SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020)

Configuring the NCU

3.2 Insert NX module

Note

This setting cannot be undone

Please note that once set, the DP address of an NX cannot be subsequently changed. The

NX modules must be connected to the DRIVE-CLiQ socket of the NCU in the real wiring that

corresponds to the permanently assigned DP address.

If you have incorrectly set the DP address of an NX, delete this NX from the project and add

a new one.

The DP address of the NX module is specified in accordance with your setting and the

appropriate I/O addresses of the telegrams are set automatically.

Note

Default I/O addresses of the telegrams

Depending on the set DP address, the appropriate I/O addresses of the telegrams are set

automatically.

Change this setting only when the I/O addresses of your telegrams differ from the default

setting!

You can also find information on the wiring between NCU and NX in the properties of the DP

Integrated interface on the NCU and NX under "PROFIBUS address".

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.2 Insert NX module

Result

The NX module has been inserted into the project and connected to an NCU.

Note

Handling the NX

● If NX modules were connected with the NCU and the NCU is subsequently deleted, the NX

modules are kept in the project as unconnected slave modules. They can be subsequently

assigned to another NCU. The parameter settings of the NX modules are retained.

● If the DP address of the NX is specified, then the I/O addresses matching the default setting

on the NCK side are entered.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.3 Replacing a device or upgrading firmware

3.3

Replacing a device or upgrading firmware

3.3.1

Replacing the NCU

You can replace different NCUs. By replacing a device within the same device family, you can

change to another NCU with a different expansion stage, with a different firmware version and

other properties.

Rules for replacing an NCU

● It is not possible to replace an NCU with another controller of a different device family.

(You may be able to perform a migration.)

● It is not possible to replace an NCU with an NCU of the same project stage with the same

or previous firmware version.

● If you replace an NCU by another NCU, then automatically all of the integrated

subcomponents of the NCU (SINAMICS Integrated, PLC, NCK, CP, HMI) are also replaced.

● If you have connected NX modules to an NCU and replace the NCU, the connection

between the devices remains, provided the used interfaces exist on both NCUs. If the used

interface on the replaced NCU does not exist, the connection will be separated.

3.3.2

Replacing an NX

You can replace a device with a different NX type. The version of an NX is determined by the

version of the NCU. Correspondingly, for a connected NX, you can only replace the type: An

NX10.3 can be replaced by an NX15.3 and vice versa.

Rules for replacing an NX

If you replace NX10.3 with NX15.3, please note that NX10.3 only supports a maximum of three

servo axes, whereas NX15.3 supports up to six servo axes.

For more information about the configuration of the drive objects, see Adapting the number of

drives (Page 129)

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.3 Replacing a device or upgrading firmware

3.3.3

Basic procedure

Note

Changing the firmware version of the configured NCU or NX

The firmware version of the configured hardware and the real hardware must match. Otherwise

it is possible that you configure version-dependent non-detectable properties in the TIA Portal

that the real hardware does not support.

To replace the firmware version for a group (NCU with NX), the replacement on the NCU must

be initiated. Interconnected NXs are then also replaced automatically.

Procedure

To replace a device, proceed as follows:

1. Switch to the device view.

2. Select the device that you want to replace in the "<Select device>" drop-down list.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.3 Replacing a device or upgrading firmware

5. Select the required firmware version in the "Version" drop-down list.

Note

Solving compatibility problems

If the two devices are not compatible or only have restricted compatibility, you can find

further information in Section "Compatibility information".

If required, click "Cancel" and correct the problems before continuing.

6. Confirm the dialog with "OK".

Result

The device has been replaced.

If you uploaded the firmware version, your telegram configuration was retained. Note that the

default telegram I/O addresses of telegram 701 have changed as of V4.7 SP2.

See also: Telegram configuration and I/O addressing schematics, Resetting telegrams

Further information

Further information on device replacement can be found in the information system of the TIA

Portal, keyword "Replacing".

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.4 Establish the communication connection

3.4

Establish the communication connection

Procedure

To establish a communication connection between two devices, proceed as follows:

1. In the "Online" menu, select the "Accessible devices" command.

2. In the drop-down lists "Type of PG/PC interface" and "PG/PC interface", search for the

interface used.

If no devices are accessible at an interface, the connecting line between the PG/PC and the

device is interrupted. If devices are accessible, the connecting line is shown and the devices

accessible at the selected interface of the PG/PC are displayed in a list.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.4 Establish the communication connection

3. If you have connected a new device in the meantime, click the "Refresh" button to refresh

the list of accessible devices.

4. Using "Display", transfer to the project navigator the device that has been found in the

"Online accesses" folder.

The subfolder of the interface to which the selected device is connected is selected in the

project tree.

Note

Several identical devices

If several identical devices can be accessed from the PG, by clicking on the "Flash LED"

button you can then display which device corresponds to the entry in the list of accessible

devices.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.5 Load hardware configuration into the PLC

3.5

Load hardware configuration into the PLC

Requirement

● The hardware configuration is compiled.

● A communication connection exists between the PG/PC (TIA Portal) and the NCU.

Note

Loading configurations to simulated environments

If you want to use the configuration in a simulated environment, you must activate the

simulation capability in the project properties before you load the configuration into the

simulated environment or compile the hardware/software.

Note

General reset before loading into a PLC with Safety Integrated plus (F-PLC)

If the actual hardware has been operated in Safety Integrated plus (F-PLC) mode and you now

want to load a configured hardware configuration with changed Safety Integrated mode, you

must perform a general reset of the PLC prior to the loading.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.5 Load hardware configuration into the PLC

Procedure

Proceed as follows to load the configured hardware configuration into the NCU:

1. In the project navigation, right-click the device name, e.g. "CNC_1", and select the

"Hardware configuration" command in the "Download to device" shortcut menu.

Note

Scope of the data to be downloaded

Alternatively, you can select one of the other commands to start downloading additional

data to the NCU in this step.

See TIA Portal help, keyword "General information on download".

The "Extended download" dialog opens.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.5 Load hardware configuration into the PLC

Figure 3-2

Dialog using the PLC of a SINUMERIK 840D sl as an example

2. Make the following settings in the "Extended download" dialog:

- PG/PC interface: Network card used, e.g. "Intel[R] Ethernet Connection I217-V"

- Connection with interface/subnet: Specific interface on the NCU or "Try all interfaces"

3. Click on "Start search" and then select the found PLC from "Compatible nodes in the target

subnet". Alternatively, you can specify an IP address directly in the "Compatible nodes in the

target subnet" list in the "Address" column.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.5 Load hardware configuration into the PLC

4. Confirm the download with "Load".

The "Download preview" dialog opens.

Figure 3-3

"Download preview" dialog

Note

Consistency check

Before the loading, the consistency of the download is checked. This means that a check is

made as to whether the parameterized hardware of the TIA Portal project matches the

hardware that has been actually installed.

Note

Adapt the IP address?

If the IP address of your PG/PC is located in a different subnet than the PLC, a dialog box

is displayed as to whether the IP address in the PG/PC should be adapted.

5. In the "Download preview" dialog, check the settings and click "Load" to confirm the input.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

3.6

Creating SINUMERIK PLC archives

3.6.1

Creating a SINUMERIK PLC archive

Introduction

Unlike TIA Portal project archives (*.zap*), SINUMERIK PLC archives (*.arc) contain

precompiled commissioning data that you can import directly to the NCU (e.g. with SINUMERIK

Operate).

A SINUMERIK archive offers the following possibilities:

● Direct image of the data of a PLC taken into operation in a file

● Simplification of the series commissioning

● Commissioning of the PLC with the SINUMERIK archive directly on the NCU without using

a PG/PC, TIA Portal or STEP 7

● Transfer of the data to the NCU without establishing an online connection to the actual

hardware

SINUMERIK archives (*.arc) have nothing in common with TIA Portal project archives (*.zap*).

TIA Portal project archives are compressed files, each of which contains a complete project,

including the complete folder structure of the project. (See: Online help, keyword "TIA Portal

project archive").

