Signal 840c

SINUMERIK 840C
Software Version 1 to 6
Planning Guide 09.2001 Edition
Interface Description
Part 1: Signals
Manufacturer Documentation
SINUMERIK 840C
Software Version 1 to 6
Interface Description
Part 1: Signals
Planning Guide
Valid for:
Control SINUMERIK 840C/CE

Drive SIMODRIVE 611-D
Standard export version
Software Version Software Version
1.x
2.x
3.x 1.x
4.x 2.x
5.x 3.x
6.x 4.x
09.2001 Edition
SINUMERIK® documentation
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the ”Remarks” column.
Status code in ”Remarks” column:
A . . . New documentation
B . . . Unrevised reprint with new Order No.
C . . . Revised edition with new status.
If factual changes have been made on the page since the last edition, this is
indicated by a new edition coding in the header on that page.
Edition Order No. Remarks

11.92 6FC5197-0AA00-1BP0 A
06.93 6FC5197-2AA00-0BP0 C
12.93 6FC5197-3AA00-0BP0 C
10.94 6FC5197-4AA00-0BP0 C
03.95 6FC5197-4AA00-0BP1 C
09.95 6FC5197-5AA00-0BP0 C
04.96 6FC5197-5AA00-0BP1 C
08.96 6FC5197-5AA00-0BP2 C
07.97 6FC5197-6AA00-0BP0 C
01.99 6FC5197-6AA00-0BP1 C
09.01 6FC5197-6AA00-0BP2 C
This manual is included in the documentation available on CD-ROM (DOCONCD)

Edition Order No. Remarks
10.01 6FC5198-6CA00-0BG2 C
Trademarks
SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIROTEC®, SINUMERIK® and SIMODRIVE® are trade-
marks of Siemens AG. All other product and system names are registered trademarks of their
respective companies and must be treated accordingly.
Other functions not described in this documentation might be

executable in the control. This does not, however, represent an
For more information, refer to the Internet: obligation to supply such functions with a new control or when
http://www.ad.siemens.de/sinumerik servicing.
The publication was produced on the Siemens 5800 Office System. We have checked that the contents of this publication agree with
the hardware and software described herein. The information given
The reproduction, transmission or use of this document or its in this publication is reviewed at regular intervals and any
contents is not permitted without express written authority. corrections that might be necessary are made in the subsequent
Offenders will be liable for damages. All rights, including created by printings. Suggestions for improvement are welcome at all times.
patent grant or registration of a utility model or design, are reserved,
Subject to change without prior notice.
© Siemens AG 1992-2001
All Rights Reserved
Order No. 6FC5197-6AA00-0BP2 Siemens-Aktiengesellschaft

Printed in the Federal Republic of Germany
Preliminary Remarks
Notes for the reader
This manual is intended for manufacturers of machine tools with SINUMERIK 840C. It
describes the installation and cabling between control and machine as well as the signals
between PLC and machine.
The SINUMERIK documentation falls into four groups:
• General Documentation
• User Documentation
• Manufacturer Documentation
• Service Documentation
The Manufacturer Documentation for the SINUMERIK 840C control is divided into the
following parts:
• Instruction Manual
• Interface
Part 1: Signals
Part 2: Connection Conditions
• Planning Guide PLC 135 WB/WB 2/WD
• Function Macros
• Function Blocks
Package 0: Basic Functions
Package 1: Tool Management
Package 4/5: Computer Link
Package 7: Code Carrier
Package 8: PLC-controlled data input and output
Further SINUMERIK publications apply to all SINUMERIK controls (e.g. Universal Interface,
Measuring Cycles, CL 800 Cycle Language).
Consult your local Siemens office for further details.
Technical notes
• In the signal charts, the interface signals are represented by thick lines. Thin lines
represent signals symbolically or refer to internal messages.
• Signals designated with a * are so-called inverse signals, i.e. a 0 signal has an effect rather
than a 1 signal (e.g. *TEMPERATURE ERROR).
Where order numbers are given with a as placeholder, this indicates that there are several
versions available of one component.
This Guide is valid up to and including Software Version 6!

Safety-related guidelines
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WARNING
Hazardous voltages are present in this electrical equipment during
operation.
Persons who are not qualified should not be allowed to handle the
equipment/system. Non-compliance with the warnings can result in
severe personal injury or damage to property. Only qualified
personnel familiar with the installation, construction, commissioning
and operation of the equipment should be allowed to work on this
equipment/system.
Qualified personnel
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WARNING
Qualified personnel as referred to in the safety guidelines (contained
in the documentation or on the product labels) are persons who have
the following qualifications:
• Are trained and authorized to energize, de-energize, clear, ground
and tag circuits and equipment in accordance with established
safety practices.
• Are trained in the proper care, use and repair of protective
equipment in accordance with established safety practices.
• Are trained in the use of electrostatic sensitive components and
modules.
• Operating personnel who have been trained to work with
automation equipment and are conversant with the contents of
the operating and/or programming instructions in as far as they
are connected with the actual operation of the plant.
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Anyone engaged in configuring, installation, commissioning

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and repair of the control must be familiar
with the relevant documentation.

Danger notices
The notices and guidelines that follow are intended to ensure personal safety, as well as
protect the product and connected equipment and machines against damage.
The safety notices and warnings for protection against loss of life (of the users or service
personnel) or for protection against damage to property are highlighted in this document by the
terms defined here. The terms used in this document and marked on the equipment itself have
the following significance:
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DANGER
For the purpose of this document and the product labels, "Danger"
indicates that death, severe personal injury or substantial property
damage will result if proper precautions are not taken.
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WARNING
For the purpose of this document and the product labels, "Warning"
indicates that death, severe personal injury or substantial property
damage can result if proper precautions are not taken.
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CAUTION
For the purpose of this document and the product labels, "Caution"
indicates that minor personal injury or property damage can result if
proper precautions are not taken.
CAUTION
This warning notice (without warning triangle) means that a material
damage can result if the appropriate precautions are not taken.
NOTICE
This warning notice means that an undesired event or an undesired
state can result if the appropriate notices are not observed.
”Note" contains important information
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about the product, its operation or a part of the document
to which special attention is drawn.
Proper usage
• The equipment/system or the system components may only be used for the applications
described in the catalog or the technical description, and only in combination with the
equipment, components and devices of other manufacturers as far as this is
recommended or permitted by Siemens.
• The product described has been developed, manufactured, tested and the documentation
compiled in keeping with the relevant safety standards. Consequently, if the described
handling instructions and safety guidelines described for planning, installation, proper
operation and maintenance are adhered to, the product, under normal conditions, will not
be a source of danger to property or life.
Active and passive faults in automation equipment

• Depending on the particular task for which the electronic automation equipment is used,
both active as well as passive faults can result in a dangerous situation. For example, in
drive control, an active fault is generally dangerous because it can result in unauthorized
starting of the drive. On the other hand, a passive fault in a signalling function can result in
a dangerous operating state not being reported to the operator.
• This differentiation of the possible faults and their classification into dangerous and non-
dangerous faults, depending on the particular task, is important for all safety considerations
in respect to the product supplied.
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WARNING
Wherever a fault in automation equipment can result in severe
personal injury or substantial damage to property, i.e. wherever a
dangerous fault can occur, additional external measures must be
taken or equipment provided to ensure or force safe operating
conditions, even in the event of a fault (e.g. by means of independent
limit monitors, mechanical interlocks, etc.).
Guidelines for the planning of the product

The product generally forms a part of larger systems or plants. These guidelines are intended
to help integrate the product into its environment without it constituting a source of danger.
The following requires particular attention:
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Even when a high degree of safety has been included in the design of
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automation equipment, e.g. by means of multichannel configuration, it is

still imperative that the instructions contained in the documentation be
exactly adhered to. Incorrect handling can render ineffective the
preventive measures incorporated in the system to protect against
dangerous faults or new sources of danger might be created.
Further notes
If measurement or testing work is to be carried out on an active item of equipment, the rules
and regulations contained in the "VBG 4.0 Accident prevention regulations" of the German
employers liability assurance association (Berufsgenossenschaften) must be observed.
Particular attention is drawn to paragraph 8 "Permissible exceptions when working on live
parts". Only suitable electrical tools should be used.
WARNING
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• Repairs to equipment supplied by us may only be carried out by

Siemens service personnel or repair shops authorized by
Siemens to carry out such repairs. For replacement purposes,
use only parts or components that are contained in the spare
parts list. Unauthorized opening of equipment and improper
repairs can result in loss of life or severe personal injury as well
as substantial property damage.
• Before opening the equipment, always remove the power plug or
open the disconnecting switch.
• When replacing fuses, only use the fuse types specified.
• Do not throw batteries into an open fire and do not carry out any
soldering work on batteries (danger of explosion). Maximum
ambient temperature 100°C. Batteries should not be opened or
recharged. Make sure that the same type is used when replacing
batteries.
• Batteries must always be disposed of properly.
• The following points require attention when using monitors:
Improper handling, especially the readjustment of the high voltage
or fitting of another tube type can result in excessive X-ray
radiation from the unit. The license to operate such a modified
unit automatically lapses and the unit must not be operated at all.
General Overview 1
Assigned Areas 2
Description of Basic Signals FY 0 ... FY 24 3
NCK Channel/PLC Interface (DB 10 ... DB 13) as from SW 4 DB 15 4
Spindle/PLC Interface (DB 31) 5
Axis/PLC Interface (DB 32 / DB 29) 6
Data Transfer PLC/NC (DB 36 / DB 29) 7
Control of Data Transfer (DB 37) 8
Operator Panel Interface (DB 40) 9
Command Channel (DB 41) 10
Communication Area NC/PLC Interface (DB 48) 11
Display Programs for PLC Data and Messages

up to SW 2 12
Display of PLC Alarms, Messages

and Dialogs as from SW 3 13
PLC Machine Data (PLC MD) 14
Data Blocks Installed for Users (DB 66 ... DB 71) 15
Alphabetical List of Signal Names 16
Terms and Abbreviations 17

Contents
1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1 Control structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1.1 Components of SINUMERIK 840C . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.1.2 NCK area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1.1.3 MMC area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.1.4 PLC area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.1.5 PLC-machine interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.2 PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.2.1 Tasks of the PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.2.2 Structure of the PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.2.2.1 PLC operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
1.2.2.2 Difference between dynamic and static signals . . . . . . . . . . . . . . . . . . 1–13
1.2.3 Reaction to interrupt and alarm signals . . . . . . . . . . . . . . . . . . . . . . . . 1–13
2 Assigned Areas ....................................... 2–1
2.1 Flags, data formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.2 Class DB/DX data blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.3 Function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.3.1 Class FB function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.3.2 Class FX function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.4 Basic signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.4.1 Assignment of DB 1 (diagnostics) (Section 3.6) . . . . . . . . . . . . . . . . . . 2–13
2.4.2 High-speed data channels (as from SW 4) . . . . . . . . . . . . . . . . . . . . . 2–16
2.4.2.1 DB 2 Configuration DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
2.4.2.2 DB 3 Data transfer areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
2.5 NCK/PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
2.5.1 Channel-specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
2.5.1.1 Signals to NCK channel (DB 10 ... DB 13, as from SW 4 DB 15) ..... 2–18
2.5.1.2 Signals from NCK channel (DB 10...DB 13, as from SW 4 DB 15) .... 2–20
2.5.1.3 Auxiliary functions from NCK channel (DB 10 ... DB 13,
as from SW 4 DB 15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
2.5.1.4 Axis-specific Safety Integrated signals (DB28) (as from SW 5.4) . . . . . . 2–29
2.5.1.5 Axis-specific GI signals (DB 29) 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
2.5.1.6 Axis-specific 611-D signals (DB 29) . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
2.5.1.7 M signals (DB 30) decoded according to list . . . . . . . . . . . . . . . . . . . . 2–32
2.5.2 Spindle-specific signals (DB 31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–33
2.5.2.1 Signals from spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–33
2.5.2.2 Signals to spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–33
2.5.2.3 Spindle-specific GI signals from spindle . . . . . . . . . . . . . . . . . . . . . . . 2–34
2.5.2.4 Spindle-specific GI signals to spindle . . . . . . . . . . . . . . . . . . . . . . . . . 2–34
2.5.2.5 Star-delta switchover, 611D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35
2.5.3 Axis-specific signals (DB 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37
2.6 Data transfer interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
2.6.1 Data transfer PLC/NCK (DB 36) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
2.6.2 Control of data transfer (DB 37) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40
2.7 Operator panel/PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41
2.7.1 Key signals from operator panel (DB 40) . . . . . . . . . . . . . . . . . . . . . . 2–41
2.7.2 Display dialog line (DB 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43
2.7.3 Menu selection (DB 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–44
2.7.4 Cursor data (DB 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45
2.7.5 User key signals (DB 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
2.7.6 Command channel interface (DB 41) . . . . . . . . . . . . . . . . . . . . . . . . . 2–48
2.8 General interface NCK/PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–50
2.8.1 Signals to/from NCK (DB 48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–50
2.9 PLC messages (DB 58) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–52
2.9.1 Softkey function calls DB 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–56
2.10 PLC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–57
2.11 Configuring distributed machine peripherals (DMP) . . . . . . . . . . . . . . . 2–58
2.12 Set-up DBs for users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–68
2.12.1 Icon selection in the MMC (DB 66) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–68
2.12.2 Internal machine control panel (DB 67) . . . . . . . . . . . . . . . . . . . . . . . . 2–70
2.12.3 Data words for users (DB 68) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–70
2.12.4 Data bits for users (DB 71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–71
2.13 Decoding list for M signals (DB 80 ... DB 83) ................... 2–71
3 Description of Basic Signals FY 0...FY 24 .................... 3–1
3.1 PLC auxiliary signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3.2 PLC ready signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3.3 Signals for alarm-controlled machining . . . . . . . . . . . . . . . . . . . . . . . . 3–7
3.4 NC ready signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.5 Individual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.6 Diagnostics (DB 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
4 NCK Channel/PLC Interface (DB 10 ... DB 13, as from SW 4 DB 15) 4–1
4.1 SINUMERIK 840C terms and structure ....................... 4–1

4.1.1 Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.2 Operating mode group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.3 Channel-specific interface signal exchange . . . . . . . . . . . . . . . . . . . . . 4–4
4.2 Signals to NCK channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.2.1 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.2.2 Feedrate modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.2.3 Program control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
4.2.4 General feed disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
4.2.5 Read-in disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22
4.2.6 NC Start disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23
4.3 Signals from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23
4.3.1 Program commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23
4.3.2 Select program control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
4.3.3 Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33
4.3.4 Ready signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–35
4.4 Output of auxiliary functions and block information . . . . . . . . . . . . . . . . 4–38
4.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–38
4.4.2 Behaviour in different modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39
4.4.3 Description of information signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4.4.4 T/H word routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.4.5 TEACH IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48
4.5 Structure of program coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–49
4.5.1 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–49
4.5.2 NCK/PLC user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–50
4.5.3 PLC function blocks FX 38, FX 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–51
5 Spindle/PLC Interface (DB 31) ............................ 5–1
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.2 Signals from spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.3 Signals to spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
5.4 Signals from following spindle to PLC, DB 31 for the GI function . . . . . . 5–23
5.5 Signals from PLC to following spindle for GI function . . . . . . . . . . . . . . 5–29
5.6 Interface signals for drive 611D (DB 29/DB31) . . . . . . . . . . . . . . . . . . 5–33
6 Axis/PLC Interface (DB 32/DB 29) .......................... 6–1
6.1 Signals from axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

6.2 Signals to axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.2.1 Signals for endlessly turning rotary axis . . . . . . . . . . . . . . . . . . . . . . . 6–24
6.3 Signals from following axis to PLC, DB 29 ..................... 6–27
6.3.1 Axis-specific 611D signals (DB 29) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–36
6.4 Structure of M decoding list (DB 30) ......................... 6–44
7 Data Transfer PLC/NC (DB 36) ............................ 7–1
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

7.1.1 Machine data (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.1.2 Tool offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.1.3 R parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.1.4 Zero offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
7.2 Data transfer PLC initiative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.2.1 Structure with example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.2.2 Description of job-specific interface signals . . . . . . . . . . . . . . . . . . . . . 7–14
7.3 Data transfer NC initiative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
8 Control of Data Transfer (DB 37) .......................... 8–1
8.1 Description of interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

8.2 Signals for PLC initiative data transfer . . . . . . . . . . . . . . . . . . . . . . . . 8–1
9 Operator Panel Interface (DB 40) .......................... 9–1
9.1 Key signals from operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2

9.1.1 Operating mode group (BAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
9.1.2 Softkey function signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
9.2 Display dialog line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
9.3 Menu selection interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
9.3.1 Softkey function calls DB 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–24
9.3.1.1 Overview of softkey function calls from PLC . . . . . . . . . . . . . . . . . . . . 9–26
9.3.1.2 Messages of softkey function calls . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–27
9.3.2 Signals from PLC to NCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–28
9.3.3 Signals from the NC to the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–31
9.4 Cursor data to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–32
9.5 User key signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34
10 Command Channel (DB 41) .............................. 10–1
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

10.2 Signals in the command channel header . . . . . . . . . . . . . . . . . . . . . . . 10–2
10.3 User interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3
10.4 Net data for command channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7
10.4.1 Net data of the path dimension function . . . . . . . . . . . . . . . . . . . . . . . 10–7
10.4.2 Net data for DIVISION function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8
10.4.3 Net data for S EXTERNAL function . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9
10.4.4 Net data for the M19 tsr function (incremental spindle positioning) . . . . . 10–11
10.4.5 Net data for the transformation function . . . . . . . . . . . . . . . . . . . . . . . 10–13
10.4.6 Net data for coupled motion function . . . . . . . . . . . . . . . . . . . . . . . . . 10–14
10.4.7 Net data of the ”Temperature compensation” function ............. 10–16
10.4.8 Net data of ”Read/write IKA data” function ..................... 10–18
10.4.9 Net data of ”Travel against fixed stop” function . . . . . . . . . . . . . . . . . . 10–25
10.5 Error codes, general errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
10.6 Error codes, function-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–29
10.6.1 Errors, function 1, path dimension, static . . . . . . . . . . . . . . . . . . . . . . . 10–29
10.6.2 Errors with function 2, division increment . . . . . . . . . . . . . . . . . . . . . . 10–30
10.6.3 Errors with function 3, S external . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31
10.6.4 Errors with function 5, M19 tsr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–32
10.6.5 Errors with function 6, transformation . . . . . . . . . . . . . . . . . . . . . . . . . 10–33
10.6.6 Errors with function 7, coupled motion . . . . . . . . . . . . . . . . . . . . . . . . 10–34
10.6.7 Errors with function 9, temperature compensation . . . . . . . . . . . . . . . . 10–35
10.6.8 Errors with function 10/11, ”Read/write IKA data” ................ 10–36
10.6.9 Errors with function 12, travel against fixed stop ................. 10–37
10.7 Detailed error coding with command channel error number 200 ...... 10–38
11 Communication Area NC/PLC Interface (DB 48) ............... 11–1
11.1 Signals to NCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

11.2 Signals from NCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8
12 Display Programs for PLC Data and Messages

up to Software Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
12.1 Structure of display programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1

12.1.1 Configuring of message texts in alarm lines and dialog boxes up to SW 2 12–3
12.1.1.1 Signal descriptions DB 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3
12.1.1.2 Configuring of alarm attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4
12.1.1.3 Configuring of dialog boxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5
12.1.1.4 Creating the text file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7
12.1.1.5 Possibilities of dialog box configuring . . . . . . . . . . . . . . . . . . . . . . . . . 12–8
12.1.1.6 Example of dialog box configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8
12.2 PLC status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
12.3 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11
12.3.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13
12.3.2 Operational messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14
12.3.3 Message groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15
12.3.4 Bit fields for messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16
12.3.5 Assigned areas for messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–19
12.3.6 PLC machine data for messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20
12.3.7 Creating message texts on the WS800A workstation . . . . . . . . . . . . . . 12–22
12.3.8 Creating PCF files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22
12.3.9 Loading and saving PCF files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23
12.3.10 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25
12.4 Interface message signals DB 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–27
13 Display of PLC Alarms, Messages and Dialogs as from SW 3 .... 13–1
13.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

13.2 Interface signals for alarms and messages . . . . . . . . . . . . . . . . . . . . . 13–2
13.3 Interface message signals B 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–5
13.3.1 Interface signals for dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–9
13.4 Configuring alarm/message/dialog texts and attributes . . . . . . . . . . . . . 13–9
13.4.1 Defining display attributes by means of the MELDATTR file . . . . . . . . . 13–9
13.4.2 Generating a MELDATTR user file . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–13
13.4.3 Configuring the attributes of the PLC user alarms/messages/dialogs . . . 13–15
13.4.4 Important notes on the configuration of dialog boxes . . . . . . . . . . . . . . 13–18
13.4.5 The MELDTEXT file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–18
13.4.6 Generating a MELDTEXT user file . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–19
13.4.7 Configuring the message texts for the PLC alarms/messages/dialogs . . 13–20
13.4.8 Number of text characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–21
13.4.9 Formattings in the text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–21
13.5 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–22
13.6 Conversion program ALT840C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–23
13.7 Example for alarm configuration, SW 3 . . . . . . . . . . . . . . . . . . . . . . . . 13–23
13.8 Generating of an info text file for the alarms and messages ......... 13–25
14 PLC Machine Data (PLC-MD) ............................. 14–1
15 Data Blocks Installed for Users (DB 66 ... DB 71) .............. 15–1
16 Alphabetical List of Signal Names ......................... 16–1
17 Terms and Abbreviations ................................ 17–1

11.92 1 General Overview
1.1 Control structure
1 General Overview
The following subsections are designed to provide an insight into the SINUMERIK 840C control
structure.
They describe:
• the division of SINUMERIK 840C into areas

• the tasks of the individual areas and
• they provide information on the mechanical design of the control.
The SINUMERIK 840C comprises three principal areas:

• the NCK (Numerical Control Kernel)
• the PLC (Programmable Logic Controller)
• the MMC area (Man Machine Communication)
The NCK area performs parts of the classic NC tasks, i.e. the workpiece program execution by
means of block processing and interpolation, and axis and spindle actuation via the position
controllers.
The PLC area represents the machine's interface control and controls machine-specific
function procedures for the auxiliary axes, tool magazines and monitoring devices.
The display and operating functions as well as the master control of the MMC operating modes
are implemented in the MMC area (see diagram).
© Siemens AG 1992 All Rights Reserved 6FC5197- AA00 1–1

SINUMERIK 840C (PJ)
1–2
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1 General Overview
Display
Machine
Services
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machine control
Data
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Basic system
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Standard
Program-
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Operation
Simulation
Parameters
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NCK-UMS
© Siemens AG 1992 All Rights Reserved

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NCK
• MAP 3.0
6FC5197- AA00
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• SINEC H1
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• Active V.24
SINUMERIK 840C (PJ)

12.93
1.1.1 Components of SINUMERIK 840C

A detailed list of the SINUMERIK 840C components and their features can be found in the
SINUMERIK 840C Catalog and in the Interface Description, Part 2. Some of these components
are briefly introduced here to give an overall view of the mechanical design of the control.
The most obvious component of SINUMERIK 840C is the operator panel with machine control
panel. Although the operator panel is housed separately from the central unit, it is connected
serially to it.
The central unit consists of a single-tier rack which houses the printed circuit boards of the
control. In addition to the central unit, SIMATIC expansion units and DMP modules can also be
added on to expand the input/output signals.

SINUMERIK 840C (PJ)
1 General Overview 03.95
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SINUMERIK slimline operator panel (with inscriptions)
1–4 © Siemens AG 1992 All Rights Reserved 6FC5197- AA00

SINUMERIK 840C (PJ)
I:
F:
E:
B:
A:
H:
D:
C:
12.93
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SINUMERIK 840C (PJ)

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1 General Overview
1–5
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1 General Overview
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SBC RS232C (V.24)

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stored workpiece-oriented.
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Parameters for the control

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Machine

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The SINUMERIK 840C incorporates communication units from MMC and from NCK
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the NC area. The part program memory in the NCK area is not battery backed. The part
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programs can be stored in the data management part of the hard disk (MMC). The data is
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Part programs for workpieces that are currently being machined are stored and managed in
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6FC5197- AA00
SINUMERIK 840C (PJ)
12.93
1.1.2 NCK area
Parameters for the control

The NC contains different types of control parameters:
• Machine data
All the data fixed by the tool manufacturer which are required for adapting the control to
the particular machine tool are stored in the machine data. They include, for example, the
position of the reference point, the quantity and names of the axes, characteristics for
acceleration and deceleration of the drives and spindle speeds or feed rates. The machine
data can be protected by a flexible password.
• Setting data
Setting data are data which can be changed by the machine operator or user. They
include, for example, working area limitations.
• PLC machine data
PLC machine data are located in the link RAM NC-PLC area and are used by the
manufacturer to define the machine control panel and machine options etc.
The PLC machine data are transferred to the PLC at every cold restart of the NC. All PLC
machine data do not become active until cold restart of the PLC.
• Tool offsets
The machine operator stores the geometry and wear data of his tools in the tool offsets.
UMS (user memory submodule)

The operator interface can be configured in order to adapt the functionality of the control to
the particular machine and to the requirements of the user. Machine-specific functions (e.g.
cycles) or operator interfaces (displays, menus, messages) can be created on the
programming workstation ”WS 800A”. The functions, texts and displays in the machine and
parameter areas configured by the machine manufacturer are stored in the UMS. The UMS is
a data file on the hard disk on the MMC-CPU of the SINUMERIK 840C. This file is loaded into
the NCK when the control powers up and supplements the operator interface of the NCK.
NCK structure
The NCK area is divided into channels, each channel acting like an independent NC control.
Each NCK channel has its own block processing and interpolator.
The NCK channels are grouped in operating mode groups. The axes and spindles of the
machine are assigned to operating mode groups via machine data. Each NCK channel of an
operating mode group can, however, only be controlled by one NCK channel at any one time.
Each axis has a position controller. A position control loop occurs when a drive is connected to
the NC via a measuring system. The same applies to spindles with encoders.
In its maximum configuration, SINUMERIK 840C contains 2 operating mode groups (as from
SW 4: 6) and 4 NC channels (as from SW 4: 6). It can have a maximum of 15 servo loops
(486 CPU) of which a maximum of 6 can be for spindles.
Up to 30 servo loops can be defined with software version 5 and higher (611D).
Example:
The 30 servo loops could be divided into:
• 30 axes or 24 axes plus 6 spindles
• No fictitious axes can be defined in addition to the 30 axes.
The limitation to max. 15 real axes or spindles (axes/spindles with servo loops) for analog
drives still applies.
The number of servo loops is limited to 9 when using the 386 CPU.

SINUMERIK 840C (PJ)
1.1.3 MMC area
1.1.3 MMC area

The MMC area is divided into the
• basic system and
• applications.
The basic system comprises the following:

• standard operating system (FlexOS),
• driver,
• data management,
• master control,
• MMC operator communication system,
• basic tools, such as an ASCII and DIN editor,
• display manager,
• communications coordination.
The following MMC areas are implemented in the application area:

• machine,
• parameters,
• programming,
• diagnostics
• services and
• simulation (as from SW 3)
1.1.4 PLC area
The PLC area contains the interface control. Machine-specific signals are evaluated or
switched here. Within the PLC, the basic signals are regrouped, arranged according to the
type of signal and denoted ”user interface”. A list of all user interface signals required for the
PLC user program appears in Section 2. A detailed description of these signals is to be found
in the following sections.
Data communication between the NCK and the PLC is via a communications RAM. In the case
of SINUMERIK 840C, with the exception of the basic signals, all signals are stored in data
blocks (DB).

SINUMERIK 840C (PJ)
1.1.4 PLC area
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MMC
Operator panel
Messages
Data transfer hard disk and RS232C (V.24)
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Data NC-PLC Interface
Basic signals FY 0-24 Operating
manage-
System
ment Diagnostics DB 1...4
Interface NCK channel 1 to 4 (up to 6 DB 10-13
Traversing as from SW 4)
logic Modes, program modification, (15 as from SW4)
Ready signals, auxiliary functions User
Axis-specific 611D and GI signals DB 29 program
Decoded M signals DB 30
Spindle-specific signals DB 31
Position Axis-specific signals DB 32
control
PLC-NCK data transfer DB 36
Control of data transfer DB 37
Operator panel DB 40
Computer Command channel DB 41
link
NCK/PLC communication DB 48
PLC messages DB 58
PLC machine data (MD) DB 60
PLC MD words, function blocks DB 61
Master computer PLC MD words, users DB 62
PLC MD bits for basic program DB 63
PLC MD bits, function blocks DB 64
PLC MD bits, users DB 65
DB installed for users, words DB 68
DB installed for users, bits DB 71
Computer link DB 101, 102
Internal interface User interface
Set and actual values Input and output

Axes and spindles Machine control
Overview of NCK-PLC interface
NCK PLC data transfer is executed by the PLC operating system (BESY).

SINUMERIK 840C (PJ)
1.1.5 PLC-machine interface
1.1.5 PLC-machine interface

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Please refer to the Installation Lists for the assignment of inputs and
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outputs via input and output modules, DMP modules and the machine
control panel, and the setting of addresses. A description of the
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hardware is contained in the Interface Description, Part 2.
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Input/output overview:
Inputs
Bit No.
Byte No. 7 6 5 4 3 2 1 0
0
Physical interface with process image
(input modules, DMP modules, machine control panel)
127
128
Physical interface without process image
(input modules, DMP modules)
255
Outputs
Bit No.
Byte No. 7 6 5 4 3 2 1 0
0
Physical interface with process image
(output modules, DMP modules, machine control panel)
127
128
Physical interface without process image
(output modules, DMP modules)
255

SINUMERIK 840C (PJ)
1.2 PLC program
1.2 PLC program

The following subsections provide some information on:
• the structure of the PLC program
• the tasks of the PLC program
• the distribution of tasks between the PLC operating system and the PLC user program
• the fundamental mechanisms of signal and data transfer
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The ”PLC 135 WB/WB2/WB Planning Guide SINUMERIK 840C/880”
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provides a detailed introduction to programming the PLC
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1.2.1 Tasks of the PLC program
The SINUMERIK 840C can control a variety of machines. Controlling the drives is among other
things one of the classic tasks of the NC which is carried out in the NCK area.
In addition to the machine signals which are required for controlling the drives, there are other
signals, different from machine to machine, which cannot be processed with the usual NC
functionality. The control is adapted to the signal range of the machine by equipping the PLC
area with I/O submodules for creating and switching machine-specific signals.
The PLC user program must establish the connection between the machine-specific signals
and the NC functions. This means that the PLC user program creates the signals required by
the NC from the machine-specific signals and vice versa i.e. it creates the signals required by
the machine from the control signals.
In addition, the PLC user program should use the special features of a machine which are not
included in the NC functions. The PLC user program must therefore implement these potential
machine functions, activate them when required and monitor them.
Examples of PLC program tasks:

• implementation of monitoring facilities
• activation of machine-specific reactions in the event of errors
• controlling auxiliary axes
• tool magazine management
• execution of auxiliary functions
1.2.2 Structure of the PLC program
The PLC program consists of the PLC operating system (BESY) and the PLC user program.
The user program is created by the machine manufacturer.

SINUMERIK 840C (PJ)
1.2.2.1 PLC operating system

The PLC operating system organizes the exchange of signals and data between the PLC user
program and the NCK. The individual tasks are as follows:
• Organization of system start

• Preparation of basic signals (flag "0", "1")
• Signal exchange with inputs/outputs
• Exchange of basic signals for channels, axes, spindles
• M decoding
• Data transfer NCK PLC
• Control of data transfer via the PLC
• Acquisition of operator panel signals
• Saving or loading of FW 200/224 ... 254 during time or alarm processing (depending on
machine data)
Organization of system start

The PLC operating system can be customized to the user-specific channel, spindle and axis
structures of the control via the PLC machine data (see Installation Guide). At cold restart, the
PLC operating system checks the machine data and is configured accordingly. In the event of
contradictory or incorrect PLC machine data, the PLC operating system branches into the
STOP state.
The OB 20 of the PLC user program is called up at system start and processes any
commands inserted by the user. The user thus has the possibility to insert a number of
functions in the system start. System start is completed when OB 1 is called up the first time.
When the OB 1 has been processed completely, the PLC is operating cyclically.
Calling up the user program

The PLC operating system calls up organization blocks. These organization blocks represent
the upper level of the PLC user program. These are especially organization blocks for:
• cyclical processing (OB 1)

• interrupt-controlled processing (OB 2)
• alarm-controlled processing (OB 3)
• aperiodic processing (OB 4)
• time-controlled periodic processing (OB 5 - OB 7)
The machine manufacturer can structure his PLC program according to these criteria by
calling up program blocks (PB) from the relevant organization blocks (OB).

SINUMERIK 840C (PJ)
Preparation of basic signals in the flag area

The flag bytes (FY) contain the basic signals for the PLC program. These include (for example)
ready signals, basic setting signals, interrupt signals and alarm signals. The PLC operating
system provides information on the system state for the PLC user program via the basic
signals.
The flag area contains the flag bytes FY 0 to FY 255. The basic signals are located in FY 0 to
FY 24. The area FY 25 to FY 255 can be used freely by the user.
Important:
The flag area FY 200 - 223 is also partly used by SIMATIC© function blocks.
Data formats:
All word-oriented interface signals are output and input as fixed-point numbers.
Specific reference is made to exceptions.
1.2.2.2 Difference between dynamic and static signals
There are static and dynamic signals.

Static signals are only set or reset by the communicating partners (PLC user program or NC).
Static signals retain their value through several PLC cycles, as long as they are not changed
by one of the communicating partners.
Dynamic signals on the other hand are reset by the PLC operating system after one PLC
cycle. Dynamic signals only occur in the direction going towards the PLC i.e. from the NC or
operator panel.
Some dynamic signals are also present in the form of static signals, e.g. M functions.
1.2.3 Reaction to interrupt and alarm signals
There are interrupts which are triggered by machine signals (hardware interrupts) and program
interrupts which are triggered by the PLC operating system due to edge changes of alarm
signals.
Hardware interrupts
Hardware interrupts can only be processed in a particular PLC operating mode, the special
mode. The PLC operating system makes an image of the signals which trigger interrupts in the
flag area and this image makes it possible to read off which signal has triggered the interrupt.
The user interface OB2 is then called up.
The signals which trigger hardware interrupts can be masked. It can be determined which
edge of a signal triggers the interrupt via machine data.
Program interrupts due to edge changes of alarm signals

The user can declare certain input bytes as alarm bytes via machine data. The signals stored
there trigger program interrupts.
In contrast to hardware interrupts, signals do not trigger program interrupts directly. The PLC
operating system updates the list of the ingoing alarm signals in the alarm bytes periodically
(approx. every 10ms). If it detects that an edge change has taken place in an alarm byte, OB 3
is activated.
END OF SECTION

SINUMERIK 840C (PJ)
12.93 2 Assigned Areas
2.1 Flags, data formats
2 Assigned Areas
2.1 Flags, data formats
FY 0 Basic signals
.
24
25 e.g. auxiliary flags or for
. dynamic assignment by
. interface signals
. e.g. interface channel 1
. channel 2
. etc.
.
.
. Available to the user
.
.
.
.
.
199
200 Reserved for function
. blocks (see note)
224
. Saved area on changing plane
. and restarting
.
FY 255
Notes:
1. For the purposes of simple programming, the interface signals from data blocks can be
copied into the flag area FY 25 - FY 199 using function macros FB 70 and FB 71.
Function macros are function blocks that are programmed in assembler and integrated in
the PLC operating system.
2. The flag area FY 200/224 - 255 (depending on machine data) is saved by the system
program when the machining plane is changed and also in the event of a restart. The flag
area is uploaded at the end of the relevant program.
This flag area can also be utilized by the user for intermediate results.
The flag area FY 200 - FY 255 is partly used by function blocks (see FB Package
Description). If the user does not utilize these function blocks, these flags can be used in
the same way as the area FY 25 - FY 199.
Important:
The flag area FY 200 - 255 is also partly used by SIMATIC function blocks.
Data formats:
All word-oriented interface signals are output and input as fixed-point numbers. Specific
reference is made to exceptions.

SINUMERIK 840C (PJ)
2 Assigned Areas 04.96
2.2 Data blocks
2.2 Class DB/DX data blocks

Data blocks DB 1 ... 149 are reserved for Siemens applications.
Data blocks DB 150 ... 255 can be utilized by the user.
Data blocks DX 0 ... 105 are reserved for Siemens applications.
Data blocks DX 106 ... 255 can be utilized by the user.
DB No. DB design. DB name Pack.
1 * DIAG-DB Diagnostics DB OS
2 * STATUS-DB PLC status channel 1)/high-speed data channel 2) OS
3 * DATKAN-DB PLC data channel 1)/high-speed data channel 2) OS
4 * FM/BM-DB Error and operational messages OS
10 * NS KN 1 Interface NC channel 1 OS
14 * NS KN 5 Interface NC channel 5 2) OS
15 * NS KN 6 Interface NC channel 6 2) OS
28 SI Interface signals for Safety Integrated 3) FB
29 NS ELG ELG signals and 611-D signals OS
30 * DEC MFU Decoded M functions (list) OS
31 * SPI SIG Interface for spindle-specific signals OS
32 * ACHS SIG Interface for axis-specific signals OS
33 Reserved
34 E-PU Input buffer, computer link CL
35 A-PU Output buffer, computer link CL
36 * DUE NC Interface for data transfer NC <-> PLC OS
37 * SER SCH. Control of data transfer OS
38 RK:ZW-DB Status DB computer link CL
39
40 * NS BEDT. Interface operator panel OS
41 * NS KK Interface command channel OS
48 * NS COM Interface communication NC/PLC interface OS
49
58 * MELD Interface for general messages OS
59 DB-ZENTRAL Softkey function calls (central DB in link RAM) OS
60 * MDG WO MD words operating system OS
61 * MDF WO MD words function blocks OS
62 * MDA WO MD words user OS
63 * MDG BI MD bits basic program OS
64 * MDF BI MD bits function blocks OS
65 * MDA BI MD bits user OS
66 IKO-DB Icon drive circuit in the MMC
67 INT-MSTT Internal machine control panel
68 * SEA WO SE user words OS
69
70
71 * SEA BI SE user bits OS
Abbreviations: Note:
OS PLC operating system The data blocks marked * are set up and initialized by the PLC
CL Computer link operating system at each restart following a reset. These blocks are
SE Setting data always reinitialized in the event of an automatic restart.
FB Description of
Functions
Safety Integrated
_______
1) Up to SW 2
2) As from SW 4
3) As from SW 5.4

SINUMERIK 840C (PJ)
2.2 Data blocks
76 Quit FM/BM Acknowledgement signals EM/OM 2) 0

77 DB FM/BM DB status words EM/OM 2) 0
78 Quit FM/BM Acknowledgement signals EM/OM 2) 0
79 QUITFMBM Acknowledgement signals EM/OM 2) 0
80 LMDKN 1 List for M decoding NC channel 1 UR
84 LMDKN 5 List for M decoding NC channel 5 3) UR
85 LMDKN 6 List for M decoding NC channel 6 3) UR
99 Log-Part Assignment user interface/logic partner target CL

100 NCDAT-T Texts for file transfer image (operator prompt) CL, 4
101 * EIN ASS Input user interface CL
102 * AUS ASS Output user interface CL
103 ZWSP-WZD Intermediate memory tool data CL, 4
104 WZ-V-BO Tool management operator interface
105 Reserved CL
. .
. .
. .
122 Reserved CL
123
124
125 S-SIGNALE Standard signals CL
126 FORM-DB Format list 6
127 ZUST-DB Status DB 6
128 E-PUFFER User interface input user data DB 6
129 A-PUFFER User interface output data DB 6
130 Reserved 6
131
132
133 1
134 ZW-STAZ Status DB for tool life, quantity 1
135 ZW Status words DB for tape input 1
136 DYNPUFF 1 Dynamic buffer 1
144 ZW-DATVT Status words DB data distributor 1) 1
145 ZW-BT Status words DB operator panel 1) 1
146 ZW-ANZBT Display parameters operator panel 1
147 ZW-MESS Interface measurement 1
148 TO-DATVT TO memory distributor 1
149 TO-DATLS Buffer for TO data read/write (FB 61/FB 62) 1
150 ZW-WZV Status words tool management 1
0 FB package 0 operating system at each restart following a reset. These blocks
1 FB package 1 are always reinitialized in the event of an automatic restart.
6 FB package 6 _______
CL Computer link 1) The data blocks marked 1) are set up contiguously depending on the tool
UR User management configuration.
2) Up to SW 2
EM Error message
3) As from SW 4
OM Operational message
UI User interface

SINUMERIK 840C (PJ)
2.2 Data blocks
151 KENN 1 Identifiers 1

154 IDENT 1 Ident number 1
155 IDENT 2 Ident number 1
156 DUPLO Duplo number 1
157 ANWEND 1 User data 1) 1
164 D-NR. 1 Reference list 1) 1
173 ERSATZPL Alternative location number 1) 1
174 WZAUF1 L1 Tool holder L1 1) 1
178 ADAGE1 L1 Adapter geometry L1 1) 1
182 ADALAGE Adapter position 1) 1
0 FB package 0 operating system at each restart following a reset. These blocks are
1 FB package 1 always reinitialized in the event of an automatic restart.
CL Computer link
The data blocks marked 1) are set up contiguously depending on
UR User
the tool management configuration.
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DB 150 to DB 182 (maximum) are required to implement tool

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management. The actual number of data blocks depends on the ”width”

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of the magazine table.

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SINUMERIK 840C (PJ)
2.3 Function blocks
2.3 Function blocks

2.3.1 Class FB function blocks
Function blocks FB 0 ... 199 are reserved for Siemens applications.

Function blocks FB 200 ... 255 can be utilized by the user.
FB No. FB design. FB name Pack.
11 * EINR-DB Create data blocks OS

12 * WDTRG Retriggering of cycle time monitoring OS
17 STATUS PLC status channel 2) 0
30 MUL:16 Multiply two binary-coded numbers 16 bits each 0

31 Reserved
32 DIV:16 Div. two binary-coded numbers 16 bits each 0
33 DIV:32 Div. two binary-coded numbers 32 bits each 0
34 Reserved
35 DIV/100 Divide by 100 0
36 ADD:32 Add two binary-coded numbers 0
37 SUB:32 Subtract two binary-coded numbers 0
38 Reserved
39 DUAL/BCD Code conversion binary/BCD 4 decades 0
40 COD:16 Convert fixed point binary number (16 bits) into BCD code 0
number
41 COD:32 Convert fixed point binary number (32 bits) into BCD code 0
number (used flags FW 220, 222)
42 COD:B4 Convert BCD code number (4 decades) into fixed point binary 0
number
43 COD:B8 Convert BCD code number (8 decades) into fixed point binary 0
number
44 Reserved
45 GST-FMBM Basic setting fault/operational messages 2) 0
45 ANLAUF Basic setting interrupts and messages 3) 0
47 PSP:FMBM Buffer memory fault/operational messages 0
48 FMBM:HSG Auxiliary signals for fault/operational messages 2) 0
48 FMBM:MMC Auxiliary signals for EM/OM 3) 0
49 UP:57/58 Subroutine FB57, FB58 0
50 UP:FB49 Subroutine FB49 0
51 UP:FB45 Subroutine FB45 0
52 * BTR 8 16 Block transfer between 8-bit and 16-bit memory1)
54 FM-ANZ Display fault messages 0
55 BM-ANZ Display operational messages 0
56 MG-ANZ Display message groups 2) 0
57 FM-ABFR Interrogate fault messages 0
58 BM-ABFR Interrogate operational messages 0
59 MG-ABFR Interrogate message groups 2) 0
60 * BLOCK-TR Block transfer OS
61 * NCD-LESE Read NC data OS
62 * NCD-SCHR Write NC data OS
63 * Reserved OS
64 * Reserved OS
OS PLC operating system The blocks marked * are function macros integrated in the PLC
0 FB package 0 operating system.
(See Function Macros Description)
_______
2) Up to SW 2
3) As from SW 3

SINUMERIK 840C (PJ)
65 * M-STACK Transfer flag Flag stack OS

66 * STACK-M Flag stack Transfer flag OS
67 * T:RI ACH Transfer direction keys (840C T version) to axes OS
68 * AP RUF Aperiodic program call OS
69 * G-DECOD G functions decoding OS
70 * T:NS EAM Transfer interface DB to I/Q/F OS
71 * T:EAM NS Transfer I/Q/F to interface DB OS
72 * T:NCK DB Transfer NC channel DB channel OS
73 * T:DB NCK Transfer DB channel NC channel OS
74 * T:SPI DB Transfer spindle DB spindle OS
75 * T:DB SPI Transfer DB spindle spindle OS
76 * T:ACH DB Transfer axis DB axis OS
77 * T:DB ACH Transfer DB axis axis OS
78 * T:MS KN Transfer machine control panel NC channel OS
79 * T:MS ACH Transfer machine control panel DB axis (840C M version) OS
88 * BA-LAMPE Modes - LED activation OS

89 * BAA-LESE Read block initial address OS
91 AK2:V/R Sequence cascade forwards/backwards 0

92 AK3:AUT Sequence cascade automatic 0
93 ALS:V/R Sequence cascade forwards/backwards Graph 5 0
94 ALS:AUT Sequence cascade automatik Graph 5 0
95 RK:S880 Computer link FB CL, 4
96 RK:TWZD Reserved, transfer TO data CL, 5
97 Reserved CL
98 Reserved CL
99 Reserved CL
100 RK:GLOBA Global functions CL, 4
101 RK:MELDG Messages CL, 4
102 RK:NCDAT File transfer (operator prompt) CL, 4
103 Reserved CL
104 Reserved CL
105 Reserved CL
106 Reserved CL
107 UP:FB101 Subroutine for FB101 CL, 4
108 UP:CL880 Subroutine CL, 4
109 Reserved CL
110 SUCH Search word 0
111 SUCHROUT Search routine 1
112 LEERPL1 Empty location search without preset 1
113 * SUCH-SYM Search direction symmetrical OS
114 SUCH-VOR Search direction forwards 1
115 SUCH-RWS Search direction backwards 1
116 WZV-INIT Set up tool management
117 EINR-MAG Set up magazine table 1
118 WZ-GR:ST Tool size standard 1
119 Reserved 1
120 Reserved 1
OS PLC operating system The blocks marked * are function macros integrated in the PLC
0 FB package 0 operating system. (See Function Macros Description)
1 FB package 1
4 FB package 4 of the
computer link
CL Computer link

SINUMERIK 840C (PJ)
121 Reserved 1
122 LEERPL2 Empty location search with preset 1
123 WZ-BS Prepare tool 1
124 UP: T=ID Subprogram TO-search T = Ident 1
125 UP: T=PL Subprogram TO-search T = Location 1
126 Reserved 1
128 TRANSFER Transfer TO data 1
129 Reserved 1
130 TOS-VER Subprogram 1
131 UP: MD-B Subprogram MD bits 1
132 UP: MD-W Subprogram MD words 1
133 RI-AUSW Direction selection 1
134 TODAT-W Subprogram 1
135 D-NR:WZW D-No. loading after TO change 1
136 WZDAT-LS Read TO data 1
137 Reserved 1
138 DYN-PUFF Management of I/O data buffer 1
139 DAT-VERT Processing of I/O data buffer 1
140 UP: FB139 FB 139 subprograms 1
141 UP: KC-0 FB 139 subprograms 1
142 UP: KC1-4 FB 139 subprograms 1
143 UP: KC5-7 FB 139 subprograms 1
144 UP:KC8+9 FB 139 subprograms 1
145 BEL-CDTR Load tool with code carrier 6
146 ENT-CDTR Unload tool with code carrier 6
147 CT-FORMAT Formatting 6
148 Reserved 6
149 Reserved 6
150 Reserved 1
151 Reserved 1
152 NP-SIF Subprogram 1
153 AD-AD Subprogram 1
154 RK: AW-SS User interface to CL (processing) 1
155 LOCHSTEG Tape input 1
156 STAZ/VWG Tool life monitoring / early warning limit 1
157 STUE/VWG Quantity monitoring / early warning limit 1
158 WZ-SPER Tool disable 1
159 BCD-DUAL BCD-DUAL conversion 1
160 1) Central call block 1
161 1) SR control 1
162 1) Reserve 1
163 1) Reserve 1
164 1) Transfer TO selection 1
165 1) Reserve 1
166 1) Signal: load spindle 1
167 1) Signal: unload spindle 1
168 1) Acknowledge spindle 1
169 1) Reserve 1
170 1) Buffer storage allocation 1
Abbreviations:
1 FB package 1
6 FB package 6
_______
1) The blocks are given in the operator interface example of tool management.

SINUMERIK 840C (PJ)
171 1) Magazine allocation 1

172 1) Tool selection according to T No. 1
173 1) Load/unload magazine from preselection / spindle 1
174 1) Reserve 1
175 1) TO data display from buffer storage allocation 1
176 1) TO data modification from buffer storage allocation 1
177 1) TO data display from magazine allocation 1
178 1) TO data modification from magazine allocation 1
179 1) TO selection according to cursor pos. from magaz. alloc. 1
180 1) Additional cutting edge from buffer storage and magazine 1
181 1) Additional cutting edge from load 1
182 1) Load 1
183 1) Unload 1
184 1) Reserve 1
185 1) Manual acknowledge 1
186 1) Manual termination magazine / spindle 1
187 1) Display next cutting edge 1
188 1) Reactivate TO 1
189 1) Delete next cutting edge 1
190 1) Select load display tape 1
191 1) Acknowledge tape positive / negative 1
192 1) Terminate tape 1
193 1) Reserve 1
194 1) Reserve 1
195 Reserved 1
196 Reserved 1
197 WZ-LISTE Create tool list 1
198 TAUSCHL Create exchange list 1
199 FIFO Buffer processing 1
Abbreviations:
1 FB package 1
_______
1) The blocks are given in the operator interface example of tool management.

SINUMERIK 840C (PJ)
2.3.2 Class FX function blocks

Function blocks FX 0 ... 99 are reserved for Siemens applications.
FX No. FX design. FX name Pack.

