En 828D Complete Commissioning v44 1

SINUMERIK 828D
Commissioning Documentation
Sinumerik 828D
Edition 2012.1
Training Manual
This document was produced for training purposes.

Siemens assumes no responsibility for its contents.
SINUMERIK 828D
Commissioning Manual for

Turning and Milling machines
Valid for:
Sinumerik 828D Software 4.4

Start
Machine Test
Contents
Protocol
B002
B060
Service & B061
System
Commissioning Menu Structure
Overview B021
Tools
Access Levels/
Time and Date
Settings
B041
Machine and
Setting Data
B007 B045 B044 B032
Electronic Network Licensing of RCS
Logbook Configuration Options Commander
B017
Data
Management
B010 B051 B053 B008

B030
PPU Line and Axis and Profinet
Digital Inputs
Connections & Motor Drive Connections
& Outputs
Diagnostics Modules Diagnostics & Diagnostics
B026
Creating a
PLC Program
B068 B031
B058 B019
Commission- PLC Alarms B033
PLC Onboard S7-200 PLC
ing and PLC Functions
Diagnostics Instructions
Sequence Messages
B084
Encoder
Adjustments
B101 B102 B020

B009 B011
Servo Tool Maintenance
Easy Extend Easy Screen
Optimization Management Planner
B018
Easy
Messenger
B006 B016
Appendix A B029
Electrical Additional
Hardware Analogue
Cabinet Axis
Differences Spindle
Design Installation
Appendix B
Technology
Settings
Appendix C
PLC Interface
End
SIEMENS TEST PROTOCOL
Machine Test Protocol Sinumerik 828D
Product / Version Machine type / Serial No. Company / Location
Sinumerik 828D SW4.4
Distribution list
Name Company / e-mail Name Company / e-mail
Department Department
Title Published by
Machine Test Protocol Sinumerik 828D Gary Jones
I DT MC MT P2
Document no. Date
xx.yy
File name:
Protocol version 1.0
RTM_Machine Test Protocol Sinumerik 828D SW4_4.doc
Copyright © Siemens AG 2008 All Rights Reserved.

Contents
1 RESPONSIBLE PERSONS: ................................................................................................................................................................................4
1.1 Schedule .....................................................................................................................................................................................................................................................................................4
1.2 Participants carrying-out the test............................................................................................................................................................................................................................................4
2 SUMMARY AND RESULT ...................................................................................................................................................................................5
2.1 Summary ...................................................................................................................................................................................................................................................................................5
2.2 Result .........................................................................................................................................................................................................................................................................................5
2.3 Release Siemens ........................................................................................................................................................................................................................................................................5
2.4 Release from Machine Tool Builder........................................................................................................................................................................................................................................5
3 BACK UP .............................................................................................................................................................................................................6
3.1 Modified data ............................................................................................................................................................................................................................................................................6
3.2 Data Backup..............................................................................................................................................................................................................................................................................6
4 CHANGE LOG .....................................................................................................................................................................................................7
4.1 Changes to the machine............................................................................................................................................................................................................................................................7
5 SYSTEM DESCRIPTION .....................................................................................................................................................................................8
5.1 Machine .....................................................................................................................................................................................................................................................................................8
Doc-Nr.:xx.yy Page 2/32 Date: 11.04.2012 Protocol version 1.0

5.2 Control.......................................................................................................................................................................................................................................................................................8
6 TEST OBJECTIVE ...............................................................................................................................................................................................9
6.1 Note ............................................................................................................................................................................................................................................................................................9
7 FUNCTIONS TESTED........................................................................................................................................................................................10
8 DETAILED TEST................................................................................................................................................................................................11
8.1 Machine area...........................................................................................................................................................................................................................................................................11

8.1.1 Jog Æ Ref .........................................................................................................................................................................................................................................................................11
8.1.2 Jog Æ MCP ......................................................................................................................................................................................................................................................................13
8.1.3 Jog Æ HMI Softkeys ........................................................................................................................................................................................................................................................17
8.1.4 MDA Æ Teachin ..............................................................................................................................................................................................................................................................19
8.1.5 MDA Æ HMI Softkeys ....................................................................................................................................................................................................................................................20
8.1.6 MDA Æ MDA Æ Teachin ...............................................................................................................................................................................................................................................22
8.1.7 AUTO ...............................................................................................................................................................................................................................................................................23
8.2 Parameter ................................................................................................................................................................................................................................................................................25

8.2.1 Easy extend.......................................................................................................................................................................................................................................................................25
8.2.2 Measure tool .....................................................................................................................................................................................................................................................................25
8.2.3 Setting data .......................................................................................................................................................................................................................................................................25
8.2.4 Magazine...........................................................................................................................................................................................................................................................................26
8.2.5 Tool List............................................................................................................................................................................................................................................................................27
8.3 Geometry .................................................................................................................................................................................................................................................................................28

8.3.1 Circularity test HMI..........................................................................................................................................................................................................................................................28
8.3.2 Renishaw circularity test...................................................................................................................................................................................................................................................28
8.4 Safety Integrated.....................................................................................................................................................................................................................................................................28

8.4.1 Safety related functions ....................................................................................................................................................................................................................................................28
8.5 Startup .....................................................................................................................................................................................................................................................................................29

8.5.1 Save data...........................................................................................................................................................................................................................................................................29
8.6 Password protection ...............................................................................................................................................................................................................................................................30


8.6.1 Securing data areas ...........................................................................................................................................................................................................................................................30
1 Responsible persons:
1.1 Schedule
Test carried out at (OEM Name):

From
To
1.2 Participants carrying-out the test
Name Company / Department

2 Summary and result

2.1 Summary
2.2 Result
Release of the machine recommended (YES/NO/Reason): ___________
2.3 Release Siemens

Machine can be released for Sale: Confirm with Signature
Siemens
Date Author Company / Department Signature
2.4 Release from Machine Tool Builder
Machine Manufacturer
Date Name Company / Department Signature

3 Back up
3.1 Modified data
Machine data number Original Value New Value
3.2 Data Backup
Create data backup after completing the test (NC/PLC Archive, display machine data) and attach it to the protocol.
Appendices:
- ____________ (NCPLC Archive)

- ____________ (Drive Archive)(Sinamics)
- ____________ (HMI Archive)
- ____________ (Clone TGZ file for series production)

4 Change Log
4.1 Changes to the machine.
Date Change Reason Teste Responsible person Signature

d

5 System description
5.1 Machine
Type
Serial No.
Configuration
Axes
Spindle
Measuring devices
Miscellaneous
5.2 Control
NC type Sinumerik 828D
Serial No.
Machine control panel
Software version:
User software
PLC Application

6 Test objective
6.1 Note
The test plan extends the commissioning documentation of 828D.
The application is tested with the current test plan, which helps to achieve for the most part an error-free interaction of SINUMERIK with the machine. No guarantee for fault-free machine application can be
guaranteed.
Siemens is not responsible for the PLC safety related functions which are implemented on the Machine. The Machine tool builder is responsible in satisfying the receiving countries “Safety regulations regarding
CNC machine tools” regulations.
Basic knowledge of operation and programming of 828D is necessary for carrying out the test. In case of some test tasks, it is necessary to start an automatic program or to trigger the machine functions. It is,
therefore, explicitly indicated that all operations that trigger machine functions should only be carried out by the employee of the machine manufacturer, who is authorized to do this.
The necessary programs are to be created directly at the machine.
The test plan is valid for the current Software version
ALL RELEVANT TESTS HAVE TO BE CARRIED OUT WITH THE FOLLOWING CONDITIONS:
1) Siemens Code(DIN) and ShopMill/ShopTurn with Æ Metric system of units

2) Siemens Code(DIN) and ShopMill/ShopTurn with Æ Inch System of Units
3) ISO / dialect with Æ Metric system of units
4) ISO / dialect with Æ Inch system of units

7 Functions tested
Confirm the functions as per the test plan
Test No. Function Result / Accepted/To Do

8.1 Machine
8.1.1 Jog Æ Ref
8.1.2 Jog Æ MCP
8.1.3 Jog Æ HMI Softkeys
8.1.4 MDA Æ Teachin
8.1.5 MDA Æ HMI Softkeys
8.1.6 MDA Æ MDA Æ Teachin
8.1.7 AUTO Æ DRF, Jog
8.2 Parameter
8.2.1 Easy extend
8.2.2 Tool measure
8.2.3 Setting data
8.2.4 Magazine
8.2.5 Tool List
8.3 Geometry
8.3.1 Circularity test HMI
8.3.2 Renishaw circularity test
8.4 Safety integrated

Test No. Function Result / Accepted/To Do

8.4.1 Safety related functions
8.5 Startup
8.5.1 Save data
8.6 Password protection
8.6.1 Securing data areas
8 Detailed Test
8.1 Machine area
8.1.1 Jog Æ Ref
Technology Test Description Teste OEM Alternative / or Teste Reason for OEM To Do´s
No d Comments / not d Alternative
relevant
T+M
1 Machine Start-up in Jog-REF
T+M Automatic referencing (Jog -
2 REF Cycle start)
T+M Reference not necessary

(Absolute measuring
3
system)(Startup in JOG)
T+M Prevention of Axis faults, when

starting in axis operation, the
Spindles with axis functionality
4
should be referenced during the
referencing procedure.

