Overview: Commissioning Pathways for SINUMERIK 840D
The SINUMERIK 840D controller family supports two distinct hardware generations that materially change the commissioning toolset:
- SINUMERIK 840D (classic) paired with SIMODRIVE 611D drive modules — the original digital drive concept with FDD/MSD signal structure on the PROFIBUS-DP link.
- SINUMERIK 840D sl paired with SINAMICS S120 — the slim-line NCU with DRIVE-CLiQ fiber-optic drive backplane, introduced as the successor platform.
Both generations expose the same machine data (MD), setting data (SD), and option data architecture, so the commissioning tool question — SinuCom NC versus the Commissioning Tool — applies to either platform with minor interface differences. The decisive variable is the HMI (Human Machine Interface) you run on top of the NCU, not the drive bus. Selecting the right commissioning tool is governed by the rules in the SINUMERIK 840D sl Commissioning Manual (CNC Commissioning: NC, PLC, Drive) and the official SITRAIN course NC-840DSL.
SinuCom NC: The Complete Engineering Front-End
SINUCOM NC (sometimes written SinuCom NC) is the full-function commissioning environment for the SINUMERIK 840D line. It is a Windows PC application that talks to the NCU over Ethernet and exposes the entire NC/PLC/drive parameter tree.
Functional scope:
- Read and write every Machine Data (MD) — general MD, axis-specific MD, channel MD, and drive MD.
- Read and write every Setting Data (SD) — runtime-adjustable parameters grouped by axis and channel.
- Read and write Option Data and Compile cycles references.
- Integrated Trace with the improved multi-channel scope function — record up to 16 signals simultaneously, export to CSV for offline analysis in tools such as SinuCom Trace Viewer or MATLAB.
- Safety Integrated acceptance test sequence — drives the SI commissioning wizard, generates the test log (PDF/XML), validates SLS, SLP, SOS, SS1, SS2, STO, SBC against the configured safety MD.
- Drive commissioning dialogs for both SIMODRIVE 611D (on the 840D classic) and SINAMICS S120 (on the 840D sl) — including automatic control-parameter calculation and motor identification run.
- NCK and PLC online diagnostics — version display, service displays (axis utilization, following error, contour deviation), and password-protected MD export/import.
Because the SinuCom NC user interface follows the classic SINUMERIK service-screen style, the operating metaphor differs sharply from HMI Advanced. Field engineers accustomed to HMI Advanced's mask-based navigation typically require a half-day orientation before becoming productive in SinuCom NC.
Commissioning Tool: The Stripped HMI Advanced
The Commissioning Tool is a deliberately reduced HMI Advanced image. It reuses the HMI Advanced look-and-feel so operators transitioning from production screens to commissioning do not face a parallel learning curve, but it ships only the screens required for startup and optimization.
Functional scope:
- Same HMI Advanced mask layout, menu structure, and operator controls — minimizes retraining.
- Startup functions for configuration and optimization of SIMODRIVE 611D or SINAMICS drives coordinated with the SINUMERIK NC.
- Axis-commissioning dialogs, including reference-point setting, encoder adjustment, and jerk-limited test traverse.
- Trace with a single-channel record-and-display path (sufficient for axis-by-axis verification but not the multi-channel analysis of SinuCom NC).
- Compact operator-front mask tree covering the most-edited MD groups.
The Commissioning Tool does not contain the full HMI Advanced operator functionality. Production screens, program management, tool management, and the full alarm/messages mask set are not bundled with the commissioning image. After startup, the operator panel is replaced with (or rebooted into) the production HMI Advanced image.
HMI Dependency Matrix
The choice between SinuCom NC and the Commissioning Tool is determined entirely by the HMI variant present on the SINUMERIK panel. The dependency table below summarizes the supported combinations.
| HMI Variant on the Panel | Commissioning Tool Required? | SinuCom NC Required? | Typical Use Case |
|---|---|---|---|
| HMI Advanced (full license) | No | No (except for Safety Integrated) | Production line with built-in commissioning screens; no PC needed for routine startup |
| HMI Advanced on PC/PG (developer seat) | No | No (except for Safety Integrated) | Office-based engineering and remote startup |
| HMI Embedded (OP 010 / OP 012 / OP 015 / TP 015A) | Yes | No (except for Safety Integrated) | Cost-optimized machine with stripped operator panel; full commissioning loaded only on the PC side |
| No HMI (headless / black-box NCU) | No | Yes | OEM building their own HMI, retrofit, or test bench where the PC tool is the sole commissioning access |
| Any variant, Safety Integrated acceptance test | Optional | Strongly recommended | Mandatory SI acceptance per EN ISO 13849-1 and IEC 61508 requires SinuCom NC for the structured test log |
Functional Comparison: SinuCom NC vs Commissioning Tool
| Capability | SinuCom NC | Commissioning Tool |
|---|---|---|
| Operator interface style | SinuCom service-screen style (dedicated commissioning UI) | Identical to HMI Advanced mask set |
| Full Machine Data access | Yes — all MD, SD, option data | Partial — commissioning-relevant MD groups only |
| Trace / Scope channels | Up to 16 simultaneous, dual-timebase, CSV export | Single-channel service trace |
| Safety Integrated acceptance test | Yes, wizard-driven, signed test log | Display of SI status only; no acceptance wizard |
| SIMODRIVE 611D support | Yes (840D classic) | Yes (840D classic) |
| SINAMICS S120 support | Yes (840D sl) | Yes (840D sl) |
| PLC online diagnostics | Yes — status, force, cross-reference | Limited — status only |
| Drive optimization (auto controller tuning) | Yes — full auto-tuning dialog | Partial — basic current and speed loop presets |
| Runtime cost / licensing | Paid license (perpetual or floating) | Paid license (typically bundled with HMI Advanced media) |
| PC dependency | Always — PC is the only access | Conditional — required only with HMI Embedded or headless NCU |
Commissioning the NC, PLC, and Drive — Step 1
Per the SINUMERIK 840D sl Commissioning Manual, the first phase of any startup is the three-stage NC/PLC/drive bring-up.
- NC commissioning — load the NCK software from the CF card, configure the NCU via the NCK commissioning switch (rotary switch positions 0–7), and verify the NCK version string appears in the HMI diagnostics mask.
- PLC commissioning — establish the PROFIBUS-DP (840D classic) or PROFINET (840D sl) link to the PLC, transfer the PLC user program via STEP 7 / TIA Portal, and confirm the cyclic OB1 communication is running (status LED on the PLC module).
- Drive commissioning — commission the SIMODRIVE 611D modules (with the original 840D) or the SINAMICS S120 line modules and motor modules (with the 840D sl) one at a time. Use the Commissioning Tool or SinuCom NC drive dialog to set motor code, encoder type, and run the automatic current-loop and speed-loop identification.
Do not proceed to Step 2 until each axis is verified by a 1 mm test traverse in JOG mode at low feedrate override (F=5%). This isolates mechanical binding from drive-tuning issues before the second phase adds NC and PLC application complexity.
Commissioning NC Functions, PLC Program, and HMI — Step 2
Step 2 builds on the verified NC/PLC/drive base.
- NC functions — configure technology functions (e.g., MD20150 $MC_GCODE_DEFAULT_VALUES for default G-code behavior), tool compensation (MD20360 $MC_TOOL_PARAMETER_DEF_MASK), and interpolation behavior (MD20270 $MC_CUTTING_EDGE_DEFAULT).
- PLC user program — load the machine-specific PLC program: axis-enable chain, spindle enable, feed-hold logic, tool-changer handshake, and the M-code decoding (FC19/FM352 in classic PLC, or equivalent in TIA-Portal-based PLC 1500). The PLC program must expose the interface DBs (DB10, DB11, DB31..DB61) before JOG can function.
- HMI application — load operator screens, alarm texts, and the M:N mapping for the MCP (Machine Control Panel) keys.
JOG Setup Requirements
Basic axis jogging on a SINUMERIK 840D is not a single function but the cooperative result of three subsystems. The MCP alone will not move an axis until the following interface signals are all in the correct state.
| Interface Bit / Signal | Source | Meaning |
|---|---|---|
| DB31.DBX0.0 — drive enable / spindle reset | PLC → NCK | Power section released to drive |
| DB31.DBX0.1 — drive enable (pulse enable) | PLC → NCK | Controller enable for the axis drive |
| DB31.DBX0.7 — position-controller enable | PLC → NCK | Position control loop closed in NCK |
| DB11.DBX0.0 — mode group ready | NCK → PLC | NCK reports mode group ready for JOG |
| DB11.DBX4.0 — active mode = JOG | NCK → PLC | Confirms the JOG mode was selected |
| DB31.DBX4.0..7 — axis JOG +/-, rapid, inc | MCP/PLC → NCK | Direction and increment selection from the MCP |
For a basic simulation bench that does not need a physical MCP, the SinuCom NC Manual JOG panel can drive DB31.DBX4.0..7 directly over the Ethernet service interface, bypassing the MCP hardware layer entirely. This is the fastest path to jogging a single virtual axis for software validation.
Safety Integrated Commissioning
When the machine carries a Safety Integrated (SI) axis, both the 840D classic and the 840D sl require a parameterized acceptance test before the axis can be released for production. The test validates the configured Safety Integrated MD against the actual sensor and actuator wiring. SinuCom NC is the recommended tool because it:
- Walks the engineer through the structured test sequence mandated by EN ISO 13849-1 PL d/e and IEC 61508 SIL 2/3.
- Records the test results and produces a signed PDF / XML acceptance log archive.
- Compares the actual signal response times (e.g., STO activation time) against the values declared in the safety MD set.
For a headless NCU with no operator panel, SinuCom NC is the only practical way to execute the SI acceptance and generate the log the integrator must archive with the machine file.
Selecting the Right Tool for the Job
Apply the following decision tree when commissioning a new 840D installation.
- Does the machine have HMI Advanced (full panel or PC/PG)? — Use the built-in commissioning screens. Install SinuCom NC only if Safety Integrated acceptance is required or if advanced multi-channel trace is needed for closed-loop tuning.
- Does the machine have HMI Embedded (OP 010 / 012 / 015 / TP 015A)? — Install the Commissioning Tool on a PC connected to the NCU Ethernet service port. The panel runs the production HMI Embedded image; the PC runs the Commissioning Tool image for startup and optimization.
- Does the machine have no HMI at all? — Install SinuCom NC on a PC. The PC is the sole commissioning access point.
- Is Safety Integrated present? — In any of the above cases, install SinuCom NC and reserve it for the SI acceptance workflow.
Installation, Licensing, and Connectivity Notes
Both tools connect to the NCU over the X120 Ethernet service interface (or X127 / X130 on the 840D sl NCU 7x0.3). Default addressing used by the commissioning software is:
- NCU 840D classic: 192.168.214.1 (NCU), 192.168.214.2 (PC)
- NCU 840D sl: 192.168.1.1 / DHCP on X127, 192.168.214.1 on X120 (when configured)
Firewall rules on the commissioning PC must allow TCP ports 102 (S7ONLINE / OPC UA discovery) and 4840 (OPC UA server on the NCU). Both SinuCom NC and the Commissioning Tool use the S7ONLINE access point configured in the Set PG/PC Interface utility — the access point is S7ONLINE -> TCPIP -> <network adapter MAC>.
Field-Proven Caveats
- Never skip the axis-by-axis bring-up. Configuring all axes at once, then powering the machine, hides which axis caused a DRIVE-CLiQ or PROFIBUS fault. The Commissioning Manual mandates per-axis verification before proceeding.
- Encoder replacement requires re-referencing. After swapping a motor or encoder on a SINAMICS S120 module, run the automatic encoder adjustment from the drive commissioning dialog and then the reference-point homing sequence.
- Service Pack (SVC) alignment. SinuCom NC and the Commissioning Tool must match the NCK Service Pack level. A v4.95 SinuCom NC cannot attach to an NCK running v4.8, even though the basic MD structure looks identical.
- Password reset. If the previous integrator changed the NCK password, the only recovery path is the NCK cold restart with the rotary switch in position 1 — note that this clears all drive parameters and forces a full recommissioning. Document the password in the project file before closing the site.
- Trace sampling rate. SinuCom NC trace can sample at the NCK servo cycle (typically 1 ms to 4 ms depending on axis configuration). The Commissioning Tool's single-channel trace is limited to 8 ms minimum sampling and cannot be used for current-loop analysis.
Frequently Asked Questions
What is the difference between SinuCom NC and the Commissioning Tool on a SINUMERIK 840D?
SinuCom NC is a complete commissioning environment that exposes every machine data, setting data, and option data field; it includes the multi-channel trace, the Safety Integrated acceptance wizard, and the SINAMICS / SIMODRIVE 611D optimization dialogs. The Commissioning Tool is a stripped HMI Advanced image — it shares the HMI Advanced look-and-feel but provides only the startup and optimization screens, without the full HMI operator functionality.
Which tool is required when the machine runs HMI Embedded only?
Use the Commissioning Tool on a PC connected to the NCU Ethernet service port. The HMI Embedded panel on the machine runs the production HMI image; the PC runs the Commissioning Tool for startup, drive optimization, and axis verification.
Do I need SinuCom NC to run JOG on a basic 840D simulation?
Not necessarily. The Commissioning Tool can jog an axis once the PLC program drives the required interface bits (DB31.DBX0.0, DBX0.1, DBX0.7 for axis enable, plus DB31.DBX4.0..7 for direction). However, if the machine has no HMI and no MCP, SinuCom NC provides a manual JOG panel that drives the JOG bit directly over Ethernet and is the fastest path to a 1 mm test traverse for software validation.
Why does my JOG button on the MCP not move the axis?
JOG requires the PLC program to set the drive enable chain: DB31.DBX0.0 (spindle reset), DB31.DBX0.1 (pulse enable), and DB31.DBX0.7 (position-controller enable), plus the NCK must report DB11.DBX0.0 mode-group-ready. A missing or incorrectly wired MCP-to-PLC interface (default on DB7 / DB8) is the most common cause of a dead JOG on first power-up.
Is the Commissioning Tool free of charge?
No. Both SinuCom NC and the Commissioning Tool are typically delivered against a paid license. Confirm the entitlement level with your Siemens regional office before quoting commissioning time, and ensure the installed version matches the NCK Service Pack on the machine's CF card.
Can I commission Safety Integrated with the Commissioning Tool?
The Commissioning Tool displays Safety Integrated status fields but does not run the parameterized acceptance sequence or generate the signed acceptance log. For SI acceptance per EN ISO 13849-1 / IEC 61508, install SinuCom NC and run the SI acceptance wizard to produce the required archive.
Does the same toolset work for 840D classic (SIMODRIVE 611D) and 840D sl (SINAMICS S120)?
Yes. Both SinuCom NC and the Commissioning Tool support the SIMODRIVE 611D drive modules of the original 840D and the SINAMICS S120 line/motor modules of the 840D sl. The drive commissioning dialogs are the same; only the underlying drive-bus transport (PROFIBUS-DP vs DRIVE-CLiQ) and the corresponding MD groups differ.