1 SI Self-installation OS
2 Reserved
3 Reserved
4 Reserved
5 Reserved
6 Reserved
7 SIMULAT Simulation of a part program 1
8 WZ-GRIEP Tool size default via EPROM 1
9 Reserved 1
10 Reserved 1
11 Reserved 1
12 Reserved 1
13 Reserved
14 BEL-CDTR Load code carrier 7
15 ENT-CDTR Unload code carrier 7
16 UP-CDTR Subroutine code carrier 7
17 Reserved CL
18 Reserved CL
19 Reserved CL
20 Reserved CL
21 Reserved CL
22 Reserved
23 Reserved
25 Reserved
26 DAT-EIN PLC-controlled data input 8
27 DAT-AUS PLC-controlled data output 8
28 DAT-UHR Date/Time of day 8
29 Reserved CL
30 Reserved CL
31 GRAYDUAL GRAY/Binary code converter 0
32 DUALGRAY Binary/GRAY code converter 0
33 RECHNEN Contour and technology computation CP
34 MESSEN Measuring in JOG mode CP
35 RESREQ Trigger link bus reset CL
36 Reserved CL
37 Reserved CL
38 PRO-K01 Program coordination 1) 0
39 PRO-K02 FX 38 subroutine 0
40 RK:WZABF Computer link, scan tool 5
41 RK:WZM Computer link, report tool 5
42 RK:WZBEL Computer link, load tool 5
43 RK:WZENT Computer link, unload tool 5
44 RK:WZBGB Computer link, load magazine assignment data 5
45 RK:KASSE Tool cassette machining 5
46 Reserved
47 Reserved
48 UPWZKASS Subroutine tool cassette machining 5
49 E/A-TRAN Data transfer I/O buffer tool management 5
50 UPWZDIAL TOOL DIALOG subroutine 5
51 Reserved
52 Reserved
53 Reserved
54 Reserved
Abbreviations:
0 FB package 0
1 FB package 1
5 FB package 5
7 FB package 7
8 FB package 8
OS Operating system
CP Cycle package _______
CL Computer link 1) As from SW 2

SINUMERIK 840C (PJ)
FX No. FX design. FX name Pack.
55 Reserved
56 Reserved
57 Reserved
58 Reserved
59 Reserved
60 Reserved
67 Reserved
68 PRO-MESS Logging of measured data 8
69 TP-UEB Transfer part program 8
70 TP-BEARB Process part program 8
71 DRU-AUSG Printout 8
72 PRO-UP1 Subroutine 8
73 OEM-SEND Send data to MMC (reserved for OEM customers) 2)
74 OEM-EMPF Receive data from MMC (reserved for OEM customers) 2)
75 AX-G-FKT Decode axis-specific G functions 2)
76 Reserved 8
77 Reserved address computation flag area 8
78 Reserved 8
79 Reserved OS
80 Reserved OS
81 Ikonen Display of icons 1) 0
82 STERNDRE Star-delta changeover 2) 0
83 Reserved PG functions
87 Reserved PG functions 0
88 Reserved PG functions 0
89 Reserved
90 Reserved
91 Reserved
92 Reserved
93 Reserved
94 Reserved
95 Reserved
96 Reserved
97 Reserved
98 Reserved
99 Reserved
Abbreviations:
OS PLC operating system
8 FB package 8
0 FB package 0
Important:
1. Make sure that there is no risk of confusion with SINUMERIK blocks. Users must not use
SINUMERIK standard block names or assign SINUMERIK library numbers to their user
blocks.
2. In the range FB 0...FB 199
FX 0...FX 99, SINUMERIK blocks have absolute priority.
If SINUMERIK blocks must be used at a later time with numbers that coincide with user
block numbers, the user block numbers must be renamed.
_______
1) As from SW 2
2) As from SW 3
3) SINUMERIK 840C, OEM-Doku, User's Guide
4) Planning Guide Function Macros

SINUMERIK 840C (PJ)
2.4 Basic signals
2.4 Basic signals
PLC auxiliary signals (Section 3.1)
Bit No.
Byte No. 7 6 5 4 3 2 1 0
FY 0 Flashing
frequency
0.5 Hz One Zero
FY 1 No. of current processing level (OB No.)
FY 2 Basic setting
OB 7 OB 6 OB 5 OB 4 OB 3 OB 2 OB 1
FY 3 Cold restart
OB 7 OB 6 OB 5 OB 4 OB 3 OB 2 OB 1 OB 20
FY 4 Parameter test
OB 7 OB 6 OB 5 OB 4 OB 3 OB 2 OB 1
FY 5 Addressing Block Info bit for

error segment alarm PLC
detection violation package 2) number 1)
FY 6 Processing delay Group

message
OB 7 OB 6 OB 5 OB 4 OB 3 OB 2 LIM/SIM
PLC ready signals (Section 3.2)
Bit No.
Byte No. 7 6 5 4 3 2 1 0
FY 7
FY 8 Interrupt inputs for interrupt byte 1

7 6 5 4 3 2 1 0

7 6 5 4 3 2 1 0

7 6 5 4 3 2 1 0
FY 11 Interrupt inputs for interrupt byte 4 or central

interrupt byte on INT PLC
_______
1) Always ”1” with 840C
2) As from SW 3

SINUMERIK 840C (PJ)
2.4 Basic signals
Signals for alarm-controlled machining (Section 3.3)

Bit No.
Byte No. 7 6 5 4 3 2 1 0
FY 12 Negative edge of process alarm byte

Byte No. n
FY 13 B y t e N o. ( n + 1 )
FY 14
B y t e N o. ( n + 2 )
FY 15
B y t e N o. ( n + 3 )
FY 16 Positive edge of process alarm byte

Byte No. n
FY 17
B y t e N o. ( n + 1 )
FY 18 B y t e N o. ( n + 2 )
FY 19 B y t e N o. ( n + 3 )
NC ready signals (Section 3.4)

Bit No.
Byte No. 7 6 5 4 3 2 1 0
FY 20
FY 21 2nd 1st
interface interface
CL CL
Signal to Signal
FY 22 CSB: data from CSB:
power
Drives
ready
NC CPU
ready
MMC CPU
saved (from ready
SW 6.3) failure (from (from SW 6) (from SW 6)
SW 6.3)
FY 23
Individual signals (Section 3.5)

Bit No.
Byte No. 7 6 5 4 3 2 1 0
FY 24 Probe Probe NC alarm Over-tem- Tempera-

selected selected with proces- CPU perature/ ture pre- Battery NC alarm
1 2 sing stop failure fan failure warning prewarning on

SINUMERIK 840C (PJ)
2.4.1 Assignment of DB 1 (diagnostics) (Section 3.6)
15 14 13 12 11 10 9 8
Bit No.
DW
No. 7 6 5 4 3 2 1 0
Actual cycle time
Cycle times DW 0
(KF format in ms)
Minimum cycle time
DW 1
Maximum cycle time

DW 2
15 14 13 12 11 10 9 8
Bit No.
DW
No. 7 6 5 4 3 2 1 0
ID of I/O type DL 10
DR 10
Input I/O group not ready

Input I/O DL 12
15 14 13 12 11 10 9 8
group
not ready
DR 12 7 6 5 4 3 2 1 0
1: Fault
0: no fault DL 13 31 30 29 28 27 26 25 24
DR 13
23 22 21 20 19 18 17 16
Output I/O group not ready

Output I/O DL 14 15 14 13 12 11 10 9 8
group
not ready
DR 14 7 6 5 4 3 2 1 0
1: Fault
0: no fault DL 15
31 30 29 28 27 26 25 24
DR 15 23 22 21 20 19 18 17 16

SINUMERIK 840C (PJ)
15 14 13 12 11 10 9 8
Bit No.
DW
No. 7 6 5 4 3 2 1 0
Number of lost requests during LIM/SIM OB2
Semaphore DW 16
technique within Number of lost requests during LIM/SIM OB3
processing levels DW 17
DW 18
DW 19
DW 20
DW 21
Event counter Event counter processing time delay
DW 22 OB 2
processing time OB 3
delay DW 23
OB 4
DW 24
OB 5
DW 25
OB 6
DW 26
OB 7
DW 27
15 14 13 12 11 10 9 8
Bit No.
DW
No. 7 6 5 4 3 2 1 0
Fault message DW 30
Input byte .
.
1: Fault .
0: No fault DW 45
Fault message DW 46
Output byte .
.
1: Fault .
0: No fault DW 61
Display DW 70
status register .
.
DMP modules .
DW 159
Error fine coding

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
Error fine coding in diagnostics DB error number

DW 160
DW 161
:
DW 167

SINUMERIK 840C (PJ)
Software releases
Bit No.
Byte No. 7 6 5 4 3 2 1 0
DW 168 PLC software

Software release Int. version number
DW 169 Reserved
DW 170 Interface DMP 1st interface

DW 171 Interface DMP 1st interface

Module code 1) Slot number (hexadecimal)
DW 172 Interface DMP 2nd interface

DW 173 Interface DMP 2nd interface or INTEU/16B

DW 174 Interface PLC 135 WB2/WD

DW 175 Interface PLC 135 WB2/WD

DW 176 Reserved
DW 177 Reserved
Note:
The order of the I/O modules does not solely depend on the slot position. The following
allocations always apply:
– The interface PLC/interface 135 WD is always the 3rd interface
– The INTEU 16 bit is always the 2nd interface
– The interface DMP can be set as the 1st or 2nd interface, depending on its slot number
counting from left to right.
– With the PLC 135 WD, a second interface DMP can be used in the 18 SEP subrack
(SEP=standard slot dimension).
_______
1) Module code (binary)
1010 01 xx Interface DMP
0110 11 xx INT EU/16B
0111 10 xx Interface PLC/135 WB2
1000 11 xx Interface 135 WD
xx =ˆ Hardware version

SINUMERIK 840C (PJ)
2.4.2 High-speed data channels
2.4.2 High-speed data channels (as from SW 4)

2.4.2.1 DB 2 Configuration DB
Configuration DB (see Installation Instructions, Section 12)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 0 Operating mode
With Read/
acknowl. write STROBE
DR 0 Error code of NC
DL 1 J o b N o. o f P L C
DR 1 No. of data transfer area
DL 2 Updating rate NC
DR 2 Function identifier
DL 3 Configuration parameter 1 LOW
DR 3 Configuration parameter 1 HIGH
DL 7 Reserved
DR 7 Reserved
.. .. ..
. . .
DL 31 Reserved
DR 31 Reserved

SINUMERIK 840C (PJ)
2.4.2 High-speed data channels
2.4.2.2 DB 3 Data transfer areas
Data transfer areas (see Installation Instructions, Section 12)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 0 Activation bits of PLC

Data Data Data Data Data Data Data Data
channel 8 channel 7 channel 6 channel 5 channel 4 channel 3 channel 2 channel 1
DR 0 Activation bits of PLC
DL 1 Activation bits of PLC
DR 1 Activation bits of PLC
DL 2 S t a t u s b i t s of NC " C o n f i g u r a t i o n o f d a t a c h a n n e l v a l i d "
DR 2 S t a t u s b i t s of NC " C o n f i g u r a t i o n o f d a t a c h a n n e l v a l i d "
DL 3 S t a t u s b i t s of NC " C o n f i g u r a t i o n o f d a t a c h a n n e l v a l i d "
DR 3 S t a t u s b i t s of NC " C o n f i g u r a t i o n o f d a t a c h a n n e l v a l i d "
DW 4 Reserved
. . .
.. .. ..
DR 12 Synchronous data channels New value New value
Control bits Writing of Reading of
NC data NC data
DW 13 Reserved
Pointer to data tranfer area 1
DL 14 ( = N o. o f d a t a w o r d )
Pointer to data tranfer area 2
DR 14 ( = N o. o f d a t a w o r d )
.. .. ..
. . .
P o i n t e r t o d a t a t r a n f e r a r e a 31
DL 29 ( = N o. o f d a t a w o r d )
P o i n t e r t o d a t a t r a n f e r a r e a 32
DR 29 ( = N o. o f d a t a w o r d )
DL 30
DR 30
DL x Job No. (Acknowledgement from NC)
Control bits
DR x Error on Error on Synchron- "New value” "New value”
writing NC reading NC ous data writing of reading of
data data channel NC data NC data
DL VALUE
x+1 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DR VALUE
DL VALUE
DR VALUE
______________
x = data transfer area nos. 1 to 32 via pointers (DW 14 to 29)

SINUMERIK 840C (PJ)
2.5 NCK/PLC interface
2.5 NCK/PLC interface

2.5.1 Channel-specific signals
2.5.1.1 Signals to NCK channel (DB 10 ... DB 13, as from SW 4 DB 15)
Signals to NCK channel (Section 4.2)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 0 DRF 1) Reset 1)2) CANCEL 4)
No reduction
DR 0 Skip block Single block DEC single Dry run feed M01 active of channel
block rate path
velocity8)
DL 1 Feedrate Feedrate override

override
ESR On effective E D C B A
Rapid Rapid traverse override

DR 1 traverse
override
ESR Off effective D C B A
Execution Block
Bl. search
Internal WAIT Progr. Program
DL 2 from exter- search with
with calcu-
lation as from
mark synchr. start/end step Break Clear
nal calculation last main
with block cycles off (PSTEP) 5) (BRK) 5) (CLR) 5)
search 8) 7)
block
DR 2 Delete Delete no.

distance to of subrout.
go passes NC Stop NC Start
DL 3 Spindle number 6)
C B A
DR 3
DL 4 Block skip at several levels (activation) 3)

Level 8 Level 7 Level 6 Level 5 Level 4 Level 3 Level 2 Level 1
DR 4
DL 5 Operating modes 1)
JOG TEACH IN MDA AUT
DR 5 Functions
REPOS REF VAR 10 000 INC 1 000 INC 100 INC 10 INC 1 INC
_______
1) For SW 1: If this signal is selected in the 1st channel (master channel) of an operating mode group, it also
applies to all other channels in the group. The reset signal specific to the operating mode group can be
selected only in the master channel.
2) SW 2 (RESET): The effect of RESET is channel-specific. Single channels of a mode group can be set to the
reset state without influencing other channels.
3) As from SW 2
4) As from SW 2: Whether Cancel is to act on all channel-specific alarms or to the selected (current) channel
only can be set by MD 50008.0.
5) As from SW 3
6) As from SW 3, power indication becomes active in the operating mode basic displays for digital spindles.
7) SW 5 and higher
8) As from SW 5.6

SINUMERIK 840C (PJ)
Signals to NCK channel (Section 4.2)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 6 General feed disable

m+7 m+6 m+5 m+4 m+3 m+2 m+1 m+0
DR 6 General feed disable
m+15 m+14 m+13 m+12 m+11 m+10 m+9 m+8
a n d r e a d - i n d i s a bl e
m+23 m+22 m+21 m+20 m+19 m+18 m+17 m+16
m+31 m+30 m+29 m+28 m+27 m+26 m+25 m+24
m+39 m+38 m+37 m+36 m+35 m+34 m+33 m+32
m+47 m+46 m+45 m+44 m+43 m+42 m+41 m+40
DL 9 Read-in disable
m+55 m+54 m+53 m+52 m+51 m+50 m+49 m+48
DR 9 Read-in disable
m+63 m+62 m+61 m+60 m+59 m+58 m+57 m+56
DL 10 Read-in disable
m+71 m+70 m+69 m+68 m+67 m+66 m+65 m+64
DR 10 Read-in disable
m+79 m+78 m+77 m+76 m+75 m+74 m+73 m+72
DL 11 NC start disable
m+87 m+86 m+85 m+84 m+83 m+82 m+81 m+80
DR 11 NC start disable
m+95 m+94 m+93 m+92 m+91 m+90 m+89 m+88
DL 12
DR 12
Chan- Interface Message text address

nel DB m
1 DB 10 6000
2 DB 11 6100
3 DB 12 6200
4 DB 13 6300
5 DB 14 6400 (as from SW 4)
6 DB 15 6500 (as from SW 4)
Notes:
• The bytes DL 6 ... DR 11 can also be analyzed for error and/or operational messages. The
setting is made using PLC MD 6032 - 6047.
• The NC start disable is not active in other mode groups. If, e.g. the channels 1 and 2 of
mode group 1 are disabled for NC Start, NC Start becomes active in the channels of mode
group 2.

SINUMERIK 840C (PJ)
2.5.1.2 Signals from NCK channel (DB 10...DB 13, as from SW 4 DB 15)
Signals from NCK channel (Section 4.3)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 13 M00 M02/ G33/ Block Program Program

/ M30/ G63 G00 G96 search interrupted running
M01 Reset active
DR 13 Transform- G36 2)
ation active
DEC single Dry run Feedrate Teach in/

DL 14 Skip block Reserved block feedrate M 01 override for DRF Play back
selected selected selected selected rapid trav. selected (as from
selected SW 6)
Block
DR 14 Execution Block search with Extended Progr. Program Break Clear
from ex- search with calculation overstoring start/end step
ternal calculation as from last active 3) cycles off 4) (PSTEP) 2) (BRK) 2) (CLR) 2)
main block
Internal
WAIT marker
Bl. search (channel
DL 15 Bl. search
with calc.
with calc. as
fr. last main
waits for
block w/o synchroni-
without error
error zation)
(as from
SW 6)
Error during Error during ESR 1) ESR 1)

DR 15 block bl. search with
monitoring response is
search with calc. as from
is active 3) triggered 3)
calc. last main bl.
Protection
space NC alarm Mode
DL 16 NC START adaptation with NC START Channel in group NC alarm
disable not possible machining possible reset present
(as from stop ready
SW 6)
DR 16
_______
1) As from SW 2
2) As from SW 3
3) As from SW 4
4) As from SW 5

SINUMERIK 840C (PJ)
2.5.1.3 Auxiliary functions from NCK channel (DB 10 ... DB 13,

as from SW 4 DB 15)
Modification signals (Section 4.4.3)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 17 F D H T S M word 3 M word 2 M word 1

Modifi- Modifi- Modifi- Modifi- Modifi- Modifi- Modifi- Modifi-
cation cation cation cation cation cation cation cation
DR 17 Last in- Fast M word 3 M word 2 M word 1

auxiliary not not not
formation function 1) decoded decoded decoded
Decoded M functions (Section 4.4.3)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 18 Dynamic M signals
M7 M6 M5 M4 M3 M2 M1 M0
DR 18 Static M signals
M7 M6 M5 M4 M3 M2 M1 M0
M15 M14 M13 M12 M11 M10 M9 M8
M15 M14 M13 M12 M11 M10 M9 M8
M23 M22 M21 M20 M19 M18 M17 M16
M23 M22 M21 M20 M19 M18 M17 M16
M31 M30 M29 M28 M27 M26 M25 M24
M31 M30 M29 M28 M27 M26 M25 M24
_______
1) As from SW 2

SINUMERIK 840C (PJ)
Decoded M functions (Section 4.4.3)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
M39 M38 M37 M36 M35 M34 M33 M32
M39 M38 M37 M36 M35 M34 M33 M32
M47 M46 M45 M44 M43 M42 M41 M40
M47 M46 M45 M44 M43 M42 M41 M40
M55 M54 M53 M52 M51 M50 M49 M48
M55 M54 M53 M52 M51 M50 M49 M48
M63 M62 M61 M60 M59 M58 M57 M56
M63 M62 M61 M60 M59 M58 M57 M56
M71 M70 M69 M68 M67 M66 M65 M64
M71 M70 M69 M68 M67 M66 M65 M64
M79 M78 M77 M76 M75 M74 M73 M72
M79 M78 M77 M76 M75 M74 M73 M72
M87 M86 M85 M84 M83 M82 M81 M80
M87 M86 M85 M84 M83 M82 M81 M80
M95 M94 M93 M92 M91 M90 M89 M88
M95 M94 M93 M92 M91 M90 M89 M88
M99 M98 M97 M96
M99 M98 M97 M96

SINUMERIK 840C (PJ)
Stored words of block information (Section 4.4.3)
Data
wort No. High-order byte (DL) Low-order byte (DR)
Extended address M word 1 (binary)

DW 31
Bit 15 Bit 0
M word 1 (binary)
DW 32
Bit 15 Bit 0

DW 33
Bit 15 Bit 0
M word 2 (binary)
DW 34
Bit 15 Bit 0

DW 35
Bit 15 Bit 0
M word 3 (binary)
DW 36
Bit 15 Bit 0
Extended S address (binary or BCD)

DW 37
Bit 15 101 100 Bit 0
S word (binary or BCD)

DW 38
Bit 31 107 106 105 104 Bit 16
S word (binary or BCD)

DW 39
Bit 15 103 102 101 100 Bit 0
Chan. Interface NC MD for BCD output

DB
S T D H F
1 DB 10 5440.3 -.4 -.5 -.6 -.7
2 DB 11 5441.3 -.4 -.5 -.6 -.7
3 DB 12 5442.3 -.4 -.5 -.6 -.7
4 DB 13 5443.3 -.4 -.5 -.6 -.7
5 1) DB 14 5444.3 -.4 -.5 -.6 -.7
6 1) Db 15 5445.3 -.4 -.5 -.6 -.7
_______
*) As from SW 4

SINUMERIK 840C (PJ)
Stored words of block information (Section 4.4.3)
Data
word High-order byte (DL) Low-order byte (DR)
No.
Extended T address (binary or BCD)

DW 40 101 100
Bit 15 Bit 0
T word (binary or BCD)

DW 41 107 106 105 104
Bit 31 Bit 16
T word (binary or BCD)

DW 42 103 102 101 100
Bit 15 Bit 0
Extended H address (binary or BCD)

DW 43 101 100
Bit 15 Bit 0
H word (binary or BCD)

DW 44 107 106 105 104
Bit 31 Bit 16
H word (binary or BCD)

DW 45 103 102 101 100
Bit 15 Bit 0
D word (binary or BCD)

DW 46 102 101 100
Bit 15 Bit 0
Extended F address
DW 47 101 100
Bit 15 Bit 0
1)
F word
DW 48 10n+7 10n+6 10n+5 10n+4
Bit 31 Bit 16
1)
F word
DW 49 10n+3 10n+2 10n+1 10n
Bit 15 Bit 0
Select block skip at several levels 2)

DL 51
Level 8 Level 7 Level 6 Level 5 Level 4 Level 3 Level 2 Level 1
DR 51
_______
1) Is dependent on input resolution (e. g. 10–3=ˆn=–3) and on G95 (n=–3) or G94 (n=–2). The speed is higher
than with G95 by a factor of 10.
2) As from SW 2

SINUMERIK 840C (PJ)
aa
2)
1)
a
aa
a
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
aa aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
10.94
a
aa
a aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
a
aa
a
aa
________
DL 55
DL 54
DL 53
DL 52
Byte No.
DR 55
DR 54
DR 53
DR 52
a
aa
a
aa
a
aa
a aaaaaaaaaaaaaaaaaaaaa
As from SW 4
aa
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
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7
15
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SINUMERIK 840C (PJ)

a
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6
14
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101
103
105
107
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5
aa aaaaaaaaaaaaaaaaaaaaa
13
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aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
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4
12
6FC5197- AA00
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Chann. 6 2) Chann. 5 2)
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Bit No.
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3
11
Command code
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Channel 4
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These signals must not be overwritten in the program coordination function.

a
aa
a
Marker/program number (BCD)
a
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Signals from program coordination 1)
Program coordination (SET) active in

Program coordination (SET) active in
a
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2
10
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Channel 3
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100
102
104
106
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aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
a
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9
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Channel 2
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aaaaaaaaaaaaaaaaaaaaa
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8
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0
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coord.
modific.
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Program
Channel 1
2 Assigned Areas
2–25
aa
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Signals to program coordination 2)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 56 Buffer
assigned
DR 56 Buffer for command code
DL 57 Buffer for marker/program number (BCD)
DR 57 Buffer for marker/program number (BCD)
DL 58 Buffer for marker/program number (BCD)
DR 58 Buffer for marker/program number (BCD)
DL 59 Buffer for program coordination (SET) active in
DR 59 Buffer for program coordination (SET) active in

Chann. 6 3) Chann. 5 3) Channel 4 Channel 3 Channel 2 Channel 1
DL 60 Program coordination (ACT) reached in
DR 60 Program coordination (ACT) reached in

Chann. 6 3) Chann. 5 3) Channel 4 Channel 3 Channel 2 Channel 1
DL 61 Detailed error coding
DR 61 Detailed error coding
End of pro- NC alarm

DL 62 gram 3166 "Wrong Read-in NC START
reached program disable
[WAIT E] coordination" 1) 1)
________
1) These signals are to be used only for program coordination.
2) These signals must not be overwritten in the program coordination function.
3) As from SW 4

SINUMERIK 840C (PJ)
T/H word routing (Section 4.4.4)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 63 Suppress
T/H word Reserved
routing
DR 63 Coordi- Suppress
nation error routing H word T word
message message valid valid
DW 64 Bit 15 Source channel number (address extension, binary) Bit 0
DW 65 Bit 15 Routed T word Bit 0

103 102
DW 66 Bit 15 Routed T word Bit 0
101 100
DW 67 Bit 15 Routed H word (address extension) Bit 0
101 100
DW 68 Bit 15 Routed H word Bit 0
103 102
DW 69 Bit 15 Routed H word Bit 0

101 100
Chan- IS DB NC MD for BCD output

nel S T D H F
1 DB 10 5440.3 -.4 -.5 -.6 -.7
2 DB 11 5441.3 -.4 -.5 -.6 -.7
3 DB 12 5442.3 -.4 -.5 -.6 -.7
4 DB 13 5443.3 -.4 -.5 -.6 -.7
51) DB 14 5444.3 -.4 -.5 -.6 -.7
61) DB 15 5445.3 -.4 -.5 -.6 -.7

SINUMERIK 840C (PJ)
TEACH-IN: Axis marking (signals from NCK channel, Section 4.4.5) 1)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 70 2) Axis 8 Axis 7 Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1

DL 80 3)
DR 70 2) Axis 16 Axis 15 Axis 14 Axis 13 Axis 12 Axis 11 Axis 10 Axis 9
DR 80 3)
DL 81 3)
DR 71 2) Store Axis 30 Axis 29 Axis 28 Axis 27 Axis 26 Axis 25
traversed
DR 81 3) axes only
TEACH-IN: Axis marking (signals to NCK channel, Section 4.4.5) 1)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0

DL 82 3)
DR 72 2) Axis 16 Axis 15 Axis 14 Axis 13 Axis 12 Axis 11 Axis 10 Axis 9
DR 82 3)
DL 83 3)
DR 73 2) Store Axis 30 Axis 29 Axis 28 Axis 27 Axis 26 Axis 25
traversed
DR 83 3) axes only
Note:
In SW 3, the TEACH-IN axis markings are stored in DW 70-73, as from SW 4 in DW 80-83.
_______
1) As from SW 3
2) SW 3
3) As from SW 4

SINUMERIK 840C (PJ)
04.96
2.5.1.4
a
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a aaaaaaaaaaaaaaaaaaaaaaaaaaaa
a aa aaa
SINUMERIK 840C (PJ)

a
a a
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a a
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a
aaaaaaaaaaaaaaaaaaaaaaaaaaaa
a
a a
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a a
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a
a a
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a a
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a a
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a a
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a aa aaa aaaaaaaaaaaaaaaaaaaaaaaaaaaa
aa
a aa
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a aa
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a a
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a aa aaa

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aaaaaaaaaaaaaa
a
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a a
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a a
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a a
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6FC5197- AA00
a
a a
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a a
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a a
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a a
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a a
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a a
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a a
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For a further description, refer to the
a
a a
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The Safety Integrated function is an option.
a
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a
SINUMERIK Safety Integrated documentation.
a
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Axis-specific Safety Integrated signals (DB28) (as from SW 5.4)
2 Assigned Areas
2–29
2.5.1.5 Axis-specific GI signals (DB 29) 1)
Signals from axis (Section 6.3)

15 14 13 12 11 10 9 8
Byte No.
7 6 5 4 3 2 1 0
Acceleration
DL k limitation ESR Compensat. Wait for
synchronous monitoring controller pos.-related FA overlay Synchroniz-
active is active active switching 2) active ation busy Link active
Controlled Accel. warn Veloc. warn Synchron- Synchron-
DR k follow-up Maximum Maximum threshold threshold ous motion ous motion
motion FA acceleration velocity reached reached fine coarse
DL Synchroniz. ESR
position response is
k+1 reached triggered
DR Identifier ESR
following response is Request Request
k+1 axis progrmd. 2) LINK Off LINK On
Signals to axis (Section 6.3)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL Activate Pos.-related On-the-fly

ESR switching synchroni- LINK–ON
k+2 monitoring ON 2) zation ON
DR Disable
ESR LINK–OFF
k+2 monitoring
DL
k+3
Compensate Acceleration Enable Compensat-
DR synchr. limit ESR ory Enable
motion SYNCHRON- response 2) controller following Interlock Interlock
k+3 difference * OUS ON axis overlay LINK–OFF LINK–ON
Axis Address K Axis Address K

1 0 16 60
2 4 17 64
3 8 18 68
4 12 19 72
5 16 20 76
6 20 21 80
7 24 22 84
8 28 23 88
9 32 24 92
10 36 25 96
11 40 26 100
12 44 27 104
13 48 28 108
14 52 29 112
15 56 30 116
_______
1) As from SW 3
2) As from SW 4
* See DB 31, K+27, bit 7 for description of signal

SINUMERIK 840C (PJ)
2.5.1.6 Axis-specific 611-D signals (DB 29)
Signals from axis
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL User- User- User- User- User- User- Heat sink Motor

progr.ble 1) progr.ble 1) progr.ble 1) progr.ble 1) progr.ble 1) progr.ble 1) prewarning temperature
k+120 message 6 message 5 message 4 message 3 message 2 message 1 1) prewarng. 1)
DR Drive Motor Motor

Pulse switched on Drive ready selection bit selection bit Parameter Parameter Parameter
k+120 enable 1) 2) 1) 1 1) 0 1) block 2 1) block 1 1) block 0 1)
DL Traverse
request
k+121 drive test 2)
ZK2 generator ZK2 ZK2 DC link
ZK2 DC link
DR speed <
minimum
emergency
retraction or
voltage <
emergency voltage <
warning
k+121 speed
generator axis DC link gener-
retraction
threshold threshold
(MD 1604)
(MD 1635) ator active (MD 1634)
Signals to axis
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
Ramp-
DL Reserve Reserve Reserve Reserve Set speed 2nd function
611D-XM1 611D-XM1 611D-XM1 611D-XM1 smoothing torque generator
k+122 1) 1) 1) 1) 1) limit 1) rapid stop 1)
DR Motor Motor Motor

Pulse Integrator selection selection bit selection bit Parameter Parameter Parameter
k+122 enable 1) disable 1) executed 1) 1 1) 0 1) block 2 1) block 1 1) block 0 1)
DL Motion
enable drive
k+123 test 2)

1 0 16 60
2 4 17 64
3 8 18 68
4 12 19 72
5 16 20 76
6 20 21 80
7 24 22 84
8 28 23 88
9 32 24 92
10 36 25 96
11 40 26 100
12 44 27 104
13 48 28 108
14 52 29 112
15 56 30 116
_______
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a
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aaaaaaaaaaa
a
a
a
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aaaaaaa
The description of these signals is identical to the signals:

aaa
a
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aaa
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”Interface signals for the drive 611D”, DB 31.

a
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1) SW 3, used by 611D
2) SW 3, used by SERVO

SINUMERIK 840C (PJ)
2.5.1.7 M signals (DB 30) decoded according to list
Signals decoded according to list (Section 6.4)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
The bit field is common to all channels. A maximum of 64 M functions per channel can be
decoded according to the list.
Decoding list contents

Chan. Decoding PLC MD Def. of Def. of
list for decoding Extended M M address DW No. bit No.
address in DB30 in DB30
1 DB 80 6009.0
2 DB 81 .1 0 - 63 0-7
1 - 99 0 - 9999 (KY) (KY)
3 DB 82 .2
(KF) (KF) stat. bit
4 DB 83 .3
5 1) DB 84 .4
6 1) DB 85 .5 1st DW 0 DW 1 DL 2 DR 2
value
2nd DW 3 DW 4 DL 4 DR 5
value
.
.
.
.
.
.
64th DW 190 DW 191 DL 192 DR 192

value
_______
1) As from SW 4

SINUMERIK 840C (PJ)
2.5.2 Spindle-specific signals (DB 31)

2.5.2.1 Signals from spindle
Signals from spindle (Section 5.2)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL k Actual Spindle Spindle Spindle

rotation Prog. speed Spindle in position Spindle syn- positioning Speed limit
clockwise too high set range reached stop chronized active exceeded
Set gear stage

Change
DR k gear C B A
2.5.2.2 Signals to spindle
Signals to spindle (Section 5.3)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL Switch over Spindle Spindle override

servo gain Controller Input set override
k+1 factor (Kv) enable value 0 effective D C B A
DR Initiate C Actual gear stage

Spindle Invert axis opera-
k+1 reset M03/M04 tion C B A
1) Feed-
DL forward
Channel number 2)
k+2 control off* E D C B A
DR Resyn-
Set rotation Oscillation Basic Position chronize Acknowl- PLC spindle
k+2 cw speed speed spindle spindle edge M19 control
DL Spindle disable
k+3 n+7 n+6 n+5 n+4 n+3 n+2 n+1 n+0
DR Spindle disable
k+3 n+15 n+14 n+13 n+12 n+11 n+10 n+9 n+8
_______
1) SW 2 and higher
2) NC MD 540*.2 must be set for this function.
* Signal is active at 0

SINUMERIK 840C (PJ)
2.5.2.3 Spindle-specific GI signals from spindle 1)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
Accelera- Compensat- Following
DL tion limit ESR ory spindle
synchron- monitoring controller overlay Synchroni-
k+24 ous active is active active active zation busy Link active
Controlled
DR follow-up Accel. warn Veloc. warn Synchro- Synchro-
motion of Maximum Maximum threshold threshold nous motion nous motion
k+24 foll. spindle acceleration velocity reached reached fine coarse
Synchroniz-
DL ation ESR
position response is
k+25 reached triggered
DR Identifier ESR
following response is Request Request
k+25 spindle programd 2) LINK-OFF LINK-ON
DL Slave
operation C axis
k+49 active 3) active 2)
DR
k+49
GI = Gear interpolation
2.5.2.4 Spindle-specific GI signals to spindle 1)
Signals to spindle
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL Activate Pos.-related On-the-fly

ESR switching synchroniza- LINK–ON
k+26 monitoring ON tion ON
DR Disable
ESR LINK–OFF
k+26 monitoring
DL
k+27
DR Compensate Acceler. limit Enable Compens. Enable foll.
synchroniz. SYNCHRO- ESR controller spindle Interlock Interlock
k+27 difference NOUS response 2) ON overlay LINK–OFF LINK–ON
_______
1) As from SW 3
2) As from SW 4
3) As from SW 4.4

SINUMERIK 840C (PJ)
Notes:
• A maximum of 15 servo loops is possible (axes and spindles). With Software Version 5
and higher, max. 30 servo loops are possible (axes and spindles) with digital drives.
• The message text address n is required for the error and operational messages. The
SPINDLE DISABLE signals can additionally be checked for error messages via PLC MD
6034. The results of this check can be set as operational messages via PLC MD 6042.
The function blocks required for the check/display are contained in FB package 0.
Spindle Address K Message text PLC MD for

address processing 3)
1 0 8000 6012.0
2 4 8020 .1
3 8 8040 .2
4 12 8060 .3
5 16 8080 .4
6 20 8100 .5
2.5.2.5 Star-delta switchover, 611D
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL User-pro- User-pro- User-pro- User-pro- User-pro- User-pro- Heat sink Motor

grammable grammable grammable grammable grammable grammable temperature temperature
k+72 message 6 1) message 5 1) message 4 1) message 3 1) message 2 1) message 1 1) prewarng. 1) prewarng. 1)
DR Pulses are Drive Drive ready Motor Motor Parameter Parameter Parameter
enabled 1) switched on 1) selection bit selection bit set 2 1) set 1 1) set 0 1)
k+72 2) 1 1) 0 1)
DL Travel
request
k+73 drive test
ZK2 generator ZK2 DC link
Reserved ZK2 emergen-
DR speed <
minimum cy retraction
voltage<
emergency
ZK2 DC link
voltage <
k+73 speed
generator axis
or DC link
genertr active
retraction
threshold
warning
threshold
(MD 1635) (MD 1634) (MD 1604)
_______
3) Up to SW 2

SINUMERIK 840C (PJ)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL Parking Slave Gear ratio

spindle 2) operation monitoring
k+50 active 5) off 3)
DR Reserved
k+50
DL Reserved
k+51
DR Actual parameter set number Parameter group
"Speed ratio" 4) "Position control" 4)
k+51 Bit 2 Bit 1 Bit 0 Bit 2 Bit 1 Bit 0

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
Ramp-
DL Reserve Reserve Reserve Reserve Set speed function
611D-AM1 611D-AM1 611D-AM1 611D-AM1 smoothing 2nd torque generator
k+74 1) 1) 1) 1) 1) limit 1) rapid stop 1)
DR Motor Motor Motor Drive 611-D
Pulse Disable selection selection selection Parameter Parameter Parameter
k+74 enable 1) integrator 1) executed 1) bit 1 1) bit 0 1) set 2 1) set 1 1) set 0 1)
DL Motion
enable
k+75 drive test

1 0 16 60
2 4 17 64
3 8 18 68
4 12 19 72
5 16 20 76
6 20 21 80
7 24 22 84
8 28 23 88
9 32 24 92
10 36 25 96
11 40 26 100
12 44 27 104
13 48 28 108
14 52 29 112
15 56 30 116
_______
3) GTS = Gear stages as from SW 3
4) As from SW 4
5) As from SW 4.4

SINUMERIK 840C (PJ)
2.5.3 Axis-specific signals (DB 32)
Signals from axis (Section 6.1)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
Speed Position Reference Travel Travel Position reached with

DL k controller control Axis in set point command command exact stop
active 1) active range reached + – fine coarse
DR k Slave IKA IKA/TK Rounding Axis is in the
operation warning velocity axis in reduction
acitve 4) limit 1) exceeded 1) position area 5)
DL X
DR X FA reached FaF active

1) 1)
DL Cam Cam Cam Cam Cam Cam Cam Cam

4+ 4- 3+ 3- 2+ 2- 1+ 1-
X+1 1) 1) 1) 1) 1) 1) 1) 1)
DR
X+1
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL *Decel. 2nd software

Follow-up Feed disable ref. point Parking Controller limit switch
k+1 Mirroring mode simult. axis approach axis enable + –
dyn. SW Handwheel active
Conventional Rapid
DR traverse Feedrate Axis
limit sw.
monitoring
k+1 + – overlay 1:100 disable passive 5) 2 1
2)Feed- Setting of Referencing MEAS. Slave
DL forward reference w/o internal SYSTEM operation
Travel limit
k+2 control off dimensn 3) setpt entry 3) 1/2 active 4) + –
DR Reverse Axis-specific override
Axis direction of Override
k+2 reset rotation active E D C B A
DL Feed disable
k+3 n+7 n+6 n+5 n+4 n+3 n+2 n+1 n+0
DR Feed disable
k+3 n+15 n+14 n+13 n+12 n+11 n+10 n+9 n+8
_______
1) As from SW 3, IKA = Interpolation and compensation with tables, TK = Temperature compensation (when
IKA used as compensation)
2) As from SW 2
3) As from SW 4
4) As from SW 4.4
5) As from SW 5.6
* Signal is active at 0

SINUMERIK 840C (PJ)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL Sensor Acknowl. Acknowl.

FA for FA for FAF
x+2 reached 1) reached 1) active 1)
DR
x+2
DL Select cam Select cam Select cam Select cam
parameter 4 parameter 3 parameter 2 parameter 1
x+3 1) 1) 1) 1)
DR Reserved Actual parameter set number Actual parameter set number

"Speed ratio" 3) "Position control" 3)
x+3 Bit 2 Bit 1 Bit 0 Bit 2 Bit 1 Bit 0
x=120, 124, 128, ... 236 (axis 30)

Axis Address K Message text PLC MD for Axis Address K Message text PLC MD for
processing 2) processing2)
address address
1 0 8200 6016.0 16 60 8500 6017.7
2 4 8220 6016.1 17 64 8520 6018.0
3 8 8240 6016.2 18 68 8540 6018.1
4 12 8260 6016.3 19 72 8560 6018.2
5 16 8280 6016.4 20 76 8580 6018.3
6 20 8300 6016.5 21 80 8600 6018.4
7 24 8320 6016.6 22 84 8620 6018.5
8 28 8340 6016.7 23 88 8640 6018.6
9 32 8360 6017.0 24 92 8660 6018.7
10 36 8380 6017.1 25 96 8680 6019.0
11 40 8400 6017.2 26 100 8700 6019.1
12 44 8420 6017.3 27 104 8720 6019.2
13 48 8440 6017.4 28 108 8740 6019.3
14 52 8460 6017.5 29 112 8760 6019.4
15 56 8480 6017.6 30 116 8780 6019.5
Notes:
• A maximum of 30 axis data blocks (real and fictitious) is possible (max. 15 servo loops for
axes and spindles together). Max. 30 servo loops are possible with software version 5 and
higher (611D). No fictitious axes can be defined in addition to the 30 "axes".
The limitation to max. 15 real axes or spindles (axes/spindles with servo loops) for analog
drives still applies.
• The message text address n is required for the error and operational messages.
The FEEDRATE DISABLE signals can additionally be checked for error messages via
PLC MD 6035. The results of this check can be set as operational messages via
PLC MD 6043. The function blocks required for the check/display are contained in
FB package 0.
_______
1) As from SW3, FA=fixed stop, FAF=travel against fixed stop
2) Up to SW 2
3) As from SW 4

SINUMERIK 840C (PJ)
2.6 NData transfer interface
2.6 Data transfer interface

2.6.1 Data transfer PLC/NCK (DB 36)
Status data transfer (Section 7.2.2)
15 14 13 12 11 10 9 8
No. Byte No. Bit No.
interface
byte 7 6 5 4 3 2 1 0
Error Data Data Data Data
1 DL 0 Value 1- Number Access dis- transfer transfer transfer transfer
Value 3 format abled ended assigned busy Fifo full requested
2 DR 0 Value 1- Number Access dis- transfer transfer transfer transfer

Data transfer alarm-controlled

15 14 13 12 11 10 9 8
No. in- Byte No. Bit No.

terface
byte
7 6 5 4 3 2 1 0
Notes:
1) If the PLC goes into the stop state because of a parameterization error, the number of the
interface byte is entered in the high-order byte of ACCU 2.
2) If several jobs are entered in the buffer for data transfer, a job with the number 65 will be
processed before the others.
3) Data transfer is effected by function macros FB 61 (read) and FB62 (write).

SINUMERIK 840C (PJ)
2.6.2 Control of data transfer (DB 37)
2.6.2 Control of data transfer (DB 37)
Interface signals
15 14 13 12 11 10 9 8
Byte No. Bit No.

7 6 5 4 3 2 1 0
File transfer File transfer

DL 0 active in progress
DR 0
Signals for data transfer initiative PLC (see Section 8)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
Start Start
DL 1 Abort 3)
output 2) input 1)
Error in data Data transfer
DR 1 transfer ended
DW 2 - D a t a t y p e f o r d a t a t r a n s f e r (see table Section 8.2)
DW 3
DW 4 I n i t i a l n u m b e r f o r d a t a t r a n s f e r (see table Section 8.2)
DW 5 E n d n u m b e r f o r d a t a t r a n s f e r (see table Section 8.2)
DL 6 C h a n n e l n u m b e r f o r d a t a t r a n s f e r (see table Section 8.2)
DR 6 Reserved
DW 7 E r r o r c o d e (see table Section 8.2)
DW 8 D e v i c e t y p e (see table Section 8.2, states on which devices data can be input or output)
DW 9 Device No. 4)
DW 10 - Workpiece name ending with 0h (states which workpiece is being machined (corresponds to directory)
during data transfer with the hard disk).
DW 15
DW 16 - Reserved
DW 28
DL 29 States which data are being read into the NCK
Circular Tool Program Part
MSD/FDD buffer list data programs
DR 29 States which data are being read out of the NCK
Program Part
data programs
DL 30 States for which data read-in has been disabled (with DL 31)
Program Part
data programs
DR 30 States for which data read-out has been disabled (with DL 31)
Program Part
data programs
DL 31 Disables reading in of named data into the NCK (must be confirmed in DL 30)
Circular Tool Program Part
buffer list data programs
DR 31 Disables reading out of named data from NCK (must be confirmed in DR 30)
Program Part
data programs
_______
1) Data transfer MMC NCK (as from SW 3 1) RS232C (V.24) MMC, MMC NCK (as from SW 3)
2) Data transfer NCK MMC (as from SW 3 2) RS232C (V.24) MMC, NCK MMC (as from SW 3)
3) Reserved, not allowed for use in SW 1, 2 and 3
4) As from SW 3

SINUMERIK 840C (PJ)
2.7 Operator panel/PLC interface
2.7 Operator panel/PLC interface

2.7.1 Key signals from operator panel (DB 40)
The operator panel signals cannot be changed by the PLC user program, they are only
monitored.
The operator panel signals are transmitted in the NCK operating areas:
MACHINE, PARAMETERS, EDIT NC and NCK DIAGNOSIS only.
Key signals from operator panel (Section 9.1)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 0 Group A softkeys (dynamic signals)
Softkey 7 Softkey 6 Softkey 5 Softkey 4 Softkey 3 Softkey 2 Softkey 1
DR 0 Group A softkeys (static signals)
Softkey 7 Softkey 6 Softkey 5 Softkey 4 Softkey 3 Softkey 2 Softkey 1
DW 1
DW 2
DL 3 Group F selection cursor key group (dynamic signals)

Page Page
down up
DL 4 Group F selection cursor key group (dynamic signals)

Change Change Large
Acknowl. actual Search
value
mode grp.1) channel 1) alarm displ.
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DL 5 Group D correction keys (dynamic signals)

Clear Cancel Edit Input
DL 6 Group E Group A (dyn.)

Help Recall ETC
The static signals are stored in DR.
_______
1) Mode group and change channel is a dual assignment key.

SINUMERIK 840C (PJ)
2.7.1 Key signals from operator panel (DB 40)
Operating mode groups (Section 9.1.1)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 7
DR 7 Operating mode group number
Softkey function signals (Section 9.1.2)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 8 Dynamic function signals

7 6 5 4 3 2 1 0
DR 8 Static function signals

7 6 5 4 3 2 1 0

15 14 13 12 11 10 9 8

15 14 13 12 11 10 9 8

255 254 253 252 251 250 249 248

255 254 253 252 251 250 249 248
DL 40
DR 40 Function
number
change
DL 41 Bit 15
Softkey function number
Bit 8
DR 41 Bit 7
Softkey function number
Bit 0

SINUMERIK 840C (PJ)
2.7.2 Display dialog line (DB 40)
2.7.2 Display dialog line (DB 40)
Display dialog line (Section 9.2)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 43
DR 43
DW 44
Assigned by internal signals
DW 45
DW 46
DW 47
DW 48
DL 49 Acknowl. Strobe
function function n.
result valid valid
DR 49 Function number
DL 50 Function result
DR 50 Dialog text number

SINUMERIK 840C (PJ)
2.7.3 Menu selection (DB 40)
2.7.3 Menu selection (DB 40)
Menu selection (Section 9.3)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 51 Start
signal
from user
Own Acknowledgements
DR 51 insertion Insertion Insertion
active already act. Fault executed
DL 52
Job number (1 ... 11)
DR 52 (function code number)
Menu number/dialog text No. (1 ... 65535)

DL 53
(When the WS 800A programming workstation is used, the menu numbers are limited to 999.)
DR 53 Reference to DW x in DB 59 for SK function of PLC 1)
DL 54 Mode group number/software component 2) (1 ... 4)3)
DR 54 Channel number/software component 2) (1 ... 4)3)
Request Key lock to NCK

DL 55 for
key lock INPUT EDIT CANCEL
DR 55 Unassigned
DL 56 Spezial
recall
DR 56 Displayed channel from NC (1 ... 4)3)
_______
1) As from SW 4
2) Software component, relevant for the "alarm concept"
3) As from SW 4; 6 channels

SINUMERIK 840C (PJ)
2.7.4 Cursor data (DB 40)
2.7.4 Cursor data (DB 40)
Cursor (Section 9.4)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 57
Data group base
DR 57
Data type base
DL 58
DB / DX number base (1 ... 255)
DR 58
Unassigned
DL 59
DW number base (0 ... 2042)

DR 59
DL 60
Data group pointer
DR 60
Data type pointer
DL 61
DB / DX number pointer (1 ... 255)
DR 61
Unassigned
DL 62
DW number pointer (0 ... 2042)

DR 62
DL 63
Block number (0 ... 65535)

DR 63

SINUMERIK 840C (PJ)
2.7.5 User key signals (DB 40)
User key signals (Section 9.5)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DW 64
Reserved
DW 99
DL 100 User-assignable keys 1st customer key submodule (dynamic signals) 3)

Key 1 Key 2 Key 3 Key 4 Key 5 Key 6 Key 7 Key 8
DR 100 User-assignable keys 1st customer key submodule (static signals) 3)

DL 101 User-assignable keys 1st customer key submodule (dynamic signals) 3)

Key 9 Key 10 Key 11 Key 12 Key 13 Key 14 Key 15
DR 101 User-assignable keys 1st customer key submodule (static signals) 3)

DL 102 LEDs 1st customer key submodule 3)

LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 LED 8
DR 102 LEDs 1st customer key submodule 3)
LED 9 LED 10 LED 11 LED 12 LED 13 LED 14 LED 15
DL 103 Key hexadecimal code (KYRU II code)
DR 103 Status byte
DL 104
DR 104 Menu
MMC 2) Status Set-up number
active Area 1) image menu change User menu
DW 105 Menu number
_______
1) 0 ... data area
1 ... machine area
2) As from SW 2
3) 1st machine control panel

SINUMERIK 840C (PJ)
User key signals (Section 9.5)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 106 User-assignable keys 2nd customer key submodule (dynamic signals) 1)

DR 106 User-assignable keys 2nd customer key submodule (static signals) 1)

DL 107 User-assignable keys 2nd customer key submodule (dynamic signals) 1)

DR 107 User-assignable keys 2nd customer key submodule (static signals) 1)

DL 108 LEDs 2nd customer key submodule 1)

LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 LED 8
DR 108 LEDs 2nd customer key submodule 1)

LED 9 LED 10 LED 11 LED 12 LED 13 LED 14 LED 15
DL 109 Key hexadecimal code (ASCII code)
DR 109 Status byte
Vertical softkeys (dynamic)

DL 110 SK SK SK SK SK SK SK
14 13 12 11 10 9 8
Vertical softkeys (static)
DR 110 SK SK SK SK SK SK SK
14 13 12 11 10 9 8
DW 111 Reserved
:
DW 149
_______
1) 2nd machine control panel

SINUMERIK 840C (PJ)
2.7.6 Command channel interface (DB 41)
Command channel (DB 41) (Section 10.1)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 0 Reserved
DR 0 Request bits
UI 8 UI 7 UI 6 UI 5 UI 4 UI 3 UI 2 UI 1
DL 1 Reserved
DR 1 Error bits
UI 8 UI 7 UI 6 UI 5 UI 4 UI 3 UI 2 UI 1
DL 2 Reserved
DR 2 Reserved
DL 3 Reserved
DR 3 Reserved
DL 4 Reserved
DR 4 Reserved
DL 5 Reserved
DR 5 Reserved
Note:
The number of user interfaces (UI) is set in PLC MD 33.

