Siemens Sinumerik 840DiE sl Manual 

Software Version System Software for 840Di sl/840DiE sl 1.4 01/2007 Edition SINUMERIK 840Di sl Manual General Information 1 Hardware Descriptions 2 Design 3 EMC and ESD Measures 4 Power On and Power–Up 5 PLC Commissioning 6 Ethernet Communication 7 PROFIBUS Communication 8 Drive Commissioning (SINAMICS) 9 Drive Commissioning (SIMODRIVE) 10 NC Commissioning with HMI Advanced 11 Alarm and Message Texts 12 Axis and Spindle Test Run 13 Drive Optimization with HMI Advanced 14 User Data Backup/ Standard Commissioning 15 Software Installation/ Update and Data Backup 16 License Management 17 Specific Data and Functions 18 Small SINAMICS Glossary A Abbreviations B

The status of each edition is shown by the code in the ”Remarks” column. Status code in the ”Remarks” column: A New documentation. . . . . . B Unrevised reprint with new Order No. . . . . . C Revised edition with new status. . . . . . Edition Order No. Remarks 10/2005 6FC5397–4CP10–0BA0 A 03/2006 6FC5397–4CP10–1BA0 C 01/2007 6FC5397–4CP10–2BA0 C Trademarks All product names mentioned may be trademarks or product designations of Siemens AG or their suppliers, whose use by third parties for their own purposes may infringe the rights of the trademark owners. Copyright © Siemens AG 2007 We have checked the contents of this manual for agreement with the hardware and software described. Nevertheless, differences might exist and therefore we cannot guarantee that they are completely identical. The data in this document is regularly checked and the necessary corrections are included in the following editions. Suggestions for improvement are also welcome. Subject to change without prior notice. Siemens–Aktiengesellschaft Printed in the Federal Republic of Germany 3ls

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition PREFACE The SINUMERIK documentation is subdivided into 3 parts:
General Documentation
User Documentation
Manufacturer/Service Documentation An overview of publications, which is updated monthly and also provides infor- mation about the language versions available, can be found on the Internet at: http://www.siemens.com/motioncontrol Follow menu items – ”Support” –> ”Technical Documentation” –> ”Overview of Documentation”. The Internet version of DOConCD (DOConWEB) is available at: http://www.automation.siemens.com/doconweb Information about training courses and FAQs (Frequently Asked Questions) can be found in internet under: http://www.siemens.com/motioncontrol and there under the menu item ”Support” This documentation is intended for manufacturers/end users of machine tools and production machines who use SINUMERIK 840Di sl and SINAMICS S120. This documentation only describes the functionality of the standard version. Additions or revisions made by the machine manufacturer are documented by the machine manufacturer. Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such func- tions with a new control or when servicing. For the sake of simplicity, this documentation does not contain all detailed infor- mation about all types of the product and cannot cover every conceivable case of installation, operation, or maintenance. If you have any technical questions, please contact our hotline: Europe/Africa Asia/Australia America Phone +49 180 / 5050 – 222 +86 1064 719 990 +1 423 262 2522 Fax +49 180 / 5050 – 223 +86 1064 747 474 +1 423 262 2289 Internet http://www.siemens.com/automation/support–request E–Mail mailto:[email protected] SINUMERIK documentation Target group Standard scope Technical support SINUMERIK 840Di sl Manual Preface

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Notice Country telephone numbers for technical support are provided under the following Internet address: http://www.siemens.com/automation/service&support For questions on the documentation (suggestions, corrections), please send a fax or e–mail to the following address: Fax +49 9131 98 63315 E–Mail mailto:[email protected] A fax form is available at the end of this document. http://www.siemens.com/motioncontrol Search: SINUMERIK 840Di sl The Link Box on the SINUMERIK 840Di sl page gives you direct access to all important information about the product. This manual provides detailed information required for the configuration and commissioning of a SINUMERIK 840Di sl system. This manual describes the control system design and the interfaces of the indi- vidual components. The commissioning procedure with SINUMERIK 840Di sl (NCK, PLC and drives) is also described. For detailed information about individual functions, function assignment and performance data of individual components, please refer to the appropriate document for the subject concerned (e.g. manuals, function descriptions etc.). Separate documents are available for user–oriented activities. These include, for example, generating part programs and handling controls. Separate information is also available for operations that the machine tool manufacturer must carry–out. These include, for example, configuring/engineer- ing, installation and programming the PLC. Questions about the manual SINUMERIK Internet address SINUMERIK 840Di sl Link box Aims SINUMERIK 840Di sl Manual Preface

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition The following help functions are available with this description of functions:
Overall table of contents
Appendix with abbreviations and references, glossary
Index If you require information about a certain term, please look in the Appendix for the specific Chapter Index for the particular term. Both the chapter number and the page number are listed where you will find this particular information. This manual contains information which you should observe in order to ensure your own personal safety, as well to avoid material damage. Notices referring to your personal safety are highlighted in the manual by a safety alert symbol; notices referring to property damage only have no safety alert symbol. Depending on the hazard level, warnings are indicated in a descending order as follows: If multiple levels of hazards can occur, the warning is always displayed with the highest possible level. If a warning with a warning triangle is to indicate physical injury, the same warning may also contain information about damage to property. The following danger and warning signs are used in this document. Explanation of symbols used: ! Danger This symbol indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken. ! Warning This symbol indicates that death, severe personal injury or substantial property damage may result if proper precautions are not taken. ! Caution This warning (with the triangular symbol) means that minor physical injury or damage to property can occur if the appropriate precautions are not taken. Caution This warning (without the warning triangle) means that material damage may result if proper precautions are not taken. Notes on how to use this manual Safety notes Danger and warning strategy SINUMERIK 840Di sl Manual Preface

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Notice This warning means that an undesirable result can occur if the information is ignored. Explanation of symbols Note The symbol always appears in this documentation where further, explanatory information is provided. Machine Manufacturer This pictorial symbol always appears in this document to indicate that the machine manufacturer can affect or modify the function described. Never ignore information provided by the machine manufacturer! The following notices are intended firstly for your personal safety and secondly to prevent damage occurring to the products described or any connected de- vices and machines. ! Warning Operating electrical equipment has parts and components that are at hazardous voltage levels. Actions by an unqualified device/system operator or failure to observe the warning notices may result in serious physical injury or material damage. Only suitably qualified personnel, trained in assembling, installing, commissioning or operating the product should work on this device/system. Should it be necessary to test or take measurements on live equipment, then the specifications and procedures defined in Accident Prevention Regulation VBG 4.0 must be adhered to, in particular § 8 ”Permissible deviations when working on live components”. Suitable electric tools should be used. Further notes Danger notices SINUMERIK 840Di sl Manual Preface

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition ! Warning
Repairs to devices that have been supplied by our company must only be carried out by SIEMENS Customer Service or by repair centers authorized by SIEMENS. When replacing parts or components, only use those parts that are included in the spare parts list.
Before opening the device, always disconnect the power supply.
EMERGENCY STOP devices complying with EN 60204 IEC 204 (VDE 0113) must remain effective in all automation equipment modes. Resetting the EMERGENCY STOP device must not cause an uncontrolled or undefined restart.
Anywhere in the automation equipment where faults might cause major material damage or even physical injury, in other words, where faults could be dangerous, additional external precautions must be taken, or facilities must be provided, that guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch, mechanical interlocks etc.) ! Caution
Connecting cables and signal cables should be installed so that inductive and capacitive interference does not in any way impair the automation functions. SINUMERIK 840Di sl Manual Preface

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Electrostatically Sensitive Devices ! Important Handling of modules containing devices sensitive to electrostatic discharge:
When handling electrostatically sensitive devices, make sure that operator, workplace and packing material are properly grounded.
Generally, electronic modules must not be touched unless work has to be carried out on them. When handling PC boards make absolutely sure that you do not touch component pins or printed conductors.
Touch components only if – you are permanently grounded by means of an antistatic chain, – you are wearing ESD boots or ESD boots with grounding strips in conjunction with ESD flooring.
Modules may be placed only on electrically conductive surfaces (table with ESD top, conductive ESD foam plastic, ESD packing bags, ESD transport containers).
Keep modules away from visual display units, monitors or TV sets (minimum distance from screen > 10 cm).
Do not bring ESD–sensitive modules into contact with chargeable and highly–insulating materials, such as plastic sheets, insulating table tops or clothing made of synthetic materials.
Measurements on modules are allowed only if – the measuring instrument is properly earthed (e.g. equipment grounding conductor), or – before measuring with a potential–free measuring instrument, the probe is briefly discharged (e.g. touch the unpainted metal parts of the control housing). Setup and operation of the device/equipment/system in question must only be performed using this documentation. Only qualified personnel should be al- lowed to commission and operate the device/system. Qualified persons are defined as persons who are authorized to commission, to ground, and to tag circuits, equipment, and systems in accordance with established safety prac- tices and standards. Please note the following: ! Warning The equipment may only be used for single purpose applications explicitly described in the catalog and in the technical description and it may only be used along with third–party devices and components recommended by Siemens. To ensure trouble–free and safe operation of the product, it must be transported, stored and installed as intended and maintained and operated with care. ESD Notes Qualified personnel Proper use SINUMERIK 840Di sl Manual Preface

