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

Ctrl-E Analysis

3.1 SENTRON PAC3200/4200

Parameterizing SENTRON PAC

You have the option of parameterizing the measuring device in the following ways:

● Using the input keys and display of the SENTRON PAC

● Using a PC connected to the SENTRON PAC, which has the software this has been

supplied (powerconfig).

After booting select the language and the measuring device is then ready for operation.

3.1.3

Commissioning the PAC PROFIBUS expansion module (840D sl)

To communicate via Profibus, the SENTRON PROFIBUS module in combination with Sentron

PAC3200/4200 must be parameterized differently.

1. Select SENTRON PAC "Settings" > "PROFIBUS modules".

- OR -

For SENTRON PAC4200, select "Settings" > "Expansion modules" > "MOD1" >

"PROFIBUS MODULE".

2. Press "Enter".

You obtain the following information in the subsequent window:

- Order number

- Serial number of the SENTRON PROFIBUS module

- Firmware version of the SENTRON PROFIBUS module

- PROFIBUS ADDR.:

The DP address of module is displayed here.

3. Press "Enter".

This means that you have the option of entering the same PROFIBUS address as in the

automation system.

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

3.1.4

Commissioning the expansion module PAC PROFINET (828D)

To communicate via PROFINET, the SENTRON SWITCHED ETHERNET PROFINET module

in combination with Sentron PAC3200/4200 must be parameterized differently.

1. Select SENTRON PAC "Settings" > "SWITCHED ETHERNET".

- OR -

Select SENTRON PAC "Settings" > "Expansion modules" > "MOD1" > "SWITCHED

ETHERNET".

2. Press "ENTER".

You obtain the following information in the subsequent window:

- Order number

- Serial number of the SENTRON SWITCHED ETHERNET PROFINET module

- Firmware version of the SENTRON SWITCHED ETHERNET PROFINET module

- The first character of the NameOfStation of the SENTRON SWITCHED ETHERNET

PROFINET module that can be a maximum of 26 characters

- IP-ADDR.:

The IP address of the module is displayed here.

3. Using the menu item "- ->", open the next window and obtain among other things the

information about the SUBNET address of the module.

Specifying/changing the device name

The device name can only be entered (it must be specified) using the powerconfig software

in the submenu "Expansion slot1".

● Sentron PAC3200: pac3200-pn22

● Sentron PAC4200: pac4200-pn21

The next time that the 828D boots, the 828D IO controller assigns the correct IP address to

the expansion module according to the device name:

● pac4200-pn21 --> 192.168.214.21

● pac3200-pn22 --> 192.168.214.22

3.2

Commissioning the PLC for SENTRON PAC

3.2.1

SINUMERIK 840D sl

3.2.1.1

Commissioning the PLC with PROFIBUS

PROFIBUS is commissioned with the PLC Toolbox 4.6 or higher.

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

Preconditions

● Configure the hardware, save and compile the project

● Generating the system data for the PLC

● Install the Toolbox software, which also contains the libraries for the PLC basic program of

an NCU 7x0.3.

Note

PLC Toolbox 4.6SP1 requires STEP 7 V5.5 SP3 or higher.

Procedure

You are on the main screen of the SIMATIC Manager.

1. Select the "File" > "Open" menu and then click on the "Libraries" tab.

2. Select the library for the PLC basic program "bp7x0_46" and confirm the dialog with "OK".

3. You have inserted the library and selected the PLC program under "PLC-First-Startup 840D

sl" > "SINUMERIK" > "PLC317F-3 PN/DP " > "S7 Program".

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

PROFIBUS interface

PROFIBUS must be configured with a data transfer rate of 12 Mbit/s.

Setting the PROFIBUS address

Set the PROFIBUS address of the expansion module either directly at the SENTRON PAC or

enter using the powerconfig software.

References

Additional information about commissioning the PLC can be found in the following references:

CNC Commissioning Manual: NCK, PLC, drive / SINUMERIK 840D sl

3.2.1.2

Commissioning the PLC with PROFINET

PROFINET is commissioned with the PLC Toolbox 4.6 or higher. This requires SIMATIC STEP

7 V5.5SP3 or higher.

Preconditions

● Configure the hardware, save and compile the project

● Generating the system data for the PLC

● Install the Toolbox software, which also contains the libraries for the PLC basic program of

an NCU 7x0.3PN.

● GSDML for PAC PROFINET

http://support.automation.siemens.com/WW/view/de/50186868

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

References

Additional information about commissioning the PLC can be found in the following references:

CNC Commissioning Manual: NCK, PLC, drive / SINUMERIK 840D sl

3.2.2

SINUMERIK 828D

The PLC of the 828D has a fixed PLC I/O image.

Using the general machine data MD12986[...], the possible peripheral connections (addresses)

are activated or deactivated. When delivered, these addresses are deactivated for the Sentron

devices by entering the address.

Activating the peripheral connection

● SENTRON PAC4200

I address

132 ... 135

Total active power

(value saved from SENTRON PAC)

136 ... 139

Active energy, imported, tariff 1 (instantaneous value)

140 ... 143

Active energy, exported, tariff 1 (instantaneous value)

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

For example, you activate the logical input address 132 by changing the machine data MD[...]

with entry 132 to -1.

● SENTRON PAC3200

I address

144 ... 147

Total active power

(value saved from SENTRON PAC)

148 ... 151

Active energy, imported, tariff 1 (instantaneous value)

152 ... 155

Active energy, exported, tariff 1 (instantaneous value)

For example, you activate the logical input address 144 by changing the machine data MD[...]

with entry 144 to -1.

The measured values are transferred in the float format.

References

Additional information about commissioning the PLC can be found in the following references:

SINUMERIK 828D Turning and Milling Commissioning Manual

3.3

Commissioning the PLC for Ctrl-E Analysis

3.3.1

Configuring the energy consumption display for SINUMERIK 840D sl

The energy consumption is displayed in the "SINUMERIK Ctrl-E Analysis" window.

See also

Signals for controlling energy-saving profiles (Page 46)

Signals for parameterization (Page 47)

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Data block

DB9907

Signal

Meaning

Symbol

Format

direction

Name: Sentron-

Pac

DB9907.DBX0.0

PLC -> HMI

Display manual value

ManualVal

BOOL

DB9907.DBX0.1

PLC -> HMI

SENTRON PAC rep-

SentronPacMach

BOOL

resents the complete

machine

DB9907.DBX0.2

PLC -> HMI

Imported active ener-

FeedInEnergyReadSP

BOOL

gy is read from SEN-

TRON PAC

DB9907.DBX0.3

PLC -> HMI

Exported active ener-

FeedBackEnergyReadSP

BOOL

gy is read from SEN-

TRON PAC

DB9907.DBX1.0

PLC -> FW

Measuring request to

MeasAuto

BOOL

PLC FW

DB9907.DBX2.0

HMI -> FW

Measurement is run-

MeasAct

BOOL

ning

DB9907.DBD4

PLC -> HMI

Manual value

ManualValue

REAL

DB9907.DBD8

FW -> HMI

Total active

ActivePowerItem

REAL

power

DB9907.DBD12

MeasAuto

Measured imported

ActiveEnergyItem

REAL

== 0:

active energy tariff1

PLC -> HMI

MeasAuto

== 1:

FW -> HMI

DB9907.DBD16

MeasAuto

Measured exported

ReactiveEnergyItem

REAL

== 0:

active energy tariff1

PLC -> HMI

MeasAuto

== 1:

