A68 Start-Up Sequence For Commissioning - E

A68 Commissioning Startup Sequence
1 Short Description
To ensure the required level of compatibility and consistency between machines that have been con-
figured with the SINUMERIK 840D sl controller, a defined commissioning sequence must be ob-
served. This document describes this sequence.
The sequence that consists of seven parts is shown in the following diagram:
• Hardware
• Software installation tools
• HMI for PCU50.3
• PLC
• SINAMICS drive
• NCU
• Machine acceptance tests
Hardware:
Connection/grounding A6
Standards
Software:
Commissioning software Section 2
User software
HMI PCU50.3:
Language/technology Section 3
PLC:
Hardware configuration Section 4
Program
Sinamics drives:
Section 5
Configuration
NC:
Commissioning functions Section 6
Diagnosis/service aids Section 7
Machine acceptance tests A103
SINUMERIK 840D sl Initial commissioning, training manual Page 1 A68

Section 2 Commissioning Software
Notes
2 Software
Software tools are required for the commissioning of the 840D SL control-
ler. These tools must be installed on the PG or laptop of the commission-
ing person.
The following software is required:
1. Step7 V5.4
2. Toolbox Configuration files
3. Step7 Addons V5.4 Contained in toolbox
4. Starter 4.0 Drive configuration
5. HMI 7.3 HMI-Advanced
6. NCU-SysSW 1.4 CD System software CD
7. Update Agent Optional
8. WinSCP
The required software should be installed on the commissioning PC as fol-

lows:

Section 2 Step7 Software Commissioning
Notes
After the Step7 CD is inserted, the installation process normally starts automati-
cally. If this does not occur, start the installation by calling Setup.exe in the root
directory of your CD.
Caution: Depending on the hardware, the installation process can

take as long as 40 minutes!
Start the installa-

tion by calling
Setup.exe on the
CD ROM
You should always restart your computer after the installation has completed.

Section 2 Software Toolbox Commissioning
Notes
The Toolbox must now be installed. If it is available only as a self-extracting
SL_TOOLBOX.EXE, start this file, for example, with a double-click. Otherwise you
can ignore the next two items.
Start the extract by se-

lecting “Next”.
You must now select and confirm the save location.
The installation process is now identical for both versions.
Start the SETUP.EXE, for example, with a double-click.

Notes
After the start, the following selection box appears. At least the PLC base program
and the Sinumerik add-on must be selected. NCVar Selector and PLC Symbol
Generator can be selected optionally.
Activate the
required op-
tions –
normally ALL
Now only the GSD files from \toolbox\8x0d\GSD need to be installed.

Notes
Select the variant in the listbox: from the directory.
Then click the Search button, select from the installation path of the Toolbox, e.g.
the subdirectory ..\8x0d\GSD\MCP_310_483.
Select the appropriate file to be installed for the required language, e.g.
Si018109.gsg for German. The available languages are
Si ... .gse English

Si ... .gsf French
Si ... .gsg German
Si ... .gsi Italian
Si ... .gss Spanish
Click the Install button.

Section 2 Software Starter Commissioning
Notes
You should now install STARTER 4.0. This is required within Step7 to simplify the
use of special functions.
Confirm the “Next” prompt and accept the license agreement. Ensure that
you read the contained information, in particular, the part with the compatibil-
ity restrictions that can only be reached by scrolling.

Section 2 Software HMI-Advanced Commissioning
Notes
An HMI-Advanced is always required for commissioning the 840D sl. It does not
matter whether it runs on the PG or on a PCU50.3.
For the installation on a PCU50.3, copy the complete contents of the installation
directory from your PG to the PCU50.3 on drive D: in the "INSTALL" directory and
restart the PCU50.3.
As an alternative, start the installation by calling the Setup.exe in the installation
directory. This, however, must be performed using the keyboard/mouse of the
PCU50.3.
The PG version of the HMI-Advanced must be installed by calling Setup.exe on
the PG.
HMI-Advanced can also be installed in the form of the commissioning tool on

the PG.

Section 2 TCP/IP Commissioning: PG Setting
Notes
TCP/IP PG setting
For a commissioning with PG, you must change the network setting on the PG. A
commissioning using PCU is also necessary for this item, because we must use
Step7 to change the hardware configuration.
You can find this setting as follows:
-> Network environment (on the desktop) -> right mouse button (=context
menu) -> Properties
-> Local Area Connection -> right mouse button -> Properties

Section 2 TCP/IP Commissioning: PG setting
Notes
-> ‘Alternative configuration‘ tab
Make the following setting there:
Port X120: For access using port X120, set (see (5))
IP address = 192.168.214.250 (appropriate: .250 .. 254)
Subnetmask = 255.255.255.0
Port X127: Access using port X127 (service port) is being prepared:
IP address = 192.168.215.2 (appropriate: ..2 ... 9)
Subnetmask = 255.255.255.224

Section 2 WinSCP Software Commissioning
Notes
WinSCP is also installed as part of the installation of the HMI-Advanced / commis-
sioning tool. This freeware tool is required in order to transfer data from and to the
flashcard. A service shell can also be started that can then be used to start tools
on the NCU, e.g. “sc”.
The logon data for a connection with X120 is:
Host name: 192.168.214.1
User name: manufact for empty Flashcard: admin
Password: SUNRISE

Section 2 WinSCP Software Commissioning
Notes
Possible parameters for sc:
Further information about sc is contained in the CNC Commissioning Manual,

Part 5 (Base Software) IM7 Chapter 4, Service Commands!

Section 2 NCU System Software Commissioning Software
Notes
This step is only necessary when no flashcard with the correct software version is
present. After inserting the system software CD, the NCU software must be in-
stalled from the appropriate directories.
NCU SysSW CD figure: Structure of the software version 1.3
This software is supplied as an update image.

This can also be used to write to an empty CF card.
The installation of the NCU software requires the NCU Service System V1.50.07
or later on a USB stick. The update/reinstallation can be made using either
WinSCP or TCU.
Details for the procedure are contained in the “siemensd.rtf” file in the root direc-
tory of the CD.
Warning: For an update, always use sc restore –update … to ensure

that the USER path is retained! The –full or without parameter
causes the complete card to be overwritten. Beforehand, ensure that
you save the license keys from /card/keys!
An update using TCU requires a USB keyboard (switch uppercase/

lowercase). WinScp is required for an update without TCU.

Notes
1. Installation of the NCU Software:
The installation of the NCU software requires NCU Service System V1.50.07 or later
on a USB stick. The update/reinstallation can be made using either WinSCP or TCU.
1.1 Installation of the NCU Service System on a USB Stick:

The NCU Service System is present as USB stick image in the emer-
gency_bootsys_ncu directory of the supplied DVD. The installdisk.exe copy program
is also present there. Connect a 512 MB USB stick, preferably Siemens 6ES7648-
0DCx0-0AA0, to your PG or PC (with Windows XP) and determine the associated
drive letter. Execute installdisk to copy the NCU Service System to the USB stick:
installdisk --verbose --blocksize 1m <image file> <drive letter:>
( -- means two minus characters)
Example:
installdisk --verbose --blocksize 1m D:\ TMP\linuxbase-512M.img X:
This is done best in a DOS shell. You require administrator rights on your PG/PC.
When installdisk completes, remove the USB stick from the PG/PC and reinsert it.
You will now see an empty USB stick in Windows. Now copy the required NCU soft-
ware (file with the .tgz extension) from the ncu_sw directory on the supplied DVD to
this stick.
The USB stick can be inserted in one of the two USB slots of the NCU 7x0. The NCU
boots from this USB stick when it starts. The operation is made either using a TCU
attached to the NCU or from PG/PC with WinSCP using "Open Terminal". The use of
the NCU Service System is described in the /IM7/ documentation on the supplied
DVD.
1.2 Update of an NCU 7x0 with NCU SW 1.3 (>= NCU Version 01.03.01)
IMPORTANT: This procedure concerns only existing systems with NCU SW
01.03.01, but not for preliminary software with a version less than 01.03.01! For NCU
software with a version less than 01.03.01, see 2.3.
For an update, all user data on the CF card in the /user, /addon, /oem directories and
the license key is retained.
ο Boot the NCU from the USB stick (see 1.1).
ο Use F2 / Softkey 2 to select the Service Shell.
ο Log on as "manufact" user. This may require an external keyboard because
user names must be entered in lowercase letters.
ο After the $ prompt of the Service Shell, enter the following command: sc re-
store -update -force /data/<ncw-sw>.tgz The software update has completed when
the $ prompt reappears.
ο Remove the USB stick.
ο Boot the NCU (F3 / Softkey 3 "Restart").
The PLC, drives and NC can then be placed into operation.
1.2.1 Update using WinSCP