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Contents 1 General Information on the SINUMERIK 840Di sl 1-21 . . . . . . . . . . . . . . . . . . . . . . . 1.1 Overview of SINUMERIK 840Di sl 1-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1 System components 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2 System software packages and quantity frameworks 1-22 . . . . . . . . . . . . . 1.1.3 Hardware components 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.4 Software components 1-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.5 Real–time properties 1-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.6 System integrity 1-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.7 Failure safety 1-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.8 Deactivation 1-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.9 UPS system 1-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Overview of software components 1-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Notes on commissioning 1-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Standard/export version 1-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 840Di start–up 1-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.1 Menu command: Window 1-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hardware Descriptions 2-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Overview of hardware components 2-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 MCI2 board for 840Di sl 2-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Module 2-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Interface description 2-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 Module replacement 2-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.4 Technical data 2-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MCI board extension slot variant 2-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Module 2-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Installation instructions 2-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Interface description 2-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 Technical data 2-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Cable distributor 2-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 SINUMERIK Industrial PC 2-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1 SINUMERIK PCU 50.3 2-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 SINUMERIK operator panel fronts 2-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 Operator panel front OP 012 2-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 TCU (Thin Client Unit) 2-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Floppy disk drives 2-73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1 Floppy disk drive 3.5” (USB) 2-73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 Power supply 2-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1 SITOP POWER standard 24V/10A 2-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 Uninterruptible power supply (UPS) 2-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.10.1 SITOP POWER DC UPS MODULE 15 2-76 . . . . . . . . . . . . . . . . . . . . . . . . . 2.10.2 SITOP POWER ACCU MODULE 24 V DC/10 A/3.2 AH 2-78 . . . . . . . . . . . 2.11 I/O module PP72/48 2-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.1 Module 2-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.2 Interface description 2-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.3 Power supply 2-87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.4 Grounding 2-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.5 Dimension drawing 2-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.6 Technical data 2-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 ADI4 (Analog Drive Interface for 4 Axes) 2-91 . . . . . . . . . . . . . . . . . . . . . . . . 2.12.1 Module 2-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Diagnostic repeater for PROFIBUS DP 2-93 . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.1 Module 2-93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Design 3-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 System overview 3-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 Operator panels and touch panels 3-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 PROFIBUS DP components 3-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 MPI components 3-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.4 PCU components 3-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Electrical design 3-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 MCI board and PROFIBUS DP 3-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 MCI board and MPI bus 3-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3 MCI board extension 3-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.4 PCU 50.3 3-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Overview of connections 3-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1 MCI board and MCI board extension 3-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 PCU50 3-103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 EMC and ESD Measures 4-105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Interference suppression measures 4-105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 ESD measures 4-106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Power–On and Power–Up 5-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Preparing for commissioning 5-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Checklist 5-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Recommended sequence for first commissioning 5-108 . . . . . . . . . . . . . . . . 5.2 First power–up 5-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Basic commissioning of the system software 5-109 . . . . . . . . . . . . . . . . . . . . 5.2.2 Basic commissioning of the PLC 5-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Booting 5-111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 SRAM handling 5-111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Start–up after battery replacement (PCU backup battery) 5-112 . . . . . . . . . 5.3.3 Start–up after replacement of the MCI board 5-112 . . . . . . . . . . . . . . . . . . . . 5.3.4 Power up after reinstallation/update of the 840Di sl software 5-114 . . . . . . . 5.3.5 Start–up after replacement of the PCU or the MCI board 5-115 . . . . . . . . . . 5.3.6 Start–up after importing a backup copy 5-115 . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.7 Start–up after power failure/Power Fail 5-115 . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.8 Power–up with shutdown signal 5-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 5.4 Service Desktop 5-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Activation 5-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 SINUMERIK–specific applications 5-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Setting the boot response for the Service Desktop 5-119 . . . . . . . . . . . . . . . 5.4.4 System information after ”Fatal exceptional error” 5-119 . . . . . . . . . . . . . . . . 5.4.5 Starting OEM programs 5-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.6 User–specific HMI start–up images 5-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.7 HMI Explorer 5-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.8 SW installation/update 5-122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 ServiceCenter 5-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Activation 5-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2 Setting NCK/PLC startup mode 5-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3 Backup/restore functions 5-125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Configuring the network link of PCU (LAN/WAN) 5-126 . . . . . . . . . . . . . . . . . 5.7 License management 5-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1 License management with the Automation License Manager 5-127 . . . . . . . 5.7.2 License management with SinuCom NC 5-127 . . . . . . . . . . . . . . . . . . . . . . . . 6 PLC Commissioning 6-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 General 6-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 Compatibility 6-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Performance data 6-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3 PLC program 6-130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.4 Installing the PLC basic program library 6-130 . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.5 STEP 7 example projects 6-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.6 PLC user program 6-132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Commissioning 6-134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 Basic requirements 6-134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2 External communications link: Ethernet 6-135 . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.3 External communications link: MPI/PROFIBUS 6-135 . . . . . . . . . . . . . . . . . . 6.2.4 Local communications link: SOFTMC 6-136 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.5 Check PLC status and communication interface 6-136 . . . . . . . . . . . . . . . . . 6.2.6 First commissioning 6-137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Creating a SIMATIC S7 project 6-139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Creating a project 6-140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Inserting Station 300 6-140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.3 HW Config 6-141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.4 Inserting the 840Di sl Rack 6-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.5 Parameterizing the PROFIBUS interface (X101) 6-143 . . . . . . . . . . . . . . . . . 6.3.6 Parameterizing the PROFIBUS interface (X102) (optional) 6-144 . . . . . . . . 6.3.7 Parameterizing the MPI interface (X102) (optional) 6-145 . . . . . . . . . . . . . . . 6.3.8 Parameterization of the communications processor (CP 840D sl) (Ethernet) 6-145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.9 Networking PG/PC and PCU (Ethernet) 6-147 . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Creating a PLC program 6-152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 PLC basic program 6-152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.2 PLC user program 6-153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Creating a PROFIBUS configuration 6-153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 Loading the configuration 6-154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) -- 01/2007 Edition 6.6.1 Requirements 6-154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.2 Loading the configuration 6-154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.3 Series startup file 6-155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 Testing the PLC program 6-156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.1 Start--up behavior 6-156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.2 Cyclic operation 6-157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.3 Monitor/control using the SIMATIC Manager 6-157 . . . . . . . . . . . . . . . . . . . . . 6.7.4 Monitor/control using HMI Advanced 6-158 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 Load configuration into PG (PLC --> STEP 7) 6-160 . . . . . . . . . . . . . . . . . . . . 7 Ethernet Communication 7-161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 General 7-161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Ethernet PCU connections 50.3 7-161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Determining the PCU Ethernet communication parameters 7-161 . . . . . . . . 7.1.3 Checking an Ethernet connection 7-162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 SINUMERIK 840Di sl commissioning tool: SinuCom NC 7-163 . . . . . . . . . . 7.3 SINAMICS drive commissioning tool: STARTER 7-163 . . . . . . . . . . . . . . . . . 7.4 External HMI Advanced 7-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 MCP 483C IE 7-165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5.1 Conditions for general commissioning 7-165 . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5.2 Parameterization of the MCP 7-166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5.3 MCP functions 7-168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5.4 Linking to the basic PLC and user program 7-169 . . . . . . . . . . . . . . . . . . . . . . 7.5.5 Input/output image 7-171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PROFIBUS DP Communication 8-175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 General 8-175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.1 PROFIBUS DP interfaces of the MCI board 8-175 . . . . . . . . . . . . . . . . . . . . . 8.1.2 PROFIBUS DP with Motion Control option 8-175 . . . . . . . . . . . . . . . . . . . . . . 8.1.3 Message format for cyclic DP communication 8-176 . . . . . . . . . . . . . . . . . . . . 8.1.4 Description of a DP cycle 8-177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.5 Networking rules 8-178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Requirements 8-180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Creating a PROFIBUS configuration 8-183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Requirements 8-183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2 Inserting DP slaves 8-184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.3 Final parameterization of the isochronous DP slaves 8-185 . . . . . . . . . . . . . 8.3.4 Generating system data blocks (SDB) 8-190 . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.5 Loading a configuration into the PLC 8-191 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.6 PROFIBUS diagnosis 8-191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 SIMATIC I/O devices (ET200...) 8-192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 DP slave: I/O Module PP72/48 8-192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 GSD file 8-192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 Inserting a DP slave 8-193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3 Setting PROFIBUS parameters 8-193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.4 Setting the I/O addresses 8-194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 DP slave: MCP 310 8-195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 General conditions for commissioning 8-195 . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 8.6.2 Parameterization of the MCP 8-196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.3 Functions of the machine control panel 8-198 . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.4 Configuring the DP slave: MCP 310 8-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.5 Linking to the basic PLC and user program 8-203 . . . . . . . . . . . . . . . . . . . . . . 8.6.6 Input/output image 8-206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 DP slave: MCP 483 8-209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Conditions for general commissioning 8-209 . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2 Parameterization of the MCP 8-210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.3 Functions of the machine control panel 8-211 . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4 Configuring the DP slave: MCP 483 8-213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.5 Linking to the basic PLC and user program 8-216 . . . . . . . . . . . . . . . . . . . . . . 8.7.6 Input/output image 8-219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 DP slave: ADI4 8-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1 Slave OM 8-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.2 Inserting DP slave 8-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 DP slave: SINAMICSS120 8-223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.1 SlaveOM for SINAMICS 8-223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.2 Inserting the DP slave 8-223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.3 Parameterizing DP slaves 8-224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.4 Dependencies of PROFIBUS DP communication 8-228 . . . . . . . . . . . . . . . . 8.10 DP slave: SIMODRIVE drives 8-231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.1 SlaveOM 8-231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.2 Inserting the DP slave 8-231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.3 Parameterizing DP slaves 8-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.4 Dependencies of PROFIBUS DP communication 8-236 . . . . . . . . . . . . . . . . 8.11 DP slave: Diagnostic repeater for PROFIBUS DP 8-238 . . . . . . . . . . . . . . . . 8.11.1 Function 8-238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11.2 Application range 8-239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11.3 Connection and commissioning 8-239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Drive Commissioning (SINAMICS) 9-241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Requirements 9-241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 Basic requirements 9-241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.2 Safety information 9-242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 ONLINE commissioning 9-243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.1 Creating a new project 9-244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.2 Drive unit: Acquiring the component topology and configuring automatically 9-247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.3 Drive: Configuring the motors and encoders 9-250 . . . . . . . . . . . . . . . . . . . . . 9.2.4 Control Unit: Selecting the PROFIBUS message frame 9-252 . . . . . . . . . . . 9.2.5 Infeed: Selecting the PROFIBUS message frame 9-252 . . . . . . . . . . . . . . . . 9.2.6 Drive unit: Checking the configuration 9-253 . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.7 Drive unit: Configuring the PROFIBUS message frame 9-255 . . . . . . . . . . . 9.2.8 Control Unit: Error acknowledgement (BICO interconnection) 9-256 . . . . . . 9.2.9 Control Unit: Infeed operation (BICO interconnection) 9-257 . . . . . . . . . . . . . 9.2.10 Control Unit: Infeed ready to start (BICO interconnection) 9-258 . . . . . . . . . 9.2.11 Infeed: Error acknowledgement(BICO interconnection) 9-259 . . . . . . . . . . . . 9.2.12 Infeed: Enable (BICO interconnection) 9-260 . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.13 Drive: Enable OFF3 (BICO interconnection) 9-261 . . . . . . . . . . . . . . . . . . . . . 9.2.14 Drive unit: Saving parameters 9-262 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 9.2.15 Drive: Running the motor 9-262 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.16 Settings of specific parameters 9-263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 Example for systems with more than 6 drives 9-264 . . . . . . . . . . . . . . . . . . . . 9.3.1 Installation and basic commissioning 9-264 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.2 Drives of Control Unit 2: Additional BICO interconnection 9-265 . . . . . . . . . . 9.4 Further terminal assignments 9-268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.1 Proposal for terminal assignment: 1st CU (X122) 9-268 . . . . . . . . . . . . . . . . . 9.4.2 Proposal for terminal assignment: 1st CU (X132) 9-269 . . . . . . . . . . . . . . . . . 9.4.3 Proposal for terminal assignment: 2nd – nth CU (X122) 9-269 . . . . . . . . . . . 9.4.4 Proposal for terminal assignment: 1st CU with 2nd – nth CU 9-270 . . . . . . . 9.4.5 Example: CU interconnection with line contactor 9-271 . . . . . . . . . . . . . . . . . 9.5 Fundamentals 9-272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.1 Drive unit: Firmware upgrade 9-272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drive Commissioning (SIMODRIVE) 10-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 SIMODRIVE 611 universal/E, POSMO CD/CA and SI 10-275 . . . . . . . . . . . . 10.1.1 Commissioning variants 10-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.2 Preconditions for an online connection 10-277 . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.3 Setting a PROFIBUS address (SIMODRIVE 611 universal/E) 10-277 . . . . . . 10.1.4 Setting PROFIBUS address (SIMODRIVE POSMO SI/CD/CA) 10-279 . . . . 10.1.5 Setting the MPI interface 10-280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.6 Setting the routing information 10-281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.7 Starting online operation 10-282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Installing SimoCom U 10-283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 NCK Commissioning with HMI Advanced 11-285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 General procedure 11-285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Machine and setting data 11-285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2.1 Display and input 11-287 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2.2 Protection levels 11-288 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2.3 Machine data display filter 11-291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 System data 11-292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.1 Resolutions 11-292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.2 Normalization of physical quantities of machine and setting data 11-294 . . . 11.3.3 Changing scaling machine data 11-296 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.4 Loading default machine data 11-297 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.5 Switching over the measuring system 11-298 . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.6 Traversing ranges 11-300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.7 Positioning accuracy 11-300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.8 Cycle times 11-301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.9 Velocities 11-305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 Memory configuration 11-306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.1 DRAM memory 11-307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.2 SRAM memory 11-308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Axes and spindles 11-310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.1 Axis configuration 11-310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.2 Axis names 11-313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.3 Drive configuration 11-314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.4 Setpoint/actual value channels 11-318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 11.5.5 Incremental measuring system settings 11-321 . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.6 Parameterization of absolute measuring systems 11-324 . . . . . . . . . . . . . . . . 11.5.7 Parameterization of a 2nd measuring system with ADI4 11-326 . . . . . . . . . . . 11.5.8 DSC (Dynamic Servo Control) 11-329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.9 Drive optimization 11-330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.10 Rotary axes 11-331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.11 Positioning axes 11-332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.12 Indexing axes 11-333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.13 Parameter sets of axis/spindle 11-334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.14 Position controller 11-336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.15 Speed setpoint matching 11-340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.16 Drift compensation 11-343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.17 Velocity matching (axis) 11-344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.18 Monitoring functions (axis) 11-347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.19 Referencing an axis 11-355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.20 Spindle basic data 11-366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.21 Setpoint/actual value channels of spindle 11-369 . . . . . . . . . . . . . . . . . . . . . . . 11.5.22 Gear stages 11-369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.23 Measuring systems of spindle 11-370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.24 Speeds and setpoint adjustment for spindle 11-372 . . . . . . . . . . . . . . . . . . . . . 11.5.25 Position spindle 11-374 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.26 Synchronizing spindle 11-375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.27 Spindle monitoring 11-377 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.28 Spindle data 11-380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6 Handwheels 11-383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6.1 General 11-383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6.2 Connection via cable distributor 11-383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6.3 Connection via PROFIBUS 11-384 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6.4 Connection via Ethernet 11-387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 Digital and analog I/O devices 11-389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7.1 Parameterization of the number of inputs/outputs used 11-389 . . . . . . . . . . . 11.7.2 Assignment of inputs/outputs to the signal modules 11-390 . . . . . . . . . . . . . . 11.7.3 System variable $A_...[n] 11-391 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7.4 Digital input/output bytes and system variables 11-392 . . . . . . . . . . . . . . . . . . 11.7.5 Time–based reaction 11-393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7.6 Configuration example 11-394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8 Loadable compile cycles 11-399 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8.1 Loading a compile cycle 11-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8.2 Interface version compatibility 11-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8.3 Software version of a compile cycle 11-401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8.4 Supplementary conditions 11-402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8.5 Activating and licensing technology functions 11-402 . . . . . . . . . . . . . . . . . . . . 11.8.6 Data descriptions (MD) 11-403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9 PROFIBUS DP 11-404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9.1 Setting the parameters for the shut–down behavior 11-404 . . . . . . . . . . . . . . . 11.9.2 Data descriptions (MD) 11-404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10 Initial settings 11-405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11 NCK/PLC diagnostics 11-406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11.1 Menu: Diagnostics 11-406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11.2 Menu: Settings 11-410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 12 Alarm and Message Texts 12-413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Alarm and message texts 12-413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.1 Configuration file MBDDE.INI 12-413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.2 Standard text files 12-414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.3 User text files 12-414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.4 Syntax for alarm text files 12-416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.5 Setting the alarm log properties 12-418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Axis and Spindle Test Run 13-421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Prerequisites 13-421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1.1 Drives: SINAMICS S120 13-421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1.2 Drives: SIMODRIVE 13-421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1.3 NCK/PLC interface signals 13-422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 Axis dry run 13-423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 Spindle dry run 13-424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Drive Optimization with HMI Advanced 14-427 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 Overview 14-427 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2 Measuring functions 14-428 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 Miscellaneous functions 14-430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 Frequency response measurements 14-432 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4.1 Measurement of current control loop 14-433 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4.2 Speed control loop measurement 14-434 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4.3 Position control measurement 14-437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 Graphic display 14-440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 Trace function 14-443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6.1 Trace function properties 14-443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6.2 Main menu and operation 14-444 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6.3 Parameterization 14-445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6.4 Performing the measurement 14-447 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6.5 Display function 14-448 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7 File function 14-451 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8 Print graphic 14-453 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9 Automatic controller setting 14-456 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9.1 Drives: SINAMICS S120 14-456 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9.2 Drives: SIMODRIVE 611 universal 14-457 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 User Data Backup/Standard Commissioning 15-459 . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Explanations on data backup 15-459 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 Creating a series commissioning file 15-460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2.1 General 15-460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2.2 HMI Advanced (option) 15-462 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2.3 SinuCom NC 15-463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3 Considerations when saving PLC data 15-464 . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 Reading in a series startup file with HMI Advanced 15-465 . . . . . . . . . . . . . . . 15.5 SINAMICS S120 standard commissioning with STARTER 15-466 . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 16 Software Installation/Update and Data Backup 16-467 . . . . . . . . . . . . . . . . . . . . . . . . . 16.1 PTP network connection 16-467 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1.1 Establishing a network connection 16-467 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1.2 Configuring the external computer (Windows NT) 16-468 . . . . . . . . . . . . . . . . 16.1.3 Configuring the external computer (Windows XP) 16-470 . . . . . . . . . . . . . . . . 16.1.4 Configuring the PCU 16-471 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2 Partitioning of the PCU hard disk 16-472 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3 Software installation/update (Windows) 16-473 . . . . . . . . . . . . . . . . . . . . . . . . . 16.4 Restoring the as–delivered state 16-474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.1 Requirements 16-474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.2 Restoring the partitions 16-474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.3 Installation of the SINUMERIK 840Di sl applications 16-475 . . . . . . . . . . . . . . 17 License Management 17-477 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1 Fundamentals 17-477 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.1 Important terms 17-477 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.2 Overview 17-478 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.3 Web License Manager 17-478 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.4 Automation License Manager 17-479 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.5 License database 17-479 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.6 MCI board and hardware serial number 17-480 . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.7 SINUMERIK License Key 17-481 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1.8 Browser settings for using the A&D Mall 17-482 . . . . . . . . . . . . . . . . . . . . . . . . 17.1.9 Proxy settings for the download of license information 17-483 . . . . . . . . . . . . 17.2 Assigning via Web License Manager 17-484 . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2.1 You can execute an assignment via direct access as follows 17-484 . . . . . . . 17.2.2 You can execute an assignment via customer login as follows 17-485 . . . . . 17.3 Assigning via Automation License Manager 17-487 . . . . . . . . . . . . . . . . . . . . . 17.3.1 Overview of the functions 17-487 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3.2 Installing the Automation License Manager 17-488 . . . . . . . . . . . . . . . . . . . . . . 17.3.3 Enabling/disabling SINUMERIK plug–ins 17-489 . . . . . . . . . . . . . . . . . . . . . . . . 17.3.4 Assigning parameters to the TCP/IP communication with a control system 17-490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3.5 How to refresh the navigation view: ”Manage” 17-493 . . . . . . . . . . . . . . . . . . . 17.3.6 Displaying the license information of a piece of hardware 17-493 . . . . . . . . . . 17.3.7 Creating a control image (offline) 17-494 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3.8 Performing a license requirement alignment for a piece of hardware 17-495 17.3.9 Transferring license information for a control image (offline) to a control system (online) 17-497 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 840Di sl–specific Data and Functions 18-499 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 Interface signals 18-499 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1.1 840Di sl–specific interface signals 18-499 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1.2 Interface signals not supported 18-499 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2 Expanded message frame configuration/evaluation of internal drive variables 18-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.1 Description of the function 18-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.2 Requirements 18-503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.3 Configuring: SINAMICS S120 and SIEMENS message frame 116 18-504 . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 18.2.4 Configuring: SINAMICS S120 and expanded message frame configuration 18-504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.5 Configuring: SIMODRIVE 18-508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.6 Constraints 18-512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.7 Data descriptions (MD, system variable) 18-513 . . . . . . . . . . . . . . . . . . . . . . . . 18.2.8 Alarms 18-514 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3 Travel to fixed stop with high–resolution torque reduction 18-515 . . . . . . . . . . 18.3.1 Description of the function 18-515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.2 Comparison 18-516 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.3 Parameterization: SINAMICS S120 18-516 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.4 Parameterization: SIMODRIVE 18-516 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.5 Parameterization: External drives 18-517 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.6 Parameter assignment: SINUMERIK 840Di sl NCK 18-517 . . . . . . . . . . . . . . . 18.3.7 Constraints 18-518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.8 Data description (MD) 18-519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.9 Alarms 18-519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A Small SINAMICS Glossary A-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B Abbreviations B-525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C References C-531 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D EC Declaration of Conformity D-533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E Index I-535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 840Di sl Manual Contents