FW -> HMI

DB9907.DBD20

PLC -> FW

Total active

ActivePowerSentron

REAL

power

in watts from SEN-

TRON

DB9907.DBD24

PLC -> FW

Imported active ener-

ActiveEnergySentron

REAL

gy at tariff 1 (F) in Wh

from SENTRON

DB9907.DBD28

PLC -> FW

Exported active ener-

ReactiveEnergySentron

REAL

gy at tariff 1 (F) in Wh

from SENTRON

DB9907.DBD32

FW -> HMI

Imported active ener-

ActiveEnergyDay

REAL

gy in kWh current day

to HMI

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

DB9907

Signal

Meaning

Symbol

Format

direction

Name: Sentron-

Pac

DB9907.DBD36

FW -> HMI

Exported active ener-

ReactiveEnergyDay

REAL

gy in kWh current day

to HMI

DB9907.DBD40

FW -> HMI

Imported active ener-

ActiveEnergyPrevDay

REAL

gy in kWh previous

day to HMI

DB9907.DBD44

FW -> HMI

Exported active ener-

ReactiveEnergyPrevDay

REAL

gy in kWh previous

day to HMI

DB9907.DBD48

FW -> HMI

Imported active ener-

ActiveEnergyMonth

REAL

gy in kWh month to

HMI

DB9907.DBD52

FW -> HMI

Exported active ener-

ReactiveEnergyMonth

REAL

gy in kWh month to

HMI

DB9907.DBD56

FW -> HMI

Imported active ener-

ActiveEnergyPrevMonth

REAL

gy in kWh previous

month to HMI

DB9907.DBD60

FW -> HMI

Exported active ener-

ReactiveEnergyPrevMonth

REAL

gy in kWh previous

month to HMI

DB9907.DBD64

FW -> HMI

Imported active ener-

ActiveEnergyYear

REAL

gy in kWh year to HMI

DB9907.DBD68

FW -> HMI

Exported active ener-

ReactiveEnergyYear

REAL

gy in kWh year to HMI

DB9907.DBD72

FW -> HMI

Imported active ener-

ActiveEnergyPrevYear

REAL

gy in kWh previous

year to HMI

DB9907.DBD76

FW -> HMI

Exported active ener-

ReactiveEnergyPrevYear

REAL

gy in kWh previous

year to HMI

DB9907.DBB96

PLC -> HMI

Presentation of the

ProductionAct

Byte

energy consumption

in the status display

Note

Evaluation of the energy consumption of the complete machine

If you have installed SENTRON PAC in the main circuit of the machine or SENTRON PAC

evaluates the energy consumption of the complete machine, set bit DB9907.DBX0.1 to 1.

As a consequence, in the display for Ctrl-E Analysis, the line "SentronPAC" is removed and

the measured value of the SENTRON PAC is entered into the line "Total machine".

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Data block for auxiliary systems

Up to 10 auxiliary systems are supported by the data block. A data structure is defined for each

auxiliary system. In order to display the energy/power of an auxiliary system in the HMI, bit 0

of the first byte of the data structure must be set.

Auxiliary system

Start of the data structure

End of the data structure

Auxiliary system 1 (n=0)

DB9907.DBB100

DB9907.DBB139

Auxiliary system 2 (n=40)

DB9907.DBB140

DB9907.DBB179

Auxiliary system 3 (n=80)

DB9907.DBB180

DB9907.DBB219

Auxiliary system 4 (n=120)

DB9907.DBB220

DB9907.DBB259

Auxiliary system 5 (n=160)

DB9907.DBB260

DB9907.DBB299

Auxiliary system 6 (n=200)

DB9907.DBB300

DB9907.DBB339

Auxiliary system 7 (n=240)

DB9907.DBB340

DB9907.DBB379

Auxiliary system 8 (n=280)

DB9907.DBB380

DB9907.DBB419

Auxiliary system 9 (n=320)

DB9907.DBB420

DB9907.DBB459

Auxiliary system 10 (n=360)

DB9907.DBB460

DB9907.DBB499

DB9907

Signal

Meaning

Identifier

Format

direction

Name: SentronPac

DB9907.DBX(100+n).0

PLC ->

FW calculates the energy/

ProcessAux

BOOL

FW/HMI

power of the auxiliary sys-

tem

DB9907.DBX(100+n).1

PLC ->

Actual value update

ReadEnergy

BOOL

FW/HMI

DB9907.DBX(100+n).2

PLC ->

Measurement in progress

MeasACT

BOOL

FW/HMI

DB9907.DBX(100+n).3

PLC ->

1: Differential values are

MeasMode

BOOL

FW/HMI

written to the variables for

the measurement end

0: Absolute values are

written to the variables for

the measurement start

and measurement end

DB9907.DBX(100+n).4

PLC ->

1: Energy

InputMode

BOOL

FW/HMI

0: Power

DB9907.DBX(100+n).7

PLC ->

Delete data structure

ResetAux

BOOL

FW/HMI

DB9907.DBD(104+n)

PLC ->

Active power or active en-

ActivePowerAux

REAL

FW/HMI

ergy of the auxiliary sys-

tem

DB9907.DBD(108+n)

FW ->

Active energy drawn by

ActiveEnAux

REAL

HMI

the auxiliary system in

kWh

DB9907.DBD(112+n)

FW ->

Active energy supplied by

ReActiveEnAux

REAL

HMI

the auxiliary system in

kWh

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

DB9907

Signal

Meaning

Identifier

Format

direction

Name: SentronPac

DB9907.DBD(116+n)

FW ->

Active energy drawn by

ActiveEnAuxMeasON

REAL

HMI

the auxiliary system at

the measurement start in

kWh

DB9907.DBD(120+n)

FW ->

Active energy supplied by

ReActiveEnAuxMeasON

REAL

HMI

the auxiliary system at

the measurement start in

kWh

DB9907.DBD(124+n)

FW ->

Active energy drawn by

ActiveEnAuxMeasOFF

REAL

HMI

the auxiliary system at

the measurement end in

kWh

DB9907.DBD(128+n)

FW ->

Active energy supplied by

ReActiveEnAuxMeasOFF

REAL

HMI

the auxiliary system at

the measurement end in

kWh

3.3.2.1

Programming the PLC user program for SINUMERIK 828D

Via the expansion modules, SENTRON PAC devices provide the total active power in the unit

W and the active energy data in Wh. In HMI the units kW and kWh are used.

PLC firmware

The PLC firmware offers the following functions:

● Provision of the total active power [kW]

● Provision of the values for imported and exported active energy [kWh]

for the current day, month and the current year as well as for the previous day, previous

month and the previous year.

The values of the current time periods are updated in every cycle. If one of the time periods

changes (new day, new month or new year) then the "current" variables of the time period

that changes is copied into its previous day, previous month or previous year variables and

the "current" variables are accumulated again starting from 0.

● Two measuring procedures for imported and exported active energy [kWh]

- Measurement carried out by the PLC firmware (see "Measurement control HMI → FW

and PLC → FW")

- The user calculates and writes the measured values

This allows user-specific measuring routines to be implemented.

The two values of measured imported energy [kWh] (DBD12) and the measured exported

energy [kWh] (DBD16) are made available for the HMI. The source of the values as well as

measuring procedure and measuring duration (start, stop) are defined using measurement

control bits.

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Programming the PLC user program

● You take the total active power from the input address and transfer the value to

DB9907.DBD20. This must be realized according to the following point "Adapt byte

sequence".

● You take the imported active power from the input address and transfer the value to

DB9907.DBD24. This must be realized according to the following point "Adapt byte

sequence".

● You take the exported active power from the input address and transfer the value to

DB9907.DBD28. This must be realized according to the following point "Adapt byte

sequence".

● If the control bits DB9907.DBX0.2 and DBX0.3 are equal to 0, then the HMI counts the

energy on the basis of the total active power transferred from the SENTRON between the

start and stop.

● If the imported and exported energy is to be directly evaluated by SENTRON PAC

(DB9907.DBX0.2 and DBX0.3 equal to 1), then program this measurement in the user

program as follows:

- SENTRON PAC devices permanently cumulate the "imported active energy (tariff 1)"

or "the exported active energy (tariff 1)" separately when their supply voltages are

connected.

- With the positive edge of the signal "Measurement running" (DB9907.DBX2.0) you

buffer these instantaneous values from SENTRON (imported and exported active

energy T1)

- Cyclically generate the differences between the energy data now being counted minus

the initial values, divide the differences by 1000.0 and transfer the results to

DB9907.DBD12 (for measured imported active energy T1) and DB9907.DBD16

(measured exported active energy T1) up to the STOP signal (falling edge).

- During the measurement, the increasing difference (energy in kWh) is displayed on the

HMI, which can then be read as measured value with Stop measurement.

Adapting the byte sequence

Save the values of the SENTRON PAC so that the byte sequence of the double words is

swapped over (Endian conversion).