SINUMERIK 840C (PJ)
Command channel (Section 10.2)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL
m (High)
Function number
DR
m (Low)
DL
m+1 (High)
Error number
DR
m+1 (Low)
DL DB = 0
m+2 DX = 1
DR Source DB/DX number

m+2
DL
m+3 (High)
Data word number
DR
m+3 (Low)
DL DB = 0
m+4 DX = 1
DR Target DB/DX number (IKA) 1)

m+4
(SW 3 and
higher)
DL
m+5 (High)
(SW 3 and
higher) Initial DW No. of target DB (IKA) 1)
(Low)
DR
m+5
DL
m+6
Reserved
DR
m+6
Note: Possible function numbers:

m =6 UI 1 1=Static path dimension
m =13 UI 2 2=Division increment
m =20 UI 3 3=S-external
m =27 UI 4
m =34 UI 5 5 =M19 over several revolutions
m =41 UI 6 6 =Transformation
m =48 UI 7 7 =Coupled motion
m =55 UI 8
9 =Temperature compensation 1)
10=Read IKA data 1)2)
11=Write IKA data 1)2)
12=Travel to fixed stop 1)
_______
1) As from SW 3

SINUMERIK 840C (PJ)
2.8 General interface NCK/PLC

2.8.1 Signals to/from NCK (DB 48)
Signals to NCK (Section 11.1)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 0 Status Keyswitch Operator Cycle Control with-

Warm
write setting 1 Screen dark panel disable
out operator
restart
disable (colour black) disable panel
DR 0 Transfer Activate Keyswitch setting

cam cam/axis 2 3
values 1) assignm. 1) 0 (color green) (color red)
DL 2
DR 2 PLC trigger signal 3)
Trace 4 Trace 3 Trace 2 Trace 1
DL 44) Collision Collision Collision Collision Collision Collision Collision Collision

monitoring monitoring monitoring monitoring monitoring monitoring monitoring monitoring
off 16 off 15 off 14 off 13 off 12 off 11 off 10 off 9
DR 44) Collision Collision Collision Collision Collision Collision Collision Collision
DL 64) Collision Collision Collision Collision Collision Collision Collision Collision
DR 64) Collision Collision Collision Collision Collision Collision Collision Collision
DL 8
DR 84) Enable
"Freeze
IKA"
DL k4)
DR k4) Request: Acknow- Switch on Switch off

Freeze IKA ledge error IKA
signal IKA
DL 744) Reduction area Off
Pr. zone 16 Pr. zone 15 Pr. zone 14 Pr. zone 13 Pr. zone 12 Pr. zone 11 Pr. zone 10 Pr. zone 9
DR 74 4)
Reduction area Off
DL 764) Reduction area Off
DR 764) Reduction area Off
_______
1) As from SW 3
2) IKA=Interpolation and compensation with tables
3) As from SW 4: The Trace functions are described in the Installation Instructions SINUMERIK 840C, Section
drive servo start-up applications
4) As from SW 6

SINUMERIK 840C (PJ)
Signals from NCK (Section 11.2)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 1 Screen
(SW 5 an
higher)
DR 1 Cam values Cam/axis NC modi- Warm
transferred assignm. fies cam restart
1) activated 1) param. 1) ended
DL 3
DR 3
DL 54) Protection Protection Protection Protection Protection Protection Protection Protection

zone zone zone zone zone zone zone zone
collision 16 collision 15 collision 14 collision 13 collision 12 collision 11 collision 10 collision 9
DR 54) Protection Protection Protection Protection Protection Protection Protection Protection
DL 74) Protection Protection Protection Protection Protection Protection Protection Protection
DR 74) Protection Protection Protection Protection Protection Protection Protection Protection

DL
k+14)
DR Change Output Output IKA in
limitation limitation limitation IKA frozen intermediate Error signal
returned IKA is on IKA is off
k+14) output minimum maximum state
DL 754) Protection zone adaptation active
DR 754) Protection zone adaptation active
DL 774) Protection zone adaptation active
DR 774) Protection zone adaptation active
IKA No. Address K IKA No. Address K

1 10 17 42
2 12 18 44
3 14 19 46
4 16 20 48
5 18 21 50
6 20 22 52
7 22 23 54
8 24 24 56
9 26 25 58
10 28 26 60
11 30 27 62
12 32 28 64
13 34 29 66
14 36 30 68
15 38 31 70
16 40 32 72
_______
1) As from SW 3
2) IKA=Interpolation and compensation with tables
3) As from SW 4: The Trace functions are described in the Installation Instructions SINUMERIK 840C, Section
drive servo start-up applications
4) As from SW 6

SINUMERIK 840C (PJ)
2.9 PLC messages (DB 58)
Control signals (Section 12.4)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
Display in message line Alarm with Acknowl.
DL 0 Acknowl. NC
emergency Error 1) Operational highest PLC error
stop*) messages messages1) Page priority 2) message
States (Section 12.4)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DR 0 NC in PLC emerg. PLC PLC ope-

emergency stop error rational
stop state message message 3) message 3)
Emergency stop to NC (Section 12.4)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 1 Message
9007 9006 9005 9004 9003 9002 9001 9000
DR 1 Message
9015 9014 9013 9012 9011 9010 9009 9008
DL 2 Message
9023 9022 9021 9020 9019 9018 9017 9016
DR 2 Message
9031 9030 9029 9028 9027 9026 9025 9024
_______
*) Static signal
1) SW 1 and SW 2 only
2) As from SW 3
3) As from SW 3: Error message = alarm
Operational message = message

SINUMERIK 840C (PJ)
Messages (Section 12.4)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 3 Message
9039 9038 9037 9036 9035 9034 9033 9032
DR 3 Message
9047 9046 9045 9044 9043 9042 9041 9040
DL 4 Message
9055 9054 9053 9052 9051 9050 9049 9048
DR 4 Message
9063 9062 9061 9060 9059 9058 9057 9056
DL 5 Message
9071 9070 9069 9068 9067 9066 9065 9064
DR 5 Message
9079 9078 9077 9076 9075 9074 9073 9072
DL 6 Message
9087 9086 9085 9084 9083 9082 9081 9080
DR 6 Message
9095 9094 9093 9092 9091 9090 9089 9088
DL 7 Message
9103 9102 9101 9100 9099 9098 9097 9096
DR 7 Message
9111 9110 9109 9108 9107 9106 9105 9104
DL 8 Message
9119 9118 9117 9116 9115 9114 9113 9112
DR 8 Message
9127 9126 9125 9124 9123 9122 9121 9120
DL 9 Message
9135 9134 9133 9132 9131 9130 9129 9128
DR 9 Message
9143 9142 9141 9140 9139 9138 9137 9136
DL 10 Message
9151 9150 9149 9148 9147 9146 9145 9144
DR 10 Message
9159 9158 9157 9156 9155 9154 9153 9152
DL 11 Message
9167 9166 9165 9164 9163 9162 9161 9160
DR 11 Message
9175 9174 9173 9172 9171 9170 9169 9168

SINUMERIK 840C (PJ)
Messages (Section 12.4)

15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 12 Message
9183 9182 9181 9180 9179 9178 9177 9176
DR 12 Message
9191 9190 9189 9188 9187 9186 9185 9184
DL 13 Message
9199 9198 9197 9196 9195 9194 9193 9192
DR 13 Message
9207 9206 9205 9204 9203 9202 9201 9200
DL 14 Message
9215 9214 9213 9212 9211 9210 9209 9208
DR 14 Message
9223 9222 9221 9220 9219 9218 9217 9216
DL 15 Message
9231 9230 9229 9228 9227 9226 9225 9224
DR 15 Message
9239 9238 9237 9236 9235 9234 9233 9232
DL 16 Message
9247 9246 9245 9244 9243 9242 9241 9240
DR 16 Reserved
DL 17 Message
9257 9256 9255 9254 9253 9252 9251 9250
DR 17 Message
9265 9264 9263 9262 9261 9260 9259 9258
DL 18 Message
9273 9272 9271 9270 9269 9268 9267 9266
DR 18 Message
9281 9280 9279 9278 9277 9276 9275 9274
DL 19 Message
9289 9288 9287 9286 9285 9284 9283 9282
DR 19 Message
9297 9296 9295 9294 9293 9292 9291 9290
DL 20 Message
9305 9304 9303 9302 9301 9300 9299 9298
DR 20 Meldung
9313 9312 9311 9310 9309 9308 9307 9306
DL 21 Message
9321 9320 9319 9318 9317 9316 9315 9314
DR 21 Message
9329 9328 9327 9326 9325 9324 9323 9322

SINUMERIK 840C (PJ)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 22 Message
9337 9336 9335 9334 9333 9332 9331 9330
DR 22 Message
9345 9344 9343 9342 9341 9340 9339 9338
DL 23 Message
9353 9352 9351 9350 9349 9348 9347 9346
DR 23 Message
9361 9360 9359 9358 9357 9356 9355 9354
DL 24 Message
9369 9368 9367 9366 9365 9364 9363 9362
DR 24 Message
9377 9376 9375 9374 9373 9372 9371 9370
DL 25 Message
9385 9384 9383 9382 9381 9380 9379 9378
DR 25 Message
9393 9392 9391 9390 9389 9388 9387 9386
DL 26 Message
9401 9400 9399 9398 9397 9396 9395 9394
DR 26 Message
9409 9408 9407 9406 9405 9404 9403 9402
DL 27 Message
9417 9416 9415 9414 9413 9412 9411 9410
DR 27 Message
9425 9424 9423 9422 9421 9420 9419 9418
DL 28 Message
9433 9432 9431 9430 9429 9428 9427 9426
DR 28 Message
9441 9440 9439 9438 9437 9436 9435 9434
DL 29 Message
9449 9448 9447 9446 9445 9444 9443 9442
DR 29 Message
9457 9456 9455 9454 9453 9452 9451 9450
DL 30 Message
9465 9464 9463 9462 9461 9460 9459 9458
DR 30 Message
9473 9472 9471 9470 9469 9468 9467 9466
DL 31 Message
9481 9480 9479 9478 9477 9476 9475 9474
DR 31 Message
9489 9488 9487 9486 9485 9484 9483 9482
DL 32 Message
9497 9496 9495 9494 9493 9492 9491 9490
DR 32 Reserved
Note:
• PLC machine data are used to determine whether messages are to be treated as error or
operational messages.
• The function blocks for message interrogation and display are contained in FB package 0.

SINUMERIK 840C (PJ)
2.9.1 Softkey function calls (DB 59)
2.9.1 Softkey function calls DB 59 1)
Softkey function calls (Section 9.3.1)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL x
Error message
DR x
Valid only with error acknowledgement in DB 40 (DR 51, bit 1)
DL
x+1
Function number (1 ... 65535)
DR
x+1
DL
x+2
Number of parameters (max. 49)
DR
x+2
DL
x+3
Parameter 1
DR
x+3
DL
x+4
Parameter 2
DR
x+4
.
..
DL
x+y
Parameter n
DR
x+y
Note:
DB 59 is initialized by the operating system with a length of 128 DW. x=any DW, default in
DB 40, DR 53.
_______
1) As from SW 4

SINUMERIK 840C (PJ)
2.10 PLC machine data
2.10 PLC machine data
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A description of the PLC machine data is to be found in the
Installation Guide Instructions (IA), see table below !

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Division of PLC MD
Section in
PLC MD DB Meaning Softkey Installations
Instructions
0
to DB60 MD for operating system System data 8.2
839
2000
to DB61 MD for function blocks FB data 8.3
2849
4000
to DB62 MD for user User data 8.4
4349
6000
to DB63 MD bits for operating system System bits 8.5
6599
7000
to DB64 MD bits for function blocks FB bits 8.6
7799
8000
to DB65 MD bits for user User bits 8.7
8199

SINUMERIK 840C (PJ)
2.11 Configuring distributed machine peripherals (DMP)

General
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Compact DMP,
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IP 65, DMP I/O
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PLC MD 136
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=0 = No. DB/DX
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DB/DX configuring
Machine data configuring
(free)
PLC MD 34-135
Configuring module DB/DX
• Machine control panel • Machine control panel
• Handheld unit • Handheld unit
• 1 distributed interrupt byte
• Max. 4 distributed interrupt bytes
per interface (1 module per interface)
The distributed machine peripherals can either be addressed via machine data or via
configuring modules. Mixed configuring is not possible, i.e. once you have chosen a
configuring method, you must also configure the machine control panel and the handheld unit
in the same way.
Exception: The central interrupt byte of the IF-PLC/PLC 135 WD is always configured via
PLC MD 30.
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aaaaaaaa
The simultaneous use of central interrupts and interrupt-generating DMP

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is not permissible.
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Note:
Up to SW 2: 8 terminal blocks per line can be used. The machine control panel is
addressed as a terminal block. The initial address of the machine control panel
I/O image must be entered in PLC MD 128.
As from SW 3: A total of 15 DMP stations can be connected to the 135WB2/INTPLC or 135
WD modules. Handheld unit, machine control panel and IP65 module are
counted as DMP stations.
In each line, a maximum of 8 DMP stations is allowed for the INTDMP module.
The handheld unit and the distributed interrupt are to be connected in line 1.

SINUMERIK 840C (PJ)
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PLC MD 134
PLC MD 131
PLC MD 130
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Interrupt routing
SINUMERIK 840C (PJ)

each terminal block.

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In the example this means:

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2, 160-modules can also be used.
X
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PLC MD 6068 ... 6072 interrupt edges

e.g.: DMP compact
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PLC MD 6074 ... 6078 interrupt enables

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6FC5197- AA00
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86
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No. of interrupt byte of 1st INT-DMP

No. of interrupt byte of 1st INT-DMP
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4 analog input modules can be inserted into the slots 1 ... 4.

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4 analog output modules can be inserted into the slots 5 ... 8.

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One interrupt byte is possible per interface (caution: not per line):
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No. of interrupt byte of IF-PLC/PLC 135WD 1st line

1st line
2nd line
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Configuring the distributed machine peripherals via machine data
Module
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byte
byte
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terminal block" a maximum of 4 input modules and 4 output modules are possible.
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necessary requirement of DMP machine data configuring. In the example, "DMP compact
The initial address is defined in the machine data (e.g. PLC MD 34 = 80). Fixed slots are a
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The input and output modules are word addressed. Machine data must be configured using
The analog DMP modules are treated like the digital modules. 4 modules can be inserted in
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e.g. 1st interrupt

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consecutive fixed addressing. Only one byte can be assigned for output modules. As from SW
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2 Assigned Areas
2–59
Configuring the distributed machine peripherals via the configuring block DB or DX
Division of the configuring DBs
15 0
DB head
DWn Module status
Configuring block
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n+1 Interface no.
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n+2 MPC no.
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n+3 Terminal block no.
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n+4 Initial address I 1st module or
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n+5 Initial address O conventional module
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Initial address E 8th module
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n+19 Initial address A
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Configuring block
for next terminal
block
Configuring block Interrupt status

for INT input DWi
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i+1 No. of 1st INT byte

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i+3 No. of 3rd INT byte

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i+4 No. of 4th INT byte

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i+5 Edge selection Edge selection

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1st INT byte 2nd INT byte
Edge selection Edge selection

3rd INT byte 4th INT byte
Enable Enable
1st INT byte 2nd INT byte
Enable Enable
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i+8 3rd INT byte 4th INT byte

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Module status: Identifier for each terminal block (data type KC)
UN = Module active (UNIT Not blocked)
UB = Module active (UNIT Blocked)
Interface no.: Number of INT-PLC/PLC 135 WD/INT-DMP interface module (data type KF)
1 = 1st INT-DMP
2 = 2nd INT-DMP (not with SW 1 and SW 2)
3 = INT-PLC/PLC 135 WD

SINUMERIK 840C (PJ)
MPC no.: No. of MPC line (data type KF)

0 = Block not assigned, must remain reserved
1 = Line 1
2 = Line 2
Terminal block no.: No. of DMP terminal block in line (1 ... 15) (data type KF)
1 = Terminal block 1 (switch position E)
2 = Terminal block 2 (switch position D)
.
.
.
15 = Terminal block 15 (switch position 0)
Interrupt status: Identifier for each interrupt byte (data type KF)
IN = Interrupt active (Interrupt Not blocked)
IB = Interrupt blocked (Interrupt Blocked)
No. of INT byte 0 ... 255 (data type KF)

Preset the unassigned INT bytes with -1.
Edge selection: Bit-by-bit assignment of interrupt-generating edges (data type KF)

0: 1 0 edge
1: 0 1 edge
Enable: Bit-by-bit enabling of interrupt inputs (data type KF)

0: Interrupt input disabled
1: Interrupt input enabled
Notes:
• If PLC machine data 136 >< 0 is set, the value in this machine data states the DB or DX
module number in which the extended configuring data are stored.
MD 136 = 1 ... 255 DB no. 1 ... 255
MD 136 = 1000 ... 255 DX no. 0 ... 255
20 DWs are required for each module. Nine DWs are needed for interrupt routing.
• If the configuring DB is missing (in MD 136) or incorrect, i.e. has impermissible values or
data words are missing (incomplete block lengths), the PLC goes into the stop state with
error message 33 and additional error information.

SINUMERIK 840C (PJ)
Configuring notes for different types of module
DMP 16 I/O DW n Module status UN/UB
Machine control panel DW n+1 Interface no. 1/3

(8 I/O bytes assigned) DW n+2 MPC no. 1/2
Handheld unit DW n+3 Terminal block no. 1...15
(24 I/O bytes assigned)
DW n+4 Initial address inputs 1st IW 0...254
IP 65 DW n+5 Initial address outputs 1st QW 0...254
DW n+6 free -1
: -1
DW n+19 free -1
DMP 32 I DW n Module status UN/UB
DW n+1 Interface no. 1/3
DW n+2 MPC no. 1/2
DW n+3 Terminal block no. 1...15
DW n+4 Initial address inputs 1st IW 0...254
DW n+5 free -1
DWn+6 Initial address outputs 2nd IW 0...254
DW n+7 free -1
: -1
DW n+19 free -1
DMP compact DW n Module status UN/UB

16 I DW n+1 Interface no. 1/3
8 Q
16 Q DW n+2 MPC no. 1/2
ANALOG IN DW n+3 Terminal block no. 1...15
ANALOG OUT
DW n+4 Initial address inputs 1st module 0...254
DW n+5 Initial address outputs 1st module 0...254
DW n+6 Initial address inputs 2nd module 0...254
DW n+7 Initial address outputs 2nd module 0...254
: 0...254
DW n+18 Initial address inputs 8th module 0...254
DW n+19 Initial address outputs 8th module 0...254
• 8 output modules fill a whole output word, the high byte of the output word cannot be used
• Preset all unassigned inputs/outputs with -1.

SINUMERIK 840C (PJ)
I/O submodules are routed and entered in the address list by the PLC according to the
information in the configuration lists.
Any double addressing of I/O submodules in different interface modules is recognized by the
PLC and displayed as an error.
Double addressing within an INT-PLC/PLC 135 WD or within an INT-DMP is signalled as an
MD error by the interface.
Free configuring examples:
• 16 I/Q
Initial address I: DW n+4
Initial address Q: DW n+5
• 32 I
Initial address I: 1st word DW n+4
Initial address I: 2nd word DW n+6
• IP 65
Initial address I: DW n+4
Initial address Q: DW n+5
• Handheld unit, machine control panel

Initial address I: 1st byte DW n+4
Initial address Q: 1st byte DW n+5
Caution:
With handheld unit and machine control panel, in each case only the first byte is
configured, subsequent bytes are used consecutively. For the machine control panel, the
initial address of the I/O image must be entered in MD 128.
• DMP compact module

Configurable on each I or Q module (depending on the component complement):
e.g. module 1: either DW n+4 (if I)
or DW n+5 (if Q)
contains the byte address
• Analog input/output reference module

The analog modules are configured like the digital modules. 4 of each can be inserted as
required.

SINUMERIK 840C (PJ)
Interrupt routing
• The central interrupt byte of the IF-PLC/PLC 135 WD or decentralized peripheral bytes can
be used for the interrupt routing. Central interrupts and interrupt-generating DMPs must
not be used as the same time.
• A total of 4 interrupt bytes are possible.
• A maximum of 4 interrupt bytes can be used. This also applies to the central interrupt
byte, e.g.
INT-PLC, module 2, 2 interrupt byte address
INT-DMP, module 5, 1 interrupt byte address
Central interrupt byte, 1 interrupt byte address
• The interrupt-generating peripheral bytes can be distributed amongst the modules as
required.
• All interrupt bytes of an interface must be located on the same module.
• The initial address of a sequence of interrupt bytes must be a module initial address.
• If the central interrupt byte of the INT-PLC/PLC 135 WD is used, it is always the fourth
interrupt byte (must always be configured through MD 30).
• OB 2 must be enabled. PLC MD 6050.2 and the PLC CPU must operate in special mode.
PLC MD 6051.0 = 0.
• OB 2 is activated with every interrupt request. Flag bytes 8 to 11 also show the interrupt-
triggering bit.
• Flag bytes 8 to 11 must be reset by the user program in organization block 2.
Definition of flag bytes FY 8 to FY 11
FY 8 Interrupt inputs 1st INT byte

FY 9 Interrupt inputs 2nd INT byte
FY 10 Interrupt inputs 3rd INT byte

FY 11 Interrupt inputs 4th INT byte
(if the central interrupt byte is defined, then the 4th interrupt
byte is always the central one).

SINUMERIK 840C (PJ)
Free configuration of the DMP using the DMP compact terminal block as an example
e.g. 2nd terminal block

rotary switch setting "D"
Slot
O X QB 0 1
I IB 5 IB 4 2
O X QB 20
I IB 7 IB 6 .
.
I IB 9 IB 8 .
O QB 4
X Gap
O QB 60
In contrast to machine data configuring, fixed slot and address configuring is not necessary
here. The modules are addressed by word. Gaps are permissible.
Defining machine data

You define the number of the configuring block with PLC MD 136, e.g.
DB 200 PLC MD 136 = 0200
DX 200 PLC MD 136 = 1200
Example: (interrupt byte is IB 6)
INT-PLC/PLC 135 WD
TB no. Switch position Input/output addresses
interface module
Machine control panel 1 E IB 64/ QB 64
DMP compact terminal block 2 D
1st module QB 0
2nd module IW 4
3rd module QB 20
4th module IW 6
5th module IW 8
6th module QB 4
7th module X Gap
8th module QB 60

SINUMERIK 840C (PJ)
DX 200 without interrupt processing
0 KS = ”UN”; UN = terminal block enabled/UB = terminal block disabled

1 KF = + 00003; INT-PLC/PLC 135 WD interface
2 KF = + 00001; Line 1
3 KF = + 00001; Terminal block 1 machine control panel rotary switch "E"
4 KF = + 00064; Inputs IB 64 onwards
5 KF= + 00064; Outputs QB 64 onwards
6 KF = - 00001;
7 KF = - 00001;
8 KF = - 00001;
9 KF = - 00001;
10 KF = - 00001;
11 KF = - 00001;
12 KF = - 00001;
13 KF = - 00001;
14 KF = - 00001;
15 KF = - 00001;
16 KF = - 00001;
17 KF = - 00001;
18 KF = - 00001;
19 KF = - 00001;
20 KS = ”UN”; UN = terminal block enabled/UB = terminal block disabled
21 KF = + 00003; Interrupt PLC/PLC 135 WD interface = 3rd INT DMP = 1
22 KF = + 00001; Line 1
23 KF = + 00002; Terminal block 2 DMP compact rotary switch "D"
24 KF = - 00001; 1st module QB 0
25 KF = + 00000;
26 KF = + 00004; 2nd module IW 4
27 KF = - 00001;
28 KF = - 00001; 3rd module QB 20
29 KF = + 00020;
30 KF = + 00006; 4th module IW 6
31 KF = - 00001;
32 KF = + 00008; 5th module IW 8
33 KF = - 00001;
34 KF = - 00001; 6th module QB 4
35 KF = + 00004;
36 KF = - 00001; 7th module Gap
37 KF = - 00001;
38 KF = - 00001; 8th module QB 60
39 KF = + 00060;
Any data not required must be preset with "-1".

SINUMERIK 840C (PJ)
DX 200 with interrupt processing
40 KS = ”iN”; Interrupt processing IN = switch on, IB = switch off

Address IB 0 - 255, -00001 = switch off
41 KF = 6 1st interrupt byte, e.g. IB6
42 KF = –00001; 2nd interrupt byte
43 KF = –00001; 3rd interrupt byte
44 KF = –00001; 4th interrupt byte (only if PLC MD 30 is not used)
Edge evaluation 0 edge = 0 1
1 edge = 1 0
45 KM = 11001111 00000000 1st byte / 2nd byte
46 KM = 00000000 00000000 3rd byte / 4th byte
Enable bit = 1, disable bit = 0
47 KM = 11111111 00000000 1st byte / 2nd byte
48 KM = 00000000 00000000 3rd byte / 4th byte

SINUMERIK 840C (PJ)
2.12 Set-up DBs for users
2.12 Set-up DBs for users

2.12.1 Icon selection in the MMC (DB 66) 1)
Icon selection (Section 15)
15 14 13 12 11 10 9 8
Byte No. Bit No.
7 6 5 4 3 2 1 0
DL 0 3rd icon field
DR 0 2nd icon field
DL 1
DR 1
DL 2
DR 2
DL 3
DR 3
_______
1) As from SW 2

SINUMERIK 840C (PJ)
•
•
•
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Notes:
Icon 5
Icon 4
Icon 3
Icon 2
Icon 1
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a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
Axis running:
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
The icon 1
aa
a
Override = 0%:
aa
a aa
aa
aaaa
aaaa
aaaaaaa
a aaa aa aa a aaa
Program running:
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
SINUMERIK 840C (PJ)

a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a a
aa
aaaa
Program interrupted:
a aaa aa aa a aaa aa aa
a
0%
Icon
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a aa
aaaaa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
aaaaa aa aa a aa
aa
a
a
a
aa
a
aa
a
aa
a
aa
a
aa
a
aa
a
aa
a
aa
a
aa
aaa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a

a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
panel
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aa
Block search,
Axis in motion
aa
a
Override = 0%
aa
a aa
aa
aaaa
aaaa
aaaaaaa
a aaa aa aa a aaa
Program running
a aaa aa aa a aaa
Data input/output
program interrupt
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
override = 0%
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aaa
cannot be overwritten by the PLC program.

a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
All other values lead to no icons being displayed.

a aaa aa aa a aaa
6FC5197- AA00
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aaa
search was triggered.

a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
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aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aaa
DL 0
DL 0
DR 0
DR 0
a aaa aa aa a aaa
DB66
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aaa
No icons are displayed in the graphic programming system (WOP).

a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aaa
For the icons, three icon fields are available underneath the clock.
a aaa aa aa a aaa
The FX 81 (package 0) function block supplies the interface DB 66

a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
Bit 1 = 1
Bit 0 = 1
Bit 1 = 1
Bit 0 = 1
a aaa aa aa a aa
Display
aa
a aa
aa
aaaa
aaaa
aaaa aa
aaa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aaa
on start of data input/output
a
a a
aa
aa
a a
aa
a a
aa
a a
a a
aa
aa
a
a aaa aa aa a aaa
if the ”Program running” signal is present in one channel

a aaa aa aa a aaa
Clear
a aaa aa aa a aa
=0
=0
=0
=0
if the ”Program running” signal is not present in any of the

aa
a aa
aa
aaaa
aaaa
aaaaaaa
aa
a
Display of the icons is effected across all channels and axes. The following priorities apply:
as soon as a travel command is present in one axis and not a aaa aa aa a aaa
via the RS232 (V.24) DC interface
a aaa aa aa a aaa
mode change or M00/M01 is active in one channel or if block

a aaa aa aa a aaa
data input/output is displayed in the 1st icon field as standard and
a aaa aa aa a aaa
if feedrate override is set to 0% on at least one machine control

a aaa aa aa a aaa
channels and, in addition, a program interrupt caused by STOP,

a aaa aa aa a aaa
2 Assigned Areas
a aaa aa aa a aa
2–69
2.12.1 Icon selection in the MMC (DB 66)
aaaaaaaaaaaa a
2.12.2 Internal machine control panel (DB 67)
2.12.2 Internal machine control panel (DB 67) 1)
Internal machine control panel (Section 15)
15 14 13 12 11 10 9 8
PLC Bit No.

MD No.
Byte No. 7 6 5 4 3 2 1 0
DL 0
DR 0
DL 1
DR 1 RESET
(from editor)
DL 2
DR 2
DL 3
DR 3
The internal machine control panel offers the possibility of simplifying safety-relevant operator
inputs in the NCK for any customer application. The ”direct change into the editor to the
position of the block pointer” function is set by the NC-RESET bit on selection of the editor.
This RESET can be effected by evaluating the bit and transferring it to the relevant channel
DB, thus obviating the need for additional operator inputs.
2.12.3 Data words for users (DB 68)
Data words (Section 15)
DW No.
PLC High byte (DL) Low byte (DR)
DW 0
.
..
DW 63
_______
1) As from SW 2

SINUMERIK 840C (PJ)
2.12.4 Data bits for users (DB 71)
2.12.4 Data bits for users (DB 71)
Data bits for users (Section 15)
Byte No.
DL 0
..
.
DR 15
2.13 Decoding list for M signals (DB 80 ... DB 83) 1)
Decoding list for M signals
DW No.
DW Extended address
m+0
DW M address
m+1
DW Bit address, DW No. Bit address, bit No.
m+2
Notes:
• Address m is derived from the following number of the M function definition:
M function m
1 0
2 3
3 6
. .
. .
. .
64 189
• The table must be completed consecutively starting with the first entry. No gaps are
allowed between entries. If fewer than 64 M functions are defined, the remaining entries
must be preset to 0. All unavailable entries are at the end of the table.
• The decoding lists are channel-specific; decoding list DB 80 is intended for NC channel 1,
so that DB 83 accordingly belongs to NC channel 4.
• The decoding message according to list is activated as a channel-specific function by
means of MDs.
_______
1) As from SW 4: 6 channels; DB 80 ... DB 85
END OF SECTION

SINUMERIK 840C (PJ)
11.92 3 Description of Basic Signals FY 0...FY 24
3.1 PLC auxiliary signals
3 Description of Basic Signals FY 0...FY 24
FLASHING FREQUENCY 0.5 HZ FY 0, bit 7
The system program provides a flashing frequency of 0.5 Hz in flag F 0.7. The pulse/no-pulse
ratio is 1:1.
ONE FY 0, bit 1
Flag with defined one signal.
ZERO FY 0, bit 0
Flags with defined zero signal.

The flags ONE and ZERO are used to switch FB parameters which are not required but have
to assume a certain signal state, or which produce a defined result of logic operation (RLO).
ACTUAL OB NO. FY 1
OB No. from which a branch was made into the user program (fixed-point number).
No. Assigned OBs
1 OB 1 Cyclic program
2 OB 2* Alarm-controlled program
3 OB 3 Alarm-controlled program
4 OB 4 Aperiodic program
5 OB 5* Time-controlled program
6 OB 6 Time-controlled program
7 OB 7 Time-controlled program
255 PLC operating system is active
_______
* These OBs are processed only in special mode (PLC MD 6051.0=0).

SINUMERIK 840C (PJ)
3 Description of Basic Signals FY 0...FY 24 06.93
BASIC SETTING (OB 1 to OB 7) FY 2, bits 1 to 7
1 signal: A warm restart or cold restart has taken place. The processing plane of the
relevant OB is called up after DB 20 for the first time.
0 signal: After the last warm restart the relevant OB has been executed completely at least
once.
After a warm restart or cold restart of the PLC, the basic signals are set for the duration of the
first complete program execution of the relevant processing plane.
The PLC operating system sets the basic signals back to zero after the first complete
execution of the relevant processing plane.
Example of application:
Using this signal, program parts can be put into a defined initial state after Power On.
Depending on the initial settings, an initialization routine can be called up in every OB.
Notes:
• When the processing plane is interrupted by Power Off:
The basic setting signal of the processing plane which is interrupted by a mains failure
(e.g. by Power Off) is not set immediately after a warm restart. The basic setting signal for
this processing plane is set after completion of execution of the processing plane, so that
it is set for the duration of the next execution of the relevant OB.
The basic setting signal to an OB is therefore not set while the relevant processing plane
is active.
• Several processing planes active at Power Off:
If several processing planes are active simultaneously when program execution is
interrupted (at Power Off), their basic setting signals are set only after all the remaining
interrupted processing planes have been executed after warm restart. This is illustrated in
the example that follows.
Example: Time alarm in the event of mains failure

The PLC is operating in the normal mode. There is a branch from OB 1 to a program module
(represented here by PB X).
Situation before warm restart:

A time alarm occurs when the program module PB X is to be executed. The PLC operating
system therefore first branches to OB 6. During processing of OB 6 the supply voltage for the
PLC fails.This means that in the event of program interruption as the result of a mains failure,
the processing planes OB 1 to OB 6 are active.
Situation on warm restart:

The basic setting signals of all processing planes other than OB 1 and OB 6 are set. The
program execution continues from the point where it was interrupted in OB 6. At the end of
OB 6, OB 1 becomes active once more, i.e. the JU PB X command, which was interrupted by
the time alarm, is first completed and then relayed to PB X. At the end of the OB 1 module,
the PLC operating system sets the basic setting signals for OB 1 and OB 6.

SINUMERIK 840C (PJ)
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaa
OB 6
aaaaaaaa
POWER OFF
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaaaaaa
aaaaaaaa
OB 1
Time alarm Warm restart with GST = 1 for all
BE OB except OB 1, OB 6
JU PB X
JU PB X is executed
aaa
a
a
a
a
a
aa
a
a
a
a
a
a
a
a
aaaaa
a
a
a
a
aaa
a
a
a
a
a
a
a
PB X
a
a
a
a
a
a
a
aa
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
BE
a
a
a
a
a
a
a
a
a
a
a
aa
a
a
a
a
a
a
a
a
a
aaaaaaa a
GST OB 1=1
a
a
a
a
a
a
a
a
a
a
a
a
aa
a
a
a
a
a
a
a
a
aaaaaaa
a
a
a
a
a
a
a
a
a
a
a
aa
a
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a
a
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a
a
a
a
a
a
a
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a
a
a
a
a
aa
a
a
a
a
a
a
a
a
GST OB 6=1
a
a
a
a
a
a
a
a
a
a
aa
a
a
a
a
a
a
a
a
a
a
a
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a
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a
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a
a
a
a
a
a
a
a
a
a
a
a
a
BE
The basic setting signals of the processing planes interrupted by Power Off (here OB 1
and OB 6) are set only after the completion of their remaining execution.
Setting the basic setting signals on warm restart - example : interrupted time alarm
COLD RESTART (OB 1 to OB 7, OB 20) FY 3
1 signal: After initiation of cold restart by PLC operator.

0 signal: After first complete processing of the relevant organization block.
Note on application:
Using this signal, program parts can be put into a defined initial state after a cold restart. After
a cold restart, data records usually also have to be normalized (in contrast to warm restart)
because the PLC is very often reset before a cold restart. The cold restart signals indicate a
preceding cold restart during initial state processing, i.e. they remain set until the relevant
processing time has been fully executed for the first time following a cold restart.
Note on OB 20
The OB 20 has its own cold restart signal. If the signal is zero, this means that the OB 20 was
called in the warm restart branch. If the OB 20 is interrupted in the warm restart branch with
F 3.0 = 0 (i.e. OB 20 undergoing warm restart), the initiated command sequence is not con-
tinued. Instead, the OB 20 is executed again from the beginning with a cold restart
(F 3.0 = 1).
Note on FY2 and FY3

Warm restart: only FY2 is set
Cold restart: FY2 and FY3 are set

SINUMERIK 840C (PJ)
PARAMETER TEST (OB 1 to OB 7) FY 4, bits 1 to 7
1 signal: a) After warm restart

b) After cold restart
c) After a transfer of blocks PG PLC
0 signal: a) After first complete processing of the plane concerned following initiation by
warm or cold restart
b) After completion of data transfer PG PLC and complete processing of the
relevant organization block.
2 tc
Signal diagram for block transfer
1 Block transfer PG PLC

2 PARAMETER TEST (tc PLC cycle time)
Note on application:
After a cold or warm restart and after the PG has transferred blocks during operation, the
parameterization of the function blocks may have been modified.
By means of the PARAMETER TEST signals for OB 1 to OB 7, the parameters can be chec-
ked to determine whether they have been modified. This restricted parameter test reduces the
processing time of a block during normal operation.
Example:
:
AN F 4.1
JC=FORT
:
Test routine
:
ADDRESSING ERROR DETECTION FY 5, bit 7
1 signal: The addressing error detection function is selected.

0 signal: The addressing error detection function is not selected (default).

SINUMERIK 840C (PJ)
Note:
Monitoring is activated by the STEP 5 command AFF (enable addressing error detection). The
STEP 5 command AFS (inhibit addressing error detection) is the default and deactivates
monitoring.
When the addressing error detection has been enabled and a non-existent input/output is
addressed, the PLC branches to the STOP state with the error number 8AH.
BLOCK SEGMENT VIOLATION FY 5, bit 6
1 signal: Block segment violation possible.

0 signal: Block segment violation not possible.
As a block can lie above segment limits, not only the offset address but also the segment
number must be taken into account for absolute address computation.
INFO BIT FOR ALARM PACKAGE (FB PACKAGE 0), AS FROM SW3 FY 5, bit 5
1 signal: By the PLC operating system

For alarm processing in package 0 (display of alarms) at least one item of
information is available from MMC, i.e. at least one element is in the mail box.
0 signal: By the PLC operating system
Mail box is empty
PLC number FY 5, bit 0
1 signal: Always PLC 1

0 signal: No significance for the 840C
PROCESSING DELAY (OB 2 to OB 7) FY 6, bits 2 to 7
1 signal: Processing delay effected by the relevant OB.

0 signal: No meaning
Note:
If time or process-alarm controlled program execution is called again before it has been
completed, the PLC operating system sets the relevant PROCESSING DELAY bit (depending
on PLC MD 6048 ). These bits are deleted with a cold or warm restart.
The user can set bits within MD 6048 in accordance with the OB No. (except OB 1). If, for
example, bit 4 and bit 5 are set, the PLC operating system causes the control to assume stop
status in the event of a processing delay activated by OB 4 or OB 5. However, the relevant
bits in FB 6 are not set. A processing delay activated by the other OBs does not lead to the
stop condition, but causes the bit corresponding to the OB No. in FB 6 to be set.

SINUMERIK 840C (PJ)
GROUP MESSAGE LIM/SIM FY 6, bit 1
1 signal: One or several bits in DB 1 "Lost requests during LIM/SIM OB 2 to OB 7" is/are
set.
0 signal: No bit in DB 1 "Lost requests during LIM/SIM OB 2 to OB 7" is set.
3.2 PLC ready signals
INTERRUPT INPUTS FY 8 and FY 9, 10, 11
1 signal: Signal change at interrupt input

0 signal: No signal change
After processing the response program (OB 2), the signal change bits must be reset by the
user. If this is omitted, the PLC branches to the stop state with an error message (fine error
coding F9).
Note:
• Interrupts can be processed only in the special mode of the PLC.
• A maximum of 4 interrupt bytes are possible. Interrupt signals can either be interfaced via
the interface PLC/PLC 135 WD module (central interrupt byte) or via DMP modules
(distributed interrupt byte).

SINUMERIK 840C (PJ)
3.3 Signals for alarm-controlled machining
NEGATIVE EDGE FY 12 to FY 15
1 signal: A change in signal state from 1 to 0 has occurred at the relevant bit of the alarm
byte.
0 signal: No effect
POSITIVE EDGE FY 16 to FY 19
1 signal: A change in signal state from 0 to 1 has occurred at the relevant bit of the alarm
byte.
0 signal: No effect
Notes:
Using PLC MD 124-127 the user defines a maximum of 4 contiguous process alarm bytes
within the available inputs. The process alarm bytes may be in the range of central or
distributed I/Os. Machine control panel input bytes are not allowed.
The PLC operating system checks the alarm bytes for modifications. If a modification is
determined, the active program is interrupted either at the block or command limit, depending
on the setting of the PLC mode (PLC MD 6051), and the OB 3 is called (depending on special
mode/normal mode).
The user interface for alarm-controlled programs is OB 3.
The operating system stores 0 1 transitions of the alarm byte in FY 16 and the 1 0
transitions in FY 12 are present until the next alarm or cancelled by user. The user can branch
his program using the ”signals for alarm processing”.
If, for example, the inputs I 0.0 to I 0.7 are interrogated in the processing program, the
following instructions must be programmed, e.g. at the start of the alarm program (update I/O
scan and PII):
:L PY 0
:T IB 0
If outputs have to be switched off because of an alarm, these should suitably be output to the
process I/Os at the end of the OB 3:
:L QB 5
:T PY 5
Example
Program branching depending on the activating signal change, e.g. in IB 0.
:
A F12.0
JC PB 5
A F16.0
JC PB 6
:

SINUMERIK 840C (PJ)
a
aa
aaa
aaa
aa
aa
a a
aa
a a
aaaaaaaaa a
aaaaaa
a a
aaaaaaa a
aaaa
aaaaaa
aa
a
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
3–8
3.5
3.4
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
Note:
Note:
Note:
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active.
a
aa
aa
aa
aa
aa
aa a
aa
a a
aa
a a
a a
aa a
a a
a a
aa
a a
aa
a a
aa a
a a
aa
a a
a a
aa
aa
0 signal:
1 signal:
1 signal:
1 signal:
0 signal:
1 signal:
0 signal:
1 signal:
a
aa
aa
aa
aa
aaa
aa
a a
aa
aaaa
aa aa a
aa
a a
aaaaaa
aaaa
aa a
aa
a a
aaaa
aaaaaaa
aa
a
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
NC ALARM
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
MMC CPU READY

INTERFACE CL 1, 2
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
No NC alarm
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
of all channels).
Signal to CSB: data saved

MM CPU failure.
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
a a
aa
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
aa
a
NC ready signals
Individual signals
a
aa
aa
aa
aa
aa
aa
a a
aa
a a
aa
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Signal from CSB: power failure

The signal is reset with NCK Reset.

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DRIVES READY (SW 6 and higher)

NC CPU READY (SW 6 and higher)
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The signal is reset with "Drive coupling off".

Drives are ready for operation.

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b) Computer link module failure.
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Part 2, Connection Conditions, Section 2.3.6.2

Part 2, Connection Conditions, Section 2.3.6.2
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The NC CPU is ready for operation.

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a) Computer link module not available.
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The MMC CPU cyclically contacts the PLC CPU.
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Computer link module is available and cyclically contacts the PLC CPU.
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After synchronization with the NCK, the PLC is running cyclically. The ”MMC CPU ready”
signal is given by the NC to the PLC, as soon as the MMC NCK ready signal monitoring is
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For further information, refer to the documentation SINUMERIK 840C, Interface Description
For further information, refer to the documentation SINUMERIK 840C, Interface Description
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FY 21, bits 6 and 7
At least one NC alarm is active (consisting of block- or sequence-related alarms

FY 24, bit 0
FY 22, bit 7
FY 22, bit 6
FY 22, bit 2
FY 22, bit 1
FY 22, bit 0
6FC5197- AA00
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SINUMERIK 840C (PJ)

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3.5 Individual signals
BATTERY PREWARNING FY 24, bit 1
After Power On, the voltage of the installed batteries is cyclically checked for compliance with
the permissible lower limit. This permits a battery failure (on the central service board) to be
identified in good time during extended periods of NC operation.
1 signal: Battery voltage is below limit value.
0 signal: Battery voltage is above lower limit value.
Note:
The battery should only be changed when the NC is switched on, to avoid data loss due to the
absence of memory back-up.
TEMPERATURE PREWARNING FY 24, bit 2
1 signal: Activates first threshold of temperature monitoring ( 55°C) because ambient

temperature is too high
0 signal: No effect
OVERTEMPERATURE/FAN FAILURE FY 24, bit 3
1 signal: Activates second threshold of temperature monitoring because ambient

temperature is too high
or
fan monitoring is activated because of fan failure
0 signal: No effect
Note:
The work process is not interrupted. A relay contact opens on the central service board which
the NC user must use to take the necessary precautions to prevent damage to the hardware
(relay contact: X111 KL. 3/4).
CPU FAILURE FY 24, bit 4
1 signal: Failure of MMC CPU during operation

0 signal: No CPU failure
Note:
Initiate orderly machine stoppage in the event of MMC-CPU failure.
NC ALARM WITH PROCESSING STOP FY 24, bit 5
1 signal: At least one NC alarm, consisting of block or sequence-related alarms of all

channels, with the effect of stopping processing of the control, is active.
0 signal: No NC alarm to stop processing is active.

SINUMERIK 840C (PJ)
3.5 Individual signals
PROBE SELECTED 1 and 2 FY 24, bits 6 and 7
1 signal: Probe selected

0 signal: Probe not or no longer selected
3
tv1 tv1
tv2 tv2
1: Probe signal at NC input

2: Recognition of probe signal in NC
3: PROBE SELECTED signal at interface (approx. 1.5 x IPO scan time+cycle time PLC (min.
3-4 ms))
Note:
• To permit output of the interface signal, the probe has to output the signal for at least one
PLC signal otherwise the ”probe selected” signal cannot be scanned by the user. The
probe signal has the effect ”Delete distance to go”
• By means of hardware jumpering on the CSM module, it can be established whether the
probe is treated as a normally-open or normally-closed contact.
• The probe must be activated for the NC by the CL 800 command @720 or G720=G722.

SINUMERIK 840C (PJ)
3.6 Diagnostics (DB 1)
ACTUAL CYCLE TIME DW 0

MINIMUM CYCLE TIME DW 1
MAXIMUM CYCLE TIME DW 2
The cycle time (time that the PLC program takes for one run) is stored in these data words in
KF format in msec. These values are deleted each time the PLC is started up (cold or warm
restart). These values are invalidated with FB 12.
ID OF I/O TYPE DW 10, bit 0 ... 15

INPUT I/O GROUP NOT READY DW 12, bit 0 ... 15
DW 13, bit 0 ... 15
OUTPUT I/O GROUP NOT READY DW 14, bit 0 ... 15
DW 15, bit 0 ... 15
ERROR SIGNAL I BYTE DW 30 to DW 45
ERROR SIGNAL O BYTE DW 46 to DW 61
IMAGE OF STATUS REGISTER OF DMP MODULES DW 70 to DW 159
1 signal: The I/O group corresponding to the set bit is not ready, I/Os not ready.
0 signal: No I/O group malfunction.
Notes:
• One I/O group comprises 8 bytes of address space in the I/O area.
• An error is also identified if the I/O device has changed, that is to say if the I/O device
identified by the PLC does not correspond to the I/O device anticipated according to the
information in the machine data. This situation can occur, for instance, if modules are
rearranged.
Extended error message in the case of I/O failure

MD 6560 and the following (STOP/no STOP in the case of a failure of one I/O module) are no
longer effective.
This means that the PLC goes into the STOP state if an I/O module fails.
In the case of I/O failures in cyclic operation, the following DB 1 assignment applies:
DW 10 Identification of I/O type

– Central I/O, TPx, LPx =1
– 16 bit link =3
– DMP =4
DW 12 ... 13 Error message input groups
DW 10 Identification of I/O type

– Central I/O, TPx, LPx =1
– 16 bit link =3
– DMP =4

SINUMERIK 840C (PJ)
DW 12 ... 13 Error message input groups

DW 14 ... 15 Error message output groups
1 bit per group
One group=8 bytes
DW 30 ... 45 Error message input byte
DW 46 ... 61 Error message output byte

1 bit per byte
DW 70 ... 159 Image of status registers of DMP modules
Assignment of status registers of DMP modules
7 6 5 4 3 2 1 0
DEZNAU
Wire break
Transmission error
Overtemperature
OUTDS
Configuration change input
Configuration change output
Module started
(as of SW 3.1 of Interface-DMP)
In addition, the following error messages are entered at addresses F0000 to F0003:
F0000: Error number
F0001: Identification of type of I/O (see DW 10 in DB 1)
F0002: Identifier input, output (I/O)
F0003: Byte number
NUMBER OF LOST
REQUESTS DURING LIM/SIM (OB 2...OB 7) DW 16...DW 21
A program section can be protected against interrupts caused by program levels OB 2 to OB 7

by means of the Step-5 commands LIM and SIM. In this context the PLC user program
disables the processing of requests for OBs that could interfere with the program section.
The PLC operating system counts the number of requests for a disabled OB. When the PLC
user program enables processing of the OBs again, the PLC operating system checks whether
the disabled OB was requested in the intervening period. A distinction is made between the
following cases:

SINUMERIK 840C (PJ)
Disabled OB not requested during processing disable.

No special measures are necessary in this case.
Disabled OB requested once during processing disable.

In this case the disabled OB is activated now, when processing is enabled. Therefore, no
request for the OB has been lost.
Disabled OB requested several times during processing disable.

The most recent request for the OB during the processing disable can now be implemented:
the OB is activated. First of all the number of lost requests for the OB is entered in the
relevant data word, DW 16 ... DW 21, in DB 1. Stated more accurately, the number is added
to the contents of the data word.
With reference to the counter contents in NUMBER OF LOST REQUESTS OB 2 ... OB 7, the
PLC user program can therefore determine, for example, whether time slices or interrupts have
been lost and then trigger appropriate reactions as necessary.
Notes:
The counter contents in NUMBER OF LOST REQUESTS OB 2 ... OB 7 are not reset by the
PLC operating system; where applicable, the PLC operating system adds new values to the
current counter contents. The PLC user program can reset the counter contents in NUMBER
OF LOST REQUESTS OB 2 ... OB 7 to zero if required.
Event counter processing time delay OB 2 ... 7

Event counter processing time delay in OB 2 ... 7 has been removed from pseudo address
F0004 ... F0009 (PG function AUSGABE ADR:AG) and moved to DB 1 (DW 22 ... 27). If a
processing time delay occurs in OB 2 ... 7 and no stop has been set in the machine data the
corresponding identifier is set in flag byte 6 and the current value of the associated data word
is increased by 1 - an overflow is not detected.
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Diagnostics DB
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DB 1
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DW 22 Event counter processing time delay in OB 2

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Event counter processing time delay in OB 7

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DW 27
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SINUMERIK 840C (PJ)
1)
3–14
_______
and 167.
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ACCU 2
ACCU 1
Example:
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DW 164
DW 163
DW 162
DW 161
DW 160
DW 167
DW 166
DW 165
DW 165
DW 160
aaaaa aaaaa aaaaaaaaaaaaaaaa aaaa aa a aa aa a aa aa aa aaa a aa aaa aa aa a aa aa a a aaa aa aa aaa aaa
DW 1641)
DW 1631)
DW 1621)
DW 1611)
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ERROR NUMBER
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Detailed error coding
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SUPPLEMENTARY ERROR DATA
additional error information is interchanged.

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DB 1
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Supplementary error data

Reserved
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Diagnostics DB
ACCU 2, low word

ACCU 1, low word
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Diagnostics DB
Error number
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1st word
4th word
3rd word
2nd word
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00 00 H
00 00 H
00 00 H
00 00 H
00 79 H
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F0004
F0003
F0002
F0001
F0000
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diagnostics DB (DB 1) in data words 160 to 164 (equivalent to PG function OUTPUT
The PLC detailed error identifiers and the supplementary error data are stored in the
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For some error numbers between OUTPUT ADDR: PLC F0000 and DB1 high/low, representation of the
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OUTPUT ADDR:PLC
Same as address with
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DW 161 to DW 164
DW 167
DW 166
DW 160
6FC5197- AA00
ADDR:PLC, F0000). In addition, ACCU 1 low and ACCU 2 low are displayed in data words 166
SINUMERIK 840C (PJ)

09.95
00 79 H means PLC stop by means of mode selection switch. No supplementary error data
exist for this error.
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An explanation of detailed error coding is contained
in the Diagnostics Guide.
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Software releases
SOFTWARE RELEASES DW 168 to DW 175
The releases of the PLC software and the interface DMP firmware are stored in the
diagnostics DB (DB 1). Furthermore, the module code and the slot numbers of the Interface
DMP and INT EU/16B interfaces are entered.
Diagnostics DB
DB 1
DW 168 Software release Int. version No. PLC software
DW 169 Reserved
DW 170 Software release Int. version No. Interface-DMP

1st interface
DW 171 Module code1) Slot No.
Interface-DMP
(hexadecimal)
DW 172 Software release Int. version No. Interface-DMP

2nd interface
DW 173 Module code1) Slot No. Interface-DMP,
(hexadecimal) INT EU/16B
DW 174 Software release Int. version No. Interface PLC 135 WB2/-WD
3rd interface
DW 175 Module code 1) Slot No. Interface PLC 135 WB2/-WD
(hexadecimal)
DW 176 Reserved
DW 177 Reserved
_______
1) Module code (binary)
1010 01 xx Interface-DMP
0110 11 xx INT EU/16B
1011 10 xx Interface PLC 135 WB2
1000 11 xx Interface PLC 135 WD
xx =ˆ Hardware version
END OF SECTION

SINUMERIK 840C (PJ)
09.95 4 NCK Channel/PLC Interface (DB 10 ... DB 13, as from SW 4 DB 15)
4.1 SINUMERIK 840C terms and structure
4 NCK Channel/PLC Interface (DB 10 ... DB 13,

as from SW 4 DB 15)
4.1 SINUMERIK 840C terms and structure
4.1.1 Channel
The control has a channel structure. An NCK channel is effectively an NC in its own right with
program, decoding, block processing and interpolation. The SINUMERIK 840C simultaneously
operates with several tools and includes the loader in the machine tool. Thus, SINUMERIK
840C can be expanded to comprise 15 servo loops1) (simultaneously active!) for allocation of
axes, spindles and/or auxiliary axes/auxiliary spindles, as required. The maximum number of
work spindles is, however, restricted to six.
In accordance with the machine configuration, the NC axes, the tool slide, the work spindles
and the loader are combined to form axis groups. Each axis group is allocated its own inter-
polator with associated program processing, which is called a channel. The SINUMERIK 840C
has up to 4 autonomous channels, as from SW 4 up to 6 autonomous channels.
A single-spindle, double-slide turning machine with milling unit, tool turrets and integral loader
is used in the following to illustrate the application of the channel structure.
S1
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Slide 1 X1
Z1
T1
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Loader
(Xf)
C3 S3
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Q4
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T2
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Slide 2
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S2
Schematic representation of a single-spindle, double-slide turning machine for turning/milling with integral
_______
1) With SW 5 and higher, a max. of 30 servo loops (digital drives) are possible. The limitation to 15 servo loops
for analog drives and 6 spindles still applies.

SINUMERIK 840C (PJ)
4 NCK Channel/PLC Interface (DB 10 ... DB 13, as from SW 4 DB 15) 10.94
4.1.1 Channel
The machine units

• slide 1, main spindle, auxiliary spindle
• turret 1,
• slide 2,
• turret 2 and
• loader
can be allocated to the channels of the SINUMERIK 840C as follows:
Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6

Special tasks X1 X2 Q4
Z1 Z2 Q5
S1 T2
C3, S3 S2
Xf
Yf
T1
Slide 1 Slide 2 Loader
The fictitious axes Xf and Yf are required for face-end milling of turned parts (TRANSMIT).
Within the control, the axes are treated in the same way as real axes, i.e. all the required
machine data must be set.

SINUMERIK 840C (PJ)
4.1.2 Operating mode group
4.1.2 Operating mode group

The channels are put into higher-level operating mode groups. A single operating mode
group contains the channels that always have to work simultaneously in the same mode for
operational reasons. Within the operating mode group, each axis can be programmed in each
channel. The loader is allocated its own operating mode group. This arrangement permits
operation of the loader setting-up mode during workpiece production. Up to 2 operating mode
groups are possible, and as from SW 4 up to 6 mode groups.
The assignment of:

• NCK channels operating mode groups
• NC axes operating mode groups
• spindles operating mode groups
is effected by way of NC machine data (see Installation Guide, Instructions).
The assignment of axes to the channels is not effected by way of machine data but in the part
program. This means that within one operating mode group, an axis can run in different
channels, although not simultaneously.
Using the previous example, the control structure can be shown thus:
Central part program memory
Channel 1 Channel 2 Channel 3 Channel 4
Slide 1 Slide 2 Loader
Operating mode group 1 Op. mode grp. 2
Assigned
axes/spindles:
X1 Z1 S1 S3/C3 3X2 Z2 S2 Q4 Q5
In addition to the machining channels in which the programs for controlling the working units
are run, further channels can be allocated special tasks. In this case, channel 1 controls the
execution of save programs that allow tools to be retracted or changed after tool breakage so
that workpiece machining can be continued. This program is not necessarily dedicated to
channel 1. Depending on the workpiece being manufactured, machining programs must be
created for all channels and are read into the central part program memory of the NCK.