SINUMERIK 840Di sl Manual (HBIsl) -- 01/2007 Edition General Information on the SINUMERIK 840Di sl 1.1 Overview of SINUMERIK 840Di sl With the SINUMERIK 840Di sl, Siemens can provide a complete PC--integrated control that controls the drive units and I/Os through the standard fieldbus PROFIBUS DP with Motion Control functionality and therefore permits a distrib- uted design of the overall system. It therefore constitutes the basis for PC-- based automation solutions and is generally designed especially for applica- tions with the following requirements: S Distributed automation solutions in the fields of PLC I/Os and drives. S Fully PC--integrated control, owing to increased integratability in the target or current automation environment. Analog drives ADI4 Operator panel front (e.g. OP012) I/O modules PP72/48 SIMATIC DP ET 200 Handwheels Measuring pulses Fast I/Os PROFIBUS--DP (1) (12 MBaud) Networking(TCP/IP) (e.g., company network) PCU 50.3 MCI board extension (option) PROFIBUS--MCP (machine control panel) PROFIBUS DP diagnostic repeater MCI board PROFIBUS--DP (2) (12 MBaud) SINAMICS S120 Networking(TCP/IP) (e.g. MCP, TCU, programming device) USB (standard I/O) Fig. 1-1 System overview of SINUMERIK 840Di sl 1

1-22 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1.1.1 System components This manual refers to the following system components: System components Version SINUMERIK 840Di sl system software SW 1.4 SINUMERIK Industrial PC PCU 50.3–C: 1.5 GHz, 512 MB DRAM PCU 50.3–P: 2.0 GHz, 1024 MB DRAM PC operating system Windows XP ProEmbSys MCI board MCI2 board for 840Di sl Notice It is not possible to combine the named system components with older versions. 1.1.2 System software packages and quantity frameworks The following system software packages are available for SINUMERIK 840Di sl:
6 axes system software
20 axes system software The system software packages are each designed for the following quantities: 6 axes 20 axes Basic configuration Maximum Basic configuration Maximum Axes 3 6 5 20 Channels 1 2 1 10 Mode groups 1 2 1 10 Channels per mode group 1 2 1 10 Basic configuration: Default number of available components Maximum: Maximum possible number of components with additional options 1.1.3 Hardware components The hardware basis for the SINUMERIK 840Di sl is an industrial PC further referred to as PCU (PC–Unit) from Siemens A&D, in conjunction with the MCI board (Motion Control–Interface). The SINUMERIK 840Di sl is available with the following PCU 50.3 versions, each with 24 V power supply:
PCU 50.3–C: 1.5 GHz, 512 MB SDRAM
PCU 50.3–P: 2.0 GHz, 1024 MB SDRAM System software packages Quantity framework PCU 1 General Information on the SINUMERIK 840Di sl

1-23 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition The PCU 50.3 features interfaces to connect the SINUMERIK operator panel fronts (OP 0xx) as well as standard PC interfaces for connecting, e.g., monitor, keyboard, mouse, and Ethernet connection. The PCU 50.3 has the following slots: – 1 x PCI (length: max. 175 mm, occupied with option MCI board exten- sion and MCI board extension slot variant) – 1 x PCI (length: max. 265 mm, occupied by the MCI board) The MCI2 board, further referred to as the MCI board is a short PCI plug–in card with integrated SIMATIC S7 compatible CPU:
PLC317–2 DP as a routing–capable DP Master. The MCI board has the following external interfaces: – PROFIBUS DP with Motion Control Functionality (Master) – MPI (Multi–Point Interface)/PROFIBUS–DP (Master/Slave) – MCI board extension (option) This interface (X101) can be used to connect drives, distributed ext. I/Os, machine control panels, programming units, etc. via PROFIBUS DP with motion control capability (clocked and isochronous data exchange between the DP master and DP slaves) to the SINUMERIK 840Di sl. Both the PLC and the NC have direct access to this PROFIBUS interface. Unlike the PROFIBUS DP interface (X101), interface (X102) can only be ac- cessed via the PLC. As a result, no drives and no NC I/Os can be operated via this interface. The interface (X102) can also be operated as an MPI interface. A maximum of four fast digital I/Os, two sensing probes and two handwheels each can be connected using the optional MCI board extension slot variant. Either differential or TTL handwheels can be operated. The module is inserted into a slot in the PCU and is connected to the MCI board via a ribbon cable. SINUMERIK 840Di sl is available with the components from the new SINAMICS range of drives offering the following characteristics: – SINAMICS S120 The drive components from the SIMODRIVE range of drives offering the follow- ing characteristics can also be used: – SIMODRIVE 611 universal and universal E with option module MotionControl with PROFIBUS DP PCU interfaces PCU slot MCI2 board PROFIBUS DP interface X101 PROFIBUS DP X102 interface MCI board extension slot variation (option) Digital drives 1 General Information on the SINUMERIK 840Di sl

1-24 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition – SIMODRIVE POSMO CD/CA – SIMODRIVE POSMO SI distributed servo drive – SIMODRIVE POSMO A (not suitable for interpolatory procedures) Note SINAMICS S120 and SIMODRIVE drives cannot be operated in parallel on a SINUMERIK 840Di sl. To operate drives with an analog setpoint interface via PROFIBUS, the following interface module is available: – ADI4 (Analog Drives Interface for 4 Axes). For use as distributed I/Os, the module range SIMATIC DP ET 200 (for connec- tion conditions, see SIMATIC documentation) and the I/O module PP 72/48 are available. You can select one of the operator panel fronts from the SINUMERIK range (OP 010, OP 010C, OP 010S, OP 012, OP 012T, OP 015, OP 015A, TP 015A) as an operator component. A TCU (Thin Client Unit) permits distributed connection of an operator panel to the PCU. The TCU and PCU communicate via the Ethernet. 1.1.4 Software components The SINUMERIK 840Di sl is based on the following software components: SINUMERIK 840Di sl runs on the Windows XP ProEmbSys operating system with Service Pack 2. Windows XP is the platform on which all applications, such as the individual user interfaces of the HMI modular system and the commissioning tools run. As is generally known, Windows XP does not have full real–time capability. We call this soft real time. So SIEMENS has developed a procedure that allows operation of NC system software in hard real time without making it necessary to modify Windows XP (see Subsection 1.1.5, Page 1-26). The NC system software mostly has the same functionality as the SINUMERIK 840D. It comprises both simple Motion Control processes (positioning and linear interpolation) and complex automation tasks of the type found on machining centers, handling and mounting, machine tools, and machine tool–related applications. Analog drives I/Os Operator panel front TCU Windows XP NC system software 1 General Information on the SINUMERIK 840Di sl

1-25 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition The NCK (Numerik Control Kernel) is part of the NC system software that realizes the real–time capability of the SINUMERIK 840Di sl. The NCK is characterized by the following features: – The NCK is automatically started when Windows powers up. – The NCK runs cyclically in the background. – The current status of the NCK is displayed on the SINUMERIK 840Di sl standard user interface 840Di start–up: Menu command Window > Diagnostics > NC/PLC – The NCK is automatically ended when you exit Windows XP. – When the NCK is ended, it writes the remanent SRAM data from NCK and PLC to the hard disk of the PCU as a backup copy. The PLC system software, like the NC system software, largely has the same functionality as the SINUMERIK 840D. SinuCom NC is a Windows–based tool for commissioning the SINUMERIK 840Di sl NC offering the possibilities for the: – interactive parameterization of the NC – option management and license management – management of series startup files. The Windows–based user interface 840Di start–up (see Section 1.5, Page 1-38) offers basic operation functionality to allow the operator to become familiar with the SINUMERIK 840Di sl. 840Di start–up is part of the scope of supply of a SINUMERIK 840Di sl and is already installed on the hard disk of the PCU. The following components of the SINUMERIK HMI modular system can be used optionally:
SINUMERIK HMI Advanced HMI Advanced is the SINUMERIK standard user interface intended espe- cially for machine tools.
SIMATIC Protool/Pro and Protool/Pro option SINUMERIK SIMATIC Protool/Pro and Protool/Pro Option SINUMERIK are configuring packages for creating technology–specific user interfaces. The ProTool/Pro runtime system is required to run a configured user inter- face.
SINUMERIK HMI Programming Package The HMI Programming Package can be used to integrate OEM high–level language applications using standardized interfaces (COM/OPC). The OEM obtains as much flexibility as possible for developing user interfaces using standard development tools (such as Visual C++). NCK PLC system software SinuCom NC 840Di start–up Optional HMI components 1 General Information on the SINUMERIK 840Di sl

1-26 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition The HMI Programming Package basically contains interface descriptions and corresponding example applications. Detailed information on the OPC interface can be called from the Internet at the address of OPC Foundation (http://www.opcfoundation.org.). Note For a detailed list of the installed software components or the ones required to prepare for installation, please refer to Section 1.2, Page 1-33. 1.1.5 Real–time properties Windows XP is not an operating system designed for hard real–time require- ments. Hard real–time requirements mean the operating system will respond to an external event within a defined time frame of a few µseconds. The NC system software is therefore integrated into Windows XP as a ”Kernel mode driver”. This means it has its own integrated real–time system that runs concurrently with Windows XP to ensure the conditions for real–time processing are met. Real–time violations occur when unsuitable PC components block interrupt processing for too long, stopping the NC system software from being activated at the specified time. Inappropriate PC components are drivers or hardware extensions that have an adverse effect on the real–time behavior due to overly long interrupt disable times or PCI bus disables in PCI bus mastering. With real–time violations exceeding 200 µs, we cannot guarantee that the NC system software will operate correctly. The system will respond appropriately for the magnitude of the real–time violation: – Display of an error message – Alarm with axis stop from the NC – Alarm and drive–independent axis stop. The real–time response can be monitored in the NCK latency displays in the system diagnostics of the 840Di Start–up (see Subsection 1.5, Page 1-38) or the NC/PLC diagnostics of HMI Advanced (see Subsection 11.11, Page 11-406). The following points must be taken into account for screen resolution and depth of color settings on the PCU.
Screen resolution The standard screen resolution setting depends on the optimized value that was set for the operator panel. This value was defined for technical reasons and should be adhered to. Real–time violations Screen resolution and depth of color 1 General Information on the SINUMERIK 840Di sl

1-27 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition
Color depth The default color depth setting is 65536 colors. Higher values can, in certain circumstances, increase the CPU time used by Windows XP and occasion- ally also by the real–time operating system. If it is necessary to test the screen resolution or switch to a different resolution and/or color depth, the NCK must be terminated first. Otherwise a malfunction may occur in the real–time response. Notice Screen savers that modify the screen resolution when activated must not be used in conjunction with SINUMERIK 840Di sl. The NCK is integrated in Windows XP as a ”SINUMERIK–NC” service. This service must be started and stopped manually in the service dialog box. Windows Start menu: Start > Programs > Administrative Tools > Services > ”SINUMERIK–NC” ! Warning The NCK must be stopped before testing/switching the screen resolution and/or color depth on the PCU and started again explicitly after testing/switching using the Windows XP service ”SINUMERIK–NC”. Otherwise a malfunction may occur in the real–time response. 1.1.6 System integrity To offer high quality and wide functionality of the entire system, SINUMERIK 840Di sl comes completely configured and ready to operate. For this purpose, the system components used are subject to a certification procedure with Siemens as the system manufacturer. This is to certify and document compliance with real–time capability of the whole configuration. If PC components (hardware or software) are modified or expanded by a third party, compliance with product features cannot be guaranteed. These are the sole responsibility of the OEMs or the user who has made the modifications. The effect of the changes to the system software can be read on the user inter- face of the ”840Di Startup” or ”HMI Advanced” commissioning tool (see Section 11.11.1, Page 11-406). It graphically displays whether the installed hardware or software violates the real–time conditions. Testing or switching over Terminating the NCK 1 General Information on the SINUMERIK 840Di sl

1-28 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1.1.7 Failure safety If Windows XP detects a fatal exception error during the operation of the NC system software, the following steps are taken:
Windows XP stops.
An error message appears on screen.
NC and PLC continues to operate normally.
The NC signals the fatal exception error detected to the PLC via the ”PC OS fault” interface signal. Depending on the current machining situation, the PLC user program can either continue or step machining. After completion of machining, the PLC user program can request a shutdown of the PC by sending the ”PC shutdown” interface signal. The ”PC shutdown” interface signal causes the following actions: – Retentive NC and PLC data are stored – NC and PLC are closed down – The Windows XP ”Blue Screen” is displayed – (Optional) The PCU reboots The behavior of Windows XP in the event of a fatal exception error (Blue Screen) can be configured via the Control Panel: Windows Start menu: Start > Settings > Control Panel > System Note For a brief description of the ”PC OS fault” and ”PC shutdown” interface signals, please refer to Subsection 18.1.1, Page 18-499. Notice The ”PC shutdown” interface signal must be reset in the organization block OB100 (cold restart) of the PLC. A power failure lasting more than 5 ms is detected by the POWER FAIL func- tionality of the SINUMERIK 840Di sl as a fault scenario and the following ac- tions are initiated: – The background lighting of the operator panel display is switched off – NC and PLC are closed down properly – The NC and PLC user data are saved in the SRAM of the MCI board. The battery–backed user data are available again immediately the next time the SINUMERIK 840Di sl is booted. The SINUMERIK 840Di sl is therefore ready to use again immediately, without data loss. If the power supply recovers before final PCU shutdown, the following message box is displayed: Fatal exception error (blue screen) Power failure 1 General Information on the SINUMERIK 840Di sl

1-29 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Interrupt: Power–Fail detected, NCK/PLC restart with OK. SINUMERIK 840Di sl NCK/PLC Notice 1. Supply voltage A supply voltage of the PCU of at least 24 V is required to ensure consistency of the NC and PLC user data. References /BH/ Operator Components, Manual Chapter: PCU 50.3 2. UPS system The internal power backup time after a power failure is not long enough for Windows NT to shut down correctly. To remedy this, we recommend using an uninterruptible power system (see Subsection 1.1.9, Page 1-31). 3. Replacing the MCI board or PCU battery When Windows XP is shut down correctly, the current NCK and PLC user data are saved to the SRAM of the MCI board and to the PCU’s hard disk. If the MCI board or PCU battery is replaced after a power failure, this will result in a data loss of the battery–backed user data on the SRAM of the MCI board. How to proceed further: see Subsection 5.3.3, Page 5-112. The SINUMERIK 840Di sl monitors three different temperatures for their respec- tive thresholds: 1. Housing temperature 2. CPU module temperature 3. CPU temperature Error response
Interrupt: ”2110 NCK temperature alarm”
Logbook entry: ”Alarm: Critical temperature” Cause of errors/error handling One of the 3 monitored temperatures has reached or exceeded its threshold value. A temperature change of at least 3°C below the threshold is required for the alarm to reset. If the temperature alarm occurs, the user and/or the machine manufacturer (PLC user program) must decide whether to interrupt machining and end and shut down the SINUMERIK 840Di sl. Temperature monitor 1 General Information on the SINUMERIK 840Di sl