The CTRL_E and SENTRON blocks are located in the following directory:

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Example for SINUMERIK 828D with SENTRON PAC3200

Swap over the byte sequence of the total active power in ID144:

For the total active power, the numerical value of 18.4 is supplied from SENTRON. This

corresponds to a hexadecimal value of 0x41933334, which is located just like this in the double

word ID144. To be further processed by the PLC, the sequence of these four bytes must be

swapped over: 0x34339341.

Also the values for the active energy import tariff 1 and active energy export tariff 1 must be

handled in this way.

Figure 3-5

SWAP_DW subroutine

Figure 3-6

Byte sequence

You can find the SWAP_DW subroutine on the Toolbox-CD under Examples\PLC

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Measurement control HMI → FW and PLC → FW

● With a 1 signal of the control bit "MeasAuto" (DBX1.0), the user requests that the firmware

makes the measurement.

If this bit is not set, then the user is responsible for calculating and writing the measured

values.

● Using a 1 signal of the control bit "MeasAct" (DBX2.0), via the HMI it is signaled as to when

the measurement should be made: 0→1 start measurement, 1→0 stop measurement.

The firmware only evaluates this signal if control bit "MeasAuto" (DBX1.0) is set.

Measurement carried out by the firmware

For these measurements, the cyclic increases in the energy values are accumulated in the

measured variables.

The behavior for different signal sequences of both measurement control signals are described

in the following:

● DBX1.0 is set first

If DBX1.0 ("MeasAuto") is first set, and then remains statically present, every 0-1 edge of

DBX2.0 ("MeasAct") deletes the measured value and then starts the measurement.

If DBX2.0 is reset, the measurement is canceled and the measured value remains constant.

The sequence is repeated at the next 0-1 edge of DBX2.0.

0HDVXUHG

YDOXH

'%;

Figure 3-7

Measurement control signal DBX1.0 is set first

● DBX2.0 is set first

If DBX2.0 ("MeasAct") is set first, and then remains statically present, every 0-1 edge of

DBX1.0 ("MeasAuto") accumulates the measured value without deleting the previous value.

If DBX1.0 is reset, the measurement is only interrupted and the measured value remains

constant.

0HDVXUHG

YDOXH

'%;

Figure 3-8

Measurement control signal DBX2.0 is set first

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System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Analysis

3.4 Commissioning the HMI for Ctrl-E Analysis

3.4

Commissioning the HMI for Ctrl-E Analysis

No additional adaptation is required.

As soon as the DB1001 (840D sl) or the DB9907 (828D) is available and actively assigned

with data words, then the HMI automatically accepts this data.

If you have configured auxiliary systems, these devices are displayed as "AUX1" to "AUX10"

in the Ctrl-E analysis. You can assign these devices language-dependent display texts.

3.4.1

Changing display texts of the auxiliary systems

The display texts for the auxiliary systems are stored in the "slnrgauxunits_xxx.ts" file. A

dedicated file must be created for each supported language. The file names differ by the

language code. Set the appropriate language code for "xxx" (e.g. "slnrgauxunits_eng.ts" for

English).

Structure of the "slnrgauxunits_xxx.ts" file

In the "slnrgauxunits_xxx.ts" file, the text identifiers from the software are assigned language-

dependent texts.

Tag

Meaning

source

Text identifier

The auxiliary systems are identified with "AUX_UNIT_1" to

"AUX_UNIT_10".

translation

Text which is displayed on the user interface.

You can enter single and multi-line texts. "%n" is used to generate a line

break.

chars

Text length (number of characters)

lines

Number of lines

Procedure

1. Copy the "slnrgauxunits_deu.ts" template file from the directory: siemens/sinumerik/

hmi/template/lng.

2. Save the file to the /oem/sinumerik/hmi/lng or /user/sinumerik/hmi/lng

directory.

3. If required, change the file name.

If you wish to create texts for additional languages, then a separate file must be created

for each language. Save the file with the appropriate language code in the file name.

4. Open the file and enter the text to be displayed between the <translation> and </translation>

tags.

5. Restart SINUMERIK Operate.

The file must still be converted into a binary format so that the texts can be displayed during

the program runtime. This conversion is only executed when the HMI powers up.

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Ctrl-E Analysis

3.6 Power display in the status line of the "Machine" operating area

3.5

Long time measurement

In order that you can read the usage values in the Ctrl-Energy initial window and in the "Long

time measurement" window, program the PLC user program as specified in Chapter 2.3.1.1

(840D sl) or 2.3.2.1 (828D).

3.6

Power display in the status line of the "Machine" operating area

The current energy consumption is displayed in the first line of the status display in the

"Machine" operating area in the form of colored bars.

To show the power display set DB1001.DBX3.0 = 1 in the STEP 7 program of the PLC.

The following machine statuses are displayed:

Displaying the machine status

DB1001.DBB96 = 0

Red bar upwards - the machine is unproductive

DB1001.DBB96 = 1

Dark green bar upwards - the machine is productive and consumes

energy

DB1001.DBB96 = 2

Light green bar downwards - the machine feeds energy back into

the line supply (generator operation)

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System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

To optimize the energy consumption, you have the option of defining energy saving profiles

and saving them.

Controlling the energy-saving states of the machine

The following pre-defined energy-saving profiles are available when the system is delivered:

● Simple energy-saving mode (machine standby)

A specific interface signal is initiated if the control has not exited the reset state after a

defined time. Using this signal, with the PLC a pre-defined energy state is established,

where, for example it is still possible to operate the machine for setting-up purposes.

● Full energy-saving mode (NC standby)

A specific interface signal is initiated if none of the keys on the machine control panel at

the control has been pressed for a specific time. A pre-defined energy state can be

established with the PLC using this signal, where it is still possible, for example, to transfer

programs to the control or edit them.

● Maximum energy-saving mode (auto shut-off)

An additional interface signal is initiated if, at the control, no key on the operator panel and

machine control panel has been pressed for a defined time and there is no active

communication with the external device. Via the PLC, the main switch is automatically

opened, e.g. using the undervoltage release function.

These predefined energy-saving profiles only become effective if the control system is in the

reset state. They can be blocked using a PLC user signal. The energy-saving profiles can be

changed at any time and supplemented to include up to a total of 8 profiles.

For instance, you have the option of assigning a customer key to an energy-saving profile,

with which the control can be immediately shut down.

4.1

Commissioning the PLC for Ctrl-E Profiles

4.1.1

Overview

In every machine tool, the PLC is the central part of the control for the peripherals and mounted

equipment/devices. Each machine can have several operating stations.

The energy-saving profiles are managed and stored in the PLC. The signals to monitor energy

within the machine are available in the PLC; these signals can then be appropriately logically

combined in the PLC user program.

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System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

SINUMERIK 840D sl

In SINUMERIK 840D sl, "Ctrl+Energy" is integrated in the basic program (FB15). Data for each

energy-saving profile is saved in DB1000, which is supplied with the Toolbox.

SINUMERIK 828D

In SINUMERIK 828D, "Ctrl+Energy" is integrated in the PLC firmware. The data for each

energy-saving profile is saved in the DB9906, which is included in the Programming Tool 828D.

In the other versions, for the "basic program (FB15)" for 828D, "PLC firmware" applies.

Energy-saving profiles

The PLC supports 8 energy-saving profiles. After the relevant configured delay times have

expired, the energy-saving profiles are individually active. The total time up until the energy-

saving profile is activated is obtained from its activation time plus the prewarning time. During

the two time intervals, the selected signals, enabled using masking, are monitored for any

activity and the profile only becomes finally active when the signals are completely inactive.

Of course, when required OEMs can configure either one or both times with zero.

The energy-saving profile in the PLC is characterized by the following data:

● the maximum time for T1 - the activation time

● the maximum time for T2 - the prewarning limit time of the user

● the actual value for T1

● the actual value for T2

● masking of the signals to assume/exit the energy-saving state

The times have the units of seconds, are 16 bits wide and unsigned. A maximum time is

therefore approximately 18 hours.

Note

The time until the energy-saving profile has been finally activated is obtained by adding the

actual values of T1 and T2

The data for each energy-saving profile is saved in DB1000 for the 840Dsl and in DM9906 for

the 828D.

4.1.2

Automatic state machine PLC functions

The automatic state machine shows the functionality in the PLC.

The state transition "OFF" results in a change into the "Energy-saving state inactive" from

every other state. This corresponds to "waking up" the machine.

