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SINUMERIK FM-NC

Installation and Start-Up Guide 07.2000 Edition

Manufacturer/Service Documentation

Preface, Contents

General Preparations Design

1 2 3 4 5 6 7 8 9 10 11 12 13 A B

SINUMERIK FMNC

Settings, MPI Nodes EMC and ESD Measures

Installation and Start-up Guide Power On and Power-Up Manufacturer/Service Documentation Parameterization of the FMNC PLC Alarm and Message Texts Axis and Spindle Dry Run Drive Optimization Data Saving
Valid for: Control SINUMERIK FMNC Software Version 3

Software/Hardware Replacement Miscellaneous Abbreviations References General Index

07.2000 Edition

SINUMERIK documentation
Printing history Brief details of this edition and previous editions are listed below. The status of each edition is shown by the code in the Remarks column. Status code in the Remarks column: A . . . . . New documentation. B . . . . . Unrevised reprint with new Order No. C . . . . . Revised edition with new status. If factual changes have been made on the page since the last edition, this is indicated by a new edition coding in the header on that page. Edition 07.94 06.95 04.96 07.2000 Order No. 6FC5 297-0AB00-0BP0 6FC5 297-2AB00-0BP0 6FC5 297-3AB00-0BP0 6FC5 297-3AB00-0BP1 Remarks A C C C

This manual is included in the documentation available on CD-ROM (DOCONCD) Edition Order No. Remarks 09.01 6FC5 298-6CA00-0BG1 C
Trademarks SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr und SIMODRIVEr are trademarks of Siemens. Other product names used in this documentation may be trademarks which, if used by third parties, could infringe the rights of their owners.

Further information is available on the Internet under: http://www.ad.siemens.de/sinumerik

Other functions not described in this documentation might be executable in the control. However, no claim can be made regarding the availability of these functions when the equipment is first supplied or for service cases. We have checked that the contents of this document correspond to the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information contained in this document is, however, reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement. Subject to changes without prior notice.

This publication was produced with Interleaf V 7 The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including those created by patent grant or registration of a utility model or design, are reserved.

Siemens AG 1994 2000. All rights reserved.

Order No. 6FC5 297-3AB00-0BP1 Printed in the Federal Republic of Germany

Siemens-Aktiengesellschaft

Preface
Notes for the reader
The SINUMERIK documentation is organized in 3 parts:

S General Documentation S User Documentation S Manufacturer/Service Documentation

Objective

The Installation and Start-Up Guide provides the information required for start-up and servicing.

Standard scope

This publication describes the structure of the control system and the interfaces of the various components. Also, the procedure for starting up the system is described and all data, signals, PLC blocks and alarms relevant to the startup are listed. Information on the individual functions, the assignments of the functions and the performance data for the various components can be found in more specific documentation (manuals, description of functions, etc.). Separate descriptions are available for user-oriented activities such as writing part programs and operating the control. There are also separate descriptions for work to be performed by the machine manufacturer such as configuring, design, programming of the PLC.

Note This guide contains a description of standard start-up and initial start-up (up to and including axis or spindle). The start-up of other functions can be found in the appropriate function description.

Search aids

To help the reader, this Guide offers not only a list of contents but also the following appendices: 1. List of Abbreviations 2. List of References 3. Index

Siemens AG 2000 All Rights Reserved SINUMERIK FM-NC Installation and StartUp Guide (IAF) 07.2000 Edition

Preface

07.2000

Important This Installation and Start-Up Guide is valid for SINUMERIK FMNC, Software Version 3, with MMC 100/100.2/102 or MMC 103

The SINUMERIK FMNC alarms are listed and described in the References: /DA/, Diagnostics Guide

Further help for start-up and in tracing errors is given in the References: /FB/, D1, Diagnostics Tools

Contents

The Installation and Start-up Guide includes:

S Description of the overall design and the interfaces of the various


components in order to provide an overview of how the individual components interact.

S The procedure for standard start-up, initial start-up and start-up of a standard machine and also data saving.

Target groups

The Installation and Start-Up Guide includes information for:

S the person starting up the installation after it has been configured and
erected,

S the service engineer for checking and interpreting the status displays and
alarms.

Notes

The following notes have a special significance and are used in the documentation:

Note This symbol appears in the documentation whenever background information is provided.

Important This symbol appears in the documentation whenever attention has to be paid to something of particular importance.

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Warning notes

The following warning notes with different level of severity are used in this publication:

Danger This symbol appears whenever death, severe bodily injury or substantial material damage will occur if the appropriate precautions are not taken.

Caution This symbol appears whenever minor bodily injury or material damage can occur if the appropriate precautions are not taken.

Warning This symbol appears whenever death, severe bodily injury or substantial material damage can occur if the appropriate precautions are not taken.

Technical notes
Trademarks
IBM is registered trademark of International Business Corporation. MSDOS and WINDOWST is a registered trademark of Microsoft Corporation. The following notation and abbreviations apply in this documentation:

Notation

S PLC interface signals > IS Signal name (Signal data)


Examples: IS MMCCPU1 Ready (DB10, DBX108.2) i.e. the signal is stored in data block 10, data byte 108, bit 2. IS Feed/spindle override (DB3134, DBB0) i.e. the signals are located for specific axes/-spindles in datablocks 31 to 34, datablock byte 0.

S Machine data > MD: MD_NAME (designation) S Setting data > SD: SD_NAME (designation) S The symbol 8 means corresponds to.
Effectiveness of alterations
After altering data (e.g. machine data) attention must also be paid to the question as to when the alterations will become effective (e.g. after Power ON or IMMEDIATE).

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Further notes

If it is necessary to perform measuring or testing work on the active device, the stipulations and instructions for complying with the accident prevention specifications VBG 4.0 must be observed, in particular 8 Permissible deviations when working on active parts. Other, similar specifications will certainly apply in countries outside of Germany. Suitable electrical tools must be used. Warning

S Repair on equipment supplied by our company may only be carried out by


SIEMENS Service or repair stations authorized by SIEMENS. Any defective parts or components are only to be replaced by parts contained in the relevant spare parts list.

S Disconnect the power supply before opening the equipment. S Emergency Stop facilities according to EN 60204 IEC 204 (VDE 0113 Part
1) must remain operative in all operating modes of the automation equipment. Any disengaging of the Emergency Stop facility must not lead to uncontrolled or undefined restart.

S Wherever faults occurring in the automation equipment can lead to


substantial material damage or even grievious bodily injury, i.e. are potentially dangerous faults, additional external precautions must be taken or facilities must be provided ensuring or enforcing safe operation even when a fault occurs (e.g. independent limit switches, mechanical interlocks etc.).

Caution

S Connecting and signal lines must be installed so as to safely prevent


inductive and capacitive interferences from affecting automation functions.

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Preface

ESD notes

Electrostatically Sensitive Devices Important Handling of electrostatically sensitive devices (ESD)

S When handling electrostatically sensitive components make sure the


operator, workplace and packing material are properly earthed.

S Generally, electrostatically sensitive components must not be touched


unless work has to be carried out on them. Always handle printed circuit boards without touching pins or printed conductors.

S Touch components of the equipment only if


you are permanently earthed by means of an antistatic chain you are wearing ESD boots or ESD boots with earthing strips in conjunction with an ESD flooring.

S Modules may be set down only on electrically conducting surfaces (table


with ESD top, conductive ESD foam plastic, ESD packing bags, ESD transport containers).

S Keep modules away from visual display units, monitors, or TV sets (minimum distance from screen > 10 cm).

S Modules must not be allowed to come into contact with electrically


insulating materials such as plastic film, insulating table tops or clothing made of synthetic fibers.

S 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 instrument, the probe is briefly discharged (e.g. touch the bare, earthed metal control housing).

Use for intended purpose only

The SINUMERIK FM-NC may be used only for the applications provided for in the Installation and Start-Up Guide and only in conjunction with non-Siemens equipment and components recommended or authorized by Siemens.

Contact addresses

Should you encounter problems or have questions on reading the Installation and Start-Up Guide, please contact the Siemens office specified on the reply sheet provided at the end of this manual.

Hotline

If you have any queries, please contact:

S SINUMERIK Hotline for FM-NC and FM354:


Tel.: Fax.: Fax.: Tel.: +49 180 525 8008 +49 180 525 8009 +49 911 895 7002 or +49 911 895 7000.

S SIMATIC Hotline for PLC-CPU and AS300 modules:


J

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Siemens AG 2000 All Rights Reserved SINUMERIK FM-NC Installation and StartUp Guide (IAF) 07.2000 Edition

Contents
1 General Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 2 General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 1-16 1-18 2-23 2-24 2-26 2-26 2-32 2-36 2-36 2-36 2-37 2-37 2-38 2-40 2-46 2-46 2-48 2-49 2-50 2-51 2-52 3-53 3-54 3-55 3-58 3-60 3-66 4-69 4-70 4-71

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.4 2.5 2.5.1 2.5.2 2.5.3 2.6 2.7 2.8 Integration of FM-NC module (NCU 570.2) in the S7-300 PLC . . . . . Overviews of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of connections for FM-NC (NCU 570.2) . . . . . . . . . . . . . . . . Overview of connections for FM 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply requirements of entire S7-300 system . . . . . . . . . . . . . . FM-NC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 354 power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module power supply options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-up battery service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interfaces of operator panel with MMC . . . . . . . . . . . . . . . . . . . . . . . . . Machine control panel interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interfaces of the standard machine control panel . . . . . . . . . . . . . . . . . Interfaces of machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface for customer operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand-held unit (HHU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COROS OP 27 operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Settings, MPI Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.2 3.3 3.4 3.5 MPI networking rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nonstandard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of an MCP and HHU configuration on MPI bus with STEP7 V5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of distribution of MPI addresses . . . . . . . . . . . . . . . . . . . . . . .

EMC and ESD Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.2 Measures to suppress interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measures to protect ESD-sensitive components . . . . . . . . . . . . . . . . .

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Power On and Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 Start-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of system software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of entire system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of FM-NC (NCU 570.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of PLC-CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MMC102/103 BIOS setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of MMC 100/102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of machine control panel (MCP) . . . . . . . . . . . . . . . . . . . . . . . .

5-73 5-74 5-74 5-75 5-76 5-78 5-79 5-80 5-81 5-81 6-83 6-84 6-85 6-87 6-89 6-91 6-92 6-92 6-96 6-100 6-104 6-105 6-105 6-109 6-111 6-120 6-121 6-129 6-135 6-138 6-139 6-140 6-141 6-143 6-145 6-145 6-147 6-149 6-150 6-151 6-153

Parameterization of the FM-NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 6.2 6.3 6.4 6.5 6.6 6.6.1 6.7 6.8 6.9 6.10 6.10.1 6.10.2 6.10.3 6.10.4 6.10.5 6.10.6 6.10.7 6.10.8 6.10.9 6.10.10 6.10.11 6.10.12 6.10.13 6.10.14 6.10.15 6.10.16 6.10.17 6.10.18 6.11 Machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection level strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator control functions for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . Initialization of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK FMNC configuration/system data . . . . . . . . . . . . . . . . . . General configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of operations for initial start-up . . . . . . . . . . . . . . . . . . . . . . . Sequence of operations for starting up a series machine . . . . . . . . . . Axes and spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Encoder matching (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setpoint routing (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Velocity/speed matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring functions (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference point approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference point approach for stepper motors . . . . . . . . . . . . . . . . . . . . Extension to 5th axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic settings for operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration and machine data of local P bus of FM-NC . . . . . . . . . . Spindle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Encoder matching (spindles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speeds and setpoint adjustment (spindles) . . . . . . . . . . . . . . . . . . . . . . Spindle positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring functions (spindles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-up of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.2 7.3 7.4 7.5 7.6 7.7 PLC applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode switch on CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU: Status and error displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU: MPI Multi-point interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU operating status for FM-NC start-up . . . . . . . . . . . . . . . . . . . . . . . Overview of organization blocks, function blocks, DBs . . . . . . . . . . . . Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-155 7-156 7-160 7-162 7-163 7-163 7-165 7-165 8-167 8-168 8-170 8-173 9-177 9-178 9-179 9-180 10-183 10-184 10-184 10-185 11-187 11-188 11-189 11-193 11-194 11-195 11-195 11-196 11-199 11-199 11-200 11-200 11-202 11-204

Alarm and Message Texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.2 8.3 Alarm text files for MMC100/100.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm text files for MMC 102/103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Syntax for alarm text files of cycles and PLC alarms . . . . . . . . . . . . . .

Axis and Spindle Dry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2 9.3 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Drive Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 10.2 10.3 General principles of optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aim of optimization procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the speed control loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Data Saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 11.2 11.3 11.4 11.5 11.5.1 11.5.2 11.6 11.6.1 11.6.2 11.6.3 11.7 11.8 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving via MMC 100/100.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving via MMC 102/103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving data on a PCMCIA memory card . . . . . . . . . . . . . . . . . . . . . . . . Data saving from MMC 102/103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving from MMC 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving from MMC 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line checksums and MD numbers in MD files . . . . . . . . . . . . . . . . . . . Line checksums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine data numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abortion of MD import . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on loading and saving machine data . . . . . . . . . . . . . . . . . . . . . . Machine/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Software/Hardware Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 12.1.1 12.1.2 12.2 12.2.1 12.2.2 12.2.3 12.3 12.3.1 12.3.2 12.4 12.4.1 12.4.2 12.4.3 12.5 Upgrading FM-NC software (firmware update) . . . . . . . . . . . . . . . . . . . Procedure for updating firmware on FM-NC . . . . . . . . . . . . . . . . . . . . . Procedure for updating firmware on FM354 . . . . . . . . . . . . . . . . . . . . . Upgrading MMC 100/100.2 software . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of MMC 100/100.2 system diskette(s) . . . . . . . . . . . . . . . . Installation of MMC100/100.2 application diskette . . . . . . . . . . . . . . . . Installation of MMC 100.2 software via PCMCIA . . . . . . . . . . . . . . . . . Upgrading MMC 102/103 software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation via MMC 102/103 floppy drive . . . . . . . . . . . . . . . . . . . . . . . Installation via PC/PG to MMC102/103 . . . . . . . . . . . . . . . . . . . . . . . . . Hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special notes for CPU318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM-NC hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-205 12-206 12-206 12-207 12-208 12-210 12-216 12-221 12-225 12-225 12-226 12-230 12-230 12-233 12-233 12-234 13-235 13-236 13-236 13-237 13-238 13-239 A-243 B-249

13

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 13.1.1 13.1.2 13.2 13.3 Tool Box software package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents of tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application of tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assessing machine data via part program . . . . . . . . . . . . . . . . . . . . . . . O & M for FM-NC with OP 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A B C

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-261

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1
General Preparations

1
1-16 1-18

1.1 1.2

General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.1 General requirements

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1.1

General requirements

Introduction

This Installation and Start-Up Guide describes the procedure for starting up the basic control functions. Please refer to Descriptions of Functions/Manuals (see Documentation requirements) for further reference material relating to special NCK, MMC, PLC or drive functions. The following software is required to start up the SINUMERIK FM-NC: 1. PCIN for transmission of data between PC/PG and MMC Order No. 6FX2 0604AA002XB0 (German, English, French). Order from: WK Frth 2. SIMATIC STEP7 3. Tool Box for SINUMERIK FM-NC Order No. 6FC5 2520AX200AB0 Supplied on 3.5 diskettes with: Basic PLC program Sample machine data sets NC variable selector OP27 sample configuration

Software requirements

4. Software for generating user applications and transferring them to MMC: MMC 100: System diskette and applications diskette MMC 100.2: 2 system diskettes and 1 application diskette.

Equipment and accessory requirements

The following equipment and accessories are required to start up the SINUMERIK FM-NC: 1. PC/PG with MPI interface (e.g. PG 740) 2. MPI cable 3. V24 cable with 9-pin connector (socket)

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1.1 General requirements

Documentation requirements

The following documentation is required to start up the SINUMERIK FM-NC: 1. Configuring, Manuals NCU 570 and FM 354 /PHF/ Order No.: 6FC5 297-3AC00-0BP0 2. Operator Components Manual /BH/ Order No.: 6FC5 297-6AA50-0BP0 3. Description of Functions, Basic Machine (Part 1) /FB1/ Order No.: 6FC5 297-6AC20-0BP0 4. Installation and start-up documentation and equipment for starting up analog or stepper drives (according to manufacturers specifications). 5. Lists /LIS/ Order No.: 6FC5 297-6AB70-0BP0 6. Description PCIN /PI/ (supplied with software)

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1.2 Requirements for start-up

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1.2

Requirements for start-up

Requirements for commencing start-up

Before an installation with SINUMERIK FMNC can be started up, it is essential that all mechanical and electrical equipment has been fully installed. The axis and spindle drives have already been started up (speed control loop) according to the relevant manufacturer specifications. The S7300 system has been configured and started up. Customer personnel must be available to provide assistance with configuring tasks and machine operation.

Installation design with SINUMERIK FMNC

The component variants and their design are described in References: /PHF/, SINUMERIK FM-NC manual /S7H/, SIMATIC S7-300 manual /BH/, Operator Components manual

Note The information contained in this Guide regarding

S connection and ambient conditions, S cable installation and lengths, cable shielding, S electromagnetic compatibility (EMC), S earthing system, insulation, class of protection and degree of protection, S back-up batteries, etc.
must be taken into account when the installation with the SINUMERIK FMNC is set up and must be tested prior to start-up.

Jumper connections

The following jumper connections must be made on the components and tested prior to start-up. References: /PHF/, SINUMERIK FM-NC manual /S7H/, SIMATIC S7-300 manual

Note Please refer to the Description of the PLC S7300 for jumper connections on the PLC I/O devices.

Visual inspection/ wiring and cabling

All wiring and cabling must be installed. In order to identify obvious wiring and termination faults, the installation must be inspected visually.

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1.2 Requirements for start-up

Particular attention is to be paid to the following:

S Cable installation
To avoid electrical interference, power and signal cables must not be laid in the same cable duct. A check must be made to ensure that all cables are properly installed/routed and correctly connected to the actual value sensors (measuring system) and to the drives (setpoint). Any cables assembled by the customer must be checked for adequate quality/workmanship, particularly the shield cabling.

S Earthing system check


To ensure fault-free operation of the system, it is essential that any external interference is diverted effectively. The earthing system must comply with the specifications laid down in the SINUMERIK FMNC Planning Guide. In this respect, it is particularly important that: the earthing system complies with requirements stated in DIN VDE 0160, a common earthing system is provided for the NC, drive and machine, the earth connections are taken in a start connection to a central earthing point equipotential bonding is provided between the individual components a PE connection is provided and relays and motors are equipped with interference suppression elements.

S Power supply check


A check must be made to ensure that the power supply cable connections for all S7300 system function modules and the power supply tolerance range are correct.

Machine data

In order to start up the system, the basic data (velocities, timers, names, etc.) and information which were produced in the course of design and configuration of the installation must be made available. These data cover all areas of the control system. The data required to start up basic functions are listed below.

Table 1-1 MD No. General data 10000

Basic data for start-up Machine data name Unit

Machine axis name [axis no.]: 0...3

Channel data 20050 20060 20070 20080 Axis data 30110 30130 30200 30220 30230 Setpoint assignment: Drive number Output type of setpoint Number of encoders Actual value assignment: Drive number Input on drive module Assignment between geometry and channel axes Geometry axis name in channel Machine axis number valid in channel Channel axis name in channel

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Table 1-1 MD No. 30240 30300 30310 30320 31000 31010 31020 31030 31040 31050 31060 31070 31080 31350 31400 32000 32010 32020 32200 32250 32260 32300 34000 34010 34020 34030 34040 34050 34060

Basic data for start-up, continued Machine data name Type of actual value sensing Rotary axis Modulo conversion for rotary axis Modulo 360 degrees display for rotary axes and spindle Direct measuring system (linear scale) [encoder no.]: 0,1 Division period for linear scales [encoder no]: 0,1 Encoder marks per revolution [encoder no]: 0,1 Leadscrew pitch Encoder is directly mounted on machine [encoder no.]: 0,1 Denominator load gearing Numerator load gearing Denominator measurement gearing [encoder no.]: 0,1 Numerator measurement gearing [encoder no.]: 0,1 Stepping frequency at maximum speed (only relevant for stepper motors) Steps per stepper motor revolution (only relevant for stepper motors) Maximum axis velocity Conventional rapid traverse Conventional axis velocity Servo gain factor Rated output voltage Rated motor speed Axis acceleration Axis with reference point cam Approach reference point in minus direction Reference point approach speed Maximum path to reference cam Creep speed [encoder no.]: 0,1 Direction reversal to reference cam Maximum path to reference mark. Maximum distance from 2 reference marks in the case of distance-coded measuring systems. [encoder no.]: 0,1 Reference point approach speed Reference point distance/target point [encoder no.]: 0,1 Reference point value [cam no.]: 0...3 Position measuring system type Reference mark distance [encoder no.]: 0,1 Differential distance between two reference marks with distance-coded scales [encoder no.]: 0,1 Length measuring system is inverted [encoder no.]: 0,1 Exact stop limit coarse Exact stop limit fine Standstill tolerance mm, degrees mm/rev Hz mm/min, rev/min mm/min, rev/min mm/min, rev/min 1/s % rev/min mm/s2, rev/s2 mm/min, rev/min mm, degrees mm/min, rev/min mm , degrees Unit

34070 34080 34100 34200 34300 34310 34320 36000 36010 36030

mm/min, rev/min mm, degrees mm, degrees mm, degrees mm, degrees mm, degrees mm, degrees mm, degrees

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1.2 Requirements for start-up

Table 1-1 MD No. 36050 36100 36110 36200 36300 36400

Basic data for start-up, continued Machine data name Clamping tolerance 1st software limit switch minus 1st software limit switch plus Threshold value for speed monitoring Encoder limit frequency [encoder no.]: 0,1 Tolerance band for contour monitoring Unit mm, degrees mm, degrees mm, degrees mm/min, rev/min Hz mm, degrees

Spindle data 35000 35010 35040 35100 35110 35120 35130 35140 35150 35200 35210 35300 35400 35410 Assignment between spindle and machine axis Gear step change possible Independent spindle reset Maximum spindle speed Maximum speed for gear step change Minimum speed for gear step change Maximum gear step speed Minimum gear step speed Spindle speed tolerance Acceleration in speed control mode Acceleration in position control mode Creep speed Oscillating speed Acceleration in oscillation mode rev/min rev/min rev/min rev/min rev/min Factor rev/s2 rev/s2 rev/min rev/min rev/s2

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Design

2
Integration of FM-NC module (NCU 570.2) in the S7-300 PLC . . . . . Overviews of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of connections for FM-NC (NCU 570.2) . . . . . . . . . . . . . . . . Overview of connections for FM 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply requirements of entire S7-300 system . . . . . . . . . . . . . . FM-NC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 354 power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module power supply options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-up battery service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interfaces of operator panel with MMC . . . . . . . . . . . . . . . . . . . . . . . . . Machine control panel interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interfaces of the standard machine control panel . . . . . . . . . . . . . . . . . Interfaces of machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface for customer operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand-held unit (HHU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COROS OP 27 operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2-26 2-26 2-32 2-36 2-36 2-36 2-37 2-37 2-38 2-40 2-46 2-46 2-48 2-49 2-50 2-51 2-52

2.1 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.4 2.5 2.5.1 2.5.2 2.5.3 2.6 2.7 2.8

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2.1 Integration of FM-NC module (NCU 570.2) in the S7-300 PLC

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2.1

Integration of FM-NC module (NCU 570.2) in the S7-300 PLC

2
Overview
The SINUMERIK FM-NC comprises a SIMATIC S7-300 programmable logic control and an FM-NC function module (NCU 570.2) as an I/O module. In this system, the S7-300 CPU performs the functions of a PLC-CPU while the NC functionality is provided by the FM-NC function module (NCU 570.2). A function module can operate a maximum of four position-controlled axes/spindles. The system can be extended to include a fifth axis/spindle through connection of an FM 354 module to the local P bus of the FM-NC. A maximum of two spindles can be implemented with one FM-NC.

Start-up device e.g. PG740 Operator panel with MMC V24 PC/PG with STEP7

Hand held unit HHU

Operator panel OP 27

MPI Machine control panel (MCP)/ interface to customer op. panel/ narrow machine control panel

to next rack P bus local P bus

PS 24 V 2/5/10 A

SIMATIC S7-300 CPU

IM

SM dig./anal.

SM dig./anal.

FM-NC (NCU 570.2)

FM 354

SM

24 V

C bus

Encoder Servo and/or stepper drive

Encoder Drive 10 V Servo drive

PS IM SM FM 354 CPU MPI

Power supply Interface module Signal module (I/O module) Function module as axis expansion PLC (Programmable Logic Control) of FM-NC Multi Point Interface (multipoint serial interface)

Fig. 2-1

Integration of FM-NC into the S7-300 system

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2.1 Integration of FM-NC module (NCU 570.2) in the S7-300 PLC

NCU 570.2

The NCU 570.2 constitutes the NC area. The NCU 570.2 communicates

S with the SIMATIC S7-300 CPU via the serial P (peripherals) and C (communications) buses,

S with the FM 354 (as axis extension) or with digital input/output modules via
the serial local P bus,

S with up to four servo drives via a "10 V interface and/or with up to four stepper drives via pulse interfaces,

S with incremental or absolute measuring systems via four measuring circuit


interfaces and

S with operator panels (OP), programming devices (PG) and machine control
panels (MCP), etc. of various rating classes via the multi-point serial interface (MPI). The following can be connected via a 20-pin front connector with single-wire terminals:

S 2 probes S 4 sensing elements, e.g. proximity sensors S 2 handwheels.


The NC area can be extended if required by installing an FM 354 which is controlled by the NCU 570.2 via a local bus. Furthermore, additional NC-specific inputs and outputs can be implemented through the installation of additional signal modules (without exceeding the maximum configuration per tier) which are driven via the local P bus.

FM 354

The FM 354 communicates as an axis extension module

S with the NCU 570.2 via a serial local P bus, S with the SIMATIC S7-300 CPU during power-up via the serial local P bus, S with a servo drive via a "10 V interface and S with an incremental or absolute measuring system via a measuring circuit
interface. The following can be connected via a 20-pin front connector with single-wire terminals:

S 4 digital inputs S 4 digital outputs


Start-up
Since the FM-NC is an integral component of the S7-300 installation, with the PLC-CPU acting as the master, the entire S7-300 system must be started up first. To start up the entire S7-300 system, please refer to the following documentation: References: /S7H/, SIMATIC S7-300 manual /PHF/, SINUMERIK FM-NC manual /BH/, Operator Components manual

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2.2
2.2.1

Overviews of connections
Overview of connections for FM-NC (NCU 570.2)

2
Interfaces and front panel elements
Fig. 2-2 shows the interfaces of the FM-NC (NCU 570.2) to the S7-300 system and to the NC machine.

DIN rail Slot for memory module (PCMCIA) Start-up switch

Bus connector (hidden) SIMATIC interface (P bus and C bus) Bus connector SIMATIC interface (local P bus)

Front cover (hinged)

Label plate

Front view without front covers

Start-up switch
SF BAF DC5V DIAG

Slot for memory module (PCMCIA)

X2

X3

X4

Error and status displays

1 1 1 1 1 1 1 1 1 1 2

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0

Compartment for backup battery

Front connector

L+ M L+ M

X5

X6

Power supply connection X10 Fig. 2-2 Layout of interfaces and front elements

Drive interface X2

Measuring system interfaces X3...X6

I/O interface X1

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2.2 Overviews of connections

Interfaces

S SIMATIC interface
Rear-panel connectors (on left in Fig. 2-2) for connecting the NCU 570.2 to other control components via the S7-300 backplane bus (P and C buses) Rear-panel connectors (on right in Fig. 2-2) for connecting NCU 570.2 to S7-300 modules to extend NCU 570.2 functionality (local P bus)

S Drive interface
50-pin D-sub connector (X2) for connecting the power sections for a maximum of four drives (analog drives and/or stepper drives)

S Measuring system interfaces


D-sub sockets (X3...X6) to which up to a maximum of four position encoders can be connected via 15-pin connectors.

S I/O interface
20-pin front connector (X1) for connecting the handwheels, high-speed inputs and probes and for wiring up the NC-READY relay.

S Power supply connection


4-pin screw-type terminal block (X10) for connecting the 24 V load power supply.

S Memory module interface


68-pin memory module interface for PCMCIA (JEIDA memory card)

Operator controls

Start-up switch (rotary switch)

Battery compartment

for connection of a lithium battery, pre-assembled with connector The start-up switch is provided to assist start-up. It can be actuated by means of a screwdriver. 4 LEDs for error and status displays

Displays

S SF (red) Group error


This LED indicates an error status of the NCU 570.2. In order to eliminate the error, it may be necessary to start up or install the system again, to update the firmware or to replace a hardware component.

S DIAG (yellow) Diagnosis


This LED indicates various diagnostic statuses. If you are not using an operator panel (OP) or a programmer (PG) to indicate error statuses, the flashing of this LED will help you to localize the causes of errors.

S BAF (red) Battery fault


Flashing of this LED indicates that the battery needs to be changed. When it lights up continuously, the data contents of the buffered memory may no longer be stored. A restart is required after replacement of the battery.

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S DC 5V (green) Logics supply connected


This LED indicates that the hardware is ready to operate. If it does not light up, check the following:

Is mains power supply OK? Is load power supply defective? Is module incorrectly connected? Is control incorrectly configured (sum of rated and starting currents too high)? or Is module defective?

S LED display when FM-NC (NCU 570.2) is in Normal state


LED SF: LED BAF LED DC 5V LED DIAG OFF OFF ON Rapid, regular flashing = NC sign of life (3 Hz)

Table 2-1 provides you with an overview of the LED error indications on the NCU 570.2 module. In the table, the following mean: 1 0 n/1 x
Table 2-1 SF

= = = =

ON OFF Periodic flashing for indefinite time Not significant for fault/error described

Summary of LED error displays BAF DC5V DIAG Meaning Remark

Hardware/Power supply: 1 1 0 X X X 1 0 0 X X X HW fault1) 5 V failure 24 V failure Replace FM-NC (NCU 570.2) Replace FM-NC (NCU 570.2)/remove external connections Check 24 V incoming supply/remove external connections/replace FM-NC (NCU 570.2)

1) LED combination even when PLC-CPU is switched off or not connected (no 5 V power supply on P bus). Battery monitoring: X 1 X X Battery failure Scan: During power-up Remedy: Replace battery (System must be started up again) Scan: Cyclic Remedy: Replace battery a.s.a.p.

1/1

Battery warning, voltage below limit

Power-up and SW monitoring: (With this error/fault group, we recommend that you run the FM-NC (NCU 570.2) up again with a SW update. If this does not eliminate the error/fault, then the FM-NC (NCU 570.2) must be replaced). 1 1 0 1 x X 1 x X 1 1/1 0 RAM error in COM (power-up aborted) COM power-up error, parameterization by S7-300 missing. Power-up Status display

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Table 2-1 SF 0 0 0 0 0 0 0 0 0 1

Summary of LED error displays, continued BAF X X X X X X X X X x DC5V X X X X X X X X X x DIAG 1 2/1 3/1 4/1 5/1 6/1 7/1 8/1 9/1 10/1 to 17/1 1/1 PLC STOP COM watchdog NCK watchdog Internal NCK SW error: NRK timer/memory/link Internal NCK SW error: Processor FAULTs Internal NCK SW error: Plane run Internal NCK SW error: Stack overflow, MM error COM-NCK power-up error NCK-PLC power-up error Access error on local P bus HW or SW error/fault on a module connected to local P bus of FM-NC After POWER ON or RESET Please contact the SIEMENS AG Hotline (Tel.: +49 9313 / 98 3836) Meaning Remark PLC RUN and POWER OFF/ON

1/1

RAM error

Measuring system monitoring: 1 X X 2/1 Encoder supply failure Check measuring system and connection

Start-up and checksum check, update: 1 1/1 1/1 1/1 X X X X X X X X 1 X 2/1 3/1 No start-up synchronization Update request COM checksum error NCK checksum error Update COM Update NCK Update request after 30 s

After initiation of update: 1/1 1/1 1/1 1/1 0 0 0 x x x x X X X x x x x X X X x 2/1 3/1 4/1 1 4/1 5/1 Update request Checksum error during COM update Checksum error during NRK/NCK update Group error during NRK/NCK decompression Flash deletion in progress Flash programming in progress Update complete, o.k. Status display Status display Status display, power OFF/ON

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Connector pin assignments

Table 2-2 provides you with a list of the connector pin assignments for the power supply and connectors X1 to X6
Table 2-2 PIN PIN assignment of front connectors on FM-NC (NCU 570.2) MD 30120 CTRLOUT_NR Designation

Terminal block for 24 V load power supply 1/3 2/4 L+ (DC 24 V) M (frame)

X1: Handwheel and I/O connection, 20-pin front connector X1 1/2 3/4 7/8 9/10 5 6 11/12 X1 13 14 15 16 17 NCRDY.1/.2 (ready to operate) (NC READY contact) Digit. input 1 (I0/BERO1) Digit. input 2 (I1/BERO2) Digit. input 3 (I2/BERO3) Digit. input 4 (I3/BERO4) Digit. input 5 (I4/MEPU1) For connection of probes please refer to: References: 18 /FB/, M4, Measuring Cycles Digit. input 6 (I5/MEPU2) For connection of probes please refer to: References: 19 20 Not assigned M (reference potential for inputs) /FB/, M4, Measuring Cycles 6 5 Handwheel 1, track A (A1, A1_N) Handwheel 1, track B (B1, B1_N) Handwheel 2, track A (A2, A2_N) Handwheel 2, track B (B2, B2_N) Handwheel voltages: P5_EXT M5_EXT

X3 to X6 (axes 1 to 4): 15-pin D-sub socket connector, measuring system interface X3 to X6 4/6 5 7/9 2/3 10/11 15/14 13/12 1 (X3) 2 (X4) 3 (X5) 4 (X6) Measuring system power supply: P5EXT Measuring system power supply:P24EXT MEXT Absolute encoder: Shift clock cycle (CLS, CLS_N) Incremental encoder: Zero mark (N, N_N) Track A/SSI data (A/DATA, A/DATA_N) Track B (B, B_N)

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Table 2-2 PIN

PIN assignment of front connectors on FM-NC (NCU 570.2), continued MD 30120 CTRLOUT_NR Designation

X2: 50-pin D-sub plug connector, drive interface X2 1/34 2/35 3/36 4/37 5/38 6/39 18/19 40/7 41/8 20/21 9/42 10/43 26/27 44/11 45/12 28/29 14/47 15/48 16/49 17/50 1 2 3 4 4 3 2 1 2 3 4 1 Analog setpoint (SW1, BS1) Analog setpoint (BS2, SW2) Analog setpoint (SW3, BS3) Analog setpoint (BS4, SW4) Clock pulse 1 (PULS1, PULS1_N) Directional pulse 1 (DIR1, DIR1_N) Enable signal 1 (ENABLE1, ENABLE1_N) Clock pulse 2 (PULS2, PULS2_N) Directional pulse 2 (DIR2, DIR2_N) Enable signal 2 (ENABLE2, ENABLE2_N) Clock pulse 3 (PULS3, PULS3_N) Directional pulse 3 (DIR3, DIR3_N) Enable signal 3 (ENABLE3, ENABLE3_N) Clock pulse 4 (PULS4, PULS4_N) Directional pulse 4 (DIR4, DIR4_N) Enable signal 4 (ENABLE4, ENABLE4_N) Servo enable 1 (RF1.1, RF1.2) Servo enable 2 (RF2.1, RF2.2) Servo enable 3 (RF3.1, RF3.2) Servo enable 4 (RF4.1, RF4.2)

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2.2 Overviews of connections

07.2000

2.2.2

Overview of connections for FM 354

Interfaces and front panel elements

Fig. 2-3 shows the interfaces of the FM-354 to the S7-300 system and to the NC machine.

DIN rail

Label on module: FM 354 F.SERVO MOTOR

Bus connector (hidden) SIMATIC interface (local P bus)

Label plate Front cover (hinged) Front view without front covers
SF

Bus connector SIMATIC interface (local P bus)

ENCODER X3

Status and error displays

DC5V DIAG

1 1 1 1 1 1 1 1 1 1 2
ANAL.OUT X2

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0

Front connector I0 I1 I2 I3
RM

Measuring system interface X3 Drive interface X2

Q0 Q1 Q2 Q3

Display for digital inputs and outputs

I/O interface X1

Fig. 2-3

Layout of interfaces and front elements

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07.2000

2.2 Overviews of connections

Interfaces

S SIMATIC interface
Rear-panel connectors for connecting the FM 354 to the FM-NC (NCU 570.2) via the local P bus or to the SIMATIC S7-300 CPU during system power-up.

S Drive interface
9-pin D-sub connector (X2) for connecting the drive unit (analog drive or stepper motor)

S Measuring system interfaces


15-pin D-sub socket (X3) to which one position encoder can be connected.

S I/O interface
20-pin front connector (X1) for connecting the digital inputs/outputs are wiring up the power supply

Displays

12 LEDs for error and status displays

S SF (red) Group error


This LED indicates an error status of the FM 354. In order to eliminate the error, it may be necessary to start up or install the system again, to update the firmware or to replace a hardware component.

S DIAG (yellow) Diagnosis


This LED indicates various diagnostic statuses. If you are not using an operator panel (OP) or a programming device (PG) to indicate error statuses, the flashing of this LED will help you to localize the causes of errors.

S DC 5V (green) Logics supply connected


This LED indicates that the hardware is ready to operate. If it does not light up, check the following: Is mains power supply OK? Is load power supply defective? Is module incorrectly connected? Is control incorrectly configured (sum of rated and starting currents too high)? or Is module defective?

S I0...I3 (yellow) Digital inputs


These LEDs display the enabled input.

S Q0...Q3 (yellow) Digital outputs


These LEDs display the enabled output.

S RM (yellow) Drive unit ready (not used for FM-NC)


This LED indicates that the drive unit is ready.

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2.2 Overviews of connections

07.2000

S LED display when FM 354 connected to local P bus of FM-NC is in Normal


state LED SF: LED DC 5V LED DIAG OFF ON Flashes only in the case of axes with measuring system, at a rate dependent on the set basic clock cycle time of FM-NC (MD_ENC_TYPE=2 or 5 MN 10050 SYSCLOCK_CYCLE_TIME = 0.006 illuminated for 3 s, dark for 3 s) ON only in the case of an axis without measuring system (MD_ENC_TYPE=0; e.g. spindle without measuring system or simulation axis)

LED DIAG

Table 2-3 provides you with an overview of the LED error indications on the FM 354 module. In the table, the following mean: 1 0 n/1 x B
Table 2-3 SF 1 0 1 0

= = = = =

ON OFF Periodic flashing for indefinite time Not significant for fault/error described Flashing

Summary of LED error displays DC5V x 1 1 1 DIAG x 0 0 1 Meaning HW fault or SW error FM 354 power-up not detected by SIMATIC S7-300 CPU RESET FM 354 power-up detected by SIMATIC S7-300 CPU, but 354 module not parameterized as 5th axis by FM-NC or axis without measuring system Normal state; FM 354 as 5th axis of FM-NC with measuring system Remark FM 354 SW update or replace FM 354 module Check SDB 100 in PLC program Module in RESET state Axis parameterized without measuring system or FM 354 or FM-NC (NCU 570.2) defective

No error/fault

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07.2000

2.2 Overviews of connections

Connector pin assignments

Table 2-4 provides you with a list of the connector pin assignments for connectors X1 to X3.
Table 2-4 PIN PIN assignment of front connectors on FM 354 Designation

X1: Handwheel and I/O connection, 20-pin front connector X1 3 4 5 6 9 10 11 12 13 14 19 20 Digit. input 1 (DE1) Digit. input 2 (DE2) Digit. input 3 (DE3) / Probe 2 Digit. input 4 (DE4) / Probe 1 Positive input of controller message (RM_P) (not with FMNC) Negative input of controller message (RM_N) (not with FMNC) Digit. output 1 (DA1) Digit. output 2 (DA2) Digit. output 3 (DA3) Digit. output 4 (DA4) Load power supply: 24 V M

X3: 15-pin D-sub socket connector, measuring system interface X3 4/6 5 7/9 2/3 10/11 15/14 13/12 Measuring system power supply: Measuring system power supply: P5EXT P24EXT MEXT Absolute encoder: Shift clock cycle (CLS, CLS_N) Incremental encoder: Zero mark (N, N_N) Track A/SSI data (A/DATA, A/DATA_N) Track B (B, B_N)

X2: 9-pin D-sub plug connector, drive interface X2 1/6 9/5 Analog setpoint (SW, BS) Controller enable 1 (RF1.1, RF1.2)

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2.3 Power supply

07.2000

2.3
2.3.1

Power supply
Power supply requirements of entire S7-300 system
The S7-300-CPU can buffer mains supply interruptions lasting up to 5 ms (guaranteed minimum period). After a power failure, a back-up period of at least 50 ms is still available in the NCU 570.2.

2
Mains buffering

Note In order to bridge power supply interruptions of > 5 ms, the FM-NC, FM 354 and PLC-CPU (or the entire S7-300 under ideal conditions) should be operated on a common 24 V power supply which guarantees the power supply back-up time required by the customer. PS 307 power supply modules (2 A, 5 A and 10 A) should preferably be used, depending on power requirements. These modules are capable of buffering supply failures of 20 ms.

POWER OFF/ON

If the customer prefers to use a separate power supply for the FM-NC, FM 354 and PLC CPU 314 as an alternative to the above solution, then he must ensure that all modules are powered up/down simultaneously when POWER OFF/ON is selected. The FM-NC cannot be powered up via POWER OFF/ON separately from the PLC CPU 314.

2.3.2

FM-NC power supply


4-way screw-type terminal block
Terminals 1 and 3: Terminals 2 and 4: L+ +24 V load power supply M 0 V load power supply (frame)

Power supply connection

Power requirement Polarity reversal protection

Approx. 1 A load current. FM-NC cannot operate when the polarity is reversed. LED DC5V is off. LED DC5V lights up when the poles have been properly connected.

Important Equipotential bonding must be provided if the S7-300-CPU and FM-NC are supplied by different load power supplies.

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07.2000

2.3 Power supply

2.3.3

FM 354 power supply


20-pin front connector X1 Terminal 19: Terminal 20: L+ +24 V power supply M 0 V power supply (frame)

Power supply connection

Power requirement Polarity reversal protection

Approx. 350 mA load current (with encoder supply). FM 354 cannot operate when polarity is reversed. LED DC 5V is off. LED DC 5V lights up when the poles have been properly connected.