T+M Additional equipment requiring

reference point approach should
be referenced prior to the first
5
NC Start (Turret). “Alarm
prevention”
T+M Prior to referencing it should be

possible to change to JOG and
manually move the axis to a safe
position.
If the axis is resting on the
Hardware limit switch, it should
6 be possible to JOG the axis
away in the opposite direction.
The message "Axis lies on
Hardware end limit" should
remain even after powering the
machine off and on.
T+M Restarting the reference

procedure (interruption / E-Stop)
should be possible without
7
having to switch the machine off
and on.
T+M Repeating the referencing

procedure should be possible,
after reaching reference point -
8
repeating the process without a
fault message.
T+M The feedrate and Spindle enable

signals should not be active
immediately after power-on of
the machine. The operator must
9
enable these signals with the
respective key presses on the
MCP

8.1.2 Jog Æ MCP
Technolog Test Description Teste OEM Alternative / or Teste Reason for OEM To Do´s
y No d Comments / not d Alternative
relevant
T+M If the axis is resting on the
Hardware limit switch, it should
1 be possible to JOG the axis
away in the opposite direction.
T+M It should be possible in the

RESET state to change to JOG
2
mode
T+M When changing from REF to Jog

- Operator must select again the
3 required axis. There should be
no pre selected axis.
T+M Select axis - the axis should

travel in the defined direction
when the (+- Pushbutton) is
4 pressed. The axis should travel
with the feedrate defined in the
NC machine data.
T With Turning machines it should

also be possible to move more
axes at the same time. The
5
machine builder has to realize
this in the PLC.
M With Milling machines it is also

possible to Jog axes
simultaneously; however the
6
machine builder has to realize
this in the PLC.

T+M The machine builder should also

ensure that the rotary axis can
be jogged, including rotary axis
7
functionality with Spindles.
C+ button = spindle direction M4
C- button = spindle direction M3
T+M The feedrate override should be
effective on all axes which can
be Jogged. All axes should come
8
to standstill when the feed
override is set to zero.

relevant
T+M When the feed stop button is
pressed the Jog plus and minus
buttons should have no effect on
9
any axis motion. The axis should
all come to a stop.
T+M When the spindle stop button is

pressed the Jog plus and minus
buttons should have no effect on
10
the spindle motion. The spindles
should all come to a stop.
T When Spindle direction buttons

are available, the spindle should
move clockwise or anti-clockwise
11 dependent upon which button is
press. The default speed is
defined in the machine data.
T+M The Spindle override should

correct the currently controlled
12
spindle/s.
T+M Do all axis move according to

13 the work plane, defined in the
DIN standard.
T+M When direction keys are pressed
simultaneously, the axis in
motion should stop immediately.
Further motion can only be
14
achieved when both buttons are
once again released, and the
desired direction button pressed
again

T+M WCS >><< MCS

With key not pressed (MCS)
the axis should be moved using
the Machine axis interface, and
the axis will move on an
individual basis, without active
rotations.
15
With key pressed (WCS) the
axis should be moved using the
Channel axis interface, and the
axis will move on an individual
basis, with active rotations.

8.1.3 Jog Æ HMI Softkeys

relevant
T+M T,S,M Æ T-D
Select a tool from the tool list,
using SK TOOL and IN
MANUAL. Press cycle start tool
should be transferred into the
spindle or positioned before the
work piece.
1 The tool must not rotate if
already present in the spindle or
present before the work piece.
Repeat the process with other
tools from the magazine.
Prior to changing from a driven
tool, the rotating tool should be
stopped prior to changing.
T+M Spindle Æ
Set a spindle speed and activate
2 "Cycle Start" (together with
spindle M function) Repeat the
procedure with further spindles.
T+M Spindle gear changeÆ
3 Change gear, if a gear box is
available on the machine.
T+M Spindle direction Æ
Program M3 and M4 on all
spindles which are available on
4
the machine and ensure for the
programmed code that spindle
rotates in the correct direction.

relevant
T+M
5
T+M Measure Tool Æ

Manual Æ
Test with all types of possible
6 tools
Automatic Æ
Test with all types of possible
tools
T+M Position Æ
All axis must be available,
ensure that it is possible to move
7
the spindle (C-Axis function)
without first running in spindle
operation
T+M MCS / WCS Æ
8 Should change only the display
from MCS/WCS
T+M Hand wheel Æ
Test in both MCS and WCS
Syncron-actionsÆ.
show currently active
9
SYNACT
Settings Æ
Test and acknowledge
functionality of the Setting data’s

8.1.4 MDA Æ Teachin

relevant
T+M Teach-in Æ
It should be possible to Jog the
1
axis in MDA - Teach-in
OPTION
2

8.1.5 MDA Æ HMI Softkeys

relevant
T+M Program Control Æ
When the PRT checkbox is set
the axis should work internally,
and not physically move the axis.
The signal should work only in
1
Automatic mode - when
changing to Jog/MDA the signal
should not be active except
when an external switch is used.

DRY - When selected, the axis
should move with the feedrate
2 which is defined in Settings. This
should only be available in
Automatic.

M01 - When selected, the next
occurrence of M01 in the NC
3 program should cause the NC
program to stop and wait for the
next NC start.

When DRF is selected it should
be possible in the Automatic
mode of operation to move the
4 axis with the Hand wheel, the
position will be stored in the DRF
offset.
OPTION

relevant
SKP - When selected, the next
5 NC block with the Skip block
instruction will not be executed.
T+M G functions Æ
G - Functions for the reset state
of the machine - To be checked
6 for:
Turning
Milling
T+M Auxiliary functions Æ

Machine tool builder should
check that the functions which
7
he does not allow in MDA are
not processed.
T+M >> Extend SK Æ

All G functions
G - Functions for the reset
8 state of the machine - To be
checked for:
Turning
Milling
T+M > Extend menu Æ
Hand wheel Æ
Move axis using Hand wheel in
9 the machine axis interface or
using Geoax interface in
connection with Teach-in mode
OPTION

8.1.6 MDA Æ MDA Æ Teachin

relevant
T+M MDA Æ
Tool change in MDI window -
T01 + Cycle start for Turning
1 machines
T01 M06 + Cycle start for Milling
machines.
T+M MDA Æ
It should not be possible to Jog
2 the axis in MDA - exception :
Teach-in is active
T+M Teach-in Æ
Hand wheel Æ
Move axis using Hand wheel in
3 the machine axis interface or
using Geoax interface in
connection with Teach-in mode
OPTION
4

8.1.7 AUTO
relevant
T+M Move axis using Hand
wheel/Jog/Inc in the machine
1 axis interface to generate a DRF
offset
OPTION
T+M Jog in Automatic Æ
Jog Mode Mask is set to 0 as
standard, which means you are
not able to Jog the axis in
Automatic, with the exception of
Teach-in.
2 Jog Mode Mask is set to 1,
means you are able to Jog the
axis in Automatic. The machine
builder should explicitly set this
machine data when he requires
this functionality.
T+M AUTO Æ
3
Cycle start
T+M AUTO Æ
4
Cycle Stop
T+M AUTO Æ
5
Cycle single block
T+M AUTO Æ
6
Program reset
T+M AUTO Æ
7
Feed Stop in Program effect
T+M AUTO Æ
8
Spindle stop in Program - effect
T+M AUTO Æ
9
Feed override = 0

T+M AUTO Æ
10
Spindle override = 50
T+M AUTO Æ
11
Effect of E-Stop
T+M Program control Æ
12
PRT - Program Test
13
DRY - Dryrun feedrate
14
M01 - Program stop
DRF - Differential hand wheel
15
offset
OPTION
16
SKP - Block skip
T+M Block search Æ
M,S,T,H - Effect
17
Search to Tool

8.2 Parameter
8.2.1 Easy extend

relevant
T+M Test the commissioning of
1 machine builder options
T+M Test the activation / deactivation

