.8.2 Machine data numbers 11-282. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.8.3 Aborting MD import 11-282. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.9 Machine/setting data 11-284. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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11.10 Saving PLC data 11-284. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Software and Hardware Replacement 12-285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.1 Software update 12-285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.2 Upgrading the MMC 100/100.2/101 software 12-286. . . . . . . . . . . . . . . . . . . .

12.3 Upgrade of MMC 102/103 software Version 4.x or earlier 12-287. . . . . . . . . .

12.4 Upgrading the NC 12-288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.4.1 Standard upgrade 12-288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.4.2 Series start-up via NC card (SW 4.4 and higher) 12-289. . . . . . . . . . . . . . . . .

12.4.3 SINUCOPY–FFS (SW 4.4 and higher) 12-291. . . . . . . . . . . . . . . . . . . . . . . . . .

12.5 Hardware replacement 12-296. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.6 Battery/fan replacement 12-296. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 MMC 13-299. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 Miscellaneous 14-301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.1 Tool box software package 14-301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.1.1 Content of tool box 14-301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.1.2 Application of the tool box 14-301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.2 Machine data access via part program 14-302. . . . . . . . . . . . . . . . . . . . . . . . . .

A Abbreviations A-305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B References B-311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C Index Index-321. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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04.00

Notes

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SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

General Preparations

1.1 Preconditions

This Installation and Start-Up Guide describes the procedure for starting up the

basic control functions including drive-related functions. More detailed informa-

tion about special NCK, MMC, PLC or drive functions can be found in the De-

scriptions of Functions/Manuals (see “Documentation requirements”).

You will need the following software to start up the SINUMERIK 840D:

1. PCIN 4.4 for transmission of data to/from MMC

Order no.: 6FX2 060–4AA00–2XB0 (German, English, French), order from:

WK Fürth

2. Start-up tool for digital SIMODRIVE 611 (applies only to MMC100)

Order No. 6FC5 255–jAX00–0AB0, supplies on 3.5” floppies

3. SIMATIC Step7 HiGraph

4. Toolbox for SINUMERIK 840D

Order No. 6FC5 252–jAX21–0AB0

Supplied on 3.5” floppies:

–Basic PLC program

–Standard machine data blocks

–NC variable selector

5. Applies only to MMC100: Software for creating PLC alarm texts and for

transmission to MMC100 (integrated in MMC 100 system software)

You will need the following equipment and accessories to start up the

SINUMERIK 840D:

1. Programming device with MPI interface (PG740)

2. MPI cable for PG740

3. V.24 cable with 9-way connector (female)

Introduction

Software

requirements

Equipment and

accessory

requirements

03.96

1.2 Standard/export version

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

You will need the following documentation to start up the SINUMERIK 840D:

1. Catalog NC 60.1, Ordering Information/BU/

Order no.: E86060–K4460–A101–A6

2. Manual /PHD/

Order no.: 6FC5 297–5AC10–0BP2

3. Operator Components Manual /BH/

Order no.: 6FC5 297–5AA50–0BP2

4. Description of Functions, Basic Machine (Part 1) /FB/

Order no.: 6FC5 297–5AC20–0BP2

5. Description of Functions, Drive Functions /FBA/

Order no.: 6SN1 197–0AA80–0BP5

6. Lists /LIS/

Order no.: 6FC5 297–5AB70–0BP2

7. Description PCIN 4.4 /PI/

Order no.: 6FX2 060–4AA00–4XB0

8. Diagnostics Guide /DA/

Order no.: 6FC5 297–5AA20–0BP2

1.2 Standard/export version

On account of the approval required for certain control functions as stipulated in

the German Export List, two configuration variants are available for the

SINUMERIK 840D.

The standard version (840D) 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 (840DE) the following options are not available:

SInterpolation with more than 4 axes

S5-axis milling package

SHelical interpolation 2D + n (n greater than 2)

SOEM package

The following restrictions apply to options that can be used:

SSag compensation is restricted to the traversing of a path of up to 10 mm.

SAdaptive control

The corresponding option bits can be set but they have no effect (alarm when

programming the functions). The export version requires no export approval

with respect to its type.

Up-to-date information about types and scope of options can be found in

References: /BU/ Catalog NC 60.1.

(If a requirement exists for export approval with respect to the intended use this

is not affected and might even exist in addition.)

Documentation

requirements

Export approval

1 General Preparations 04.00

03.96 1.2 Standard/export version

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The specific nature of the control is determined by the system software that is

available in two versions (standard and export). In other words, the

requirements for approval of the system software (refer also to the delivery

notes or invoice for information in this respect) is handed down to the control

system with the installation. This point must be observed in particular when

converting or upgrading the system software because the requirements for

export approval for the control can change accordingly.

In addition to the information provided on the delivery note and invoice, the

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 must be pasted into the

control logbook. In the case of license orders, a corresponding number of

labels is provided and the same applies to these.

When the control has been booted, the export versions can be identified by the

additional character ’E’ in the Service screen (NC information). The identification

of the control variants 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.

Identification of

the

control

1 General Preparations

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1 General Preparations

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Configuration

2.1 Mechanical configuration 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Overview 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Mains infeed module 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 NCU 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.4 General configuration of SINUMERIK 840D system 2-23. . . . . . . . . . . . . .

2.2 Electrical configuration 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Component connections 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 Mains infeed connection (OI, I/RF) 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.3 Motor connection 2-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.4 Encoder connection 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.5 Connection of MMC100 and MMC102/103 2-30. . . . . . . . . . . . . . . . . . . . . .

2.2.6 Configuration of components for digitizing 2-32. . . . . . . . . . . . . . . . . . . . . . .

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2.1 Mechanical configuration

2.1.1 Overview

SIMODRIVE

NCU MSD

MS (I/RF, OI) FDD

QWERTY keyboard

Operator panel

SIMATIC STEP7–300 I/O devices

SIMODRIVE 611D

Machine control panel

SINUMERIK 840D

SIEMENS

PS IM SMs

SIEMENS

NCU terminal block

Fig. 2-1 System overview of SINUMERIK 840 with SIMODRIVE 611 (diagrammatic)

2 Confi

uration

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2.1.2 Mains infeed module

The mains infeed module performs the following tasks:

SSupplies power for the SINUMERIK 840D and axis modules

SGenerates the DC link voltage for the motors

SRegenerative feedback (I/RF) or braking resistor (OI) for generator-mode

operation

If the internal braking resistance is not sufficient, pulsed resistor modules can be

installed.

The I/RF module feeds back into excess DC link energy generated during brak-

ing the supply system.

The I/RF or OI module is installed as the first module on the left.

References: PJ1/ Planning Guide for SIMODRIVE 611D

Mains infeed

module

Open-loop-

controlled infeed

Infeed/regenerative

feedback module

I/RF

Arrangement of

mains infeed

module

2 Confi

uration

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2.1.3 NCU

Operator panel interface

Reserved

P–BUS/K–BUS interface

(PLC I/O devices)

PG–MPI interface

I/O device interface

(cable distribution cabinet)

Various error and status LEDs

(H1/H2)

7-segment display (H3)

RESET button (S1)

NMI button (S2)

PLC start-up switch

Digitizing module connection

NCK start-up switch

SIMODRIVE 611D interface

PCMCIA slot

(X173)

Device bus interface

MEMORY–CARD

X130B

X130A

X121 X111

X102/

103

X101

X112

X122

RESETNMI

X172

+5 V

PF0

–

L2DP

Fig. 2-2 Interfaces, control and display elements of NCU module

2 Confi

uration

03.96 2.2 Electrical configuration

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2.1.4 General configuration of SINUMERIK 840D system

SIMODRIVE

NCU MSD

NE (I/RF, UE) FDD

SIEMENS

FDD FDD

Bus terminating

connector

Fig. 2-3 General configuration of SINUMERIK 840D

2.2 Electrical configuration

2.2.1 Component connections

2 Confi

uration

03.96

2.2 Electrical configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Floppy1)

X4 X6

X10

MCP

Power supply

–X102

–X112

–X122

–X111

–X121

X130B

X130A

MEMORY–CARD

–X172

QWERTY

MPI bus cable

SIMATIC S7–300 IM connecting cable

MPI cable

SIMATIC S7–300 I/O devices

PS SMs

X20

NCU

Operator panel

(rear view)