You can create a PLC archive with the SINUMERIK Toolbox and load it to the NCU (e.g. with

SINUMERIK Operate) in order to simplify the actual commissioning.

You can create the following SINUMERIK archives:

Archive type

Command in the TIA

Data included

Portal

PLC hardware upgrade ar-

Only hardware...

● Hardware data (SDB) of the PLC

chive (Page 48)

PLC commissioning ar-

Hardware and all pro-

● Hardware data (SDB) of the PLC

chive (Page 50)

gram blocks...

● Program blocks of the PLC

● Hardware data (SDB) of the CP

PLC reload archive

Selected program

● Program blocks of the PLC

(Page 52)

blocks...

Note

Editing SINUMERIK archives (.arc)

After you have created a SINUMERIK archive, you can open and edit it with various tools.

See: External tools for SINUMERIK archives (Page 48)

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

Note

Handling of F-blocks for SINUMERIK archives

Because F-blocks must always be saved together with the associated hardware configuration,

F-blocks cannot be saved in reload archives.

Further information

● General information on NCU series commissioning archives can be found in Section

"Saving and managing data" of the "SINUMERIK 840D sl, SINAMICS S120 Commissioning

CNC:NCK, PLC, Drive for TIA" Commissioning Manual.

● Information about the differences of the archives that were created with STEP 7 V5.x is

available at "Handling SINUMERIK archives".

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

3.6.2

Available SINUMERIK archive types

There are different types of archives which you can create in different ways. Essentially, you

cannot use the TIA Portal to create archives that contain NC, drive or HMI data. However, you

can save a finely granular selection of translated program blocks as an archive in the TIA Portal

with the "PLC reload archive".

Archive type

Command in the TIA

Command in SINU-

Data contained

Portal

MERIK Operate

NCU commissioning ar-

Softkey "Commission-

The contained data can be configured as fol-

chive

ing archive", option but-

lows in the dialog:

ton "Create commis-

● NC data

sioning archive"

- With or without compensation data

- With or without compile cycles

● PLC data (all or none)

● Drive data (ACX format or ASCII format)

● HMI data (all HMI data or a configurable

selection)

PLC commissioning ar-

Hardware and all pro-

Softkey "Commission-

● Hardware data (SDB) of the PLC

chive (Page 50)

gram blocks...

ing archive", option but-

● Program blocks of the PLC

ton "Create commis-

● Hardware data (SDB) of the CP

sioning archive"; only

enable "PLC data" in

the dialog

PLC hardware upgrade

Only hardware...

Softkey "Commission-

● Hardware data (SDB) of the PLC

archive (Page 48)

ing archive", option but-

● Hardware data (SDB) of the CP

ton "Create PLC hard-

ware upgrade archive

(only SDBs)"

PLC reload archive

Selected program

● Program blocks of the PLC

(Page 52)

blocks...

(configurable in the dialog)

Complete archive

<Ctrl> + <Alt> + S

All data (not configurable)

Original status archive

Softkey "Commission-

Original status (factory setting) of all subcom-

ing archive", option but-

ponents or a selection of specific subcompo-

ton "Create archive

nents and data (configurable in the dialog)

original status"

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

Note

Distinguishing between TIA Portal project archives and SINUMERIK archives

SINUMERIK archives (*.zap14) have nothing in common with TIA Portal project archives

(*.arc):

● SINUMERIK archives contain precompiled commissioning data that you can import directly

to the NCU.

● TIA Portal project archives are compressed files, each of which contains a complete project,

including the complete folder structure of the project.

See: TIA Portal online help, search term "TIA Portal project archive".

3.6.3

External tools for SINUMERIK archives

Overview

Various tools are available to open and edit the created SINUMERIK archives:

Tool

Purpose

Available from

SinuCom ARC

Editing of SINUMERIK archives

SinuCom commissioning/service tools

in the SIEMENS Industry Mall (https://

eb.automation.siemens.com/

mall/en/us/Catalog/Product/

6FC5250-7AY00-7AG0)

Create MyConfig

Extensive software, including functions

Create MyConfig in the SIEMENS In-

such as:

dustry Mall (https://

eb.automation.siemens.com/

● Data comparison of SINUMERIK

mall/en/us/Catalog/Products/

archives

10167653)

● Manipulation of SINAMICS data in

drive archives

● Creation of a SINAMICS archive

with defined topology

3.6.4

Creating a PLC hardware upgrade archive

Requirement

● The data carrier to be used or storage location is available and has sufficient storage space.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

Procedure

To create a hardware upgrade archive, proceed as follows:

1. In the project tree, right-click the device name, e.g. "CNC_1", and select "Create

SINUMERIK archive > Hardware only" in the shortcut menu.

The "Create SINUMERIK archive" dialog opens.

Figure 3-5

"Create SINUMERIK archive" dialog with hardware

2. Make the required settings:

Element

Purpose

File name

Enter the desired file name of the SINUMERIK archive in the text field.

File extensions cannot be changed

The file extension (.arc) is not displayed and cannot be changed.

Path

Click Browse and select a directory, or enter the directory directly.

Default storage location for data export

The used path is shown as the default setting the next time you export an archive.

To specify the default setting for the data export in the settings, switch to "General >

General > Data exchange > Storage location for data export" in the settings.

Author

Name of the author or a person responsible for the project.

The default setting corresponds to the setting of the user name in the TIA Portal

under: "Extras > Settings > General > General settings > User name".

Comment

Input of a comment for the SINUMERIK archive.

As default setting, the comment field contains an entry whether the archive contains

only hardware or hardware and all program blocks.

3. Click "Create archive" to confirm your input.

Result

The SINUMERIK archive is created and stored in the path that you have specified.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

3.6.5

Creating a PLC commissioning archive

Requirement

● If possible, the "Program blocks" folder should not contain any program blocks of not

activated axes/spindles or the tool management.

You can also save unused program blocks in the archive, although this extends the time

required for creating and loading the archive.

● The data carrier to be used or storage location is available and has sufficient storage space.

Note

Handling of F-blocks for SINUMERIK archives

The handling of F-blocks depends on the used Safety Integrated mode:

● If Safety Integrated is inactive or Safety Integrated (SPL) is active, F-blocks are not stored

in the SINUMERIK archive.

● In Safety Integrated plus (F-PLC) mode, F-blocks are saved in PLC commissioning

archives.

Note the additional information in the Readme file for SINUMERIK Toolbox: "Start >

Siemens Automation > Documentation > Readmes > German".

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

Procedure

To create a PLC commissioning archive, proceed as follows:

1. In the project tree, right-click the device name, e.g. "CNC_1", and select "Create

SINUMERIK archive > Hardware and all program blocks" in the shortcut menu.

The "Create SINUMERIK archive" dialog opens.

Figure 3-6

"Create SINUMERIK archive" dialog with hardware data and program blocks

2. Make the required settings:

Element

Purpose

File name

Enter the desired file name of the SINUMERIK archive in the text field.

File extensions cannot be changed

The file extension (.arc) is not displayed and cannot be changed.

Path

Click Browse and select a directory, or enter the directory directly.

Default storage location for data export

The used path is shown as the default setting the next time you export an archive.

To specify the default setting for the data export in the settings, switch to "General >

General > Data exchange > Storage location for data export" in the settings.

Author

Name of the author or a person responsible for the project.

The default setting corresponds to the setting of the user name in the TIA Portal

under: "Extras > Settings > General > General settings > User name".

Comment

Input of a comment for the SINUMERIK archive.

As default setting, the comment field contains an entry whether the archive contains

only hardware or hardware and all program blocks.

3. Click "Create archive" to confirm your input.

Result

The SINUMERIK archive is created and stored in the path that you have specified.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

3.6.6

Creating a PLC reload archive

You can save the program blocks of the PLC as reload archive in the TIA Portal.

Note

F-blocks are not saved in reload archives

The F-blocks used in the SINUMERIK Safety Integrated plus (F-PLC) mode are not saved in

reload archives.

If you want to save F-blocks in a SINUMERIK archive, you can save them together with the

associated hardware configuration in a PLC commissioning archive.