Important Equipotential bonding must be provided if the S7-300-CPU and FM 354 are supplied by different power supplies.

2.3.4

Module power supply options

L1 L2 L3 N PE

Low-voltage distribution e.g. TNS system (3 x 400 V)

Rail CPU
PE M L N L+ M L+ M L+ M M

PS 307

NCU 570.2

FM 354

Earthing bar in cabinet Rail CPU


PE M M

NCU 570.2

FM 354

Earthing bar in cabinet


AC DC L+ L

L+ M

L+ M

L+ M

Fig. 2-4

Module power supply options

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2.3 Power supply

07.2000

2.3.5

Back-up battery service


The FM-NC has a back-up battery which acts as the power supply for the buffered RAM.

2
Battery connection

It must be ensured that the battery is properly connected (notch on battery connector must face towards right or lug towards left and positive pole downwards, connector is inserted in battery compartment).

Compartment for back-up battery

SF BA D F C 5V DIAG

X2

X3

X4

L+ M L+ M

X5

X6

Fig. 2-5

Insertion of back-up battery

A battery fault is detected in the case of incorrect connection.

!
Battery voltage monitoring

Important An incorrectly inserted battery may discharge and have to be replaced.

The battery voltage is monitored in two phases: 1st phase: Battery warning The battery must be replaced if LED BAF starts to flash. Buffered data will remain safe for several weeks depending on how often the control is switched on. The battery must be replaced as quickly as possible after output of a battery warning. The system need not be started up again. Error message: 2100 NCK battery warning threshold reached

Important The battery must be replaced when the control system is switched on (otherwise data will be lost).

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2.3 Power supply

2nd phase: Battery fault The BAF LED lights up steadily when the battery voltage has dropped below the minimum value required to buffer the RAM. During control power-up, the system automatically branches to the start-up mode with default values and the error message Standard machine data loaded is set. A new battery must be inserted before buffered data are reloaded or entered again. If buffered data have been lost, please proceed as described in Section 11 or 3.

S Battery type: Li battery set with connecting lead,


size 1/2 AA, capacity approx. 850 mAh, voltage min. 3.6 V

S Service life: Minimum 2 years, typically 4 to 6 years depending


on control system service period. Error message: 2102 NCK battery alarm

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2.4 Interfaces of operator panel with MMC

07.2000

2.4

Interfaces of operator panel with MMC

Operator panel with individual components

Fig. 2-6 shows a view of the rear of the operator panel with its individual components. For a detailed description and diagrams of these components, please refer to References: /BH/, Operator Components manual

1)

2)

MMC Power supply ISA adapter3)


4) X3 S1 S2 X6 X5 X4 Chassis X10

Equipotential bonding conductor

Power supply

1) 2) 3) 4)

Housing edge MMC 100/100.2 Housing edge MMC 102/103 not with MMC 100 not with MMC100.2

24 V0 V PE
Fig. 2-6 Operator panel with individual components

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07.2000

2.4 Interfaces of operator panel with MMC

Interfaces and operating elements of MMC 100

The interfaces and operating elements of the MMC 100 are shown in Fig. 2-7.

2
MMC 100 NC keyboard interface Power supply interface LCD interface

RESET button NMI button


X10

S1 X3 S2 X6 X5 X4

Operator panel interface (MPI) VGA interface

External keyboard interface (keyboard must be set to XT keyboard

RS 232 serial interface

Fig. 2-7

Interfaces and operating elements of MMC 100

Interfaces on MMC 100

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

Operating elements

S RESET button S1 S NMI button S2

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2.4 Interfaces of operator panel with MMC

07.2000

Interfaces and operating elements of MMC 100.2

The interfaces and operating elements of the MMC 100.2 are shown in Fig. 2-8 .

2
Memory module interface for PCMCIA X201

NC keyboard interface X142

X201

LCD interface X141 Power supply interface X3 DIP switch S3 S3


1 8

Cover for memory module interface

X201
Reset button MF2 external keyboard interface

COM2 serial interface RS232 (in preparation) Fig. 2-8

COM1 serial interface RS232

VGA monitor interface

MPI operator panel interface

Interfaces and operating elements of MMC 100.2

Interfaces on MMC 100.2

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

Operating elements on MMC100.2

S RESET button S1 S DIP switch S3

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2.4 Interfaces of operator panel with MMC

Interfaces I and op erating elements of MMC 102/103

The interfaces and operating elements of the MMC 102/103 are shown in Fig. 2-9.

2
X153 X152

ISA interface

X151

NC keyboard interface
X142
SIEMENS

Hard disk Power supply interface

X141

LCD interface

Battery Mass storage interface IDE

7-segment display

LPT1

Button S2 PCMCIA option interface for MMC103

X122

Button S1

D12 S1 S2

X8 X6
COM2 COM1

X3 X5 X4

X121

X11 X10 X9

X7

VGA

MPI Operator panel interface (MPI) VGA interface

Floppy disk drive interface

External keyboard/ mouse port

Parallel printer port (LPT1)

Serial interfaces RS232

Fig. 2-9

Interfaces and operating elements of MMC 102/103

Interfaces on MMC 102/103

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

Operating elements on MMC 102/103

The buttons S1 and S2 have the following functions:

S MMC102:
RESET button S1 NMI button S2

S MMC103:
NMI button S1 RESET button S2

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2.4 Interfaces of operator panel with MMC

07.2000

Interfaces on ISA adapter

The ISA adapter interfaces are shown in Fig. 2-10. The ISA adapter is an extension for the CPUs MMC 102.

2
X153 X152 X151

ISA interface

X220 Fig. 2-10 ISA adapter interfaces

ISA slot interface

ISA adapter interfaces

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

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X221

07.2000

2.4 Interfaces of operator panel with MMC

Interfaces on PCI adapter

The PCI adapter interfaces are shown in Fig. 2-11. The PCI adapter is an extension for the CPUs MMC 103.

Card interface

2
8/16bit card interface

X153

X151 X220 X221 X4

X122 X123 X121

PCI interface

PCI slot interface

Fig. 2-11

PCI adapter interfaces

PCI adapter interfaces

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

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X3

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2.5 Machine control panel interfaces

07.2000

2.5
2.5.1

Machine control panel interfaces


Interfaces of the standard machine control panel

2
Interfaces and operating elements of standard MCP
The following interfaces, switches and display elements are present on the rear of the standard machine control panel (MCP): Equipotential bonding conductor terminal LEDs 1...4

1 2 3 4 X20
ON

S3

3 4

1 2

X10

Power supply interface Operator panel interface Switch S3 Emergency stop button

1 SHIELD Fig. 2-12

2 M24

3 P24

Rear view of machine control panel, M and T versions

Interfaces

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

Switch S3

The baud rate, transmission cycle time, bus address and hardware can be set via switch S3. The standard switch settings are as follows:
Standard settings of switch S3 1 2 off 3 on 4 off 5 on 6 on 7 off 8 off Meaning Baud rate: 187.5 kbaud Transmission cycle time: 100 ms Bus address: 6

Table 2-5

6FC5 203 0AD10-0AA0

off

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2.5 Machine control panel interfaces

Other settings for the machine control panel are shown in the following table. These table data apply to MCPs and to the customer operator panel interface (Section 2.6).
Table 2-6 1 on off on on off off on off on off on on on on on on on on off off off off off off off off on on on on off off off off on on on on off off off off on on off off on on off off on on off off on on off off on off on off on off on off on off on off on off on off off on 2 Possible settings for S3 3 4 5 6 7 8 Meaning: Baud rate: 1.5 Mbaud Baud rate: 187.5 kbaud 400 ms transmission cycle time 200 ms transmission cycle time 100 ms transmission cycle time 50 ms transmission cycle time Bus address: 15 Bus address: 14 Bus address: 13 Bus address: 12 Bus address: 11 Bus address: 10 Bus address: 9 Bus address: 8 Bus address: 7 Bus address: 6 Bus address: 5 Bus address: 4 Bus address: 3 Bus address: 2 Bus address: 1 Bus address: 0 Series HW (MCP) Interface for customer operator panel

References:

/BH/, Operator Components manual

LEDs 1...4

The LEDs have the following meaning:


Table 2-7 Designation LEDs 1 and 2 LED 3 LED 4 Reserved POWER: Lights up when voltage (24V) is present SEND: Changes state after data have been sent LEDs 1...4 on machine control panel Meaning

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2.5 Machine control panel interfaces

07.2000

2.5.2

Interfaces of machine control panel OP032S

Interfaces and operating elements of MCP OP032S


Operator panel interface (MPI) DIP switch (8-way), assignments Outputs Power supply interface

The following interfaces, switches and display elements are present on the rear of the machine control panel OP032S:

X20

S3
ON "

LED: X36 X35 X10


Pin

1 2 3 4

Connector 1x6-pin

4 1

4 1

Pin

4 1

4 1

X10 P24 M24 Shield Equipotential bonding conductor terminal Displays: Inputs LED 1, 2: not used LED 3: POWER (24 V supply) LED 4: SEND, changes state on protocol transmission

Fig. 2-13

Rear view of machine control panel OP032S

Interfaces

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

Switch S3

The baud rate, transmission cycle time, bus address and hardware can be set via switch S3. The standard switch settings are as follows:
Table 2-8 1 on 2 off Standard settings of S3 for MSTT OP32S 3 on 4 off 5 on 6 on 7 off 8 off Meaning: Baud rate: 1.5 MBaud Transmission cycle time: 100 ms Bus address: 6

Note For use with the FM-NC, a baud rate of 187.5kBaud is to be set at the MCP OP032S (see Possible settings in Table 2-9). Switch S3.1 is to be set to the position OFF.

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2.5 Machine control panel interfaces

Other settings for the machine control panel are shown in the following table. These table data apply to MCP OP032S.
Table 2-9 1 on off on off off off on off on on on on on on on on off off off off off off off off on on on on off off off off on on on on off off off off on on off off on on off off on on off off on on off off on off on off on off on off on off on off on off on off on off 2 Possible settings for S3 for MCP OP032S 3 4 5 6 7 8 Baud rate: 1.5 MBaud Baud rate: 187.5 kBaud 200 ms transmission cycle time / 2400 ms receipt monitoring 100 ms transmission cycle time / 1200 ms receipt monitoring 50 ms transmission cycle time / 600 ms receipt monitoring Bus address: 15 Bus address: 14 Bus address: 13 Bus address: 12 Bus address: 11 Bus address: 10 Bus address: 9 Bus address: 8 Bus address: 7 Bus address: 6 Bus address: 5 Bus address: 4 Bus address: 3 Bus address: 2 Bus address: 1 Bus address: 0 Interface MPI customer operator panel Series HW Meaning:

2.5.3

2nd machine control panel


Two machine control panels can be operated with the SINUMERIK FM-NC. The 2nd MCP must be parameterized in the basic program parameters of FB1 in OB100.

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2.6 Interface for customer operator panel

07.2000

2.6

Interface for customer operator panel

Interface

A customer operator panel can be connected via this interface. 64 digital inputs and 64 digital outputs with C-MOS level (5V) are provided on the module for this purpose.

Interfaces, switches and display elements

The interface to the customer operator panel has the following interfaces, switches and display elements:

X20 X211 Operator panel interface Equipotential bonding conductor terminal X10
ON

X221

X231 H3 H1 LEDs H4 H2

S3 "

Power supply interface

Switch S3

LED 1...4

P24 M24 SHIELD

Fig. 2-14

Front view of interface for customer operator panel

Interfaces

For a detailed description and diagrams of the interfaces (e.g. pin assignment), please refer to References: /BH/, Operator Components manual

Switch S3

The baud rate, transmission cycle time, bus address and hardware can be set on switch S3. The default switch settings are as follows:
Table 2-10 1 off 2 off Default settings of switch S3 3 on 4 off 5 on 6 on 7 off 8 on Meaning: Baud rate: 187.5 kBaud Transmission cycle time: 100 ms Bus address: 6

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2.7 Hand-held unit (HHU)

2.7

Hand-held unit (HHU)

Overview

The hand-held unit is connected to the MPI line via a distributor. The distributor is designed for mounting in a control cubicle or separate housing.

ON 4 S1 3 2 ON OFF S1 S2 S2 2 1 4 3 1

OFF Default settings Reserved 187.5 kBaud IDLE time 100 ms

Bus address 15

Fig. 2-15

Position of DIP switches in HHU (default setting)

DIP switch setting for MPI

The default setting (delivery state) of the DIP switches should be used when the HHU is operated on the MPI interface.
Table 2-11 S1 1 off S1 2 on S1 and S2 settings in HHU S1 3 off off on on on on on on on on off off off off off off off off on on on on off off off off on on on on off off off off on on off off on on off off on on off off on on off off on off on off on off on off on off on off on off on off S1 4 off S2 1 on S2 2 on S2 3 on S2 4 on Meaning: Delivery state Baud rate: 187.5 kbaud Bus address: 15 Bus address: 14 Bus address: 13 Bus address: 12 Bus address: 11 Bus address: 10 Bus address: 9 Bus address: 8 Bus address: 7 Bus address: 6 Bus address: 5 Bus address: 4 Bus address: 3 Bus address: 2 Bus address: 1 Bus address: 0

References:

/BH/, Operator Components manual

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2.8 COROS OP 27 operator interface

07.2000

2.8

COROS OP 27 operator interface

Overview

To operate and monitor (O & M) the FM-NC, it is possible to connect an operator interface (OP 27) to the CPU via the MPI interface. The FM-NC communicates with the OP 27 via the backplane bus. The interfaces on the OP 27 are shown in the following diagram.

CPU MPI P24 M24 Relay contacts 24 V DC; 0.3 A OP 27 IF1 A IF2 Power supply

FM-NC NCU 570.2

Memory Extension

IF1 B

Equipotential bonding conductor connection

V24/TTY optional

Printer

PC/PG

Fig. 2-16

Interfaces of OP 27

Connecting cable

Standard cables are available to make the connections shown.

Terminal block

The supply voltage is connected via the four-pin terminal block supplied as follows: 1. Connect leads to terminals (conductor cross-section: 0.5...2.5 mm2) 2. Insert terminal block in lower plug connector on OP 27

Ground terminal

The ground terminal must be connected to the cubicle ground.

References for COROS operator interfaces

References:

/ST7/, SIMATIC S7, Catalog ST 70

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Settings, MPI Nodes

3
3
3-54 3-55 3-58 3-60 3-66

3.1 3.2 3.3 3.4 3.5

MPI networking rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nonstandard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of an MCP and HHU configuration on MPI bus with STEP7 V5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of distribution of MPI addresses . . . . . . . . . . . . . . . . . . . . . . .

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3.1 MPI networking rules

07.2000

3.1

MPI networking rules

Basic rules

The following basic rules must be observed with respect to network installations: 1. The bus line must be terminated at both ends. To do so, switch in the terminating resistor in the MPI connector in the first and last nodes. Switch out all other terminating resistors.

Note Only two terminating resistors may be activated in the same line at a time.

2. At least one termination must be supplied with a 5V voltage. For this purpose, the MPI connector with active terminating resistor must be connected to a device that is connected to the power supply.

Note Connecting the MPI connector to the PLC (CPU) is ideal for this purpose.

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

Note Unused spurs should be removed wherever possible.

Example


MMC 100/102 PG MCP MPI ON PLCCPU FM-NC NCU 570.2 ON Fig. 3-1 Network installation with terminating resistors

ON

Terminating resistor activated in connector

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3.2 Standard configuration

3.2

Standard configuration
PLCCPU mit SINUMERIK FM-NC, MMC and a machine control panel (MCP) or interface to customer operator panel on MPI bus.

Standard application

Hardware requirements

The following hardware components are required for the minimum configuration

S AS300 PLC-CPU (315, 316, 614, .., 318) S SINUMERIK FM-NC NCU 570.2 with firmware version from V 03.xx S MMC S MCP or interface to customer operator panel.

Software

STEP7

Baud rate

MPI bus nodes operate at 187.5 kbaud.

Bus addresses

Every node on the MPI bus must have a bus address (0...31). Fig. 3-2 shows the default settings for the MPI bus addresses.


Operator panel with MMC 1 2 PLCCPU


MCP/interface to customer operator panel 6 3 FM-NC NCU 570.2


Programming device with S7 0

MPI 187.5 kbaud


Fig. 3-2

MPI bus addresses

Standard application for SINUMERIK FM-NC

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3.2 Standard configuration

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Setting of bus addresses

The addresses of the bus nodes can be set as follows:

S MMC 100/100.2
Default address: 1 Setting in configuration file NETNAMES.INI using application software References: /FB/, B3, Several Operator Panels and NCUs

S MMC 102/103
Default address: 1 Setting in operating area Startup/MMC/Operator panel

S Programming device
Default address: 0 Setting in STEP7 via menu Extras / PG/PC interface

S PLC-CPU
Default address: 2 Setting in STEP7 hardware configuration under menu item Edit/Object properties/General/Properties/MPI After changing the MPI address, it is necessary to load the configuration into the target module via menu item Target system/Load into module. It is only possible to change the MPI address if the PLC-CPU is in STOP. References: /S7H/, S7 Manual or /S7HT/, Start-up MPI Bus Nodes manual

S FM-NC (NCU 570.2)


Default address: 3 Setting: The PLC-CPU ascertains the MPI bus address of the FM-NC for its rack configuration while the S7-300 system is being booted. This slotdependent MPI address is then transferred to the C-bus modules. Based on its own MPI address, the PLC-CPU increments by one the MPI address for each C-bus module Example:

MPI


PLCCPU SM FM SM FM-NC NCU 570.2 2 3 4 MPI addresses for C-bus modules

Fig. 3-3

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3.2 Standard configuration

Important It must be ensured that the addresses of other MPI nodes (e.g. MCP = 6) are not overlapped when the addresses are consecutively numbered in this way.

S Standard MCP / MCP OP032S / Interface to customer operator panel


Default address: 6 Setting via DIP switch S3
Table 3-1 1 off 2 off Settings on DIP switch S3 for standard application 3 on 4 off 5 on 6 on 7 off 8 off

Meaning:
Standard MCP / MCP OP032S: Baud rate: 187.5 kbaud Transmission cycle time: 100 ms Bus address: 6 Interface to customer operator panel Baud rate: 187.5 kbaud Transmission cycle time: 100 ms Bus address: 6

off

off

on

off

on

on

off

on

Assigned inputs/outputs in PLC-CPU

The following bytes in the PLC-CPU are assigned for the MCP or interface to customer operator panel (applies when SDB210 of the basic program Library is used):

S Input bytes 118...125 S Output bytes 120...127 S Status bytes for error detection, output double word 108 (evaluated by basic
program) These parameters on FB1 in OB100 (basic program) for the MCP are already set.

Note The input and output bytes given above are addresses in the range of the 4th rack. If this address range in the 4th rack is being used, different input, output and status ranges must be assigned in the PLC-CPU and a new SDB210 must be generated (see Section 3.3).

Communication PLCMCP does not start

If communication does not commence after a PLC reset (all display LEDs of the MCP flashing), the following points should be checked:

S Cable and connector wiring S DIP switch S3 (default setting) S SDB210 from basic program diskette not loaded

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3.3 Nonstandard configuration

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3.3

Nonstandard configuration

Overview

To name an example, the connection of additional MPI bus nodes would constitute a nonstandard configuration. The following are nonstandard features:

S Connection of a hand-held unit (HHU)


References: /BH/, Operator Components manual

S Connection of a second MCP S Connection of further PLCs


Nonstandard settings with regard to the HHU, MCP and PLC are specified in the global data configuration (see Section 3.4 ).

S Connection of an OP 27 operator panel


(Configuration via ProTool.) References: /ST7/, Catalog ST 70

S Connection of further FM-NCs


(Configuration via the PLC basic program on FB1 in OB100.)

S Connection of positioning modules FM 353/FM 354 (not on local


P bus of the FM-NC) (Configuration via the startup tool.) References: /S7S/, /S7L/, SIMATIC S7-300 manuals You must adjust the communications parameters and possibly the switch settings (addresses) of the bus nodes.

Procedure

To be able to enter a new configuration it is necessary to define global data in STEP7. Select the object MPI network in the STEP7 project and then select Define global data in the menu Extras. The following procedure assumes that the user is acquainted with the handling of this tool. 1. Set up a new project in STEP7. A separate station is to be set up for each of the components (PLC, HHU, ...) which are linked together via MPI. 2. Link the MPI nodes, i.e. interconnect CPU programs with MPI address (hardware configuration). 3. Define global data and enter the desired configuration 4. Compile this configuration. A new SDB210 (system data block) will be created for each CPU program. The SDB210 for the component MCP/HHU is meaningless, because the settings of the basic data parameters are made with DIP switches or via the keyboard. 5. Set the cyclical transmit pattern. Once the configuration has been compiled successfully for the first time, the Conversion factor (SR) and Status (GDS) can be activated and then input. 6. Compile your configuration again. 7. Transfer the SDB210 (from the CPU program of the PLC) to the PLC.

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3.3 Nonstandard configuration

Note The SDBs are not displayed in the STEP7 project manager by default. They are listed by double-clicking on the object System data. 8. Make the device-specific settings for all nodes: You now need to set the GD identifiers from the table of global data definitions for the components (HHU,..). 9. You must set the input, output and status parameters for call FB1, DB7 in OB 100 in the basic PLC program for all operator control components (MCP, HHU).

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3.4 Example of an MCP and HHU configuration on MPI bus

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3.4

Example of an MCP and HHU configuration on MPI bus with STEP7 V5x

Requirements

PG/PC with STEP7 V5.x, PLC-CPU, FM-NC, MCP, HHU, (MMC)


MPI bus 187.5 kBaud 1 0


PG with S7 Operator panel with MMC 2 3 PLCCPU FM-NC NCU 570.2 14 MCP Inputs: Outputs: Status: Input byte (EB) 118...125 Output byte (AB) 120...127 Output doubleword (AD) 108


15 Distributor HHU Fig. 3-4

Inputs: Outputs: Status:

Flag byte (MB) 20...25 Flag byte (MB) 0...19 Flag double word (MD) 26

Example of an MCP and HHU configuration on an MPI bus

Call STEP 7

Set up new project with the name Example. 3 stations must then be set up for the Example project.

S PLCCPU S MCP S HHU


Assignment of stations
The 3 stations are assigned as follows:

S PLC-CPU e.g. for the CPU315 S MCP for the machine control panel S HHU for the handheld unit.

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3.4 Example of an MCP and HHU configuration on MPI bus

Networking

Networking must be activated for each CPU station in the hardware configuration. The CPU stations of the MCP/HHU do not have their own CPU. Any CPU can be selected (e.g. CPU315). To aid identification, the selected CPU for the MCP is given the name MCP-CPU and that for the HHU the name HHUCPU. CPU315 is selected for the PLCCPU. The individual CPUs are linked on a network with the following MPI addresses:

S PLC-CPU with MPI address 2, S MCP-CPU with MPI address 14 and S HHU-CPU with MPIaddress 15.
Networking procedure for each CPU station: 1. Select the CPU in the hardware configuration and then the menu function Edit/Object properties/General/Properties 2. Set the MPI address 3. Select MPI(1) 187.5 kbit/s 4. Confirm Properties - MPI interface with OK 5. Confirm Properties CPU 315 with OK 6. Use the menu command Save and compile station to save the configuration

Define global data

Select the object MPI network in the STEP7 project and then the menu function Extras/Define global data. The table GD; Define global data [MPI(1) (global data) Example] is displayed.

Table of global data

You must now call the CPU stations in this table. 1. Click with the mouse in the field next to GD identifiers (the column is highlighted). 2. Select CPU in the Edit menu. 3. A window Select CPU is displayed. Click on the project Example. The three CPU stations PLC-CPU, MCP and HHU are displayed. 4. Select PLC-CPU/CPU315 5. The table now contains the entry PLC-CPU/CPU315 6. Click on the empty field alongside and repeat steps 2. to 5. for the stations MCP and HHU, in this order. 7. You will then have a table with the three stations.

GD; Define global data [MPI(1) (global data) Example]


GD identifiers GD GD GD PLC-CPU /CPU315 MCP/ MCP-CPU HHU/ HHU-CPU

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Enter areas for transmitting and receiving

You can now make the entries for the MCP and HHU in the global data table . 1. Start in column PLCCPU/CPU315 by selecting the first field. 2. Enter data area for reception or transmission from Fig. 3-4 For MCP/MCPCPU AB120:8 is the entry for the receive area and EB118:8 is the entry for the transmit area. AB 8 bytes are received starting at AB120 and EB 8 bytes are transmitted starting at EB118.) For HHU/HHUCPU MD0:20 is the entry for the receive area and MD20:6 is the entry for the transmit area. (MD0:20 20 bytes are received starting at MD0 and MD20:6 6 bytes are transmitted starting at MD20.) 3. Declare the transmit and receive areas to be such, i.e. activate the appropriate field in the table. Then select Transmitter in the Edit menu. The transmit area is then marked with and highlighted. 4. The table with all its entries then looks like this:

GD; Define global data [MPI(1) (global data) Example]


GD identifiers GD GD GD GD PLC-CPU /CPU315 >AB120:8 EB118:8 >MB0:20 MB20:6 MCP/ MCP-CPU AB120:8 >EB118:8 MB0:20 >MB20:6 HHU/ HHU-CPU

Note The order in which inputs are made (transmit, receive) affects the way in which GD identifiers are assigned and should be noted carefully as shown by the above example.

Compilation

You now need to select Compile in the menu GD table. The GD identifiers are generated during compilation. They are displayed in table as the result of compilation.

GD; Define global data [MPI(1) (global data) Example]


GD identifiers GD 1.1.1 GD 1.2.1 GD 2.1.1 GD 2.2.1 PLC-CPU /CPU315 >AB120:8 EB118:8 >MB0:20 MB20:6 MCP/ MCP-CPU AB120:8 >EB118:8 MB0:20 >MB20:6 HHU/ HHU-CPU

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3.4 Example of an MCP and HHU configuration on MPI bus

Setting scan rate

Click on menu View/Reducing factors. The table below appears with the SR parameters.

GD; Define global data [MPI(1) (global data) Example]


GD identifiers SR 1.1 GD 1.1.1 SR 1.2 GD 1.2.1 SR 2.1 GD 2.1.1 SR 2.2 GD 2.2.1 8 >AB120:8 8 EB118:8 8 >MB0:20 8 MB20:6 PLC-CPU /CPU315 8 AB120:8 8 >EB118:8 8 MB0:20 8 >MB20:6 MCP/ MCP-CPU HHU/ HHU-CPU

Altering SR parameters

The transmission rate for the MCP and HHU must be set. The default setting is one transmission every 8 PLC cycles. You must specify a value of 1, 2, 4 or 8. Only 4 and 8 are allowed for transmission. Example of a global data table with altered SR parameters: Value 1 can be set for the receiver.

GD; Define global data [MPI(1) (global data) Example]


GD identifiers SR 1.1 GD 1.1.1 SR 1.2 GD 1.2.1 SR 2.1 GD 2.1.1 SR 2.2 GD 2.2.1 4 >AB120:8 1 EB118:8 4 >MB0:20 1 MB20:6 PLC-CPU /CPU315 1 AB120:8 4 >EB118:8 1 MB0:20 4 >MB20:6 MCP/ MCP-CPU HHU/ HHU-CPU

When you have changed the SR parameters, you must compile your configuration again (command Compile in menu GD table).

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Activate status

Click on menu View/GD status. The following table appears GD; Define global data [MPI(1) (global data) Example]
GD identifiers GST GDS 1.1 PLC-CPU /CPU315 MCP/ MCP-CPU HHU/ HHU-CPU

SR 1.1 GD 1.1.1 GDS 1.2 SR 1.2 GD 1.2.1 GDS 2.1 SR 2.1 GD 2.1.1 GDS 2.2 SR 2.2 GD 2.2.1

4 >AB120:8

1 AB120:8

1 EB118:8

4 >EB118:8

4 >MB0:20

1 MB0:20

1 MB20:6

4 >MB20:6

You now need to specify the status double words for GDS1.2 and GDS2.2 (receive data). Extract from the global data table: GD; Define global data [MPI(1) (global data) Example]
GD identifiers GDS 1.2 GDS 2.2 PLC-CPU /CPU315 AD108 MD26 MCP/ MCP-CPU HHU/ HHU-CPU

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

Transfer SDB210

SDB210 is created in the course of compilation. Transfer the SDB210 for the CPU program CPU315 to the PLC-CPU (PLC must be in the STOP state). Procedure in STEP7: 1. Click on menu Target system/Load 2. In the download window, select PLC-CPU/CPU315 and confirm with OK. 3. Put PLC into RUN mode (restart)

Set MCP and HHU

MPI address 14 on the MCP must be set according to GD parameters 1.1.11.2.1. The default MPI address 15 can be left unchanged on the HHU. The default settings for GP parameters 2.1.1...2.2.1 remain valid. The hardware switch settings are described in: Section 2.5 for MCP and Section 2.7 for HHU

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3.4 Example of an MCP and HHU configuration on MPI bus

Parameterization of HHU

Before the HHU can exchange data with the PLC-CPU via the MPI interface, the GD parameters created must also be set in the HHU. To set these parameters, proceed as follows:
HHU display 1. 2. 3. 4. 5. 6. 7. REC-GD-No: 2 REC-GBZ-No: 1 REC-OBJ-No: 1 SEND-GD-No: 2 SEND-GBZ-No: 2 SEND-OBJ-No: 1 2 1 1 2 2 1 Value Operator action Press the left-hand and right-hand keys in the 1st line together while the HHU is being booted. Use keys + and to select the value and transfer with the AUTO key (2nd key from left in 1st line) Select and transfer Select and transfer Select and transfer Select and transfer Select and transfer

When the last value is transferred, the HHU joins the Waiting for PLC queue. Bit 7 in byte 0 of the output signal must be set to 1 (in the example M0.7: = TRUE) for data to be exchanged with the HHU. Note: The directional terms SEND and REC are applied as viewed by the HHU, i.e. SEND: HHU transmits data to the PLC-CPU.

MPI address setting (HHU)

The MPI address can be changed by switch S2 on the HHU (see Section 2.7), while the baud rate is changed with switch S1. The switch settings corresponding to different MPI bus addresses for the HHU are shown in Table 2-11 in Section 2.7. The delivery state is S1.3=OFF and S2.1...S2.4=ON (187.5 kBaud, MPI address 15)

Example: Parameterization of FB1 in basic PLC program

The following parameter settings must be made on the FB1 for operator components MCP and HHU. MCPNum := MCP1In:= MCP1Out:= MCP1StatRec:= HHU:= HHUIn:= HHUOut:= HHUStatRec:= References: 1 P#E118.0 P#A120.0 P#A108.0 1 P#M20.0 P#M0.0 P#M26.0 (one MCP) (input signals MCP) (output signals MCP) (status double word) (HHU on MPI bus) (input signals BHG) (output signals BHG) (status double word)

/FB/, P3, Basic PLC Program

2nd machine control panel

Two machine control panels can be operated with the SINUMERIK FM-NC. The settings and configuration via SDB210 are the same as for the project Example for the 1st machine control panel and HHU. The parameters assigned automatically via the communication configuration must be set on the machine control panels. The basic program parameters on FB1 in OB100 must be updated to effect monitoring of both machine control panels.

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3.5 Example of distribution of MPI addresses

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3.5
Overview

Example of distribution of MPI addresses


The following diagram shows you an example of how MPI addresses are distributed.


Address: MPI 1

Operator panel with MMC


Address: MPI 6 Addr.: MPI 7 PLC-CPU


OP 27 Address: MPI 10 MCP


Addr.: MPI 2 PLC-CPU Fig. 3-5


Address: MPI 8 PLC 320 Address: MPI 9 PLC 448 Address: MPI 3 PLC 320

1st FM-NC NCU 570.2

2nd FM-NC NCU 570.2

3rd FM-NC NCU 570.2

Example of how MPI addresses are distributed

A description of how to set the addresses for the MMC and MCP modules can be found in Section 3.2.

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3.5 Example of distribution of MPI addresses

MPI address of OP 27

A sample configuration for the OP 27 is included in the Toolbox for the SINUMERIK FM-NC (File OP27_NCx.PDB). The MPI address for the OP 27 is determined when the module is configured with ProTool. Call the following menu in this configuring tool: Edit / Properties / Parameters The following subdisplay appears: SIMATIC S7 - 300/400 In this screen, you can set the following OP and network parameters:

S Address [ ] S Interface [ ] S Baud rate [ ]

10 is set here in the sample configuration IF1 B is entered here in the sample configuration 187.5 is entered here in the sample configuration

It is also necessary to set the MPI address of the module from/to which the OP 27 is to read/write variables in display SIMATIC S7 - 300/400. This address is set to 3 in the sample configuration. In the example above, the OP 27 can read and write variables from the 3rd FM-NC.

2 PLCs on the MPI bus

The MPI addresses of the PLC-CPUs must be distributed such that addresses do not overlap on the MPI bus (Note: PLC increments addresses for MPI (C bus) nodes). Since the default address for the PLC-CPU is 2, PLC-CPUs will need to be started up individually if several are connected to the bus, i.e. 1. The PLC-CPU which is to be assigned the MPI address 7 must be linked to the MPI bus first. 2. The address for this PLC-CPU must then be changed from 2 to 7 (see Section 3.2). 3. The 2nd PLC-CPU is then connected to the MPI bus. Its MPI address remains unchanged as 2.

GD circuits, SDB210

Useful data telegrams are exchanged cyclically between the nodes within the GD circuits. The GD circuits are set up in the PLC via parameter block SDB210 (transmit cycle, data areas, source and target addresses). Although the following MPI nodes have an MPI address, they are addressed additionally by the PLC-CPU via the so-called GD circuit number.

S MCP S HHU S Interface to customer operator panel


Note The PLC-CPU in the SINUMERIK FM-NC is capable of addressing up to 4 devices via GD circuit numbers (MCP, HHU, interface to customer operator panel and, for example, 2nd MCP).

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EMC and ESD Measures

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4.1 4.2

Measures to suppress interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measures to protect ESD-sensitive components . . . . . . . . . . . . . . . . .

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4.1 Measures to suppress interference

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4.1

Measures to suppress interference


To ensure safe, interference-free operation of the installation, it is essential to use the cables specified in the individual diagrams. Both ends of the shield must always be connected conductively to the equipment enclosures. Exception: If external equipment (such as printers, programming devices, etc.) is connected, standard shielded cables connected at one end may also be used.

Shielded signal leads

These external devices may not be connected to the control during normal operation. However, if the system cannot be operated without them, then the cable shields must be connected at both ends. Furthermore, the external device must be connected to the control via an equipotential bonding lead.

Precautionary measures

To ensure that the entire installation (control, power section, machine) has the greatest possible immunity to interference, the following EMC measures must be taken:

S Signal leads and load leads must be routed at the greatest possible distance
from one another.

S The cables supplied by SIEMENS must be used as signal cables from and
to the NC or PLC.

S Signal leads must not be routed close to strong external magnetic fields
(e.g. motors and transformers).

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


all other leads/cables.

S If signal leads cannot be laid at a sufficient distance from other leads, then
they must be installed in shielded cable ducts (metal).

S The distance (noise field) between the following leads should be as small as
possible: Signal lead and signal lead Signal lead and associated equipotential bonding lead Equipotential bonding lead and PE conductor (routed together)

Important For further information about interference suppression measures and connection of shielded cables, please refer to References: /EMC/, EMC Guidelines

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4.2 Measures to protect ESD-sensitive components

4.2

Measures to protect ESD-sensitive components

Important Handling of modules at risk from ESD:

S When electrostatic components are handled, it must be ensured that


personnel, workstation and packaging are properly earthed.

S As a general principle, electronic modules should only be touched if this


absolutely unavoidable (owing to repair work, etc.). When you are handling PCBs, therefore, make sure that you never touch any submodule pins or conducting paths.

S You may only touch components if


you are constantly connected to earth by means of an anti-static chain you are wearing anti-static shoes or anti-static shoes with earthing strip in conjunction with an anti-static floor surface. Modules must always be placed on a conductive surface (table with anti-static covering, electrically conductive foam rubber, anti-static packaging materials, anti-static transport container).

S Modules must always be placed on a conductive surface (table with antistatic covering, electrically conductive foam rubber, anti-static packaging materials, anti-static transport container).

S Modules must not placed near VDUs, monitors or television sets (not closer
than 10 cm from screen).

S Modules must not be allowed to come into contact with electrically


insulating materials such as plastic foil, insulating table tops or clothing made of synthetic fibres.

S Measurements may only be taken on modules if


the measuring instrument is earthed (e.g. via PE conductor) or the measuring head on a potential-free instrument is discharged briefly (e.g. by being brought into contact with bare metal part of control housing) before the measurement is taken.

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Power On and Power-Up

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5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

Start-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of system software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of entire system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of FM-NC (NCU 570.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of PLC-CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MMC102/103 BIOS setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booting of machine control panel (MCP) . . . . . . . . . . . . . . . . . . . . . . . .

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5.1 Start-up sequence

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5.1

Start-up sequence
All mechanical and electrical installation work must be complete. Before the system is started up, it is important to ensure that the control and its components power up correctly. It is also essential that the equipment is installed in accordance with the EMC guidelines given in the previous section. The start-up procedure is detailed below. The order in which the individual steps are taken is not mandatory, but recommended: 1. Check that PLC Start-up has been completed successfully 2. Check the connection of the NC back-up battery (Section 2.3.5) 3. Check that SINUMERIK FM-NC powers up correctly

Start-up sequence

4. Transfer PLC user program and alarm texts 5. Set axis configuration 6. Set axis-specific machine data Setpoint matching Encoder matching Velocities Monitoring functions Spindle data, rotary axis

7. Perform axis and spindle test runs 8. Optimize drives 9. Save data

5.2

Power on
The installation should be inspected visually for any obvious faults or defects. Make sure that the mechanical installation of components is correct and that electrical connections are firmly in place. Make sure that all electrical connections have been made correctly before switching on the power supply. Check the supply voltages 230 V AC and 24 V DC as well as the shields and earthing connections. Before commencing with start-up, check that the address and switch settings on the MCP, HHU and PLC I/O devices are correct for your application. Reset them if required. References: /BH/, Operator Components manual

Visual inspection

Address/switch settings

Power on sequence Power on

The components MCP, HHU and MMC can be switched on in any desired sequence if they are physically installed. Switch on the power supply on all components and on the mains supply module. However, the LEDs on the mains supply module may not indicate any errors/faults in the power supply.

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5.3 Booting of system software

5.3

Booting of system software

Overview

The system software is already loaded in the delivery state. The control is booted after the power supply is connected.

Operator control and display elements relevant to booting

The following operator control and display elements are relevant for booting the SINUMERIK FM-NC (NCU 570.2):

S Error and status LEDs S Start-up switch on FM-NC (NCU 570.2) S Start-up switch on PLC-CPU

5
Error and status LEDs Memory module interface (JEIDA) SF BAF DC5V FRCE RUN STOP RUN_P RUN Memory module interface (S7 memory card with user program) Start-up switch PLC-CPU Fig. 5-1 FM-NC (NCU 570.2) SF BAF DC5V DIAG
14 13 12 15 0 1 2

3 4 5 6 11 10 9 8 7

STOP MRES

Operator control and display elements for booting

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5.3.1

Booting of entire system

Overview

Since the PLC views the FMNC as being an FM module, it boots it in the course of the S7300 system boot.

Basic booting process

When the PLC is booted, it detects the configuration level (rack configuration) by means of the ID run via the P-bus and then transfers the slot-dependent C-bus parameters (C-bus initialization via P-bus). The communication bus (K bus) (MPI) then runs up on the communications module (COM). Data can now be exchanged according to the S7 protocol via the K bus (MPI). The remaining configuration data (system data blocks) are loaded via the K bus (MPI) from the PLC, operator panel (OP) or programmer (PG) to the COM module of the FMNC.

5
Booting of FM 354 as 5th axis

The configuration of the local P bus is also detected in the course of the S7300CPU system boot and transferred to the FMNC (including the module address of the FM 354). This process can only take place if the local P bus is configured in the SDB100.

I/O address of FMNC and FM 354

The FMNC configuration address is entered in parameter nc_laddr: = of the basic program =B 100, Call FB1, DB7. The address is derived from the FMNC slot. The slots are assigned from left to right as follows: 1 Power supply 2 PLCCPU 3 Interface module 411 Signal modules, FMNC, FM 354
Table 5-1 FMNC configuration address Slot number 4 5 6 7 8 9 10 11 FMNC/FM 354 address 256 272 288 304 320 336 352 368

Example: If the FMNC is inserted in slot 10, then the parameters setting nc_laddr: =352 must be written for FB1. References: /S7H/, Manual

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5.3 Booting of system software

Note The module addresses are displayed in the hardware configuration in the STEP7 project.

Components involved in booting


Operator panel with MMC 100/102 (OP) MPI

MCP

PG

5
Local P bus

P bus K bus COM NCK PLCCPU FMNC

FM 354 S7-300

Fig. 5-2

Components involved in FMNC booting process

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5.3.2

Booting of FM-NC (NCU 570.2)

Overview

After POWER ON, the packed NCK system software is fetched from the internal memory (FLASH), unpacked, stored on the dynamic RAM and then processed.

Start-up switch

There is a start-up switch on the NCU 570.2 (see Fig. 5-1). It is used in the start-up process and can be operated by means of a screwdriver. The following switch settings are relevant.
Table 5-2 Settings with the start-up switch of the FM-NC Meaning Normal booting from the internal memory (FLASH) Booting from the internal memory and loading of default values Switch to restoring of software and user data (see Section 11.4) Updating of firmware and user data (see Section 12.1.1)

Position 0 1 3 6

Booting times

Booting of the software from the internal memory (start-up switch = 0/1) takes approximately 1 minute and 30 seconds.

Status displays (LEDs) during booting

The booting status is displayed as follows:

S PLC-CPU:

5 V DC (green) RUN (green) STOP (yellow) Other LEDs 5 V DC (green) RUN (green) Other LEDs 5 V DC (green) Other LEDs 5 V DC (green) DIAG (yellow)

ON flashes ON OFF

Booting complete:

ON ON OFF ON OFF ON flashes (sign of life approx. 8 Hz) ON flashes (approx. 4 sec ON / 4 sec OFF) ON ON

S FM-NC (NCU 570.2):


Booting complete:

S Local axis with measuring system (if present)


Booting complete: 5 V DC (green) DIAG (yellow)

S Local axis without measuring system (if present)


Booting complete: 5 V DC (green) DIAG (yellow)

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5.3 Booting of system software

5.3.3

Booting of PLC-CPU

PLC general reset

A GENERAL RESET erases the contents of the program memory in the PLCCPU. The contents of the diagnostics buffer in the PLC-CPU are not erased. There are two methods to effect a general reset: 1. Via STEP7 on the programming device 2. Via the PLC start-up switch on the CPU module
Table 5-3 Position 0 1 Settings with the PLC start-up switch Meaning PLC RUN PROGRAMMING: RUN state. It is possible to intervene in the PLC program without activating a password. PLC RUN: RUN state. The program can only be accessed for reading via the programmer. After activation of the password, it is possible to intervene in (i.e. change) the PLC program. PLC STOP: STOP state. MRES: A module reset (general reset function) can be executed with the switch in this setting.

