Cam740 Help

Diagnosis for Sinumerik, Sinamics or Simatic S7

'Cam740' may be used for diagnosis of Sinumerik 840D, Sinamics or Simatic S7 systems connected via Ethernet, Profibus, MPI or any other interface supported by Siemens S7 systems.

Offline functions, without a connection to a live PLC system:
- Sinumerik alarm bit calculator: DB2 bit for a specific alarm number or alarm number for a specific bit in DB2
- Sinumerik M function calculator: Channel DB bit for quick decoding of an M function
- Sinumerik Fast IO calculator: DB10 bits for monitoring or control of a specific NCK fast input
- Sinamics Help for Alarms: Display the help for a Sinamics specific alarm number

Online functions, when the program is connected to a live PLC system:
- Sinumerik axis / channel diagnosis: a live screen with the status of some of the most important enable signals for axis / channel diagnosis
- Sinumerik OEM Alarm monitor / change bit status - Sinumerik M function logger
- Sinamics drive status diagnosis

Cam740 program is based on the older 'Monitor5' program. ... Goto Monitor5

No installation is needed, the program is portable and saves all data in .INI files in own folder.

To 'uninstall' simply delete the folder.

Download ... Goto GitHub

Connection to a live Simatic PLC / Sinumerik / Sinamics

	Target System; Settings for connection:
	Interface:	the connection interface options are:
	- "TCP/IP":	Connection type may be 'PG', 'OP' or 'S7 Basic'. There is no functional difference.
	- "S7ONLINE":	Connection type may be 'MPI / PROFIBUS', 'TCP/IP' or 'ISO Ethernet'.
	PLC Address:	set here the address of the target system (Step7-PLC or Sinamics Drive)
	Rack:	Step7 rack of the CPU (usually Rack 0).
	Slot:	Step7 slot of the CPU. Typical values are: Slot 0 for S7-1500 or Slot 1 for S7-1500 in Sinumerik ONE or Slot 2 for S7-300 series

Diagnosis Sinumerik 840D/One

	Target System; Settings for connection:
	X127:	(Service Interface): Address: 192.168.215.1
	X120:	(System Network): Address: 192.168.214.1
	X130:	(Company Network): Address: set by network administrator

	Sinumerik 840D: Rack 0, Slot 2
	Sinumerik ONE: Rack 0, Slot 1

Offline Functions:
Some functions of this program may be used offline.

Alarm Calculator:

Enter an Alarm number in the 'Alarm' field and press ENTER. Corresponding bit from DB2 is calculated in 'DB2 bit'. Examples: 510008, 700040, etc
Enter a bit number from DB2 in 'DB2 bit' field and press ENTER. Corresponding Alarm number is calculated in 'Alarm' field. Examples: DB2.DBX185.5 or DBX185.5 or 185.5

Note: When Connected, bit status (Alarm SET or Alarm NOT SET) is displayed and may be changed online with 'Set Bit' and 'Reset bit' buttons.

M Function Calculator:

Note: This function calculate only the 'Fast M decode' bits in Channel DB area from PLC. Only M0 to M99 are decoded, without extension. A full monitoring of M functions bits is available in '840D Func' Area.
For more information on decoding M function bits in PLC see the corresponding help.

Enter the Channel number in 'Chan' field and M function number in 'M fct.' field. Both DB number and bit number are calculated in 'bit' field. Examples: 'Chan:' 1 and 'M fct:' 3 or 'Chan:' 1 and 'M fct:' M3
Enter a bit number in 'bit' field and press ENTER. Corresponding M function number is calculated in 'M fct' field. If no DB number is entered, channel number is set to 0 (zero). Examples: DB22.DBX198.3 or DBX198.3 (no channel number will be calculated) or 198.3 (no channel number will be calculated)

Note: When Connected, bit status (M function SET or M function NOT SET) is displayed and may be changed online with 'Set Bit' and 'Reset bit' buttons.