Note

In the PLC reload archive, existing data blocks overwrite any CPU DBs during reading in

If you import into a PLC reload archive a CPU DBs that already exists on the control system, the

CPU DBs on the control system will always be overwritten. Therefore the option "Overwrite

existing blocks with identical number on the PLC for import" does not affect CPU-DB.

Therefore, do not store data blocks that already exist on the NCU as CPU DB in the PLC reload

archive.

If you have already overwritten CPU DBs, you can find further information in the information

system, keyword "Inconsistency in data blocks".

Requirement

● If possible, the "Program blocks" folder should not contain any program blocks of not

activated axes/spindles or the tool management.

Although you can save unused program blocks in the archive, this extends the time required

for creating and loading the archive.

● The data carrier to be used or storage location is available and has sufficient storage space.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

Procedure

To create a reload archive, proceed as follows:

1. You have several ways of selecting the program blocks to be archived:

- Select the desired program blocks in the project tree or in the project tree overview. Then

right-click one of the selected program blocks.

You can change the actual program blocks to be exported later in the "Create

SINUMERIK archive" dialog.

- Right-click the program blocks folder of the PLC or a higher-level folder.

You can select the program blocks to be exported later in the "Create SINUMERIK

archive" dialog.

2. Click "Selected program blocks" in the "Create SINUMERIK archive" in the shortcut menu.

The "Create SINUMERIK archive" dialog opens.

Figure 3-7

"Create SINUMERIK archive" dialog with expanded "Block selection" section

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring the NCU

3.6 Creating SINUMERIK PLC archives

3. Make the required settings:

Element

Purpose

Block selection

In the "Block selection" section, you can check your selection or select the

program blocks to be saved.

If you have organized program blocks as groups, they are displayed as an

expandable folder in the block selection.

File name

Enter the desired file name of the SINUMERIK archive in the text field.

File extensions cannot be changed

The file extension (.arc) is not displayed and cannot be changed.

Path

Click Browse and select a directory, or enter the directory directly.

Default storage location for data export

The used path is shown as the default setting the next time you export an

archive.

To specify the default setting for the data export in the settings, switch to

"General > General > Data exchange > Storage location for data export" in

the settings.

Author

Name of the author or a person responsible for the project.

The default setting corresponds to the setting of the user name in the TIA

Portal under: "Extras > Settings > General > General settings > User name".

Comment

Input of a comment for the SINUMERIK archive.

If the "Insert selected blocks as comment" checkbox is activated, all con-

tained program blocks are entered automatically with symbolic name and

block number.

Overwrite existing

If the checkbox is activated, existing program blocks with the same block

blocks with identical

number will be replaced on the NCU during the import of the archive.

number on the PLC

If the checkbox is deactivated, any program blocks of the archive with the

for import

same block number will not be imported.

Restart the PLC af-

If the checkbox is activated, the PLC will be restarted automatically after

ter import of the new

importing the archive.

program blocks

You can also deactivate the checkbox and, for example, make other instal-

lation or commissioning work before you manually restart the PLC or the

complete NCU.

4. Click "Create archive" to confirm your input.

Result

The SINUMERIK archive is created and stored in the path that you have specified.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1

General information about the PLC program

4.1.1

Introduction

The PLC program is constructed modularly. It comprises the two parts:

● PLC basic program

The PLC basic program organizes the exchange of signals and data between the PLC user

program and the NCK, HMI, and machine control panel components.

Use the appropriate PLC basic program depending on the firmware version of an NCU.

- SINUMERIK 840D sl PLC basic program V4.5.x.x

- SINUMERIK 840D sl PLC basic program V4.7.x.x

- SINUMERIK 840D sl PLC basic program V4.8.x.x

- SINUMERIK 840D sl PLC Basic Program V4.9.2.x

● PLC user program

The PLC user program is the user-specific part of the PLC program by which the PLC basic

program has been augmented or extended.

4.1.2

Execution structure

Overview

The following organization blocks contain the entry points for the appropriate parts of the PLC

basic program (and user program):

● OB100 [OB100] (Cold restart)

● OB1 [OB1] (Cyclic execution)

● OB40 [OB40] (Process interrupt)

● Asynchronous errors

- OB82 [OB82] (Diagnostics alarm)

- OB86 [OB86] (Module failure)

The RUN_UP [FB1] function block is the startup block of the PLC basic program. The call of

RUN_UP [FB1] in the OB100 [OB100] must be supplied with data.

The following figure illustrates the structure of the PLC program:

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

%DVLF SURJUDP

5HVWDUW

8VHU SURJUDP

0&3 VLJQDOV

%DVLF SURJUDP

+7b VLJQDOV

7RRO PDQDJHPHQW

6SLQGOH FRQWURO

6WDUW $683

8VHU SURJUDP

5HDG ZULWH WDJ

3, VHUYLFHV

6WDU GHOWD

'LVSOD\ FRQWURO

(UURU DQG RSHUDWLQJ

PHVVDJHV

%DVLF SURJUDP

+DUGZDUH LQWHUUXSW

8VHU SURJUDP

%DVLF SURJUDP

'LDJQRVWLF LQWHUUXSW

8VHU SURJUDP

%DVLF SURJUDP

5DFN IDLOXUH

8VHU SURJUDP

Figure 4-1

Structure of the PLC program

Cyclic operation (OB1)

From a chronological viewpoint, the PLC basic program runs ahead of the PLC user program.

The complete processing of the NCK-PLC interface is carried out in cyclic mode. A cyclic

monitoring function is activated between PLC and NCK once boot-up and the first OB1 cycle

have been completed. A PLC failure produces the "2000 Sign-of-life monitoring PLC" alarm in

SINUMERIK Operate.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Start-up behavior of the PLC

The PLC always starts up in RESTART mode, i.e. the PLC operating system runs OB100 after

initialization and starts cyclic operation at the beginning of OB1. No return is made to the

interruption point (for example, in the event of a power failure).

There are both retentive and non-retentive areas for the markers, timers and counters. The

areas are contiguous and are divided by a parameterizable limit, where the area with the higher-

value address range is defined as the non-retentive area. Data blocks are always retentive.

RESTART start type (OB100)

If the retentive area has no battery backup (backup battery is empty) start-up is prevented. The

following operations are performed during a cold restart:

● UStack, BStack and non-retentive flags, timers and counters are deleted

● The process output image (POI) is deleted

● Process and diagnostics alarms are canceled

● The system status list is updated

● Parameterization objects of modules (from SDB100 onwards) are evaluated or default

parameters are output to all modules in single-processor mode

● Cold restart (OB100) is executed

● The process input image (PII) is imported

● The command output inhibit (BASP) is canceled

Further information

The block descriptions and other information about the PLC basic program are contained in the

P3 section of the SINUMERIK 840D sl Basic Functions Manual. Basic PLC program.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

4.1.3

Using copy templates

Introduction

The "Global libraries" folder of the "Libraries" TaskCard contains the system library of the

SINUMERIK PLC program for your device version: "SINUMERIK 840D sl PLC basic program

V4.x.x.x".

Figure 4-2

Master copies of the SINUMERIK PLC program

Under the "Master copies" folder there are four subfolders with different contents. You can copy

the contents of these subfolders in their entirety or you can copy the individual objects as

needed.

● Using the Ctrl or shift key, you can select several objects of the same type and then copy

them.

● If you copy a master copies folder in its entirety (e.g. "840D sl PLC BP"), the folder structure

is imported, i.e. new groups (subfolders) are created (Page 82) in your "Program blocks"

folder.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Table 4-1

Use and content of the master copies of the PLC basic program

Folder

Purpose

Contents

840D sl PLC Ba-

This master copy is intended

The master copy contains all the blocks that you require for the maximum

sic Program

to create a completely new

configuration (31 axes, 10 channels).

project.

Use of axis/channel DB

If your machine is using fewer axes or channels, you can either copy only

the required blocks or you can delete the blocks that are not required in the

project tree after copying.

If you have blocks in your project that are not required, this increases,

for example, the time required for the loading or export of the PLC symbols.

Use of ALMSG_DB [DB2]

This master copy contains ALMSG_DB [DB2] in the variant Exten-

dAlMsg=False.