After the NCU powered up, every energy-saving profile in the state "Energy-saving state

inactive" and the actual values of the times T1 and T2 are set to the maximum values.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

An energy-saving profile runs through the displayed automatic state machine if the associated

"energy-saving profile initialized" bit is set. The HMI resets this bit before changing the times

or the signal mask, and sets it after the values have been consistently written into the PLC.

When the "Energy-saving profile active" bit is set, then an energy-saving profile is considered

to have been assigned.

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State monitoring

Transition to "RUN"

All of the signals that have been enabled for evaluation using the following masking bits, are

inactive

(also see Chapter 3.1.5.2.):

DBX 11.0, DBX 11.1, DBX 11.2

HMI activities

DBX 12.0

MCP activities

DBX 13.0 - DBX 13.7

NCK channel activities

DBX 14.0, DBX 14.1

NCK channel activities

DBX 15.0, DBX 15.1

Master computer and PLC prohibit signals

The specified signals refer to energy-saving profile 1.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Transition to "OFF"

DBX 10.1 == 1 ("deactivate profile") or delete the profile: highest priority and independent

of the profile initialization

- OR -

0-1 edge at the DBX 10.0 ("profile is initialized")

- OR -

At least one of the signals that have been enabled for evaluation using the following masking

bits, is inactive (also see Chapter 3.1.5.2.):

DBX 11.0, DBX 11.1, DBX 11.2

HMI activities

DBX 12.0

MCP activities

DBX 13.0 - DBX 13.7

NCK channel activities

DBX 14.0, DBX 14.1

NCK channel activities

DBX 15.0, DBX 15.1

Master computer and PLC prohibit signals

The specified signals refer to energy-saving profile 1.

4.1.3

Checking the energy-saving states

The following signals are checked when entering or retaining the energy-saving profile. The

signals can be masked for each energy-saving profile.

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Signal

Function

Generated by the HMI

Keyboard has been used

This signal is set if in the last second the keyboard of the SINUMERIK control was used.

This signal is only available once for each control system and is automatically linked through

(state condition "No key press-

the masking. In the case of several operator panels, the group signal of all keyboards is

ed on the operator panel")

used. For a keystroke, the HMI sets this bit and the PLC handles the reset process.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Signal

Function

Data transfer active

This signal is set if data is being transferred. After completion of the data transfer, the HMI

resets this bit. This includes the use of a USB memory medium, a V24 connection or a

(state condition "No communi-

network drive.

cation with an external device

active (USB, Ethernet, V24)")

This signal is also set when generating or importing a commissioning archive. This signal

is only available once for each control system and is automatically linked through the mask-

ing. In the case of several operating stations, the group signal is formed. Acyclic S7 com-

munication in the sense of a connected engineering system or an external HMI does not

apply as data transfer in the sense of this signal.

Screen change active

This signal is set if a screen is being changed. After processing, the PLC resets the bit.

This signal is only available once for each control system and is automatically linked through

(state condition "No screen

the masking. For several operator stations, the group signal is formed here.

change realized")

Generated by the PLC basic program (828D: PLC firmware)

Machine control panel used

This signal is set if the machine control panel in the PLC is used. To do this, a specified

address range of the inputs is monitored in the PLC.

(state condition "No key press-

ed on the machine control pan-

● For 840D sl, the ranges addressed via parameters DB7 MCP1In and MCP2IN

el")

● For 828D, the input range of the PN-MCP

This signal is only available once for each control system and is automatically linked through

the masking. The group signal is formed when several machine control panels are being

used.

NCK activity

This signal is set if the NCK channel is not in the Reset channel state.

(state condition "NC channel/

Note: Static synchronized actions, which are also active in the Reset channel state = TRUE,

channels in reset")

are not detected and must be taken into account by the user.

From the PLC user program interface

Master computer prohibits

Using this signal, an external master computer or a coupled control system can prevent

that the energy-saving profile is activated. This signal is available in the user interface for

(state condition "master com-

each energy-saving profile.

puter signal prohibits")

PLC user program signal

Using this signal, from the user program in the PLC, an energy-saving profile can be pre-

vented from being activated. This signal is available in the user interface for each energy-

(state condition "PLC user sig-

saving profile.

nal prohibits")

4.1.4

PLC user program

The following signals are available in the user program for controlling the energy-saving

profiles. These signals are not masked within the energy profile, and are available for each

profile.

Signal

Function

Control signal to "directly acti-

The energy-saving profile is immediately activated when this signal is set. The two timers

vate the energy-saving profile"

are set to zero. For the case that the energy profile has already been activated, no change

is made.

Set time to prewarning limit

When setting this signal, the timer for the prewarning limit T₂ is set to its setpoint and is

then restarted. This is also the case, even if the energy-saving profile is already active. The

activation is then reset, and after the prewarning time is set again.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Signal

Function

Feedback signal, "prewarning

This signal is set by the basic PLC program (FB15) if the timer has expired and the pre-

time T₁ expired"

warning is output on the HMI.

Feedback signal, "prewarning

This signal is set by the basic PLC program (FB15) if, after the prewarning limit has been

time T₂ expired"

reached, also the prewarning time of the corresponding energy profile has expired. This

means that this signal is equivalent to the information "Energy-saving state active".

Note

Shutdown auxiliary equipment

If auxiliary equipment is also to be shut down using the "Prewarning time expired" signal, which

acknowledges the shutdown process, then using a normal PLC timer and the signal "PLC user

program signal", a monitoring function can be installed in the basic PLC program. If the auxiliary

equipment has still not been run down after the PLC timer has expired, then the energy-saving

state can be exited again using the "PLC user program signal".

4.1.5

Interface signals 840D sl

4.1.5.1

Signals for controlling energy-saving profiles

Dynamic data are cleared when the control powers up.

The signals described in the following section refer to energy-saving profile 1.

Control signals (user program)

DB1000

DBX0.0

Directly activate energy-saving profile

DBX0.1

Set time to prewarning limit

Control signals (HMI)

DB1000

DBX1.0

Directly activate energy-saving profile

Signals to check the energy-saving state (user program)

DB1000

DBX2.0

Master computer prohibits energy-saving state

DBX2.1

PLC user program signal prohibits energy-saving state

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Status signals

DB1000

DBX4.0

Energy-saving profile is active

DBX4.1

Prewarning limit T1 reached

Actual values

DB1000

DBW6

Actual value T₁

DBW8

Actual value T₂

4.1.5.2

Signals for parameterization

Retentive parameterization data.

Effectiveness (HMI → PLC)

DB1000

DBX 10.0

Energy-saving profile configured

DBX 10.1

Disable energy-saving profile

Masking (HMI → PLC)

DB1000

DBX 11.0

Keyboard has been used

DBX 11.1

Data transfer active

DBX 11.2

Screen change active

DBX 12.0

Machine control panel used

DBX 13.0

NCK channel 1

DBX 13.1

NCK channel 2

DBX 13.2

NCK channel 3

DBX 13.3

NCK channel 4

DBX 13.4

NCK channel 5

DBX 13.5

NCK channel 6

DBX 13.6

NCK channel 7

DBX 13.7

NCK channel 8

DBX 14.0

NCK channel 9

DBX 14.1

NCK channel 10

DBX 15.0

Master computer prohibits*

DBX 15.1

PLC user program signal prohibits*

*prohibits changing into the energy-saving mode

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Maximum times (HMI → PLC)

DB1000

DBW 16

Activation time T₁

DBW 18

Time for the prewarning limit T₂

Additional profile instances

DB1000

DBW 20

Energy-saving profile 2

DBW 40

Energy-saving profile 3

DBW 60

Energy-saving profile 4

DBW 80

Energy-saving profile 5

DBW 100

Energy-saving profile 6

DBW 120

Energy-saving profile 7

DBW 140

Energy-saving profile 8

4.1.6

Interface signals 828D

4.1.6.1

Signals for controlling energy-saving profiles

Dynamic data are cleared when the control powers up.