2 of machine builder options
8.2.2 Measure tool

relevant
T+M Measure the length of the Tool
1
T+M Measure the Diameter / radius of

2 the tool
8.2.3 Setting data

relevant
T+M Spindle data - minimum spindle
speed should be set to a value
1
not equal to 0

8.2.4 Magazine
relevant
T+M Relocate a tool in the Magazine
1
T+M Position the Magazine

2
T+M Rename a tool

3
T+M Disable magazine locations -

4
T+M Test oversize tools

5
T+M Test tools with fixed locations

6
T+M Test interruption scenarios in tool

changer
Reset the channel
7
Emergency stop
Isolator switch
M Test Hand loaded Tools in

8
program

8.2.5 Tool List

relevant
T+M Enter a new tool directly in the
1 spindle

2 Magazine

3 Buffer
T+M Delete a tool directly in Spindle

4
T+M Delete a tool from the Magazine

5
T+M Delete a tool from the buffer

6
T+M Unload the tool in the spindle

7
T+M Machine with sub-spindle should

be possible to create 2 tools for
8 1 turret position (different tool
types !!!)
T+M It must be possible to

program/call a tool with tool
9 name (e.g. T="name") and also
turret position T1
T+M
10 Relocate a tool in the Spindle
T+M
11 Tool Change in Inch and Metric

8.3 Geometry
8.3.1 Circularity test HMI

relevant
T+M
1 Geometry axis
T+M
2 Thread boring
8.3.2 Renishaw circularity test

relevant
T+M
1 Machine axis
T+M
2 Geometry axis
8.4 Safety Integrated
8.4.1 Safety related functions

relevant
T+M
1 Function STO
T+M
2 Function SS1
T+M
3 Function SBR

8.5 Startup
8.5.1 Save data

relevant
Save Data
1
L6 Optimised, Spindle Tool =

2
Pre-selected Tool

8.6 Password protection
8.6.1 Securing data areas

relevant
T+M Key switch Æ
Tools
1
Tool wear length and radius
Tool length and radius
T+M Key switch Æ
2
Create a tool
T+M Key switch Æ
3
Delete a tool
T+M Programming Æ
4
Open program
T+M Programming Æ
5
Edit program
T+M Programming Æ
6
Select program (NC)
T+M Offsets Æ
fine
7
coarse
T+M Password Æ
Delete SUNRISE after power on
8
All other power on retained
10
11

Not categorized
Technology Test Description Teste OEM Alternative / or Teste Reason for OEM Alternative To Do´s
No d Comments / not d
relevant
T+M
1 Electrical Cabinet Protocol
T+M EUNA data input in

2
Prototype
T+M
3 EUNA data Upload Test
T+M Clone backup available for

4
Series machines.
T+M PLC written according to
5
PLC Design document
T+M Country specific safety
regulations included in
6
PLC program + door
interlocks etc.
T+M NCK, HMI, PLC and Drive
7
archives tested.
T+M TGZ file for series
8
production tested
10
11
12


B060 System Overview
Module Description:
The Sinumerik 828D system is made up of a variety of hardware components.

This module gives a graphical overview of those components and shows where each component is
connected.
A brief description of the hardware components is given.
Module Objective:
Upon completion of this module you will know the Sinumerik 828D system and the components
which make up the system.
Content:
Sinumerik
System Overview
828D & PPU Information
Machine Control Panels
Drive Components
NX10 Module
Drive-CLiQ Hub & Sensor Modules
PLC Periphery Modules
Hand-held Units
SINUMERIK 828D V4.4 Page 1 This document was produced for training purposes.
B060
B060
B060 Page 2 SINUMERIK 828D

System Overview B060
System Overview: Description

System Overview:
START
The Sinumerik 828D system is made up of a variety of hard-
ware components. This module gives a graphical overview of
those components and shows where each component is con-
nected.
A brief description of the hardware components is given. System
Overview
828D & PPU

Information
Machine
Control
Panels
Drive
Components
NX10 Module
Drive-CLiQ
Hub & Sensor
Modules
PLC
Periphery
Modules
Hand-held
Units
System Overview:
END
Notes :
SINUMERIK 828D Page 3 B060

System Overview 828D S120 Book size
PP72/48 PN PLC I/O

PN/PN MCP483 PN OR MCP310 PN
Coupler
To
other
828D
GSM/GPRS
Modem
PN1 & PN2
Profinet
Interfaces
+24V DC Supply Mini
X1 PN2 PN1 RS232 HHU
Interface
Compact Flash Front-
X140 Connection
ports
}
X145 Sinumerik X122 Sinamics kit
USB 2.0 828D & PPU X132 Digital I/O
X125
X127
X127-Service
(Linux OS) X242
X252 } NCK Digital I/O and
Spindle analogue out
X143
Ethernet X100 X101 X102 X130 Hand-wheels
X130-Factory Ethernet
DMC20
X100 to X102 DriveCLiQ Interface DriveCLiQ
Hub
Teleservice
Modem
Filter NX10 S120

Sinamics S120
Booksize
DMS
Scales/encoders
via SMx & DMC
modules
Reactor
Notes :

System Overview 828D Combi
PP72/48 PN PLC I/O
PN/PN MCP483 PN OR MCP310 PN
Coupler
To
other
828D
GSM/
GPRS
PN1 & PN2 Modem
Profinet
Interfaces
+24V DC Supply
Mini
RS232
X1 PN2 PN1 HHU
Interface
Compact Flash Front-
X140 Connection
ports
USB 2.0
X145
X125
Sinumerik
828D & PPU
X122
X132 } Sinamics
Digital I/O
kit
X127
(Linux OS) X242
X252 } NCK Digital I/O and
Spindle analogue out
X127-Service X143
Ethernet X100 X101 X102 X130 Hand-wheels
X130-Factory Ethernet
X100 to X102 DriveCLiQ Interfaces
DMC20
DriveCLiQ
Teleservice Hub
Modem
Sinamics
Filter Combi Two additional
DMS-TTL 5V Module axes-S120
Direct to Combi (3/4 axes) single/double
compact
modules
DMS
Scales/encoders
via SMx & DMC
Max 5 circuits
Reactor
Notes :

828D controller with integrated PPU (Panel Processing General Information

Unit) The PPU model number gives information about the control-
ler:-
PPU2xx.1
PPU260/280 0 - Vertical
Vertical variant 1 - Horizontal
10.4” TFT Colour
Screen. 4 -Basic
6 - Standard
8 - Performance
PPU Horizontal layout:
6FC5370-3AT20-0AA0
PPU241.2 Turning version without system software
6FC5370-3AM20-0AA0
PPU241.2 Milling version without system software
PPU261/281 6FC5370-5AA20-0AA0
Horizontal PPU261.2 Standard version without system software
variant
10.4” TFT 6FC5370-7AA20-0AA0
Colour PPU281.2 Performance version without system software
Screen.
PPU Vertical layout:
6FC5370-4AT20-0AA0
PPU240.2 Turning version without system software
PPU240
Horizontal 6FC5370-4AM20-0AA0
variant PPU240.2 Milling version without system software
8.4” TFT
Colour 6FC5370-6AA20-0AA0
Screen. PPU260.2 Standard version without system software
6FC5370-8AA20-0AA0
PPU280.2 Performance version without system software
PPU241 Software- (Current system software delivered on CF

Vertical variant card):
8.4” TFT Colour
Screen. Milling
6FC5832-2GY00-0YA0 Basic for PPU240/PPU251

6FC5831-2GY00-0YA0 Standard for PPU260/PPU261
6FC5830-2GY00-0YA0 Performance for PPU280/PPU281
Turning
6FC5832-1GY00-0YA0 Basic for PPU PPU240/PPU241

6FC5831-1GY00-0YA0 Standard for PPU260/PPU261
6FC5830-1GY00-0YA0 Performance for PPU280/PPU281
Blank Compact Flash Card 1GB:
6FC5313-5AG00-0AA0
Notes :

Specifications PPU interfaces and status LEDs (Rear):
Input voltage- 24V DC +20% /-15% X1-24V DC supply