The used DB2 variant must match in the startup for parameterization of the

RUN_UP [FB1] in OB100 [OB100] (parameter ExtendAlMsg).

840D sl PLC Ba-

This master copy is used to

This master copy contains all the know-how-protected blocks that you re-

sic Program

upgrade blocks after the firm-

quire for the maximum configuration (31 axes, 10 channels).

(upgrade)

ware version of an NCU is up-

Blocks to be changed by the user are not included (no organization blocks

dated, i.e. if you have carried

and not FC12 [FC12], Diagnose [FB29], DB4 [DB4], DB5 [DB5]).

out a device replacement

Use of axis/channel DB

(Page 33) or a migration.

If your machine is using fewer axes or channels, you can either copy only

the required blocks or you can delete the blocks that are not required in the

project tree after copying.

If you have blocks in your project that are not required, this increases,

for example, the time required for the loading or export of the PLC symbols.

Use of ALMSG_DB [DB2]

This master copy contains ALMSG_DB [DB2] in the variant Exten-

dAlMsg=False.

The used DB2 variant must match in the startup for parameterization of the

RUN_UP [FB1] in OB100 [OB100] (parameter ExtendAlMsg).

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Folder

Purpose

Contents

ALMSG_DB_Ex

You need this master copy if

This master copy contains ALMSG_DB [DB2] in the variant Exten-

tendAlMsg

you use the PLC alarm exten-

dAlMsg=True (PLC alarm extension via AL_MSG [FC10]).

sion via AL_MSG [FC10] (Ex-

The used DB2 variant must match in the startup for parameterization of the

tendAlMsg=True).

RUN_UP [FB1] in OB100 [OB100] (parameter ExtendAlMsg).

Otherwise you use the DB2

variant "Exten-

dAlMsg=False", which is con-

tained in the two above-

named master copies folders.

External source

Contains master copies for

Contains the following master copies, from which you can generate the

files

different external sources

blocks named below:

(STL).

● bhg_db_awl

You can copy these sources

- strdat [DB<xy>]

into the folder "External sour-

● diagnose.awl

ces", e.g. under "CNC_1 >

PLC_1 > External sources".

- FB29 [FB29]

You edit objects in the "Exter-

- DB80 [DB80]

nal sources" folder using an

- DB81 [DB81]

external text editor, e.g. Mi-

crosoft Editor.

- FC99 [FC99]

See also: Create blocks from

● gpob840d.awl

external sources (Page 84)

- OB1 [OB1]

- OB100 [OB100]

- OB40 [OB40]

- OB82 [OB82]

- OB86 [OB86]

● mdeclist.awl

- DB75 [DB75]

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Note

Selecting the appropriate master copy for ALMSG_DB [DB2]

There are 2 different variants of the block ALMSG_DB [DB2]. The used DB2 variant

(ALMSG_DB [DB2]) must match in the startup for parameterization of the RUN_UP [FB1] in

OB100 [OB100] (parameter ExtendAlMsg).

● DB2 variant "ExtendAlMsg=False"

This variant is contained in the master copies folders "840D sl PLC Basic Program" and

"840D sl PLC Basic Program (upgrade)".

If you use the previous procedure (default value of the parameter ExtendAlMsg in RUN_UP

[FB1]), you do not need to explicitly copy the "ALMSG_DB_ExtendAlMsg" master copy.

● DB2 variant "ExtendAlMsg=True"

This variant is exclusively contained in the separate master copies folder

"ALMSG_DB_ExtendAlMsg".

If you use the extension of the PLC alarms via AL_MSG [FC10], you must use the right

master copy, i.e. copy it separately into your "Program blocks" folder.

Further information about the extension of the PLC alarms via AL_MSG [FC10] is available

under the keyword "ExtendAlMsg" in the Basic Functions Manual, in particular, in the

"Extensions of the PLC alarms via block FC 10" section.

Further information

● General information on handling libraries in the TIA Portal can be found in the TIA Portal

online help, Section "Using libraries".

● The block descriptions and other information about the PLC basic program is contained in

the SINUMERIK 840D sl Basic Functions Manual in the P3: Basic PLC program section.

4.1.4

Block listing as table

In the following, you will find a list of all of the blocks of the SINUMERIK PLC basic program that

are included in the supplied master copy "840D sl PLC Basic Program".

The master copy "840D sl PLC Basic Program (upgrade)" contains the same blocks, except for

blocks with user-specific adaptations.

Further information

● Information about other blocks of the basic program (e.g. blocks generated at runtime on the

NCU) or the operational principle of the basic program is contained in the SINUMERIK 840D

sl / 828D Basic Functions Manual.

● Information about the changed handling of specific blocks compared with STEP 7 V5.x is

available in the "Migrating SINUMERIK projects" help.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Table 4-2

Organization blocks (OB)

Address

Name

Description

Called PLC basic pro-

gram block

OB1

Cycle OBs are higher-level logic blocks in the program which are cy-

GP_HP [FC2]

clically processed and in which you can program instructions or call

additional blocks.

OB40

Hardware interrupt OBs interrupt the cyclic program processing due to

GP_PRAL [FC3]

a hardware event.

OB82

Diagnostic error interrupt OBs interrupt the cyclic execution of the pro-

GP_DIAG [FC5]

gram if the diagnostic-capable module for which the diagnostic inter-

rupt was enabled detects an error.

OB86

A rack or station failure OB is called, for example, in the event of failure

GP_DIAG [FC5]

of a rack or station in the distributed I/O.

OB100

Startup OBs are processed once when the mode of the CPU switches

RUN_UP [FB1] with

from STOP to RUN. After execution of the startup OB, the execution of

gp_par [DB7]

the cycle OB is started.

Table 4-3

Function blocks (FBs)

Address

Icon

Description

FB1

RUN_UP

The block configures and initializes the basic program, starts synchroniza-

tion between PLC and NCK, is called in OB100 with instance DB gp_par

[DB7].

FB2

GET

The block is used for reading NC tags.

FB3

PUT

The block is used for writing NC tags.

FB4

PI_SERV

The block is used for starting PI services.

FB5

GETGUD

The block is used for reading global user data (GUD) from the NC and for

determining the GUD tag address.

FB7

PI_SERV2

The block is used for starting PI services that are defined in PI [DB16].

FB9

M2N

The block is used for switching over operating components (MCP/OP)

which are connected with one or several control modules NCU; uses the

signals from MMC [DB19].

FB10

SI_relay

Safety Integrated (SPL) block: Safety relay

FB11

SI_BrakeTest

Safety Integrated (SPL) block: Brake test

FB29

Diagnostics

Diagnostic routines for the PLC user program with logging of signal states

and signal changes.

Table 4-4

Functions (FCs)

Address

Icon

Description

FC2

GP_HP

The block processes the cyclic part of the basic program, is called at

the beginning of OB1.

FC3

GP_PRAL

The block processes the block-synchronous part of the basic program,

is called at the beginning of OB40.

FC5

GP_DIAG

The block is used to record module disruptions and failures, is called

at the beginning of the following OBs: OB82, OB83, OB86.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Address

Icon

Description

FC6

TM_TRANS2

The block transfers position and status information of the tools to the

tool management interface in connection with Multitool.

FC7

TM_REV

The block acknowledges an implemented tool change of a turret to the

tool management interface.

FC8

TM_TRANS

The block transfers position and status information of the tools to the

tool management interface.

FC9

ASUB

The block starts asynchronous subprograms, the prerequisite is that it

must be selected and parameterized by an NC program or by the PI

service ASUP.

FC10

AL_MSG

The block evaluates the signals entered in DB2, generates incoming

and outgoing error and operating messages of the operating software

and acknowledges error messages. Optionally, influencing of the

block and stop signals can commence.

FC12

Call interface for users for auxiliary functions, the block is called on an

event-driven basis in the basic program when new auxiliary functions

are available.

FC13

BHGDisp

The block handles the display control for the handheld unit (HHU or

HT 2).

FC17

Ydelta

The block is used for star-delta changeover for digital main spindle

drives.