The update using WinSCP is possible for systems without TCU on the NCU, e.g. from
a PCU 50. To do this, log on with WinSCP as "manufact" for the NCU and copy the
required NCU software (the file with the .tgz extension) from the ncu_sw directory on
the supplied DVD to /card/user/system/home/manufact on the NCU. Then enter the
following command for Commands / Open Terminal:
sc restore -update -force <ncu-sw>.tgz
The software installation has completed when the "Syncing disks .... done" message
appears. A reboot of the NCU is then required. The <ncu-sw>.tgz file on the NCU
should be deleted.
Note: During the installation, messages can be issued indicating that the communica-
tions partner has not responded for some time. These messages can be ignored. Do
not terminate the connection for such messages.

Notes
1.3 Reinstallation of the NCU software 1.4 on CF Card
IMPORTANT: Because this procedure deletes the complete contents of the existing
CF card, it can also be used for an empty CF card.
ο Boot the NCU from the USB stick (see 1.1).
ο Select the Service Shell using F2 / Softkey 2.
ο Log on as "manufact" user, for empty CF card with "admin", "SUNRISE"
password. This may require the use of an external keyboard because the user name
must be entered in lowercase characters.
ο After the operator prompt $ of the Service Shell, enter the following com-
mand: sc restore -full /data/<ncu-sw>.tgz The software installation has completed
when the $ prompt reappears.
ο Remove the USB stick.
ο Boot the NCU (F3 / Softkey 3 "Restart").
ο For an initial startup with TCU(s), the logon of the TCU(s) is required on
the system. The TCU name (default TCUx) and the address of an assigned MCP
must be specified. Currently, 255 must always be entered!
The PLC, drives and NC then can be placed into operation.
General notes:
After the reinstallation of the NCU SW 1.4 on CF card, a general reset of the NCU
and PLC must be performed: switch SIM/NCK to position 1, switch PLC to posi-
tion 3 and switch OFF/ON.
The license key must be saved before a licensed CF card is overwritten. The key
is contained in the 'keys.txt' file in the /card/keys/sinumerik path. The key can be
saved, for example, with WinSCP from the PG/PC. The licenses are permanently
assigned to the CF card (card-Id) and can only be used on this card.
Data backups should be imported in the sequence NC, PLC, drive. After importing
the PLC archive (HW Config), the system must be switched off and on. If this is
not done, problems occur with the import of the drives archive using HMI Emb.
This means it is desirable to create separate NC, PLC, etc., archives.
Contour handwheel only with PROFIBUS MCP
The display of the active synchronous actions is incorrect for the HMI-Adv.
Notes for the PLC:

The Toolbox V01.04.04 is required.
The FB1 has been given new parameters. This means the call in the OB100 must
be reparameterized.
The DB2 can be setup in an extended variant.
The current cycle time is no longer available in the DB5 but in the DB8. The cycle
time can also be fetched using the start information of the OB1.
AGSend / AGReceive is not released for V1.4.
The planned configuration <> actual configuration activation causes the PLC to
stop. Workaround: perform the test in the user program (e.g. with the SIMATIC
FC125 and FB125 blocks in the corresponding error OBs).
The PLC series commissioning file must be created in the stop status of the PLC.
If this is not done, it cannot be guaranteed that the PLC enters cyclical operation
after loading the data backup.

Notes
Notes for the PLC:

The X127 service interface should be used only for Step 7.
The machine control panel (MCP) is operated on the PROFIBUS or Ethernet.
Mixed operation is not permitted.
The Replace Object function has not been released in the PLC HW Config.
The PROFIBUS 1 must be configured so that the CU, infeed and drives softkeys
are shown on the HMI.
Notes for HMI-Embedded:

The HMI-Embedded Software V07.20.06 as part of the NCU Software 1.4 is
started automatically when the NCU7x0 starts. The HMI-Embedded is also called
"internal HMI".
HMI-Embedded can only be operated with TCU using an operator panel con-
nected with Ethernet to the X120 of the NCU7x0.
The configuration data, such as PLC message and alarm text, augment user in-
terface ("wizard"), must be saved in the appropriate directories /card/user/
sinumerik/hmi/... or /card/oem/sinumerik/hmi/... on the CF card of the NCU (see
IM2, BE1 documentation). The access to the file system on the CF card is only
possible "online", namely, in the running NCU. The data can be transferred using
either a USB stick or network connection from the HMI user interface
(commissioning/HMI area) or using a network connection and the WinSCP tool.
IMPORTANT: the file names for configuration files must normally be written in
lowercase characters.
The 9990 SW_OPTIONS display MD has no significance. All HMI options must
be activated from the license management.
The "additional 256 MB HMI user memory on the CF card" option is required for
saving parts programs and archives on the CF card ("local drive"). Warning: be-
cause the NCK general reset also clears the option, the "local drive" is no longer
available until the option is reset. Any existing data is retained.
For the operation of an NCU without TCU (i.e. with HMI-Advanced on PCU 50), it
is desirable to deactivate the HMI-Embedded. This can be done using the "sc dis-
able hmi" command in the Service Shell.
The copying of a file to the CF card with overwrite of an existing file with the same
name causes the "internal error" message to be issued. The file with the same
name must be deleted beforehand.
The 9210 USER_CLASS_WRITE_ZOA display-MD has no effect for "active zero-
point offsets" in the Parameter area.

Section 2 Update Agent Commissioning Software
Notes
When the Update Agent CD is inserted, the installation process normally starts
automatically. If this does not occur, start the installation by executing Setup.exe
in the root directory of your CD.
Start the installa-

tion by selecting
the softkeys
Installation notes are contained in the “siemensd.txt” file. Software notes that
could not be placed in the documentation are also contained there.

Section 3 HMI: Language/Technology
Notes
3 HMI/Technology
The use of a TCU does not require any special software installation. All required
information is contained on the NCU memory card. This is also the case for the
JobShop variants.
When a PCU50.3 is used, additional software must be installed, in particular for

JobShop. Proceed as follows:
While observing the notes contained in the 840D sl CNC Commissioning Manual,
Part 3 (ShopTurn or ShopMill), copy the data from the PCU50.3 directory of your
JobShop CD into the D:\Install directory of the PCU50.3. Then restart the
PCU50.3. ShopMill or ShopTurn will be installed on the PCU50.3 during the sub-
sequent startup. The installation completes after answering the resulting prompts
and the subsequent restart of the PCU50.3.
Any required foreign languages should now be installed. Observe any notes con-
tained in the "Siemensd.txt" file in the root directory on the associated CD.
Deactivate the DHCP Server in the NCU for PCU50.3!