Power Consumption 60W
Protection –Front operator panel IP65 X100 to X102 -Drive Cliq interface
Rear of PPU IP20
X130-Ethernet factory network-Configurable to receive an IP
Operational temperature 0-45 °C address automatically or a manually assigned fixed address
Operational Relative humidity 5 to 90 % @ 25°C (No can be used.
condensation) Do not use addresses in the following ranges:
192.168.214.xxx and 192.168.215.xxx. These are reserved
Horizontal model Vertical model for the system.
Width 310mm (12.2 in) 483mm (19 in)
Height 380mm (15 in) 220mm (8.66 in) X135-USB interface
Depth 105mm (4.13 in) 105mm (4.13 in)
X140-RS232 interface
General information X122 & X132-Digital I/O for Sinamics
The controller is available in vertical or horizontal formats. X242 & X252-Digital I/O for NCK
The functionality of the two variants is identical.
The PPU includes “Qwerty” and numerical keyboard inputs X143-Hand-wheels x 2
and shortcut keys to specific machine areas.
The 828D encompasses the HMI, NC, PLC and CU logical PN1 & PN2 - Profinet interfaces. (Only PN1 available for
components. PPU240/PPU241)
PPU interfaces and status LEDs (Front): LED Indicators:

X125 USB interface
X127 Ethernet service port-DHCP server (IP address Name Colour Description
192.168.215.1) Issues addresses up to 192.168.215.31. FAULT Red Fault present
X145 Compact Flash (CF) interface SYNC Green Synchronisation OK
LED indicators: Rx/Tx Yellow Network activity (1 each for PN1,

PN2 & X130 interfaces)
Name Colour Description Link Green Network connected (1 each for

PN1, PN2 & X130 interfaces)
RDY Green System ready
NC Orange NC ready (Flashes at approximately
1Hz)
CF Yellow CF card activity
Notes :

The following tables highlight the technical specifications of the 828D controller.
Key:-
 In preparation
 Delivered as standard
 Option
- Not available
PPU240/241 PPU260/261 PPU280/281
Turning Milling Turning Milling Turning Milling
System Performance
Number of axes with standard configuration 3 4 3 4 3 4
Maximum number axes/spindles/positioning axes 5 5 6 6 8 6
Each additional axis/spindle      
Each additional positioning axis      
Maximum number of interpolating axes 4 4 4 4 4 4
Maximum number of machining channels 1 1 1 1 1 1
Minimum block cycle time 9ms 3ms 6ms 2ms 6ms 1ms
CNC user memory (buffered) 1MB 1MB 3MB 3MB 5MB 5MB
CNC Functions
Tool management with tool life monitoring and workpiece
     
count
Replacement tools      
Maximum number of tools/cutting edges 80/160 80/160 128/256 128/256 256/512 256/512
Number of settable zero offsets 50 50 100 100 100 100
Safety Integrated (Safe Torque Off, Safe Brake Control)      
Asynchronous subroutines (ASUP)      
Synchronised actions and high speed auxiliary function out-
     
put
Acceleration with jerk limitation      
Look Ahead (Number of blocks) 1 50 1 100 1 150
Compressor for 3-axis machining -  -  - 
Advanced surface -  -  - 
A, B, C spline interpolation      
TRANSMIT and peripheral surface transformation      
Travel to fixed stop      
Travel to fixed stop with Force Control      
Inclined axis for no orthogonal Y axis - - - -  -
Synchronous spindle function for sub-spindle
- - - -  -
(CP Static)
Synchronous spindle function for sub-spindle
 -  -  -
(CP Basic)
Pair of synchronised gantry axes -  -  - 
Temperature compensation      
Bidirectional lead-screw error compensation      
Multi-dimensional sag compensation - -    
Master/slave for drives - -  -  -
Analysis of internal drive values - -  -  -
Notes :

PPU240.1/241.1 PPU260/261 PPU280/281

Turning Milling Turning Milling Turning Milling
CNC Programming and Operation
Programming language (DIN66025 and high level
     
language expansion)
Online ISO dialect interpreter      
Technology cycles for drilling and milling      
Technology cycles for turning  -  -  -
Residual material detection and machining      
Programming support for technology cycles (Program
     
GUIDE)
ShopMill/ShopTurn machining step programming      
Measuring cycles      
Simulation in plane display      
Simulation in 3-D display      
Simultaneous recording (Real-time simulation of current
     
machining operation)
Extended operator functions for complex turning and
     
milling tasks.
Contour hand-wheel      
Network drive management      
Remote diagnosis function RCS host      
PLC Functions
Integrated PLC based on SIMATIC S7-200      
PLC periphery modules PP72/48D, PP72/48D 2/2A PN      
Ladder viewer and on board add-on editor      
PLC cycle 9ms 9ms 6ms 6ms 6ms 6ms
Maximum number of PLC ladder steps 12,000 12,000 24,000 24,000 24,000 24,000
Servo synchronous High Speed PLC Task      
Reaction time to process events (Terminal to terminal) <9ms <9ms <6ms <6ms <3ms <3ms
Maximum number of digital inputs/outputs 216/144 216/144 288/192 288/192 360/240 360/240
Maximum number of analogue inputs/outputs 6/6 6/6 8/8 8/8 10/10 10/10
PN/PN coupler      
Commissioning and Service Functions
Easy Screen-easy creation of user screens (OA Run-
     
time licence for over 5 user screens)
Service Planner for maintenance tasks      
Easy Extend management of machine components      
Easy Archive data archiving      
Notes :

Machine Control Panels Interfaces:-

X10 24V DC supply
Machine Control Panel MCP310C PN X20 Ethernet port 1
X21 Ethernet port 1
The MCP310 is recommended for use with the vertical style X30 Feed override switch input
PPU. X31 Spindle override switch input
X51 User input connections
X53 User output connections
H1 LED POWER OK
H2 LED BUSSYNC
H3 LED BUSFAULT
S2 IP address selection switch
Machine Control Panel MCP483C PN
The MCP483 is recommended for use with the horizontal

style PPU.
Hardware information
Part Number:-
6FC5303-0AF23-0AA1
Features:-
 49 mechanical keys with LED
Indicators (16 user assignable)
 Feed override control(16 positions)
 Key switch
 Emergency stop/Spindle override optional
Hardware information
 6 x Pre-drilled holes for hard wired user buttons
 Connections for 9 user Inputs & 6 outputs Part Number:-
 Connection via Profinet 6FC5303-0AF22-0AA1
Features:-
 50 mechanical keys with LED indicators (17 user
Consumable items: assignable)
 Spindle & feed override control.
6FC5247-0AF13-1AA0-Feed override rotary switch incl. cap,
 Key switch
button, pointer & dials
 Emergency stop button
6FC5247-0AF12-1AA0-Spindle  2 x Pre-drilled holes for hard wired user buttons
override rotary switch incl. cap, button, pointer & dials  Connection via Ethernet
 2 x Hand-wheel connections
 Connections for 9 user Inputs & 6 outputs
 Connection via Profinet
Consumable items:
6FC5247-0AF13-1AA0-Feed override, rotary switch incl. cap,

button, pointer & dials
6FC5247-0AF12-1AA0-Spindle override rotary switch incl.

cap, button, pointer & dials
Notes :

General information
Interfaces:-
X10 24V DC supply
Line modules are responsible for generating the DC link sup-
X20 Ethernet port 1
ply for the drive system.
X21 Ethernet port 2
They require 3-phase AC for the DC link and +24V DC for the
X30 Feed override switch input
electronic supply.
X31 Spindle override switch input
The DC link and 24V DC voltages are distributed to other
drive modules in the system via a bus bar system.
The modules are available in several variants of size and
functionality.
Smart Line Modules (SLM)
These modules are capable of mains regeneration but the
DC link is not stabilised.
SLM modules of 5 & 10 Kw do not connect to the DriveCliq
LED Indicators:-
network.
H1 LED POWER OK LED
Modules of 16 Kw and above do connect to the DriveCliq.
H2 LED BUSSYNC (Bus ok & synchronised)
H3 LED BUSFAULT (Bus fault)
Active Line Modules (ALM)
S1 Hand-wheel type selection switch
These modules are capable of mains regeneration and the
S2 IP address selection switch
DC link is stabilised.
All ALM modules are connected to the DriveCliq network.
Drive Components
Line Modules
Interfaces:-
SLM (5 & 10Kw variant)
X21-Enable, ready and fault signals
X22-Regeneration inhibit and fault reset signals
X24-24V DC electronics supply
U1, V1, W1-3-Phase supply
X200, X201, X202-DriveCliq connections
SLM (16Kw and above) & ALM (all variants)

X21-Enable & temperature sensor input
X24-24V DC electronics supply
U1, V1, W1-3-Phase supply
Smart Line Module Active Line Module
Notes :