SINUMERIK 840C (PJ)
•
•
4–4
aa
4.1.3
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NCK
1 to 4
SW 4:
1 to 6)
(as from
channels
DW 0 to DW 12
DW 13 to DW 69
signals to NCK channel
signals from NCK channel
Overview of the channel-specific signals

Link RAM
4.1.3 Channel-specific interface signal exchange
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DB80
DB83
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ding acc.
decoding
Standard
4 NCK Channel/PLC Interface (DB 10 ... DB 13, as from SW 4 DB 15)
Channel-specific interface signal exchange
(channel 4), as from SW 4 to DB 15 (channel 6), and is divided into:
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a a
aa
a a
aa
a a
aa
aa
a a
aa
aa
a a
aa
aa
aa
a
M signals
a
aa
a a
aa
aa
a a
a a
aa
a a
a
aaa
aa
aa
a a
a a
aa
a a
aa
aa
aa
a a
aa
aa
a a
a a
aa
aa
aa
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
aa
aa
a a
aa
aa
a a
aa
aa
aa
a
Submodes
function macros FB 70 and FB 71 are contained in the PLC operating system.

aa aaa a aa a aaa a aa aaaa aaa a aaaaa a aa a aa aa a aa a aa aa aaa aaa aaaa
M00 to M99
Feed control
a
aa
a a
aa
aa
a a
a a
aa
a a
a a
aa
aa
a
DB30 a
a a
aa
a a
aa
aa
aa
a a
aa
aa
a a
a a
aa
aa
aa
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
aa
aa
a a
aa
aa
a a
aa
aa
aa
a
Ready signals
aa aaa a aa a aa a aa aaaa aaa a aaaaa a aa a aa aa a aa a aa aa aaa aaa aaaa

Modific. signals
Program control
aa aaa a aa aaaaa a aa aaaa aaa a aaaaa a aa a aa aa a aa a aa aa aaa aaa aaaa
(static, dynamic)
(static, dynamic)
Softkey selection
aa aaa a a a aa aaaa aaa a aaaa a aa a aa aa a a a aa aa aaa aa aaaa

Block information
Operating modes
Auxiliary functions
aa
a aa
a aa
a aa
a aaaa
Acknowledgement
DB10 to DB13
aa
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aa
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a aa
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aa
aaaa aa
aaaaa aa
a aa
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aaaa
aa aa a aa
a aa
aa aa
aaaa
aa
aaaaa aaa
M signals acc. to list
a
aa
a a
aa
aa
a a
a a
aa
a a
a a
aa
a a
aa
aa
aa
a a
aa
aa
a a
a a
aa
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aa
aa
a a
a a
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a a
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a a
aa
a a
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aa
a a
a a
aa
a a
aa
a a
aa
aa
a a
aa
aa
a aaaa
a
aa aaa a
aaaaaaaa aa a
a a
aa
a a
aa
aa
aa
a a
aa
aa
a a
a a
aa
aa
aa
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
aa
aa
a a
aa
aa
a
a aa aaaa aaa a aaaaa a aa a aa aa a aa a aa aa aaa aaa aa
FB 71) are available for transferring signals between the data words and flag words. The
a
a a
aa
a a
aa
aa
aa
a a
aa
aa
a a
a a
aa
aa
aa
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
a a
aa
a a
a a
aa
a a
aa
a a
aa
aa
a a
aa
aa
a a
aa
a
aaa
aa
a
aaaaa
aa a
a
As the processing of bit signals in data blocks is awkward, two function macros (FB 70 and
a aa aaaa aaa a aaaaa a aa a aa aa a aa a aa aa aaa aaa aa aa aa a
DW 0
a aa aaaa aaa a aaaaa a aa a aa aa a aa a aa aa aaa aaa aa aa aa a

DW 69
DW 31
DW 30
DW 18
DW 17
DW 16
Program commands DW 13
DW 12
The channel-specific interface NCK/PLC is stored in data blocks DB 10 (channel 1) to DB 13
PLC
a aa aaaa aaa a
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aaaaaaaa a
6FC5197- AA00
SINUMERIK 840C (PJ)
10.94
M area
DB 10 Basic signals
25
DW 0 FB 70 Dynamic area
Interface
channel 1
FB 71
DW 30 86
99
FB 70: T: NS>EA FB 71: T: EA>NS

K QUTY F QUTY
1 QUAD 31.25 AN/Q
F ZITY K ZITY
31.25 AN/Z 1 ZIAD
F 0.0 PASP
F 0.0 ZASP
Signal exchange DB channel 1 with flags
Signal transfer interfaces DB Flag area
DB interfaces Signal exchange by Flag area

means of FB 70 / 71
DL 0 FY 25
DR 0 FY 26
DL 1 FY 27
DR 1 FY 28
DL 2 FY 29
DR 2 FY 30
Assignment data bytes flag bytes

SINUMERIK 840C (PJ)
Several bits are available for each of the signals, GENERAL FEED DISABLE, READ-IN
DISABLE, NC START DISABLE.
If, for example, a different bit is set for each machine function that has to activate feed disable,
it is easy to determine which function initiated feed disable in the event of a fault. Each set bit
can be allocated a message text, so that the operator can be informed of the diagnosis.
DBm
DW 6 General feed disable

General feed
DW 7 1 disable
General feed disable interface
and read-in disable
DW 8 Read-in disable
DW 9 1 interface
Read-in disable
DW 10
DW 11 NC Start disable NC Start

1 interface
NC Start
FB PLC MD
Bytes for
Interrogate error
messages messages
PLC MD
Bytes for
Buffer Buffer
oper.
memory memory
messages
error oper.
messages messages
Channel-specific messages
For GENERAL FEED DISABLE, note that this channel-specific signal is effective only in the
automatic operating modes. If axis travel has to be suppressed independent of the operating
mode, this must be effected by means of the axis-specific signal FEED DISABLE.
Per operating mode group, as many axes can be traversed simultaneously in JOG mode as
channels are assigned to it.

SINUMERIK 840C (PJ)
4.2 Signals to NCK channel
4.2 Signals to NCK channel

4.2.1 Operating modes
DRF SELECTED D 0.15
1 signal: Handwheel operation also becomes effective during AUT/TEACH IN or MDA

mode (differential resolver offset).
0 signal: No handwheel operation possible during AUT or MDA modes.
Notes:
1) In the AUT and MDA modes, handwheels 1 and 2 (e.g. activated by a key operated
switch) can be used to set a permanent path offset (according to the smallest set input
resolution). The offset is shown separately and remains effective even beyond absolute
blocks.
2) DRF SELECTED (DB 10 - 15, D 14.9) softkey function can be used for the selection. The
signal is transmitted by FB 78.
RESET D 0.14
1 signal: Channel is reset; the reset states are set (e.g. with G functions); the alarms of
the channel are cancelled
0 signal: No channel reset
Notes:
1) SW 1: The RESET signal must be given by the PLC (e.g. by the RESET key). The signal
is interpreted only by the 1st channel of a mode group and affects all channels.
The 1st channel of a mode group is set by means of NC MD.
SW 2: The RESET has a channel-specific effect. Single channels of a mode group can
be set to the RESET state without influencing other channels in doing so.
2) EMERGENCY STOP can be cancelled only by ACKNOWLEDGE EMERGENCY STOP.
CANCEL D 0.13
1 signal: Cancel alarms of the channel are acknowledged (signal level must be present for
at least one PLC cycle)
as from SW 2: Whether Cancel is to be effective for all channel-specific alarms or
for the selected (current) channel only can be set via MD 5008.0.
0 signal: No acknowledgement

SINUMERIK 840C (PJ)
4.2.2 Feedrate modification

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Extended Stop and Retract (ESR) On (from SW 6.2) D 1.15
1 signal: Extended Stop and Retract (ESR) On
FEEDRATE OVERRIDE EFFECTIVE D 1.13
1 signal: The selected FEEDRATE OVERRIDE is effective for a specific channel.

0 signal: The selected FEEDRATE OVERRIDE is ineffective; the 100 % override value is
stipulated.
Note:
Axis-specific deletion of this signal can be achieved with NC setting data (NC SE 560*.0).
This is recommended, for example, if a turret is controlled by an auxiliary axis in the same
mode group.
Using the FEEDRATE OVERRIDE EFFECTIVE signal, the feedrate override switches can be
enabled, e.g. with the key operated switch, while setting up a new NC program.
FEEDRATE OVERRIDE D 1.8 to 1.12
The feedrate override can be preselected with the selector switch on the machine control
panel or via the PLC as follows:
Position Code Override value Note:

E D C B A in % The percentage values given in the table
1 0 0 0 0 1 0 are stored as machine data (NC MD 100 -
2 0 0 0 1 1 1 130). Only the machine data for positions
3 0 0 0 1 0 2
4 0 0 1 1 0 4 1 to 23 are entered as standard; the
5 0 0 1 1 1 6 standard machine data can be altered. The
6 0 0 1 0 1 8 other machine data can be entered
7 0 0 1 0 0 10
8 0 1 1 0 0 20 subsequently. It is thus possible to
9 0 1 1 0 1 30 evaluate the codes for positions 24 to 31,
10 0 1 1 1 1 40 supplied by a connected code switch or
11 0 1 1 1 0 50
12 0 1 0 1 0 60 PLC program.
13 0 1 0 1 1 70
14 0 1 0 0 1 75
15 0 1 0 0 0 80
16 1 1 0 0 0 85
17 1 1 0 0 1 90
18 1 1 0 1 1 95
19 1 1 0 1 0 100
20 1 1 1 1 0 105
21 1 1 1 1 1 110
22 1 1 1 0 1 115
23 1 1 1 0 0 120
24 1 0 1 0 0
25 1 0 1 0 1
26 1 0 1 1 1
27 1 0 1 1 0
28 1 0 0 1 0
29 1 0 0 1 1
30 1 0 0 0 1
31 1 0 0 0 0

SINUMERIK 840C (PJ)
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Extended Stop and Retract (ESR) Off (from SW 6.2) D 1.7
1 signal: Extended Stop and Retract (ESR) Off
RAPID TRAVERSE OVERRIDE EFFECTIVE D 1.5
1 signal: Channel-specific effect of the selected rapid traverse override.

0 signal: The selected rapid traverse override is ineffective; the 100 % override value is
stipulated.
Notes:
• Axis-specific deletion of this signal can be achieved with NC setting data (NC SE 560*.1).
This is recommended, for example, if a turret is controlled by an auxiliary axis in the same
mode group.
• The softkey function RAPID TRAVERSE OVERRIDE EFFECTIVE (DB 10 - 13, D 14.0) can
be used to make the selection. The signal is transmitted by FB 78.
Using the RAPID TRAVERSE OVERRIDE EFFECTIVE signal, the rapid traverse override
switches can be enabled, e.g. with the key operated switch, while setting up a new NC
program.
RAPID TRAVERSE OVERRIDE D 1.0 to 1.2
The RAPID TRAVERSE OVERRIDE can be selected with the selector switch on the customer
control panel as follows:
Position Code Override value in %

D C B A
1 0 0 0 1 1
2 0 0 1 1 10
3 0 0 1 0 50
4 0 1 1 0 100
5 0 1 1 1
6 0 1 0 1
7 0 1 0 0
8 1 1 0 0
Notes:
• The percentage values given in the table are stored as machine data (NC MD 147-154).
Only the machine data for positions 1 to 4 are entered as standard; the other machine data
can be entered subsequently if required, thus also permitting evaluation of the codes for
positions 5 to 8 which are supplied from a coding switch or from the PLC program.
• The values given in the table are effective only if the "rapid traverse override switch
available" machine data is set. If the bit is not set, the position of the feedrate override
switch applies to RAPID TRAVERSE OVERRIDE subject to a max. value of 100%.

SINUMERIK 840C (PJ)
4.2.3 Program control

Notes on block search
There are three ways of reentering an aborted program:
• Block search with calculation
• Block search without calculation
• Block search with calculation from last main block
In part programs a distinction is made between main blocks and subblocks.
Note:
In the case of "External execution", only block search with calculation is permitted.
Block search with calculation

The control starts at the beginning of the program and
• calculates all blocks and
• outputs all auxiliary functions to the PLC, depending on the setting of ”group or output” in
NC MD 546*.
Once the target block is reached, the control begins processing from there after NC Start.
Block search without calculation

The control jumps to the specified target block and begins processing the part program from
there after NC Start. Block search without calculation is of no significance for the PLC.
Block search with calculation from last main block

The control executes a block search (without calculation) to the last main block (:) before the
target. Starting at this main block, the control performs a block search with calculation up to
the specified target block.
EXECUTION FROM EXTERNAL D 2.15
1 signal: The "Execution from external" function is activated when the signal is set. The
part program for the NC channel is read in at an interface during machining.
0 signal: The "Execution from external" function is not active or is deselected. The part
program is executed normally from the part program memory in the COM area.
Notes:
• The "Execution from external" function can be selected by the user by softkey (see
EXECUTION FROM EXTERNAL (SOFTKEY) signal) or automatically by the PLC user
program.
• The interface to be used is specified in machine data MD 130*. If this interface is already
busy when the function is initiated (by NC START), alarm 2044 "External execution error"
is issued.

SINUMERIK 840C (PJ)
• If "Execution from external" is initiated by a host computer, the PLC user program must
evaluate errors when the function is started and report to the host.
• If the external part program is executed faster than it is transmitted so that the subsequent
block is not available, workpiece machining comes to a standstill. The PLC user program
has recourse to the following options in order to prevent this in conjunction with time-
critical program sections:
– General reduction of machining feedrate (feedrate override)
– Ensure that the buffer for incoming program parts is full before time-critical program
sections, e. g. by means of read-in disable. The buffer size and free capacity can be
queried from the NC data channel.
Time-critical program sections can be marked, e. g. by special M functions, so that the
PLC user program is able to recognize them.
BLOCK SEARCH WITH CALCULATION D 2.14
1 signal: Start BLOCK SEARCH WITH CALCULATION

0 signal: No BLOCK SEARCH
Note:
The signal must remain present until acknowledged.
Activation of block search. Activation is usually effected by pressing the BLOCK SEARCH
softkeys (DB 10-13, as from SW 4 DB 15, D 14.6). The signal is transmitted by FB 78.
Signal chart
1: NC signal block search with calculation/block search as from main block (DW14)
2: PLC signal block search with calculation/block search as from main block (DW2)
3: NC signal block search active (DW13)
4: NC signal block search result (DW15)

SINUMERIK 840C (PJ)
BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK D 2.13
1 signal: Start BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK
0 signal: No BLOCK SEARCH
Note:
The signal must be present until acknowledged.
Activation of block search. Activation is usually effected by pressing the BLOCK SEARCH
softkeys (DB 10-13, as from SW 4 DB 15, D 14.5). The signal is transmitted by FB 78.
Internal WAIT mark synchronization for block search D 2.12
1 signal: Internal WAIT marks are observed for block search.

0 signal: External WAIT mark synchronization is not observed for block search.
Program start/end cycles off (SW 5 and higher) D 2.11
1 signal: No cycle is called on program start/end. Display NCY (No Cycle) is displayed in
the channel status field.
0 signal: Cycle 1-9999 (no. is set in MD 134*) is called on program start and cycle 1-9999
(no. set in MD 136*) is called on end of program.
Note:
For a detailed description see Installation Instructions, Section "NC Machine Data" MD 134*
and MD 136*.
See also DB 10 ... 15, D 14.3.
PSTEP selected (SW 3 and higher) D 2.10
1 signal: The main program blocks are executed as single blocks. In contrast to DEC, the
subroutines and the subnested subroutine levels are executed as a complete unit
when Program Step (PSTEP Procedure Step) is selected.
Program execution is then stopped before the 1st block after subroutine return in
the main program.
0 signal: Program control by PSTEP is not active.
Note:
Decoding single block (DEC), break (BRK) and program step (PSTEP) are alternatively active,
i.e. according to the principle ”one out of three”.

SINUMERIK 840C (PJ)
BREAK selected (SW 3 and higher) D 2.9
1 signal: A program interruption (BREAK) can be defined via cursor and softkey functions.
0 signal: No program interruption point can be defined.
CLEAR selected (SW 3 and higher) D 2.8
1 signal: An MDA block is automatically cleared (Clear) at end of program, Reset or

change of operating mode.
0 signal: The MDA blocks are not cleared.
DELETE DISTANCE TO GO D 2.3
0/1 transition: The distances-to-go (set/actual value difference) for all axes of the channel
are deleted. Any following error is reduced to zero. An active dwell block is
cancelled.
1/0 transition: No effect
Notes:
• The DELETE DISTANCE TO GO signal must be active for at least one PLC cycle.
• After DELETE DISTANCE TO GO, a program block with G90 has to follow for the deleted
axis at least.
• If a block with G91 follows, the value programmed under G91 is added to the programmed
axis path in the block with delete distance to go.
• DELETE DISTANCE TO GO with rounding axes leads to an alarm with processing stop.
• DELETE DISTANCE TO GO is permissible only in G01, G02 and G03 blocks (G02/G03
blocks only with 2D interpolation)
• With active 5-axis tool length compensation, the set/actual value difference is not reduced
to zero until ”Delete distance to go” has been carried out twice. No axis traverses are
allowed between the first and second ”Delete distance to go” (Cancel ”Feed Hold” on first
”Delete distance to go”).
DELETE NUMBER OF SUBROUTINE PASSES D 2.2
1 signal: Deletes the remaining number of subroutine passes.

0 signal: No effect
Notes:
• By deleting the remaining number of subroutine passes, the NC can be synchronized with
an externally reported machine position.
• The subroutine pass that is currently being executed is completed as far as M17.
• The 1 signal must be active until the end of the subroutine and has to be reset with M17.
• To interrupt a specific subroutine, @ 714 (STOP DEC) has to be programmed in the last
block before M17.

SINUMERIK 840C (PJ)
Signal chart
1: DELETE NUMBER OF SUBROUTINE PASSES signal

2: Valid M17 decoded
3: M modification signal
NC STOP D 2.1
0/1 transition: The current NC program is stopped immediately, the current block is not
concluded. Residual paths are not traversed until the next start. The axes are
brought to a controlled stop.
2
3
Signal chart
1: NC STOP signal
2: NC START signal
3: PROGRAM ACTIVE signal
4: Axis running
5: Block executed
Notes:
• If the NC program has been interrupted, additional auxiliary functions can be stored, for
example. These will be executed after the next NC START.
• When the NC START signal is given, program execution recommences at the breakpoint.
If additional auxiliary functions were stored while the program was interrupted, only these
will be effective after the first Start. Program execution is then continued with the second
NC Start.

SINUMERIK 840C (PJ)
• The NC STOP signal must be active for at least one PLC cycle.
• If data were transferred to the NC after NC STOP (e. g. tool offset), these are taken into
account immediately after NC START.
NC START D 2.0
Operating mode AUT:

0/1 transition: The selected NC program is started or continued. The progammed auxiliary
functions are output.
If data were transferred from the PLC to the NC after PROGRAM
INTERRUPTED (e. g. tool offset), these are taken into account
immediately after NC START.
1/0 transition: No effect.
Transfer of new tool offsets with NC START and NC STOP
Signal chart
1: RAPID TRAVERSE signal

2: READ-IN DISABLE signal
3: Transfer of new tool offsets
4: NC STOP signal
5: PROGRAM INTERRUPTED
6: NC START signal
Operating mode MDA

0/1 transition: The input block data are released for execution.
1/0 transition: No effect.
Operating modes JOG, INC, REPOS (overstore):

0/1 transition: The input M, S, T, H and D functions are released for execution.

SINUMERIK 840C (PJ)
Notes:
• The NC START signal must be active for at least one PLC cycle.
• Subroutines can also be selected and started directly (without main program).
SPINDLE NUMBER D 3.8 to 3.10
SPINDLE NUMBER informs the NC channel of:

• The number of the spindle from which the NC channel picks off the pulses, e.g. for
revolutional feedrate.
• The number of the spindle to which an S word without extended address is output.
• For digital spindles, power indication is activated in the operating mode basic displays as
from SW3.
Spindle Code
C B A
1 0 0 0
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
Note:
SPINDLE NUMBER defines the spindle that can be programmed without extended M and S
addresses and is displayed in the basic displays of the NC.
SKIP BLOCK /1.../8 (activation) DW4, bits 8 to 15
1 signal: The identified part program blocks are skipped.

0 signal: The identified part program blocks are not skipped.
OPERATING MODES AND FUNCTIONS DW 5
The OPERATING MODES and FUNCTIONS can, for example, be entered via machine control
panel keypad or via the PLC:
1 signal: The key concerned is pressed
0 signal: The key concerned is not pressed

SINUMERIK 840C (PJ)
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11.92
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Notes:
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From
JOG
MDA
group.
MATIC
AUTO-
TEACH-IN
Comments:
To
ning
ning
ning
ning
Stop
Stop
Stop
Stop
SINUMERIK 840C (PJ)

Run-
Run-
Run-
Run-
Reset
Reset
Reset
Reset
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X
X
X
X
X
X
X
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No operating status
Machine function overview:

ning
Run-

stationary (coarse exact stop).
AUTOMATIC
X
Stop
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X
X
X
X
X
X
X
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Reset
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not depend on the type of technology or machine.
6FC5197- AA00
ning
Run-
JOG
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X
X
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Stop
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X
X
X
X
X
X
X
X
operating status modification for each change in the mode:
Reset
ning
Run-
functions can be selected in which operating mode and operating status.

TEACH IN
Stop
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X
X
X
X
X
X
X
X
Reset
ning
Run-
2) The mode is only changed within the control once all the axes of the mode group are
MDA
machine functions can be selected in each mode. The following table shows which machine
1) The operating modes are only checked by the 1st channel (master channel) of the mode
3) If the mode changes, the operating status is also modified. The following table shows the
The operating modes are supplemented by the machine functions. The machine functions do
All machine functions are listed below. Depending on the operating status, a certain number of
Stop
4 NCK Channel/PLC Interface (DB 10 ... DB 13, as from SW 4 DB 15)
4–17
Operating AUTOMATIC MDA TEACH IN JOG

mode
Run- Run- Run- Run-
Functions Reset Stop Reset Stop Reset Stop Reset Stop
ning ning ning ning
Correction block X X
Program control
X X X X X X X X X
Overstore X X X X X X X X
Extended overstoring X X X X X X
Block search X X
PRESET offset X X X X
Program preselect X
during TEACH IN
Approach reference X
point
INC 1 ... 10 000 X X X

Inc variable
Reposition X X X
Direction keys X X X X
Handwheel X X X X
Program editing X X
SKIP BLOCK D 0.7
1 signal: The blocks marked with an oblique stroke (/) in the workpiece program are
skipped. If a series of blocks is to be skipped, this signal is effective only if it is
present before decoding the first block, preferably before NC Start.
0 signal: No blocks of the part program are skipped. If a series of blocks is to be skipped,
they are processed only if the 0 signal is present before decoding the first block.
Note:
The signal SKIP BLOCK SELECTED (DB 10 to 13, as from SW 4 DB 15, D 14.15) can be
used to make the selection (the signal is transmitted by FB 78).

SINUMERIK 840C (PJ)
SINGLE BLOCK D 0.6
1 signal: In the AUT and MDA modes, program execution in single block mode.
0 signal: No effect.
Notes:
• If a contour definition is defined in a program block, only one contour element is traversed
with each start if SINGLE BLOCK is selected. If cutter radius compensation is selected,
intermediate blocks may be inserted.
• If there is a series of G33 blocks, SINGLE BLOCK is effective only if DRY RUN
FEEDRATE is selected.
• Arithmetic blocks are not processed in the single step mode.
• The single block function can be allocated an extended function with NC MD 5004 bits 5
and 6 (mode-group-specific single block). (Refer to Installation Guide Instructions in this
connection.)
DECODING SINGLE BLOCK D 0.5
1 signal: In operating modes AUT and MDA, execution of all program blocks in the single
block mode.
Notes:
• With single block selected, usually only those blocks containing travel movements and/or
auxiliary functions are executed block by block. Using the DECODING SINGLE BLOCK
signal, pure arithmetic blocks can also be tested in the single block mode.
• The softkey function DEC SINGLE BLOCK SELECTED (DB 10-13, as from SW 4 DB 15,
D 14.13) can be used to make the selection. The signal is transmitted by FB 78.
DRY RUN FEEDRATE D 0.4
1 signal: Traverse is at the DRY RUN FEEDRATE that has been set via setting data
instead of at the programmed feedrate (with G01, G02, G03). The dry run
feedrate also applies in place of the revolutional feedrate and the feedrate for
thread cutting.
0 signal: Traverse is at the programmed feedrate. If the signal changes to ”0” within a
G33 block, the programmed feedrate does not become effective until the end of
the block.
Note:
The DRY RUN FEEDRATE SELECTED signal (DB 10-13, as from SW 4 DB 15, D 14.12) can
be used to make the selection. The signal is transmitted by FB 78.
Testing the workpiece program at increased feedrate.

SINUMERIK 840C (PJ)
M01 ACTIVE D 0.3
1 signal: The M01 in the part program leads to programmed stop.

0 signal: The M01 in the part program does not lead to programmed stop.
Note:
The M01 ACTIVE SELECTED signal (D 14.11) can be used to make the selection. The signal
is transmitted by FB 78.
Do not reduce channel (SW 6 and higher) D 0.1
1 signal: If the velocity in a channel is not to be reduced despite proximity to a protection

space, the PLC can switch off reduction of the path velocity channel specifically
with the collision monitoring reduction factor.
No reduction of the channel path velocity 1) D 0.0
1 signal: The path velocity of the channel is not reduced by the dyn. SW limit switch.
0 signal: The path velocity of the channel is reduced by the dyn. SW limit switch.
4.2.4 General feed disable
GENERAL FEED DISABLE DW 6
1 signal: Effects FEED HOLD for all interpolator controlled axes provided that no thread
cutting/drilling signal (e.g. G33-G63) is present.
0 signal: Effects FEED ENABLE for all axes.
Notes:
• The signal is effective only in the automatic modes.
• When GENERAL FEED DISABLE is selected, all axes in motion are brought to a stop on
the contour. Position control remains operative, i.e. the following error is reduced to zero.
• GENERAL FEED DISABLE is activated if at least one bit in DW 6 has a 1 signal.
• If an axis must not be traversed in any operating mode due to interlock conditions, this
must be prevented for the specific axis with FEED DISABLE.
• A message can be allocated to any FEED DISABLE bit.
_______
1) As from SW 5.6

SINUMERIK 840C (PJ)
4.2.4 General feed disable
6
7
Signal chart
1: FEED OFF signal

2: FEED ON signal
3: FEED DISABLE signal
4: Motion command (e.g. X+)
5: X axis in motion
6: Block executed
7: Controlled positioning
To interrupt machining by selecting FEED OFF on the operator panel.
GENERAL FEED DISABLE AND READ-IN DISABLE DW 7, DW 8
1 signal: Effects FEED HOLD for all interpolator controlled axes provided that no G33 to
G63 (thread cutting/tapping) signal is present. The signal is effective only in
automatic modes.
0 signal: Effects FEED ENABLE for all axes and READ-IN ENABLE.
Notes:
• See GENERAL FEED DISABLE and READ-IN DISABLE signal descriptions.
• The signal is activated if at least one bit has a 1 signal.
• A message can be allocated to any bit.

SINUMERIK 840C (PJ)
4.2.5 Read-in disable
READ-IN DISABLE DW 9 and DW 10
Operating modes AUT/MDA/TEACH IN:

1 signal: Disables transfer of data for the next block to the main memory.
0 signal: Enables transfer of data for the next block to the main memory.
Operating modes JOG, INC, REPOS or AUT interrupted (OVERSTORE):

1 signal: Activation of the auxiliary functions that have been input is disabled.
0 signal: Enables activation of the auxiliary functions that have been input at the NC
operator panel via NC START.
Notes:
• If complete execution of an auxiliary function is a precondition for processing the next
block (e.g. tool change), the automatic block change has to be prevented with READ-IN
DISABLE.
• Read-in disable is activated if at least one READ-IN DISABLE bit has a 1 signal.
• A message can be allocated to any READ-IN DISABLE bit.
• Functioning of the ”Read-in disable” interface signal is not impaired in a G501 block.
1 N20 T LF N21GXM LF
2
3
4
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
aaaa
5 N20 T LF N21...
6 T M
7 8 9 10
9
Flowchart
1: Read-in to buffer
2: Block executed
4: Data transfer
5: Content of main memory
6: Output of auxiliary functions
7: Data transfer to main memory
8: Read-in disable for tool change
9: Interrogation point for read-in enable
10: Cancel READ-IN DISABLE

SINUMERIK 840C (PJ)
4.2.6 NC Start disable
4.2.6 NC Start disable
NC START DISABLE DW 11
1 signal: No NC START signal

0 signal: NC START signal active
Notes:
• NC START DISABLE is activated if at least one bit in DW 11 has a 1 signal.
• A message can be allocated to any NC START DISABLE bit.
• NC START DISABLE is not activated in other operating mode groups.
Example of application
Suppression of renewed program execution because of lack of lubricant, for example.
4.3 Signals from NC channel

4.3.1 Program commands
M00/M01; PROGRAMMED STOP D 13.15
1 signal: Block executed, auxiliary functions output and

a) M00 in main memory or
b) M01 in main memory and M01 ACTIVE selected
0 signal: a) With NC START
b) Program abort with RESET
2
3 M00
4 tc
Flowchart

2: Block executed
3: NC block with M word M00
4: M modification signal (tc=PLC cycle time)
5: M00/M01 signal
6: NC START

SINUMERIK 840C (PJ)
Note:
If a different mode is selected when the M00/M01; PROGRAMMED STOP signal is in the 1
state, this state is maintained until the NC START or RESET signal is given.
To bring the main spindle to a stop, e.g. to carry out workpiece checks.
M02/M30; END OF PROGRAM, PROGRAM ABORT D 13.14
1 signal: a) An NC block with M02/M30 (or M17 if a subroutine, and not a main program,
has been started) has been fully executed; if traversing movements are also
programmed in this block, the signal is not output until the target position has
been reached.
b) Program has been aborted with RESET
c) Selection of MDA, PRESET or REF modes
d) After EMERGENCY STOP ACKNOWLEDGEMENT
0 signal: No end of program or abort
2
3 M02
4 tc
5 tc
Flowchart, signal chart

2: Block executed
3: NC block with M word M02
4: M modification signal (tc=PLC cycle time)
5: M02/M30 signal

SINUMERIK 840C (PJ)
Notes:
• The M02 and M30 functions are equivalent.
• The M02/M30 signal is active for only one cycle.
• Not suitable for automatic function sequences such as:
– batch counting
– bar feed,
– opening protective devices etc.
For these functions write M02/M30 in a separate block, and use the M02/M30 word or the
M02/M30 decoded M signal.
• The following must not be written in the last block of a program:
– auxiliary functions that lead to read-in disable
– S values that are to be effective beyond M02/M30.
Deleting functions activated by M, T and H words.
G33/G63; THREAD CUTTING D 13.13
Operating modes AUT, MDA

1 signal: Thread cutting has been selected with G33 or G63.
0 signal: a) Thread cutting has been deselected by G00, G01, G02, G03, G10 and G11.
b) Program ended or aborted.
2 G01 G33 G00
Signal chart

2: Contents of main memory
3: G33/G63 signal

SINUMERIK 840C (PJ)
Notes:
• The following are ineffective:
with G33/63: a) Feedrate override
b) Feed hold; (GENERAL FEED DISABLE signal is not interpreted),
c) Single block; Stop not effected until the end of the next block without
G33.
• With G33 (thread cutting), "Feed hold" can be achieved indirectly by linking G33 and
GENERAL FEED DISABLE to obtain the SPINDLE DISABLE signal.
• With G63, the NC reacts directly to the FEED DISABLE signal.
• Additional G functions can be decoded using FB 69.
G00; RAPID TRAVERSE D 13.12
AUT, MDA, TEACH IN modes

1 signal: Rapid traverse selected with G00.
0 signal: Rapid traverse block ended or aborted.
JOG, REPOS modes

1 signal: Rapid traverse and direction keys operated at the same time.
0 signal: Rapid traverse or direction key not operated.
REF mode (This signal is no longer output with SW5.1and higher)

1 signal: Reference point approach speed (DECELERATION signal = 1, i.e. reference
point not yet reached).
0 signal: Reference point reached.
Note:
Additional G functions can be decoded using FB 69.
As from SW 5.1, this signal is no longr output in reference point approach mode.
Activation of bed lubrication.
G96; CONSTANT CUTTING SPEED D 13.11
1 signal: CONSTANT CUTTING SPEED selected with G96.

0 signal: CONSTANT CUTTING SPEED not selected.
Note:
Additional G functions can be decoded using FB 69.

SINUMERIK 840C (PJ)
BLOCK SEARCH ACTIVE D 13.10
1 signal: The BLOCK SEARCH function has been started at the NC and not yet
completed.
0 signal: The BLOCK SEARCH function has been completed.
PROGRAM INTERRUPTED D 13.9

1 signal: Program interrupted by NC STOP or mode change.
0 signal: a) Program not started.
b) Program ended or aborted.
c) Program has been restarted following NC STOP or mode change.
Note:
The PROGRAM INTERRUPTED signal indicates that NC part program execution can continue
by restarting.
PROGRAM RUNNING D 13.8

1 signal: Programm started (NC START).
0 signal: a) Program interrupted by
– programmed stop (M00/M01),
– NC STOP or
– operating mode change.
b) With single block operation: block executed.
c) Program end reached (M02/M30).
d) Program aborted by RESET.
e) No further blocks in the memory (e.g. with MDA).
f) Current block cannot be executed.

SINUMERIK 840C (PJ)
Signal chart
1: NC START signal
2: PROGRAM RUNNING signal
3: M00/M01 signal
4: Position reached
5: M02/M30 signal
6: PROGRAM RUNNING display appears
Note:
The PROGRAM RUNNING signal does not change to 0 if workpiece machining is stopped by
any of the following conditions:
• Output of GENERAL FEED DISABLE, axis-specific FEED DISABLE or SPINDLE DISABLE
• READ-IN DISABLE,
• FEEDRATE OVERRIDE at "0%",
• Software limit switches or work field limit reached
• Tripping of spindle or axis monitors
• Set displacement values selected in the NC program for axes in FOLLOW-UP
OPERATION, for axes without CONTROLLER ENABLE or for PARKING AXES
• EMERGENCY STOP
TRANSFORMATION ACTIVE D 13.7
1 signal: A transformation is active

0 signal: No transformation is active
Note:
If a transformation is active, the user can determine the transformation concerned by means of
FB 69. The FB 69 call can be made conditional on the TRANSFORMATION ACTIVE signal.

SINUMERIK 840C (PJ)
RIGID TAPPING ACTIVE 1) DW 13.4
1 signal: The ”Rigid tapping” function has been selected.

0 signal: a) The G36 function is deselected from the 1st G group by programming a
different type of interpolation (G00, G01, ...).
b) The G36 function was aborted by key reset or by the SPINDLE RESET
signal, if the MD 521*.4 bit ”Abort of C axis operation on RESET/M02/M30”
is 1.
c) The G36 function is not active after powering-up the machine.
Note:
• Before selecting the ”Rigid tapping” function G36, the correct gear stage must be
engaged.
• Before selecting the function, the spindle must be switched over to C axis operation using
the INITIATE C AXIS OPERATION (DB 31, DW k+3, bit 3) signal. On calling L84 cycle,
the threading cycle is called up, the number of which is stored in MD274.
• Prior to changeover to C axis operation, the PLC user program must create the relevant
preconditions, such as
– Stop spindle or
– Preset axis-specific interface
• Since the infeed axis and the C axis interpolate when tapping, both axes must be set to
nearly the same dynamic response.
• The following machine data are valid for the infeed axis, after the spindle has been
changed over to C axis operation.
– MD 1320* Servo gain factor for rigid tapping
– MD 1260* Feed forward control factor for rigid tapping
– MD 1324* Time constant dynamic feedforward control for rigid tapping
Note:
The G36 function must not be aborted with the ”Deselect C axis operation” M function.
_______
1) As from SW 2

SINUMERIK 840C (PJ)
4.3.2 Select program control
SKIP BLOCK SELECTED D 14.15
1 signal: SKIP BLOCK submode selected.

0 signal: SKIP BLOCK submode not selected.
Note:
The SKIP BLOCK SELECTED signal must be transferred to the SKIP BLOCK Interface signal
by the PLC user program. FB 78 can also be used for this purpose.
DECODING SINGLE BLOCK SELECTED D 14.13
1 signal: DECODING SINGLE BLOCK submode selected.

0 signal: DECODING SINGLE BLOCK submode not selected.
Note:
The DECODING SINGLE BLOCK SELECTED signal must be transferred to the DECODING
SINGLE BLOCK interface signal by the PLC user program. FB 78 can also be used for this
purpose.
RY RUN FEEDRATE SELECTED D 14.12
1 signal: DRY RUN FEEDRATE submode selected.

0 signal: DRY RUN FEEDRATE submode not selected.
Note:
The DRY RUN FEEDRATE SELECTED signal must be transferred to the DRY RUN
FEEDRATE interface signal by the PLC user program. FB 78 can also be used for this
purpose.
M01 SELECTED D 14.11
1 signal: M01 ACTIVE submode selected.

0 signal: M01 ACTIVE submode not selected.
Note:
The M01 SELECTED signal must be transferred to the M01 ACTIVE interface signal by the
PLC user program. FB 78 can also be used for this purpose.

SINUMERIK 840C (PJ)
FEEDRATE OVERRIDE FOR RAPID TRAVERSE SELECTED D 14.10
1 signal: The feedrate override switch is also to act as the rapid traverse override switch.
Feedrate overrides of more than 100 % are limited to 100 % rapid traverse
override.
0 signal: The feedrate override switch is not to act as the rapid traverse overrride switch
(rapid traverse 100 %).
Notes:
• The FEEDRATE OVERRIDE FOR RAPID TRAVERSE SELECTED signal must be trans-
ferred to the RAPID TRAVERSE ACTIVE interface signal by the PLC user program.
FB 78 can also be used for this purpose.
• This signal is useful only if no separate rapid traverse override switch is provided.
DRF SELECTED D 14.9
1 signal: DIFFERENTIAL RESOLVER OFFSET function selected by softkey in the relevant

select display.
0 signal: DIFFERENTIAL RESOLVER OFFSET function not selected.
Note:
The DRF SELECTED signal must be transferred to the DRF ACTIVE interface signal by the
PLC user program. FB 78 can also be used for this purpose.
EXECUTION FROM EXTERNAL SELECTED D 14.7
1 signal: The softkey for the EXECUTION FROM EXTERNAL function is active, i.e. the
user has selected this function.
0 signal: The softkey for the EXECUTION FROM EXTERNAL function is not active, i.e. the
function has not been selected or it has been deselected.
Note:
The PLC user program must transfer the EXECUTION FROM EXTERNAL SELECTED signal
into the EXECUTION FROM EXTERNAL signal (see signal description).
BLOCK SEARCH WITH CALCULATION SELECTED D 14.6
1 signal: The BLOCK SEARCH WITH CALCULATION function has been selected.
0 signal: a) The BLOCK SEARCH WITH CALCULATION function has not been selected.
b) Following 1 signal with BLOCK SEARCH WITH CALCULATION WITHOUT
ERRORS or ERRORS DURING BLOCK SEARCH WITH CALCULATION
Note:
The BLOCK SEARCH WITH CALCULATION SELECTED signal must be transferred to the
BLOCK SEARCH WITH CALCULATION interface signal by the PLC user program. FB 78 can
also be used for this purpose.

SINUMERIK 840C (PJ)
BLOCK SEARCH WITH CALC. AS FROM LAST MAIN BLOCK SELECTED D 14.5
1 signal: The BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK
function is selected.
0 signal: a) The BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK
is not selected.
b) Following 1 signal with BLOCK SEARCH WITH CALCULATION AS FROM
LAST MAIN BLOCK WITHOUT ERROR or ERROR DURING BLOCK
SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK
Note:
The BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK SELECTED
signal must be transferred to the BLOCK SEARCH WITH CALCULATION AS FROM LAST
MAIN BLOCK interface signal by the PLC user program. FB 78 can also be used for this
purpose.
Extended overstoring active (SW 4 and higher) DR 14.4
1 signal: The ”Extended overstoring” function has been selected.

0 signal: The ”Extended overstoring” function has been deselected.
Note:
The PLC evaluates this bit to interprete the channel status. During extended overstoring
(between selection and termination), the channel status refers to the overstore ”channel”, not
to the actual NC channel; i.e. during this time, a RESET, for example, acts only on the
overstore ”channel”. The overstore ”channel” is an inserted, fictitious channel. The original
channel status is stored. Furthermore, the standard NC start interlocks should be active at the
overstore NC start.
Program start/end cycles off (SW 5 and higher) D 14.3
1 signal: The program control signal " No cycle call on program start/end" NCY (No
Cycle) is active.
0 signal: This program control is not active.
Note:
For a detailed description see Installation Instructions, Section "NC Machine Data" MD 134*
and MD 136*. See also DB 10 ... 15, D 14.3.
PSTEP, BRK, CLEAR (SW 3 and higher) D 14.2, D 14.1, D 14.0
1 signal: The relevant program modification

• Program step (PSTEP)
• Break point (BRK)
• Clear (CLEAR)
is active
0 signal: The program modification is not active
Note:
Decoding single block (DEC), break point (BRK) and program step (PSTEP) are alternatively
active, i.e. according to the principle of ”one out of three”.

SINUMERIK 840C (PJ)
4.3.3 Acknowledgements
BLOCK SEARCH WITH CALCULATION WITHOUT ERROR D 15.14
1 signal: BLOCK SEARCH WITH CALCULATION completed without errors.

0 signal: a) Error during BLOCK SEARCH WITH CALCULATION
b) BLOCK SEARCH WITH CALCULATION without error sets 0 signal
BL. SEARCH WITH CALC. AS FROM LAST MAIN BL. WITHOUT ERROR D 15.13
1 signal: BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK

completed without error.
0 signal: a) Error during BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN
BLOCK
b) BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK is
not active.
Internal WAIT marker synchronization (SW 6 and higher) D 15.8
For more detailed information see Programming Guide 840C Section 7.2.
Note:
As from SW 5.4, NCK channels are not only synchronized via ”WAIT M” commands and the
PLC (FX38 and FX39) but also NCK-internally.
If MD bit 5003.1=1 is set, the ”WAIT M” commands are no longer output to the PLC; the
NCK channels, however, are internally synchronized to the programmed ”WAIT” markers.
If a ”WAIT” marker of all NCK channels concerned has been reached, the blocks are
synchronously changed in these channels in the next IPO cycle.
The ”internal WAIT marker synchronization” is enabled via MD5003.1.
New functions
As long as an NCK channel is waiting for an NCK-internally synchronized WAIT marker, the
channel-specific interface signal ”internal WAIT marker synchronization: waiting for synchro-
nization” (DB10, DL15.8) is set to 1. The interface signal is reset if the WAIT marker condition
is either fulfilled by the other NCK channels or if NC-STOP/RESET is present in the channel.
ERROR DURING BLOCK SEARCH WITH CALCULATION D 15.6
1 signal: Error during BLOCK SEARCH WITH CALCULATION.

0 signal: BLOCK SEARCH WITH CALCULATION completed without error.

SINUMERIK 840C (PJ)
ERROR DURING BLOCK SEARCH WITH CALC. AS FROM LAST MAIN BLOCK D 15.5
1 signal: Error during BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN
BLOCK.
0 signal: BLOCK SEARCH WITH CALCULATION AS FROM LAST MAIN BLOCK
completed without error.
1 6
2
tc
6
3
7
4
tc tc
8
Signal chart
1: BLOCK SEARCH signal via softkey

2: NC START signal
3: BLOCK SEARCH ACTIVE signal
4: BLOCK SEARCH signal to NC channel
5: BLOCK SEARCH WITHOUT ERROR signal or ERROR DURING BLOCK SEARCH
6: BLOCK SEARCH signal is cancelled internally
7: User cancels BLOCK SEARCH
8: BLOCK SEARCH WITHOUT ERRORS or ERRORS DURING BLOCK SEARCH signals
cancelled internally
tc: PLC cycle time
ESR monitoring is active D 15.1
1 signal: The monitoring functions for the EXTENDED STOP AND RETRACTION are
activated. If one of the programmed errors occurs, the NC activates the
programmed reactions and the interface signal ESR RESPONSE IS TRIGGERED
is set.
0 signal: The retraction monitoring is switched off.
ESR monitoring is triggered D 15.0
1 signal: The EXTENDED STOP AND RETRACTION was triggered by an axis or spindle
in this channel.
0 signal: No triggering of ESR response in this channel.

SINUMERIK 840C (PJ)
4.3.4 Ready signals
4.3.4 Ready signals
NC START DISABLE D 16.15
1 signal: NC START must not be activated.

0 signal: NC START may be activated.
Notes:
• The signal must be transferred by the PLC user program to one bit of the NC START
DISABLE signals if the DESELECT AUTOMATIC NC START DISABLE PLC machine data
is set (PLC MD 6026.5).
• The signal is set in MDA mode and the overstore display for all channels of the selected
operating mode group with the exception of the channel that has just been selected. NC
START may then be effective only in the selected channel.
PROTECTION SPACE ADAPTION NOT POSSIBLE D 16.14
1 signal: Protection space adaptation is not possible if assignment "Protection space to

channel" is active (G181) and the selected plane (G16 to G19) cannot be
uniquely assigned to the coordinates of the collision monitoring (no assignment in
MD 3948*).
0 signal: Protection space adaptation is not necessary if the assignment "Protection space
to channel" is deselected (G180).
Protection space adaptation is possible if assignment "Protection space to
channel" is active (G181) and the selected planes (G16 to G19) can be uniquely
assigned to the coordinates of the collision monitoring.
NC ALARM WITH PROCESSING STOP D 16.13
1 signal: At least one channel-specific NC alarm is present which causes a channel

processing stop.
0 signal: No NC alarm with the effect of causing a processing stop is currently active.
Note:
No sequence-related alarms are reported to the PLC.

SINUMERIK 840C (PJ)
4.3.4 Ready signals
NC START POSSIBLE D 16.12
1 signal: The NC sets the signal to "1" as soon as an NC Start request is accepted by the
NCK channel.
0 signal: No acceptance of NC Start request by NCK channel.
Notes:
• The NC START POSSIBLE signal is valid only in the automatic modes.
• NC Start requests are generally required for program control purposes, e. g. for starting an
NC part program, resuming a part program after NC stop or in single block mode, for
starting block search, TEACH IN/PLAYBACK or overstore. NC Start can also be effective,
therefore, if the NCK channel is not in the reset state.
• NC Start is not permitted while a program or single block is being executed, during a block
search, or if an NC alarm with processing disable has been issued. NC Start requests are
also ignored if the mode group is not ready.
• From software version 1 onwards, the entire mode group is no longer disabled in the case
of alarms with channel-specific processing disable.
NCK CHANNEL IN RESET STATE D 16.11

1 signal: The signal is set to "1" as soon as the NCK channel is in the reset state, that is
when processing is inactive.
0 signal: The signal is reset to "0" as soon as processing takes place in the NCK channel,
e. g.
• Execution of a program
• Block search
• TEACH IN or PLAY BACK active
• Overstore active
• etc.
Note:
The NCK CHANNEL IN RESET STATE signal is valid only in the automatic modes of the NC.

SINUMERIK 840C (PJ)
4.3.4 Ready signals
OPERATING MODE GROUP READY D 16.9
1 signal: After Power On and build-up of all voltages.

0 signal: Mode group not ready. Reasons:
a) Measuring circuit error or serious axis/spindle alarm triggered
b) Hardware fault
c) Incorrect machine data
c) Drive Ready terminal-dependent
Signal chart
1: Mains voltage
2: MODE GROUP READY
3: Fault message
Notes:
• If MODE GROUP READY changes to 0:
– the feed drives and spindle drive are brought to a stop by active rapid braking (i.e. with
max. braking current), and
– all signals transferred from the NC to the PLC are changed to the inactive state (reset
state).
• All commands given to the NC must be cancelled if MODE GROUP READY carries the 0
signal.
• MODE GROUP READY does not change to "1" after the cause of the fault has been
remedied until the 1st channel of the MODE GROUP has been reset with RESET or until
the NC is switched back on after disconnecting the power supply.
• All functions stored in the intermediate and main memories of the NC are deleted.
• Signal is output only in the 1st channel of a mode group.
NC ALARM D 16.8
1 signal: At least one channel-specific NC alarm (block-related) is present.

0 signal: No NC alarm present.

SINUMERIK 840C (PJ)
4.4 Output of auxiliary functions and block information
4.4 Output of auxiliary functions and block information

4.4.1 General
The M, S, T and H auxiliary functions and D and F block information are output to the interface
together with the respective modification signals. The modification signals indicate that the
value in the relevant word is valid. The modification signals last for one PLC cycle.
The M, S, T and H auxiliary functions can be written with an extended address. If an auxiliary
function has been programmed with an extended address, this is output as well.
The output sequence is: M WORD 1, M WORD 2, M WORD 3, S, T, H, D, F
Example:
M1=5 Stop for spindle 1
M2=5 Stop for spindle 2
Example of output of several items of information programmed in one NC block:
1 N 10 M03 S T H LF
2
M03
3
S
4
T
5
H
6
7
tc
Signal chart
1: NC block with information in buffer memory

4: S modification signal
5: T modification signal
6: H modification signal
7: LAST INFORMATION signal
The following can be determined via machine data:

• Output of information before or at the beginning of the NC axis movement
(NC MD 5003.2).
• Which information is output with block search (NC MD 546*)
• Output to PLC.
• Binary or BCD information output (NC MD 544*)
• Rapid auxiliary functions

SINUMERIK 840C (PJ)
4.4.1 General
A
1
tc
2
B
1
2
tc
Signal chart
A: Information output before axis movement

B: Information output with axis movement
1: Reading NC block into main memory
2: Information at interface (word and modification signal; tc=PLC cycle time)
3: TRAVEL COMMAND signal
In the case of M functions, decoded signals are output in addition to the words, always in both
static and dynamic form. Static signals are set once by the basic program after decoding.
The following M functions are decoded:

• Without extended address: M00 to M99 in channel-specific DB (DB 10-13)
• With extended address: according to decoding list for all channels in DB 30
If an M function is not in the M00 to M99 range and not contained in the decoding list, the
M word and "M NOT DECODED" are output. For the M00 to M99 range the extended address
is = 0.
4.4.2 Behaviour in different modes
BLOCK SEARCH mode

Three types of output can be selected via NC machine data:
• During block search, the auxiliary functions are neither stored nor output; (NC MD 546*.0)
• During block search, the programmed auxiliary functions are output immediatedly with the
modification signal: (NC MD 546*.2 - NC MD 546*.7);

SINUMERIK 840C (PJ)
4.4.2 Behaviour in different modes
• During block search, the NC stores the last auxiliary function of an address in each case;
after the NC start these stored information items are output together with the relevant
modification signals. Up to three M functions are stored and output provided that they were
programmed in one block and that there were no further M functions after this block
as far as the search block.
After reaching the preselected block, information can be stored manually.
AUTOMATIC/TEACH IN mode
After decoding of the information items in the NC, these are output to the interface together
with the relevant modification signal. The modification signal lasts for one PLC cycle. The
information words are retained until a new block programmed with M, S, T, H, D, F functions
has been decoded by the NC.
JOG, MDA, AUT, TEACH IN mode interrupted

Additional M, S, T, H, D and F functions can be stored manually. The auxiliary function with
relevant modification signal is not output to the interface until NC START is issued.
2 M 29
3
tc
Signal chart
1: NC START
2: Auxiliary function e.g. M29
3: M modification signal (tc = PLC cycle time)
4.4.3 Description of information signals
M WORD 1, M WORD 2, M WORD 3, S, T, H, D, F MODIFICATION D17.8 to 17.15
1 signal: The M, S, T, H, D, or F information is output to the interface with a new value.

0 signal: The value of the relevant information is invalid.
Note:
The modification signals are valid for only one PLC cycle in each case.

SINUMERIK 840C (PJ)
LAST INFORMATION D17.7
1 signal: The last information programmed in the NC block (M, S, T, D, H or F function) is

available at the interface as a valid word with the relevant modification signal.
0 signal: The last information of the NC block is not yet available.
Note:
This signal, together with the output modification signals, is valid for one PLC cycle.
FAST AUXILIARY FUNCTIONS D17.6
1 signal: Through PLC operating system, a block is processed in the NC with one or
several ”Fast auxiliary functions” and without ”Slow auxiliary functions”.
0 signal: Through PLC operating system following a PLC cycle.
M WORD 1, M WORD 2, M WORD 3 NOT DECODED D17.0 to 17.2
This signal, together with the relevant M modification signal, is valid for one PLC cycle.
1 signal: M WORD greater than 99 (extended address = 0) and for extended address > 0
not contained in decoding list.
0 signal: M WORD less than 99 (extended address =0) and/or contained in decoding list.
STATIC M SIGNALS DR 18 to DR 30
The static signal bits are set by decoded M functions. They remain at "1" until reset by a
command in the PLC user program.
Up to three M signals can be set per PLC cycle and channel.
DYNAMIC M SIGNALS DL 18 to DL 30
Like the static signal bits, the dynamic M signal bits are set by decoded M functions, but they
remain at "1" for only one PLC cycle and are then reset by the PLC basic program. Up to
three dynamic signals can be output per PLC cycle and channel.
To switch on coolant by statically scanning a static M signal.
To switch off coolant by resetting the static M signal with a dynamic M signal.