• sc disable dhcp

Section 4 PLC: Program
Notes
4 PLC Program
Prior to the commissioning of the NCU and drives, a PLC program that contains
the hardware configuration of the machine must be loaded into the controller. The
PLC alarm text can also be installed at this time in f:/user or /card/oem/sinumerik/
hmi/lng/deu/ to allow any problems in the external I/O devices to be diagnosed
during the initial commissioning phase.
Particular attention must be paid to the commissioning startup sequence of the
controller and the drives. The necessary steps using the example of a machine
with 2 NXes, SMC, SMD and direct measuring systems are described on the fol-
lowing pages. An HT8 and three handwheels are also contained.
SP X B Y/Z
NCU ALM SMM SMM SMM DMM NX
720 16kW 30A 9A 9A 9A 15
6FC5372-0AA00-0AA0
6SL3040-0NB00-0AA0
6SL3040-0NB00-0AA0
6SL3130-7TE21-6AA1
6SL3120-1TE23-0AA1
6SL3120-1TE21-0AA1
6SL3120-1TE21-0AA1
6SL3120-1TE21-0AA1
S S H
M M U
C C B
Switch-on startup
The operating and display elements of the NCU important for the switch-on and
the startup of the SINUMERIK 840D sl are shown in the following figure:
• Various fault and status LEDs
• Status display (7-segment display)
• RESET pushbutton
• NCK commissioning switch (left-hand side)
• PLC mode switch (right-hand side)
• CompactFlash slot

Notes
LED display
• RDY (yellow) -> Read-write access to CF card,

• RDY (red) -> Watchdog (no NCK Ready),
• RDY (green) -> not used for SINUMERIK
• RUN (green) -> PLC running
• STOP (yellow) -> PLC stopped
• SU/PF (yellow) -> PLC forcing active
• SF (red) -> General PLC fault, see diagnostic buffer
• DP1 (red) -> Fault on PROFIBUS (X126)
• DP2 (red) -> Fault on PROFIBUS (X136)
• OPT (red) -> Fault on option module
NCK and PLC general reset
For the initial commissioning of the PLC, a PLC general reset must be performed
after the switch-on and startup of the NCU. To attain a defined initial state of the
complete system (NCK and PLC), the NCK must also be reset.
• PLC general reset
The general reset by deleting and initializing all system and user data
places the PLC in a defined initial state.
• Cleat NCK data
After a request to clear the NCK, at the next startup of the NCK, e.g.
after NCK reset, all user data is deleted and the system data is reini-
tialized.
NCK and PLC general reset operating steps for the initial startup
If you want to startup the controller for the first time, the following operating steps
must be performed for an NCK and PLC general reset:
1. On the NCU, turn the commissioning and mode switches to the following
positions:
– NCK commissioning switch (labeled SIM/NCK) to "1"
– PLC mode switch (labeled PLC) to "3"
2. Perform a POWER ON (switch on controller).
3. Wait until the NCU shows the following continually:
– LED STOP flashes
– LED SF illuminates
4. Turn the PLC mode switch successively to the following switch positions:
– Briefly to "2"
– Back to "3"
– LED STOP flashes initially with approx. 2 Hz and then illuminates.
5. Turn the switch for NCK and PLC back to position "0".
6. After a successful startup, the status display of the NCU shows the number
"6" and a flashing dot.
– LED RUN illuminates continually GREEN.
7. Perform a new POWER ON.
– PLC and NCK are now in cyclical operation.

Notes
Note
If a hardware RESET or POWER ON is initiated in switch position "3" on the
PLC mode switch, the complete SRAM of the PLC will be initialized and the di-
agnostic buffer not cleared. All user data must the transferred again.
If position "3" is selected for less than 3 seconds, no general reset is requested.
The STOP LED also remains off when the "2"-"3"-"2" switch is not performed
within 3 seconds after the general reset has been requested.
Note
The PLC general reset must be performed for the initial commissioning, module
replacement, battery failure, general reset request by the PLC and PLC up-
grade.
Note
Because no PLC start is performed after the PLC general reset, the following
alarms will be displayed:
• Alarm: “120201 communication failure”
• Alarm: “380040 PROFIBUS DP: configuration error 3, parameter”
• Alarm: “2001 PLC has not started up”
Startup completed
The NCU indicates the following after a successful startup:

• Number "6" and a flashing dot
• The RUN LED illuminates continually GREEN
To continue the commissioning on the user interface of the HMI, the following op-
erating steps must still be performed:
1. Press <Menu Select> or press the PG/PC <F10> button.

2. Press "Commissioning".
3. Press "Password…".
4. Press "Set password".
5. Enter the manufacturer‘s password "SUNRISE".
6. Press "OK".

Notes
The startup has completed.
In the next step, use the SIMATIC Manager to perform the commissioning of the
PLC.
Start SIMATIC Manager
Introduction
The SIMATIC Manager is a graphical user interface for the online/offline editing of
S7 objects (projects, user programs, blocks, HW stations and tools).
You can use SIMATIC Manager
• to manage projects and libraries,
• to invoke STEP 7 tools,
• to make online access to the PLC.
Start SIMATIC Manager

After the installation, the "SIMATIC Manager" icon and a "SIMATIC Manager" pro-
gram item in the "SIMATIC" start menu appear on the Windows desktop.
1. Start the SIMATIC Manager with a double-click on the icon or using the start
menu (as for all other Windows applications).
User interface
Opening the appropriate objects starts the associated editing tool. A double-click
on a program block starts the program editor and the block can be edited.
Online help
The online help for the current window is always called with the F1 function key.
Establishing a communications connection
Introduction
To load the configuration into the PLC, the required communications connection
(Ethernet) from the PG/PC to the PLC must available.
Operating steps for establishing the communications connection to the PLC
The following steps can be used with the SIMATIC Manager to set the communi-
cations connection to the PLC from the PG/PC:
1. Select from the menu command: "Options > Set PG/PC interface ...".
2. Search for the used interface in the "Access path" tab in the "Used interface
parameterization" selection box, e.g. "TCP/IP -> Realtek RTL8139/810x F...".
3. Click "OK" to confirm the parameterization.
Note
Do not select any interfaces marked with “[Auto]”.
Note
The parameterization of the PG/PC interface can be made or changed at any
time from the SIMATIC Manager.

Notes
Creating a SIMATIC S7 project
Introduction
An S7 project must be created before the basic commissioning of the PLC, the
Ethernet and the PROFIBUS communication, and the input/output data areas of
the NCK can be performed. The following steps must be performed:
• Create project
• Add the SIMATIC 300 station
• Add NCU 7x0 to HW Config
• Configure the properties of the network interfaces
• Add the machine control panel and the handwheel
What must be considered?

The PLC can also be loaded from the X130 network interface provided the IP ad-
dress of the Ethernet interface is known.
The loading of an archive can always be performed when the HMI-NCK communi-
cation is available.
Note
The configuring of the data path for the backup/restore of the drive data requires
that the PLC (CP840) is loaded! Currently, the HW Config of the CP840 itself
can ONLY be loaded from the network!
What is different for the PLC configuration with SINUMERIK 840D sl?
The following items differ for the configuration of a PLC project from that for a
SINUMERIK 840Di:
• The PLC address area for the PROFIBUS drive communication be-
gins at 4100 and cannot be changed to a smaller value
• The Subnet ID of the integrated PROFIBUS can be changed, cur-
rently use ID 0046-0010
• The original slot configuration of the drive device from the STEP7
catalog should not be modified
• The PROFIBUS machine control panel must be connected to the
master system on the X126
Creating a project
Introduction
You have started the SIMATIC Manager.
Operating steps
1. To create a new project, select the "File > New" menu command in the SI-
MATIC Manager.
2. Enter the project data in the dialog:
– Name (in the following section, as an example: PLC initial commissioning
840D sl)
– Storage location (path)
– Type
3. Click "OK" to confirm the dialog .
The SIMATIC Manager opens and displays the project window with an empty
structure of the S7 project.

Notes
Adding the SIMATIC 300 station
Introduction
Before you add the required hardware to the S7 project, the following steps must
be performed:
• Add the SIMATIC Station 300 to the project
• Start HW Config
Operating steps
1. Select <right mouse button>, "Add new object > SIMATIC 300-Station"
menu.
2. Double-click the <SIMATIC 300(1)> icon.