MMC

ISA adapter

(rear view)

Cable for data

input/output V24

1) X8/X9 on MMC 101/102 only

Parallel interface 1)

e.g. printer/streamer

MPI–PG cable

L2DP

Reserved

for servicing

to drive bus

NCU terminal block

IN OUT

X20 X21

ÄÄÄ

Distributor box

MPI cable

HHU

HHU handwheel

–X101

Cable distribution

cabinet

Fig. 2-4 Connection configuration

2 Confi

uration

03.96 2.2 Electrical configuration

2-25

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Note

For cables and connectors, see

References: /PHD/, Configuring Manual 840D

2.2.2 Connection of mains infeed module (OI, I/RF)

M600

P600

X351

X111

X121

X141

X161

X171

X172

X181

U1 V1 W1 PE1

Red

Yellow

Red

5V voltage

level faulty

Device ready

(DC link

precharged)

DC link over-

voltage

Electronics power

supply faulty

Device is not ready,

no enable signal

(term. 63, 64 or 48)

Mains fault

Power supply

Device bus

DC link connection

Red

Green

Red

LED

displays

LED displays

Fig. 2-5 Interfaces for OI and I/RF module 10–55KW

2 Confi

uration

03.96

2.2 Electrical configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

–X161

–X121

–X111

–X141

–X171

–X172

–X181

5.3

5.2

5.1

73.1

73.2

112

111

113

NS2

NS1

AS2

AS1

M500

P500

2U1

1U1

2V1

1V1

2W1

1W1

Relay contact

for

Ready message

NC contact

NO contact

Relay contact for group message I2t

and motor overtemperature

Pulse enable

Enable voltage

Drive enable signal

Reference potential for enable voltage

Enable voltage

P24

P15

N15

N24

RESET (R+term.15)

Enable voltage

Setting-up mode

Contactor energization,

start

213

Signaling contact

from mains con-

tactor

Enabling signal for internal mains

contactor

Signaling contact for starting lockout

(NC contact)

DC link power supply for mains buffering

External infeed for electronics power supply

LED displays

Fig. 2-6 Connection terminals on SIMODRIVE 611 mains supply module 10–55 KW

2 Confi

uration

03.96 2.2 Electrical configuration

2-27

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

I/RF module

Mains supply module

X111

X121

P500

2U1

1U1

2V1

1V1

2W1

1W1

112

111

113

AS1

AS2

NS1

NS2

W1V1U1 X131

X351

X141

X161

X171

X172

X181

Pushbutton contact

M500

213

S1.6

LEDs

P600

Device bus

100 k

L1 L2 L3

1U2 1V2 1W2

1U1 1W11V1

Commutating

reactor, on I/RF

module only

Mains fuses for

I/RF or OI

module

Supply

P600

M600 M600

to the

axis modules

Master switch

Leading

contact

Power section

L–

Internal mains

contactor

Important!

Terminal 48 must be de-ener-

gized 10 ms before the mains

contacts of the master switch

open (e.g. by means of leading

contact)

S1.5

S1.4

S1.3

S1.2

S1.1

L+

S1–DIP switch

1) Jumpers inserted in

delivery state

S1 Default

S1.1

S1.2

S1.3

S1.4

S1.5

S1.6

off

off*

*Do not alter

off

Fig. 2-7 Example of three-conductor connection (standard circuit)

Typical circuit

2 Confi

uration

03.96

2.2 Electrical configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

2.2.3 Motor connection

ÊÊ

X35

X432

BEROR

terminals

X341

X412

Motor encoder

Axis 2

X422

Direct position

Axis 2

M600

P600

X411

Motor

encoder

Axis 1

DC link

busbar

X421

Direct position

Axis 1

X431

Relay terminals

Pulse enable

X151

Device bus

X141

Drive bus

X351

Motor

connecting

terminals

A1 and A2

X34

Rating plate

PE terminals PE1 PE2

ÊÊ

X35

X432

BEROR

terminals

X341

M600

P600

X411

Motor

encoder

DC link

busbar

X421

Direct position

X431

Relay terminals

Pulse enable

X151

Device bus

X141

Drive bus

X351

X34

Rating plate

U2 V2 W2 PE1 PE2

Motor

connecting

terminals

X131

2-axis FDD module 1-axis FDD/MSD module

Fig. 2-8 Design of FDD/MSD modules

2 Confi

uration

03.96 2.2 Electrical configuration

2-29

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

2.2.4 Encoder connection

The motor measuring system of the connected motor must always be con-

nected to connector X411 of the same module.

Scheme for

shielding bus

SIMODRIVE

NCU MSD FDD

SIEMENS

MS (I/RF, OI)

Fig. 2-9 Connection of encoder cables

Motor measuring

system and motor

connection

2 Confi

uration

03.96

2.2 Electrical configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

2.2.5 Connection of MMC100 and MMC102/103

MMC 100

Power supply

X10

X6 X5 X4

Chassis

PE conductor

terminal

Voltage

supply

24 V 0 V PE

External keyboard interface

(the keyboard must be set

to the XT setting)

RS 232 serial inter-

face

MPI interface for

connection of oper-

ator panel

VGA

interface

RESET

button NMI

button

Fig. 2-10 Rear of operator panel with MMC 100

840D

X101

MMC 100/102/103

X20 MCP

6FX2 002–4EA04–1xx0 or

6FX2 002–4EA02–1xx0

Fig. 2-11 Connection of MMC100/102/103 to SINUMERIK 840D system

MMC100

2 Confi

uration

03.96 2.2 Electrical configuration

2-31

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

X21

X20

18D

X11

X5X6

X10

X153

X152

X151

D12 SIEMENS

X142X141

X13

ISA interface

NC keyboard

interface

Mass storage

interface IDE

PCMCIA optional

interface

Power supply

interface

LCD interface

External

keyboard/mouse

interface

Floppy disk

interface

Parallel printer interface

(LPT1)

VGA interface

Reset button

NMI button

Battery

X121 X122

COM1COM2

7-segment display

MPI interface for

connection of op-

erator panel

Fig. 2-12 Location of interfaces and control elements on MMC 101/102/103

The interfaces (e.g. pin assignments) are described and shown in detail in

References: /BH/, Operator Components Manual

MMC101, 102/103

Interfaces

2 Confi

uration

03.96

2.2 Electrical configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

2.2.6 Configuration of components for digitizing

SIMODRIVE

NCU MSD FDD

SIEMENS

I/RF

Device bus

MMC

ISA

adapter

Hard disk

drive

Power supply

X10

X6 X5 X4

Chassis

X11

Digitizing

module

Link interface

MPI cable to OP

Probe

Cable to probe

Cable from

digitizing

module to link

interface

X422

X411

X412

Laser

probe

Cable to laser probe

X421

Fig. 2-13 Configuration of components for digitizing

2 Confi

uration 04.95

03.96 2.2 Electrical configuration

2-33

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

SMMC 101/102

SISA adapter

SLink interface

SDigitizing module

SNCU 572/573 for digitizing

SConnecting cable from digitizing module to link interface

STactile probe (e.g. Renishaw SP2–1) with cable

For further information, please refer to the following documentation:

References: /FBD/Description of Functions, Digitizing

Hardware

requirements for

digitizing

2 Confi

uration

03.96

2.2 Electrical configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

2 Confi

uration

Notes

04.00

3-35

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Settings, MPI / OPI

3.1 MPI/OPI networking rules 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Standard configuration 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Standard configuration up to SW 3.1 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Standard configuration as from SW 3.2 3-40. . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Connection of a 2nd MCP/Interface customer operator panel and/or

1 HHU (up to SW 3.1) 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Connection to OPI bus 3-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Connection to MPI bus 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Example of a configuration of MCP and HHU via OPI 3-46. . . . . . . . . . . . .

3.3.4 Example of a configuration of HHU via MPI 3-47. . . . . . . . . . . . . . . . . . . . . .

3.4 Handheld unit (HHU) 3-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Settings in HHU up to software version 3.x 3-52. . . . . . . . . . . . . . . . . . . . . .