SINUMERIK 840C (PJ)
4 tc 5
Signal chart
2: Dynamic M signal
3: Static M signal (coolant ON)
4: Static M signal set
5: Static M signal reset by dynamic M signal with the user program within one PLC cycle
(tc=PLC cycle time)
M WORD 1, M WORD 2, M WORD 3 DW 32, 34, 36

EXTENDED ADDRESS M WORD 1 TO 3 DW 31, 33, 35
Up to three M functions programmed in one NC block are made available at the same time as
soon as the M modification signals are available.
Format: Fixed-point number, value range 0 to 9999

Extended address: Fixed-point number, value range 0 to 99
Note:
With the functions M3, M4, M5 and M19, the spindle referred to by the M function is
addressed by means of the extended address. Otherwise it is generally recommended to relate
the M function to a specific channel by means of the extended address.
Decoding or evaluation of M functions that are not decoded as standard or according to the
list.
S WORD, EXTENDED ADDRESS S WORD DW 37 to 39
The S value programmed in the NC is made available as soon as an S modification signal is

available.
Format: Fixed-point or BCD number, value range 0.1 to 999999
Extended address: Fixed-point or BCD number, value range 0 to 99

SINUMERIK 840C (PJ)
Notes:
• If an S value is programmed that exceeds the selected value range, only the maximum
value is output in each case. This also applies to the analog value output. The analog
output can process values from 0.1 - 1600 / 1 - 16000 only (NC MD 520*.3).
• The spindle for which the S word is valid is programmed by means of the
extended S address.
Gear stage selection from the PLC.
T WORD DW 40 to 42
The tool number (T No.) programmed in the NC is made available as soon as a T modification
signal is available.
Format: Fixed-point or BCD number, value range 0 to 99999999
Notes:
• The magazine from which the tool is to be taken is programmed by means of the
extended T address.
• For the "Tool management" function blocks (FB package 1), the T word has to be output
as a fixed-point number.
Control of automatic tool selection.
H WORD DW 43 to 45
The block information programmed in the NC is made available as soon as an H modification

signal is available.
Note:
The H word is divided into groups by means of the extended H address.

SINUMERIK 840C (PJ)
Extended address Function

(H group key)
0 Unassigned
1 Activation of tool wear / break monitor
2 Reserved
3 Set values for wear / break monitor
4 Compensation values for wear / break monitor
5... Unassigned
Switching functions on the machine.
D WORD DW 46
The programmed D address is made available as soon as a D modification signal is available.

F WORD DW 47 to 49
The F word programmed in the NC is made available as soon as an F modification signal is

available.
Extended address: Not in use at present
Amending the programmed F word with tool wear monitoring (adaptive control).
BLOCK SKIP SELECTED/1.../8 DW 51, bits 8 to 15
1 signal: ”Block skip” function selected

0 signal: ”Block skip” function not selected
Note:
The BLOCK SKIP SELECTED/1.../8 signal must be transferred to the BLOCK SKIP/1.../8
interface signal by the PLC user program. FG 78 can be used for this purpose.
PROGRAM COORDINATION DW 52 to 62
Program coordination is described in Section 4.5.

SINUMERIK 840C (PJ)
4.4.4 T/H word routing

The function is activated by PLC MD 6029 bit 0.
The previously implemented output of the T/H words to the STORED BLOCK INFORMATION
in the source channel is also effected when the routing function is activated. The routing is
executed additionally when the function is activated. The output of the T/H word to the
STORED BLOCK INFORMATION in the source channel takes place, however, only if the
target DB is not already assigned with a routing operation.
An H word programmed in the same NC block is routed together with the T word in the same
way. (An H word on its own in an NC block is not routed, but only output to the STORED
BLOCK INFORMATION in the source channel).
For routing purposes the number is stated as an extended T address in the part program. The
channel numbering ranges from 1 to 4, and from 1 to 6 as from SW 4.
COORDINATION ERROR DR 63.7
The COORDINATION ERROR bit is always set in the envisaged target channel DB, not in the
source channel DB.
1 signal: Set by PLC operating system in the event of a conflict:
– If a T word is to be entered in the STORED BLOCK INFORMATION but the
T WORD VALID and/or H WORD VALID bit is still set.
– If a T word is to be routed to DW 64 ... 66 but the T WORD VALID and/or H
WORD VALID bit is still set.
0 signal: – After POWER ON Reset
– By user
Note:
The channel DB is disabled for further routing operations as long as the COORDINATION
ERROR bit is set.
H WORD VALID DR 63.1
1 signal: Set by the PLC operating system if a routed H word and the extended H address
have been entered in DW 67 ... 69.
0 signal: – After POWER ON Reset (cold restart only).
– By user
The channel DB is disabled for further routing operations as long as the H WORD VALID bit is
set.

SINUMERIK 840C (PJ)
COMMAND "SUPPRESS ROUTING" DL 63.7
1 signal: Set by the user

Routing is suppressed in the target channel (target channel is the channel in
which this bit is set)
0 signal: Set by the user
Routing is possible in the target channel
MESSAGE "ROUTING SUPPRESSED” DR 63.6
1 signal: Set by the PLC operating system

if PLC machine data bit 6029: bit 3
= 0: Message in source channel
= 1: Message in target channel
0 signal: – Set by user
– POWER ON
T WORD VALID DR 63.0
1 signal: Set by the PLC operating system if a routed T word and the number of the
source DB have been entered in DW 64 ... 66.
0 signal: – After POWER ON Reset (cold restart)
– By user
Note:
The channel DB is disabled for further routing operations as long as the T WORD VALID bit is
set.

SINUMERIK 840C (PJ)
NUMBER OF SOURCE CHANNEL DW 64
The PLC operating system enters the number of the channel in which the T word was trans-
ferred by the NC. The number is valid only as long as the T WORD VALID and/or H WORD
VALID bits are set.
Value range: 1 ... 4, 1 ... 6 as from SW 4
Format: 16-bit binary
Data word DW 64 is cleared only with COLD RESTART, not with POWER ON Reset.
ROUTED T WORD DW 65, DW 66
The PLC operating system enters the T word supplied by the NC. The T word is valid only as
long as the T WORD VALID bit = 1.
Format: As supplied from NC.
Note:
Data words DW 65 und DW 66 are cleared only with COLD RESTART, not with POWER ON
Reset.
ROUTED H WORD DW 67 to DW 69
The PLC operating system enters the extended H address and the H word supplied by the NC.
This interface is operated only if a T word is routed in the same NC block. The information is
valid only as long as the H WORD VALID bit = 1.
Format: As supplied from NC.
Note:
Data words DW 67 to DW 69 are cleared only with COLD RESTART, not with POWER ON
Reset.

SINUMERIK 840C (PJ)
4.4.5 TEACH IN
4.4.5 TEACH IN
TEACH IN AXIS MARKING DW 70, DR 71, bit 0 ...5, DL 71 1)

DW 80, DR 81, bit 0 ...5, DL 81 2)
1 signal: The relevant axis (1 ... 30) was marked in TEACH IN mode on the operator
panel.
0 signal: No axis was selected.
STORE TRAVERSED AXES DW 71, bit 7 1)

DW 81, bit 7 2)
1 signal: ”Store traversed axes only” (TEACH IN operating mode) was selected on the
operator panel. With the TRANSFER POSITION softkey, only the positions of
traversed axes are transferred.
0 signal: ”Store traversed axes only” was not selected. With ”Transfer Position” all
selected axes are stored irrespective of whether they have been traversed or not.
TEACH IN AXIS MARKING/ DW 72, DW 73

STORE TRAVERSED AXES (SIGNALS TO NCK CHANNEL) DW 82, DW 83 2)
The signals are transferred into the DB interface to the NCK using FB 78. Here,
the signals can be manipulated via the PLC user program between the call of FB
78 and the end of OB 1. If only FB 78 is called and no further logic operations
are configured, the signals are transmitted of 1:1.
The signals set by FB 78 can be reset by the user program or signals not set can
be overwritten.
1 signal: The relevant axis was marked in TEACH IN mode or the signal ”Store traversed
axes only” was set.
0 signal: No axis was marked for position transfer. The signal ”Store traversed axes only”
is not set.
_______
1) Up to SW 3
2) As from SW 4

SINUMERIK 840C (PJ)
4.5 Structure of program coordination
4.5 Structure of program coordination

The program coordination function permits the machine user to program plaintext commands
in the part program. The coordination commands are communicated from the NC through the
PLC interface, i. e. the PLC becomes responsible for the entire coordination. The coordination
commands used in the NC part program are described in the Programming Guide. The
following sections only describe the signals of interface, machine data, setting data and
standard function blocks.
Note:
FX 38, 39 must be loaded and parameterized. See Section, PLC function blocks FX 38, FX 39.
As from SW3, coordination commands are not displayed in the message line.
4.5.1 Alarms
If the syntax is wrong, alarm 3200 is output.
3200 Program coordination - wrong syntax
Interrogation: During execution in automatic/MDA

(block-related/channel-specific)
Effect: Processing interlock
Explanation: – Syntax error: Invalid command mnemonics
– Invalid modification parameter,
illegal characters, too many parameters, missing para-
meters or characters, area violation through parameters
Remedy: Correction of faulty command
When the PLC gives a checkback signal indicating an error, alarm 3166 is output.
3166 Wrong program coordination
Interrogation: During execution in automatic/MDA

(block-related/channel-specific)
Effect: Alarm display (cancel alarm) and read-in disable for faulty channel
Explanation: Addressed channel not defined or enabled
Remedy: – Change channel addressing
– Define or enable channel

SINUMERIK 840C (PJ)
4.5.2 NCK/PLC user interface
4.5.2 NCK/PLC user interface

The user interface is set up channel-specifically in data blocks DB 10 ... 13,DB 10 ... DB 15
as from SW 4, DW 52 ... 62.
NC START DL 62, bit 0
1 signal: – Through function block

– Through function block after one PLC cycle
READ-IN DISABLE DL 62, bit 1

ERROR (NC ALARM 3166) DL 62, bit 2

Data words DW 56 to 62 are used by function blocks FX 38 and FX 39.

The data words DW 52 to DW 62 are internal signals and must not be overwritten by the user.
DETAILED ERROR CODING DW 61
Event Detailed error coding

– FB 62 terminated with error 1
– Not yet all programs terminated 2
– Not yet all Wait M markers reached 3
– The addressed channels are not enabled 4
– Wrong command code 5
– Start command for block search not enabled 6
END OF PROGRAM REACHED [WAIT-E] DW 62, bit 11
1 signal: – The programs started via coordination have been terminated.

0 signal: – No programs started, or programs are still executing.

SINUMERIK 840C (PJ)
4.5.3 PLC function blocks FX 38, FX 39

Description
The function blocks FX 38 and FX 39 support the program coordination function in the NC.
The function blocks FX 38 and FX 39 check the interface data blocks DB 10 to DB 13, DB 10
to DB 15 as from SW 4 (DW 52 to DW 55) for a coordination command being present and
evaluate the command.
With cold and warm restart, the whole user interface area for program coordination in the
channel data blocks (DW 52 ... DL 62) is deleted. At Reset, the buffer (DW 56 to DL 62) is
deleted thus allowing the NC part program to be restarted.
Supplementary data
Bib. No.: E88530-B 5638-A-50
FBs to be loaded: None
FX to be loaded: FX 38, FX 39
DBs to be loaded: None
DX to be loaded: None
Type of FX call: Unconditional
DBs to be entered: None
DX to be entered: None
Error messages: Accu 1 (FX No.)=38
%1 Block FX 39 has not been loaded
Block length: TX 38 Length 112
TX 39 Length 452
Order: FX 38 and FX 39 are components of PLC package 0
(basic functions)
Block call
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Signal description
NSBY Interface byte
Interface byte in DB 36 for the initiation of a program with FB 62.

SINUMERIK 840C (PJ)
Program example:
OB1
:
:BA FX 38
Name :PRO-K01
NSBY :KF 5 Unassigned interface byte, e.g. "5"
:
:BE
Brief description
• The user must call the block FX 38 unconditionally in OB 1 (DO FX 38) and supplies
parameter NSBY. The block FX 39 must be loaded as well.
• Block FX 38 checks whether block FX 39 has been loaded. If not, the PLC goes into
defined stop with "1" in battery 2 (error number) and "38" in accu 1 (block number).
• If the addressed channels are to be started during block search in the same channel, the
PLC machine data 6029.1 (DB 63, D 14.1 for PLC 1) must be set:
• Five coordination commands are available:
– Start
– Wait-E
– Wait-M
– Init MPF
– Init SPF
• The user interface for program coordination is installed channel-specifically in data words
DW 52 to DL 62 each of data blocks DB 10 to DB 13, and DB 10 to DB 15 as from SW 4.
• The coordination commands are present in the user interface for one PLC cycle. When the
PLC-SP has received a coordination command from the NC, it sets a modification signal
(D 52.8), which is reset in the next PLC cycle by the PLC-SP. The data in data words DW
52 to DW 55 are valid only as long as the modification signal is "1".
• When cold or warm restart are carried out, the PLC system program clears the user
interface for program coordination. When a reset is carried out, the buffer DW 56 to DL 62
is cleared by block FX 39. If an end identifier D 62.11 is present, it is maintained when a
reset is carried out.
• With each command via PLC machine data bits (DB 63), FX 39 checks whether the
addressed channels have been enabled. If not, the block sets D 62.10. The NC uses this
bit to give the NC alarm 3166 WRONG PROGRAM COORDINATION.
• Via the dynamic M signals M02, M17 or M30 the block checks whether the started
programs are completed. If so, the end identification bit D 62.11 is set. This bit is
interrogated by the Wait-E command and reset when a start command for the relevant
channel is given.
• The coordination commands Init MPF, Init SPF and start commands are executed in the
PLC cycle in which the modification signal is present. A prerequisite, however, is that a
preceding data transmission with FB 62 has been completed without errors.

SINUMERIK 840C (PJ)
• With command Wait-M and Wait-E, the buffer DW 56 to DW 59 is filled. FX 39 enters in

DW 60 (channel actual value) which channels have reached the mark or end identifier. If
the channel actual value (DW 60) equals the channel actual value (DW 59), read-in disable
is reset and the buffer cleared.
• When cold or warm restart are carried out the whole user interface for program
coordination is cleared by the PLC system program. When a reset is executed, the buffer
DW 56 to DL 62 is cleared by block FX 39. If an end identifier (D 62.11) is present, it is
retained.
• At present, the following error numbers exist (in DW 61 detailed error coding)
Event Reaction Detailed error
– FB62 completed with errors Read-in disable 1
– Not all programs have yet been completed None 2
– Not all Wait-M marks have yet been reached None 3
– The addressed channels are not enabled Read-in disable 4
– Wrong command code None 5
– Start command with block search not enabled None 6
END OF SECTION

SINUMERIK 840C (PJ)
10.94 5 Spindle/PLC Interface (DB 31)
5.1 General
5 Spindle/PLC Interface (DB 31)
5.1 General
The SINUMERIK 840C can control a maximum of six spindles. The interfaces of all spindles
are stored in data block 31. The spindle/PLC interface is set by PLC MD 6012 and PLC MD
6014.
The programmed speed/cutting speed and the spindle M commands M03, M04, M05 and M19
are evaluated in the NC. The extended NC address is used to determine which spindle the
programmed values refer to.
Example:
S2=1000 Spindle 2 is to run at 1000 rev/min
M2=5 Spindle 2 SPINDLE DISABLE
If no extended S address has been written, the S word is output to the spindle stated in DB 31
DL k+2 under channel number.
Spindle 1 Encoder Spindle 2
Spindle NC Spindle NC
channel channel
number 1 number 4 1)
DB 10, DL 3 DB 13, 1)
S - value DL 3 S - value
Channel number (DL k+2)
Intermediate memory
S - value NC
PLC spindle control

NC MD NC MD
S - value NC Basic speed Oscillation speed
Basic speed (D k+2.5)
Oscillation speed (D k+2.6)
Acceleration time constants

(NC MD 419* - 426*)
Set speed value

All data words
Controller enable
in DB 31 (D k+1.14)
Spindle control structure
_______
1) As from SW 4: 6 channels

SINUMERIK 840C (PJ)
5 Spindle/PLC Interface (DB 31) 06.93
5.1 General
The pulses of all the spindles can be read by each NCK channel. Which channel interprets
which spindle pulses is determined by means of the channel-specific SPINDLE NUMBER
signal. It is permissible for several channels to access the same spindle pulses at the same
time. This means, for instance, that on double slide lathes control can pass from channel 1 to,
say, channel 2 at v = const. without hardware switching.
The spindle-specific CHANNEL NUMBER signal is used to determine from which channel the
spindle obtains set speed values (S word). If, for example, control passes from channel 1 to
channel 2 at v = const. on a double slide lathe, the spindle-specific CHANNEL NUMBER
interface signal must change from 1 to 2.
A spindle can also be addressed from a channel in another mode group. In this case, note that
the spindle is stopped only at the RESET in the mode group in which the spindle was defined
(MD 453*). A channel reset request in the channel in which the spindle is addressed thus
stops program execution and the sindle continues to run.
Three values can be output to the drive as set speed value: S word of the NC, basic speed
and oscillating speed. If the PLC SPINDLE CONTROL signal is set, no more new S words
can be transferred by the NC program to the spindle and the operating mode of the spindle
cannot be changed. In this mode, either the spindle's direction of rotation can be switched
over or the basic or oscillating speed can be selected as required.
The allocation of the spindle number to the measuring circuit module is made via NC machine
data 400*. The spindle defined in the MD as spindle No. 1 is also the 1st spindle at the
NC/PLC interface. The SPINDLE DISABLE signals can be allocated error/operational
messages with selection made via PLC machine data (see Section 12, Display Programs for
PLC Data and Messages).
S1 S2 S3 S1 S2 S3
DB 10 DL 3=1 DB 11 DL 3=2 Actual value

Channel 1 Channel 2 selection
DB 10...13 1) PLC
G33 G33 (DL 3)
G95 G95
G04 S ... G04 S ...
G96 G96
M3, M4 M3, M4
M5, M19 M5, M19
S ... S ...
Spindle set value bus

K1 K2 K1 K2 K1 K2
Set value Selection
DB 31
DL K+2
S1 S2 S3
Main Main Aux.
spindle spindle spindle
M M M
Spindle actual value bus
Overview spindle allocation
_______
1) As from SW 4: 6 channels

SINUMERIK 840C (PJ)
5.1 General
The spindle declared as spindle 1 in the MD is also the 1st spindle at the NCK/PLC interface,
that is to say it is assigned data words 0 ... 3, 24 and 25 in DB 31.
Generally speaking, the spindle control can operate in different spindle modes:
• Control mode Controlled operation with preset spindle speed and direction of
rotation
• Oscillation mode Controlled operation with preset motor speed and direction of
rotation
• Positioning mode "Oriented spindle stop"; the spindle is incorporated in position
control
• C axis mode Spindle operated as closed-loop position-controlled rotary axis
• Following mode Spindle operates as a following spindle under position control
Notes:
• For C axis operation, the spindle is assigned an axis by means of machine data (MD 461*).
If a C axis is assigned to the spindle by MD 461* the axis-specific signals are also
evaluated.
Note in particular that the measuring circuit monitors for the axis can be switched off with
the PARKING AXIS signal so that the axis-specific measuring circuit monitors can be
suppressed.
5.2 Signals from spindle
The K address is derived for the spindles as follows:

1st spindle K=0
2nd spindle K=4
3rd spindle K=8
4th spindle K=12
5th spindle K=16
6th spindle K=20

SINUMERIK 840C (PJ)
ACTUAL DIRECTION OF SPINDLE ROTATION CLOCKWISE DW K. bit 15
1 signal: Actual direction of rotation clockwise

0 signal: Actual direction of rotation counterclockwise
Notes:
• The signal is derived from the direction of rotation of the encoder. MD 520*, bit 1 SIGN
CHANGE ACTUAL VALUE is taken into account.
• When the spindle is at a standstill, the signal corresponds to direction of rotation
clockwise.
The PLC status signal, ACTUAL DIRECTION OF ROTATION CLOCKWISE is taken from the
spindle speed actual value. This actual value is not available in the following cases:
• A spindle with encoder is operated above the frequency limit.

• A spindle does not have an encoder.
In the above cases, the speed setpoint is used to generate the status signal.
PROGRAMMED SPEED TOO HIGH DW K, bit 14
1 signal: The programmed speed or the speed calculated at constant cutting speed (G96)
is too high.
0 signal: The programmed speed or the speed calculated at constant cutting speed (G96)
lies below the permissible range.
Notes:
• Spindle speed override is taken into account when checking the limit values.
• The following limit values are taken into account in the check:
– MD 403* - MD 410* ”Maximum speed” for each gear stage
– MD 451* ”Maximum spindle speed”
– SE 401* ”Programmed spindle speed limit with G96”;
programmed with G92
– SE 403* ”Programmed spindle speed limit”;
programmed with G26
The data cells can be overwritten by the PLC using FB 62 if required.

SINUMERIK 840C (PJ)
Programmed speed too high
1
2
3 S=0 S=6000 S=2000
4
5
Signal chart
1: Speed limit of selected gear stage, e.g. 5000

2: Maximum chuck speed, e. g. 4000
3: Programmed S values in main memory
4: PROGRAMMED SPEED TOO HIGH signal
5: SPINDLE IN SET RANGE signal
The PROGRAMMED SPEED TOO HIGH signal can be used to interrupt further execution of
the NC program and output a corresponding message.
SPINDLE IN SET RANGE DW K, bit 13
1 signal: Actual speed lies within a defined range round the set speed (set range).
0 signal: Actual speed outside set range.
Notes:
• The set speed is derived from the programmed speed or, in the case of constant cutting
speed (G96), from the calculated speed, taking the speed override and speed limiting
values into account (see PROGRAMMED SPEED TOO HIGH interface signal).
• The set range is determined by the set speed and the "Spindle speed tolerance"
(MD 444*).
• Active monitoring only with speed greater than zero-speed range (MD 446*).
Enabling of axis movements, (e.g. by cancelling GENERAL FEED DISABLE) after a speed
change by setting a new S value or after changing gear.

SINUMERIK 840C (PJ)
SPINDLE POSITION REACHED DW K, bit 12
1 signal: Actual spindle position lies within a defined range (set range) round the
programmed setpoint.
0 signal: Actual spindle position lies outside the defined range.
1 3
3
2
td
Signal chart
1: Actual spindle position

2: Set position
3: Positional tolerance
4: Position control switched on
5: SPINDLE POSITION REACHED signal
6: ACKNOWLEDGE M19 signal (from PLC, td = delay time)
Notes:
• The signal is relevant only when the spindle operates in the positioning mode (e. g. M19).
• The set range is determined by the following data:
– the set position
– MD 443* "positional tolerance" with spindle positioning through NC or PLC
– the positional limit in the user data DB with "M19 over several revolutions" from the
command channel
• In the event of overshooting beyond the set range (e.g. due to incorrect optimization of the
spindle controller), the signal is cancelled.
• The ACKNOWLEDGE M 19 signal must not be given by the PLC until the spindle has
settled in position (e.g. after delay time td during which SPINDLE POSITION REACHED
has been set constant).
Tool change enable on milling machines.

SINUMERIK 840C (PJ)
SPINDLE STOPPED DW K, bit 11
1 signal: Actual speed in zero-speed range (machine data).

0 signal: Actual speed greater than zero-speed range.
Notes:
• The zero speed range is determined by MD 446* ZERO SPEED TOLERANCE.
• If the actual speed lies within the zero-speed range, the "Spindle in set range" function is
not monitored.
Enable for opening a guard.
SPINDLE SYNCHRONIZED DW K, bit 10
1 signal: The spindle is synchronized with the encoder, i. e. the encoder zero mark has
been recognized.
0 signal: The spindle is not synchronized with the encoder.
Notes:
• The position can be recorded only if the spindle is synchronized with the encoder.
• If the spindle is not synchronized with the encoder, it may be for one of the following
reasons:
– The spindle does not have an encoder.
– The zero mark has not yet been overrun following POWER ON.
– A synchronization routine triggered by RESYNCHRONIZE SPINDLE has not been
completed yet.
– Synchronism with the encoder lost owing to excessive speeds; resynchronization is
executed automatically when lower speeds are reached.
SPINDLE POSITIONING ACTIVE DW K, bit 9
1 signal: Spindle control operating in positioning mode.

0 signal: Spindle control not operating in positioning mode.
Notes:
• The positioning mode is selected by the NC command M19, the POSITION SPINDLE
signal or the M19 OVER SEVERAL REVOLUTIONS command channel function.
• The positioning mode is generally aborted by the ACKNOWLEDGE M19 signal.
• Spindle functions (resynchronization, oscillation, basic speed) are no longer possible when
spindle positioning is active.
Example:
Suppression of axis movements during positioning.

SINUMERIK 840C (PJ)
SPEED LIMIT EXCEEDED DW K, bit 8
1 signal: The actual spindle speed has exceeded the limits by more than the permitted
tolerance.
0 signal: The actual spindle speed is below the limits.
Notes:
• The following limiting values are taken into account when checking:
– MD 403* to 410* "Maximum speed" for each gear stage
– MD 451* "Maximum chuck speed"
– SD 401* "Programmable spindle speed limitation";
programmed with G26
• The permissible tolerance is determined by:
– MD 445* "Maximum spindle speed tolerance"
• If the spindle exceeds one of the speed limits by more than the permitted tolerance, all
spindles and axes of a mode group are brought to a stop and an alarm is given.
• The SPEED LIMIT EXCEEDED signal is modal and must be reset with RESET.
2
1
Signal chart
1: Preset maximum speed

2: Permissible spindle speed tolerance
3: SPEED LIMIT EXCEEDED signal
4: RESET signal

SINUMERIK 840C (PJ)
CHANGE GEAR DW K, bit 7
1 signal: Request to PLC to change to new set gear stage.

0 signal: No gear stage change requested.
Notes:
• The signal is output if the programmed S value is outside the speed range of the current
actual gear stage and a new set gear stage could be determined.
The speed ranges are defined by:
– MD 403* to 410* "Maximum speed" for each gear stage
– MD 411* to 418* "Minimum speed" for each gear stage
• Once the gear change has been made, the signal has to be reset by the PLC user
program and the new actual gear stage has to be entered in the interface.
• The speed ranges are checked only if a new S value has been specified. The PLC user
program can therefore also acknowledge the gear change (reset CHANGE GEAR interface
signal) without having changed the gear stage, if required.
• MD 521*, bit 5 "New S value after PLC acknowledgement" determines whether the spindle
is to assume the set speed until the gear change has been acknowledged.
• If the gear change is triggered directly by the NC part program (M41 ... M48, decoding by
PLC user program), the CHANGE GEAR interface signal cannot be evaluated until the
LAST INFORMATION interface signal is also present.
• If the ”Automatic gear change selection” function is not used, i.e. there is no gearbox
present or the gear stage is selected directly via M functions (M41 ...; 48), the ”gear
change” signal must be reset when the new actual gear stage has been entered in the
interface.
• The change limits are allowed to overlap.
• PLC-MD 6012 via DB63 DW 6 means spindle available.
• CHANGE GEAR is output only if the "Signal from/to spindle" PLC MD (PLC MD 6012) has
been set.
• The "CHANGE GEAR" and "SET GEAR STAGE 8" signals are set if a speed is
programmed that is greater than the maximum speed of the "highest" gear stage.
A C axis changeover is then not possible.
The machine data for the maximum speed in the unused gear stages must therefore be
written with "0". A spindle setpoint value is not output with G96 ”Constant cutting
velocity”.

SINUMERIK 840C (PJ)
3 +
4
0 t
4
5 6
–
Signal chart
1: CHANGE GEAR signal

2: Feedback signal from gear to PLC: "Gear engaged"
3: Actual spindle motor speed
4: Set value for oscillation speed
5: Oscillation, change gear
6: Gear engaged, accelerate spindle motor
Sequence:
• Controlled by the NC:
– The new set gear stage is determined and output to the interface.
– The CHANGE GEAR signal changes from 0 to 1.
– When the ”Gear change” signal is present, spindle/C axis changeover is not possible
and the spindle setpoint speed is not updated when G96 (constant cutting velocity) is
active.
• Controlled by the PLC program:
– Spindle motor decelerates to zero speed.
– Motor accelerates to oscillating speed (OSCILLATION SPEED and SET DIRECTION
OF ROTATION CW).
– Motor direction of rotation changes to facilitate gear engagement (SET DIRECTION OF
ROTATION CW).
– The user program recognizes that the gear has engaged (e. g. by means of the "Gear
engaged" signal from the gear). The new actual gear stage must then be entered in
the interface (DW K+1, bit 0 to 2) and the CHANGE GEAR signal be reset.
• Controlled by the NC:
– The spindle is enabled again and accelerated to the new speed.

SINUMERIK 840C (PJ)
S-prog.
OG8
OG7
UG8
OG6
UG7
OG5
UG6
OG4
UG5
OG3
UG4
OG2
UG3
OG1
UG2
UG1
G1 G2 G3 G4 G5 G6 G7 G8
Example: Assignment of speed ranges to gear stages
OG : Upper limit speed of gear stage

UG : Lower limit speed of gear stage
G1...G8: Gear stages 1-8
S-prog: Programmed S value
SET GEAR STAGE DW K, bit 0 to 2
In the case of automatic gear stage selection by the NC, the SET GEAR STAGE is output in
coded form to the PLC at the same time as CHANGE GEAR as follows:
Gear Code
C B A
1 0 0 0
2 0 0 1
3 0 1 0
4 0 1 1
5 1 0 0
6 1 0 1
7 1 1 0
8 1 1 1

SINUMERIK 840C (PJ)
5.3 Signals to spindle
CHANGE GAIN FACTOR Kv DW K+1, bit 15
1 signal: For position control of the spindle in the positioning mode, the gain of the position
controller is calculated from the gain factor multiplied by the factor (which varies
with the gear stage) for the gain change (MD 469*).
0 signal: For position control of the spindle in the positioning mode, the gain of the position
controller is determined directly by the gain factor (which varies with the gear
stage).
Notes:
• The individual factors are determined by machine data:
– MD 435* to 442* "Gain factor" for the position controller (for 8 gear stages)
– MD 469* "Factor for gain change"
• With some drive actuators, a change in the standardization of the analog set speeds in the
actuator can achieve steadier zero speed behaviour of the spindle in conjunction with
position control. This change must be taken into account in the control by changing the
gain factor.
• The standardization change in the drive actuator is made by a terminal signal. This signal
must always be set at the same time as the CHANGE GAIN FACTOR interface signal. It
is sensible to set the signals conditional on the SPINDLE STOPPED interface signal.
• The gain factor change must not be activated at higher speeds. The magnitude of the
transmitted set speeds must always be less than 10 V.
CONTROLLER ENABLE DW K+1, bit 14
1 signal: Speed controller for the spindle is enabled.

0 signal: Effects rapid deceleration of the spindle with maximum braking current. At the
end of a time set by machine data (MD 447*), the interface to the drive is
interrupted. Only the actual values are retained (follow-up mode).
Notes:
• The following applies if positioning mode is selected by the NC or PLC:
– If the signal is not set when the selection is made, the positioning operation is not
initiated until the signal has been set.
– If the signal is cancelled during spindle positioning, the positioning operation is only
interrupted. It is resumed when the signal is set again.

SINUMERIK 840C (PJ)
• The following applies if positioning mode is selected by the command channel:

– If the signal is not set when the selection is made the position operation is not initiated
until the signal has been set.
– If the signal is cancelled during spindle positioning, the positioning operation is only
interrupted. It is resumed whenn the signal is set again.
INPUT SET VALUE ZERO DW K+1, bit 13
1 signal: The current set speed value is overwritten with ZERO and thus effects spindle
braking in accordance with the ramp characteristic.
0 signal: No effect
Notes:
• The acceleration ramp is defined by machine data. The selection of the currently valid
machine data is made with reference to the actual gear stages and the mode:
– In control mode, MD 419* to 426* "Acceleration time constant without position control"
are used.
– In synchronous mode, MD 478* to 485* "Acceleration time constant with position
control" are used.
• The set speed 0 is normally selected automatically at the end of the program or if the
program is aborted. If this is suppressed by machine data (MD 521*, bit 6), the spindle can
be brought to a stop by the PLC user program with this signal or the SPINDLE RESET
signal.
• The programmed S value is lost when the INPUT SET VALUE ZERO signal is set.
• The positioning mode can still be selected (by NC, PLC or command channel) with the
signal set. The positioning routine is executed nevertheless.
SPINDLE OVERRIDE EFFECTIVE DW K+1, bit 12
1 signal: The spindle override (speed override) selected is taken into account when the set
speed values are defined.
0 signal: The spindle override values selected are not taken into account; the 100 %
override value is stipulated.
Note:
The override value is generally selected with the switch on the machine control panel.
Using the spindle override effective signal, the spindle override switch on the machine control
panel can be enabled while installing a new NC program.

SINUMERIK 840C (PJ)
SPINDLE OVERRIDE DW K+1, bit 8 to bit 11
The spindle (speed) override is taken into account when determining the set speeds for the
spindle if the SPINDLE OVERRIDE ACTIVE signal is set. The override value determines the
percentage of the programmed set speed output to the spindle.
The override value is generally set with the switch on the machine control panel. Refer to the
following table for the assignment of switch positions to the percentage values and their code.
Position Code Override value in

D C B A %
1 0 0 0 1 50
2 0 0 1 1 55
3 0 0 1 0 60
4 0 1 1 0 65
5 0 1 1 1 70
6 0 1 0 1 75
7 0 1 0 0 80
8 1 1 0 0 85
9 1 1 0 1 90
10 1 1 1 1 95
11 1 1 1 0 100
12 1 0 1 0 105
13 1 0 1 1 110
14 1 0 0 1 115
15 1 0 0 0 120
16 1 0 0 0 120
Note:
The percentage values given in the table are standard values which are stored as machine
data. They can be altered if required.
SPINDLE RESET DW K+1, bit 5
1 signal: Stopping of spindle.
With MD 521*, bit 6 = 1 ("No abort at Reset or M02/M03") the spindle does not react to reset
requests from the NC, but to the SPINDLE RESET signal. The following preconditions must be
fulfilled:
– The channel to which the spindle is currently assigned by the PLC (DW K+2, bits 0
to 4) is in the reset state (e. g. after key reset).
– When the spindle is stopped, the currently valid acceleration time constant is taken
into account.
0 signal: No effect

SINUMERIK 840C (PJ)
Exceptions:
• Alarms that lead to cancellation of the OPERATING MODE GROUP READY signal also
cause the spindle to stop.
• If MD 520* bit 6 (M19 BEYOND RESET) is set, the spindle will abort its M19 function only
via ACKNOWLEDGE M19.
• The C AXIS OPERATION operating mode is not deselected by reset (also SPINDLE RE-
SET).
NC MD 521* bit 6 set to "1" (spindle cannot be brought to a standstill by M30 and Reset)
PLC
Operating oscillation Spindle Spindle/reset Program in
Reset key
Mode speed/basic behaviour DW K+1.5 channel
speed
JOG – Selected Overwritten Bit = ZERO Reset
with oscillation
speed and
basic speed
JOG – Deselected Previous Bit = ZERO Reset
speed active
JOG – – Spindle Bit = ONE Reset
stopped
JOG – Selected Spindle Bit = ONE Reset
stopped
JOG – Deselected Spindle Bit = ONE Reset
stopped
MDA/AUTO – – Selected Bit = ZERO Stop
speed active
MDA/AUTO – – Selected Bit = ONE Stop
speed active
MDA/AUTO In operation – Spindle Bit = ONE Reset
stopped
MDA/AUTO – Selected Overwritten Bit = ZERO Stop
with oscillation
speed and
basic speed
MDA/AUTO – Deselected Previous Bit = ZERO Stop
speed active
MDA/AUTO – Selected Overwritten Bit = ONE Stop
with oscillation
speed and
basic speed
MDA/AUTO – Deselected Previous Bit = ONE Stop
speed active
MDA/AUTO In operation Selected Spindle Bit = ONE Reset
stopped
MDA/AUTO In operation Deselected Spindle Bit = ONE Reset
stopped
MDA/AUTO In operation Selected Rotates with Bit = ZERO Reset
oscillation and
basic speed
MDA/AUTO In operation Deselected Spindle Bit = ZERO Reset
stopped

SINUMERIK 840C (PJ)
After SPINDLE RESET and SPINDLE STOPPED, M03/004 and Sxxx must be reselected.
If a requested spindle positioning is aborted by the PLC with SPINDLE RESET, a renewed
spindle repositioning must be restarted by the PLC.
M19 is aborted with the reset key in MDA/AUTO mode even if the SPINDLE RESET FROM
PLC bit is set to 0.
INVERT M03/M04 DW K+1, bit 4
1 signal: The set voltage sign for M03/M04 is inverted.

0 signal: No inversion
Note:
A positive voltage is output with M03 as a standard. Via MD 521*, bit 1 (SIGN CHANGE
SETPOINT) an adjustment to the machine is possible.
Example:
In mechanical back gear units (e.g. drilling heads), the direction of rotation is reversed
mechanically by a gear mechanism. The correct direction of rotation can be obtained by
means of the INVERT M03/M04 interface signal.
INITIATE C AXIS OPERATION DW K+1, bit 3
1 signal: The PLC user program has concluded the preparations to initiate C axis
operation. The spindle control can now switch to C axis operation.
0 signal: Switch to C axis operation disabled.
Notes:
• By means of this signal the PLC user program can delay the switch to C axis operation
until the required preconditions have been satisfied. No block change takes place as long
as the signal is not set.
• Examples of measures required to satisfy the preconditions for the switch:
– Bring spindle to a stop
– Engage correct gear stage
– Preset axis-specific interface.
• Cancelling the signal does not abort C axis operation.
• Switch to C axis operation is not possible when PLC spindle control is active.

SINUMERIK 840C (PJ)
1
0
1: Instant of decoding M function for selecting C axis operation.

2: Measures taken by the PLC user program to prepare for C axis operation.
3: INITIATE C AXIS OPERATION
4: Block change
ACTUAL GEAR STAGE DW K+1, bit 0 to 2
A variable-speed gearbox connected between motor and spindle provides a large speed range
at the spindle. The set speed determined by the S value always refers to the speed of the
spindle and not to that of the motor. Therefore, the current gear stage has to be taken into
account when calculating the motor set speed value.
The PLC user program must therefore always output the correct actual gear stage to the NC.
The following code is used.
Code
Gear stage C B A
Bit 2 Bit 1 Bit 0
1 0 0 0
2 0 0 1
3 0 1 0
4 0 1 1
5 1 0 0
6 1 0 1
7 1 1 0
8 1 1 1
Notes:
• Gear stage 1 is allocated to the lowest spindle speed range.
• If fewer than 8 gear stages are provided, codes for unavailable gear stages must not be
transferred to the NC.
FEEDFORWARD CONTROL OFF DW K+2, bit 15
1 signal: The feedforward control is inactive. The active feedforward control parameters
are cleared when the signal is set.
0 signal: The feedforward control becomes active. The feedforward control parameters
defined in the machine data are taken into account in the set value calculation.
The feedforward control is always active when the control powers up, it is not
deactivated until the signal is set.

SINUMERIK 840C (PJ)
CHANNEL NUMBER DW K+2, bit 8 to 12
The PLC user program must assign one channel to each spindle from which it receives its
setpoint values. The channel numbers are encoded as follows:
If a spindle is switched as C axis in a channel, it should be switched off in the same channel.
If the spindle is to be switched off in another channel, it must previously be assigned to the
relevant channel.
Code
Channel number E D C B A
Bit 12 Bit 11 Bit 10 Bit 9 Bit 8
0 0 0 0 0 0
1 0 0 0 0 1
2 0 0 0 1 0
3 0 0 0 1 1
4 0 0 1 0 0
5 1) 0 0 1 0 1
6 1) 0 0 1 1 0
SET ROTATION CLOCKWISE DW K+2, bit 7
1 signal: The set voltage which has been parameterized to correspond to clockwise
rotation is output.
0 signal: The set voltage which has been parameterized to correspond to counter-
clockwise rotation is output.
Notes:
• The SET ROTATION CLOCKWISE signal is effective only in conjunction with the PLC
SPINDLE CONTROL signal.
• The sign of the set voltage is parameterized by:
– INVERT M03/M04 signal
– MD 521*, bit 1 "Sign change set value"
• The signal determines the direction of rotation in oscillating mode or in control mode with
basic speed (BASIC SPEED signal)
OSCILLATION SPEED DW K+2, bit 6
1 signal: Request for oscillation mode.

_______
1) As from SW 4

SINUMERIK 840C (PJ)
t1 t2
n+
1
Oscillation mode
1: Motor oscillation speed

2: SPINDLE SET ROTATION CW signal (t1 not equal to t2)
Notes:
• The signal is effective only if the PLC SPINDLE CONTROL signal is also set.
• The oscillation speed is determined by MD 450*. It refers not to the spindle speed but to
the motor speed (unit: %).
• The direction of rotation is determined by the SET ROTATION CW and INVERT M03/M04
signals. MD 521*, bit 1 ("Setpoint sign change") is also taken into account.
• The speed override is disregarded.
• The programmed values (S value, direction of rotation) are reactivated when the
OSCILLATION SPEED or PLC SPINDLE CONTROL signal is cancelled.
• The oscillation mode is not aborted by Reset.
• The acceleration time constants do not have any significance in oscillation mode.
Example:
Gear changing with oscillation of drive motor speed to facilitate gear engagement (see
description of CHANGE GEAR signal).
BASIC SPEED DW K+2, bit 5
1 signal: A fixed basic speed is specified for the spindle.

0 signal: No effect

SINUMERIK 840C (PJ)
Notes:
• The signal is effective only when the PLC SPINDLE CONTROL signal is also set.
• The basic speed is defined by MD 449*. It is a spindle speed, which should be very slow.
A change in this MD becomes effective immediately.
• The speed override is taken into account.
• The direction of rotation is defined by SET ROTATION CLOCKWISE and INVERT
M03/M04 signals. Furthermore, MD 521, bit 1 ("Sign change set value") is taken into
account.
• If the BASIC SPEED or PLC SPINDLE CONTROL signal is again cancelled, the pro-
grammed values (S value, direction of rotation) become active again.
• The setting of the basic speed is not aborted by reset.
• The applicable acceleration time constants are taken into account.
At the low basic speed, the spindle can be positioned manually.
POSITION SPINDLE DW K+2, bit 4
1 signal: Request for positioning mode.

Notes:
• The set spindle position is determined by MD 452*.
• If the spindle is stationary, the position is approached by the shortest path. The spindle
rotates at the creep speed specified in MD 427* to 434*.
• If the spindle is not stationary at the time of the request, positioning is carried out with the
direction of rotation being retained.
• In the positioning mode, MD 478* to 485* "Acceleration time constant with position control"
are used.
• The functions M03 or M04 stored on the NC are deleted by the POSITION SPINDLE
signal. The stored S value, however, is retained and becomes active again when the
ACKNOWLEDGE M19 signal is given and M03 or M04 is then programmed.
• Position spindle must not be selected as long as G96 (constant cutting speed) is active.
Positioning the spindle to the tool change position; a tool change can be programmed only
with M06 without M19 if the PLC is activated on the basis of M06 POSITION SPINDLE.

SINUMERIK 840C (PJ)
RESYNCHRONIZE SPINDLE D K+2, bit 3
1 signal: The spindle is resynchronized with the encoder.

0 signal: No effect
Note:
RESYNCHRONIZE SPINDLE is effective only in conjunction with PLC SPINDLE CONTROL.
Resynchronization of the encoder and spindle control when, for example, the encoder is
changed with the drilling head.
ACKNOWLEDGE M 19 D K+2, bit 2
1 signal: An M 19 in the NC is cancelled, i.e. the position control is interrupted.

0 signal: No effect
Note:
The ACKNOWLEDGE M 19 signal is effective only in conjunction with PLC SPINDLE
CONTROL. The M03, M04 auxiliary functions are equivalent to the ACKNOWLEDGE M 19
PLC signal if they are activated by the program or by overstoring. POSITION SPINDLE must
be acknowledged using this signal.
PLC SPINDLE CONTROL DW K+2, bit 0
1 signal: Enables PLC interface signals

– SET ROTATION CLOCKWISE
– OSCILLATING SPEED
– BASIC SPEED
– POSITION SPINDLE
– SPINDLE SYNCHRONIZATION
– ACKNOWLEDGE M19
0 signal: Spindle control by the NC or command channel.
Notes:
• If a new request is transmitted from the NC part program to the spindle, it does not
become effective until the PLC SPINDLE CONTROL interface signal is cancelled.
• If several of the above-mentioned signals are present simultaneously, the following
priorities (in descending order) apply:
– POSITION SPINDLE
– OSCILLATION SPEED
– BASIC SPEED

SINUMERIK 840C (PJ)
SPINDLE DISABLE DW K+3
1 signal: Causes the spindle to stop, the spindle speed being reduced according to the
acceleration time constants (at least one signal = 1).
With spindle positioning by M 19 or POSITION SPINDLE, the positioning process
is interrupted by setting the SPINDLE DISABLE signal.
0 signal: Effects spindle drive enable, the spindle being accelerated according to the
acceleration time constants.
With spindle positioning selected by M 19 or by POSITION SPINDLE from the
PLC, the positioning process is continued.
Notes:
1) If the spindle disable signal is given, set speed value ZERO is selected.
2) When the spindle is enabled again, the previous set speed value becomes effective.
3) Spindle disable is activated if at least one bit is set.
4) A message (error or operational message) can be allocated to any bit (see Section 12,
Display Programs for PLC Data and Messages).
5) The acceleration time constants are stored in NC MD 419* without position control. In the
positioning mode, MD 478* to MD 485* are used.
Example:
C DB 31 ;Spindle-specific signals
L DR 0 ;Signals from spindle (VDI 1)
T FY 200
A F 200.7 ;Gear change request from spindle to PLC
= F 203.0 ;Monitoring for maximum gear stage speed Off
L FY 203
T DL 50 ;Signals to spindle (VDI 2). Set ”Monitoring Off”
AN F 200.7 ;Gear change request from spindle to PLC
JC END
.
JU FB 123 ;Change gear stage
.
R F 200.7 ;Acknowledge gear change request
L FY 200
T DR 0
END: BE

SINUMERIK 840C (PJ)
5.4 Signals from following spindle to PLC, DB 31 for the GI function
5.4 Signals from following spindle to PLC, DB 31 for the GI function 1)
Additional spindle-specific signals are provided in data block DB 31 for the ”Gear interpolation”
functionality. These can be utilized when one of the spindles is used as a following spindle in a
GI grouping. The following spindle is interlocked in follow-up mode against all requests from
the system (except controller enable). An explanation of the ”Gear interpolation” function is to
be found in the Installation Instructions, Description of Functions.
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The address K is derived for the following spindles as follows:
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1st spindle K=0
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2nd spindle K=4
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3rd spindle K=8
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4th spindle K=12
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5th spindle K=16
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6th spindle K=20
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ACCELERATION LIMIT SYNCHRONOUS ACTIVE DW K+24, bit 14
1 signal: When the maximum acceleration limit of the following spindle is reached, the
following spindle can no longer follow the leading axes/spindles. The resulting
positional deviation to the leading axes/spindles is added up and subsequently
traversed after the acceleration process. Positional synchronism will then be re-
established.
0 signal: Any positional deviation to the leading axes/spindles possibly occurring during
acceleration of the following spindle is not taken into account. This means that
the following spindle is no longer in positional synchronism with the leading
axes/spindles.
Note:
The maximum permissible acceleration for the following spindle is specified in the
”Acceleration time constant with position control” (NC MD 478*-485*).
ESR MONITORING IS ACTIVE 2) DW K+24, bit 13
1 signal: The monitoring functions for EXTENDED STOP AND RETRACTION are
is set.
0 signal: The retraction monitoring is switched off.
_______
1) As from SW 3
2) The ESR function is described in detail in the Installation Instructions, SW 5.

SINUMERIK 840C (PJ)
COMPENSATORY CONTROLLER ACTIVE DW K+24, bit 12
1 signal: The compensatory controller is switched on. The current partial actual values of
the following axis and of the leading axes/spindles are checked under
consideration of the linking factors. Additive setpoint speeds are calculated from
the deviations of the partial actual values and output to the following axis.
0 signal: The compensatory controller is switched off.
Note:
The compensatory controller serves to compensate for load disturbances. It increases the
stiffness of the link.
FOLLOWING SPINDLE OVERLAY ACTIVE DW K+24, bit 10
1 signal: An additional traversing movement can be overlaid on the following spindle. This
enable signal is also required for on-the-fly synchronization of the leading and
following drive. The overlay path is traversed at the M19 creep speed as speed
offset.
0 signal: The following spindle is not traversed with overlay at this moment.
SYNCHRONIZATION BUSY DW K+24, bit 9
1 signal: ”On-the-fly synchronization” was triggered via PLC or NC. The synchronization
process has not yet been completed, the synchronization positions have not yet
been reached.
0 signal: ”On-the-fly synchronization” is currently not active.
Notes:
• The signal is reset by the system when the synchronization positions are reached.
• The SYNCHRONIZATION POSITION REACHED interface signal indicates when the
synchronization position has been reached.
LINK ACTIVE DW K+24, bit 8
1 signal: The spindle operates as a following spindle within an active GI grouping.

0 signal: The spindle is not involved in an active GI grouping as a following spindle.
Note:
Programming the linking factor ”0” causes the signal to be reset.

SINUMERIK 840C (PJ)
CONTROLLED FOLLOW-UP MOTION OF FOLLOWING SPINDLE DW K+24, bit 6
1 signal: The following spindle follows up under control due to a fault. The set values for
the following spindle are derived from the actual values of the leading
axis/spindle.
0 signal: The configured type of link between the following spindle and the leading
axis/spindle is active.
MAXIMUM ACCELERATION DW K+24, bit 5
1 signal: The set value for acceleration of the following spindle is greater than the
maximum value specified in NC MD 478*-485*. The following spindle traverses at
maximum acceleration, the positional deviation to the leading axes/spindles
increases. Alarm 2060* ”Acceleration limit” is triggered.
0 signal: The current acceleration of the following spindle is less than the maximum
acceleration.
Note:
The signal is relevant to the following spindle in synchronous operation.
MAXIMUM SPEED DW K+24, bit 4
1 signal: The setpoint speed of the following spindle is higher than the maximum speed.
The following spindle rotates at maximum speed. The positional deviation to the
leading axes/spindles increases leading to a loss of synchronism. Alarm 2059*
”Speed limit” is triggered.
0 signal: The current speed is less than the maximum speed.
Notes:
• The maximum speed of the following spindle is determined by the minimum values of the
following data:
– NC MD 403*-410* Maximum speed of gear stage
– NC MD 451* Maximum chuck speed
– SD 403* Programmed spindle speed limit (G26)
– SD 401* Programmed spindle speed limit (G92)
• The signal is relevant to the following spindle in synchronous operation.
ACCELERATION WARNING THRESHOLD REACHED DW K+24, bit 3
1 signal: The acceleration of the following spindle has exceeded the warning threshold
(NC MD 494*). Increasing acceleration still involves the risk of synchronism being
disturbed between the leading axes/spindles and the following spindle.
0 signal: Acceleration is lower than the acceleration warning threshold.

SINUMERIK 840C (PJ)
Notes:
• The signal is automatically removed by the control as soon as the current acceleration
drops below 7/8 of the warning threshold.
• Monitoring can be deselected with NC MD 526* bit 3 ”Suppress acceleration limit”.
• The signal is significant for the following spindle in synchronous mode.
SPEED WARNING THRESHOLD REACHED DW K+24, bit 2
1 signal: The speed of the following spindle has exceeded the warning threshold (NC MD
494*). The following spindle may now no longer be able to follow the leading
axes/spindles, involving the risk that the synchronism between the leading
axes/spindles and the following spindle will be disturbed.
0 signal: The speed is lower than the speed warning threshold.
Notes:
• The signal is automatically removed by the control as soon as the current speed drops
below 7/8 of the warning threshold.
SYNCHRONOUS MOTION FINE DW K+24, bit 1
1 signal: The positional deviation of the following spindle to all configured leading axes/
spindles is less than the ”Synchronization fine” (NC MD 491*) tolerance band.
0 signal: The positional deviation of the following spindle to all configured leading axes/
spindles is greater than the ”Synchronization fine” (NC MD 491*) tolerance band.
Notes:
• The tolerance band is determined by the offset angle between leading and following
spindle and the Synchronization fine (NC MD 491*) tolerance.
SYNCHRONOUS MOTION COARSE DW K+24, bit 0
1 signal: The positional deviation of the following spindle to all configured leading
axes/spindles is less than the ”Synchronization coarse” (NC MD 492*) tolerance
band.
0 signal: The positional deviation of the following spindle to all configured leading
axes/spindles is greater than the ”Synchronization coarse” (NC MD 492*)
tolerance band.
Notes:
• The tolerance band is determined by the offset angle between leading and following
spindle and the ”Synchronization coarse” (NC MD 492*) tolerance.

SINUMERIK 840C (PJ)
SYNCHRONIZATION POSITION REACHED DW K+25, bit 14
1 signal: The synchronization process with ”On-the-fly synchronization” is completed, the

following spindle now traverses in positional synchronism with the synchronization
position to the leading spindle.
0 signal: The synchronization position has not yet been reached.
Note:
The SYNCHRONIAZTION BUSY signal is reset when the synchronization position is reached.
On-the-fly synchronization can be aborted with RESET as long as the SYNCHRONIZATION
BUSY signal is set. The link is activated nevertheless.
ESR RESPONSE IS TRIGGERED 2) DW K+25, bit 13
1 signal: This spindle has triggered the ”Extended stop and retraction”.
0 signal: No triggering of ESR response.
SPINDLE IS A FOLLOWING SPINDLE DW K+25, bit 7
1 signal: The spindle was configured as a following spindle in a GI grouping.