3. Double-click the <hardware> icon.
The HW Config for adding the required hardware starts.
4. Select "View > Catalog" in the menu. The catalog with the modules opens.

Notes
Adding NCU 7x0 to the HW Config
Introduction
The "HW Config" user interface shows principally:
• The station window
The station window has two parts. The upper part shows the station
structure graphically; the lower part shows the detail view of the se-
lected module.
• Hardware catalog
This catalog contains the NCU 7X0 that you require for configuring
the hardware.
Use the following operating steps to add, for example, an NCU 720.1.
Operating steps
1. Select "View > Catalog".
2. Search for the module in the catalog under "SIMATIC 300 > SINUMERIK >
840D sl > NCU 720.1".
3. Select "NCU 720.1" by clicking with the left mouse button and drag it with
pressed mouse button in the "Station structure" station window.
Release the mouse button to configure in the dialog the properties of the
interfaces of the CP 840D sl processor contained on the NCU 720.1.
Configuring the properties of the network interfaces
Introduction
You configure the following network interfaces in the STEP7 project to be used to
access the NCU 7X0:
• PROFIBUS DP
• Ethernet
• Integrated PROFIBUS
When a new project is created using the catalog, the configuration of the
PROFIBUS interface will be called automatically.

Notes
PROFIBUS DP without handwheels operating steps
1. Select the NCU 720.1 with the left mouse button and drag it with pressed
mouse button to the "Station structure" station window.
2. Release the mouse button to configure in the dialog the properties of the
PROFIBUS DP interface for the X126 socket (machine control panel).
3. Because you have an Ethernet machine control panel, no configuration is

necessary here. Click "Cancel".
4. The NCU 720.1 module with SINAMICS S120 is added to the HW Config.
Note
By pressing the <F4> button and confirming the prompt for "New assignment"
you can rearrange the display in the station window to make it clearer.
As next step, specify the properties for the Ethernet interface.
The PROFIBUS 1 must be configured so that the CU softkeys, infeed and

drives are displayed on the HMI.

Section 4 PLC: Program 3. Handwheels
Notes
HW Config with handwheel module steps: Activate DP
1. Go with the mouse pointer to the X126 socket and press the right mouse
button.
2. After releasing the mouse button, configure in the dialog the properties of
the PROFIBUS DP interface for the X126 socket (machine control panel /
handwheel module).
3. The equidistant from the dialog must be set using Options button.
The cycle of 2 ms should be set equal to the MD 10050 system cycle. The PROFIBUS for
PLC in the current SW version must have the same parameters (equidistant and cycle time)
as the integrated PROFIBUS. Otherwise an NC alarm will be output.

Notes
PROFIBUS DP operating steps with the handwheel module
1. Select with the left mouse button the handwheel module and with pressed
mouse button move it to the "Station structure" station window.
2. After releasing the mouse button, set the address of the
HANDWHEEL MODULE (normally 6).
3. Open the SINUMERIK HANDWHEEL MODULE folder icon and double-click

the handwheel to add it.

Notes
Handwheel machine data
e.g. 1st +2nd handwheel on MCP 483C IE and 3rd handwheel on
HWM
The NC software can address internally max. 6 handwheels (Index [0]..[5]):

11346 HANDWH_TRUE_DISTANCE = 3 (SIEMENS mode, const. increments)
11350 HANDWHEEL_SEGMENT[0..1] = 7 (TCP/IP)
11350 HANDWHEEL_SEGMENT[2] = 5 (PROFIBUS)
11351 HANDWHEEL_MODULE[0..1] =0
11351 HANDWHEEL_MODULE[2] =1
11352 HANDWHEEL_INPUT[0..1] =0
11352 HANDWHEEL_INPUT[2] = 1 (1st handwheel on HWM)
11353 HANDWHEEL_LOGIC_ADDRESS[0] = 258
11353 HANDWHEEL_LOGIC_ADDRESS[1] = 260
11353 HANDWHEEL_LOGIC_ADDRESS[2] = 262 (data address from
PLC HW Config)
PLC handwheel
The operational status of the handwheel can be diagnosed in the PLC using the
status of the word. This requires the reloading into the area where the status can be
read:
The diagnostic capability of the created handwheel pulses exists independent of the
status of the handwheel selection, EMG-STOP, drive configuration, etc…
The counter of the handwheel pulses is reset to “0” when the PLC is restarted.
No mixed operation between Ethernet and PROFIBUS MCPs!

Notes
Ethernet interface operating steps
The initial commissioning of an internal HMI with a PG/PC requires a configured

Ethernet interface. Our example uses the interface for the X120 socket.
1. Double-click "CP 840D sl" in the base rack of the NCU 720.1. The
"Properties - Ethernet interface CP 840D sl" dialog opens.
2. After clicking the "Properties" button, you can recreate an Ethernet inter-
face.
The interface of the X120 socket is used for the current commissioning of the in-
ternal HMI. You must change the IP address.
1. Enter for the X120 socket the IP address "192.168.214.1" and the subnet-
mask "255.255.255.0".
2. Click "New" and then "OK" to create the Ethernet interface.
3. Click "OK" twice.
As next step, specify the properties for the integrated PROFIBUS.

Notes
Integrated PROFIBUS operating steps
The integrated PROFIBUS for communication with the SINAMICS S120 requires a
single Subnet-ID. This Subnet-ID must be defined for the external HMI in the
MMC.ini.
1. Click in the station window the line of the integrated PROFIBUSes
"PROFIBUS Integrated: DP master system" and click with the right mouse
button to select the "Object properties" menu item.
2. Select the "Properties" button from the "General" tab. Enter the "0046-0010"
ID in the "S7 subnet-ID" field.
3. Click "OK" twice.
Message frame length and input/output addresses

The message frame length and the input/output address for the communication of
the PLC to the drive (can be viewed using the SINAMICS Integrated object prop-
erties) have default settings and do not need to be configured.
As next step, add two NX components.
Add NX to HW Config
Introduction
The sample configuration contains two NX components for the X/Y axis and the B
axis. These components must be also included in the HW Config when the SI-
MATIC-S7 project is created.
Operating steps
1. Select the NX module (NX10, NX15) from "PROFIBUS DP > SINAMICS >
SINUMERIK NX…" in the hardware catalog.
2. Select the "SINUMERIK NX …" module with the left mouse button and drag
it to the "PROFIBUS Integrated DP-Mastersystem" line in the "Station struc-
ture" station window.
3. The "DP Slave Properties" dialog opens.

Notes
In this dialog, enter the address for the integrated PROFIBUS.

By default, "15" is specified for the first NX15.
Note
The NX must be wired appropriately with the NCU using DRIVE-CLiQ. A fixed
DRIVE-CLiQ socket is provided for the associated address.
The following table contains the wiring settings:
1. Enter the address and click "OK".
2. Click "OK" to confirm the wiring message.

3. Release the mouse button to add the NX module (see following figure)

Notes
Repeat these steps and add another NX15 with the address 14.
End the hardware configuration and load it into the PLC
To end the overall configuration and to create the system data for the PLC, the
project must be saved and compiled.
1. Select the "Station > Save and compile" menu.
2. Click the "Load into module" button to load the configuration to the PLC.
The "Select target module" dialog box shows automatically both configured
communications partners.
3. Click "OK" to confirm the loading into these two modules.

4. Confirm the following displayed dialogs with "OK" or "No" for the "…Should
the module be started now (restart)?" prompt.
Note
You can test the communications interface using "Target system > Diagnosis >
Operating status".