Line Modules-continued The motor modules convert the DC link voltage into a vari-
able AC voltage which is then output to the servo
Motors.
Part Numbers-SLM
Motor Modules are supplied with 24V DC via the ALM/SLM
6SL3130-6AE15-0AB0 5Kw Internal cooling
All motor modules are connected to the DriveCliq network.
6SL3130-6AE21-0AB0 10Kw “ “
They are available in one or two axis variants and can be
6SL3130-6TE21-6AA3 16Kw “ “
internally or externally cooled.
6SL3130-6TE23-6AA3 36Kw “ “
6SL3131-6AE15-0AA0 5Kw External cooling
6SL3131-6AE21-0AA0 10Kw “ “
Interfaces:-
Part Numbers-ALM
Single MM
6SL3130-7TE21-6AA3 16Kw Internal cooling
X1-Output to Motor.
6SL3130-7TE23-6AA3 36Kw “ “
X21-Enable & temperature sensor input
6SL3130-7TE25-5AA3 55Kw “ “
6SL3130-7TE28-0AA3 80Kw “ “
6SL3130-7TE31-2AA3 120Kw “ “
Double MM
6SL3131-7TE21-6AA3 16Kw External cooling
X1 & X2-Output to Motors
6SL3131-7TE23-6AA3 36Kw “ “
X21-Enable & temperature sensor input (Motor 1)
6SL3131-7TE25-5AA3 55Kw “ “
6SL3131-7TE28-0AA3 80Kw “ “
X200, X201, X202, X203-DriveCliq connections
6SL3131-7TE31-2AA3 120Kw “ “
Motor Modules (MM)
Part Numbers-single modules

6SL3120-1TE13-0AA3 1.6Kw Internal cooling
6SL3120-1TE15-0AA3 2.7Kw “ “
6SL3120-1TE21-0AA3 4.8Kw “ “
6SL3120-1TE21-8AA3 9.7Kw “ “
6SL3120-1TE23-0AA3 16Kw “ “
6SL3120-1TE24-5AA3 24Kw “ “
6SL3120-1TE26-0AA3 32Kw “ “
6SL3120-1TE28-5AA3 46Kw “ “
6SL3120-1TE31-3AA3 71Kw “ “
6SL3120-1TE32-0AA3 107Kw “ “
6SL3121-1TE13-0AA3 1.6Kw External cooling
6SL3121-1TE15-0AA3 2.7Kw “ “
6SL3121-1TE21-0AA3 4.8Kw “ “
6SL3121-1TE21-8AA3 9.7Kw “ “
6SL3121-1TE23-0AA3 16Kw “ “
6SL3121-1TE24-5AA3 24Kw “ “
6SL3121-1TE26-0AA3 32Kw “ “
6SL3121-1TE28-5AA3 46Kw “ “
6SL3121-1TE31-3AA3 71Kw “ “
6SL3121-1TE32-0AA3 107Kw “ “
Part Numbers-double modules

6SL3120-2TE13-0AA3 2 x 1.6Kw Internal cooling.
6SL3120-2TE15-0AA3 2 x 2.7Kw “ “
6SL3120-2TE21-0AA3 2 x 4.8Kw “ “
6SL3120-2TE21-8AA3 2 x 9.7Kw “ “
Single MM Double MM 6SL3121-2TE13-0AA3 2 x 1.6Kw External cooling
6SL3121-2TE15-0AA3 2 x 2.7Kw “ “
6SL3121-2TE21-0AA3 2 x 4.8Kw “ “
6SL3121-2TE21-8AA3 2 x 9.7Kw “ “
Notes :

Motor Modules (MM) S120 Book-sized Compact Combi Drive (Combined Line and Motor Modules)
The S120 book sized motor modules are use to expand the The Combi drive unit consists of a Line Module and either 3 or
number of drives the Sinamics Combi drive system to the 4 Motor Modules, the first of which is dedicated to the Spindle.
maximum of 6. The modules are only available with internal They must always be connected to the DriveCLiQ network via
cooling. controller interface X100.
The number of axes can be increased by adding Sinamics
Interfaces:- S120 Booksized Compact Motor Modules up to the maximum
Single MM allowed by the system.
X1-Output to Motor.
X21-Enable & temperature sensor input .
X200, X201, X202-DriveCliq connections.
Double MM
X1 & X2-Output to Motors.
X200, X201, X202, X203-DriveCliq connections.
Part Numbers and Power ratings
Smart Spindle Axis 1 Axis 2 Axis 2

Part Numbers:- Line Motor Motor Motor Motor
Part Number
Module Module Module Module Module
Single Modules 1 2 3 4
6SL3420-1TE13-0AA0 3/9 Amps 3 Axes
6SL3420-1TE15-0AA0 5/15 Amps
6SL3420-1TE21-0AA0 9/27 Amps 16 Kw 18 A 5A 5A - 6SL3111-3VE21-6FA0
6SL3420-1TE21-8AA0 18/54 Amps
16 Kw 24 A 9A 9A - 6SL3111-3VE21-6EA0
Double Modules
20 Kw 30 A 9A 9A - 6SL3111-3VE22-0HA0
6SL3420-2TE11-0AA0 2 x 1.7/5.1 Amps
6SL3420-2TE13-0AA0 2 x 3/9 Amps 4 Axes
6SL3420-2TE15-0AA0 2 x 5/15 Amps
16 Kw 18 A 9A 5A 5A 6SL3111-4VE21-6FA0
16 Kw 24 A 9A 9A 9A 6SL3111-4VE21-6EA0
20 Kw 30 A 12 A 9A 9A 6SL3111-4VE22-0HA0
Notes :

Braking Modules & Resistors Part Numbers-

6SL3100-1AE31-0AB0 Braking Module 1.5Kw rated power
6SN1113-1AA00-0DA0 Braking Resistor 0.3Kw rated power
If the regenerative capability of the line module is inadequate it
6SL3100-1BE31-0AA0 Braking Resistor 1.5Kw rated power
can be supplemented by the inclusion of a braking module.
These modules fit neatly into the drive system.
Further braking capacity can be added in the form of braking
resistors which connect to the braking module. Braking resis-
tors require good ventilation and ideally need to be mounted
externally. Control Supply Modules
Braking modules and resistors can also facilitate the controlled

The Control Supply Module is a 24V/20A DC Power Supply
shut down of the drives in the event of a power failure.
Unit.
It is used to maintain the 24V DC in the event of a power
Another feature is the fast discharge of the DC link. This fea-
failure.
ture is used to quickly discharge the capacitors so that mainte-
nance tasks can be carried without having to await natural
The initial power to the module is taken from the line supply,
discharge times. Fast discharging should only be carried out 1
when a power failure occurs power is taken from the residual
to 2 times per week to avoid damaging the capacitors.
voltage of the DC link.
The braking module is connected to the DC link and 24V DC
Part Number:-6SL3100-1DE22-0AA0
bus systems.
Connector X21 on the braking module is used for enable/fault/

ready signals.
Connector X1 is for connecting the external resistor.
Braking resistor
Control Supply
Module
Braking Module
Notes :

NX10 Module Drive-CLiQ Hub & Sensor Modules
NX10 Module (Numerical Control Extension) DMC20 Drive-CLiQ Hub
General information
General information
The requirement for additional Drive-CLiQ ports is catered for
Since the integrated control unit (CU) can control only 6
by the DMC20.
axes, an NX10 module is required to achieve the maximum
There are 6 Drive-CLiQ ports, 5 of these are available for
number of 8 axes allowed by the system.
additional devices such as direct measuring systems.
The modules are of the same design as the Sinamics S120
The remaining port is used for connecting to the PPU/Drive-
drives and fit neatly into the drive rack.
CLiQ network.
All modules have to be connected to the DriveCliQ
network.
Part Number:-
6SL3055-0AA00-6AA0
The drive enable connections are not required to be physi-
cally connected, these signals are mirrored with the CU Interfaces:-
connections:-  X500 - Drive-CLiQ, Connects to PPU/Drive-CLiQ network
X122.1 = OFF1
X122.2 = OFF3
 X501 to X505 - Drive-CLiQ, additional devices
 X524 - 24V DC supply
Part Number:-  RDY - LED indicator
6SL3040-0NC00-0AA0
Interfaces:-
 X100 to X103 DriveCliQ
 X122 4 x digital inputs & outputs
 X124 24V DC supply
NX10
Notes :