1-30 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1.1.8 Deactivation To ensure safe operation of the SINUMERIK 840Di sl, Windows XP must be shut down correctly before the PCU is switched off. Note Windows XP is shut down correctly as follows. – Windows XP start bar: Start > Shutdown – PLC interface signal: ”PC shutdown”, see Subsection 18.1.1, Page 18-499 Failure to shut down Windows XP correctly can damage the Windows XP instal- lation and prevent the SINUMERIK 840Di sl from operating. On correct shutdown of Windows XP the following occurs: – The SINUMERIK 840Di sl components NC and PLC are terminated correctly – The NC and PLC user data in the SRAM of the MCI board and on the hard disk of the PCU are backed up. If the PCU is switched off without first correctly shutting down Windows XP, the SINUMERIK 840Di sl’s POWER FAIL functionality: – ends the NC and PLC correctly; – saves the NC and PLC user data in the SRAM of the MCI board. The NC and PLC user data cannot be backed up on the hard disk of the PCU. Notice If you switch off the PCU without first having correctly shut down Windows XP, please observe the following: 1. Supply voltage A supply voltage of the PCU of at least 24 V is required to ensure consistency of the NC and PLC user data. References /BH/ Operator Components, Manual Chapter: PCU 50.3 2. UPS system The internal power backup time after switch–off is not long enough for Windows NT to shut down correctly. To remedy this, we recommend using an uninterruptible power system (see Subsection 1.1.9, Page 1-31). 3. Replacing the MCI board or PCU battery When Windows XP is shut down correctly, the current NCK and PLC user data are saved to the SRAM of the MCI board and to the PCU’s hard disk. If the MCI board or the PCU battery is replaced after the abnormal shutdown of Windows XP, this will result in loss of the battery–backed user data on the SRAM of the MCI board. How to proceed further: see Subsection 5.3.3, Page 5-112. Windows XP NC and PLC 1 General Information on the SINUMERIK 840Di sl

1-31 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1.1.9 UPS system The PCU features POWER FAIL detection that, in conjunction with the NC system software, ensures that the user data are backed up in the SRAM of the MCI board on a PCU power failure or power–off without Windows XP first having been shut down correctly. The internal power backup time is not long enough for Windows XP to shut down correctly. This can be avoided by using a UPS, e.g. SITOP POWER DC UPS MODULE 15 (see Section 2.10, Page 2-76). The UPS also backs up the power supply of the PCU for a settable duration or until a set battery voltage limit has been reached. This gives the user time to correctly shut down Windows XP manually, or per- mits automatic shutdown via a status signal from the UPS to the PLC, which then passes the ”PC shutdown” interface signal to the NC. The above UPS has the following connection options to signal the current sta- tus to the SINUMERIK 840Di sl: Table 1-1 Connection options of the UPS system Terminal Signal to Comment 1) UPS –> PCU: USB connection Windows XP The UPS functionality is configured: see Con- figuration below. Advantage: also works when the PLC user pro- gram is not active. Disadvantage: does not work in the event of serious exceptions from Windows XP (BlueScreen) 2) Signal terminals via free interconnection –> S7 I/O inputs PLC The UPS functionality is configured using the PLC user program. Advantage: also works in the event of a fatal exception error of Windows XP (BlueScreen) Disadvantage: PLC user program must be active 3) Signal terminals via free interconnection –> MCI board extension inputs NC The UPS functionality is configured using menu: Settings in HMI Advanced (see Subsec- tion 11.11.2, Page 11-410). Advantage: also works in the event of a fatal exception error of Windows XP (BlueScreen) and when the PLC user program is not active. Requirement: MCI board extension (option) Note re 3) For information on the boot response of the SINUMERIK 840Di sl with pending shutdown signal, see Subsection 5.3.8, Page 5-116. Notice One of the following connection variants must be used for full back–up protection: – Variant 1: Connection 1) and 2) – Variant 2: Connection 3) Physical SRAM Connection options 1 General Information on the SINUMERIK 840Di sl

1-32 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition SITOP POWER DC UPS module15 with SITOP POWER ACCU MODULE SIEMENS SITOP POWER standard 24V/10A SINUMERIK 840Di sl PROFIBUS DP ET 200 I/Os 2) Free wiring 1) USB connection Line infeed 110/220VAC, 60/50Hz 3) Free wiring 1) MCI board 2) MCI board extension (option) 1) 2) Fig. 1-2 Possible connections: UPS The UPS functionality can be configured in two ways:
When using SITOP POWER DC UPS MODULE 15 (see Subsection 2.10, Page 2-76) with a special software tool. Download: http://www.siemens.de/sitop > Further topics: Download Software DC UPS 15 A
With Windows XP standard tools. Start bar: Start > Settings > Control Panel > Power Options > tab card: UPS Notice If the SINUMERIK user interface HMI Advanced (option) is installed on the PCU, the following application must be executed with the UPS software: F:\mmc2\hmiexit.exe to end HMI Advanced before the PCU is shut down. Configuration 1 General Information on the SINUMERIK 840Di sl

1-33 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1.2 Overview of software components The software components listed below are part of the SINUMERIK 840Di sl system software. The first time the PCU is booted, all the software components required to operate the SINUMERIK 840Di sl are automatically installed. Other software components including engineering tools or SIMATIC S7 add–on soft- ware are also available for installation on the PCU or an external computer. Note See Section 5.4.7, Page 5-121 for information on how to determine the installation path of the SINUMERIK 840Di sl system software (CD path). Before installing a software component, please read the information (*.txt, *.rtf, *.wri) for each application. The basic software essentially comprises the following components:
840Di sl basic software (installed) – NCK–specific real–time drivers – 840Di start–up
PLC system software (installed)
NCK system software (installed)
PCU basic software (installed) – Windows XP Pro with SP2, English version – Internet Explorer 6, English version – HMI Explorer – MPI driver – Norton Ghost – Norton GhostWalker – ServiceCenter under Windows PE – PCU–specific drivers – TCU Support
HMI basic software (installed) – HMI–specific display and communications drivers The Engineering Tools include applications for the commissioning of the SINUMERIK 840Di sl NC and SIMODRIVE drives:
SinuCom NC (installed) Commissioning tool for SINUMERIK 840Di sl NC
SIMODRIVE 611 universal tool box Contents: – PLC Parameterization Toolbox Various files for assigning parameters to an S7 configuration with SIMODRIVE drives (611U, POSMO SI, CD, CA) and PROFIdrive communication (see readme.txt) (example files: \611utb\toolbox\\) Basic software Engineering Tools 1 General Information on the SINUMERIK 840Di sl

1-34 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition – SimoCom U Commissioning tool for SIMODRIVE 611 universal/E and SIMODRIVE POSMO SI, CD/CA drives (installed and for installation: \611utb\SimoComU\Setup.exe) – SIMODRIVE 611 universal drive firmware (firmware file: \611utb\Sys611U\\611u.ufw) – SIMODRIVE 611 universal option module: ”Motion Control with PROFIBUS DP” firmware (firmware file: \611utb\dpc31\\v1sl.ufw) – SIMODRIVE POSMO SI, CD/CA drive firmware (firmware file: \611utb\SysPosmo\\posmo.ufw) Note SINAMICS drives The commissioning tool: STARTER is not included in the SINUMERIK 840Di scope of supply. The STARTER must be purchased separately. References: Catalog: NC 61 > SINAMICS S120 Drive System The SIMATIC S7 add–on software contains sample programs and applications:
PLC Toolbox The PLC Toolbox contains the following components: – PLC basic program – SINUMERIK Add–On for STEP 7 e.g. SlaveOM for SINUMERIK 840Di sl, GSD file for PROFIBUS MCP – NC variable selector – PLC Symbol generator (installation software: \installs\add_on\plc_tb\setup.exe)
GSD file for I/O modules PP72/48 Device master file with the required information in ASCII format required for integration of the I/O module PP72/48 into a SIMATIC project as DP slave. (DMF file: \support\siem80a2.gsd)
PLC application example Sample application of a SIMATIC S7 project for SINUMERIK 840Di sl with PROFIBUS machine control panel MCP 483 or MCP 310. (ZIP file: \support\840dismp\840disl_smpl.zip) (archive file: \support\840dismp\840disl_smpl.arc) Note The PLC Toolbox should be installed on the PG/PC on which the SIMATIC STEP 7 is already installed. SIMATIC S7 add–on software 1 General Information on the SINUMERIK 840Di sl

1-35 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1.3 Notes on commissioning This SINUMERIK 840Di sl Manual describes the basic commissioning of the following components:
SINUMERIK 840Di sl NC and PLC
SINAMICS S120 drives
Ethernet communication
PROFIBUS DP and DP components Notice We recommend performing commissioning of the SINUMERIK 840Di sl according to the sequence in which the chapters of this manual are laid out. To commissioning the SINUMERIK 840Di sl, the following software is required (part of a SINUMERIK 840Di sl):
NCK commissioning: – 840Di start–up – SinuCom NC
PLC commissioning, including MPI and PROFIBUS communication: – SlaveOM for SIMODRIVE drives – PLC basic program
SIMODRIVE drive commissioning – SimoCom U To commissioning the SINUMERIK 840Di sl, the following software is needed (not part of a SINUMERIK 840Di sl):
PLC commissioning, including MPI and PROFIBUS DP communication: – SIMATIC Manager STEP 7: as from Version 5.3, Service Pack 2 – SlaveOM for SINAMICS drives (part of STARTER)
SINAMICS drive commissioning – STARTER The following hardware components are required for commissioning:
a programming device with MPI/PROFIBUS interface, e.g., PG740: – Creation of the SIMATIC S7 project for commissioning of the PLC, as well as the MPI and PROFIBUS communication Software Additional software Additional hardware 1 General Information on the SINUMERIK 840Di sl

1-36 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition – Installation of additional software on the PCU To install software on the PCU see Chapter 17, Page 17-477.
Communications link: PG/PC with NC, PLC and drives – Ethernet cable – MPI/PROFIBUS cable Note No programming device is required in the following cases: – SIMATIC Manager STEP7 is installed on the SINUMERIK 840Di sl PCU – A PG/PC is used to install additional software To install software on the PCU, see Section 17, Page 16-467. The following documentation is required for commissioning:
/BH/ Operator Components Manual – Operator panel fronts – PCU 50.3 – Machine control panels – Operator panel, handheld terminal HT8 Depending on the NC and PLC functions used, the relevant Descriptions of Functions:
/FB/ Description of Functions – Basic Functions
/FB/ Description of Functions – Extended Functions
/FB/ Description of Functions – Special Functions
/LIS/ Lists – Overview of the functions – Machine, Setting Data and Variables – Interface Signals and PLC Blocks.
/DA/ Diagnostics Guide, Contents: – Alarms Drive commissioning:
SINAMICS – SINAMICS S120 Commissioning Manual
SIMODRIVE – /FBU/SIMODRIVE 611 universal and universal E Closed–Loop Control Components for Speed Control and Positioning – /POS3/SIMODRIVE SI and CD/CA Distributed Servo Drive Systems Documentation 1 General Information on the SINUMERIK 840Di sl

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1.4 Standard/export version Because certain control functions require an export license in accordance with the German Export List, the SINUMERIK 840Di sl is available in two versions. The standard version SINUMERIK 840Di sl can contain the full scope of func- tions of the control but this does mean that it requires export approval with re- gard to its type. In the export version SINUMERIK 840DiE sl, e.g. the following options are not available:
Interpolation with more than 4 axes
Machining package 5 axes
Helical interpolation 2D + n (n greater than 2)
OEM package The following restrictions apply to options that can be used:
Sag compensation: limited to traversing a maximum distance of 10 mm. Note A complete overview of options not available on the export version are listed in: Catalog NC 61 The corresponding option bits can be set but they have no effect (alarm output if functions programmed). The export version requires no export license with re- spect to its type. (This does not mean that there is not export license requirement with respect to the intended use. This is a separate matter and may apply in addition.) The characteristics of the control are defined by the system software which is available in two versions (standard and export). This means that the export li- cense requirement of the system software (for details see delivery note or in- voice) is passed on to the control system on which it is installed. It is important to be aware of this in the case of updates/upgrades of the system software because this might affect the export license requirement. In addition to the information provided on the delivery note and invoice, the hardware components supplied with the system software are also clearly identi- fied by adhesive labels as standard or export versions. Note The adhesive labels supplied additionally in the packaging are intended to identify the control after commissioning and must be pasted into the control log book. In the case of license orders, a corresponding number of labels is provided, which must also be pasted into the log book. Export license requirement Identification of the control 1 General Information on the SINUMERIK 840Di sl

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition When the control has booted, the export version can be identified by the addi- tional character ’E’ on the Service screen of the NCU version.
HMI Advanced (option): Diagnosis operating area > Service displays > Version > Version NCU Identification of control variants in this way is important for service personnel and can also be helpful as evidence on export, especially when using the em- bargo–exempt certificates provided for the export version. 1.5 840Di start–up The user interface 840Di start–up included in the scope of supply of the SINUMERIK 840Di sl is intended as an initial introduction to SINUMERIK 840Di sl functionality. The user interface comprises the following functions:
Display of main screens
Display of alarms and messages
Management of part programs
ASCII editor
NC, PLC, and PROFIBUS diagnoses
Logbook The menu bar comprises the following menu commands:
File
Edit
Window
Display The functions that can be called using the menu commands File and Edit are context–sensitive, i.e. only those functions are offered that are possible in the context of the currently active window. Example:
The part program management window is selected. The menu command Edit provides the following functions: – Copy – Paste – Paste ... – Load – Unload
The window for display of the axis actual values is selected. The menu com- mand Edit provides no further functions. Overview of the functions Menu bar Context–sensitive menu functions 1 General Information on the SINUMERIK 840Di sl

SINUMERIK 840Di sl Manual (HBIsl) -- 01/2007 Edition 1.5.1 Menu command: Window The menu command Window provides the following functions: Menu command Functionality Window Main screen General data Display of: -- Channel status -- Program status Axis actual values Display of: -- Axis names -- Axis positions in the selected coordinate system -- Distance--to--go -- Feedrate -- Override Switchover of the position display between: -- MCS -- WCS Current block display Display of: -- Part programs and up to 3 blocks Program control Selection of: -- Machine function SBL1 -- SBL2 after each block -- PRogram Test G functions/H functions Display of: -- Current G functions -- Current H functions Program pointer Display of: -- Program name of the selected part pro- gram -- Number of passes P -- Block number -- Program levels: Main program and 3 subroutine levels Alarm Display of current alarms and messages Alarm log Display of all alarms and messages in chro- nological order 1 General Information on the SINUMERIK 840Di sl

SINUMERIK 840Di sl Manual (HBIsl) -- 01/2007 Edition Menu command Functionality Part programs S Management of part programs Menu command File -- New ... -- Open -- Delete -- Exit Menu command Edit -- Copy -- Paste -- Load -- Unload -- Select S Editing part programs: -- Menu command File > Open -- Double--click the file with the left mouse button Editor Editing files Start the editor with: -- Menu command File > Open -- Double--click the file with the left mouse button Menu command File -- Open -- Close -- Cut -- Exit Menu command Edit -- Copy -- Paste -- Load -- Unload -- Select Diagnostics PROFIBUS Bus Display of bus configuration: -- Baud rate -- Cycle time -- Synchr. portion (TDX) Display of status: -- Configuration -- Bus status Slaves Display of: -- Slave no. (DP address) -- Assignment -- Active on the bus -- Synchr. with NC -- Number of slots -- Details 1 General Information on the SINUMERIK 840Di sl