2 3

Operator inputs for PLC restart

The following operation initiates a PLC RESTART: Turn PLC start-up switch from STOP position to RUN position.

Operator inputs for PLC general reset

The following operations with the PLC start-up switch initiate a GENERAL RESET of the PLC-CPU: 1. Turn operating mode switch to STOP position (set STOP operating state) LED STOP lights up. 2. Turn operating mode switch to MRES position and keep it there until STOP LED lights up again (request general reset) LED STOP goes out and lights up again. 3. Within 3 seconds, turn operating mode switch to settings STOP-MRESSTOP LED STOP flashes first at frequency of approx. 2 Hz and then lights up again LED FORCE lights up If the switch is not kept in the MRES position for 3 seconds, then no general reset is requested. The STOP LED also remains off if the switch does not change positions STOP-MRES-STOP within 3 seconds.

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4. After LEDs STOP and FORCE are alight again, turn operating mode switch to the RUN position LEDs STOP and FORCE go out and LED RUN (green) lights up The PLC program memory is now erased, PLC is operating in cyclic mode A GENERAL RESET erases the contents of the program memory in the PLCCPU. The contents of the diagnostics buffer in the PLC-CPU are not erased.

Note If a GENERAL RESET is initiated (according to procedure described above) when the back-up battery is not installed, then the entire SRAM of the PLC is erased, i.e. the diagnostics buffer contents are also erased. These data can then no longer be accessed. If the switch is not kept in position 3 (MRES position) for 3 seconds, then no general reset is requested. The STOP LED also remains off if the switch does not change positions STOP-MRES-STOP within 3 seconds. References: /S7H/, Manual

PLC status displays during booting

The LEDs of the PLC-CPU are in the following state while the PLC-CPU is being booted:

S 5 V DC (green) ON S RUN (green)


flashes

S STOP (yellow) ON

5.3.4

MMC102/103 BIOS setup


The defaults in the BIOS of the MMC102 can be displayed directly on the screen during booting through selection of the key combination

MMC102/103

S CTRL + ALT + ESC on a connected PC keyboard S CTRL + ALT + Alarm acknowledge on a Qwerty keyboard.
MMC103
The plug-and-play-capable Standard BIOS with Power Management with ELITE BIOS is called when booting the MMC103 by pressing the key

S DEL on a connected PC or Qwerty keyboard.


Note The BIOS setup settings are described in References: /BH/, Operator Components manual

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5.3 Booting of system software

5.3.5

Booting of MMC

MMC booting

After the power supply has been switched on, the MMC is booted automatically. The system software is installed in the factory and is ready to run. The basic display appears on the screen if the MMC has been booted successfully.

Problems during booting

MMC100 / 100.2 If the MMC100 cannot establish a connection to the NC, then the message wait for NCU connection: x seconds (x 0 1 to 60 seconds). If a connection has still not been established after this time, then rebooting takes place soon after. Check the following:

S Is the FM-NC (NCU module) ready to operate (LED DIAG flashes at 3 Hz)? S Is the MPI cable inserted, is cable attached properly to connector?
MMC 102 / 103 If the MMC102/103 is not booted, i.e. the screen remains dark, check the 24 V DC power supply. If the power supply is present at the power unit on the MMC102/103 and the seven-segment display on the rear panel does not light up, then the MMC102/103 module is defective. If the MMC102/103 is booted, but cannot establish a connection to the NC, then the message Communications to NC failed is output. In this case, please check the following:

S Is the FM-NC (NCU module) ready to operate (LED DIAG flashes at 3 Hz) S Is the MPI cable inserted, is cable attached properly to connector? S Is the baud rate in menu Start-up/MMC/operator panel set correctly? It
must be set to 1.5 mbaud (password for protection level 2 required).

5.3.6

Booting of machine control panel (MCP)

MCP booting

The flashing LEDs on the MCP indicate that the panel is booting. When booting is completed, the LEDs continue to flash until the MCP receives control telegrams from the PLC.

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Parameterization of the FM-NC

6
6-84 6-85 6-87 6-89 6-91 6-92 6-92 6-96 6-100 6-104 6-105 6-105 6-109 6-111 6-120 6-121 6-129 6-135 6-138 6-139 6-140 6-141 6-143 6-145 6-145 6-147 6-149 6-150 6-151 6-153

6.1 6.2 6.3 6.4 6.5 6.6 6.6.1 6.7 6.8 6.9 6.10 6.10.1 6.10.2 6.10.3 6.10.4 6.10.5 6.10.6 6.10.7 6.10.8 6.10.9 6.10.10 6.10.11 6.10.12 6.10.13 6.10.14 6.10.15 6.10.16 6.10.17 6.10.18 6.11

Machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling machine and setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection level strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator control functions for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . Initialization of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK FMNC configuration/system data . . . . . . . . . . . . . . . . . . General configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of operations for initial start-up . . . . . . . . . . . . . . . . . . . . . . . Sequence of operations for starting up a series machine . . . . . . . . . . Axes and spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Encoder matching (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setpoint routing (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Velocity/speed matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring functions (axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference point approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference point approach for stepper motors . . . . . . . . . . . . . . . . . . . . Extension to 5th axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic settings for operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration and machine data of local P bus of FM-NC . . . . . . . . . . Spindle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Encoder matching (spindles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speeds and setpoint adjustment (spindles) . . . . . . . . . . . . . . . . . . . . . . Spindle positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring functions (spindles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-up of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.1 Machine and setting data

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6.1

Machine and setting data

Parameterization Overview of machine and setting data

Machine and setting data are used to adjust the control so that it matches the machine. The machine and setting data are divided into the following areas:
Table 6-1 Overview of machine and setting data Area Machine data From 1000 to 1799 From 9000 to 9999 From 10000 to 18999 From 19000 to 19999 Machine data for drives Machine data for operator panel General machine data Reserved Channel-specific machine data Reserved Axis-specific machine data Reserved Designation

From 20000 to 28999 From 29000 to 29999 From 30000 to 38999 From 39000 to 39999 Setting data From 41000 to 41999 From 42000 to 42999 From 43000 to 43999

General setting data Channel-specific setting data Axis-specific setting data

The machine and setting data are listed in: References: /LIS/, Lists

Option data

Option data are used to enable options. They are included in the scope of delivery of the relevant option.

Input of machine data

Appropriate displays are provided for the input of machine data. To select displays: When the Area switchover key is selected on the MMC, a menu bar with the areas Machine, Parameters, Program, Services, Diagnosis and Start-up is displayed. Select Start-up and then Machine data.

Note Machine data can be input only if the password for protection level 2 EVENING has been set.

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6.2 Handling machine and setting data

6.2

Handling machine and setting data

Number and identifier

MD and SD are addressed by number or by name (identifier). The number and name are displayed on the MMC. The following must also be noted:

S Active S Protection level S Unit S Default value S Value range


Active The levels at which a data becomes active are listed below in order of priority. A change to the data takes effect after:

S POWER ON (po) Switch FM-NC power supply OFF/ON S NEW_CONF (cf)


Set MD active on MMC RESET key on operating unit Changes at block ends in program mode

S RESET M2/M30 at program end S RESET (re) RESET key on operating unit S IMMEDIATE (so) after entry of value
Protection level Protection level 4 or higher (keyswitch position 3) must be activated to display machine data. The appropriate protection level must generally be enabled by means of password EVENING to start up the system.

Unit

The unit refers to the default setting for the machine data SCALING_FACTOR_USER_DEF_MASK and SCALING_FACTOR_USER_DEF and SCALING_SYSTEM IS METRIC = 1. Depending on the MD SCALING_SYSTEM_IS_METRIC, the physical units differ as follows:

MD 10240 = 1 mm mm/min m/s2 m/s3 mm/rev

MD 10240 = 0 inch inch/min inch/s2 inch/s3 inch/rev

is entered in the field if the MD is not based on any physical unit.

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Default value

This is the value to which the machine data is preset. Some machine data are provided with different default values depending on the NCU used.

Note When data is entered via the MMC, the input value is limited to 10 places plus decimal point and sign.

Value range (minimum and maximum value) Data type

Specification of the input limits. If no value range is specified, the data type determines the input limits and is entered in the field. BOOLEAN BYTE DOUBLE Machine data bit (1 or 0) Integer values (from 128 to 127) Real and integer values (from " 4.19*10307 to " 1.67*10308) DWORD Integer values (from 2.147*109 to 2.147*109 ) STRING Character string (maximum 16 characters) consisting of capital letters with digits and underlining UNSIGNED WORD Integer values (from 0 to 65536) SIGNED WORD Integer values (from 32768 to 32767) UNSIGNED DWORD Integer values (from 0 to 4294967300) SIGNED DWORD Integer values (from 2147483650 to 2147483649) WORD Hex values (from 0000 to FFFF) DWORD Hex values (from 00000000 to FFFFFFFF) FLOAT DWORD Real values (from "8.431037 to "3.371038)

Example of MD file

The default setting of the MDs is not specific to any technology. As an aid for the initial start-up of machines, three example MD files are supplied on the 1st tool box diskette with the FMNC. The purpose of these files is to support initial start-up with respect to the MD settings for specific technologies.

S md_fr_a.tea S md_dr_a.tea S md_dr_s.tea

Example of MD setting for 4-axis milling machine with local P bus (FM 354) Example of MD setting for lathe with analog drive Example of MD setting for lathe with stepper motor drive

Please refer to the supplied readme file: readme.txt for further details.

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6.3 Protection level strategy

6.3

Protection level strategy

Protection levels

Protection levels for enabling data areas are implemented in the SINUMERIK FM-NC. There are protection levels 0 to 7; is the highest and 7 is the lowest. Protection levels

S 0 to 3 are disabled by means of a password and S 4 to 7 by means of keyswitch positions.


The operator only has access to information protected by one particular level and the levels below it. The machine data are assigned various protection levels as standard. Protection level 4 (keyswitch position 3) and higher is required to display machine data. The appropriate protection level must generally be disabled with password EVENING for start-up procedures.

Note For information about changing protection levels, refer to References: /BA/ Operators Guide /FB/ A2, Various Interface Signals

Table 6-2

Protection level strategy Locked by Password Password: SUNRISE (default) Password: EVENING (default) Password: CUSTOMER (default) Keyswitch position 3 Keyswitch position 2 Keyswitch position 1 Keyswitch position 0 Area Siemens Machine manufacturer Service engineer User Programmer, machine setter Qualified operator Trained operator Semi-skilled operator

Protection level 0 1 2 3 4 5 6 7

Protection levels 03

Protection levels 0 to 3 require the input of a password. The password for level 0 provides access to all data areas. The passwords can be changed after activation (not recommended). If, for example, the passwords have been forgotten, then the system must be re-initialized (NCK general reset). This sets all passwords back to the standard of this software version. The password remains valid until it is reset with softkey Delete password. A POWER ON does not reset the password.

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Protection levels 47

Protection levels 4 to 7 require a particular keyswitch setting on the machine control panel. Three keys of different colours are provided for this purpose. Each of these keys is capable of providing access to particular data areas. The associated interface signals are located in DB10, DBX56.
Table 6-3 Meaning of keyswitch positions Switch position 0 = Remove key position 0 and 1 0 to 2 0 to 3 Protection level 7 67 57 47

Key colour All Black Green Red

Redefinition of protection levels

The user has the option of changing the protection level priority. Only protection levels of a lower priority may be assigned to machine data. Levels of a lower or higher priority may be assigned to setting data. Example: %_N_SGUD_DEF File for global variables ;$PATH=/_N_DEF_DIR REDEF $MA_CTRLOUT_SEGMENT_NR APR 2 APW 2 (APR ... read authorization) REDEF $MA_ENC_SEGMENT_NR APR 2 APW 2 (APW ... write authorization) REDEF $SN_JOG_CONT_MODE_LEVELTRIGGRD APR 2 APW 2 M30 The file becomes active when the next _N_INITIAL_INI is read in. Different protection levels are specified for writing (changing) or reading (part program or PLC). Example: MD 10000 is protected by levels 2 / 7, i.e. protection level 2 (password) must be disabled to write it and protection level 7 to read it. Keyswitch position 3 or higher is required to reach the machine data area. References: /BA/, Operators Guide /FB/, A2, Various Interface Signals

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6.4 Operator control functions for start-up

6.4

Operator control functions for start-up

Overview

The operator control functions are divided into the areas Program, Machine, Services, Parameters, Diagnosis and Startup. The Diagnosis and Startup areas are the most important with respect to start-up.

After pressing the area switchover key, you can reach the area menu bar from any operator control area.

Startup

The area and basic display are selected with the Startup softkey. From this basic display menus can be selected for:

S Machine data S User views (only MMCs 102/103) S NC S PLC S Drives / servo (only MMCs 102/103) S MMC S Tool management
Machine data

The following menu is selected with the Machine data softkey in the area Startup:

OK

Fig. 6-1

Basic display for machine data

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Start-up

The Start-up softkey can be used to select menus for:

S Alarms S Messages S Alarm log (only MMC103) S Service display S PLC startup
References: /BA/, Operators Guide

SW version

The software versions of the control system can be called by selecting Service displays/Version in the operator control area Diagnosis.

Start-up switch (SW) on MMC

The following start-up functions can be called with softkey NC in the Start-up menu.

S Normal booting
... initiates a RESET in the FMNC.

S Booting with default values (start-up mode)


... initiates a RESET in the FMNC followed by a booting operation with the default values.

Important User data are deleted or overwritten. See Section 11.7, heading Handling of machine data.

S Start software update


... initiates the update request (see Section 12.1) in the FMNC.

Start-up switch (HW) on FM-NC

The start-up switch on the FM-NC determines the method by which the FM-NC is booted. The following switch settings are relevant for the start-up process:

S 0 Normal booting from internal memory (FLASH) S 1 Booting from internal memory and start-up with default values S 3 Switch to restoring of complete software of the NCU570.2 S 6 Start-up from PCMCIA and switch to update mode of the complete
FM-NC software.

Axes service display

The MMC provides a service menu to support axis start-up: Diagnosis/Service display/Service axes This menu displays axis parameters (following error, etc.) which support axis start-up.

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6.5 Initialization of system

6.5
General

Initialization of system
The initialization process establishes a basic state. The buffered storage areas are initialized and default values stored in the system assigned to the data. The control cannot power up correctly unless this basic state is established. An initialization operation must be carried out

S when the system is switched on for the first time, S in the case of a hardware defect and S after data have been lost.
The FMNC can detect whether the stored RAM contains valid data. If it does not, the system is automatically initialized with default values. This initialization process can also be initiated through appropriate inputs via the MMC with subsequent NCK reset: Start-up/NC/Start-up switch. After an initialization process, the FMNC can power up without any error messages and the system is now ready for initial or series start-up.

FMNC initialization

To initialize the system, the operations listed below must be performed in the order specified: 1. Switch on FMNC When the FMNC is booted for the first time (after initial insertion of battery), the contents of the SRAM are deleted and the machine data set to default values. 2. Execute PLC overall reset. A PLC overall reset can be implemented in 2 different ways: Via the programmer with STEP7 Via the PLC start-up switch on the front panel of the PLCCPU.

3. Load the PLC basic program with the programmer. Transfer the basic program to the PLCCPU. 4. Switch control (CPU 314 with FM-NC) off/on The control powers up with default data and PLC basic program.

MMC 100 initialization

The MMC area (operator panel area) need not be initialized. The system software is loaded ready to run at the factory. Loading of manufacturer data and of languages other than the standard for the MMC 100 is described in Section 8.

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6.6

SINUMERIK FMNC configuration/system data

6.6.1

General configuration
The control operates according to time cycles which are defined via machine data. The basic system clock cycle is defined in seconds; the other time cycles are calculated through multiplication with the basic system clock cycle.

Control time cycles


Table 6-4

Control time cycles Machine data Name Basic system clock cycle Example MD 10050 = 0.006 s > 6 ms

10050: SYSCLOCK_CYCLE_TIME 10060: POSCTRL_SYSCLOCK_TIME_RATIO 10070: IPO_SYSCLOCK_TIME_RATIO

Factor for position control MD 10060 = 1 > 1 @ 6 ms = 6 ms clock cycle (LT) Factor for interpolator clock cycle MD 10070 = 3 > 3 @ 6 ms = 18 ms

6
Note Only in exceptional cases may the values entered deviate slightly from this basic setting (in default values). The values must be adjusted such that the control operates reliably with the set functionality.

Optimization of time cycles

The recommended optimization procedure is described below:

S Define the desired number of axes with time cycles set to default values. S Adjust time cycles as desired and start a program in the AUTOMATIC mode.
If no alarms occur which indicate timing problems on the position control or interpolator levels, then the settings can be transferred. If the set time cycles are too short, then the alarm 4240 MD standard values for IPO and positional cycle loaded is displayed and the appropriate default (standard) values are loaded.

Internal physical quantities

The control uses the following physical quantities for internal calculation purposes regardless of the selected basic system (metric or inch): Linear position Angular position Linear velocity Angular velocity Linear acceleration Angular acceleration Linear jerk Angular jerk Time Servo gain factor Rotational feedrate Linear position (compensation value) Angular position (compensation value) 1 mm 1 degree 1 mm/s 1 degree/s 1 mm/s2 1 degree/s2 1 mm/s3 1 degree/s3 1s 1/s 1 mm/degree 1 mm 1 degree

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6.6 SINUMERIK FMNC configuration/system data

Switchover from metric to inch system

A control system is switched over from the metric to inch system by means of MD 10240: SCALING_SYSTEM_IS_METRIC (basic system metric, active after POWER ON). The additional conversion factor is specified in MD 10250: SCALING_VALUE_INCH (conversion factor for switchover to INCH system, factor = 25.4). The existing data are converted to inches after power ON and displayed. After switchover data must be entered in inches. The basic programming setting (G70, G71) is switched over on a channel-specific basis in MD 20150: GCODE_RESET_VALUES [12]. The standard units for the machine data physical quantities are as follows: Physical quantity Linear position Angular position Linear velocity Angular velocity Linear acceleration Angular acceleration Linear jerk Angular jerk Time Servo gain factor Rotational feedrate Linear position (compensation value) Angular position (compensation value) Metric 1 mm 1 degree 1 mm/min 1 rev/min 1 mm/s2 1 rev/s2 1 mm/s3 1 rev/s3 1s 1/s 1 mm/rev 1 mm 1 degree Inch 1 inch 1 degree 1 inch/min 1 rev/min 1 inch/s2 1 rev/s2 1 inch/s3 1 rev/s3 1s 1/s 1 inch/rev 1 inch 1 degree

Physical quantities for inputs/outputs

The physical quantities for the input/output of machine and setting data (V24, MMC 100) can be defined systemwide via MD 10220: SCALING_USER_DEF_MARK (activation of scaling factors) and MD 10230: SCALING_FACTORS_USER_DEF (physical quantities scaling factors). If the appropriate activation bit is not set in MD 10220 (activation of scaling factors), then scaling is implemented internally with the conversion factors listed below (default setting, exception servo gain factor). If all bits are set in MD 10220 and if the default settings are to remain valid, then the following scaling factors must be entered in MD 10230.

Table 6-5 Index No. 0 1 2 3 4 5 6 7 8

Physical quantities for inputs/outputs Physical quantity Linear position Angular position Linear velocity Angular velocity Linear acceleration Angular acceleration Linear jerk Angular jerk Time Input/output 1 mm 1 degree 1 mm/min 1 rev/min 1 1 m/s2 rev/s2 Internal unit 1 mm 1 degree 1 mm/s 1 degree/s 1 1 mm/s2 degree/s2 1 1 0.016666667 6 1000 360 1000 360 1 Scaling factor

1 m/s3 1 rev/s3

1 mm/s3 1 degree/s3

1s

1s

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Table 6-5 Index No. 9 10 11 12

Physical quantities for inputs/outputs Physical quantity Servo gain factor Rotational feedrate Linear position (compensation value) Angular position (compensation value) Input/output 1m/min @ mm 1 mm/rev 1 mm 1 degree 1/s 1 mm/degree 1 mm 1 degree Internal unit Scaling factor 16.66666667 1/360 1 1

If the activation bit is set and the default settings retained, then the factors specified above correspond to those in MD 10230 (scaling factors for physical quantities).
Input values for machine data

MD 10220 Scaling factor activated? yes MD 10230 Scaling factor

no

Internal scaling

Internal physical quantity

Fig. 6-2

Changing physical quantities

Example: The user wishes to enter the linear velocity in m/min. The internal physical quantity is mm/s.
1 m @1000 mm @1 min [m/min] = min @ 1 m @ 60 s = 1000/60 [mm/s] = 16.666667

The machine data must be entered as follows: MD 10220: SCALING_USER_DEF_MASK = H4 (activation of new factor) and MD 10230: SCALING_FACTORS_USER_DEF [2] = 16.6666667 (scaling factor for linear velocity in m/min) The machine data are automatically converted to these physical quantities after input of the new scale and power ON. The new values are displayed on the MMC and can then be saved. The unit of the physical quantities for programming in the part program is specified in the Programming Guide.

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Internal calculation resolutions

The internal control calculation resolutions are entered in MD 10200: INT_INCR_PER_MM (calculation resolution for linear positions) and MD 10210: INT_INCR_PER_DEG (calculation resolution for angular positions). The default value for this machine data is 1000. The control thus calculates as standard in 1/1000 mm or 1/1000 degrees. If greater accuracy is required, only these two machine data need to be changed. It is useful to enter machine data in powers of 10 (100, 1000, 10000). Rounding (and thus also falsification) of the internal values is implemented only for finer units. However, it is essential that the measuring system is adapted to this degree of accuracy. The internal calculation resolution also determines the accuracy with which positions and selected offset functions are calculated. Changes to the MD have no influence on the velocities and cycle times which can be attained. The number of decimal places for position values on the operator panel screen must be set in MD 9004: DISPLAY_RESOLUTION (input resolution). Exception: On MMCs 100/100.2/102, the spindle speed is always displayed with three decimal places regardless of the setting in MD 9004. On MMC103 the display resolution is determined by MD9010: SPIND_DISPLAY_RESOLUTION.

Input and display limit values

Machine data for velocities and positions are not or only slightly limited by the input limits in the machine data. The input value limitation depends on what values can be displayed and input on the operator panel. This limit is reached at 10 digit positions plus decimal point plus sign.

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6.7

Memory configuration

Hardware configuration

The NCU 570.2 has the following hardware configuration:

S DRAM 4 MB S FLASH 4 MB S Buffered SRAM 0.5 MB S PCMCIA 4 MB

Memory areas

The memory areas for user data in the NC are preset to suit most user requirements during an NCK general reset. The following areas can be adjusted to achieve optimum utilization of the available user memory:

S Tool offsets

S User variables S R parameters S Compensations (e.g.: LEC) S Protection zones S Frames


The memory must be sectionalized before commencement of the actual start-up process because all buffered user data (e.g. part programs, drive data are lost when the memory is re-allocated. Machine data, setting data and options are not erased.

Changing memory areas

The areas for user data (general, channel-specific and axis-specific) are set to default values during control initialization, thus ensuring that the control powers up reliably. The machine manufacturer has the possibility of entering data which change the memory partitioning (SRAM) within individual subareas (e.g. tool offsets, user variables, R parameters, macros). This applies to MD 10010: ASSIGN_CHAN_TO_MODE_GROUP (cannot be altered with FM_NC) and all machine data within the range of MD 18000 to 18999 (general MDs), MD 28000 to 28999 (channel-specific MDs) and MD 38000 to 38999 (axis-specific MDs). The memory (SRAM) should be structured during system initialization if possible since all buffered user data (e.g. part programs, drive boot files) are lost when the memory is re-partitioned! Options as well as machine and setting data are retained. These machine data become active after power ON. If the machine data for the memory configuration (SRAM, DRAM) are set such that the memory cannot be structured meaningfully (e.g. insufficient memory capacity), the standard configuration is applied and an alarm displayed.

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Note The user should first check whether sufficient memory is available (MD 18050) before data areas are enlarged (e.g. local user variables or function parameters). If more dynamic memory is required than is actually available, then the SRAM will also be erased during the next booting process without prior warning and all MD set to their default values.

References:

/DA/, Diagnostics Guide /FB/, S7, Memory Configuration

Danger If the memory is not partitioned immediately during system initialization, all control data will be lost! Before machine data changes are made, all NC and drive data must be backed up (see Section 11). To back up NC data, please proceed as follows:

S S S S S

Change machine data (including MDs for memory partitioning) Back up data Initiate NCK power-up Load data back to the control Initiate NCK power-up

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Erasure of SRAM through MD change

The following machine data cause a re-configuration of the control SRAM in individual cases when their contents are changed. When a change is made, the alarm 4400 MD alteration will cause reorganization of buffer (data loss!) is generated. When this alarm is output, all data must be backed up because all buffered user data will be erased during the next power-up. MD 10010: ASSIGN_CHAN_TO_MODE_GROUP[n] MD 18080: MM_TOL_MANAGEMENT_MASK (tool management memory) MD 18082: MM_NUM_TOOL (number of tools) MD 18084: MM_NUM_MAGAZINE (number of magazines) MD 18086: MM_NUM_MAGAZINE_LOCATION (number of magazine locations) MD 18090: MM_NUM_CC_MAGAZINE_PARAM (number of magazine data) MD 18092: MM_NUM_CC_MAGLOC_PARAM (number of magazine location data) MD 18094: MM_NUM_CC_TDA_PARAM (number of tool-specific data) MD 18096: MM_NUM_CC_TOA_PARAM (number of TOA data) MD 18098: MM_NUM_CC_MON_PARAM (number of monitoring data) MD 18100: MM_NUM_CUTTING_EDGES_IN_TOA (tool offsets per TOA module) MD 18110: MM_NUM_TOA_MODULES (number of TOA modules) MD 18118: MM_NUM_GUD_MODULES (number of GUD files) MD 18120: MM_NUM_GUD_NAMES_NCK (number of global user variables) MD 18130: MM_NUM_GUD_NAMES_CHAN (number of channel-specific user variables) MD 18140: MM_NUM_GUD_NAMES_AXIS (number of axis-specific user variables) MD 18150: MM_GUD_VALUES_MEM (memory location for user variables) MD 18160: MM_NUM_USER_MACROS (number of MACROS) MD 18190: MM_NUM_PROTECT_AREA_NCKC (number of protection zones) MD 18230: MM_USER_MEM_BUFFERED (user memory in SRAM) MD 18270: MM_NUM_SUBDIR_PER_DIR (number of subdirectories) MD 18280: MM_NUM_FILES_PER_DIR (number of files) MD 18290: MM_FILE_HASH_TABLE_SIZE (hash table size for files of a directory) MD 18300: MM_DIR_HASH_TABLE_SIZE (hash table size for subdirectories) MD 18310: MM_NUM_DIR_IN_FILESYSTEM (number of directories in passive file system) MD 18320: MM_NUM_FILES_IN_FILESYSTEM (number of files in passive file system) MD 18330: MM_CHAR_LENGTH_OF_BLOCK (max. length of an NC block) MD 18340: MM_NUM_CEC_NAMES (number of LEC system variables) MD 18342: MM_CEC_MAX_POINTS[n] (max. number of intermediate points) MD 18350: MM_USER_FILE_MEM_MINIMUM (minimum user memory in SRAM) MD 28050: MM_NUM_R_PARAM (number of channel-specific R parameters) MD 28080: MM_NUM_USER_FRAMES (number of settable frames) MD 28085: MM_LINK_TOA_UNIT (assignment of a TO unit to a channel) MD 28200: MM_NUM_PROTECT_AREA_CHAN (number of files for protection zones) MD 38000: MM_ENC_COMP_MAX_POINTS [n] (number of interpolation points with interpol. compensation) MD 38010: MM_QEC_MAX_POINTS (number of values for QEC) (not relevant for FM-NC)

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Exception: A change to MD 18350: MM_USER_FILE_MEM_MINIMUM results in re-configuration only in cases where the unassigned SRAM for the passive file system is lower than defined in MD 18350.

Displaying unassigned SRAM and DRAM

MD 18060: INFO_FREE_MEM_STATIC (display data of unassigned static memory). This data cannot be written! The data contents specify how much SRAM is available for the passive file system at the instant of power-up. After a system initialization process, the maximum available memory in the file system must be read. If changes are made to machine data which influence the buffer requirement (e.g. global user variables, number of points for LEC), then the amount of memory available for the passive file system also changes. The minimum size of the passive file system is defined in MD 18350: MM_USER_FILE_MEM_MINIMUM and is calculated on the basis of MD 18230: MM_USER_MEM_BUFFERED minus all other buffered user data. MD 18050: INFO_FREE_MEM_DYNAMIC (display data of unassigned dynamic memory) This data cannot be written! The data contents specify how much DRAM is currently available for the enlargement of unbuffered user data areas by means of machine data.

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6.8

Sequence of operations for initial start-up

Overview

When the system is started up for the first time, it is advisable to work through the following points in succession. To assist the user, the most important machine data of the individual subareas are listed below. If further information is required, the user can refer to Chapters in this Guide specified in brackets. A detailed description of the machine data and interface signals is given in the function descriptions referred to in the lists.

Check essential preconditions

S Control system design S Connection of components S Cabling, jumpering, voltages S Machine data

Initialize system (Section 6.5)

S Switch on control (CPU and FMNC) S NCK automatically loads default values S PLC overall reset (with SK in Overall reset mode menu) S Load PLC basic program via programmer S Set options S Define memory areas for user data which deviate from default settings (see
Section 6.7) MD 10010: ASSIGN_CHAN_TO_MODE_GROUP[n] (cannot be changed for FM-NC) MD 18000 to MD 18999 MD 28000 to MD 28999 MD 38000 to MD 38999

S Switch control off/on


Load PLC user program
Load the PLC user program using the programmer and incorporate into the PLC basic program. References: /S7H/, Manual /FB/, P3; Basic PLC Program

Enter user data for operator panel

The followingsequence applies for the MMCs 100/100.2

S Switch off MMC S Switch on MMC100 while actuating key 6 on the operator panel or switch
on MMC100.2 and actuate key 6 on the operator panel as soon as the serial number appears on the display

S Load manufacturer data to MMC (Section 11.7)


Cycle alarm texts, error and operational message texts

S Switch MMC off/on

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6.8 Sequence of operations for initial start-up

Enter control configuration

S Enter basic settings for operator panel (Section 6.10.10)


MD 9000: LCD_CONTRAST (only MMC100/100.2 with mono display) MD 9001: DISPLAY_TYPE (for MMCs 100/100.2) MD 9002: DISPLAY_MODE (for MMCs 100/100.2) MD 9003: FIRST_LANGUAGE (for MMCs 100/100.2) MD 9004: DISPLAY_RESOLUTION MD 9006: DISPLAY_BLACK_TIME (for MMCs 100/100.2)

S NCK machine data


Control system time cycles (Section 6.6.1) MD 10050: SYSCLOCK_CYCLE_TIME MD 10060: POSCTRL_SYSCLOCK_TIME_RATIO MD 10070: IPO_SYSCLOCK_TIME_RATIO Control system calculation resolutions (Section 6.6.1) MD 10200: INT_INCR_PER_MM MD 10210: INT_INCR_PER_DEG Scaling machine data (Sections 6.6.1 and 6.2) MD 10220: SCALING_USER_DEF_MASK [n] MD 10230: SCALING_FACTORS_USER_DEF [n] MD 10240: SCALING_SYSTEM_IS_METRIC MD 10250: SCALING_VALUE_INCH MD 30300: IS_ROT_AX Axis assignments (Section 6.10.1) MD 20050: AXCONF_GEOAX_ASSIGN_TAB [n] MD 20060: AXCONF_GEOAX_NAME_TAB [n] MD 20070: AXCONF_MACHAX_USED [n] MD 20080: AXCONF_CHANAX_NAME_TAB [n]

S Initiate NCK power-up


Start up axis and spindle

S Axis and spindle: Enter machine data for


Assignment of actual values and setpoints (Sections 6.10.2 and 6.10.15) MD 30110: CTRLOUT_MODULE_NR [n] MD 30130: CTRLOUT_TYPE [n] MD 30220: ENC_MODULE_NR [n] MD 30230: ENC_INPUT_NR [n] MD 30240: ENC_TYPE [n] MD 30310: ROT_IS_MODULO MD 30320: DISPLAY_IS_MODULO Encoder matching (Sections 6.10.3 and 6.10.14) MD 31000: ENC_IS_LINEAR [n] MD 31010: ENC_GRID_POINT_DIST [n] MD 31020: ENC_RESOL [n] MD 31030: LEADSCREW_PITCH MD 31040: ENC_IS_DIRECT [n] MD 31050: DRIVE_AX_RATIO_DENOM [n] MD 31060: DRIVE_AX_RATIO_NUMERA [n] MD 31070: DRIVE_ENC_RATIO_DENOM [n] MD 31080: DRIVE_ENC_RATIO_NUMERA [n]

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Start up axis and spindle (continued)

S Axis-specific: Enter machine data for


SSI encoder MD 14000: ENC_SSI_BAUD_RATE MD 34400: ENC_SSI_STATUS MD 34410: ENC_SSI_MESSAGE_LENGTH MD 34420: ENC_SSI_MESSAGE_FORMAT Axis velocities (Section 6.10.5) MD 32000: MAX_AX_VELO MD 32010: JOG_VELO_RAPID MD 32020: JOG_VELO MD 34020: REFP_VELO_SEARCH_CAM MD 34040: REFP_VELO_SEARCH_MARKER [n] MD 34070: REFP_VELO_POS MD 36200: AX_VELO_LIMIT [n] Axis control (Section 6.10.5) MD 32200: POSCTRL_GAIN MD 32300: MAX_AX_ACCEL Axis monitoring functions (Section 6.10.6) MD 36000: STOP_LIMIT_COARSE MD 36010: STOP_LIMIT_FINE MD 36030: STANDSTILL_POS_TOL MD 36040: STANDSTILL_DELAY_TIME MD 36060: STANDSTILL_VELO_TOL MD 36100: POS_LIMIT_MINUS MD 36110: POS_LIMIT_PLUS MD 36300: ENC_FREQ_LIMIT[n] MD 36400: CONTOUR_TOL Axis reference point approach (Section 6.10.7) MD 34000: REFP_CAM_IS_ACTIV MD 34010: REFP_CAM_DIR_IS_MINUS MD 34030: REFP_MAX_CAM_DIST MD 34050: REFP_SEARCH_MARKER_REVERSE [n] MD 34060: REFP_MAX_MARKER_DIST [n] MD 34080: REFP_MOVE_DIST [n] MD 34090: REFP_MOVE_DIST_CORR [n] MD 34100: REFP_SET_POS [n] MD 34110: REFP_CYCLE_NR MD 34200: ENC_REFP_MODE [n] MD 34300: ENC_REFP_MARKER_DIST [n] MD 34310: ENC_MARKER_INC [n] MD 34320: ENC_INVERS [n] MD 34330: REFP_STOP_AT_ABS_MARKER [n]

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Start up axis and spindle (continued)

S Spindle-specific: Enter machine data for


Spindle definition (Section 6.10.12) MD 30300: IS_ROT_AX MD 30320: DISPLAY_IS_MODULO MD 35000: SPIND_ASSIGN_TO_MACHAX MD 35010: GEAR_STEP_CHANGE_ENABLE MD 35040: SPIND_ACTIVE_AFTER_RESET MD 35500: SPIND_ON_SPEED_AT_IPO_START Speeds (Section 6.10.15) MD 35100: SPIND_VELO_LIMIT MD 35110: GEAR_STEP_MAX_VELO [n] MD 35120: GEAR_STEP_MIN_VELO [n] MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL [n] MD 35220: ACCEL_REDUCTION_SPEED_POINT MD 35230: ACCEL_REDUCTION_FACTOR Spindle positioning (Section 6.10.16) MD 35210: GEAR_STEP_POSCTRL_ACCEL [n] MD 35300: SPIND_POSCTRL_VELO MD 35350: SPIND_POSITIONING_DIR MD 36000: STOP_LIMIT_COARSE MD 36010: STOP_LIMIT_FINE MD 32200: POSCTRL_GAIN MD 36400: CONTOUR_TOL Spindle synchronization (Section 6.10.17) MD 34090: REFP_MOVE_DIST_CORR [n] MD 34100: REFP_SET_POS [n] MD 34200: ENC_REFP_MODE [n] Spindle monitoring functions (Section 6.10.18) MD 36060: STANDSTILL_VELO_TOL MD 35130: GEAR_STEP_MAX_VELO_LIMIT [n] MD 35140: GEAR_STEP_MIN_VELO_LIMIT [n] MD 35150: SPIND_DES_VELO_TOL

S Initiate NCK power-up


Test axis and spindle
Check

S Safety signals (e.g. EMERGENCY STOP, HW limit switch) S Traversing path, velocity, speed and direction of rotation (Sections 9.2 and
9.3)

S Optimize axes and spindles S Check machine functions


Backup data
See Section 11

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6.9
Note

Sequence of operations for starting up a series machine


See also Section 11.2 Series start-up via V24.

Check essential preconditions

S Control system design S Connection of components S Cabling, jumpering, voltages S Machine data

Initialize system (Section 6.5)

S Switch on control (CPU and FM-NC) S NCK automatically loads default values S PLC overall reset (with SK in Overall reset mode menu) S Load PLC basic program via programmer S Switch control off and on again

Load PLC user program

Load the PLC user program using the programmer and incorporate into the PLC basic program. References: /S7H/, Manual

Enter user data for operator panel with MMC100/100.2

The user data are entered as follows for the MMCs 100/100.2:

S Switch off MMC S Switch on MMC100 while actuating key 6 on the operator panel or switch
on MMC100.2 and actuate key 6 on the operator panel as soon as the serial number appears on the display

S Load manufacturer data to MMC (Section 11.7)


Cycle alarm texts, error and operational message texts

S Switch MMC off and on again


Read in the data for this machine Test axis and spindle
See Section 11

Check

S Safety signals (e.g. EMERGENCY STOP, HW limit switch) S Traversing path, velocity, speed and direction of rotation (Sections 9.2 and
9.3)

S Optimization of axis and spindle (start-up software for drive) S Check machine functions
Back up data
See Section 11

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6.10
6.10.1

Axes and spindles


Axis configuration

Overview

The SINUMERIK FM-NC is supplied as standard with the following configuration: NCU 570.2: 1 channel and 4 axes

Machine axes

These are all the axes on the machine. They are defined as geometry axes or additional axes.

Geometry axes

These are used to program the workpiece geometry. The geometry axes form a rectangular coordinate system (2D or 3D). Tool offsets are only included in calculations for geometry axes.

Additional axes

In contrast to geometry axes, there is no geometric relationship between additional axes such as

S rotary axes S revolver axes S positioned-controlled spindle


Axis configuration
The axis configuration is defined on 3 levels: 1. Machine level 2. Channel level 3. Program level Machine level MD 10000 AXCONF_MACHAX_NAME_TAB An axis name is defined for each machine axis in MD 10000 AXCONF_MACHAX_NAME_TAB. Example: Turning machine with X, Z, C axis/spindle
MD 10000 Index X1 0 Z1 1 C1 2 3 4

Milling machine 4 axes + spindle/C axis


X1 0 Y1 1 Z1 2 A1 3 C1 4

Example for milling machine: MD 10000 AXCONF_MACHAX_NAME_TAB[0] = X1 AXCONF_MACHAX_NAME_TAB[1] = Y1 AXCONF_MACHAX_NAME_TAB[2] = Z1 AXCONF_MACHAX_NAME_TAB[3] = A1 AXCONF_MACHAX_NAME_TAB[4] = C1

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Channel level

S MD 20070 AXCONF_MACHAX_USED[0...4]
The machine axes are assigned to a geometry channel by means of the channel-specific MD. Turning machine
1 2 3 0 0

Milling machine
1 2 3 4 5

S MD 20080 AXCONF_CHANAX_NAME_TAB[0...4]
This MD defines the names of the axes in the channel. Enter the names of the geometry and additional axes here.
X Y C X Y Z A C

Program level

S MD 20060 AXCONF_GEOAX_NAME_TAB[0...4]
This MD specifies the names to be used in the part programs for the geometry axes (workpiece axes not specific to machine).
X Y1) Z X Y Z

1) The 2nd geometry axis coordinate must also be assigned a name (e.g. Y) for a transformation, e.g. TRANSMIT.

S MD20050 AXCONF_GEOAX_ASSIGN_TAB[0...4]
Defines the assignment between the geometry axes and the channel axes (MD20070) without transformation. (For assignment with an active transformation, please refer to: References: /FB/, K2 Coordinate Systems, Axis Types, Axis Configuration, ...) Note the relationship with the inclusion of tool offsets in the calculation (G17, G18, G19).
1 0 2 1 2 3

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Axis assignments in system

The axis designators AX1 to AX4 always apply in the system. In addition, a name can be entered in MD 10000: AXCONF_MACHAX_NAME_TAB for every machine axis. However, this name is significant only for the following functions:

S S S S S S S S
Axis assignment with respect to a channel

Loading, saving and display of machine data Machine-axis-specific reference point approach (G74) Measurements Fixed-point approach (G75) Display in AXMD menu and with axis alarms Display in machine-related actual value system Handwheel function Traversal from PLC

Machine axes can be assigned by means of MD 20070: AXCONF_MACHAX_USED to an active channel which in turn is assigned to a mode group by means of MD 10010: ASSIGN_CHAN_TO_MODE_GROUP. These axes can also be activated in MD 20070. A distinction is made between additional axes and geometry axes (GEOaxis) in the channel. Geometry axes are imaged on machine axes via a transformation. If no transformation is selected, then the GEOaxes are imaged as standard 1:1 on the appropriate machine axes. Additional axes are machine axes which can be programmed in addition to the GEOaxes (e.g. rotary axes). A machine axis which is not defined in the channel cannot be addressed in this channel.
MD 20070: AXCONF_MACHAX_USED Machine axes used in channel MD 20080: AXCONF_CHANAX_NAME_TAB An axis name must be assigned to every machine axis defined in the channel. MD 20050: AXCONF_GEOAX_ASSIGN_TAB Assignment between GEOaxis and machine axis. AXCONF_GEOAX_ASSIGN_TAB [0] = 1 AXCONF_GEOAX_ASSIGN_TAB [1] = 2 AXCONF_GEOAX_ASSIGN_TAB [2] = 3 X to X, Y to Y, Z to Z

Machine axis no. for channel 1 2 3 4 5 X Y Z A B Axis name in channel

Assignment of GEOaxes

X Y Z GEOaxis

A B Additional axes

MD 20060: AXCONF_GEO_AX_NAME_TAB Name of GEOaxes

Fig. 6-3

Axis configuration in channel (default settings)

Note There must be no gaps in the list of machine axes to be traversed (MD: 20070_AXCONF_MACHAX_USED). The relevant machine axis is activated through entry in this list, i.e. a machine axis which is not entered in any channel in $MC_AXCONF_MACHAX_USED is not included in the calculation and therefore not affected by the closed-loop control function.