Sensor Modules (SMC & SME) Sensor Modules (SMC & SME)-continued
SMC30
General information
Sensor modules are required to convert non-DriveCliq encoder

signals into DriveCliq signals.
They are available for cabinet mounting (SMC) and external
mounting (SME)
Several variants of each are available:-
SMC30
For the evaluation of the following measuring systems:-
Incremental with TTL/HTL signals
SSI with incremental TTL/HTL signals
SSI without incremental signals
SMC10/SMC20 (Temperature evaluation-KTY84-130 can also be used)
SMC10 Interfaces:-
For the evaluation of 2-pole resolvers & Multi-pole resolvers,
including motor temperature evaluation (KTY84-130)  X500 DriveCliq
 X520 TTL measuring system input (25 pin D-type con-
Interfaces:- nector)
 X500 DriveCliq  X521 HTL/TTL measuring system input (Screw type
 X520 Measuring system input (25 pin D-type connector) connector)
 X524 24V DC supply  X531 “ measuring system input (Screw type
connector)
 Status LED’s
 Status LED’s
Part Number:-  X524 24V DC supply
6SL3055-0AA00-5AA0 Note-The extra measuring system interfaces offer more flexibil-
ity for connecting the encoder, The device however can only
SMC20 handle a single encoder.
Incremental sin/cos 1v pp Part Number:-
Absolute EnDat encoders 6SL3055-0AA00-5CA1
SSI with incremental signals Sin/Cos 1V pp
(Temperature evaluation-KTY84-130 can also be used)
Interfaces:-
 X500 DriveCliq
 X520 Measuring system input (25 pin D-type connector)
 X524 24V DC supply
 Status LED’s
Part Number:-
6SL3055-0AA00-5BA1
Notes :

Sensor Modules (SMC & SME)-continued PLC Periphery Modules
SME20/SME25 PP72/48D PN Modules (Combined I/O module)

Incremental sin/cos 1v pp with C and D tracks 5V supply-
S1
SME20
Absolute EnDat encoders 5V supply-SME25
Absolute SSI with incremental signals 5V supply Sin/Cos 1V
pp-SME25 X111
Interfaces:-
 DriveCliq-also supplies 24V DC
 Measuring system input
Part Number:-
6SL3055-0AA00-5EA0-SME20 X222
6SL3055-0AA00-5HA0-SME25
X2 X2
Port Port X333
2 1
X1
SME20/SME25
PP72/48D PN modules are a compact component which
connect to the Profinet network (Ports PN1 or PN2 of the
SME120/SME125 NCU). A 24V DC supply is required.
Incremental sin/cos 1v pp with C and D tracks 5V supply- There are two variants, one of which is all digital while the
SME120 second offers both digital and analogue functionality (only for
Absolute EnDat encoders 5V supply-SME125 PLC).
(Temperature evaluation-KTY84-130 can also be used)
24 digital inputs and 16 digital outputs are available on each
Interfaces:- of the 3 ribbon connectors giving a total of 72 inputs and 48
 DriveCliq-Also supplies 24V DC outputs for each module.
 Measuring system input
 Hall effect sensor input A maximum of 3 PP72/48 modules with the PPU240/PPU241
controllers.
 Temperature sensor input A maximum of 4 PP72/48 modules with the PPU260/PPU261
controllers.
Part Number:- A maximum of 5 PP72/48 modules with the PPU280/PPU281
6SL3055-0AA00-5JA0-SME120 controllers.
6SL3055-0AA00-5KA0-SME125
Part numbers:-
6FC5311-0AA00-0AA0 Digital only (PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue (PP72/48 2/2A PN)
Interfaces:-
S1-Adressing switch-Default setting of 9
X1-24V DC Supply
X2-Profinet network ports 1 & 2
SME120/SME125
X111 digital inputs/outputs-ribbon connector
X222 digital inputs/outputs-ribbon connector (first byte has
fast gating hardware)
X333 digital inputs/outputs- ribbon connector
Notes :

PN/PN Coupler Hand-held Units
Hand Held Unit (HHU)
Hand held units allow the operator to manually control the

machine remotely from the main operator panel.
HHU with coiled cable, connector and mounting device:-
PN/PN Coupler
The PN/PN coupler is used to link two Profinet networks so

that data can be exchanged between them.
The HHU offers manual axis movement via hand wheel or jog
The coupler requires a +24V DC supply. buttons.
A rotary switch is used to select the required axis, it is only
One coupler is allowed per controller. possible to select one axis at a time from the maximum of five
axes.
Part number:- Safety is provided via a 2 channel emergency stop button and
-6ES7158-3AD00-0AX0 a 3 position “Dead mans” enable button.
The casing has magnets which are useful to attach the unit to
Interfaces:- any suitable metallic surface, alternatively a holder can be
X1 Port 1 & 2 Profinet 1 Network purchased for this purpose.
X2 Port 1 & 2 Profinet 2 Network A terminating connector is available to facilitate the (Cold)
PS1 & PS2 +24V DC supply removal of the HHU without affecting the machine operation.
In addition to the +/- & Rapid jog buttons there are three user
LED’s assignable buttons.
SF1 Group fault for Profinet 1 network (Red)
SF2 Group fault for Profinet 2 network (Red) The signals from the HHU are split into three categories.
BF1 Bus fault for Profinet 1 network (Red) 1. The emergency and enabling buttons should be used
BF2 Bus fault for Profinet 2 network (Red) in the safety/enabling circuit of the machine.
MT1 Maintenance display Profinet 1 network (Yellow) 2. The jog and axis selection should be done via the user
MT2 Maintenance display Profinet 2 network (Yellow) PLC program
ON Power supply +24V DC (Green) 3. The hand-wheel signals need to be taken to X143 of
LINK Connection on (Green) One per Profinet connection the PPU
RX/TX Data Exchange (Yellow) One per Profinet connection
A connection kit that must be ordered separately is required
for connection of the mini HHU.
Notes :

Part numbers:-
6FX2007-1AD03 Mini HHU with coiled cable, 1.5m (4.92 ft)

stretches to 3.5m (11.5 ft).
6FX2007-1AD13 Mini HHU with straight cable, 5m (16.4 ft).
6FX2006-1BG03 Non assembled connection kit with termi-

nator.
6FX2006-1BG13 Non assembled connection kit without

terminator.
6FX2006-1BG20 Pre assembled connection kit with termi-

nator.
6FX2006-1BG25 Pre assembled connection kit without ter-

minator.
6FX2006-1BG70 Holding cradle
Notes :

Connection method
A separately ordered connection kit is used with the Mini HHU which allows the three sets of
signals to be separated according to their functionality.
Flange Socket
Flange socket
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 PPU X143 Hand-wheel connections
Emergency Stop and safety circuits
X51 X52 X55
1 2 3 4 1 2 3 4 1 2 3 4
MCP X51, X52, X55 DU box connectors for axis selection

and jog signals
Standard addresses for X51, X52 & X55

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Axis selection switch
F2 button F1 button Rapid Jog minus Jog plus (Binary)
IB122
X55.2 X55.1 X52.3 X52.2 X52.1
X51.3 X51.2 X51.1
F3 button
IB123
X55.3
Notes :

Hand-held Units
B060
Mini Hand Held Unit Colour Codes
Emergency Stop Enabling Button Axis Selection Function/jog/rapid Keys Hand-wheel bk - Black
br - Brown
rd - Red
ye - Yellow
gn - Green
bu - Blue
System Overview
vt - Violet
gy - Grey
wh - White
pk - Pink
wh bn gn ye gy pk bu rd bl vt ye/ gy/ rd/ wh/ bn/ wh/ wh/ gy/ wh/ pk/ wh/ bn/ wh/
bn pk bu gn gn ye gy bn pk bn bu bu rd
1 2 3 4 5 6 7 8 9 10 16 11 12 13 14 15 17 24 18 19 20 21 22 23 HHU plug/flange socket
Page 21
Connection kit
wh br gn ye gy pk bu wh br vt rd bu pk gy ye gn bk br wh bu pk ye gn
1 2 3 4 5 6 7 1 2 3 4 1 2 3 1 2 3 2 1 6 5 4 3
X51 X52 X55 X143
Connector block MCP310/483PN PPU

B060: END
Notes :
B060
SINUMERIK 828D
B060 END System Overview

B002 Service and Commissioning Tools
Module Description:
In order to integrate the Sinumerik 828D CNC to a machine tool, software tools are required. The
tools enable the machine tool builder to create the PLC program for the machine and also assist in
the drive configuration.
These tools, including service tools are supplied on a DVD, the DVD is called the Toolbox DVD
and is included in the scope of delivery.
Software included in the toolbox:
 PLC828 Programming Tool (PLC user program)

 Start-up Tool (configuration of drives)
 Configuration Data (rescue card image, examples e.g. for Easy Extend)
RCS Commander is not included in the toolbox but is required for certain commissioning/service
procedures.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
 Install the software tools from the toolbox DVD.