0 signal: The spindle was not configured as a following spindle in a GI grouping
Note:
The PLC can recognize from this signal if a GI grouping was defined for a spindle, even if the
link is not active.
ESR RESPONSE IS PROGRAMMED 1) 2) DW K+25, bit 5
1 signal: When ”Extended stop and retraction” has been programmed for this spindle via
the G commands (G422 to G426). With this signal, a response can be started via
the "ESR response enabled" interface signal.
The ESR function is described in the SINUMERIK 840C, SW 4 Installation
Instructions.
0 signal: No ESR response is programmed for this spindle.
_______
1) As from SW 4
2) The ESR response is described in detail in the Installation Instructions, SW 4.

SINUMERIK 840C (PJ)
REQUEST LINK OFF DW K+25, bit 1
1 signal: The signal is set if a link is to be switched off (Source: part program, PLC or
input image), however, the conditions for a deactivation (e.g. INTERLOCK LINK
OFF, PLC SPINDLE CONTROL signals) are not yet satisfied. Part program block
change is halted until the conditions are met.
0 signal: No change of LINK ON status requested. The signal is also reset when the PLC
SPINDLE CONTROL or INTERLOCK LINK ON signal is reset.
REQUEST LINK ON DW K+25, bit 0
1 signal: The signal is set if a link is to be switched on (Source: part program, PLC or
input image), however, the conditions for an activation (e.g. INTERLOCK LINK
ON signal) are not yet satisfied. Part program block change is halted until the
conditions are met.
0 signal: No change of LINK OFF status requested. The signal is also reset when the PLC
SPINDLE CONTROL or INTERLOCK LINK OFF signal is reset. The link will then
become active. If other conditions should have prevented the link from becoming
active, the conditions must first be satisfied and subsequently a new LINK ON
must be triggered.
Slave operation is active1) DW K+49, bit 9
1 signal: Slave mode is switched on (see Installation Instructions, Section 12, Function
Description).
0 signal: The spindle in question is in normal mode.
C axis active DW K+49 bit 8
1 signal: The spindle is active as C axis.

0 signal: Spindle is active
_______
1) As from SW 4.4

SINUMERIK 840C (PJ)
5.5 Signals from PLC to following spindle for GI function
5.5 Signals from PLC to following spindle for GI function 1)
ACTIVATE ESR MONITORING DW K+26, bit 13
0/1 edge: The emergency retraction monitoring for the following spindle is switched on.
Notes:
• The emergency retraction threshold is specified in NC MD 493*.
• The ACTIVATE ESR MONITORING signal is set as check-back signal.
• As from SW 4, errors leading to ESR responses can be programmed; the signal is not
restricted to MD 493*.
ON-THE-FLY SYNCHRONIZATION ON DW K+26, bit 9
0/1 edge: On-the-fly synchronization of the following spindle with all configured leading
axes/spindles is triggered. A LINK ON signal is generated internally. The
SYNCHRONIZATION BUSY signal is set. This bit is cancelled again by the
system when the synchronization positions are reached and the
SYNCHRONIZATION POSITION REACHED signal is set.
LINK ON DW K+26, bit 8
0/1 edge: Activates the link of all configured axes/spindles with the following spindle
with the current linking factors.
Notes:
• This signal affects all configured leading axes/spindles. Selective linking via the PLC is not
possible. The linking factors must have been programmed in advance or derived from the
GIQ data during power up.
• The LINK ACTIVE signal is set by way of acknowledgement.
DISABLE ESR MONITORING 2) DW K+26, bit 5
0/1 edge: The emergency retraction monitoring for the following spindle is switched off.
Note:
• The ACTIVATE ESR MONITORING signal is reset as check-back signal.
• The monitoring function can also be switched on/off from PLC. If it is switched on from
PLC, it can also be switched off from PLC. If it is switched off from PLC, it is switched off
for all channels.
_______
1) As from SW 3

SINUMERIK 840C (PJ)
LINK OFF DW K+26, bit 0
0/1 edge: Deactivates the link of all configured leading axes/spindles with the following axis.
Notes:
• This signal affects all configured leading axes/spindles. Selective delinking via the PLC is
not possible.
• The LINK ACTIVE signal is reset by way of acknowledgement.
CORRECT SYNCHRONISM DIFFERENCE DW K+27, bit 7
1 signal: The PLC signal "Correct synchronism difference" corrects the setpoint to the
following address by the synchronism error between the leading and following
addresses so that the synchronism difference no longer results in a system
deviation. Both the controller and drive must be enabled and the gearbox
coupling must be switched on while this signal is applied.
0 signal: Position and/or comensatory controller correct the synchronism error
Notes:
• This function is particularly important where synchronous spindle pairs are used. When the
workpiece is transferred by the following drive, an angle offset between the leading and
following drives can result for mechanical reasons when the chuck is closed. This offset
cannot be eliminated while the drives are coupled via the workpiece. This can be avoided
with the signal CORRECT SYNCHRONISM DIFFERENCE.
• This signal should be activated:
– After closure of the mechanical coupling, if the power transmission is without slip.
– When teh drives are mechanically coupled and position control is acitvated.
• If both drives are mechanically coupled the signal must be canceled so that precise
synchronization is maintained.
ACCELERATION LIMIT SYNCHRONOUS DW K+27, bit 6
1 signal: The acceleration limit synchronous is activated.

0 signal: The acceleration limit synchronous is not activated.
Notes:
• The acceleration limit synchronous for the following spindle enables the following spindle
to traverse in positional synchronism with the leading axes/spindles again after
accelerations. Any positional deviations possibly occurring during acceleration are added
up and traversed after the acceleration phase.
• The ACCELERATION LIMIT SYNCHRONOUS ACTIVE signal is set as soon as the
acceleration limit becomes active.
• The maximum acceleration of the following spindle is determined by the ”Acceleration time
constant with position control” (NC MD 478*-485*).

SINUMERIK 840C (PJ)
ENABLE ESR RESPONSE 1) 2) DW K+27, bit 5
1 signal: With this static signal, the PLC can enable a programmed (signal: "ESR
response is programmed" is set) ESR response. Without this signal, a spindle
movement is not possible (safety signal).
COMPENSATORY CONTROLLER ON DW K+27, bit 4
1 signal: The compensatory controller is activated from the PLC.

0 signal: The compensatory controller is not activated.
Notes:
• The compensatory controller serves to compensate for load disturbances. It increases the
stiffness of the link.
• The COMPENSATORY CONTROLLER ACTIVE signal is set by way of acknowledgement.
ENABLE FOLLOWING SPINDLE OVERLAY DW K+27, bit 2
1 signal: An additional motion can be overlaid on the movement of the following spindle
predetermined by the leading axes/spindles. This overlaid movement is
automatically preset for on-the-fly synchronization to enable traversing to the
programmed angular difference.
0 signal: No overlaid movement of the following spindle is possible.
Note:
Alarm 2058* ”Following spindle overlay not enabled” is output when an attempt is made to
traverse the following axis with overlay without an enable signal given.
INTERLOCK LINK OFF DW K+27, bit 1
1 signal: The link between the following spindle and the leading axes/spindles cannot be
switched off.
0 signal: The link between the following spindle and the leading axes/spindles can be
switched off.
Notes:
• If this interlock signal was present when a LINK OFF signal was programmed, the link is
not switched off until this interlock signal is reset.
• Block change is interlocked as long as this signal is present and a link is to be switched
off. The REQUEST LINK OFF signal is set.
_______
1) As from SW 4

SINUMERIK 840C (PJ)
INTERLOCK LINK ON DW K+27, bit 0
1 signal: The link between the following spindle and the leading axes/spindles cannot be
switched on.
0 signal: The link between the following spindle and the leading axes/spindles can be
switched on.
Notes:
• If this interlock signal was present when a LINK ON signal was programmed, the link is not
switched on until this interlock signal is reset.
on. The REQUEST LINK ON signal is set.
• The signal has no influence on an active link.
The effects stated below apply in addition to the interface signals described:
SERVO ENABLE (spindles)

• The LINK ON status is retained when the SERVO ENABLE signal is removed with an
active GI link (operating leading/following drives). The drive is brought to a standstill. GI
monitoring remains active.
• The link is not switched on if the SERVO ENABLE is not set when LINK ON is selected.
The REQUEST LINK ON signal is set. For switching on the link, a new LINK ON request
must be programmed after the SERVO ENABLE was set.
Disable spindle
• LINK ON is retained when DISABLE SPINDLE is set for a leading spindle. The spindle is
brought to a standstill. The servo enable remains active.
• The following spindle cannot be influenced via this signal.

SINUMERIK 840C (PJ)
5.6 Interface signals for spindle/drive 611D (DB31)
5.6 Interface signals for spindle/drive 611D (DB31)1)
Parking spindle DB 31, DW K+50, bit 11 1)
MSD and FDD:

1 signal: Spindle is in parked position.
0 signal: Spindle is not in parked position.
Notes:
• If a spindle is declared a PARKING SPINDLE, monitoring of the connection encoder
measuring circuit module is switched off. No alarm is therefore triggered if this connection
is separated.
• The spindle/axis is resynchronized if the signal to the PARKING SPINDLE is removed.
Slave operation is active 3) DW K+50, bit 9
1 signal: Slave operation is activated (see Function description)

0 signal: The spindle in question is in normal mode
Gear stage monitoring off 1) DW K+50 2), bit 8
1 signal: The maximum gear stage speed is not taken into account in the monitoring of the
spindle speed limit. It is therefore possible to switch from a higher gear stage to a
lower gear stage without stopping the spindle. Only monitoring of maximum
chuck speed (MD 451*), maximum spindle speed (SWITCHING DEVICE 403*)
and, if G 96 is acitvated, limitation to G 92 S is activated. The maximum gear
stage speed (MD 403*) is no longer monitored.
_______
1) As from SW 3
2) Spindle Address y
1 48
2 52
3 56
4 60
5 64
6 68

SINUMERIK 840C (PJ)
Parameter group "Position control" (bit 0 .. 2) 2) DW K+51, bit 0-2

Parameter group "Speed ratio" (bit 0 .. 2) 2) DW K+51, bit 3-5
These three bits can be used to switch over in binary coded form between a maximum of 8
parameter sets, e.g.:
001 =ˆ Parameter set 1
011 =ˆ Parameter set 3 etc.
Notes:
• To ensure that the changeover for the spindle is executed via this interface signal,
MD 522*, bit 4 "Switchover parameter groups separately" must be set. In this case, the
interface signals for the actual gear stage (DB 31, DW K+1, bit 0-2) are irrelevant. The
display of the actual gear stage in the service screen is still updated in accordance with
the interface signals, but otherwise has no effect.
If the bit is not set, the PLC signals for the actual gear stage are used; the PLC signals for
the various parameter groups are not effective.
With spindle/C axis, MD 522*, bit 4 "Switchover parameter groups separately" influences
both the changeover behavior of the spindle and of the C axis. "Switchover separately" is
permanently set for normal axes. C axes can be influenced via the spindle MD bit in such
a way that all parameter groups ("Position controller", "Speed ratio" and "Drive") are
switched over jointly via the interface of the "Position controller" parameter group.
• The "Parameter set changeover" function is described in the SINUMERIK 840C, SW 5
Installation Instructions.
• Effective only with extended parameter set changeover NC MD 523*, 0.
_______
1) As from SW 3
2) As from SW 4
3) As from SW 4.4

SINUMERIK 840C (PJ)
Parameter block (0), (1), (2) DW K+72, bit 0, 1, 2
MSD and FDD 1)

Confirmation of the currently active parameter set.
The 3 bits are always to be interpreted together as a binary number.
Motor selection bit 0 DW K+72, bit 3
MSD and FDD 1)

Confirmation of star-delta operation or changeover of motor.
1 signal: Delta operation or motor 2
0 signal: Star operation or motor 1
Motor selection bit 1 DW K+72, bit 4
MSD and FDD 1)

Reserved for later applications.
Drive ready DW K+72, bit 5
MSD and FDD:

Drive ready message
1 signal: Drive ready
0 signal: Drive not ready
– Enable terminals missing:
KL.663, submodule-specific pulse enable
KL.64, central drive enable
KL.63, central pulse enable
– Infeed/feedback hardware, summation error, Power on
Note:
• 611D machine data 1012 bit 2 "Drive ready"
observe dependency of terminals
• Observe interface signal DB 29 DW 120 bit 5
_______
1) FDD as from SW 4

SINUMERIK 840C (PJ)
Drive switched on DW K+72, bit 6
MSD and FDD:

1 signal: Drive switched on/drive has ramped-up
0 signal: Drive not switched on
Pulses are enabled DW K+72, bit 7
MSD and FDD:

Enable pulse confirmation
1 signal: All enable signals are present
0 signal: Pulse-controller enable missing, enable terminals not set,
status class 1 error present, switch motor is active,
P53 bit 13=1
Motor temperature prewarning DW K+72, bit 8
MSD and FDD:

ZK2 message, motor temperature exceeds the value in P063/P291 with MSD and in P1602
with FDD. If the temperature remains too high, a status class 1 error (ZK1) is output after an
elapse of the time set in P065 (MSD) or in P1603 (FDD).
FDD:
If a motor temperature=0 is measured, an interruption of the PTC motor thermistor is
assumed and the bit is also set. A reaction to this situation is initiated via the PLC program. In
this case, there will be no reaction in the drive. If the motor temperature=0 is still measured
after the time set in P1603 has elapsed, the ZK1 Reset error (”Motor temperature N...”) is
issued.
Heat sink temperature prewarning DW K+72, bit 9
MSD and FDD:

ZK2 message, heat sink temperature too high. If the temperature remains too high, a ZK1
error is output after 20 seconds.

SINUMERIK 840C (PJ)
User-programmable messages 1 to 6 DW K+72, bit 10 ... 15
MSD:
6 MSD-specific messages. The messages can be freely assigned to the 6 status bits via
P241/P246. The following messages are preset:
Message 1: Ramp-up phase ended
Message 2: M–D<M–dx
Message 3: n–act<n–min
Message 4: n–act<n–x
Message 5: n–act<n–set
Message 6: Variable message function 1
FDD:
The message assignments for feed drive are firmly specified:
DW K+72, bit 10: freely programmable
bit 11: freely programmable
bit 12: n–act<n–min
bit 13: n–act<n–x
Travel request drive test DW K+73, bit 15
1 signal: Drive test requested (drive stationary) or active (drive operating). The signal is
set as soon as a drive test was started and the parameter assignment has been
established to be faultless. The signal is removed at the end of the drive test as
soon as the drive has been brought to a standstill and has resumed its former
operating mode.
0 signal: Drive test not active
DC link voltage < Warning threshold (MD 1604) 1) DW K + 73, bit 0
ZK2 message, that the DC link voltage has fallen below the value determined in MD 1604.
MD 1604 is described in the SINUMERIK 840C, SW 4 Installation Instructions.
_______
1) SW 4 and higher

SINUMERIK 840C (PJ)
DC link voltage<Emergency retraction threshold (MD 1634)1) DW K+73, bit 1
ZK2 message, that the DC link voltage has fallen below the value determined in MD 1634 as
emergency retraction threshold.
When the DC link voltage falls below the emergency retraction threshold, emergency retraction
responses are initiated which are defined in MD ZWK_NOTR_M. The machine data (MD) are
described in the SINUMERIK 840C, SW 4 Installation Instructions.
Emergency retraction or DC link generator active 1) DW K+73, bit 2
ZK2 message, that emergency retraction or DC link generator is active.

• If the voltage thresholds MD 1634 and MD 1631 in the infeed/regenerative-feedback unit
are unequal and MD 1631 > MD 1634, generator operation starts without an emergency
retraction being initiated simultaneously for the infeed/regenerative-feedback unit axes.
The emergency retraction threshold is thus recognized only when the generator axis is no
longer capable of supporting the DC link. In this case, emergency retraction is not carried
out due to the lack of energy. In order to prevent this, NC emergency retraction responses
must be initiated on the other axes, when the actual speed of the generator axis has fallen
below a minimum speed (MD 1635).
• In the case of a communication failure (failure of "sign-of-life”) of one axis, the other axes
must be treated by the NC in accordance with their operating mode. If, for example, the
axis that failed is an emergency retraction axis, it will perform an emergency retraction.
Consequently, coupled axes must perform an emergency retraction controlled by the NC.
UZWK
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MD_U_GEN_OFF
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MD_U_GEN_ON
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MD_U_GEN_HUB
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ZK2
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"ZWK_GEN_AKTIV"
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Conditions for switching on/off the ZK2 message "Generator active"

SINUMERIK 840C (PJ)
Generator speed < Minimum speed

Generator axis (MD 1635) 2) DW K+73, bit 3
ZK2 message, that the generator speed has fallen below the value of the minimum speed of
the generator axis in MD 1635.
MD 1635 is described in the SINUMERIK 840C, SW 4, Installation Instructions.
Parameter set (0, 1, 2) DW K+74, bit 0, 1, 2
MSD and FDD 1)

The 3 bits are used to select one of the eight gear stages available and to activate the
associated parameter set. The 3 bits are always interpreted together as a binary number.
Motor selection bit 0 2) DW K+74, bit 3
MSD:
Request star-delta changeover or motor changeover.
1 signal: Delta operation or motor 2
0 signal: Star operation or motor 1
Motor selection bit 1 1) DW K+74, bit 4

MSD:
Reserved for later applications
Motor selection executed 1) DW K+74, bit 5
MSD:
This bit is used by the PLC to confirm changeover of the motor contactors for star/delta
changeover or motor changeover.

SINUMERIK 840C (PJ)
Disable integrator DW K+74, bit 6
MSD and FDD:

Disable integrator of speed controller
1 signal: Disable integrator
0 signal: Enable integrator
Pulse enable DW K+74, bit 7
MSD and FDD:

1 signal: Enable pulses (enable signal is only given if all other enable signals are present)
0 signal: Disable pulses
Ramp-function generator rapid stop DW K+74, bit 9
MSD:
1 signal: Specifies setpoint speed 0, braking without ramp-function generator ramp
(see MD 522* bit 3)
Second torque limit DW K+74, bit 10
MSD:
Activates 2nd torque limit set in P041.
_______
1) FDD as from SW 4
2) As from SW

SINUMERIK 840C (PJ)
Set speed smoothing DW K+74, bit 11
MSD:
Activates interpolation of the setpoint speed from the position controller cycle into the speed
controller cycle.
Activates rounding of the setpoint speed parameterized via P019.
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XR = Position controller cycle
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XINT = Speed controller cycle
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N–set = Set value from NC
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N–NRS = Set value MSD internal
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N–set (k)
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N–set (k-1)
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0 XINT XR 2 XR 3 XR
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Function diagram of interpolation filter
Motion enable drive test DW K+75, bit 15
MSD and FDD:

1 signal: PLC enable for drive test is present. The drive test (traversing movement) is
started with NC Start.
0 signal: PLC enable missing. The drive test is aborted at NC Start, i.e. the travel request
is cancelled and the drive resumes its former status.
If the drive test is already active (drive operating), the traversing movement is
stopped and the drive subsequently resumes its former operating mode.
Note:
The effect of the signal depends on the parameterization of the drive test by the user.
Selection can be made in the ”Function generator” and ”Measurement” installation functions if
the ”Enable motion for drive test” enable signal is to be active:
1. Enable ”internal” without enable signal from PLC with NC Start.
2. Enable through enable signal from PLC with NC Start.
3. Enable through enable signal from PLC without NC.

SINUMERIK 840C (PJ)
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5–42
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Step 4:
Step 3:
Step 2:
Step 1:
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PLC
MSD/AM control
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Message “Contactor
Waiting for message
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Motor contactor 1 open

changeover completed”
Close motor contactor 2
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5 Spindle/PLC Interface (DB 31)
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from the drive.
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FX82 is used for this function.
Star/delta changeover request

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Wait until motor contactor 1 is open

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Wait until motor contactor 2 is closed

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2 separate contactors and is executed in 4 steps.
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performed using the “Star/delta switching” function block.
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END OF SECTION
switching operation via motor selection bit 0.
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the “Motor selection performed” interface signal.
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The function block must be called up separately for each spindle.
611D
completed”
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Enable pulses
Remove pulses
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Wait for message

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Reload motor data
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“Contactor changeover

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Pulses removed message
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Contactor 2 (new status) is switched on after a specified waiting time.
A defined switching logic (time-controlled) for star to delta switching and vice versa is
Removal of the “Motor selection performed” interface signal and advising the
disable” and the acknowledgement of the advised motor selection are available
After another waiting time, completion of changeover is reported to the drive via
Contactor 1 (former status) is switched off as soon as the confirmation of “Pulse
6FC5197- AA00
The function block is effective for digital main spindle drives only. Changeover is performed via
SINUMERIK 840C (PJ)

07.97
09.95 6 Axis/PLC Interface (DB 32/DB 29)
6 Axis/PLC Interface (DB 32/DB 29)
General notes
The SINUMERIK 840C can control a maximum of 15 1) servo loops (total of axes and spindles
= 15 2)). The interfaces of all spindles are stored in data block 32. The PLC axis interface
is set axis-specific by means of PLC machine data (PLC MD 6016 to 6022). In the setting-up
modes, the axes cannot be influenced by the channel-specific GENERAL FEED DISABLE
signal. A feed disable can be effected only with the axis-specific FEED DISABLE signal.
In principle, each channel of an operating mode group can effect motion of all axes allocated
to the same operating mode group. However, the same axis may not be activated by several
channels at the same time. In exceptional circumstances, certain axes can be disabled for
certain channels by means of NC MD.
The allocation of axis number servo loop module is made via NC machine data 200*.
The allocation of axis number axis name is made via NC machine data 568*. The axis
defined in the MD as the 1st axis is also the 1st axis at the NCK/PLC interface.
The axis-specific FEED DISABLE signals can be allocated fault/operational messages with
selection made via PLC machine data (refer to Section 12, Display Programs for PLC Data and
Messages).
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The K addresses for the axes are as follows:
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1st axis K=0 10th axis K=36
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2nd axis K=4 11th axis K=40
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3rd axis K=8 12th axis K=44
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4th axis K=12 13th axis K=48
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7th axis K=24 .
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8th axis K=28 .
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9th axis K=32 .
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30th axis K=116
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_______
1) As the TRANSMIT function requires fictitious axes, up to 30 interpolators are contained in the software
of the NC.
2) With SW 5 and higher up to 30 servo loops (sum of axes and spindles = 30).

SINUMERIK 840C (PJ)
6 Axis/PLC Interface (DB 32/DB 29) 04.96
6.1 Signals from axis
SPEED CONTROLLER ACTIVE DW K, bit 15
1 signal: Speed controller active.

0 signal: Speed controller not active.
POSITION CONTROL ACTIVE DW K, bit 14
1 signal: The axis is in position control.

0 signal: No position control, e.g. in the event of a servo loop fault.
Example:
Activate a holding brake on a vertical axis in the event of a position control failure.
Axis in set range DW K, bit 13
1 signal: The axis (ERA) is within the tolerance set in MD 1152* (see Installation Guide
Instructions, Section 6).
REFERENCE POINT REACHED DW K, bit 12
1 signal: Reference point reached and axis synchronized.

The signal is present until the power supply is switched off.
0 signal: a) Before synchronizing the axis after switching machine on.
b) With *DECELERATION during repeated reference point approach.
c) With the PARKING AXIS PLC signal present.
d) After switching off the 611D drive electronic module
3
2000 units
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1: *DECELERATION signal
2: Measuring system zero mark signal
3: Measuring system zero mark
4: Zero mark plus 2000 units travel in the reference point approach direction
5: Reference point in the range: zero mark plus (2000 units ± 9999 units ref. point shift)
6: REFERENCE POINT REACHED signal

SINUMERIK 840C (PJ)
Notes:
• The reference point can be shifted by means of the "Reference point shift" machine data
in the range ± 9999 units, referred to the 2000 units point (MD 244*).
After reaching the reference point position, the actual value memory of the axis is set to
the reference point value (specified in machine data MD 240*) and the ”REFERENCE
POINT REACHED” signal is output.
• For each axis, NC MD 560*.4 can be used to determine whether the reference point has
to be reached for NC START.
Suppression of the start signal (NC START) if, for example, a parking axis has not been
synchronized when it is activated.
TRAVEL COMMAND +, – DW K, bit 11 and bit 10
AUT/MDA/TEACH IN mode
1 signal: If movement is to take place in the relevant axis direction, e.g. after transfer into
the main memory of a block containing a coordinate value for the axis.
0 signal: a) Block executed
b) Axis disable present
c) Abort with RESET

3: GENERAL FEED DISABLE signal
4: TRAVEL COMMAND signal (e.g. X+)
5: Block executed

SINUMERIK 840C (PJ)
JOG/INC mode
1 signal: Axis selected and direction key pressed.
0 signal: a) Direction key no longer pressed and interpolator output is 0.
b) In the increment (INC) mode, after traverse with incremental feed.
c) Abort with RESET
d) On traverse with handwheel.
REF mode
1 signal: a) Approach to reference point without automatic direction recognition: pressing
the relevant direction key for approach to reference point.
b) Approach to reference point with automatic direction recognition: a direction
key is pressed.
0 signal: Reference point reached.
Note:
With axis clamping, continuous path operation is impossible if the clamp is not released until
the travel command is given.
Clamp release, e.g. on rotary tables.
POSITION REACHED WITH EXACT STOP COARSE/FINE DW K, bit 8 and 9
AUT/MDA/TEACH IN mode
Exact stop coarse:

1 signal: a) The axis has reached the programmed set value up to the tolerance of the
coarse exact stop window (machine data MD 204*), or
b) is already within the fine exact stop window.
0 signal: The axis is outside the coarse exact stop window.
Exact stop fine:

1 signal: The axis has reached the programmed set value up to the tolerance of the fine
exact stop window (machine data MD 208*).
0 signal: The axis is outside the fine exact stop window.
Note:
• The COARSE or FINE POSITION REACHED signals are also "1" if the AUTOMATIC
mode has been interrupted by RESET, an NC alarm or mode change (AUT
INTERRUPTED).
• If the axis is moved with G01, the EXACT STOP COARSE signal is output only when the
EXACT STOP FINE has also been reached.
Example:
Enabling tool change when the turret has reached the change position.

SINUMERIK 840C (PJ)
JOG/INCR/REPOS mode
Exact stop coarse:

1 signal: a) The axis has reached the specified set value up to the tolerance of the
coarse exact stop window (machine data MD 204*), or
b) is already within the fine exact stop window; no direction key and no
handwheel has been operated, or handwheel has been operated and feed
hold is active.
0 signal: The axis is outside the coarse exact stop window; a direction key or handwheel
has been operated.
Exact stop fine:

1 signal: The axis has reached the specified set value up to the tolerance of the fine exact
stop window (machine data MD 208*); no direction key and no handwheel has
been operated, or handwheel has been operated and feed hold is active.
0 signal: The axis is outside the fine exact stop window; a direction key or handwheel has
been operated.
Slave operation is active 2) DW K, bit 7
1 signal: Slave mode is active (see function description).

0 signal: The spindle in question is in normal operation.
IKA warning limit exceeded 1) DW K, bit 6
1 signal: The IKA warning limit (MD 356*) was exceeded in positive or negative direction.
0 signal: The IKA warning limit was not exceeded.
IKA/TK velocity exceeded 1) DW K, bit 5
1 signal: The IKA/TK velocity set in machine data 1148* (axis-specific) was exceeded in
one axis.
_______
1) Only for IKA as compensation
2) SW 4.4 and higher

SINUMERIK 840C (PJ)
Rounding axis in position DW K, bit 4
0 signal: a) Axis has not yet reached reference point

b) Parking axis
c) Follow-up mode for this axis
d) Traverse command (+/–) for this axis
e) EMERGENCY OFF signal
f) C axis in spindle operation
1 signal: Reference point reached and/or axis in rounding position (Coarse exact stop
reached)
Note:
The ROUNDING AXIS IN POSITION interface signal is effective only in conjunction with NC
MD 560* bit 2, ”Rounding to whole/half degrees” and bit 3 ”Rounding with rotary axes”.
Axis is in the reduction range 2) DW K, bit 3
0 signal: Following axis is not in the reduction range.

1 signal: Following axis is in the reduction range. The PLC can transmit a message on the
basis of the output signals.
NFAKAKT, travel against fixed stop active 1) DW K+120, bit 6
0 signal: Travel against fixed stop is not active

1 signal: Travel against fixed stop is active
This signal can be used for analog and digital drives.
NFESTANER, fixed stop reached 1) DW K+120, bit 7
0 signal: Fixed stop not reached

1 signal: Fixed stop reached
+/- Cam 1) DW K+120, bit 8...15
0 signal: No software cam active

1 signal: Confirmation to PLC indicating that software cam was reached
This signal can be used for analog and digital drives.
_______
1) As from SW 3
2) As from SW 5.6

SINUMERIK 840C (PJ)
6.2 Signals to axis
6.2 Signals to axis
MIRRORING DW K+1, bit 15
Mirroring is possible for all axes. Version A or B can be selected via axis-specific machine
data.
0 signal: Mirroring not effective
1 signal: Version A
Mirroring of
– programmed values
– cutter radius compensation or tool nose radius compensation (G41, G42)
– tool length compensation
No mirroring of
– zero offset
1 signal: Version B
Mirroring of
– programmed values
– cutter radius compensation (G41, G42)
No mirroring of
– zero offset
– tool length compensation
Example 1, SINUMERIK 840C turning machine:

Mirroring of X axis, version A
(Mirroring in the X axis causes the axis to be mirrored)
X+
1
Z– Z+
2
X–
Mirroring in the X axis
1: normal: Machining behind the turning centre

2: mirrored: Machining in front of the turning centre
Note:
Activate mirroring in the part program in progress is active only after G714 or G200.

SINUMERIK 840C (PJ)
6.2 Signals to axis
Example 2, SINUMERIK 840C turning machine:

Mirroring of the Z axis, version B
(Mirroring in the Z axis causes the tool to be mirrored)
X+
2 1
Z– Z+
X–
Mirroring in the Z axis
1: Normal machining
2: Mirrored workpiece
Example 3, SINUMERIK 840C milling machine:

Mirroring in the main axis X, version B
(Mirroring in the main axes X, Y, Z always causes the workpiece to be mirrored)
Y+
2 1
X– X+
Y–
Mirroring e.g. in the X axis
1: Normal machining
2: Workpiece mirrored in X

SINUMERIK 840C (PJ)
6.2 Signals to axis
FOLLOW-UP OPERATION DW K+1, bit 14
1 signal: NC position control loop open: no controller enable; the actual value is further
updated.
0 signal: Normal state; NC position control loops closed.
Notes:
• With the axis stationary, the 1 signal opens the position control loop.
• If the axis is in motion, the 1 signal effects rapid deceleration with maximum braking
current, opens the position control loop after the time delay set by machine data has
expired and sets an alarm. Then only the actual position value is retained.
• All axes moving with interpolation are stopped if FOLLOW-UP OPERATION is set for one
axis. Axes with FOLLOW-UP OPERATION not set can be stopped only by selecting the
set speed value ZERO. The following error of these axes is still eliminated.
• An alarm is output if FOLLOW-UP OPERATION is specified for an axis moving with
interpolation. Further execution of the NC program is then no longer possible.
• After cancellation of follow-up operation (0 signal), the axis does not have to be
resynchronized (no approach to reference point) if the max. permissible speed of the axis
has not been exceeded at any time.
• To avoid incorrect positioning, follow-up operation must be cancelled in the AUT
mode only if the NC program is in the STOP state.
• If a rotary axis (C axis) is to be operated as a spindle, the axis-specific monitoring func-
tions can be switched off by setting the FOLLOW-UP OPERATION and PARKING AXIS
SIGNALS. Setting of the PARKING AXIS signal also deletes the REFERENCE POINT
REACHED signal.
If C axis operation is then selected again, the set values of the axis mut be updated.
Reference point approach can be avoided.
Feed disable simultaneous axes DW K+1, bit 13
1 signal: The current speed setpoint value is overwritten with 0. As a result, the spindle
brakes according to the accelaration ramp.
0 signal: No effect. (See also DB 32 DW K+1, bit 13 "Input set value 0".
*DECELERATION REFERENCE POINT APPROACH DW K+1, bit 12
Operating mode REFERENCE POINT APPROACH only:

1/0 transition: Effects deceleration of the selected axis to the reference point creep speed
(NC MD 284*).
0/1 transition: Effects traverse to the zero mark of the measuring system plus
(2000 units travel±reference point offset).
_______
* Signal is 0-active

SINUMERIK 840C (PJ)
6.2 Signals to axis
a) Reference point approach without automatic direction recognition
3 Z
R
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1: Starting point for reference point approach

2: Reference point approach speed
3: Creep speed
6: Actuating cam
7: Limit switch
Sequence:
The Z axis must be located at the starting point, e. g. in the negative direction from the
reference point. The operator presses the Z + key and the axis approaches the reference
point. As soon as the actuating cam passes the limit switch, the *DECELERATION signal
changes from 1 to 0; the axis decelerates to creep speed. When the actuating cam has
cleared the limit switch, the *DECELERATION signal changes from 0 to 1 and initiates the
approach to the next zero mark of the measuring system. As soon as the zero mark signal
appears, the axis homes in to the reference point.
Peripheral condition:
The limit switch that issues the *DECELERATION signal should be a normally closed switch. If
the connection to the limit switch is interrupted, this can be recognized and actuation of the
axis movement prevented.

SINUMERIK 840C (PJ)
6.2 Signals to axis
b) Reference point approach with automatic direction recognition
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1: Starting point for reference point approach

2: Reference point approach speed
3: Creep speed
6: Actuation cam
7: Limit switch
8: Traversing range end, traverse path limit
Sequence 1:
The Z axis must be located at the starting point, e.g. in the negative direction from the
reference point. The operator presses the Z+ key declared as the starting key for reference
point approach. The axis approaches the traversing range end at which the reference point is
located; the direction is recognized by *DECELERATION signal = 1. As soon as the actuating
cam passes the limit switch, the *DECELERATION signal changes from 1 to 0; the axis
decelerates to zero and then accelerates to creep speed in the opposite direction. When the
actuating cam has cleared the limit switch, the *DECELERATION signal changes from 0 to 1
and initiates the approach to the next zero mark of the measuring system. As soon as the zero
mark signal appears, the axis homes in to the reference point.
Sequence 2:
If the axis is already located between the traversing range end and the reference point at the
start of the reference point approach (*DECELERATION signal = 0) and the Z+ key is then
pressed, the Z axis approaches the reference point in the negative direction at creep speed.

SINUMERIK 840C (PJ)
6.2 Signals to axis
Peripheral conditions:
• Because of the specific design of the actuating cam (length: from traversing range end to
switching point), this procedure is suitable only for reference points situated near the
traversing range end.
• The cam must not leave the limit switch from the switching point to the traversing range
end (end of traverse path), i.e. the *DECELERATION signal remains at 0.
• The limit switch that issues the *DECELERATION signal should be a normally closed
switch. If the connection to the limit switch is interrupted (*DECELERATION signal = 0),
the axis can accelerate only to creep speed.
• In the reference point approach mode, rapid traverse override is effective.
PARKING AXIS DW K+1, bit 11
1 signal: Axis in parking position.

0 signal: Axis is in position control.
Notes:
• If an axis is declared a PARKING AXIS, the monitoring of the connection between the
measuring sensor and the measuring circuit module is switched off. Therefore no alarm is
given if this connection is cut (e.g. in order to remove the axis such as a rotary table from
the machine).
• If the PARKING AXIS signal is removed, the axis has to be resynchronized. As from SW 4
the actual value of the current position must be specified by means of PRESET.
CONTROLLER ENABLE DW K+1, bit 10
AUT/MDA mode
1 signal: Closes the position control loop of the relevant axis.
0 signal: 1. With the axis stationary, the position control loop is opened.
2. If the axis is in motion, rapid deceleration is effected. The drive is brought to
a stop with maximum braking current and the position control loop opened
after the time delay set by machine data has expired.
3. All axes moving with interpolation are stopped if controller enable is cancelled
for one axis. Axes with CONTROLLER ENABLE still set can be stopped only
by selecting the set speed value ZERO. The following error for these axes is
reduced to zero.

SINUMERIK 840C (PJ)
6.2 Signals to axis
Notes:
• If the controller enable signal is cancelled (e. g. in order to clamp the axis) and then set
again, the axis, which has possibly been forced out of position through mechanical or
electrical influences, is repositioned to the position it had when the controller enable signal
was cancelled.
• The controller enable signal is to follow the pulse enable signal. When switching off, the
controller must first be disabled before the pulse enable signal is removed.
Setting-up modes:
1 signal: Effects closing of the position control circuit for the relevant axis.
0 signal: 1. With the axis stationary, the position control loop is opened.
2. If the axis is in motion, rapid deceleration is effected.
Notes:
• A following error remaining after rapid deceleration remains stored and is eliminated
following a renewed controller enable.
• An NC alarm is output if the controller enable is cancelled while an axis is in motion. The
alarm is also given when a last thread cutting block without G09 and then another axis is
programmed, for which the controller enable signal is missing.
• During normal operation the controller enable signals must always be present for all axes
to be moved with interpolation.
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1: TRAVEL COMMAND signal (e.g. X+)

2: X axis clamp
3: CONTROLLER ENABLE X signal
4: FEED DISABLE X signal
5: *Controller disable X
6: X axis in motion (td = delay time)
7: td = delay time (NC MD 156 or 1224*)

SINUMERIK 840C (PJ)
6.2 Signals to axis
Sequence:
1) The axis travel command (e.g. X -) releases the clamp and enables the controller.
2) Control enable cancels controller disable.
3) As soon as the clamp is released, the feed enable signal is given and axis traverse
commences.
4) If the travel command is removed, the axis stops and is clamped again; the feed enable
signal is cancelled.
5) After clamping, the controller enable signal is cancelled; the controller enable signal is
output again after a delay time of td (machine data).
2nd SOFTWARE LIMIT SWITCH +/– DW K+1, bit 8 and 9
1 signal: 2nd software limit switch effective for +/- direction.

0 signal: 1st software switch effective.
Reduction of permissible traversing range with the tailstock swung in.
JOG +/– DW K+1, bit 6 and 7
1 signal: In the setting-up modes, the axis is moved in the preset direction.
0 signal: No effect
Notes:
• The axis traversing speed is determined by machine data (MD 288* for feedrate, MD 292*
for rapid traverse) in accordance with the operating mode.
• If the plus (+) and minus (-) keys of an axis are pressed at the same time, no travel
command is given.
• Per operating mode group, the maximum number of axes to be traversed simultaneously
is equal to the number of channels belonging to the operating mode group. If several
direction keys are pressed simultaneously, the time sequence might decide which keys
are active.
• On the 840C M-version control, the PLC standard function block FB 79 can be used to
transfer the DIRECTION KEYS and RAPID TRAVERSE OVERLAY to the axis-specific
interface in the PLC according to the position of the axis selector switch. FB 67 is
available for this function on the 840C T version.
RAPID TRAVERSE OVERLAY DW K+1, bit 5
1 signal: While traversing in the JOG or REPOS setting-up modes via JOG +/, the rapid
traverse rate is selected.
0 signal: Traversing in JOG mode at the speed determined by machine data (MD 292*).

SINUMERIK 840C (PJ)
6.2 Signals to axis
FEEDRATE 1:100 DW K+1, bit 4
1 signal: The feedrate is stepped down by a factor of 100 in the setting-up modes.
0 signal: The feedrate determined by the NC MD for traversing in the jog mode (MD 299*)
is effective.
Note:
FEEDRATE 1:100 is effective only in the setting-up modes. FEEDRATE 1:100 and the
feedrate override switch then have a multiplying effect. In the automatic modes, this function is
activated by M 36 and M 37.
AXIS DISABLE DW K+1, bit 3
1 signal: No set speed value is output to the relevant machine axis (axis disabled). The
position control loop remains closed.
0 signal: Normal state.
Note:
• To avoid incorrect positioning, AXIS DISABLE must not be removed until after program
end or abort.
• As from SW 5.7, no axis synchronization to the actual real axis actual value is performed
when Axis disable is active.
Starting up a new NC program for the first time without axis traversing.
DYN. SW LIMIT SWITCH MONITORING PASSIVE 1) DW K+1, bit 2
1-signal: Dynamic SW limit switch monitoring is off.

0-signal: Dynamic SW limit switch monitoring is on.
HANDWHEEL 1, 2 ACTIVE DW K+1, bit 0 to 1
Selecting the handwheels assigns them to the axes.

1 signal: The handwheel corresponding to the bit effects axis traversing.
0 signal: The handwheel corresponding to the bit has no effect on the axis.
Notes:
• Each handwheel can be assigned to any axis.
• Each axis may be assigned to only one axis at a time.
• Only one handwheel per axis may be active, i. e. only one of the two bits DW K+1, 0 to
1 may be set.
_____________
1) As from SW 5.6

SINUMERIK 840C (PJ)
6.2 Signals to axis
TRAVEL LIMIT +, – DW K+2, bit 8 and 9
The interface control issues a TRAVEL LIMIT signal for both directions of each axis when a
travel limit switch is actuated. The provision of these axis and direction-specific signal obviates
the need for a retraction logic circuit in the interface control.
1 signal: Effects controlled approach or rapid deceleration with following error elimination.
0 signal: Normal state.
One of three braking methods applies when a travel limit switch is actuated:
a) Controlled approach
Initiated by the TRAVEL LIMIT signal. The NC brakes the axis in accordance with the
machine data for acceleration.
b) Rapid deceleration with following error elimination
If the "Instant stop at limit switch" bit is set in the machine data (NC MD 5003.7 common
to all axes), set speed = 0 is output immediately after the LIMIT SWITCH signal.
The position control loop remains closed and the following error is eliminated. The program
does not have to be restarted.
c) Rapid deceleration with maximum braking current
If controller enable is refused at the same time as the LIMIT SWITCH signal is output, the
position control loop is opened; the drives are then normally brought to a stop with
maximum braking current. Any following error is automatically worked in. The program has
to be restarted.
Overview
Braking method Rapid deceleration with Rapid deceleration with Controlled approach a)
maximum braking current c) following error elimination b)
Digital speed setting

(position set value) v v
(Position control loop
opened)
t t
Machine set value with max

2mm
limit switch signal v v a b v
a = Machine position b b
a a
b = Digital position s s s
Foll. error. A A A
Position control loop open closed closed
Activated by Limit switch + controller "Limit switch" + "instant "Limit switch" signal
enable refusal stop at limit switch" bit

SINUMERIK 840C (PJ)
6.2 Signals to axis
The position of the mechanical limit switch is at point A.

The position of the software limit switch should be located before the mechanical limit switch.
Software limit switches

The software limit switches are active after the reference point has been approached.
a) Setting-up modes
The axis is braked before the software limit switch is reached so that the switch is not
tripped.
b) Automatic
Before travel commands are output, a check is carried out at each NC start to determine
whether the software limit switch is tripped. If so, the block is not executed and an NC
alarm is output.
Activate slave operation 2) DW K+2, bit 11
1 signal: Slave operation is activated (see function description).

2 signal: Axis in question is switched to normal operation.
MEASURING SYSTEM 1/2 1) DW K+2, bit 12
1 signal: The actual value of the 2nd measuring system is used.

0 signal: The actual value of the 1st measuring system is used.
Notes:
• For axes, the actual value assignment for the 1st measuring system is made in NC MD
200*, for the 2nd measuring system the actual values are assigned in NC MD 1388*.
• For spindles in C axis operation, the actual value assignment for the 1st measuring system
is made in NC MD 200*, for the 2nd measuring system the actual values are assigned in
NC MD 400*. The spindle encoder (NC MD 400*) is always used for the spindle modes
and changeover of measuring systems is not possible.
• If a C axis is assigned to the spindle, all measuring system specific MDs must be entered
both for the spindle and the axis.
• The actual value of the selected measuring system is used for all functions, particularly for
position control and for absolute value computation. The 1st measuring system (NC MD
200*) is the reference system for axes and spindles in C axis operation and presets the
accuracy of position control.
• In the case of changeover of measuring systems the offset between the two actual values
is immediately traversed. A tolerance band can be specified in MD 1216* which the offset
between the actual values must not exceed. If the offset is greater than this tolerance, no
changeover takes place and an alarm is triggered.
• Reference point approach is carried out with the measuring system selected by the
MEASURING SYSTEM 1/2 signal.
_______
1) As from SW 2
2) As from SW 4

SINUMERIK 840C (PJ)
6.2 Signals to axis
FEEDFORWARD CONTROL OFF 1) DW K+2, bit 12
1 signal: The feedforward control is inactive. The active feedforward control parameters are
cleared when the signal is set.
0 signal: The feedforward control is activated. The feedforward control parameters defined
in the machine data are taken into account in set value computation. The
feedforward control is always active when the control powers up, it is not
deactivated until the signal is set.
SET REFERENCE DIMENSION 2) DW K+2, bit 14
“Set reference dimension” can be used to set an axis at any position to the “Axis referenced”
status without an explicit referencing process.
1 signal: • Setting of the absolute system to the value of MD 240*
• Enabling of LEC, IKA compensation
• Enabling of SW limit switch monitoring
• Setting of bit DB 32, DW k+0, bit 12, ”Reference point reached”
0 signal: Axis is not set to the "Axis referenced" status.
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1 1 Set reference dimension
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If the axis to be referenced is not stationary, the “Reference point reached” signal is not set
and, in addition, the axis-specific RESET alarm MD 1028* “Unable to set reference dimension”
is triggered. The “Set reference dimension” function can be initiated in all operating modes.
You will find a detailed description of the functions in the Installation Guide, Section 10
(Installation of axis, spindle), in Section: Set reference dimension via PLC request (SW 4 and
higher).
Referencing without internal setpoint entry 2) DB 32, DW K+2, bit 13
1 signal: The NC waits for an external travel command to approach the reference point.
Internal travel commands are suppressed.
Travelling is possible without enabling, e.g. for manual axes. In the case of a
manual axis, the follow-up mode must be active.
0 signal: “Normal” referencing by the NC is active.
_______
1) As from SW 2
2) As from SW 4

SINUMERIK 840C (PJ)
6.2 Signals to axis
FEED DISABLE DW K+3
Operating mode AUT/MDA
1 signal: 1. Effects feed disable of the relevant axis.

2. Effects feed disable of all axes moving with interpolation if the feed
disable signal is given for one axis. In this event, all axes are brought to a
standstill along the contour. Position control remains operative, i.e. the
following error is reduced to zero.
0 signal: No feed disable, if all signals in DW K+3 = 0.
1: Travel command (e.g. X+)

2: Travel command (e.g. Z+)
3: FEED DISABLE X signal
4: FEED DISABLE Z signal
5: X axis in motion
6: Z axis in motion
Setting-up modes:
1 signal: Effects feed enable of the relevant axis.

0 signal: Effects feed disable of the relevant axis.
Notes:
• Feed disable is activated if at least one bit has a 1 signal.
• A message (error or operational message) can be allocated to any bit (see Section 12).
• FEED DISABLE is also effective for G33 (NC alarm: thread cutting, hold).
_______
1) As from SW 4

SINUMERIK 840C (PJ)
6.2 Signals to axis
Acknowledge for ”Travel against fixed stop” signal active 1) DW K+122, bit 0
1 signal: TRAVEL AGAINST FIXED STOP ACTIVE (DRK+120, bit 6) not acknowledged
0 signal: TRAVEL AGAINST FIXED STOP ACTIVE acknowledged
Acknowledge for ”Travel against fixed stop reached” signal ”, QFESTANER 1)

DW K+122, bit 1
Sensor signal for Travel against fixed stop reached 1), SFESTERRDL DW K+122,bit
The signal is active only if MD 1804*, bit 3=1.

1 signal: Fixed stop not reached
0 signal: Fixed stop reached
The acknowledge signals for the ”Travel against fixed stop” function are not evaluated when
using digital axes. These signals being nevertheless present, we recommend to set them to 0
signal when using digital drives.
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tum 80 ms 611 MSM, 660 MSD

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Signal chart: Select ”Travel against fixed stop” without switchover to current-controlled
operation
1: NFAFAKT: TRAVEL AGAINST FIXED STOP ACTIVE DR x, bit 6

is set by the NC as soon as the FAF selection block (G221) is being processed. This
signal remains at 1 until the FAF (G220) block is deselected. The PLC output PLCOUT96
must be set as follows dependent on this signal.
NFAFAKT=0 PLCOUT96=0 (current limiting Off)
NFAFAKT=1 PLCOUT96=1 (current limiting On)
_______
1) As from SW 3

SINUMERIK 840C (PJ)
6.2 Signals to axis
2: NFESTANER: FIXED STOP REACHED DR x, bit 7

is set by the NC after fixed stop reached has been recognized in the NC. This signal
remains at 1 until deselection (G220 block) is made.
3: QFAFAKT: ACKNOWLEDGEMENT TRAVEL AGAINST FIXED STOP ACTIVE

DL x+2, bit 0
The PLC acknowledge signal QFAFAKT must be set to 1 after the wait time tum. Axial feed
towards the programmed target position is not enabled by the NC until the acknowledge
signal is given.
4: QFESTANER: ACKNOWLEDGEMENT FIXED STOP REACHED DL x+2, bit 1

The acknowledge signal must be set to 1 by the PLC after NFESTANER was set to 1 by
the NC. This signal must remain at 1 until NFESTANER=1. The QFESTANER=1 signal
status terminates FAF selection in the NC and causes a block change.
5: PLCOUT96
Selection of terminals 96 from the PLC
6: PLCOUT22
Selection of terminal 22 from the PLC FAF=Travel against fixed stop
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Signal chart: Select ”Travel against fixed stop” with switchover to current-controlled
operation

is set by the NC as soon as the FAF selection block is being processed. This signal
remains at 1 until FAF is deselected. The PLC must set the output PLCOUT96 dependent
on the following signals.

is set to 1 by the NC after fixed stop reached has been recognized in the NC. This signal
remains at 1 until FAF is deselected (G220).

SINUMERIK 840C (PJ)
6.2 Signals to axis

DL x+2, bit 0
The PLC must set the QFAFAKT=1 acknowledge signal after the wait time tum (time
interval between switching of PLCOUT96 and setting of QFAFAKT) has elapsed.
QFAFAKT=1 enables in the NC the feed for the axis programmed in the (G221) selection
block. QFAFAKT remains at 1 as long as NFAFAKT is set. See FAF deselection for the
reset condition.

After switchover of the drive actuator to current-controlled operation (PLCOUT22=1,
PLCOUT96=0), the PLC must set the QFESTANER acknowledge signal to 1. It causes a
block change (G221 block completed) in the NC. This signal remains active until
deselection is made. The reset conditions for QFESTANER can be seen from the FAF
deselection.
5: PLCOUT96:
NFESTANER=0 + NFAFAKT=0 PLCOUT96=0 (current limiting not effective)
NFESTANER=0 + NFAFAKT=1 PLCOUT96=1 (current limiting is effective)
The signal must be set to 0 by the PLC after current-controlled operation (PLCOUT22=1)
was switched on and the time tum has elapsed.
6: PLCOUT22:
must be set by the PLC as follows dependent on NFESTANER:
NFESTANER=0 PLCOUT22=0 (current-controlled operation Off)
NFESTANER=1 PLCOUT22=1 (current-controlled operation On)
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Signal chart: Deselect ”Travel against fixed stop” without previous switchover to
current-controlled operation

is reset by the NC as soon as the FAF deselection block (G220) is being
processed.

is reset by the NC together with NFAFAKT as soon as the FAF deselection
block (G220) is being processed.

SINUMERIK 840C (PJ)
6.2 Signals to axis

DL x+2, bit 0
must be set to 0 by the PLC after reset of PLCOUT96.

must be set to 0 by the PLC after reset of PLCOUT96 and an elapse of wait time tum.
QFESATANER=0 effects activation of position control in the NC, compensation of the axis
position with the block preparation chain and the enable of axial feed in order to allow the
retract position programmed in the deselection block to be approached.
5: PLCOUT96:
The PLCOUT96 output must be set by the PLC after NFAFAKT was set to 0 by the NC.
Caution:
The switching back of PLCOUT96 must be performed dependent on NFAFAKT.
6. PLCOUT22.
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tum 10 ms 611 FDD

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Signal chart: Deselect ”Travel against fixed stop” from current-controlled operation
Current setpoint: is set to 0 by the NC before NFAFAKT is reset.
is reset by the NC as soon as the FAF deselection block (G220) is being processed.
is reset by the NC together with NFAFAKT as soon as the FAF deselection block (G220) is
being processed.
DL x+2, bit 0
must be reset by the PLC after the NC has set the NFAFAKT signal to 0.