SINUMERIK 840Di sl Manual (HBIsl) -- 01/2007 Edition Menu command Functionality NC/PLC S NC -- Display of NC status -- ”NC Reset” -- ”Clear NC memory” S PLC -- Display of PLC status -- ”RUN--P” -- ”RUN” -- ”STOP” -- ”MRES” S Latency display -- Current value -- Maximum value -- Number of violations -- Oscilloscope Logbook Display of SINUMERIK 840Di sl system messages J 1 General Information on the SINUMERIK 840Di sl

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 1 General Information on the SINUMERIK 840Di sl Space for your notes

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Hardware Descriptions 2.1 Overview of hardware components A SINUMERIK 840Di sl can only be ordered as a complete system (PCU and MCI board).
SINUMERIK 840Di sl PCU 50.3–C 1.5 GHz/512 MB and MCI2 board, 40 GB hard disk and Windows XP ProEmbSys 24 V power supply Order number: 6FC5 220–0AA31–2AA0
SINUMERIK 840Di sl PCU 50.3–P 2.0 GHz/1024 MB and MCI2 board, 40 GB hard disk and Windows XP ProEmbSys 24 V power supply Order number: 6FC5 220–0AA33–2AA0 The following hardware components are available as spare parts:
MCI2 board for SINUMERIK 840Di sl Spare parts order number: 6FC5 222–0AA02–2AA0
Hard disk for PCU 50.3 with mounting plate and damping elements Spare parts order number: 6FC5 247–0AF08–4AA0 The following hardware components are optional and can be ordered separately:
SINUMERIK 840Di sl MCI board extension slot variant Order number: 6FC5 222–0AA00–0AA1
SINUMERIK operator panel fronts – OP 010 Order number: 6FC5 203–0AF00–0AA1 – OP 010C Order number: 6FC5 203–0AF01–0AA0 – OP 010S Order number: 6FC5 203–0AF04–0AA0 – OP 012 Order number: 6FC5 203–0AF02–0AA1 – OP 012T Order number: 6FC5203–0AF06–1AA0 – TP 012 Order number: 6FC5203–0AF07–0AA0 SINUMERIK 840Di sl: Hardware Spare parts Optional components MCI board extension Operation and display 2

2-44 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) -- 01/2007 Edition -- OP 015 Order number: 6FC5 203--0AF03--0AA0 -- TP 015A Order number: 6FC5203--0AF08--0AA0 S Components for distributed connection of SINUMERIK operator panel fronts -- TCU (Thin Client Unit) Order number: 6FC5 312--0DA00--0AA0 S USB disk drive 3.5’’ incl.1m connecting cable Order number: 6FC5 235--0AA05--1AA2 S SITOP POWER standard 24V/10A Order number: 6EP1 334--1SH01 S SITOP POWER DC UPS module 15 Order number: 6EP1 931--2EC31 S SITOP POWER ACCU MODULE 24VDC/10A/3.2AH Order number: 6EP1 935--6MD11 S7 I/O modules S SIMATIC ET 200 (distributed I/O system) for detailed order information see: References: /ST7/ SIMATIC S7 programmable logic controllers Catalog ST 70 S I/O module PP72/48 Order number: 6FC5 611--0CA01--0AA0 Interface modules S ADI4 (Analog Drive Interface for 4 Axes) Order number: 6FC5 211--0BA01--0AA2 S SINAMICS S120 For detailed order information on the SINAMICS S120, please refer to: References: /BU/ SINAMICS SINAMICS S120 Servo Control Drive System Catalog D21.2 S SIMODRIVE 611 universal with optional module MotionControl with PROFIBUS DP S SIMODRIVE 611 universal E with option module MotionControl with PROFIBUS DP S SIMODRIVE POSMO CD/CA External storage media Power supply of the PCU Uninterruptible power supply (UPS) PROFIBUS DP modules SINAMICS drives Drives: SIMODRIVE 2 Hardware Descriptions

2-45 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition
SIMODRIVE POSMO SI distributed servo drive
SIMODRIVE POSMO A For detailed ordering information on various drives, see: References: /BU/ SINUMERIK & SIMODRIVE Ordering Information Catalog NC 60 2 Hardware Descriptions

2-46 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.2 MCI2 board for 840Di sl 2.2.1 Module The MC12 board for 840Di sl is a short 32–bit PCI plug&play card. The MCI2 board referred to below simply as MCI board (Motion Control Interface) provides the following interfaces:
PROFIBUS DP with Motion Control Functionality (X101)
MPI (Multi–Point Interface) or PROFIBUS DP without Motion Control Functionality (X102) (alternative)
MCI board extension (slot variation: Section 2.3, Page 2-53) The MCI board also provides the following functionality:
PLC: Compatible with SIMATIC S7 CPU 317–2 DP
Static memory (SRAM) for storing retentive NCK and PLC–specific user data. X101: PROFIBUS DP X102: MPI/DP X2: MCI board extension X3: Backup battery X11: PCI bus *) locking screws Internal thread: UNC 4–40 *) *) *) *) Backup battery connecting cable Fig. 2-1 Module: MCI2 board for 840Di sl Designation Order No. (MLFB) MCI2 board for 840Di sl (as spare part) 6FC5 222–0AA02–2AA0 Order number: MCI2 board 2 Hardware Descriptions

2-47 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Designation Order No. (MLFB) Bus connector RS–485 for PROFIBUS DP and MPI 180° cable outlet 6GK1 500–0EA02 35° cable outlet, without PG connection socket 6ES7 972–0BA40–0XA0 35° cable outlet, with PG connection socket 6ES7 972–0BB40–0XA0 90° cable outlet, without PG connection socket 6ES7 972–0BA11–0XA0 90° cable outlet, with PG connection socket 6ES7 972–0BB11–0XA0 2.2.2 Interface description Interfaces of the MCI board module Table 2-1 Interface overview: MCI board Interface Designation Type PROFIBUS DP X101 Socket MPI/DP X102 Socket MCI board extension X2 Plug connector Buffer voltage X3 Plug connector PCI bus X11 Direct connector LED 1 DP1 LEDs LED 2 DP2 LEDs Interface description PROFIBUS DP interface (X101):
Connection: 9–pin SUB–D socket connector
Pin assignment Table 2-2 Pin assignment: PROFIBUS DP interface (X101) Pin Designation Type1) Function 1 Not assigned – – 2 Not assigned – – 3 RS–DP B RS 485 differential signals 4 RTS O Request to Send 5 GNDext VO External ground 2) 6 P5ext VO Ext. 5V power supply 2) 7 Not assigned – – 8 XRS DP B RS 485 differential signals 9 Not assigned – – 1) VO Voltage Output O Output B Bidirectional 2) Pin 5 and 6 can only be used to supply the bus termination resistances
Connecting cable: See Section 3.3.2, Page 3-103 Interface description MPI/DP interface (X102):
Connection: 9–pin SUB–D socket connector
Pin assignment Order no.: Bus connector Interface overview PROFIBUS DP interface (X101) MPI/DP interface (X102) 2 Hardware Descriptions

2-48 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Table 2-3 Pin assignment: MPI interface (X102) Pin Designation Type1) Function 1 Not assigned – – 2 Not assigned – – 3 RS–MPI/DP B RS 485 differential signals 4 RTS O Request to Send 5 GNDext VO External ground 2) 6 P5ext VO Ext. 5V power supply 2) 7 Not assigned – – 8 XRS–MPI/DP B RS 485 differential signals 9 Not assigned – – 1) VO Voltage Output O Output B Bidirectional 2) Pin 5 and 6 can only be used to supply the bus termination resistances
Connecting cable: See Section 3.3.2, Page 3-103 Notice The PROFIBUS DP (X101) and MPI/DP bus (X102) interfaces are isolated both from one another and from the PCU. Interface description of the backup voltage connection (X3):
Connection: 2–pin plug connector
Pin assignment Table 2-4 Pin assignment: Backup voltage connection (X3) Pin Designation Type1) Function 1 BATT– VI Backup voltage minus 2 BATT+ VI Backup voltage plus 1) VI Voltage input The diagnostics LEDs ”DP 1” und ”DP 2” are only used to display the internal status of the MCI board. A diagnosis with regard to the PROFIBUS DP commu- nication of the interfaces is not possible via the LEDs. Backup voltage connection (X3) Diagnostic LEDs (DP1/DP2) 2 Hardware Descriptions

2-49 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.2.3 Module replacement If the MCI board is to be inserted as a replacement (either only the MCI board or together with the PCU), you will need a new license key. Consult the central hotline. You will need the: – HW series number of the old MCI board – HW series number of the new MCI board The HW series number of the MCI board is to be found on the rating plate of the module (see Fig. 2-2). HW series number Fig. 2-2 MCI2 board: HW series number For instructions on how to enter the license key, see Subsection 5.7, Page 5-127. Note If the MCI board is to be inserted as a replacement (either only the MCI board or together with the PCU), you will need a new license key. ! Warning Operating electrical equipment has parts and components that are at hazardous voltage levels. Failure to properly maintain the equipment can result in death, serious bodily injury or substantial material damage. When servicing these devices, you should therefore observe all notices provided in this section and attached to the product itself. – This device may only be serviced by appropriately qualified personnel. – Before starting any maintenance and service work, disconnect the device from power supply. – Use authorized spare parts only. – Strictly observe the prescribed maintenance intervals, as well as the instructions for repair and replacement. License key 2 Hardware Descriptions

2-50 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Notice The module contains electrostatically sensitive devices. Electrostatically discharge your own body before touching the module. The simplest way of doing this is to touch an electrically conductive grounded object (e.g. a bare metal part of a cabinet or a power receptacle ground conductor). To change the module, proceed as follows: 1. Check that there is a suitable series startup file (NCK and PLC) available before removing the module. For information on how to create a series startup file, please refer to Chapter 15, Page 15-459. 2. Shut down the SINUMERIK 840Di sl and Windows XP correctly. Use one of the following methods to do this:
Windows XP taskbar: Start > Shut Down
Interface signal: ”PC shutdown”, see Section 18.1.1, Page 18-499 3. Disconnect your PC from power supply. 4. Remove the screws from the cover of the housing (Fig. 2-3) and open the housing of your PC, observing the relevant safety regulations. Screws of the cover of the housing Fig. 2-3 Cover of the housing of the PCU 50.3 5. Optional: Remove interconnecting cable to the MCI board extension module, interface X2. 6. Remove the fastening screw (Fig. 2-4) and remove the module holding– down device. Execution 2 Hardware Descriptions

2-51 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Board retainer Fixing screw Plastic support Fig. 2-4 Mounting of the module 7. Remove the cable connection X3 (backup battery) from the module. X3 backup battery Fig. 2-5 Backup battery connector 8. Loosen the fastening screw on the cover plate of the module and remove the module while observing ESD measures. 9. Insert the new module into the appropriate slot on the mother board and fasten it using the fastening screw on the cover plate. 10. Insert the cable connection X3 (backup battery) into the module. 11. Mount the board retainer. 12. Optional: Insert the connecting cable to the MCI board extension module, interface X2. 13. Close the housing of your PC and fasten the screws from the cover of the housing (Fig. 2-3). 14. Connect your PC to power supply again and start it. 2 Hardware Descriptions

2-52 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.2.4 Technical data Safety Degree of protection IP 00 Safety class I, acc. to VDE 0106 P1: 1982 (IEC 536) Safety regulations EN61131–1 Approvals CE, UL, CSA Power consumption 5 V Typically 3.75 W Maximum 5 W Mechanical data Dimensions PCI card, short Weight 140 g Ambient environmental conditions Heat dissipation Open circuit ventilation Temperature limits Operation Storage/transport – MCI board alone – –40 ... 70 °C – MCI board in PCU 50.3 5 ... 55 °C –20 ... 60 °C Tested to DIN IEC 68–2–1, DIN IEC 68–2–2 (DIN EN 60068–2–2), DIN IEC 68–2–14 Limits for relative humidity 5 ... .80 % 5 ... .95 % Tested to DIN IEC 68–2–30 Per minute Per hour Temperature change Max. 1 K Max. 10 K Condensation Not permissible Quality assurance to ISO 9001 Vibrational load during operation Category 3M4 Frequency range 10 ... 58 Hz/58... 200 Hz Const. excursion/acceleration 0.075 mm/1 g Tested to – module in PCU 50.3 DIN EN 60068–2–6 Shock load during operation Acceleration 50 m/s2 Duration of nominal shock 30 ms Tested to – module in PCU 50.3 DIN EN 60068–2–6 Notice The specified safety regulations, certifications, degree of protection and safety class only apply if the module is plugged into a SINUMERIK PCU 50.3. 2 Hardware Descriptions

2-53 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.3 MCI board extension slot variant 2.3.1 Module The MCI board extension slot variant provides the following functions as an optional expansion board of the MCI board: – 4 binary inputs (isolated) – 4 binary outputs (isolated) – 2 measuring inputs (isolated) – 2 handwheels (non–isolated). Either differential or TTL handwheels (switch S1) can be operated on the module. X4: MCI board extension X121: Cable distributor PCI bus (mechanical) *) locking screws Internal thread: UNC 4–40 Switch S1 *) *) Fig. 2-6 MCI board extension slot variation Designation Order No. (MLFB) MCI board extension slot variation (option) 6FC5 222–0AA00–0AA1 Caution Connection or disconnection of the cable distributor to or from interface X121 on the module is only allowed when the equipment is de–energized. Before you plug in or remove the cable connector, switch off the PCU (shut down Windows XP correctly!). Otherwise, short circuits might occur on the module. This could destroy the module. Order number: 2 Hardware Descriptions

2-54 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition With switch S1 you can select the type of handwheel that is to be operated on the module: – Differential handwheels: Switch S1 closed (on delivery) – TTL handwheels: switch S1 open Differential or TTL handwheels can only be operated alternately. Switch S1: Switch position open Fig. 2-7 Switch S1 switch position open (TTL handwheels) Notice You select between differential and TTL handwheels on the module using switch S1 before installing the module. Switch S1 2 Hardware Descriptions

2-55 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.3.2 Installation instructions The connecting cable with the MCI board is part of the scope of supply and is already plugged into the MCI board extension slot variation. To install the module, proceed in the sequence described below. ! Warning Operating electrical equipment has parts and components that are at hazardous voltage levels. Failure to properly maintain the equipment can result in death, serious bodily injury or substantial material damage. When servicing these devices, you should therefore observe all notices provided in this section and attached to the product itself. – This device may only be serviced by appropriately qualified personnel. – Before starting any maintenance and service work, disconnect the device from power supply. – Use authorized spare parts only. – Strictly observe the prescribed maintenance intervals, as well as the instructions for repair and replacement. Notice The module contains electrostatically sensitive devices. Electrostatically discharge your own body before touching the module. The simplest way of doing this is to touch an electrically conductive grounded object (e.g. a bare metal part of a cabinet or a power receptacle ground conductor). 1. Shut down the SINUMERIK 840Di sl and Windows XP correctly. Use one of the following methods to do this:
Windows XP taskbar: Start > Shut Down
Interface signal: ”PC shutdown”, see Section 18.1.1, Page 18-499 2. Disconnect your PC from power supply. 3. Remove the screws from the cover of the housing (Fig. 2-8) and open the housing of your PC, observing the relevant safety regulations. Installing the module 2 Hardware Descriptions