3.4.2 Settings on the HHU for software version 4.x and higher 3-53. . . . . . . . . .

3.4.3 Configuring the HHU, setting the interface parameters 3-53. . . . . . . . . . . .

3.4.4 Example: Connecting the HHU to the SINUMERIK 840D 3-55. . . . . . . . . .

3.5 Handheld programming unit 3-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1 Interface signals of the HPU 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2 Standard configuration of HPU (without MCP) 3-58. . . . . . . . . . . . . . . . . . .

3.5.3 Differences from the standard HPU configuration (up to SW 3.1) 3-59. . .

3.6 Machine control panel (MCP) 3-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Customer operator panel interface 3-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Second machine control panel 3-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 MMC 100/MMC 102/103 operator panel 3-69. . . . . . . . . . . . . . . . . . . . . . . .

3.9.1 Settings on MMC 3-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.2 Language defaults 3-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

03.96

3.1 MPI/OPI, network rules

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

3.1 MPI/OPI, network rules

The following basic rules must be observed with respect to network installa-

tions:

1. The bus line must be terminated at both ends. To do so, switch in the termi-

nating resistor in the MPI connector in the first and last nodes. Switch off all

other terminating resistors.

Note

SOnly two terminating resistors may be activated in the same line at one

time.

SThe terminating resistors of the bus are permanently installed in the HHU/

HPU.

2. At least 1 terminator must be supplied with 5V voltage. This is achieved by

connecting the MPI connector with a fitted active terminating resistor to a

device that is connected to the power supply.

Note

The NC must be positioned at the end of the line.

3. Spur lines (feeder cable from bus segment to node) should be as short as

possible.

Note

Unused spurs should be removed wherever possible.

4. Each MPI node must first be connected and then activated.

When disconnecting the MPI node first deactivate the connection and then

pull out the connector.

5. One HHU and one HPU or two HHUs or two HPUs can be connected to

each bus segment. No bus terminators may be inserted in the distribution

boxes of the HHU or HPU.

If necessary, more than one HHU/HPU can be connected to a network seg-

ment with repeaters.

6. The following cables lengths for MPI or OPI for standard use without re-

peater must not be exceeded:

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

OPI (1.5 Mbaud): max. cable length in total: 200 m

3 Settin

s, MPI / OPI 04.00

03.96 3.1 MPI/OPI, network rules

3-37

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

ËËËËËËË

840D control

ËËËËËË

MCP

ËËËËË

MMC

100/102/103

ËËËËË

OPI

MPI

Terminating resistor

integrated

ËËË

Distribu-

tion box

ËËË

HHU

ËËË

Distribu-

tion box

ËËË

HPU

Terminating resistor

fitted in connector

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

MPI: HPU, 840D control

OPI: HHU, 840D control

ËËËË

ËËËËËËË

840D control

ËËËË

MCP

ËËËËËË

MMC

100/102/103

OPI

Terminating resistor

fitted in connector

OP030

Terminating resistor

integrated

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

OPI: MCP, control

Example A

Example B

3 Settin

s, MPI / OPI

05.97

03.96

3.2 Standard configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

3.2 Standard configuration

3.2.1 Standard configuration up to SW 3.1

SINUMERIK 840D with MMC100/102/103 and a machine control panel (MCP)

or customer operator panel interface on OPI

Minimum firmware version V 03_01_01 for

SMCP

SInterface to customer operator panel / PP031

Version 1.x or higher

Each node on the MPI/OPI bus must be allocated a bus address (0...31).

ËËËËË

MMC

100/102/103

ËËËËË

NCK

PLC

ËËËËËËË

MCP/interface to

customer operator

panel

OPI 1.5

Mbaud

Standard bus addresses

X101

SINUMERIK 840D

ËËËËË

Programming

device/

start-up tool

MPI 187.5

kbaud

X122

Fig. 3-3 Standard application for SINUMERIK 840D

Standard

application

Hardware

requirements

STEP7

Bus addresses

3 Settin

s, MPI / OPI 05.98

03.96 3.2 Standard configuration

3-39

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Note

Cable with 3 MPI connectors (Order No.: 6FX2002–4EA04–IAF0 (IBA0))

SThis cable is used for connecting a standard machine consisting of MMC,

MCP and NCK via OPI/MPI.

SIt must not be used for setting up an m:n installation.

SComponents must not be connected using internal bus terminators (e.g.

HHU, HPU), because the cable is already fitted with bus terminators.

Table 3-1 Settings on DIP switch S3 for standard application

1 2 3 4 5 6 7 8 Meaning:

on off on off on on off off MCP:

Baud rate: 1.5 Mbaud

Cyclical transmit pattern: 100 ms

Bus address: 6

on off on off on on off on Interface to customer operator

panel:

Baud rate: 1.5 Mbaud

Cyclical transmit pattern: 100 ms

Bus address: 6

The following bytes in the PLC CPU are assigned for the MCP or interface to

the customer operator panel:

SInput bytes 0–7

SOutput bytes 0–7

SStatus bytes for error detection, output bytes 8–11, 12–15 (evaluated by

basic program)

The parameters on FB1 (basic program) for the MCP are already set to the de-

fault values for the standard application.

If communication does not commence after a PLC reset (MCP LEDs flashing),

the following points should be checked:

SFirmware version of MCP/interface to customer operator panel must be

V03_01_01 or higher

SCable and connector wiring

SDIP switch S3 (standard application)

Setting the MCP/

interface to

customer operator

panel

Assigned inputs/

outputs in the

PLC CPU

Communication

does not start

3 Settin

s, MPI / OPI

03.96

3.2 Standard configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

3.2.2 Standard configuration as from SW 3.2

Either one or two machine control panels (interface to customer operator pan-

els, HPUs, PP031) and/or HHUs can be connected in SW 3.2 or higher by set-

ting the parameters of the basic PLC program (FB1). In this case, it is no longer

necessary to set the parameters with the STEP 7 “Communication Configura-

tion” tool.

The procedure used to connect these components using “Communication

Configuration”, as described in the sections below, no longer has to be

followed with software versions SW 3.2 and higher.

References: /FB/ Description of Functions, Basic Machine (Part 3), PLC Basic

Program

SINUMERIK 840D with MMC100/102/103 and a machine control panel (MCP)

or customer operator panel interface on OPI

Minimum firmware version V 03_01_01 for

SMCP

SInterface to customer operator panel / PP031

Each node on the MPI/OPI bus must be allocated a bus address (0...31).

SW < 3.2

Standard

application

Hardware

requirements

Bus addresses

3 Settin

s, MPI / OPI 05.98

03.96 3.2 Standard configuration

3-41

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

ËËËËË

MMC

100/102/103

ËËËËË

NCK

PLC

ËËËËËËË

MCP/interface to

customer operator

panel

OPI 1.5

Mbaud

Standard bus addresses

X101

SINUMERIK 840D

ËËËËË

Programming

device/

start-up tool

MPI 187.5

kbaud

X122

Fig. 3-4 Standard application for SINUMERIK 840D

*) Address depending on software version:

Address NCK to MPI = address PLC+1=3

PLC 314 SW 3.5 and higher

Note

The logical addressing of components in the PLC basic program is performed

by means of the bus address parameter setting (for the machine control panel)

or the GD circle (for the handheld operator unit). The GD circles are always

used for physical addressing on the OPI/MPI. Each machine control panel,

customer operator panel interface, etc., must be addressed with a separate GD

circle.

In the control, the conversion of the bus address in the associated GD circle is

performed via the PLC program.

The bus address, and therefore the setting of the associated GD circles, are set

on the machine control panel by means of DIP–FIX switches.

The same GD circles are set, however, with different bus addresses on the MPI

for machine control panel, customer operator panel, PP031 and handheld pro-

gramming unit components. Allowance should be made for this when using

more than one machine control panel, etc.

The table below shows the relationship.

Bus address and

GD circle

3 Settin

s, MPI / OPI05.98

03.96

3.2 Standard configuration

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Table 3-2 Relationship between bus address and

GD circle

Bus addresses on the

MPI

GD circle

15,14,13 1

12,11 2

10, 9 3

8, 7 4

6 8

5, 4 5

Example:

Two machine control panels (MCPs) are to be connected to the MPI of a con-

troller. The first MCP can be connected to bus address 15 (GD circle 1), and the

second to bus address 12 (GD circle 2).