SINUMERIK 840C (PJ)
6.2 Signals to axis

must be set to 0 by the PLC after the reset of PLCOUT22 and an elapse of wait time tum.
QFESATANER=0 effects activation of position control in the NC, compensation of the axis
position with the block preparation chain and the enable of axial feed in order to allow the
retract position in the selection block to be approached.
5: PLCOUT96:
6: PLCOUT22:
must be set to 0 by the PLC program after the reset of NFESTANER.
Select cam parameters1...4 1) DW K+123, bit 8...11
1 signal: One pair of cams (1 ... 4) is assigned to the axis. One pair of cams can always be
assigned to one axis only via one bit of the PLC/NC interface, otherwise alarm 20
is output.
0 signal: The axis is not assigned to the cam pair.
As a result, the cam positions of one cam pair are invalid.
Actual parameter set number "Position control" (bit 0 .. 2) 2) DW K+123, bit 0-2
Actual parameter set number "Speed ratio" (bit 0 .. 2) 2) DW K+123, bit 3-5
These three bits can be used to switch over in binary coded form between a maximum of 8
parameter sets, e.g.:
001 =ˆ Parameter set 1
011 =ˆ Parameter set 3 etc.
Note:
The ”Parameter set changeover” function is described in the SINUMERIK 840C, SW 4
Installation Instructions.
6.2.1 Signals for endlessly turning rotary axis

Note:
The signals are analog to the spindle-specific interface signals.
Axis in set range DWK bit 13
1 signal: The actual speed lies within a defined range round the set speed (set range).
0 signal: Actual speed outside set range.
_______
1) SW 3 and higher
3) SW 4 and higher

SINUMERIK 840C (PJ)
6.2 Signals to axis
Feed disable simultaneous axis DW K+1 bit 5
1 signal: The current set speed value is overwritten with 0 and thus effects axis braking in
accordance with the acceleration ramp.
0 signal: No effect
Note:
This signal for the rotary axis is similar to the spindle-specific interface signal: "Input set value
0".
Axis reset DW K+1 bit 7
1 signal: Stopping of axis.

The conditions of the "Spindle reset" do not apply. The reset is triggered when
the signal is set.
0 signal: No effect
Reverse direction of rotation DW K+2 bit 6
1 signal: The sign defined for the set voltage is inverted.

0 signal: No effect
Note:
The signal is effective only during the program commands G103/G104; the "Commands are
inverted".
Reversal of the direction of rotation during the traversing movement is not possible with this
signal.
Override effective DW K+2 bit 5
1 signal: The set feedrate override (axis override) is effective.

0 signal: The set override values are not taken into account. The 100% value is always
stipulated.
Note:
The override is effective only with ”Endlessly turning rotary axis” and not with ”Simultaneous
axis”.

SINUMERIK 840C (PJ)
6.2.1 Signals for endlessly turning rotary axis
Axis-specific override DW K+2 bit 0...4
The feedrate override can be stipulated via the PLC as follows:
Position Code Override value in %
E D C B A
1 0 0 0 0 1 0
2 0 0 0 1 1 1
3 0 0 0 1 0 2
4 0 0 1 1 0 4
5 0 0 1 1 1 6
6 0 0 1 0 1 8
7 0 0 1 0 0 10
8 0 1 1 0 0 20
9 0 1 1 0 1 30
10 0 1 1 1 1 40
11 0 1 1 1 0 50
12 0 1 0 1 0 60
13 0 1 0 1 1 70
14 0 1 0 0 1 75
15 0 1 0 0 0 80
16 1 1 0 0 0 85
17 1 1 0 0 1 90
18 1 1 0 1 1 95
19 1 1 0 1 0 100
20 1 1 1 1 0 105
21 1 1 1 1 1 110
22 1 1 1 0 1 115
23 1 1 1 0 0 120
24 1 0 1 0 0
25 1 0 1 0 1
26 1 0 1 1 1
27 1 0 1 1 0
28 1 0 0 1 0
29 1 0 0 1 1
30 1 0 0 0 1
31 1 0 0 0 0
Note:
The axis-specific override is not effective for simulaneous axes.

SINUMERIK 840C (PJ)
6.3 Signals from following axis to PLC, DB 29
6.3 Signals from following axis to PLC, DB 29 1)

Especially, for the "Gear Interpolation" functionality, additional axis-specific signals are
provided in this data block which can be used when one of the axes is used as a following axis
in a GI grouping.
An explanation of the "Gear Interpolation" function is to be found in the Installation
Instructions, Section Description of Functions.
The K addresses for the following axes are:
1st axis K=0 10th axis K=36
2nd axis K=4 11th axis K=40
3rd axis K=8 12th axis K=44
7th axis K=24 :
8th axis K=28 :
ACCELERATION LIMIT SYNCHRONOUS ACTIVE DW K, bit 14
1 signal: When the maximum acceleration limit of the following axis is reached, it can no
longer follow the leading axes/spindles. The resulting positional deviation to the
leading axes/spindles is added up and subsequently traversed after the
acceleration phase. Positional synchronism is then re-established.
0 signal: The positional deviation to the leading axes/spindles possibly occurring during
acceleration of the following axis is ignored. In such a case, the following axis is
no longer position-synchronous to the leading axes/spindles.
ESR MONITORING IS ACTIVE 2) DW K, bit 13
1 signal: The monitoring functions for the EXTENDED STOP AND RETRACTION are
is set.
0 signal: The retraction monitoring is not active.
_______
1) As from SW 3

SINUMERIK 840C (PJ)
COMPENSATORY CONTROLLER ACTIVE DW K, bit 12
1 signal: The compensatory controller is active. The current actual part positions of the
following axis and the leading axes/spindles are checked under consideration of
the linking factors. Additive set speeds are calculated from the deviations of the
actual part positions and output to the following axis.
0 signal: The compensatory controller is not active.
Note:
The compensatory controller is used to compensate for load variations. It increases the rigidity
of the link.
WAITING FOR POSITION-RELATED SWITCHING DW K, bit 11
1 signal: A defined (axis) position, where the synchronization is to be executed, is

programmed in the part program.
0 signal: Synchronization has been carried out, or the function is not active.
FOLLOWING AXIS OVERLAY ACTIVE DW K, bit 10
1 signal: An additional traversing movement can be superimposed on the following axis.

This enable is also required for on-the-fly synchronization of the leading and
following drive. With on-the-fly synchronization, the overlay path is traversed as
speed offset at incremental speed.
0 signal: The following axis cannot currently be traversed with overlay.
SYNCHRONIZATION BUSY DW K, bit 9
1 signal: "On-the-fly synchronization" was triggered via the PLC or NC. The synchronizing
operation has not yet been completed, the synchronous positions have not yet
been reached.
0 signal: On-the-fly synchronization is currently not active.
Notes:
• The signal is reset as soon as the synchronous positions are reached.
• The SYNCHRONOUS POSITION REACHED interface signal indicates that the
synchronous position has been reached.

SINUMERIK 840C (PJ)
LINK ACTIVE DW K, bit 8
1 signal: The link between at least 1 leading drive and the following axis is active.
0 signal: The link between the leading drive and the following axis is not active.
Note:
Programming of the linking factor "0" causes the signal to be reset.
CONTROLLED FOLLOW-UP MOTION OF FOLLOWING AXIS DW K, bit 6
1 signal: The following axis is under compensatory control due to a fault. As a result, the
set values for the following axis are obtained from the actual values of the leading
axis/spindle.
0 signal: The configured type of link between the following axis and the leading
axis/spindle is active.
MAXIMUM ACCELERATION DW K, bit 5
1 signal: The set value for acceleration of the following axis is greater than the maximum
values specified in NC MD 276*. The following axis traverses at maximum
acceleration, the positional difference to the leading axes/spindles increases. The
alarm 1176* "Acceleration limit exceeded" is triggered.
0 signal: The current acceleration of the following axis is less than the maximum
acceleration.
MAXIMUM VELOCITY DW K, bit 4
1 signal: The set velocity of the following axis is greater than the maximum velocity
specified in NC MD 280*. The following axis traverses at maximum velocity. The
positional difference to the leading axes/spindles increases, synchronism is lost.
Alarm 1172* "Velocity limit exceeded" is triggered.
0 signal: The current velocity is less than the maximum velocity.

SINUMERIK 840C (PJ)
ACCELERATION WARNING THRESHOLD REACHED DW K, bit 3
1 signal: The acceleration of the following axis has exceeded the warning threshold (NC
MD 1448*). The synchronism between the leading axes/spindles and the following
axis will be at risk if the acceleration is further increased.
0 signal: The acceleration is less than the acceleration warning threshold.
Notes:
• The signal is automatically removed by the control as soon as the current acceleration
drops below 7/8 of the warning threshold.
• Monitoring can be deselected by NC MD 1848* bit 3 "Suppression of acceleration limit".
VELOCITY WARNING THRESHOLD REACHED DW K, bit 2
1 signal: The velocity of the following axis has exceeded the warning threshold (NC MD
1448*). This involves the risk that the following axis can no longer follow the
leading axes/spindles and synchronism between the leading axes/spindles and
the following axis is lost.
0 signal: The velocity is less than the velocity warning threshold.
Note:
The signal is automatically removed by the control as soon as the current velocity drops below
7/8 of the warning threshold.
SYNCHRONOUS OPERATION FINE DW K, bit 1
1 signal: The positional deviation of the following axis from all configured leading
axes/spindles is less than the tolerance band "Synchronous operation fine" (NC
MD1436*).
0 signal: The positional deviation of the following axis to all configured leading
axes/spindles is greater than the tolerance band "Synchronous operation fine"
(NC MD 1436*).
SYNCHRONOUS OPERATION COARSE DW K, bit 0
axes/spindles is less than the tolerance band "Synchronous operation coarse"
(NC MD1440*).
axes/spindles is greater than the tolerance band "Synchronous operation coarse"
(NC MD 1440*).

SINUMERIK 840C (PJ)
SYNCHRONOUS POSITION REACHED DW K+1, bit 14
1 signal: The synchronizing operation with ”On-the-fly synchronization” is complete.

0 signal: The synchronizing operation is not yet complete.
ESR RESPONSE IS TRIGGERED 2) DW K+1, bit 13
1 signal: The axis has triggered the ”Extended stop and retraction”.
0 signal: ESR response is not triggered.
AXIS IS A FOLLOWING AXIS DW K+1, bit 7
1 signal: The axis was configured as a following axis in a GI grouping.

0 signal: The axis was not configured as a following axis in a GI grouping.
Note:
The PLC can recognize from this signal whether a GI grouping was defined for an axis, even if
the link is not active.
ESR RESPONSE IS PROGRAMMED 1) 2) DW K+1, bit 5
.1 signal: When an "Extended stop and retraction" has been programmed via the G
commands (G422 to G426). With this signal, a response can be started via the
interface signal "ESR response enabled".
0 signal: An ESR response for this axis has not been programmed.
1 signal: This signal is set if a link is to be switched on (Source: part program, PLC or
input image), however, the conditions for activation (e.g. signal INTERLOCK LINK
ON) are not yet satisfied. Block change of the part program is halted as long as
these conditions are not met.
0 signal: No change of the LINK OFF status has been requested.
_______
1) As from SW 4

SINUMERIK 840C (PJ)
1 signal: This signal is set if a link is to be switched on (Source: part program, PLC or
input image), however, the conditions for activation (e.g. signal INTERLOCK LINK
ON) are not yet satisfied. Block change of the part program is halted as long as
these conditions are not met.
0 signal: No change of the LINK OFF status has been requested.
Signals from PLC to following axis
ACTIVATE ESR MONITORING 1) DW K+2, bit 13
0/1 edge: Emergency retraction monitoring of the following axis is switched on.
Notes:
• The emergency retraction threshold is preset in NC MD 1444*.
• The ACTIVATE ESR MONITORING signal is set as check-back signal.
ON-THE-FLY SYNCHRONIZATION ON DW K+2, bit 9
0/1 edge: On-the-fly synchronization of the following axis with all configured leading
axes/spindles is triggered. A LINK ON is internally generated. The signal
SYNCHRONIZATION ACTIVE is set. This bit is removed by the system as
soon as the synchronous positions are reached and the SYNCHRONOUS
POSITION REACHED signal is set.
LINK ON DW K+2, bit 8
0/1 edge: Activation of the link of all configured leading axes/spindles with the following
axis with the current linking factors.
Notes:
• This signal is active for all configured leading axes/spindles. Selective coupling via the
PLC is not possible. The linking factors must have been programmed in advance or
adopted from the GIQ data during ramp-up.
• The LINK ACTIVE signal is set by way of acknowledgement.
DISABLE ESR MONITORING 1) DW K+2, bit 5
0/1 edge: Emergency retraction monitoring of the following axis is switched off.
Notes:
• The ACTIVATE ESR MONITORING signal is reset as check-back signal.
_______

SINUMERIK 840C (PJ)
LINK OFF DW K+2, bit 0
0/1 edge: Deactivation of the link of all configured leading axes/spindles with the
following axis.
Notes:
• This signal is active for all configured leading axes/spindles. Selective decoupling via the
PLC is not possible.
• The LINK ACTIVE signal is reset by way of acknowledgement.
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CORRECT SYNCHRONISM DIFFERENCE DW K+3, bit 7
1 signal: The PLC signal "Correct synchronism differnce" corrects the setpoint to the
following address by the synchronism error between the leading and following
addresses so that the synchronism difference no longer results in a system
deviation. Both the controller and drive must be enabled and the gearbox coupling
must be switched on while this signals is applied.
0 signal: Position and/or compensatory controller correct the synchronism error.1
Notes:
• This function is particularly important where synchronous spindle pairs are used. When the
workpiece is transferred by the following drive, an angle offset between the leading and
following drives can result for mechanical reasons when the chuck is closed. This offset
cannot be eliminated while the drives are coupled via the workpiece. Involvement of a
position controller/compensatory controller would cuse a torque bias. This con be avoided
with the signal CORRECT SYNCHRONISM DIFFERENCE.
• The signal schould be activated:
– After closure of the mechanical coupling, if the power transmission is without slip.
– When the drives are mechanically coupled and position control is activated.
• If both drives are mechanically coupled the signal must be canceled so that precise
synchronization is maintained.
ACCELERATION LIMIT SYNCHRONOUS DW K+3, bit 6
1 signal: The acceleration limit synchronous was activated.

0 signal: The acceleration limit synchronous was not activated.
Notes:
• The acceleration limit synchronous for the following axis ensures that the following axis will
traverse positionally synchronous to the leading axes/spindles after accelerations. Any
positional deviations possibly occurring during acceleration are added up and traversed
after the acceleration phase.
• The ACCELERATION LIMIT SYNCHRONOUS ACTIVE signal is set as soon the
acceleration limit becomes active.

SINUMERIK 840C (PJ)
ENABLE ESR RESPONSE 1) 2) DW K+3, bit 5
1 signal: With this static signal, the PLC can enable a programmed ESR response (the
"ESR response is programmed" signal). Axis movement is not possible without
this signal (safety signal).
Note:
• The axis monitoring function can also be switched on/off from PLC. If it is
switched on from PLC, it can also only be switched off from PLC. If it is switched
off from PLC, it is switched off for all channels.
COMPENSATORY CONTROLLER ON DW K+3, bit 4
1 signal: The compensatory controller is activated from the PLC.

0 signal: The compensatory controller is not activated.
Notes:
• The compensatory controller serves to compensate for load variations. It increases the
rigidity of the link.
• The COMPENSATORY CONTROLLER ACTIVE signal is set by way of acknowledgement.
POSITION-RELATED SWITCHING ON DW K+2, bit 3

1 signal: Enabling of position-related switching.
Synchronization can be carried out at the programmed (axis) position.
0 signal: The position-related switching is not active.
ENABLE FOLLOWING AXIS OVERLAY DW K+3, bit 2
1 signal: An additional motion can be overlaid on the movement of the following axis
predetermined by the leading axes/spindles. This overlaid movement can be
predetermined via G91 in the part program, in JOG or INC or via the command
channel functions, i.e. path dimension or division increment.
0 signal: No overlaid movement of the following axis is possible.
Notes:
• Alarm 1168* ”Following axis overlay not enabled” is triggered when an attempt is made to
traverse the following axis with a overlaid movement without an enable.
• Following axis overlay is also effected with ”On-the-fly synchonization”.
_______
1) As from SW 4

SINUMERIK 840C (PJ)
INTERLOCK LINK OFF DW K+3, bit 1
1 signal: The link between the following axis and the leading axes/spindles cannot be
switched off.
0 signal: The link between the following axis and the leading axes/spindles can be
switched off.
Notes:
• If this interlock signal was present when a LINK OFF was programmed, the link is not
switched off until this interlock signal is reset.
off. The REQUEST LINK OFF signal is set.
INTERLOCK LINK ON DW K+3, bit 0
1 signal: The link between the following axis and the leading axes/spindles cannot be
switched on.
0 signal: The link between the following axis and the leading axes/spindles can be
switched on.
Notes:
• If this interlock signal was present when a LINK ON was programmed, the link is not
switched on until this interlock signal is reset.
on. The REQUEST LINK ON signal is set.
• The signal has no effect on an active link.
The effects described below apply in additon to the interface signals:
CONTROLLER ENABLE (axes)

• The LINK ON state remains active when the CONTROLLER ENABLE is removed for the
following axis with an active GI link (operating leading/following drives). The drive is braked
to a standstill and a leading axis alarm ”Controller enable traversing axis rejected” is
generated. The GI monitoring remains active.
• If CONTROLLER ENABLE is not set when selecting LINK ON, the link is not switched on.
If selection of LINK ON was made from the part program, the NC block is simply skipped
and the next NC block is executed. The REQUEST LINK ON signal is not set. Now, after
CONTROLLER ENABLE has been set, a LINK ON request must again be programmed for
switching on the link.
Feed disable
• If feed disable is active for a following axis, the leading axes and leading spindles which
are part of the GI grouping are also stopped.

SINUMERIK 840C (PJ)
•
•
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1)
6–36
Note:
0 signal:
1 signal:
0 signal:
1 signal:
_______
Drive ready
MSD and FDD:

MSD and FDD 1)

MSD and FDD 1)
MSD and FDD 1)
FDD as from SW 4
Motor selection bit 1

Motor selection bit 0
Ready indication from drive

Parameter set (0), (1), (2)
Drive not ready


Reserved for future applications

6.3.1 Axis-specific 611D signals (DB 29)

observe dependency of terminals

Drive ready for operation

Start operation or motor 1

Delta operation or motor 2
- Enable terminals missing:

KL. 64, central drive enable

KL. 63, central pulse enable

611D machine data 1012 bit 2 "Drive ready"

Observe interface signal DB 29 DW 120 bit 5

Confirmation of the currently active parameter set.


KL.663, module-specific pulse enable

Confirmation of star/delta operation or motor switchover

The 3 bits must always be jointly interpreted as a binary number.

- Infeed/feedback hardware, summation error, Power on


DW K+120, bit 0, 1, 2
DW K+120, bit 5
DW K+120, bit 4
DW K+120, bit 3

6FC5197- AA00
SINUMERIK 840C (PJ)

07.97

07.97
FDD:
issued.
0 signal:
1 signal:
0 signal:
1 signal:
MSD and FDD:

MSD and FDD:
MSD and FDD:
MSD and FDD:

SINUMERIK 840C (PJ)

Drive switched on

Pulses are enabled
Enable pulse confirmation

P53 bit 13 = 1
error is output after 20 seconds.


Motor temperature prewarning

Drive not switched on

Heat sink temperature prewarning

All enable signals are present

6FC5197- AA00
Drive switched on/drive has ramped up
time set in P065 (MSD) or P1603 (FDD) has elapsed.

status class 1 error present, motor switchover active.

Pulse/controller enable missing, enable terminals not set,

If a motor temperature = 0 is measured, an interruption of the PTC motor thermistor is

aaaaaaa after the time set in P1603 has elapsed, the ZK1 reset error ("Motor temperature N...") is aaaaaaa aaaaaaa aaaaaaa
ZK2 message, heat sink temperature too high. If the temperature remains too high, a ZK1
ZK2 message, motor temperature exceeds the value in P063/P291 with MSD and in P1602
this case, there will be no reaction in the drive. If the motor temperature = 0 is still measured

with FDD. If the temperature remains too high, a status class 1 error (ZK1) is output after the
DW K+120, bit 9
DW K+120, bit 8
DW K+120, bit 7
DW K+120, bit 6

assumed and the bit is also set. A reaction to this situation is initiated via the PLC program. In

6–37

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FDD:
MSD:
_______
Message 6:
Message 5:
Message 4:
Message 3:
Message 2:
Message 1:
As from SW 4
n–act < n–x
M–d < M–dx

n–act = n–set
n–act < n–min

bit 13: n–act < n–x

bit 12: n–act < n–min
the emergency retraction threshold.

Ramp-up phase ended

User-programmable messages 1 to 6

Variable message function 1

DW K+72, bit 10: freely programmable
P241/P246. The following messages are present:

DC link voltage < Warning threshold (MD 1604) 1)

The message assignments for FDD are firmly specified:
in the SINUMERIK 840C, SW 4, Installation Instructions

link voltage < Emergency retraction threshold (MD 1634) 1)


aaaaaaa MD 1604 is described in the SINUMERIK 840C, SW 4, Installation Instructions. aaaaaaa aaaaaaa
6 MSD-specific messages. The messages can be freely assigned to the 6 status bits via

ZK2 message that the DC link voltage has fallen below the value determined in MD 1604.

ZK2 message that the DC link voltage has fallen below the value determined in MD 1634 as
DW K+120, bit 10 ... 15
DW K+121, bit 1
DW K+121, bit 0
responses are initiated which are defined in MD 1636. The machine data (MD) are described
6FC5197- AA00
When the DC link voltage falls below the emergency retraction threshold, emergency retraction
SINUMERIK 840C (PJ)

07.97

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Emergency retraction or DC link generator active1) DW K+121, bit 2
ZK2 message that emergency retraction or DC link generator is active.

• If the voltage thresholds MD 1634 and MD 1631 in the infeed/regenerative feedback unit
are not equal and MD 1631 MD 1634, generator operation starts without an emergency
retraction being initiated simultaneously for the infeed/regenerative feedback unit axes. The
emergency retraction threshold is thus recognized only when the generator axis is no
longer capable of supporting the DC link. In this case, emergency retraction is not carried
out due the lack of power. In order to prevent this, NC emergency retraction responses
must be initiated on the other axes when the actual speed of the generator axis falls below
a minimum speed (MD 1635).
• In the case of a communication failure (sign-of-life failure) of a particular axis, the other
axes must be treated by the NC in accordance with their operating mode. If, for example,
the axis that has failed is an emergency retraction axis it will perform an emergency
retraction. Consequently, coupled axes must perform an emergency retraction controlled
by the NC.
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UZWK
600V
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MD 1633
MD 1631
+
MD 1632
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MD 1631
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ZK2
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"ZWK_GEN_AKTIV"
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Conditions for switching on/off the ZK2 message "Generator active"
_______
1) As from SW 4

SINUMERIK 840C (PJ)
aaaaaaaaaa
1)
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6–40
aaaaaaaaaa aaa
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_______
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As from SW 4
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DC link voltage
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Speed
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"ZWK_GEN_AKTIV"
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MD 1632
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MD 1631+
MD 1630
MD 1634
MD 1631
MD 1633
280V
600V
nGen
ZK2
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Generator axis (MD 1635 1)

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the generator axis in MD 1635.

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Generator operation (operating mode 6)

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Speed
setpoint
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Generator speed < Minimum speed

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Speed actual value
ON
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Operating mode6
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Generator operation
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MD 1635 is described in the SINUMERIK 840C, SW 4, Installation Instructions.

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OFF
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by NC
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Ramp up
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ZK2 message that the generator speed has fallen below the value of the minimum speed of
Time
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DW K+121, bit 3
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6FC5197- AA00
Generator operation

Time
Time
SINUMERIK 840C (PJ)

07.97

2)
1)
07.97

MSD:
0 signal:
1 signal:
0 signal:
1 signal:
_______
As from SW 4
MSD and FDD 2)

SINUMERIK 840C (PJ)

FDD as from SW 4
Parameter set (0, 1, 2)
Motor selection bit 0 1)

Motion request drive test

Drive test not active

Star operation or motor 1

Request start/delta or motor switchover

Delta operation or motor 2
6FC5197- AA00
decelerated and resumed its former operating mode.

The 3 bits are used to select one of the eight available gear stages and to activate the

associated parameter set. The 3 bits are always interpreted jointly as a binary number.

DW K+122, bit 0, 1, 2
DW K+122, bit 3
DW K+121, bit 15

as soon as the drive test is started and parameters set are known to be correct.

The signal is reset as soon as the drive test is terminated and the drive has been

Drive test requested (drive stationary) or active (drive in motion). The signal is set

6–41

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1)
6–42
FDD:
MSD:
MSD:
MSD:
1 signal:
0 signal:
1 signal:
0 signal:
1 signal:
_______
As from SW 4
MSD and FDD:
MSD and FDD:
Pulse enable
motor switchover.
Integrator disable
Second torque limit

Motor selection bit 1 1)

Disable pulses

Enable integrator
Disable integrator
Reserved for future applications

Motor selection performed 1)
(see MD 522* bit 3)

Disable integrator of speed controller
Activates 2nd torque limit set in P041

Ramp-function generator rapid stop


Enable pulses (only enabled if all other enable signals are present)
Specifies speed setpoint 0, braking without ramp-function generator ramp

With this bit the PLC confirms switchover of motor contactors for star/delta changeover or

DW K+122, bit 9
DW K+122, bit 7
DW K+122, bit 6
DW K+122, bit 5
DW K+122, bit 4
DW K+122, bit 10
6FC5197- AA00
SINUMERIK 840C (PJ)

07.97

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07.97
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MSD:
Note:
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0 signal:
1 signal:
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0
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XR
MSD and FDD:

controller cycle.

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XINT
XINT
N–soll
SINUMERIK 840C (PJ)

N–NRS
=
=
=
=
Set speed smoothing

N–soll (k-1)
Motion enable drive test

Function diagram of interpolation filter

XR

started with NC Start.

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Set value from NC

Speed controller cycle
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Set value MSD internal

Position controller cycle
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N–soll (k) aaaaaaaaaaaaaa aaaaaaa
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6FC5197- AA00
N–NRS
3. Enable with enable signal from PLC without NC.

2 XR
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the "Enable motion for drive test" enable signal is to be active:
2. Enable through enable signal from PLC and with NC Start.

is canceled and the drive resumes its former status.

Activates rounding of the setpoint speed parameterized with P019.
1. Enable "internal" without enable signal from PLC with NC Start.

N–soll (k+1)

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3 XR

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The effect of the signal depends on the parameterization of the drive test by the user.
stopped and the drive subsequently resumes its former operating mode.
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PLC enable for drive test is present. The drive test (traversing movement) is
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If the drive test is already active (drive in motion), the traversing movement is
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Activates interpolation of the setpoint speed from the position controller cycle into the speed
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DW K+123, bit 15
DW K+122, bit 11
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Selection can be made in the "Function generator" and "Measurement" installation functions if
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PLC enable missing. The drive test is aborted on NC Start, i.e. the travel request
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6–43
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6.4 Structure of M decoding list (DB 30)

For decoding the M functions with extended address, one data block per channel must be
compiled as a decoding list. A maximum of 64 M words can be decoded by list per NC
channel. Also, the function has to be selected via PLC machine data (PLC MD 6009).
Channel Decoding lists

1 DB 80
2 DB 81
3 DB 82
4 DB 83
5 DB 84 1)
6 DB 85 1)
Decoding list contents
Ext. M addr. M address Definition Definition

of of
DW No. Bit No.
in DB 30 in DB 30
0 - 99 0 - 999
(KF) (KF) 0 - 63 0-7
(KY) (KY)
stat. bit
1st value DW 0 DW 1 DL 2 DR 2
2nd value DW 3 DW 4 DL 5 DR 5
64th DW 190 DW 191 DL 192 DR 192

value
_______
1) As from SW 4

SINUMERIK 840C (PJ)
Notes:
1) The bit No. refers to the static signal. The dynamic signal (bit address in DL) is addressed
automatically.
2) The M addresses must be stored in ascending order, i.e. first all M addresses with
extended address 1, then extended address 2 etc. Within a group (extended address), the
M addresses must also be addressed in ascending order (see example for decoded M
function).
3) The decoding list may be compiled with 6, 12, 24, 48, 96 or 192 data words only. If the
number of M functions lies between the stated values, round up to the next permissible
number and fill up the remaining data words with zero.
Example:
For 9 M functions, the DB must be set up with 48 DWs.
Number of Number of DWs in

M functions decoding list
1 M function 6
2 M functions 6
4 M functions 12
8 M functions 24
16 M functions 48
32 M functions 96
64 M functions 192
Example for decoded M function:

An extended M address is programmed in the NC as follows:
N 100 ... M2=8 ... LF
In the decoding list belonging to the channel (e.g. DB 80 for channel 1), an allocation is made
to a bit in DB 30 for each extended M address provided by the user. The allocation is
determined by the user in 3 data words.
Decoded M function:
M2= 8 SETS D 5.3
M2= 15 SETS D 5.5
M3= 10 SETS D 20.5
M3= 61 SETS D 21.6
Structure of decoding list:

-1. ER.ADR 0 : KF = +00002;
-1. M-ADR 1 : KF = +00008;
-1. BIT-AD 2 : KY = 005,003;
-2. ER-ADR 3 : KF = +00002;
-2. M-ADR 4 : KF = +00015;
-2. BIT-AD 5 : KY = 005,005;
-3. ER-ADR 6 : KF = +00003;
-3. M-ADR 7 : KF = +00010;
-3. BIT-AD 8 : KY = 020,005;
-4. ER-ADR 9 : KF = +00003;
-4. M-ADR 10 : KF = +00061;
-4. BIT-AD 11 : KY = 021,006;

SINUMERIK 840C (PJ)
Example for extended M addresses:

Synchronization of the machine (channel 1) and loader (channel 3) by means of M functions
with extended address.
All M functions effecting read-in disable for channel 1 are output in one byte.
All M functions effecting read-in disable for channel 3 are output in one byte.
Program
channel 3 DB 80 PB 10
. DB 30 Channel 1
. Decoding list
. channel 1 M signals according
N5 M3=80 to list
.
.
.
Signals for
Operating channel 1
program
Program
channel 1 PB 30
. Channel 3
.
. Signals for
N20 M1=79 channel 3
. DB 82
.
.
Decoding list
channel 3
Synchronization of machine and loader by means of M signals
Use of M functions with extended addresses:

The following M functions must not be used with M functions with extended addresses:
M00 Programmed Stop
M01 Conditional Stop
M02 End of program
M03 Clockwise spindle rotation
M04 Counter clockwise spindle rotation
M05 Spindle Stop
M17 End of subroutine
M19 Position spindle
M30 End of program
M36 Feed 1:100
M37 Feed 1:1
END OF SECTION

SINUMERIK 840C (PJ)
10.94 7 Data Transfer PLC/NC (DB 36)
7.1 General
7 Data Transfer PLC/NC (DB 36)
7.1 General
Data transfer can be initiated by either the NC or the PLC.

In the case of NC initiative, the transfer is triggered via commands in cycle language CL 800;
all locations in the PLC can be read and written. The data are stored in R parameters in the
NC or transferred from R parameters to the PLC.
MMC
NC initiative:
reading and
writing of PLC
data via @ Link RAM
commands Read/write Data
command PLC
operating
NC
Data driver system PLC data
initiative
a
a
a
a
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a
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Command
Cycles
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a
Read/write
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Data
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PLC status Data type
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PLC data
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@ com-
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Data
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a
mands
PLC initiative:
FB 62
reading and
writing of NC PLC
initiative Write NC
data NC data data DB
Command
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Data Data type FB 61 Data

a
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Data
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Read
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a
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a
a
NC
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a
a
data
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a
a
a
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a
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a
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a
a
NCK PLC
a
a
a
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a
a
a
a
a
a
a
Structure of data transfer NCK/PLC
With data transfer activated by the PLC, the following NC data can be read/written:
– Machine data – External set values
– Setting data – Program data
– Tool offsets – Program selection
– Zero offsets – R parameters
– Actual values – NC alarms
– Softkey functions
– Write NC blocks

SINUMERIK 840C (PJ)
7 Data Transfer PLC/NC (DB 36) 10.94
7.1 General
Note:
As from SW 4 of SINUMERIK 840C, the "Flexible memory configuration" function enables
operator intervention in the memory configuration.
Modifications can thus be programmed in the following area (see "Installation Instructions
SW 4"):
1. User data
• Part programs
• UMS data
• IKA data
• R parameters
• Tool data
2. Drive software
3. Number of axis-specific measured values
4. Number of block buffers in the block memory.
7.1.1 Machine data (MD)

The values stored in the machine data are determined when installing and starting up the
machine and are normally not altered again.
If machine data are altered (e.g. to achieve optimization), note that alterations do not generally
take effect immediately but only, for example, after a reset; refer to the MD list for exact
information. The machine data are divided into NC and PLC machine data. Within each of
these groups, they are divided up into MD words and MD bits:
Machine data words:
CL 800 word FB
Group Area
parameterization
Machine General 0 – 999 MDN <Word>
data NC
Channel-specific 1000 – 1999
Axis-specific 1 2000 – 3999
Spindle-specific 4000 – 4999
Axis-specific 2 1100 –14519

SINUMERIK 840C (PJ)
08.96 7 Datenübergabe PLC/NC (DB 36)
7.1.1 Maschinendaten (MD)
Machine data bits:
CL 800 word FB
Group Area
parameterization
Machine General 5000 – 5199 MDNBI <Byte>
data NC <Bit>
Channel-specific 5400 – 5599 MDNBY <Byte>
Spindle-specific 5200 – 5399
Leadscrew error 6000 – 9699
compensation
Note:
The @ command allocations are to be found in the ”SINUMERIK 840C Programming Guide”
7.1.2 Tool offsets

Depending on the structure of the TO memory, between 204 and max. 819 1) tool offset
blocks can be stored in the NC for the active tools. They can be divided into areas which
correspond to the tool magazines or turrets on the machine via machine data (NC MD 13,
210 - 226).
D1 1
.
.
. TO area 1
Chan- Dn
nel TO area Offset
1 1 D1
.
. TO area 2
.
2 1
Dn
3 2
.
4 4
.
.
52) 52)
62) 62) D1
.
. TO area n
.
Dn 204
(819) 1)
_______
1) As from SW 4, flexible memory configuration and thus modification of the TO memory is possible (see
Installation Instructions)
2) As from SW 4

SINUMERIK 840C (PJ)
7.1.2 Tool offsets
The individual TO areas are structured as follows:
T No. Type Geometry Wear 1)

PO P1 P2 P3 P4 P5 P6 P7
D1
D2
Dn
See text N. c. Miscellaneous N. c.=Next

P8 P9 P10 P11 . . . . . . . . . . P15 cutting edge
D1
D2
Dn
The significance of P memories P0 to P4 and P10/P11 is fixed, whereas columns P11 to P15
can be assigned in accordance with the specific machine (e.g. service life, quantity,
permissible cutting force).
As standard, the contents of P memories P5 to P7 are taken into account as wear. This
function can be deactivated with machine data 5007.6. The P memories P8 and P9 can be
declared as additional tool offset memories by machine data (MD 5007.3) and thus also be
taken into account. Alternatively, they can be assigned by the user.
The number of P memories is determined by machine data. The minimum number is 10, thus
giving a total of 409 (819)2) one-edged tools.
The number of tools can be calculated by the following formula:

(32.768) 2)
n = INT ( ––––––––– )
P·4
where n = No. of tool cutting edges
16384 = Available TO memory in bytes
P = No. of P memories (MD 13)
(Width of P memory 4 bytes)
Assignment of columns P0 to P11 of the TO areas:

P0: T No. with 8 decades
P1: Type with 2 decades. With reference to the type, the tools are divided into the
following groups:
Type 1 ... 9: Tools with X, Z and radius compensation, e.g. lathe tools.
Type 10 ... 19: Tools with length compensation, e.g. drills.
Type 20 ... 29: Tools with length and radius compensation, e.g. end-milling cutters.
Type 30 ... 39: Tools with 2x length and 1x radius compensation, e.g. angular milling
cutters.
_______
1) Default setting
2) As from SW 4, flexible memory configuration and thus modification of the TO memory is possible (see
Installation Instructions)

SINUMERIK 840C (PJ)
7.1.2 Tool offsets
Decade 100 determines in which direction of the selected compensation plane the offsets are
to be effective.
P2 ... P9: Assignment depends on type, as follows:
(P8/P9 only with MD 5007.3=”1”)
Type Geometry
P2 P3 P4
1 ... 9 Length 1 Length 2 Radius
10 ... 19 Length --- ---
20 ... 29 Length --- Radius
30 ... 39 Length 1 Length 2 Radius
Type Wear 1) Base dimension 2)

P5 P6 P7 P8 P9
1 ... 9 Length 1 Length 2 --- Length 1 Length 2
10 ... 19 Length --- --- Length ---
20 ... 29 Length --- Radius Length ---
30 ... 39 Length 1 Length 2 Radius Length 1 Length 2
Depending on these machine data, the values P2/P5/P8, P3/P6/P9 and P4/P7 are added on.
P10: With multi-edged tools (e.g. recessing tools), the D No. for the next cutting edge is
stated (0 = no text cutting edge). With the last cutting edge, reference is made to
the address of the 1st cutting edge, but with a minus sign.
Examples for assignment of tool offsets
Lathe tools
1. Lathe tool: Assignment of offset memory:
T No. Type Geometry
P0 P1 P2 P3 P4
Dn 100 1..9 X Z R
Wear Addit. TO or D no.

or unassigned unassigned n.c. Service life etc.
P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 ... P32
X Z - X Z SZ ST
SL= Service life

Qty= Quantity
D No. n.c.= D No. of next cutting edge of the same tool
_______
1) Standard setting (MD 5007.6)
2) Activated by MD 5007.3 otherwise unassigned

SINUMERIK 840C (PJ)
7.1.2 Tool offsets
Programming: Tool call: T 100 (Dn)

:
:
2. Recessing tool: Assignment of offset memory:
T No. Type Geometry
P0 P1 P2 P3 P4
Dn 100 1..9 X1 Z1 R1
Dm 100 1..9 X2 Z2 R2
Wear Addit. or D nr. Service life etc.

or unassigned unassigned n.c.
P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 ... P32
Dn X1 Z1 - X Z m 0 SZ ST
Dm X2 Z2 - X Z 0 n - -
Programming: Tool call: T 100 (Dn) (e.g. for left cutting edge)
:
:
Dm (e.g. for right cutting edge)
7.1.3 R parameters
The NC CPU has channel-oriented R parameters for each channel. In addition, central R
parameters common to all channels are stored in the static RAM.
The channel-oriented and central R parameters are differentiated by the R parameter
addresses.
Local, global, transfer R parameters and pointers are available for each channel. To ensure
that cycles compiled at various locations can operate smoothly together, the R parameters are
defined for the individual tasks as follows:
Address 1) Designation Effect

0 - 49 Transfer R parameters
50 - 99 Local R parameter pointers Channel-oriented R
parameters
100 - 149 Global R parameters
declared channel-dependent
150 - 699
Global R parameters de-
clared channel-independent
700 - 999 Central R parameters
1000 - 1299 Additional central R paramtrs
10000 - 10019 ASCII R parameters (see Reserved for the function
Operator's Guide SINUME- "Select part program for
RIK 840C, SectionR parmtrs) editing".
Note:
ASCII R parameters
When an MDA input image is selected, the PLC cannot write an ASCII block. FB 62 is
acknowledged negatively with an error message. In the case of an error, bit 7 "error value 1 -
value 3" of the corresponding interface signal is set in DB 36.
_______
1) As from SW 4, flexible memory configuration is possible; selection of the local and central R parameters
can change. This function is described in detail in the Installation Instructions.

SINUMERIK 840C (PJ)
7.1.3 R-ParameterR parameters
Transfer R parameters:
These are used to transfer values between subroutines. They must be provided with the
desired values before calling a subroutine.
Local R parameters:
These are valid only within a subroutine. When a subroutine is called, the contents of the R
parameters required in the subroutine for local variables are saved at the start of the
subroutine and uploaded again at the end. This means that the original value is present in the
”local” R parameters again after returning to the program from which the call was made. By
saving and uploading the ”local” R parameters, the same parameters can be used repeatedly.
Pointers:
R parameters as pointers are used primarily for indirect data field addressing. The command
does not contain the address of the line out of which something is to be read or into which
something is to be entered, but the address of an R parameter containing the address of the
line.
Examples:
a) Direct addressing of an R parameter
R67 0 R50
=R50
Transfer
V R67
The addresses of both R parameters are contained in the command.
b) Indirect addressing of an R parameter
R67 60 R50
=R50
0 R60
Transfer
V R67

SINUMERIK 840C (PJ)
7.1.3 R parameters
The address of the R parameter whose contents are to be read out is located in the cell to
which the 2nd operand of the command points.
Since pointers belong to the group of local variables, they are also saved and uploaded. They
can therefore be used for multiple assignments.
Global R parameters
These retain their validity over all program levels. They can therefore be used to exchange
information between all subroutines of a single channel.
For declaration purposes, global R parameters are divided into channel-dependent declared
(R100 - R149) and channel-independent declared (R150 - R199 ) R parameters.
R parameters R100 - R149 can be declared differently for each channel, whereas R
parameters R150 - R199 can be declared jointly for several channels.
Subroutines that run only on one specific channel (e.g. machine-dependent cycles), therefore,
use the R parameters between R100 and R149. All programs that run on several channels
(e.g. standard cycles) use the R parameters R150 - R199.
Central R parameters:
The central parameters are R parameters and common to all channels. These R parameters
only exist once but can be read and written from all channels.
7.1.4 Zero offsets

The zero offsets and tool offsets are calculated for each NC axis as follows:
Machine Programmed or
actual value external position
DRF offset
– + Total of all
offsets
PRESET Adjustable ZOs

– G54/G55/G56/G57
offset
Programmable ZOs
Difference G58/G59
Machine- between the
oriented actual External ZOs
two positions:
value distance to go Tool offsets
Workpiece-
oriented actual
value

SINUMERIK 840C (PJ)
7.2.1 Structure with example
7.2 Data transfer PLC initiative

Data can be exchanged between the PLC and NC via data channels.
2 function blocks for activating the transfer of data are available in the system program:
Read NC data (FB 61) and write NC data (FB 62).
LInk
RAM FB61 NCD-LES
Data Ope- LES User

channel rating NSBY program
NC/PLC system ANZ PLC
PLC FIFO DTY
Initiative jobs WER
ZFPN
ZIEL
DB 36
Status-
data
transfer
DB n
Data
Structure of data transfer PLC initiative
The function blocks enter the parameters for data transfer (data type, data source, data
destination) in an internal interface. The interface is a first-in first-out (FIFO) register with a
maximum capacity of 8 jobs. Even when several jobs are involved, this ensures that they are
executed in the correct sequence.
Each job must still be allocated an interface byte indicating the status of data transfer (DB 36,
DW 0 - DL 32 corresponds to 65 interface bytes). Data transfer can be checked and branches
can be implemented in the user program according to these acknowledgements.

SINUMERIK 840C (PJ)
READ
(FB 61) 1 2 1
Data transfer
assigned 1
Data transfer
ended
1 FB internal implementation
2 User implementation
Assignment of status byte at interface (DB 36)
Error Access Data transfer FIFO Data

Value 1 - Number disabled assigned transfer
ended assigned busy
Value 3 format requested
Principal signal paths, data transfer NC/PLC
If data transfer is initiated at FB 61 at the READ input, for example, the DATA TRANSFER
ASSIGNED signal is immediately output at the interface. Since this signal remains present until
the end of data transfer, it can be used to effect read-in disable, for instance. When data
transfer has ended, the DATA TRANSFER ENDED signal is output; this signal is not reset until
the user cancels the READ signal at the FB.
In order to reduce the load on the PLC program caused by repeated calls of the FB 61/62
function blocks, they can be called either unconditionally or conditionally.
The advantage of an unconditional block call is that the FB can be easily initialized. However,
in the inactive state of data transfer, approx. 0.2 ms of the PLC cycle are taken up by the
block change and some logic operations.

SINUMERIK 840C (PJ)
8
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1
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2
7
9
3
9 7
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1: READ/WRITE
2: DAA TRANSFER REQUESTED
3: FIFO ASSIGNED
4: DATA TRANSFER BUSY
5: DATA TRANSFER ASSIGNED
6: DATA TRANSFER ENDED and (possibly) error
7: Signal change by FB
8: Signal change by user
9: Signal change by FB; omitted if FIFO not yet full
tD: Assignment of internal interface by data transfer
t c: PLC cycle time

SINUMERIK 840C (PJ)
Alternatively, the FBs can also be called conditionally; i.e. the FBs have to be processed only
until the job has been transferred to the job buffer (FIFO). This is indicated by the DATA
TRANSFER BUSY signal. In the inactive state of data transfer, only approx. 0.008 ms of the
PLC cycle are taken up.
1
9
tc
2
10
7
7
3
10
tD
4
7 7
5
7
tc
6
Signal path with conditional block call
1: READ/WRITE
2: DATA TRANSFER REQUESTED
3: FIFO ASSIGNED
4: DATA TRANSFER BUSY
5: DATA TRANSFER ASSIGNED
6: DATA TRANSFER ENDED and (possibly) error
7: Signal change by FB
8: Signal change by user
9: User no longer calling block
10: Signal change by FB; omitted if FIFO not yet full
tc: PLC cycle time
tD: Assignment of internal interface by data transfer
If the function blocks are incorrectly parameterized (e.g. data source in the PLC unknown), the
PLC branches into the stop loop. The number of the interface byte and an error ID are stored
in ACCU2 of the interrupt stack.

SINUMERIK 840C (PJ)
Language notation<CL 800>

<VAR> =ACPM<WERT> <VAR>: R parameter address
R30 =ACPM 3 ACPM: Machine-oriented
actual axis position
<WERT>: Axis No.
PLC
FB 61 NCD-LESE
F150.0 – LESE Function:
16 – NSBY
1 – ANZ Actual value of axis 3 is
AC – DTY1 transferred in DB 150 into DW 10
PM – DTY2 and 11
– DTY3 (BCD number without decimal
3 – WER 1 point)
0 – WER 2
0 – WER 3
B0 – ZFPN
150 – DBZI
10 – DWZI
DB – TYZI
Parameterization of FB 61 for reading the ”machine-oriented actual axis value” of the 3rd axis
In the case of data transfer by the PLC, the number format is converted according to
parameter ZFPN of FBs 61 and 62. In principle, the following number formats are possible:
Parameter ZFPN Format Destination/source in PLC DBs

BI Bit pattern DR n
F. Fixed-point number 32 bits DW n, DW n+1
B. BCD number with sign and DW n, DW n+1, DW n+2
decimal point

SINUMERIK 840C (PJ)
R parameter cell NC PLC data words

(fixed-point, 32 bit)
DW n
»ZFPN« Bit 31 Bit 16
1234.5678
Format Bit 15 Bit 0
conversion
DW n+1
Parameter»ZFPN« PLC value
F0 1234
F1 1234
F2 12345
F3 123456
• •
• •
• •
NC/PLC data transfer, format conversion with fixed-point representation in the PLC
For further information on parameterization of FB61 and FB62, refer to the description of
function macros.
7.2.2 Description of job-specific interface signals
DATA TRANSFER REQUESTED D 0.8, D 0.0 to DL 32
1 signal: FB READ or WRITE signal is 1.

0 signal: a) With 0 1 edge of data transfer ended or fault during data transfer signal.
b) READ or WRITE signal is 0.
FIFO ASSIGNED D 0.9, D 0.1 to DL 32
1 signal: Job cannot be entered in FIFO at the moment. With READ and WRITE = 1,
repeated attempts are made until successful.
0 signal: No effect

SINUMERIK 840C (PJ)
7.2.2 Description of job-specific interface signals
DATA TRANSFER BUSY D 0.10, D 0.2 to DL 32
1 signal: Job entered in buffer or job being executed.

0 signal: After 1 signal, if DATA TRANSFER ENDED is 0.
DATA TRANSFER ASSIGNED D 0.11, D 0.3 to DL 32
1 signal: FIFO ASSIGNED and DATA TRANSFER BUSY signals are 1.

Actuation of READ-IN DISABLE during data transfer.
DATA TRANSFER ENDED D 0.12, D 0.4 to DL 32
1 signal: Job completed with or without NC error message.

0 signal: After 1 signal, if READ or WRITE is 0 at FB 61/62.
NUMBER FORMAT ERROR D 0.14, D 0.6 to DL 32
1 signal: Job completed with NC error message. The number format FB parameter is
inadmissible (e.g. an actual axis value is read as a bit pattern).
0 signal: After 1 signal only if READ/WRITE signal is again 0.
ACCESS DISABLED D 0.13, D 0.5 to DL 32
1 signal: The job is rejected as the interface is assigned or access to the data field is not
possible.
Note:
The job is rejected if, for example, one tries to preselect a program number via FB 62 and the
channel in question is not in the reset state.
VALUE 1 - VALUE 3 ERROR D 0.15, D 0.7 to DL 32
1 signal: Job completed with NC error message. The VALUE 1 - VALUE 3 FB parameters
cannot be interpreted by the NC (e.g. a non-existent machine data is addressed).
0 signal: After 1 signal only if READ/WRITE signal is again 0.

SINUMERIK 840C (PJ)
7.3 Data transfer NC initiative
7.3 Data transfer NC initiative

PLC data can be accessed directly by the NC. The NC requests or supplies data via an
interface; data transfer takes place via the PLC operating system.
MMC
Link RAM
Read/write
Data
command
PLC
NC operating
Data driver initiative system PLC data
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NC initiative: Read and write PLC data using @ commands
PLC data for the NC CPU can be read and written using @ commands in the cycle language
CL 800.
Appropriate commands are available for data types E, A, M, T, Z, D (see CL 800 documenta-
tion). Data from the PLC are written in R parameters by the @ command; data to the PLC
must be entered in an R parameter before calling the @ command. This function permits data
to be exchanged between the PLC and NC cycles without a PLC user program; the user
merely has to reserve certain data storage areas (e.g. a data block) in the PLC for data
transfer purposes.
Note:
In the event of major data storage areas being altered in the PLC by an NC program, users are
recommended to set a strobe bit in the PLC after completing the data transfer. This obviates
the need for time-consuming comparisons of data fields to identify alterations. Certain bits can
be set in the PLC as strobes via @ commands; M functions can also be used.
END OF SECTION

SINUMERIK 840C (PJ)
04.96 8 Control of Data Transfer (DB 37)
8.1 Description of interface signals
8 Control of Data Transfer (DB 37)
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As from software version 3, the data transfer through the RS232C (V.24)
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can be controlled via DB 37.
8.1 Description of interface signals
FTR IN PROGRESS D 0.12
1 signal: The signal "FTR in progress" (File Transfer in progress) is only set if a file
transfer has been requested by the user (via DB 37 or "Computer link file
transfer" display).
0 signal: No File Transfer in progress
FTR ACTIVE: D 0.13
1 signal: File transfer between computer link and NCK is active

0 signal: No file transfer active
8.2 Signals for PLC initiative data transfer

• The data transfer between MMC and NCK and also between RS232C (V.24) and MMC is
possible in both directions.
• Exclusively workpieces and data files of workpieces are transferred from the LOCAL
directory. The data files must have the established tape identifiers TOA1, ZOA1, MPF ...
as file names. (TEA and PCF are not possible!)
• For channel-specific data (e.g. RPA4), data type and channel number must be stored in
two different data words (e.g. RPA4 DW 2: RPA, DL6: 4).
• For transfer, a channel number must always be written (1 - 6).
• Jobs with wrong parameters, e.g. non-existent program number, are not executed and will
be acknowledged with an error message (see error code).
• A workpiece name must always be specified.
• Note: In the case of data transfer via DB 37, the keyswitch position (access rights) is not
scanned.
• For data transfer through RS232C (V.24), the interface parameters set in the operator
interface (see SINUMERIK 840C Operator's Guide, ”Services” Section) apply.
• Workpieces or individual workpiece files can be transferred in PC and punch tape (LS)
format.
• Direct transfer between RS232C (V.24) and NCK is not possible.

SINUMERIK 840C (PJ)
8 Control of Data Transfer (DB 37) 10.94
DATA START INPUT D 1.8
1 signal: Start of data transfer from MMC to NCK or from RS232C (V.24) to MMC
0 signal: By the user at:
a) TRANSFER ENDED
b) ERROR DURING DATA TRANSFER
Notes:
• After the start of data input, data must be available at the interface within the set time
(device setting) or else the monitor will respond.
• All parameters must be assigned before activating data transfer.
• When a name is specified for a data file, only this data file of the workpiece is transferred.
• The workpiece is stored under MMC data management.
DATA START OUTPUT D 1.9
1 signal: Start of data transfer from NCK to MMC or from MMC to RS232C (V.24)
0 signal: By the user at:
a) TRANSFER ENDED
b) ERROR DURING DATA TRANSFER
Notes:
• Several data files of one type can be transferred, as MPF [from, to] or SPF [from, to].
• All parameters must be assigned before activating data output.
DATA TRANSFER ENDED D 1.0
1 signal: After recognition of the end criterion of data input/output

0 signal: a) No effect
b) After the 1 signal if the
– DATA START INPUT
– DATA START OUTPUT
signals are 0
– after one cycle

SINUMERIK 840C (PJ)
ERROR DURING DATA TRANSFER D 1.1
1 signal: After incorrect data input/output

0 signal: After the 1 signal if the
– DATA START INPUT
– DATA START OUTPUT
– ABORT
signals are 0
Note:
The error message can be triggered by:
a) Missing or erroneous data at data input
b) Incorrect data type at data output
c) By transmitting several data files without waiting for the acknowledgement signal between
the data files
d) Wrong assignment of the function (e.g. wrong channel number or wrong device number)
Signal charts:
1 3
Data input/output
1. Data start output or input
2. TRANSFER ENDED or ERROR DURING DATA TRANSFER
3. User cancels signal 1
4. PLC operating system cancels signal 2

SINUMERIK 840C (PJ)
DATA TYPE DW 2, DW 3
INITIAL NUMBER DW 4
END NUMBER DW 5
CHANNEL NUMBER DL 6
The following table shows which initial number, end number and channel number is assigned
to the individual data words.
Data type Initial no. End no. Channel no.