Note: With 'Monitor' button the status change is monitored, retained and displayed even for 1-PLC-cycle changes. To reset the status press 'Monitor' button once more.

Fast IO Calculator:

Enter an NCK Fast Input number in the 'Fast IO' field and press ENTER. Corresponding bits for 'PLC disable of the input', 'PLC set value' and 'Actual value from Hardware' from DB10 are calculated in the corresponding fields.

Note: When Connected, bit status is displayed.

Generic Variable:

The status of up to 3 variables may be monitored and/or changed online.
Online Monitoring:

When online, some data regarding Axis status and Channel status are displayed.

Area '840D Functions'

Monitor NC functions (NC to PLC):

Monitor and record all the M (Miscellaneous), S (Spindle Speed), T (Tool) functions, D (cutting edges for a tool) or H (as Integer or as Real) functions sent from a Part Program to PLC.
There are two windows so is possible to monitor simultaneous two types of functions (e.g. T and D functions) from the same Channel or from two different Channels of the NC.

M functions (NC to PLC):

M functions are commands, written in G Code, in the part program, but executed by the PLC.
Example: Start the cooling for the tool in main Spindle: the command is written in the part program (e.g. M07) but the valve for cooling liquid is controlled by PLC.
Using M functions is the most common way to transfer binary commands from NC to PLC.

Decoding M functions in the PLC:
With Sinumerik 840, there are 3 methods to decode the M functions in PLC.

1. Direct decoding (Quick M functions)

The most simple method to decode M functions is to use the direct decode signals from 'Channel DB' in PLC.
Each bit is set for a single PLC cycle.
Only first 99 functions are decoded.
The M function index is not decoded.
A small calculator for the bit and a monitoring function is available in 'Area 840' of 'Cam740' program.

2. Decoding using a List of Functions (DB75, DB76)

Another method for decoding M function in PLC is using a List of Functions.
This method was very popular in the '90s but is rarely used now.
Precondition:
Must be activated in OB100, in FB1, DB7 call:    CALL FB 1, DB7
   ...
   ListMDecGrp := ___ //number of decoded function groups, max. 16 groups
   ...

Hint for service: If in OB100, in FB1 call you see ListMDecGrp > 0 and DB75 and DB76 are present in the PLC, this method is used to decode M functions for this machine.

3. Scan the modified values

Another method for decoding M function in PLC is using a scan for 'modified' status of the functions.
This method is used also by 'Cam740' program.

Into an NC block is possible to have a maximum of 5 calls for M functions.
Eack time a block with M fct. call is running in NC, the following bits are set, for a single PLC cycle, in Channel DB in the PLC.

'Cam740' is scanning the bits in DB2n.DBX 58.0 ... 58.4

If DB2n.DBX58.0 = 1 => read M function number from DBD70 and M fct. extension from DBW68
If DB2n.DBX58.1 = 1 => read M function number from DBD76 and M fct. extension from DBW74
If DB2n.DBX58.2 = 1 => read M function number from DBD82 and M fct. extension from DBW80
If DB2n.DBX58.3 = 1 => read M function number from DBD88 and M fct. extension from DBW86
If DB2n.DBX58.4 = 1 => read M function number from DBD94 and M fct. extension from DBW92

H functions (NC to PLC):

H functions are commands, written in G Code, in the part program, but executed by the PLC, used in order to transfer numerical values from NC to PLC.
Into an NC block is possible to have a maximum of 3 calls for H functions.
'Cam740' is scanning the bits in DB2n.DBX 64.0 ... 64.2

If DB2n.DBX64.0 = 1 => read H function number from DBD142 and H fct. extension from DBW140
If DB2n.DBX64.1 = 1 => read H function number from DBD148 and H fct. extension from DBW146
If DB2n.DBX64.2 = 1 => read H function number from DBD154 and H fct. extension from DBW152

See also:
MD22110 $MC_AUXFU_H_TYPE_INT (type of H-auxiliary function is an integer)
MD22230 $MC_AUXFU_H_SYNC_TYPE (output time of the H functions)
Ref.: Function Manual, Basic Functions; Chapter "H2: Auxiliary function outputs to PLC”

T functions (NC to PLC):
D functions (NC to PLC):

Into an NC block is possible to have a maximum of 3 calls for T functions.