Control signals (user program)

DB9906

DBX0.0

Directly activate energy-saving profile

DBX0.1

Set time to prewarning limit

Control signals (HMI)

DB9906

DBX1.0

Directly activate energy-saving profile

Signals to check the energy-saving profile (user program)

DB9906

DBX2.0

Master computer prohibits energy-saving state

DBX2.1

PLC user program signal prohibits energy-saving state

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Status signals

DB9906

DBX4.0

Energy-saving profile is active

DBX4.1

Prewarning limit T1 reached

Actual values

DB9906

DBW6

Actual value T₁

DBW8

Actual value T₂

4.1.6.2

Signals for parameterization

Retentive parameterization data.

Effectiveness (HMI → PLC)

DB9906

DBX10.0

Energy-saving profile configured

DBX 10.1

Disable energy-saving profile

Masking (HMI → PLC)

DB9906

DBX11.0

Keyboard has been used

DBX11.1

Data transfer active

DBX11.2

Screen change active

DBX12.0

Machine control panel used

DBX13.0

NCK channel 1

DBX13.1

NCK channel 2

DBX15.0

Master computer prohibits*

DBX15.1

PLC user program signal prohibits*

*prohibits changing into the energy-saving mode.

Maximum times (HMI → PLC)

DB9906

DBW16

Activation time T₁

DBW18

Time for the prewarning limit T₂

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

Additional instances

DB9906

DBW20

Energy profile 2

DBW40

Energy profile 3

DBW60

Energy profile 4

DBW80

Energy profile 5

DBW100

Energy profile 6

DBW120

Energy profile 7

DBW140

Energy profile 8

4.2

Creating and editing energy-saving profiles

You can make the following changes in the list of energy-saving profiles in the commissioning

mode:

● Creating new energy-saving profiles with prewarning time and activation time period.

● Changing state conditions, prewarning time and activation time period

● Deleting energy-saving profiles

● Importing externally generated energy-saving profiles into the system

● Backing up energy-saving profiles on an external medium

Note

Maximum number of energy-saving profiles

A maximum of 8 energy-saving profiles can be created.

If the maximum number of profiles already exists, then the "New" softkey is no longer

available. To create a new energy-saving profile, remove a profile using the "Delete" softkey

or change an existing profile using the "Change" softkey.

Note

Access level of the energy-saving profiles for users

You specify the access level for the "Energy-saving profiles" softkey in the "Parameter"

operating area using the machine data 51071 $MNS_ ACTIVATE_CTRL_E (protection level

1 as standard; this must be explicitly enabled by the manufacturer).

Note

Designations of energy-saving profiles that have been created

The names of the new energy-saving profiles that have been created are only visible at the

control where you generated them.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

Energy conditions

The following criteria are available for configuring an energy-saving profile:

State conditions

Meaning

No key on the operator panel pressed

To activate the energy-saving profile, it is not permis-

sible that an operator panel key is pressed.

No key on the machine control panel pressed

To activate the energy-saving profile, it is not permis-

sible that a machine control panel key is pressed.

No screen change realized

To activate the energy-saving profile it is not permis-

sible that a screen is being changed.

No communication with an external device ac-

To activate the energy-saving profile, it is not permis-

tive (USB, Ethernet, V24)

sible that data is being exchanged with an external

device, for example.

NC channel/channels in Reset

To activate the energy-saving profile, NC channel/

channels must be in the Reset state.

Master computer signal prohibits

To activate the energy-saving profile, it is not permis-

sible that a signal is received from the master com-

puter.

PLC user signal prohibits

To activate the energy-saving profile, it is not permis-

sible that a signal is received from the PLC user pro-

gram.

The OEM can logically combine other state condi-

tions with this signal and influence the profiles.

Activation of the energy-saving profile after

Here, you enter the time period after which the ener-

gy-saving profile is activated.

Prewarning after

Here, you enter when the system starts to display the

prewarning.

Note:

If you enter the same value into the "Activation of the

energy-saving profile after" and "Prewarning after"

fields, then no message is displayed specifying the

remaining time up until the energy-saving profile is

activated.

Note

Protection levels for editing energy-saving profiles

You define the protection level that is required in order to create or edit an energy-saving profile

in machine data 51072 $MNS_ACCESS_EDIT CTRL_E (default, protection level 2 (service)).

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

Procedure

Select the "Startup" operating area.

Press the "HMI" and "Ctrl-Energy" softkeys.

The window "SINUMERIK Ctrl-Energy: Definition of the energy-saving

profile" is opened.

Newly creating/changing energy profiles

Position the cursor on the line where you wish to create a new energy-

saving profile and press the "New" softkey.

The window "SINUMERIK Ctrl-Energy: Definition of the energy-saving

profile" is opened.

In the "Designation" field, enter the desired name for the new energy-

saving profile. Activate the required state conditions. Specify the times to

display the prewarning limit and to activate the energy-saving profile.

- OR -

Position the cursor on the energy-saving profile that you want to edit and

press the "Change" softkey.

The window "SINUMERIK Ctrl-Energy: Definition of the energy-saving

profile" is opened.

In the "Designation" entry field, enter the modified name of the energy-

saving profile. Select or deselect the state conditions that should be ef-

fective for the modified energy-saving profile - and when required, change

the time data.

Press the "OK" softkey.

The new or modified energy-saving profiles are activated.

The modified texts (def_conditions<long>.ts) are saved in the \oem\sinu-

merik\hmi\lng directory.

Importing energy-saving profiles

Press the "Import profile" softkey.

The "Import energy-saving profiles" window is displayed.

Select the required XML file and press the "OK" softkey. After a prompt,

the energy-saving profiles are downloaded into the PLC.

The associated text files (def_conditions<long>.ts) are saved in the \oem

\sinumerik\hmi\lng directory.

Note:

After importing the energy-saving profiles, a restart is required in order

to make the profiles effective.

Exporting energy-saving profiles

Press the "Export profiles" softkey.

The window "Export energy-saving profiles: Select storage location"

opens.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

Select the required storage location and press the "OK" softkey.

The language-neutral state data are stored in the XML format, the asso-

ciated texts in a .ts file. You have the option of selecting a name for the

XML file (default: def_conditions.xml).

The text files are saved under a fixed name. All of the defined energy-

saving profiles are always exported.

Note:

Please note that the energy-saving profiles supplied from Siemens are

also deleted. It is recommended that the energy-saving profiles are al-

ways exported and backed up.

Deleting energy-saving profiles

Select the energy-saving profile that you want to delete from the list and

press the "Delete" softkey.

Confirm the prompt with "OK" to remove the profile.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Reactive power compensation

The Active Line Modules of the SINAMICS S120 series offer the option of compensating

capacitive or inductive reactive current. As standard, this function is used to compensate for

the system's own modules.

In addition, within a sensible scope, this feature can be used to compensate other (generally

inductive) loads connected to machine.

As a result of the properties of the SINAMICS S120 Active Line Module as actuator on one

hand, the properties of SENTRON PAC4200 as measuring element as well as additional PLC

blocks (also as controller), this function can be implemented with the SINUMERIK 840D sl also

independent of NC software releases.

Further information

Please contact your local sales organization if you require additional information regarding

reactive power compensation.

Function schematic

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Principle of operation of reactive power compensation

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Flux reduction

In the drive parameters (p1581 [0..n]), the rated magnetization for induction motors - which is

normally 100% - can be permanently reduced. This includes the switching times for reducing

and building up the flux (r1578, r1579[0…n]).

In this case, not only can the magnetizing losses in the motors be reduced at standstill, but

also during operations that only require a lower power.

Optimization criterion

Under no-load conditions, the percentage value of the rated magnetization is reduced in steps

of between 5-10% to just above a value where the no-load behavior starts to become uneven.

From this limit value onwards, rough operating behavior can be heard as a result of the

significantly fluctuating active current.

It makes sense to monitor the current characteristic and this transition point using a trace

function.

Options for use

You have various options to specifically use this.

● Permanently set the actual parameter set p1581 [0] to the determined value <100%.

Taking into consideration the time constants, the flux is automatically reduced if the

instantaneous active power permits this. If more active power is demanded, then the flex

automatically increases back up to 100% with the corresponding time constant. This does

not have a negative impact on the process.

● Preselecting various parameter sets

If load changes are to be expected in a time shorter than the time constant (e.g. for an

interrupted roughing cut with facing head milling tools), it may be more favorable for the

process if the flux is permanently controlled by pre-selecting various parameter sets by

knowing the machining to be expected or the tool involved.