2-56 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Screws of the cover of the housing Fig. 2-8 Cover of the housing of the PCU 50.3 4. Remove the fastening screw of the module holding–down device (Fig. 2-9) of the MCI board and remove the module holding–down device. Board retainer Fixing screw Plastic support Fig. 2-9 Mounting of the module 5. Remove the blanking plate of the free PCI slot. 6. Insert the module carefully but firmly into the PCI slot and tighten the con- nector plate of the module. 7. Plug the connector of the connecting cable into the MCI board. Make sure that the latches of the connectors have securely engaged on both modules: – MCI board: Interface X2 – MCI board extension: Interface X4 8. Mount the module holding–down device again. 9. Close the housing and fix it again with the two housing screws. 2 Hardware Descriptions

2-57 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.3.3 Interface description Interfaces of the MCI board extension slot variant Table 2-5 Interfaces of the MCI board extension slot variation interface Designation Type Cable distributor X121 Connector MCI board extension X4 Plug connector Interface description of the cable distributor interface (X121):
Connector: 37–pinSub D connector (see cable distributor Section 2.4, Page2-61)
Pin assignment: Table 2-6 Pin assignment: Interface X121 Pin Designation Type1) Function 1 M24EXT VI/VO 24 V ground, 24 V output ground 2 M24EXT VI/VO 24 V ground, 24 V output ground 3 DOUT_CON(1) O 2nd output 24 V 4 DOUT_CON(0) O 1st output 24 V 5 DIN_CON(3) I 4th input 24 V 6 DIN_CON(2) I 3rd output 24 V 7 DIN_CON(1) I 2nd input 24 V 8 DIN_CON(0) I 1st input 24 V 9 MEPU0_S I 1st probe input (signal: 24 V) 10 MEPU0_C I 1st probe input (reference: 0 V) 11 MPG1_XA I Input 2nd handwheel, track A inverted 12 P5 VO Optional 5 V handwheel power supply 13 P5 VO Optional 5 V handwheel power supply 14 MPG1_XB I Input 2nd handwheel, track B inverted 15 MPG0_XA I Input 1st handwheel, track A inverted 16 P5 VO Optional 5 V handwheel power supply 17 P5 VO Optional 5 V handwheel power supply 18 MPG0_XB I Input 1st handwheel, track B inverted 19 Not assigned – – 20 P24EXT VI 24 V output load power supply 21 P24EXT VI 24 V output load power supply 22 DOUT_CON(3) O 4th output 24 V 23 DOUT_CON(2) O 3rd output 24 V 24 MEXT VO 24 V input ground 25 MEXT VO 24 V input ground 26 MEXT VO 24 V input ground 27 MEXT VO 24 V input ground 28 MEPU1_S I 2nd probe input (signal) 29 MEPU1_C I 2nd probe input (0 V) 30 MPG1_A I Input 2nd handwheel, track A 31 M VO Handwheel PS ground, TTL handwh. ground Interface overview Cable distributor (X121) 2 Hardware Descriptions

2-58 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Table 2-6 Pin assignment: Interface X121 Pin Function Type1) Designation 32 M VO Handwheel PS ground, TTL handwh. ground 33 MPG1_B I Input 2nd handwheel, track B 34 MPG0_A I Input 1st handwheel, track A 35 M VO Handwheel PS ground, TTL handwh. ground 36 M VO Handwheel PS ground, TTL handwh. ground 37 MPG0_B I Input 1st handwheel, track B 1) VI/VO Voltage Input/Voltage Output VI Voltage Input VO Voltage Input I Input O Output ext. power supply +24V stabilized +24V 0V Optocoupler MCI board extension X121 Pin number: 5...8 M 24...27 Power supply of the digital inputs Optocoupler Drivers 20,21 M 3,4,22,23 1,2 Relays ext. power supply +24V stabilized +24V 0V MCI board extension X121 Pin number: Power supply of the digital outputs 2 Hardware Descriptions

2-59 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Electrical data of the digital input interface:
Isolated from the board electronics
Common ground (MEXT) Electrical data of the digital output interface:
Isolated from the board electronics
Common ground and with regard to the external power supply (M24EXT)
Rated current: 500 mA Electrical data of the differential handwheel interface:
Connected to the board electronics
Signals used: – MPGx_A – MPGx_B – MPGx_XA – MPGx_XB Electrical data of the TTL handwheel interface:
Connected to the board electronics
Signals used: – MPGx_A – MPGx_B – M Notice The optional power supply of the handwheels (P5) is electronically protected with 2A. The maximum continuous load is 1 A. Per handwheel 500 mA. Electrical data of the probe interface:
Isolated both from one another and from all other voltage areas (board elec- tronics, digital inputs/outputs and handwheels)
Signal delay active edge: 10 us
Signal delay inactive edge: 100 us Note The maximum cable length is 25 m for all functions. Digital inputs Digital outputs Differential handwheels TTL handwheels Probe 2 Hardware Descriptions

2-60 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.3.4 Technical data Table 2-7 Technical data for MCI board extension, slot version Safety Degree of protection IP 20 Safety class Safety class I, in accordance with VDE 0106 P1: 1982 (IEC 536) Safety regulations EN61131–1 Approvals CE, UL, CSA Electrical data Maximum Typical Power consumption without I/Os 500 mW 350 mW Power consumption with I/Os 2.1 W 850 mW both handwheels per handwheel Max. current–carrying capa- city of the 5 V power supply 1A 500mA Mechanical data Dimensions Short PCI card Weight 110g Ambient environmental conditions Heat dissipation Open circuit ventilation Operation Storage/transport Temperature limits 5 ... 55°C –40 ... 70°C Tested to DIN IEC 68–2–1, DIN IEC 68–2–2 (DIN EN 60068–2–2), DIN IEC 68–2–14 Limits for relative humidity 5 ... .80% 5 ... .95% Tested to DIN IEC 68–2–30 Per minute Per hour Temperature change Max. 1K Max. 10K Condensation Not permissible Quality assurance to ISO 9001 Vibrational load during operation Category 3M4 Frequency range 10 ... 58 Hz/58... 200 Hz Const. excursion/acceleration 0.075 mm/1 g Tested to – module in PCU 50.3 DIN EN 60068–2–6 Shock load during operation Acceleration 50m/s2 Duration of nominal shock 30 ms Tested to – module in PCU 50.3 DIN EN 60068–2–6 Notice The specified safety regulations, certifications, degree of protection and safety class only apply if the module is plugged into a SINUMERIK PCU 50.3. 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.4 Cable distributor Designation Order No. (MLFB) Cable distributor 6FX2 006–1BA02 The cable distributor consists of a connector jacket for a 37–pin Sub–D connec- tor with enlarged interior. The cable distributor is used to split the I/O electronic handwheel extension interface (X121) to a maximum of 7 single cables. These must be connected in the order shown in Table 2-9, Page 2-63. To supply the digital outputs, an external 24 V supply is possible at the cable distributor. Cable 6FX2002–4AA21–0 Cable 6FX2002–4AA41–0 90 Fig. 2-10 Cable distributor Insert the appropriate individual cable in the opened cable distributor at the as- sociated connector X1 to X10. Place the cable in the appropriate cable guide. Make sure that the shield jackets that became free have a large conductive connection to the metallic contact areas of the cable distributor. See Fig. 2-11, Page 2-62. Locate the upper terminal bar in such a way that its ”teeth” are fac- ing the ”teeth” of the lower terminal bar and then retain the upper housing sec- tion. Order number Cable connection 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition This will reliably press the cable shields between the contact areas of the con- tact springs and contact them safely. The shield potential is reliably routed to the housing of the PCU using the contact springs of the cable distributor on the front panel of the PCU. Open Closed X1 X2 X4 X5 X6 X7 X8 X9 X1 0 X3 X11 Cable inlets Terminal caps Contact surfaces Plug–in connectors X1...X10 S3 S4 S5 S1 S2 Sub–D socket connector S6 S1 to S6: Fig. 2-11 Position of the interfaces of the cable distributor The DIP FIX switches in the cable distributor must be set as follows: Table 2-8 Setting the DIP–FIX switches in the cable distributor Switch S1 S2 S3 S4 S5 S6 Open x x x x Closed x x Location of interfaces DIP FIX switches 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Table 2-9 Connector assignments Connector No. Cable No. I/O X1 1 1st handwheel X2 1 (top) 1st handwheel X3 2 2nd handwheel X4 2 2nd handwheel X5 3 2nd probe X6 4 4 binary inputs X7 4 4 binary inputs X8 5 4 binary outputs X9 6 Supply for 4 binary outputs X10 7 (bottom) 1st probe Notice When assembling the cable distributor, make absolutely sure that the supplied washer is installed correctly and the coding pins are installed. The cable distributor is fastened using the two supplied adapter plates at the X121 cable distributor interface of the MCI board extension module using screws. Cable distributor: Top view Cable distributor: Side view Adapter plate Fig. 2-12 Mounting the cable distributor Connector assignments Mounting 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Connector designation: X1...X10 Connector type: DU–BOX plug connectors Table 2-10 Connector pin assignment of the cable distributor Pin no. 37–pin connec- tor Signal name DU BOX connector no./pin Cable No. Cable order No. 6FX2002–4AA.... Core color I/Os Terminal 9 10 – MEPUS 0 – MEPUC 0 X10/2 X10/1 X10/4 X10/3 7 41–0 rd or br bk shield 1st probe 1st probe Signal +24 V Reference 0 V 1 20 2 21 M24EXT P24EXT M24EXT P24EXT X9/2 X9/1 X9/4 X9/3 6 41–0 rd or br bk shield Parameteriza- tion of the 4 bi- nary outputs/of the MPI connec- tor Ground 24 V Ground 24 V 3 22 4 23 OUTPUT 1 OUTPUT 3 OUTPUT 0 OUTPUT 2 X8/2 X8/1 X8/4 X8/3 5 41–0 rd or br bk shield 4 binary outputs 2nd output 4th output 1st output 3rd output 5 24 6 25 7 26 8 27 INPUT 3 MEXT INPUT 2 MEXT INPUT 1 MEXT INPUT 0 MEXT X7/2 X7/1 X7/4 X7/3 X6/2 X6/1 X6/4 X6/3 4 21–0 rd or br bk gn ye vio bl shield 4 binary inputs 4th input ground 3rd input ground 2nd input ground 1st input ground 28 29 – MEPUS 1 – MEPUC 1 X5/2 X5/1 X5/4 X5/3 3 41–0 rd or br bk shield 2nd probe 2nd probe Signal +24 V Reference 0 V 11 30 12 31 13 32 14 33 MPG1 XA MPG1 A MPG1 5V MPG1 0V MPG1 5V MPG1 0V MPG1 XB MPG1 B X4/2 X4/1 X4/4 X4/3 X3/2 X3/1 X3/4 X3/3 2 21–0 rd or br bk gn ye vio bl shield 2nd handwheel 6FC9320–5DB XA A 5 V 0 V 5 V 0 V XB B 15 34 16 35 17 36 18 37 MPG0 XA MPG0 A MPG0 5V MPG0 0V MPG0 5V MPG0 0V MPG0 XB MPG0 B X2/2 X2/1 X2/4 X2/3 X1/2 X1/1 X1/4 X1/3 1 21–0 rd or br bk gn ye vio bl shield 1st handwheel 6FC9320–5DB XA A 5 V 0 V 5 V 0 V XB B Connection assignment 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Signal names MPG0, 1 5 V Supply voltage 1st/2nd handwheel 5 V MPG0, 1 0 V Supply voltage 1st/2nd handwheel 0 V MPG0, 1 A, XA 1st/2nd differential handwheel input A, XA MPG0, 1 B, XB 1st/2nd differential handwheel input B, XB MEPUS 0, 1 1st/2nd meas. pulse signal MEPUC 0, 1 1st/2nd meas. pulse common (reference ground) INPUT [0...3] 1st to 4th binary NC input MEXT Ext. ground (reference ground for binary NC inputs) OUTPUT [0...3] 1st to 4th binary NC output M24EXT External 24 V supply ( – ) for binary NC outputs P24EXT External 24 V supply ( + ) for binary NC outputs Notice The maximum current carrying capacity of the handwheel interface is 1 A for both handwheels. 500 mA per handwheel. Color Depth rd Red or Orange bn Brown bk Black gn Green ye Yellow vt Violet bu Blue 2 Hardware Descriptions

2-66 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.5 SINUMERIK Industrial PC 2.5.1 SINUMERIK PCU 50.3 *) Orientation with reference to operation with OP 012 top *) **) Fixing screws Housing cover **) **) Fig. 2-13 PCU 50.3: Perspective view with installed hard disk drive PCU as spare part with MCI board: Designation Order No. (MLFB) with Windows XP ProEmbSys and MCI board: PCU 50.3–C/1.5 GHz, 512 MB SDRAM 6FC5 220–0AA31–2AA0 PCU 50.3–P/2.0 GHz, 1024 MB SDRAM 6FC5 220–0AA33–2AA0 The SINUMERIK industrial PC ”PCU 50.3” provides, together with the MCI board, the basis for the SINUMERIK 840Di sl. The PCU 50.3 has the following important features:
Versions: – Celeron M, 1.5 GHz, 512 MB SDRAM – Pentium M, 2.0 GHz, 1024 MB SDRAM
Hard disk min. 40 GB (replaceable)
Operating system Windows XP ProEmbSys with Service Pack 2
Robust design (continuous operation, high noise immunity)
Compact dimensions for space–saving installation
Easy installation with four screws on the rear of the operator panel front Order number Features 2 Hardware Descriptions

2-67 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition
Mounting position and location to a large degree variable
Screen resolution 640 x 480, up to max. 1600 x 1200
Power Supply: 24 V DC
Interfaces to peripheral devices: – 1 x PROFIBUS DP (max. 12 Mbaud) – 1 x DVI–I interface for external monitor – 2 x Ethernet connections 10/100 Mbaud – 1 x CF card shaft (covered) – 4 x high–speed USB ports (USB 2.0)
Interfaces to operator panel front: – LVDS panel interface (channel 1 and optional channel 2) – I/O USB panel interface – Additional high–speed USB port (USB 2.0)
No. of slots – 1 x PCI (length: max. 265 mm, occupied by the MCI board) – 1 x PCI (length: max. 175 mm, occupied with option MCI board exten- sion slot variant) The following options are offered:
Memory expansion up to max. 2048 MB
External floppy disk drive Mounting brackets are required to mount the PCU directly behind the operator panel front: – Mounting bracket MLFB: 6FC5 248–0AF20–2AA0 When installing spare parts please note the following:
When replacing the PCU, remove the mounting brackets (MLFB 6FC5 248–0AF20–2AA0) from the defective PCU and attach to the replacement part. For the complete documentation on the PCU 50.3, please refer to: References: /BH/ Operator Components Manual Component PCU 50.3 Options Mounting bracket Spare part installation References 2 Hardware Descriptions