Note

If, for example PLC-PLC cross-communication is to be configured on the MPI

using the STEP 7 “Communication Configuration” tool, and one or more MCPs

are connected to the MPI, you should ensure that the allocation of GD circles is

unique. The STEP 7 “Communication Configuration” tool allocates GD circles in

ascending order starting with GD circle 1. If the MCPs are connected to the

operator panel interface, there is no effect on PLC-PLC communication on the

MPI.

Example:

“Communication Configuration” allocates GD circles 1 and 2 for PLC-PLC

cross-communication. A first MCP on the MPI can then be connected to GD

circle 3 (bus address 9 or 10), and a second MCP on the MPI can be connected

to GD circle 4 (bus address 7 or 8).

MPI interface and

GD circle

3 Settin

s, MPI / OPI 05.98

03.96 3.3 Connection of a 2nd MCP/customer OPI and/or 1 HHU (up to SW 3.1)

3-43

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

3.3 Connection of a 2nd MCP/customer OPI and/or 1 HHU

(up to SW 3.1)

The following configurations are permissible:

S2 MCPs/customer operator panel interfaces/PP031 connected to OPI

S1 HHU connected to either OPI or MPI

Machine control panels (MCP), customer operator panel interfaces and hand-

held units (HHU) are parameterized independently of the bus interface (OPI,

MPI) in the basic PLC program.

The parameters for the 1st MCP are preset.

In addition to the parameter settings in the basic PLC program, the MPI also

has parameters that must be set by means of the STEP 7 “Communication

Configuration” tool.

ÇÇÇÇÇ

MMC

100/102/103

ÇÇÇÇÇ

OP 030

110

1 MCP

MCP/interface to

customer operator

panel

Max. 2 MCP/customer

operator panel inter-

faces and 1 HHU can be

connected to the OPI.

OPI

ËËËËË

NCK

PLC

X101

SINUMERIK 840D

MPI

X122

OPI

Max. 4 devices (incl. 1 HHU)

can be addressed on the MPI

via GD circuits.

Distribu-

tion box

HHU

Distribu-

tion box

HHU Standard configuration

Optional

Another

device

HHU connection

to either OPI/MPI

Standard bus

addresses

Fig. 3-5 Example: MPI/OPI bus nodes with standard bus addresses

3 Settin

s, MPI / OPI

03.96

3.3 Connection of a 2nd MCP/customer OPI and/or 1 HHU (up to SW 3.1)

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

The handheld unit (HHU) should be connected to the OPI so the user can bene-

fit from the following advantages:

SEasier start-up

SReduction in communication tasks for PLC

If the HHU is operated on the MPI, it must be parameterized by means of the

STEP 7 “Communication Configuration” tool in addition to the parameter set-

tings in the basic PLC program. Data exchange between the PLC and HHU is

assisted by one of the four possible GD circuits in the PLC.

The following documents are also required:

References: /BH/ Operator Components Manual

/FB/, P3, Basic PLC Program

/S7HT/ Manual, Application of Tools

3.3.1 Connection to OPI bus

The following features are examples of deviations from the standard configura-

tion:

SChanging the address assignment of the input, output or status bytes for the

MCP in the PLC.

SAdditional connection of a handheld unit (HHU) to the OPI.

SConnection of a 2nd MCP

You must adjust the communication parameters and possibly the switch settings

(addresses) of the bus nodes.

1. Call FB1, DB7 must be parameterized for all operator control components

(MCP, HHU) in OB 100 in the basic PLC program.

2. The status pointers (double word) for each operator control component must

be configured for each component in FB1 for monitoring purposes.

See example in Section 3.3.3.

Connection of

HHU

Documentation

requirements

Example

Procedure

3 Settin

s, MPI / OPI

03.96 3.3 Connection of a 2nd MCP/customer OPI and/or 1 HHU (up to SW 3.1)

3-45

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

3.3.2 Connection to MPI bus

The following features are examples of deviations from the standard configura-

tion:

SAdditional connection of a handheld unit (HHU)

In this case, you must adjust the communication parameters and possibly the

switch settings (addresses) of the bus nodes.

You must use the STEP7 “Communication Configuration” tool to input a new

configuration. The following description of how to proceed is based on the as-

sumption that you already know how to use this tool.

1. Set up a new project and CPU programs with the STEP7 tool. You must set

up a CPU program for each component in the installation (PLC, HHU, etc.)

which is linked via the MPI.

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

3. Call STEP7 “Communication Configuration” tool and enter the desired con-

figuration.

4. Compile this configuration. A new SDB210 is generated for each CPU pro-

gram. The SDB210 for the HHU component is meaningless since the GD

parameters are set by means of DIP switch or keyboard.

5. Set the cyclical transmit pattern. Once the configuration has been compiled

successfully for the first time, the “Reduction ratio” and “Status” can be acti-

vated and then input.

6. Compile your configuration again.

7. Transfer the SDB210 (from the CPU program of the PLC) to the PLC.

Note

By default, the STEP7 project manager (S7 TOP) does not display the SDBs.

The SDB display is activated in the View / Set filter menu “All modules with

SDBs”.

8. Make the device-specific settings for all nodes:

You now need to set the GD identifiers from the “Communication Configura-

tion” table for the components (HHU, etc.).

9. Call FB1, DB7 must be parameterized for all operator control components

(MCP, HHU) in OB 100 in the basic PLC program.

10. You must configure the status pointer (double word) for the HHU in FB1 for

monitoring purposes.

See example in Section 3.3.3.

Note

For a description of the “Communication Configuration” tool and its applica-

tions, please refer to

References: /S7HT/ SIMATIC Step7 Manual, Start-up of MPI

Bus Nodes

Example

Procedure

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3.3.3 Example of a configuration of MCP and HHU via OPI

SMCP with firmware version V 03_01_01

SHHU with firmware version V 01_01_02

ÇÇÇÇÇ

MMC

100/102/103

ÇÇÇÇÇ

OP 030

110

1 MCP

OPI

ËËËËË

NCK

PLC

X101

SINUMERIK 840D

MPI

187.5 kbaud

X122

OPI

Distribu-

tion box

HHU

Standard bus

addresses

Fig. 3-6 Example of configuration of MCP and HHU via OPI

The following parameter settings must be made for the MCP and HHU operat-

ing components in FB1.

MCPNum:=1 (one MCP)

MCP1In:=P#E0.0 (MCP input signals)

MCP1Out:=P#A0.0 (MCP output signals)

MCP1StatRec:=P#A12.0 (status double word)

MCP1StatSend:=P#A8.0 (status double word)

MPIBusAdr:=6

BHG:=2 (HHU on OPI)

BHGIn:=P#M20.0 (HHU input signals)

BHGOut:=P#M0.0 (HHU output signals)

BHGStatRec:=P#M26.0 (status double word)

BHGStatSend:=P#M30.0 (status double word)

The other HHU parameters are set to appropriate defaults.

See FB basic program.

Note

Note the DIP switch settings (switches S1 and S2 in the HHU).

Preconditions

Parameterization

of basic PLC

program FB1

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3.3.4 Example of a configuration of HHU via MPI

STEP7 version 1.x and HHU with firmware version 01_01_02.

ÇÇÇÇÇ

MMC

100/102/103

1 MCP

OPI

ËËËËËË

NCK

PLC

X101

SINUMERIK 840D

MPI

187.5 kbaud

X122

OPI

Inputs: MB 20 – 26

Outputs: MB 0 – 19

Status double word: MD 26

Distribu-

tion box

HHU

Fig. 3-7 Example of configuration of HHU via MPI

Set up new project with the name Example.

You must set up 2 CPU programs for the Sample project.

SAS314

SHHU

The 2 CPU programs are assigned as follows:

AS314 is for the PLC–CPU, HHU for the handheld unit.

Preconditions

Call STEP 7

Assignment of

CPU programs

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A network must be activated via the configuration for every CPU program. Since

there is no separate order number for the HHU CPU programs, the standard

order number of the AS314 must be used. MPI address 2 is networked for the

AS314 CPU program and MPI address 15 for the HHU program. “0” must al-

ways be entered as the MPI SUB network number.

“Networking” sequence for each CPU program:

1. Set “Module networked”.

2. Set MPI address and enter SUB network no. 0.

3. Confirm with “OK”.

4. Save the configuration with “Save”.

Start the Communication Configuration tool and set up a new file.“table 1” ap-

pears.