FC18

SpinCtrl

The block controls axes and spindles from the user program.

FC19

MCP_IFM

The block is used for transferring data from the machine control panel

(MCP milling version) to the NC/PLC interface.

FC21

Transfer

The block is used for high-speed data exchange between PLC and

NCK.

FC22

TM_DIR

The blocks provides the shortest path and direction of motion for po-

sitioning a tool magazine or turret (indexing axis).

FC24

MCP_IFM2

The block is used for transferring data from the machine control panel

(MCP milling version compact) to the NC/PLC interface.

FC25

MCP_IFT

The block is used for transferring data from the machine control panel

(MCP turning version) to the NC/PLC interface.

FC26

HPU_MCP

The block is used for transferring data of the HT 8 to the NC/PLC

interface.

FC1005

Block transfers data to Ethernet CP.

FC1006

Block receives data from Ethernet CP.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Table 4-5

Data blocks (DBs)

Address

Icon

Description

DB2

ALMSG_DB

Interface between user program and AL_MSG [FC10], contains bit

arrays for blocking and stop signals as well as fault and status mes-

sages.

Comment: If you use the DB2 variant "ExtendAlMsg = True", you

must copy it from the separate master copies folder

"ALMSG_DB_ExtendAlMsg". The other folders contain the variant

"ExtendAlMsg = False".

DB4

Block contains configuration data for tool management and the pa-

rameterization of the alarms for the bit fields in the ALMSG_DB

[DB2] as fault or status message for the DB2 variant "ExtendAlMsg

= False".

DB5

Interface between user program and AL_MSG [FC10], contains the

parameterization of the alarms for the bit fields in the ALMSG_DB

[DB2] as fault or status message for the DB2 variant "ExtendAlMsg

= True".

DB7

gp_par

Instance DB from RUN_UP [FB1]. Contains parameters for config-

uring operating components and other parameters of the basic pro-

gram.

DB8

DB only for internal use in the basic program.

DB10

Interface between user program and NC, contains signals from/to

the NC, PLC and operating software.

DB11

Mode group

Interface between user program and mode groups, contains signals

from/to the NC, PLC and operating software.

DB15

General communication

DB16

Interface for PI_SERV2 [FB7], contains definitions for all available PI

services.

DB18

SPL

Safety Integrated data (SPL)

DB19

MMC

Interface for PI_SERV2 [FB7], contains definitions for all available PI

services.

DB21...DB30

Chan1...Chan10

Interface between user program and channel, contains signals from/

to channel 1...10.

DB31...DB61

Axis1...Axis31

Interface between user program and axis/spindle, contains signals

from/to axis/spindle 1...31.

DB71

TMLoadIF

Interface between user program and tool management, contains

signals from/to Load/Unload magazine

DB72

TMSpindleIF

Interface between user program and tool management, contains

signals for spindle as change position.

DB73

TMRevIF

Interface between user program and tool management, contains

signals for turret.

DB77

MCP/BHG (SDB210)

DB1000

CtrlE

Interface between user program and operating software, contains

energy saving profiles for Ctrl-Energy.

DB1001

SentronPac

Interface between user program and operating software, contains

signals for SENTRON PAC energy monitoring devices.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

Address

Icon

Description

DB1002

ISM_TS

Interface between user program and operating software, contains

signals for spindle temperature sensors.

DB1071

TMLoadIF_MT

Interface between user program and tool management, contains

signals from/to Load/Unload magazine (multitool).

DB1072

TMSpindleIF_MT

Interface between user program and tool management, contains

signals for spindle as change position (multitool).

DB1073

TMRevIF_MT

Interface between user program and tool management, contains

signals for turret (multitool).

4.1.5

Blocks with user-specific adaptations

In the following, you will find a list of all of the blocks of the SINUMERIK PLC basic program

which always require user-specific adaptations and therefore cannot be automatically

upgraded. These blocks are therefore not contained in the master copy "840D sl PLC Basic

Program (upgrade)".

Table 4-6

Blocks with user-specific adaptations

Block type

Address

Icon

Remark

Organization block

OB1

Organization blocks are not available in the "840D sl PLC

Basic Program (upgrade)" master copy due to the necessa-

OB40

ry user-specific calls.

OB82

You can copy these blocks individually as needed from the

OB86

"840D sl PLC Basic Program" master copy and then import

OB100

your adaptations into the newly copied blocks.

Function block

FB29

Diagnostics

Function

FC12

Data block

DB2

ALMSG_DB

Comment: The master copy "840D sl PLC Basic Program

(upgrade)" contains the version "ExtendAlMsg = False", not

the version "ExtendAlMsg = True".

DB4

DB5

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

4.1.6

Assignment overview

From the following block number assignment overview, you can find out whether a specific

block number (or block address) can be used for the PLC user program, or whether it is

assigned or reserved by Siemens or the PLC basic program.

Table 4-7

Assignment of FB numbers

FB number

Availability

Occupied by

Reserved

Siemens

Occupied

Siemens (PLC basic program)

2...14

Reserved

Siemens

Occupied

Siemens (PLC basic program)

16...29

Reserved

Siemens

30...999

Freely available (user

program)

1000...1009

Reserved

Siemens

1010...1019

Reserved or available

Exclusively available for F blocks of Safety Integra-

ted plus (F-PLC)

1020...1023

Reserved

Siemens

1024...7999

Freely available (user

program)

Table 4-8

Assignment of FC numbers

FC number

Availability

Occupied by

0...1

Reserved

Siemens

2...3

Occupied

Siemens (PLC basic program)

Reserved

Siemens

Occupied

Siemens (PLC basic program)

6...29

Reserved

Siemens

30...999

Freely available (user

program)

1000...1023

Reserved

Siemens

1024...7999

Freely available (user

program)

Table 4-9

Assignment of DB numbers

DB number

Availability

Occupied by

Reserved

Siemens

2...11

Occupied

Siemens (PLC basic program)

Occupied

Siemens (computer link and

transport system interface)

13...14

Reserved

Siemens (PLC basic program)

15...16

Occupied

Siemens (PLC basic program)

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

DB number

Availability

Occupied by

Occupied

Siemens

Occupied

Siemens (PLC basic program:

Safety Integrated (SPL))

Occupied

Siemens (PLC basic program)

Occupied

Siemens (SINUMERIK CPU-DB)

21...30

Occupied¹

Siemens (PLC basic program:

Channel DB)

31...61

Occupied¹

Siemens (PLC basic program:

Axis DB)

62...70

Freely available (user program)

71...73

Occupied¹

Siemens (PLC basic program:

tool management)

74...77

Occupied

Siemens (PLC basic program)

78...80

Reserved

Siemens

81...999

Occupied¹

Siemens (ShopMill, ManualTurn)

1000...1002

Occupied

Siemens (PLC basic program)

1003...1008

Reserved

Siemens

1009

Occupied

Siemens (Safety Integrated plus

(F-PLC))

SI_DiagDB [DB1009] (automati-

cally generated)

1010...1019

Reserved or available

Exclusively available for F blocks

of Safety Integrated plus (F-PLC)

1020...1070

Reserved

Siemens

1071...1073

Occupied

Siemens (PLC basic program)

1074...1099

Reserved

Siemens

1100...16000

Freely available (user program)

¹Not recommended for use, but possible with limitations. Data blocks of channels, axes/

spindles and tool management functions that have not been activated can be used by the user,

but this can result in conflicts when upgrading or migrating the PLC basic program.

Further information

Information about the PLC basic program of the SINUMERIK 840D sl is contained in the P3

section of the SINUMERIK 840D sl Basic Functions Manual: PLC basic program for

SINUMERIK 840D sl.

4.1.7

Generating blocks at runtime on the NCU

In specific circumstances, some of the basic PLC program blocks are generated by the NCU at

runtime:

● If you do not load them explicitly onto the NCU

● If you load blocks with an unexpected size onto the NCU, for example because blocks do not

match the machine configuration (e.g. DB20 [DB20] or AL_MSG [DB2]) or because of a

different runtime version.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.1 General information about the PLC program

This concerns the following blocks:

● All axis/channel DBs actually used

● ALMSG_DB [DB2]

● DB3 [DB3]

● DB9 [DB9]

● BAG [DB11]

● DB17 [DB17]

● MMC [DB19]

The configuring of these blocks is optional and required only when, for example, you

symbolically address them. Although warnings are issued when the configuration is compiled,

the program can be executed because of the blocks generated at runtime.