2-68 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Table 2-11 Technical data for PCU 50.3 with MCI board Safety Safety class I per IEC 60536 Degree of protection to EN 60529 IP20 Approvals CE Electrical data Input voltage 24 VDC Max. power consumption 1 x PCI slot (length: min. 140 mm) 1 x PCI slot (length: max. 288 mm) 3.3 V 5 V 12 V –12 V 2 A 2 A 0.3 A 0.05 A Power consumption PCU PCI slot 1) max. 190 W 15 W Main power outage buffering time min. 20 ms Mechanical data Dimensions (mm) Width 297 Height 267 Depth 81.7 Weight Approx. 7.2 kg Mechanical ambient condi- tions (with OP 012) Operation Transport (in packaging) Vibration stressing 10 – 58 Hz: 0.075 mm 58 – 200 Hz: 9.8 m/s2 DIN IEC 60068–2–6 5 – 9 Hz: 6.2 mm 9 – 500 Hz: 19.6 m/s2 DIN IEC 60068–2–6 Shock stressing 50 m/s2, 30 ms, 18 shocks DIN IEC60068–2–27 250 m/s2, 6 ms, 18 shocks DIN IEC60068–2–29 Noise < 55 dB(A) to DIN 45635–1 Ambient environmental conditions Heat dissipation Open circuit ventilation Condensation, spraying water and icing Not permissible Air inlet Without caustic gases, dusts and oils Operation Storage/transport (in transport packaging) Applicable standards DIN IEC 60068–2–1 DIN IEC 60068–2–2/–2–14 Climate class 3K5 1K3/2K4 Temperature limits 9 W 2): 5 ... 55 °C 14 W 2): 5 ... 50 °C 24 W 2): 5 ... 45 °C –20 ... 60 °C Temperature change Max. 10 K/h Max. 18 K/h Limits for relative humidity 10 ... to 80 % at 25° C 5 ... to 95% at 25° C Permissible change in the rel- ative air humidity max. 0.1% /min 1) All of the slots must not exceed this total output 2) Max. power of additional extensions e.g.,: MCI board extension, PC card, USB interface; the MCI board is already plugged in Technical data 2 Hardware Descriptions

2-69 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.6 SINUMERIK operator panel fronts SINUMERIK operator panel fronts can be connected to the PCU either cen- trally, i.e. directly via LVDS or USB interfaces, or decentrally with TCU (Thin Client Unit) via Ethernet. In the following section, the OP 012 operator front is described as an example in detail. 2.6.1 Operator panel front OP 012 Alphabetic key group Numerical key group Cursor key group Control key group USB front interface Mouse Area switchover ”ETC” key Softkeys Machine area Recall Softkeys and direct keys Softkeys and direct keys Fig. 2-14 View of OP 012 operator panel front Designation Order No. (MLFB) SINUMERIK OP 012 6FC5 203–0AF02–0AA1 The OP 012 operator front provides the following features:
12.1” TFT flat screen (color); resolution 800 x 600 pixels
Membrane keyboard with alpha, numeric, cursor and control keypad
Softkeys/direct keys: – 2 x 8 horizontal rows of keys with softkey function – 2 x 8 vertical key rows with softkey and direct key functions Order number Features 2 Hardware Descriptions

2-70 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition – Direct keys connectable using PP031–MC or directly to the I/Os
Shift key for switchover to the second key level (not for switching over the letters, since uppercase letters only)
Integrated mouse
Status LEDs for power supply and overtemperature
USB interface at front
Degree of protection IP65
Can be combined with PCU or TCU
External floppy disk drive can be connected For detailed documentation about the operator panel front OP 012 please see: References: /BH/ Operator Components Manual Operator panel front OP 012 References 2 Hardware Descriptions

2-71 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.7 TCU (Thin Client Unit) X203/X204: 2 USB–A ports X202: Ethernet interface X201: Compact Flash interface X207/X208: Interfaces for connection to the operator panel front (covered) Ethernet cable Fig. 2-15 TCU with Ethernet cable plugged in Designation Order No. (MLFB) TCU (Thin Client Unit) 6FC5312–0DA00–0AA1 A TCU permits the distributed connection of SINUMERIK OP/TP operator panel fronts and the SINUMERIK PCU. The features include the following:
Communication with the PCU is performed via Industrial Ethernet (10/100 Mbaud) in a separate sub–network with DHCP server (on the PCU).
Permits large distances between the PCU and operator panel front (maxi- mum possible distance between two network nodes/access points: approx. 100 m).
Graphics resolutions: 640x480 to 1024x768 pixels; depth of color: 16 bits
Interfaces: – 1 x Ethernet 10/100 Mbaud – 1 x Compact Flash – 2 x USB 1.1 for connection of mouse and keyboard – Interfaces for operator panel front: LVDS interface for SINUMERIK OP, USB interface for SINUMERIK OP (internal) Order number Features 2 Hardware Descriptions

2-72 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Comprehensive documentation about the configuration and commissioning of the TCU are to be found in: References: /BH/ Operator Components Manual Distributed configuration with TCU References: /IAM/ HMI Commissioning Manual TCU Commissioning (IM5) References Structure Commissioning 2 Hardware Descriptions

2-73 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.8 Floppy disk drives 2.8.1 Floppy disk drive 3.5” (USB) Fig. 2-16 External 3.5” floppy disk drive with USB interface Designation Order No. (MLFB) 3.5” disk drive with USB interface incl. 1 m USB connecting cable 6FC5 235–0AA05–1AA2 Cover (spare part) 6FC5 247 – 0AA20 – 0AA0 The disk drive is used to read in and save data from/to 3.5” disks with a maxi- mum capacity of 1.44 MB. The disk drive has the following features:
USB interface: Version 1.1
Can be inserted into customized operator panel fronts
Bootable
Input voltage 5.25 V DC
Power consumption, max. 2.5 W
Degree of protection to DIN EN 60529 IP 54 (front) IP 00 (rear) For a complete description of the 3.5’’ floppy disk drive (USB), please refer to: References: /BH/ Operator Components Manual 3.5” disk drive (USB) Order number Features References 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.9 Power supply 2.9.1 SITOP POWER standard 24V/10A Fig. 2-17 View: SITOP POWER standard 24V/10A Designation Order No. (MLFB) SITOP POWER standard 24V/10A 6EP1 334–1SH01 The SITOP POWER Standard 24V/10A power supply mode provides the follow- ing features:
Input voltage nominal value 120/230 V AC
Input voltage range 93 ... 132 V/187 ... 264 V
Power failure back–up time > 20 ms
Line frequency nominal value 50/60 Hz
Line frequency range 47 ... 63 Hz
Input current nominal value 3.5/1.7 A
Inrush current (25 °C) 55 A
Output voltage nominal value 24 V DC
Output voltage tolerance ± 3 %
Efficiency > 87 % Order number Features 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition
Output current nominal value 10 A
Electron. short–circuit protection with automatic restart
Galvanic isolation (SELV acc. to EN 60950)
Class of protection (IEC 536; VDE 1006 T1) class I
Degree of protection (VDE 0470, IEC 529) IP 20
Radio interference level (EN 55011) class A 2 Hardware Descriptions

2-76 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.10 Uninterruptible power supply (UPS) 2.10.1 SITOP POWER DC UPS MODULE 15 USB interface Fig. 2-18 View: SITOP POWER, DC–UPS MODULE 15 Designation Order No. (MLFB) SITOP POWER DC UPS module 15 (USB interface) 6EP1 931–2EC42 The SITOP POWER DC UPS module 15 provides the following features:
Compact design (HxWxD: 125 mm x 50 mm x 125 mm)
Nominal input voltage 24 V DC
Nominal output voltage 24 V DC
Nominal output current 15 A DC
High efficiency approx. 96 %
Class of protection (IEC 536; VDE 1006 T1) Class III
Degree of protection (VDE 0470, IEC 529) IP 20
Setting options – Connection threshold – Charging current – End–of–charge voltage – Operating state ON/OFF – Backup time – Interruption of output voltage
Protection and monitoring functions – Reverse voltage protection – Overcurrent and short–circuit protection Order number Features 2 Hardware Descriptions

2-77 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition – Exhaustive discharge protection – Accu test
Signaling of current status via LED – Normal operation – >85 % full charge – Battery standby supply – Buffer standby not available (alarm)
Additional output of all signals via a PC–capable interface: – Type ....–2EC31: Serial Interface – Type ....–2EC41: USB interface The USB interface corresponds to specification 2.0. Communication is however only performed at ”full speed” corr. to 12 Mbaud. A commercial type four–core shielded USB cable with a maximum cable length of 3 m can be used. Table 2-12 Signal assignment of USB connector Pin Signal Designation 1 VBUS Power supply 2 D– Transmitted data 3 D+ Transmitted data 4 GRD Ground USB interface 2 Hardware Descriptions

2-78 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.10.2 SITOP POWER ACCU MODULE 24 V DC/10 A/3.2 AH Fig. 2-19 View: SITOP POWER lead–acid battery module Designation Order No. (MLFB) SITOP POWER ACCUMODULE 24 V DC/10 A/3.2 AH 6EP1 935–6MD11 The SITOP POWER LEAD–ACID MODULE 24 V DC/10 A/3.2 AH features the following:
It has two maintenance–free, closed lead–acid batteries from the same lot, which are installed in a holder and connected in series.
Complete with battery retainer and terminals
Low self–discharge rate of approx. 3 % per month (at +20 °C)
Short circuit protection (battery fuse 15 A/32 V)
Class of protection (IEC 536; VDE 1006 T1) Class III
Degree of protection (EN 60 529; VDE 0470 T1) IP 00 Order number Features 2 Hardware Descriptions

2-79 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.11 I/O module PP72/48 2.11.1 Module X111 X222 X333 X1: Power Supply X2: PROFIBUS S1: DIL switch for setting the PROFIBUS address LED: OVTEMP LED: POWER LED: EXCHANGE LED: READY Digital inputs/outputs (50–pin ribbon cable connector) ON 1 8 OFF Fig. 2-20 I/O module PP72/48 Designation Order No. (MLFB) I/O module PP72/48 6FC5 611–0CA01–0AA0 I/O module PP72/48 is a simple module (without a separate housing) for con- necting digital input/outputs as part of an automation system based on PROFIBUS DP. The module has the following important features:
PROFIBUS DP connection (max. 12 MBaud)
72 digital inputs and 48 digital outputs
Onboard status display by means of 4 diagnostic LEDs To power the module and the digital outputs, an external power supply source (+24 V DC) is required. Order number Features 2 Hardware Descriptions

2-80 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.11.2 Interface description Interfaces of I/O module PP72/48 Table 2-13 Interfaces of I/O module PP72/48 Interface Designation Type Power supply connection X1 Screw–terminal block PROFIBUS DP X2 Socket PROFIBUS DP address S1 DIL switch Digital input/outputs 1 X111 Ribbon cable connector Digital input/outputs 2 X222 Ribbon cable connector Digital input/outputs 3 X333 Ribbon cable connector Interface description of the external power supply (X1):
Screw–terminal block MSTBVA 2,5/3–G–5,08, Phoenix
Pin assignment Table 2-14 Pin assignment: Ext. power supply (X1) Pin Designation Type 1) Function 1 P24 VI External power supply of the module (+24 V) 2 M24 VI Reference for external supply 3 PI VI Protective conductor of the external supply 1) VI Voltage input
Connecting cable The required connecting cables must be provided by the user: – Wire, conductor cross section: 1.0 – 1.5 mm2 (AWG17 – AWG16)
Power supply For data concerning the power supply, see Subsection 2.11.3, Page 2-87. Interface overview External power supply (X1) 2 Hardware Descriptions

2-81 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Interface description of the PROFIBUS DP interface (X2):
Connection: 9–pin SUB–D socket connector
Pin assignment Table 2-15 Pin assignment: PROFIBUS DP (X2) Pin Designation Type 1) Function 1 – – – 2 – – – 3 RxD/TxD–P B Receive/transmit data P (B line) 4 RTS O Request to Send 5 DGND VO Data reference potential (M5V) 6 VP VO Supply voltage plus (P5V) 7 – – – 8 RxD/TxD–N B Receive/transmit data N (A line) 9 – – – 1) VO Voltage Output O Output B Bidirectional
Connector – 6ES7972–0BA40–0XA0; cable outlet 350, without PC socket connector – 6ES7972–0BB40–0XA0; cable outlet 350, with PC socket connector – 6ES7972–0BA11–0XA0; cable outlet 900, without PG socket connector – 6ES7972–0BB11–0XA0; cable outlet 900, with PG socket connector
Cable – 6XV1830–0EH10; by the meter, non–trailable – 6XV1830–3BH10; by the meter, trailable
Additional technical specifications Maximum possible data rate: 12 Mbits/s The PROFIBUS address of the ADI4 can be set in the range 1 to 127 using switch S1. Table 2-16 Meaning of switch S1 Switch Significance 1 PROFIBUS address: 20 = 1 2 PROFIBUS address: 21 = 2 3 PROFIBUS address: 22 = 4 4 PROFIBUS address: 23 = 8 5 PROFIBUS address: 24 = 16 6 PROFIBUS address: 25 = 32 7 PROFIBUS address: 26 = 64 8 Not used Notice A newly set PROFIBUS address will only come into effect after power OFF/ON. PROFIBUS DP (X2) PROFIBUS address (S1) 2 Hardware Descriptions

2-82 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Interface description of the digital input/output interfaces (X111/X222/X333):
Connector: 50–pin ribbon cable connector
Pin assignment on each connector. Table 2-17 Pin assignment (X111/X222/X333) Pin Signal designation Type 1) Pin Signal designation Type 1) 1 M VO 26 Input 2.7 I 2 P24OUT VO 27 – – 3 Input 0.0 I 28 – – 4 Input 0.1 I 29 – – 5 Input 0.2 I 30 – – 6 Input 0.3 I 31 Output 0.0 O 7 Input 0.4 I 32 Output 0.1 O 8 Input 0.5 I 33 Output 0.2 O 9 Input 0.6 I 34 Output 0.3 O 10 Input 0.7 I 35 Output 0.4 O 11 Input 1.0 I 36 Output 0.5 O 12 Input 1.1 I 37 Output 0.6 O 13 Input 1.2 I 38 Output 0.7 O 14 Input 1.3 I 39 Output 1.0 O 15 Input 1.4 I 40 Output 1.1 O 16 Input 1.5 I 41 Output 1.2 O 17 Input 1.6 I 42 Output 1.3 O 18 Input 1.7 I 43 Output 1.4 O 19 Input 2.0 I 44 Output 1.5 O 20 Input 2.1 I 45 Output 1.6 O 21 Input 2.2 I 46 Output 1.7 O 22 Input 2.3 I 47 DOCOMx VI 23 Input 2.4 I 48 DOCOMx VI 24 Input 2.5 I 49 DOCOMx VI 25 Input 2.6 I 50 DOCOMx VI 1) VI Voltage Input VO Voltage Output I Signal Input O Signal Output x with x = 1,2,3 Digital inputs/outputs (X111/X222/X333) 2 Hardware Descriptions

2-83 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Digital inputs
Terminal assignment for the digital inputs The following figure shows an example of the terminal assignment for the digital inputs on connector X111. Connectors X222 and X333 are assigned analogously. PP72/48 X111, X222, X333 pin number: 2 26 4 3 : : : : P24OUT (+24VDC) : : : : M 1 P24OUText ext. power supply +24V stabilized +24V 0V 1 Receiver Receiver Receiver 2 Fig. 2-21 Terminal assignment for the digital inputs 1 If you are using the internal power supply P24OUT 2 If you are using an external power supply P24OUText
Internal power supply (P24OUT) The internal power supply for the digital inputs (X111, X222, X333: Pin 2) is derived from the general power supply of module X1, pin 2 (P24). Specifica- tion: See Section 2.11.3, Page 2-87 Caution A max. current of Iout = 0.5 A on X111, X222, X333: Pin 2 must not be exceeded. An exceeding of the maximum current might destroy the module.
External power supply (P24OUText) If an external power supply is used for the digital inputs, its reference ground must be connected with X111, X222, X333: Pin 1 (M). X111, X222, X333: Pin 2 (P24OUT) then remains open. For specification of the external power supply, see Subsection 2.11.3, Page 2-87. 2 Hardware Descriptions