You now need to call the CPU programs in table 1.

1. Using the mouse, click on the field next to GD identifiers (the column is then

color-highlighted).

2. Click “Select CPU module” under menu item “PLC functions”.

3. A window headed “Select CPU” appears. Click on project Example and the

2 CPU programs are displayed: as314, bhg.

4. Select as314.

5. Table 1 appears with entry as314//CPU1::

6. Click on empty field to the right of it and repeat steps 2 to 5 above in the

order given for CPU program bhg.

7. The result will be Table 1 containing the 2 CPU programs.

table 1

GD identifiers as314//CPU1:: bhg//CPU1::

Networking

Call

communication

configuration

Table 1

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You can now make the entries for the HHU in table 1.

1. Start in column as314//CPU1:: by selecting the first field.

2. Enter data area for reception or transmission from Fig. 3-6.

For bhg//CPU1::

mb0 : 20 is the receive area and

mb20 : 6 is the entry for the transmit area.

(mb0 : 20 means that 20 bytes are received starting at mb0 and

mb20 : 6 means that 6 bytes are transmitted starting at mb20.)

3. Declare the transmit and receive areas to be such. The transmit area is then

marked with “»”.

4. Table 1 with all its entries then looks like this:

table 1

GD identifiers as314//CPU1:: bhg//CPU1::

GD »mb0:20 mb0:20

GD mb20:6 »mb20:6

Note

The order in which inputs are made (transmit, receive) affects the way in which

GD identifiers are assigned and should be carefully observed as shown by the

above example.

You now need to select compilation.

The GD identifiers are generated during compilation. The GD identifiers are dis-

played in Table 1 as the result of compilation.

table 1

GD identifiers as314//CPU1:: bhg//CPU1::

GD 1.1.1 »mb0:20 mb0:20

GD 1.2.1 mb20:6 »mb20:6

Click the View / Reduction ratio menu. Table 1 below appears with the SR pa-

rameters.

table 1

GD identifiers as314//CPU1:: bhg//CPU1::

SR 1.1 8 8

GD 1.1.1 »mb0:20 mb0:20

SR 1.2 8 8

GD 1.2.1 mb20:6 »mb20:6

Enter areas for

transmitting and

receiving

Compilation

Setting the

reduction ratio

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The transmission rate for the HHU must be set.

The default setting is one transmission every 8 PLC cycles. With a PLC cycle

time of 25 ms, the default then corresponds to a key scan of 200 ms. This may

be too slow for some applications. To change the transmission rate, the “Reduc-

tion ratio”, i.e. the SR parameters, need to be changed.

You must specify a value of 1, 2, 4 or 8. Only 4 and 8 are allowed for transmis-

sion. The transmission to and from the HHU is then activated at a correspond-

ing frequency (e.g. every 4th PLC cycle). Example of table 1 with altered SR

parameters:

table 1

GD identifiers as314//CPU1:: bhg//CPU1::

SR 1.1 4 1

GD 1.1.1 »mb0:20 mb0:20

SR 1.2 1 4

GD 1.2.1 mb20:6 »mb20:6

When you have changed the SR parameters, you must compile your configura-

tion again.

Click the View / Status menu. Table 1 below is then displayed.

table 1

GD identifiers as314//CPU1:: bhg//CPU1::

GST

GDS 1.1

SR 1.1 4 1

GD 1.1.1 »mb0:20 mb0:20

GDS 1.2

SR 1.2 1 4

GD 1.2.1 mb20:6 »mb20:6

You now need to specify the status double words for GDS1.2.

Extract from table 1:

table 1

GD identifiers as314//CPU1:: bhg//CPU1::

GDS 1.2 md26

Once you have entered the status, you must compile your configuration again.

Changing the SR

parameters

Activate status

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The SDB 210s have been generated during compilation. Transfer SDB 210 for

CPU program as314 to the PLC–CPU (PLC must be in the STOP state).

Procedure:

1. Click on File/Download to PLC menu

2. Download window appears. Select as314//CPU1:: and confirm with OK.

3. Switch PLC into RUN mode (restart).

The default address 15 can be left unchanged on the HHU, only the GD param-

eters at 1.1.1–1.2.1 must be set, see Section 3.4.

The following parameter settings must be added to FB1 for the HHU.

HHU:=1 (HHU on MPI bus)

BHGIn:=P#M20.0 (HHU input signals)

BHGOut:=P#M0.0 (HHU output signals)

BHGStatRec:=P#M26.0 (status double word)

The other HHU parameters are set to appropriate defaults.

SDB210

Set HHU

Parameterization

of basic PLC

program FB1

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3.4 Handheld unit

The software version of the HHU appears on the display after power up until

communication between the PLC and the HHU has been established.

Example: Display on the HHU

Waiting for PLC

V04.01.01 F

→ Software version of the HHU is V4.11

→ Bus address of the HHU is FH (15)

3.4.1 Settings on the HHU up to software version 3.x

ON OFF

Reserved

187.5 kbaud

Bus

address 15

IDLE time

100 ms

Default settings

Fig. 3-8 Position of DIP switches in HHU with default setting

The default setting (setting when supplied) should be used for operating the

HHU on the MPI of the 840D.

Table 3-3 Settings on switches S1 and S2 in HHU

Meaning:

off on off off on on on on Default setting

off Baud rate: 187.5 kbaud

Display software

version of HHU

DIP switch

settings for MPI

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S1 “3” must be set to “on” when operating the HHU on the OPI.

Table 3-4 Settings on switches S1 and S2 in HHU

Meaning:

off on off off on on on on Default setting

on Baud rate: 1.5 Mbaud OPI

off

Bus address: 15

Bus address: 14

Bus address: 13

Bus address: 12

Bus address: 11

Bus address: 10

Bus address: 9

Bus address: 8

Bus address: 7

Bus address: 6

Bus address: 5

Bus address: 4

Bus address: 3

Bus address: 2

Bus address: 1

Bus address: 0

3.4.2 Settings on the HHU for software version 4.x and higher

The settings for “baud rate” and “bus address” parameters made with switches

S1 and S2 on the HHU no longer apply to software version 4.x and higher.

These bus parameters can be reconfigured from this software version

(cf. Section 3.4.3).

3.4.3 Configuring the HHU, setting interface parameters

The GD parameters must be set before the submodule can communicate via

the MPI interface. The setting can be activated during power-up (i.e. while wait-

ing for the first GD message frame from the PLC (“Waiting for PLC” state) via

the HHU interface by means of key combination Jog (top far left) and T2

(top far right). The individual parameters are then interrogated via the HHU dis-

play and entered via the HHU keyboard. You can change the default values

with the + and – keys within the permitted value range. You can switch to the

next parameter with the Automatic key. Selection of the next parameter

causes the preceding parameter to be stored in the Flash EPROM. The param-

eters need therefore only be set during start-up and when interfaces are

changed. If the interface parameter settings are not activated after power-up,

the stored values are used or the default values (see table) loaded.

DIP switch

settings for OPI

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HHU AS 314

(PLC)

Send

Receive

Fig. 3-9 Sending and receiving as seen from the HHU

Separate GD parameters are used for sending and receiving.

GD 1 . 1 . 1

Object number

GI number (global identifier)

GD circuit number (global data no.)

Fig. 3-10 Meaning of the GD parameters

Note

The GD parameters of the HHU and AS314 and PLC block FB1 must agree.

Table 3-5 Value range for GD parameters of the HHU

Designation Display Default

value

Value

range

PLC FB1

parameters

Receive GD circuit no. Rec-GD-No: 2 1–16 HHU Send

GD No

Receive GI no. Rec-GBZ-No: 1 1–255 HHU Send

GBZ No

Object no. for receive

Rec-Obj-No: 1 1–255 HHU Send

Obj No

Send GD circuit no. Send-GD-No: 2 1–16 HHU Rec

GD No

Send GI no. Send-GBZ-No: 1 1–255 HHU Rec

GBZ No

Object no. for send GI Send-Obj-No: 1 1–255 HHU Rec

Obj No

SW 4

and

high–

Baud rate Baud rate: 187.5 k

(baud)

187.5 /

1.5 M

Bus address Bus address: 15 0–15

Meaning of the GD

parameters

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3.4.4 Example: Connecting the HHU to the SINUMERIK 840D

1. Make the electrical connections on the distribution box and HHU.

When the HHU supply is connected, the following message must appear on

the display: “Waiting for PLC V 04.01.01 F”,

in which F stands for node no. 15 (default setting).