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Assignment of actual values and setpoints

The control must be informed of the interface via which setpoints and actual values are to be exchanged with the drive. In the FMNC control system, only one actual value input can be defined for each axis so that the maximum possible setting for MD 30200: NUM_ENCS is 1. The actual value which is active for the position control is selected via the PLC user interface. The following parameters must be specified for the FMNC: Drive segment With the FMNC, a value of 0 (default setting) must be entered in the MD for those axes which are supplied directly with setpoints and actual values by the FMNC. A value of 2 must be entered in the MD for the 5th axis which receives its setpoints and actual values from the FMNC via the local P bus. MD 30100: CTRLOUT_SEGMENT_NR (setpoint) MD 30210: ENC_SEGMENT_NR (actual value) Drive module The module number entered corresponds to the number of the module which drives the motor. 1 must be entered for an FMNC control.

MD 30110: CTRLOUT_MODULE_NR (setpoint) MD 30220 ENC_MODULE_NR (actual value) Interface The number of the actual value input or of the setpoint interface (1 to 4 for FMNC or FM 354 1) of the drive module is defined in this parameter. MD 30120: CTRLOUT_NR (setpoint) MD 30230: ENC_INPUT_NR (actual value)

Important In order to guarantee that the control powers up reliably, all activated axes are declared as simulation axes (without hardware) during initialization. MD30130: CTRLOUT_TYPE = 0 (simulation) MD30240: ENC_TYPE = 0 (simulation) When the axes are traversed, the control loop is simulated and no alarms are output. For the purpose of axis or spindle start-up, MD 30130 must be set to 1 or MD 30240 to 2, or to the value corresponding to the hardware identifier. The user can select in MD 30350: SIMU_AX_VDI_OUTPUT whether the interface signals of a simulation axis are output at the PLC interface (e.g. during program test, start-up).

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Example of actual value and setpoint assignments

Closedloop control

Manipulatedvariable branch Manipulatedvariable branch

Manipulatedvariable routing

M M

30240 ENC_TYPE = 0 (simulation) 30200 NUM_ENCS Act.-value process. Actual-value routing Act.-value process.

G G

30200 NUM_ENCS

Present only on test set-ups or real installations

Fig. 6-4

Block diagram showing setpoint and actual-value routing

6.10.2

Axis data

Overview

4 linear axes are active by default with the SINUMERIK FM-NC. The assignment for rotary axis and spindle must be made during startup.

Distinction between linear axis and rotary axis

MD 30300: IS_ROT_AX must be set for a rotary axis. This setting causes Rotary axis to be selected internally and the control to be switched over from mm to degrees. In addition, there is the rotary axis display referred to 360 degrees, MD 30320: DISPLAY_IS_MODULO (modulo 360 degrees display for rotary axes) and the modulo programming MD 30310: ROT_IS_MODULO (modulo conversion for rotary axis and spindle). These MD are activated after POWER ON. When MD 30300 is set followed by power ON, the active axis machine data (e.g. for velocity, acceleration, jerk) are converted automatically to the new physical unit. Example: Velocity = 10000 mm/min and linear axis is set. After the conversion to rotary axis, the value 27.77777778 is entered in this MD with a unit of rev/min.

Axis types

Indexing axis The user must specify in MD 30500: INDEX_AX_ASSIGN_POSTAB (indexing axis assignment) which global list (general machine data 10900: INDEX_AX_LENGTH_POS_TAB1 or MD 10910: INDEX_AX_POS_TAB1 for list 1 and MD 10920 or MD 10930 for list 2) with indexing positions is to be used. Concurrent positioning axis The axis can be defined as a Concurrent positioning axis in MD 30450: IS_CONCURRENT_POS_AX.

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Exception regarding machine data parameterization

In the case of machine data which are stored as a field, the first value is always assigned to the first parameter, e.g. 1st reference point value, 1st encoder number. This is not the case for the following machine data for which the assignment is made by means of a special function. In the case of machine data with the field parameter Control parameter set no., the first field is used for normal axis operation. If the axis interpolates with a spindle, e.g. with G331 (tapping without compensating chuck), the selected gear stage determines the appropriate field (1st gear stage > field index 1). This applies to all machine axes which can be traversed by means of geometry axes (see Section 6.1). MD 31050: DRIVE_AX_RATIO_DENOM (denominator load gearing) MD 31060: DRIVE_AX_RATIO_NUMERA (numerator load gearing) MD 32200: POSCTRL_GAIN (servo gain factor) MD 32800: EQUIV_CURRCTRL_TIME (substitute time constant, current control loop for feedforward control) MD 32810: EQUIV_SPEEDCTRL_TIME (substitute time constant, speed control loop for feedforward control) MD 32910: DYN_MATCH_TIME (dynamic response matching time constant) MD 36200: AX_VELO_LIMIT (threshold value for speed monitoring)

Example: MD 32200: POSCTRL_GAIN [0,AX1] = 1 (servo gain factor for normal axis operation) MD 32200: POSCTRL_GAIN [1,AX1] = 1 (servo gain factor for G331 and active spindle gear stage 1) MD 32200: POSCTRL_GAIN [3,AX1] = 1 (servo gain factor for G331 and active spindle gear stage 3)

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6.10 Axes and spindles

6.10.3

Encoder matching (axis)

Overview
NCCPU 3 2 1 0 (Local P bus) 30220 ENC_MODULE_NR 1 30210 ENC_SEGMENT_NR (FMNC = 0) (Local P bus = 2) 1 3 2 4 1 1

FMNC 30240 ENC_TYPE:

FM 354 (optional)

30230 ENC_INPUT_NR = 0 Simulation = 1 Raw signal encoder (not FMNC) = 2 Square-wave encoder = 3 Stepper motor = 4 EnDat absolute encoder (for SINUMERIK 840D only) = 5 SSI encoder

MD for measuring-circuit routing: 30210 ENC_SEGMENT_NR = 0 or 2 for FMNC local bus) 30220 ENC_MODULE_NR =1 30230 ENC_INPUT_NR = 1...4 (FMNC = 1...4, FM = 1, handwheels = 5,6) 30240 ENC_TYPE = 0, 2, 3 and 5 (for FM-NC) 0, 2, and 5 (for FM 354) Example: 5th axis (FM 354) ENC_SEGMENT_NR = 2 ENC_MODULE_NR =1 ENC_INPUT_NR =1 ENC_TYPE =2 Fig. 6-5 Measuring circuit assignment (FMNC)

The control requires scaled encoder signals for a closed position control loop. In order to match the encoder, the encoder type and prevailing mechanical conditions must be known and entered in the machine data (other values are not required). The control then calculates the resolution referred to the internal calculation resolutions (MD: INT_INCR_PER_MM; MD INT_INCR_PER_DEG) automatically. The following machine data must be set when the data are input: IS_ROT_AX ENC_IS_LINEAR ENC_IS_DIRECT Distinction between rotary and linear axis Linear scale or rotary encoder Encoder directly mounted on machine or motor

Please refer to the function descriptions for detailed information. References: /FB/, G2, Velocities, Actual Value Systems, Cycle Times R2, Rotary Axes

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Matching rotary encoders


Table 6-6

The following table lists all the data which must be entered for the sake of encoder matching.

Machine data for matching rotary encoders Machine data Linear axis Encoder on motor Encoder on machine 0 0 1 Marks/rev mm/rev Load rev Encoder rev See note See note Rotary axis Encoder on motor 1 0 0 Marks/rev Encoder on machine 1 0 1 Marks/rev

30300: IS_ROT_AX 31000: ENC_IS_LINEAR 31040: ENC_IS_DIRECT 31020: ENC_RESOL 31030: LEADSCREW_PITCH 31080: DRIVE_ENC_RATIO_NUMERA 31070: DRIVE_ENC_RATIO_DENOM 31060: DRIVE_AX_RATIO_NUMERA

0 0 0 Marks/rev mm/rev Motor rev Encoder rev Motor rev Load rev

Motor rev Encoder rev Motor rev Load rev

Load rev Encoder rev See note See note

31050: DRIVE_AX_RATIO_DENOM

Note These MD are not required to match the encoder (path evaluation), but they must be entered correctly for the sake of setpoint calculation otherwise the desired servo gain factor will not be obtained. The load revolutions are entered in MD 31050: DRIVE_AX_RATIO_DENOM and the motor revolutions in MD 31060: DRIVE_AX_RATIO_NUMERA. 1st example of encoder matching Linear axis X1 with rotary encoder (2500 pulses) on motor, internal multiplier 4 (standard, INTV), motor/leadscrew gearing 5/1, leadscrew pitch 10 mm, 1000 increments per mm MD 30300: IS_ROT_AX [X1] = 0 MD 31000: ENC_IS_LINEAR [0,X1] = 0 MD 31040: ENC_IS_DIRECT [0,X1] = 0 MD 31020: ENC_RESOL [0,X1] = 2500 MD 31030: LEADSCREW_PITCH [X1] = 10 MD 31080: DRIVE_ENC_RATIO_NUMERA [0,X1] = 1 MD 31070: DRIVE_ENC_RATIO_DENOM [0,X1] = 1 MD 31060: DRIVE_AX_RATIO_NUMERA [0,X1] = 5 MD 31050: DRIVE_AX_RATIO_DENOM [0,X1] = 1 MD 10200: INT_INCR_PER_MM = 1000 Internal resolution = 1 @ MD31080 @ MD31050 @ MD31030 @ MD10200 MD31020 @ INTV @ MD31070 @ MD31060 1 @ 1 @ 1 @ 10 mm @ 1000/mm 2500 @ 4 @ 1 @ 5 = 0.2

Internal resolution = Result:

1 encoder increment corresponds to approximately 0.2 increments of the internal unit.

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2nd example of encoder matching Rotary axis C with rotary encoder (1024 pulses) on motor, internal multiplier 4 (standard, INTV), motor/leadscrew gearing 5/1, 1000 increments per degree MD30300: IS_ROT_AX [C] = 1 MD31000: ENC_IS_LINEAR [0,C] = 0 MD31040: ENC_IS_DIRECT [0,C] = 0 MD31020: ENC_RESOL [0,C] = 1024 MD31080: DRIVE_ENC_RATIO_NUMERA [0,C] = 1 MD31070: DRIVE_ENC_RATIO_DENOM [0,C] = 1 MD31060: DRIVE_AX_RATIO_NUMERA [0,C] = 5 MD31050: DRIVE_AX_RATIO_DENOM [0,C] = 1 MD10210: INT_INCR_PER_DEG = 1000 360 @ MD31080 @ MD31050 @ MD10210 MD31020 @ INTV @ MD31070 @ MD31060 360 @ 1 @ 1 @ 1000/degree 1024 @ 4 @ 1 @ 5 = 17.5781

Internal resolution =

Internal resolution =

Result: 1 encoder increment corresponds to approximately 17.5781 increments of the internal unit.

SSI encoder matching

Alongside incremental encoders the FMNC can also be used with SSI encoders with the telegram types

S 13-bit (only single-turn encoder), S 21-bit (max.12-bit resolution/revolution) and S 25-bit (max. 13-bit resolution/revolution).
Connection is similarly at the measuring system interfaces X3...X6. The pin assignment is to be taken from References: /PHF/, Planning, NCU570 and FM354 Manuals

The encoder type is to be set with MD30240_ENC_TYPE=5 (SSI encoder). The following machine data are used to match the SSI encoder to the FMNC:

S MD14000: ENC_SSI_BAUD_RATE
Baud rate setting for SSI encoder, Value: 0,1 250 kHz (default value) Value: 2 400 kHz Value: 3 500 kHz Value: 4 1 MHz

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SSI encoder matching, continued

S MD34220: ENC_ABS_TURNS_MODULO
(valid from product version 3.07.11) The absolute position of an axis is reduced to the range entered here when the absolute encoder is switched on. The value should correspond to the travel range (in turns) of the absolute encoder actually in use. Default setting: 1 (corresponds to singleturn) Min. input value: 1, max. input value: 4096

S MD34400: ENC_SSI_STATUS
Synchronization for SSI encoder, default value=0 Bit 0 (value code) Value=0 > Gray code Value=1 > binary code Bit 1 (parity test) Value=0 > no Value=1 > yes Bit 2 (parity) Value=0 > uneven parity Value=1 > even parity Bit 3 (measurement) Value=0 > measurement not planned Value=1 > activate for measurement Bit 4 (probe selection) Value=0 > probe 1 at connector X1.17 Value=1 > probe 2 at connector X1.18

S MD34410: ENC_SSI_MESSAGE_LENGTH
Telegram length for SSI encoder, Value: 0 25 bits for multi-turn encoder (default value) Value: 1 13 bits for single-turn encoder Value: 2 21 bits for multi-turn encoder Value: 3 25 bits for multi-turn encoder

S MD34420: ENC_SSI_MESSAGE_FORMAT
Format of SSI telegram. For SSI encoders the number of increments per revolution of the encoder is here used to set the telegram format within the telegram length. Value: 0 right-justified Value: 1 8192 increments per revolution in fir-tree format Value: 2 4096 increments per revolution in fir-tree format Value: 3 2048 increments per revolution in fir-tree format Value: 4 1024 increments per revolution in fir-tree format Value: 5 512 increments per revolution in fir-tree format Value: 6 256 increments per revolution in fir-tree format Value: 7 128 increments per revolution in fir-tree format Value: 8 64 increments per revolution in fir-tree format Value: 9 32 increments per revolution in fir-tree format Value: 10 16 increments per revolution in fir-tree format Value: 11 8 increments per revolution in fir-tree format Value: 12 4 increments per revolution in fir-tree format Value: 13 2 increments per revolution in fir-tree format The following machine data are also affected:

S MD34320: ENC_INVERS (length measuring system is inverse) S MD34200: ENC_REFP_MODE = 0 (referencing mode, 0=no RP travel) S MD31020: ENC_RESOL (number of increments to base 2) S MD30240: ENC_TYPE = 5 (type of actual value encoder) S MD34090: REFP_MOVE_DIST_CORR (reference point offset)

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Encoder matching with linear measuring systems

The following table lists all the data which need to be entered in order to match the encoder.
Table 6-7 Machine data for encoder matching with linear measuring systems Machine data MD 30300: IS_ROT_AX MD 31000: ENC_IS_LINEAR MD 31010: ENC_GRID_POINT_DIST MD 34320: ENC_INVERS 0 1 Division Inverted Linear axis

Example: Linear axis with a glass scale which has a division period of 0.020 mm. Internal multiplier 4 (standard, INTV). Internal calculation resolution = 1000 increments per mm. MD31010 @ 11) @ MD10200 Internal resolution = internal multiplier (INTV) Internal resolution = Result: A division period corresponds to approximately 5 increments of the internal unit. 0.02 mm @ 1000/mm 4 = 5

Table Y Leadscrew (Y is 2nd machine axis)

NC-CPU

3 2 1 0 1 1 3 2 4 1 1 1

FM-NC ENC_SEGMENT_NR[0, Y] ENC_MODULE_NR[0, Y] ENC_INPUT_NR[0, Y] =2 =1 =1

FM 354 =2 =1 =1

CTRLOUT_SEGMENT_NR[Y] CTRLOUT_MODULE_NR[Y] CTRLOUT_NR [Y]

Fig. 6-6

Example of a measuring-circuit and setpoint assignment with an FM 354 as an additional axis on FM-NC

1)

Position control cycle factor (MD 10060) is preset to a value of 1 in the FMNC.

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Actual value encoder on spindle


Controller

CTRLOUT_LIMIT (%)

RATED_VELO (degrees/s) M

31030 LEADSCREW_PITCH

Wire word 36710 DRIFT_LIMIT (%) AX_MOTION_DIR = 1 RATED_OUTVAL (%) DRIVE_AX_RATIO_NUMERA DRIVE_AX_RATIO_DENOM =

Spindle with linear axes only

Number of motor revolutions Number of load (spindle) revolutions

Fig. 6-7

Actual value encoder on spindle

Actual value processing

S Linear axis

IS_ROT_AX = 0

6
M Load gearing Table Spindle Linear scale 31000 ENC_IS_LINEAR = 1 31010 ENC_GRID_POINT_DIST 34320 ENC_INVERS Fig. 6-8 Linear scale

ENC_IS_DIRECT = 0 ENC_IS_LINEAR = 0 M G ENC_RESOL Measurement gearing: DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM LEADSCREW_PITCH = main spindle pitch 1 . DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DRIVE . . LEADSCREW_PITCH INT_INKR_PER_MM = Number of spindle revolutions Number of encoder revolutions

int resolution = Number of encoder markings, calculated allowing for external multiplier if applicable Fig. 6-9

ENC_RESOL multiplication Encoder increment/revolutions

Rotary encoder on machine

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ENC_IS_LINEAR = 0 G ENC_RESOL

ENC_IS_DIRECT = 0 Table M LEADSCREW_PITCH Number of motors = Number of spindle revolutions Number of motor revolutions Number of encoder revolutions . multiplication DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM . LEADSCREW_PITCH . INT_LNCR_PER_MM

DRIVE_AX_RATIO_NUMERA DRIVE_AX_RATIO_DENOM DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM Internal resolution = . ENC_RESOL 1 . =

DRIVE_AX_RATIO_DENOM DRIVE_AX_RATIO_NUMERA

Fig. 6-10

Rotary encoder on motor

S Rotary axis

IS_ROT_AX = 1

ENC_IS_DIRECT = 1 ENC_RESOL M L G ENC_IS_LINEAR = 0 DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM = Number of load (spindle) revolutions Number of encoder revolutions . DRIVE_ENC_RATIO_NUMERA . INT_INCR_PER_DEG DRIVE_ENC_RATIO_DENOM

360 Internal resolution = ENC_RESOL . multiplication Fig. 6-11 Rotary encoder on machine

ENC_IS_DIRECT = 0 ENC_IS_LINEAR = 0 G ENC_RESOL M DRIVE_AX_RATIO_NUMERA DRIVE_AX_RATIO_DENOM DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM Intern. resolution = . = L LEADSCREW_PITCH = Number of motor revolutions Number of load revolutions

Number of motor revolutions Number of encoder revolutions . . . DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM INT_INCR_PER_DEG

360 ENC_RESOL . multiplication DRIVE_AX_RATIO_DENOM DRIVE_AX_RATIO_NUMERA

Fig. 6-12

Rotary encoder on motor

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S Stepper motor without encoder

31000 ENC_IS_LINEAR = 0 G SM FM-NC 31400 STEP_RESOL

MD 30240 ENC_TYPE = 3 MD 30130 CTRLOUT_TYPE = 2 L 31030 LEADSCREW_PITCH = = Number of motor revolutions Number of load revolutions Number of motor revolutions Number of encoder revolutions

31060 DRIVE_AX_RATIO_NUMERA 31050 DRIVE_AX_RATIO_DENOM DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM 360 STEP_RESOL

Internal resolution =

DRIVE_AX_RATIO_DENOM DRIVE_AX_RATIO_NUMERA

INT_INCR_PER_DEG

The encoder in stepping motor controls is simulated in the FMNC. The value Pulse per step revolution must be entered in MD 31020 ENC_RESOL.

Fig. 6-13

Stepping motor without encoder

Although encoderless stepper motors have no external encoder, the following encoder machine data must be observed (due to internal pulse feedback): MD30130_NUM_ENCS = 1 MD31020__ENC_RESOL = 31400_STEP_RESOL = steps per stepper motor revolution

Note For further information about motor rotation monitoring, please refer to References: /FB/, S6 Stepping Motors

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S Stepper motors with encoder


Stepper motor drives with encoder must be treated like normal drives except for MD settings MD30240 ENC_TYPE 0 3, MD30130 CTRLOUT_TYPE = 2, MD31020 ENC_ RESOL = pulses per encoder revolution MD31400 STEP_RESOL = steps per stepper motor revolution and MD30130 NUM_ENCS = 1

ENC_IS_DIRECT = 0 ENC_IS_LINEAR = 0 G ENC_RESOL SM DRIVE_AX_RATIO_NUMERA DRIVE_AX_RATIO_DENOM DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM Int. resolution = = STEP_RESOL L

MD 30240 ENC_TYPE 0 3 MD 30130 CTRLOUT_TYPE = 2

LEADSCREW_PITCH = Number of motor revolutions Number of load revolutions

Number of motor revolutions Number of load revolutions . . DRIVE_ENC_RATIO_NUMERA DRIVE_ENC_RATIO_DENOM

360 ENC_RESOL . Multiplication DRIVE_AX_RATIO_DENOM DRIVE_AX_RATIO_NUMERA

INT_INCR_PER_DEG

Fig. 6-14

Rotary encoder on stepper motor

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6.10.4

Setpoint routing (axis)


3 2 1 0

(local P bus) 30110 CTRLOUT_MODULE_NR 1 1 1 1

NCCPU

30100 CTRLOUT_SEGMENT_NR (FMNC = 0) (FM 354 = 2)

1 3

2 4

X2 Output 1 2 3 PIN analog Increm. 1 35 3 37 5/6 40/41 9/10 44/45 = 0 Simulation = 1 Standard = 2 Stepper motor = 3 Unassigned FMNC FM 354 (optional)

30120 CTRLOUT_NR (for FMNC = 1...4, for FM 354 = 1)

30130 CTRLOUT_TYPE:

MD for setpoint routing: CTRLOUT_SEGMENT_NR CTRLOUT_MODULE_NR CTRLOUT_NR CTRLOUT_TYPE Fig. 6-15 = 0 (FMNC) and 2 (FM 354) =1 = 1...4 (FMNC = 1...4, FM = 1) = 0...3

Measured variable (setpoint) assignment (FMNC)

Setpoint adaptation for axes without drive

Axes which are activated but not connected to a drive system must be assigned a value of 0 (simulation) in MD 30130: CTRLOUT_TYPE.

Note MD 30120: CTRLOUT_NR simultaneously routes the Controller enable signals (X2 pin 14/47, pin 15/48, etc.). Controller output X2, pin 16/49, is therefore assigned, for example, to setpoint out 3 (X2 pin 3/36, MD 30120: CTRLOUT_NR = 3).

Setpoint for stepper motor

The setpoint routing function for stepper motors without measuring system (MD 30130. CTRLOUT_ TYPE = 2) also routes the appropriate actual value feedback. For example, if the 3rd setpoint output is generated (MD 30120: CTRLOUT_NR = 3) for the 2nd channel axis, then the stepping pulses are also fed back to the 3rd actual value input. Actual value connector 3 may not therefore have a measuring system assigned to it. The steps per stepper motor revolution must be entered in MD31400 STEP_RESOL (corresponds to MD31020 ENC_RESOL for SM with encoder).

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6.10.5

Velocity/speed matching
The following machine data must be defined: MD 32000: MAX_AX_VELO (maximum axis velocity) MD 32010: JOG_VELO_RAPID (conventional rapid traverse) MD 32020: JOG_VELO (conventional axis velocity) MD 34020: REFP_VELO_SEARCH_CAM (reference point approach speed) MD 34040: REFP_VELO_SEARCH_MARKER [n] (creep speed) MD 34070: REFP_VELO_POS (reference point approach speed) These velocity/speed values, which can be set via machine data, are used to match the drive to the machine. Their purpose is to preclude the risk of damage resulting from incorrectly adapted axis velocity settings.

Machine data

Note When new velocity/speed values are entered, the velocity/speed monitor (MD 36200: AX_VELO_LIMIT) must be adapted accordingly.

6
These velocity/speed values must be transferred to the drive after scaling for the drive control. The setpoint output is scaled internally in the NC. In order to ensure correct setpoint scaling, it is essential to enter the correct load gearbox data! MD 31060: DRIVE_AX_RATIO_NUMERA MD 31050: DRIVE_AX_RATIO_DENOM The following data are also relevant in terms of velocity/speed adaptation: MD 32250: RATED_OUTVAL (speed setpoint scaling) MD 32260: RATED_VELO (motor speed scaling) References: /FB/, G2 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control

Acceleration characteristic with break-point

Optimum start/stop characteristics at low velocities, i.e. in the vicinity of the start/ stop frequency of the stepper motor, can be obtained by means of the acceleration characteristic with break-point. In this case, a steeper characteristic is set for the lower velocity range of the stepper motor than for the upper range. References: /FB/, S6, Stepper Motors

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Activation
The acceleration characteristic with break-point is activated by means of machine data or NC language commands. MA_ACCEL_TYPE_DRIVE = 1 This characteristic is the basic setting for each axis. It is not permissible to violate any of the parameters specified for the acceleration characteristic in any motion situation. Effect: 1. The acceleration characteristic with break-point is always active for motions by single axes (positioning, oscillation, JOG, ...). It is not permissible to switch over to BRISKA (constant acceleration over entire velocity range) or SOFTA (constant jerk). 2. If at least one axis with setting MA_ACCEL_TYPE_DRIVE = 1 is involved in the path motion and there is no DRIVE active, the dynamic limit values are reduced (equivalent path characteristic).

DRIVE NC language commands The acceleration characteristic with break-point is activated for the path motion by means of language command DRIVE or with machine data MC_GCODE_RESET_VALUE[20] = 3. Setting 3 of MD MC_GCODE_RESET_VALUE[20] means that the acceleration characteristic with break-point is active after POWER ON. MA_ACCEL_TYPE_DRIVE is not relevant in this case. The machine data MA_ACCEL_REDUCTION_SPEED_POINT MA_ACCEL_REDUCTION_FACTOR MA_ACCEL_REDUCTION_TYPE of the axes involved in the motion determine (together with the geometry) the path characteristic. Transformation: When a kinematic transformation is active, the axis cannot be traversed with DRIVE acceleration characteristics. The BRISK command is selected internally. If MA_ACCEL_TYPE_DRIVE is set for at least one of the path axes involved, the equivalent characteristic for the path is activated. DRIVEA(AXIS) NC language commands Activation of acceleration characteristic with break-point for single-axis motions (positioning axes).

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Examples of how to activate characteristic: Machine data: DRIVE as power ON setting MC_GCODE_RESET_VALUE[20] = 3 Parameters of axis characteristic: X axis MA_ACCEL_REDUCTION_SPEED_POINT[X] = 0.4 MA_ACCEL_REDUCTION_FACTOR[X] = 0.85 MA_ACCEL_REDUCTION_TYPE[X] = 2 MA_ACCEL_TYPE_DRIVE[X] = 1 MA_ACCEL_REDUCTION_SPEED_POINT[Y] = 0.0 MA_ACCEL_REDUCTION_FACTOR[Y] = 0.6 MA_ACCEL_REDUCTION_TYPE[Y] = 1 MA_ACCEL_TYPE_DRIVE[Y] = 1 MA_ACCEL_REDUCTION_SPEED_POINT[Z] = 0.6 MA_ACCEL_REDUCTION_FACTOR[Z] = 0.4 MA_ACCEL_REDUCTION_TYPE[Z] = 0 MA_ACCEL_TYPE_DRIVE[Z] = 0

Y axis

Z axis

NC program: N10 G1 X100 Y50 Z50 F700 N15 Z20 N20 BRISK N25 G1 X120 Y70 N30 Z100 N35 POS[X] = 200 FA[X] = 500 N40 BRISKA(Z) N40 POS[Z] = 50 FA[Z] = 200 N45 DRIVEA(Z) N50 POS[Z] = 100 N55 BRISKA(X) ... Path motion (X, Y, Z) with DRIVE Path motion (Z) with DRIVE Switchover to BRISK Path motion (Y, Z) with equivalent characteristic Path motion (Z) with BRISK Positioning motion (X) with DRIVEA Activate BRISKA for Z Positioning motion (Z) with BRISKA Activate DRIVEA for Z Positioning motion (Z) with DRIVE Causes error message

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Control data

The closed-loop control loop for an axis consists of the drive speed control loop and a higher-level position control loop in the NC. With the FMNC control system, the speed control loop is located in the drive unit; only the position control loop is situated in the FMNC itself.

AX_EMERGENCY_STOP_TIME Setpoints Setpoint processing Braking ramp Manip. var. processing Controller trigger DRIFT_LIMIT CTRLOUT_LIMIT

Control loop model

Controller

Monitoring

Logic

Following error

CONTOUR_TOL

FOLLOW_TIME, HOLD_TIME ENC_CHANGE_TOL ENC_FREQ_LIMIT STSTILL_VELO_TOL Actual value processing

STOP_LIMIT_COARSE STOP_LIMIT_FINE POSITIONING_TIME STSTILL_DELAY_TIME STSTILL_POS_TOL CLAMP_POS_TOL

AX_VELO_LIMIT ENC_CHOICE

Actual value processing

Fig. 6-16

Overview of position controller machine data

FIPO FIPO_TYPE

Jerk limitation

Dynamic response adaptation DYN_MATCH_ENABLE DYN_MATCH_TIME

AX_JERK_ENABLE AX_JERK_TIME POSCTRL_GAIN POSCTRL_SIMU_ENABEL

Feedforward control

Controller

Manipulated-varia ble processing AX_COMP_ENABLE AX_MOTION_DIR = +1

NUM_ENCS

Actual-value processing ENC_FEEDBACK_POL = 1 ENC_COMP_ENABLE (SSFK) BACKLASH Fig. 6-17 FMNC control parameters

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In FMNC Position setpoint from interpolator nset Position controller nset

In motorized rheostat iset Speed controller iset Current controller Motor Encoder

Position actual value

Fig. 6-18

Control loops

Traversing direction

If the axis does not traverse in the desired direction, then the direction can be adjusted in MD 32100: AX_MOTION_DIR (traversing direction). The direction is reversed when a value of 1 is entered. The control direction of the position controller is taken into account internally. If the control direction of the position measuring system is incorrect, then it can be reversed in MD 32110: ENC_FEEDBACK_POL (actual value sign). In order to obtain a high degree of contour accuracy with interpolated axes, it is necessary to set a high servo gain (KV) factor for the position controller. However, an excessively high KV factor causes overshoots, instability and impermissibly high loading of the machine. The maximum permissible KV factor depends on the design and dynamic response of the drive and on the mechanical quality of the machine. Definition of KV factor: KV =
Velocity [m/min]

Servo gain

Following error [mm]

The SG factor is entered in MD 32200 POSCTRL_GAIN according to the following conversion formula: SG [s1] = KV @

[m/min]
[mm]

m = min mm
@

1000 mm 1 min 1 m 60 s

= KV @ 16.667 s1

To achieve an KV factor of 1, MD 32200: POSCTRL_GAIN must be set to 1. Allowance is made for the factor 16.667 by MD 10220: SCALING_USER_DEF_MASK and MD 10230: SCALING_FACTORS_USER_DEF. For continuous path control, all axes included in the interpolation must have the same dynamic response. They must all have the same following error at a given velocity, in other words, the axes must all have the same servo gain factor.

Note Axes which interpolate with one another must have the same following error at a given velocity. This can be achieved by setting the same KV factor or through dynamic response matching via MD 32900: DYN_MATCH_ENABLE and MD 32910: DYN_MATCH_TIME. References: /FB/, G2, Velocities, Actual Value Systems, Closed-Loop Control

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Stepper motor control loop

In order to obtain a satisfactory acceleration curve for axes with a stepper motor, it is necessary to match the KV factor to the internal control loop feedback (stepper motor pulses are fed back internally as an actual value). The servo clock cycle must be set to 6 ms for this purpose. MD 10050: SYSCLOCK_CYCLE_TIME = 0,006 MD 10060: POSCTRL_SYSCLOCK_TIME_RATIO = 1. The KV factor must be set to between 2 and 3 in MD 32200: POSCTRL_GAIN. The automatic drift compensation (MD 36700_DRIFT_ENABLE = 1) must be updated for stepper motor axes.

Checking the loop gain

If an factor is already known for the machine in question, this can be set and checked. If the maximum KV factor is not known, then it must be worked out on the basis of the least dynamic axis within the interpolation group. To check the factor, the axis acceleration must be reduced via MD 32300: MAX_AX_ACCEL in order to ensure that the drive does not reach its current limit during acceleration and braking. In the case of rotary axes and spindles, the KV factor must also be checked at high speeds (e.g. for spindle positioning, tapping). The approach behaviour at various speeds can be checked by means of a storage oscilloscope. The speed setpoint is recorded for this purpose.

6
nset [V] Poor

nset [V] Good Well selected Kv factor

Badly selected Kv factor

t [ms]
Fig. 6-19 Speed setpoint characteristic

t [ms]

No overshoots may occur while the drive is approaching the static statuses; this applies to all speed ranges. Causes of overshoots in position control loop

S Acceleration too high (current limit is reached) S Error in speed controller (re-optimization necessary) S Rise time of speed controller too high S Mechanical backlash S Load fluctuations S Mechanical components canted
For reasons of safety, the KV factor should be set slightly lower than the maximum permissible value. A static check of the factor can be executed by selecting the Service display menu in the Service axis display. The actual KV factor must correspond precisely to the set value since monitoring functions, which are based on the factor, will otherwise respond (e.g. contour monitoring).

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Acceleration

The axes are accelerated and braked at a value no higher than the acceleration value entered in MD 32300: MAX_AX_ACCEL. The maximum acceleration can be influenced additionally via MD 32310: MAX_ACCEL_OVL_FACTOR which is an overload factor for velocity step changes. Ideally, this MD should be set to a value between 1.2, ... 1.3. The set acceleration should allow the axes to be accelerated and positioned rapidly and accurately while ensuring that the machine is not unduly loaded. The acceleration default settings are in the 0.5 m/s2 to 2 m/s2 range. The acceleration data entered can be either empirical values or the maximum permissible acceleration values which the user must calculate. The data must always be checked after entry by means of an oscilloscope. Checking and calculating acceleration values: Setting: Identification: Measur. points: MD 32300: MAX_AX_ACCE Overshoot-free acceleration and approach with rapid traverse velocity under maximum load (heavy workpiece). DAC outputs on X2 of FMNC

Checking and calculating acceleration values

After the acceleration has been entered, the axis is traversed rapidly; the actual current value and the analog voltage at output X2 of the FMNC in the drive speed control loop are recorded. This recording shows whether the drive reaches the current limit. While traversing rapidly, the drive may reach the current limit briefly. However, the current must be well below the current limit before the rapid traverse velocity or the final position is reached. Slight load changes during machining must not cause the current limit to be reached. Excessive current during machining causes falsification of the contour. It is therefore advisable in this case as well to enter a slightly lower acceleration value in the MD than the maximum permissible value. Axes can be assigned different acceleration values even if they do interpolate with one another.

nset

nact

iset +

iset

Example of well selected acceleration value

The current limit is reached in this example (evident from the fact that the actual current value stays at the maximum over a period of time). A lower acceleration value must be selected in this case.

Fig. 6-20

Correlation between acceleration and actual current value

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AX_JERK_ENABLE AX_JERK_TIME

POSCTRL_GAIN

Fine interpolation FIPO_TYPE

Jerk limitation

Dynamic response matching DYN_MATCH_ENABLE DYN_MATCH_TIME

Feedforward control

Closed-loop control

Speed setpoint processing

FRICT_COMP_ENABLE AX_MOTION_DIR

IS position meas. system 1/2 FFW_MODE FFW_ACTIVATION_MODE VELO_FFW_WEIGHT AX_INERTIA EQUIV_SPEEDCTRL_TIME EQUIV_CURRCTRL_TIME Actual value processing

ENC_FEEDBACK_POL ENC_COMP_ENABLE BACKLASH

Fig. 6-21

Additional parameters for position control

Dynamic matching

When dynamic matching is implemented for one geometry axis, then the dynamic response matching function must be activated (MD 32900 = 1) for all further axes to ensure that the dynamic response of all axes is identical.

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6.10.6

Monitoring functions (axis)


References: /FB/, A3, Axis Monitoring, Protection Zones

Positioning monitor

When an axis is being positioned, a monitoring function checks whether it reaches the position window (exact stop). It also checks whether an axis for which no traversing command has been issued remains within a certain tolerance window (zero speed control, clamping tolerance). MD 36000: STOP_LIMIT_COARSE (coarse exact stop)

S INTSIG Position reached with coarse exact stop (DB3148, DBX60.6)


MD 36010: STOP_LIMIT_FINE (fine exact stop)

S INTSIG Position reached with fine exact stop (DB3148, DBX60.7)


MD 36020: POSITIONING_TIME (coarse exact stop delay)

S This MD represents the delay after which the actual value must have
reached the Fine exact stop tolerance window when the setpoint position at the block end is reached.

S If the value does not reach the fine exact stop window within this time, the
alarm 25080 axis [name] positioning monitoring is generated.

S The control switches to follow-up mode.


MD 36030: STANDSTILL_POS_TOL (zero speed tolerance)

S The machine data specifies the position tolerance which a stationary axis
may not leave.

S If the axis leaves the tolerance window, the alarm 25040 axis [name] zero
speed monitoring is output. The control switches to follow-up mode. MD 36040: STANDSTILL_DELAY_TIME (zero-speed monitoring delay time)

S This MD represents the delay after which the actual value must have
reached the Zero-speed tolerance window when the setpoint position at the block end is reached.

S If the value does not reach the position tolerance within this time, the alarm
25040 axis [name] zero speed monitoring is generated. The control switches to follow-up mode. MD 36050: CLAMP_POS_TOL (clamping tolerance)

S Position tolerance while the Clamping in progress signal is present at the


PLC interface. If the tolerance is exceeded, the alarm 26000 axis [name] clamping monitoring is generated.

S INT SIG Clamping in progress (DB3134 DBX2.3).


MD 36060: STANDSTILL_VELO_TOL (threshold for Axis stationary signal)

S Position tolerance while the Axis stationary signal is present at the PLC
interface.

S INTSIG Axis/spindle stationary (DB31 to 34, DBX61.4)

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v or s

Actual value Interface signal Clamping in progress

CLAMP_POS_TOL Setpoint STANDSTILL_POS_TOL STOP_LIMIT_COARSE STOP_LIMIT_FINE

STANDSTILL_ DELAY_TIME

Exact stop fine signal Exact stop coarse signal

POSITIONING_TIME

Fig. 6-22

Positioning, zero-speed and clamping monitoring

Position monitoring by means of hardware limit switches

It is possible to implement a monitor for each axis via the hardware interface. A signal is provided for each traversing range limit; this signal is transmitted to the FMNC as soon as the appropriate limit has been reached. The alarm Hardware limit switch is then output. The relevant axis or the axes included in the interpolation group are then shut down. The braking method applied can be set via MD 36600: BRAKE_MODE_CHOICE (braking mode for hardware limit switch).

Important If the relevant axis is operated by a stepping motor, then MD 36600: BRAKE_MODE_CHOICE must be set to 0 (braking characteristic).

Machine data, interface signals and alarms MD 36600: BRAKE_MODE_CHOICE = 1 (rapid braking with setpoint 0) MD 36600: BRAKE_MODE_CHOICE = 0 (braking according to characteristic) INTSIG Hardware limit switch minus (DB3134, DBX12.0) INTSIG Hardware limit switch plus (DB3134, DBX12.1) Alarm 21614 channel [name1] axis [name2] hardware limit switch [+/] The axis must be traversed in the opposite direction away from the switch in JOG mode.

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Position monitoring by means of software limit switches

2 software limit switch values can be specified in the machine data for each axis. The active software limit switch is selected via the PLC. The axis does not traverse beyond the software limit switch. The monitoring function is activated after reference point approach and is deactivated after PRESET. Machine data, interface signals and alarms: MD 36100: POS_LIMIT_MINUS (1st software limit switch minus) MD 36110: POS_LIMIT_PLUS (1st software limit switch plus) MD 36120: POS_LIMIT_MINUS2 (2nd software limit switch minus) MD 36130: POS_LIMIT_PLUS2 (2nd software limit switch plus) INTSIG 2nd software limit switch minus (DB3134, DBX12.2) INTSIG 2nd software limit switch plus (DB3134, DBX12.3) Alarm 10614 channel [name1] block [no.] axis [name2] has reached software limit switch +/ Alarm 10616 channel [name1] axis [name2] stationary at software limit switch +/ (JOG) Alarm 10701 channel [name1] block [no.] axis [name2] programmed end point is behind software limit switch +/

Position monitoring by means of working area limitation

In addition to software limit switches, a working area limitation can be specified for geometry axes. The limitation can be entered via setting data or specified by means of G25/G26 from the program. It is activated via setting data or from the program. The monitoring function is active after reference point approach. Setting data and alarms: SD 43400: WORKAREA_PLUS_ENABLE (working area limitation active in pos. direction) SD 43410: WORKAREA_MINUS_ENABLE (working area limitation active in neg. direction) SD 43420: WORKAREA_LIMIT_PLUS (working area limitation plus) SD 43430: WORKAREA_LIMIT_PLUS (working area limitation minus) Alarm 10618 channel [name1] block [no.] axis [name2] has reached working area limitation +/ Alarm 10620 channel [name1] axis [name2] stationary at working area limitation +/ (JOG) Alarm 10719 channel [name1] block [no.] axis [name2] working area limitation +/

Working area limitation (for GEO axes only) Fig. 6-23

2nd SW limit switch (can be activated via PLC)

1st SW limit switch

EMERGENCY STOP HW limit Mechanical switch traversing limit

Overview of end limitations

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Velocity limitation

The velocity is limited internally in the FMNC. The setpoint is limited on a percentage basis in MD 36210: CTRLOUT_LIMIT. An alarm is generated if the setpoint is exceeded for the time period set in MD 36220: CTRLOUT_LIMIT_TIME. The axes are braked down to zero speed along a braking ramp when the position control loop is open (MD 36610: AX_EMERGENCY_STOP_TIME). This MD must contain the time within which the axis can brake to zero from maximum velocity. MD 36210: CTRLOUT_LIMIT (maximum speed setpoint) MD 36220: CTRLOUT_LIMIT_TIME (monitoring time for maximum speed setpoint) MD 36610: AX_EMERGENCY_STOP_TIME (braking ramp time in event of faults) Alarm 25060 axis [name] speed setpoint limitation

Velocity monitoring

This monitoring function is provided to ensure that axes whose velocity is limited in theory owing to the prevailing mechanical conditions (e.g. pulse encoder) traverse correctly. The actual velocity monitoring function is always active provided, however, that the selected encoder is operating below its limit frequency. Alarm 25030 is output when the threshold value is exceeded. MD 36200: AX_VELO_LIMIT (threshold value for velocity monitoring) MD 36610: AX_EMERGENCYSTOP_TIME (braking ramp time in the event of faults) Alarm 25030 axis [name] actual velocity alarm limit

Contour monitoring

This monitoring function is provided to ensure that the part program is processed within a tolerance band, MD: CONTOUR_TOL. The function is based on the continuous comparison between the measured following error and the following error predicted on the basis of the NC position setpoint. Contour monitoring is always active in position-controlled operation. If the tolerance band is violated, then the alarm Contour monitoring is generated and the axes are braked along a set braking ramp.