Notes
5. Close the "HW Config" window.
In the next step, create the PLC program.
Creating the PLC program
Introduction
The following steps for creating a PLC program describe the creation of a base
program.
The SIMATIC STEP7 documentation describes how you can change and extend a
user program.
Adding the PLC base program

You have performed a hardware configuration, saved and compiled the project,
and created the system data for the PLC.
You have installed the Toolbox software that also contains the libraries for the
PLC base program of an NCU 7x0.
The following operating steps describe the opening of a library and the copying of
the sources, the icons and the individual blocks into your project.
You are in the base screen of the SIMATIC Manager.
Open library and sources, copy icons and blocks operating steps
1. Select the "File > Open " menu and then the "Libraries" tab.
2. Select the library of the PLC base program, e.g. "bp7x0_11" and click "OK"
to confirm the dialog.
You have added the library and selected the PLC program from "840D sl
PLC initial commissioning > SINUMERIK > PLC 317 2DP > S7-program".

Notes
3. Copy the sources, blocks and icons into the PLC program.
OB 1 overwrite
The adding of the blocks overwrites the existing organization block OB1. Confirm
the prompt with "Yes" to overwrite the block.
You have created the PLC base program.
In the following section, you modify some data in the OB100 for the machine con-
trol panel.
Modifying the Ethernet machine control panel in the OB100
Introduction
If the configuration has been set as described below, the PLC base program auto-
matically transfers the signals of the machine control panel (MCP signals) and the
addresses of the MCP in the HW Config.
Operating steps
Open "OB100" under "blocks" with a double-click.
The following parameters must be set in the OB100:
MCPNum := 1
MCP1IN := P#E 0.0
MCP1OUT := P#A 0.0
MCP1StatSend := P#A 8.0
MCP1StatREc := P#A 12.0
MCPBusAddress := 192
MCPBusType = B#16#55
This completes the configuration of the PLC base program.
In the next step, load the project into the PLC.
PLC communication - BHG only using GD circles. No parameterization of FB 1.
Project for PLC
Introduction
To load the configured PLC project, the following prerequisites must be satisfied:

Notes
Prerequisite
• An Ethernet network connection exists between STEP7 and the PLC.
• The configuration to be loaded represents the actual station structure.
• NCU7x0 is active:
– NCK is in cyclical operation
– PLC is in the RUN or STOP state
General conditions
The following general conditions for the system data blocks govern the loading of
the configuration:
• HW Config
When the configuration is loaded using HW Config, only those modules with
their associated system data blocks selected in HW Config for loading the
configuration are loaded. However, for example, global data defined in the
SDB 210 is not loaded from the HW Config.
You have loaded the HW Config into the module in the previous section,
"Complete hardware configuration and load into the PLC".
• SIMATIC Manager
When the configuration is loaded using SIMATIC Manager, all system data
blocks are loaded into the module. The following operating steps describe
the loading of the system data blocks into the module (PLC).
Note
When the PLC program is loaded in the "RUN" operating state, each loaded
block becomes active immediately. Because this can cause inconsistencies
for the execution of the active PLC program, prior to loading the configura-
tion, the PLC should be placed in the "STOP" operating state.
Operating steps for loading system blocks into the module

1. To load the configuration of the system blocks, switch to the SIMATIC Man-
ager.
2. Select in the SIMATIC Manager in the directory of the PLC the "Blocks >
right mouse button > Target system > Load" directory (see following figure)
or click the "Load" icon .

Notes
3. If no connection has yet been established to the target system, you must
successively confirm the following dialog prompts with the specified re-
sponse:
– For "Check the required sequence of the blocks for the correct function" -
> "OK"
– For "Should the system data be loaded?" -> "Yes"
– For "Should the system data on the module be completely deleted and
replaced with offline system data? -> "Yes"
– For "The module is currently in the STOP state. Should the module be
started now (restart)"? -> "No"
You have now loaded the PLC program into the PLC and the PLC is in the
"STOP" state.
Note
If the PLC has been stopped using the SIMATIC Manager, it must also be
started using the SIMATIC Manager. However, a start using the PLC mode
switch is also possible.
Warning
A "NCK reset" is needed to synchronize the PLC NCK.
Perform NCK reset
Introduction
You are in the "Commissioning" menu on the HMI:
Note
Because you have an Ethernet machine control panel with Ethernet hand-
wheel, a "7" for "Ethernet" must be entered for each of the two handwheels in
the MD11350[x] HANDWHEEL_SEGMENT general machine data.

Notes
The STOP state of the PLC temporarily assumed during loading the configuration
is interpreted by the NCK, with the associated alarm response, as failure of the
PLC.
Alarm response
• Press the button and select the "Diagnosis > Alarms" menu.
The following display of the alarms on the HMI can result:
To synchronize the PLC NCK, a "NCK Reset" is necessary.
Operating steps to initiate NCK Reset
1. Press the button and select the "commissioning" menu.

2. Press the "NCK-Reset" softkey.
3. Answer the "Do you want to initiate an NCK Power-on-Reset (warm start)?"
prompt by pressing the "Yes" softkey.
The PLC enters the RUN state.
PLC initial commissioning completed
You have now completed the initial commissioning of the PLC.

PLC and NCK are in the following state:
• LED RUN illuminates GREEN continually.
• The status display shows a "6" with a flashing dot.
PLC and NCK are in cyclical operation.
You continue with the steps for commissioning the SINAMICS drives.

Section 5 SINAMICS Drives: Configuration
Notes
5 SINAMICS Drives
Commissioning SINAMICS drives
Introduction
You have completed the commissioning of the PLC.
The drive parameters are configured using the HMI in the "Commissioning" oper-
ating area.
Commissioning sequence
The initial commissioning of the SINAMICS drives should be performed in the fol-
lowing order:
1. Transfer the topology to the HMI
2. Establish the factory setting (if a commissioning has already been per-
formed)
3. Update the component firmware (if necessary)
4. Parameterize the infeed (if present)
Note
Prior to starting the commissioning, switch off all drive enables!
5. Parameterize the drive modules

6. Identify the ALM (if present)
7. Optimize the drives
Enter the commissioning of the SINAMICS drives
Introduction
The commissioning of the SINAMICS drives is performed in the "Commissioning"
operating area.
Enter the commissioning of the SINAMICS drives
1. Once you have completed the commissioning of the PLC, you will see the
following user interface.

Notes
The commissioning of the SINAMICS drives has been started. In the next step,
use Fast commissioning to transfer the topology of the drive to the HMI.
NCU Fast commissioning (transfer topology)
Introduction
The Fast commissioning of the SINAMICS drives in conjunction with the HMI al-
lows the following:
• Transfer of the topology of the drive set to the NCK.
With the transfer of the topology, all components connected to the DRIVE-
CLiQ will be detected and the drive-internal data traffic initialized.
• Drive object assignment for the PROFIBUS connection.
The PROFIBUS connection using the associated message frames are pro-
vided with the configuration in the HW Config.
• Drive object assignment for the drive parameters.
Operating steps
1. The cursor is positioned in the "Drive system" menu (see previous figure)
on the Control Unit (e.g. "CU_003").
2. Press the "Drive devices" softkey.
The HMI detects that the topology has not yet been transferred.
The Fast commissioning begins. The following prompts are displayed:

Notes
3. Press "OK" twice to start the Fast commissioning.

During the topology transfer, the following notes appear:
4. Confirm the information with "OK".

The topology matching for the drive components involved for the NCU has
completed.
The following display appears for components detected on the drive group:
As next step, place the NX with the associated drive components into operation.

Notes
Fast commissioning NX (topology transfer)
Introduction
You have performed a topology transfer of the associated drive components for
the NCU.
You have also added two NXs to the NCU in the HW Config.
When you click the <Recall> button to switch to the "drive system" menu, you will
receive an overview of the associated components.
The NX ("CU_CX32_126") is the only drive device that does not yet have any sub-
ordinate drive components.
You have two possibilities of performing the topology recognition for additional
drive modules:
• Topology recognition using the "Drive system" menu
• Topology recognition using the "Drive devices" menu
Operating steps using the "Drive system" menu

1. Use cursor keys to select the NX (e.g. " CU_CX32_126").
2. Press the "Drive devices" softkey.
The HMI detects that no topology transfer has been performed. The Fast
commissioning begins.
3. Start the prompts for the topology transfer by clicking "OK" twice.
4. End the information by clicking "OK".