If this involves one of the blocks of the basic program that you do not require (e.g. unused axis

DB, channel DB, FB or FC), you can delete it. This reduces, for example, the time required for

loading or exporting the PLC symbols and for working with SINUMERIK archives.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.2 Opening the PLC basic program system library

4.2

Opening the PLC basic program system library

Procedure

Proceed as follows to open and display the system library of the PLC basic program:

1. Switch to the "Libraries" task card.

2. Select the PLC basic program that matches the firmware version of the inserted NCU:

- SINUMERIK 840D sl PLC basic program V4.5.x.x

- SINUMERIK 840D sl PLC basic program V4.7.x.x

- SINUMERIK 840D sl PLC basic program V4.8.x.x

- SINUMERIK 840D sl PLC Basic Program V4.9.2.x

Result

The system library of the PLC basic program has been opened. Information on handling can be

found under Using copy templates (Page 58) and Adding the PLC basic program (Page 70).

Further information

The block descriptions and other information about the PLC basic program are contained in the

P3 section of the SINUMERIK 840D sl Basic Functions Manual. PLC basic program.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.3 Adding the PLC basic program

4.3

Adding the PLC basic program

You can copy blocks of the PLC basic program from the respective system library. The "840D

sl PLC Basic Program" folder that it contains is meant for creating a completely new project.

You can copy the PLC basic program blocks in their entirety or individually.

Requirement

● A SINUMERIK 840D sl NCU is inserted.

● In the project, there are no blocks from other creators in the range of numbers of the PLC

basic program (Page 66).

Procedure

To copy program blocks of the basic program from a master copy to the program blocks folder

of the project tree, proceed as follows:

1. Switch to the "Libraries" task card and open the PLC basic program that matches the

firmware version of the inserted NCU:

- SINUMERIK 840D sl PLC basic program V4.5.x.x

- SINUMERIK 840D sl PLC basic program V4.7.x.x

- SINUMERIK 840D sl PLC basic program V4.8.x.x

- SINUMERIK 840D sl PLC Basic Program V4.9.2.x

See also: Replacing a device or upgrading firmware (Page 33), Using copy templates

(Page 58)

2. Open the folder "Master copies > 840D sl PLC Basic Program"

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.3 Adding the PLC basic program

– Copying specific PLC basic program blocks

Open the master copies folder and, if applicable, other lower-level folders and manually

define the blocks which you would like to copy by selecting them and then dragging and

dropping them into the program blocks folder.

To select successive objects, click on the first object, press and hold the Shift key and

then click on the last object.

To select non-successive objects, press and hold the Ctrl key and click on the objects

one-by-one.

Strg

The blocks are copied to your project. If applicable, the "Conflicts during copying"

(Page 74) dialog is displayed.

Note

Copy further required blocks separately (e.g. DB2 variant "ExtendAlMsg=True")

If you are using PLC basic program blocks that are not contained in the master copies folder

"840D sl Basic Program > 840D sl PLC BP", you must copy them separately:

● DB2 variant "ExtendAlMsg=True" from the master copies folder

"ALMSG_DB_ExtendAlMsg"

● Different external STL sources from the master copies folder "External source files"

See: Using copy templates (Page 58), Create blocks from external sources (Page 84)

4. In the project tree, right-click "Program blocks" and select the "Software (compile all blocks)"

command in the "Compile" shortcut menu.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.3 Adding the PLC basic program

Result

The blocks of the SINUMERIK PLC basic program have been copied to your project. Any

copied folder structure (Page 82) has been imported.

Figure 4-3

Program blocks folder

Now you can check the copied blocks and, if applicable, manually delete the PLC basic

program blocks that you do not require (e.g. unused axis DB, channel DB, FB or FC).

If you have unused blocks in your project, some tasks take unnecessarily long, e.g. the loading

or the creation and import of SINUMERIK archives.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.4 Conflicts when copying blocks

4.4

Conflicts when copying blocks

Two different conflict types can occur during the copy and insert of program blocks:

● If several blocks with the same block numbers exist in the program blocks folder, a message

is not displayed immediately. Because duplicate block numbers are flagged only during the

compilation,

compile your project after performing a copy in order to detect any conflicts early.

Figure 4-4

Error message when block numbers or addresses are used multiple times

If duplicate block numbers exist, proceed as follows:

- If this involves one of the blocks of the basic program that you do not require (e.g. unused

axis DB, channel DB, FB or FC), you can delete it.

- If a user block has the same block number as a required basic program block, you must

change the number of the user block.

● The presence of duplicate symbolic block names is checked already during the copy action.

A message is issued if conflicts result because of existing symbolic names.

The dialog offers you the following ways of rectifying the conflict:

- You can cancel the copy process, search for the duplicate blocks in the project tree and

delete them before you initiate the copy process again. In this case, click in the "Cancel"

dialog box.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.5 Correcting OB1

4.5

Correcting OB1

When inserting the blocks from a master copy of the library, the existing organization block OB1

is duplicated because it has a different name in the library than in the newly created PLC.

● Block in project tree: Main [OB1] or the name of your migrated block.

● Block in library: OB1 [OB1]

When the project is compiled, a message is displayed that there may only be one object of the

type "OB1".

Procedure

To identify the not required version of the OB1 and to rectify the problem, proceed as follows:

1. Delete one of the duplicated OB1 blocks in the "program blocks" folder:

- If the "program blocks" folder prior to the insertion contained only the empty Main [OB1]

standard block, you can delete it.

- If you have already programmed your own instructions in the OB1, this block normally

already contains the call for the basic program and you can delete the newly added "OB1

[OB1]" block.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.6 Upgrading the PLC basic program

4.6

Upgrading the PLC basic program

If you upgraded the firmware of an NCU or carried out a project migration, you should then also

upgrade the PLC basic program to the current version.

However, it is essential that you check beforehand whether you would inadvertently overwrite

your own blocks (see requirement).

Requirement

● Block number ranges of the SINUMERIK PLC basic program in the project are not occupied

by blocks of other creators or you have checked which blocks of other creators are located

in the SINUMERIK number range (Page 66).

Procedure

To upgrade the PLC basic program, proceed as follows:

1. Switch to the "Libraries" task card and open the PLC basic program that matches the

firmware version of the inserted NCU:

- SINUMERIK 840D sl PLC basic program V4.5.x.x

- SINUMERIK 840D sl PLC basic program V4.7.x.x

- SINUMERIK 840D sl PLC basic program V4.8.x.x

See also: Replacing a device or upgrading firmware (Page 33), Using copy templates

(Page 58)

2. Open the folder "Master copies > 840D sl PLC Basic Program (upgrade)"

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.6 Upgrading the PLC basic program

Depending on the block number assignment in your project, select one of the following

options:

Assignment of the PLC

Possible procedure

GP No. range

Through blocks of other

Overwriting specific PLC basic program blocks

creators

1. Open the lower-level master copies folders and select only those

PLC basic program blocks that you use in your project.

- To select successive objects, click on the first object, press and

hold the Shift key and then click on the last object.

Exclusively through PLC

- To select non-successive objects, press and hold the Ctrl key

basic program blocks

and click on the objects one-by-one.

2. Drag and drop the selected blocks into your "Program blocks"

folder, e.g. under "CNC_1 > PLC_1 > Program blocks".

Exclusively through PLC

Overwriting the PLC basic program including folder structure as a whole

basic program blocks

Drag and drop the entire master copies folder "840D sl PLC BP" into

your "Program blocks" folder, e.g. under "CNC_1 > PLC_1 > Program

blocks".

The blocks are copied to your project. A check is made for duplicate block names and

the "Conflicts during copying" dialog (Page 74) is displayed.