Significance
(DW 2-3, KC) (DW 4, KF) (DW 5, KF) (DL 6, KF)
”MPF” Main programs 0 9999 –
”SPF” Subroutines 1 9999 –
”TOA” Tool offsets TOA area 0 819 1) 1–4
(G54 -G57) – – 0
”ZOA” Zero offsets
Angle of rotation – – 1–6
Central 700 1299 1) 0

”RPA” R parameters
Channel-specific 0 699 1) 1–6
”SEA1” NC setting data 0 9999 –
”SEA4” Cycle setting data 0 999 1–6
”JOB” Workpiece list – – 1–6
”IKA1” IKA ratio number 1–32 1–32 –
”IKA2” Curve pointer 1–32 1–32 –
”IKA3” Curve values 1–16000 1) 1–16000 1) –
Table 1: Permitted data types with areas
Note:
• The ASCII characters DATA TYPE FOR DATA OUTPUT must be entered left-justified.
• The data type "JOB" is only possible for data transfer from the hard disk to the NCK and
RS232C (V.24). It triggers the generation of a "workpiece list" in which the data to be
transferred to the NCK can be defined. If no workpiece list is available, all the data in the
specified directory are transferred.
_______
1) As from SW 4, the "Flexible memory configuration" function can be used to program a modification in the
memory areas, depending on the NCK CPU used. You can thus shift the initial and end numbers of the
memory areas. Observe the following when entering the end number:
maximum values R parameters 9999
TOA 1638
IKA3 65535

SINUMERIK 840C (PJ)
Example:
Output of part programs 10 to 20
.
.
.
C DB 37
L KCMP
T DW 2
L KCF
T DW 3
L KF 10
T DW 4
L KF 20
T DW 5
SU D 1.9
.
.
.selected workpiece is not available for transfer from MMC to NCK
Error code DW 7
Error code
Error
(hexadecimal)
03 General error (e.g. diskette is not inserted)
04 The RS232C (V.24) interface is disabled (through WOP or PG-SW)
40 The selected workpiece is not available for transfer from MMC to NCK
4F Several data files have been transmitted without waiting for an
acknowledgement signal
44 The function has been incorrectly defined, e.g.
– wrong channel number
– wrong device number
Device for data transfer DW 8

Device number DW 9
It is possible to set a device for data transfer.

The following values can be entered:
DW 8 DW 9
Device in plaintext
Device type Device numbers
Hard disk in MMC area
0 –
(workpiece name DW 10 - DW 15 must be entered)
RS232C (V.24) hard disk 1st to 3rd interface
2 number
(specification of workpiece name)
5 Computer link - file transfer –
All errors occurring in data transfer NCK MMC are output in the form of dialog boxes.

SINUMERIK 840C (PJ)
Workpiece name DW 10 to DW 15
Here the workpiece name can be entered in ASCII code in string form (max. length 8 bytes). It
defines a directory (workpiece) with which the specified data are transferred. The workpiece
name is completed with the end identifier 0H.
For a more accurate specification of the JOB data type, it is absolute necessary to add the
workpiece name. For the workpiece name, a maximum of 8 characters are entered left-
justified. The specification is made in KC format.
The workpiece name is always a subdirectory of the directory LOCAL.
Indicate: Read in data into NCK DL 29
Bit 0 = 1 Read part programs into the NCK

Bit 1 = 1 Read program data into the NCK
Bit 2 = 1 Read workpiece list into the NCK
Bit 3 = 1 Read circular buffer into the NCK
Bit 0-3 = 0 No significance
Indicate: Read data out of NCK DR 29
Bit 0 = 1 Read part programs from the NCK into the device defined in DW 8
Bit 1 = 1 Read program data from the NCK into the device defined in DW 8
Indicate the disabling of data for reading in DL 30
Bit 0 = 1 Part programs disabled for reading in data

Bit 1 = 1 Program data disabled for reading in data
Bit 2 = 1 Workpiece disabled for reading in data
Bit 3 = 1 Circular buffer disabled for reading in data
Indicate the disabling of data for reading out DR 30
Bit 0 = 1 Part programs disabled for reading out data

Bit 1 = 1 Program data disabled for reading out data

SINUMERIK 840C (PJ)
8.2 Description of job-specific interface signals
Disable reading in of data DL 31
Bit 0 = 1 Part programs disabled for reading in

Bit 1 = 1 Program data disabled for reading in
Bit 2 = 1 Workpiece list disabled for reading in
Bit 3 = 1 Circular buffer disabled for reading in
Disable the reading out of data DR 31
Bit 0 = 1 Part programs disabled for reading out

Bit 1 = 1 Program data disabled for reading out
END OF SECTION

SINUMERIK 840C (PJ)
03.95 9 Operator Panel Interface (DB 40)
9 Operator Panel Interface (DB 40)
SINUMERIK 14” colour monitor with NC keypad

SINUMERIK 840C (PJ)
9 Operator Panel Interface (DB 40) 11.92
9.1 Key signals from operator panel
9.1 Key signals from operator panel

Note:
The operator panel key symbols are not transferred to the PLC with acknowledgement control
(except for configured softkey function numbers).
The PLC operating system updates the key image in DB 40 once at the start of the PLC cycle.
If the key is pressed for less than the duration of one PLC cycle, the key signal is not updated
in DB 40.
STATIC KEY SIGNALS D 0.6 to D 0.0
1 signal: Key pressed

0 signal: Key not pressed
Note:
If several keys are pressed at the same time, only the key that was pressed first will have any
effect.
DYNAMIC KEY SIGNALS DW 0, DL 3 to DL 6
1 signal: Key pressed

0 signal: – Key not pressed
– After one PLC cycle
Note:
If several keys are pressed at the same time, only the key that was pressed first will have any
effect.
9.1.1 Operating mode group (BAG)
OPERATING MODE GROUP DR 7
The display on the screen can be changed to a specific operating mode by pressing the
OPERATING MODE GROUP key or, in the case of SINUMERIK 840C, selecting OPERATING
MODE GROUP in the machine window. The number of the operating mode group valid for the
display is output as a binary number.
When the control is switched on, 0 is output; that is not the operating mode group that is
obtained automatically after the control has run up.

SINUMERIK 840C (PJ)
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DB 40
static,
14
COOL-
signals
system
ANT ON
Softkey function signals
a
Function
dynamic/
menu no.
Operating
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15
COOL-
6FC5197- AA00
ANT OFF
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the M functions; i.e. a static and a dynamic bit are output.
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the machine control panel).

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modes) can be routed accordingly by the OPERATING MODE GROUP switch.
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list
initiating any movements.Only keys protected against accidental

User
operation may be used to perform movements (e.g. customer keys on

Softkey-controlled machine operation can thus be accomplished using the SOFTKEY
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Note that machine protection regulations prohibit softkey operation from

number
program
Function
terminal can then be used to allocate a FUNCTION NUMBER to any configured softkey.
When the softkey is pressed, this FUNCTION NUMBER is output to the PLC. The output
the softkey must be output to the PLC after the softkey is pressed. The NC programming
The user can program both displays and softkey menus at the NC programming terminal in
order to adapt operation to a specific machine. To permit this, a signal uniquely assigned to
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If only one machine control panel is available, operating mode specific signals (e.g. operating
SOFTKEY FUNCTION NUMBERS in the range 0 - 255 are decoded by the PLC program like
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9 Operator Panel Interface (DB 40)
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9–3
9.1.1 Operating mode group (BAG)
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9.1.2 Softkey function signals
The following figure shows the logic structure of the sequences of motion with softkey function
signals. For example, if the COOLANT ON is to be initiated with function number 14 and COO-
LANT OFF is to be initiated with function number 15, the PLC operating system sets the static
signal (DB 40, D 9.6) and the dynamic signal (DB 40, D 9.14) for number 15 when the COO-
LANT ON signal has been pressed. With the dynamic signal, the store must be made ready for
the counter command (COOLANT OFF). The store state is transferred to the output store with
the activation key. To ensure that the preselection stores are effective only for as long as the
relevant display is on the screen, all preselection bits are cancelled when the display is dese-
lected (page = menu number change).
1 1
F 14 dyn. F 15 dyn.
D 9.14 D 9.15
Menu No. change

(D 104.1)
1 1
1 1
F 14 stat. F 15 stat.
S R S R
D 9.6 D 9.7
Q Q
Activate function
Protected key e.g. key 1 of the
& & customer keys on the machine
control panel
(D100.7)
Coolant
S R ON
( A 1.1)
Coolant pump
All data bits in DB 40

1 Signals set by PLC operating system
Logic structure for interpretation of a function number

SINUMERIK 840C (PJ)
Relevant PLC program in a statement list:

.
.
.
C DB 40
L DW 9 Function signals 8-15

T FW 224 Load
L DL 100 Dynamic signals customer keys

T FY 226 Load 1 - 8
L DL 104.1 Menu number change

T FY 227 Load
A F 224.6 Coolant on, dynamic

O F 227.1 Coolant off, static
R F 225.7
A F 224.7
O F 227.1 Coolant off, dynamic
R F 225.6 Coolant on, static
A F 226.7
A F 225.6 Function COOLANT ON
S Q 1.1 Activate
A F 226.7
A F 225.7 Function COOLANT OFF
R Q 1.1 Activate
.
.
.
The user can also send back the number of a dialog text line and a function result (to DB 40),
both referring to the function number of the pressed softkey. The dialog text line number
and/or function result must be entered in the same PLC cycle in which the softkey function
number is made available in DB 40/DR 49.
In this way, dialog texts can be displayed at the operator panel and/or subsequent menus
stated that also have to be generated via a programming workstation.
If a softkey with configured softkey function number is pressed on the operator panel, this
softkey function number (DW 41) is transferred and a strobe bit (DB 40/D 49.14)) set to ”1” in
DB 40.
The user can now obtain the function number and send back a function result (DL 50) and a
dialog text number (DR 50) to DB 40 in the same PLC cycle; these are declared valid by
means of an acknowledgement bit (DB 40/D 49.15).

SINUMERIK 840C (PJ)
DYNAMIC FUNCTION SIGNALS DL 8 to DL 39
1 signal: Configured softkey operated

0 signal: After one PLC cycle
STATIC FUNCTION SIGNALS DR 8 to DR 39
1 signal: Configured softkey operated

0 signal: By user
Note:
SOFTKEY FUNCTION NUMBERS 0 - 255 are decoded and transferred to DB 40 with
acknowledgement control.
SOFTKEY FUNCTION NUMBER CHANGE D 40.0
1 signal: FUNCTION NUMBER changed

0 signal: After one PLC cycle
SOFTKEY FUNCTION NUMBER DW 41
SOFTKEY FUNCTION NUMBER of the last softkey operated with a softkey function number. A
softkey FUNCTION NUMBER is valid only during FUNCTION NUMBER CHANGE. A 16-bit
fixed-point number is output. Only the numbers 0 - 255 are decoded.
The SOFTKEY FUNCTION NUMBERS must be input with the NC programming workstation.
Note:
Some softkey function numbers are assigned by the PLC operating system for display and
operation purposes:
F No. Function
F000
F001
F002 Display Message group Channel 1
F00A Display Messages spindle
F00B Display Messages axes
F00C Display Messages PLC

SINUMERIK 840C (PJ)
Example:
Indexed call of blocks following softkey operation:
.
.
A DB 40
P D 40.0
B DW 41
SPB PB0
Function number
Dec. Hex. Reserved for
0 0000
Statically and
dynamically
decoded User /
255 0FFF
256 0100
Manufacturer
Function No.
4096 0FFF available only
4097 1000 in absolute
61440 EFFF
form
F000
SIEMENS
F0FF
(Not statically
F100 / dynamically
decoded) SIEMENS
FFFF
F100
} Reserved for Package 3 (operation for tool management)
F13F
F140
F141 } Reserved for contour calculators and technology computers

SINUMERIK 840C (PJ)
9.2 Display dialog line
9.2 Display dialog line
ACKNOWLEDGEMENT FUNCTION RESULT VALID D 49.15
1 signal: FUNCTION RESULT (DL 50) and DIALOG TEXT NUMBER (DR 50) valid
0 signal: Otherwise
STROBE FUNCTION NUMBER VALID D 49.14
1 signal: A softkey with configured function number has been operated at the operator
panel.
0 signal: Otherwise
FUNCTION NUMBER DR 49
FUNCTION RESULT DL 50
DIALOG TEXT NUMBER DR 50
Transfer of data to NC.
9.3 Menu selection interface
The PLC can interrupt the present menu tree structure and insert a menu itself via a new
interface in DB 40 (not in start-up mode).
Menu insertions are only possible in the MACHINE and PARAMETER operating areas.
When the RECALL key is pressed the inserted menu (ENTRY MENU EM) is replaced on the
screen by the previous menu (EXIT MENU XM).
The menu selection functions should only be performed if the MMC is ready. MMC Ready can
be scanned in F22.0.
The EMs and XMs can be located in the system and user areas.
Description of the specification of exit menus via the PLC:

The PLC is also able to specify a new XM which is displayed instead of the previous XM when
the RECALL key is pressed.
Care should be taken that the new XM is located in the same area (machine/data) as the
original XM. If this is not the case, it can happen in conjunction with the function ”no basic
image with change from the data to the machine area, or with operating mode /operating mode
group change” that the new XM is identified as the basic image of the machine area when
changing into the machine area. In this way the rigid separation between machine and data
area is avoided. The regular basic image is selected by SHIFT RECALL in this case.
As many insertions as required can be made from the PLC. The original exit menu is obtained,
however, with RECALL.
The SPECIAL RECALL function can be used to prevent a return to the original XM. By
pressing the recall key, the SPECIAL RECALL bit is made available to the user for one PLC
cycle in DB 40.

SINUMERIK 840C (PJ)
Description of the function ”No basic display when changing from Data area to
Machine area, or with operating mode/operating mode group change”
An additional function, NO BASIC DISPLAY WHEN CHANGING FROM DATA AREA TO
MACHINE AREA, OR WITH OPERATING MODE OR OPERATING MODE GROUP CHANGE,
is available to the PLC to prevent the relevant basic display from appearing in the event of a
mode or mode group change. The same holds true for a change from the data to the machine
area. If this function is activated before a mode or mode group change or before a change to
the data area, the menu selected is stored when exiting the machine area of the operating
mode for reactivation after returning to the machine area of the same operating mode. If the
signal is not set, the stored menus are cleared in the event of a mode or mode group change.
If the signal is set when leaving the machine area and in addition a menu is displayed by the
PLC, this menu is not stored as the basic menu. Data area menus can only be stored using
the data area key.
The INPUT, EDIT AND CANCEL keys can be independently disabled or enabled with individual
bits.
Besides menu changes, the PLC is also able to execute channel and mode group changes.
Independent mode group or channel changes (without menu insertion) can be effected.
The MENU STACK RESET function deletes all stored insertions. This function can be
triggered by the PLC or by the operator (SHIFT RECALL). The active mode group number at
the interface is transferred to the PLC. This is no longer the mode group key code, but the
actual mode group number. The activated NC channel at the operator panel is also reported to
the PLC.
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XM = Exit menu Basic display Basic display
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JOG AUTO
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EM = Entry menu
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Menu insertion
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Return via RECALL key or PLC signal
Menu insertion by PLC and return to exit menu

SINUMERIK 840C (PJ)
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XM = Exit menu Basic display Basic display
JOG AUTO
EM = Entry menu
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New exit menu
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from PLC
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Original return path
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continuation
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Menu insertion by PLC with specification of a new RECALL menu
List of normal menu blocks up to SW 3
MB NUMBER: MENU BLOCK DESIGNATION
MB 001 : PARAMETER basic display

MB 002 : TEACH IN : Preset : Help
MB 003 : MDA : Preset : Help
MB 004 : JOG : Preset : Help
MB 005 : DB : PP : Tool offsets Geo+Base
MB 006 : AUTOMATIC : Basic display with current block
MB 007 : AUTOMATIC : Overstore
MB 008 : AUTOMATIC : Preset DRF
MB 009 : AUTOMATIC : Program control
MB 010 : AUTOMATIC : etc. Block search
MB 012 : DPL : AUT : Program modification : ETC
MB 013 : AUTOMATIC : Preset : Help
MB 014 : AUTOMATIC : Block search : Help
MB 015 : JOG : Overstore
MB 017 : JOG : Handwheel
MB 018 : MDA : Basic display
MB 019 : MDA : Overstore

SINUMERIK 840C (PJ)
MB 020 : TEACH IN : Basic display : Help

MB 021 : MDA : Program control
MB 022 : TEACH IN : Basic display
MB 023 : TEACH IN : Overstore
MB 024 : DPL : AUTOMATIC : Basic display : ETC : Block search
MB 025 : TEACH IN : Program control
MB 026 : DB : Data In/Out : Set devices, further interfaces
MB 029 : DPL : AUTOMATIC : Program modification : ETC : Block search
MB 030 : DB : PP : Tool offsets, wear
MB 031 : DB : Diagnostics: Start-up: NC MD: Rows of bits: Chan.-spec. bits 1
MB 032 : DB : PP : Zero offset
MB 033 : DB : PP : Angle of rotation
MB 034 : DB : PP : Plane
MB 035 : DB : PP : R parameter central
MB 036 : DB : PP : R parameter channel-specific
MB 037 : DB : Diagn. : Start-up : NC MD : Rows of bits : Axis-specific bits 1
MB 038 : DB : SD : Axial bits
MB 039 : DB : SD : General bits
MB 040 : DB : SD : Cycle data : System data
MB 041 : DB : SD : Cycle data : System bits
MB 042 : DB : SD : Cycle data : User data
MB 043 : DB : SD : Cycle data : User bits
MB 044 : DB : Setting data : Spindle data
MB 045 : DB : Data In/Out : Interface 1
MB 046 : DB : Data In/Out : Set devices
MB 047 : DB : Diagn.: Start-up: NC MD: Rows of bits: Channel-specific bits 2
MB 048 : DB : Programming
MB 049 : DB : Programming : Overview main program
MB 050 : DB : Programming : Overview subroutine
MB 051 : AUT : Program modification : ETC
MB 052 : DB : Diagn. : Start-up : NC MD : Rows of bits : Axis-specific bits 2
MB 053 : DB : Diagnostics : PLC error messages
MB 054 : DB : Diagnostics : Cycle alarms
MB 055 : DB : Diagnostics : PLC operational messages
MB 056 : DB : Diagnostics : Start-up : NC MD : Rows of bits :Comp. flags
MB 057 : DB : Diagnostics : PLC messages groups : Spindle
MB 058 : DB : Diagnostics : PLC messages groups : Axis
MB 059 : DB : Diagnostics : PLC messages groups : Other
MB 060 : DB : Programming : Overview main program: Help
MB 061 : DB : Diagnostics : SA : PLC status : Overview
MB 062 : AUT : Program modification : ETC : Block search
MB 063 : DB : Diagnostics : SA : PLC status : IW : KH
MB 064 : DB : Diagnostics : SA : PLC status : IW : KF
MB 065 : DB : Diagnostics : SA : PLC status : IW : KT
MB 066 : DB : Diagnostics : SA : PLC status : IW : KC
MB 067 : DB : Diagnostics : SA : PLC status : QW : KM
MB 068 : AUT : Program modification : ETC : Block search : Help
MB 069 : DB : Diagnostics : SA : PLC status : QW : KH

SINUMERIK 840C (PJ)
MB 070 : DB : Diagnostics : SA : PLC status : QW : KF

MB 071 : DB : Diagnostics : SA : PLC status : QW : KT
MB 072 : DB : Diagnostics : SA : PLC status : QW : KC
MB 073 : DB : Diagnostics : SA : PLC status : FW : KM
MB 074 : DB : Programming : Overview PLC texts
MB 075 : DB : Diagnostics : SA : PLC status : FW : KH
MB 076 : DB : Diagnostics : SA : PLC status : FW : KF
MB 077 : DB : Diagnostics : SA : PLC status : FW : KT
MB 078 : DB : Diagnostics : SA : PLC status : FW : KC
MB 079 : DB : Diagnostics : SA : PLC status : DB
MB 080 : DB : Diagnostics : SA : PLC status : DB : DW : KM
MB 081 : DB : Programming : Overview subroutines : Help
MB 082 : DB : Diagnostics : SA : PLC status : DB : DW : KH
MB 083 : DB : Diagnostics : SA : PLC status : DB : DW : KF
MB 084 : DB : Diagnostics : SA : PLC status : DB : DW : KT
MB 085 : DB : Diagnostics : SA : PLC status : DB : DW : KC
MB 086 : DB : Diagnostics : SA : PLC status : DB : DD parallel : KH
MB 087 : TEACH IN : Program modification : ETC : (Block search with calcul.)
MB 088 : DB : Diagnostics : Start-up : NC MD : Channel memory data
MB 089 : DB : Diagnostics : SA : PLC status : DX
MB 090 : DB : Diagnostics : SA : PLC status : DX : DW : KM
MB 091 : DB : Programming : M functions : Help
MB 092 : DB : Diagnostics : SA : PLC status : DX : DW : KH
MB 093 : DB : Diagnostics : SA : PLC status : DX : DW : KF
MB 094 : DB : Diagnostics : SA : PLC status : DX : DW : KT
MB 095 : DB : Diagnostics : SA : PLC status : DX : DW : KC
MB 096 : DB : Diagnostics : SA : PLC status : DX : DD parallel : KH
MB 097 : DB : Programming : G functions G groups 1 and 2 : Help
MB 098 : TEA : PB : ETC : (Block search with calculation) : Info
MB 099 : DB : Diagnostics : SA : PLC status : Z
MB 100 : DB : Diagnostics : SA : PLC status : T
MB 101 : JOG : INC variable
MB 102 : DB : SD : Spindle data : ETC
MB 103 : DB : Diagnostics : NC alarms
MB 104 : DB : Diagnostics : Start-up : NC MD : General data
MB 105 : DB : SD : General data : ETC
MB 106 : DB : Diagnostics : Start-up : NC MD : Channel data
MB 107 : DB : Diagnostics : Start-up : NC MD : Axial data 1
MB 109 : DB : Diagnostics : Start-up : NC MD : Spindle data
MB 110 : DB : Programming : G functions G groups 3 to 7 : Help
MB 111 : DB : Diagnostics : Start-up : NC MD : Display data
MB 112 : DB : Diagnostics : Start-up : NC MD : Rows of bits : General bits
MB 113 : DB : Diagnostics : Start-up : NC MD : Rows of bits : Spin.-spec. bits
MB 114 : DPLANZ AUTOMATIC : Basic display
MB 115 : DB : Diagnostics : Start-up : PLC MD : Sytem data
MB 117 : DB : Diagnostics : Start-up : PLC MD : FB data
MB 118 : DB : Diagnostics : Start-up : PLC MD : User data
MB 119 : DB : Diagnostics : Start-up : PLC MD : Sytem bits
MB 120 : DB : Diagnostics : Start-up : PLC MD : FB bits

SINUMERIK 840C (PJ)
MB 121 : DB : Diagnostics : Start-up : PLC MD : User bits

MB 122 : DB : Diagnostics : Start-up : Cycle MD : User data channel
MB 123 : DB : SD : General bits : ETC
MB 124 : DB : Diagnostics : Start-up : Cycle MD : User bits channel
MB 125 : DB : Diagnostics : Start-up : Cycle MD : User data central
MB 126 : DB : Diagnostics : Start-up : Cycle MD : User bits central
MB 127 : DB : SD : Scale : ETC
MB 128 : DB : Diagnostics : Start-up : Cycle MD : System data channel
MB 129 : DB : Diagnostics : Start-up : Cycle MD : System bits channel
MB 130 : DB : Diagnostics : Start-up : Cycle MD : System data central
MB 131 : DB : Diagnostics : Start-up : Cycle MD : System bits central
MB 132 : DB : Setting data: Working area limitation
MB 133 : DB : Setting data: General data
MB 134 : DB : Diagnostics : NC alarms
MB 135 : DB : Diagnostics : PLC message groups : channel
MB 136 : DB : Diagnostics : Service displays : Axes and spindles 1-4
MB 137 : DB : Diagnostics : SA : PLC status : IW : KM
MB 138 : DB : Data in/out : Interface 2
MB 139 : DPLANZ AUTOMATIC : Overstore
MB 140 : DPLANZ AUTOMATIC : Program modification
MB 142 : DPLANZ AUTOMATIC : Current block
MB 143 : JOG : Basic display
MB 144 : JOG : Reference point approach
MB 145 : DB : Programming : Support : Plane
MB 146 : DB : Programming : Support : Plane : Plane G16
MB 147 : DB : Setting data : Scale
MB 148 : DB : Diagnostics : Service displays : Axes and spindles 5-8
MB 149 : DB : Diagnostics : Service displays : Single axis 1-4
MB 150 : DB : Diagnostics : Service displays : Spindles individually
MB 151 : DB : Diagnostics : Service displays : NC information
MB 152 : DB : Diagnostics : SA : Single axis : Drift compensation axes 5-11
MB 153 : DB : Diagnostics : SA : Single axis : Drift compensation axes 12-18
MB 154 : DB : Diagnostics : Service displays : PLC error detection
MB 155 : DPL : AUT : PB : ETC : Block search : Help
MB 156 : DB : Diagnostics : Service displays : Axes 9-16
MB 159 : DB : Setting data : Start angle
MB 160 : DB : Diagnostics : Service displays : UMS information
MB 161 : AUTOMATIC : Basic display : ETC
MB 162 : AUTOMATIC : Overstore : ETC
MB 163 : DB : SD : Axial bits : ETC
MB 164 : DB : SD : Spindle data : Start angle : ETC
MB 165 : TEACH IN : ETC : Block search with calculation
MB 166 : TEACH IN : ETC : Block search with calculation
MB 169 : DB : Programming : Help : G function G groups 15-19
MB 170 : DB : SD : General bits : Help
MB 171 : DB : SD : Axial bits : Help

SINUMERIK 840C (PJ)
MB 172 : DB : Programming : Overview PLC texts : Help

MB 173 : DPLANZ JOG : Basic display
MB 174 : DPLANZ JOG : Overstore
MB 175 : DPLANZ JOG : INC-variable
MB 176 : DPLANZ AUTOMATIC : Current G function
MB 177 : DPLANZ JOG : Reference point approached
MB 178 : DB : Programming : Help : G function G groups 21 and 22
MB 179 : Finish threading/setting-up
MB 180 : DPL AUTOMATIC basic display : ETC block search
MB 181 : DPL AUTOMATIC overstore : ETC block search
MB 182 : DPL AUTOMATIC current block ETC : Block search
MB 183 : AUTOMATIC overstore ETC : Block search
MB 184 : AUTOMATIC correction block ETC : Block search
MB 186 : AUTOMATIC current block ETC : Block search
MB 187 : TEACH IN : Basic display : ETC
MB 188 : DB : SD : General data : ETC : Axis/spindle converter
MB 193 : JOG : Finish threading/setting-up
MB 196 : DPLANZ : JOG : Finish threading/setting-up
MB 197 : DPLANZ : AUTOMATIC : Preset DRF
MB 199 : DPLANZ : AUTOMATIC : Preset : Help
MB 200 : DPLANZ : AUTOMATIC : Correction block : ETC : Block search
MB 201 : DPLANZ : AUTOMATIC : Block search : Help
MB 203 : DPLANZ : AUTOMATIC : Basic display : ETC
MB 204 : DPLANZ : AUTOMATIC : Overstore : ETC
MB 205 : DPLANZ : AUTOMATIC : G functions : ETC
MB 207 : DPLANZ : AUTOMATIC : Auxiliary functions : ETC
MB 208 : DB : Diagnostics : SA : Drift compensation axes 19-25
MB 209 : DB : Diagnostics : SA : Drift compensation axes 26-30
MB 210 : ETC for tool offsets GEO+BASE
MB 211 : ETC for tool offsets wear
MB 212 : ETC for zero offset
MB 213 : ETC for angle of rotation
MB 214 : ETC for PLANE
MB 215 : ETC for R parameters channel-specific
MB 216 : ETC for R parameters central
MB 217 : Channel-specific ASCII R parameter
MB 238 : Setting data : ETC
MB 239 : DB : Setting data : Axis/spindle converter
MB 243 : DB : SD : Spindle data : ETC : Axis/spindle converter
MB 244 : DB : SD : General bits : ETC : Axis/spindle converter

SINUMERIK 840C (PJ)
MB 245 : DB : SD : Scale : ETC : Axis/spindle converter

MB 246 : DB : SD : Axial bits : ETC : Axis/spindle converter
MB 247 : DB : SD : Spindle data : Start angle : ETC : Axis/spindle converter
MB 248 : M : AUT GB : Program editing
MB 249 : M : DPL.AUT GB : Program editing
List of start-up menu blocks up to SW 3
MB 001 : DB : Diagnostics : NC MD : Display file : ETC

MB 002 : UZ : Data In/Out : Interface 1
MB 003 : UZ : Data In/Out : Set devices
MB 004 : UZ : Diagnostics : IBN : NC MD : Rows of bits : Channel bits 2
MB 005 : UZ : Initialize NC data
MB 006 : UZ : Delete/load machine data
MB 007 : UZ : Set display design
MB 008 : UZ : NC alarms
MB 009 : UZ : Data In/Out : Interface 2
MB 011 : Overall reset branch : Data I/O : Set devices, further interfaces
MB 012 : DB : Diagnostics : Start-up : NC MD : Axial data 1 : etc.
MB 013 : DB : Diagnostics : Start-up : NC MD : Axial data 2 : etc.
MB 014 : DB : Diagnostics : Start-up : NC MD : Spindle data : etc.
MB 015 : UZ : Overall reset
MB 016 : UZ : PLC functions
MB 017 : UZ : Overall reset
MB 018 : UZ : DB : Diagnostics : Start-up : NC MD : General data
MB 019 : UZ : DB : Diagnostics : Start-up : NC MD : Channel data
MB 020 : UZ : DB : Diagnostics : Start-up : NC MD : Axial data 1
MB 021 : UZ : DB : Diagnostics : Start-up : NC MD : Axial data 2
MB 022 : UZ : DB : Diagnostics : Start-up : NC MD : Spindle data
MB 023 : Unassigned
MB 024 : UZ : DB : Diagnostics : Start-up : NC MD : Bit rows : General bits
MB 025 : UZ : DB : Diagnostics : Start-up : NC MD : Bit rows : Channel bits 1
MB 026 : UZ : DB : Diagnostics : Start-up : NC MD : Bit rows : Axial bits 1
MB 027 : UZ : DB : Diagnostics : Start-up : NC MD : Bit rows : Axial bits 2
MB 028 : UZ : DB : Diagnostics : Start-up : NC MD : Bit rows : Spindle bits
MB 029 : UZ : DB : Diagnostics : Start-up : NC MD : Bit rows : Comp. flags
MB 030 : UZ : DB : Diagnostics : Start-up : MD : PLC : System data
MB 031 : UZ : DB : Diagnostics : Start-up : MD : PLC : FB data
MB 032 : UZ : DB : Diagnostics : Start-up : MD : PLC : User data
MB 033 : UZ : DB : Diagnostics : Start-up : MD : PLC : System bits
MB 034 : UZ : DB : Diagnostics : Start-up : MD : PLC : FB bits
MB 035 : UZ : DB : Diagnostics : Start-up : MD : PLC : FB User bits
MB 036 : UZ : DB : Diagnostics : Start-up : MD : Cycles : User data channel
MB 037 : UZ : DB : Diagnostics : Start-up : MD : Cycles : User bits channel
MB 038 : UZ : DB : Diagnostics : Start-up : MD : Cycles : User data central
MB 039 : UZ : DB : Diagnostics : Start-up : MD : Cycles : User bits central
MB 041 : UZ : DB : Diagnostics : Start-up : MD : Cycles : Sys. data channel

SINUMERIK 840C (PJ)
MB 042 : UZ : DB : Diagnostics : Start-up : MD : Cycles : Sys. bits channel

MB 043 : UZ : DB : Diagnostics : Start-up : MD : Cycles : Sys. data central
MB 044 : UZ : DB : Diagnostics : Start-up : MD : Cycles : System bits central
MB 045 : DB : Diagnostics : Start-up : NC MD : Channel data : etc.
List of menu blocks as from SW 4
MB 001* : DB : Root menu

MB 002 : DB : Parameter : SD : Scale : Position measuring signals
MB 003 : DB : Parameter : SD : Scale : Spindle data : Position meas. signals
MB 004 : DB : Parameter : SD : Gen. data : Position measuring signals
MB 005 : DB : PP : Tool offsets Geo + Base
MB 006 : AUTOMATIC : Basic display with current block
MB 007 : AUTOMATIC : Overstore
MB 009 : AUTOMATIC : Program control
MB 010 : AUTOMATIC : etc. Block search
MB 011 : TEA : Block-by-block teaching
MB 012 : DPL : AUT : Program control : ETC
MB 013 : AUTOMATIC : Preset : Help
MB 015 : JOG : Overstore
MB 016 : TEACH IN : Overstore : ETC : Block search
MB 017 : JOG : Handwheel
MB 018 : MDA : Basic display
MB 019 : MDA : Overstore
MB 020 : TEACH IN : Overstore : Help
MB 021 : MDA : Program control
MB 022 : TEACH IN : Basic display
MB 023 : TEACH IN : Overstore
MB 024 : DPL AUTOMATIC : Basic display : ETC : Block search
MB 025 : TEACH IN : Program control
MB 026 : Diagnostics : SA : NC SA : Axis individually : ETC : Drift
compensation axis
MB 027 : TEACH IN : ETC : Block search
MB 029 : DPL : Automatic : Program control : ETC : Block search
MB 030 : DB : PP : Tool offsets, wear
MB 031 : DB : Diagn. : Start-up : NC MD : Rows of bits : Chan.-spec. bits 1
MB 032 : DB : PP : Zero offset
MB 033 : DB : PP : Angle of rotation
MB 034 : DB : PP : Plane
MB 035 : DB : PP : R parameter central
MB 036 : DB : PP : P parameter channel-specific
MB 037 : DB : Diagnostics : Start-up : NC MD : Rows of bits : Axis-spec. bits 1
MB 038 : DB : SD : Axial bits
MB 039 : DB : SD : General bits
MB 040 : DB : SD : Cycle data : System data
MB 041 : DB : SD : Cycle data : System bits

SINUMERIK 840C (PJ)
MB 042 : DB : SD : Cycle data : User data

MB 043 : DB : SD : Cycle data : User bits
MB 044 : DB : Setting data : Spindle data
MB 045 : Diagnostics: SA : NC SA : Axis ind. : ETC : Drift comp. axes 5-8
MB 047 : DB : Diagn. : Start-up : NC MD : Rows of bits : Chan.-spec. bits 2
MB 048* : DB : Programming
MB 049 : DB : Programming : Overview main program
MB 050 : DB : Programming : NCK : Editing : Storing
MB 051 : AUT program control ETC
MB 052 : DB : Diagnostics : Start-up : NC MD : Rows of bits : Axis-spec. bits 2
MB 055 : Diagn. : SA : NC SA : Ax 5-8 and sp 5+6 : ETC : Drift comp. axes
MB 056 : DB : Diagnostics: Start-up : NC MD : Rows of bits : Comp. flags
MB 057 : Diagn.: SA : NC SA : Ax 5-8 and sp 5+6 : ETC : Drift comp. axes
9-12
13-16
17-23
MB 060 : DB : Programming : Help
MB 061 : DB : Diagnostics : SA : PLC status : Overview
MB 062 : AUT : Program control : ETC : Block search
MB 063 : DB : Diagnostics : SA : PLC status : IW : KH
MB 064 : DB : Diagnostics : SA : PLC status : IW : KF
MB 065 : DB : Diagnostics : SA : PLC status : IW : KT
MB 066 : DB : Diagnostics : SA : PLC status : IW : KC
MB 067 : DB : Diagnostics : SA : PLC status : QW : KM
MB 068 : AUT : Program control : ETC : Block search : Help
MB 069 : DB : Diagnostics : SA : PLC status : QW : KH
MB 070 : DB : Diagnostics : SA : PLC status : QW : KF
MB 071 : DB : Diagnostics : SA : PLC status : QW : KT
MB 072 : DB : Diagnostics : SA : PLC status : QW : KC
MB 073 : DB : Diagnostics : SA : PLC status : FW : KM
MB 074 : DB : Programming : NC editing : Editor settings
MB 075 : DB : Diagnostics : SA : PLC status : FW : KH
MB 076 : DB : Diagnostics : SA : PLC status : FW : KF
MB 077 : DB : Diagnostics : SA : PLC status : FW : KT
MB 078 : DB : Diagnostics : SA : PLC status : FW : KC
MB 079 : DB : Diagnostics : SA : PLC status : DB
MB 080 : DB : Diagnostics : SA : PLC status : DB : DW : KM
MB 081 : DB : Programming : Overview subroutines : Help
MB 082 : DB : Diagnostics : SA : PLC status : DB : DW : KH
MB 083 : DB : Diagnostics : SA : PLC status : DB : DW : KF
MB 084 : DB : Diagnostics : SA : PLC status : DB : DW : KT
MB 085 : DB : Diagnostics : SA : PLC status : DB : DW : KC
MB 087 : DB : Parameter : SD : Sp. data : Start angle : Position meas. signals
MB 089 : DB : Diagnostics : SA : PLC status : DX

SINUMERIK 840C (PJ)
MB 090 : DB : Diagnostics : SA : PLC status : DX : DW : KM

MB 091 : DB : Programming : NC editor help : Help
MB 092 : DB : Diagnostics : SA : PLC status : DX : DW : KH
MB 093 : DB : Diagnostics : SA : PLC status : DX : DW : KF
MB 094 : DB : Diagnostics : SA : PLC status : DX : DW : KT
MB 095 : DB : Diagnostics : SA : PLC status : DX : DW : KC
MB 098 : DB : Programm. help : Continue
MB 099 : DB : Diagnostics : SA : PLC status : C
MB 100 : DB : Diagnostics : SA : PLC status : T
MB 101 : JOG : INC variable
MB 102 : NC info (for MMC)
MB 103 : PLC display : NC machine data
MB 104 : Machine data : General data
MB 105 : PLC status
MB 106 : DB : Diagnostics : Start-up : NC MD : Channel data 1
MB 109 : DB : Diagnostics : Start-up : NC MD : Spindle data 1
MB 111 : TEACH IN : MDA mode
MB 112 : DB : Diagnostics : Start-up : NC MD : Rows of bits : General bits
MB 113 : DB : Diagnostics : Start-up : NC MD : Rows of bits : Spindle-sp. bits
MB 114 : DPLANZ AUTOMATIC : Basic display with current block
MB 115 : DB : Diagnostics : Start-up : PLC MD : System data
MB 116 : DB : Programming : G functions G gr. 8 to 12 : Help
MB 117 : DB : Diagnostics : Start-up : PLC MD : FB data
MB 118 : DB : Diagnostics : Start-up : PLC MD : User data
MB 119 : DB : Diagnostics : Start-up : PLC MD : System bits
MB 120 : DB : Diagnostics : Start-up : PLC MD : FB bits
MB 121 : DB : Diagnostics : Start-up : PLC MD : User bits
MB 122 : DB : Diagnostics : Start-up : Cycle MD : User data channel
MB 123 : DPL_AUT : GB : ETC : SS
MB 124 : DB : Diagnostics : Start-up : Cycle MD : User bits channel
MB 125 : DB : Diagnostics : Start-up : Cycle MD : User data central
MB 126: DB : Diagnostics : Start-up : Cycle MD : User bits central
MB 127 : Diagnostics : Service display : NC service : Axes and spindles 1-4
MB 128 : DB : Diagnostics : Start-up : Cycle MD : System data channel
MB 129 : DB : Diagnostics : Start-up : Cycle MD : System bits channel
MB 130 : DB : Diagnostics : Start-up : Cycle MD : System data central
MB 131 : DB : Diagnostics : Start-up : Cycle MD : System bits central
MB 132 : DB : Setting data : Working area limitation
MB 133 : DB : Setting data : General data
MB 134 : Diagnostics : SA : NC SA : Ax 5-8 and 5+6 : ETC : Drift comp. ax
24+30
MB 135 : Diagnostics : SA : NC SA : Ax 9-16 : ETC : Drift comp. axes 13-16
MB 136 : Diagnostics : SA : NC SA : Ax 9-16 : ETC : Drift comp. axes 17-23
MB 137 : DB : Diagnostics : SA : PLC status : IW : KM
MB 138 : DB : Programming : NCK
MB 139 : DPLANZ AUTOMATIC : Overstore

SINUMERIK 840C (PJ)
MB 140 : DPLANZ AUTOMATIC : Program control

MB 141 : DB : Programming : G functions G gr. 13 and 14 : Help
MB 142 : DPLANZ AUTOMATIC : Help functions
MB 143 : JOG : Basic display
MB 144 : JOG : Reference point approach
MB 145 : DB : Programming : Support : Plane
MB 146 : DB : Programming : Support : Plane : Plane G16
MB 147 : DB : Setting data : Scale
MB 148 : Diagnostics : SA : NC SA : Further axes 5-8 : Spindles 5+6
MB 149 : Diagnostics : Service display : NC service : Axis individually
MB 150 : Diagnostics : Service display : NC service : Spindle individually
MB 151 : Diagnostics : SA : NC SA : Ax 9-16 : ETC : Drift comp. ax 24-30
MB 152 : Diagnostics : SA : NC SA : Ax 1-4 and sp 1-4 : ETC : Drift comp. ax
MB 153 : Diagnostics : SA : NC SA : Ax and sp : ETC : Drift comp. axes 5-8
MB 154 : M : TEACH IN : Program editing : Block search
MB 155 : DPL : AUT : PB : ETC : SS : Help
MB 156 : Diagnostics : SA : NC SA : Further axes 9-16
MB 157 : Diagnostics : SA : NC SA : Ax and sp. : ETC : Drift comp. axes 17-23
MB 158 : M : AUT : PP edit.: SS
MB 159 : DB : Setting data : Start angle
MB 161 : Automatic : Basic display : ETC
MB 162 : Automatic : Overstore : ETC
MB 163 : UMS info
MB 164 : DB : SD : Spindle data : Start angle : ETC
MB 165 : TEACH IN : Overstore : ETC
MB 166 : Diagnostics : SA : NC SA : Ax individually : ETC : Drift comp. ax 24-30
MB 168 : JOG : .. : Finish threading : Setting-up
MB 169 : DB : Programming : Help : G funct. G gr. 15-19
MB 170 : DB : SD : General bits : Help
MB 171 : DB : SD : Axial bits : Help
MB 172 : JOG : .. : Finish threading : Setting-up
MB 173: DPLANZ JOG : Basic display
MB 174 : DPLANZ JOG : Overstore
MB 175 : DPLANZ JOG : INC variable
MB 176 : DPLANZ AUTOMATIC : Current G functions
MB 177 : DPLANZ JOG : Reference point approached
MB 178 : DPL_AUT : Overstore : ETC : SS
MB 179 : Finish threading : Setting-up
MB 180 : DPL AUTOMATIC Basic display : ETC block search
MB 181 : DPL AUTOMATIC Overstore : ETC block search
MB 182 : DPL AUTOMATIC Current block ETC : Block search
MB 183 : AUTOMATIC Overstore ETC : Block search
MB 184 : DPL_JOG : .. : ETC
MB 185 : DB : Program. : Overview subrout. : Help : Help
MB 186 : DB : Data In/Out : File transfer with computer link
MB 187 : TEACH IN : ETC
MB 188 : Machine data initial display for Windows solution

SINUMERIK 840C (PJ)

MB 193 : DB : PP : Tool offsets : Geometry (new tool offset)
MB 194 : DB : Program. : NC editor help : Help : Cursor keys
MB 195 : DB : PP : Tool offset : Basis and wear (new tool offset)
MB 196 : ETC for GEO and basis, wear (new tool offset)
MB 197 : DPLANZ : AUTOMATIC : Preset DRF
MB 198 : TEA : Block-by-block teaching. Setting block format
MB 199 : DPLANZ : Automatic : Preset : Help
MB 200 : ETC for GEO and basis, wear (new tool offset)
MB 201 : DB : PP : Plane (new tool offset)
MB 203 : DPLANZ Automatic : Basic display : ETC
MB 204 : DPLANZ Automatic : Overstore : ETC
MB 205 : DPLANZ Automatic : G functions : ETC
MB 206 : DPL_JOG : .. : Finish threading : Setting-up
MB 207 : DPLANZ : Automatic : Help functions : ETC
MB 210 : ETC for GEO + BASIS
MB 211 : DPL_AUT : PB : ETC : SS
MB 212 : DPL_AUT : GF : ETC : SS
MB 213 : DPL_AUT : HF : ETC : SS
MB 214 : M : AUT : PP edit. : SS
MB 215 : DB : Programming : Help : G functions group 7
MB 216 : DB : Programming : Help : G functions groups 20, 24-27
MB 217 : Channel-spec. ASCII R parameter
MB 218 : M : TEACH IN : ETC : SS : PB
MB 219 : M : TEACH IN : UeS : ETC : SS : PB
MB 220 : M : TEACH IN : ETC : PK : SS : PB
MB 221 : M : AUT : PP edit. : SS : PB
MB 222: M : DPLAUT : PK : SS : PB
MB 223 : M : AUT : SS : HLP
MB 224 : M : DPLAUT : SS : HLP
MB 225 : Param. : Diagn. : SA : Notebook
MB 226 : Parameter : Diagnostics : SA : Notebook : Notebook Siemens
MB 227 : Parameter : Diagnostics : SA : Notebook : Noteb. Siemens :
Progr.disp.
MB 228 : Parameter : Diagnostics : SA : Notebook : Noteb. Siemens :
Progr.disp.
MB 229 : ETC for JOG : Overstore (finish thread./setting-up)
MB 230 : ETC for JOG : INC variable (finish thread./setting-up)
MB 231 : ETC for JOG : Basic display (finish thread./setting-up)
MB 232 : ETC for DPLANZ JOG : Basic display (finish thread./setting-up)
MB 233 : ETC for DPLANZ JOG : Overstore (finish thread./setting-up)
MB 234 : ETC for DPLANZ JOG INC variable (finish thread./setting-up)
MB 237 : TEACH IN : MDA mode : Program control
MB 238 : Setting data ETC
MB 239 : Axis/spindle converter

SINUMERIK 840C (PJ)
MB 240 : Editing display for test only, later MB048!!!

MB 241 : TEACH IN : Edit mode
MB 242 : TEACH IN : Edit mode : Setting block format
MB 243 : DB : Progr. : Help : Continue : Continue
MB 244 : DB : Progr. : Help : Cont. : Cont. : Cont.
MB 245 : DB : Progr. : Help : Cont. : Cont. : Cont. : Cont.
MB 246 : DB : Progr. : Help : Cont. : Cont. : Cont. : Cont. : Cont.
MB 247 : DB : DS : Spindle data : Start angle : ETC : Axis/spindle converter
MB 248 : M : AUT GB : Programm. editing
MB 249 : M : DPL.AUT GB : Programm. editing
MB 250 : DB : Parameter : SD : Position measuring signals
MB 251 : AUT : GB : ETC : Search : Program control
MB 252 : DB : Parameter : SD : ETC : Fixed stop
MB 253 : Setting data : ETC : Gear interpolation
MB 254 : TEACH IN : ETC : Program editing
MB 255 : M : DPL.AUT GB : Programm. editing : ETC
MB 256 : AUT : Program editing : ETC
MB 257 : TEACH IN : Edit mode : ETC
MB 258 : TEACH IN : Block-by-block teaching : ETC
MB 259 : TEACH IN : ETC : Progr. editing : ETC
MB 260 : DB : Programming : ETC
MB 261 : AUT : PB : ETC : SS : Program control
MB 262 : MDA : Basic display : ETC
MB 263 : MDA GB : ETC : F/S on-line
MB 264 : TEACH IN GB : ETC : F/S on-line
MB 265 : Machine data : General data 1
MB 266 : DPLAUT : Overstore : Prog. : Selecting job
MB 267: Machine data : General data 2
MB 268 : AUT : Overst. : ETC : SS : Program control
MB 269 : Machine data : Channel data 2
MB 270 : Machine data : Channel data 2 (to channel-spec. bits 2)
MB 271 : DPL AUT : Program control : Selecting prog./job
MB 272 : Automatic : ETC : Axis-spec. G functions
MB 273 : TEA : ETC : Axis-spec. G functions
MB 274 : MDA basic display : ETC : Axis-spec. G functions
MB 275 : Machine data : Channel data : Bit lists
MB 276 : Machine data : Spindle data : Spindle data 2
MB 277 : Machine data : General bits 1
MB 278 : Machine data : General data 1 : Rows of bits
MB 279 : DB : Programm. : NC editor help : M funct. : Help
MB 280 : Machine data : General data 2 : Rows of bits
MB 281 : Machine data : Axial data : Axial data 3
MB 282 : MD : Axial data : Axial data 4
MB 283 : MD : Axial data : Axial data 3 : Rows of bits
MB 284 : MD : Axial data : Axial data 4 : Rows of bits
MB 285 : MD : Spindle data : Spindle data 2 : Rows of bits
MB 286 : DB : Programming : NCK : Save
MB 287 : DB : Programming : NCK : Copy
MB 288 : AUT : Selecting prog./job
MB 289 : AUT : Overstore : Selecting prog./job

SINUMERIK 840C (PJ)
MB 290 : AUT : Program control : Selecting prog./job

MB 291 : AUT : Program editing : Save
MB 292 : TEACH IN : ETC : Program editing : Save
MB 293 : TEACH IN : Overstore : ETC : Save
MB 294 : TEACH IN : ETC : Save
MB 295 : DPL : AUT

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SINUMERIK 840C

Control SINUMERIK 840C/CE

Edition Order No. Remarks

This manual is included in the documentation available on CD-ROM (DOCONCD)

Other functions not described in this documentation might be

Order No. 6FC5197-6AA00-0BP2 Siemens-Aktiengesellschaft

Notes for the reader

This Guide is valid up to and including Software Version 6!

Anyone engaged in configuring, installation, commissioning

and repair of the control must be familiar

with the relevant documentation.

to which special attention is drawn.

Active and passive faults in automation equipment

Guidelines for the planning of the product

automation equipment, e.g. by means of multichannel configuration, it is

• Repairs to equipment supplied by us may only be carried out by

Description of Basic Signals FY 0 ... FY 24 3

NCK Channel/PLC Interface (DB 10 ... DB 13) as from SW 4 DB 15 4

Spindle/PLC Interface (DB 31) 5

Axis/PLC Interface (DB 32 / DB 29) 6

Data Transfer PLC/NC (DB 36 / DB 29) 7

Control of Data Transfer (DB 37) 8

Operator Panel Interface (DB 40) 9

Command Channel (DB 41) 10

Communication Area NC/PLC Interface (DB 48) 11

Display Programs for PLC Data and Messages

Display of PLC Alarms, Messages

PLC Machine Data (PLC MD) 14

Data Blocks Installed for Users (DB 66 ... DB 71) 15

Alphabetical List of Signal Names 16

Terms and Abbreviations 17

1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 Control structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

2 Assigned Areas ....................................... 2–1

2.1 Flags, data formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

3 Description of Basic Signals FY 0...FY 24 .................... 3–1

3.1 PLC auxiliary signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

4 NCK Channel/PLC Interface (DB 10 ... DB 13, as from SW 4 DB 15) 4–1

4.1 SINUMERIK 840C terms and structure ....................... 4–1

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

6 Axis/PLC Interface (DB 32/DB 29) .......................... 6–1

6.1 Signals from axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

7 Data Transfer PLC/NC (DB 36) ............................ 7–1

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

8 Control of Data Transfer (DB 37) .......................... 8–1

8.1 Description of interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

9 Operator Panel Interface (DB 40) .......................... 9–1

9.1 Key signals from operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2

10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

11 Communication Area NC/PLC Interface (DB 48) ............... 11–1

11.1 Signals to NCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

12 Display Programs for PLC Data and Messages

12.1 Structure of display programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1

13 Display of PLC Alarms, Messages and Dialogs as from SW 3 .... 13–1

13.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

14 PLC Machine Data (PLC-MD) ............................. 14–1

16 Alphabetical List of Signal Names ......................... 16–1

17 Terms and Abbreviations ................................ 17–1

• the division of SINUMERIK 840C into areas

1.1 Control structure

The SINUMERIK 840C comprises three principal areas:

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