S MD 36400: CONTOUR_TOL (contour monitoring tolerance band) S MD 36610: AX_EMERGENCY_STOP_TIME (braking ramp time in the
event of faults)

S Alarm 25050 axis [name] contour monitoring.

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Encoder monitoring

Encoder limit frequency and zero mark

S Encoder limit frequency monitoring


The frequency entered in MD: ENC_FREQ_LIMIT is monitored. If this is exceeded, the alarm Encoder frequency exceeded is output and the axes braked to zero speed. IS Referenced/synchronized is reset (DB3135, DBX60.4, DBX60.5) Example: Encoder with 2048 pulses mounted directly on motor, limit frequency 200 kHz, nmax = (flimit/pulses)  60 sec = 5900 rpm Result: It must be ensured that this speed is not reached at maximum axis velocity (MAX_AX_VELO). MD 36300: ENC_FREQ_LIMIT (encoder limit frequency INTSIG Encoder limit frequency exceeded 1 (DB3134, DBX60.2) INTSIG Encoder limit frequency exceeded 2 (DB3134, DBX60.3) Alarm 21610 axis [name] encoder frequency exceeded

S Zero mark monitoring


The zero mark monitoring is activated in MD: ENC_ZERO_MONITORING. If more pulses are lost than specified in the MD, then the alarm Zero mark monitoring is generated and the axes are braked down to zero speed. MD 36310: ENC_ZERO_MONITORING (zero mark monitoring) MD 36610: AX_EMERGENCY_STOP_TIME (braking ramp time in event of faults) Alarm 25020 axis [name] zero mark monitoring

AX_EMERGENCY_STOP_TIME
Setpoints Interpolator Setpoint processing Braking ramp

Position controller

DAW 10 V

Drive

Control loop model

CTRLOUT_LIMIT

CONTOUR_TOL
Following error

ENC_ZERO_MONITORING STSTILL_VELO_TOL ENC_FREQ_LIMIT


Actual value proc. Act. val. enc.

STOP_LIMIT_COURSE STOP_LIMIT_FINE POSITIONING_TIME SANDSTILL_DELAY_TIME SANDSTILL_POS_TOL CLAMP_POS_TOL

AX_VELO_LIMIT

Fig. 6-24

Monitoring functions in SINUMERIK FMNC

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Note The time setting in MD 36620: SERVO_DISABLE_TIME (controller enable shutdown delay) must always be higher than the time set in MD 36610: AX_EMERGENCY_STOP_TIME (braking ramp time in event of faults). If this is not the case, the braking ramp in MD 36610 cannot take effect.

Automatic drift compensation

The analog system (" 10 V) of the FMNC is equipped with an automatic drift compensation function so that it can be compensated if required. The automatic drift compensation function must always be activated for axes with a stepper motor drive. The following three machine data are important for this function:

S MD 36700: DRIFT_ENABLE (automatic drift compensation) S MD 36710: DRIFT_LIMIT (drift limit value)

6
!

S MD 36720: DRIFT_VALUE (basic drift value)

Important The use of direct measuring systems and activation of the Automatic drift compensation function (MD 36700 DRIFT_ENABLE = 1) causes the axis concerned to oscillate as a result of mechanical backlash. The oscillation amplitude is dependent on the magnitude of the backlash, the total servo gain and on the concrete dynamic conditions (e.g. mass, vertical or horizontal axis).

Stepper motor rotation monitoring with BERO

The BERO for rotation monitoring is connected in the same way as for referencing with BERO. The BERO can be connected in parallel for referencing purposes or can be used as the rotation monitor. However, the rotation monitoring function must then be deactivated during referencing and it must be ensured that the reference BERO does not output any switching pulse edges when the monitoring function is active. A modulo counter (modulo 1 revolution) counts the actual value increments. The modulo counter value is stored as a machine data. MD: 31100 BERO_CYCLE Repeat cycle of BERO edge in actual value increments

Modulo counter

Activation (zeroing)

The rotation monitor can be activated or deactivated via INTSIG Rotation monitoring ON/OFF DB3134 DBX24.0. When the BERO has been actuated for the first time, it is zeroed, i.e. the modulo counter contents are noted as the BERO zeroing value. The BERO edge (1 = positive edge) can be selected in MD: 31120 BERO_EDGE.

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Comparison

Every time the BERO is actuated again, a check is made to establish whether the value of the modulo counter contents is close to the stored BERO zeroing value. In this case, a BERO tolerance can be included in the calculation by means of MD: 31110 BERO_EDGE_TOL. If the comparison has a negative result, the INTSIG Rotation monitoring error is output to the PLC (DB3134 DBX96.0). The monitoring is automatically deactivated at the same time and a new reference point approach is then required.

6.10.7
Overview

Reference point approach


After the control has been switched on, it must be synchronized (referenced) with the position measuring system of every machine axis. Referencing must be carried out for axes with incremental measuring systems and with distancecoded reference marks. Axes with an SSI encoder do not need to be referenced. References: /FB/, R1, Reference Point Approach

Reference cam calibration If the position measuring system has several zero marks which repeat at cyclic intervals (e.g. incremental rotary indirect position measuring system mounted on motor), the reference cam must be calibrated exactly. If the reference cam is not calibrated precisely, an incorrect zero mark may be evaluated. In this case, alarm 20002 Zero mark missing may be output, resulting inevitably in a measured value offset. The reference cam is signalled by the PLC to the NCK by means of IS Reference point approach delay. The following factors influence how the reference cam is detected by the the control (NCK) in terms of time:

S Switching accuracy of reference cam switch S Time delay of reference cam switch (NC switch) S Time delay at PLC input S PLC cycle time S Cyclical time for updating NCKPLC interface S Interpolation cycle S Position control cycle
The best solution in practice has been to adjust the edge of the reference cam required for synchronization in the centre between two zero marks.

Warning An incorrect zero mark may be evaluated if the reference cam is not calibrated exactly. This causes the control to detect the machine zero point incorrectly and to move the axes to incorrect positions. Software limit switches, protection zones and working area limitations are all referred to incorrect positions and cannot therefore afford any protection for the machine. The difference corresponds in each case to " one revolution of the encoder.

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General machine data and interface signals MD 34000: REFP_CAM_IS_ACTIVE (axis with reference cam) MD 34110: REFP_CYCLE_NR (axis sequence with channel-specific reference point approach) INTSIG Activate referencing (DB21, DBX1.0) INTSIG Referencing active (DB21, DBX33.0)

Reference point approach with incremental measuring systems

There are three phases of reference point approach with incremental measuring systems: Phase 1: Phase 2: Phase 3: Approach reference cam Synchronize with zero mark Approach reference point

S Machine data and interface signals for phase 1


MD 11300: JOG_INC_MODE_LEVELTRIGGRD (INC/REF in JOG mode)

MD 34010: REFP_CAM_DIR_IS_MINUS (approach reference point in minus direction) MD 34020: REFP_VELO_SEARCH_CAM (reference point approach velocity) MD 34030: REFP_MAX_CAM_DIST (maximum path to reference cam) INTSIG Traversing keys plus/minus (DB3134, DBX8.6/DBX8.7) INTSIG Reference point approach delay (DB3134, DBX12.7)

S Machine data for phase 2


MD .34040: REFP_VELO_SEARCH_MARKER (creep speed) MD 34050: REFP_SEARCH_MARKER_REVERSE (direction reversal to reference cam) MD 34060: REFP_MAX_MARKER_DIST (maximum path to reference mark)

S Machine data and interface signals for phase 3


MD 34070: REFP_VELO_POS (reference point approach speed) MD 34080: REFP_MOVE_DIST (reference point distance/target point) MD 34090: REFP_MOVE_DIST_CORR (reference point offset/absolute MD 34100: REFP_SET_POS (reference point value) INTSIG Reference point value 1...4 (DB3134, DBX2.4, 2.5, 2.6, 2.7) INTSIG Referenced/synchronized 1, 2 (DB3134, DBX60.4, DBX60.5)

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Reference point approach with distance-coded reference marks

There are two phases of referencing for axes with distance-coded reference marks: Phase 1: Phase 2: Synchronize by travelling over 2 reference marks (2 measuring intervals) Traverse to target point

General machine data MD 34310: ENC_MARKER_INC (differential distance between two reference marks) MD 34320: ENC_INVERS (measuring system inverted)

S Machine data and interface signals for phase 1


MD 11300: JOG_INC_MODE_LEVELTRIGGRD (INC and REF in jog mode) MD 34010: REFP_CAM_DIR_IS_MINUS (approach reference point in minus direction) MD 34040: REFP_VELO_SEARCH_MARKER (creep speed) MD 34060; REFP_MAX_MARKER_DIST (maximum path to reference mark) MD 34300: ENC_REFP_MARKER_DIST (reference mark distance) INTSIG Traversing keys plus/minus (DB3134, DBX8.6/DBX8.7) INTSIG Referenced/synchronized 1, 2 (DB3134, DBX60.4, DBX60.5)

S Machine data and interface signals for phase 2


MD 34070: REFP_VELO_POS (reference point approach speed) MD 34080: REFP_MOVE_DIST (reference point distance/target point) MD 34090; REFP_MOVE_DIST_CORR (reference point offset/absolute offset) MD 34330: REFP_STOP_AT_ABS_MARKER (without target point) INTSIG Referenced/synchronized 1, 2 (DB3134, DBX60.4, DBX60.5)

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6.10.8

Reference point approach for stepper motors

Overview

The basic sequence of referencing steps and the possible machine data settings are no different to those for referencing with an incremental encoder (cf./ FB/, R1 Reference point approach). A BERO encoder which is mounted, for example, on the motor shaft or spindle, takes the place of the incremental encoder zero pulse. Synchronization takes place with the rising edge of the BERO (single-edge evaluation) or with the BERO centre (two-edge evaluation. Note: MD 34200: ENC_REFP_MODE

Ablauf

S Phase 1: Travel to reference point cam (mech. cam or BERO, cf. /FB/, R1,
Reference Point Approach),

S Phase 2: Synchronization with reference point BERO (zero pulse simulator),

6
Synchronization with BERO reference point

basic sequence as described in /FB/, R1, Reference Point Approach, Section Reference Point BERO replaces zero mark,

S Phase 3: Travel to reference point (cf. /FB/, R1, Reference Point Approach).

A digital input is required for the transfer of switching edges to the control. The FMNC provides four digital inputs at inputs X13 to X16 on connector X1 (connector for handwheel and I/O device connection) for this purpose. There is a fixed assignment between the four rapid digital inputs and the measuring circuits.

BERO edge

When the selected BERO edge appears, the appropriate actual value register is latched. Referencing can therefore take place at very high velocities, the maximum upper limit corresponding to half the maximum actual value counter per SERVO clock cycle. It must be noted that only one latch is provided per axis. The positive edge of the BERO is interpreted as a zero pulse. The selection is made via MD 34200 ENC_REF_MODE = 2. The positive edge and the negative edge of the reference point BERO are overtravelled in succession and the relevant actual values register. The average value is the synchronization point at which phase 2 ends and phase 3 begins. The selection is made in MD 34200 ENC_REF_MODE = 4. The two-edge evaluation function allows any drift to be compensated. In this case, the maximum permissible velocity is additionally limited by the fact that the time between the two edges including any switching delay of the BERO must be longer than 1 SERVO clock cycle.

Single-edge evaluation Two-edge evaluation

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6.10.9

Extension to 5th axis

Overview

The SINUMERIK FM-NC is supplied as standard with the following configuration: 1 channel, 4 axes It is not possible to extend the channels. If you wish to increase the number of axes to 5, then you must connect an FM 354 to the local P bus of the FM-NC.

Extension to 5 axes

References:

/FB/, L1, Local P Bus

By connecting an FM 354 (FM servo) to the local P bus of the FM-NC, it is possible to increase the number of machine axes controlled by the FM-NC from four to five. All the parameter settings and all the calculations for the 5th axis are performed in the FM-NC. The FM 354 acts as an actual value input and a setpoint output. When the FM 354 (FM servo) is correctly configured as the 5th axis of the FM-NC, the yellow LED DIAG flashes in accordance with the selected basic clock cycle time. Example: If machine data MN10050 SYSCLOCK_CYCLE_TIME is parameterized as 0.006, then the DIAG LED flashes in a 6-second cycle (3 s bright and 3 s dark). The 5th axis (FM 354) need not be the 5th channel axis of the FM-NC. The 5th axis is parameterized in exactly the same way as the other four axes. The setpoint output of the FM 354 (on the local P bus) is assigned to an axis with axis machine data MA30100 CTRLOUT_SEGMENT_NR[n] = 2 (identifier of local P bus). The actual value input (measuring system) is assigned to the appropriate axis with axis machine data MA30210 ENC_SEGMENT_NR[n] = 2 (identifier of local P bus).

Important It is not permissible to mix the axes of a setpoint output of the FM-NC and the actual value input of the 5th axis (FM 354), i.e. the setpoint output and the actual value input of the 5th axis may only be operated on the same channel axis.

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6.10.10 Basic settings for operator panel


Screen
MD 9000: LCD_CONTRAST (contrast) The contrast setting can be entered directly into the machine data on MMCs 100/100.2 with monochrome display or else made in the operator control area Startup via the softkeys LCD brighter and LCD darker. MD 9001: DISPLAY_TYP (monitor type) The monitor type (LCD monochrome, LCD colour, CRT colour) is entered in this MD.

Language

MD 9003: DISPLAY_LANGUAGE (foreground language) The MMC user interface is supplied as standard with two languages (English, German); English is the default setting. The language can be switched over in the operator control area Startup via the softkey Change language.

Display resolution

MD 9004: DISPLAY_RESOLUTION (display resolution) The display resolution for position values on the screen is set in this MD. The maximum screen display capacity is 10 digits plus decimal point and sign (e.g. 4 places after decimal point, max. display =+/999999.9999). Exception: On MMCs 100/100.2 the spindle speed is always displayed with three decimal points regardless of the setting of MD 9004. On MMCs 102/103 the display resolution for the spindle speed is set via MD 9010: SPIND_DISPLAY_RESOLUTION (spindle speed display resolution)

Screen darkening

MD 9006: The time which elapses before the screen is darkened (assuming that no key is actuated on the operator panel in the meantime) is entered in this MD (for MMCs 100/100.2).

User data protection levels V24 interfaces

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

The settings of the MMC V24 interface are stored for back-up purposes in machine data 9300 and above. The setting for 3 different devices is made in the Services menu via an input display.

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6.10.11 Configuration and machine data of local P bus of FM-NC


References: /FB/, L1, FMNC Local Bus

Overview

The purpose of the FMNC local P bus is to extend the functionality of the FMNC. An FM 354 (FM servo) and digital input and output modules (SMs) can be connected to this bus. These modules increase the number of FMNC axes from four to five and provide the FMNC with digital inputs and outputs.

FM 354 as 5th axis

No more than one FM 354 (FM servo) may be connected to the local P bus as a 5th axis.

Inputs/outputs

The hardware for a maximum for 20 digital inputs and 20 digital outputs (nos. 9 to 28) may be connected to the local P bus. Nos. 1 to 8 are always simulation inputs/outputs. Example: Nos. 1 to 8 Nos. 9 to 24 Nos. 25 to 32 No hardware (simulation inputs) 2 signal modules with 8 digital inputs each FM 354 with 4 digital hardware inputs (nos. 25 ... 28) and 4 simulation inputs (nos. 29...32)

Machine data for inputs/outputs

The following machine data are used to assigned the input/output modules to the FMNC:

S MN10362 HW_ASSIGN_ANA_FASTIN[0...3] S MN10364 HW_ASSIGN_ANA_FMSTOUT[0...3] S MN10366 HW_ASSIGN_DIG_FASTIN[0...3] S MN10368 HW_ASSIGN_DIG_FMSTOUT[0...3]


The following applies to these MDs:
MD: 02 0x 01 0x Byte no. Submodule no. Slot in local P bus Local P bus

Example: The local P bus of the FMNC is configured as follows:


... FMNC NCU 570 16 dig. outputs 1 Q9...16 Q17...24 16 dig. inputs 2 I9...16 I17...24 FM 354 (FM servo) 3 I25...28 Q25...28

Slot in local P bus

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The machine data settings are therefore as follows: MN10366...IN[0] MN10366...IN[1] MN10366...IN[2] MN10366...IN[3] MN10368...OUT[0] MN10368...OUT[1] MN10368...OUT[2] MN10368...OUT[3] = = = = = = = = 02 02 02 02 02 02 02 02 02 02 03 00 01 01 03 00 01 01 01 01 01 01 01 01 01 02 01 00 01 02 01 00 I 9...16 I17...24 I25...28 not assigned Q 9...16 Q17...24 Q25...28 not assigned

!
Setting the usable dig. inputs/outputs

Important The FM 354 (FM servo) has four digital inputs/outputs which can be addressed via front connector X1. The remaining digital inputs/outputs of the byte (29...32) can be addressed as simulation inputs/outputs.

The input and output bytes are activated with the machine data

S MN10300 FASTIO_ANA_NUM_INPUTS S MN10310 FASTIO_ANA_NUM_OUTPUTS S MN10350 FASTIO_DIG_NUM_INPUTS S MN10360 FASTIO_DIG_NUM_OUTPUTS


Possible setting value 1 2 3 4 Meaning 1...8 NCK I/O without hardware (simulation) 9...16 ext. I/O of FMNC (local P bus) 17...24 ext. I/O of FMNC (local P bus) 25...32 ext. I/O of FMNC (local P bus)

Configuration

The PLC (CPU) reads the configuration of the local P bus in exactly the same way as the configuration of the P bus during booting of the FM-NC. The rack configuration is displayed in the online view of the STEP7 hardware configuration. The local bus is parameterized in the offline view of the hardware configuration as follows:

S Select the module NCU-570 S Select Object properties/Basic parameters in the menu Edit S Activate Process alarm generation and Local bus segment with Yes S Confirm configuration with OK and transfer to the control with the menu
command Target system/Load to module (SDB100 is generated and transferred to the PLC). The local P bus is then activated.

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6.10.12 Spindle data

Overview

In the SINUMERIK FMNC control system, the spindle is a sub-function of the entire axial functionality. The machine data for the spindle are therefore located among the axis machine data (from MD 35000 onwards). For this reason, data must be entered for a spindle which are described in the chapters relating to axis start-up. The following description contains merely a cross-reference to these MD.

Note The standard machine data do not include any spindle setting. An appropriate start-up operation must be performed in order to define a spindle (see Section 6.2 Example MD file).

References:

/FB/, S1, Spindles

6
Spindle definition
The following machine data are required to define a spindle: MD30300: IS_ROT_AX (rotary axis) MD 30320: DISPLAY_IS_MODULO (display referred to 360 degrees) MD 35000: SPIND_ASSIGN_TO_MACHAX (assignment between spindle and machine axis) Entry of spindle number under which the spindle is to be addressed. The following spindle operating modes are provided:

Spindle operating modes

S Open-loop control mode (M3, M4, M5) S Oscillation mode (support for gear changing operations) S Positioning mode (SPOS, SPOSA) S Synchronous mode S Rigid tapping
In spindle mode, the feedforward control switches on as standard (FFW mode = 1). Exception: In the case of rigid tapping, the feedforward control acts only when activated explicitly (e.g. by means of the programming command FFWON). The set of parameters is selected that corresponds to the current gear stage. Example: 2nd gear stage ! Parameter set [2]

Axis mode

It is possible to switch directly from spindle mode into axis mode provided that the same drive is used for both modes. The machine data for one axis must be applied in axis operation. In axis mode, the first parameter set (index [0]) is selected irrespective of the current gear stage. After the spindle has been positioned, the rotary axis can be programmed directly with the axis name. INTSIG Axis/spindle (DB3135, DBX60.0)

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General machine data definitions

MD 20090 SPIND_DEF_MASTER_SPIND (master spindle reset position in channel) MD 35020: SPIND_DEFAULT_STATUS (spindle initial setting) This MD allows a spindle initial setting to be defined. The following are possible:

S Speed control without/with position control S Positioning mode S Axis mode


The time at which the spindle initial setting acts is defined by means of MD 35030 SPIND_DEFAULT_ACTIVATION. The following are possible:

S POWER ON S POWER ON and program start S POWER ON, program start and reset

MD 35040 SPIND_ACTIVE_AFTER_RESET (independent spindle reset) This MD determines whether the spindle must be stopped by a RESET or a program end. If the MD has been set, a termination of the spindle functions must be initiated explicitly via a program command or the INTSIG Spindle reset (DB3148, DBX2.2). MD 35010 GEAR_STEP_CHANGE_ENABLE (gear stage changeover possible. Spindle has several gear stages). If this machine data is not set, the system assumes that the spindle has no gear stages. A gear stage changeover is therefore impossible.

Exception regarding machine data parameterization

In the case of machine data which are stored as a field, the first value is always assigned to the first parameter, e.g. 1st reference point value, 1st encoder number. This is not the case for the following machine data with the field parameter Gear stage no. and Control parameter set no.. With these data, the selected gear stage determines the appropriate field index. The field with the index 0 is not used for the spindle machine data. See Section 6.10.2. MD 35110: GEAR_STEP_MAX_VELO (nmax for gear stage changeover) MD 35120: GEAR_STEP_MIN_VELO (nmin for gear stage changeover) MD 35130: GEAR_STEP_MAX_VELO_LIMIT (nmax for gear stage) MD 35140: GEAR_STEP_MIN_VELO_LIMIT (nmin for gear stage) MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL (acceleration in speed control mode) MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode) MD 31050: DRIVE_AX_RATIO_DENOM (denominator load gearing) MD 31060: DRIVE_AX_RATIO_NUMERA (numerator load gearing) MD 32200: POSCTRL_GAIN (loop gain factor) MD 36200: AX_VELO_LIMIT (threshold value for speed monitoring) Example MD 35110: GEAR_STEP_MAX_VELO [0,AX1] = 500 (not used for spindle) MD 35110: GEAR_STEP_MAX_VELO [1,AX1] = 500 (nmax for gear stage change, gear stage 1) MD 35110: GEAR_STEP_MAX_VELO [2,AX1] = 1000 (nmax for gear stage change, gear stage 2)

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6.10.13 Spindle configuration

Machine data for setpoints and actual values

Setpoints: MD 30100 CTRLOUT_SEGMENT_NR MD 30110 CTRLOUT_MODULE_NR MD 30120 CTRLOUT_NR MD 30130 CTROUT_TYPE Actual values: MD 30210 ENC_SEGMENT_NR MD 30220 ENC_MODULE_NR MD 30230 ENC_INPUT_NR MD 30240 ENC_TYPE

Note Further information about the spindle configuration can be found in Section 6.10.1 .

6.10.14 Encoder matching (spindles)

Machine data for encoder matching

For the purpose of matching the spindle encoder, the same machine data apply as for the axis. MD: IS_ROT_AX must always be set for the spindle so that the encoder is always matched in relation to one revolution. In order to obtain a display which is always referred to 360 degrees, MD: DISPLAY_IS_MODULO must be set.
Table 6-8 Machine data for encoder matching Machine data Rotary axis Encoder on motor 30300: IS_ROT_AX 31000: ENC_IS_LINEAR 31040: ENC_IS_DIRECT 31020: ENC_RESOL 31080: DRIVE_ENC_RATIO_NUMERA 31070: DRIVE_ENC_RATIO_DENOM 31060: DRIVE_AX_RATIO_NUMERA 31050: DRIVE_AX_RATIO_DENOM 1 0 0 Marks/rev Motor rev Encoder rev Motor rev Load rev Encoder on spindle 1 0 1 Marks/rev Load rev Encoder rev See note See note

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Note These MD are not required to match the encoder, but they must be entered correctly for the sake of setpoint calculation. Load revolutions are entered in MD 31050: DRIVE_AX_RATIO_DENOM and motor revolutions in MD 31060: DRIVE_AX_RATIO_NUMERA.

1st example of encoder matching: Spindle with raw signal encoder (500 pulses) mounted directly on the spindle. Internal multiple = 4. Internal calculation resolution = 1000 increments per degree. 360 degrees Internal resolution = MD31020 @ 4 360 @ 1 @ 1000 500 @ 4 @ 1 MD31080 MD31070

@ 1000

Internal resolution =

= 180

The encoder increment corresponds to 180 internal increments. An encoder increment corresponds to 0.18 degrees (highest possible positioning resolution). 2nd example of encoder matching: Spindle with rotary encoder on motor (2048 pulses), internal multiple = 4, 2 gear stages: Gear stage 1: Motor/spindle = 2.5/1 Gear stage 2: Motor/spindle = 1/1 Gear stage 1 360 degrees Internal = resolution MD31020 @ 4 360 degrees Internal = resolution 4 @ 2048 puls. @ MD31080 MD31070 1 1 1 2.5 @ MD31050 MD31060 @ 1000 Incr/degr.

@ 1000 puls./deg. = 17.5781

One encoder increment corresponds to 17.5781 internal increments. An encoder increment corresponds to 0.0175781 degrees (highest possible positioning resolution). Gear stage 2 360 degrees Internal = resolution MD31020 @ 4 360 degrees Internal = resolution 4 @ 2048 puls @ MD31080 MD31070 @ 1 1 @ 1 1 @ MD31050 MD31060 @ 1000 Incr/deg.

@ 1000 puls./degr. = 43.945

One encoder increment corresponds to 43.945 internal increments. One encoder increment corresponds to 0.043845 degrees (highest possible positioning resolution).

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6.10.15 Speeds and setpoint adjustment (spindles)


Speeds
With the SINUMERIK FMNC control, the spindle speed output is implemented in the FMNC. The control contains the data for 5 gear stages. These stages are defined by a minimum and maximum speed for the stage itself and by a minimum and maximum speed for the automatic gear stage changeover. A new gear stage is output only if the newly programmed speed setpoint cannot be traversed in the present gear stage. The setpoint output ramp is defined by the input of an acceleration value for control operation; it is possible to specify a reduced acceleration rate in order to take account of the torque limitation in the field weakening range. For the sake of simplification, the oscillation times for gear stage changeovers can be specified directly in the FMNC; the oscillation function must otherwise be implemented in the PLC. The oscillation function is initiated via the PLC.

Speeds for conventional operation Direction of rotation

The spindle speeds for conventional operation are entered in axis machine data MD 32010: JOG_VELO_RAPID (conventional rapid traverse) and MD 32020: JOG_VELO (conventional axis velocity). The direction of rotation is specified via the appropriate directional keys for the spindle on the MCP. The rotational direction with respect to a spindle corresponds to the traversing direction with respect to an axis (see Section 6.10.5).

Setpoint adaptation

These speed data must be transferred in scaled form to the drive for the drive control. The values are scaled in the NC on the basis of the gear stage speed definitions. The maximum speed setpoint is specified at the maximum gear stage speed. The spindle attains the desired speed via the mechanical gear stage. Machine data and interface signals: MD35110: GEAR_STEP_MAX_VELO (maximum speed for gear stage changeover) MD35120: GEAR_STEP_MIN_VELO (minimum speed for gear stage changeover) MD35130: GEAR_STEP_MAX_VELO_LIMIT (gear stage maximum speed) MD35140: GEAR_STEP_MIN_VELO_LIMIT (gear stage minimum speed) MD35200: GEAR_STEP_SPEEDCTRL_ACCEL (acceleration in speed control mode) MD35220: ACCEL_REDUCTION_SPEED_POINT (speed for reduced acceleration) MD35230: ACCEL_REDUCTION_FACTOR (reduced acceleration)

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MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed) MD 35410: SPIND_OSCILL_ACCEL (acceleration in oscillation mode) MD 35430: SPIND_OSCILL_START_DIR (start direction in oscillation mode) MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for direction M3) MD 35450: SPIND_OSCILL_TIME_CCW (oscillation time for direction M4) MD 31060: DRIVE_AX_RATIO_NUMERA (numerator load gearing) MD 31050: DRIVE_AX_RATIO_DENOM (denominator load gearing) MD 32010: JOG_VELO_RAPID (conventional rapid traverse) MD 32020: JOG_VELO (conventional axis velocity) INTSIG Change over gear DB31 to DB34, DBX82.3 INTSIG Setpoint gear stage DB3134, DBX82.0 to DBX82.2 INTSIG No speed monitoring for gear changeover DB31 to 34, DBX16.3 INTSIG Gear stage changed over DB31 to DB34, DBX16.3 INTSIG Setpoint gear stage DB31 to DB34, DBX16.0 to DBX16.2 INTSIG Oscillation speed DB31 to DB34, DBX18.5 INTSIG Oscillation via PLC DB31 to DB34, DBX18.4 INTSIG Oscillation mode DB31 to DB34, DBX84.6 INTSIG Control mode DB31 to DB34, DBX84.7 INTSIG Traverse keys minus DB31 to DB34, DBX4.6 INTSIG Traverse keys plus (DB31 to DB34, DBX4.7

Speed (rev/min Max. spindle speed Max. speed of gear stage 2 Max. speed for gear stage 2 changeover

Max. speed of gear stage 1 Max. speed for gear stage 1 changeover

Min. speed for gear stage 2 changeover

Min. speed for gear stage 2 Min. speed for gear stage 1 changever Min. speed for gear stage 1 Min. spindle speed 0


Gear stage 1 Gear stage 2

Fig. 6-25

Example of speed ranges with automatic gear stage selection (M40)

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6.10 Axes and spindles

6.10.16 Spindle positioning

Overview

The control provides an oriented spindle stop function with which the spindle can be moved into a certain position and held there (e.g. for tool changing purposes). Several programming commands are available for this function which define the approach and program processing. References: /PA/, Programming Guide

Functionality

S To absolute position (0 360 degrees) S Incremental position (+/ 999999.99 degrees) S Block change when position reached S Block change on block end criterion
The control brakes the spindle down to creep speed at the acceleration rate for speed operation. If the creep speed has been reached (INT Spindle in setpoint range), the control branches into position control mode and the acceleration rate for position control mode and the SG factor become active. The interface signal Exact stop fine is output to indicate that the programmed position has been reached (block change when position reached). The acceleration rate for position control mode must be set such that the current limit is not reached. The acceleration rate must be entered separately for each gear stage. If the spindle is positioned from zero speed, it is accelerated up to a maximum speed corresponding to creep speed; the direction is defined via machine data. The contour monitoring function is activated as soon as the control mode switches to position control.

Machine data and interface signals

MD 35300: SPIND_POSCTRL_VELO (creep speed) MD 35350: SPIND_POSITIONING_DIR (direction of rotation on positioning from zero speed) MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode) MD 36000: STOP_LIMIT_COARSE (exact stop coarse) MD 36010: STOP_LIMIT_FINE (exact stop fine) MD 32200: POSCTRL_GAIN (SG factor) MD 36400: CONTOUR_TOL (contour monitoring) INTSIG Position reached with exact stop fine/coarse (DB31 to DB34, DBX60.6/60.7) INTSIG Positioning mode (DB31 to DB34, DBX84.5)

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6.10.17 Spindle synchronization

Overview

The spindle must synchronize its position with the measuring system. The spindle position is always synchronized with the zero mark of the encoder or with a Bero signal connected to the FMNC drive module. MD 34200 ENC_REFP_MODE is used to specify through which signal synchronization is effected (zero mark via BERO).

When is synchronization necessary?

S After switch-on of the control if the spindle is moved with a programming


command.

S The PLC signal Re-synchronize spindle 1/2 always cancels the Refer-

enced/synchronized 1/2 signal; the spindle is re-synchronized with the next reference signal. After every gear stage changeover (MD 31040: ENC_IS_DIRECT=0) quency is programmed. When the speed drops to below the encoder limit frequency, the spindle is re-synchronized. If the synchronized state has been lost, it is impossible to implemented functions such as rotational feedrate, constant cutting velocity, tapping with and without compensating chuck, positioning and axis modes.

S The spindle goes out of synchronism if a speed above the encoder limit fre-

To synchronize the spindle, it must always be rotated via a programming command (e.g. M3, M4, SPOS). It is not sufficient to enter a spindle speed via the directional keys of the appropriate axis on the machine control panel.

Machine data and interface signals

MD34100: REFP_SET_POS (reference point value, zero mark position) The position of the reference signal during synchronization is entered in this MD. MD34090: REFP_MOVE_DIST_CORR (reference point offset, zero mark offset) The zero mark offset resulting from the synchronization process is entered here. MD34200: ENC_REFP_MODE (position measuring system type) INTSIG Re-synchronize spindle 1,2 (DB31 to DB34, DBX16.4 or 16.5) INTSIG Referenced/synchronized 1,2 (DB31 DB34, DBX60.4 or 60.5)

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6.10.18 Monitoring functions (spindles)

Axis/spindle stationary

If the velocity/speed drops below the value entered in MD 36060: STANDSTILL_VELO_TOL, then the interface signal Axis/spindle stationary is output. The path feed is then enabled if MD 35500: SPIND_ON_SPEED_AT_IPO_START is set.

Spindle in setpoint area

If the spindle reaches the tolerance range specified in MD 35150: SPIND_ DES_VELO_TOL, then the signal Spindle in setpoint range is output. The path feed is then enabled if MD 35500: SPIND_ON_SPEED_AT_IPO_ START is set.

Minimum and maximum spindle speeds

The maximum spindle speed is entered in MD SPIND_MAX_VELO_LIMIT and the minimum in MD SPIND_MIN_VELO_LIMIT. The NCK limits the speeds to the set values. However, if the actual speed exceeds the set value by the speed tolerance (drive error), then the interface signal Speed limit exceeded is output and alarm 22050 Channel [name] block [number] spindle [number] maximum speed reached is output. The spindle speed is also monitored via MD AX_VELO_LIMIT; an alarm is generated when the speed threshold is exceeded.

Maximum spindle speed

The maximum spindle speed is entered in MD 35100: SPIND_VELO_ LIMIT. The NCK limits the speed to this value. If, however, the speed is exceeded by the speed tolerance in spite of the NCK limitation (drive error), then the INTSIG Speed limit exceeded is output together with the alarm 22100 channel [name] block [number] spindle [number] maximum chuck speed exceeded. The spindle speed is also monitored by MD 36200; AX_VELO_LIMIT; an alarm is generated if the set value is exceeded. In position-controlled mode (e.g. SPCON), the maximum speed (control reserve) specified via MD or setting data is limited to 90% internally in the control.

Minimum and maximum gear stage speeds

The maximum gear stage speed is entered in MD 35130; GEAR_STEP_MAX_VELO_LIMIT and the minimum speed in MD 35140: GEAR_STEP_MIN_VELO_LIMIT. The speed cannot leave this range when the appropriate gear stage is engaged.

Programmable spindle speed limitations

Function G25 S... permits a minimum spindle speed to be programmed and function G26 S... a maximum spindle speed limitation. The limitation is active in all operating modes. Function LIMS=... allows a spindle speed limit for G96 (constant cutting velocity) to be specified. This limitation is operative only when G96 is active.

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Maximum encoder limit frequency

The maximum encoder limit frequency (MD 36300: ENC_FREQ_LIMIT) is monitored. If this limit is exceeded, the synchronization is lost and the spindle functionality reduced (thread, G95, G96). The position measuring systems which are out of synchronism are automatically re-synchronized as soon as the speed drops below the encoder limit frequency again. The encoder limit frequency value must be such that the mechanical encoder speed limit is not exceeded or else the synchronization from high speeds will be incorrect.

MD36300 ENC_FREQ_LIMIT MD36200 AX_VELO_LIMIT MD35100 SPIND_VELO_LIMIT MD35130 GEAR_STEP_MAX_VELO_LIMIT MD35110 GEAR_STEP_MAX_VELO Programmable spindle speed limitation G26 Programmable spindle speed limitation G92

Speed n

Programmable spindle speed limitation G25 MD35120 GEAR_STEP_MIN_VELO MD35140 GEAR_STEP_MIN_VELO_LIMIT MD36060 STANDSTILL_VELO_TOL INTSIG Axis/spindle stationary (DB3134, DBX61.4) Spindle speed range Speed range of active gear stage Speed range limited by G25 and G26 Speed range for constant cutting velocity through G92 INTSIG Referenced/synchronized (DB3134, DBX60.4/60.5) Actual speed monitoring Maximum spindle speed Fig. 6-26 Spindle monitoring ranges

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6.11 Start-up of functions

6.11

Start-up of functions

What are functions?

In this case, Functions refers to the NC functions of the FMNC (e.g. H1 handwheel, E1 electronic gearing, etc.), each of which represents an independent function complex while forming part of the total functionality of a CNC. References: /FB/, Description of Functions

Basic functions

These are functions that are always contained in the FMNC and are included in the basic description of functions.

Extended functions

These are functions which cannot be described as basic functions (e.g. S3 synchronization spindle, T2 table interpolator). They must be ordered specially by the customer (options). These, together with the basic functions, represent the total functionality of the FMNC.

6
Description of functions
A function description is provided for all functions. These descriptions contain detailed information about the functions and how to deal with them, a data description (MD, SD variable) and a signal description. References: /FB/, Description of Functions

Starting up a function

The functions must be adapted to the machine controlled by the FMNC and to the specific requirements of the customer, i.e. they must be started up. A description of how the functions are adapted and started up is given in References: /FB/, Description of Functions

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PLC

7
PLC applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode switch on CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU: Status and error displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU: MPI Multi-point interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU operating status for FM-NC start-up . . . . . . . . . . . . . . . . . . . . . . . Overview of organization blocks, function blocks, DBs . . . . . . . . . . . . Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-156 7-160 7-162 7-163 7-163 7-165 7-165

7.1 7.2 7.3 7.4 7.5 7.6 7.7

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7.1

PLC applications
References: References: /FB/, P3, PLC Basic Program /S7H/, Manual

The SIMATIC S7300 CPU is used as an interface control.

Interface between NC and PLC

Data are exchanged between the NC and PLC via the P-bus and C-bus.

Operator panel MCP

MPI

K bus P bus

Bus driver

DB PLC user program User interface

Basic program PLC system SW

7
PLC

CPU

COM

NCK FMNC

Fig. 7-1

NCPLC link

General

The program is modular, i.e. it is structured according to NCK functions. Furthermore, a distinction is made between the various routine levels specified by the operating system. These are as follows:

S Starting and synchronization S Cyclic operation S Process alarm processing


The relevant section of the basic program must be called by the user in OBs 1, 40 and 100.

Tool Box

The basic PLC program is part of the FM-NC Tool Box.

Special notes concerning CPU 318

Observe the special notes given in Section 12.4.1 when using a CPU 318

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7.1 PLC applications

Structure

The following diagram provides an overview of how the basic PLC program is structured:

OB100 Complete restart

FB1 Start-up

User program OB1 Cyclic processing FC2 GPOB1 NCK Mode group Channel Axis Spindle FC14 MCP FC6 TD (for 840D) FC(15/16/9) User program Conc. axes, ASUP, etc. FC10 Error and operational messages FC19/25 MCP MCP_IFM MCP_IFT FC8/22 TD TM_Trans TM_Dir OB40 Process alarm FC3 GP_PRAL G group distributor

Aux./G function distributor M decoder M, S, F distributor

User program

Fig. 7-2

Structure of PLC basic program

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Start-up, cyclic operation and sign-of-life monitoring

The CPU always powers up in the COMPLETE RESTART mode, i.e. the PLC operating system runs through OB100 after initialization and then begins cyclic operation at the start of OB1. No re-entry is made at the interruption point (e.g. in the case of power failure). In terms of time, the basic program is executed before the PLC user program is processed. The NC/PLC interface is completely processed in cyclic operation. The present G functions are transmitted to the PLC on the process alarm level if the function is activated. A cyclical monitoring function is activated between the PLC and NCK after termination of power-up and the first OB1 cycle. In the event of PLC failure, the alarm 2000 sign of life monitoring PLC.

COMPLETE RESTART start-up mode

There are both retentive and non-retentive areas for flags, timers and counters. Both areas are contiguous and are separated by a parameterizable limit, the area with the high-order area addresses being defined as the non-retentive area. PLC data blocks are always retentive. If the retentive area is not buffered, then start-up is inhibited. The following points are processed during restart.

S Erase Ustack, Bstack and non-retentive flags, timers and counters

S Erase process image of outputs (PIO) S Discard process and diagnostic alarms S Update system status list S Evaluate parameterization objects of modules (as of SD100) or output default parameters to all modules in single-processor operation

S Process restart OB (OB100) S Read in process image of inputs (PII) S Cancel command output inhibit

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7.1 PLC applications

Functions of PLC basic routine

The basic routine organizes the exchange of signals and data between the PLC user program and the internal NCK interface.

SFC User interface OB1


BP cyclic section Message acquisition Signals to NC VDI signal transfer MCP signals Transfer MCP signals VDI signal transfer Alarms & messages Diagnostic buffer

MMC2)

PLC NC signals

Control signals

to NC

ASUP interface Concurrent positioning axis MCP signals

MMC1)

HIFUdistributor M decoder M,S,T,F routing

7
Signals from MMC Signals from NC

OB40
BP interrupt-driven section Transfer, acknowledgem. rapid HIFU G group decoder

HIFI buffer

NC PLC signals

MSD signals

from NC

Status signals Auxiliary functs. G functions Alarm status

1) Entry by variable service 2) Transfer by message services

Fig. 7-3

Data flow between NC/PLC

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7.2 Mode switch on CPU

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7.2

Mode switch on CPU

Overview

Since the FMNC is a module of the automation system 300, the PLC (CPU) functions as the system master. This means that the system CPU, i.e. the PLCCPU, must be successfully started up before any start-up measures for the FMNC can be undertaken. References: /FB/, P3, PLC Basic Program /S7H/, Manual Fig. 3-4 shows the CPU elements which are relevant for starting up the FMNC:

S Mode switch, S Status and error display S Multi-point interface MPI

Status and Error display

SF BAF DC 5 VC FORCE RUN STOP RUNP RUN STOP MRES

Memory card slot

Mode switch

Back-up battery compartment Jumper(removable) Connection for power supply and function earth
6 1

M L+ M

Multi-port interface MPI

9 5

Fig. 7-4

Elements of a PLCCPU

The positions of the elements of the PLCCPU may deviate slightly from the layout shown in Fig. 7-4 (e.g. in case of CPU 318).