2. Check that the HHU is capable of bus operation:

––––> “BMPI” must be printed on rating plate on rear of unit.

3. Make a permanent bus cable connection at the end of the bus

(wire up inside connector instead of detachable connection!)

Note bus settings: OPI (on NCU at X101)

MPI (on NCU at X122)

4. Deactivate the terminating resistors in the last bus connector

(terminating resistors are integrated in the HHU).

5. Set the DIP switches in the HHU:

S 1.3 ON ––––> OPI (1.5 Mbaud)

S 1.3 OFF –––> MPI (187.5 kbaud)

6. Parameterize FB 1:

HHU 0 = No HHU

1 = HHU on MPI

2 = HHU on OPI

BHGIn 1st input byte

BHGOut 1st output byte

–––> Byte n+0, bit 7 must be set continually to “1”

by the PLC!

BHGStatSend Status data word Send

BHGStatRec Status data word Receive

BHGInLen B#16#6

BHGOutLen B#16#14

BHGTimeout S5T#700MS

BHGCycl S5T#400MS

BHGRecGDNo 2

BHGRecGBZNo 2

BHGRecObjNo 1

BHGSendGDNo 2

BHGSendGBZNo 1

BHGSendObjNo 1

7. Check whether data from FB 1 are included in data view, otherwise update.

8. The Send / Rec data are preset in the HHU. No further parameters need to

be set. The data must be set as follows for checking purposes only:

BHGRecGDNo 2

BHGRecGBZNo 1

BHGRecObjNo 1

BHGSendGDNo 2

BHGSendGBZNo 2

BHGSendObjNo 1

9. For the purpose of integration in the PLC, the TOOL box contains a file

“HHU.exe” as a programming example.

10. For HHU on MPI (SW4.x):

BHG = 2 and

BHGMPI = TRUE

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3.5 Handheld programming unit

The handheld programming unit (HPU) is especially suitable for handling tasks.

It is connected to the SINUMERIK 840D via the MPI or OPI interface and can

be used either instead of or in addition to an MMC/MCP.

The HPU includes the operating functions of the MCP.

The state of the operator elements (button pressed/released) is entered in an

8-byte data block and transferred cyclically by global data service to the PLC.

The operator elements are evaluated by the PLC.

The following MCP functions can be executed on an HPU with a standard as-

signment:

SStart and stop programs

SChange operating mode

SManually traverse 5 axes in both directions

SChange override

SSwitch programs to Reset

SSwitch over WCS/MCS for travel commands

SActivate single block

SSelect increments (INC1, INC10, ...)

The following MCP functions are not provided by the HPU and are assigned

permanent values:

SSpindle speed override

SSpindle start/stop

SKeyswitch

SFeedrate start/stop

The software version of the HPU appears in the display after power up until

communication between the PLC and the HPU has been established.

Functions

Non-available

functions

Display software

version of HPU

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Example: Display on the HPU

Waiting for PLC

V04.01.01 B

→ Software version of the HPU is V4.11

→ Bus address of the HPU is Bhex (11)

3.5.1 Interface signals of the HPU

The MCP simulation is available for the HPU. The MCP simulation of the HPU

must be parameterized as an MCP in function block FB1 so that the PLC basic

program can monitor the failure of the HPU.

The parameter setting for the start address n is set in the PLC user program

(FB1).

Table 3-6 Interface HPU –> PLC

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

IBn REF TEACH AUTO MDA JOG QUIT RESET WCS/MCS

IBn+1 Reserved U4 U3 Shift key U2 U1 INC REPOS

JOG keys positive direction

IBn+2 Reserved Reserved C/6 B/5 A/4 Z/3 Y/2 X/1

JOG keys negative direction

IBn+3 Reserved Reserved C/6 B/5 A/4 Z/3 Y/2 X/1

IBn+4 Signal Diagno Service System Param Correct Program Machine

IBn+5 F5 F4 F3 F2 1F Step Modify Insert

IBn+6 Reserved Reserved + –S2 S1 START STOP

IBn+7 Reserved

Note:

– Only keys displayed against a gray background are evaluated by the basic PLC program (FC26).

– Keys U1 to U4 and F1 to F5 or their inputs may be freely assigned by the PLC user.

FC 26 also exists and is analogous with PLC functions FC 19 and FC 25. It is

described in

Reference: /FB/P3, Basic PLC Program

Input signals

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Machine data that specify the coding of compensation values must be set as

follows:

SMD 12000: OVR_AX_IS_GRAY_CODE = 1

SMD 12020: OVR_FEED_IS_GRAY_CODE = 1

SMD 12040: OVR_RAPID_IS_GRAY_CODE = 1

SMD 12060: OVR_SPIND_IS_GRAY_CODE = 1

By default, the following signals are not influenced by the MCP emulation, they

are initialized when the control is started up:

SKeyswitch to position 0

SSpindle speed override to 0

SRapid traverse overlay to 0

Only “BAGNo” and “ChanNo” parameters are provided for FC 26. For this rea-

son, the user needs to determine the information that is otherwise transferred to

the caller via parameters “FeedHold” and “SpindleHold”.

3.5.2 Standard configuration of the HPU (without MCP)

The standard configuration comprises a SINUMERIK 840D with

MMC100/102/103 and an HPU.

+ The parameter assignment at FB1 for the HHP operating components corre-

spond to those of the 1st MCP:

MCPNum:=1 (one HPU)

MCPIn:=P#I0.0 (HPU input signals)

MCPOut:=P#Q0.0 (HPU output signals)

MCPStatRec:=P#Q12.0 (status double word)

Signals not

supported

Parameterizing the

PLC basic

program FB1

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3.5.3 Deviations from the standard HPU configuration

(up to SW 3.1)

The following documents are also required:

References: /BH/ Operator Components Manual

/FB/, P3, Basic PLC Program

/S7HT/ Manual, Application of Tools

The following features are examples of deviations from the standard configura-

tion:

SChanges to the address assignment

of the input, output or status bytes,

or flag area or data block

SAdditional connection of an MCP

An example is given using the following configuration:

–PLC–CPU AS314

–MCP

–HPU

You must adjust the communication parameters and possibly the switch settings

(addresses) of the bus nodes.

To set a new configuration, first press the Define global data softkey. The fol-

lowing description of how to proceed is based on the assumption that you are

already familiar with this menu.

1. Set up a new project and CPU programs with the STEP7 tool. You must set

up a CPU program for each component of the system (PLC, MCP, HHU, 2nd

MCP, HPU...).

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

3. Call “Global data” menu (via File manager / MPI network / Options /

Global Data softkeys) and enter the desired configuration.

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

5. Set the cyclical transmit pattern. Once the configuration has been compiled

successfully for the first time, the “Reduction ratio” and “Status” can be acti-

vated and then input.

6. Compile your configuration again.

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

8. Call FB1, DB7 must be parameterized for all operator control components

(MPI nodes) in OB 100 in the basic PLC program.

9. The status pointer (double word) must be configured in FB1 for each compo-

nent for monitoring purposes.

Documentation

requirements

Example

Procedure

SIMATIC S7,

Version 2.1

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Note

For a description of the “Global data” menu and its applications, please refer to

References: /S7HT/ SIMATIC Step7 Manual, Start-up of MPI

Bus Nodes

A network must be activated via the configuration for every CPU program. Since

there is no separate order number for the MCP/HHU CPU programs, the stan-

dard order number of the AS314 must be used.

CPU program MPI address

AS314 2

MCP 6

HHU 15

HPU 11

“0” must always be entered as the MPI SUB network number.

“Networking” sequence for each CPU program:

1. Set “Module networked”.

2. Set MPI address and enter SUB network no. 0.

3. Confirm with OK softkey

4. Save the configuration with Save softkey

The SDB supplied in the basic PLC program is valid for the first MCP or the

HPU and must be reconfigured as required.

Networking

SDB

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Call the “Global data” menu and set up a new file. “table 1” appears.

You must call the CPU programs in table 1.

1. Using the mouse, click on the field next to GD identifiers (the column is then

color-highlighted).