 Install the RCS Commander software tool.
 Connect to the controller with each of the software packages.
Content:
Sinumerik
Toolbox Installation.
RCS Commander Installation.
Network Settings.
Online Connection-RCS Commander.
Online Connection-PLC828 Programming Tool.
Online Connection-Start-up Tool.
B002
B002

Service and Commissioning B002
Service and Commissioning Tools: Description Service and

Commissioning
Tools:
START
Toolbox Installation:
Each controller is delivered with a DVD which contains the

software tools required for service and commissioning work.
Toolbox
The tools are automatically installed by running a the
Installation
“setup.exe” file found on the root of the DVD
The following software will be installed:
PLC828 Programming Tool - Creating, editing and diagnos- RCS

ing the PLC user program. Commander
Installation
Start-up Tool - Configuration of drives during the commis-
sioning stage.
Configuration Data - A rescue card image, which used in the

event of a system card failure, is installed in the following Network
path: C:\Program Files\Siemens\Toolbox 828D\V04040100. Settings
(V04040100 represents the version of toolbox)
The DVD also contains example files of PLC user projects,

Easy Extend and Tool Management.
Online
Connection:
RCS Commander:
RCS
Commander
The RCS Commander software tool is not delivered as part of
the toolbox and has to be obtained separately. Installation is
achieved by running a “Setup.exe” file.
Online
The software is used for service, commissioning and remote Connection:
access. These functions are explained in detail in other PLC Programming
Modules Tool
Network Connection:
Online
The software tools communicate to the controller via Connection:
Ethernet. Start-up
The external PC needs to be set to allow communication to Tool
take place.
When the Toolbox installation is complete a connection to the
controller will be made with the PLC828 Programming Tool, Service and
Start-up Tool and RCS Commander Commissioning
Tools:
END
Notes :

B002 Service and Commissioning
Toolbox Installation Software licence agreement:-
Toolbox content:
- Configuration Data:- image for replacement card.
- Programming Tool PLC828:- For Creating/Loading/Editing
the PLC user program.
- Start-up Tool:- For the configuring of the drives.
Installation Process
Installation is started with “setup.exe” on the Toolbox DVD.
Double click the “Setup.exe” Software to be installed is dependant upon the required task.
file to start the toolbox installa-
tion.
Note:-
The default installation path is “C:\Program

Files\Siemens\Toolbox 828D.
It is good practice to avoid installing to the C drive of the com-
puter. This drive typically contains the operating system
installation folders.
Use the “Browse” button to select another more suitable drive.
Notes :

Note:- Start-up Tool Installation RCS Commander Installation
The 828D controller operates with the Sinamics drive system, RCS Commander allows a remote operation between the
therefore the “Solution Line” variant should be selected. 828D controller and a computer.
This can be changed later using the NCU connection wizard if Data such as part programs etc can be transferred between
it is necessary to work also on the Powerline system. the remote computer and the controller.
A viewer is included which is used to view and change the
controller settings remotely (Dependant upon access rights).
The software can also be used to write images to compact
flash cards for service and commissioning tasks.
The RCS commander software is not part of the toolbox DVD.
Installation:
To install the RCS Commander software, locate the

“Setup.exe” file in the root of the RCS Commander DVD. Start
the installation by double clicking the file.
Acknowledge any further dialogue boxes and allow the

Double click the Setup.exe” file
installation to fully complete.
to start the installation.
Acknowledge any dialogue boxes and allow the installation

to complete.
Notes :

Network Settings: Ethernet port X127 of the controller is a DHCP server and
issues IP addresses. The computer has to be set to obtain an
X127 is a DHCP server with a fixed IP address of 192.168.215.1 IP address automatically.
Addresses 192.168.215.2 to 192.168.215.31 are automatically

issued to any PC connected to X127.
The network adapter name is required.

This can be found in the “Network connections” area of the com-
puter:
Click “Internet
Protocol (TCP/IP)”
from the list and
then select
“Properties”.
Ensure that
“Obtain an IP
address
automatically” is
selected.
Confirm the
changes with the
OK key.
In the following example the network adapter is of the type:
“Marvell Yukon 88E8055 PCI-E Gigabit Ethernet Controller”
The adapter type will vary between computer types.
Notes :

Online Connection-RCS Commander
Double click the “RCS Commander” icon which is found on the
PG/PC desktop.
When the program is opened for the first time after the
The access level determines which data can be accessed via
installation it is necessary to assign a password for encryption
RCS Commander. The “Manufacturer” login grants the most
purposes.
access, the “User” login is the most restrictive.
Select the login and enter the password.
Passwords:
Manufacturer-SUNRISE
Service-EVENING
User-CUSTOMER
A dialogue box appears where the choice of connection is

made.
A default connection is available, this is specifically for
connecting to X127 of the controller (IP address 192.168.215.1).
After a short delay the data folders of the controller will

appear in the lower half of the RCS Commander program, this
indicates a successful connection was made.
It is necessary to login with a password depending on the ac-

cess level required:
Notes :

Online Connection - PLC Programming Tool A dialogue box opens giving the opportunity to cancel the
changes. Accept by selecting the “OK” button.
An Ethernet cable is required to connect between X127 of the
controller and the PG/PC.
Start the Programming tool. A shortcut is auto-

matically placed on the desktop during
Installation.
Locate and select the “Communications” option

found in the left “View” column of the program-
ming tool. The selected adapter will be shown on the right of the dia-
logue box.
The IP address of the controller should be entered in the
“Communication Parameters\Remote Address” section.
The default IP address of X127 is 192.168.215.1.
A communication protocol is not active.

Double click the area highlighted.
Chosen adapter.
The correct adapter should be selected from the list and con-
firmed with the “OK” button.
Note: Adapter types will not necessarily be the ones shown in

this example.
Enter the IP address of the

controller.
Select the correct X127 - 192.168.215.1
network adapter.
After entering the IP address, double click the “Double click

to Refresh” icon.
Notes :

If the connection is successful an icon of the controller will Online Connection: Start-up Tool
appear.
During installation a folder is created on the desktop of the
computer. Within this folder are shortcuts for starting the “NC
Connect Wizard” and the “Start-up Tool and the start-up tool.
The PLC828 Programming Tool is

now connected to the controller.
Start the wizard and select the “840D Solutionline” option.
Notes :

Select the “Engineering Tools (Recommended)” option.

X127 has a fixed address of 192.168.215.1.
The connection setting can be saved under a suitable name

for future use, do not change any other settings.
Select “Finish” to complete the task.
Connection/cabling information is provided, a crossover or

straight cable can be used depending upon the network
adapter of the PG/PC.
Notes :

Setting the PG/PC Interface
It is also necessary to check the PG/PC interface setting to

ensure that the software is able to communicate. These
settings are checked in the “Control Panel” area of the PG/
PC.
In the “Control Panel” area, select and open the “Set PG/PC
Interface” program.
Connect an ethernet cable between the computer and port

X127 of the controller. Run the Start-up tool via the “Start-Up
Tool” shortcut.
The software will boot to the following screen:
The Access point and network adapter have to be selected.

The Access Point required is the “Sinumerik_CP” option.
The network adapter is the one identified earlier in the
module on Page 6
The “Access Point

of the Application” To exit the software select the F10 key on the PG/PC
needs to be keyboard followed by the “EXIT” soft-key.
selected from the
list.
(SINUMERIK_CP)
Select the
network adapter
which is in use.
B002: END
Notes :

B002 END Service and Commissioning

B061 Menu Structure
Module Description:
The SINUMERIK 828D system is split into 6 menu areas. Each menu area is sub-divided to allow
the user easy access to the necessary areas of the system.
Menu Areas:
 Machine
 Parameter
 Program
 Program Manager
 Diagnostics
 Start-up
Module Objective:
Upon completion of this module you will know the menu areas of the SINUMERIK 828D system.
Content:
Sinumerik
Menu Select Button

Mode Selection
Menu Selection
Menu Area: Machine (JOG Mode)
Menu Area: Machine (MDA Mode)
Menu Area: Machine (AUTO Mode)
Menu Area: Parameter
Menu Area: Program
Menu Area: Program Manager
Menu Area: Diagnostics
Menu Area: Start-up
Short Cut Keys
B061
B061

Menu Structure B061
Menu Structure: Description Menu

Structure:
START
Menu Area:
The SINUMERIK 828D system is split into 6 menu areas.
Program
Each menu area is sub-divided to allow the user easy access
Manager
to the necessary areas of the system.
Menu Areas: Menu Select

Button
 Machine Menu Area:
 Parameter Diagnostics
 Program
 Program Manager Mode
 Diagnostics Selection
 Start-up
Menu Area:
Start-up
Menu
Selection
Short cut
keys
Menu Area:
Machine (JOG
Mode)
Menu
Structure:
END
Menu Area:
Machine (MDA
Mode)
Menu Area:
Machine
(AUTO Mode)
Menu Area:
Parameter
Menu Area:
Program
Notes :

B061 Menu Structure
Menu Select Button
The menu system of the SINUMERIK 828D is accessed via the “Menu Select” button.
The location of the “Menu Select” button is always to the lower right of the screen of the operator panel.
Examples:
Notes :

Menu Structure B061
Mode Selection
Pressing the Menu Select button reveals 6 horizontal menu soft-keys and 5 vertical soft-keys.
Vertical Soft-key Functionality
The 5 vertical soft-keys can be used to change between the machine modes: This can also be
achieved via the Machine Control Panel.
Automatic mode (AUTO) is selected.
Manual Data Automatic mode (MDA) is selected.
Jog mode (JOG) is selected.
Reposition mode (REPOS) is selected.
Reference Point (REF POINT) mode is selected.
Notes :

B061 Menu Structure
Menu Selection
The 6 horizontal soft-keys are used to select the different menus.