Note: Programmed T functions are not output to the PLC when tool management is active (as in any actual version of Sinumerik 840D/One). In this case no data is detected by monitoring the PLC.

8 decade T numbers are only available under DBD118 "T function 1".
Programmed D functions with names (e.g. D=CUTTING EDGE_1) cannot be output to the PLC in ASCII format.
5-decade D numbers are only available as DBW130 "D function 1".
The REAL format corresponds to the floating-point representation in STEP 7 (24-bit mantissa and 8-bit exponent). This floating point format supplies a maximum of seven valid places.

Diagnosis Sinamics S120/G120

Connection, Interfaces:

	Sinamics G120:
	Locate the Profinet or the Profibus interface
	You may need to find out the Ethernet address / Profibus address using another software (Starter, StartDrive, TIA Portal, etc).
	Rack: 0
	Slot: Any
	Sinamics S120:
	You may use X127 (Ethernet Service Interface) or any Profibus / Profinet interface if available
	You may need to find out the Ethernet address / Profibus address using another software (Starter, StartDrive, TIA Portal, etc).
	Rack: 0
	Slot: Any

Object number:

	Sinamics G120:
	For single drives (such as Sinamics G120, G120D, G120C, G120X, etc.) the object number is not relevant. The Control Unit is connected to the Power Module and together are a Drive Object: a system with the capability to control the motor, save parameters, receive commands, etc.
	Sinamics S120:
	Drive systems with modular architecture, such as Sinamics S120, have a more complex architecture. Various components are linked, via DC-Link Busbar and via Drive-Cliq interface system to control one or more motors. In such a system the motor is not controlled by a single piece of hardware, as in a 'Single Drive', more linked components are needed to control the motor.
	Example: in the left picture is represented a modular system controlling 3 motors. - 1st module (the small one from the left) is the Control Unit - 2nd module is the Line Module: a rectifier that converts the alternate current from the mains into direct current. - 3rd module is a Double Motor Module: two inverters modulating the direct current from the Line Module into alternate current used to control the motors. - 4th module is a Single Motor Module: an inverter modulating the direct current from the Line Module into alternate current used to control the motor.
	(1) In Sinamics S120 systems, the Control Unit is considered a Drive Object. In our example it will be the first Object.
	(2) A modular system needs a rectifier module. Some rectifiers such as Active Line Module have parameters and are considered a Drive Object in the system. In our example the Active Line Module (rectifier) is the 2nd Object.
	(3) and (4) A double Motor Module has two independent inverter bridges, each one capable to supply the AC voltage for a motor. Each inverter has it's own parameters and, together with the motor, the motor encoder and the encoder electronics (such as a Sensor Module) are Drive Objects. In our example, Drive Object (3) is constituted from the first inverter of the Double Motor Module, the first motor and any encoder electronics present. Drive Object (4) is constituted from the second inverter of the Double Motor Module, the second motor and any encoder electronics present.
	(5) Drive Object (5) is constituted form the last Motor Module, the last motor and the encoder electronics.

Versions:
v23.06.24: First test version. Complete rewrite of Monitor5 project.

Cam740 is using Snap7 under LGPL3 License to communicate with the Sinumerik/Sinamics/Step7 equipment.
Cam740 is using Qt under LGPL3 License.
Cam740 may also use S7ONLINE interface if the DLL file is provided by user and a license is activated.

Cam740

Diagnosis for Sinumerik, Sinamics or Simatic S7

Connection to a live Simatic PLC / Sinumerik / Sinamics

Diagnosis Sinumerik 840D/One

Offline Functions:

Alarm Calculator:

M Function Calculator:

Online Monitoring:

Area '840D Functions'

Diagnosis Sinamics S120/G120