2. Click “Select CPU module” under menu item “PLC functions”.

3. A window headed “Select CPU” appears. Click on project Example and the

3 CPU programs are displayed: as314, MCP, HPU.

4. Select as314.

5. table 1 appears with entry as314//CPU1::

6. Click on the empty field to the right of it and repeat steps 2 to 3 above in the

order given for the HPU CPU programs.

7. The result is table 1 containing the 3 CPU programs.

table 1

GD identifiers as314/CPU1 MCP/CPU1 HPU/CPU1

You can now make the entries for the HPU in table 1.

1. Start in column as314//CPU1:: by selecting the first field.

2. Define and enter data area for receipt and transmission

For mstt//CPU1::

Receive area: qb0 : 8 Starting from qb0, 8 bytes are sent from the

PLC to the MCP.

Transmit area: ib0 : 8 Starting from ib0, 8 bytes are received by

the MCP.

For HPU//CPU1::

Receive area: qb16 : 8 Starting from qb16, 8 bytes are sent from

the PLC to the HPU.

Transmit area: ib16 : 8 Starting from ib16, 8 bytes are received by

the HPU.

3. Declare the transmit and receive areas to be such. The transmit area is then

marked with “»”.

4. table 1 with all its entries then looks like this:

Calling the “Define

global data” menu

table 1

Enter areas for

transmitting and

receiving

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table 1

GD identifiers as314/CPU1:: MCP/CPU1:: HPU/CPU1::

GD »qb0:8 qb0:8

GD ib0:8 »ib0:8

GD »qb16:8 qb16:8

GD ib16:8 »ib16:8

Note

The order in which inputs are made (transmit, receive) affects the way in which

GD identifiers are assigned and should be noted carefully as shown by the

above example.

Now select compiling.

The GD identifiers are generated during compilation. The GD identifiers are dis-

played as the result in table 1:

table 1

GD identifiers as314/CPU1:: MCP/CPU1:: HPU/CPU1::

GD 1.1.1 »qb0:8 qb0:8

GD 1.2.1 ib0:8 »ib0:8

GD 2.1.1 »qb16:8 qb16:8

GD 2.2.1 ib16:8 »ib16:8

Compiling

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Click the View / Reduction ratio softkeys. The following table 1 with the SR

parameters appears:

table 1

GD identifiers as314/CPU1:: MCP/CPU1:: HPU/CPU1::

SR 1.1 8 8

GD 1.1.1 »qb0:8 qb0:8

SR 1.2 8 8

GD 1.2.1 ib0:8 »ib0:8

SR 2.1 8 8

GD 2.1.1 »qb16:8 qb16:8

SR 2.2 8 8

GD 2.2.1 ib16:8 »ib16:8

The transmission rate for the HPU must be set.

The default setting is one transmission that takes place every 8 PLC cycles.

With a PLC cycle time of 25 ms, the default then corresponds to a key scan of

200 ms. This may be too slow for some applications. To reduce the transmis-

sion rate change the “reduction ratio”, i.e. the SR parameters.

You must specify a value of 1, 2, 4 or 8. Only 4 and 8 are allowed for transmis-

sion. The transmission to and from the HPU is then activated at a correspond-

ing frequency (e.g. every 4th PLC cycle).

Example of table 1 with altered SR parameters:

table 1

GD identifiers as314/CPU1:: MCP/CPU1:: HPU/CPU1::

SR 1.1 4 1

GD 1.1.1 »qb0:8 qb0:8

SR 1.2 1 4

GD 1.2.1 ib0:8 »ib0:8

SR 2.1 4 1

GD 2.1.1 »qb16:8 qb16:8

SR 2.2 1 4

GD 2.2.1 ib16:8 »ib16:8

When you have changed the SR parameters, you must compile your configura-

tion again.

Setting the

reduction ratio

Changing the SR

parameters

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3.5 Handheld programming unit

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Click the View / Status softkeys in the menu.

The following table 1 appears:

table 1

GD identifiers as314/CPU1:: MCP/CPU1:: HPU/CPU1::

GST

GDS 1.1

SR 1.1 4 1 1

GD 1.1.1 »qb0:8 qb0:8 qb0:8

GDS 1.2

SR 1.2 1 4 4

GD 1.2.1 ib0:8 »ib0:8 »ib0:8

GDS 2.1

SR 2.1 4 1

GD 2.1.1 »qb16:8 qb16:8

GDS 2.2

SR 2.2 1 4

GD 2.2.1 ib16:8 »ib16:8

Now enter the status double words for GDS1.2 and GDS 2.1.

Extract from table 1:

table 1

GD identifiers as314/CPU1:: MCP/CPU1:: HPU/CPU1::

GDS 1.2 ad12

GDS 2.2 ad24

Once you have entered the status, you must compile your configuration again.

The SDB has been generated during compilation. Now transfer the SDB for

CPU program as314 to the PLC CPU. (PLC must be in the STOP state).

Procedure:

1. Click on File/Download to PLC menu

2. Download window appears. Select as314//CPU1:: and confirm with OK soft-

key.

3. Switch PLC into RUN mode (restart).

The default setting for the MCP is 6 and the MPI address for the HPU is 14. The

address is set in FB1 for each device.

The default addresses are:

MCP: 6

HPU: 11

Activate status

SDB

HPU address

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SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

The following parameter settings must be made for the MCP and HPU operating

components in FB1:

MCPNum:=1 (one MCP)

MCP1In:=P#E0.0 (MCP input signals)

MCP1Out:=P#A0.0 (MCP output signals)

MCPStatRec:=P#Q12.0 (status double word)

MPCBusAdr:= 6,

HPU:=1 (one HPU)

HPUIn:=P#F16.0 (HPU input signals)

HPUOut:=P#F16.0 (HPU output signals)

HPUStatRec:=P#F24.0 (status double word)

HPUBusAdr:= 11,

Parameterization

of basic PLC

program FB1

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3.6 Machine control panel (MCP)

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

3.6 Machine control panel (MCP)

The following interfaces, switches and display elements are located on the rear

of the machine control panel:

Operator panel

interface (MPI)

Power supply interface

Switch S3

X10

X20

S3 31

Emergency

STOP button

”

1234

LEDs 1...4

Connection for equipotential bonding conductor

12 3

SHIELD M24 P24

Fig. 3-11 Position of interfaces on rear panel of MCP

The interfaces (e.g. pin assignment) are described in detail in

References: /BH/, Operator Components Manual

Table 3-7 Meaning of LEDs 1...4 on rear panel of MCP

Designation Meaning

LEDs 1 and 2 Reserved

LED 3 POWER: Lights up when voltage (24 V) is present

LED 4 SEND: Changes state after transmission of data

If the “feed start” and “feed stop” keys are pressed while the MCP is powering

up, the software version is displayed in the left-hand, center and right-hand LED

blocks.

The module must have firmware version V 03_01_01 or higher.

Example After the software version display has been activated, 3/1/1 LEDs light up in the

left-hand/center/right-hand LED blocks.

––> SW version v03_01_01 is installed.

Interfaces,

switches and

display elements

Interfaces

LEDs 1...4

Display software

version of MCP

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Table 3-8 Meaning of switch S3 for machine control panel

1 2 3 4 5 6 7 8 Meaning:

off

Baud rate: 1.5 Mbaud

Baud rate: 187.5 kbaud

off

200ms cycle transmit pattern / 2400 ms receive monitoring

100ms cycle transmit pattern / 1200 ms receive monitoring

50 ms cycle transmit pattern / 600 ms receive monitoring

off

Bus address: 15

Bus address: 14

Bus address: 13

Bus address: 12

Bus address: 11

Bus address: 10

Bus address: 9

Bus address: 8

Bus address: 7

Bus address: 6

Bus address: 5

Bus address: 4

Bus address: 3

Bus address: 2

Bus address: 1

Bus address: 0

on Interface to customer operator panel

off MCP

on off on off on on off off Default setting

on off on off on on off off Default setting for 840D

Baud rate: 1.5 Mbaud

Cyclical transmit pattern: 100 ms

Bus address: 6

Switch S3

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3.7 Customer operator panel interface

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

3.7 Customer operator panel interface

A customer operator panel can be connected via the interface. 64 digital inputs

and 64 digital outputs with C-MOS level (5 V) are available on the module for

this purpose.