Example ((see the interface signals at the spindle DB31-61.DBB21))

Bit0: = 0:

p1581 [0] = 100%;

p1578 [0] and p1579 [0] = factory setting, e.g. for an interrupted cut

Bit0: = 1:

p1581 [1] < 100%;

p1578 [1], p1579 [1], adapted for partial load or no load

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

User know-how

Machine manufacturers are being increasingly confronted with special demands from users

regarding proving energy consumption data or displaying limit values, for example.

Using SINUMERIK Integrate Run MyScreens (Easy Screen), it is possible to visualize the

functions obtained from these requirements, and also position them in the context of Ctrl-

Energy.

Displaying additional measuring data

The SENTRON PAC 3200/4200 Power Monitoring Devices provide, in different expansion

stages, a wealth of electrical measured data.

In addition to the active power/active energy displayed today in SINUMERIK Operate, using

Easy Screen, you have the option of displaying, for example, the reactive power/reactive

energy and the apparent power/apparent energy of the measuring location in customized

screen forms.

References

More information on the various measuring options is available in the following references:

● SENTRON PAC3200 Power Monitoring Device Manual

● SENTRON PAC4200 Power Monitoring Device System Manual

7.1

Commissioning user screen forms

General procedure

● You create your own screen forms in SINUMERIK Integrate Run MyScreens (Easy Screen),

for example in a xxx.com file.

● You insert the new "xxx.com" project file name in "easyscreen.ini" in the "Parameter" area.

● Save the modified "easyscreen.ini" in the following directory: oem\sinumerik\hmi\cfg\.

● If the released horizontal softkey 7 in the extended softkey bar of the "Parameter" operating

area is already used with a "yyy.com", then you have the option of programming the vertical

softkey 4 behind the "Ctrl-Energy" softkey for an additional "xxx.com".

An additional neutral "aufruf.com" file is created with the following start softkeys:

//S(START)

VS4=("Start XXX")

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

User know-how

7.1 Commissioning user screen forms

PRESS(VS4)

LM("maske_xxx","xxx.com")

END_PRESS

HS7=("Start YYY")

PRESS(HS7)

LM("maske_yyy","yyy.com")

END_PRESS

//END

These start calls directly access the specified screen forms of the relevant *.com files. A start

softkey in these particular *.com files can be omitted.

● Save the project files "xxx.com", "yyy.com" and "aufruf.com" in the following directory: oem

\sinumerik\hmi\proj\.

References

Additional information on the design and configuration of user interfaces is provided in the

following references on SINUMERIK Integrate Run MyScreens (Easy Screen):

Programming Manual Easy Screen (BE2); SINUMERIK 840D sl

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

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" columns.

Status code in the "Remarks" column:

New documentation.

Unrevised reprint with new Order No.

Revised edition with new status.

Edition

Order No.

Remarks

06.03

Included in online help only -

03/2007

Included in online help only -

07/2008

included in online help only -

Registered trademarks

All names with the protective right label ® are registered trademarks of the Siemens AG. The

other product and system names in this document may be registered trademarks of their

respective companies and must be treated accordingly.

Disclaimer of liability

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.

Bestell-Nr. included in online help only -

Siemens-Aktiengesellschaft.

07/2008

Preface

Structure of the documentation

SINUMERIK documentation is organized in 3 parts:

• General documentation

• User documentation

• Manufacturer/Service Documentation

An overview of publications (updated monthly) indicating the language versions

available can be found on the Internet at:

http://www.siemens.com/motioncontrol

Follow menu items "Support" → "Technical Documentation" → "Ordering

Documentation" →"Printed Documentation".

The Internet version of the DOConCD (DOConWEB) is available at:

http://www.automation.siemens.com/doconweb

Information about training courses and FAQs (Frequently Asked Questions) can be

found at the following web site:

http://www.siemens.com/motioncontrol under menu option "Support"

Reader group

This manual is intended for users of machine tools with

SINUMERIK 840D sl/ 840Di sl and SINAMICS drive,

SINUMERIK 840D/ 840Di/ 810D and SIMODRIVE.

Standard version

This Parameter Manual only describes the functionality of the standard version.

Extensions or changes made by the machine tool manufacturer are documented by

the machine tool manufacturer.

Other functions not described in this documentation might be executable in the

control. This does not, however, represent an obligation to supply such functions

with a new control or when servicing.

Further, for the sake of simplicity, this documentation does not contain all detailed

information about all types of the product and cannot cover every conceivable case

of installation, operation or maintenance.

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

iii

Preface

07/2008

Technical Support

If you have any questions, please get in touch with our Hotline:

Europe / Africa

Phone

+49 180 5050 - 222

Fax

+49 180 5050 - 223

Internet

http://www.siemens.de/automation/support-request

America

Phone

+1 423 262 2522

Fax

+1 423 262 2200

E-mail

mailto:techsupport.sea@siemens.com

Asia / Australia

Phone

+86 1064 719 990

Fax

+86 1064 747 474

E-mail

mailto:adsupport.asia@siemens.com

Note

Country telephone numbers for technical support are provided under the following

Internet address:

http://www.siemens.com/automation/service&support

Calls are subject to charge, e.g. € 0.14/min on the German landline network.

Tariffs of other hone providers may differ.

Questions about the documentation

If you have any queries (suggestions, corrections) in relation to this documentation,

please fax or e-mail us:

Fax

+49 9131 98 - 2176

E-mail

mailto:docu.motioncontrol@siemens.com

Fax form: See the reply form at the end of the document.

SINUMERIK Internet address

http://www.siemens.com/sinumerik

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

07/2008

Preface

Aim

This document explains how to install the SINUMERIK SinuCom

Installation/Service Tools and describes its functionality. The purpose of the

SinuCom Installation/Service Tools is to facilitate start-up and installation of the

SINUMERIK 840D sl/ 804Di sl/ 840D/ 840Di/ 810D.

On the SINUMERIK 840D/810D the tool is started from the PG/PC in online mode

(PG/PC control via OPI). It is included in the Software on the SINUMERIK 840Di.

Standard scope

This publication describes the standard scope of functions. Any extensions or

modifications to the standard scope made by the machine manufacturer will be

documented by the machine manufacturer. Please contact your local Siemens

sales office for further information about other publications relating to SINUMERIK

840D/840Di/810D and publications that are applicable to all SINUMERIK controls

(e.g. universal interface, measuring cycles ...).

Other functions not described in this documentation might be executable in the

control. This does not, however, represent an obligation to supply such functions

with a new control or when servicing.

Important

This System Description is applicable to the following control types:

SINUMERIK 840D sl / SINUMERIK 840DE sl (export version)

SINUMERIK 840D powerline / 840DE powerline (export version)

SINUMERIK 840Di powerline / 840DiE powerline (export version)

SINUMERIK 810D powerline / 810DE powerline (export version)

with operator panel types OP 010, OP 010C, OP 010S, OP 12 or OP 15

(PCU 50, PCU 70/ NCU 710, NCU 720, NCU 730).

Notes

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

Note

This symbol always appears in this documentation to draw your attention to

further information relevant to the subject in hand.

Important

This symbol always appears in the documentation when important information is

being conveyed.

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

Preface

07/2008

Additional ordering options

Appears in the documentation whenever a described function is not contained in

the standard version but may be ordered as an option.

Safety information

This manual contains notices that you should observe to ensure your own personal

safety, as well as to protect the product and connected equipment. Notices

referring to your personal safety are highlighted in the manual by a safety alert

symbol; notices referring to property damage only have no safety alert symbol. The

warnings are shown below in decreasing order of danger.

Danger

Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury or in substantial property damage.

Warning

Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury or in substantial property damage.

Caution

Used with the safety alert symbol indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury or in property

damage.

Caution

Used without safety alert symbol indicates a potentially hazardous situation

which, if not avoided, may result in property damage.

Notice

Used without the safety alert symbol indicates a potential situation which, if not

avoided, may result in an undesirable result or state.

If several hazards of different degrees occur, the hazard with the highest degree

must always be given priority. If a warning note with a warning triangle warns of

personal injury, the same warning note can also contain a warning of material

damage.

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

07/2008

Preface

Qualified personnel

Start-up and operation of the device/equipment/system in question must only be

performed using this documentation. The device/system must only be started and

operated by qualified personnel. Qualified personnel as referred to in the safety

guidelines in this documentation are those who are authorized to start up, earth

and label units, systems and circuits in accordance with the relevant safety

standards.