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7.2 Mode switch on CPU

Mode switch settings

The order in which the mode switch settings are described corresponds to the order in which they are arranged on the CPU. The explanatory information refers to an unprotected CPU. (Please refer to the STEP7 description for an explanation of the various protection levels of the CPU).
Table 7-1 Mode switch on CPU Meaning RUN program operating status Explanation The CPU is processing the user program. The key cannot be removed in this position. Programs can be

Mode switch setting RUNP

S read out of the load memory by


means of the PG (CPU PG) the CPU (PG CPU).

S transferred to the load memory of


RUN RUN operating status The CPU is processing the user program. The keyswitch can be removed in this position to prevent unauthorized persons from changing the operating mode. Programs in the load memory of the CPU can be read out by means of the PC (CPU PG). The program in the load memory cannot be changed in the RUN mode! ( STEP7 description). The CPU is not processing a user program. The key can be removed in this position to prevent unauthorized persons from changing the operating mode. Programs can be

STOP

STOP operating status

S read out of the load memory by


means of the PG (CPU PG) the CPU (PG CPU).

S transferred to the load memory of


MRES Memory reset Keyswitch position to reset the memory of the CPU. A special sequence of operations must be followed to reset the memory via the keyswitch (see CPU Manual, Chapter 8.3 of SIMATIC S7300). See Sections 7.5 and 5.3.3

References:

/S7H/, Manual

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7.3 CPU: Status and error displays

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7.3

CPU: Status and error displays

Meaning of status and error displays

The status and error displays are explained in the order in which they are arranged on the CPU.
Table 7-2 Display SF (red) Status and errors displays of CPU Meaning Group error Explanation Lights up in the case of S hardware faults

battery failure or no back-up with mains ON S I/O faults. Use PG to determine exact fault/error (read out diagnostics back-up). BAF (red) DC5V (green) FORCE (yellow) Battery fault 5 V DC supply for CPU and S7300 bus Reserved Lights up if battery is defective or missing. Flashes if battery needs to be replaced. Lights up if internal DC 5 V supply is O.K. The FORCE functions assigns a defined value to a variable. The variable is writeprotected and cannot be altered from any location. The write-protective remains effective until it is cancelled again by the UNFORCE function. If the FORCE LED is off, then no FORCE job is present. Lights up when the CPU is processing the user program. Flashes (2 Hz) during CPU start-up (STOP display also lights up during start-up; outputs are enabled once STOP display has gone out). Flashes (0.5 Hz) when the breakpoint test function is active (STOP display also lights up). Lights up when

S S S S S S

firmware errors programming errors computational errors timing errors defective memory card

RUN (green)

RUN operating state

STOP (yellow)

STOP operating state

S breakpoint test function is active


(RUN display also flashes).
Flashes at 3 s intervals if CPU requests memory reset.

CPU is not processing a user program,

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7.4 CPU: MPI Multi-point interface

7.4

CPU: MPI Multi-point interface

Definition: Multipoint interface MPI

The interface on the PLCCPU which allows connection of equipment such as PGs is designated the multi-point interface because several items of equipment (i.e. at various points in configuration) can access the CPU via this interface. In other words, the PLCCPU with an MPI multi-point interface is has a networking capability without any additional modules! The FMNC is also connected via this interface (e. g. PG MPI PLC CPU C-bus FMNC).

Other equipment

The following items of equipment can be connected to the MPI multi-point interface:

S Programming devices (PG/PC), each with MPI interface S OPs (e.g. OP 27) S MMC S MCPs S other S7300 controllers.
Connectors
Use only Siemens bus connectors or PG cables to connect equipment to the MPI multi-point interface. References: /BU/, Ordering Information

7.5

CPU operating status for FM-NC start-up

Cyclic operation

The PLCCPU must be operating in the cyclic mode. The VDI interface (PLC/ NC) interface is active (OB1 processing) in cyclic operation. The mode switch must be set to RUN and only the green LEDs DC5V and RUN are alight on the status and error display.

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7.5 CPU operating status for FMNC start-up

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COMPLETE RESTART and MEMORY RESET via mode switch

By setting the mode switch to the appropriate position, the COMPLETE RESTART and MEMORY RESET functions can be executed as described below:

S COMPLETE RESTART
Turn mode switch from STOP position to RUN position.

S MEMORY RESET
Turn mode switch to STOP position (select STOP operating state) LED STOP lights up Turn mode switch to MRES position and hold it there until STOP LED lights up again (request memory reset) LED STOP goes out and lights up again. Turn mode switch to positions STOPMRESSTOP within 3 seconds LED STOP first flashes at approx. 2 Hz and then lights up again LED FORCE lights up No memory reset is requested if the switch is held in the MRES position for less than 3 seconds. The STOP LED also remains off if the switch position is not changed from STOPMRESSTOP within 3 seconds.

Once LEDs STOP and FORCE are alight, turn mode switch to RUN position LED STOP and LED FORCE go out and LED RUN (green) lights up PLC memory is now reset and PLC is operating in cyclic mode

The program memory of the PLC is erased by the MEMORY RESET function. System data blocks and the PLC diagnostic back-up are not erased.

Note If the MEMORY RESET function is initiated (using procedure described above) when the back-up battery is not installed, then the entire SRAM of the PLC is erased, i.e. the system data blocks and diagnostic back-up are also erased. These data can no longer be accessed. The system data blocks must be transferred to the memory again. No memory reset is requested if the switch is held in position 3 (MRES) for less than 3 seconds. The STOP LED also remains off if the switch position is not changed from STOPMRESSTOP within 3 seconds. References: /S7H/, Manual

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7.6 Overview of organization blocks, function blocks, DBs

7.6

Overview of organization blocks, function blocks, DBs


References: /FB/, P3, Basic PLC Program

7.7

Interface signals
The interface signals are listed in References: /LIS/, Lists

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7.6 Overview of organization blocks, function blocks, DBs

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Alarm and Message Texts

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8.1 8.2 8.3

Alarm text files for MMC100/100.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm text files for MMC 102/103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Syntax for alarm text files of cycles and PLC alarms . . . . . . . . . . . . . .

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8.1 Alarm text files for MMC100/100.2

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8.1

Alarm text files for MMC100/100.2

Description

The installation routine stored on the MMC100/100.2 application diskette (see Section 12.2.2) transfers

S configuration settings, S texts, S the configured interface and S the user software
from the update directory on your PC/PG to the MMC100/100.2 hardware. This section describes the ways in which the alarm text files can be adapted beforehand.

Preconditions

S PC/PG with DOS 6.x or higher S V.24 cable between the COM interface of the MMC100/100.2 (X6) and the
COM1 or COM2 interface of your PC/PG

S At least 3 MB free space on hard disk S The following description is based on the assumption that you have already

8
More than one language

transferred the software from the supplied application diskette for MMC100 (no. 2) or MMC100.2 (no. 3) to the hard disk of your PC/PG as described in Section 12.2.2.

MMC100/100.2 can be assigned two languages in online mode. These are referred to as the foreground and background languages. It is possible to exchange the foreground and background languages of the MMC system using the application diskette as described in Section 12.2.2. During installation, it is possible to select any combination of two of the languages on the application diskette as the foreground and background languages. The languages German and English are to be found on the application diskette. Other languages are available on language diskettes and must be saved into the same directory as the application diskette. The language selection menu is expanded to reflect the available languages.

Alarm texts/ message texts

The texts with the Siemens standard entries are stored on your PC/PG. They are to be found under the drive (<drive>) and directory (<path>) you selected, in the following subdirectory: <drive>:\<path>\PROJ\TEXT\<LANGUAGE DIRECTORY>. Example: If you select drive C and confirm the default directory path, the German alarm and message texts are to be found in directory C:\MMC100PJ.APP\PROJ\TEXT\D.

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8.1 Alarm text files for MMC100/100.2

Language directory

The letters used for <LANGUAGE DIRECTORY> have the following meanings: Standard languages for MMC100/100.2: D G German English

Further languages for MMC100/100.2 (available on language diskettes): F I E F U KO N P PL S X Z C TW French Italian Spanish Finnish Hungarian Korean Dutch Portuguese Polish Swedish Russian Czech Chinese (simplified) Chinese (standard)

Files

The text file names start with A and end in the extension .TXT: ALC.TXT Compile cycle alarm texts ALM.TXT MMC alarm texts ALMC.TXT Measuring cycle texts ALN.TXT NCK alarm/message texts ALNX.TXT NCK extended alarm texts ALP.TXT PLC alarm/message texts ALPU.TXT User PLC alarm/message texts ALSC.TXT Standard cycle texts ALUC.TXT User cycle alarm/message texts ALZ.TXT Cycle alarm texts ASY.TXT System error texts

Editor

The DOS editor EDIT must be used to edit the files. User-specific alarm and message texts can be inserted into the text files ALPU.TXT and ALUC.TXT. The standard texts contained in the text files are hereby overwritten by user-specific texts. An ASCII editor, e.g. DOS editor, must be used for this purpose. New entries can be added to alarm text files. Please refer to Section 8.3 for the applicable syntax rules. The number and order of the alarm/message texts must be identical for the selected languages.

Conversion and transmission

After the text contents have been modified, the text files must be converted and transferred to the MMC (Section 12.2.2).

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8.2 Alarm text files for MMC 102/103

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8.2

Alarm text files for MMC 102/103

Storage of text files

Files containing error texts are stored on the hard disk in the directory C:\DH\MB.DIR\ . The error text files intended for use are activated in the file MBDDE.INI. To ensure that your personal settings are maintained after a future software update, you must store the user-specific configurations in directory C:\USER. If there is no file MBDDE.INI in the directory C:\USER on the MMC102/103, it must be copied from the directory C:\MMC2 as described below: 1. Switch to the DOS Shell via the operator control area Startup / MMC / DOS Shell 2. When the DOS prompt C:\MMC2> appears, enter the following command: C:\MMC2>COPY MBDDE.INI C:\USER and confirm with RETURN. 3. Enter EXIT and confirm once more with RETURN to return to the MMC interface. The following block in the file MBDDE.INI integrates the alarm text files: ... [Textfiles] MMC=c:\dh\mb.dir\alm_ NCK=c:\dh\mb.dir\aln_ PLC=c:\dh\mb.dir\plc_ ZYK=c:\dh\mb.dir\alc_ CZYK=c:\dh\mb.dir\alz_ UserMMC= UserNCK= UserPLC=c:\dh\mb.dir\myplc_ UserZyk= UserCZyk= ...

Configuration in MBDDE.INI

Standard files

The standard alarm texts in ASCII format are stored in the following files in directory C:\dh\mb.dir on the hard disk of the MMC102/103: MMC NCK PLC Cycles ALM_xx.COM ALN_xx.COM, ALNX_xx.COM ALP_xx.COM ALC_xx.COM, ALZ_xx.COM, ALSC_xx.COM, ALMC_xx.COM

In these file names, xx stands for the code of the appropriate language. The standard files should not be changed by the user to store his own error texts. If these files are replaced by new ones when other software is loaded on the MMC102/103, then the added or modified user-specific alarms will be lost. The user should store his own alarm texts in user files.

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8.2 Alarm text files for MMC 102/103

User files

The user can replace the error texts stored in the standard files by his own texts or add new ones to them. To do so, he must load additional text files to directory C:\DH\MB.DIR via the Services operating area. The directory and the names of the text files are set as parameters in the file C:\USER\MBDDE.INI by means of an editor provided in the area Startup / MMC. The editor is used to edit the file MBDDE.INI in the directory C:\USER. Example: Configuration of two additional user files (texts for PLC alarms, altered alarm texts NCK) in file MBDDE.INI: ... User NCK = C:\DH\MB.DIR\MYNCK_ User PLC = C:\DH\MB.DIR\MYPLC_ ... The texts from the user files overwrite standard texts with the same alarm number. Alarm numbers which do not already exist in the standard texts are added.

Note The alarm/message texts of the selected languages must be defined for the same numbers.

Editor

An ASCII editor must be used for editing (e.g. the DOS editor EDIT).

Alarm text languages

A language is assigned to the user alarm texts for the MMC102/103 by means of the text file name. The appropriate code and the extension .COM are added to the user file name entered in MBDDE.INI. The codes are assigned to the different languages as follows: Standard languages of the MMC102/103: gr uk German English

Further languages for the MMC102/103 (available on language diskettes): fr it sp ko nl pl po sw cz hu Example: myplc_gr.com mynck_uk.com File for German user PLC alarm texts File for English user NCK alarm texts French Italian Spanish Korean Dutch Polish Portuguese Swedish Czech Hungarian

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8.2 Alarm text files for MMC 102/103

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Note The maximum length of an alarm text is 110 characters for a 2-line display. Changes to alarm and message texts do not take effect until the MMC has powered up again. The languages English and German are implemented in the standard software. Further languages are available on language diskettes and can be installed separately. When you generate text files, make sure that the date and time of day on your PC are set correctly or else your texts may not be displayed!

Example for a user alarm text file

File with German user texts, PLC: C:\DH\MB.DIR\MYPLC_GR.COM: 700000 0 0 DB2.DBX180.0 gesetzt 700001 0 0 Schmierdruck fehlt A second text file with the language code for the selected background language (e.g. English) must contain texts for the same alarm numbers, e.g.: C:\DH\MB.DIR\MYPLC_UK.COM: 700000 0 0 DB2.DBX180.0 set 700001 0 0 missing lubricator pressure

The parameter to be set in the file C:\USER\MBDDE.INI for this example is: ... User PLC = C:\DH\MB.DIR\MYPLC_ ...

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8.3 Syntax for alarm text files of cycles and PLC alarms

8.3

Syntax for alarm text files of cycles and PLC alarms

Alarm numbers

The following alarm numbers are available for the cycle and PLC alarms:
Table 8-1 No. range 60000 60999 61000 61999 62000 62999 63000 64999 65000 65999 66000 66999 67000 67999 68000 69000 510000 511315 600100 600815 Reserved PLC alarms for channel PLC alarms for axis and spindle PLC alarms for user User area 0 User area 1 L User area 24 Reserved Cycle alarms (user) Display, NC start disable Display, NC start disable, no motion Display Reset Reset Cancel Alarm numbers for cycle and PLC alarms Designation Cycle alarms (Siemens) Effect Display, NC start disable Display, NC start disable, no motion Display Erase by Reset Reset Cancel

700000 700063 700100 700163 L 702400 702463

Reset keys

PLC alarms are acknowledged by means of a key defined according to customer specification. In this case, a distinction is made only between alarms and messages. Messages do not need to be acknowledged. There are no priorities between the groups, merely a chronological sequence. The difference between error and operational messages is determined when the message is output via the PLC.

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8.3 Syntax for alarm text files of cycles and PLC alarms

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Format of text file for cycle alarm texts

The text file for cycle and compile cycle alarms is structured as follows:
Table 8-2 Alarm number 60100 60101 ... 65202 Structure of text file for cycle alarm texts (example) Display 1 1 ... 0 Help ID 20 20 ... 18 Text or alarm number No D number % 1 programmed 60100 ... Axis %2 in channel %1

// Alarm text file for cycles in German

Alarm number: Alarm number Display: The alarm display mode is determined here: 0: Display in the alarm line 1: Display in a dialog box Help ID: MMC 102/103

Text or alarm number: The associated text is specified with the position parameters in inverted commas. The text must not otherwise contain any inverted commas. An existing text can be used by means of a reference to the appropriate alarm text. The alarm text file can include comment lines which must start with //. The alarm text may be a total of 110 characters in length for a 2-line display. If the text is too long, it is cut off and marked with the * symbol. Parameter %1: Channel number Parameter %2: Axis name

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8.3 Syntax for alarm text files of cycles and PLC alarms

Format of text file for PLC alarm texts

The ASCII file for PLC alarm texts has the following format:
Table 8-3 Alarm no. 510000 600124 600224 600324 Structure of text file for PLC alarm texts (example) Display 1 1 1 1 Help ID 5 78 78 78 Text Channel %K VSP disab. Feed disable axis %A 600124 600224 Text on MMC Channel 1 VSP disab. Feed disable axis 1 Feed disable axis 2 Feed disable axis 3

// Alarm text file for PLC alarms

Alarm number: The alarm number consists of the event number (2 digits), signal group (2 digits) and the signal number (2 digits). These parameters are parts of a diagnostic element of the CPU. References: /FB/, P3, PLC Basic Program
Signal group 03 1116 2128 118 09 (disable) (GEO axes) (additional axes) (axis no.) (user no.) Signal number 099

Event number 5x (for channels)

60 (for axis and spindle) 70 (for user)

099 099

Display: The alarm display mode is determined here: 0: Display in the alarm line 1: Display in a dialog box Help ID: Index for HELP files, default setting 0

Text or alarm number: The associated text is specified with the position parameters in inverted commas. The text must not otherwise contain any inverted commas. An existing text can be used by means of a reference to the appropriate alarm text. The alarm text file can include comment lines which must start with //. The alarm text may be a total of 110 characters in length for a 2-line display. If the text is too long, it is cut off and marked with the * symbol. Parameter %K: Parameter %A: Parameter %N: Parameter %Z: Channel number (2nd digit of alarm number) The parameter is replaced by the signal group number (e.g. axis no., user area no., sequence cascade no.). Signal number Status number

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Axis and Spindle Dry Run

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9.1 9.2 9.3

Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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9.1 Preconditions

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9.1

Preconditions

Axis enabling

To allow an axis to be traversed from the control system, it is necessary to supply enabling terminals on the drive and to set enabling bits on the interface. Enabling signals on drive The FM-NC supplies the drive system with enabling commands via the drive interface (X2). In addition to analog setpoints or clocking and direction pulses, the Controller enable or Enable signal (for stepper motor) are output on this interface (see Section 2.2 Overview of Connections). Enabling via PLC interface The following signals must be made available at the PLC interface for axis or spindle: IS Controller enable IS Pulse enable IS Position measuring system 1 (DB31 48, DBX2.1) (DB31 48, DBX21.7) (DB31 48, DBX1.5)

The following signals on the interface must not be set or else the axis/spindle motion will be disabled: IS Feed/spindle override switch (DB31 48, DBX0) not at 0% IS Axis/spindle disable (DB31 48, DBX1.3) IS Distance to go/spindle reset (DB31 48, DBX2.2) IS Feed stop/spindle stop (DB31 48, DBX4.3) IS Traverse key disable (DB31 48, DBX4.4) IS Ramp-function generator disable (DB31 48, DBX20.1) References: /FB/, A2, Various Interface Signals

Limit switches

Setting of hardware limit switches and interface signal check:

S Hardware limit switch PLUSD S Hardware limit switch MINUSD

B31 48.DBX12.1 B31 48.DBX12.0

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9.2 Testing the axis

9.2

Testing the axis


Check NC controller enabling signals at connector X2 Check interface signals (DB 31 34) DBX 0 Feed override switch DBX 1.7 Override active DBX 1.4 Follow-up mode DBX 1.5 Position measuring system 1 DBX 1.6 Position measuring system 2 DBX 1.3 Axis disable DBX 2.2 Delete distance to go DBX 2.1 Controller enable DBX 8.7/8.6 Traversing keys DBX 8.3 Feed stop Check machine data MD 3200032050 Velocities MD 3600036620 Monitoring functions MD 32110 Actual value sign Axis moving? yes no Axis check in Service Display menu

Disable axis (in HW and via PLC)

Start up speed controller acc. to drive manufacturers specifications

Enter machine data for NC

Select JOG mode and enable axis

Travel direction OK? yes Specified path 10 mm

no

Check MD32100 FIX_MOTION_DIR

9
Path evaluation OK? ja no Check MD31000 MD31080 (encoder matching) Traverse with feedrate Rapid traverse

Alarm? no

yes

Interpret alarm and check machine data for velocity adaptation

Following error OK? yes End

no

Check MD 32200 (KV factor) MD 32910 (dynamic response matching) MD 31050/31060 (load gearing) MD 32610 (feedforward control) MD for velocity adaptation

Note If further optimization measures are required, please refer to Section 10.

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9.3 Testing the spindle

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9.3

Testing the spindle

Disable spindle (in HW and via PLC)

Check NC controller enabling signals (connector X2) Check interface signals (DB 31 34) DBX0 Spindle override DBX1.7 Override active DBX1.5/DBX1.6 Position measuring system 1/2 DBX1.3 Axis/spindle disable DBX2.1 Controller enable DBX16.7 Delete S value DBX3.6 Velocity/spindle speed limitation and MD 35160 DBX4.3 Feed stop/spindle stop DBX20.1 HLGSS DBX2.2 Spindle reset when MD 35050=1 DBX21.7 Pulse enable Check machine and setting data MD 3510035150 Spindle speed limitation MD 36200 AX_VELO_LIMIT SD 60200JOG_SPIND_SET_VELO SD 60210SPIND_MAX_VELO_G26 SD 60220SPIND_MIN_VELO_G25

Enter machine data for NC and setting data

Enable spindle (controller enable NC)

Enter speed

Spindle rotating? yes

no

Rotation direction OK? yes Specified speed 100 rev/min

no

Change MD32100 AX_MOTION_DIR

yes

Actual speed OK? yes

no

Check MD31000 31080 (encoder matching)

IS Spindle in setpoint range (DB31 34, DBX83.5)? Change over gear stage

no

yes

Check machine data and interface signals MD 3511035140 Speeds for gear stages MD 35150 Spindle speed tolerance IS Actual gear stage (DB3134, DBX16) IS Select drive parameter set (DB3134, DBX21) IS Setpoint gear stage (DB3134, DBX82) IS Active drive parameter set (DB3134, DBX93)

no

All gear stages tested? yes yes 1

Position spindle? no End

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9.3 Testing the spindle

(Spindle positioning)

Position reached from high speed and zero speed? Change over gear stage yes

no

no

All gear stages tested? yes End

Check machine data MD 36000 Exact stop coarse MD 36010 Exact stop fine MD 32200 SG factor MD 35210 Acceleration in position control range MD 35300 Creep speed MD 35300 Encoder limit frequency Check encoder matching Check spindle synchronization

Note If any further optimization measures are required, please following the instructions in the relevant drive manufacturer documentation.

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Drive Optimization

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10.1 10.2 10.3

General principles of optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aim of optimization procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the speed control loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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10.1

General principles of optimization

Overview

These optimization instructions should be viewed as a recommendation. The user may find that he needs to modify the recommended procedure in order to allow for the marginal conditions of the application in question. These instructions apply only to axes which are operated under position control (linear and rotary feed axes, spindles operating temporarily under position control, robot axes). In order to meet the generally high machining quality requirements, it is particularly important to carefully optimize those axes which are directly involved in workpiece machining.

Procedure

In order to optimize the required axes, it is necessary to record the machine performance in SYSTEM OPERATION. It is advisable to execute the required axis motions in fixed or optional incremental dimensions using the axis direction keys or by means of the NC program applying appropriate feedrates and traverse paths.

10.2

Aim of optimization procedure


The aim of the optimization procedure is to achieve overshoot-free positioning with minimum ramp-up and braking times and to ensure that the axis motion is free of vibration, particularly when the position control loop is in the steady state (both in rapid traverse mode and at low traversing velocities if applicable). To achieve higher machining accuracy, those axes whose motion is directly connected with workpiece machining, can be mutually coordinated in terms of response as described below after individual optimization:

S Enter lowest Kv factor value (32200 POSCTRL_GAIN) for all axes,

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S Set the same dynamic response for all axes via


MD 32900: DYN_MATCH_ENABLE MD 32910: DYN_MATCH_TIME References: /FB/, G2 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control

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10.3 Checking the speed control loop

10.3

Checking the speed control loop

Requirement

The speed control loop must be started up under strictest observation of the drive manufacturers specifications.

Optimization

Once the speed control loop has been started up and you are ready to commence optimization, please check that

S all required machine data been entered, S the drive does not move with a setpoint voltage of 0.000 V, S the drive reaches the set rapid traverse velocity with a setpoint voltage of
9.000 V (32010 JOG_VELO_RAPID),

S you know the transient reaction time constant and S the axis moves smoothly at very low velocity setpoints.
Speed control loop
The speed control loop response basically determines the quality of position control which can be achieved. It is therefore important to eliminate any obvious deficiencies in the speed loop before proceding with further optimization measures.

Warning Subsequent changes to the rapid traverse value or the 9 V assignment of the drive actuator will alter the physical positional loop gain!

Satisfactory position loop optimization is generally achieved with the usual velocity control loop setting for a one-off, approximately 5 to 10 % overshoot with a setpoint step change from zero to rapid traverse and back. This response quality should also be obtained with very small setpoint step changes (100 mV and smaller in some cases).

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Data Saving

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11.1 11.2 11.3 11.4 11.5 11.5.1 11.5.2 11.6 11.6.1 11.6.2 11.6.3 11.7 11.8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving via MMC 100/100.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving via MMC 102/103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving data on a PCMCIA memory card . . . . . . . . . . . . . . . . . . . . . . . . Data saving from MMC 102/103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving from MMC 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data saving from MMC 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line checksums and MD numbers in MD files . . . . . . . . . . . . . . . . . . . Line checksums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine data numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abortion of MD import . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on loading and saving machine data . . . . . . . . . . . . . . . . . . . . . . Machine/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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11.1 General

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11.1

General

When to save data

You should save your data

S after start-up, S after changing machine-specific settings, S during servicing (e.g. after replacing hardware, upgrading software) so that
you can put the system back into operation as soon as possible and

S during start-up before altering the memory configuration to make sure that
no data are lost during start-up.

NCK/PLC/MMC

There are three types of data to be saved on the SINUMERIK FM-NC, i.e. 1. Saving data for FM-NC 2. Saving data for PLC-CPU (with STEP7) 3. Saving data for MMC when MMC 102/103 is installed

Series start-up/ area-specific archiving

There are basically two methods of saving data, each of which has a specific purpose. 1. Series start-up Provision is made for the generation of so-called series start-up files. These allow a specific configuration to be transferred complete to other controls with the same SW version that are, for example, operating on the same machine type. This type of file cannot be modified externally using an ASCII editor. Series start-up files contain all relevant settings (except for compensation data). They must be created for NCK and also for the MMC if an MMC 102/103 is installed. On the FMNC, you can also store data (memory dump) on a PCMCIA memory card. The saved data can be retrieved in the same FMNC (e.g. if data is lost) or into other FMNCs.

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2. Area-specific archiving To ensure that archived data can be transferred to controls on which future SW versions are installed or to other FM-NC controls, it is advisable to archive data on an area-specific basis, i.e. each data area is stored in a separate file which can be edited later with an ASCII editor. Data are read out or read back in again in several steps. Only in this way can compensation data be saved. MMC data are not divided up.

Required accessories

You will require the following accessories in order to save data:

S PC/PG with DOS 6.x or higher (e.g. PG 740) S PCIN data transfer program for PC/PG S V24 cable
References: /Z/, Catalog NC Z (Accessories)

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11.2 Data saving via MMC 100/100.2

11.2

Data saving via MMC 100/100.2

Texts for error messages, operational messages and cycle alarms Sequence of operations

These texts are parts of the operator panel system software. They must be reloaded after hardware component replacement or software upgrading. The messages must be available in the correct format for this purpose (see Section 12.2, Upgrading MMC 100/100.2 software). The texts cannot be read back.

(Data saving)
1. Connect programming device/PC to interface X6 on the MMC. 2. Select Services operating area on the MMC. 3. Select V24 PG/PC interface (vertical softkey) 4. Select Settings and check or enter the parameter settings of the V.24 interface. Default setting. Device type: Baud rate: Parity: Data bits: Stop bits: RTS/CTS 9600 baud None 8 1

Character for XON: 11H(ex) Character for XOFF: 13H(ex) Format: Tape format, deselected for series start-up or for saving areas of drive data Select tape format for saving areas of all other data.

Continue with Series start-up or Area-specific archiving.

Note The PLC-CPU must always be started up before series start-up of the FM-NC.

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Series start-up

(Data saving)
5. MMC interface configuration (see above, tape format deselected) 6. Start PCIN data transfer program (Data In) on PC/programming device. 7. Select Start-up data on MMC (MMC Services operating area, data output Data Out); NCK (FM-NC) and PLC (do not use for FM-NC) areas are displayed after selection of the Input key. 8. First select NCK and start the read-out process (Start softkey).

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Area-specific archiving

5. MMC interface configuration (see above, select tape format). 6. Start PCIN data transfer program (Data In) on PC/programming device, specify file name for the archive. 7. Select data area to be output on MMC (MMC Services operating area, data output Data Out). 8. Select the heading Data and then select the following areas in the order given from the list that is then displayed: All Machine data Setting data Option data Global user data Tool and magazine data Protection zones R parameters Zero offsets Sag/angle compensation Quadrant error compensation Display machine data LEC/measuring system error compensation

When the areas are output, the internal area identifier used in each case appears on the top line of the display. 9. Start the read-out process (Start softkey) and acknowledge any related input requests on the operator panel.

Recommendation

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MD 11210 UPLOAD_MD_CHANGES_ONLY should be set to 1. With this setting, the transferred files contain only those data which deviate from the default. This is of advantage with respect to future SW upgrades.

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11.2 Data saving via MMC 100/100.2

Sequence of NCK data for series start-up

The NCK data are output in the following sequence and notation:
Table 11-1 NCK data Meaning Options Global memory and channel configuration Scaling NCK Reset Channel-specific memory configuration NCK Reset Macros (SMAC/MMAC/UMAC) (MD, R parameters, etc.) NCK Reset Display machine data Global main programs Global subprograms User cycles Standard cycles All workpieces with all files

Designation in the archive file _N_NC_OPT _N_CFG_GLOBAL_INI _N_CFG_SCALING_INI @@_N_IBN_SS _N_CFG_CHAN_INI @@_N_IBN_SS /_N_DEF_DIR _N_INITIAL_INI @@_N_IBN_SS /_N_BD_DIR /_N_MPF_DIR /_N_SPF_DIR /_N_CUS_DIR /_N_CST_DIR /_N_WKS_DIR

Note STEP7 must be used to save PLC_CPU area data. References: /S7HT/ Manual

Loading archiving data

1. Set the protection level to Manufacturer (password SUNRISE). 2. Connect the programming device/PC to interface X6 on the MMC. 3. Select the Services operating area on the MMC. Continue with steps listed under Reading in series start-up or Reading in area-specific archive data.

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Reading in series start-up files

4. Select the MMC interface configuration V24 PG/PC as above (tape format deselected). 5. Start the PCIN data transmission program on the programming device/PC. Select the NCK series start-up file to be read into control for transmission under Data Out . Select Data In in the Services area on the MMC and start data import by selecting the Start softkey. Acknowledge any input requests displayed on the MMC. 6. After another NCK reset, the control powers up with the imported data sets.

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Reading in areaspecific archive data

4. Select the MMC interface configuration V24 PG/PC as above and set tape format. Start the PCIN data transfer program on the programming device/PC. Select the archive file to be read into control for transmission under Data Out. Select Data In in the Services area on the MMC. Start data import by selecting the Start softkey. The file is automatically detected and loaded accordingly.

5. Read in option data, initiate NCK reset. 6. Load the machine data file and actuate NCK reset. If you then receive messages about a reconfiguration of the memory or restandardization of machine data, then you must read in the machine data file again and reset the control. Generally speaking, this process must be carried out two to three times. 7. If global user data must be activated, then the so-called N_INITIAL_INI file (Table 11-2) must be read out through selection of the setting All data as for area-specific archiving. 8. Read in archive file for global user data. 9. Read the saved N_INITIAL_INI file back in to activate the global user data. 10. Then load the other areas.

Note Check/correct the interface settings after display of a message regarding memory reconfiguration.

Transmission error

If data transmission is aborted with an error message, check the following:

S Is the password at the correct protection level?

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S Are the interface parameters (V24 PG/PC) correct? S Has MD 32700, ENC_COMP_ENABLE been set to 0 before importing LEC
data?

S Has MD11220 INI_FILE_MODE been set to 1 or 2?

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Table 11-2

Data in _N_INITIAL_INI file Data not contained in file _N_INITIAL_INI

File _N_INITIAL_INI

S Option data S Machine data S Setting data S Tool offsets S Zero offsets S Global user data S Local user data S R parameters

S Compensation data
Leadscrew error compensation Quadrant error compensation Sag compensation

S Display machine data S Workpieces S Global part programs S Global subroutines S User cycles S Standard cycles S Definitions and macros

11.3

Data saving via MMC 102/103

Via V.24

To archive or read in data, proceed in exactly the same way described in Section 11.2:

S Series start-up with selection possibility for areas


NCK (complete) MMC (with option of saving only partial areas of the MMC data)

S Area-specific archiving
Saving or re-importing individual data areas (Data In, Data Out and Data Selection softkeys)

Via MMC hard disk

You can divert data saving to archive files to the MMC102 hard disk.

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Via diskette

When a diskette drive is connected to the MMC, it is possible to save or re-import data using diskettes. Data are saved via the Services operating area. References: /BA/, Operators Guide

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11.4

Saving data on a PCMCIA memory card

Overview

The PCMCIA (JEIDA) memory card is a functional component of the SINUMERIK FM-NC and can be purchased together with the control or at a later date. For data to be saved to a PCMCIA memory card, you need an FM-NC with system software 3.7 or higher and an 8 MB PCMCIA memory card.

Data saving sequence

1. Control in RESET state following normal powerup (startup switch in position 0, program or motion not active) 2. Insert the PCMCIA memory card into the FM-NC 3. Set start-up switch on FM-NC to position 3 4. The LED DIAG flashes twice cyclically while the complete data of the FM-NC are being saved to the PCMCIA card Note: If an error occurs during data saving (memory dump) to the PCMCIA card, the LED DIAG flashes once cyclically. 5. Data saving is complete as soon as LED DIAG flashes three times cyclically. You can then turn the control off. 6. Remove the PCMCIA card from the FM-NC and turn the startup switch back to position 0. 7. Turn FM-NC on. The FM-NC powers up in the normal operating state.

Use of data saved on PCMCIA

The saved data can be used for the following functions:

S For series start-up of an FM-NC S For replacement of hardware on the FM-NC requiring the transfer of the software version and data from the defective FM-NC to a new FM-NC.

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Importing saved data from PCMCIA
1. Insert PCMCIA memory card into control after control OFF 2. Start-up switch to position 6 3. Control ON system software and data are transferred from the PCMCIA memory card to the control (see also Section 12.1 Firmware update) LED DIAG flashes 4 times cyclically during data transfer 4. As soon LED DIAG flashes 5 times cyclically, data transfer is complete. You can now turn the control OFF 5. Remove PCMCIA memory card from the FM-NC 6. Start-up switch in position 0 7. Turn the control ON. The control is booted with the system software and the saved data from the PCMCIA memory card.

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11.5 Data saving from MMC 102/103

11.5

Data saving from MMC 102/103

Overview

With MMC102/103 it is possible to make backups on a connected VALITEK streamer. These backups can be restored to the MMC102/103 at any time in the future. With MMC103 it is possible to create a backup on a hard disk (from version 4.04).

11.5.1

Data saving from MMC 102

Sequence for data saving from MMC102 (backup)

Proceed as follows to save data from MMC 102: 1. Hold key 6 pressed when switching on the MMC until the following main menu appears on the display. Main menu 1. Install / Update MMC System 2. Install / Update Standard Software 3. DOS Shell 4. Start Windows (Service Mode) 5. MMC System Check 6. Reboot System (Warmboot) 7. Backup/Restore with VALITEK Streamer 8. Start PC Link 9. End (Load MMC) 2. Select 7 (Backup/Restore with VALITEK Streamer) and you will be presented the following menu: PLEASE SELECT : 1. Select VALITEK Streamer Type 2. Test Connection to Streamer 3. Backup System 4. Backup Userdata 5. Restore from Tape 6. Uninstall MMC102 (Delete Files) 7. Return to Main Menu 3. Select the streamer type you are using in submenu 1. You can test the connection to the streamer via submenu 2. 4. Select submenu 3 to copy the system data from the MMC102 to the streamer. Select submenu 4 to copy the user data from the MMC102 to the streamer.

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Sequence to restore the data to MMC102

Proceed as follows to restore the data from the connected streamer to the MMC102: 1. Hold key 6 pressed when switching on the MMC until the following main menu appears on the display. 2. Select 7 (Backup/Restore with VALITEK Streamer) and you will be presented the following menu: PLEASE SELECT : 1. Select VALITEK Streamer Type 2. Test Connection to Streamer 3. Backup System 4. Backup Userdata 5. Restore from Tape 6. Uninstall MMC102 (Delete Files) 7. Return to Main Menu 3. Select 5 (Restore from Tape) to restore the data from the streamer to the MMC102.

11.5.2

Data saving from MMC 103

Sequence for data saving from MMC 103 (backup)

Proceed as follows to save data from MMC 103: 1. When the MMC powers up (after switching on the operator panel) press the key 6 on the operator panel keyboard briefly while the message Starting MS DOS or Starting MS Windows 9x is displayed.

PLEASE SELECT: 1 2 3 4 5 6 7 8 9 Install/Update MMC System MMC Configuration Tool DOS Shell Start Windows (Service Mode) MMC System Check Reboot System (Warmboot) Backup/Restore Start PC-Link End (Load MMC)

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Your Choice [1,2,3,4,5,6,7,8,9] ?


Fig. 11-1 Main menu MMC103

2. Select 7 (Backup/Restore) to display the menu for data saving and data restoring. The system prompts you to enter a password with: passwd:

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3. Enter one of the passwords for levels 0 2. System Manufacturer Service

The following menu is displayed:

PLEASE SELECT: 1 2 3 4 Harddisk Backup / Restore with GHOST Backup / Restore with Valitek Uninstall MMC102 (Delete Files) Return to Main Menu

Your Choice [1,2,3,4] ?

Fig. 11-2

Backup/Restore menu MMC103

4. Select 2 (Backup/Restore with Valitek) to save data on a Valitek streamer. Select 1 in the submenu (Select Valitek Streamer Type) to set the Valitek streamer you are using. Select 3 (Backup System with Valitek Streamer) to save the system data. Select 4 (Backup Userdata with Valitek Streamer) to save the user data. or (from version 4.04) Select 1 (Harddisk Backup/Restore with GHOST) to save data to a hard disk. Select 1 in the submenu (Configure GHOST Parameter) to parameterize the connection and set the backup file. Select 2 (Harddisk Backup to ...) to start data saving. Follow the instructions displayed on the MMC103.

Sequence to restore the data to MMC103

Proceed as follows to restore the data to the MMC103: 1. When the MMC powers up (after switching on the operator panel) press the key 6 on the operator panel keyboard briefly while the message Starting MS DOS or Starting MS Windows 9x is displayed.

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PLEASE SELECT: 1 2 3 4 5 6 7 8 9 Install/Update MMC System MMC Configuration Tool DOS Shell Start Windows (Service Mode) MMC System Check Reboot System (Warmboot) Backup/Restore Start PC-Link End (Load MMC)

Your Choice [1,2,3,4,5,6,7,8,9] ?


Fig. 11-3 Main menu MMC103

2. Select 7 (Backup/Restore) to display the menu for data saving and data restoring. The system prompts you to enter a password with: passwd: 3. Enter one of the passwords for levels 0 2. System Manufacturer Service

The following menu is displayed:

PLEASE SELECT: 1 2 3 4 Harddisk Backup / Restore with GHOST Backup / Restore with Valitek Uninstall MMC102 (Delete Files) Return to Main Menu

Your Choice [1,2,3,4] ?

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Fig. 11-4

Backup/Restore menu MMC103

Select 1 in the submenu (Select Valitek Streamer Type) to set the Valitek streamer you are using. Select 5 (Restore from Valitek Tape) to restore the data from the streamer to the MMC103. or (from version 4.04) 4. Select 1 (Harddisk Backup/Restore with GHOST) to restore the data from a hard disk. Select 1 in the submenu (Configure GHOST Parameter) to parameterize the connection and to set the path to the backup file. Select 3 (Harddisk Restore from ...) to restore the data to the MMC 103 from the set harddisk path.

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11.6 Line checksums and MD numbers in MD files

11.6

Line checksums and MD numbers in MD files

Overview

A check facility has been created through the introduction of line checksums to back-up files for machine data (INI and TEA files). By saving the files themselves, it is possible to dispense with the Manufacturer write authorization when these backed-up files are read in again. The purpose of introducing machine data numbers (MD numbers) in the back-up files is to facilitate the communication of machine data values for servicing purposes and automatic processing of MD back-up files in some cases. The following two subsections describe line checksums and machine data numbers in detail.

11.6.1

Line checksums

Properties of line checksums

S A line checksum is generated only for lines with machine data assignments. S Machine data numbers generated at the same time on request (MD 11230
bit 1 = 1) are included in the line checksum.

S The line checksum is positioned immediately after the machine data


assignment preceded by a blank space and apostrophe.

S The checksum consists of 4 HEXA characters. S The line checksum is only ever generated by the control on creation of an
MD back-up file and not by external editors on PC or programming device.

S The generation of line checksums is preset (MD11230 Bit 0 = 1), but can be
deselected (MD11230 Bit 0 = 0) in individual cases.

S ;<Comment> can be added later to lines with checksums without affecting


the sum check. Example of a line with checksum:

$MC_AXCONF_MACHAX_USED[0]=1 2F34 Evaluation of line checksums


No write authorization is required to read in machine data files with valid line checksums. To load

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S machine data without line checksum, S modified MD values with deleted line checksum and S MD files from SW version 1 or 2,
it is necessary to have the Manufacturer write authorization. When loading machine data files, the user can select how the system should respond to errors in the machine data file. See 11.6.3 Abortion of MD import. If the file contains incorrect values, then the current values are never overwritten.

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11.6.2

Machine data numbers

Archive files

S Machine data numbers are positioned as block numbers (e.g. N20070) in


front of an MD assignment line.

S There is a blank between the machine data number and MD assignment. S The MD number refers to the machine data in total. Any existing field values
are not represented in the MD number.

S It is possible to select/deselect the generation of MD numbers in front of MD


assignment lines in INI and TEA files. MD 11230 bit 1 = 1 MD 11230 bit 1 = 0 Generate MD number Do not generate MD number.