The module must have firmware version V 03_01_01 or higher.

X231

LEDs

X20

MPI connection

X10

X221X211

289.4

64.7

207.3

92.7

7.2

3.5

Holes 3.6

Equipotential bonding connection



Fig. 3-12 Front view of interface to customer operator panel

If only the customer operator panel is to be connected, then the bus address

must be set to 6 as for the MCP (standard application).

Table 3-9 Setting for 840D: Switch S3 on interface for customer operator panel

1 2 3 4 5 6 7 8 Meaning:

on off on off on on off on Baud rate: 1.5 Mbaud (OPI)

Cyclical transmit pattern: 100 ms

Bus address: 6

Connector designation: X10

Connector type: 3-pin Phoenix terminal block, straight

Table 3-10 Pin assignment of X10 connector on interface to customer operator panel

X10

Pin Name Type

1 SHIELD VI

2 M24 VI

3 P24 VI

Interface

Location of the

interfaces

Switch S3, default

setting

Power

supply

interface

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3.8 Second machine control panel

Two machine control panels can be operated with the SINUMERIK 840D. The

second MCP must be parameterized in the basic program parameters in FB1.

3.9 MMC 100/MMC 102/103 operator panel

3.9.1 Settings on the MMC

The operator panel interface (OPI) with a baud rate of 1.5 Mbaud is set as the

default on the MMC.

SMMC 100

The MMC100 is automatically set to the baud rate.

SMMC102/103

The MMC102/103 must be set to a baud rate of 1.5 Mbaud in the “Start-up/

MMC/Operator panel” menu.

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” softkey 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).

MD 9003: FIRST_LANGUAGE (foreground language for MMC 100)

SMMC100

One of two languages can be called in the MMC 100.

SMMC102/103

The MMC102/103 is always supplied with a selection of languages. English

is the default setting.

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).

MD 9006 (for MMC100):

In this MD you set the time after which the screen saver is to be activated. The

screen saver is activated if none of the keys on the operator panel have been

pressed within the specified time.

OPI (default)

Screen

Language

Display resolution

Screen

saver

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3.9 MMC 100/MMC 102/103 operator panel

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

The protection levels for user data are set in machine data 9200 to 9299.

The settings of the V.24 interface on the MMC for data backup are stored from

MD 9300 onwards. The settings for 3 different devices are made in the “Ser-

vices” menu via an input display.

3.9.2 Language default

To be able to switch between the two configured languages even when the op-

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 softkey from right).

3. Switch to the highest level with RECALL.

4. Select “Change language” (3rd vertical softkey from top).

One of two languages can be called alternately in the MMC100. These are de-

fined while the MMC software is being loaded. While the control is in operation,

the operator can switch between these two languages only by selecting the

softkey “Change language” in the “Start-up” display.

On the MMC102/103 there are several methods of switching over between lan-

guages while the control is in operation:

SSwitchover between two preset languages.

SOnline change of the second language.

The selectable languages are set and managed in a file. When the language is

switched in online operation, the first language remains as originally set and

only the second language can be changed.

The vertical softkey labeled “Change language” in the “Start-up” display is used

to switch between two languages. The switchover takes effect immediately. This

key can only be used to switch between two predefined languages.

Protection levels

for user data

V.24 interfaces

Language

switchover

MMC 100

MMC 102/103

Language

switchover

concept

Switchover

between two

languages

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SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

Different languages are selected in the “Start-up/MMC/Languages” display (pro-

vided that languages have been loaded). This display provides the user with a

list of the available languages. The user selects one language and confirms the

selection with “OK”. The user can then change over between the first language

and the language just set by selecting the “Change language” softkey in the

“Start-up” display. The 2nd language can always be changed in online mode.

The languages installed on the MMC102/103 on delivery are English and Ger-

man. The two supplementary packages (1 and 2) are also available.

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

The languages to be used on the MMC are configured in file c:\mmc2\mmc.ini.

The required changes in the file described below can be made with the editor

which can be called under Start-up//MMC.

Two languages can be configured from the languages listed below:

GR German (standard)

SP Spanish

FR French

UK English (standard)

IT Italian

Example:

1st language German, 2nd language English

File MMC.INI must be altered as shown below:

Excerpt from mmc.ini:

...

[LANGUAGE]

Language=GR

LanguageFont=Europe

Language2=UK

LanguageFont2=Europe

...

Note

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.

Online change of

the 2nd language

Install language

packages

Definition of

usable

languages

Default setting

without activating

logographic

languages

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3.9 MMC 100/MMC 102/103 operator panel

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

2 languages can be configured from the languages listed below:

GR German (standard)

SP Spanish

FR French

UK English (standard)

IT Italian

TW Chinese (Taiwan) pictographic language

CH Chinese (Mandarin) pictographic language

Example:

1st language German, 2nd 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=español, français, english, italiano

LanguageList=GR, CH, TW, SP, FR, UK, IT

FontList=Europe, China, China, Europe, Europe, Europe, Europe

LBList=chinese, taiwan, español, français, english, italiano

AddOnProd=c:\cstar20\cstar20.exe

...

To be able to operate the control with pictographic languages, the appropriate

add-on product must be installed for each selectable language. Languages

based on different add-on products cannot be configured at the same time.

Note

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.

Default setting

with logographic

languages

Add-on products

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EMC / ESD Measures

4.1 Measures to suppress interference

To ensure safe, interference-free operation of the installation, it is essential to

use the cables specified in the individual diagrams. Both ends of the shield must

always be conductively connected to the equipment housing.

Exception:

SIf external equipment (such as printers, programming devices, etc.) is

connected, standard shielded cables connected at one end may also be

used.

These external devices may not be connected to the control during normal

operation. However, if the system cannot be operated without them, then the

cable shields must be connected at both ends. Furthermore, the external

device must be connected to the control via an equipotential bonding lead.

To ensure that the entire installation (control, power section, machine) has the

greatest possible immunity to interference, the following EMC measures must

be taken:

SSignal leads and load leads must be routed at the greatest possible distance

from one another.

SSignal cables from and to the NC or PLC must be supplied by SIEMENS.

SSignal leads must not be routed close to strong external magnetic fields

(e.g. motors and transformers).

SPulse-carrying HC/HV leads must always be laid completely separately from

all other leads/cables.

SIf signal leads cannot be laid at a sufficient distance from other leads, then

they must be installed in shielded cable ducts (metal).

SThe distance (noise field) between the following leads should be as small as

possible:

–Signal lead and signal lead.

–Signal lead and associated equipotential bonding lead.

–Equipotential bonding lead and PE conductor (routed together).

!Important

For more information about interference suppression measures and connection

of shielded cables, please refer to

References: /EMC/, EMC Guidelines

Shielded

signal leads

Precautionary

measures

03.96

4.2 Measures to protect ESD-sensitive components

SINUMERIK 840D Installation and Start-Up Guide (IAD) – 04.00 Edition

4.2 Measures to protect ESD-sensitive components

!Important

Handling of modules at risk from ESD:

SWhen electrostatic components are handled, it must be ensured that per-

sonnel, workstation and packaging are properly grounded.

SAs a general principle, electronic modules should only be touched if this is

absolutely unavoidable (owing to repair work, etc.). When you are handling

PCBs, therefore, make sure that you never touch any submodule pins or

conducting paths.

SYou may only touch components if

–you are constantly connected to earth by means of an antistatic chain

–you are wearing antistatic shoes or antistatic shoes with grounding

strips in conjunction with an antistatic floor surface.

SModules must always be placed on a conductive surface (table with antista-

tic covering, electrically conductive foam rubber, antistatic packaging mate-

rials, antistatic transport container).

SModules must not be placed near VDUs, monitors or television sets (not

closer than 10 cm from screen).

SModules must not be allowed to come into contact with chargeable, electri-

cally insulating materials such as plastic foil, insulating table tops or clothing

made of synthetic fibers.

SMeasurements may only be taken on modules if

–the measuring instrument is grounded (e.g. via PE conductor) or

–the measuring head on an isolated instrument is discharged briefly (e.g.

by being brought into contact with bare metal part of control housing)

before the measurement is taken.

4 EMC / ESD Measures

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Power On and Power-Up

5.1 Start-up sequence 5-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .