Complete OEM E

SINUMERIK 802D solution line
Machine Commissioning Handbook
Training Manual Edition 2006.7
Training Material
SINUMERIK 802D sl
Machine Commissioning
Handbook
Valid for
Control Software
SINUMERIK 802D sl 1.2
Edition 07.2006
Module content for OEM´s.
Machine Commissioning
System overview C60 Install additional axis C16

Select Hardware (Sizer) C4 Optimization with Starter C55
Design of Electrical Cabinet C6 On - board optimization C56
Line modules C51 Interface signals C63
Installation of Commissioning Tools C2 Machine data lists C64
Protection levels C21 PLC Instruction list C65
RCS Data transfer tool C1 Component mounting dimensions C62
Pushbutton test (MCP) C8
Profibus configuration C61
LED Diagnosis Drive C9
LED Diagnosis HMI C10
MCPA signal test C11
Save Data Backup C17
Restore Data Backup C18
External data backup and restore C19
Diagnose PLC program C28
Diagnose PLC alarm C31
Creating alarm texts C29
Alarm structure C37
Diagnosis of Cycle alarms C39
Editing of NC Machine data C41
Drive Diagnostic parameters C53
Service Displays C58
Start-up sequence C68
Creating the PLC program C26
Loading the PLC program C27
PLC Subroutine library C35
PLC Functions C33
Commissioning of Options C44
ISO Dialect commissioning C85
Start-up of NC parameters C40
Display options C22
Preparation of series machines C67
Language settings C12
Reference - encoder adjustment C84
C60 802D sl System overview
1 Brief description
Module objective:
Upon completion of this module you will know the system architecture.
Module Description:
The 802D sl system is built from various components, this module gives graphically an overview of
these components, that an impression can be seen of the complete system.
Module Content:
 Graphic overview of 802D sl CNC system
Graphic overview of Section 2

802D sl CNC system
SINUMERIK 802D sl 1st Commissioning, Training Manual Page 1 C60

Section 2 Graphic overview of 802D sl CNC system
Notes
1 – S1 Upright format: 6FC5303-0DT12-1AA0

5A： 6EP1333-3BA00 2 – S2 NC full keyboard
3 – S3 Broad format::6FC5303-0DM13-1AA0
10A： 6EP1334-3BA00
6FC5370-0AA00-AA0 Cable, delivered together Electronic
20A： 6EP1436-3BA00 with the keyboard
handwheel
6FC9320-5DC01
DC24V Power Supply 1
X9
To
X1
e.g. SITOP/ PS307 1
supply 2 SINUMERIK Terminal connection
X30
802D sl
3 6FC5312-0DA01-0AA0 6FC5303-0AF30-1AA0
PCU
X1202 X1201
6FX8 002-1AA01-10
X222 X111
RS232 RS232 cable Ribbon
210.3
MCPA
X6
adapter connection
option
6FX8 002-1AA01-10 cable
Insert to 2x37
RS232 cable:
X20 X2 X1 X6
6FX2 003-0DS00 A1B1
PROFIBUS connector:
Analog spindle speed set point

6ES7 972-0BA41-1XA0
2 A2B2 A1B1
PC
X1 X2
PROFIBUS cable:  100 m 328 ft 6XV1 830-0EH10 (unit: meter)
6FC5611-0CA01-0AA0
X111
6FX2002-1DC00- 1..0
PP 72/48
 DRIVE CLiQ for ALM Inverter
 DRIVE CLiQ for SLM
X222
Spindle motor
X333
1Vpp – SMC20： 6SL3055-0AA00-5BA1
TTL – SMC30： 6SL3055-0AA00-5CA0
3 Terminal
strip
2 A2B2 A1B1 converter
X1 X2
Terminal
6EP5406-5AA00
Spindle encoder interface:
6FC5611-0CA01-0AA0
Machine tools
X111
strip
electric
converter
SMC30： 6FX5002-2CD01-10
SMC20： 6FX5002-2CG00-10
PP 72/48
SLM: 6SL3131-6AE-0AA0
ALM: 6SL3131-7TE-6AA1
Terminal
6SL3121-2TE-AA
6SL3121-1TE-AA
X222
strip
converter
Terminal
X333
strip
converter
2
A2B2 A1B1
Smart line X1 X2
module Terminal
6FC5611-0CA01-0AA0
Machine tools
or 2-axes
X111
2-axes 1-axis 50-pin ribbon strip

6EP5406-5AA00
electric
Active line Motor module

cable converter
module (power section) Motor module Motor module
PP 72/48
Filter (power section) (power section) Terminal

X222
strip
Encoder
converter
Mains Terminal
X333
supply strip
converter
Reactor
6ES7 158-0AD01-0XA0
Option DP/DP Other DP
X1
X2
Coupler master
Servo motor signal cable: 6FX5002-2DC10-10

伺服电机 power cable: 6FX5002-5S-10
Servo motor: 1FK7-5AF71-1D5 Spindle motor signal cable: 6FX5002-2DC10-10
Spindle motor:1PH7-2QF02-00
伺服电机 power cable: 6FX5008-1BB-10

C4 Hardware Configuration with SIZER
1 Brief Description
Module Objective:
U p o n co m p le tio n o f th is m o d u le yo u ca n u se th e p ro g ra m “S IN A M IC S M IC R O M A S T E R S IZ E R ” a n d
configure a system containing Sinamics hardware components.
Module Description:
The operation of the program SINAMICS MICROMASTER SIZER is explained in more detail and an
overview of the configuration options is given by means of examples.
The following systems are supported by the software for project configuration:
 Single drives with MICROMASTER 4, SIMATIC ET200S FC, SINAMICS G110, G120, G130,
G150
 S150 sectional drives with SINAMICS S120 with the controller versions SINAMICS CU320,
SIMOTION (D425, D435, D445, C230-2, P350) or SINUMERIK SL (802D sl, 840D sl, 840 Di sl)
In combination with SIMOTION or SINUMERIK, it is possible to configure expansion boards. These

drive versions can be mixed within a project as desired, i.e. with SINAMICS MICROMASTER SIZER,
it is possible to implement comprehensive configurations for overall applications.
Module Content:
 Basics of SINAMICS MICROMASTER SIZER
Basics of SINAMICS
MICROMASTER SI- Section 2
ZER

Section 2 Basics of SINAMICS MICROMASTER SIZER
Notes
S ta rt th e p ro g ra m a n d cre a te a n e m p ty p ro je ct via “P ro je ct” “N e w … ”.

Then, set the project name, master data and project settings (Fig. C4-1).
Master
Project settings
Figure C4-1 - Creating a project
The user interface with the graphical wizards is displayed (Fig. C4-2).
Workflow
Project navigator
Result display
Working area
Hints
Figure C4-2 - User interface

In the project navigator, all connected objects and their status are
displayed. The workflow shows the physically required process of the drive
configuration (arrow direction). The highlighting (yellow frame) identifies
the component you are currently working on . In addition to that, the status
is indicated with a green check or a red cross. The hints area contains
n o te s o n th e cu rre n t ste p . In th e “R e su lts” ta b , th e re su lts o f th e
configuration are displayed (parts list, technical data, characteristics, etc).

Notes
For a complete configuration of the drive, all steps in the workflow have to
be executed. The current status is highlighted. Each entry in the workflow
h a s a stru ctu re w h ich ca n b e o p e n e d w ith “+ ”. T o ch a n g e th e d a ta , click
the respective button (Fig. C4-3). To proceed to the next step, press the
corresponding blue symbol with the text.
Button
Figure C4-3 - Workflow
Execute all steps of the workflow to create the configuration. Comfortable wizards
like the Motor wizard (Fig. C4-4) will support you.
When all steps have been executed correctly, the results can bee seen in the result
display.

Notes
V ia th e o b je ct ite m “S yste m co m p o n e n ts”, th e sp e cific se ttin g s fo r th e re -

spective controller and the axis assignment can be executed in the
“T o p o lo g y” m e n u (F ig . C 4 -5).
Model selection
Axis assignment
Figure C4-5 - Drive system
For the use of double motor modules, these have to be configured as sin-
gle motor modules first. They can then subsequently be combined under
th e m e n u ite m “D o u b le M o to r M o d u le s” (F ig . C 4 -6).
Figure C4-6 - Double motor module

Notes
As a result of your configuration, all required information is displayed in a

su m m a rize d fo rm u n d e r th e “R e su lt” ta b (F ig . C 4 -2). This is, among other
things, the characteristics of the motors, a quantity list, technical data, and
dimensioned drawings (Fig. C4-7).
Figure C4-7 - Dimensioned drawings motor
Figure C4-8 - 3D view motor
All data can be converted into Excel format (*.xls) via an export function
(“O p tio n s” m e n u ) fo r fu rth e r p ro ce ssin g . T h e co n fig u ra tio n is th u s co m -
pleted.

C51 Smart Line Module / Active Line Module
1 Brief Description
Module Objective:
Upon completion of this module you can locate and understand the functionality of the Smart Line
Module (SLM) and Active Line Module (ALM) connections.
Module Description:
SLM and ALM are two variants of the energy regeneration for the SINAMICS drive family. Depending
on the requirements of an application, there are Smart Line Modules available for the temporary gen-
erator operation and Active Line Modules for especially high plant availability and network quality.
The design and functions of the modules are described.
Module Content:
 Functions
 Hardware description
 Interfaces
Smart Line Modules

Section 2
Active Line Modules

Section 3

Section 2 Smart Line Modules
Notes
In the case of SINAMICS with a Smart Line Module, the line-commutated

units in IGBT technology (Insulated Gale Bipolar Transistor) feed the brak-
ing energy back into the network. Thus, braking resistors and complex
measures for heat dissipation can be omitted.
Smart Line Module
The SLM provides the motor with a non-stabilized DC voltage at the DC

output. In the regenerative feedback mode, the current is in block format.
The feedback can be deactivated via a terminal since the SLM has no
DRIVE-CliQ connection.
The pre-loading of the DC link starts immediately after the application of
the supply voltage and is independent of its rotating field direction. Loading
the DC link is possible after the release of the module. Voltage activation
requires an optional main contactor.

Section 2 Smart Line Modules
Notes
Terminal block X1 Smart Line Module 5 and 10 kW network connection
Terminal block X21 Smart Line Module
Terminal block X22 Smart Line Module
Terminal block X24 Smart Line Module - 24 V terminal adapter

Section 3 Active Line Module
Notes
Active Line Modules in IGBT technology supply the connected drives with
a constant voltage. With a fast vector control, a sinusoidal current is gener-
ated.
ALMs are used when, apart from being capable of energy regeneration,
the compensation of supply voltage dips is required for drives or high de-
mands are made on the quality of the fed-back current. The constantly
controlled DC link voltage which decouples the motor from the supply volt-
age brings highest failure safety.
...
Active Line Module
The capability of energy regeneration of the module can be deactivated via

parameters. The pre-loading of the DC link starts immediately after the ap-
plication of the supply voltage and is independent of its rotating field direc-
tion. Loading the DC link is possible after the release of the module. Volt-
age activation requires an optional main contactor.

Terminal block X1 Active Line Module 16 kW network connection Notes
Terminal block X1 Active Line Module 26 to 120 kW network connection
X200-X202 - Drive-CliQ interface
Terminal block X21 - EP terminal
Terminal block X24 - 24 V terminal adapter

Notes

C2 Installation of commissioning tools
1 Brief description
To ensure the necessary level of compatibility and consistency between machines configured with
the SINUMERIK 802D sl controller , a defined set of commissioning tools are required. How to install
the tools, is described in this document.
The procedure used to install these tools is described here:
 Software installation
Software:
Commissioning Software Section 2
User Software

Section 2 Commissioning Software
Notes
Software tools are required to commission the 802D SL Controller. These
tools are delivered on CD with each controller.
These tools have to be installed on the commissioning engineers PC or
laptop computer
.
Example of CD:
The following software is contained on the CD:
1. Adobe Reader
2. Automation License Manager Installation optional RCS Viewer
3. Licenses
4. PLC Library PLC Example files
5. Programming tool PLC 802
6. RCS 802 Data transfer tool
7. Step 7 Utils for Starter
8. Starter Drive configuration
9. Toolbox Configuration files
The software contained on the CD should be installed on the

commissioning PC as follows:

Notes
Start SW
installation by
calling Setup.exe
in the route of the
Activate
relevant
options—

Notes
Activated
options
During the installation various dialog boxes will appear. The dialog boxes
should be acknowledged and where necessary installation data should be
entered and confirmed.

Section 2 Principle of operation
Notes
In the following picture, a successful connection can be seen when in the
left window a directory for the Control 802 can be seen.
Successful con-
nection, controller
can now be seen
Section 3 Transfer data from the controller
3.1 Transfer data from the controller
Drag the required file from the displayed directory simply to your LOCAL
drive.
NC programs stored
on CNC: can be copy
and paste to destina-
tion or drag & drop
SINUMERIK 802D sl Operating and Service Training Manual Page 5 C1

Section 4 Transfer data to the controller
Notes
4.1 Transfer data to the controller
Drag the required file from the displayed LOCAL directory simply to your
DESTINATION CNC drive.
NC programs stored
LOCALLY: can be copy
tion or drag & drop

C21 Protection Levels
1 Brief Description
Module Objective:
Upon completion of this module you are able to change protection levels.
Module Description:
The SINUMERIK 802D sl provides a protection level concept for the release of data areas.
Access to programs, data and functions is user-oriented.
There are protection levels 0 to 7, 0 being the highest and 7 the lowest level.
Module Content:
 Setting the protection level
Setting the protection

Section 2
level

Section 2 Setting the protection level
Notes
The SINUMERIK 802D provides a protection level concept for the release
of data areas.
The default passwords for the protection levels 1 to 3 are the following:
Attention:
During a system startup during which the standard machine data is loaded,
the passwords are set to their default values. For a safe access protection,
the default passwords should be changed.
The protection levels used with passwords can be influenced via softkeys
a s fo llo w s: “S e t P a ssw o rd ”, “C h a n g e P a ssw o rd ”, “D e le te P a ssw o rd ”.
Set / change /
delete password
The passwords for the four possible password levels with their respective
access rights can be entered in the SYSTEM operating area via the soft-
ke y “S e t P a ssw o rd ”

Notes
Protection levels 1 ... 3
The protection levels 1 to 3 require the entry of a password. The pass-
words can be changed after their activation. If the passwords are, for ex-
ample, no longer known, a new initialization (startup with standard ma-
chine data) has to be carried out. During that, all passwords are set to the
standard of this software version.
Protection levels 4 ... 7

The protection level 7 is set if no password and no protection level inter-
face signal is set. The protection levels 4 to 7 can be set without a pass-
word by the PLC user program by setting bits in the user interface.
Please bear in mind that a password remains valid until the access right is
re se t a g a in w ith th e so ftke y “D e le te P a ssw o rd ”. T h e a cce ss rig h t is th u s
not deleted automatically by POWER ON!

Notes

C1 RCS802 Data Transfer Tool
1 Brief description
Module objective:
Upon completion of this module you can use the RCS802 Data transfer tool to transfer data to/from
the control.
Module description:
NC programs can be written internally (Direct to the NC memory) or externally (computer / laptop).
The programs which are created can be transferred using the RCS802 tool to/from the control.
Module content:
• Principle of operation
• Transfer data from the controller
• Transfer data to the controller
Principle of operation
Section 2
Transfer data from the

controller Section 3
Transfer data to the

controller Section 4

Notes
2.1 Principle of operation RCS802:
RCS — Remote Control System for the 802D SL CNC Controller.
The RCS802 tool works on the principle of creating a permanent online

connection to the CNC controller. This permanent connection can be
RS232C or Ethernet.
To connect using RS232C the controller and the connected PC should
have the same configuration settings, Baud rate, stop bits etc.
To connect using Ethernet the controller and connected PC should have
compatible IP addresses.
This online connection permits a data transfer possibility over a long period
of time without a disruption in the transfer of data.
RS232C online connection:
The following sequence of operations should be carried out to obtain an

online serial connection to the controller:
1) Start RCS 802 Click to start

RCS 802
application
The following screen can be seen:
Activate online con-

nection on/off toggle
Connection
type
Explorer Settings and

type window connection
status

Notes
Configure interface on the control.
For an online connection the interface on the controller first has to be con-
figured and activated, this is carried out in the SYSTEM area of the con-
troller.
To enter the SYSTEM area of the controller press the key combination—
SHIFT+ ALARM, the following screen will be displayed:
Online status
change and
RS232C settings
Online status
with PLC softkey
OFF
Press softkey PLC to enter the following picture and configure interface.

Notes
With softkey “Connect ON” the interface will be activated with the dis-
played settings (Baud rate 38400, Stop bits 1, Parity Even, Data bits 8) the
external PC should be setup with the same settings. The following picture
will be seen:
Interface is active
and can be deacti-
vated with
“Connect OFF”
Symbol
RS232C active
3) Configure interface RCS802 Tool.
Click the online

symbol to config-
ure and attain an
online connection

Notes
In the following picture, a successful connection can be seen when in the
left window a directory for the Control 802 can be seen.
Successful con-
nection, controller
can now be seen
Section 3 Transfer data from the controller
3.1 Transfer data from the controller
Drag the required file from the displayed directory simply to your LOCAL
drive.
NC programs stored
on CNC: can be copy
tion or drag & drop

Section 4 Transfer data to the controller
Notes
4.1 Transfer data to the controller
Drag the required file from the displayed LOCAL directory simply to your
DESTINATION CNC drive.
NC programs stored
LOCALLY: can be copy
tion or drag & drop

C8 Pushbutton Tests
1 Brief description
Module objective:
Upon completion of this module you can identify which Machine Control Panel (MCP) is installed and
perform a pushbutton test
Module description:
There are two possibilities currently existing to connect a Machine control panel to the 802D SL CNC.
1. The first variant is to connect an MCP to the (additionally required) MCPA board, section 2.1.
2. The second variant is to connect the MCP to the PLC periphery, section 2.2
The hardware differs between the two variants, the part numbers (MLFB) are given in the respective
sections.
In certain cases it may become necessary to perform a pushbutton test. The objective of the test, is
to determine whether or not a pushbutton / LED on the machine control is defect.
Module content:
• Hardware identification
• Hardware interface
Hardware identification
Section 2
Hardware interface
Section 3

Section 2 Hardware identification
Notes
• To carry out a pushbutton test, it is necessary to differentiate be-
tween the two MCP variants
• It is not possible to differentiate without looking into the control cabi-

net itself.
2.1 Identification of MCP connected to MCPA interface module.
MCPA
Board
MCP

Section 2 Hardware identification
Notes
2.2 Identification of MCP connected to PLC periphery board.
Periphery Board PP72/48 MCP

Section 3 Hardware interface
Notes
3.1 General information regarding the Machine Control Panel
• The following diagram shows the layout of the 802D machine control panel.
• The layout is independent of the MCP types.
• The CNC functionality is independent of the MCP types.
• The source of the inputs of the MCP differs between MCP types.
• The destination of the customer LED's differs between MCP types.
For ease of signal (pushbutton) testing each key and lamp is assigned in the dia-
gram a mnemonic address:
Example: NC START key is given mnemonic #27

+X key is given mnemonic #17
Etc.
This mnemonic is used to trace the signal flow of the keys and lamps.
[VAR]
Jog
Ref Point
Auto
Single Block
MDA
Spindle Left
Spindle Stop
Spindle Right
Reset
Rapid
Cycle Stop

Section 3 Hardware interface—MCP pushbutton test with periphery version
The machine control panel will be connected to the first of a possible 3 periphery Notes
boards. The start address of this board is 0.
Periphery board PP72/48

Machine control panel
X111 X1201
X222 X1202
X333

Section 3 Hardware interface—MCP pushbutton test with periphery version
Notes
3.2 Pushbutton testing examples based on MCP diagram on previous
page:
A) NC START Pushbutton.
NC START = mnemonic #27

#27 = X1202 / X222 Pin 5 24V m=0 I 3.2
B) NC STOP Pushbutton
NC STOP = mnemonic #26 Pin 4 24V m=0 I 3.1
Due to the update time of the HMI software you should press the key for a longer
duration for the test.
The signals can be then tested using the PLC status display “See hand
book module C32”
Customer LED testing examples based on MCP diagram on previous

page:
The standard 802D sl machine control panel has 6 customer LED's which
are used to acknowledge the function which is activated by the corre-
sponding key press.
The LED's are controlled by the machine tool builder’s PLC program. After
pressing the corresponding key and the lamp does not come on, this does
not necessarily mean that the lamp is defect. In such a case it can mean
that the function which has been activated by the key cannot be acknowl-
edged.
Example: Force lubrication, with no oil in lubrication tank.
Often in such cases a lamp test can be performed with a combination of

key presses. Please see the machine tool builder’s documentation of how
in this case to perform the lamp test.
After performing a pushbutton test, it may be found that all pushbuttons are defect
and not just one key or lamp.
In the case where all keys and lamps are not working the MCPA board should be
tested, or the periphery board for MCP to periphery.
See hand book module C11 for MCPA diagnostic

See hand book module C32 for periphery testing

Section 3 Hardware interface - MCP pushbutton test with MCPA version
Notes
Machine control panel Machine control IF
X1202
X1201
X1
X2
When the machine control panel is connected to MCPA interface board, as can be
seen above, the signals cannot be checked directly in the periphery address area.
The only possibility is to look for the signals in the internal interface which is ad-
dressed with letter V
The area V10001000 —> V10001006 are the input signals from MCP to PLC
The byte V11001000 output signals PLC —> MCP (LED's)
Pushbutton testing examples based on above diagram:
A) NC START Pushbutton.
NC START = mnemonic #27

#27 = V10001003.2
B) NC STOP Pushbutton
NC STOP = mnemonic #26

#26 = V10001003.1
Due to the update time of the HMI software you should press the key for a longer
duration for the test.
The signals can be then tested using the PLC status display “see hand
book module C32”

C61 Profibus configuration
1 Brief description
Module Objective:
Upon completion of this module you can connect the periphery modules to the control.
Module Description:
Up to three periphery modules can be connected to the 802D sl controller, this modules shows how
to address the modules and where they can be found in the controls addressable range.
Module Content:
 Profibus configuration
 Connecting the Profibus
Profibus configuration Section 2
Connecting the
Section 3
Profibus

Section 2 Profibus configuration
Notes

Section 2 Profibus configuration
Notes

Section 3 Connecting the Profibus
Notes

C9 LED Diagnosis—Drive
1 Brief description
Module objective:
Upon completion of this module you can locate the status LED's and determine the module status.
Module description:
The 802D SL controller has extensive diagnostic possibilities, one of which is the LED diagnostic on
the drive modules.
It is possible using the LED status to determine quickly the hardware status of the drive boards.
Before investigating faults using external diagnostic tools (HMI alarm, Starter etc) a status should first
be taken of the drive LED's.
Module content:
• Locating the status LED's

• Status of Motor Module LED's
• Status of Active Line Module LED's
• Status of Smart Line Module LED's
• Status of Smart Line Module ≥ 16kW LED's
Locating the status

LED's
Section 2
Status of Motor Mod-

ule LED's Section 3
Status of Active Line

Section 3
Module LED's
Status of Smart Line

Section 4
Module LED's
Status of Smart Line

Section 3
Module ≥ 16kW LED's

Section 2 Locating the status LED's
2.1 Locating the status LED’s Notes
As can be seen from the picture below, the status LED´s are located al-
ways in the same place on the board.
Ready
DC Link
Section 3 MM LED's, ALM LED´s, SLM LED´s ≥ 16kW
3.1 MM LED's, ALM LED´s, SLM LED´s ≥ 16kW
The LED´s for the:
• Active Line Module

• Motor Module
• Smart Line Module ≥ 16kW
are having the same function, therefore the table below can be used for
these module types.
In the case where a fault diagnosis is not possible a status of the LED´s
should be given to the OEM or to Siemens service personnel.
(only when module is ready)

Section 4 MM LED's, ALM LED´s, SLM LED´s ≥ 16kW
Notes
4.1 MM LED's, ALM LED´s, SLM LED´s ≥ 16kW
The LED´s for the:
• Smart Line Module
are having different functionality, therefore the table below can be used for
this module type.

C10 LED Diagnosis HMI
1 Brief description
Module objective:
Upon completion of this module you can locate the status LED's and determine the status of the CNC
controller
Module description:
The 802D SL controller has extensive diagnostic possibilities, one of which is the LED diagnostic on
the CNC Controller.
It is possible using the LED status to determine quickly the hardware status of the CNC controller.
Before investigating faults using external diagnostic tools (HMI alarm, Starter etc) a status should first
be taken of the controller LED's.
Module content:
• Locating the Status LED's

• Status of CNC Controller LED's
Locating the Status

LED's
Section 2
Status of CNC Control-

ler LED's Section 3

Section 2 Locating the Status LED's
Notes
2.1 Locating the Status LED's
As can bee seen from the picture below, the status LED´s are located
above the LCD display on the right hand side, behind the plastic cover.
Section 3 Status of CNC Controller LED's
3.1 Status of CNC Controller LED's
In the case of ERR (red) a further investigation is required, using internal

and external diagnostic tools in general.

C11 MCPA Signal tests
1 Brief description
Module objective:
Upon completion of this module you can locate the MCPA board in the system and perform a hard-
ware diagnosis of the analogue spindle speed setpoint. For a diagnostic of the connected MCP. see
hand book module C8(Pushbutton test)
Module description:
The MCPA board (below) can be used to drive an analogue spindle and also to connect an MCP.
Diagnosing MCP signals can be carried out with the help of module C8 (pushbutton test).
When hardware is not correctly commissioned it can result in damage to hardware, in this case the
MCPA board itself.
Module content:
• Identification of MCPA in the system

• Analogue spindle interface test
Identification of MCPA
in the system
Section 2
Analogue spindle inter-

face test Section 3

Section 2 Identification of MCPA in the system
2.1 Identification of MCPA in the system Notes
As can bee seen from the picture below, the MCPA board is connected to
the rear of the CNC Controller itself, directly to the internal bus.
Analogue Spindle
Interface X701
X1021
X1020
MCP Interface
Section 3 Analogue spindle interface test

3.1 Analogue spindle interface test
X1 – to X1201 on MCP
X2 – to X1202 on MCP
Description: X1021 Pin 1 – to +24V
X1021 Pin 10 – to 0V
X701 Pin 1: Analog spindle output（56）

X701 Pin 6: Analog spindle output 0V reference signal（14）
X701 Pin 5: Analog drive enable RF1(65)
X701 Pin 9: Analog drive enable RF2(9)
X701 Pin 4: Digital output for unipolar spindle –Direction 1
（Reference ground: Pin10 of X1021）
X701 Pin 3: Digital output for unipolar spindle – Direction 2
(Reference ground: Pin 10 of X1021）
Setting the polarity of analog spindle output as follows:

• when MD30134 = 0: ±10V : enable X701.5 and X701.9
• when MD30134 = 1: 0-10V: enable X701.4 Direction
X701.3
when MD30134 = 2: 0-10V : Spindle CCW X701.3 Spindle
CW X701.4
Note:
X1021 Pin 1 necessary for spindle output
Due to the use of a 9 pin D sub connector the voltages can only
be tested at the drive end of the cable.
To generate a setpoint voltage e.g.S500 M3 should be pro-
grammed in MDI mode.

C17 Save Data
1 Brief description
Module objective:
Upon completion of this module you can Save Data which is stored in the volatile data to the internal
Flash memory of the CNC Controller.
Module description:
The 802D SL controller executes with data which is stored in volatile memory. This volatile memory is
retained using a GoldCap capacitor. If the machine is powered off for more than 50 hours, the data
which is stored in the volatile memory can be lost. It is therefore necessary to Save this data to Flash
memory when the machine is switched off for periods which are longer than 50 hours. When neces-
sary this previously saved data can be reloaded to the volatile memory from the Flash memory.
All data excluding the PLC program are saved, the PLC is stored always in non-volatile memory
(Flash memory) and will not be lost upon dissipation of the GoldCap.
Module content:
• Performing a Data Save
Performing a Data
Save
Section 2

Section 2 Performing a Save Data
Notes
2.1 Performing a Save Data
To perform a Saving of data, you have to enter the “System Area”. To en-
ter the “System Area” proceed as follows:
On NC Keyboard — Press the key SHIFT + ALARM
Keyboard (upright)
Keyboard (broad)
To perform a “Save Data” the password “CUSTOMER” has to be set.
Password
CUSTOMER
To Save Data

Section 2 Performing a Save Data
Notes
Confirm with OK to save data..
To Save Data
Confirm with OK
It is also possible to see in the above picture, which data will be saved.

C18 Restore Saved Data
1 Brief description
Module objective:
Upon completion of this module you can restore the data which is stored in the flash memory to the
internal SRAM (active, volatile) memory of the CNC controller.
See hand book module C17 Save data
Module description:
The 802D SL controller executes with data which is stored in volatile memory. This volatile memory is
retained using a GoldCap capacitor. If the machine is powered off for more than 50 hours, the data
which is stored in the volatile memory can be lost. It is therefore necessary to Save this data to Flash
memory when the machine is switched off for periods which are longer than 50 hours. When neces-
sary this previously saved data can be reloaded to the volatile memory from the Flash memory.
All data excluding the PLC program are saved, the PLC is stored always in non-volatile memory
(Flash memory) and will not be lost upon dissipation of the GoldCap.
This module describes the methods of restoring the previously saved data.
See hand book module C17 Save data
Module content:
• Performing a Restore of saved data
Performing a Restore
of saved data
Section 2

Section 2 Restoring Saved Data
2.1 Restoring Saved Data Notes
The “Saved data ” can be restored in several ways:
• SELECT picture at Startup

• Automatic (in case of data loss)
The system can detect loss of data, upon data loss the saved data will be
loaded into the volatile memory automatically.
Saved data can be restored by the user at any time by pressing the SE-
LECT key when prompted at Startup time of the control.
The following picture then appears—one of the two will appear dependant
upon which password is activated.
The alarm 004062 indicates to the operator that “saved data” has been
loaded, this alarm can be acknowledged with the reset key.
CUSTOMER Password set
EVENING—SUNRISE Password set

C19 External data Backup + Restore with CF card
1 Brief description
Module objective:
Upon completion of this module you can save to a Compact flash card, a complete backup of the
control.
Module description:
Due to component defect, it may become necessary to exchange the CNC system. In such a case
the “Saved data” function is not of any use. It becomes necessary to previously store a complete
backup of the controls machine specific data. Saving the data is described in this module and also
loading the data back to a replacement control.
Module content:
• Saving all data to CF Card

• Restoring data from CF card
Saving all data to CF

Card Section 2
Restoring data from

Section 3
CF card

Section 2 Saving All data to Compact Flash card
Notes
2.1 Saving All data to Compact Flash card
All data can be saved to a CF card using Copy and Paste functionality. To
use the feature a CF card should be inserted into the controller, as can be
seen below:
The CF card can be up to 2GB, and should be formatted using the FAT16
or FAT32 file system.
To make a backup of the machine configuration, that the controller can be

restored to it's original state requires that two archives should be saved to
the CF card. These two files can be saved to the card in the SYSTEM area
of the control. i.e. NC/PLC archive and HMI archive
The SYSTEM area of the control is reached by pressing the key : SHIFT +
ALARM.
The entry point for saving data is through softkey Start-up files, see picture
below:
Entry for sav-

ing data

Section 2 Saving All data from Compact flash card
Notes
The following display can then be seen:
The two files previously mentioned can be saved by copying the contents
of the HMI and the NC/PLC directories into two archives.
The following picture describes this process:
Move cursor to NC/

PLC directory and
press SK Copy
The destination should now be selected and the Paste function can be
used to save the files to the respective card. The destination is the
“Customer CF card”

Section 2 Saving All data from Compact flash card
Notes
After pressing Paste softkey

change file name to
e.g. NC_PLC.ARC and con-
firm with OK softkey
The above should be repeated for the HMI archive.

The two archives should be now visible on the CF card. The CF card
should now be removed from the system and stored safely.
To reflect the newest changes this process should be carried out on a
regular basis.
Both archives saved to

CF, card can now be re-
moved and stored safely.

Section 3 Restoring All data from Compact flash card
Notes
3.1 Restoring All data from Compact flash card
In the case of component exchange it will be necessary to reload the previ-

ously saved archives to achieve a functional machine.
The following steps should be carried out in order to reload the data previ-
ously stored on the CF card.
The controller should first be switched on and the password for the SER-
VICE should be set: The password for a new CNC component is always
the default “EVENING”, this should be changed after new installation to
prevent mishandling of the system in the future.
Once the password is set the system should be switched OFF and ON and
the Startup menu entered with the SELECT key when prompted.
See picture below:
Choose menu option “Startup with default data” and confirm with the
ENTER key.
The control will now make a new start, wait until the control is finished
starting up and once again enter the SERVICE password.
You should see the message “004060 Standard machine data is loaded”.
Using copy from CF card and paste to CNC the backup data can be re-
stored to the control. See the following diagrams:

Notes
Select HMI archive

and with COPY soft-
key prepare for paste
operation to CNC
Select HMI directory

and press “paste”
softkey

Notes
Confirm the dialog box with the OK softkey, the HMI archive will now be
read into the controller.
During this reading in process the controller will reboot once, the process
will take approximately 1 minute to complete.
This procedure should be repeated for the NC/PLC archive, the CNC will
reboot more times and the process takes approximately 4 minutes to com-
plete. The NC_PLC archive should be copied to the NC PLC directory and
not the HMI.
Upon completion of this process the machine should be functional again.
Note: The HMI archive should be read in first because the specific PLC
alarms are in the NC/PLC archive.

C28 Diagnose PLC Program
1 Brief description
Module objective:
Upon completion of this module you can use the built-in PLC program displays to diagnose faults.
Module description:
The 802D SL controller has extensive diagnostic possibilities, one of which is the online display of the
PLC program.
It is possible using this function to quickly evaluate logic faults or external switching faults on the ma-
chine. To use this function effectively previous knowledge of PLC programming is advantageous.
Module content:
• Locating the PLC Program displays

• Navigating the displays
• Program status ON/OFF
• Searching
• Cross referencing
Locating the PLC Pro-

gram displays
Section 2
Navigating the displays

Section 3
Program status ON/

Section 4
OFF
Searching
Section 5
Cross referencing
Section 6

Section 2 Locating the PLC Program displays
2.1 Locating the PLC Program displays Notes
The PLC Program display can be found in the “SYSTEM area”. The dis-
plays are only available when the “SERVICE” password is set or higher.
To enter the “SYSTEM” area press the key “SHIFT + ALARM”.
In the system area you will see the softkey PLC, upon pressing the softkey
PLC the following picture is displayed:
When entering the PLC area, the default for the control is to open the
“Program list” picture. This function is explained in the hand book module
C33.
The PLC Program displays can be found by pressing the softkey “PLC
Program”
The following picture can be seen:

Section 3 Navigating the displays
3.1 Navigating the displays Notes
Project name, Version , Cycle time, Processing time.

Notes
Status >> Bits, Bytes, Words, DWords with the possibility to
change
Overview Input, Output, Marker area with the possibility to

change

Notes
Status >> logic online/offline
Define which block

with softkey
“Program block”
Status >> logic online/offline as Window 1

Define which block with softkey “Program block”

Notes
Locator >> Where is it used? And as what?
Section 4 Program status ON/OFF
4.1 Program status ON/OFF
With Program status ON, a real-time picture can be seen of the logic con-
trolling the machine.
switch OFF to
conserve proces-
sor resources

Section 5 Searching
Notes
5.1 Searching
Search / Find: the function can be used context sensitive to find operands
or symbols located in the body of the PLC program or cross reference
table.
Section 6 Cross referencing
6.1 Cross referencing
Find all occurrences of operands in the PLC program

C31 Diagnose PLC alarm
1 Brief description
Module objective:
Upon completion of this module you can use the built-in PLC program displays to diagnose a PLC
generated fault.
Module description:
The 802D SL controller has extensive diagnostic possibilities, one of which is the online display of the
PLC program.
It is possible using this function to quickly find the source of a PLC generated fault, and quickly re-
solve an external fault on the machine. e.g. faulty sensor.
Module content:
• Structure of an alarm
• Function of alarm
• Cross referencing
Structure of an alarm
Section 2
Function of alarm
Section 3
Cross referencing
Section 4

Section 2 Structure of an alarm
2.1 Structure of an alarm Notes
To identify external faults from the generated PLC fault, it is necessary to

understand the structure of the alarm.
Structure:
700000 Hydraulic pressure low
700001 Tailstock not in position
700002 Axis %d in parked position ——- Axis 1 in parked position
Axis 2 in parked position
Alarm Num- Variable = 1 Alarm Text
Alarm Number PLC Signal PLC variable NC MD alarm Text File

configuration
700000 16000000.0 16001000 14516[0] Alarm 1
700001 16000000.1 16001004 14516[1] Alarm 2
700002 16000000.2 16001008 14516[2] Alarm 3
700003 16000000.3 16001012 14516[3] Alarm 4
700004 16000000.4 16001016 14516[4] Alarm 5
700005 16000000.5 16001020 14516[5] Alarm 6
700006 16000000.6 16001024 14516[6] Alarm 7
700007 16000000.7 16001028 14516[7] Alarm 8
700008 16000001.0 16001032 14516[8] Alarm 9
700009 16000001.1 16001036 14516[9] Alarm 10
700010 16000001.1 16001040 14516[10] Alarm 11
700011 16000001.1 16001044 14516[11] Alarm 12
700012 16000001.1 16001048 14516[12] Alarm 13
.. .. .. .. ..
.. .. .. .. ..
.. .. .. .. ..
.. .. .. .. ..
700063 16000007.7 16001252 14516[63] Alarm 63
Variable definition
%d Decimal value displayed

%x Hexadecimal value displayed
%b Binary value displayed
%o Octal value is displayed
%u Unsigned integer is displayed
%f Floating point number is displayed
PLC Signal
The alarm 700000 is generated with the corresponding PLC signal, the
reaction from the NC is defined in the NC machine data 14516[index].

Section 3 Function of alarm
3.1 Function of alarm Notes
Alarms are generated for a purpose, the purpose is primarily to protect the
machine operator in the case of a dangerous situation and secondly to
protect the machine from damage.
To cater for the above two cases we can react in two ways:
1) Pure PLC reaction

2) PLC >> NC reaction
The first is to use the alarm to warn the operator of a problem, e.g. coolant
is low in the machine. In such a case the axis can be prevented from mov-
ing by various disable signals in the PLC interface.
The second case is to configure the alarm in such a way that the NC can
react itself. e.g. in the case of an alarm NC start can be automatically in-
hibited.
The possibilities are listed below:
MD 14516[index] Meaning
Bit 0 NC Start inhibit
Bit 1 Read-in disable
Bit 2 Feed disable for all axis
Bit 3 Emergency stop
Bit 4 PLC Stop
Bit 5
Bit 6 Cancel with Delete key
Bit 7 Power on

Section 4 Cross reference
4.1 Cross reference Notes
It may become necessary to track an alarm to it's source.

A logic condition generates the alarm, the logic condition has to be found
in the PLC program and diagnosed using status.
To find the logic, the cross reference function should be used.
See the following picture:
Result

C29 Creating Alarm Texts
1 Brief Description
Module Objective:
Upon completion of this module you will be able to create user-specific alarm texts.
Module Description:
The machine builder has two options for defining his alarm texts.
The configuration process is described here.
Module Content:
 Alarm texts
Alarm texts
Section 2

Section 2 Alarm texts
Notes
The user has two options for defining own alarm texts:
 directly in the controller

 via the toolbox
In th e 8 0 2 D , th e m e n u ca n b e o p e n e d via “S yste m ” “P L C ” “E d it
A la rm T e xt“.
Own texts
Alarm text
With the arrow keys, the respective alarm text is selected in the editor. The
corresponding message can be edited with the tabulator key . The
ch a n g e d te xt is sa ve d w ith th e so ftke y “S a ve ”.
If the user does not assign a user alarm text, only the alarm number is dis-
played.

Notes
Changing the OEM text via the toolbox:
 user alarm : alcu.txt
is a lso p o ssib le . T o d o so , th e m e n u “S e le ct O E M ” h a s to b e ca lle d fro m

th e “T o o lb o x M a n a g e r” B y se le ctin g a n d e d itin g th e te xt file a n d th e n click-
in g th e b u tto n “T ra n sfe r to 8 0 2 ”, th e te xts a re lo a d e d to th e co n tro lle r.
Edit and trans-

fer texts

Notes

C37 Alarm Structure NC
1 Brief description
Module objective:
Upon completion of this module you will be able to identify an NC alarm.
Module description:
The 802D SL controller has extensive diagnostic possibilities, one of which is the display of the active
NC alarm.
With this knowledge you can find in the diagnostic guide, and interpret the fault.
Module content:
• Locate the alarm display

• Find the alarm description in the diagnostic guide
Locate the alarm dis-

play
Section 2
Find the alarm descrip-

tion in the diagnostic Section 3
guide

Section 2 Locate the alarm display
Notes
2.1 Locate the alarm display
The alarm display has to be selected in order to interpret the active alarm.
The display can be selected with the ALARM key on the NC keyboard. The
following display will be seen :
The alarm number determines whether an alarm is an NC alarm, the num-

ber range can be seen in the following table:
Section 3 Find the description in the diagnostic guide
3.1 Find the description in the diagnostic guide
A description of the alarm can be found in the 802D sl Diagnostic Guide.

C39 Diagnosis of Cycle Alarms
1 Brief Description
Module Objective:
Upon completion of this module you are able to find and diagnose alarms from the standard cycles.
Module Description:
Faulty or missing parameter assignments in cycles lead to a program abort.

Furthermore, messages which do not interrupt operation are displayed.
Module Content:
 Available cycles
 Troubleshooting
Available cycles
Section 2
Troubleshooting Section 3

Section 2 Available cycles
Notes
Cycles are technology subroutines with which certain process sequences

can be implemented universally. The adaptation of the cycles to the con-
crete problem is done via geometry and machining parameters.
The following standard cycles are available:

 Drilling cycles
CYCLE81 Drilling, centering
CYCLE82 Drilling, counterboring
CYCLE83 Deep-hole drilling
CYCLE84 Tapping without compensating chuck
CYCLE840 Tapping with compensating chuck
CYCLE85 Reaming 1 (boring 1)
CYCLE86 Hollowing (boring 2)
CYCLE87 Drilling with stop 1 (boring 3)
CYCLE88 Drilling with stop 2 (boring 4)
CYCLE89 Reaming 2 (boring 5)
 Hole pattern cycles

HOLES1 Row of holes
HOLES2 Circle of holes
 Milling cycles
CYCLE71 Face milling
CYCLE72 Contour milling
CYCLE76 Rectangular spigot milling
CYCLE77 Circular spigot milling
LONGHOLE Elongated hole
SLOT1 Milling pattern grooves located on a circle
SLOT2 Milling pattern circular grooves
POCKET3 Milling rectangular pocket (with any milling tool)
POCKET4 Milling circular pocket (with any milling tool)
CYCLE90 Thread milling
 Turning cycles
CYCLE93 Groove
CYCLE94 Undercut (form E and F in accordance with DIN)
CYCLE95 Cutting with relief cuts
CYCLE96 Thread undercut
CYCLE97 Thread cutting
CYCLE98 Thread chain
The cycles are stored on the controller in the path \CST (Siemens cycles)
when the technology package (milling or turning) is generated.

Section 3 Troubleshooting
Notes
An alarm is released and thus the machining aborted when faulty condi-
tions are detected in a cycle.
Moreover, the cycles issue messages in the message line of the controller.
Messages do not interrupt the machining .
In the cycles, alarms are generated with numbers from 61000 to 62299.
The range of numbers is subdivided with respect to alarm response and
cancel criterion
Cancel criteria and alarm responses

Alarm number Cancel criterion Alarm response
61000 ... 61999 NC_RESET Block preparation in the NC is

canceled.
62000 ... 62999 Cancel key Block preparation is interrupted,
the cycle can be continued with NC start
after having canceled the alarm.
The error codes are classified as follows:
6 _ X _ _
X=0 General cycle alarms

X=1 Alarms of the drilling, hole pattern and milling cycles
X=6 Alarms of the turning cycles

Notes
Alarms
Alarm Alarm text Source Explanation, remedy
number
61000 “N o to o l o ffse t a c- SLOT1 D-correction has to be programmed before

tive ” SLOT2 the cycle call.
POCKET3
POCKET4
CYCLE71
CYCLE72
61001 ”T h re a d p itch CYCLE84 Check the parameter for thread size or
w ro n g “ CYCLE840 pitch value (might be contradictory).
61002 ”M a ch in in g typ e SLOT1 The VARI parameter value for the machin-
d e fin e d in co rre ctly” SLOT2 ing type is wrong and has to be changed.
POCKET3
POCKET4
CYCLE71
CYCLE72
61003 “N o fe e d ra te p ro -
CYCLE71 The parameter for the feedrate is wrong
grammed in the
CYCLE72 and has to be changed.
cycle “
61009 “A ctive to o l n u m b e r CYCLE71 No tool (T) has been programmed before
= 0“ CYCLE72 the cycle call.
61010 “F in ish in g a llo w a n ce CYCLE72 The finishing allowance on the base is lar-
to o la rg e “ ger than the total depth, it has to be dimin-
ished.
61011 “S ca lin g n o t p e rm it- CYCLE71 A scaling factor which is impermissible for
te d “ CYCLE72 this cycle is active.
61101 ”R e fe re n ce le ve l CYCLE71 With a relative value for the depth, either
d e fin e d in co rre ctly” CYCLE72 the values for the reference and retraction
CYCLE81 plane have to be selected differently or an
up to CY- absolute value has to be entered for the
CLE89 depth.
CYCLE840
SLOT1
SLOT2
POCKET3
POCKET4
61102 ”N o sp in d le d ire ctio n CYCLE86 The parameter SDIR (or SDR in CY-
p ro g ra m m e d ” CYCLE88 CLE840) has to be programmed.
CYCLE840
POCKET3
POCKET4
61103 ”N u m b e r o f h o le s is HOLES1 No value for the number of holes has been

ze ro ” HOLES2 programmed.
61104 ”C o n to u r vio la tio n o f SLOT1 Faulty parameterization of the milling pat-
the slots / elongated SLOT2 tern in the parameters defining the position
h o le s” of the slots / elongated holes on the circle
and their form.
61105 ”C u tte r ra d iu s to o SLOT1 The diameter of the used cutter is too large
la rg e ” SLOT2 for the shape to be made; either a tool with
POCKET3 a smaller radius has to be used or the con-
POCKET4 tour has to be changed.
61106 ”N u m b e r o r d ista n ce HOLES2 Faulty parameterization of NUM or INDA,

of the circle ele- SLOT1 the arrangement of the circle elements
m e n ts” SLOT2 within a full circle is impossible.

Notes
Alarms (continued)
Alarm Alarm text Source Explanation, remedy

number
61107 ”F irst d rillin g d e p th CYCLE83 First drilling depth opposite to the total
d e fin e d in co rre ctly” drilling depth.
61108 POCKET3 The parameters _RAD1 and _DP for

“N o p e rm issib le va l-
POCKET4 the determination of the path for the
ues for parameter
depth infeed have been specified incor-
_R A D 1 and _D P 1“
rectly.
61109 The value of the parameter for the mill
“P a ra m e te r _ C D IR POCKET3
direction _CDIR has been specified
d e fin e d in co rre ctly“ POCKET4
incorrectly and has to be changed.
61110 “F in ish in g a llo w a n ce POCKET3 The finishing allowance on the base
on the base > depth POCKET4 has been specified larger than the
in fe e d “ maximum depth infeed; either diminish
the finishing allowance or increase the
depth infeed.
61111 “In fe e d w id th > to o l CYCLE71 The programmed infeed width is larger
d ia m e te r“ POCKET3 than the diameter of the active tool; it
POCKET4 has to be diminished.
61112 “T o o l ra d iu s n e g a tive ” CYCLE72 The radius of the active tool is nega-
tive, which is impermissible.
61113 “P a ra m e te r _ C R A D POCKET3 The parameter for the corner radius

too large for corner _CRAD has been specified too large, it
ra d iu s“ has to be diminished.
61114 “M a ch in in g d ire ctio n CYCLE72 The machining direction of the cutter
G41/G42 defined in- radius compensation G41/G42 has
co rre ctly“ been selected incorrectly.
61115 “A p p ro a ch o r re tra ct CYCLE72 The approach or retract mode for the
mode (straight line/ contour has been defined incorrectly;
circle/plane/space) check parameter _AS1 or _AS2.
d e fin e d in co rre ctly“
61116 “A p p ro a ch o r re tra ct CYCLE72 The approach or retract path has been
p a th = 0 “ specified with zero, it has to be in-
creased; check parameter _LP1 or
_LP2.
61117 “A ctive to o l ra d iu s < = CYCLE71 The radius of the active tool is negative
0“ POCKET3 or zero, which is impermissible.
POCKET4
61118 “L e n g th o r w id th = 0 “ CYCLE71 The length or width of the milling sur-
face is impermissible; check the pa-
rameters _LENG and _WID.
61124 CYCLE71 For active simulation without tool, it is
“In fe e d w id th n o t p ro -
always necessary to program a value
g ra m m e d “
for the infeed width _MIDA.
62100 ”N o d rillin g cycle a c- No drilling cycle has been called
HOLES1
tive ” modally before calling the hole pattern
HOLES2
cycle.

Notes
Alarms (continued)
Alarm Alarm text Source Explanation remedy

number
61601 ”M a ch in e d p a rt CYCLE94 The programmed machined part diameter is too
diameter too CYCLE96 small.
sm a ll”
61602 ”T o o l w id th CYCLE93 The grooving steel is larger than the programmed
defined incor- groove width.
re ctly”
61603 ”G ro o ve fo rm CYCLE93 The radii/chamfers on the groove base do not match
defined incor- the groove width. A face groove on a contour ele-
re ctly“ ment running in parallel to the longitudinal axis is
impossible.
61604 ”A ctive to o l CYCLE95 Contour violation in relief cut elements caused by
violates pro- the
grammed con- clearance angle of the used tool, i.e. use a different
to u r” tool or check the contour subroutine.
61605 ”C o n to u r p ro - CYCLE95 Impermissible relief cut element detected.

grammed in-
co rre ctly”
61606 ”F a u lt d u rin g CYCLE95 A fault has been detected during the preparation of
contour prepa- the contour; this alarm is always connected to a
ra tio n ” NCK alarm 10930 ... 10934, 15800 or 15810
61607 ”S ta rtin g p o in t CYCLE95 The starting point reached before the cycle call is
programmed not outside the rectangle described by the contour
in co rre ctly” subroutine.
61608 ”W ro n g cu ttin g CYCLE94 A cutting edge position 1...4, matching the undercut
edge position CYCLE96 form, has to be programmed.
p ro g ra m m e d ”
61609 ”F o rm d e fin e d CYCLE94 Check the parameter for the undercut form.
in co rre ctly” CYCLE96
61611 “N o in te rse c- CYCLE95 No calculation of the intersection possible with the
tio n fo u n d “ contour. Check the contour programming or change
the infeed depth.

Notes
The picture shows a cycle alarm. Apart from the alarm number and alarm
text, there are also measures for canceling the alarms (RESET) and notes
given.

Notes

C41 Editing of NC Machine data
1 Brief description
Module objective:
Upon completion of this module you can locate the NC machine data, set the password and make
changes.
Module description:
During the life of a machine it may become necessary to change the values of certain NC machine
data. The necessity arises e.g. due to wear on mechanical components, the axis performance can
therefore deteriorate. In some case, further mechanical damage can be prevented with the help of
the NC machine data.
A change should only be carried out in conjunction with recommendations from the machine tool
builder.
Module content:
• Location of NC machine data

• Setting password
• Changing machine data + data save
Location of NC ma-
chine data
Section 2
Setting password
Section 3
Changing machine
data + data save Section 4

Section 2 Location of NC machine data
2.1 Location of NC machine data Notes
The NC machine data is located in the System area. The system area can
be entered with the key combination “SHIFT + ALARM”. The following de-
scribes graphically how to enter the Machine data area:
Machine data
entry point
General MD
10000-19800
Channel MD
20050-29000
Note:
Axis MD Drive machine data should
30100-38000 only be changed under
supervision from experts

Section 3 Setting password
Notes
3.1 Setting password
In order to make changes to the NC machine data, the corresponding

password must be set. Certain machine data can only be changed with the
SERVICE or MANUFACTURER password, in this case, contact the builder
of the machine.
The following sequence shows graphically how to change/activate the
password.
Enter new
password
level
Change stan-
dard password
Password cancelled
Keyswitch active
Section 4 Changing machine data + data save
4.1 Changing machine data + data save
When the necessary password is activated the machine data can be

changed.
Machine data’s are each having an activation criteria, this criteria deter-
mines when the new machine data value will become active. This criteria
is written in the machine data list next to the respective data.
Po = after powering on
Re = after pressing Reset key on machine control panel
Cf = after powering on
Im = immediately
After making changes to the machine data, it is important to make a

new backup see hand book module’s C19 and C17

C53 Drive diagnostic parameters
1 Brief description
Module objective:
Upon completion of this module you can locate the Drive machine data, set the password and locate
the diagnostic parameters.
Module description:
In the case of a fault, it is useful to have an overview of the fault conditions which may be existing in
other areas of the control. It is often in the case of an axis alarm that a fault in the drive may be the
cause.
Module content:
• Location of drive diagnostic parameters

• Setting password
Location of drive diag-

nostic parameters
Section 2
Setting password
Section 3

Section 2 Location of drive diagnostic parameters
2.1 Location of drive diagnostic parameters Notes
The NC machine data is located in the System area. The system area can
be entered with the key combination “SHIFT + ALARM”. The following de-
scribes graphically how to enter the Machine data area and how to navi-
gate to the drive diagnostic area:
Status 0 =
ok
No drive error
existing

Section 2 Location of drive diagnostic parameters
Notes
Status ≠ 0
not ok
Operational
status
Further important diagnostic parameters can be found under the softkey

“Parameter displays”. The most important parameters can be seen in the
following table, and the values can be passed to the relevant service
personnel upon request:

Section 3 Setting password
Notes
3.1 Setting password
In order to see the data, the correct password should be set.
Enter new
password
level
Change stan-
dard password
Password cancelled
Keyswitch active

C58 Service displays
1 Brief description
Module Objective:
Upon completion of this module you will be able to locate the service displays and use the informa-
tion to diagnose faults on the machine.
Module Description:
The 802D sl controller offers in the SYSTEM area tools, which can be used to diagnose problems
existing on the machine. These tools can be used to optimize or to diagnose faults in the NC and
drive parts of the system.
Module Content:
 Locating the Service displays

 Content of service displays
Locating the service

displays
Section 2
Content of service
displays Section 3

Section 2 Locating the service displays.
Notes
The service displays can be found in the SYSTEM area of the control. To enter
the SYSTEM are the key combination SHIFT + ALARM should be used:

Section 3 Content of service displays.
Notes
The areas which are for service interesting are:
 Service axis
 Service drives
Service axis. Service drives.
The following information is available in The following information is available in

the service axis area: the service drives area:
Following error Pulse enable PLC

Control deviation Speed controller enable NC
Contour deviation (axial) DC Link voltage
Servo gain factor (calculated) Ramp-function generator rapid stop
Active measuring system Enable pulses
Position act. Val. Meas. system 1 Drive ready
Position setpoint Booting phase
Abs. comps. Value meas. system 1 Speed setpoint
Compensation sag + temperature Speed actual value
Speed actual value (to max speed) Smoothed current actual value
Spindle speed setpoint prog. Motor temperature
Spindle speed setpoint actual Setpoint speed filter 1
Pos. offset referred to LA/LS act val Integrator inhibit
Pos. offset referred to LA/LS setpt Actual parameter set
Feed override Parking axis
Spindle override Setpoint parameter set (drive)
Actual gear stage Heatsink temperature warning
Parameter set (axis) Motor temperature warning
Controller mode Booting completed
Status display (referenced) Threshold torque not reached
QEC learning active Minimum speed not reached
Fixed stop reached Threshold speed not reached
Torque limitation value Actual speed = setpoint speed
Variable message 1

Section 3 Content of service displays.
Notes

C68 Start-up sequence for commissioning
1 Brief description
To ensure the necessary level of compatibility and consistency between machines configured with
the SINUMERIK 802D sl controller , a defined commissioning procedure has to be followed. This
procedure is described in this document.
The procedure can be seen in the following diagram consisting of 7 parts:

 Hardware
 Software installation
 HMI
 PLC
 Drive
 NCK
 Machine acceptance tests
Hardware:
Connections/Earthing
Standards C6
Software:
Commissioning Software Section 2
User Software
HMI:
Language/Technology Section 3
PLC:
Program/Alarms Section 4
Drive:
Section 5
Configuration
NC:
Commission functions Section 6
Drive matching
Machine acceptance
tests C103

Notes
Software tools are required to commission the 802D SL Controller. These
tools are delivered on CD with each controller.
These tools have to be installed on the commissioning engineers PC or
laptop computer
.
Example of CD:
The following software is contained on the CD:
1. Adobe Reader
2. Automation License Manager Installation optional RCS Viewer
3. Licenses
4. PLC Library PLC Example files
5. Programming tool PLC 802
6. RCS 802 Data transfer tool
7. Step 7 Utils for Starter
8. Starter Drive configuration
9. Toolbox Configuration files
The software contained on the CD should be installed on the

commissioning PC as follows:

Notes
Start SW
installation by
calling Setup.exe
in the route of the
Activate
relevant
options—

Notes
Activated
options
During the installation various dialog boxes will appear. The dialog boxes
should be acknowledged and where necessary installation data should be
entered and confirmed.
Section 3 HMI: Language/Technology
Preparing the Controller —
The controller should be powered up (24V supply) for 5 minutes prior

to installing any software. This period of time allows the internal
storage capacitor to charge, thus preventing data loss. After 5
minutes power off / on the control before loading any software
After the 5 minute period the HMI commissioning procedure can be

started.

Notes
Proceed as follows to install the language files and required technology.
Activate OEM Password

P a ssw o rd ―S U N R IS E ‖
Has to activated
Restart System with SELECT at system start
C o n firm ―S ta rtu p w ith

d e fa u lt d a ta ‖ E N T E R
Startup Menu
key
Normal Startup
Reload saved user data
Startup with default data
PLC Stop
PLC overall reset / default PLC program
HMI Startup with default data
Remove drive data
Remove drive data/default data
Software update
A llo w syste m to re b o o t a n d o n ce a g a in e n te r p a ssw o rd ―S U N R IS E ‖

Notes
Connect RCS802 to 802D SL
RCS802 connected
Control connected
Select Controller type > 802D SL
Controller type

Notes
Select SW version of controller
Select new project for machine type
New project and

decide upon the
1st and 2nd
language. The
language can later
be changed.
―C re a te ‖, w ill
generate a new
project on your
harddisk.

Notes
New project
generated.
Project directory structure within RCS802
Your project can be found in the

In sta lla tio n p a th o f th e ―T o o lb o x
8 0 2 D S L ‖ w h ich w a s in sta lle d to
your PC. The exact path can be
seen in the left window.

Notes
Transferring required languages to the control
The system languages are installed

u sin g o p tio n ―S e le ct L a n g u a g e ‖.
The languages can be selected and
transferred to the control with the
following dialog box.
Acknowledge the
dialog boxes.
Transferring configuration file to control (T,M)
The controller can be configured as a Turning machine, or configured as a

Milling machine. A configuration file has to be loaded to make this
definition.
The configuration files can be

found in the installation directory
of the Toolbox 802D SL, under
subdirectory \Techno

Notes
The relevant
configuration file should
(using COPY and
PASTE) be transferred to
th e ―S ta rt-up archive(NC/
P L C )‖ fo ld e r.
NOTE:
Please paste to the folder
and not inside the folder.
Acknowledge the transfer and the

configuration file will be installed.
To make the first language the default language, Display machine data
202 should be set to 1 and this should be followed by a new start.

Section 4 PLC: Program/Alarms
Notes
Prior to commissioning the drive, a PLC program should be loaded
into the controller which can control the external equipment of the
machine. The PLC alarm text can also be installed at this time, helping to
diagnose any external periphery problems which may exist in the 1st
commissioning phase.
Special attention has to be given to the start-up sequence of the control
and drives.
Examples for various configurations can be found on the following pages.
The PLC program can based upon a delivered example or with the
―P ro g ra m m in g T o o l P L C 8 0 2 ‖ w ritte n n e w .
Typical machine functions can also be quickly implemented with the help
of our Subroutine library.

Notes
Programming Tool PLC802 Examples
The example projects can be found in the above directory after installation
o f th e ―P ro g ra m m in g T o o l P L C 8 0 2 ‖ to o l, fro m th e T o o lb o x C D .
If you would like your PLC to based upon one of our examples simply
double click the example name, the tool will start automatically with the
desired example which can be later renamed under file functions.
E xa m p le w ith ―S A M P L E _ M IL L .P T P ‖
Standard blocks are

used from the PLC
library to reduce the
development time of
the machine.
The PLC library is
described in module
C35 and the use of
the tool itself in
module C26
The PLC should be
extended for
machine specific
functions in Ladder
diagram format.

Programming Tool PLC802 New program without Library Notes
To start the programming tool without the library: use START– All
Programs– Programming Tool
PLC802— this will start the tool without the
PLC program
can be
created new

Notes
The PLC alarm text file
Save and
transfer to
control
Section 5 Drive: Configuration
Start-up sequence for Control and drive. Hardware switching
The start-up sequence for the controller is described in module C6

Notes
Start-up sequence for Sinamics S120 drive.
The Sinamics drive system is started up in three phases:
1. Updating the drive firmware
2. Automatic drive configuration with CNC controller
3. Changes to standard— DMS (Direct measuring system) etc.
Updating the drive firmware
Press [SHIFT]+[ALARM] to enter the SYSTEM screen

Notes

Notes
IMPORTANT
Automatically configuring the drive
Automatically configuring the drive consists of two steps:

1. Setting Factory defaults
2. Running automatic configuration Makro

Setting Factory defaults

Notes

Notes
Running automatic configuration Makro

Notes

Notes
Drive object alignment (Drive MD 978)
The axis configuration in the CNC part of the control as to match the
configuration which is in the regulator of the drive. These two components
communicate through the Profibus protocol which is configured in the PLC.
The configuration in the PLC is fixed and must be matched to the drive.
The matching to the PLC is carried out with Drive MD978. Depending upon
the axis configuration values have to be entered here.
The values which are input refer to the component number. The
component numbers differ dependant upon whether a SLM or an ALM is
P978 SLM Description ALM Description

P978[0] 2 Servo 1 3 Servo 1
P978[5] 255 Not available 255 Not available
P978[6] 1 CU 802D sl 1 CU 802D sl
P978[7] 255 Not available 2 ALM
P978[8] 0 PZD end 255 Not available
P978[9] 0 0 PZD end
The above is an example, the actual values will be dependant upon how
th e d rive is p h ysica lly co n n e cte d , ―D rive click‖.
The following should be carried out when the above automatic sequence fails.
1. Press [SHIFT]+[ALARM] to enter the SYSTEM screen, click [MD]-[Drive
MD] - select SINAMICS_I
2. Search Drive MD P15, enter macro number according to the type of infeed
modules: 150005
3. Search Drive MD R2， when R2=10, drive configured.。
4. Data saving:
5. Wait until drive MD P977 is set from 0-1-0, data saving completed.
6. Power off the 802D sl and the drive unit, then power on again.

Notes
Installing a direct measuring system. (Optional)
Principal
802D SL PCU
X1 X2
X203
X202
X201
X200
SMC 20
X E
Single axis module(Spindle)

Power infeed module(SLM)
Double axis module(X,Y)
Double axis module(Z,A)

Y E E SP D
Z E
A E
In the above diagram, it is shown how to connect a direct measuring

system to the drive. The direct encoder is connected to an SMC board, the
SMC board is then connected to the drive system through the drive click
interface.
Regarding the drive click interface; during automatic drive configuration,
the actual drive topology will be acknowledged.
This topology often has to be changed to achieve the required topology.
A free drive click interface is used to connect the SMC module, this free
interface is often located on another module (other than in this case the
Spindle module). When this is the case, and automatic configuration has
been executed the encoder (SMC) is found and configured automatically
to the wrong axis. The steps which are required to attach a direct
measuring system often start by disconnecting this falsely configured
encoder and assigning it to the correct axis.
This can be achieved with the Starter tool, deactivate the encoder for the
falsely configured axis and for the required axis create a second encoder.
The second encoder will automatically be taken from the pool of free drive
click components. (This free component will be the external encoder)
Process
The following can be seen (for the above example) in After topology is
the topology after automatic configuration. acknowledged.
SMC is falsely
connected to
servo 6 and not to
the required
Servo 2

Notes
Due to the physical connection on the second double axis module, the
Sinamics Starter assigns the encoder as the second measuring system for
the second servo on this module, in this case Servo6 in the system.
Select Servo6 and disconnect the second measuring system, this can be
d o n e in th e ―C o n fig u ra tio n ‖ se ctio n .
Remove encoder
assignment for servo 6
After changing the encoder assignment for servo 6 the following can be
seen in the topology.
Encoder no
longer assigned
The free encoder is now available for the Servo 2 and can be connected to
th e S e rvo 2 u sin g th e ―C o n fig u ra tio n ‖ se ctio n .

Notes
Encoder activated
and configured for
Servo 2
Upon activation and configuration of the encoder for Servo 2, the following can be
seen in the topology:
Encoder is now
available but not yet
connected to the
correct interface.
You can move the encoder in the topology display to the physically correct
position using drag and drop.
This Project SET

topology can now be
downloaded to the drive.
Make online connection
and download.

Section 6 NC: Commission functions - Drive matching
Notes
NC MD configuration for setpoint and actual value acquisition
Assignment of drive modules:

The control system is connected with the drive via buses. The control system will
establish physical connections with the drive according to following machine data:
Note: The axis number depends on the connecting sequence with the DRIVE
CLiQ line:
For the drive system configured with SLM, the 1st motor module connected to X1
on the 802D sl is assigned an axis no. 1, and the rest on the analogy of this;
For the drive system configured with ALM, X1 on 802D sl is connected to X200
on ALM, and the 1st motor module connected to X201 on ALM using a drive bus
is assigned an axis no. 1, and the rest on the analogy of this
Position control enable:

Each axis of the control system is defined as simulation axis ex works, which
means that the system will neither output any command to the drive unit, nor read
the motor position signal. Setting machine data below can activate a position
controller and have the corresponding axis run in order.
At this point the control should start-up without alarms.

C26 Creating a PLC Program
1 Brief Description
Module Objective:
Upon completion of this module you will know what is required in order to create a PLC program.
Module Description:
The programming tool PLC802 describes the creation of a PLC program.
Module Content:
 Creation of a PLC program
Creation of a
Section 2
PLC program

Section 2 Creation of a PLC program
Notes
The programming tool PLC802 is based on STEP 7-Micro/WIN 32 for
S7-200.
Navigation bar Operations tree Cross references Status table Symbol table
Output window Status line Program editor Local variables table
W ith “F ile ” “N e w ”, a n e m p ty p ro je ct is cre a te d .
A s th e n e xt ste p , th e C P U typ e h a s to b e se le cte d . T o d o so , se le ct “P L C

“C P U T yp e ” a n d th e n th e a u to m a tio n syste m yo u u se
With that, the program can check the parameter range according to the
selected target system.
You can now set the communication or wait with that until you wish to load
the program into the target system (see module C27).

Notes
Only LAD programs can be created for programming. Switching over to
STL (read-o n ly) is p o ssib le via th e “D isp la y” m e n u .
LAD or STL(view)
In
that, a network must have a maximum of 32 fields horizontally and a maxi-
mum of 32 fields vertically.
The elements are dragged via drag&drop from the operations tree in the
program editor to the desired position. The cursor automatically prevents
that you drop the operation at an inadmissible position (e.g. at the position
of a network title or at the position of the parameter of another operation).
When entering an operation in LAD, the parameters are represented by

question marks at the beginning: ??.? or ????.
The question marks indicate that the parameter has not been assigned
yet. You may enter a constant value or an absolute, symbolic or variable
address for the parameters of the element. You may enter the address
right away when entering the operation or later. When clicking a parameter
or an operation with the right-hand mouse key, the popup menu is dis-
played. Here, you can quickly define addresses in the symbol table or se-
lect an address from up to five suggestions.

Notes
A s a n o p tio n , th e “S ym b o lic A d d re ssin g ” ca n b e a ctiva te d via th e “V ie w ”

menu if you have assigned symbolic addresses in the SIMATIC symbol
table or in the local variables table.
The program can be checked for faults. You translate the program with the
b u tto n s in th e to o lb a r o r w ith th e co m m a n d s in th e “T a rg e t S yste m ” m e n u .
All faults that have possibly occurred are displayed in the output window.
For each fault, the position (network, row and column) as well as the fault
type are stated. You can double-click a fault line to display the code of the
network which contains the fault in the program editor.
T h e p ro g ra m ca n th e n b e tra n sfe rre d to th e co n tro lle r via “F ile ”

“D o w n lo a d ” a n d sta rte d w ith “R U N ”.

C27 Loading a PLC Program
1 Brief Description
Module Objective:
Upon completion you are able to load a new PLC program to the controller.
Module Description:
This module describes the establishment of a communication connection and the download of the
PLC program to the controller. The function is checked via the program status.
Module Content:
 Loading a PLC program
Loading a PLC program Section 2

Section 2 Loading a PLC program
Notes
Establishing the communication connection
The connection between the controller and the PG is established via the
serial RS232 COM interface X8
In th e p ro g ra m m in g to o l, a ll im p o rta n t va lu e s a re se t via th e “V ie w ” m e n u
“C o m m u n ica tio n ”. In th e syste m co n tro l, th e e n try P L C 8 0 2 (P P I) in th e
“S e t P G /P C In te rfa ce ” h a s to b e se le cte d o n th e re sp e ctive C O M p o rt (h a s
to b e id e n tica l w ith th e co m m u n ica tio n p a ra m e te rs o f th e 8 0 2 D : “S yste m ”
“P L C ” “S te p 7 C o n n e ctio n ”).

Notes
W ith th e co m m a n d “D o u b le -click F o r U p d a te ”, th e a u to m a tic se a rch fo r

connected devices is started. The canceled address can nevertheless also
be entered directly in the left part of the menu.
Double click to actualise
T o te st th e co n n e ctio n , va rio u s va lu e s ca n b e re a d o u t via “T a rg e t S yste m ”

“In fo rm a tio n ”.
Loading a program to the CPU
Loading the completed PLC program to the controller requires only a few
more steps. First of all, the program should be checked for faults via
“T a rg e t S yste m ” “C o m p ile ”. W ith “L o a d T o C P U ”, th e p ro g ra m is
transferred to the controller.
W ith th e co m m a n d “u p lo a d ”, th e cu rre n t p ro g ra m o n th e C P U ca n b e re -
loaded to the PG.
T h e syste m ’s o p e ra tin g sta te ca n n o w b e ch a n g e d w ith “R U N / S T O P ”.
RUN / STOP
To test the program, the current state of the PLC program can be dis-
p la ye d via th e m e n u “T e st” “P ro g ra m S ta tu s”

Notes

C35 PLC Subroutine Library
1 Brief Description
Module Objective:
Upon completion of this module you can write a PLC program using Subroutines from the Library.
Module Description:
The SINUMERIK 802D is a compact NC system, ideally suited for turning or milling machines.
This module describes the PLC Subroutine Library, its use and the resources it uses.
Module Content:
• PLC subroutine library
PLC subroutine library

Section 2

Section 2 PLC subroutine library
To use the library, Programming Tool PLC802 is required, and can be

found on the toolbox CD which is delivered to the OEM with each control-
ler.
In order to acquaint users with the 802 PLC programming, four PLC exam-
ple projects are made available with the programming tool.
• SUBR_LIBRARY.PTP
Library program with all provided subroutines
• SIMULATION.PTP
Simulation program
• SAMPLE_TURN.PTP
Program example for a turning machine
• SAMPLE_MILL.PTP
Program example for a milling machine
In the project SUBR_LIBRARY.PTP, a number of subroutines for basic

functions such as Emergency Stop or axis and coolant control are made
available, this should be used as a template. The project SIMULA-
TION.PTP is a user PLC program for testing the 802D without a control
panel.
The two other projects can be used as examples to clarify the principle of
operation of subroutines. The library and the example programs are de-
signed for a standard axis configuration, but they can be adapted.
For further information, please refer to the pdf file “PLC_appl_Program.pdf”

(path: ..\Siemens\Programming Tool PLC802\Lib802Dsl\).
The functions of all subroutines are described in detail:
• PLC_INI (PLC Initializing)

• EMG_STOP (Emergency Stop)
• MCP_802D (802D MCP signal transferring)
• SPD_OVR (Spindle override with toggle keys)
• MCP_SIMU (MCP simulation)
• MCP_NCK (MCP signal processing)
• HANDWHL (Handwheel selection)
• AXES_CTL (Feed axes and Spindle control )
• MEAS_JOG (Measuring in Jog mode)
• COOLING (Coolant control)
• LUBRICAT (Lubricating control)
• TURRET1 (Turret with Hall Effect Device position sensor)
• TURRET2 (Control of a turret with binary encoder)
• TOOL_DIR (Tool change direction)
• MGZ_INI (Initialization on tool magazine table)
• MGZ_SRCH (Search tool from magazine)
• MGZ_RNEW (Refresh magazine table)
• TOGGLE
The programs are loaded to the CPU as described in Module C27.
SINUMERIK 802D sl 1st Commis-

Section 2 PLC subroutine library

Description of PLC Subroutine Library V02.00.00 for
SINUMERIK 802D sl
SINUMERIK 802D sl Page: 1 / 53 All right reserved ©

PLC Subroutine library Date: 09.04.2006
Change Log 4
1. GENERAL DESCRIPTION 6
1.1. Purpose of the library PLC application programs 6
1.2. Pre-condition 7
1.3. Arrangement of symbol table 10
1.4. Arrangement of subroutine library 10
1.5. MCP Interface Description (refer to Chapter 18.2.1 and 18.2.2 in
Functional Description) 11
2. ASSIGNMENT OF THE SYMBOL TABLES 12

2.1. Symbol table 1 12
2.2. Symbol table 2 13
2.3. Symbol table 3 - Symbol table15 13
2.4. Symbol table 16: IS_MCP 13
2.5. Symbol table 17: IS_HMI 13
2.6. Symbol table 18: IS_AUX 14
2.7. Symbol table 19: IS_NCK 14
2.8. Symbol table 20: IS_CHA 14
2.9. Symbol table 21, 22, 23, 24, 25: IS_AX1, IS_AX2, IS_AX3, IS_AX4, IS_AX5 14
2.10. Symbol table 26: MD_PLC 14
2.11. Symbol table 27: ALARM 14
2.12. Symbol table 28: NV_MEM 14
2.13. Symbol table 29: SPC_MEM 15
2.14. Symbol table 30: SBR_MEM 15
2.15. Symbol table 31 and 32: reserved for library program 15
3. DESCRIPTION OF THE SUBROUTINES LIBRARY 16

3.1. Subroutine 32 - PLC_INI (PLC Initializing) 16
3.2. Subroutine 33 - EMG_STOP (Emergency Stop) 18
3.3. Subroutine 34 - MCP_802D (802D MCP signal transferring) 20
3.4. Subroutine 35 - SPD_OVR (Spindle override with toggle keys) 27
3.5. Subroutine 37 - MCP_SIMU (MCP simulation) 28
3.6. Subroutine 38 - MCP_NCK (MCP signal processing) 28
3.7. Subroutine 39 - HANDWHL (Handwheel selection) 29
3.8. Subroutine 40 - AXES_CTL (Feed axes and Spindle control ) 30
3.9. Subroutine 43 - MEAS_JOG (Measuring in Jog mode) 32
3.10. Subroutine 44 - COOLING (coolant control) 34
3.11. Subroutine 45 - LUBRICAT (Lubricating control) 35
3.12. Subroutine 46 - TURRET1 (Turret with Hall Effect Device position
sensor) 36
3.13. Subroutine 47 - TURRET2 (Control of a turret with binary encoder) 38
3.14. Subroutine 48 - TOOL_DIR (Tool change direction) 39
3.15. Subroutine 49 - MGZ_INI (Initialization on tool magazine table) 40

3.16. Subroutine 50 - MGZ_SRCH (Search tool from magazine) 42
3.17. Subroutine 51 - MGZ_RNEW (Refresh magazine table) 42
3.18. Subroutine 36, 41, 42 and Subroutine 52 ...58 and 60 …62 are reserved for
subroutine library 43
3.19. Subroutine 59 - GRINDING_CTL (Grinding control) 27
3.20. Subroutine 63 - TOGGLE 43
4. PLC USER ALARMS USED IN SUBROUTINE LIBRARY 46
5. SAMPLE PLC APPLICATION PROGRAMS 46

5.1. PLC Application Program for simulation 46
5.2 Sample PLC Application Program for a Turning Machine 49
5.3 Sample PLC Application Program for a Milling Machine 51

Change Log
V 01.05.00:
New functions
• Measuring in JOG mode
(usable with Version SINUMERIK 802D SW 01.01.05 or higher)
MEAS_JOG (SBR43) V1.0
Needs: PLC_INI (SBR32) V1.4, MCP_NCK (SBR38) V1.4
• Tool Magazine
MGZ_INI (SBR49) V1.0, MGZ_SRCH (SBR50) V1.0, MGZ_RNEW (SBR51) V1.0
Improvements
• Data exchange to PLC User Interface improved
TURRET1 (SBR46) V1.4, EMG_STOP (SBR33) V1.4 , MCP_NCK (SBR38) V1.4
• Signal names have been changed :

V10000004.0 ... V10000005.6 from CK0 ... CK5 to CK1 ... CK6 now.
V16002000.3 from EMG_STOP to EMGY_STOP
• Functionality of spindle keys has been changed. The trigger mode of CCW and CW keys can choose
with MD 14512[19] Bit0 (momentary or continuous).
MCP_802D (SBR34) V1.4
V 01.06.00:
Improvements
• Signal names have been changed :
V10000001.0 and V11000001.0 from not used to CONTINUOUSLY (CONT) now.
MCP_802D (SBR34)
• M133.5 is continuously traversing and M133.6 most significant Bit of INC buffer now.
MCP_802D (SBR34) V1.5, MCP_SIMU (SBR37) V1.4, MCP_NCK(SBR38) V1.5
V 01.07.00:
Improvements
• New interface signals for MCP 802D sl are used in SBR34 (VB10001000, VB10001001,
VB10001002, VB1001003, VB10001004, VB10001005, VB11001000).
• Description subroutine SBR34 and sample PLC application programs are changed.
V 01.08.00:
Improvements
• New interface signals from HMI are used in SBR38 (AUTO from area V18000000.0,
MDA V18000001.1. JOG V18000000.2, Mode change disable V18000000.5,

REF V18000001.2 to NCK interface).
V 02.00.00 for 802D solution line:
New functions
• Grinding
GRINDING_CTL (usable with Version SINUMERIK 802D sl SW 01.01.06 or higher)
GRINDING_CTL (SBR59) V01.00
Improvements
• New interface signals from NCK are used in SBR59 (V28001001.4, V28001001.5, V28001001.6),
V28001001.6, V38005004.0, V38025004.0), SBR60 (V27000002.5).
• M134.0 OS_REV_CMD flag for M-command enable oscillation reversal in SBR59

1. General Description
SINUMERIK 802D sl is a compact numerical control system with profibus drive interface,
ideally suited for turning and milling machines.
To adapt the SINUMERIK 802D to machine tools, machine control logic must be designed
with the PLC Programming Tool. The tool used is PLC 802 Version 3.0 or higher, The PLC
tool contains STEP7-Micro / WIN32 V3.0 programming language.
This document describes the PLC Subroutine Library V02.00.00 & is designed for Machine
Tool Builders who have basic knowledge of CNC and PLC functioning & programming.
Please, refer to following documents for more detailed information on 802D sl:
• SINUMERIK 802D sl Operating instructions

• SINUMERIK 802D sl Function description
• SINAMICS S120 documents
1.1.Purpose of the library PLC application programs

To acquaint the users with PLC programming tool, 4 PLC projects are provided in the
Internet site: http://www.siemens.com/sinumerik802d.
SUBR_LIBRARY.PTP Library program with all subroutines provided and an empty
main program (OB1)
SIMULATION.PTP Simulation program
SAMPLE_TURN.PTP Sample program for turning (lathe) machine
SAMPLE_MILL.PTP Sample program for milling machine
In project file SUBR_LIBRARY.PTP a variety of subroutines are provided for basic

functions such as emergency stop control, axes control, coolant control, lubrication control
and turret control for turning machines.
The project SIMULATION.PTP is an application PLC program for testing your 802D sl
without Machine control panel. The other 2 project files can be used as samples to show
how to make use of the subroutines in the project file SUBR_LIBRARY.PTP for turning or
milling machines.
Customers can just download the project files from the Internet and read these samples to
understand how a subroutine is programmed and how the subroutine is called. These files
can be saved (SUBR_LIBRARY.PTP) in a new project. By organizing the subroutines,
modifying or adding the necessary networks most of the machine tool requirements can be
met or addressed.
Just download your PLC application program into
SINUMERIK802D sl and test it until all the functions work.

1.2. Pre-condition
The subroutine library and the sample PLC application programs are designed for
standard axis configurations. By downloading one of the initialization files from installed
toolbox (path:Toolbox 802D_sl\Version\Techno\Config Siemens), the standard axis
configurations can be completed. The file SETUP_T.ARC is for turning machine the file
SETUP_M.ARC is for milling machine, the file SETUP_N.ARC, SETUP_N_MC.ARC is for
nibbling machine and the file SETUP_G_C.ARC, SETUP_G_C_INC.ARC is for cylindrical
grinding machine. (Further information you find in the readme.txt in the toolbox path.)
By downloading the configuration file SETUP_T.ARC from toolbox, the axes configuration
can be changed to a turning machine with 2 feed axes and 1 spindle.
Axis number Axis Name Axis interface address

1st axis X1 V3800 xxxx
2nd axis Z1 V3801 xxxx
3rd axis SP V3802 xxxx
By downloading the configuration file SETUP_M.ARC from toolbox, the axes configuration
can be changed to a milling machine with 4 feed axes and one spindle:

2nd axis Y1 V3801 xxxx
3rd axis Z1 V3802 xxxx
4th axis SP V3803 xxxx
5th axis A1 V3804 xxxx
By downloading the configuration file SETUP_N_MC.ARC from toolbox, the axes

configuration can be changed to a nibbling machine with 4 feed axes:

2nd axis Y1 V3801 xxxx
3rd axis C1 V3802 xxxx
4th axis C2 V3803 xxxx
By downloading the configuration file SETUP_G_C.ARC from toolbox, the axes

configuration can be changed to a cylindrical grinding machine with 4 feed axes:

2nd axis Z1 V3801 xxxx
3rd axis C1 V3802 xxxx
4th axis SP1 V3803 xxxx
To understand the subroutines in the library, the following preconditions must be taken into
consideration.

1.2.1.Division of the System Resources
The system resources can be divided into 3 parts. They are PLC system, NCK, and PLC
programming tool. In this chapter, these available resources are listed and further, divided
& described into resources for sample program and resources free for user.
1.2.2. Resources
1.2.2.1. Resource of PLC

Inputs: I0.0 … I8.7 (72 inputs on 1st PP module with address 9)
I9.0 … I17.7 (72 inputs on 2nd PP module with address 8)
Outputs: Q0.0 … Q5.7 (48 outputs on 1st PP module)
Q6.0 … Q11.7 (48 outputs on 2nd PP module)
Global Memory: M0.0 … M255.7
Retentive Memory: V14000000.0 … V14000127.7 (128 bytes)
User Alarm: V16000000.0 … V16000003.7 (32 user alarms)
Timers: T0 … T15 (16x100ms timers),
T16 … T31 (16x10ms timers)
Counters: C0 … C31 (32 counters)
1.2.2.2. Resource of NC
PLC Machine Data: MD14510 / MD14512 / MD14514
MD14510 User Data INT: V45000000 … V45000062 (32 words)

MD14512 User Data HEX: V45001000 … V45001032 (32 bytes)
MD14514 User Data Real: V45002000 … V45002028 (8 Dword)
1.2.2.3. Resource of Programming Tool
Symbol tables: SYM1 … SYM32
Subroutines: SBR0 … SBR63
1.2.3. Resource free for customers
1.2.3.1. Resource of PLC

Inputs: I0.0 … I17.7 (144 inputs)
Outputs: Q0.0 … Q11.7 (96 outputs)
Retentive Memory: V14000000.0 … V14000063.7 (64 bytes)
Timers: T0 … T15 (16x100ms timers)
Counters: C0 … C23 (24x counters)
Resource of NC

MD14514 User Data Real: V45002000 … V45002028 (8 Dword)
Resource of Programming Tool
Symbol tables: SYM1 … SYM15 (15 symbol tables)
Subroutines: SBR0 … SBR31 (32 subroutines)
1.2.3.2. Resource reserved for sample programs

Resource of PLC
Inputs: -
Outputs: -
Retentive Memory: V14000064.0 … V14000127.7 (64 bytes) (for machining
center, V14000000.0 to V14000040.7 are reserved)
Timers: no 100ms timers reserved
Counters: C24 … C31 (8x counters)
Resource of NC
MD14514 User Data Real: no
Resource of Programming Tool
Symbol tables: SYM16 … SYM32 (17 symbol tables)
Subroutines: SBR32 … SBR63 (32 subroutines)

1.3. Arrangement of symbol table
SYM Name Content of the symbol table
1 PP_1 I/O of PP module 1 will be defined by customers
2 PP_2 I/O of PP module 2 will be defined by customers
3 ~ 15 Reserved for customer
16 IS_MCP Interface signal from and/or to MCP
17 IS_HMI Interface signal from and/or to HMI
18 IS_AUX Interface signal of auxiliary function from NCK
19 IS_NCK Interface signal from and/or to NCK
20 IS_CHA Interface signal from and/or to CHANNEL
21 IS_AX1 Interface signal from and/or to AXIS 1
26 MD_PLC PLC Machine Data for Siemens Subroutine
27 ALARM User Alarms
28 NV_MEM Retentive data area (None Volatile Memory)
29 SPC_MEM Special Memory Bit
30 SBR_MEM Definition of Memory for library PLC application program
31 ~ 32 Reserved for library PLC application program
1.4. Arrangement of subroutine library

SBR Name Subroutine description
0 ~ 30 - Free for customer application
31 USR_INI Reserved for user initializing (called by SBR32 PLC_INI)
32 PLC_INI Initialization of the control
33 EMG_STOP Emergency Stop (including drive power on and power off sequence)
34 MCP_802D Transfer I/O of 802D MCP to interfaceV1000xxxx and V1100xxxx
35 SPD_OVR Spindle override code generator (gray code) to interface V1000 0008
36 Reserved
37 MCP_SIMU Simulating override switches and acknowledging the active signals
38 MCP_NCK MCP_HMI signal (from V1000 000x) to NCK
39 HANDWHL Handwheel(s) for 3 axis (MCS and WCS) selected from PLC
40 AXIS_CTL Enable control for 4 Feed Axis and spindle Control (hardware limit
switch, and brake release if necessary)
41 ~ 42 Reserved
43 MEAS_JOG Measuring in Jog
44 COOLING Coolant control
45 LUBRICAT Lubrication control (interval and time)
46 TURRET1 Turret control 1 (Hall effect device sensor turret with 4 or 6 position)
47 TURRET2 Turret control 2 (encoder sensor turret like SAUTER turret)
48 TOOL_DIR Make out the direction of tool change
49 MGZ_INI Initialization of holder table of tool magazine (max. 40 tools)
50 MGZ_SRCH Search holder position of programmed tool from magazine
51 MGZ_RNEW Refresh holder table
52 ~ 62 Reserved for library PLC application programs
63 TOGGLE Toggle switch K1 ~ K6; Delay Switch K7, K8

1.5. MCP Interface Description (refer to Chapter 18.2.1 and 18.2.2 in Functional
Description)
1000 Signals from MCP [w/r]

Interface MCP to PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Operating Mode
10000000 NC- Single JOG MDA AUTOM
STOP block
Spindle function Protec- Machine function
10000001 NC- Spindle Spindle Spindle tion REF REPOS CONT
START CW STOP CCW level 7
Feed Protec- Machine function
10000002 START STOP Var. INC tion INC1000 INC100 INC10 INC1
level 4
Protection level Feed override
10000003 RESET 6 5 E D C B A
Axis Traverse keys Optional Customer keys (CK)

th th
10000004 4 Axis 4 Axis Rapid
- + overlay CK5 CK4 CK3 CK2 CK1
Axis Traverse keys
rd rd nd nd st st
10000005 free CK6 3 Axis 3 Axis 2 Axis 2 Axis 1 Axis 1 Axis
- + - + - +
Free customer Free customer keys
10000006 free free free free free free free
Free customer keys

10000007
free free free free free free free free
Spindle Override
10000008 “0” “0” “0” E D C B A
1100 Signals to MCP [w/r]

Interface MCP to PLC
Operating Mode
11000000 NC- Single JOG MDA AUTOM
STOP block
Spindle function Machine function
11000001 NC- Spindle Spindle Spindle free REF REPOS CONT
START CW STOP CCW
Feed Machine function
11000002 START STOP Var. INC free INC1000 INC100 INC10 INC1
11000003 free free free free free free free free
Axis Traverse keys Customer keys LED`s

th th
11000004 4 Axis 4 Axis Rapid
- + overlay CLED5 CLED4 CLED3 CLED2 CLED1
Axis Traverse keys
rd rd nd nd st st
11000005 free CLED6 3 Axis 3 Axis 2 Axis 2 Axis 1 Axis 1 Axis
- + - + - +
Free customer keys Free customer keys
11000006 free free free free free free free
Free customer keys

11000007 free free free free free free free free

2. Assignment of the symbol tables
• List of Symbols used in the subroutine library obey the same convention:
1. Leading characters are for destinations:

P_ - to PLC interface
H_ - to HMI interface
N_ - to NCK interface
M_ - to MCP interface
2. subsequent characters are for areas:
C_ - Channel
1_ - Axes
M_ - MCP
Other short forms in the symbols:
HWL - Hardware Limit
HW - Handwheel
RT - Rapid Traverse
TK - Traverse Key
ACT - active
SEL - selected (activated)
3. Max. 11 upper case character to compose a symbol (include the leading
character). No special characters such as =, +, -, [, ] etc. are allowed except
underscore.
2.1. Symbol table 1

For 1st PP module
With this symbol table, all the physical inputs and outputs of PP module can be defined by
the customers according to their specific application.
Here customer can Module name, the

number of socket and
define a symbol for I0.0
pin are indicated here.
Customer can also
add the wire label of
I0.0 after colon.

2.2. Symbol table 2
For 2nd PP module
With this symbol table, all the physical inputs and outputs of PP module can be defined by
the customers according to their specific application.
2.3. Symbol table 3 - Symbol table15

These symbol tables are reserved for the application programs of customers.
CAUTION
! If the color of your symbol is changes automatically to RED, the symbol is
not accepted the programming tool. Check if special character is used or
if leading character is a digit.
CAUTION
! If a waved underscore appears under your symbol, the symbol is
duplicated. Check duplicate name or address.
2.4. Symbol table 16: IS_MCP

User Data Interface is defined and symbolized for MCP in this symbol table, i.e.
V1000 xxxx: Signals from MCP to PLC
V1100 xxxx: Signals to MCP
All main programs (OB1) and subroutines in the library PLC application programs access
the signals from MCP which are symbolized here in this table.
The signals from MCP should be transferred to this interface signal area in a subroutine. In
case 802D MCP is used, Subroutine 34 can be used to convey the signals from inputs /
outputs of MCP to the interface. In a similar way, if a customer has his own MCP, he is
only required to write a subroutine to transfer the signals from MCP to this User Data
Interface. Then all the subroutines in the library are available for application.
2.5. Symbol table 17: IS_HMI

Interface Signals from and to HMI are symbolized in this symbol table, i.e.
V1700 0xxx: Signal from HMI – Program Control (retentive, read only)
V1900 0xxx: Signal from HMI – Simulation active (retentive read only)
V1900 1xxx: Signal from HMI – Handwheel selection (retentive read only)
V1900 5xxx: Signal to HMI – Operator key lock (retentive read/write)

2.6. Symbol table 18: IS_AUX
Interface Signals from NCK channel are listed in this symbol table, i.e.
V2500 0xxx: Signal from NCK channel – Auxiliary function (read only)
V2500 1xxx: Signal from NCK channel – decoded M functions (read only)
V2500 2xxx: Signal from NCK channel – T function transferred (read only)
V2500 3xxx: Signal from NCK channel – M function transferred (read only)
V2500 5xxx: Signal from NCK channel – D function transferred (read only)
V2500 6xxx: Signal from NCK channel – H function transferred (read only)
2.7. Symbol table 19: IS_NCK

Interface Signals to and from NCK are listed in this symbol table, i.e.
V2600 xxxx: General signal to NCK (read/write)
V2700 xxxx: General signal from NCK (read only)
2.8. Symbol table 20: IS_CHA

V3000 xxxx: Mode signal to NCK (read/write)
V3100 xxxx: Mode signal from NCK (read only)
V3200 xxxx: Control signal to NCK (read/write)
V3300 xxxx: Control signal from NCK (read only)
2.9. Symbol table 21, 22, 23, 24, 25: IS_AX1, IS_AX2, IS_AX3, IS_AX4, IS_AX5
V380x xxxx: Axis control signals to NCK (read/write)
V390x xxxx: Axis control signals from NCK (read only)
2.10. Symbol table 26: MD_PLC

PLC Machine Data from NCK are listed in this symbol table, i.e.
V4500 0xxx: reflected MD14510 USER_DATA_INT (read only)
V4500 1xxx: reflected MD14512 USER_DATA_HEX (read only)
V4500 2xxx: reflected MD14514 USER_DATA_FLOAT (read only)
There are 32 Machine Data in each area. The last 16 Machine Data of each area are
reserved for the library PLC application program.
2.11. Symbol table 27: ALARM

Activating BIT of PLC Alarms of NCK (V1600 000x) are listed in this symbol table. There
are 32 User Alarms which can be activated by PLC application. The last 16 alarms are
reserved for the library PLC application program.
2.12. Symbol table 28: NV_MEM

There are 128 bytes in this retentive data area and the data used in the library are listed
(V1400 xxxx). The last 64 bytes are reserved for the library PLC application program.

2.13. Symbol table 29: SPC_MEM
There are 7 special memory bits in 802D sl (SM0.0 … SM0.6).
2.14. Symbol table 30: SBR_MEM

All the memories used in the Subroutines Library are listed in this table. These are used as
global variables for diagnosis purpose and arranged in the order of subroutines.
2.15. Symbol table 31 and 32: reserved for library program

3. Description of the subroutines library
The PLC machine data used for the subroutines in the library are listed here to have an
overview:
USER_DATA_INT:
MD14510[16] - Machine type
0: not defined (Initializing according to MD14512[16])
1: Turning machine
2: Milling machine
21: Cylindrical grinding machine
31: Nibbling machine with mechanical coupled punching die
32: Nibbling with servo axis coupled punching die
MD14510[22] - Turret clamping time (unit: 0.01s)

MD14510[24] - Lubrication interval (unit: 1min)
MD14510[25] - Lubrication duration (unit: 0.01s)
USER_DATA_HEX:
MD14512[16] Axis configuration (in case MD14510[16]=0)
Bit 0 - 1st axis is configured.
Bit 1 - 2nd axis is configured
Bit 2 - 3rd axis is configured
Bit 3 - 4th axis is configured
Bit 4 - 5th axis is configured
MD14512[18] special configuration of the machine tool
Bit 0 - Spindle without override switch
Bit 1 - Drive Optimization
Bit 2 - Lubrication at first power on
Bit 3 - When 802D MCP used, User Key1 is Feed Enable toggle key
Bit 4 - External spindle stop signal
Bit 6 - Hardware limits independent from PLC
Bit 7 - Only one hardware limit switch for each axis (with Bit6=0)
MD14512[19] Bit 0 = 0 Spindle key CW and CCW work as momentary trigger mode
Bit 0 = 1 Spindle key CW and CCW work as continuous trigger mode
3.1. Subroutine 32 - PLC_INI (PLC Initializing)

3.1.1. Purpose of Subroutine 32
This subroutine is executed at the 1st PLC cycle to set some interface signals according
to the configuration defined by PLC machine data. In this subroutine the following
interface signals are set:
V32000006.7 - feed override active for NCK channel
V380x0001.5 - Measuring system 1 for the axes defined
V380x0001.7 - feed override active for the axes defined

And also the Machine Data MD14512[18] Bit0 will be evaluated in the program to
determine whether the spindle override switch is installed.
At end of Subroutine 32, Subroutine 31: USR_INI is called. The initialization of customer
PLC project should be programmed in this subroutine.
3.1.2. Local Variable Definition – no local variable defined
3.1.3. Global Memory occupied

24 bytes are defined in the retentive data area and are assigned in this subroutine with
gray code values for applications of rotary gray code switches to select axis, operation
mode etc. See symbol table SYM28 (NV_MEM), from VB14000101 ~ VB14000124.
3.1.4. Corresponding PLC Machine Data

One WORD PLC machine data is defined for the machine type.
MD14510[16] - Machine type
0: not defined (Initializing according to MD14512[16])
1: Turning machine
2: Milling machine
I.e. for turning machine the axes is configured as below:

1st axis X axis
2nd axis Z axis
3rd axis Spindle
And for milling machine the axes is configured as below:
1st axis X axis
2nd axis Y axis
3rd axis Z axis
4th axis Spindle
5th axis A axis
MD14512[16] Axis configuration (in case MD14510[16]=0)
Bit0 - 1st axis is configured.
Bit1 - 2nd axis is configured
Bit2 - 3rd axis is configured
Bit3 - 4th axis is configured
Bit4 - 5th axis is configured
MD14512[18] special configuration of the machine tool
Bit0 - Spindle without override switch
3.1.5. Sample of Subroutine Call
Network 1 Initialization
SCAN_1ST PLC_INI
EN

3.1.5.1. Subroutine 33 - EMG_STOP (Emergency Stop)
CAUTION
! Please check whether this subroutine complies with all the relevant safety
requirements.
3.1.6.Purpose of Subroutine 33
This subroutine handles the emergency stop sequence according to the timing diagram
described in “Function Description”, as well as the power on and off sequence of the
Supply Infeed module. For detailed information about Supply Infeed module please
refer to 611U start-up guide.
On Infeed supply Spindle stop will be synchronized here

module:
Terminal 64
Terminal 63
Terminal 48
t t t t
Power Off sequence Power On sequence
The precondition of this subroutine is that the standard configuration of turning and
milling machine are used. When the enable on the drive is off, i.e. when Terminal 64 is
reset to zero, axes and spindle are braking to standstill. This subroutine evaluates a
feedback signal from V390X0001.4 – n<nmin, or an external spindle stop signal (e.g. an
analog spindle without encoder) according to MD14510[16].
MD14510[16]=0 means non standard configuration. In this case an external spindle stop
signal (for example, zero speed signal from a frequency converter) must be connected to
the subroutine to detect a spindle zero speed.
Drive Enable and Disable signal come from User Data area V1000 xxxx.
2 alarms may be activated from this subroutine:
Alarm 700016 – DRIVE NOT READY
Alarm 700017 – I2/T ALARM FOR INFEED MODULE
Feed Stop to channel will be activated by any alarms from the subroutine library. The
cancellation Feed Stop is RESET after alarm condition is cleared.
Important ! For machine tools with neither digital or analog spindle used, the PLC
machine data should be specified like following table. Otherwise the
emergency can not be released.
For turning machine For milling machine
MD14510[16]=0 MD14510[16]=0
MD14512[16] Bit 0 = 1 MD14512[16] Bit 0 = 1
Bit 1 = 1 Bit 1 = 1
Bit 2 = 1

3.1.7. Local Variable Definition
Inputs:
DELAY WORD Power on / off sequence delay (Unit:10ms)
E_KEY BOOL Emergency Stop Key (NC)
T_72 BOOL Terminal 72 of Infeed module: Drive ready (NO)
T_52 BOOL Terminal 52 of Infeed module: I2/t monitoring (NO)
HWL_ON BOOL any of the hardware-limit switches is active (NO) 1)
SpStop BOOL Spindle Stop (NO) 2)
1)
From subroutine 40 (AXIS_CTL) an output signal is set to “1” when any of the
hardware limit switch active. The signal can be connected to this subroutine to
trigger emergency stop in case of over limit.
2)
By Emergency Stop, spindle standstill signal from NCK will be evaluated before
disable the drive system to make sure that spindle can be stopped if PLC
machine data MD14510[16] = 1 or 2 (i.e. by turning or milling machine tools). If
MD14510[16]=0, this external signal will then be evaluated .
3)
NO – Normal Open; NC – Normal Close
Outputs:
T_48 BOOL To Terminal 48 of Infeed module: Contactor control
T_63 BOOL To Terminal 63 of Infeed module: Pulse enable
T_64 BOOL To Terminal 64 of Infeed module: Controller enable
T_48m M130.0 Status of Terminal 48 of the power module
D_T64m M130.6 Delay for Terminal 64 before verify ready signal
SP_STOPm M130.4 Spindle comes to standstill
PO_END M130.7 Power Up procedure ended
Three 10ms timer are used in this subroutine:
D_T64_T63 T24 Delay from Terminal 64 is off till Terminal 63 off
D_T63_T48 T25 Delay from Terminal 63 is off till Terminal 48 off
D_PON T26 Delay after Power On
MD14510[16] – Machine type is evaluated in this subroutine
Network 2 Emergency Control
ONE EMG_STOP
EN
50 DELAY T_48 Q0.0

I0.0 E_KEY T_63 Q0.1
I0.1 T_72 T_64 Q0.2
I0.2 T_52
Q0.7 HWL_ON
I0.4 SpStop

3.2. Subroutine 34 - MCP_802D (802D MCP signal transferring)
Subroutine34 transferring the input signals from 802D MCP to interface area for further
processing. By using sinumerik 802D the MCP 802D is connected via I/O’s from the PP-
module. The key layout is shown in the figure below and the key assignment can be
found in the following table:
MCP 802D
X1201
Pin Signal Type Description Pin Signal Type Description
1 M Output GND 2 L+ Output +24V
3 Im+0.0 Input #1 4 Im+0.1 Input #2
9 Im+0.6 Input #7 10 Im+0.7 Input #8
11 Im+1.0 Input #9 12 Im+1.1 Input #10
13 Im+1.2 Input #11 14 Im+1.3 Input #12
15 Im+1.4 Input #13 16 Im+1.5 Input #14
17 Im+1.6 Input #15 18 Im+1.7 Input #16
19 Im+2.0 Input #17 20 Im+2.1 Input #18
21 Im+2.2 Input #19 22 Im+2.3 Input #20
23 Im+2.4 Input #21 24 Im+2.5 Input #22
25 Im+2.6 Input #23 26 Im+2.7 Input #24
27 not connected 28 not connected
31 On+0.0 Output LED1 32 On+0.1 Output LED2
37 On+0.6 Output 38 On+0.7 Output
47 DOCOM1 Input 24VDC 48 DOCOM1 Input 24VDC
X1202
1 M Output GND 2 L+ Output +24V
3 Im+3.0 Input #25 4 Im+3.1 Input #26
5 Im+3.2 Input #27 6 Im+3.3 Input
7 Im+3.4 Input 8 Im+3.5 Input
11 Im+4.0 Input Feed_OV_A 12 Im+4.1 Input Feed_OV_B
13 Im+4.2 Input Feed_OV_C 14 Im+4.3 Input Feed_OV_D
15 Im+4.4 Input Feed_OV_E 16 Im+4.5 Input
19 Im+5.0 Input Sp_OV_A 20 Im+5.1 Input Sp_OV_B
21 Im+5.2 Input Sp_OV_C 22 Im+5.3 Input Sp_OV_D
23 Im+5.4 Input Sp_OV_E 24 Im+5.5 Input

For the sinumerik 802D sl you put preferably the MCP 802D sl via MCPA module.
MCP 802D sl
X1201
9 M GND 10 Im+1.0 Input #9
11 Im+1.1 Input #10 12 Im+1.2 Input #11
13 Im+1.3 Input #12 14 Im+1.4 Input #13
15 Im+1.5 Input #14 16 Im+1.6 Input #15
17 Im+1.7 Input #16 18 M GND
19 Im+2.0 Input #17 20 Im+2.1 Input #18
21 Im+2.2 Input #19 22 Im+2.3 Input #20
23 Im+2.4 Input #21 24 Im+2.5 Input #22
25 Im+2.6 Input #23 26 Im+2.7 Input #24
27 M GND 28 On+0.0 Output LED1
33 On+0.5 Output LED6 34 not connected
35 not connected 36 M GND
X1202
1 Im+3.0 Input #25 2 Im+3.1 Input #26
3 Im+3.2 Input #27 4 not connected
9 M GND 10 Im+4.0 Input Feed_OV_A
11 Im+4.1 Input Feed_OV_B 12 Im+4.2 Input Feed_OV_C
13 Im+4.3 Input Feed_OV_D 14 Im+4.4 Input Feed_OV_E
19 Im+5.0 Input Sp_OV_A 20 Im+5.1 Input Sp_OV_B
21 Im+5.2 Input Sp_OV_C 22 Im+5.3 Input Sp_OV_D
23 Im+5.4 Input Sp_OV_E 24 not connected
Further information about the hardware components you find in the Start-up guide/ Operating
instructions.