2-84 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition
Connecting cable: The required connecting cables (ribbon cables) must be provided by the user..
Electrical specification of the digital inputs: Table 2-18 Electrical specification of the digital inputs: Digital inputs Min. Typical Max. 5 A Nominal Voltage at high signal level (UH) 15V 1) 30V 24V Input current IIN at VH 2mA – 15mA – Voltage at low signal level (UL) –30V – +5V 0V Signal delay time TPHL 2) 0.5 ms – 3 ms –
Supply voltage of the digital inputs 1) typical output voltage: VCC – IOUT
RON VCC: actual operating voltage (P24OUT) at X111, X222, X333: Pin 2 max. output current IOUT: 500 mA per pin max. short–circuit current: 4 A (max. 100
s, VCC= 24 V) internal resistance RON: 0.4 
2) Moreover, the PROFIBUS communication time and the application cycle time must be taken into account.
Polarity reversal causes neither high level nor destruction of the inputs. 2 Hardware Descriptions

2-85 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Digital outputs
Terminal assignment for the digital outputs The following figure shows an example of the terminal assignment for the digital outputs on connector X111. Connectors X222 and X333 are assigned analogously. Drivers Drivers Drivers : : : : PP72/48 X111, X222, X333 pin number: 47,48,49,50 (DOCOMx) M 31 1 (M) : : : : Relays ext. power supply +24V stabilized +24V 0V 32 46 Fig. 2-22 Terminal assignment for the digital outputs
Connecting cable: The required connecting cables (ribbon cables) must be provided by the user.
Supply voltage: To power the digital outputs, an external 24 V DC power supply source must be connected to DOCOMx (X111, X222, X333: Pin 47, 48, 49, 50). The reference ground of the external power supply source must be con- nected to X111, X222, X333: Pin 1 (M). For further data, see Subsection 2.11.3, Page 2-87. Caution At the user end, it must be ensured that the maximum current drawn per DOCOMx Pin (X111, X222, X333: Pins 47, 48, 49, 50) does not exceed 1 A. The power supply (+24 V DC) for the digital outputs must therefore be connected to all 4 pins (X111, X222, X333: Pin 47, 48, 49, 50) for each DOCOMx. 2 Hardware Descriptions

2-86 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition
Electrical specification of the digital outputs: Table 2-19 Electrical specification of the digital outputs Digital outputs Min. Typical Max. 5 A Nominal Voltage at high signal level (UH) VCC – 3 V 1) VCC 24V Output current IOUT – – 250mA – Voltage at low signal level (UL) – – – Output open Leakage current at low level – 50
A 400
A – Signal delay time TPHL 2) – 0.5 ms – – Maximum switching frequency 2) Resistive load 100Hz – – – Inductive load 2Hz – – – Lamp 11Hz – – –
1) UH_typical = VCC – IOUT
RON VCC: actual operating voltage IOUT: maximum output current (see above) maximum short–circuit current: 4A (max. 100
s, VCC= 24V) RON: internal resistance = 0.4
2) Moreover, the PROFIBUS communication time and the application cycle time must be taken into account.
Incorrect connection causes neither high level nor destruction of the outputs.
General electrical properties – No electrical isolation – Current limitation to maximum 500 mA – Protection against: short–circuit, overtemperature, and loss of ground – Automatic disconnection in case of undervoltage 2 Hardware Descriptions

2-87 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition The module has 3 LEDs through which the module status is displayed. Table 2-20 LED: Status display Designation Color Description POWER Green Power supply OVTEMP Red Overtemperature indication EXCHANGE Green Cycl. data exchange with DP master in progress READY Red Ready for cycl. data exchange with DP master 2.11.3 Power supply The supply voltage (24 V DC) of the I/O module PP72/48 is connected to the screw terminal block X1. See Subsection 2.11.2, Page 2-80. To power the digital outputs (+24 V DC), an external power supply source is required. The power supply is connected through terminals X111, X222, X333, pins 47, 48, 49, 50 (DOCOMx). If the internal power supply from X111, X222, X333, Pin 2 (P24OUT) is not used to power the digital inputs, it can be replaced by an external power supply source (+24 V DC) as an option. The reference ground of the power supply source must be connected with X111, X222, X333, Pin 1 (GND). X111, X222, X333, Pin 2 (P24OUT) then remains open. The external power supply voltages must be generated as functional extra–low voltages with safe electrical isolation (according to IEC 204–1, Section 6.4, PELV) and must be grounded centrally by the user. The reference ground of the terminals X111, X222, X333, pin 1 (GND) must be connected to a common grounding point with the reference ground of the power supply of the I/O module PP27/48. Caution The external power supply voltages must be generated as function extra–low voltages with safe electrical isolation (IEC 204–1, Section 6.4, PELV) and must be grounded centrally by the user. Moreover, the external power supply voltages for the I/O modules PP72/48, the digital outputs, and optionally the digital inputs must meet the specifications according to Table 2-21. LED: Status display Module Digital outputs Digital inputs Specification of the power supply voltages (+24 V DC) 2 Hardware Descriptions

2-88 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Table 2-21 Specification of the power supply voltage P24OUT, Voltage Minimum 20.4 V Nominal 24 V Maximum 28.8 V Minimum (dynamic) 18.5 V Maximum (dynamic) 30.2 V Non–cyclic overvoltage Max. (absolute, transient) 35 V Max. duration 500 ms Min. recovery time 50 s Max. events per h 10 Voltage failure for min. power supply voltage Max. duration 1) 50 ms Min. recovery time 1 s Max. events per h 10 Power consumption Maximum approx. 40 W On the module side the power supplies must be protected against:
Polarity reversal
Short–circuit (elec. current limitation of the outputs)
Overload (fuse protection). 2.11.4 Grounding The module must be installed according to EN 60204. If a large–area, permanent metallic connection with the central ground point through the rear panel is not possible, the mounting plate must be connected to the grounding by means of a line (cross section >10 mm2). ! Caution A protective conductor must be connected. 2 Hardware Descriptions

2-89 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.11.5 Dimension drawing 10 170 10.5 306 325 194 35 6.5 10 35 Fig. 2-23 Dimension drawing: I/O module PP72/48 2 Hardware Descriptions

2-90 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.11.6 Technical data Technical data of I/O module PP72/48 Safety Degree of protection IP 00 Safety class Safety class I, in accordance with VDE 0106 P1: 1982 (IEC 536); Protection against ingress of foreign bodies and water in accordance with IEC 529 Approvals UL/CSA, CE Power consumption At nominal load 11W Mechanical data Dimensions WxHxD [mm] 194 x 325 x 35 Weight Approx. 0.3 kg without mounting plate Approx. 1.2 kg with mounting plate Ambient environmental conditions Heat dissipation Open circuit ventilation Operation Storage/transport Temperature limits 0 ... 50°C –20 ... 55°C/–40 ... 70 °C Limits for relative humidity 5 ... 95 % without condensation 5 ... 95 % without condensation Condensation Not permissible Atmospheric pressure 700 ... 1060 hPa 700 ... 1060 hPa Transportation altitude – –1000 ... 3000 m Shock stress during transportation Free fall in transport packa- ging 1000 mm 2 Hardware Descriptions

2-91 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.12 ADI4 (Analog Drive Interface for 4 Axes) 2.12.1 Module X1: X2: S2: X3: X4–2: X5–1: X4–1: X5–2: Encoder connection for Axis 1 DIL switch for setting the PROFIBUS address PROFIBUS connection External power supply 24 V DC Analog setpoint outputs 10 V DC, Axis 1–4 X6–2: Connection for digital input signals X6–1: Connection for digital output signals H1: H2: PW TMP EXCH RDY Connection for protective ground Screw M6 Diagnostic LEDs Encoder connection for Axis 3 Encoder connection for Axis 2 Encoder connection for Axis 4 1 8 OFF ON corr. to PROFIBUS address: AH = 10D Fig. 2-24 Connection overview for ADI4 2 Hardware Descriptions

2-92 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Designation Order No. (MLFB) ADI4 6FC5 211–0BA01–0AA2 The interface module ADI4 is suitable for operating up to 4 drives with an ana- log setpoint interface on the PROFIBUS DP. The module has the following essential features:
PROFIBUS DP connection (max 12 Mbits/s)
4 servo interfaces each with one: – Input: TTL/SSI encoder for incremental and absolute measuring systems – Outlet: 10 V analog
General and drive–specific digital input/output signals
Onboard status display by means of 4 diagnostic LEDs To power the module and the digital outputs, an external power supply source (+24 V DC) is required. Notice Please observe the following framework conditions for operating the ADI4 DP slave:
An ADI4 DP slave can only be operated on an equidistant PROFIBUS DP (see Subsection 8.8, Page 8-222).
An ADI4 DP slave is not a DP standard slave certified as compliant with the PROFIDrive profile, e.g. the ADI4 DP slave does not support acyclic communication. For detailed documentation about the operator panel front OP 012 please see: References: /ADI4/ Analog drive port for 4 axes Order number Features References 2 Hardware Descriptions

2-93 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 2.13 Diagnostic repeater for PROFIBUS DP 2.13.1 Module Fig. 2-25 View: Diagnostic repeater for PROFIBUS DP Designation Order No. (MLFB) Diagnostic repeater for PROFIBUS DP 6ES7 972–0AB01–0XA0 The diagnostics repeater with online line diagnostics for PROFIBUS DP offers the following main features:
Module–specific features: – PROFIBUS DP standard slave (DP–V1) – Data transmission speed: 9.6 kBaud to 12 MBaud – Maximum depth of cascading: 9 – Redundant operation: no
Automatic detection of fault type and fault location
Distance given in line diagonistics: – Resolution: 0.5 m – Accuracy: 1 m
Repeater throughput time: – Baud rates 1.5 Mbaud: 2.5 TBIT + 153 ns; (12MBaud: TBIT = 83.3 ns) – Jitter: 1T = 1/48 MHz = 20.83 ns
Monitoring function of isosynchronous PROFIBUS – DP bus cycle (TDP): min. 1 ms, max. 32 ms – Tolerance range TDP monitoring: 2
s – Tolerance range TDX monitoring: 10
s
Supply voltage: Rated voltage 24 V DC (20.4 to 28.8 V) Order number Features 2 Hardware Descriptions

2-94 © Siemens AG 2007 All Rights Reserved SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition
Permissible ambient conditions: – Operating temperature 0 °C to +60 °C – Transport/storage temperature –40 °C to +70 °C – Relative humidity max. 95 % at 25 °C
Mechanical design: – Dimensions (B X H X T) 80 x 125 x 67.5 – Weight 300 g
Degree of protection: IP20 A full description of the diagnostic repeater for PROFIBUS DP is to be found in: References: Manual SIMATIC diagnostic repeater for PROFIBUS DP Drawing number: A5E00352937–01, 10/2004 Edition Order number (MLFB): 6ES7972–0AB00–8AA0  References 2 Hardware Descriptions

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Design 3.1 System overview 3.1.1 Operator panels and touch panels OP 012 OP 015 OP 010S OP 010C OP 010 TP 012 TP 015A Possible configurations: – Centralized configuration: Connection of the OP/TP directly to the PCU – Distributed configuration: Connection of the OP/TP to a TCU (Thin Client Unit). Communication with the PCU via Ethernet. PCU 50.3 OP 012T Fig. 3-1 System overview of SINUMERIK 840Di sl Operator panels and touch panels 3

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 3.1.2 PROFIBUS DP components SINUMERIK 840Di sl PCU 50.3 MCI board Machine control panel MCP 310 Decentr. I/O system SIMATIC ET 200 PROFIBUS DP (1) SINAMICS S120 Mini HHU ADI4 I/O Module PP72/48 PROFIBUS DP (2) Machine control panel MCP 483 PG/PC e.g. SIMATIC Power PG X102 X101 1) Only the PLC has access to the PROFIBUS DP (2), interface X102. Therefore no drives and no I/Os of the NC can be operated via this PROFIBUS line. Diagnostic repeater for PROFIBUS DP 1) Pushbutton Panel MPP 438H SIMODRIVE 611 universal option module: MotionControl with PROFIBUS DP Alternative Fig. 3-2 System overview of SINUMERIK 840Di sl PROFIBUS DP (schematic) 3 Design

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 3.1.3 MPI components Industrial PC: PCU 50.3 MCI board ÄÄ ÄÄ Distributor box Handheld unit type B–MPI MPI bus or PG/PC e.g. SIMATIC Power PG X102 X101 Fig. 3-3 System overview of SINUMERIK 840Di sl MPI (schematic) 3.1.4 PCU components Industrial PC: PCU 50.3 Keyboard (QWERTY) 3.5” diskette drive CD–ROM drive Mouse SIEMENS SITOP DC UPS module 15 with SITOP POWER lead–acid module Monitor SIEMENS SITOP POWER standard 24V/10A Optionally PG/PC e.g. SIMATIC Power PG Fig. 3-4 System overview of SINUMERIK 840Di sl PCU components (as a diagram) 3 Design

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 3.2 Electrical design 3.2.1 MCI board and PROFIBUS DP MCI board SIMATIC DP ET200 SINAMICS S120 Alternative: SIMODRIVE 611 universal with optional module: MotionControl with PROFIBUS DP X101 X2 X102 X126 I/O Module PP72/48 X2 ADI4 X2 Machine control panel MCP 310 Machine control panel MCP 483 PG/PC e.g. SIMATIC Power PG Diagnostic repeater for PROFIBUS DP 1) Only the PLC has access to PROFIBUS DP (2), interface X102. Therefore no drives and no I/Os of the NC can be operated via this PROFIBUS line. Alternatively also parameterizable as an MPI bus. 1) Pushbutton Panel MPP 438H Fig. 3-5 SINUMERIK 840Di sl MCI board and PROFIBUS DP components 3 Design

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition Note For details on general accessories, such cables, connectors and prefabricated cables, please refer to: References: Catalog NC 61, MOTION–CONNECT 3.2.2 MCI board and MPI bus MCI board Machine control panel (rear view) X102 X20 Distributor box Handheld unit type B–MPI ÄÄ ÄÄ X4 X5 X101 X2 / X5 PG/PC e.g. SIMATIC Power PG Fig. 3-6 SINUMERIK 840Di sl MCI board and MPI bus components 3.2.3 MCI board extension MCI board extension 2x sensor 2x handwheel 4x digital input 4x digital output X121 X4 Cable distributor Fig. 3-7 SINUMERIK 840Di sl MCI board extension 3 Design

SINUMERIK 840Di sl Manual (HBIsl) – 01/2007 Edition 3.2.4 PCU 50.3 SIEMENS Power Supply 24 V DC Keyboard (QWERTY) Ext. CD–ROM drive Mouse MCI board extension (option) X101 X102 X121 MCI board SITOP POWER 10 with SITOP DC UPS Module 15 and SITOP POWER lead–acid battery module Ext. monitor 4x USB (2.0) PROFIBUS/MPI CF card slot Power switch (On/Off switch (only standby) for the power supply unit) Ext. Operator Panel (OP) via a Thin Client Unit (TCU) Company network Ethernet 2 Ethernet 1 DVI–I System network PG/PC e.g. SIMATIC Power PG Fig. 3-8 SINUMERIK 840Di sl: PCU 50.3 (right housing) I/O interface for connecting the I/O cable of the operator panel front LVDS interface for connecting a TFT display cable Optimum connection for the operator panel front with USB 2.0 front port Fig. 3-9 SINUMERIK 840Di sl: PCU 50.3 (rear housing) 3 Design