Correct usage

Note the following:

Warning

The unit may be used only for the applications described in the catalog or the

technical description, and only in combination with the equipment, components

and devices of other manufacturers where recommended or permitted by

Siemens. This product can only function correctly and safely if it is transported,

stored, set up, and installed correctly, and operated and maintained as

recommended.

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

vii

07/2008

Contents

1 Product SinuCom

1-13

1.1 Product features

1-14

1.2 Scope of supply

1-16

1.3 Permissible PC platforms

1-17

2 Installation

2-19

2.1 Installation variants

2-20

2.2 Installation of SinuCom NC

2-20

2.3 Installation of SinuCom FFS

2-22

2.4 Installation of SinuCom CFS

2-23

2.5 Installation of SinuCom ARC

2-24

2.6 Installation of SinuCom PCIN

2-25

2.7 Uninstalling

2-26

3 General Operating Sequences

3-27

3.1 Installation and start-up with SinuCom NC

3-28

3.2 Help functions

3-29

3.3 Using the keyboard

3-32

4 SinuCom NC: Functions

4-33

4.1 Document Scope and Supported Systems

4-34

4.1.1 Scope of this Manual

4-34

4.1.2 Supported Systems and NCK Versions

4-34

4.1.3 Supported Languages

4-34

4.2 What's New in SinuCom NC 7.50

4-35

4.3 Main Menu

4-35

4.4 Toolbar Buttons

4-36

4.5 Alarm Messages

4-36

4.6 Machine Data ("MD")

4-37

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

Contents

07/2008

4.6.1 Viewing and Configuring MD

4-37

4.6.2 Machine Data Project Tree

4-39

4.6.3 Service Data

4-41

4.7 Archiving

4-42

4.8 SinuCom NC Trace

4-43

4.8.1 Overview: How Trace is Used

4-44

4.8.2 Sessions and Their Content

4-49

4.8.3 Reference Waveforms

4-52

4.8.4 Toolbars and Menus

4-54

4.8.5 Context Menus

4-68

4.8.6 Dialogs

4-73

4.8.7 Trace Symbol Import Wizard (TSIW)

4-88

4.8.8 Trace Setup Wizard (TSW)

4-94

4.9 Safety Integrated Acceptance Test Wizard

4-99

4.9.1 Example:

4-99

4.9.2 Common Screen Contents

4-101

4.9.3 Custom Templates

4-104

5 SinuCom FFS: Functions

5-109

5.1 Operation

5-110

5.2 Display of the NC image

5-110

5.3 Displaying/editing the FFS image

5-110

5.4 Writing/Reading an NC image to NC card

5-111

6 SinuCom CFS: Functions

6-113

6.1 Operation

6-114

6.1.1 Create projekt

6-114

6.1.2 Set up project views

6-116

6.1.3 Generate image

6-117

6.1.4 Read in / out image on the CompactFlash Card

6-117

6.1.5 Select language

6-118

7 SinuCom ARC: Functions

7-119

7.1 Operation

7-120

7.2 Displaying the contents of the archive

7-120

7.3 Editing the archive contents

7-120

7.4 Creating an archive

7-122

8 SinuCom PCIN: Functions

8-123

8.1 Operation

8-124

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

1 Product SinuCom

07/2008

1.1 Product features

This program package supports simple and effective startup of

SINUMERIK 840D sl/ 840Di sl and SINUMERIK 810D/ 840D/ 840Di controls on

CNC machines.

On the SINUMERIK 810D/ 840D/ 840D sl the tool is started from the PG/PC in

online mode (PG/PC control via the OPI interface), in the case of the SINUMERIK

840Di/ 840Di sl it is included in the software.

Product components

The installation/service tools SinuCom comprises five tools:

1. SinuCom NC

- SinuCom NC Trace

- SinuCom NC SI

2. SinuCom FFS

3. SinuCom CFS

4. SinuCom ARC

5. SinuCom PCIN

Functions

The installation/service tools tool SinuCom offers the following functions:

• Use of the Trace functionality

• Safety Integrated Acceptance Test Wizard

• Creation of CompactFlash Card images

• Series commissioning file management

• Transfer of CNC user data

Note

The NC card is programmed with standard tools (e. g. Cardware) that are not

contained in the included in the scope of supply of SinuCom FFS.

A Flash File System (FFS) is comparable with a DOS data medium, e.g. a diskette.

Before data can be archived, the system must be formatted. Then the directory

structures can be created and files stored in a suitable format.

The data medium is an electrically erasable PROM (EEPROM). This means that

before writing the relevant sector must be erased. Algorithms written for the module

identification are required for erasing and writing. They largely determine the speed

with which data are written.

An FFS system can be read directly from DOS/WINDOWS.

Because the NC system software also stored on the NC card does not exist in FFS

format, this can only be performed with “SINUCOPY-FFS”.

Note

Please read the A&D software marketing guidelines before duplicating software.

1-14

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07/2008

1 Product SinuCom

1.1 Product features

SinuCom NC Trace

SinuCom NC Trace function is used for the dynamic recording of CNC, PLC and

HMI variables, and of drive signals that are available via the CNC. These variables

can be displayed, printed out or stored in a file, similar to using an oscillograph or

logic analyzer. The SinuCom NC Trace function provides support in:

• Fault detection and fault correction

• Machine performance analysis, benchmarking and tuning

• Process performance analysis, benchmarking and tuning

SinuCom NC SI

SinuCom NC SI integrated acceptance test, it supports the original equipment

manufacturer (OEM), and optimizes the process:

• Verification of machines in accordance with EU Machinery Directive EN

954-1 (control category 3)

• Testing of safety functions (partly automated) during the machine

acceptance

• Logging of measured data and test results incl. Trace function records

• Testing of single/special-purpose machines, machine components (as a

partial test) and series machines as series startup

• Shorter startup times since, in the new acceptance mode, power-on alarms

during the acceptance test are acknowledged by RESET

• User-friendly operation due to controlled execution and the automatic

configuration of the Trace functions.

• Unambiguous quality verification for original equipment manufacturers as

well as customers and for dealings with government agencies.

SinuCom FFS

SinuCom FFS is used to generate an image for the PC card of the CCU/NCU of

SINUMERIK 810D/840D (powerline). It contains:

• Processing of the flash file system

• Preparing the image for programming the PC card

• Integrated help

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

1-15

1 Product SinuCom

07/2008

1.2 Scope of supply

SinuCom CFS

SinuCom CFS is used to generate an image for the SINUMERIK 840D sl NCU’s

CF card, in Ext3 format. It contains:

• Preparing the image for programming the CF card

• Integrated help

SinuCom ARC

SinuCom ARC simplifies the processing of series startup files:

• Reading, deleting, inserting and changing series startup files

• Integrated help

SinuCom PCIN

The SinuCom PCIN program is used to send and receive CNC user data, such as

machine data and part programs, via the serial interface between a Siemens

PC/PG and a Siemens control.

It contains:

• Setting up and interrogating V.24 interface

• Editing archive files

• Storing files from directories individually

• Secure data transmission

• Integrated help

The service tool SinuCom PCIN can be operated with the mouse or keyboard.

1.2 Scope of supply

Supply medium

The installation/service tools SinuCom is supplied on DVD.

Licenses

The following licenses are available:

• Single license

• Single license without data medium

• Software Update Service

• Update for certain SW version

Foreign languages

The installation/service tools SinuCom is supplied in six languages

(English/German/French/Spanish/Italian/Chinese, ATW Certificate Exportlist,

Service Data only). Language switchover only takes effect after rebooting.

1-16

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

07/2008

1 Product SinuCom

1.3 Permissible PC platforms

Ordering data

Table 1-1

Ordering data

Order No.

SinuCom

6FC5 250-

AY00-

Installation/Service tools

on DVD including

SinuCom NC (Trace/SI)

SinuCom FFS, SinuCom CFS,

SinuCom ARC, SinuCom PCIN,

documentation

Languages English/German

License

• Single license, current SW version

...............-

........-

• Single license, particular software

...............-

........-

version

• Copy license

...............-

........-

Software maintenance

• Software maintenance service

...............-

........-

• Order updates separately, particular

...............-

........-

SW version

Example for a particular software version, e.g. SW 7.3: 6FC5 250-7

-3...