Note

Copy further required blocks separately (e.g. DB2 variant "ExtendAlMsg=True")

If you are using PLC basic program blocks that are not contained in the master copies folder

"840D sl Basic Program > 840D sl PLC BP", you must copy them separately:

● DB2 variant "ExtendAlMsg=True" from the master copies folder

"ALMSG_DB_ExtendAlMsg"

● Different external STL sources from the master copies folder "External source files"

See: Using copy templates (Page 58)Create blocks from external sources (Page 84)

Select the option "Replace existing objects and move to this location" and confirm with "OK".

In the project tree, right-click "Program blocks" and select the "Software (compile all blocks)"

command in the "Compile" shortcut menu.

Result

The PLC basic program has been upgraded and is currently compiled.

Now you can check the copied blocks and, if applicable, manually delete the PLC basic

program blocks that you do not require (e.g. unused axis DB, channel DB, FB or FC).

If you have unused blocks in your project, some tasks take unnecessarily long, e.g. the loading

or the creation and import of SINUMERIK archives.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.7 Copying blocks from one project into another

4.7

Copying blocks from one project into another

Procedure

Proceed as follows to import blocks from an existing project:

1. From the "View" menu, choose the command "Reference projects".

The "Reference projects" palette is displayed under the project tree.

2. Click the "Open reference project" icon in the "Reference projects" palette, select the

project, and confirm with "Open".

The project is opened (write-protected) and the associated project structure is displayed in

the "Reference projects" palette.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.7 Copying blocks from one project into another

3. Navigate in the reference project to the "Program blocks" folder and select the blocks that

you want to copy.

4. Drag-and-drop the blocks from the reference project to the "Program blocks" folder of your

current project.

Note

Copy additional objects separately (e.g. tags or PLC data types)

When you copy the program blocks, objects that belong together, such as tags, PLC data

types or technology objects, are not automatically included in the copy. This applies both to

copying from reference projects and to copying to another PLC.

Error messages are issued during the compilation, e.g. if the tags used in the copied

program block are not defined in the tag table.

Therefore, additionally copy the objects used by the copied blocks.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.7 Copying blocks from one project into another

Note

Conflicts due to names, addresses or numbers that are used multiple times

When you paste objects from a reference project whose names have already been used in

the project, these are automatically renamed under certain circumstances:

● If you copy objects with the same name into the same folder or the same group, the

"Conflicts when copying" dialog is displayed.

● If you copy objects with assigned names to a different folder (or group), the newly pasted

objects are renamed without asking.

A check for duplicate block numbers or addresses is only done during the conversion,

however.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.8 Use and handling of groups

For example, this function is useful in the following situations:

● Creation of a dedicated group for the blocks of the basic program and of the user program.

This allows you to display individually the editable blocks of the user program.

● Organize specific related program blocks (e.g. axis DBs).

● Organize specific program blocks in a group in order to save them quickly and easily in

a reload archive (Page 52).

To maximize the overview window, select the "program blocks" folder and click the "Maximize/

minimize the view" icon in the project navigation toolbar.

Information about the overview window can be found in the information system of the TIA

Portal, keyword "overview window".

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.9 Create blocks from external sources

4.9

Create blocks from external sources

You do not manage external source files (e.g. *.STL or *.SCL) in TIA Portal in the "Program

blocks" folder, but in the "External sources" folder, e.g. under "CNC_1 > PLC_1 > External

sources". You can then generate blocks from the sources maintained there. These are saved

in the "Program blocks" folder.

You do not edit the files in the "External sources" folder using a TIA Portal editor, but with any

external editor, which you define under Windows.

Requirement

● An external source is available in STL or SCL format.

● The mnemonic set in the TIA Portal corresponds to the setting used in the external source.

These settings are found in the menu bar of the TIA Portal as follows: "Extras > Settings >

General > General settings > Mnemonic".

Note

Use of German mnemonics in external source files of the PLC basic program

The mnemonic setting "German" is required in all external source files contained in the copy

templates of the PLC basic program. This affects the files "bhg_db_awl", "diagnose.awl",

"gpob840d.awl" and "mdeclist.awl".

The process fails if the setting does not correspond to the setting of the source file when the

block is generated.

Procedure

1. In the project tree, select the "Add new external file" command in the "CNC_1 > PLC_1 >

External sources" folder.

2. Select the external file (*.STL or *.SCL) that you want to add in the "Open" dialog.

The external file is copied to the "External sources" folder in the project tree.

Note

Displaying external sources (e.g. STL files) using an external editor

The internal editor of the TIA Portal does not display external sources.

If you add and open an external source in the TIA Portal, the file will be opened with the

application linked with the associated file type (e.g. STL) in Windows (e.g. Microsoft Editor).

See also: TIA Portal online help, search term "Using external source files"

3. Right-click the external source, then select the "Generate blocks from source" command in

the shortcut menu.

Result

You have successfully generated blocks from an external source.

Further information about external sources of the PLC basic program system library can be

found in the SINUMERIK 840D sl Basic Functions Manual.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.10 Exporting PLC symbols for SINUMERIK Operate

4.10

Exporting PLC symbols for SINUMERIK Operate

4.10.1

Creating and loading PLC symbols

You can make PLC symbols defined in the TIA Portal available for SINUMERIK Operate in able

to use them for various functions there. You must export the symbols of the associated PLC in

the TIA Portal and then import into SINUMERIK Operate.

Note

Deleting unwanted blocks before exporting PLC symbols

If you have saved unwanted blocks in your project, this lengthens the time required for

exporting and importing PLC symbols.

Consequently, delete unwanted blocks that you copied previously from the basic program

library prior to the export.

See: General information about the PLC program (Page 55)

Requirement

● The software has been compiled completely.

● The associated languages are activated as project languages in the TIA Portal.

See: Information system, "Activate project languages" section

Note

Comments only in German or English

Because SINUMERIK Operate can manage only German and English comments, you can

export only German and English comments from the TIA Portal.

● The PLC symbols to be exported are valid.

Note

Only valid PLC symbols are exported

The following PLC symbols are not taken into account during the export:

● PLC symbols of know-how-protected blocks

● PLC symbols of F-blocks

● Internal PLC symbols

● Invalid/faulty PLC symbols

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.10 Exporting PLC symbols for SINUMERIK Operate

Procedure overview

Table 4-10

Example procedure for creating and loading PLC symbols

Step

Description

If necessary, check or edit symbols in the TIA Portal

● You can change the symbolic names of blocks by right-clicking the block and selecting

"Rename" from the shortcut menu.

● You can change symbols of the individual elements in the block editor.

● PLC variables for Flags, Times, Input, Output, Timer and Counter can be changed in the

associated table field (e.g. under "CNC_1 > PLC 1 > PLC variables > Display all variables")

Exporting PLC symbols with the TIA Portal (Page 86)

If necessary, make export files available on the NCU or PCU, e.g. using a USB FlashDrive

Importing PLC symbols in SINUMERIK Operate (Page 89)

4.10.2

Exporting PLC symbols

Note

Deleting unwanted blocks before exporting PLC symbols

If you have saved unwanted blocks in your project, this lengthens the time required for

exporting and importing PLC symbols.

Consequently, delete unwanted blocks that you copied previously from the basic program

library prior to the export.

See: General information about the PLC program (Page 55)

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.10 Exporting PLC symbols for SINUMERIK Operate

Requirement

● The software has been compiled completely.

● The associated languages are activated as project languages in the TIA Portal.

See: Information system, "Activate project languages" section

Note

Comments only in German or English

Because SINUMERIK Operate can manage only German and English comments, you can

export only German and English comments from the TIA Portal.

● The PLC symbols to be exported are valid.

Note

Only valid PLC symbols are exported

The following PLC symbols are not taken into account during the export:

● PLC symbols of know-how-protected blocks

● PLC symbols of F-blocks

● Internal PLC symbols

● Invalid/faulty PLC symbols

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.10 Exporting PLC symbols for SINUMERIK Operate

Procedure

To export PLC symbols for SINUMERIK Operate, proceed as follows:

1. In the project tree, right-click on the PLC or NCU and select the "Export PLC symbols for

SINUMERIK Operate " in the shortcut menu.