5. Repeat this procedure for the second NX.

Notes
Operating steps using the "Drive devices" menu
1. You are in the "Drive devices" menu (see last figure "Menu "Drive devices"
after topology matching").
2. Press the "Drive device+/Drive device-" vertical softkey to select the next
drive module, the NX (e.g. " CU_CX32_126").
3. The HMI detects that no topology transfer has been performed. The Fast
commissioning begins. Start the prompts for the topology transfer by click-
ing "OK" twice.
4. End the information by clicking "OK".

5. Repeat this procedure for the second NX.
Topology matching completed

The topology matching for the drive devices with the associated drive components
has completed.
As next step, you can establish the factory setting.
The software supplied on the CompactFlash Card is initialized with the factory set-
tings.
For the initial commissioning, you can continue with the steps for performing the
updates of the component firmware.
If you have already performed a commissioning, then continue with the operating
steps for establishing the factory settings. You must then perform another topol-
ogy matching.
If it does not continue without message, the temporary setting of MD13150

SINAMICS_ALARM_MASK to “FFFF” rather than “909H” helps.
If an error occurs during the drive archive import, cancel the import and view
“Commissioning / Drive System / Drive Devices / Topology”.
The problem devices/ports are highlighted in color there.

Notes
Establish the factory setting
Introduction
Prior to establishing the factory setting, ensure that the PLC no longer issues any
enable to the drive.
Procedure for activating the factory settings

1. You are in the "Commissioning > Drive system > Drive devices" menu.
2. Press the "Control Unit MD" softkey.
3. Use the "Drive device+/Drive device-" vertical softkeys to select the NCU or
NX for which the factory setting is to be made.
4. To check when the factory setting activation has completed, select the
r3988 parameter for monitoring.
5. Press the "Save/Reset" vertical softkey.
6. Press "Factory settings" and answer the subsequent "Do you really want to
…?" prompt with "Yes".
7. Communication will be lost temporarily. During this time, "#" will be dis-
played for the machine data values.
8. Check startup status: r3988 = 200H, if yes, then press the "Save/" softkey to
save the factory settings.
9. Wait until the "drive [drive name (drive number)] has been saved" message
line is output.
10. Switch off the system (drive set without power).
11. Switch on the system again to bring in the next step all SINAMICS compo-
nents to a single firmware version.
Should problems occur, WinSCP can also be used to directly delete the /card/
user/sinamics/data directory.
Updating the component firmware
Introduction
Before the initial commissioning, all SINAMICS components should be brought to
a single firmware version. The associated required software is stored as part of
the SINAMICS software on the CompactFlash card. An update of single compo-
nents can, for example, be necessary after a component replacement and will
then be indicated with the drive-specific alarm A01006 "Firmware update DRIVE-
CliQ component <no.> required".
Prerequisite
All NCU/NX components can be addressed (connected using DRIVE-CLiQ).
Operating steps
1. You are in the "Commissioning > Drive devices > Configuration" menu .
2. Select the NCU or NX using the "Drive device+/Drive device-" vertical soft-
key.
3. Press the "Load firmware..." vertical softkey.
4. The "Load all" softkey can be used to access all associated components.
Note
Depending on the form of the SINAMICS drive group, a complete update of
the component firmware on the CU/NX can take approx. 30 minutes.
A flashing LED indicates the component on which the firmware is being up-
dated.

Notes
5. Answer the prompt "Should the firmware from the CompactFlash card be
loaded into the component?..." with "Yes".
6. Press "OK" when the firmware update has completed.
7. This procedure must be started for each drive device (NCU/NX)!
You can now continue with the parameterization of the drive components.

Notes
Commissioning using a drive wizard
Introduction
On the HMI, perform the drive configuration using a drive wizard. You configure
the following drive components:
• Active Line Module (infeed)
• Motor Module, motor and encoder (drives)
Drive configuration
The drive configuration can be called from the "Commissioning > Drive system"
menu.
1. Press the appropriate softkey for the drive component that you want to con-
figure:
– "Infeeds" for ALM
– "Drives" for SERVO
2. The configuration is performed as follows:
– Select the component using the "infeed+/infeed-" or "drive+/drive-" vertical
softkey
– Press the "Change" vertical softkey and execute the drives wizard using
the "Next >" horizontal softkey.
– In the displayed dialog, parameterize the appropriate configuration.
The following "Infeed parameterization" and "Drive component parameterization"
sections list the dialog in detail.

Notes
Parameterization of the infeed
Introduction
You want to configure/parameterize the infeed (Active Line Module) for your SI-
NAMICS drive. You have selected the "Commissioning > Drive system > Infeeds"
menu. You are in the following menu:
Operating steps
1. If several infeeds are present, select the infeed using "infeed+/infeed-".
2. Press the "Change" vertical softkey.
3. Confirm the "...Pulse lock prerequisite" message with "OK".
4. If necessary, assign a name.

5. Execute the drives wizard using the "Next >" horizontal softkey.
6. The preassigned settings in the following dialogs are default settings and
can be accepted with "Next >":

Notes

Notes
7. The configuration of the infeed has completed. You can check the configu-
ration in the summary.
8. Press the softkey "Finish >".
The HMI transfers the configuration to the infeed and saves it.
9. Press the "Recall" button to configure the drives in the next step.

Notes
Parameterization of the drives
Introduction
You use the drives wizard to parameterize/configure the following components for
a drive:
• Motor Module (power unit)
• Motor
• Encoder
Parameterize/configure
You are in the "Commissioning > Drive system" menu
1. Press the "Drives" softkey to parameterize/configure the following drives:

– Drives with a third-party motor
– Drives with SMI (DRIVE-CLiQ)
The drive wizard identifies the associated drive construction and guides you
through the parameterization in the dialog.

Notes
Drives with a third-party motor
Introduction
If a Motor Module (power unit) is connected with a motor whose encoder is con-
trolled using SMC (Sensor Module Cabinet), namely not using SMI (Sensor Mod-
ule Integrated), you then have various configuration possibilities.
• Standard motors contained in a list with the associated motor data.
• Third-party motors with motor data sets (MDS) that can be selected from a
list or whose motor data can be freely configured.
In our example, a power unit should be configured with a third-party motor and
encoder. You have selected the "Commissioning > Drive system > Drives" menu.
You are in the following menu:
Operating steps
1. Use the "drive+/drive-" vertical softkeys to select the drive.
3. If a commissioning has already been performed, press "Recommission" and
"OK".

Notes
4. The drive wizard identifies the power unit (Motor Module). You can assign a
name.
5. Execute the drives wizard using the "Next >" horizontal softkey.
6. The following dialogs for parameterization are displayed successively:
7. Select the "Enter motor data" button and the motor type.
8. Press "Next >".
9. You can select the brake control in the "Motor holding brake configuration"
dialog.
If during the topology transfer an attached brake is detected, the system will
automatically activate the brake control and show "Brake control after exe-
cution control" as standard here.
10. Press "Next >".

Notes
11. Use the "Cursor Up/Cursor Down" keys to select in the motor data list the
parameters to be changed.
12. Enter the motor data.
13. Press "Next >". If you have activated the "Equivalent circuit diagram data"
and select "Next >", you will see the following dialog:
14. You can enter further motor data.

15. Press "Next >".

Notes
16. For the encoder 1, you can select from previously assigned encoders.
17. Press "Next >".
18. Select the motor encoder from the list.

19. Press "Next >".

Notes
20. Check/setup the number of DDS (Drive Data Set) that can be used.
21. Select the closed-loop control and the message frame.
22. Press "Next >".
23. Select OFF2 as terminal assignment for input 2.