Evaluation of MD numbers

When machine data files are read back in, the control evaluates the MD numbers as follows: If errors are found in MD files during import, then the MD number is displayed as a block number with the appropriate alarm.

11.6.3

Abortion of MD import

Control reactions

If, during the import of machine data files (INI files) to controls, files are read in

S which contain errors S which do not match the checksum,


then alarms are generated and the import process aborted in some cases. It is possible to select the following control reactions to errors by setting machine data MD 11220 appropriately:

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MD 11220 value 0 1 2

Reaction to errors Output of an alarm, abortion on detection of 1st error (as in SW versions 1 and 2). Output of an alarm, continuation of file import, output of number of errors at file end by means of alarm Import process continues to end of file even if errors are detected. Output of number of errors at file end by means of alarm.

In all cases where at least one error is detected in the MD file, the name of the affected file is output by means of alarm 15180.

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Other reactions:

S MD containing errors do not overwrite current MD. S The current MD are not overwritten when an attempt is made to load MD
with no line checksums without adequate write authorization.

S CHANDATA instructions for non-existent channels (MD for multiple channel


configuration are not set) cause import process to be aborted.

S Invalid file end causes import process to be aborted.


MD 11220
MD 11220 INI_FILE_MODE must be reset explicitly. An earlier setting is not accepted in the course of series start-up.

Example

S Import machine data and output alarms generated on import. S % character here stands for file name or number of errors. S MD 11220 = 1, i.e. output of an alarm for every error, continuation of
processing, output of number of errors at end of file by means of an alarm.

MD file CHANDATA(1) $MC_AXCONF_GEOX_NAME_T AB[0]=X $MC_AXCONF_GEOX_NAME_T AB[1]=Y

Alarms

15180 Program % cannot be processed as INI file $MC_AXCONF_GEOX_NAME_T AB[99]=A $MC_MM_REORG_LOG_FILE_MEM=1000 $MC_AXCONF_GEOX_NAME_T AB=X $MC_MM_REORG_LOG_FILE_MEM[1]=100 $MN_UNKNOWN_MD=1 M17 15185 % Error detected in INI file 17020 Illegal array index 1 17090 Value greater than upper limit 12400 Element does not exist 12400 Element does not exist 12550 Name % not defined

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11.7

Notes on loading and saving machine data

Loading of scaling machine data

Machine data also include data which define how machine data are scaled with respect to their physical unit (e.g. velocities). These scaling data are as follows:

S MD 10220: SCALING_USER_DEF_MASK
(activation of scaling factors)

S MD 10230: SCALING_FACTORS_USER_DEF
(scaling factors of physical quantities)

S MD 10240: SCALING_SYSTEM_IS_METRIC (basic system metric) S MD 10250: SCALING_VALUE_INCH


(conversion factor for switchover to INCH system)

S MD 30300: IS_ROT_AX (rotary axis)


When machine data are loaded (via MMC, V.24 interface, program), they are scaled according to the physical unit which is currently valid. If this data set contains a new scale (e.g. rotary axis declaration), those machine data which are dependent upon scaling data are converted to the new scale after the next Power ON. The MD do not then contain the expected values (e.g. rotary axis traverses at very low F values). Example: The control has been started up with default values. The 4th axis is defined as a rotary axis in the MD file to be loaded and contains the following machine data: $MA_IS_ROT_AX[A1] = 1 (rotary axis) $MA_MAX_AX_VELO [A1] = 1000 [rev/min] (maximum axis velocity) When the MD set is loaded the velocity is interpreted with respect to a linear axis (default setting $MA_IS_ROT_AX[A1]=0) and normalized according to the linear velocity. During the next Power ON process, the control detects that this axis is defined as a rotary axis and normalizes the velocity with reference to rev/min. The value in the machine data is then no longer 1000, but 2.77777778 (1000/360). If the MD file is loaded again, the axis is already defined as a rotary axis and the velocity is interpreted as the rotary axis velocity. The MD then contains the value 1000 that is interpreted in rev/min by the control system. Suggestions for step-by-step loading of machine data 1. Change the machine data concerned manually via the MMC (MD 10220, 10230, 10240, 12050, 30300) and then initiate an NCK power-up. Import the MD set via the V.24 interface and then initiate another NCK power-up. 2. Generate an MD set with the scaling machine data (MD 10220, 10230, 10240, 10250, 30300). Load this MD set and initiate an NCK power-up. Read in the complete MD set and then initiate another NCK power-up. 3. As an alternative to the methods above, an MD set can also be loaded twice (via V.24 interface) with an NCK power-up operation after each loading.

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Note If a scaling MD is altered, then the control outputs alarm 4070 Scaling data changed.

Saving altered values

When machine and setting data are saved, MD 11210: UPLOAD_MD_CHANGES_ONLY can be set to define whether all data or only those data which deviate from the defaults are to be output via the V.24 interface. UPLOAD_MD_CHANGES_ONLY = 1 Output only those data which deviate from the defaults. UPLOAD_MD_CHANGES_ONLY = 0 Output all data. If a value has been changed in a data which is stored as an array, then the complete MD array is always output (e.g. MD 10000: AXCONF_MACHAX_NAME_TAB).

Note If may be useful to perform a data saving operation in which only altered machine data are saved prior to upgrading software in cases where the defaults in the new software are not the same as those in the earlier version. This applies particularly to machine data which are assigned SIEMENS protection level 0.

Loading of standard data

Standard machine data can be loaded in a number of different ways.

Note With methods 1 and 2, the entire SRAM on the NCU module is re-initialized. All user data are also erased. Save your user data first, if necessary.

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S Method 1 Startup switch of MMC user interface (SW switch)


Select Start-up/NC/Start-up switch. The menu Start-up FMNC is displayed. Use softkey Startup mode to select Powerup with default values (start-up). Start the powerup with standard machine data by selecting softkey OK. After the FMNC has powered up again, the message 4060 Standard MD have been loaded is displayed. Any password setting is deleted.

S Method 2 Start-up switch on FM-NC (HW switch)


Switch position 1 and subsequent NCK RESET or POWER ON starts FM-NC powerup with standard machine data. Any password setting is deleted.

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S Method 3 MD 11200: INIT_MD


(Load standard MD on next power-up) Certain input values in MD: INIT_MD allow various data areas to be loaded with default values on the next NCK power-up. The machine data is displayed in HEX format. After MD:INIT_MD has been set, POWER ON or NCK RESET must be initiated. After the FMNC has powered up again, the message 4060 Standard MD have been loaded is displayed and MD 11200 INIT_MD is set to the value 0. Any password setting remains valid. Meaning of input values of MD11200 Value 0 On the next power-up, no MD are overwritten with the default settings. (The stored machine data remain valid.) Value 1 (bit 0 set) All MDs which are not memory-configuring data will be overwritten with default values during the next power-up operation. Value 2 (bit 1 set) All memory-configuring MDs will be overwritten with default values during the next power-up operation. Memory-configuring MDs are:

S MD 10010: ASSIGN_CHAN_TO_MODE_GROUP S All machine data starting with MM_ or following MDs
MD 18000 18999 (general MDs) MD 28000 28999 (channel-specific MDs) MD 38000 38999 (axis-specific MDs)

Value 3 (bits 0 and 1 set) All MDs will be overwritten with default values during the next power-up operation. Value 4 (not for FMNC)

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11.8

Machine/setting data

The machine/setting data are listed in References: /LIS/ Lists

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12-206 12-206 12-207 12-208 12-210 12-216 12-221 12-225 12-225 12-226 12-230 12-230 12-233 12-233 12-234

12.1 12.1.1 12.1.2 12.2 12.2.1 12.2.2 12.2.3 12.3 12.3.1 12.3.2 12.4 12.4.1 12.4.2 12.4.3 12.5

Upgrading FM-NC software (firmware update) . . . . . . . . . . . . . . . . . . . Procedure for updating firmware on FM-NC . . . . . . . . . . . . . . . . . . . . . Procedure for updating firmware on FM354 . . . . . . . . . . . . . . . . . . . . . Upgrading MMC 100/100.2 software . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of MMC 100/100.2 system diskette(s) . . . . . . . . . . . . . . . . Installation of MMC100/100.2 application diskette . . . . . . . . . . . . . . . . Installation of MMC 100.2 software via PCMCIA . . . . . . . . . . . . . . . . . Upgrading MMC 102/103 software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation via MMC 102/103 floppy drive . . . . . . . . . . . . . . . . . . . . . . . Installation via PC/PG to MMC102/103 . . . . . . . . . . . . . . . . . . . . . . . . . Hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special notes for CPU318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM-NC hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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12.1

Upgrading FM-NC software (firmware update)

Requirements

The following are required to replace the FM-NC and FM 354 system software:

S for FM-NC:
A memory card (PCMCIA) with the new software version

S for FM354:
a diskette with the system software, including the file README.TXT, a PC/PG with MPI interface, with WINDOWS95 and STEP7 from version 3.1

Changing system SW

A change of system SW in the FM-NC and FM 354 may by required for the following reasons:

S A new, different system SW (new SW version) may be required. S After replacement of an FM hardware component, it may be necessary to
load the currently valid system SW into the new hardware (to maintain the SW version of the FM component). This point applies only if the new hardware has been ordered with the wrong system SW.

12.1.1

Procedure for updating firmware on FM-NC

FM-NC firmware update

When the software is updated from the PCMCIA memory card, the system SW of the FM-NC (NCK and COM) is automatically loaded. The system SW software on an FM 354 remains unaffected (i.e. it is not updated from the PCMCIA card).

Note Before updating the firmware, it is essential to create a back-up of all data and all SW programs which are not part of the system SW (see Section 11).

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Procedure for update from PCMCIA

Proceed as follows: 1. Switch the control OFF 2. Turn start-up switch on the FM-NC to position 6 3. Switch the control ON. The control switches into update state. The LED DIAG on the FM-NC flashes cyclically four times in this state. 4. The control then switches into the state update complete. The LED DIAG signals this state by flashing cyclically five times. You can switch the control OFF as soon as the firmware update is complete. Note: In configurations that include more than one FM-NC, the control must not be switched off after updating of the firmware until the all the other FM-NCs have also completed the updating of their firmware.

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5. Turn the start-up switch on the FM-NC to position 0 and switch the control ON. The FM-NC is booted with default values after a firmware update. 6. Where appropriate, any saved data and programs can now be restored to the FM-NC.

12.1.2

Procedure for updating firmware on FM354

FM354 firmware update

Read the file README.TXT on the update diskette before starting the firmware update. Proceed as follows to perform the update: 1. If SDB>=1000 are present in the control, perform a general reset without a memory card inserted. 2. Switch the CPU into the state STOP and connect the PG/PC via the free MPI interface. 3. Set the MPI time-out on your PC/PG to 100s. Note down the previously set time-out so that it can be restored later. The setting is made, for example, via: Control panels / Set PG/PC interface / MPI interface / Properties / Time Out 4. Start the update by entering A:\FMUPDATE.EXE under START / Run. You can modify the update language before activating Start data processing. 5. In the following dialog, enter the MPI address of FM354 (<=14) and select Switch FM into update state. The FM signals its update readiness through cyclic flashing of the red LED SF. 6. Set the value 14 under MPI address of FM354. (Refer also to the file README.TXT on the update diskette) 7. Start the update process by clicking on Start data transfer to FM. The progress of the update is indivated as follows: Deletion: Programming: LED DIAG lights LED DIAG flashes 4 times cyclically

Update completed: LED DIAG flashes 5 times cyclically

An automatic RESET is effected on the FM354 once the update process is completed. 8. Repeat steps 5. to 7. if the firmware update is to be performed for further FM354s in the system. If there are no further axis expansion modules requiring firmware to be loaded, you can close the dialog box on the PG/PC. 9. Where appropriate, you must perform another general reset of the CPU with a memory card inserted. Switch the CPU and FM354 off and back on again to enable them to boot together. 10. Restore the original MPI time-out on the PC/PG (see Step 3.).

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12.2

Upgrading MMC 100/100.2 software

How is software supplied?

The MMC 100/100.2 software is supplied on two or three 3.5 diskettes. Their contents are as follows: 1. System diskette (MMC100) or two system diskettes (MMC100.2) Boot software System software User software

2. Application diskette Alarm text files in 2 standard languages Configuration files for MMC 100/100.2 MD Configuration file for several operator panels

System diskette(s)

By loading the system diskette(s), you will obtain a functional standard MMC system for the foreground language English and the background language German. The alarm text and message files contain only Siemens texts.

Application diskette

After loading the application diskette, you are able to

S adapt and extend alarm text files S select one or two other languages to those previously available after loading
diskette 1/2 (there are no more than 2 languages on the MMC 100/100.2 at any time; other languages besides the standard languages are available on language diskettes).

S make special MMC MD settings S adapt configuration parameters for several operator panels S transfer user-defined screenforms for PLC status to the MMC.
Details of how to use the two diskettes are given below. Rules about adapting files before transferring them to the MMC100/100.2 can be found in Section 11.2 Data saving via MMC 100/100.2.

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System software areas

The system software on the MMC 100/100.2 is divided into the following areas:

S Boot software S System software S User software


The MMC software is stored on FEPROMs. The boot software area contains software components which are required for system software booting as well as the software which permits the system software to be loaded in the case of a new software version. All files required for MMC operation are contained in the system software. Languages other than English and German can be retroinstalled. The user software area contains all system texts, message texts for the PLC-CPU and cycle alarm texts.

Note The boot software area also contains software components which are required for a software exchange. If these components are missing or incapable of running (e.g. after power failure during upgrading), then a new software version can be installed only at the appropriate Siemens works.

In order to upgrade the system software (software version) of the MMC, a bootstrap status must be established in the MMC. A PC/PG from which the new system software can be loaded is also required. Directories occupying approximately 3 MB are set up on the PC/PG hard disk. The data which are selected for transfer during installation are stored in these directories.

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12.2.1

Installation of MMC 100/100.2 system diskette(s)

Note

See also SYS_READ.TXT on the system diskette.

Preconditions

S PC/PG with MS-DOS 6.x or later S MMC and PC/PG are connected via a V.24 (zero modem) cable. S The compression software ARJ.EXE must be available. S At least 3 MB free space is available on the hard disk of the PC/PG.

Functions of SYS_INST.EXE

The software and associated files supplied on diskette are prepared for use on the MMC 100/100.2 by means of file SYS_INST.EXE (runs under DOS) and the PC/programming device. They are then transferred to the MMC. The user can select the areas to be loaded.

Installation procedure

The software installation procedure is menu-assisted. The following sequence of operations is recommended for installation: 1. Save control-specific data via the MMC V24 interface. 2. Switch off MMC. 3. Connect the defined serial interface of the PC with the MMC interface (MMC interface: X6). 4. On the MMC100, press key 6, switch on the operator panel and hold down key 6 until a display with PCIN appears on the display. On the MMC100.2, press key 6 during booting as soon as the serial number is displayed. If a PCMCIA memory card is inserted in the MMC100.2 during booting, a menu box appears in which you select 1 Update with PCIN (COM1:). The MMC is now ready to receive data via the V24 interface.

PCIN VERSION MMCIN 1.1 (c) SIEMENS AG 1994 COM1: 19200 , NONE,8,1 XON/XOFF

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V24 INI

DATA_IN

DATA_OUT

EXIT

PCIN
Fig. 12-1

Light

VERSION MMCIN System Upload 1.1 Copyright (c) SIEMENS AG 1994

Display on MMC 100 when bootstrapping state is reached

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5. Go into DOS command mode (Windows not active) on your PC/PG. Insert the system diskette (on MMC100.2 system diskette 1) into the PC/PG disk drive and switch over to disk drive (e.g. with A: Return). Call program SYS_INST.EXE on the diskette. (A:\SYS_INST.EXE and start by pressing Return) The following menu appears:

System installation MMC100(.2) < 1> < 2> < 3> < ESC > = = = = Install system disk on hard disk Install system disk on hard disk & on MMC-hardware Select optional files to install Quit program!

Please make your choice

< F1 > Help

Fig. 12-2

PC screen after SYS_INST.EXE has been called

1 2

Install the system diskette on the hard disk of your PC/PG by selecting 1. Install the system diskette on the hard disk of your PC/PG and on the hardware of the MMC 100 by selecting 2. Choose the files to be installed on the MMC 100 by selecting 3.

ESC Abort the installation process and end the program by pressing ESC. 6. Now select 3.

Select files to install < 1> < 2> < 3> < 4> < ESC > = = = = = VGABIO28.EXE SYSBIO31.EXE ROMDOS30.BIN MMCIN_27.EXE Return to main menu! NO NO NO NO

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Please make your choice

< F1 > Help

Fig. 12-3

Files to be selected for MMC 100

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Select files for installation < 1> < ESC > = = ROMDOS_2.BIN Return to main menu! NO

Please make your choice Fig. 12-4 Files to be selected for MMC 100.2

< F1 > Help

Mark all the files by selecting the corresponding numbers to switch between NO (deselected) and YES (selected). 7. Return to the main menu by pressing ESC (see Fig. 12-2) 8. Now select 2.

Copyright (c) Siemens AG 1996,1997, all rights reserved

Installation kit version 04.04 Install system disk on hard disk

Select drive for installation Drive : ESC F1 RETURN

Fig. 12-5

Selection of drive

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9. Select the drive on which you wish to install the system diskette contents. Continue by pressing Return.

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Copyright (c) Siemens AG 1996,1997, all rights reserved

Installation kit version 04.04 Install system disk on hard disk

Select path for installation Path : C:\MMC100PJ.SYS ESC F1 RETURN

Fig. 12-6

Selection of path

10. Select the path to which you wish to unpack the files. The files are copied to the specified drive and unpacked. Any hard disk or network drive with write authorization can be selected. The following path is set up as standard, whereby <drive> stands for the selected drive (e.g. C:\): <drive>:\MMC100PJ.SYS Note: The directory must not already exist and/or contain files. You may alter the path specified by the system. The installation data are installed under the drive and path you enter. Continue by pressing Return.

Transfer software to hardware MMC100 Selected COM port : COM1 < 1> < 2> < ESC > = = = Install software via serial line select COM port Quit program!

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< F1 > Help

Please make your choice Fig. 12-7 Selection of interface on MMC100

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Transfer software to hardware MMC100.2 Selected COM port : COM1 < 1> < 2> < 3> < ESC > = = = = Install software via serial line Create Flash Memory Card image Select COM port Quit program!

Please make your choice Fig. 12-8 Selection of interface on MMC100.2

< F1 > Help

11. Select 2 (MMC100) or 3 (MMC100.2) to specify the serial interface of the PC/PG through which MMC and PC/PG are linked. 12. Press ESC to quit this submenu. 13. Select 1 to install the software on the MMC. The communications software PCIN transfers to software to the MMC.

Note If on the MMC100 the VGA-BIOS is upgraded together with other booting software parts, then the software is transferred to the MMC100 in 2 steps.

The following steps are only relevant for the MMC100. Step 1 involves the transferring of the VGA-BIOS. A reboot is then effected automatically on the MMC100 and you receive the following message on the PC/PG:

ANNOUNCEMENT Transfer of VGA-BIOS succesfully completed Please reboot your MMC100 and press 6 on MMC100 to restart PCIN! Press RETURN on PC/PG if MMC100-PCIN is ready for receiving data!

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Fig. 12-9

RETURN

Data transfer to MMC100 - Step 2

14. Hold the key 6 pressed while the MMC is booting until a screen with PCIN appears on the display. If the MMC user interface is displayed, trigger the booting of the MMC100 again and hold the key 6 on the MMC100 pressed until a screen with PCIN appears on the display. 15. Continue with the data transfer at the PC/PG by pressing RETURN. Step 2 transfers the remaining selected software areas. When the transfer is complete, the MMC100 reboots.

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If data transmission cannot be started from the PC, then an error message is output. Are cables connected correctly? Is correct interface selected? Is there a hardware defect?

16. The upgrading of the software is not completed. The saved operator panel data can now be loaded again if necessary.

Note When the software on other MMC 100/100.2 devices is updated, the update can be started from the drive of your PC/PG with SYS_INST.EXE. You will find SYS_INST.EXE in the path specified under point 10 under directory INSTUTIL.

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12.2.2

Installation of MMC100/100.2 application diskette

Note

See also APP_READ.TXT on application diskette.

Preconditions

S PC/PG with MS-DOS 6.x or later. S PC/PG and MMC are connected with a V.24 (zero modem) cable. S The boot and system software for MMC100/100.2 must already have been
loaded (see Sections 12.2.1 and 12.2.3).

S The compression software ARJ.EXE must be available. S At least 3 MB of free space is needed on the PC/PG hard disk.
Functions of APP_INST.EXE
The software and associated files supplied on diskette are prepared for use on the MMC100/100.2 using file APP_INST.EXE (runs under DOS) and a PC/PG. They are then transferred to the MMC. The user can make specific adjustments if necessary:

S Selection of languages to be loaded S Modification of alarm texts, message texts, etc. to special requirements S Adjustment of operator panel parameters S Adjustment of configuration parameters for several operator panels and
NCUs.

S User-defined screenforms for PLC status display on MMC100/100.2


If only the user software with the two standard languages German and English is to be loaded without any other modifications, then proceed as follows:

Installation without modifications

Perform the steps in the order in which they are listed below. Some message texts and submenus have been simplified. 1. Save the control-specific data via the V.24 interface of the MMC.

12

2. The MMC is disconnected from the power supply. 3. Connect the defined serial interface of the PC/PG to the interface of the MMC (X6). 4. On the MMC100, press key 6, switch on the operator panel and hold down key 6 until a display with PCIN appears on the display. On the MMC100.2, press key 6 during booting as soon as the serial number is displayed. If a PCMCIA memory card is inserted in the MMC100.2 during booting, a menu box appears in which you select 1 Update with PCIN (COM1:). The MMC is now ready to receive data via the V24 interface.

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PCIN VERSION MMCIN 1.1 (c) SIEMENS AG 1994 COM1: 19200 , NONE,8,1 XON/XOFF

V24 INI

DATA_IN

DATA_OUT

EXIT

PCIN

Light

VERSION MMCIN System Upload 1.1 Copyright (c) SIEMENS AG 1994

Fig. 12-10 Display on MMC when bootstrapping state is reached

5. Go into DOS command mode (Windows not active) on your PC/programming device. Insert the application diskette into the PC disk drive and switch over to this drive (e.g. with A: Return). Call program APP_INST.EXE on the diskette (e.g. APP_INST.EXE Return) The following menu appears:

Copyright (c) Siemens AG 1996,1997, all rights reserved

Installation kit version 04.04 Install applikation disk on hard disk

Select drive for installation Drive : ESC F1 RETURN

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Fig. 12-11 PC screen after APP_INST.EXE has been called, selection of drive

6. Select the drive on which you wish to install the application diskette contents. Continue by pressing Return.

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Copyright (c) Siemens AG 1996,1997, all rights reserved

Installation kit version 04.04 Install system disk on hard disk

Select path for installation Path : C:\MMC100PJ.SYS ESC F1 RETURN

Fig. 12-12 Selection of path

7. Select the path to which you wish to unpack the files. The files are copied to the specified drive and unpacked. Any hard disk or network drive with write authorization can be selected. The following path is set up as standard: <drive>:\MMC100PJ.APP <drive> here stands for the selected drive (e.g. C:) Note: The data are installed under the drive and path you enter. If files already exist under the specified path, you are asked whether these files are to be deleted. It is also possible to specify a different destination directory. Continue by pressing RETURN.
Install application on hardware MMC100(.2) First language : English < 1> < 2> < ESC > = = = Second language : German

Install all modules on hardware Modify configuration Esc to quit!

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Please make your choice < F1 > Help Fig. 12-13 Setting the configuration

1 2

Start installing data by selecting 1. Choose your applications (see Installation with modifications) by selecting 2.

ESC Abort the installation and end the program by pressing ESC.

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8. Now select 1. The files to be installed are displayed.

Transfer software to hardware MMC100 Selected COM port : COM1 < 1> < 2> < ESC > = = = Install software via serial line select COM port Quit program!

Please make your choice

< F1 > Help

Fig. 12-14 Selection of interface with MMC100

Transfer software to hardware MMC100.2 Selected COM port : COM1 < 1> < 2> < 3> < ESC > = = = = Install software via serial line Create Flash Memory Card image select COM port Quit program!

Please make your choice Fig. 12-15 Selection of interface with MMC100.2

< F1 > Help

9. Select 2 (MMC100) or 3 (MMC100.2) to select the serial interface of the PC/ PG through which the MMC and PC/PG are linked. Press ESC to return to the above screen. 10. Now select 1. The installation process is started. If data transmission cannot be started from the PC, then an error message is output. Are cables connected correctly? Is correct interface selected? Is there a hardware defect?

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11. As soon as the PC has signalled that all data have been loaded, the MMC is rebooted. The software is now upgraded and the control system should be fully operational again. 12. The saved operator panel data can now be loaded again if necessary.

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Installation with modifications

Proceed as in the case of an installation without modifications up to point 7. 8. Now select point 2 as shown in Fig. 12-13. Changing applications:
Install application on hardware MMC100 First language : English <1> < 2> < 3> <4> < 5> < ESC > = = = = = = Second language : German

Change first language Change second language Edit ASCII files Edit text files for first language Edit text files for second language Return to previous menu!

Please make your choice

< F1 > Help

Fig. 12-16 Setting the configuration

1 2 3 4 5

Select 1 to change the setting for the first language. Select 2 to change the setting for the second language. Select 3 to make the modifications you require (see APP_READ_TXT). Select 4 to edit the language files for the set first language Select 5 to edit the language files for the set second language.

ESC Select ESC to quit the submenu (see Fig. 12-13) Next step: See Installation without modifications, points 10. to 12.

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12.2.3

Installation of MMC 100.2 software via PCMCIA

Preconditions

S PC/PG with MS-DOS 6.x or later and WINDOWS S Flash burner S 4 MB flash memory card (PCMCIA) S Software SINUCOPY V01.03.05 or later S Two system diskettes and one application diskette for MMC100.2

Installation via PCMCIA for MMC100.2

When installing MMC100.2 software via PCMCIA, proceed at first as described in Section 12.2.1 under Installation procedure, steps 1. to 10. If you wish to load the standard configuration without specific modifications, proceed as described under Installation via PCMCIA without modifications. If you wish to make individual changes, proceed as described under Installation mit PCMCIA with modifications .

Installation via PCMCIA without modifications

If you wish to load the standard configuration without specific modifications, proceed as follows: 13. In the screen shown in Fig. 12-8, select 2 (Create Flash Memory Card image).

Copyright (c) Siemens AG 1996,1997, all rights reserved Installation kit version 04.04 Please wait!

Select drive for copying the Flash Memory Card image Drive : ESC F1 RETURN

Fig. 12-17 Selection of drive for flash memory card image

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14. Select the drive to which the flash memory card image (file MMC100_2.ABB) is to be copied. Continue by pressing Return

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Copyright (c) Siemens AG 1996,1997, all rights reserved Installation kit version 04.04 Please wait!

Select path for copying the Flash Memory Card image Path : C:\ ESC F1 RETURN

Fig. 12-18 Selection of path for flash memory card image

15. Select the path under which the image file is to be saved. The file MMC100_2.ABB will be copied to the specified path. The default setting is the root directory of the selected drive (e.g. C:\). Continue by pressing Return A message is displayed to confirm that the image file has been created successfully and to indicate the path under which MMC100_2.ABB has been saved. Continue by pressing Return 16. End the program SYS_INST.EXE by pressing ESC. 17. Start the software SINUCOPY and write the flash memory card image MMC100_2.ABB to the PCMCIA. 18. Continue with the steps described under Procedure for software update via PCMCIA later in this Section.

Installation via PCMCIA with modifications

If you wish to load the standard configuration with individual modifications, proceed as follows: 1. End the program in the screen shown in Fig. 12-8 by pressing ESC. 2. Perform the following steps as described in Section 12.2.2: Steps 5. to 7. under Installation without modifications and Step 8. under Installation with modifications.

3. In the screen shown in Fig. 12-15, select 2 (Create Flash Memory Card image).

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4. The system data which are already stored on the hard disk are required to create the memory card image. In the following screens you must specify the drive and path under which the system files have been stored. If you used the default settings for the intermediate saving, the entries will be C for the drive and MMC100.SYS for the path.

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Copyright (c) Siemens AG 1996,1997, all rights reserved Installation kit version 04.04 A running system needs systemdisk-data! Therefore:

Please enter drive for copying the Flash Memory Card image Drive : ESC F1 RETURN

Fig. 12-19 Specifying the drive for system files

Enter the drive on which the MMC100.2 system files are to be found and confirm your entry by pressing RETURN.

Copyright (c) Siemens AG 1996,1997, all rights reserved Installation kit version 04.04 A running system needs systemdisk-data! Therefore:

Please enter Pfad for copying the Flash Memory Card image Drive : C:\ ESC F1 RETURN

Fig. 12-20 Specifying the path for system files

5. Enter the path under which the system files have been stored and confirm your entry by pressing RETURN.

Copyright (c) Siemens AG 1996,1997, all rights reserved Installation kit version 04.04 Please wait!

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Select drive for copying the Flash Memory Card image Drive : ESC F1 RETURN

Fig. 12-21 Selecting the drive for the flash memory card image

6. Select the drive on which the flash memory card image (file MMC100_2.ABB) is to be saved and confirm your entry with RETURN.

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Copyright (c) Siemens AG 1996,1997, all rights reserved Installation kit version 04.04 Please wait!

Select path for copying the Flash Memory Card image Path : ESC F1 RETURN

Fig. 12-22 Selecting the path for the flash memory card image

7. The next screen requests that you enter the path for the image file. The file MMC100_2.ABB will be copied to the specified path. The default setting is the root directory of the selected drive (e.g. C:\). Continue by pressing RETURN. 8. A message is displayed to confirm that the image file has been created successfully and to indicate the path under which MMC100_2.ABB has been saved. Confirm by pressing RETURN. 9. End the program APP_INST.EXE by pressing ESC. 10. Start the software SINUCOPY and write the flash memory card image MMC100_2.ABB to the PCMCIA. 11. Continue with the steps described under Procedure for software update via PCMCIA later in this Section.

Procedure for software update via PCMCIA

The PCMCIA memory card containing the memory image MMC100_2.ABB can be used to transfer the software to any number of MMCs. To do so, proceed as follows: 1. Insert the PCMCIA with the flash memory card image into the memory card slot of the MMC100.2. 2. Reboot the MMC100.2 and press the key 6 on the operator panel as soon as the serial number appears on the display. If a memory card is inserted at this point, a menu box is displayed. 3. Select Update from PC-Card by pressing the key 0 on the operator panel. The update process takes approximately 1 minute. When the updating is complete, you will be prompted to Remove PC-Card 4. Remove the memory card from the MMC100.2. The MMC100.2 is rebooted automatically. The installation of the system software is now complete. The same PCMCIA memory card can be used to transfer the system software to further MMC100.2 modules. In this case repeat steps 1. to 4. as often as necessary.

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12.3 Upgrading MMC 102/103 software

12.3
12.3.1

Upgrading MMC 102/103 software


Installation via MMC 102/103 floppy drive

Operator action

During MMC booting (after control has been switched on), while the message Starting MS DOS or Starting MS Windows 9x is displayed: 1. Press key 6 on the operator panel keyboard just once and briefly. The following menu is displayed:

PLEASE SELECT: 1 2 3 4 5 6 7 8 9 Install/Update MMC System Install/Update Standard Software DOS Shell Start Windows (Service Mode) MMC System Check Reboot System (Warmboot) Backup/Restore with VALITEK Streamer Start PC-Link End (Load MMC)

Your Choice [1,2,3,4,5,6,7,8,9] ?


Fig. 12-23 Main menu MMC102(/103)

2. Press key 1. The system requests you to enter a password with: passwd: 3. Enter one of the passwords for levels 0 2. System Manufacturer Service

The following menu is displayed:

PLEASE SELECT MEDIUM: 1 2 3 4 5 Install from Floppy Disk Install via Serial/Parallel Line Install from VALITEK Streamer Return to Main Menu Reboot

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Your Choice [1,2,3,4,5] ?


Fig. 12-24 Submenu1 MMC102(/103)

4. Press key 1.

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The system requests you to insert the first diskette with the message:

Please insert Installation Floppy #1 (Hit n to ABORT Installation) Continue[y] 5. Insert the diskette and press Y if you want to continue with the installation. Installation is menu-assisted. The data are initially put into a clipboard. After successful transfer to the clipboard, the SETUP menu is offered. When you confirm CONTINUE, the data are transferred to the destination directory. A booting of the MMC is then initiated.

12.3.2

Installation via PC/PG to MMC102/103

Operator actions on PC/PG

1. Establish a parallel or serial (V24) connection between PC/PG and MMC. 2. Insert installation diskette 1 in PC/PG. 3. Switch over to the disk drive (e.g. A: RETURN) 4. Start the installation program DOSSETUP at the command line The installation start screen is displayed on the PC/PG. This screen includes a warning that any user data will be overwritten by the installation. At the same time it offers two methods to proceed with installation: You have two Choices: 1. 2. Install directly from Floppy to MMC 10x (Single Installation) (Only some batchfiles will be copied to the selected Diskdrive) Install once to local Harddisk and then multiple to MMC 10x (You will need about xx MB free space on your harddisk!)

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Continue with installation (y/n)? [y] _


Fig. 12-25 Start screen of installation program (excerpt)

You can later choose one of two installation methods: 1. 2. Load directly from floppy of PC/PG to MMC102/103 Load once to hard disk of PC/PG and transfer later to one or several MMC102/103 modules

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Once you have saved the user data of the control system if requested to do so by a message text, you can continue with Y. 5. The system now displays the default settings for the disk drive on the PC/PG method 1 or 2 and the directory.

Please check the installation parameters: Installation from drive Copy files to disk Copy (batch) files to directory : : : A: N C:\MMC102

Would you like to change anything (y/n)? [n].


Fig. 12-26 Installation parameters

Note Copy files to disk: N Copy files to disk: Y means direct loading from FD of PC/PG to MMC102 (method 1, single installation) means load data once to hard disk of PC/PG (method 2, multiple installation)

The type of connection between PC/PG and MMC is recognized automatically by the communications software and does not need to be set.

If you select y to be able to enter changes, these changes will be requested one by one. You are then returned to the screen shown in Fig. 12-26. If the default settings are correct for your system, or if you have made all the changes you require, press n. 6. Switch PC/PG to Server mode (press Y key). End PC/PG server mode by pressing Alt + F4 once all data have been transferred.

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Operator actions on MMC 102

During MMC booting (after control has been switched on), while the message Starting MS DOS or Starting MS Windows 9x is displayed: 1. Press key 6 on the operator panel keyboard once and briefly. The following menu is displayed:

PLEASE SELECT: 1 2 3 4 5 6 7 8 9 Install/Update MMC System Install/Update Standard Software DOS Shell Start Windows (Service Mode) MMC System Check Reboot System (Warmboot) Backup/Restore with VALITEK Streamer Start PC-Link End (Load MMC)

Your Choice [1,2,3,4,5,6,7,8,9] ?


Fig. 12-27 Main menu MMC102(/103)

2. Press key 1 The system request you to enter a password with: passwd: 3. Enter one of the passwords for levels 0 2. System Manufacturer Service

The following menu is displayed:

PLEASE SELECT MEDIUM: 1 2 3 4 5 Install from Floppy Disk Install via Serial/Parallel Line Install from VALITEK Streamer Return to Main Menu Reboot

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Your Choice [1,2,3,4,5] ?


Fig. 12-28 Submenu 1 MMC102(/103)

4. Press key 2 (Install via Serial/Parallel Line) The installation is menu-assisted. The data are initially put into a clipboard. After successful transfer to the clipboard, the SETUP menu is offered. When you confirm CONTINUE, the data are transferred to the destination directory. A booting of the MMC is then initiated.

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Transfer of SW from PC/PG hard disk to MMC

If you have chosen method 2 as described above and have copied files from the floppy disk to the hard disk of the PC/PG, proceed as follows to transfer them on to the MMC102/103: 1. Establish a parallel or serial connection between PC/PG and MMC. 2. Change to the directory which you specified under Copy (batch) files to directory:... in the screen shown in Fig. 12-26 (e.g. C:\MMC102) 3. Call: C:\MMC102\INSTALL2.BAT 4. Take the action described above under Operator action on MMC102.

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12.4

Hardware replacement

Overview

You can replace all components that are ordered via an MLFB (order number). All data must be saved before any component is removed (see Section 11).

12.4.1

Special notes for CPU318

Special requirement of CPU318

When replacing or using a CPU318 for the first time, attention must be given to the changes described below.

S SIMATIC STEP7 from V5.x is required to be able to use CPU318.


Global data for MCP and CPU318
Global data are exchanged between the CPU and MCP with the system data block SDB210. The previously supplied SDB210 (Toolbox up to V03/06) is not supported by the CPU318. The standard MPI address 6 cannot be used for the MCP in conjunction with the CPU318.

S CPU318 is able to use SDB210 from the project GDCOPU318 on the


Toolbox diskette 1 from V03/07 (see also file PLCFMNCD.TXT on Toolbox diskette 1). To be able to use this SDB210 the MPI address 14 must be set as follows at the DIP switch of the MCP:
Table 12-1 1 on 2 off Setting of switch S3 on the MCP 3 on 4 on 5 on 6 on 7 off 8 off Meaning: Baud rate: 187.5 kBaud Transmission cycle time: 100 ms Bus address: 14

S With the global data communication in STEP7 it is possible to create a user


specific SDB210 independently of the above-mentioned SDB210. In this case you can define individually selected transmit, receive and status data together with a free MPI address, except address 6. (see Section 3.3: Nonstandard configuration)

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12.4 Hardware replacement

Connecting FM-NC and MMC via CPU318

When using a CPU318, the connection between MMC and FM-NC is via the CPU318. The FM-NC is addressed by the CPU by means of a rack-slot address. This address must be specified in the configuration file NETNAMES.INI of the MMC. The rack-slot addresses are defined as follows:
Table 12-2 Rack slot addresses: Rack 0 Rack 1 Rack 2 Rack 3 Rack-slot addresses Slot 4 4 36 68 100 Slot 5 5 37 69 101 Slot 6 6 38 70 102 Slot 7 7 39 71 103 Slot 8 8 40 72 104 Slot 9 9 41 73 105 Slot 10 10 42 74 106 Slot 11 11 43 75 107

The valid rack-slot address is derived from the subrack and slot at which the FM-NC is installed. This address can be taken from Table 12-2 and must be entered into the configuration file NETNAMES.INI.

Modification of NETNAMES.INI

The procedure for modification of the configuration file NETNAMES.INI is dependent on the MMC hardware you are using.

S MMC100/100.2
The configuration is modified using the application diskette on the PC/PG and subsequently transferred to the MMC100/100.2. Proceed as described in Section 12.2.2 under Installation with modifications. In the submenu Modify configuration (Fig. 12-16) select for example <3> Edit ASCIIfiles. In the next menu select <1> Edit MPI configuration data. The configuration file NETNAMES.INI is opened with the DOS editor EDIT. Modify the block [param NCU_1] in accordance with your requirements and save your modifications with the menu command File/Save. An example for the configuration of the file NETNAMES.INI for use of an FM-NC with CPU318 is enclosed below as orientation. Quit the editor (menu File/Quit). When you have made all the necessary modifications, transfer the application to the MMC100/100.2 as described in Section 12.2.2.

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S MMC102/103
The configuration is modified by means of a DOS editor at the MMC. Select the operator area Startup/MMC/DOS Shell. Copy the configuration file into the user directory by entering the following command line at the DOS prompt C:\MMC2>: C:\MMC2>COPY NETNAMES.INI C:\USER. Then select EXIT to return to the MMC user interface.

Note The user-specific settings in the file NETNAMES.INI should be made under the USER path. The configuration files under the USER path take priority over the standard configuration files. The configuration file with the same name under the path MMC2 remains unaltered.

Select the operator area and command Startup/MMC/Editor. Then select the path C:\USER, find the configuration file NETNAMES.INI and open the file for editing. Modify the block [param NCU_1] in accordance with your requirements. An example for the configuration of the file NETNAMES.INI for use of an FM-NC with CPU318 is enclosed below as orientation. Quit the editor by selecting the softkey Close Editor. The modified parameters do not become effective until the next time the MMC102/103 is booted. Initiate rebooting of the MMC.

Example: An FM-NC is installed at the eighth slot (Slot 8) on the first subrack (Rack 0). The rack-slot address 8 is to be taken from Table 12-2 and specified as a parameter in the block [param NCU_1] of the file NETNAMES.INI: : : [param NCU_1] nck_adress =2, rack_slot =8 plc_adress =2 name =NCU_1 : :

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12.4.2

CPU hardware replacement

Transferring data to new CPU hardware

Data saving for the CPU is done with SIMATIC STEP7. If the CPU hardware is replaced, the basic program and the user program must be loaded into the new CPU hardware.

12.4.3

FM-NC hardware replacement

Transferring data to new FM-NC hardware

The FM-NC (NCU 570) can only be replaced as a complete unit. The data saved beforehand can be loaded into the new FM-NC.

S The procedure for data saving via the MMC is described in Sections 11.2
and 11.3.

S The data of the FM-NC to be replaced can also be saved without external
devices (PG/PC) by saving to a PCMCIA memory card. The saved data can then simply be reloaded after replacement of the FM-NC hardware (see Section 11.4 Saving data on a PCMCIA memory card). References: /PHF/, Manual Configuring, Manual NCU 570 and FM 354 /BH/, Manual Operator Components

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12.5 Battery replacement

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12.5

Battery replacement
Caution You should never attempt to revitalize dead batteries through heat or any other treatment. The batteries must not be charged as this could cause them to leak or explode. Failure to observe this warning could lead to physical injury or property damage. There are SRAMs and timers backed up by batteries in the PLC-CPU, FM-NC and MMC 102. Data are saved to these in the event of power failure. The back-up voltage is monitored by the control and a monitoring signal output. Once the monitoring function has responded, the battery must be replaced within 6 weeks. References: /S/H/, Manual Design of an S7-300 /BH/, Manual Operator Components

Replacement of battery on FM-NC

When does the battery need to be replaced? The battery must be replaced when an error message indicating a battery problem is output. In addition, the LED BAF indicates the status of the battery voltage and the buffered memory. The battery does not require any maintenance for at least two years. It may not need to be replaced for five or more years depending on its condition. However, since the battery becomes less and less effective with increasing age, we would recommend that it is replaced after five years at the latest.

S LED BAF flashes


The buffered data are still safe, but the battery is beginning to lose its charge. It must be replaced.