The "Export PLC symbols for SINUMERIK Operate" dialog opens.

2. Enter the settings:

- Select the languages whose PLC symbols you want to export. Only those languages that

you previously selected under "Project languages" are actively displayed.

Note

Comments only in German or English

Because SINUMERIK Operate can manage only German and English comments, you

can export only German and English comments from the TIA Portal.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.10 Exporting PLC symbols for SINUMERIK Operate

- Select the storage location in which the exported PLC symbols are to be saved. Use, for

example, a USB FlashDrive to subsequently copy the files to the NCU.

3. Click "Export" to start the export operation.

Result

The PLC symbols will be copied to the chosen storage location. The "PlcSym.snh" file is

created. Depending on your settings, the files are also created with German or English

comments: "PlcSym_GR.snt" and "PlcSym_UK.snt".

Note

Notation

The notation (upper and lower case) of the file names created by the program is mandatory and

must not be changed.

4.10.3

Importing PLC symbols

Requirement

● The symbol export files are available on the NCU or PCU, e.g. using a USB FlashDrive

Note

Notation

The notation (upper and lower case) of the file names created by the program is mandatory

and must not be changed.

● The current PLC symbols in SINUMERIK Operate have been saved

Note

Saving or deleting old symbol tables

Note that already existing files are overwritten during the export if you confirm that this

should be done. Furthermore, it can lead to inconsistencies if not all files are exported.

We recommend that the old files are backed up or deleted before a new export, or the files

are exported to an empty directory.

Procedure

To use PLC symbols exported from the TIA Portal in SINUMERIK Operate, proceed as follows:

1. Copy the symbol export files in the following directory on the CF card of the NCU or PCU:

/oem/sinumerik/plc/symbols

2. Restart SINUMERIK Operate.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.10 Exporting PLC symbols for SINUMERIK Operate

3. After the startup, confirm the "Diagnosis", ">>" and "NC/PLC variables" horizontal softkeys.

4. Select the "Insert variables" softkey.

The imported symbols are displayed in the "NC/PLC variables" table and can be imported.

Further information

Detailed information on how you can load the PLC symbols to the control system are contained

in the SINUMERIK 840D sl Universal Operator Manual under the "Loading PLC symbols"

keyword.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Programming the PLC

4.11 Edit blocks

4.11

Edit blocks

The individual blocks of the PLC basic program or the user program can be edited directly in the

TIA Portal using the STEP 7 editors.

Information about these functions and editors is available in the higher-level help

"Programming the PLC" and in the STEP 7 Professional System Manual. (Sometimes functions

for specific PLCs are discussed there. Information that also concerns the SINUMERIK 840D sl

PLCs is marked with "S7-300".)

If you are converting from the STEP 7 V5.x toolbox, you also find special information about

programming a PLC in the sections of the "Migrating SINUMERIK projects" help.

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring networks

5.1

Configuring an Ethernet Interface

Procedure

In order to set the Ethernet interface, proceed as follows:

1. In the network view, click the CP in the basic rack of the NCU.

2. Under the "Properties" tab in the inspector window, select the "PN/IE interface > Ethernet

addresses" entry.

3. Set the IP address matching your real configuration. If the PG/PC is connected to X127, the

following IP address applies:

Hardware factory setting on the NCU for socket X127

IP address: 192.168.215.1

Subnet mask: 255.255.255.0

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring networks

5.2 Configuring PROFIBUS DP

5.2

Configuring PROFIBUS DP

Procedure

Configuring the PROFIBUS DP address on the PLC

1. In the network view, click the PLC in the basic rack of the NCU.

2. In the "Properties" tab, in the inspector window, select the entry "DP Interface > PROFIBUS

address".

The settings of the PROFIBUS address are displayed.

3. In the Parameters area, set the DP address of the interface on the PLC under "Address".

This is transferred from the configuration to the PLC during the load action.

Configuring the PROFIBUS DP address for the ADI4 module

1. In the network view, click the "DP" interface of the ADI4.

2. In the inspector window "Properties", select the entry "PROFIBUS address".

3. Under "Address" set the DP address that matches the hardware. The configured address

must match the hardware address. It is not accepted automatically.

Information about setting the DP address on the hardware is contained in the "ADI4 - Analog

drive interface for 4 axes" Device Manual.

Checking the transmission speed of the ADI4

Although you can view the "Transmission speed" parameter in the DP interface properties, you

must select the bus system to change it:

1. Click the bus system.

2. In the "Properties" inspector window, check under "Network settings" the "Transmission

speed" entry. The ADI4 module can be operated only with the transmission speed 12 Mbit/

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring networks

5.3 Configuring Integrated PROFIBUS (DP Integrated)

5.3

Configuring Integrated PROFIBUS (DP Integrated)

Procedure

To check the PROFIBUS addresses, proceed as follows:

1. In the network view, click the DP Integrated interface of the PLC or select the interface in the

device overview.

2. In the "Properties" tab, in the inspector window, select the entry "PROFIBUS address".

Result

The DRIVE-CLiQ sockets of the real hardware are displayed to which the NX modules must be

connected.

Note

Cycle clock settings

You can only make the cycle clock settings on the PROFIBUS Integrated subnet and not

directly on the interface: For the selected subnet, you find the cycle clock settings under

"Equidistance" in the inspector window.

Observe the rules for setting the clock cycle at the field buses (see Commissioning Manual,

"Commissioning CNC: NCK, PLC, drive").

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring networks

5.4 Configuring PROFINET

5.4

Configuring PROFINET

Procedure

In order to set the PROFINET interface, proceed as follows:

1. In the network view, click the PLC in the basic rack of the NCU.

2. Under the "Properties" tab in the inspector window, select the "PROFINET interface >

Ethernet addresses" entry.

3. Check under "IP protocol" whether the correct IP address is set ("192.168.0.1" in the

example).

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

Configuring networks

5.5 Configuring PROFINET IO with IRT

5.5

Configuring PROFINET IO with IRT

5.5.1

Overview

IRT (Isochronous Realtime Ethernet) is a transmission method in which the PROFINET

devices are synchronized very precisely.

The following example configuring sequences serve as an aid for the configuring and provide

an overview of this chapter content.

● Configuring NC-controlled drives isochronously (handling overview) (Page 101)

● Configuring I/O used by NC isochronously (handling overview) (Page 102)

You can, however, make most settings for the clock synchronization in TIA Portal in any order.

You can orient yourself on the following notes:

● Isochronous modules identification in the hardware catalog (Page 99)

● Rules and requirements for clock synchronization (Page 97)

● Match values between PROFINET IO and PROFIBUS Integrated (Page 111)

● General information concerning isochronous mode is also contained in the TIA Portal online

help in Section "Configuring IRT communication".

If, instead, you want to operate drives or I/O isochronously via the PLC, proceed as for a CPU

S7-300. (Use the OB61 as isochronous alarm OB or the TPA1 as process image, and do not

enter the drive or I/O addresses in the machine data.)

5.5.2

Rules and requirements

Irrespective whether you configure isochronous I/O used by NC or isochronous NC-controlled

drives, the value of the TDP send clock must be identical in the complete system (all devices,

modules, submodules and bus systems):

● You can find these settings in the TIA Portal at the following locations:

- Properties of the PROFINET IO system under "Domain management > Sync domains >

Sync-Domain_x > Send clock".

- Properties of the PROFIBUS Integrated bus system under "Equidistance > DP cycle".

This applies, e.g. even when you connect drives via PROFINET as well as PROFIBUS

Integrated. The default setting of the PROFIBUS DP cycle (send clock) at the integrated

PROFIBUS is 2 ms.

During the configuring of drives, the values of the T_I and T_O times must also be identical in the

complete system:

● Properties of the IO device under "PROFINET interface > Extended options > Isochronous

mode".

● Properties of the bus system (e.g. PROFIBUS Integrated_1) under "Equidistance".

SINUMERIK 840D sl STEP 7 Toolbox V16

Configuration Manual, 12/2019, 6FC5397-0GP40-0BA1

SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020) - page 105