24. Press "Next >".

Notes
25. The configuration of the drive module with third-party motor has completed.
You can check the configuration in the summary.
26. Press the "Finish >" softkey.
27. Confirm the prompt with "Yes".
In the next step, parameterize a drive module with an SMI motor.

Notes
Drives with SMI (DRIVE-CLiQ)
Introduction
You have a drive object with a power unit (Single/Double Motor Module) that con-
trols an SMI motor.
With the following operating steps, configure/parameterize the power unit, SMI
motor and encoder.
You have selected the "Commissioning > Drive system > Drives" menu. You are
in the following menu:
Operating steps
1. Use the "drive+/drive-" vertical softkeys to select the drive module.
2. You can use the field for the "Recognition using LED" to check which hard-
ware module is currently being configured.
When you click the field, an LED on the Motor Module illuminates.

Notes
4. The drive wizard identifies the power unit (Motor Module).
You can assign a name.
Press the "Next >" horizontal softkey to execute the drives wizard.
5. The following dialogs for parameterization are displayed successively:
6. The drive wizard identifies the motor.

7. Press "Next >".
8. Select the brake control.

If during the topology transfer an attached brake is detected, the system will
automatically activate the brake control and show "Brake control after exe-
cution control" as standard here.
9. Press "Next >".

Notes
10. For the encoder 1, you can select from previously assigned encoders.
11. Press "Next >".
12. The drive wizard automatically detects the encoder.

13. Press "Next >".

Notes
14. Check/setup the number of DDS (Drive Data Set) that can be used.
15. Select the closed-loop control and the message frame.
16. Press "Next >".
17. Select OFF2 as the terminal assignment for input 2.

18. Press "Next >".

Notes
19. The configuration of the drive module with SMI motor has completed. You
can check the configuration in the summary.
20. Press the "Finish >" softkey.
21. To configure additional drive modules, use the "drive+/drive-" vertical soft-
keys to select the drive module.
Begin the configuration with the "Change" vertical softkey.
You have now completed the configuration, in the next step, check in the supply
system data for the power supply and, if necessary, make the appropriate set-
tings.

Notes
Check/set the power supply system data settings for the power
supply
Introduction
The power supply system data setting of the power supply in the SINAMICS must
be checked/set during the commissioning!
Procedure for checking/setting the power supply system data settings

To check/set the power supply system data in the SINAMICS, proceed as follows:
1. In the "Commissioning > Machine data > Infeed-MD" operating area, select
the machine data for the infeed (ALM).
2. Set ALM: p10=1
3. Enter ALM: p210= current power supply system (rated) frequency at the
installation location
4. Enter ALM: p211= current power supply system (rated) voltage at the instal-
lation location
5. Set ALM: p3900=3 (implicit execution p340=1)
6. Set ALM: p3410=5 perform power supply system identification (see
"Identification ALM->Infeed/configuration" section, "Manual power supply
system identification of the ALM" section)
The saving of any changed p210/p211 parameters is performed as part of the
power supply system identification and does not need to be explicitly initiated
manually.

Notes
Identification/optimization ALM->Infeed
Introduction
The identification of the ALM performs an optimization of the closed-loop control in
the ALM. For this purpose, for example, the inductance and capacitance of the DC
link are determined and the optimum controller data for the boost converter deter-
mined.
The identification can be performed only when the controller with the drive has
been placed in operation.
Procedure for the automatic identification of the ALM

The identification of the ALM is performed automatically by the system in the cur-
rent SINAMICS version when the X122.1 enable terminal is activated after an ini-
tial drive commissioning. For this purpose, an internal automatic optimization proc-
ess is started, duration approximately 20 seconds.
The X122.1 enable terminal should not be switched off during this optimization
process to avoid terminating the optimization. If the optimization was terminated, it
can be performed later user-controlled using manual identification.
Procedure for the manual identification of the ALM

For the identification of the ALM, proceed as follows:
1. Remove the ALM enable (OFF1) (X122.1) by the commissioning technician.
2. Select the machine data for the infeed (ALM) in the "Commissioning > Ma-
chine data > Infeed-MD" menu.
3. Initiate the identification on the ALM: p3410 = 5.
4. Activate the ALM enable (The enable must remain during the processing of
the first step of the identification!).
5. The controller data of the ALM will be reset automatically and the power
supply system identification starts running.
6. Once the identification has been performed, p3410 is written automatically
to 0 and the values for the controller data of the ALM will be saved auto-
matically. Check: p3402 = 9. (The enable must also remain set during the
processing of this step of the identification!).
7. Remove the ALM enable (X122.1) by the commissioning technician.
8. The optimized data of the ALM will be saved automatically. A manual save
is not necessary (p977 = 1).
Initial commissioning of the SINAMICS drives com-

pleted
Initial commissioning of the SINAMICS drives completed
You have now completed the initial commissioning of the SINAMICS drives.
The transfer of the topology has completed successfully:
• All upper LEDs of the drive modules illuminate GREEN.
• The lower LEDs of the drive modules always illuminate unchanged YEL-
LOW.
You continue with the steps for commissioning the NCK. You have selected the
"Commissioning" operating area.

Section 6 Drive: Configuration
Notes
6 Drive: Configuration
Commissioning NCK<->drive communication

Introduction
The initial commissioning of the PLC and SINAMICS drives has completed.
What is configured next?

You configure the NCK machine data used to communicate with the drive. This is:
• General machine data
The general machine data required for the communication with the drive is
initialized with default values. These values can be transferred during the
initial commissioning. These values are:
– The message frame type for the transfer
– The logical addresses for the PLC
• Axis-specific machine data
For the axis machine data, you specify the axis component for the transfer
of the setpoints and actual values for the associated axis.
General and axis-specific machine data assignment

The following table uses an example SINAMICS S120 component construction
(an NCU (CU), an ALM, three Motor Modules (MM)) to illustrate the assignment of
the NCK machine data for input/output address / message frame / setpoint / actual
value.
1)
Default value, do not change

Notes
Axis drive assignment
You can view on the HMI the assignment of the axis to the drive in the
"Commissioning > Drive system > Drive devices > PROFIBUS connections"
menu.
You can use the "Change..." vertical softkey to change this assignment.
Input/output address and message frame configuration
Introduction
The following general machine data is initialized with default values (also see the
previous table).
MD13050 DRIVE_LOGIC_ADDRESS (axis address)
MD13060 DRIVE_TELEGRAM_TYPE (message frame type)
MD13120 CONTROL_UNIT_LOGIC_ADDRESS (CU address)
Note
Because these values agree with the initialization values in the HW Config,
no customization is required here.
Setpoint and actual value configuration
Introduction
The following axis machine data must be customized for each axis (also see the
previous table):
• MD30110 CTRLOUT_MODULE_NR (setpoint channel)
• MD30220 ENC_MODUL_NR (actual value channel)
• MD30130 CTRLOUT_TYPE (setpoint output type)
• MD30240 ENC_TYPE (actual value acquisition)

Notes
Operating steps
1. Select the Axis-MD softkey in the Commissioning > Machine data operating
area.
2. Use Axis+ to select the appropriate axis.
3. Find the MD30110 CTRLOUT_MODULE_NR for the setpoint channel.
4. Enter the drive number.
5. Find the MD30220 ENC_MODUL_NR for the actual value channel.
6. Enter the drive number.
7. Find the MD30130 CTRLOUT_TYPE for the setpoint output.
8. Enter "1".
9. Find the MD30240 ENC_TYPE for the actual value acquisition.
10. Enter "1" for incremental encoder or "4" for absolute encoder.
11. Use Axis+ to select the appropriate next axis and continue with step 3 for
the next drive.
NCK<->drive communication commissioning completed
NCK-PLC communication commissioning completed

You have brought the following into operation:
• PLC
• SINAMICS drives
• NCK-PLC communication
The basic commissioning is now finished. You can now move the axes.