1.3 Permissible PC platforms

The product components of SinuCom can be used on the following PC platforms:

Table 1-2

Windows

2000

SinuCom

Yes

SinuCom

Yes

FFS

SinuCom

Yes

CFS

SinuCom

Yes

ARC

SinuCom

Yes

PCIN

Note

SinuCom 07.01 and later can only be installed with Windows XP.

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

1-17

2 Installation

07/2008

2.1 Installation variants

The installation/service tools SinuCom includes four different installation variants:

1. SinuCom NC only

2. SinuCom FFS only

3. SinuCom CFS only

4. SinuCom ARC only

5. SinuCom PCIN only

2.2 Installation of SinuCom NC

Requirements

SinuCom NCrequires Windows® XP professional (SP1 or SP2).

SinuCom NC occupies approximately 7 MB in the Windows® system directory and

approximately 52 MB in the SinuCom NC directory. If HMI Advanced is not already

installed, an additional 156 MB are required.

The program is included in the scope of delivery of the SINUMERIK 840Di sl.

Procedure

1. Insert the DVD into the drive of your PG/PC

2. Start Windows Explorer (or MS-DOS).

3. Change to the CD/DVD-drive.

4. Open the folder "SinuCom NC”.

5. Start the program "Setup.exe”. This program starts up an operator-guided

installation of SinuCom NC.

6. A warm start must be performed on the PG/PC after the installation.

The info files "siemensd.txt" (German) and "siemense.txt" (English) are copied into

the SinuCom NC directory on your hard disk by the SETUP program, so this

information is still available to you after installation.

Starting SinuCom NC

"SinuCom NC" is started as follows:

1. Double-click the "SinuComNC" icon.

2. Via the Windows task bar of the PG/PC: "Start" → "Programs" →

"SinuCom" → "SinuComNC".

2-20

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2 Installation

2.2 Installation of SinuCom NC

Note

On 840Di, the 840Di software is usually installed before the optional HMI

Advanced software. In this case, SinuCom NC will not automatically be installed

on softkey 9. To make this softkey operational, SinuCom NC must be reinstalled

after the complete installation of the 840Di software.

Note

SinuCom NC can be run without a mouse by using a keyboard.

Establishing a connection to the NC

Starting with SinuCom NC, the "NCU Connection Wizard" (NCW) is the preferred

tool for connecting the NCK, PLC, and drives.

Starting NCU Connection Wizard

•

Via the Windows taskbar of the PG/PC: "Start" → "Programs" → "SinuCom"

→ "NC Connect Wizard".

•

If SinuCom NC is unable to connect at startup, a message automatically

appears that provides the NCW as a selection.

The wizard makes a selection of MPI or Ethernet connections available, based on

the answers to a few questions. Changes made using the NC Connection Wizard

(NCW) become effective only after SinuCom NC has been restarted.

For SINUMERIK powerline systems, a number of drivers are provided; however, if

the driver appropriate to your MPI hardware does not appear, you may have to

obtain and install the driver separately (e. g., from SIMATIC Software).

SINUMERIK solution line uses an Ethernet connection that requires no drivers.

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

2-21

2 Installation

07/2008

2.3 Installation of SinuCom FFS

Requirements

• SinuCom FFS runs under Windows Me/NT 4.0/XP.

• SINUMERIK 810D/840D powerline.

• SinuCom FFS requires approx. 1.2 MB.

• Before you can install SinuCom FFS you must first close down all other

applications (not the Explorer).

When copying the software, be sure to follow the A&D software marketing

guidelines!

Procedure

1. Insert the DVD into the drive of your PG/PC

2. Start Windows Explorer (or MS-DOS).

3. Change to the CD/DVD-drive.

4. Open the folder "SinuCom FFS”.

5. Start the program "Setup.exe”. This program starts up an operator-guided

installation of SinuCom FFS.

6. A warm start must be performed on the PG/PC after the installation.

The info files "siemensd.txt" (German) and "siemense.txt" (English) are copied into

the SinuCom NC directory on your hard disk by the SETUP program, so this

information is still available to you after installation.

Note

• You can choose any drive name for the OMNI97 device: Enter the drive letter

in menu "Control Panel/Device Manager/Drives/OMNI97".

• Windows NT: Enter the drive letter in menu "OmniControl/DriveLetter".

Starting SinuCom FFS

"SinuCom FFS” is started as follows:

• Double-click the "SinuCom FFS" icon

• Via the Windows task bar of the PG/PC: "Start” → "Programs" → "SinuCom" →

"SinuComFFS"

2-22

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2 Installation

2.4 Installation of SinuCom CFS

Requirements

• SinuCom CFS requires the Windows XP software platform.

•

156 MB memory space is required to install the SINUMERIK 840D sl system

software.

• SinuCom CFS occupies approx. 1 MB memory space.

• Terminate all applications (except the Explorer) before installing SinuCom CFS.

Procedure

Insert the DVD into the drive of your PG/PC.

Start Windows Explorer (or MS-DOS).

Change to the CD/DVD-drive.

Open the folder "SinuCom CFS”.

Start the program "Setup.exe”. This program starts up an operator-guided

installation of SinuCom CFS.

A warm start must be performed on the PG/PC after the installation.

The info files "siemensd.txt" (German) and "siemense.txt" (English) are copied into

the SinuCom NC directory on your hard disk by the SETUP program, so this

information is still available to you after installation.

Starting SinuCom CFS

"SinuCom CFS” is started as follows:

• Double-click the "SinuCom CFS" icon

• Via the Windows task bar of the PG/PC: "Start” → "Programs" → "SinuCom" →

"SinuComCFS"

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

2-23

2 Installation

07/2008

2.5 Installation of SinuCom ARC

Requirements

• SinuCom ARC runs under Windows ME, Windows NT 4.0, Service Pack 6, and

higher), WindowsXP or Windows 2000.

• SinuCom ARC requires approx. 0.7 MB.

• Before you can install SinuCom ARC you must first close down all other

applications (not the Explorer).

Procedure

1. Insert the DVD into the drive of your PG/PC

2. Start Windows Explorer (or MS-DOS).

3. Change to the CD/DVD-drive.

4. Open the folder "SinuCom ARC”.

5. Start the program "Setup.exe”. This program starts up an operator-guided

installation of SinuCom ARC.

6. A warm start must be performed on the PG/PC after the installation.

The info files "siemensd.txt" (German) and "siemense.txt" (English) are copied into

the SinuCom ARC directory on your hard disk by the SETUP program. So this

information is still available to you after installation.

Starting SinuCom ARC

SinuCom ARC is started as follows:

1. Double-click the "SinuCom ARC" icon.

2. Via the Windows task bar of the PG/PC: "Start" → "Programs" → "SinuCom"

→ "SinuComARC".

3. In the "SinuCom NC" program via the menu "Options" → "SinuComARC".

2-24

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2 Installation

2.6 Installation of SinuCom PCIN

Requirements

• SinuCom PCIN runs under Windows 95/ 98/ ME/ NT 4.0/ 2000/ XP.

• SinuCom PCIN requires approx. 1.2 MB.

• HMI-Advanced SW 6.1.05.

• Before you can install SinuCom PCIN you must first close down all other

applications (not the Explorer).

Procedure

1. Insert the DVD into the drive of your PG/PC

2. Start Windows Explorer (or MS-DOS).

3. Change to the CD/DVD-drive.

4. Open the folder "SinuCom PCIN”.

5. Start the program "Setup.exe”. This program starts up an operator-guided

installation of SinuCom PCIN.

6. A warm start must be performed on the PG/PC after the installation.

The info files "siemensd.txt" (German) and "siemense.txt" (English) are copied into

the SinuCom PCIN directory on your hard disk by the SETUP program. So this

information is still available to you after installation.

Starting SinuCom PCIN

"SinuCom PCIN” is started as follows:

• Double-click the "SinuCom PCIN" icon.

• Via the Windows task bar of the PG/PC: "Start" → "Programs" → "SinuCom" →

"SinuCom PCIN".

SINUMERIK 840D sl/840Di sl/ 840D/840Di/810D SinuCom (INC) - 07/2008

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SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020) - page 110