In this subroutine the physical inputs of axis traverse keys are transferred to the logic address in
the interface (V1000 xxxx). Key cross may be different according to variety of machine tool
structure. In this subroutine only 5 different key crosses are available.
802D MCP layout
L1 L2 L3
#1 #2 #3
L4 L5 L6
#4 #5 #6
#7 #8 #9
[.]
#10 #11 #12
,
#13 #14 #15
#16 #17 #18

%
+X
#19 #20 #21
-Z +Z
#22 #23 #24
-X
#25 #26 #27

%
Traverse key layout

For inclined bed turning machine For horizontal bed turning machine
#16 #17 #18 #16 #17 #18
+X -X
#19 #20 #21 #19 #20 #21
-Z +Z -Z +Z
#22 #23 #24 #22 #23 #24
-X +X
For vertical milling machine For knee-type milling machine

#16 #17 #18 #16 #17 #18
+4th +Z +Y +4th -Z -Y
#19 #20 #21 #19 #20 #21
-X +X +X -X
#22 #23 #24 #22 #23 #24
th th
-Y - Z -4 +Y +Z -4
Note: In this subroutine the feed override signals of 802D MCP are checked to be sure
that MCP is available. Otherwise an alarm will be triggered.
Alarm 700024 – 802D MACHINE CONTROL PANEL DEFECT

Inputs:
PB_0 BYTE Parameter buffer for K1 … K8
L0.0: K1: Customer key1
L0.5 K6: Customer key6
L0.6: K7: INC/VAR
L0.7: K8: JOG mode key
PB_1 BYTE Parameter buffer for K9 … K16
L1.0: K9: REF mode key
L1.1: K10: AUTO mode key
L1.2: K11: Single Block key
L1.3: K12: MDA mode key
L1.4: K13: Spindle + key
L1.5: K14: Spindle Stop key
L1.6: K15: Spindle – key
L1.7: K16: Axis key
PB_2 BYTE Parameter buffer for K17… K24
L2.0: K17: Axis key
L2.1: K18: Axis key
L2.2: K19: Axis key
L2.3: K20: Rapid traverse key
L2.4: K21: Axis key
L2.5: K22: Axis key
L2.6: K23: Axis key
L2.7: K24: Axis key
PB_3 BYTE Parameter buffer for K25… K27
L3.0: K25: RESET key
L3.1: K26: NC STOP key
L3.2: K27: NC START key
Fov BYTE Parameter buffer for Feed override

LB4: Feed Override
Sov BYTE Parameter buffer for Spindle override
LB5: Spindle Override
Drv_En BOOL Parameter feed enable key
disable. L6.0: Feed enable key. valid only when
Machine data MD14512[18] bit 3=1 then
Customer Key 1 is designed as toggle switch for drive
enable and disenable in this subroutine
I_En BOOL Parameter condition for NC start
L6.1: Condition for NC start
Xcross WORD Parameter definition for layout of traverse axis keys.
LW8: Layout of traverse keys
0: traverse key not processed in the subroutine
1: traverse key layout for inclined bed turning machine
2: traverse key layout for horizontal bed turning machine
3: traverse key layout for vertical milling machine
4: traverse key layout for knee-type milling machine
5: traverse key sequentially arranged (for variable Xcross)

Key Local Xcross Xcross Xcross Xcross
number Var. =1 =2 =3 =4
th th
#16 L1.7 +4 +4
#17 L2.0 +X -X +Z -Z
#18 L2.1 +Y -Y
#19 L2.2 -Z -Z -X +X
#20 L2.3 Rapid Rapid Rapid Rapid
#21 L2.4 +Z +Z +X -X
#22 L2.5 -Y +Y
#23 L2.6 -X +X -Z +Z
th th
#24 L2.7 -4 -4
Outputs: send out the signals from User Data to V1100 xxxx “signal for User Keys” to
LEDs BYTE Output for L1 to L6 MCP

L10.0: CLED1:
L10.1: CLED2:
L10.2: CLED3:
L10.3: CLED4
L10.4: CLED5
L10.5: CLED6
If other traverse key cross is required than those in previous samples, than use the configuration
Xcross=5 (variable key arrangement).
variable key arrangement
#16 #17 #18
#19 #20 #21
#22 #23 #24
Key Bit transfer Parameter Xcross MCP_802D

number [*written by customer] MCP_802D =5
#16 IBx MBx PB_1 Bit 7 +4. axis
#17 PB_2 Bit 0 -4. axis
#18 PB_2 Bit 1 +1. axis
MB10 PB_1
#19 PB_2 Bit 2 -1. axis
#20 PB_2 Bit 3 Rapid
#21 PB_2 Bit 4 +2. axis
#22 PB_2 Bit 5 -2. axis MB11
#23 PB_2 Bit 6 +3. axis PB_2
#24 IB(x+1) MB(x+1) PB_2 Bit 7 -3. axis

Manufactures can connect their physical I/O addresses in such way that they get their required Xcross
by adding some networks for converting.
The Xcross configuration will be realized by bit wise connection between Ibx (IBx+1) and MBx (MBx+1)
and be transferred to PB_1 Bit7 and PB_2. This program part is written by the customer.
The absolute address is in accordance with the interface port on PP or MCPA module.
Example: #16 #17 #18
+Z +Y +X
#19 #20 #21
-A +A
#22 #23 #24
-X -Y -Z
Key Bit transfer MB10 Parameter Xcross MCP_802D

number [*written by customer] MB11 MCP_802D =5
#16 IBx MBx M11.6 PB_1 Bit 7 +4. axis
#17 M11.4 PB_2 Bit 0 - 4. axis
#18 M11.1 PB_2 Bit 1 +1. axis PB_1
MB10
#19 M11.0 PB_2 Bit 2 - 1. axis
#20 M11.3 PB_2 Bit 3 Rapid
#21 M10.7 PB_2 Bit 4 +2. axis
#22 M11.2 PB_2 Bit 5 - 2. axis MB11
PB_2
#23 M11.5 PB_2 Bit 6 +3. axis
#24 IB(x+1) MB(x+1) M11.7 PB_2 Bit 7 - 3. axis
In above example MB10 and MB11 are used, which represent the keys for MCP_802D.

Two Bytes are used in this subroutine for toggle keys as Single Block and Feed Enable:
MB 133
MB 134
While there are no feed enable and feed disable keys on 802D MCP, two possibilities are
provided by this subroutine, either using User Key 1 as toggle switch for feed enable and disable
or using external key via an input to PP module. Therefore one PLC machine data bit is defined in
MD14512[18] for this special requirement:
If MD14512[18] bit 3=1 Customer Key 1 on 802D MCP is used as toggle key for Feed Enable or
disable
If MD14512[18] bit 3=0 an external key can be connect to the subroutine. The key should be with
holding signal, i.e. 1 – feed enable; 0 – feed disable.
The Spindle key function depends on PLC machine data MD14512[19]:

If MD14512[19] bit 0=0 Spindle key CW and CCW work as momentary trigger mode
If MD14512[18] bit 0=1 Spindle key CW and CCW work as continuous trigger mode

3.2.5. Sample of Subroutine Call MCP 802D
Network 3 Transfer 802D MCP signals to interface area V1000
ONE MCP_802D
EN
IB3 PB_0 LEDs QB2

IB4 PB_1
IB5 PB_2
IB6 PB_3
IB7 Fov
IB8 Sov
ONE Drv_EN
ONE I_EN
MD_INT_16 Xcross
3.2.6. Sample of Subroutine Call MCP 802D sl
Network 3 Transfer 802D sl MCP signals to interface area V1000
ONE MCP_802D
EN
VB10001000 PB_0 LEDs VB11001000

VB10001001 PB_1
VB10001002 PB_2
VB10001003 PB_3
VB10001004 Fov
VB10001005 Sov
ONE Drv_EN
ONE I_EN
MD_INT_16 Xcross

3.3. Subroutine 35 - SPD_OVR (Spindle override with toggle keys)
The purpose of this subroutine is to provide an alternative way to change spindle override value
using toggle keys instead of using rotary gray code switch. Some customers would like to simplify
their design of their own MCP’s, using 3 toggle keys for spindle override to increase or decrease
the override value of the spindle and with a toggle key to get override of 100%. The generated
spindle override code is output to MCP interface VB10000008.
If Gcode=1, the gray code override is selected in steps of 1 not depending on the value of STEPi.
For gray coding, 15 codes are available corresponding to the 15 positions of a rotary switch.
If Gcode=0, binary override code will be generated.
If binary code is selected for spindle, one machine data must be set:
MD12060 OVR_SPIND_IS_GRAY_CODE = 0 (0: Binary code; 1: Gray code)

Inputs:
STEPi WORD Step for increasing or decreasing the override value
with the range from 1 to 10 for binary code
Gcode BOOL 1 - gray code override is selected; 0 – binary code;
OVinc BOOL toggle key for override increasing
OVdec BYTE toggle key for override decreasing
OV100 BYTE toggle key for override 100%
OV_CNT WORD MW242 buffer for override code.

3.3.4. Corresponding PLC Machine Data – no PLC machine defined
Network 4 Spindle override using toggle keys
ONE SPD_OVR
EN
10 STEPi
ZERO Gcode
I2.1 OVinc
I2.2 OVdec
I2.0 OV100

3.4. Subroutine 37 - MCP_SIMU (MCP simulation)
The purpose of this subroutine is to provide a way to operate the 802D without MCP.
With the help of Status Chart of Micro/WIN, most of the MCP functions, such as
selection of operating mode or reference point approach, NC start, stop etc., can be
simulated. The application of this subroutine can be found in chapter 5.1.
3.4.2. Local Variable Definition – no local variable is used in the subroutine
3.4.3. Global Memory used

SIM_CAM1 M249.0 Reference CAM axis 1 for simulation
SIM_T63 M249.3 for simulation of terminal 63 of drive
SIM_T64 M249.4 for simulation of terminal 64 of drive
FOV_P M250.0 Feed override increment
FOV100 M250.1 Feed override 100%
FOV_N M250.2 Feed override decrement
SOV_P M250.3 Spindle override increment
SOV100 M250.4 Spindle override 100%
SOV_N M250.5 Spindle override decrement
SIM_INC M250.7 Increment selection
FOV_POS C25 simulating feed rate override switch
SOV_POS C26 simulating spindle override switch
3.4.4. Corresponding PLC Machine Data – no machine data defined
3.5. Subroutine 38 - MCP_NCK (MCP signal processing)

The purpose of this subroutine is to transfer MCP signals in the interface V1000xxxx to
NCK interface to activate operation mode and control sequences. The main functions in
the subroutine are:
1. Selection of operation mode
2. Selection of increment
3. HMI signals to NCK channel interface
4. AXIS traversing signal to NCK axis interface with condition of no exceeding any
hardware limits.

3.5.2. Local Variable Definition – no local variable is used in the subroutine
3.5.3. Global Memory occupied – no global memory used.

MD14510[16] – Machine data is used to decide the axis number for traversing. For
example, if a turning machine is selected, the Z axis is the second axis and spindle is
third, therefore the signal of traverse key of Z axis on the MCP should be sent to 2nd axis
interface and spindle to 3rd axis interface.
Network 4 Processing MCP signals from V1000 and activating corresponding functions
ONE MCP_NCK
EN
3.6. Subroutine 39 - HANDWHL (Handwheel selection)

The purpose of this subroutine is to select handwheel in MCS or WCS according HMI
interface V1900 1xxx.
3.6.2. Local Variable Definition – no local variables are defined
3.6.3. Global Memory occupied – no memory used
MD14510[16] – Machine type is evaluated in this subroutine

Network 5 Selection handwheel according interface area V1900 1xxx
ONE HANDWHL
EN

3.7. Subroutine 40 - AXES_CTL (Feed axes and Spindle control )
The purpose of this subroutine is to control the interface signals of “Impulse enable” -
V380x4001.7 and “controller enable” (V380x0002.1), to monitor hardware limits and reference
cam signals of all axes. For spindle, the enable signal will be activated by any of the spindle
command, like Spindle CW and CCW, M03, M04, SPOS.
Motor brake will be released with the condition that no emergency stop and position controller is
active.
Two different ways are provided by the subroutine for hardware limit control. One is PLC solution
(MD14512[18] bit 6=0) and the other is hardware solution (MD14512[18] bit 6=1).
By PLC solution, the hardware limit signals, either 2 hardware limit switches (MD14512[18] bit
7=0) or only one hardware limit switch (MD14512[18] bit 7=1) can be configured for each axis.
These signals will be sent to NCK interface V380x1000.0 or V380x1000.1 and a feed stop will be
generated by NCK according to these interface signals. It is also possible to trigger a
EMERGENCY STOP by connecting the output signal OVlmt (subroutine parameter) to the input
parameter HWL_ON of subroutine 33 EMG_STOP.
The hardware solution is actually PLC independent for more safety, see the figure below:
24Vdc
Encoding of HW limit switch Hardware limit
rd E_Key _1LMTp _2LMTp _3LMTp Direction Reached
3 axis limit
Input 0 1 1 1 - Only Emg. Stop
0 0 1 1 V39000004.7 1st + over limit
_3LMTp
0 0 1 1 V39000004.6 1st - over limit
Release 0 0 0 1 V39010004.7 2nd + over limit
button 2nd limit switch 0 0 0 1 V39010004.6 2nd - over limit
0 0 0 0 V39020004.7 3rd + over limit
Input 0 0 0 0 V39020004.6 3rd - over limit
_2LMTp
Note: In case of EMERGENCY STOP or any of the
1st limit switch
hardware limits are reached, Terminal 64 switches
Input and Terminal 9 are disconnected by hardware.
_1LMTp
Emergency Stop button Terminal 9
Input
E_Key KA1
KA1 Terminal 64: control enable of Infeed
module
With above solution, the feed stop of all axes (i.e. disable Supply Infeed module by disconnecting
TERMINAL64 and T9 via a relay) will be activated by any active hardware limit switches or
Emergency Stop button by means of hardware. The Inputs signals to PLC shown in above figure
are for diagnosis purpose and to provide more information for PLC, e.g. the feed stop of Supply
Infeed module is caused by either Emergency Stop button or by one of hardware limit switches.
Note: Some precondition should be considered when this solution is used:
1. The axes should be configured one next to the other, e.g. X, Z, spindle or X, Y, Z,
spindle; This subroutine does not support the configuration like X, Y, Spindle, Z;
2. The inputs to the subroutine for hardware limit of unused axis should be assigned
with SM0.0. Otherwise the hardware limit can not be detected.

Inputs:
NODEF WORD reserved word
T_64 BOOL Status of terminal 64 of infeed module
T_63 BOOL Status of terminal 63 of infeed module
OPTM BOOL input for brake release during drive optimization (NO)
_1LMTp BOOL 1st axis hardware limit plus (NC)
_1LMTn BOOL 1st axis hardware limit minus (NC)
_1REF BOOL 1st axis reference point cam (NO)
_2LMTp BOOL 2nd axis hardware limit plus (NC)
_2LMTn BOOL 2nd axis hardware limit minus (NC)
_2REF BOOL 2nd axis reference point cam (NO)
_3LMTp BOOL 3rd axis hardware limit plus (NC)
_3LMTn BOOL 3rd axis hardware limit minus (NC)
_3REF BOOL 3rd axis reference point cam (NO)
_4REF BOOL 4th axis reference point cam (NO)
_5REF BOOL 5th axis reference point cam (NO)
Note: NO – Normal Open;
NC – Normal Close
Outputs:
_1BRK BOOL Brake release output for 1st axis (high effective)
_2BRK BOOL Brake release output for 2nd axis (high effective)
_3BRK BOOL Brake release output for 3rd axis (high effective)
OVlmt BOOL Over limit output (any of HW limit is active, also high
effective)
If only one HW limit switch (with 2 cams) is installed on the machine tool for each axis, the local
variable for positive limit switch is used for this switch signal. In the PLC program the traversing
direction is evaluated to decide the over limit direction.
SP_CMD M138.1 Spindle start command (CW or CCW)

MD14510[16] – machine type 0: not defined;
1: turning machine;
2: milling machine
MD14512[16] - axes configuration (valid only if MD14510[16]=0)

Bit 0 – 1: 1st axis is selected
Bit 1 – 1: 2nd axis is selected
Bit 2 – 1: 3rd axis is selected
Bit 3 – 1: 4th axis is selected
Bit 4 – 1: 5th axis is selected
MD14512[18] Bit 6 – 1: Hardware solution for over limit monitoring;
0: PLC solution with the condition defined by:
MD14512[18] Bit 7 – 1: only one hardware limit switch for each axis or
0: 2 hardware limit switches for both directions of an axis;

MD14512[18] Bit 1 – 1: Switch #OPTM for brake release by drive optimization;
0: Switch #OPTM is not valid.
Note: The motor brake must be released by optimization, which is controlled by

SimoCom U via RS232 interface. In this case it is necessary to install a
switch for optimization. If MD14512[18] bit1=1, the condition for brake
release is no emergency stop (V27000000.1=0) and switch #OPTM=on.
Note: an PLC alarm will be generated to provide a message that brake is
released for optimization.
Alarm 700026 – BRAKE RELEASED FOR DRIVE OPTIMIZATION
Important: After drive optimization, MD14512[18] Bit 1 should be set to “0” .

st nd rd
Network 6 Axes control for X(1 axis), Y(2 axis), Z(3 axis) and spindle
ONE AXIS_CTL
EN
0 NODEF _1BRK NULL_b

Q0.2 T_64 _2BRK NULL_b
Q0.1 T_63 _3BRK Q0.3
ZERO OPTM OVlmt NULL_b
I0.1 _1LMTp
I0.2 _1LMTn
I0.7 _1REF
I0.4 _2LMTp
I0.5 _2LMTn
I1.0 _2REF
I0.5 _3LMTp
I0.6 _3LMTn
I1.1 _3REF
ZERO _4REF
ZERO _5REF
3.8. Subroutine 43 - MEAS_JOG (Measuring in Jog mode)

This subroutine handles the information of the probe and realizes the function
“Measurement in Jog Mode”. With this subroutine it is possible to calibrate the probe and
measure the tools.
To use this subroutine, it is necessary to call up the subroutine MCP_NCK (SBR38) in the OB1.
In case if there is any change the operating area while function “Measurement in Jog Mode” is
active, this function will be stopped automatically.
Following message will be activated in this subroutine:

700031 – MEASUREMENT IN JOG IS ACTIVE

Inputs:
Meas_Enable BOOL Enable MEAS_JOG
VD14000064 DWORD Active tool number
MEAS_OPAUT M240.0 Meas in operating mode automatic

MEAS_OPJOG M240.1 Meas in operating mode jog
CHL_HMI M240.2 Meas in operating mode change look from HMI
NO_KEY M240.3 no traversing keys in the axis
OUT_HMI M240.4 operating mode automatic from HMI
FDI_MEASJOG M240.5 feed disable in Meas_JOG
ON_MEASJOG M240.6 start Meas_JOG
PROBE_ON M240.7 probe signal has released
JOG_MEASJOG M241.0 output operation mode jog in Meas_JOG
AUT_MEASJOG M241.1 output operation mode auto in Meas_JOG
CHL_MEASJOG M241.2 operation mode change look in Meas_JOG
KEY_MEASJOG M241.3 traversing keys in Meas_JOG
RES_MEASJOG M241.4 reset in Meas_JOG
ESC_MEASJOG M241.5 abort Meas_JOG
DRY_MEASJOG M241.6 dry run feed in Meas_JOG
SBL_MEASJOG M241.7 single block in Meas_JOG
3.8.4. Corresponding PLC Machine Data – no machine data defined
Network 7 Measuring in JOG Mode
ONE MEAS_JOG
EN
VD14000064 T_ACT

3.9. Subroutine 44 - COOLING (coolant control)
The coolant is controlled under JOG mode by a key on MCP and in AUTO/MDA mode
by M07/M08 for coolant on and M09 for coolant off in part program. In case of
emergency stop, coolant motor overload, or by active functions like Program Test or
simulation, coolant will be inhibited.
2 alarms will be activated from this subroutine:
Alarm 700018 – COOLING MOTOR OVERLOAD
Alarm 700019 – COOLANT LEVEL LOW
Inputs:
C_key BOOL Manual operating key (trigger signal required)
OVload BOOL Coolant motor overload (NC)
C_low BOOL Coolant level low (NC)
Outputs:
C_out BOOL Coolant output
C_LED BOOL output for status display
COOLon M150.0 Status of coolant on
3.9.4. Corresponding PLC Machine Data – no PLC machine data related
Network 7 Coolant control
ONE COOLING
EN
P_M_USER_K6
C_KEY
I2.4
OVload
I2.5
C_low
C_out Q1.0
C_LED M_LED_CK6

3.10. Subroutine 45 - LUBRICAT (Lubricating control)
Lubrication is controlled according a specified time interval for a specified duration (not
distance related). A manual key is available to start lubricating, and during power on of
the machine tool it is also possible to start lubrication. Normally the lubrication will be
started periodically in the time interval defined by input parameter Lintv. The lubrication
lasts for the duration specified by another input parameter Ltime. In case of emergency
stop, lubrication motor overload, lubrication will be not started.
2 alarms will be activated in this subroutine:
Alarm 700020 – LUBRICATING MOTOR OVERLOAD
Alarm 700021 – LUBRICANT LEVEL LOW
Inputs:
Lintv WORD Lubrication time interval (unit: 1 min)
Ltime WORD Lubrication duration (unit: 0.01s, max. 327.67s)
L_key BOOL manual lubrication key (trigger signal required)
L1st BOOL Lubrication by first PLC cycle (power on)
Ovload BOOL lubrication motor overload
L_low BOOL lubricant level low
Outputs:
L_out BOOL Lubrication output
L_LED BOOL output for status display
L_cmd M152.0 lubrication command
L_interval C24 used to calculate lubrication interval (unit: 1 minute)
L_time T27 used to calculate lubrication time (unit: 0.01s, max.
327,67s Approx. 5 min)
MD 14510 [24]: Lubrication time interval (unit: 1 min)
MD 14510 [25]: Lubrication duration (unit: 0,01 s, max. 327.67s)
Network 8 Lubrication by interval specified by MD14510[23] and duration by MD14510[24]
ONE LUBRICAT
EN
MD_INT_24 Lintv L_out Q4.5

MD_INT_25 Ltime L_LED M_LED_CK5
P_M_USER_K5 L_key
ONE L1st
I8.7 OVload
I8.6 L_low

3.11. Subroutine 46 - TURRET1 (Turret with Hall Effect Device position sensor)
This subroutine controls the kind of turret with Hall Effect Device sensor (HED).Turret
motor is controlled by PLC output. During tool search the motor turns clockwise. When
the desired tool is in-position, turret motor runs counter clockwise for a specified duration
for clamping. The subroutine verifies the parameter for turret CCW to limit the value
within 3 seconds in order to avoid the damage of the turret motor.
T function from NCK will start turret change in AUTO and MDA mode and a short strike
on the manual key will change one turret position and long press for more position turret
change in JOG mode.
During time of turret change one interface signal (V32000006.1 “Read-in disable”) is set,
so that a part program will be stopped waiting for the turret change.
In case of emergency stop, turret motor overload, or by active functions like Program
Test or simulation, turret will be inhibited.
The timing diagram for this kind of turret is shown below:
Signal Start Target Start Target

T1 T3 T6 T4
Clamp time Clamp time
Motor CW CW CCW CW CCW
Off
CCW
Tool T1
Pos. T2
T3
T4
T5
T6

Alarm 700022 – TURRET MOTOR OVERLOAD
Alarm 700023 – PROGRAMMED TOOL NUM. > MAX. TURRET NUMBER
Alarm 700026 – NO POSITION SIGNALS FROM TURRET
Inputs:
Tmax WORD max. number of tool on the turret
T_01 … T_06 BOOL tool position sensors (low effective)
T_key BOOL manual lubricating key (trigger signal required)
OVload BOOL lubricating motor overload
Outputs:
T_cw BOOL turret positioning
T_ccw BOOL turret clamping
T_LED BOOL output for status display

T_CURRENT VD14000064 Current tool (retentive data)
ClampTime MW154 Turret clamping time
T_cw_m M156.0 Turret CW flag
T_ccw_m M156.1 Turret CCW flag
CcwDelay M156.2 Turret CCW delay
K_active M156.3 Manual key is active
TC_end M156.4 Tool Change complete
Tp_ne_Tc M156.5 Programmed Tool number not equal current tool
T__P_INDX MD160 Buffer to monitor the change of the turret by JOG mode
T_CHL M168.4 Operation mode change look
T1clamp T28 Turret1 clamping timer.
MD14510[22]: Turret clamping time (unit: 0.01s max. 300 unit)
By PLC initialization if MD14510[16]=1 (turning machine), the value of MD14510[22] will
be automatically evaluated and the result will be saved in memory word MW154 which is
used by subroutine 46 for turret change.
IF MD14510[22]=0 THEN MW154= 50 (default)
IF MD14510[22]>300 THEN MW154=300 (max.)
Network 9 HED turret control
ONE TURRET1
EN
6 Tmax T_cw Q5.0

MD_INT_22 C_time T_ccw Q5.1
I7.0 T_01 T_LED M_LED_CK4
I7.1 T_02
I7.2 T_03
I7.3 T_04
I7.4 T_05
I7.5 T_06
P_M_USER_K4 T_key
I7.6 OVload

3.12. Subroutine 47 - TURRET2 (Control of a turret with binary encoder)
This subroutine is used to control turret with encoder. The encoder is installed in this
kind of turret, with the capability to index in 2 directions in order to have a shorter tool
change time. For the timing diagram and the principle, please refer turret description.
During time of turret change one interface signal (V32000006.1 “Read-in disable”) is set,
so that a part program will be stopped waiting for the turret change.
In case of emergency stop, turret motor overload, or during Program Test active or
simulation active, turret will be inhibited.
Alarm 700022 – TURRET MOTOR OVERLOAD
Alarm 700023 – PROGRAMMED TOOL NUM. > MAX. TURRET NUMBER
Inputs:
Tmax DWORD max. tool number on turret
T_1 BOOL T code A
T_2 BOOL T code B
T_3 BOOL T code C
T_4 BOOL T code D
Parity BOOL parity
Strobe BOOL signal strobe
OVload BOOL turret motor overload
T_key BOOL manual change key
Outputs:
T_cw BOOL turret CW
T_ccw BOOL turret CCW
T_CURRENT VD14000064 Current tool number (retentive data)
T_cw_m M156.0 Turret CW flag
T_ccw_m M156.1 Turret CCW flag
T__P_INDX MD160 Buffer to monitor the change of the turret by JOG mode
T_DES MD164 Destination tool number
T_DIR M168.0 Turret change direction
T_POS M168.1 Turret in-positioning
T_LOCK M168.2 Turret clamping command
T_MAG M168.3 Turret solenoid for clamping

3.12.4. Corresponding PLC Machine Data – no machine data related
Network 9 Control of turret with encoder
ONE TURRET2
EN
8 Tmax T_cw Q1.6

1000 Delay T_ccw Q1.7
I3.0 T_1 Magnet Q1.5
I3.1 T_2 LED M_LED_CK4
I3.2 T_3
I3.3 T_4
I3.4 Parity
I3.5 Strobe
I3.6 OVload
I3.7 P_indx
P_M_USER_K4 T_key
3.13. Subroutine 48 - TOOL_DIR (Tool change direction)

The purpose is to identify the direction and pre-indexing position of the turret or tool
chain according to the maximum tool number and programmed tool number. In
subroutine library this subroutine is called by subroutine 47 - TURRET2 for turrets like
from SAUTER Company. Tool number should be limited between 2 and 64.
Inputs:
Tmax DWORD max. tool number on turret
Pnum DWORD programmed tool number
Pcurr DWORD current turret position
Outputs:
P_INDXo DWORD pre-indexing position; one position before the destination
in direction of shortest way.
DIR BOOL tool change direction: 1 - CW; 0 - CCW

3.13.3. Global Memory occupied – no global memory defined
Network 9 Make out the direction of turret as well as pre-indexing position
ONE TOOL_DIR
EN
12 Tmax P_INDEXo P_INDEXo

P_C_TFUNC Pnum DIR M20.1
T_CURRENT Pcurr
3.14. Subroutine 49 - MGZ_INI (Initialization on tool magazine table)

In order to realize tool magazine control for machining center, which requires random
access of tools from magazine, PLC library provides some subroutines for magazine
management. These subroutines include initialization, searching for position of the
destination tool, refreshing holder table.
It is defined in the library that the number of tool holders of a magazine must not exceed
40. Initialization is to establish a table in retentive data area VB14000000 to
VB14000040 representing up to 40 tools on the magazine.
After initialization, the tool holders on the magazine contain the same number of tools as
holders and no tool in the spindle.
In tool change, the holder with programmed tool should be allocated first. The number of
the holder is used to control the magazine to turn clockwise or counter clockwise to
exchanging position.
After ATC exchanges the tools on the holder and spindle, the holder table should be
refreshed. The programmed tool is on the spindle and existing tool on spindle, should be
put back into empty holder. Please refer the following table for principal.
The control logic for magazine as well as ATC is hardware dependent, therefore should
be designed by machine tool builders.

TOOL on Table After ini. T5 M06 T8 M06 T16 M6 T0 M06 T15 M06 T10 M06
SPINDLE VB14000000 0 5 8 16 0 15 10
T_HOLDER_1 VB14000001 1 1 1 1 1 1 1
T_HOLDER_2 VB14000002 2 2 2 2 2 2 2
T_HOLDER_3 VB14000003 3 3 3 3 3 3 3
T_HOLDER_4 VB14000004 4 4 4 4 4 4 4
T_HOLDER_5 VB14000005 5 0 0 0 16 16 16
T_HOLDER_6 VB14000006 6 6 6 6 6 6 6
T_HOLDER_7 VB14000007 7 7 7 7 7 7 7
T_HOLDER_8 VB14000008 8 8 5 5 5 5 5
T_HOLDER_9 VB14000009 9 9 9 9 9 9 9
T_HOLDER_10 VB14000010 10 10 10 10 10 10 15
T_HOLDER_11 VB14000011 11 11 11 11 11 11 11
T_HOLDER_12 VB14000012 12 12 12 12 12 12 12
T_HOLDER_13 VB14000013 13 13 13 13 13 13 13
T_HOLDER_14 VB14000014 14 14 14 14 14 14 14
T_HOLDER_15 VB14000015 15 15 15 15 15 0 0
T_HOLDER_16 VB14000016 16 16 16 8 8 8 8
The purpose of this subroutine is to establish a table for tool magazine representing the
positions of the tools on the magazine. After initialization the table is arranged in the
following way:
Number of Tool Holder Tool number on the holder

1 1
2 2
… …
39 39
40 40
It is possible to have 64 tools for SINUMERIK802D. But in subroutine library, only 40

tools are permitted. For magazine more than 40 tool, the following subroutine should be
modified before application: SBR49–MGZ_INI, SBR50–MGZ_SRCH, and SBR51–
MGZ_RNEW.
3.14.2. Local Variable Definition – no local variable defined
3.14.3. Global Memory occupied – no global memory defined
Network 12 Tool Magazine Initialization
ONE MGZ_INI
EN

3.15. Subroutine 50 - MGZ_SRCH (Search tool from magazine)
The purpose of this subroutine is to find the holder location from magazine, which
contains the wanted tool.
Inputs:
P_TOOL DWORD Programmed tool number
Outputs:
HD_No DWORD Holder number with programmed tool
Find BOOL 1: tool is found, 0: not found
3.15.3. Global Memory occupied - no global memory defined
3.15.4. Corresponding PLC Machine Data - no
Network 32 Finding holder from magazine which contains programmed tool
P_C_TFCT1_C MGZ_SRCH
EN
P_C_TFUNC P_TOOL HD_No MD40

Find M32.5
3.16. Subroutine 51 - MGZ_RNEW (Refresh magazine table)

The purpose of this subroutine is to refresh magazine table after tool exchange, in order
to have a correct magazine table, the subroutine actually exchanges the tool number on
the spindle (located in VB14000000) with tool number in the holder which contains
programmed tool.
Inputs:
P_TOOL DWORD Programmed tool number
Outputs:
HD_No DWORD Holder number with programmed tool
Find BOOL 1: tool is found, 0: not found

3.16.3. Global Memory occupied - no global memory defined
3.16.4. Corresponding PLC Machine Data - no
Network 34 Refresh magazine table
ONE MGZ_RNEW
EN
SPD_TOOL: VB14000000 T_No

HDcurrent: C0 HD_NO
3.18. Subroutine 36, 41, 42 and Subroutine 52 ... 58, 60 … 62 are reserved for
subroutine library
3.19. Subroutine 59 – GRINDING_CTL

This subroutine handles the program control for grinding. The key_1 to key_4 allows making a
program break, dressing interruption while grinding, hand wheel overlay or manual oscillation
reversal. By each activated key the oscillation reversal will be active apart from axis oscillation
reversal manual and activating program break. These two functions are enabled with an
M-command. All commands will be active after NC-start.
Inputs:
KEY_1 BOOL Key for activating program break
KEY_2 BOOL Key for dressing interruption while
grinding
KEY_3 BOOL Key for hand wheel overlay
KEY_4 BOOL Key axis oscillation reversal manual
P_N_EN_OS_REV BOOL M-command enable oscillation reversal
P_N_DEL_EN_OS_REV BOOL M-command deleting enable oscillation
reversal

OS_REV_CMD M134.0 Flag for M-command enable oscillation reversal

MD 14510[16] - machine type 0: not defined
22: face grinding
Network 12 Grinding control

ONE GRINDING_CTL
0 NODEF
I3.0 KEY_1
I3.1 KEY_2
I3.2 KEY_3
I3.3 KEY_4
V25001003.3 P_N_EN_OS_REV
V25001003.4 P_N_DEL_EN_OS_REV
3.20. Subroutine 63 - TOGGLE

Toggle switch is a kind of switch with one push of the key (input of the subroutine) to turn
the output on and second push to turn the output off.
Delayed-switch is a kind of switch, with which once the key (input of the subroutine) is
pressed, the output will be on for the time interval defined by parameter “Delay7” (for key
7) and “Delay 8” for key 8.
There are 6 toggle switches and 2 delayed-switches are available in this subroutine to
simplify the PLC application program of the customers. This subroutine can put in the
main program.
The bit parameter for key inputs and outputs can be connected to physical input or
output or to any memory bits. All the unused bit inputs can be connected to “ZERO”
(M251.0), all the unused byte inputs connected to byte constant “0”, all unused bit
outputs connected to “NULL_b” (M255.7).

Symbol Var. Data Comment
Type type
Delay 7 IN WORD Delay time of switch 7 (unit 10 ms)
Delay 8 IN WORD Delay time of switch 8 (unit 10 ms)
Ki_1 IN BOOL Toggle key 1
Ki_7 IN BOOL Delayed key 7 (delay switch)
Ki_8 IN BOOL Delayed key 8 (delay switch)
Ko_1 OUT BOOL Switch 1 output
Ko_7 OUT BOOL Switch 7 output (delayed)
Ko_8 OUT BOOL Switch 8 output (delayed)
3.20.3. Global Memory used
Symbol Address Comment
K1st1 … K8st1 MB245 Toggle key status 1
K1st2 … K8st2 MB246 Toggle key status 2
K1on … K8on MB247 Toggle key status ON
Network 2 Toggle switch for customer application
ONE TOGGLE
EN
40 Delay7 Ko_1 M_LED_CK1

200 Delay8 Ko_2 M_LED_CK2
P_M_USER_K1 Ki_1 Ko_3 M_LED_CK3
P_M_USER_K2 Ki_2 Ko_4 M_LED_CK4
P_M_USER_K3 Ki_3 Ko_5 NULL_b
P_M_USER_K4 Ki_4 Ko_6 NULL_b
ZERO Ki_5 Ko_7 M12.6
ZERO Ki_6 Ko_8 M12.7
I0.0 Ki_7
I0.1 Ki_8

4. PLC User Alarms used in Subroutine Library
There are several user alarms activated in the subroutines. In the table below the alarms
are listed. In case an alarm comes, please pay attention to this table to know from which
subroutine the alarm is activated.
Alarm Interface Alarm Description Activated in

Number Address Subroutine
700016 V16000002.0 DRIVES NOT READY SBR33: EMG_STOP
700017 V16000002.1 I2/T ALARM FOR INFEED MODULE
700018 V16000002.2 COOLANT MOTOR OVERLOAD SBR44: COOLING
700019 V16000002.3 COOLANT LEVEL LOW
700020 V16000002.4 LUBRICATING MOTOR OVERLOAD SBR45: LUBRICAT
700021 V16000002.5 LUBRICANT LEVEL LOW
700022 V16000002.6 TURRET MOTOR OVERLOAD SBR46: TURRET1
700023 V16000002.7 PROGRAMMED TOOL NUM. > MAX. TURRET SBR47: TURRET2
NUMBER
700024 V16000003.0 802D MACHINE CONTROL PANEL DEFECT SBR34: CP_802D
700025 V16000003.1 BRAKE RELEASED FOR DRIVE OPTIMIZATION SBR40: AXES_CTL
700026 V16000003.2 NO POSITION SIGNALS FROM TURRET SBR46: TURRET1
700031 V16000003.7 MEASURING IN JOG IS ACTIVE SBR43: MEAS_JOG
Feed stop to channel (V32000006.0) will be activated by any alarms from the subroutine library.
To remove the feed stop, clear the alarm condition first and then RESET.
5. Sample PLC Application Programs

There are some special flags that will used in the project files:
SM0.0 - always “1” symbolized as ONE
M251.0 - always “0” (cleared every cycle in subroutine 33), symbolized as ZERO.
(Note: these two bits will finally be replaced with bit constant later)
M255.7 - for unused output bit, symbolized as NULL_b
MB255 - for unused output byte, symbolized as NULL_B
MW254 - for unused output word, symbolized as NULL_W
MD252 - for unused output double word, symbolized as NULL_D
5.1. PLC Application Program for simulation

5.1.1. Purpose of the Simulation Program
The purpose of the simulation program is to provide a way to test the system without
MCP before all 802D components are installed on the machine tool. This simulation
program works with the help of Status Chart of the programming tool. Customers can
simulate the MCP to traverse the axes and spindle, change override, and select
increment, etc.

Hardware connected:
Drive CLiQ PROFIBUS
Sinamics for X and Z

Sinamics for spindle
Infeed power supply
802D
PP module
Keyboard
Note: Here all enable signals on the drive unit must in the case of
simulation enabled.
But these enable signals must be controlled by PLC when
application on the machine tools
Subroutine 37 SIMU_MCP monitors the status such as mode change, NC start, stop,
etc. acknowledges mode changes, generates the override value and also simulates
reference cams via global memory bits for feed axis and spindle. The change of feed
and spindle overrides is carried out via Status Chart. (Refer to chapter 3.4)
Program organization (OB1)

Call condition Subroutine name Description
1st PLC cycle (SM0.1) PLC_INI (SBR32) Initializing
Every cycle (SM0.0) EMG_STOP (SBR33) For enable drives
Every cycle (SM0.0) MCP_SIMU (SBR37) Simulating MCP
Every cycle (SM0.0) MCP_NCK (SBR38) Transferring MCP to NCK interface
Every cycle (SM0.0) AXES_CTL (SBR39) Enabling NCK interface signals
5.1.2. PLC Machine Data related
The related PLC MD is MD14510[16] for machine type.
5.1.3. Application
1. Connect hardware component according to the Start-up and Installation Manual as the figure
above.
2. Power on the NC and drives. Set RS232 interface to “STEP7-Connect” on 802D.
3. Start Programming Tool PLC V3.0 and set Communication parameter to match the setting in
NC.
4. Open the project file: SIMULATION.PTP and download it to 802D. Start PLC.
5. Open the “Status Chart” of the programming tool and give a “1” to the mask in the new value
column of the desired function, and then click the icon with mouse key to write the value to
the 802D.

5.2. Sample PLC Application Program for a Turning Machine
5.2.1 Purpose of the sample turning machine

SAMPLE_TURN.PTP is an application program for turning machine. Through this
sample 802D customers can learn how an application is composed using subroutine
library, and how to make use of the subroutines in the library. Another purpose for this
sample is that for turning machines with similar configuration can be used directly, or
make simply modification to build a PLC application program quickly.
This sample program is suitable for turning machines with following configuration:
• 2 Feed axes: X and Z; 2 HW limit switches for each axis
• 1 digital spindle: SP
• Turret (with HED sensor) of 6 tools
• Lubrication system (Interval and duration are controlled by PLC)
• Cooling system
• 802D: One PP module (2 connector X111 and X222 are reserved 802D MCP,
X333 for machine In- / Outputs)
• 802D sl: One PP module (2 connector X111 and X222 are reserved 802D MCP,
or
one PP module (X333 for machine In- / Outputs)
MCP 802D sl is connected via additional MCPA module with the
control 802D sl (X1201 to X1 and X1202 to x2).

Input / Output assignment:
Terminal Block X333
Signal Terminal Description Note
M 1 Ground of 24VDC
L+ 2 Output 24VDC as Common for all inputs in X333
I 6.0 3 Emergency stop button Button: NC
I 6.1 4 Limit switch X+ NC
I 6.2 5 Limit switch X- NC
I 6.3 6 Limit switch Z+ NC
I 6.4 7 Limit switch Z- NC
I 6.5 8 Reference Cam X NO
I 6.6 9 Reference Cam Z NO
I 6.7 10
I 7.0 11 T1 Sensor NC
I 7.6 17 Turret motor overload Thermal relay NC
I 7.7 18
I 8.0 19 T72 Supply Infeed module ready NO
2
I 8.1 20 T52 I /t monitoring NO
I 8.2 21
I 8.3 22
I 8.4 23 Coolant level low NC
I 8.5 24 Coolant motor overload NC
I 8.6 25 Lubricant level low NC
I 8.7 26 Lubricating motor overload NC
27,28,29,30 Not connected
Q 4.0 31 TERMINAL48 control contactor of Supply Infeed
module
Q 4.1 32 TERMINAL63 pulse enable
Q 4.2 33 TERMINAL64 control enable
Q 4.3 34 X axis motor brake release
Q 4.4 35 Coolant output
Q 4.5 36 Lubrication output
Q 4.6 37
Q 4.7 38
Q 5.0 39 Turret CW
Q 5.1 40 Turret CCW
Q 5.2 41
Q 5.3 42
Q 5.4 43
Q 5.5 44
Q 5.6 45
Q 5.7 46
L+ 47, 48 Input 24VDC for all outputs
• 802D MCP installed

Terminal Block X111 for MCP X1201
Note: the connecting of MCP and PP is different from SAMPLE_MILL.PTP
Definition of User keys on MCP

Customer Key 1 Drive enable (toggle key)
Customer Key 2
Customer Key 3
Customer Key 4 Tool change key
Customer Key 5 Manual lubricating key
Customer Key 6 Manual cooling key
5.2.2 Program Organization (OB1)
Every cycle (SM0.0) MCP_802D (SBR34) 802D MCP signals to MCP interface
Every cycle (SM0.0) COOLING (SBR44) Cooling control
Every cycle (SM0.0) LUBRICAT (SBR45) Lubricating control
Every cycle (SM0.0) TURRET1 (SBR44) Turret of HED sensors
The related PLC MD are:

MD14510[16] = 1 - for turning machine.
MD14510[22] = value - turret clamping time (unit: 0.01S)
MD14510[24] = value - Lubrication interval (unit: 1.0 Min.).
MD14510[25] = value - Lubrication duration (unit: 0.01S).
5.3 Sample PLC Application Program for a Milling Machine

5.3.1. Purpose of the sample milling machine
SAMPLE_MILL.PTP is an application program for milling machine. Through this sample
802D customers can learn how an application is composed using subroutine library, and
how to make use of the subroutines in the library. Another purpose for this sample is that
for milling machines with similar configuration can be used directly, or make simply
modification to build a PLC application program quickly.
This sample program is suitable for milling machines with following configuration:
• 3 Feed axes: X, Y and Z; 2 HW limit switches for each axis

• One digital spindle: SP (4th axis)
• Lubrication system (interval and duration are controlled by PLC)
• Cooling system
• 802D: One PP module (2 connector X222 and X333 are reserved 802D MCP,
• 802D sl: One PP module (2 connector X222 and X333 are reserved 802D MCP,
or
one PP module (X111 for machine In- / Outputs)
MCP 802D sl is connected via additional MCPA module with the
control 802D sl (X1201 to X1 and X1202 to x2).

Input / Output assignment:
Terminal Block X111
Signal Terminal Description Note
M 1 Ground of 24VDC
L+ 2 Output 24VDC as Common for all inputs in X111
I 0.0 3 Emergency stop button Button: NC
I 0.1 4 Limit switch X+ NC
I 0.2 5 Limit switch X- NC
I 0.3 6 Limit switch Y+ NC
I 0.4 7 Limit switch Y- NC
I 0.5 8 Limit switch Z+ NC
I 0.6 9 Limit switch Z- NC
I 0.7 10 Reference Cam X NO
I 1.0 11 Reference Cam Y NO
I 1.1 12 Reference Cam Z NO
I 1.2 13
I 1.3 14
I 1.4 15
I 1.5 16
I 1.6 17
I 1.7 18
I 2.0 19 T72 Supply Infeed module ready NO
2
I 2.1 20 T52 I /t monitoring NO
I 2.2 21
I 2.3 22
I 2.4 23 Coolant level low NC
I 2.5 24 Coolant motor overload NC
I 2.6 25 Lubricant level low NC
I 2.7 26 Lubricating motor overload NC
27,28,29,30 Not connected
Q 0.0 31 Terminal 48: control contactor of Supply module
Q 0.1 32 Terminal 63 pulse enable
Q 0.2 33 Terminal 64 control enable
Q 0.3 34 Z axis motor brake release
Q 0.4 35 Coolant output
Q 0.5 36 Lubrication output
Q 0.6 37
Q 0.7 38
Q 1.0 39
Q 1.1 40
Q 1.2 41
Q 1.3 42
Q 1.4 43
Q 1.5 44
Q 1.6 45
Q 1.7 46
• 802D MCP installed

Definition of User keys on MCP
Customer Key 1 Drive enable (toggle key)
Customer Key 2
Customer Key 3
Customer Key 4
Customer Key 5 Manual lubricating key
Customer Key 6 Manual cooling key

5.3.2. Program Organization (OB1)

Every cycle (SM0.0) MCP_802D (SBR34) 802D MCP signals to MCP interface
Every cycle (SM0.0) COOLING (SBR44) Cooling control
Every cycle (SM0.0) LUBRICAT (SBR45) Lubricating control
The related PLC MD are:

MD14510[16] = 2 - for milling machine.
MD14510[24] = value - Lubrication interval (unit: 1.0 Min.).
MD14510[25] = value - Lubrication duration (unit: 0.01S).
Note:
Load initialization file setup_M.ini to PCU. Standard milling configuration is for 4
feed axes and one spindle, so it is necessary to modify the setting. Machine data
MD20070[5]=0 will cancel axis A1

C33 PLC Functions
1 Brief description
Module Objective:
Upon completion of this module you will be able to:
Select an NC program form the PLC

Read and Write specific NC variables
Read the actual position of an axis
Module Description:
T automate certain tasks on a CNC machine it may become necessary to select a program from the
PLC, or to read the actual position of an axis or dependant upon certain machine conditions, the
changing of a system variable. This module describes these functions.
Module Content:
 Selection of an NC program from the PLC

 Read actual position of an axis
 Change system variables from the PLC
Selection of an NC
program from the PLC
Section 2
Read actual position of

an axis Section 3
Change system
Section 4
variables from the PLC

Section 2 Selection of an NC program from the PLC
Notes
Creating a Program List able to be called by PLC
A maximum of 255 programs can be contained in the program list:
1~100 User protection level（ CUSTOMER）
101~200 Machine Manufacturer protection level (EVENING)
201~255 Protection level reserved for Siemens, can not be used .
The selection of the program by PLC is based on the program no.
C re a te a P ro g ra m L ist d ire ctly: se le ct “S yste m ” “P L C ”  “P ro g ra m L ist”
(switch the window with key ):
RS 232 table
or alternatively, load the Program List from PC into the

802D sl using the RCS tool.
File format: %_N_PLCPROG_LST
;$PATH=/_N_CUS_DIR
1|PART1.MPF
2|PUMP.MPF
3|PART2.MPF
54|CUTTING.MPF
Note: ： S e p a ra to r in th e file ca n b e "|” o r T A B .
Selecting a program in the Program List using the PLC
Use MOV_B in the application to transfer the program no. to PLC HMI interface:
V33000003.7 MOV_B
EN ENo
5 IN OUT VB17001000
Note: The program no. in VB17001000 is automatically deleted by the PLC once
they have been received by the control system.
Signals from HMI to PLC
Program has been selected: V17002000.0
(HMI  PLC, read only, signal width: 1 PLC cycle)
Program selection error: V17002000.1
（ HMI  PLC, read only, signal width: 1 PLC cycle）
Saving or restoring currently active machining programs with the PLC
VB17001001 = 1 Save currently active machining programs (missing after power off)
VB17001001 = 2 Restore saved machining programs
Notes: Value in VB17001001 is automatically deleted by the PLC once they have
been received by the control system.
Signals from HMI to PLC:
Execute command: V17002001.0 (HMI  PLC read only, signal width: 1 PLC cycle)
Command execution error: V17002001.1
(HMI  PLC read only, signal width: 1 PLC cycle)

Section 3 Read actual position of an axis
The axis actual values and distances-to-go can be read out Notes
using PLC applications in the 802D sl. Proceed as follows:
Activate axis values reading function via PLC applications:

V26000001.1=1 – request for axis actual values
V26000001.2=1 – request for axis dist
Address Address (distance-to- Axis Data type
(axis actual value) go)
Floating point
VD57000000 VD57000004 1st axis
value
Floating point
VD57010000 VD57010004 2nd axis
value
Floating point
VD57020000 VD57020004 3rd axis
value
Floating point
VD57030000 VD57030004 4th axis
value
Floating point
VD57040000 VD57040004 5th axis
value
Example for reading axis actual values:

Network 4 Read Z axis position,
ONE MOV_R
EN ENO
VD57020000 IN OUT MD20

VD57020000 M4.5
<=
125.4

Section 4 Change system variables from the PLC
Notes

Notes

Notes

C44 Commissioning of Options
1 Brief Description
Module Objective:
Upon completion of this module you will be able to commission the 3 listed options.
Module Description:
Depending on the control model, various options can be generated. This module describes the 3
listed options.
Module Content:
 Communication via Ethernet

 Tool monitoring
 Travel to fixed stop
Communication via
Ethernet Section 2
Tool monitoring
Section 3
Travel to fixed stop Section 4

Section 2 Communication via Ethernet
Notes
This screenshot option is available with 802D sl pro only.
For communication via Ethernet, a connection between the computer and

the controller has to be established (crossed cable for direct connection).
To be able to access the controller via Ethernet, you have to be registered
a n d lo g g e d o n . T h is is d o n e in th e “S yste m ” o p e ra tin g a re a “R S C L o g -
on”
RCS log-on
RCS log-on
Defaults
Name: SERVICE
Password: $SERVICE$
Or
See SK Authorisation for new user
Entering user name and password

Section 2 Communication via Ethernet
Notes
You can access the control via a company network (with or without DHCP)
or locally.
T h e fo llo w in g se q u e n ce o f o p e ra tio n s is re q u ire d : “S yste m ” o p e ra tin g a re a
“S e rvice D isp la y” “S e rvice C o n tro lle r” “S e rvice N e tw o rk”.

Section 3 Tool monitoring
Notes
General information
This option is available with 802D sl plus and pro only.
The tool monitoring function allows the monitoring of the

 tool time
 workpiece count
of the active cutting edge of the active tool.
It is possible to activate both monitoring functions simultaneously for one
tool.
There are monitoring counters available for each type of monitoring. The
monitoring counters run from a set value > 0 to zero. When a monitoring
counter reaches the value <= 0, the limit value is regarded as being
reached. An alarm message is transferred and an interface signal issued.
Before that, another interface signal is issued when a cutting edge has
reached the preset warning limit. The tool monitoring data as well as the
type and state of monitoring are stored in system variables. System vari-
ables can be read and described in the NC program.
Activation
To activate this option, the password for protection level 2 or higher has to
be entered .
The tool monitoring is activated via the following machine data:

MD 18080: MM_TOOL_MANAGEMENT_MASK
MD 20310: TOOL_MANAGEMENT_MASK.
Sequence of operations for changing the MD 18080:
“S yste m ” o p e ra tin g a re a “M a ch in e D a ta ” “G e n e ra l M D ” .

Notes
MD 18080: MM_TOOL_MANAGEMENT_MASK
The alarm 4400 points out that a NC start-up with the changed date results
in a reorganization of the buffered memory. Thus, all the buffered user
data (parts programs, tool data, GUD, etc.) are lost.
S e q u e n ce o f o p e ra tio n s fo r ch a n g in g th e M D 2 0 3 1 0 : “S yste m ” o p e ra tin g

a re a “M a ch in e D a ta ” “C h a n n e l M D ” .
If the tool monitoring option is available, the changed machine data be-
comes effective after a NC start-up. If this option is not available, the data
is reset.
If the controller comprises unsecured user data, a data backup has to be

carried out before the next NC start-u p “S yste m ” o p e ra tin g a re a “
Startup files.
A new archive must be made prior to NC reset, this archive should be

loaded to the system to activate the new functions without data loss.

Notes
MD 20310: TOOL_MANAGEMENT_MASK

Section 4 Travel to fixed stop
Notes
General information
This option is available with 802D sl plus and pro only.
W ith th e fu n ctio n “T ra ve l T o F ixe d S to p ” it is p o ssib le to b u ild u p d e fin e d

forces for the clamping of workpieces (e.g. for quills and grippers). More-
over, mechanical reference points can be approached. With an adequately
reduced torque, simple measuring processes are also possible without the
use of a sensor.
Activation
To activate this option, the password for protection level 2 or higher has to
be entered.
“T ra ve l T o F ixe d S to p ” is a ctiva te d via M D 3 7 0 0 0 : F IX E D _ S T O P _ M O D E .

This function can then be started from the NC program. Sequence of op-
e ra tio n s: “S yste m ” o p e ra tin g a re a A xis M D
MD 37000: Travel to fixed stop
If th e o p tio n “T ra ve l T o F ixe d S to p ” is a va ila b le , th e ch a n g e d m a ch in e d a ta

becomes effective after a NC start-up.

Section 4 Travel to fixed stop
Notes

C85 ISO Dialect Commissioning
1 Brief Description
Module Objective:
Upon completion of this module you will be able to install the ISO dialect.
Module Description:
Apart from the SIEMENS NC programming language, another programming language ISO dialect
with a modified G code instruction set can be activated. The required files and their storage location
as well as the procedure for installation are described in this module.
Module Content:
 Setup files
 Procedure
Setup files
Section 2
Procedure
Section 3

Section 2 Setup files
Notes
For the commissioning of the ISO dialect M (for milling) or T (for turning),
the respective setup files have to be loaded from the toolbox to the control-
ler.
After having installed the toolbox in the standard directory of the PC, the
setup files for milling are located, for example, at C:\Programs\Siemens\Toolbox
802D_sl\ V01002001\Techno\Milling\Config_ISO:
 setISO_M.arc Milling with cycle package

 ISOG70_M.ini
 millG22.ini.
The setup files for turning are, for example, in the directory
C:\Programs\Siemens\Toolbox 802D_sl\V01002001\Techno\Turning\Config_ ISO:
 setISO_T.arc Turning with cycle package

 ISOTra_T.arc Turning with transformation
 turnG22.ini
 ISO_x_T.ini Machine data for the Tracyl function -
peripheral surface milling
(x corresponds to the rotary axis A, B, or C).
Setup files for the ISO dialect T

Section 3 Procedure
Notes
For the commissioning of the ISO dialect, a connection via RS232 or

Ethernet has to exist between the PC and the controller.
After switch-on and start-up of the controller, the password for protection
le ve l 2 o r h ig h e r is se t in th e “S yste m ” o p e ra tin g a re a .
Password dialog
Setting the password
(Entering the password is also possible after having established the con-
nection with the help of the Snapshot function of RCS802D.)
After having started the RCS802D on the PC, the type of connection can
b e se le cte d a n d co n fig u re d , if n e ce ssa ry, via “S e ttin g ” “C o n n e ctio n ”.
Selecting the connection
With the help of the icon, the connection between PC and controller is
established.

Section 3 Procedure
Notes
Connect
Characteristics of the Ethernet connection

and logged on. During log-on, the user name and password of the cur-
rently logged on RCS user has to be entered.
Log-on
The required installation files have to be copied from the directory of the
toolbox to the Data folder of drive A of the 802D sl and a NCK RESET to
be triggered.
Triggering a NCK RESET

Section 3 Procedure
Notes
During the transmission, the controller is started up several times. In that,

the entry of the password and the copying of the installation files has to be
repeated.
Repetition of the copying process
The start-up files have to be overwritten.
Overwriting the start-up files
The following message is displayed after the successful installation:
Successful installation
For more detailed information, please refer to the log file.

At the end, a NCK RESET is again carried out automatically.
After that, the controller is configured for the ISO dialect.

Section 3 Procedure
Notes
ISO dialect
802D sl with ISO dialect

C40 Start-up of NC Parameters
1 Brief Description
Module Objective:
Upon completion of this module you are able to set the basic NC parameters for the startup of the NC
system.
Module Description:
The controller can be started in different ways. This has effects also on the loading of parameters.
Parameters which are preassigned by machine data can be changed or restricted via setting data.
Moreover, it is possible to display workpiece counters and runtimes.
Module Content:
 Controller start-up
 Setting data
Controller start-up
Section 2
Setting data
Section 3

Section 2 Controller start-up
Notes
The following screen is displayed after having switched on the controller:
B y p re ssin g th e b u tto n s “S h ift” a n d “A la rm ”, yo u a cce ss th e S yste m o p e r-

ating area.
Keyboard 802d sl
Startup
System operating area

Section 2 Controller start-up
Notes
The type of controller start-u p ca n b e se le cte d via “S ta rt-u p “N C ”.
NC start-up
The different types of start-up have the following effects:
 Normal start-up
Remanent data remains unchanged.
Current PLC machine data is taken over.
 Start-up with default data
Remanent data is deleted.
Standard PLC machine data is loaded.
 Start-up with saved data
Saved remanent data and saved PLC machine data is loaded.

Section 3 Setting data
Notes
T h e se le ctio n o f th e se ttin g d a ta is d o n e via “O ffse t/P a ra m ” o n th e ke y-

b o a rd a n d th e so ftke y “S e ttin g D a ta ”.
Setting data basic screen
If th e va lu e fo r “JO G F e e d ra te ” a n d “S p in d le S p e e d ” is ze ro , th e co n tro lle r

uses the value stored in the machine data. Restrictions for the minimum
and maximum spindle speed are only possible within the limits defined in
the machine data.
“R e strictio n W ith G 9 6 ” re fe rs to th e p ro g ra m m a b le u p p e r sp e e d lim it a t

co n sta n t cu ttin g sp e e d . T h e va lu e e n te re d fo r “D ry R u n F e e d ra te ” is u se d
when the dry run function is selected in the automatic mode during pro-
gram execution instead of the programmed feedrate. By changing the
“S ta rtin g A n g le F o r T h re a d ”, a m u ltip le th re a d ca n b e cu t w h e n re p e a tin g
the thread cutting operation.
For making entries, the cursor has to be positioned on the respective field
a n d th e va lu e b e co n firm e d e ith e r w ith “In p u t” o r b y m o vin g th e cu rso r.
The softkeys are for branching off to further menu levels.

The working area limitation effects the geometry and additional axes. The
so ftke y “S e t A ctive ” a ctiva te s/d e a ctiva te s th e va lu e s fo r th e a xis se le cte d
via the cursor.
B y p re ssin g th e so ftke y “T im e s/C o u n te rs”, th e va rio u s w o rkp ie ce co u n te rs

and runtimes / intervention times are displayed. The timer is automatically
zeroed with default values during the controller start-up.

Section 3 Setting data
Notes
Working area limitation
Times / counters
Explanations
 Parts total
Number of required workpieces
 Parts requested
Total number of produced workpieces
 Number of parts
Number of all workpieces produced since the start time
 Total runtime
Total runtime of all NC programs in the automatic mode
 Program runtime
Runtime of the selected NC program
 Feedrate runtime
Runtime of the path axes of all NC programs without active
rapid traverse

Notes
W ith th e so ftke y “O th e r”, a ll se ttin g d a ta e xistin g in th e co n tro lle r su b d i-

vided in
 general,
 axis-specific
 channel-specific
are displayed.
Setting data

C22 Display Options
1 Brief Description
Module Objective:
Upon completion of this module the display machine data can be adapted to the machine.
Module Description:
Various machine data and settings (resolution, colour) can be implemented on the controller to adapt
these to the individual requirements. This chapter describes the machine data which is of general
importance.
Module Content:
 Machine data
 Display settings
Machine data
Section 2
Display settings
Section 3

Section 2 Machine data
Notes
Display machine data
In th e m e n u “S yste m ” “M a ch in e D a ta ” “D isp la y M D “, a ll im p o rta n t

parameters not assigned to a specific group are stored. Among these are
settings for language, protection levels, V24 connection, coordinate posi-
tions and work load displays (see Figure C22-1).
Parameters
Effectiveness
Effectiveness
The effectiveness levels are listed according to their priority.

A change of data is effective after:
 POWER ON (po) Switch-on/-off of the SINUMERIK 802D sl

 NEW_CONF (cf) with RESET on the PLC interface
 RESET (re) with RESET on the PLC interface or at program end
 SOFORT (so) immediately after having entered the value
Selection of some important machine data.
Number : 202 - First Language with protection level 2/3

In SINUMERIK 802D there are two languages available simultaneously.
Different languages than the ones installed in the as-supplied state can be
loaded during commissioning.
Effective after Power On
Number : 203 - Display Resolution with protection level 2/3

This machine data item is for the position display to define the number of
decimal places with metric systems for linear axes and generally for rotary
axes.
Effective immediately

Section 2 Machine data
Notes
Number : 221 - User_Class_Dir_Access with protection level 3/3

This value is for selecting the protection level of the directory access.
Number : 247 - V24_PG_PC_Baud with protection level 3/3

For setting the baud rate between PG and PC
Number : 330 - CMM_POS_Coordinate_System with protection level 3/7

Coordinate layout of the machine with 7 positions
Number : 360 - Spindle_Load_Displ1 with protection level 3/3

For switching on the work load display for spindle 1

Section 3 Display settings
Notes
T h e co lo r o f th e d isp la y ca n b e a d a p te d in d ivid u a lly via th e “S yste m ” m e n u
b y se le ctin g “M a ch in e D a ta ” “C h a n g e C o lo r” .
Colours
Here, the color of the softkeys and the windows can be changed by select-
ing RGB and brightness .

C67 Preparation of Series machine
1 Brief description
Module objective:
Upon completion of this module you can serially commission machines of the same type using a CF
Card.
Module description:
For the serial production of machine tools, it is necessary to install the machines commissioning data
without hindering the production flow process. The process is described in this document. The
following diagram shows graphically the production flow process.
Empty
Data
NCK + PLC + Drive
Machine Builder Production Line Pos 5: Install control

Installation of control data from Master Software 10mins
Mount Mount Preparation Mount
Prepare
To Handler / Customer
Notes
Module content:
 Sequence of events to produce the serial data

 Sequence of events to load the Serial data into the next machine.
Sequence of events to
produce the Serial data
Section 2
Sequence of events to load

the Serial data into the next Section 3
machine.

Section 2 Sequence of events to produce the Serial data
Notes
Saving All prototype data to Compact Flash card
The CF card can be up to 2GB, and should be formatted using the FAT16
or FAT32 file system.
To make a backup of the serial machine configuration, that the data can be
transferred to the series machine requires that two archives should be
saved to the CF card. These two files can be saved to the card in the
SYSTEM area of the control. i.e. NC/PLC archive and HMI archive
The SYSTEM area of the control is reached by pressing the key : SHIFT +
ALARM softkey combination.
The entry point for saving data is through softkey Start-up files, see picture
below:
Entry for
saving data

Notes
The following display can then be seen:
The two files previously mentioned can be saved by copying the contents
of the HMI and the NC/PLC directories into two archives.
The following picture describes this process:
The destination should now be selected and the Paste function can be
used to save the files to the respective card. The destination is the
“C u sto m e r C F ca rd ”

Notes
After pressing Paste softkey

change file name to
e.g. NC_PLC.ARC and
confirm with OK softkey
The above should be repeated for the HMI archive.

The two archives should be now visible on the CF card. The CF card
should now be removed from the system and stored safely.
Both archives saved to

CF, card can now be
removed and stored
NOTE:
The archives which are saved to the card should not contain any machine
specific information, pitch error compensation as an example.
This data has to be generated separately for each series machine.

Sequence of events to load the Serial data into
Section 3 the next machine.
Notes
Transferring series data from Compact flash card to machine
In the case of series machine production it will be necessary to reload the

previously saved prototype data to serially produced machines.
The following steps should be carried out in order to reload the data
previously stored on the CF card.
The controller should first be switched on and the password for the
SERVICE should be set: The password for a new CNC component is
a lw a ys th e d e fa u lt “E V E N IN G ”, th is sh o u ld b e ch a n g e d a fte r n e w
installation to prevent mishandling of the system in the future.
Once the password is set the system should be switched OFF and ON and
the Startup menu entered with the SELECT key when prompted.
See picture below:
Startup Menu
Normal Startup
Reload saved user data
Startup with default data
PLC Stop
PLC overall reset / default PLC program
HMI Startup with default data
Remove drive data
Remove drive data/default data
Software update
C h o o se m e n u o p tio n “S ta rtu p w ith d e fa u lt d a ta ” a n d co n firm w ith th e

ENTER key.
The control will now make a new start, wait until the control is finished
starting up and once again enter the SERVICE password.
Y o u sh o u ld se e th e m e ssa g e “0 0 4 0 6 0 S ta n d a rd m a ch in e d a ta is lo a d e d ”.
Using copy from CF card and paste to CNC the series data can be
installed to the control. See the following diagrams:

Notes
Select HMI archive

and with COPY
softkey prepare for
paste operation to
Select HMI directory

a n d p re ss “p a ste ”
softkey

Notes
Confirm the dialog box with the OK softkey, the HMI archive will now be
read into the controller.
During this reading in process the controller will reboot once, the process
will take approximately 1 minute to complete.
This procedure should be repeated for the NC/PLC archive, the CNC will
reboot more times and the process takes approximately 4 minutes to
complete. The NC_PLC archive should be copied to the NC PLC directory
and not the HMI.
Note: The HMI archive should be read in first because the specific PLC
alarms are in the NC/PLC archive.
Machine specific data can now be installed, any axis which are having
absolute measuring systems can be synchronised.
When the process is complete a new machine specific archive should be
made. This archive should be archived with the machine tool builder and a
copy delivered with the machine to the customer.

C12 Language Setting
1 Brief Description
Module Objective:
Upon completion of this module, you can install different languages on the control.
Module Description:
English is set as the standard foreground and background language. Further languages can be inte-
grated and changed in the controller with the help of the RCS 802D toolbox.
Module Content:
 Creation of the connection RCS 802D toolbox

 Language setting
Creation of the con-

nection
Section 2
RCS 802D toolbox
Language setting
Section 3

Section 2 Creation of the connection RCS 802D toolbox
Notes
In order to change the preset language configuration in the 802D, the RCS
802D toolbox has to be installed. First of all, a connection between the
controller and the computer has to be created. This is done via the menu
“S e ttin g s”
“C o n n e ctio n ” (F ig . C 1 2 -1). You can chose from a connection via
RS232 or Ethernet (crossed cable).
Figure C12-1 - Creating a connection
The selection is made via the settings in the system control under the
m e n u ite m “S e t P G /P C In te rfa ce ”.
For the configuration of the serial RS232 interface, the following settings
have to be made analogously to the local COM port parameters (Fig. C12-
2 ) in th e m e n u : “S yste m ” “P L C ” “S T E P 7 C o n n e ctio n ”.
Figure C12-2 - RS232 parameters

Section 2 Creation of the connection RCS 802D toolbox
Notes

and lo g g e d o n . T h is is d o n e via “S yste m ” “R S C L o g -o n ”.
RCS log-on
You can access the controller via your company network (with or without
DHCP) or locally (Fig. C12-4).
“S yste m ” “S e rvice D isp la y” “S e rvice C o n tro lle r“ “S e rvice N e t-
w o rk”
IP address
Figure C12-4 - Network configuration
T h e m e n u ca n n o w b e e xite d via “S a ve ” a n d th e la n g u a g e se ttin g b e

started in the toolbox.

Section 3 Language setting
Notes
First of all it has to be checked if the correct controller is set:

“S e ttin g s” “T o o lb o x” “C o n tro lle r” (se e F ig . C 1 2 -1).
V ia th e m e n u “O p tio n s” “C o n n e ct” o r th e b u tto n th e se t co n n e ctio n

to the target system can now be established. If using the Ethernet protocol,
this has to be configured with the IP address (Fig. C12-5) before. To do so,
enter any connection name and the IP address of the 802D. As described
in the previous section, this address can be found in Figure C12-4. If using
the RS232 connection, the respective COM interface has to be selected.
Connect
C12-5 - Establishing the connection

Access to the controller via Ethernet is password-protected. When logging
on, the user name and password of the currently logged-on RCS user has
to be entered (Fig. C12-4).
After the online connection has been established, a new project can be
created or an old one opened.
“S e ttin g s” “T o o lb o x” “S e le ct V e rsio n a n d P ro je ct” (se e F ig . C 1 2 -1).
C12-6 - Project selection

Notes
V ia th e “N e w ” b u tto n , a n e w p ro je ct is cre a te d in w h ich a n y n a m e ca n b e

entered and the first and second standard language be selected. The pro-
je ct is cre a te d via “C re a te ”.
C12-7 - Language manager toolbox
To change the language of the help system in the 802D, open the menu
“G e n e ra te H e lp S yste m ” (se e F ig . C 1 2 -7). Here, languages can be added
and deleted and the individual texts be edited. After having selected the
d e sire d la n g u a g e , th e b u tto n “G e n e ra te H e lp T e xt” a n d th e n “T ra n sfe r to
8 0 2 ” h a ve to b e clicke d
(Fig. C12-8). If the transmission has been completed error-free, the help
system can be called with the new language on the controller via the
button on the NC keyboard.
Transfer C12-8 - Transferring help texts
T o ch a n g e th e H M I la n g u a g e , ca ll th e m e n u “S e le ct L a n g u a g e ” (F ig . C 1 2 -
7). All languages implemented during project configuration are displayed in
the menu window. After having selected the first and second language, the
u p lo a d is sta rte d b y clickin g th e b u tto n “T ra n sfe r to 8 0 2 ”. T h e n e w la n -
g u a g e ca n b e sw itch e d via “S yste m “ “C h a n g e L a n g u a g e ” (F ig . C 1 2 -3).

Notes
It is also possible to change the OEM texts:
 User alarm : alcu.txt (see C29)

 Message texts : alsc.txt
 Cycle alarms : alz.txt
T h e m e n u “S e le ct O E M ” h a s to b e ca lle d fro m th e “T o o lb o x M a n a g e r” fo r
that (see Fig. C12-7). The texts are loaded into the controller by selecting
th e in d ivid u a l te xt file s a n d th e n clickin g th e b u tto n “T ra n sfe r to 8 0 2 ” (F ig .
C12-9).
C12-9 - OEM texts
Transfer texts

C84 Reference - Encoder Adjustment
1 Brief Description
Module Objective:
Upon completion of this module you will be able to set the reference for absolute encoders.
Module Description:
The referencing (synchronisation) of an axis with an absolute encoder is done automatically when
switching on the controller. Therefore, the actual value of the absolute encoder has to be set once
(also in the case of replacement) during commissioning and taken on by the controller.
Module Content:
 Necessity and boundary conditions of the encoder ad-

justment
 Procedure for the encoder adjustment
Necessity and bound-

ary conditions Section 2
Procedure
Section 3

Section 2 Necessity and boundary conditions
Notes
With the adjustment, the displacement between the zero point of the ma-
chine and that of the encoder is calculated and stored. This is usually done
just once during the first commissioning. After that, the controller knows
the value and can calculate the absolute machine position from the abso-
lute encoder value at any time. This state is indicated by MD 34210:
ENC_REFP_STATE=2. The displacement is stored in MD
34090:REFP_MOVE_DIST_CORR.
Displacement
Actual value
Axis adjusted
Axis-specific encoder data after the adjustment
A repetition of the adjustment is required in the following cases:

 After the assembly/disassembly or exchange of the encoder or motor
including the attached encoder
 After having switched a possibly existing gearbox between motor
(with absolute encoder) and load
 In general always when the mechanical connection between encoder
and load was separated and not established exactly the same way
again.
When the controller detects the necessity of a re-adjustment, this is indi-

cated by the MD 34210: ENC_REFP being set to the value 0 or 1. The
switching to an encoder level with a different gearbox ratio between en-
coder and load is detected. In all other cases, the users have to overwrite
the MD 34210: ENC_REPF_STATE themselves.
When saving the machine data, the state of the MD 34210:

ENC_REFP_STATE is saved, too. Therefore, the axis is automatically de-
clared as being adjusted when loading such a data record. If the data re-
cord originates from a different machine (e.g. in the case of a series start-
up), an adjustment has to be carried out after the loading and activation of
the data.

Section 3 Procedure
Notes
The axis to be adjusted is moved to a defined position and set to the corre-
sponding actual value.
This is done as follows:
1 . “S yste m ” o p e ra tin g a re a “M a ch . D a ta ” “A xis M D ”

Set MD 34200: ENC_REFP_MODE and MD 34210: NC_REFP_STATE
to 0 and activate it with POWER ON.
MD 34200: ENC_REFP_MODE = 0 means that the actual value of the
axis is set once.
Axis-specific encoder data before the adjustment
2 . “P o sitio n ” o p e ra tin g a re a “JO G ” m o d e

Move the axis manually at low speed to a known position. The direction
with which the position is approached has to correspond to the direction
stored in the MD 34010: REFP_CAM_DIR_IS_ MINUS
(0: positive direction, 1: negative direction).
3. Enter the actual value corresponding to the approached position into the
MD 34100: REFP_SET_POS. This value can be a value given by the de-
sign (e.g. fixed stop) or a value determined by a measuring instrument at
this position.
4 . S e t M D 3 4 2 1 0 : E N C _ R E F P _ S T A T E to 1 . T h is e n a b le s th e “A d ju stm e n t”
function.
5. The changed machine data is activated via RESET.
6 . S w itch to th e “P o sitio n ” o p e ra tin g a re a “JO G -R E F ” m o d e .

Section 3 Procedure
Notes
Moving the axis manually
7. By activating the traversing key already used in Step 2, the current

displacement is entered into the MD 34090: REFP_MOVE_DIST_CORR
and MD 34210: ENC_REFP_STATE changes to 2 (axis adjusted). When
activating the correct traversing key, the axis does not move. In the actual
value display of the axis position the value entered in the MD 34100:
REFP_SET_POS and the symbol for the reference point are displayed .
8 . E xit th e “JO G -R E F ” m o d e .

C16 Installation of Additional Axes (Retrofit)
1 Brief Description
Module Objective:
Upon completion of this module you will be able to retrofit an additional axis to an existing machine.
Module Description:
If a machine is to be subsequently equipped with a new function, it is usually necessary to install an

additional axis. This requires mechanical, electrical, and software changes. This module describes
the necessary steps to integrate the axis in the controller.
Module Content:
 Retrofitting of an additional axis

 Commissioning with Starter
Retrofitting of an addi-
Section 2
tional axis
Commissioning with
Section 3
Starter

Section 2 Retrofitting of an additional axis
Notes
If there are new tasks planned for an existing machine, it is usually neces-
sary to implement an additional drive axis.
After having correctly installed the motor module with a connected drive
and wired DRIVE-CLiQ interface (below are the possibilities), the corre-
sponding parameters have to be configured.
This can be done with the STARTER commissioning tool.
The first possibility with interface available on existing double axis module.
802D SL PCU
X1 X2
X203
X202
X201
X200
X E
Double axis module(Z,A)
Y E E SP D
Z E
A E
The second possibility with interface available on new single axis module.
Direct measuring systems can also be installed if a drive click
interface is also available.
802D SL PCU
X1 X2
X203
X202
X201
X200
X E
Single axis module(A,) NEW
Single axis module(Z,)
Y E
Z E
A E E SP D
NEW

Section 2 Commissioning new axis
Notes
Sequence:
To install an additional axis on the machine, the procedure listed should be

adhered to.
1. Connect the new hardware including the drive click interface and
power up the system.
2. Connect STARTER and read out from the controller the actual
configuration, to a new project.
3. Insert in offline mode the new axis with the Starter Wizard.
4. Change in the expert list the drive data for the new axis - BICO´s
compatible to other axis.
5. Enter axis in configuration list P978[]
6. C h a n g e P L C fo r n e w a xis , e n a b le s e tc… . + P a rke d a xis sig n a ls, fo r
removal of axis.
7. Enter NC MD for new axis.
1. Connect the new hardware including the drive click interface and
power up the system.
Prerequisite for the installation of an additional axis:
In order to install an additional axis on the machine, it should be checked if

the Line Module has the necessary power available in order to power an
additional Motor Module.
A free drive click interface should be free on the bus. If in addition to the
axis a direct measuring system has to be installed, it should be checked
also that a drive click interface is available.
2. Connect STARTER and read out from the controller the actual
configuration, to a new project.
Sequence:
Double click
to Launch
Starter

Notes
Enter project name

and continue with OK
D o u b le click “in se rt
sin g le d rive u n it” to
obtain the following
dialog box.
In order to create a drive object, the following should be input to the dialog
box:
 SINAMICS in 802D as Device Type

 2.3x as SW version Note: 802D sl SW dependant
 IP as Address type Note: Protocol
 xxx.yyy.zzz.qqq as IP address Note: Destination IP address

Notes
Click ICON online

access to obtain the
following dialog box >
T h e d ia lo g b o x “O n lin e /O fflin e co m p a riso n ” sh o w s th e d iffe re n ce b e tw e e n

the offline project content and the actual content within the drive. The
offline project has to be actualised to show a true indication of the online
machine.
To actualise the offline project click > this will
result in the offline project content being the
same as the online drive.
The data is stored in the main memory of the PG (RAM) this should be
stored to file with the SAVE function on the PROJECT menu.
The following can be seen when the data has been successfully uploaded
and subsequently saved.

Notes
1. Insert in offline mode the new axis with the Starter Wizard.
U se th e “in se rt d rive ” o b je ct to
obtain the following wizard. A new
offline axis object can be inserted.
During parameterisation the BICO for the infeed in operation has to be

given, this should be given from P722.0 (X21.1) on the CU for the ALM
module and on the Servo (P864) SLM

Notes
Drive telegram 116 has to be entered in the last step of the wizard.
Telegram type 116 is a standard Sinumerik telegram which should be used
in all cases.
Telegram 116
Upon completion of the wizard, a new object will be available in your offline
project, as can be seen in the following picture:
NOTE: When installing additional components to the drive cliq interface, it

may become necessary to change the SET topology.
Do not forget !!

Notes
4. Change in the expert list the drive data for the new axis - BICO´s
compatible to other axis.
To change drive
d a ta “q u ick
commissioning
mode has to be
Various parameters have to be set which are normally set automatically by

the first commissioning. The table on the following page should be taken
into consideration:
P864 - SERVO - Should be set during new axis wizard

P849 - SERVO - Should be changed in the expert list
P488 - SERVO - Should be changed in the expert list
P922 - SERVO - Should be set during new axis wizard
P978 - CU - S h o u ld b e ch a n g e d in th e e xp e rt list : P 9 = 1 “C o m m issio n in g
m ode”
DO NOT FORGET TO RESET P9 and save all with CU P977
Notes
5. Enter axis in configuration list P978[]
The axis configuration in the CNC part of the control as to match the
configuration which is in the regulator of the drive. These two components
communicate through the Profibus protocol which is configured in the PLC. The
configuration in the PLC is fixed and must be matched to the drive.
The matching to the PLC is carried out with Drive MD978. Depending upon the
axis configuration values have to be entered here.
Has to be
changed for
new axis

Notes
The values which are input refer to the component number. The component
numbers differ dependant upon whether a SLM or an ALM is used.
P978 SLM Description ALM Description

P978[5] 255 Not available 255 Not available
P978[6] 1 CU 802D sl 1 CU 802D sl
P978[7] 255 Not available 2 ALM
P978[8] 0 PZD end 255 Not available
P978[9] 0 0 PZD end
The above is an example, the actual values will be dependant upon how the drive
is physically connected, “D rive click”.
Please do not forget P977 !!
6. C h a n g e P L C fo r n e w a xis , e n a b le s e tc… . + P a rke d a xis sig n a ls, fo r

removal of axis.
In order that the axis can be used, the relevant enables should be given in
the PLC user interface.
When retrofitting an axis to the machine, the axis is often an axis which is
not permanently attached to the machine, e.g. removable rotary axis on a
milling machine. The axis should be physically attached and detached
when the machine is switched off. When the machine is running without
the additional axis, is should be disabled in the PLC by removing the
“M e a su rin g circu it a ctive ” sig n a l a n d a ll o f th e re le va n t e n a b le sig n a ls.
(servo and pulse enable)
7. Enter NC MD for new axis.
In order to use the new NC axis the NC axial machine data has to be set.
Upon completion of the above steps, the relevant stages of the machine
test protocol should be carried out, this will test weather the axis has been
correctly installed.
When everything has been checked a new data backup should be made,
in the case of data loss in the future.

C55 Optimization with STARTER
1 Brief Description
Module Objective:
The objective of this module is the presentation of the options for diagnosing and optimizing drives
with the help of STARTER.
Module Description:
The STARTER commissioning tool provides various functions making an effective and simple diag-
nosis and optimization possible. Apart from fault and alarm displays and a diagnosis overview
(indication of the device status and operating mode of the drives), it is possible to record signals and
to analyze the control behavior.
Module Content:
 Setting of signals  Function generator

 Recording of signals  Trace function
 Analysis of the control behavior  Measuring function
Function generator
Section 2
Trace function
Section 3
Measuring function
Section 4

Section 2 Function generator
Notes
The function generator can be used for the following applications:

 Measurement and optimization of control loops
 Comparison of the dynamics with coupled drives
 Setting of a simple travel profile without a traversing program.
With the function generator, various signal shapes can be generated.
The characteristics of the function generator are the following:

 Simultaneous switching to several drives
 Freely parameterizable signal shapes settable
 Offset possible for each signal
 Start-up to offset parameterizable
 Restriction of the output signal to minimum and maximum values
possible
 Operating modes of the function generator for servo and vector
After having established an ONLINE connection, the function generator is called

either in the project tree or via the toolbar.
Online Start Trace
Calling the function generator

Section 2 Function generator
Notes
Control
priority
Drive Operating mode
Signal type
Main screen of the function generator
Operating mode, drive and signal type as well as further settings have to
be entered in the parameterization screen form.
Having the control priority, access to the selected drive is possible. It might
be necessary to carry out an online/offline adjustment.
After having loaded the settings to the target unit, the function generator
can be started .
Parameter
download Start
Starting the function generator

Section 3 Trace function
Notes
With the trace function, measured values can be recorded over a defined
period of time depending on the trigger conditions.
The characteristics of the trace function are the following:

 Four recording channels per recorder
 Two independent trace recorders per control unit
 Triggering
- Without triggering (recording immediately after start)
- Triggering to signal with edge or to level
- Trigger delay and pre-trigger possible
 Automatic or settable scaling of the display axes
 Signal measurement via cursor
 Settable trace cycle.
After having established an ONLINE connection, the function generator is

called either in the project tree or via the toolbar.
The main screen is displayed.
Main screen of the trace function
The drive and the corresponding parameter is selected.
Trace signal selection

Notes
Further parameters can be set.
Start Control priority

Parameter
download
Trigger type
Setting the trace function
be necessary to carry out an online/offline adjustment.
After having loaded the settings to the target unit, the trace recording can
be started.
The recording is represented graphically.

Section 4 Measuring function
Notes
The measuring function is for optimizing the drive control. The influence of
primary control loops can be interrupted selectively and the dynamics of
individual drives be analyzed via simple parameterization. For that, the
function generator and trace are coupled. At one point, the control loop is
supplied with the signal of the function generator and at another point, the
trace makes its recordings. By parameterizing the measuring function, the
trace is also parameterized automatically.
The characteristics of the measuring function are the following:
 Current controller setpoint step change (behind current setpoint filter)

 Current controller reference frequency response (behind current setpoint filter)
 Speed controller setpoint step change (behind speed setpoint filter)
 Speed controller disturbance variable step change (interference behind current
setpoint filter)
 Speed controller reference frequency response (behind speed setpoint filter)
 Speed controller reference frequency response (before speed setpoint filter)
 Speed controller interference frequency response (interference behind current
setpoint filter)
 Speed-controlled system (excitation behind current setpoint filter).
After having established an ONLINE connection, the measuring function is

called either in the project tree or via the toolbar (Fig. C55-8).
The main screen is displayed then (Fig. C55-9).
Measuring func-
tion
ONLINE
Calling the measuring function

Notes
Control
priority
Main screen of the measuring function
be necessary to carry out an online/offline adjustment. After having loaded
the settings to the target unit, the measuring function can be started. In
that, it is possible to select the signals to be actually measured.
Measuring function set
The result of the measurement is represented graphically.

Notes
Graphical representation of the measurement

C56 On-board Optimization
1 Brief Description
Module Objective:
Upon completion of this module zou will be able to use the integrated trace function of the 802D sl
control.
Module Description:
There is an oscilloscope function provided for the optimization of the drives, which also allows for a
graphical representation. There are several functions for the result analysis available.
Module Content:
 Trace function
Trace function Section 2
SINUMERIK 802D sl 1st Commissioning, Training Manual Page C16

Notes
In th e “S yste m ” o p e ra tin g a re a  “S e rvice D isp ly”  “S e rvo T ra ce ”, th e

servo trace main screen is displayed.
Time of the
marker position
Time base
Time difference
Change the
scaling
Save / load
Signal selection
Main screen of the servo trace
The following functions are available for the result analysis:

 Change of the scaling of abscissa and ordinate
 Measurement of a value with the help of a horizontal or vertical
marker
 Measurement of abscissa and ordinate values as the difference be-
tween two marker positions
 Storage as a file in the part program directory.
The oscilloscope function allows for the graphical representation of the

 speed setpoint
 contour deviation
 following error
 actual position value
 position setpoint
 exact stop coarse/fine.
The type of recording can be linked to various criteria allowing a synchro-

nous recording of internal control states. The setting is made after having
a ctiva te d th e so ftke y “S ig n a l S e le ctio n ”.
W ith “T ra ce D isp la y”, a n o th e r m e n u le ve l is o p e n e d , o ffe rin g so ftke ys fo r

displaying/hiding diagrams.

Notes
Axis Signal type Status
Measuring
time Trigger type
Parameterization of the measuring channel
The following can be selected as signal type:

 Following error
 Controller difference
 Contour deviation
 Actual position value
 Actual speed value
 Speed setpoint
 Compensation value
 Parameter set
 Position setpoint controller input
 Speed setpoint controller input
 Acceleration setpoint
 Controller input
 Speed precontrolled value
 Signal exact stop fine
 Signal exact stop coarse.
Status ON means that the recording is done in this channel. With Status
OFF the channel is inactive.
T h e m e a su rin g tim e is e n te re d d ire ctly in th e “M e a su rin g T im e ” in p u t fie ld .
It applies to all trace channels.
The trigger condition is selected via the toggle key:

 No trigger, the measurement is started directly after the activation of
the Start softkey
 Positive edge
 Negative edge
 Exact stop fine reached
 Exact stop coarse reached.

Notes
W ith “M a rke r In cre m e n ts”, th e m a rke r ste p s ca n b e se t .
Marker increments
W ith “S ta rt”, th e tra ce re co rd in g is sta rte d .
Trace recording

C63 Interface signals
1 Listing of Interface signals

Notes
Appendix – PLC Interface Description SINUMERIK 802D sl
11. PLC User Interface Description

PLC address ranges
Operand identifier Description Area
V NC－PLC interfaces See table below
T Timers T0 to T15 (unit: 100 ms)
T Timers T16 to T31 (unit: 10 ms)
C Counters C0 to C31
I Figure: digital inputs I0.0 to I17.7
Q Figure: digital outputs Q0.0 to Q11.7
M Flag M0.0 to M255.7
SM Special flag SM0.0 to SM0.6 (see table below)
A ACCU (logic) AC0 to AC1 (UDWORD)
A ACCU (arithmetic) AC2 to AC3 (DWORD)
Structure of V-range addresses

Operand identifier DB no. Channel and Sub-area Offset
axis no.
V 00 00 0 000
range (00-99) (00-99) (0-9) (000-999)
Special flag –SM bit definition (read only)

SM bits Description
SM0.0 Flag with defined ONE signal
SM0.1 Initial setting: first PLC cycle ’1’, following cycles ’0’
SM0.2 Buffered data lost – only valid in first PLC cycle (’0’ data ok, ’1’ data lost)
SM0.3 Power On: first PLC cycle ’1’, following cycles ’0’
SM0.4 60 s cycle (alternating ’0’ for 30 s, then ’1’ for 30 s)
SM0.5 1 s cycle (alternating ’0’ for 0.5 s, then ’1’ for 0.5 s)
SM0.6 PLC cycle (alternating one cycle ’0’, then one cycle ’1’)
Status signals from/to MCP

1000 0 xxx Signals from MCP
Interface MCP Æ PLC (Read/Write)
10000000 NC Spindle Spindle Spindle Single block JOG MDA AUTO
stop override % override override % mode mode mode mode
- 100% +
10000001 NC Spindle Spindle Spindle Key switch REF REPOS
start CCW STOP CW 3 mode mode
10000002 Feed Variable Key switch Machine function
Enable Disable INC 0 INC1000 INC100 INC10 INC1
10000003 Reset Key switch Key switch Feed override switch（gray code）
2 1 E D C B A
10000004 Traversing keys User keys
th th
-4 +4 rapid KT4 KT3 KT2 KT1 KT0
10000005 Traversing keys
rd rd nd nd st st
T17 KT5 -3 +3 -2 +2 -1 +1
10000006 User-defined keys User-defined key
T9 T10 T11 T12 T13 T14 T15 T16
10000007 User-defined keys
T1 T2 T3 T4 T5 T6 T7 T8
10000008 Spindle override switch（gray code）
“0” “0” “0” E D C B A
93 Copyright © Siemens AG All Rights Reserved

SINUMERIK 802D sl Appendix – PLC Interface Description
1100 0 xxx Signals to MCP

Interface PLC Æ MCP (Read/Write)
11000000 NC Spindle Spindle Spindle Single block JOG MDA AUTO
stop override % override override % mode mode mode mode
- 100% +
11000001 NC Spindle Spindle Spindle Key switch REF REPOS
start CCW STOP CW 3 mode mode
11000002 feed variable Key switch Machine function
Enable Disable INC 0 INC1000 INC100 INC10 INC1
11000003
11000004 Traversing keys LED user keys

th th
-4 +4 rapid LED5 LED4 LED3 LED2 LED1
11000005 Traversing keys
rd rd nd nd st st
T17 LED6 -3 +3 -2 +2 -1 +1
11000006
11000007
Status signals from MCPA

1000 1 xxx Signals from MCPA
Interface MCPA Æ PLC (Read/Write)
10001000 Key#8 Key#7 Key#6 Key#5 Key#4 Key#3 Key#2 Key#1
JOG INC User key 6 User key 5 User key 4 User key 3 User key 2 User key1
th
4 - Spindle Spindle Spindle MDA Single Block Auto Referencing
CCW stop CW mode mode mode in JOG
th st nd rd rd nd st
4 + 1 - 2 - 3 + Rapid 3 - 2 + 1 +
10001003 Key#27 Key#26 Key#25
NC start NC stop Reset
10001004 Feed override
E D C B A
10001005 Spindle override
E D C B A
Status signals to MCPA

1100 1 xxx Signals to MCPA
Interface PLC Æ MCPA (Read/Write)
11001000 LED 6 LED 5 LED 4 LED 3 LED 2 LED 1
User key 6 User key 5 User key 4 User key 3 User key 2 User key 1
Copyright © Siemens AG All Rights Reserved 94

Reading/writing NC variables
1200 0 xxx NC data interface
Interface PLC Æ NCK (Read/Write)
12000000 Variable Start
read: 0 /
write: 1
12000001 Number of variables
1200 1 xxx Signals from MCP

Interface PLC Æ NCK (Read/Write)
120x1000 Variable index
1：tool data；2：tool edge no.；3：zero offset；4：current no. of axes；5：R parameters
120x1001 Area number
120x1002 Line index for NCK variable x (WORD)
120x1004 Column index for the NCK variable x (WORD)
120x1006
120x1008 Writing: Data to NCK variable x (WORD)
Reading/writing NC variables
Interface NCK Æ PLC (Read)
12002000 Error Request
In job completed
12002001

Interface NCK Æ PLC (Read)
120x3000 Valid
variable
120x3001 Access result
0: No error；1: Illegal access to object; 5: Invalid address; 10：Object does not exist
120x3002
120x3004 Reading: Data from NCK variable x (WORD)
c e c g c e
Start d h
Request
f
completed f
Error in job
c - Job start f - reset signals via the PLC

d - Request completed without error g - “Start” pre-reset，no influence on internal
access operations
e - reset ”Start” h - Error in job

For detailed description of reading/writing NC variables, see 802D sl Short

Guide for Start-Up
Retentive data area
1400 Retentive data
PLC variable (Read/Write; Bit / Byte / Word / Double)
14000000 User Data
14000001 User Data
...
14000127 User Data
User alarm: Activation

1600 Signals to HMI
PLC variable Interface PLC Æ HMI (Read/Write)
16000000 Activation of alarm number
700007 700006 700005 700004 700003 700002 700001 700000
700015 700014 700013 700012 700011 700010 700009 700008
700023 700022 700021 700020 700019 700018 700017 700016
700031 700030 700029 700028 700027 700026 700025 700024
700039 700038 700037 700036 700035 700034 700033 700032
700047 700046 700045 700044 700043 700042 700041 700040
700055 700054 700053 700052 700051 700050 700049 700048
700063 700062 700061 700060 700059 700058 700057 700056
Variable for alarm

1600 Signals to HMI
Byte
16001000 Variable for alarm 700000 (32-Bit)
.... ...
Active alarm reaction

1600 Active alarm reaction
16002000 PLC EMERGE- Feed Read-in NC start
NCY disable on disable disable
STOP STOP all axes

Program control signals from HMI (retentive area)

1700 0 xxx HMI signals (Operating mode: AUTO, selection of “Program Control”)
PLC variable Interface HMI Æ PLC (Read only)
17000000 Test run M01
feedrate selected
selected
17000001 Program Feedrate

test override for
rapid
traverse
selected selected
17000002 Skip block
selected
17000003 Measuring
in JOG
active
Reading/writing PLC variables

1700 1 000 Signals from NCK
PLC variable Interface NCK ÅÆ PLC (Read/Write)
Byte
17001000 Program selection from PLC: Program number (1 byte)
17001001 Command job from PLC: Command number (1 byte)

1: Save selected Program number；2: Select saved Program number
17000002
17000003
1700 2 000 Signals from Axis/Spindle
PLC variable Interface NCK Æ PLC (Read only)
17002000 Error Program
Program selected
selection
17002001 Error Execute
Command command
execution
Signals from HMI

1800 Selection/status signals from HMI
18000000 Start Mode group Selection from HMI
measuring changeover
in JOG disable JOG mode MDA mode AUTO mode
18000001 Machine function selection from HMI
REF REPOS
Signals form HMI (simulation)

19000000 Simulation
active

Selection signals from HMI (retentive area)

19001003 Machine Axis no. for handwheel 1
axis
C B A
axis C B A
axis C B A
Status signals to HMI (retentive area)

PLC variable Interface PLCÆHMI (Read/write)
19005000 OP key
disable
19005001 Update too

list
19005002 Enable tool
measuring
In JOG
19005003
19005004 T number for tool measuring in JOG (1 32-bit DINT )
Auxiliary function transfer from NC channel

2500 Auxiliary functions from NCK channel
25000004 M fcts. 5 M fcts. 4 M fcts. 3 M fcts. 2 M fcts. 1
change change change change change
25000006 S fcts.
change
25000008 T fcts
change
25000010 D fcts
change
25000012 H fcts. 3 H fcts. 2 H fcts. 1
change change change
Decoded M signals (M0 – M99)

2500 M functions from NCK channel (dynamic)
PLC variable Interface NCK Æ PLC (Read only; 1 PLC cycle only)
25001000 Dynamic M function
M7 M6 M5 M4 M3 M2 M1 M0
M15 M14 M13 M12 M11 M10 M9 M8
M23 M22 M21 M20 M19 M18 M17 M16
M31 M30 M29 M28 M27 M26 M25 M24
M39 M38 M36 M36 M35 M34 M33 M32
...

M99 M98 M97 M96
Transferred T functions
2500 T functions from NCK channel
Byte
25002000 T function 1 (1 32-bit DINT)
Transferred M functions
2500 M functions from NCK channel (static)
Byte
25003000 M function 1 (1 32-bit DINT)
25003004 Extended address of M function (1 byte)
Transferred S functions
2500 S funcitons from NCK channel
Byte
25004000 S function 1 (1 32-bit REAL)
25004004 Extended address of S function (1 byte)
25004008 S function 2 (1 32-bit REAL)
25004012 Extended address of S function (1 byte)
Transferred D functions
2500 D funcitons from NCK channel
Byte
25005000 D function 1 (1 32-bit DINT)
Transferred H functions
2500 H funcitons from NCK channel
Byte
25006000 H function 1 (1 32-bit REAL)
25006004 Extended address for H function 1 (byte)

General signals from/to NCK

2600 General signals to NCK
PLC variable Interface PLC Æ NCK (Read/Write)
26000000 Protection level Acknowled EMERG-
ge ENCY
EMERG- STOP
ENCY
4 5 6 7 STOP
26000001 Request Request INC inputs
axis axis in mode
distances- actual group
to-go values range
active
2700 General signals from NCK
PLC variable Interface NCKÆPLC (Read only)
27000000 EMERG-
ENCY
STOP
active
27000000 INCH Probe 1
dimension activated
System
27000002 Drive Drives in
cyclical
ready operation
27000003 Air NCK alarm
temperature is active
alarm
General signals from/to NCK

3000 Operating mode signals to NCK
PLC variable Interface PLC ÆNCK (Read/Write)
30000000 Reset Mode group Operating mode
changeover
disable JOG MDA AUTO
30000001 Machine function
REF REPOS Teach in
30000002 Machine function: INC mode
Continuous Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
traversal
3100 Operating mode signals from NCK

31000000 802D sl Active mode
READY JOG MDA AUTO
31000001 Active machine function
REF REPOS Teach in

Control signals to NCK channel

3200 Signals to NCK channel
32000000 Activate by M01 Single block
run feed Activate Activate
32000001 Activate Activate
program referencing
Test
32000002 Activate
skip block
32000004 Federate override
H G F E D C B A
32000005 Rapid traverse override
H G F E D C B A
32000006 Feedrate Rapid Program Delete Read-in Feedrate
override traverse level distance-to disable disable
-go
active override abort
active
32000007 NC stop NC stop NC Stop NC Start NC Start
axes plus
spindle at block limit disable
32000013 Do not De-activate
disable workpiece r
tool counter
32001000 Geometry axis 1 (axis 1 in WCS)
Traversing Traversing Rapid Traversing Feedrate Activate Activate Activate
keys + keys - traverse key lock stop handwheel handwheel handwheel
override 3 2 1
traversal
override 3 2 1
traversal
override 3 2 1
traversal
Status signals from NCK channel

3300 Signals from NCK channel
PLC variable Interface NCKÆ PLC (Read only)
33000000 Last action M0 / M1 Approach Action block
block active block active active
active
33000001 Program Transfor- M2 / M30 Block Revolutional Referencing
mation active search feerate
test active active active active active
33000002

33000003 Channel status Program status

Reset Interrupted active Aborted interrupted Stopped Waiting Running
33000004 NC alarm Channel- All axes All axes
with specific stationary referenced
processing NCK alarm
stop present is active
Status signals from NCK channel

Motion Motion Handwheel Handwheel Handwheel
command + command- 3 active 2 active 1 active
traversal
Motion Motion Var. INC Handwheel Handwheel Handwheel
command + command - 3 active 2 active 1 active
traversal
Motion Motion Handwheel Handwheel Handwheel
command + command - 3 active 2 active 1 active
traversal

33004000 G0
active
33004001 Workpiece External
setpoint language
reached mode active
33004003 No active
tool change
command
G functions from NCK channel

3500 G functions from NCK channel
Byte
35000000 Active G function of group 1
… …
Transferred M-/S- functions

PLC variable Interface PLCÆNCK (Read only)
370x0000 M function for spindle (DINT)
370x0004 S function for spindle (REAL)

General signals to axis/spindle

3800...3804 General signals to axis/spindle
380x0000 进给倍率
H G F E D C B A
380x0001 Override Position Follow-up Axis/spindle Sensor for Acknowle-
active measuring mode disable fixed stop dege fixed
system 1 stop
reached
380x0002 Clamping Distance-to- Controller
go/spindle enable
in progress reset
380x0003 Velocity/sp- Enable
indle speed approach to
limiting fixed stop
380x0004 Traversing keys Rapid Traversing Feedrate Activate handwheel
traverse key lock stop
override Spindle
+ - stop 3 2 1
380x0005 Machine function
traversal
3800…3804 Signals to axis
nd
380x1000 Delay. Ref. 2 software limit switch Hardware limit switch
pt.
(axis) approach ＋－＋－
380x Signals to spindle
380x2000 Gear Actual gear stage
(主轴) changed C B A
380x2001 Invert Spindle Feedrate
override
(主轴) M3/M4 Reposition- Valid for
ing spindle
380x2002 Setpoint direction of Oscillation Oscillation
rotation speed via PLC
(主轴) Left Right
380x2003 Spindle override
(主轴) H G F E D C B A
3800...3804 Signals to axis/spindle
380x4000 Speed HLGSS
setpoint
Smoothed
380x4001 Pulse Speed Parameter set selection（1 of 8）
enable controller
integrator
from
PI toP C B A

Status signals from axis/spindle

3900...3904 Signals from axis/spindle
390x0000 Position reached Referenced/ Encoder Spindle/no
limit axis
frequency
with exact with exact Synchronized exceeded
stop, fine stop, coarse
390x0001 Current Speed Position Axis/spindle Follow up
controller control loop controller stationary mode
active active active Active
390x0002 Fixed stop Activate Measure-
reached travel to ment
fixed stop active
390x0004 Motion command Handwheel active
+ - 3 2 1
390x0005 Motion command
traversal
3900...3904 Signals from axis

390x1002 Lubrication
(axis) pulse
390x Signals from spindle
390x2000 Gearbox Set gear stage
(spindle) changeover C B A
390x2001 Actual Spindle in Setpoint Setpoint Speed limit
direction of the setpoint speed speed exceeded
rotation range increased limited
(spindle) CW
390x2002 Active spindle mode Rigid Const.
tapping cutting
velocity
(spindle) Control Oscillation Positioning active
mode mode mode
3900...3904 Signals from axis/spindle
390x4000 Speed Speed
setpoint increase/de
crease
disable
smoothed active
active
390x4001 Pulse Speed Drive ready Active parameter set
controller
integrator
Enabled from PI to P C B A
PLC machine data: INT values (MD14510 USER_DATA_INT)

4500 Signals form NCK channel
PLC 变量 Interface NCK Æ PLC (Read only)
Byte
45000000 Int values (WORD/ 2 Byte)
... ...

PLC machine data: HEX values (MD14512 USER_DATA_HEX)

Byte
45001000 Hex value (HEX/ 1 Byte)
.... ...
PLC machine data: FLOAT values (MD14514 USER_DATA_FLOAT)

Byte
45002000 Float value (REAL/ 4 Byte)
.... ....
PLC user alarm reaction (MD14516 USER_DATA_ALARM)

45003000 Alarm deletion criterion 700000 alarm reaction
POWERON Delete key Not PLC STOP EMERGE- Feed Read-in Start
assigned NCY STOP disable disable disable
..

Reading/writing PLC variables

PLC variable Interface NCK ÅÆ PLC (Read/Write)
Byte
49000000 Offset [0]
49000001 Offset [1]
49000002 Offset [2]
.... …
49000511 Offset [511]
Tool management functions: Signal changes

5300 0 xxx Signals from axis/spindle
53000000 Tool limit Tool
value warning
limit
reached reached

Tool management function: transferred

5300 1 xxx Signals form NCK channel
Byte
53001000 T number for tool warning limit
Long integer (DINT)
53001004 T number for tool limit value
Long integer (DINT)
Reading axis actual values and distances-to-go

570x Signals form NCK channel
Byte
570x0000 Axis actual value
Long integer (REAL)
570x0004 Axis distance-to-go
Long integer (REAL)

C64 Machine Data Lists
1 Listing of Machine Data

Notes
Appendix – Machine Data List SINUMERIK 802D sl
10. Machine Data List

Display machine data
Number MD Identifier Cross reference
to the relevant
section/chapter
in the
Description of
Functions
Schematic view Name,miscellaneous Activation Read/write
protection level
Default value Minimum value Maximum value Data type
202 FIRST_LANGUAGE 19
Decimal Foreground language POWER ON 2/3
1 1 2 BYTE
203 DISPLAY_RESOLUTION 19
decimal Display resolution POWER ON 2/3
3 0 5 BYTE
204 DISPLAY_RESOLUTION_INCH 19
4 0 5 BYTE
205 DISPLAY_RESOLUTION_SPINDLE 19
1 0 5 BYTE
207 USER_CLASS_READ_TOA
decimal Protection level read tool geometry IMMEDIATE 2/3
3 0 7 BYTE
208 USER_CLASS_WRITE_TOA_GEO
decimal Protection level write tool geometry IMMEDIATE 3/3
3 0 7 BYTE
209 USER_CLASS_WRITE_TOA_WEAR
decimal Protection level write tool wear data IMMEDIATE 3/3
3 0 7 BYTE
210 USER_CLASS_WRITE_ZOA
Decimal Protection level for “Write settable work offset” IMMEDIATE 3/3
3 0 7 BYTE
212 USER_CLASS_WRITE_SEA
decimal Protection level for “Write setting data” IMMEDIATE 3/3
3 0 7 BYTE
213 USER_CLASS_READ_PROGRAM
decimal Protection level for “Read part program” IMMEDIATE 3/3
7 0 7 BYTE
214 USER_CLASS_WRITE_PROGRAM
decimal Protection level for “Enter part program” IMMEDIATE 3/3
3 0 7 BYTE
215 USER_CLASS_SELECT_PROGRAM
decimal Protection level for program selection IMMEDIATE 3/3
3 0 7 BYTE
218 USER_CLASS_WRITE_RPA
decimal Protection level write R parameters IMMEDIATE 3/3
3 0 7 BYTE
219 USER_CLASS_SET_V24
decimal Protection level for “Set V24” IMMEDIATE 3/3
3 0 7 BYTE
221 USER_CLASS_DIR_ACCESS
decimal Protection level for directory access IMMEDIATE 3/3
3 0 7 BYTE
222 USER_CLASS_PLC_ACCESS
decimal Protection level for PLC project IMMEDIATE 2/2
3 0 7 BYTE
223 USER_CLASS_WRITE_PWA
decimal Protection level for protected working area IMMEDIATE 2/3
3 0 7 BYTE
247 V24_PG_PC_BAUD
decimal PG: baud rate (300, 600, 1200, 2400, 4800, 9600, 19200, 38400) IMMEDIATE 3/3
7 0 7 BYTE
280 V24_PPI_ADDR_PLC
PLC station address POWER ON 3/3
2 0 126 BYTE
281 V24_PPI_ADDR_NCK
NCK station address POWER ON 3/3
3 0 126 BYTE

SINUMERIK 802D sl Appendix – Machine Data List
283 CTM_SIMULATION_DEF_X 10 (K1)

Decimal Simulation default value for X IMMEDIATE 3/7
0 -10000 10000 INTEGER
284 CTM_SIMULATION_DEF_Y 10 (K1)
Decimal Simulation default value for Z IMMEDIATE 3/7
0 -10000 10000 INTEGER
285 CTM_SIMULATION_DEF_VIS_AREA 10 (K1)
Decimal Simulation default value for display area IMMEDIATE 3/7
100 -10000 10000 INTEGER
286 CTM_SIMULATION_MAX_X 10 (K1)
Decimal Simulation of maximum display X IMMEDIATE 3/7
0 -10000 10000 INTEGER
287 CTM_SIMULATION_MAX_Y 10 (K1)
Decimal Simulation of maximum display Z IMMEDIATE 3/7
0 -10000 10000 INTEGER
288 CTM_SIMULATION_MAX_VIS_AREA 10 (K1)
Decimal Simulation of maximum display area IMMEDIATE 3/7
1000 -10000 10000 INTEGER
289 CTM_SIMULATION_TIME_NEW_POS 10 (K1)
Decimal Simulation of actual-value refresh rate IMMEDIATE 3/7
100 0 4000 INTEGER
290 CTM_POS_COORDINATE_SYSTEM 10 (K1)
Decimal Position of the coordinate system IMMEDIATE 3/7
2 0 7 BYTE
291 CTM_CROSS_AX_DIAMETER_ON 10 (K1)
Decimal Diameter for “Transverse axis active” IMMEDIATE 3/7
1 0 1 BYTE
292 CTM_G91_DIAMETER_ON 10 (K1)
Decimal Incremental feed IMMEDIATE 3/7
1 0 1 BYTE
305 G_GROUP1
Decimal User-oriented G group for positiondisplay IMMEDIATE 3/7
1 1 1000 INTEGER
306 G_GROUP2
2 1 1000 INTEGER
307 G_GROUP3
8 1 1000 INTEGER
308 G_GROUP4
9 1 1000 INTEGER
309 G_GROUP5
10 1 1000 INTEGER
310 FG_GROUP1
Decimal User-oriented G group for positiondisplay (external language) IMMEDIATE 3/7
1 1 1000 INTEGER
311 FG_GROUP2
2 1 1000 INTEGER
312 FG_GROUP3
8 1 1000 INTEGER
313 FG_GROUP4
9 1 1000 INTEGER
314 FG_GROUP5
10 1 1000 INTEGER
330 CMM_POS_COORDINATE_SYSTEM
Decimal Coordinate position of machine IMMEDIATE 3/7
0 0 7 BYTE
331 CONTOUR_MASK
Decimal Activating the 802D sl contour definition programming IMMEDIATE 3/3
0 0 1 BYTE
332 TOOL_LIST_PLACE_NO
Decimal Activating location number in tool list IMMEDIATE 3/3
0 0 1 BYTE
343 V24_PPI_ADDR_MMC
Decimal IMMEDIATE 3/3
4 0 126 BYTE

344 V24_PPI_MODEM_ACTIVE
Decimal IMMEDIATE 3/3
0 0 1 BYTE
345 V24_PPI_ MODEM _BAUD
Decimal Baud rate for modem connection IMMEDIATE 3/3
7 5 9 BYTE
346 V24_PPI_ MODEM _PARITY
Decimal Parity for modem connection IMMEDIATE 3/3
0 0 2 BYTE
377 MM_USER_CLASS_WRITE_TO_MON_DAT
Decimal Protection level for “Write user cycles” IMMEDIATE 2/3
0 0 2 BYTE
General machine data

to the relevant
section/chapter
in the
Description of
Functions
protection level
10000 AXCONF_MACHAX_NAME_TAB[0]...[4] 19
- Machine axis name POWER ON 2/2
Always - - STRING
Turning X1, Z1, SP, A1, B1 - - STRING
Milling X1, Y1, Z1, SP, A1 - - STRING
10074 PLC_IPO_TIME_RATIO 19
- Factor of the PLC task for main run POWER ON 2/2
Always 2 1 50 DWORD
10200 INT_INCR_PER_MM 3 (G2)
- Computational resolution for linear positions POWER ON 2/2
Always 1000 1 1000000000 DOUBLE
10210 INT_INCR_PER_DEG 3 (G2)
- Computational resolution for angualr positions POWER ON 2/2
Always 1000 1 1000000000 DOUBLE
10240 SCALING_SYSTEM_IS_METRIC 3 (G2)
- Metric bacis system POWER ON 2/7
Always 1 *** *** BOOLEAN
10713 M_NO_FCT_STOPRE[0]
- M function with preprocessing stop POWER ON 2/7
Always -1 *** *** DWORD
10714 M_NO_FCT_EOP
- M function active for spindle after reset POWER ON 2/7
10715 M_NO_FCT_CYCLE[0]
- M function to be replaced by a subroutine POWER ON 2/7
10716 M_NO_FCT_CYCLE_NAME
- Subroutine name for replacement of an M function POWER ON 2/7
Always “” - - STRING
10717 T_NO_FCT_CYCLE_NAME
- Subroutine name for replacement of a T function POWER ON 2/7
Always “” - - STRING
10718 M_NO_FCT_CYCLE_PAR
- M function replaced by parameters POWER ON 2/7
Always “” - - DWORD
10760 G53_TOOLCORR
- Effect with G53, G153 and SUPA POWER ON 2/2
10808 EXTERN_INTERRUPT_BITS_M96
- Activate aborted program（ASUP） POWER ON 2/2
Ext. language 0 *** *** DWORD
10810 EXTERN_MEAS_G31_P_SIGNAL[n]: 0..3
- Assignment of the measuring inputs for G31 P.. POWER ON 2/2
Ext. language 1, 1, 1, 1 0 3 BYTE
10812 EXTERN_DOUBLE_TURRET_ON
- Double-revolver head with G68 POWER ON 2/2
Ext. language 0 0 1 BOOLEAN
10880 MM_EXTERN_CNC_SYSTEM
- Def. of control ssytem to be adapted POWER ON 2/7

Always 1 2 DWORD
Turning 2 1 2 DWORD
Milling 1 1 2 DWORD
10881 MM_EXTERN_CNC_SYSTEM
- ISO_3 mode: G Code system POWER ON 2/7
0 0 0 2 DWORD
10882 NC_USER_EXTERN_GCODES_TAB[0]...[59]
- List of user-specific G commands, ext. langauge POWER ON 2/2
Always “” *** *** STRING
10884 EXTERN_FLOATINGPOINT_PROG
- Evaluation of progr. values without decimal point POWER ON 2/7
10886 EXTERN_INCREMENT_SYSTEM
- Increment system POWER ON 2/7
10888 EXTERN_DIGITS_TOOL_NO
- Number of digits for T number POWER ON 2/7
Always 2 0 8 BYTE
10890 EXTERN_TOOLPROG_MODE
HEX Tool change program with ext. language POWER ON 2/7
Always 0x00000000 0x00000000 0xFFFFFFFF DWORD
11100 AUXFU_MAXNUM_GROUP_ASSIGN 13 (H2)
- Number of auxiliary functions in AuxF groups POWER ON 2/2
Always 1 1 64 BYTE
11210 UPLOAD_MD_CHANGES_ONLY 19
HEX MD backup only for changed MD IMMEDIATE 2/2
- 0x0F 0x00 0x0FF BYTE
11240 PROFIBUS_SDB_NUMBER 3 (G2)
- Sdb1000 number POWER ON 2/2
Always 0 0 6 BYTE
11250 PROFIBUS_SHUTDOWN_TYPE 3
- Profibus Shutdown handling POWER ON 2/2
Always 0 0 2 BYTE
11290 DRAM_FILESYSTEM_MASK 3
- Select a directoy from DRAM POWER ON 2/2
Always 0 - - DWORD
11310 HANDWH_REVERSE 9 (H1)
- Threshold for handwheel direction reversal POWER ON 2/2
Always 2 0 *** BYTE
11320 HANDWHL_IMP_PER_LATCH[0]...[2] 9 (H1)
- Handwheel pulses per locking position POWER ON 2/2
Always 1., 1., 1. *** *** DOUBLE
11346 HANDWH_TRUE_DISTANCE 9 (H1)
- Handwheel travel or speed specification POWER ON 2/2
Always 0 0 3 BYTE
13060 DRIVE_TELEGRAM_TYPE[0]...[8] 3 (G2)
- Standard message frame type for Profibus DP POWER ON 2/2
Always 102, 102, 102, 102, 102 *** *** DWORD
13070 DRIVE_FUNCTION_MASK[0]...[30] 3 (G2)
- Used DP functions POWER ON 2/7
总线适配 0, 0, 0, 0, 0, … 0 *** *** DWORD
13080 DRIVE_TYPE_DP 3 (G2)
- Drive type with Profibus POWER ON 2/2
Always 0, 0, 0, 0, 0, … 0 0 3 BYTE
13200 MEAS_PROBE_LOW_ACTIVE[0] 15 (M5)
- Polarity change of the probe POWER ON 2/7
13220 MEAS_PROBE_DELAY_TIME[0] 15 (M5)
- Detection of probe deflection delay time POWER ON 2/7
Always 0.0, 0.0 0 0.1 DOUBLE
14510 USER_DATA_INT[0]...[31] 19
- User data (INT) POWER ON 2/7
Always 0 -32768 32767 DWORD
14512 USER_DATA_HEX[0]...[31] 19
- User data (HEX) POWER ON 2/7
- 0 0 0x0FF BYTE
14514 USER_DATA_FLOAT[0]...[7] 19
- User data (FLOAT) POWER ON 2/7
38 38
- 0.0 -3.40 10 3.40 10 DOUBLE
14516 USER_DATA_PLC_ALARM[0]...[63] 19
- User data (HEX) POWER ON 2/7
- 0, 0, 0, 0, ... *** *** BYTE

17530 TOOL_DATA_CHANGE_COUNTER
- Mark tool data change for HMI POWER ON 2/7
Always 0 0 1 DWORD
18040 VERSION_INF[0]...[2]
- Version and (if necessary) date of PCMCIA card POWER ON 2/7
Always 0 0 1 STRING
18080 MM_TOOL_MANAGEMENT_MASK
HEX Reserved memory for the tool management (SRAM) POWER ON 1/7
BIT0 = 1 tool management data ready
BIT1 = 1 tool monitoring data ready
BIT2 = 1 OEM &CC data ready
BIT3 = 1 memory for neighboring position
Always 0 0 0XFFFF DWORD
18102 MM_TYPE_OF_CUTTING_EDGE
- Type of D number programming (SRAM) POWER ON 2/2
Always 0 0 1 DWORD
18794 MM_TRACE_VDI_SIGNAL
- Oscilloscope-related VDI signals POWER ON 2/2
Always 0 0 0X7FFFFFFF DWORD
Channel-specific machine data

to the relevant
section/chapter
in the
Description of
Functions
protection level
20050 AXCONF_GEOAX_ASSIGN_TAB[0]...[2] 19
- Assignment “geometry/channel axis” POWER ON 2/2
Always 0 5 BYTE
Turning 1, 0, 2 0 5 BYTE
Milling 1, 2, 3 0 5 BYTE
20070 AXCONF_MACHAX_USED[0]...[4] 19
- Machine axis number valid in channel POWER ON 2/2
Always 0 5 BYTE
Turning 1, 2, 3, 0, 0 0 5 BYTE
Milling 1, 2, 3, 4, 5 0 5 BYTE
20080 AXCONF_CHANAX_NAME_TAB[0]...[4] 19
- Name of channel axis in the channel POWER ON 2/2
Always - - STRING
Turning “X”, “Z”, “SP”, “ “, “ “ - - STRING
Milling “X”, “Y”, “Z”, “SP “, “A “ - - STRING
20090 SPIND_DEF_MASTER_SPIMD 5 (S1)
- Number of master spindle POWER ON 2/7
Always 1,1,1,1, 1,1,1,1, … -1 10 DWORD
20094 SPIND_RIGID_TAPPING_M_NR 5 (S1)
- M function for axis mode (Siemens mode) POWER ON 2/7
Always 70 -1 0x7FFF DWORD
20095 EXTERN_RIGID_TAPPING_M_NR
- M function for axis mode (external mode) POWER ON 2/7
Always 29 6 0x7FFF DWORD
20108 PROG_EVENT_MASK K1
- Event-controlled program calls POWER ON 2/7
Always 0x0, 0x0, 0x0, …… 0 0xF DWORD
20140 TRAFO_RESET_VALUE K2
- Active tranformation in case of RESET (MD20110,MD20112) RESET 2/7
Always 0, 0, 0, 0, 0, 0, ... 0 8 BYTE
20156 EXTERN_GCODE_RESET_MODE[0]…[30] K2
- External G code reset mode RESET 2/7
Always - 0 1 BYTE
20204 WAB_CLEARANCE_TOLERANCE W1
- Direction reversal with SAR POWER ON 2/7
Always 0.01, 0.01, 0.01, 0.01, ... 0 plus DOUBLE
20310 TOOL_MANAGEMENT_MASK
- Activate tool management functions POWER ON 2/7
Always 0x0, 0x0, 0x0, …… 0 0xFFFFFF DWORD
20320 TOOL_TIME_MONITOR_MASK
- Time monitoring for the tool in the toolholder POWER ON 2/7
Always 0x0, 0x0, 0x0, …… - - DWORD

20360 TOOL_PARAMETER_DEF_MASK W1
- Definition of the tool parameters POWER ON 2/7
Always 0x0, 0x0, 0x0, …… 0 0xFFFFFF DWORD
20380 TOOL_CORR_MODE_G43G44 W1
- Handling of tool length compensation G43/G44 POWER ON 2/7
Always 0, 0, 0, 0, 0, 0, …… 0 2 BYTE
20384 TOOL_CORR_MULTIPLE_AXES W1
- Tool correction simultaenously for mulple axes RESET 2/7
Always 1 0 1 BOOLEAN
20550 EXACT_POS_MODE B1
- Exact stop conditions with G00 and G01 NEW CONF 2/7
Always 0, 0, 0, 0, 0, 0, …… 0 33 BYTE
20552 EXACT_POS_MODE_G0_TO_G1 PG
- Exact stop conditions with transition G00->G01 NEW CONF 2/7
Always 0, 0, 0, 0, 0, 0, …… 0 3 BYTE
20600 MAX_PATH_JERK B2
- Maximum path jerk NEW CONF 2/7
Always 100.0, 100.0, 100.0 … 0.0 *** DOUBLE
20700 REFP_NC_START_LOCK 8 (R1)
- NC start disable without reference point RESET 2/7
20730 G0_LINEAR_MODE P2
- Interpolation behavior with G0 POWER ON 2/7
20732 EXTERN_G0_LINEAR_MODE P2
- Interpolation behavior with G00 POWER ON 2/7
20734 EXTERN_FUNCTION_MASK FBFA
- Function mask for external language RESET 2/7
Always 0, 0, 0, 0, 0, 0, …… 0 0xFFFF DWORD
21000 CIRCLE_ERROR_CONST 10 (K1)
Mm Circle end point monitoring constant POWER ON 2/7
Always 0.01 *** *** DOUBLE
21010 CIRCLE_ERROR_FACTOR 10 (K1)
Mm Circle end point monitoring factor POWER ON 2/7
Always 0.001 0.0 plus DOUBLE
21020 WORKAREA_WITH_TOOL_RADIUS 2 (A3)
- Tool radius with working area limitation RESET 2/2
21160 JOG_VELO_RAPID_GEO[0]...[2] 9 (H1)
mm/min Geo axis rapid traverse in the JOG mode RESET 2/2
Always 10000., 10000., 10000. *** *** DOUBLE
21165 JOG_VELO_GEO[0]...[2] 9 (H1)
mm/min GEO axis traverse speed in the JOG mode POWER ON 2/2
Always 1000., 1000., 1000. *** *** DOUBLE
22000 AUXFU_ASSIGN_GROUP[0]...[63] 13 (H2)
- Auxiliary function group: 0...49 POWER ON 2/7
Always 1, 1, 1, 1, 1, ... 1 64 BYTE
22010 AUXFU_ASSIGN_TYPE[0]...[63] 13 (H2)
- Auxiliary function type group: 0...49 POWER ON 2/7
Always “”, “”, “”, ... - - STRING
22020 AUXFU_ASSIGN_EXTENSION[0]...[63] 13 (H2)
- Auxiliary function extension POWER ON 2/7
Always 0, 0, 0, ... 0 99 BYTE
22030 AUXFU_ASSIGN_VALUE[0]...[63] 13 (H2)
- Auxiliary function value (no. of auxiliary functions in the channel): 0...49 POWER ON 2/7
Always 0, 0, 0, 0, ... *** *** DWORD
22254 AUXFU_ASSOC_M0_VALUE 13 (H2)
- Additional M functions for program stop POWER ON 2/7
Always -1, -1, -1, -1, ... 6 0x7FFF DWORD
22256 AUXFU_ASSOC_M1_VALUE 13 (H2)
- Additional M functions for conditional stop POWER ON 2/7
Always -1, -1, -1, -1, ... 6 0x7FFF DWORD
22400 S_VALUES_ACTIVE_AFTER_RESET 5 (S1)
- S function active even after reset POWER ON 2/2
22534 TRAFO_CHANGE_M_CODE M1
- M code when switching the transformation type POWER ON 2/7
Always 0, 0, 0, 0, ... 0 99999999 DWORD
22550 TOOL_CHANGE_MODE 14 (W1)
- New tool offset with T or M function POWER ON 2/2
Always 0 0 1 BYTE
22910 WEIGHTING_FACTOR_FOR_SCALE
- Input resolution for scaling factor POWER ON 2/2

22914 AXES_SCALE_ENABLE
- Activation for axial scaling factor (G51) POWER ON 2/2
22920 EXTERN_FIXED_FEEDRATE_F1_ON FBFA
- Activate fixed feedrateF1~F9 POWER ON 2/7
22930 EXTERN_PARALLEL_GEOAX[0]…[2] FBFA
- Assignment of parallel channel geometry axis POWER ON 2/7
Always {0,0,0},{0,0,0},{0,0,0} 0 10 BYTE
24020 FRAME_SUPRESS_MODE FBFA
- Positions with frame suppression POWER ON 2/2
Always 0 0 1 DWORD
24100 TRAFO_TYPE_1 F2
- Transformtion 1 in the channel NEW CONF 7/7
Coordinate 0, 0, 0, 0, 0, 0, … - - DWORD
transformation
24110 TRAFO_AXES_IN_1[0]…[max. no. of axis] M1, F2
- Axis assignment for transformation 1 NEW CONF 7/7
Coordinate {1, 2, 3, 4, 5, 0, 0, 0, …} 0 10 BYTE
transformation
24120 TRAFO_GEOAX_ASSIGN_TAB_1[0]…[2] F2
- GEO/channelscid sddihnment for transformation 1 NEW CONF 7/7
Coordinate {0,0,0},{0,0,0},{0,0,0},… 0 10 BYTE
transformation
24130 TRAFO_INCLUDES_TOOL_2 M1,F2
- Tool handling with active 1st transformation NEW CONF 7/7
Coordinate 1 0 1 BOOLEAN
transformation
24200 TRAFO_TYPE_1 F2
- Transformation 2 in the channel NEW CONF 7/7
Coordinate 0, 0, 0, 0, 0, 0, … - - DWORD
transformation
24210 TRAFO_AXES_IN_2[0]…[最大轴数] F2
- Axis assignment for transformation 2 NEW CONF 7/7
Coordinate {1, 2, 3, 4, 5, 0, 0, 0, …} 0 10 BYTE
transformation
24220 TRAFO_GEOAX_ASSIGN_TAB_2[0]…[2] F2
- GEO/channel axis assignment for transformation 2 NEW CONF 7/7
Coordinate {0,0,0},{0,0,0},{0,0,0},… 0 10 BYTE
transformation
24230 TRAFO_INCLUDES_TOOL_2 M1, F2
- Tool handling with active 2nd transformation NEW CONF 7/7
transformation
24800 TRACYL_ROT_AX_OFFSET_1 M1
- Rotary axis offset TRACYL 1 NEW CONF 7/7
Coordinate 0.0, 0.0, 0.0, 0.0, … - - DOUBLE
transformation
24810 TRACYL_ROT_SIGN_IS_PLUS _1 M1
- Sign of the rotary axis NEW CONF 7/7
transformation
24820 TRACYL_BASE_TOOL_1 M1
- Base tool vector NEW CONF 7/7
Coordinate {0.0, 0.0, 0.0}, {0.0, 0.0, - - DOUBLE
transformation 0.0}, {0.0, 0.0, 0.0}
24850 TRACYL_ROT_AX_OFFSET_2 M1
transformation
24860 TRACYL_ROT_SIGN_IS_PLUS _2 M1
transformation
24870 TRACYL_BASE_TOOL_2 M1
transformation 0.0}, {0.0, 0.0, 0.0}
24900 TRANSMIT_ROT_AX_OFFSET_1 M1
- Rotary axis offset TRANSMIT 1 NEW CONF 7/7
transformation
24910 TRANSMIT _ROT_SIGN_IS_PLUS _1 M1
transformation

24911 TRANSMIT _POLE_SIDE_FIX _1 M1

- Limiting of working area in frong ot /after the pole NEW CONF 7/7
Coordinate 0, 0, 0, 0, 0, 0, … 0 1 BYTE
transformation
24920 TRANSMIT _BASE_TOOL_1 M1
transformation 0.0}, {0.0, 0.0, 0.0}
24950 TRANSMIT_ROT_AX_OFFSET_2 M1
- Rotary axis offset TRANSMIT 2 NEW CONF 7/7
transformation
24960 TRANSMIT _ROT_SIGN_IS_PLUS _2 M1
transformation
24961 TRANSMIT _POLE_SIDE_FIX _2 M1
- Limitation of the working area in front/after the pole NEW CONF 7/7
Coordinate 0, 0, 0, 0, 0, 0, … 0 1 BYTE
transformation
24970 TRANSMIT _BASE_TOOL_2 M1
transformation 0.0}, {0.0, 0.0, 0.0}
27100 ABSBLOCK_FUNCTION_MASK
- Block display parameterized with absolute value POWER ON 2/7
Always 0x0, 0x0, 0x0, 0x0 … 0 0X1 DWORD
27800 TECHNOLOGY_MODE 19
- Technology in the channel NEW CONF 2/2
Always 0 1 BYTE
Turning 1 0 1 BYTE
Milling 0 0 1 BYTE
27860 PROCESSTIMER_MODE 10 (K1)
HEX Activting the program runtime measurement RESET 2/7
Always 0x07 0 0x03F BYTE
27880 PART_COUNTER 10 (K1)
HEX Activate workpiece counter RESET 2/7
Always 0x0 0 0x0FFFF DWORD
27882 PART_COUNTER_MCODE[0]...[2] 10 (K1)
- Workpiece counting using a user-defined M command POWER ON 2/7
Always 2, 2, 2 0 99 BYTE
28400 LOOKAH_NUM_CHECKED_BLOCKS
Activate block display with absolute value POWER ON 2/7
Always 0 0 1 DWORD
28402 MM_ABSBLOCK
Dimension size of upload buffer POWER ON 2/7
Always 0, 0 DWORD
29000 MM_ABSBLOCK_BUFFER_CONF 12 (B1)
Number of blocks considered by the LookAhead function POWER ON 1/7
Always 10 *** *** DWORD
Axis-specific machine data

to the relevant
section/chapter
in the
Description of
Functions
protection level
30110 CTRLOUT_MODULE_NR[0] 3 (G2)

- Setpoint:Drive no./module no. POWER ON 2/2
Always 1 1 9 BYTE
30120 CTRLOUT_NR[0] 3 (G2)
- Setpoint: output to module POWER ON 2/2
Always 1 1 2 BYTE
30130 CTRLOUT_TYPE[0] 3 (G2)
- Setpoint output type POWER ON 2/2
Always 0 0 1 BYTE
30134 IS_UNIPOLAR_OUTPUT[0] 5 (S1)
- Setpoint output is unipolar POWER ON 2/2

Always 0 0 2
30200 NUM_ENCS 3 (G2)
- Number of encoders POWER ON 2/2
Always 1 0 1 BYTE
30220 ENC_MODULE_NR[0] 3 (G2)
- Actual value: Drive no./measuring circuit no. POWER ON 2/7
Always 1 1 9 BYTE
30230 ENC_INPUT_NR[0] 3 (G2)
- Actual value: Input number on module/measuring circuit board POWER ON 2/2
Always 1 1 3 BYTE
30240 ENC_TYPE[0] 3 (G2)
- Encoder type POWER ON 2/2
Always 0 0 4 BYTE
30270 ENC_ABS_BUFFERING[0] FBA, R1
- Absolute encoder: Traversing range extension POWER ON 2/7
Always 0, 0 0 1 BYTE
30300 IS_ROT_AX 6 (R2)
- Rotary axis/spindle POWER ON 2/2
30310 ROT_IS_MODULO 6 (R2)
- Modulo conversion for rotary axis/spindle POWER ON 2/2
30320 DISPLAY_IS_MODULO 6 (R2)
- Display modulo 360 degrees for rotary axis POWER ON 2/2
30350 SIMU_AX_VDI_OUTPUT 3 (G2)
- Axis signals for simulation axis POWER ON 2/2
30600 FIX_POINT_POS[0] 10 (K1)
mm, degrees Axis position with G75 POWER ON 2/7
31000 ENC_RESOL[0] 3 (G2)
- Linear scale POWER ON 2/2
31020 ENC_IS_LINEAR 3 (G2)
- Encoder lines per revolution (encoder no.) POWER ON 2/2
Always 2048 *** *** DWORD
31030 LEADSCREW_PITCH 3 (G2)
Mm Lead of the ballscrew POWER ON 2/2
31040 ENC_IS_DIRECT[0] 3 (G2)
- Encoder mounted directly on the machine (encoder no.) POWER ON 2/2
31050 DRIVE_AX_RATIO_DENOM[0]...[5] 3 (G2)
- Load gearbox denominator POWER ON 2/2
Always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD
31060 DRIVE_AX_RATIO_NUMERA[0]...[5] 3 (G2)
- Load gearbox numerator POWER ON 2/2
Always 1, 1, 1, 1, 1, 1 -2147000000 2147000000 DWORD
31070 DRIVE_ENC_RATIO_DENOM[0] 3 (G2)
- Measuring gearbox denominator POWER ON 2/2
Always 1 1 2147000000 DWORD
31080 DRIVE_ENC_RATIO_NUMERA[0] 3 (G2)
- Measuring gearbox numerator POWER ON 2/2
31122 BERO_DELAY_TIME_PLUS[0] 8 (R1)
S BERO delay time NEW CONF 2/2
31123 BERO_DELAY_TIME_MINUS[0] 8 (R1)
S BERO delay time NEW CONF 2/2
31600 TRACE_VDI_AX
- Oscilloscope-related VDI signals POWER ON 2/2
32000 MAX_AX_VELO 3 (G2)
mm/min, rpm Maximum axis velocity NEW CONF 2/7
Always 10000. (mm/min) *** *** DOUBLE
27,77 (rpm)
32010 JOG_VELO_RAPID 9 (H1)
mm/min, rpm Rapid traverse in the JOG mode RESET 2/7
Always 10000 (mm/min) *** *** DOUBLE
27,77 (rpm)
32020 JOG_VELO 9 (H1)
mm/min, rpm JOG axis velocity RESET 2/7
Always 2000 mm/min/ 5,55 rpm *** *** DOUBLE