Section 7 HT8 Inclusion
Notes
HT8 commissioning
Prerequisites:
• Only in conjunction with PCU50
• Deactivate the DHCP server on the NCU (sc disable dhcpsvr –x120)
Set the MCP address (here 191) under TCU settings (Recall + Select menu). This
value must also be parameterized as bus address on the FB1.
It is better to start the "Settings system network" manager on the PCU50 and
make the required entries there (MCP, index and VNC connection).
The connection to the NCU is required only when the machine control panel of the
HT8 or the user keys in the PLC program are to be used. Otherwise, the VNC
connection to 192.168.214.1 can be omitted.

Section 7 HT8 Inclusion
Notes
For calling the FC26, supply the BAG parameter with B#16#11 if the HT8 is used
as second MSTT.
Set the MCP2Stop parameter in the DB7 to True before the HT8 is removed.
TCU settings
Use TCU settings (Recall + Select menu) to set the MCP address (here 191). This
value must also be parameterized as bus address on the FB1.

Section 7 Diagnostic Aids
Notes
What actually happens during booting?
Start from the network
The standard associated with PXE is the Bootstrap Protocol (BOOTP) that a
server uses to distribute all configuration information to the booting clients in the
LAN. Because the Boot Server maintains all client data centrally, all devices can
be configured at a single location. One of the concrete implementations of this
procedure is the Preboot Execution Environment (PXE) developed by Intel.
At switch-on, the client sends to port 67 a boot request as broadcast to all other
devices in the LAN segment. Because at this time it does not yet have any IP ad-
dress, it uses 0.0.0.0 as sender address. It also sends the MAC address of the
LAN adapter stored in the firmware.
When the boot request reaches a Boot Server, it checks in its client database
whether the MAC address has been entered there. If it finds an entry, further con-
figuration details, such as the IP address and the operating system to be booted
with the IP address of the server that provides the operating system for this client,
are stored there.
The Boot Server sends the configuration information as broadcast to port 68 to-
gether with the MAC address of the requesting client. The device with the match-
ing MAC address accepts the response and configures the LAN adapter with the
data transferred from the Boot Server; the other network devices with a different
MAC address reject the broadcast. The client can now acts as a normal network
node with valid IP address and load its operating system from the LAN.
What does this error mean?
There is no Ethernet connection to the NCU!

Notes
If S4 is set to “F”, access to the PLC is no longer possible!
Structure of the extended DB2

Notes
Diagnostic aids
Fan module
After the failure or the removal of the fan module, the 8 appears on the seven-
segment display, RDY flashes red and all other LEDs illuminate yellow.
NCU SW card missing
Green, continuous light

Yellow, continuous light
Red, continuous light

Controlled dark
ADI4
The seven-segment display on the NCU changes to “F” when an ADI4 is inserted.
Directories on the CF card
Directory File(s) Meaning
/card/system ... Linux operating system (=BESY)

/card/keys ... License key
/card/siemens Sinamics.cfs Sinamics BESY
/card/siemens/sinumerik nck.cfs/plc.cfs/cp.cfs BESY NCK/PLC/CP
/card/siemens/sinamics/ pm0000nn.acx Macros (nn=1, 5, 150 399 ..)
data/pmacros/
device/p15/
/card/user/sinamics/data ps0000nn.acx Boot files (nn=0,1, 99)
/card/user/system/etc/ original.arc Data backup on CF card
/card/user/system/etc basesys.ini IP address settings ...

Diagnostic aids Notes
When an electrical connection is made to the MCP, all LEDs at the front of the
MCP flash while no communication is taking place between the MCP and the
PLC.
When the "Stop feed" and "Release feed" keys are pressed simultaneously, the
version number of the current software version is displayed using the now continu-
ally illuminating LEDs.
When the "Stop feed" and "Release feed" keys are pressed, a position of the IP
address is displayed each time the "Release spindle" button is pressed.
Default IP address example: 192.168.214.192
Display of the first part of the IP address: 192
The S1 switch is used to select the type of the handwheels used on the module:
• Differential handwheels
Switch S1 closed (supplied state)
• TTL handwheels
Switch S1 open
The S2 switch is used to set the address with which the MCP is addressed from
the PLC user program:

Section 7 Service Aids
Notes
Service aids
When an TCU is used, the service menu of the PCU50.3 can no longer be used
without separate monitor. The ServiceCenter Backup-Restore whose icon lies on
the desktop can be used as replacement.
Machine control panel

If an MCP IE (Industrial Ethernet) is connected to a controller, it is accessed from
the NCU with the address set at this time. Subsequent changes of the address
settings by S2 on the MCP have no effect. Work-around: Use WinSCP in the
card/system/etc/ directory to delete the udhcpd-eth0.leases file, then reboot the
NCU and the MCP.

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A68 Commissioning Startup Sequence

Diagnosis/service aids Section 7

Machine acceptance tests A103

SINUMERIK 840D sl Initial commissioning, training manual Page 1 A68

The following software is required:

The required software should be installed on the commissioning PC as fol-

SINUMERIK 840D sl Initial commissioning, training manual Page 2 A68

Caution: Depending on the hardware, the installation process can

Start the installa-

SINUMERIK 840D sl Initial commissioning, training manual Page 3 A68

Start the extract by se-

You must now select and confirm the save location.

The installation process is now identical for both versions.

Start the SETUP.EXE, for example, with a double-click.

SINUMERIK 840D sl Initial commissioning, training manual Page 4 A68

Now only the GSD files from \toolbox\8x0d\GSD need to be installed.

SINUMERIK 840D sl Initial commissioning, training manual Page 5 A68

Si ... .gse English

Click the Install button.

SINUMERIK 840D sl Initial commissioning, training manual Page 6 A68

SINUMERIK 840D sl Initial commissioning, training manual Page 7 A68

HMI-Advanced can also be installed in the form of the commissioning tool on

SINUMERIK 840D sl Initial commissioning, training manual Page 8 A68

You can find this setting as follows:

SINUMERIK 840D sl Initial commissioning, training manual Page 9 A68

Make the following setting there:

SINUMERIK 840D sl Initial commissioning, training manual Page 10 A68

SINUMERIK 840D sl Initial commissioning, training manual Page 11 A68

Possible parameters for sc:

Further information about sc is contained in the CNC Commissioning Manual,

SINUMERIK 840D sl Initial commissioning, training manual Page 12 A68

NCU SysSW CD figure: Structure of the software version 1.3

This software is supplied as an update image.

Warning: For an update, always use sc restore –update … to ensure

An update using TCU requires a USB keyboard (switch uppercase/

SINUMERIK 840D sl Initial commissioning, training manual Page 13 A68

1.1 Installation of the NCU Service System on a USB Stick:

1.2.1 Update using WinSCP

SINUMERIK 840D sl Initial commissioning, training manual Page 14 A68

Notes for the PLC:

SINUMERIK 840D sl Initial commissioning, training manual Page 15 A68

Notes for the PLC:

Notes for HMI-Embedded:

SINUMERIK 840D sl Initial commissioning, training manual Page 16 A68

Start the installa-

SINUMERIK 840D sl Initial commissioning, training manual Page 17 A68

When a PCU50.3 is used, additional software must be installed, in particular for

Deactivate the DHCP Server in the NCU for PCU50.3!

SINUMERIK 840D sl Initial commissioning, training manual Page 18 A68

SINUMERIK 840D sl Initial commissioning, training manual Page 19 A68

• RDY (yellow) -> Read-write access to CF card,

NCK and PLC general reset

SINUMERIK 840D sl Initial commissioning, training manual Page 20 A68

The NCU indicates the following after a successful startup:

1. Press <Menu Select> or press the PG/PC <F10> button.

SINUMERIK 840D sl Initial commissioning, training manual Page 21 A68

Start SIMATIC Manager