S LED BAF lights up steadily


The buffered data are lost and the control must be started up again after replacement of the battery. This state is forced by the FM-NC.

Important The load current supply must always be connected while a battery is replaced or else the buffered data (if any is still present) will be lost. Proceed as follows to replace the battery 1. Lift up the left-hand front door. 2. Remove the dead battery, pulling the battery connector out of the socket in the battery compartment. 3. Insert the battery connector into the socket in the battery compartment. The notch on the connector must point towards the right, or alternatively the lug must point towards the left and positive pole downwards). 4. Insert the battery in the battery compartment, close the front door. Battery type Only preassembled batteries with plug-in connector may be used. Order No.: 6ES79711AA000AA0

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Miscellaneous

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13.1 13.1.1 13.1.2 13.2 13.3

Tool Box software package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents of tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application of tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assessing machine data via part program . . . . . . . . . . . . . . . . . . . . . . . O & M for FM-NC with OP 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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13.1 Tool Box software package

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13.1
13.1.1

Tool Box software package


Contents of tool box

Contents

Supplied on two 3.5 diskettes with 1st diskette: Basic PLC program for FM-NC Standard machine data sets for FM-NC Sample project file OP 27 Info file SIEMENSD.TXT

2nd diskette: NC variable selector

Software requirements

The following programs are required to be able to use the Tool Box software package S PCIN software program

S SIMATIC STEP7 for creation of the PLC user program and for integration of
the PLC basic program

S COROS ProTool, V1.31 or higher for configuration of the Operator Panel


OP27

Hardware requirements

The following components are required for the connections to a control system

S PC/programmer with MPI interface, e.g. PG740 S Cable for the connection between PG/PC and MMC (V24) S Cable for the connection between PG/PC aqnd PLC (MPI)
References: /Z/, Catalog NC Z

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13.1 Tool Box software package

13.1.2

Application of tool box

Standard MD sets

The default settings for the MD are not specific to any particular technology. To provide assistance in starting up machines for the first time, three example MD files are supplied on the 1st tool box diskette with the FM-NC. The purpose of these files is to assist the user in setting the machine data for specific technologies when starting up machines for the first time.

S md_fr_a.tea
P bus (FM 354)

Example of MD setting for 4-axis milling machine with local Example of MD setting for turning machine with analog Example of MD setting for turning machine with stepper

S md_dr_a.tea
drive

S md_dr_s.tea
motor drive

Please refer to the readme file: readme.txt supplied with the tool box for further information.

Basic PLC program

See SIMATIC STEP7, User Manual References: /FB/, P3 Basic PLC Program

NC variable selector

You need the NC variable selector to be able to read and write the NCK variables from the PLC-CPU or from the OP 27. References: /FB/, P3 Basic PLC Program /LIS/, Lists, Section Variables

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13.2 Assessing machine data via part program

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13.2

Assessing machine data via part program


The machine data designation is displayed on the MMC. The internal designation of the data requires further identifiers which must be specified when a machine data is altered via programming measures or imported via the serial interface. $MM_ $MN_/$SN_ $MC_/$SC_ $MA_/$SA_ $MD_ Please note: Operator panel data General machine data/setting data Channel-specific machine data/setting data Axis-specific machine data/setting data Drive machine data $ System variable M Machine data S Setting data M, N, C, A Subarea (second letter)

Data identifiers

Data areas

Axis data are addressed via the axis name. The internal axis designation (AX1, AX2 ... AX5) or the name specified in MD 10000: AXCONF_NAME_TAB can be used as the axis name. E.g.: $MA_JOG_VELO[Y1] = 2000 The JOG velocity of axis Y1 is 2000 mm/min. The contents of a machine data must be inserted in apostrophes (e.g. X1 or H41) if they are a STRING (e.g. X1) or a hexadecimal value (e.g. H41). E.g.: $MN_SCALING_USER_DEF_MASK = H200 Activation of the scaling factor position control loop gain in 1/s. In order to address various contents of a machine data, entries in square parentheses are required. E.g.: MD FIX_POINT_POS [0,X1] = 500.000
The 1st fixed-point position of (0 = 1st, 1 = 2nd, 2 = 3rd etc.) Axis X1 is 500

Examples: $MN_AUXFU_GROUP_SPEC[2] = H41 Output instant of auxiliary functions of 3rd auxiliary function group. $MN_AXCONF_MACHAX_NAME_TAB[0] = X1 Name of 1st machine axis is X1. $MA_REF_SET_POS[0,AX1] = 100.00000 1st reference point value of axis X1 is 100 mm. Assignment of channel-specific machine data: CHANDATA(1) $MC_CHAN_NAME=CHAN1 $MC__AXCONF_GEOAX_NAME_TAB[1]=Y ... R10 = 33.75 Assignment channel 1 Channel name for channel 1 Name of 2nd geometry axis in channel 1 is Y R10 of channel 1

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13.3 O & M for FM-NC with OP 27

13.3

O & M for FM-NC with OP 27

Overview

A data server function is integrated in the FM-NC to allow the connection of devices (e.g. OP 27) that operate with the S7 protocol. Owing to differences in the address structure of variables and data formats used in the BTSS or S7 protocols, there are restrictions regarding the number of addressable variables and the useful value range. The OPs use only the variable services (read/write variables). The Domain and PI services of the BTSS protocol are thus omitted. File OP27_NCx.PDB on the 1st diskette in the tool box contains a sample configuration for an OP 27 with respect to FM-NC variables. In addition to FM-NC variables, you can also configure the variables of other MPI nodes in OP 27 displays.

Note This Section deals only with special features that are relevant with respect to operation and monitoring (O & I) of the FM-NC using the OP 27. It is assumed that the reader is already familiar with the ProTool configuring tool, the hardware connections and the documentation regarding the basic functions of the OP 27.

References:

/ST7/, Catalog ST70

References for OP 27 operation

S COROS ProTool, User Manual S COROS OP 25, OP 27, OP 35, OP45 Operator Panel, Product Manual S COROS ProTool Application Example, Installation and Start-Up Guide
Configuring an OP 27 for FM-NC variables
The sample configuration can be found in file OP27_NCx.PDB on the 1st diskette in the SW tool box. The file can be opened in configuring tool COROS ProTool. ProTool allows you to view, modify and extend this sample configuration. You can generate the modified/unmodified sample project in ProTool and then transfer it to the OP 27. In this sample, all variables are configured with respect to an FM-NC (control_1) with MPI address 3. In the sample, the OP 27 has MPI address 10 (see Section 3.5). Display ks_25_1 in the sample shows the configuring data for the following variables in an FM-NC system:

S S S S S S

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Channel status Active mode Axis names of 1st to 4th axes

(variable name: chanStatus) (variable name: opMode) (variable name: name, name1, ...)

Axis actual values of 1st to 4th axes (variable name: actProPos, ...) Dimensional unit of 1st to 4th axes etc. (variable name: extUnit, extUnit1, ...)

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Variable selection

For a full list of FM-NC variables, please refer to References: /LIS/, Lists, Section Variables

This document can only be used as an overview of the variables. The following variables are not supported by the FM-NC data server:

S Compile cycle S Interpolative compensation S Status data Interrupt_Status S Machine data S Setting data ov areas V and H of

Block CC Block type IK Block type SINT Block type M Block type S

Variables that are not set up until the program is running (e.g. address in ACC file) or that have an address that may change during program execution (e.g. GUD) cannot be addressed directly. There are two methods by which you can determine the necessary configuring data of FM-NC variables: Method 1 You can acquire the configuring parameters of the variables by using the Variable selector NC-VAR selector tool. You will find it on the 2nd diskette of the SW tool box (self-extracting file: *.EXE). To determine the configuring parameters of variables using the NC-VAR selector, please proceed as follows: 1. Using an editor, set the key Konv = ProTool in the profile file NC_VAR.INI (stored in user directory of NC-VAR selector). e.g.: L ; Specify conversion (Konv) either with S7 or ProTool ; Konv = S7 Konv = ProTool L

If variables must be selected for the S7 interface (e.g. for PLC-CPU), then Konv = S7 must be set. 2. Start the NC VAR selector (double-click on icon) 3. New project or Open existing project You can either create a new project or open and modify a project that already exists. 4. Select total list Select the total list of variables for the FM-NC (NCU 570) with the appropriate software version for NCU570: e.g.: ...\nc_var\data\swx_xx.570 Select this file by a double-click. The file: nc_var.mdb is displayed. Select this as well by a double-click. The full list of variables is displayed.

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5. You can select the appropriate variables from this list. The variable name is transferred to the project list when it is double-clicked. The transfer is initiated via the intermediate display Input line, column and area number in which you can also specify supplementary information about the variable (e.g. axis number, number of R parameter, field number, etc.). 6. Once you have transferred all the variables to be configured to the project list or have modified or extended and existing list, you can store it. If you have called a new project, then it must be saved under path extension *.s7d. e.g.: ...\opvar_v1.s7d\op27_v1.var 7. Go into menu Code and call the Generate function. This function generates both the *.var file and the *.p25 ASCII file (e.g. op27_v1.P25). A typical example of how this ASCII file may appear on the screen is given below:

// // File

C:\VARSTEST.S7A\VARSTEST.S7P\VARSTEST.S7D\OP27_V1.P25

// Source File : C:\VARSTEST.S7A\VARSTEST.S7P\VARSTEST.S7D\OP27_V1.VAR // Generation Date : xx-xxxx-xx Time: xx : xx // //Ran Type Variable Format Li Ci DBNr DBOffset Remark // A[1] SE TEMP_COMP_SLOPE A[2] SE WORKAREA_MINUS_ENABLE // END TABLE A1_SE_TEMP_C REAL A3_SE_WA_MIN BYTE 1 1 43910 24854 1934 43410 25366 1434

8. Close NC-VAR selector. 9. Using an ASCII editor, you can view and printout the *.p25 file. The *.p25 file contains all the configuring parameters of the selected variables such as format, DB no., and DB offset that may be needed for configuration with ProTool. Method 2 The docu file read_op.doc can be found on the 1st diskette in the SW tool box. This file contains the following:

S Instructions on how to determine the DB no. and DB offset for a variable to


be configured.

S Notes on data formats and supplementary conditions S A description of how specific workpiece programs can be selected via the
OP 27

S A list of configurable variables (Appendix A1)


J

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Abbreviations

AS ASCII ASSR AT
BCD BP C1 C BUS COM CPU CRC CTS DAC DB DBB DBX DCE DP DPR DRAM DRF

Automation System American Standard Code for Information Interchange Asynchronous Subroutine Advanced Technology Binary Coded Decimals Basic Program Channel 1 Communications Bus Communication Central Processing Unit Cutter Radius Compensation Clear To Send (serial data interfaces) DigitaltoAnalog Converter Data Block Data Block Byte Data Block Bit Data Communications Equipment Distributed Peripherals DualPort RAM Dynamic storage (RAM) Differential Resolver Function

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A. Abbreviations

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DRY DSR DTE DW EPROM ESM ETC FC FDD FEPROM FIFO

Dry Run Data Send Ready (serial data interfaces) Data Terminal Equipment Data Word Erasable Programmable Read Only Memory ElectrostaticSensitive Modules ETC key > Extension of softkey selection in the same menu Function Call (function block in PLC) Feed Drive FlashEPROM First In First Out: Memory which operates without address specification from which data are read in the same order as they were stored. Fine Interpolator Function Module Geometry Signal ground Gear Ratio Global User Data Abbreviation for hexadecimal digit Hardware limit switch Interface Module (SIMATIC S7300) Interface Module Receive Interface Module Send Increment Initializing Data Internal Multiplication

FIPO FM GEO GND GR GUD HEX HW limit switch IM IMR IMS

INC INI INTM

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A. Abbreviations

INTSIG ISO code JOG LEC LED MCP MD MDA MG MMC MPF MPI MSD NC NCK NCU NMI OB OM OP OPINT P BUS PCMCIA PII PIO PG

Interface Signal Special tape code, no. of holes per character is always even Jogging Leadscrew Error Compensation Light Emitting Diode Machine Control Panel Machine Data Manual Data Automatic Mode Group Man Machine Communication: SINUMERIK operator interface Main Program File: NC part program MultiPortInterface Main Spindle Drive Numerical Control Numerical Control Kernel (with block conditioning, traversing range, etc.) Numerical Control Unit Nonmaskable Interrupt Organization Block in PLC Operating Mode Operator Panel Operator Panel Interface Peripherals Bus Personal Computer Memory Card International Association Process Input Image Process Output Image Programming device

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A. Abbreviations

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PLC PMS1 PMS2 PRT QEC RAM RDY ROV RPA RTS SBL SD SEA SG SK SKP SM SPF SRAM SSI SW SW limit switch TC TEA TL TLRO

Programmable Logic Controller Position Measuring System 1 Position Measuring System 2 Program Test Quadrant Error Compensation Random Access Memory Ready Rapid Override RParameter Active Request To Send (serial data interfaces) Single Block Setting Data Setting Data Active Servo Gain factor Softkey Skip SIMATIC S7300 signal module, e.g. input/output modules Sub Program File Static storage (RAM) Synchronous Serial Interface Software Software limit switch Tool Change Testing Data Active Tool Tool Radius Offset

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A. Abbreviations

TO TOA VDI V24 ZO ZOA

Tool Offset Tool Offset Active Virtual Device Interface Serial interface (equivalent to RS232C) Zero Offset Zero Offset Active

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References

B
SINUMERIK 840D/840Di/810D/802S, C, D Ordering Information Catalog NC 60 Order No.: E86060-K4460-A101-A8-7600

General Documentation
/BU/

/ST7/

SIMATIC SIMATIC S7 Programmable Logic Controllers Catalog ST 70 Order No.: E86 060-K4670-A111-A3

/Z/

SINUMERIK, SIROTEC, SIMODRIVE Accessories and Equipment for Special-Purpose Machines Catalog NC Z Order No.: E86060-K4490-A001-A7-7600

Electronic Documentation
/CD6/
The SINUMERIK System (09.01 Edition) DOC ON CD (includes all SINUMERIK 840D/840Di/810D/FM-NC and SIMODRIVE publications) Order No.: 6FC5 298-6CA00-0BG1

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User Documentation
/AUE/
SINUMERIK 840D/810D/FM-NC AutoTurn Graphic Programming System Part 2: Setup Order No.: 6FC5 298-4AA50-0BP2

(07.99 Edition)

/AUK/

SINUMERIK 840D/810D/ FM-NC Short Guide AutoTurn Operation Order No.: 6FC5 298-4AA30-0BP2

(07.99 Edition)

/AUP/

SINUMERIK 840D/810D/FM-NC AutoTurn Graphic Programming System Part 1: Programming Order No.: 6FC5 298-4AA40-0BP2

(07.99 Edition)

/BA/

SINUMERIK 840D/840Di/810D/FM-NC Operators Guide Order No.: 6FC5 298-6AA00-0BP0 Operators Guide MMC Operators Guide HMI Advanced

(10.00 Edition)

/BAE/

SINUMERIK 840D/810D/ FM-NC Operators Guide Unit Operator Panel Order No.: 6FC5 298-3AA60-0BP1

(04.96 Edition)

/BAH/

SINUMERIK 840D/840Di/810D Operators Guide HT 6 (HPU new) Order No.: 6FC5 298-0AD60-0BP0

(06.00 Edition)

/BAK/

SINUMERIK 840D/840Di/810D/FM-NC Short Guide Operation Order No.: 6FC5 298-6AA10-0BP0

(10.00 Edition)

/BAM/

SINUMERIK 840D/810D Operators Guide ManualTurn Order No.: 6FC5 298-5AD00-0BP0

(02.00 Edition)

/KAM/

SINUMERIK 840D/810D Short Guide ManualTurn Order No.: 6FC5 298-2AD40-0BP0

(11.98 Edition)

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/BAS/

SINUMERIK 840D/810D Operators Guide ShopMill Order No.: 6FC5 298-5AD10-0BP1

(08.00 Edition)

/KAS/

SINUMERIK 840D/810D Short Guide ShopMill Order No.: 6FC5 298-2AD30-0BP0

(01.98 Edition)

/BAP/

SINUMERIK 840D/840Di/810D Operators Guide Handheld Programming Unit Order No.: 6FC5 298-5AD20-0BP1

(04.00 Edition)

/BNM/

SINUMERIK 840D/840Di/810D/FM-NC Users Guide Measuring Cycles Order No.: 6FC5 298-5AA70-0BP2

(06.00 Edition)

/DA/

SINUMERIK 840D/840Di/810D/FM-NC Diagnostics Guide Order No.: 6FC5 298-6AA20-0BP0

(10.00 Edition)

/PG/

SINUMERIK 840D/840Di/810D/FM-NC Programming Guide Fundamentals Order No.: 6FC5 298-6AB00-0BP0

(10.00 Edition)

/PGA/

SINUMERIK 840D/840Di/810D/FM-NC Programming Guide Advanced Order No.: 6FC5 298-6AB10-0BP0

(10.00 Edition)

/PGK/

SINUMERIK 840D/840Di/810D/FM-NC Short Guide Programming Order No.: 6FC5 298-6AB30-0BP0

(10.00 Edition)

/PGZ/

SINUMERIK 840D/840Di/810D/FM-NC Programming Guide Cycles Order No.: 6FC5 298-6AB40-0BP0

(10.00 Edition)

/PI /

PCIN 4.4 Software for Data Transfer to/from MMC Module Order No.: 6FX2 060 4AA00-4XB0 (German, English, French) Order from: WK Frth

/SYI/

SINUMERIK 840Di System Overview Order No.: 6FC5 298-5AE40-0BP0

(01.00 Edition)

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Manufacturer/Service Documentation
a) Lists

/LIS/

SINUMERIK 840D/840Di/810D/FM-NC SIMODRIVE 611D Lists Order No.: 6FC5 297-6AB70-0BP0

(10.00 Edition)

b) Hardware

/BH/

SINUMERIK 840D/840Di/810D/FM-NC Operator Components Manual (HW) Order No.: 6FC5 297-6AA50-0BP0

(10.00 Edition)

/BHA/

SIMODRIVE Sensor Absolute Encoder with PROFIBUS-DP User Guide (HW) Order No.: 6SN1197-0AB10-0YP1

(02.99 Edition)

/EMV/

SINUMERIK, SIROTEC, SIMODRIVE EMC Installation Guide Planning Guide (HW) Order No.: 6FC5 297-0AD30-0BP1

(06.99 Edition)

/PHC/

SINUMERIK 810D Configuring Manual (HW) Order No.: 6FC5 297-4AD10-0BP0

(10.00 Edition)

/PHD/

SINUMERIK 840D NCU 561.2573.2 Configuring Manual (HW) Order No.: 6FC5 297-6AC10-0BP0

(10.00 Edition)

/PHF/

SINUMERIK FM-NC NCU 570 Configuring Manual (HW) Order No.: 6FC5 297-3AC00-0BP0

(04.96 Edition)

/PMH/

SIMODRIVE Sensor Measuring System for Main Spindle Drives Configuring/Installation Guide, SIMAG-H (HW) Order No.: 6SN1197-0AB30-0BP0

(05.99 Edition)

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B References

c) Software

/FB1/

SINUMERIK 840D/840Di/810D/FM-NC Description of Functions, Basic Machine (Part 1) (10.00 Edition) (the various sections are listed below) Order No.: 6FC5 297-6AC20-0BP0 A2 A3 B1 B2 D1 D2 F1 G2 H2 K1 K2 K4 N2 P1 P3 R1 S1 V1 W1 Various Interface Signals Axis Monitoring, Protection Zones Continuous Path Mode, Exact Stop and Look Ahead Acceleration Diagnostic Tools Interactive Programming Travel to Fixed Stop Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control Output of Auxiliary Functions to PLC Mode Group, Channel, Program Operation Mode Axes, Coordinate Systems, Frames, Actual-Value System for Workpiece, External Zero Offset Communication EMERGENCY STOP Transverse Axes Basic PLC Program Reference Point Approach Spindles Feeds Tool Compensation

/FB2/

SINUMERIK 840D/840Di/810D(CCU2)/FM-NC Description of Functions, Extended Functions (Part 2) (10.00 Edition) including FM-NC: Turning, Stepper Motor (the various sections are listed below) Order No.: 6FC5 297-6AC30-0BP0 A4 B3 B4 F3 H1 K3 K5 L1 M1 M5 N3 N4 P2 P5 R2 S3 S5 S6 S7 T1 W3 W4 Digital and Analog NCK I/Os Several Operator Panels and NCUs Operation via PG/PC Remote Diagnostics Jog with/without Handwheel Compensations Mode Groups, Channels, Axis Replacement FM-NC Local Bus Kinematic Transformation Measurement Software Cams, Position Switching Signals Punching and Nibbling Positioning Axes Oscillation Rotary Axes Synchronous Spindles Synchronized Actions (up to and including SW 3) Stepper Motor Control Memory Configuration Indexing Axes Tool Change Grinding

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/FB3/

SINUMERIK 840D/840Di/810D(CCU2)/FM-NC Description of Functions, Special Functions (Part 3) (10.00 Edition) (the various sections are listed below) Order No.: 6FC5 297-6AC80-0BP0 F2 G1 G3 K6 M3 S8 T3 V2 W5 TE1 TE2 TE3 TE4 TE5 TE6 3-Axis to 5-Axis Transformation Gantry Axes Cycle Times Contour Tunnel Monitoring Coupled Motion and Leading Value Coupling Constant Workpiece Speed for Centerless Grinding Tangential Control Preprocessing 3D Tool Radius Compensation Distance Control Analog Axis Master-Slave for Drives Transformation Package for Handling Setpoint Exchange MCS Coupling

/FBA/

SIMODRIVE 611D/SINUMERIK 840D/810D Description of Functions, Drive Functions (the various sections are listed below) Order No.: 6SN1 197-0AA80-0BP6 DB1 DD1 DD2 DE1 DF1 DG1 DM1 DS1 D1

(10.00 Edition)

Operational Messages/Alarm Reactions Diagnostic Functions Speed Control Loop Extended Drive Functions Enable Commands Encoder Parameterization Calculation of Motor/Power Section Parameters and Controller Data Current Loop Control Monitors/Limitations

/FBAN/

SINUMERIK 840D/SIMODRIVE 611 digital Description of Functions ANA Module Order No.: 6SN1 197-0AB80-0BP0

(02.00 Edition)

/FBD/

SINUMERIK 840D Description of Functions Digitizing Order No.: 6FC5 297-4AC50-0BP0 DI1 DI2 DI3 DI4

(07.99 Edition)

Start-Up Scanning with Tactile Sensors (scancad scan) Scanning with Lasers (scancad laser) Milling Program Generation (scancad mill)

B-254

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B References

/FBDN/

CAM Integration DNC NT-2000 Description of Functions System for NC Data Management and Data Distribution (05.00 Edition) Order No.: 6FC5 297-6AE50-0BP0

/FBFA/

SINUMERIK 840D/840Di/810D Description of Functions ISO Dialects for SINUMERIK Order No.: 6FC5 297-6AE10-0BP0

(10.00 Edition)

/FBHLA/

SINUMERIK 840D/SIMODRIVE 611 digital Description of Functions HLA Module Order No.: 6SN1 197-0AB60-0BP1

(08.99 Edition)

/FBMA/

SINUMERIK 840D/810D Description of Functions ManualTurn Order No.: 6FC5 297-5AD50-0BP0

(02.00 Edition)

/FBO/

SINUMERIK 840D/810D/FM-NC Description of Functions Configuring of Operator Interface OP 030 (the various sections are listed below) Order No.: 6FC5 297-3AC40-0BP0 BA EU PS PSE IK

(03.96 Edition)

Operators Guide Development Environment (Configuring Package) Online only: Configuring Syntax (Configuring Package) Introduction to Configuring of Operator Interface Screen Kit: Software Update and Configuration

/FBP/

SINUMERIK 840D Description of Functions C-PLC Programming Order No.: 6FC5 297-3AB60-0BP0

(03.96 Edition)

/FBR/

SINUMERIK 840D/810D Description of Functions SINCOM Computer Link Order No.: 6FC5 297-5AD60-0BP0 NFL NPL Host Computer Interface PLC/NCK Interface

(02.00 Edition)

/FBSI/

SINUMERIK 840D / SIMODRIVE Description of Functions SINUMERIK Safety Integrated (05.00 Edition) Order No.: 6FC5 297-5AB80-0BP1

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07.2000

/FBSP/

SINUMERIK 840D/810D Description of Functions ShopMill Order No.: 6FC5 297-5AD80-0BP1

(08.00 Edition)

/FBST/

SIMATIC FM STEPDRIVE/SIMOSTEP Description of Functions Order No.: 6SN1 197-0AA70-0YP3

(11.98 Edition)

/FBSY/

SINUMERIK 840D/840Di/810D(CCU2) Description of Functions Synchronized Actions for Wood, Glass, Ceramics, Presses Order No.: 6FC5 297-6AD40-0BP0

(10.00 Edition)

/FBTD/

SINUMERIK 840D/810D Description of Functions Tool Information SINTDI with Online Help Order No.: 6FC5 297-5AE00-0BP0

(04.99 Edition)

/FBU/

SIMODRIVE 611 universal Description of Functions (05.00 Edition) Closed-Loop Control Component for Speed Control and Positioning Order No.: 6SN1 197-0AB20-0BP3

/FBW/

SINUMERIK 840D/840Di/810D Description of Functions Tool Management Order No.: 6FC5 297-5AC60-0BP2

(07.00 Edition)

/HBI/

SINUMERIK 840Di Manual Order No.: 6FC5 297-5AE60-0BP0

(06.00 Edition)

/IK/

SINUMERIK 840D/810D/FM-NC Screen Kit MMC 100/Unit Operator Panel (06.96 Edition) Description of Functions: Software Update and Configuration Order No.: 6FC5 297-3EA10-0BP1

/KBU/

SIMODRIVE 611 universal Short Description Closed-Loop Control Component for Speed Control Order No.: 6SN1 197-0AB40-0BP3

(05.00 Edition)

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B References

/PJLM/

SIMODRIVE Planning Guide Linear Motors (05.00 Edition) (on request) ALL General Information about Linear Motors 1FN1 1FN1 Three-Phase AC Linear Motor 1FN3 1FN3 Three-Phase AC Linear Motor CON Connections Order No.: 6SN1 197-0AB70-0BP1

/PJM/

SIMODRIVE Planning Guide Motors Three-Phase AC Motors for Feed and Main Spindle Drives Order No.: 6SN1 197-0AA20-0BP4

(09.00 Edition)

/PJMS/

SIMODRIVE Planning Guide 1FE1 Synchronous Built-In Motors Three-Phase AC Motors for Main Spindle Drives Order No.: (on request)

(03.00 Edition)

/PJU/

SIMODRIVE 611-A/611-D Planning Guide Inverters Transistor PWM Inverters for AC Feed Drives and AC Main Spindle Drives Order No.: 6SN1 197-0AA00-0BP4

(08.98 Edition)

/POS1/

SIMODRIVE POSMO A (02.00 Edition) Distributed Positioning Motor on PROFIBUS DP, User Manual Order No.: 6SN2197-0AA00-0BP1

/POS2/

SIMODRIVE POSMO A Installation Instructions (enclosed with POSMO A) Order No.: 462 008 0815 00

(12.98 Edition)

/POS3/

SIMODRIVE POSMO SI/CD/CA Distributed Servo Drive Technology, User Manual Order No.: 6SN2197-0AA20-0BP0

(09.00 Edition)

/S7H/

SIMATIC S7-300 Manual: Assembly, CPU Data (HW) Reference Manual: Module Data Order No.: 6ES7 398-8AA03-8AA0

(10.98 Edition)

/S7HT/

SIMATIC S7-300 Manual: STEP 7, Basic Information, V. 3.1 Order No.: 6ES7 810-4CA02-8AA0

(03.97 Edition)

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07.2000

/S7HR/

SIMATIC S7-300 Manual: STEP 7, Reference Manuals, V. 3.1 Order No.: 6ES7 810-4CA02-8AR0

(03.97 Edition)

/S7S/

SIMATIC S7-300 FM 353 Step Drive Positioning Module Order in conjunction with Configuring Package

(04.97 Edition)

/S7L/

SIMATIC S7-300 FM 354 Servo Drive Positioning Module Order in conjunction with Configuring Package

(04.97 Edition)

/S7M/

SIMATIC S7-300 (10.99 Edition) FM 357 Multi-Axis Module for Servo and Stepper Drives Order in conjunction with Configuring Package

/SHM/

SIMODRIVE 611 Manual Single-Axis Positioning for MCU 172A Order No.: 6SN 1197-4MA00-0BP0

(01.98 Edition)

/SP/

SIMODRIVE 611-A/611-D, SimoPro 3.1 Program for Configuring Machine-Tool Drives Order No.: 6SC6 111-6PC00-0AAj Order from: WK Frth

d) Installation and start-up /IAA/


SIMODRIVE 611A Installation and Start-Up Guide Order No.: 6SN 1197-0AA60-0BP5

(09.00 Edition)

/IAC/

SINUMERIK 810D Installation and Start-Up Guide (10.00 Edition) (incl. description of SIMODRIVE 611D start-up software) Order No.: 6FC5 297-4AD20-0BP0

/IAD/

SINUMERIK 840D/SIMODRIVE 611D Installation and Start-Up Guide (10.00 Edition) (incl. description of SIMODRIVE 611D start-up software) Order No.: 6FC5 297-6AB10-0BP0

/IAF/

SINUMERIK FM-NC Installation and Start-Up Guide Order No.: 6FC5 297-3AB00-0BP0

(04.96 Edition)

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B References

/IAM/

SINUMERIK 840D/840Di/810D MMC/HMI Installation and Start-Up Guide Order No.: 6FC5 297-6AE20-0BP0 IM1 IM3 IM4 HE1 BE1

(10.00 Edition)

Start-Up Functions for the MMC 100.2 Start-Up Functions for the MMC 103 Start-Up Functions for the HMI Advanced (PCU 50) Online Help Supplement Operator Interface

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B References

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Index
Basic settings for operator panel display resolution, 6-140 language, 6-140 protection levels, 6-140 screen, 6-140 V24 interfaces, 6-140 Battery connection, 2-38 Battery replacement, 12-234 Battery voltage monitoring, 2-38 BIOS-setup, MMC102, 5-80 Booting booting of FM-NC (NCU 570.2), 5-78 booting of machine control panel, 5-81 booting of MMC, 5-81 booting of PLC-CPU, 5-79 components involved in booting, 5-77 operator control and display elements, 5-75 Booting of entire system, 5-76 Booting of system software, 5-75 Bus addresses, 3-55

A
Abortion of MD import, 11-200 Acceleration characteristics with breakpoint, 6-121 Accleration characteristic with breakpoint, activation, 6-122 Address/switch settings, 5-74 Alarm text files for MMC, alarm numbers, 8-173 Alarm text files for MMC 100/100.2, files, 8-169 Alarm text files for MMC 102/103, 8-170 configuration in mbdde.ini, 8-170 example, 8-172 Alarm text files for MMC100/100.2, 8-168 Alarm text languages, 8-171 Alarm texts for MMC 102/103, editor, 8-171 Alarm texts/message texts, 8-168 APP_INST.EXE, 12-216 Applications of tool box, 13-237 Area-specific archive data, 11-192 Area-specific archiving, 11-190 Assessing machine data via part program, 13-238 data identifiers, 13-238 Axes and spindles, 6-105 testing, 9-179, 9-180 Axis and spindle dry run, 9-177 preconditions, 9-178 Axis configuration, 6-105 extension to 5th axis, 6-139 Axis data, 6-109 Axis enabling, 9-178 Axis extension, 6-139 Axis start-up encoder matching, 6-111 monitoring, 6-129 reference point approach, 6-135 setpoint routing, 6-120 testing the axis, 9-179 velocity/speed matching, 6-121 Axis start-up data, control data, 6-124

C
Checking the loop gain, 6-126 Components involved in booting, 5-77 Configuration basic settings for operator panel, 6-140 changing memory areas, 6-96 general, 6-92 internal calculation resolutions, 6-95 switchover from metric to inch system, 6-93 Configuration and machine data of local P bus of FM-NC, 6-141 FM 354 as 5th axis, 6-141 inputs/outputs, 6-141 Connector pin assignment FM 354, 2-35 FM-NC, 2-30 Control data, 6-124 COROS OP 27 operator interface, 2-52 CPU, MPI multi-point interface, 7-163 CPU operating status for FM-NC start-up, 7-163 cyclic operation, 7-163 reset, 7-164 restart, 7-164

B
Basic PLC program, 13-237

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Index-261

C General Index

07.2000

CPU314 positions of mode switch, 7-160 status and error displays, 7-162 CPU318, 12-230 MMC configuration, 12-231 rack-slot addresses, 12-231 settings of switch S3 on MCP, 12-230 STEP7, 12-230 Cycle alarms, 11-189

H
Hand-held unit (HHU), 2-51 default setting for FM-NC, 2-51 Handling machine and setting data, 6-85 Hardware replacement, 12-230 hardware replacement CPU, 12-233 hardware replacement FM-NC, 12-233 Hardware requirements, 3-55

D
Data identifiers, 13-238 Data saving, 11-187 series start-up, 11-189 Data saving via MMC100/100.2, 11-189 Data saving via MMC102/103, 11-193 Data type, 6-86 Displaying unassigned SRAM and DRAM, 6-99 Documentation, 1-17 Drive optimization aim, 10-184 checking the speed control loop, 10-185 overview, 10-184 procedure, 10-184

I
Initial start-up, 6-100 initialize system, 6-100 user data for operator panel, 6-100 Initialization of system, 6-91 FM-NC, 6-91 MMC100, 6-91 Input of machine data, 6-84 Installation of MMC100/100.2 application diskette, 12-216 Installation via PC/PG to MMC102/103, 12-226 Integration of FM-NC module in the S7-300 PLC, 2-24 Interface for customer operator panel, 2-50 default settings of switch S3, 2-50 Interfaces machine control panel, 2-46 operating elements of MMC 100, 2-41 operating elements of MMC 100.2, 2-42 operating elements of MMC 102/103, 2-44 operator panel with MMC, 2-40 operator panel with MMC 102/103, 2-43 operator panel with PCI adapter, 2-45 Interfaces NCU 570, memory module interface, 2-27

E
Editor, 8-169, 8-171 EMC and ESD measures, 4-69 Encoder matching actual value encoder on spindle, 6-116 actual value processing, 6-116 linear measuring systems, 6-115 SSI-encoder, 6-113 Encoder matching (axis), 6-111 Encoder matching (spindles), 6-145 Equipment and accessories, 1-16 Erasure of SRAM through MD change, 6-98 Evaluation of line checksums, 11-199

L
Line checksums, 11-199 Line checksums and MD numbers in MD files, 11-199 Loading archiving data, 11-191 Loading of scaling machine data, 11-202 Local P bus, 2-24, 6-141

F
FM 254 interfaces, drive interface, 2-33 FM 354, as 5th axis, 6-139 FM 354 interfaces I/O interface, 2-33 measuring system interfaces, 2-33 SIMATIC interface, 2-33

M
Machine and setting data, 6-84, 6-85 data areas, 13-238 default value, 6-86 unit, 6-85 value range, 6-86

G
General preparations, 1-15

Index-262

Siemens AG 2000 All Rights Reserved SINUMERIK FM-NC Installation and StartUp Guide (IAF) 07.2000 Edition

07.2000

C General Index

Machine control panel, settings for CPU318, 12-230 Machine control panel OP032S default settings of switch S3, 2-48 possible settings S3, 2-49 Machine data numbers, 11-200 Measures to protect ESD-sensitive components, 4-71 Measures to suppress interference, 4-70 Memory areas, 6-96 Memory configuration, 6-96 hardware configuration, 6-96 MMC 100.2, 2-42 MMC 102/103, 2-43 Modulo counter, 6-134 Monitoring functions axis, 6-129 automatic drift compensation, 6-134 by means of hardware limit switches, 6-130 contour monitoring, 6-132 encoder monitoring, 6-133 modulo counter, 6-134 stepper motor rotation monitoring with BERO, 6-134 velocity limitation, 6-132 velocity monitoring, 6-132 Monitoring functions spindles, 6-151 More than one language, 8-168 MPI networking rules, 3-54

P
PCI adapter, 2-45 PLC general reset, 5-79 PLC restart, 5-79 PLC start-up, 7-155 COMPLETE RESTART start-up mode, 7-158 PLC applications, 7-156 structure, 7-157 tool box, 7-156 PLC-CPU display elements, 5-75 Power On, 5-74 Power On and Power-Up, 5-73 Power On sequence, 5-74 Power supply, FM-NC, 2-36, 2-37 Prerequisite for start-up, basic machine data, 1-19 Problems during booting, 5-81 MMC 100/100.2, 5-81 MMC 102/103, 5-81 Properties of line checksums, 11-199 Protection level strategy, 6-87 Protection levels 03, 6-87 Protection levels 47, 6-88

R
Rack-slot addresses, 12-231 Reading in area-specific archive data, 11-192 Reading in series start-up files, 11-191 Reference cam calibration, 6-135 Reference point approach, 6-135 with distance-coded reference marks, 6-137 with incremental mreasuring systems, 6-136 Reference point approach for stepper motors, 6-138 synchronization with BERO reference point, 6-138 Requirements to be fulfilled prior to start-up documentation requirements, 1-17 equipment and accessory requirements, 1-16 machine data, 1-19 software requirements, 1-16 start-up, 1-18 visual inspection/wiring, 1-18 Requirements to be fulfilled prior to startup, jumper connections, 1-18

N
NC variable selector, 13-237 NCU 570 interfaces drive interface, 2-27 I/O interface, 2-27 measuring system interfaces, 2-27 power supply connection, 2-27 SIMATIC interface, 2-27

O
O & M for FM-NC with OP 27, 13-239 configuring, 13-239 Operational messages, 11-189 Operator control functions for start-up, 6-89 Operator controls, 2-27, 5-75 start-up switch, 2-27 start-up switch on FM-NC, 5-75 start-up switch on PLC-CPU, 5-75 Operator inputs for PLC general reset, 5-79 Overview of connections for FM 354, 2-32 for FM-NC, 2-26 Overview of machine and setting data, 6-84 Overview of organization blocks, OBs, FBs, DBs, 7-165

S
Saving altered values, 11-203 Series start-up/area-specific archiving, 11-188 Servo gain, 6-125 Setpoint routing axis, 6-120 Settings, MPI-bus, example of a configuration, 3-60 Settings, MPI nodes, 3-53

Siemens AG 2000 All Rights Reserved SINUMERIK FM-NC Installation and StartUp Guide (IAF) 07.2000 Edition

Index-263

C General Index

07.2000

Shielded signal leads, 4-70 Software upgrading MMC 100.2 installation via PCMCIA, 12-221 installation via PCMCIA with modifications, 12-222 installation via PCMCIA without modifications, 12-221 Software/hardware replacement, 12-205 Speeds and setpoint adjustment spindles, 6-147 Spindle data, 6-143 axis mode, 6-143 general machine data definitions, 6-144 speeds and setpoint adjustment spindles, 6-147 spindle operating modes, 6-143 spindle synchronization, 6-150 Spindle start-up spindle definition, 6-143 spindle positioning, 6-149 testing the spindle, 9-180 Standard application, 3-55 Standard files, 8-170 Standard MD sets, 13-237 Start-up of functions, 6-153 Start-up sequence, 5-74 Start-up switch, 2-27, 5-75 FM-NC, 2-27, 5-75 PLC-CPU, 5-75 Starting up a series machine, user data for operator panel, 6-104 STEP7, 3-55 Stepper motor control loop, 6-126 Stepper motor rotation monitoring with BERO, 6-134 Storage of text files, 8-170 Syntax for alarm text files, 8-173 Syntax for alarm texts, PLC alarm texts, 8-175

T
Text for error messages, operational messages and cycle alarms, 11-189 Tool box, 13-236 Tool box software package, 13-236 application, 13-237 basic PLC program, 13-237 contents, 13-236 hardware requirements, 13-236 NC variable selector, 13-237 software requirements, 13-236 standard MD sets, 13-237 Transfer of SW from PC/PG disk to MMC, 12-229 Traversing direction, 6-125

U
Upgrading FM-NC software, 12-206 Upgrading MMC 100/100.2 software, installation with modifications, 12-220 Upgrading MMC 100/100.2 software as supplied, 12-208 installation of MMC 100/100.2 system diskette, 12-210 installation procedure, 12-210 installation software, 12-208 Upgrading MMC 102/103 software, 12-225 installation via MMC floppy drive, 12-225 User files, 8-171

V
Velocity/speed matching axis, 6-121 acceleration characteristic with breakpoint, 6-121 Visual inspection, 5-74

Index-264

Siemens AG 2000 All Rights Reserved SINUMERIK FM-NC Installation and StartUp Guide (IAF) 07.2000 Edition

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


General Documentation
SINUMERIK SIROTEC SIMODRIVE Accessories

User Documentation

SINUMERIK 840D/810D/ FM-NC

SINUMERIK 840D/840Di/ 810D/ FM-NC/611 Catalog Ordering Info NC 60 *)

SINUMERIK 840D/810D/ FM-NC

SINUMERIK 840D/810D

SINUMERIK 840D/840Di/ 810D/ FM-NC Diagnostics Guide *)

SINUMERIK 840D/840Di/ 810D/ FM-NC Operators Guide Short Guide Operators Guide *)

Brochure

Catalog Accessories NC-Z

AutoTurn Short Guide Programming (1) Setup (2)

Operators Guide HT 6 (+ 840Di) HPU Unit Operator Panel

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SINUMERIK 840D/840Di/ 810D/ FM-NC Program. Guide Short Guide Fundamentals *) Advanced *) Cycles Measuring Cycles

SINUMERIK 840D/810D

SINUMERIK 840Di

SINUMERIK 840D/810D

SINUMERIK 840D/ 840Di/ 810D Description of Functions Synchronized Actions

SINUMERIK 840D/810D

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Operators Guide System Overview ManualTurn Short Guide ManualTurn ShopMill Short Guide ShopMill

Description of Functions ManualTurn ShopMill

Descr. of Functions Computer Link Tool Data Information System

Configuring (HW) *) FM-NC 810D 840D

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SINUMERIK SIMODRIVE 611D 840D/810D

SINUMERIK 840D/840Di/ 810D/ FM-NC Operator Components (HW) *)

SINUMERIK 840D/840Di/ 810D/ FM-NC

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SINUMERIK 840D/ 840Di/ 810D Description of Functions Tool Management

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Description of Description of Functions Functions Drive Functions *) Basic Machine *) Extended Functions Special Functions

Configuring Kit MMC 100/101 Configuring Syntax Development Kit

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Description of Functions Operator Interface OP 030

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