32100 AX_MOTION_DIR 3 (G2)

- Traversing direction (not control direction) POWER ON 2/2
Always 1 -1 1 DWORD
32110 ENC_FEEDBACK_POL[0] 3 (G2)
- Sign of actual value (control direction) POWER ON 2/2
Always 1 -1 1 DWORD
32200 POSCTRL_GAIN[0]...[5] 3 (G2)
(m/min)/mm Integral action time of the position controller NEW CONF 2/7
Always 1, 1, 1, 1, 1, 1 0 2000. DOUBLE
32300 MAX_AX_ACCEL 4 (B2)
mm/ s2, rev/ s2 Axis acceleration NEW CONF 2/7
Always 1 mm/s2 / 2.77 (rev/s2) 0.001 *** DOUBLE
32420 JOG_AND_POS_JERK_ENABLE 4 (B2)
- Enable axisal jer limitation RESET 2/2
32430 JOG_AND_POS_MAX_JERK 4 (B2)
mm/s3, degree/s3 Axial jerk RESET 2/2
Always 1000 (mm/ s3) *** *** DOUBLE
2777,77 (degree/ s3)
32431 MAX_AX_JERK 4 (B2) 12 (B1)
mm/s3, degree/s3 Maximum axial jerk when traveling along the path NEW CONF 2/7
2777,77 (degree/ s3)
32432 PATH_TRANS_JERK_LIM 12 (B1)
mm/s3, degree/s3 Max. axial jerk when traveling along the path with block transition NEW CONF 2/7
2777,77 (degree/ s3)
32450 BACKLASH 16 (K3)
Mm Backlash on reversal NEW CONF 2/2
32500 FRICT_COMP_ENABLE K3
- Friction compensation active NEW CONF 2/7
32510 FRICT_COMP_ADPT_ENABLE K3
- Friction compensation adaptation active NEW CONF 2/7
32520 FRICT_COMP_CONST_MAX[0] K3
mm/min, rpm Maximum friction compensation value NEW CONF 2/7
32530 FRICT_COMP_ CONST_MIN[0] K3
mm/min, rpm Minimum friction compensation value NEW CONF 2/7
32540 FRICT_COMP_TIME K3
s Friction compensation time constant NEW CONF 2/7
32630 FFW_ACTIVATION_MODE 16 (K3)
- Feedfoward control canb e activated from the program RESET 2/2
Always 1 *** *** BYTE
32640 STIFFNESS_CONTROL_ENABLE[0] K3
- Dynamic stiffness control NEW CONF 2/7
32642 STIFFNESS_CONTROL_CONFIG[0] K3
- Configure dynamic stiffness control NEW CONF 2/7
Always 0 0 1 BYTE
32644 STIFFNESS_DELAY_TIME[0] K3
- Dyn. Stiffness control: Delay NEW CONF 2/7
Always 0.0 -0.02 0.02 DOUBLE
32700 ENC_COMP_ENABLE 16 (K3)
- Encoder/lead error compensation NEW CONF 2/2
32810 EQUIV_SPEEDCTRL_TIME[0]...[5] 16 (K3)
S Equivalent time onstant for the speed control loop NEW CONF 2/2
Always 0.003, 0.003, 0.003, *** *** DOUBLE
0.003, 0.003, 0.003,
33050 LUBRICATION_DIST 19
mm, degrees Travel for the lubrication pulse PLC signal NEW CONF 2/7
Always 100000000 *** *** DOUBLE
34000 REFP_CAM_IS_ACTIVE 8 (R1)
- Axis with reference point cam RESET 2/2
34010 REFP_CAM_DIR_IS_MINUS 8 (R1)
- Reference point approach in the negative direction RESET 2/2
34020 REFP_VELO_SEARCH_CAM 8 (R1)
mm/min, rpm Came approach velocity RESET 2/2

Always 5000.0 (mm/min) *** *** DOUBLE

13.88 (rpm)
34030 REFP_MAX_CAM_DIST 8 (R1)
mm, degrees Max. distance to reference cam RESET 2/2
34040 REFP_VELO_SEARCH_MARKER[0] 8 (R1)
mm/min, rpm Velocity when searching for the reference mark RESET 2/2
0.833 (rpm)
34050 REFP_SEARCH_MARKER_REVERSE[0] 8 (R1)
- Direction reversal on reference cam RESET 2/2
34060 REFP_MAX_MARKER_DIST[0] 8 (R1)
mm, degrees Max. distance to reference mark RESET 2/2
34070 REFP_VELO_POS 8 (R1)
mm/min, rpm Reference point approach velocity RESET 2/2
2.77 (rpm)
34080 REFP_MOVE_DIST[0] 8 (R1)
mm, degrees Reference point distance RESET 2/2
Always –2.0 *** *** DOUBLE
34090 REFP_MOVE_DIST_CORR[0] 8 (R1)
mm, degrees Reference point offset RESET 2/2
34092 REFP_CAM_SHIFT[0] 8 (R1)
mm, degrees Reference cam shift RESET 2/2
34093 REFP_CAM_MARK_DIST[0]..[5] 8 (R1)
mm, degrees Distance between reference came and zero mark RESET 2/7
34100 REFP_SET_POS[0] 8 (R1)
mm, degrees Reference point position RESET 2/2
Always 0. *** *** DOUBLE
34110 REFP_CYCLE_NR 8 (R1)
- Order of axes when referencing RESET 2/2
Always 1 -1 5 DWORD
34200 ENC_REFP_MODE[0] 8 (R1)
- Referencing mode POWER ON 2/2
Always 1 0 7 BYTE
34210 ENC_REFP_STATE[0] 8 (R1)
- Absolute encoder adjusting status IMMEDIATE 2/2
Always 0 0 2 BYTE
34220 ENC_ABS_TURNS_MODULO 6 (R2)
- Modulo range of the rotary absolute encoder POWER ON 2/2
34990 ENC_ACTUAL_SMOOTH_TIME[0]…[5]
s Smoothing time constant for actual vaues POWER ON 2/7
Always 0.0, 0.0, … 0.0 0.5 DOUBLE
35000 SPIND_ASSIGN_TO_MACHAX 5 (S1)
- Assignment ‘spindle – machine axis’ POWER ON 2/2
Always 0 0 1 BYTE
35010 GEAR_STEP_CHANGE_ENABLE 5 (S1)
- Gear stage change possible POWER ON 2/2
35012 GEAR_STEP_CHANGE_POSITION[0]…[5] 5 (S1)
mm, degrees Gear stage change position NEW CONF 2/7
Always 0.0, 0.0, 0.0, … 0 plus DOUBLE
35020 SPINDLE_DEFAULT_MODE 5 (S1)
- Spindle park position RESET 2/7
Always 0 0 3 BYTE
35030 SPINDLE_DEFAULT_ACT_MASK 5 (S1)
HEX Activate spindle park position RESET 2/7
Always 0x00 0 0x03 BYTE
35040 SPIND_ACTIVE_AFTER_RESET 5 (S1)
- Own spindle RESET POWER ON 2/2
35100 SPIND_VELO_LIMIT 5 (S1)
Rpm Maximum spindle speed POWER ON 2/7
35110 GEAR_STEP_MAX_VELO[0]...[5] 5 (S1)
Rpm Maximum speed for gear stage change NEW CONF 2/7
Always 500., 500., 1000., 2000., *** *** DOUBLE
4000., 8000.
35120 GEAR_STEP_MIN_VELO[0]...[5] 5 (S1)

Rpm Minimum speed for gear stage change NEW CONF 2/7
Always 50., 50., 400., 800., *** *** DOUBLE
1500., 3000.
35130 GEAR_STEP_MAX_VELO_LIMIT[0]...[5] 5 (S1)
Rpm Maximum speed of gear stage NEW CONF 2/7
Always 500., 500., 1000., 2000., *** *** DOUBLE
4000., 8000.
35140 GEAR_STEP_MIN_VELO_LIMIT[0]...[5] 5 (S1)
Rpm Minimum speed of gear stage NEW CONF 2/7
Always 5., 5., 10., 20., 40., 80. *** *** DOUBLE
35150 SPIND_DES_VELO_TOL 5 (S1)
- Spindle speed tolerance RESET 2/2
Always 0.1 0.0 1.0 DOUBLE
35160 SPIND_EXTERN_VELO_LIMIT 5 (S1)
Rpm Spindle speed limitation from PLC NEW CONF 2/7
35200 GEAR_STEP_SPEEDCTRL_ACCEL[0]...[5] 5 (S1)
Umdr/s^2 Acceleration in the control mode NEW CONF 2/7
Always 30.0, 30.0, 25.0, 20.0, 0.001 *** DOUBLE
15.0, 10.0
35210 GEAR_STEP_POSCTRL_ACCEL[0]...[5] 5 (S1)
Umdr/s^2 Acceleration in the position-controlled mode NEW CONF 2/7
Always 30.0, 30.0, 25.0, 20.0, 0.001 *** DOUBLE
15.0, 10.0
35300 SPIND_POSCTRL_VELO 5 (S1)
Rpm Position controller starting speed NEW CONF 2/2
35310 SPIND_POSIT_DELAY_TIME[0]…[5] 5 (S1)
s Positioning delay time+ NEW CONF 2/2
Always 0.0,0.05,0.1,0.2,0.4,0.8 DOUBLE *** DOUBLE
35350 SPIND_POSITIONING_DIR 5 (S1)
- Direction of rotation when positioning RESET 2/2
Always 3 3 4 BYTE
35400 SPIND_OSCILL_DES_VELO 5 (S1)
Rpm Reciprocating speed NEW CONF 2/2
35410 SPIND_OSCILL_ACCEL 5 (S1)
Umdr/s^2 Acceleration when reciprocating NEW CONF 2/2
Always 16 0.001 *** DOUBLE
35430 SPIND_OSCILL_START_DIR 5 (S1)
- Starting direction when reciprocating RESET 2/2
Always 0 0 4 BYTE
35440 SPIND_OSCILL_TIME_CW 5 (S1)
S Reciprocation time for M3 direction NEW CONF 2/2
35450 SPIND_OSCILL_TIME_CCW 5 (S1)
S Reciprocation time for M4 direction NEW CONF 2/2
35500 SPIND_ON_SPEED_AT_IPO_START 5 (S1)
- Feed enable with spindle in setppoint range RESET 2/2
Always 1 0 2 BYTE
35510 SPIND_STOPPED_AT_IPO_START 5 (S1)
- Feed enable with the spindle stopped RESET 2/2
35550 DRILL_VELO_LIMIT[0]…[5] 5 (S1)
- Maximum speeds for tapping RESET 2/2
36000 STOP_LIMIT_COARSE 2 (A3)
mm, degrees Exact stop coarse NEW CONF 2/2
36010 STOP_LIMIT_FINE 2 (A3)
mm, degrees Exact stop fine NEW CONF 2/2
36020 POSITIONING_TIME 2 (A3)
S Exact stop fine delay time NEW CONF 2/2
36030 STANDSTILL_POS_TOL 2 (A3)
mm, degrees Standstill tolerance NEW CONF 2/2
36040 STANDSTILL_DELAY_TIME 2 (A3)
S Standstill monitoring delay time NEW CONF 2/2
36050 CLAMP_POS_TOL 2 (A3)
mm, degrees Claming tolerance NEW CONF 2/2

36060 STANDSTILL_VELO_TOL 2 (A3)

mm/min, rpm Threshold velocity for axis stopped NEW CONF 2/2
0,01388 (rpm)
36100 POS_LIMIT_MINUS 2 (A3)
mm, degrees 1st software limit switch minus RESET 2/7
Always –100000000 *** *** DOUBLE
36110 POS_LIMIT_PLUS 2 (A3)
mm, degrees 1st software limit switch, plus RESET 2/7
Always 100000000 *** *** DOUBLE
36120 POS_LIMIT_MINUS2 2 (A3)
mm, degrees 2nd software limit switch minus RESET 2/7
Always –100000000 *** *** DOUBLE
36130 POS_LIMIT_PLUS2 2 (A3)
mm, degrees 2nd software limit switch, plus RESET 2/7
Always 100000000 *** *** DOUBLE
36200 AX_VELO_LIMIT[0]...[5] 2 (A3)
mm/min, rpm Velocity monitoring threshold value NEW CONF 2/7
Always 11500., 11500., 11500., *** *** DOUBLE
... (mm/min)
31,944; 31,944; 31,944;
31,944; ... (rpm)
36210 CTRLOUT_LIMIT 3 (G2)
% Maximum speed stepoint NEW CONF 2/7
Always 110.0 0 200 DOUBLE
36300 ENC_FREQ_LIMIT[0] 2 (A3)
Hz Encoder limit frequency POWER ON 2/2
Always 300000 *** *** DOUBLE
36302 ENC_FREQ_LIMIT_LOW[0] 8 (R1)
% Encoder limit frequency resynchronization (at which encoder is switched on NEW CONF 2/2
again (hysteresis))
Always 99.9 0 100 DOUBLE
36310 ENC_ZERO_MONITORING 2 (A3)
- Zero mark monitoring NEW CONF 2/2
Always 0 *** ***v DWORD
36400 CONTOUR_TOL 2 (A3)
mm, degrees Contour monitoring tolerance band NEW CONF 2/2
36500 ENC_CHANGE_TOL 16 (K3)
mm, degrees Position actual-value switching tolerance NEW CONF 2/2
36600 BRAKE_MODE_CHOICE 2 (A3)
- Brake behavior at hardware limit switch POWER ON 2/2
Always 0 0 1 BYTE
36610 AX_EMERGENCY_STOP_TIME 2 (A3)
S Time of braking ramp in case of errors NEW CONF 2/2
Always 0.05 0.02 1000 DOUBLE
36620 SERVO_DISABLE_DELAY_TIME 1 (N2)
S Cutout delay controller enable NEW CONF 2/2
Always 0.1 0.02 1000 DOUBLE
36710 DRIFT_LIMIT[0] K3
% Limit value for automatic drift compensation NEW CONF 2/7
36720 DRIFT_VALUE[0] S3
% Drift base value NEW CONF 2/2
Always 0.0 -5.0 5.0 DOUBLE
37000 FIXED_STOP_MODE F1
- Mode “Traversing to fixed stop” POWER ON 2/7
Traversing to 0 0 1 BYTE
fixed stop
37002 FIXED_STOP_CONTROL F1
- Sequence control when traveling to fixed stop POWER ON 2/7
fixed stop
37010 FIXED_STOP_TORQUE_DEF F1
% Fixed stop clamping torque default setting POWER ON 2/7
Traversing to 5.0 0.0 100 DOUBLE
fixed stop
37012 FIXED_STOP_TORQUE_RAMP_TIME F1
s Time until the changed torque limit is reached NEW CONF 2/7
Traversing to 0.0 0.0 plus DOUBLE
fixed stop
37020 FIXED_STOP_WINDOW_DEF F1
mm, degrees Fixed stop monitoring window default setting NEW CONF 2/7
fixed stop

37030 FIXED_STOP_THRESHOLD F1
mm, degrees Threshold for fixed stop detection NEW CONF 2/7
fixed stop
37040 FIXED_STOP_BY_SENSOR F1
- Fixed stop detection via sensor NEW CONF 2/7
fixed stop
37050 FIXED_STOP_ALARM_MASK F1
- Enabling of the fixed-stop alarm NEW CONF 2/7
fixed stop
37060 FIXED_STOP_ACKN_MASK F1
- Marking of PLC acknowledgment:0-not wait；1-wait; 3-analog drive POWER ON 2/7
fixed stop
37610 PROFIBUS_CTRL_CONFIG P6
- Profibus control bit configuration POWER ON 2/7
Always 0 0 1 BYTE
37620 PROFIBUS_TORQUE_RED_RESOL
% Resolution of Profibus torque reduction POWER ON
Always 1 0.01 10.0 DOUBLE
38000 MM_ENC_COMP_MAX_POINTS[0] 16 (K3)
- Intermediate points for encoder/spindle compensation (SRAM)) POWER ON 1/7

C65 PLC Instruction List
1 List of PLC Instructions

Notes
Appendix – PLC instruction set SINUMERIK 802D sl
12. PLC Instruction Set
BASIC BOOLEAN INSTRUCTIONS BYTE COMPARES (signed byte)
Instruction Ladder Valid Operands Instruction Ladder Valid Operands
Symbol Symbol
Normal open Bit n n: V, I, Q, M, SM, C, T Byte == Operand a a,b: VB, IB, QB, MB,
n=1 close a = b close AC, K
==B
n=0 open a ≠ b open Where K is constant
Operand b
Normal close n: V, I, Q, M, SM, C, T a,b: VB, IB, QB, MB,
n=0 close
Bit n
Byte >= Operand a
a >= b close AC, K
n=1 open >=B
a < b open
Operand b
Bit output Bit n n: V, I, Q, M, C, T
prior 0, n=0 Byte <= Operand a a,b: VB, IB, QB, MB,
prior 1, n=1 a <= b close AC, K
<=B
a > b open
Set n: V, I, Q, M, C, T Operand b
Bit n
prior 0, not set m: 1 WORD COMPARES (signed word)
prior 1 or Ê, S
n set 1 Instruction Ladder Valid Operands
m
Reset n: V, I, Q, M, C, T Symbol
Bit n
Prior 0, no m: 1 Word == Operand a a,b: VW, IW, QW, MW,
reset R a = b close AC, K
==W
Prior 1 or Ê, m a ≠ b open
n reset 0 Operand b
Edge Up Word >= Operand a a,b: VW, IW, QW, MW,
prior Ê close a >= b close AC, K
(1 PLC cycle) P >=W
a < b open
Operand b
Edge Down
prior Ì close Word <= Operand a a,b: VW, IW, QW, MW,
(1 PLC cycle) N a <= b close AC, K
<=W
a > b open
Logical Not operand b
prior 0, later 1 NOT

prior 1, later 0 DOUBLE WORD COMPARES (signed double)
Instruction Ladder Valid Operands
Instructions (timer and counter) Symbol
Instruction Ladder Valid Operands == Operand a a,b: VD, ID, QD, MD,
Symbol a = b close AC, K
==D
Timer T xxx
EN: V, I, Q, M, SM, C, T a ≠ b open
b
Retentive TONR
PT: VW,IW,QW,MW,AC,
Operand
EN=1, Start EN ENO

K DWord >= Operand a a,b: VD, ID, QD, MD,
EN=0, Stop a >= b close AC, K
PT
If TValue>=PT, >=D
a < b open
Tbit=1 Operand b
Timer On EN: V, I, Q, M, SM, C, T
T xxx
DWord <= Operand a a,b: VD, ID, QD, MD,
Delay TON
PT: VW,IW,QW,MW,AC, a <= b close AC, K
EN=1, Start EN ENO <=D
K a > b open
EN=0, Reset
PT Operand b
If TValue>=PT,
Tbit=1 REAL WORD COMPARES (signed real)
Count up EN: V, I, Q, M, SM, C, T
C xxx Instruction Ladder Valid Operands
CU Ê, value
counted +1
CTD R : V, I, Q, M, SM, C, T Symbol
CU ENO
Rword == Operand a a,b: VD, ID, QD, MD,
R=1, reset PT: VW,IW,QW,MW,AC, a = b close AC, K
R K ==R
If Cvalue>=PV, a ≠ b open
PV
Cbit=1 Operand b
Count EN: V, I, Q, M, SM, C, T Rwod >= Operand a a,b: VD, ID, QD, MD,
C xxx
up/down a >= b close AC, K
CTUD R : V, I, Q, M, SM, C, T >=R
CU Ê,value a < b open
CU ENO
counted +1 Operand b
CD PT: VW,IW,QW,MW,AC,
CD Ê, value R K Rword <= Operand a a,b: VD, ID, QD, MD,
counted -1 AC, K
PV a <= b close
R=1, reset <=R
a > b open
If Cvalue>=PV,
Operand b
Cbit=1

SINUMERIK 802D sl Appendix – PLC instruction set
Arithmetic Instructions Logic Instructions

Instruction Ladder Symbol Valid Operands Instruction Ladder Symbol Valid Operands
Word EN: V, I, Q, M, SM, C, T Byte EN: V, I, Q, M, SM, C, T
ADD_I WAND_B
Add IN1/IN2: VW,IW,QW,MW,
EN ENO EN ENO IN1/IN2: VB,IB,QB,MB,AC,
AC,T ,C,K(<±215-1) "AND" K(<28)
If EN =1, IN1 IN1
OUT: VW,QW,MW,T,C,AC OUT: VB,QB,MB,AC
OUT=IN1 + IN2 IN2 OUT
If EN =1, IN2 OUT
EN: V, I, Q, M, SM, C, T OUT=IN1 & IN2

DWord EN: V, I, Q, M, SM, C, T
ADD_DI Word
Add EN ENO IN1/IN2: VD, ID, QD, MD,
WAND_W
AC, K(<±231-1) EN ENO IN1/IN2: VW, IW, QW, MW,

If EN =1, IN1 "AND" AC, K(<216)
OUT: VD, QD, MD, AC IN1
OUT=IN1 + IN2 IN2 OUT OUT: VW, QW, MW, AC
If EN =1, IN2 OUT
Rword EN: V, I, Q, M, SM, C, T OUT=IN1 & IN2

ADD_R
Add DWord EN: V, I, Q, M, SM, C, T
EN ENO IN1/IN2: VD, ID, QD, MD, WAND_DW
AC, K EN ENO IN1/IN2: VD, ID, QD, MD,
If EN =1, IN1
"AND"
OUT=IN1 + IN2
OUT: VD, QD, MD, AC
IN1
AC, K(<232)
IN2 OUT
OUT: VD, QD, MD, AC
EN: V, I, Q, M, SM, C, T If EN =1, IN2 OUT
Word OUT=IN1 & IN2
SUB_I
EN ENO IN1/IN2: VW,IW,QW,MW, Byte EN: V, I, Q, M, SM, C, T
Subtract AC,T ,C,K(<±215-1) "OR"
WOR_B
IN1
OUT: VW,QW,MW,T,C,AC EN ENO IN1/IN2: VB,IB,QB,MB,AC,
If EN =1, IN2 OUT K(<28)
If EN =1, IN1
OUT: VB,QB,MB,AC
OUT=IN1 - IN2 OUT=IN1 & IN2 IN2 OUT
SUB_DI
Subtract Word EN: V, I, Q, M, SM, C, T
EN ENO IN1/IN2: VD, ID, QD, MD, WOR_W
AC, K(<±231-1) "OR" EN ENO IN1/IN2: VW, IW, QW, MW,
If EN =1, IN1
OUT=IN1 - IN2
OUT: VD, QD, MD, AC AC, K(<216)
IN2 OUT If EN =1, IN1
OUT: VW, QW, MW, AC
OUT=IN1 & IN2 IN2 OUT
RWord EN: V, I, Q, M, SM, C, T
SUB_R
Subtract DWord EN: V, I, Q, M, SM, C, T
EN ENO IN1/IN2: VD, ID, QD, MD, WOR_DW
AC, K "OR" EN ENO IN1/IN2: VD, ID, QD, MD,
If EN =1, IN1
OUT=IN1 - IN2
OUT: VD, QD, MD, AC AC, K(<232)
IN2 OUT If EN =1, IN1
OUT: VD, QD, MD, AC
OUT=IN1 & IN2 IN2 OUT
Word EN: V, I, Q, M, SM, C, T
MUL
Multiply Byte EN: V, I, Q, M, SM, C, T
EN ENO IN1/IN2: VW,IW,QW,MW, WXOR_B
If EN =1, IN1
AC,T ,C ,K(<±215-1) EN ENO IN1/IN2: VB,IB,QB,MB,AC,
OUT=IN1 * IN2 OUT: VD, QD, MD, AC "XOR" K(<28)
IN2 OUT IN1
OUT: VB,QB,MB,AC
EN: V, I, Q, M, SM, C, T If EN =1, IN2 OUT
RWord OUT=IN1 & IN2
MUL_R
Multiply EN: V, I, Q, M, SM, C, T
EN ENO IN1/IN2: VD, ID, QD, MD, Word
WXOR_W
If EN =1, IN1
AC, K
OUT: VD, QD, MD, AC EN ENO IN1/IN2: VW, IW, QW, MW,
OUT=IN1 * IN2 IN2 OUT "XOR" AC, K(<216)
IN1
OUT: VW, QW, MW, AC
Word EN: V, I, Q, M, SM, C, T If EN =1, IN2 OUT
DIV
Divide OUT=IN1 & IN2
EN ENO IN1/IN2: VW,IW,QW,MW, EN: V, I, Q, M, SM, C, T
DWord
AC,T ,C,K(<±215-1) WXOR_DW
If EN =1, IN1
OUT: VD, QD, MD, AC EN ENO IN1/IN2: VD, ID, QD, MD,
OUT=IN1 / IN2 IN2 OUT
"XOR" AC, K(<232)
IN1
RWord EN: V, I, Q, M, SM, C, T OUT: VD, QD, MD, AC
DIV_R If EN =1, IN2 OUT
Divide EN ENO IN1/IN2: VD, ID, QD, MD, OUT=IN1 & IN2
AC, K Byte EN: V, I, Q, M, SM, C, T
If EN =1, IN1
OUT: VD,QD,MD,AC INV_B
OUT=IN1 / IN2 IN2 OUT EN ENO IN: VB, IB, QB, MB, AC,
"Negated" K(<28)
Square root EN: V, I, Q, M, SM, C, T OUT: VB, QB, MB, AC
SQRT
If EN =1, IN OUT
EN ENO IN1/IN2: VD, ID, QD, MD, OUT=IN1 & IN2
If EN =1, AC, K(<±231-1) EN: V, I, Q, M, SM, C, T
OUT: VD, QD, MD, AC
Word
OUT=√ IN INV_W
IN OUT
EN ENO IN: VW, IW, QW, MW, AC,
"Negated" K(<216)
OUT: VW, QW, MW, AC
If EN =1, IN OUT
OUT=IN1 & IN2

INV_DW
EN ENO IN: VD, ID, QD, MD, AC,
"Negated" K(<232)
OUT: VD, QD, MD, AC
If EN =1, IN OUT
OUT=IN1 & IN2

Appendix – PLC instruction set SINUMERIK 802D sl
Approach a Conditional /
subroutine RET Unconditional
INCREMENT, DECREMENT
SHIFT OPERATIONS
Symbol
EN: V, I, Q, M, SM, C, T Instruction Ladder Valid Operands
Byte INC_B
Symbol
EN ENO
IN: VB, IB, QB, MB, AC, Byte EN: V, I, Q, M, SM, C, T
Increment K(<28) SHL_B
OUT: VB, QB, MB, AC Shift Left EN ENO IN : VB, IB, QB, MB, AC,
IN OUT
If EN Ê, K(<28)
IN OUT
OUT = IN + 1 If EN Ê , n: VB, IB, QB, MB, AC, K
Word EN: V, I, Q, M, SM, C, T OUT=IN <<n n
OUT: VB, QB, MB, AC
INC_W
bits
EN ENO
IN: VW, IW, QW, MW, AC, Word EN:V, I, Q, M, SM, C, T
Increment T, C, K(<216) SHL_W
OUT: VW, QW, MW, AC Shift Left EN ENO IN :VW, IW, QW, MW, AC,
IN OUT
If EN Ê, T, C, K(<28)
IN OUT
DWord EN: V, I, Q, M, SM, C, T OUT=IN <<n n
OUT: VW, QW, MW, AC
INC_DW
bits
EN ENO
IN: VD, ID, QD, MD, AC, DWord EN: V, I, Q, M, SM, C, T
Increment K(<232) SHL_DW
OUT: VD, QD, MD, AC Shift Left EN ENO IN : VD, ID, QD, MD, AC,
IN OUT
If EN Ê, K(<216)
IN OUT
Byte EN: V, I, Q, M, SM, C, T OUT=IN <<n n
OUT: VD, QD, MD, AC
DEC_B
bits
EN ENO
IN: VB, IB, QB, MB, AC, Byte EN: V, I, Q, M, SM, C, T
Decrement K(<28) SHR_B
OUT: VB, QB, MB, AC Shift Right EN ENO IN : VB, IB, QB, MB, AC,
IN OUT
If EN Ê, K(<28)
IN OUT
Word EN: V, I, Q, M, SM, C, T OUT=IN <<n n
OUT: VB, QB, MB, AC
DEC_W
bits
EN ENO
IN: VW, IW, QW, MW, AC, Word EN:V, I, Q, M, SM, C, T
Decrement T, C, K(<216) SHR_W
OUT: VW, QW, MW, AC Shift Right EN ENO IN :VW, IW, QW, MW, AC,
IN OUT
If EN Ê, T, C, K(<28)
IN OUT
DWord EN: V, I, Q, M, SM, C, T OUT=IN <<n n
OUT: VW, QW, MW, AC
DEC_DW bits
EN ENO IN: VD, ID, QD, MD, AC, DWord EN: V, I, Q, M, SM, C, T
Decrement K(<232) SHR_DW
OUT: VD, QD, MD, AC Shift Right EN ENO IN : VD, ID, QD, MD, AC,
If EN Ê, IN OUT
K(<216)
IN OUT
CONVERTION OPERATIONS OUT=IN <<n n
OUT: VD, QD, MD, AC
bits
Assignment Instructions
Symbol
EN: V, I, Q, M, SM, C, T Instruction Ladder Valid Operands
Convert an
DI_REAL Symbol
Integer to ENO IN : VD, ID, QD, MD, AC,
EN
Byte EN: V, I, Q, M, SM, C, T
A Real K(<232) MOV_B
If EN =1, OUT: VD, QD, MD, AC Assign EN ENO IN : VB, IB, QB, MB, AC,
OUT= float (IN) IN OUT
K(<28)
EN: V, I, Q, M, SM, C, T If EN =1 , OUT: VB, QB, MB, AC
Convert an OUT= IN IN OUT
TRUNC
Integer to ENO IN : VD, ID, QD, MD, AC,
EN
Word EN: V, I, Q, M, SM, C, T
A Real K(<232) MOV_W
If EN =1, OUT: VD, QD, MD, AC Assign EN ENO IN : VW,IW,QW,MW,AC,
OUT= trunc (IN) IN OUT
T, C, K(<216)
If EN =1 , OUT: VW, QW, MW, AC
PROGRAM CONTROL INSTRUCTION OUT= IN IN OUT
Instruction Ladder Valid Operands EN: V, I, Q, M, SM, C, T

DWord
Symbol MOV_DW
Assign EN ENO IN : VD, ID, QD, MD, AC,
Jump to Label Conditional
K(<232)
Label JMP If EN =1 , OUT: VD, QD, MD, AC
If prior =1 OUT= IN IN OUT
Label Label Constant RWord EN: V, I, Q, M, SM, C, T

marker for LBL Range: 0...127 Assign
MOV_R
the jump EN ENO IN : VD, ID, QD, MD, AC,

K(<232)
Call a A maximum of 16- If EN =1 , OUT: VD, QD, MD, AC
SBR Name
subroutine EN Po 1
byte local data OUT= IN IN OUT
Pi1 Po m
If EN=1
Pin

SINUMERIK 802D sl Appendix – PLC instruction set
Byte EN: V, I, Q, M, SM, C, T
SWAP
exchange EN ENO IN : VW, IW, QW, MW, AC,
T, C, K(<216)
If EN =1 ,
IN High & Low IN
Byte exchange

C62 Component mounting dimensions
1 Mounting dimensions
Notes
SINUMERIK 802D sl Appendix – Dimension of components
9. Dimension of Components
Drawing dimension for the CNC Operator panel (PCU)

1) Required free space for assembly
Fig.1
Copyright © Siemens AG All Rights Reserved70

Appendix – Dimension of components SINUMERIK 802D sl
Drilling pattern for the CNC operator panel (PCU)

1) M4 (8x) or holes ø 5 (8x)
2) Maximum torque for tightening screw: 1.8Nm
Fig. 2

Dimension drawing for MCP

Fig. 3

Maximum torque for tightening screw: 1.8Nm
Drilling pattern for the machine control panel

Fig. 4

SINUMERIK 802D sl
Copyright © Siemens AG All Rights Reserved

74
Appendix – Dimension of components
5 7 Dimension
Fig.Fig. drawing for the NC full keyboard (vertical)
Drawing dimension for the NC full key baord

Dimension drawing for the NC full keyboard (vertical)

Fig. 6

Dimension drawing for the NC full keyboard (horizontal)

Fig. 7

SINUMERIK 802D sl
Copyright © Siemens AG
All Rights Reserved78
Appendix – Dimension of components
Fig. 8 Drilling pattern for the NC full keyboard (horizontal)


Drawing dimension for the PP 72/48 I/O module

Fig. 9

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SINUMERIK 802D solution line

Machine Commissioning Handbook

Training Manual Edition 2006.7

System overview C60 Install additional axis C16

 Graphic overview of 802D sl CNC system

Graphic overview of Section 2

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 1 C60

1 – S1 Upright format: 6FC5303-0DT12-1AA0

Analog spindle speed set point

PROFIBUS cable:  100 m 328 ft 6XV1 830-0EH10 (unit: meter)

2-axes 1-axis 50-pin ribbon strip

Active line Motor module

Filter (power section) (power section) Terminal

Servo motor signal cable: 6FX5002-2DC10-10

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 2 C60

In combination with SIMOTION or SINUMERIK, it is possible to configure expansion boards. These

 Basics of SINAMICS MICROMASTER SIZER

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 1 C04

S ta rt th e p ro g ra m a n d cre a te a n e m p ty p ro je ct via “P ro je ct” “N e w … ”.

Figure C4-1 - Creating a project

Figure C4-2 - User interface

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 2 C04

Figure C4-3 - Workflow

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 3 C04

V ia th e o b je ct ite m “S yste m co m p o n e n ts”, th e sp e cific se ttin g s fo r th e re -

Figure C4-5 - Drive system

Figure C4-6 - Double motor module

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 4 C04

As a result of your configuration, all required information is displayed in a

Figure C4-7 - Dimensioned drawings motor

Figure C4-8 - 3D view motor

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 5 C04

Smart Line Modules

Active Line Modules

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 1 C51

In the case of SINAMICS with a Smart Line Module, the line-commutated

Smart Line Module

The SLM provides the motor with a non-stabilized DC voltage at the DC

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 2 C51

Terminal block X21 Smart Line Module

Terminal block X22 Smart Line Module

Terminal block X24 Smart Line Module - 24 V terminal adapter

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 3 C51

Active Line Module

The capability of energy regeneration of the module can be deactivated via

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 4 C51

Terminal block X1 Active Line Module 16 kW network connection Notes

Terminal block X1 Active Line Module 26 to 120 kW network connection

X200-X202 - Drive-CliQ interface

Terminal block X21 - EP terminal

Terminal block X24 - 24 V terminal adapter

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 5 C51

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 6 C51

The procedure used to install these tools is described here:

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 1 C2

The following software is contained on the CD:

The software contained on the CD should be installed on the

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 2 C2

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 3 C2

SINUMERIK 802D sl 1st Commissioning, Training Manual Page 4 C2

Section 3 Transfer data from the controller

3.1 Transfer data from the controller

SINUMERIK 802D sl Operating and Service Training Manual Page 5 C1

SINUMERIK 802D sl Operating and Service Training Manual Page 6 C1