It is also possible to select the menus via the integrated NC keyboard of certain types of OP or the remote NC keyboard versions.
Menu Soft-keys: Brief Description
The Machine menu displays information such as the axis

positions, distances to go, feedrates, spindle speeds, active tool etc
Functionality such as manual tool selection, tool/work-piece measurement, hand-
wheel selection can be performed by selecting the relevant soft-key.
The functionality depends upon the selected operating mode.
The Parameter menu displays information such tool/magazine data, work offsets,
user variables etc.
It is possible to carry out functions such as creating tools, editing existing tool/
magazine data, editing work offsets/variables/setting data.
The Program menu is used to display a part program, only if a program is already
open will its contents be displayed. Editing of the part program is possible here. If
a part program is not already open, the Program Manager will be open.
The Program Manager menu displays the “Part program/subprogram/workpiece”

directories. Programs/subprograms/workpieces can be
created or opened for editing. It is also possible to save to/from controller using
memory devices (CF/USB) or RS232 interface.
The Diagnostics menu is used for diagnosing machine problems, information

about current/past alarms can be viewed. The status of drives, axes, networks,
NC/PLC variables, utilization etc can be viewed. It is also possible to check the
software/hardware versions of the system.
Machine information and service reports are also entered via the
diagnostics menu.
The Start-up menu is used for a wide variety of functions, these

Include password entry, machine data modifications, creating archives, creating
alarm files, time/date settings, network set-up, licensing/option selection, system
data management, servo optimisation etc.
Reboot HMI
A further soft-key is available which is used for rebooting the HMI only. This is
found via the Menu extension key.
Notes :

Menu Structure B061
Menu Area: Machine (JOG Mode)
Menu Area: Machine (MDA Mode)
Notes :

B061 Menu Structure
Menu Area: Machine (AUTO Mode)
Menu Area: Parameter
Notes :

Menu Structure B061
Menu Area: Program
Menu Area: Program Manager
Notes :

B061 Menu Structure
Menu Area: Diagnostics
Menu Area: Start-up
Notes :

Menu Structure B061
Short cut key sequences
Keys Function
In the program manager and in the program editor from the cursor position,
+ selects directories or program blocks up to the beginning of the window.
Positions the cursor to the topmost line of a window.

+
+ selects directories or program blocks up to the end of the window.
Positions the cursor to the lowest line of a window.

+
Editing box - Moves the cursor further to the right by one word.
+ Navigation - Moves the cursor in a table to the next cell to the right.
Keys Function
Editing box - Moves the cursor further to the left by one word.
+ Navigation - Moves the cursor in a table to the next cell to the left.
Editing box - Moves the cursor in the table to the beginning of the table.
+ Navigation - Moves the cursor to the beginning of a window.
In the program manager and in the program editor, selects a contiguous

+ selection of directories and program blocks.
Editing box - Moves the cursor in the table to the end of the table.
+ Navigation - Moves the cursor to the end of a window.
In the program manager and in the program editor, selects a contiguous,

+ selection of directories and program blocks.
Notes :

B061 Menu Structure
Keys Function
Moves the cursor to the last entry.

+
Moves the cursor to the last entry in the last line.

+
+ selects directories or program blocks up to the end of the window.
Deletes a word selected to the left of the cursor.

+
In the actual window, selects all entries (only in the program editor and pro-
+ A gram manager).
Keys Function
Copies the selected content. The text is located in the clipboard.

+ C
Scrolls the actual user interface through all installed languages one after the
+ L other.
Scrolls the actual operator interface through all installed languages in the
+ + L inverse sequence.
Generates a screenshot from the actual operator interface and saves it as a

+ P file in the HMI data/Logs/Screenshots folder.
Cuts out the selected text. The text is located in the clipboard.
+ X
Notes :

Menu Structure B061
Keys Function
Reactivates changes that were undone (only in the program editor).

+ Y
Inserts text from the clipboard: either pastes the text from the clipboard at
+ V the actual cursor position or pastes text from the clipboard at the position of
the selected text.
Creates a complete archive (x.arc) on an external data carrier (USB - Flash-

+ + C Drive).
Creates a complete archive (x.ard) on an external data carrier (USB - Flash-

+ + Drive).
S
Backs up the log files on the USB-FlashDrive. If a USBFlashDrive is not

+ + D inserted, then the files are backed-up in the
manufacturer's area of the CF-Card.
Keys Function
Feed over ride to maximum in Simulation

+ M
Feed over ride is increased in Simulation

+
Feed over ride to decreaced in Simulation

+
Opens the Editor to enter Asian characters.

+ S
Editing box - Deletes the first word to the of the cursor.

+ Navigation - Deletes all characters
B061: END
Notes :

B061 END Menu Structure

B021 Access levels / Time and Date settings
Module Description:
Access Levels: The data of 828D controller is protected by seven protection levels, four of which
are set via a key-switch and three by password.
The system has default access levels for restricting data of the controller. It is also possible to cus-
tomise access to individual files/folders and soft-keys as well as determine the read/write/execute
properties of certain files.
Time and Date: If at the time of installation, the time and date is not set correctly, the RSV guaran-
tee period of the controller could be effected. (See Module B007 Electronic Logbook)
Correct time/date setting is also necessary for checking when an alarm occurred or when a file
(Part program, archive etc) was created or edited.
Before the date and time settings can be edited, the access level for the “User” or higher must be
entered.
This module explains the different protection levels, how to set these levels and how to protect
individual files. The module also explains how to set the correct time/date.
Module Objective:
Upon completion of this module you will be able to set the different protection levels using a pass-
word or key switch, you will also be able to change the protection levels of individual NC pro-
grammes and set the time and date for the system.
Content:
Sinumerik
Password and key-switch information
Setting and Deleting the Password
Protection of files
Customising Soft-key Access Levels
Setting the Date and Time
B021
B021

Access Levels / Time and Date Settings B021
Protection Levels: Description Access Levels /

Time & Date:
START
Access Levels: The data of 828D controller is protected by
seven protection levels, four of which are set via a key-switch
and three by password.
Password
The system has default access levels for restricting data of
and
the controller. It is also possible to customise access to indi-
key-switch
vidual files/folders and soft-keys as well as determine the
information
read/write/execute properties of certain files.
Time and Date: If at the time of installation, the time and date
is not set correctly, the RSV guarantee period of the controller Setting and
could be effected. (See Module B007 Electronic Logbook) Deleting the
Correct time/date setting is also necessary for checking when Password
an alarm occurred or when a file (Part program, archive etc)
was created or edited.
Before the date and time settings can be edited, the access
level for the “User” or higher must be entered.
Protection of
This module explains the different protection levels, how to files
set these levels and how to protect
individual files. The module also explains how to set the cor-
rect time/date.
Customising
Soft-key
Access
Levels
Time and
Date
Setting
Access Levels /
Time & Date:
END
Notes :

B021 Access Levels / Time and Date settings
Password and key-switch information Setting and Deleting the Password
The following table shows the password/key-switch positions

and associated protection levels/users. Setting the password:
The screen for entering the password is reached via the fol-
Protection lowing key presses
Intended user:- Protected via:-
level
1 Manufacturer Password: SUNRISE
2 Service Password: EVENING

A dialogue box is opened, this box shows the current access
3 User Password: CUSTOMER
level and allows a password to be entered using the key-
board.
4 Programmer, Setter Key-switch position 3
5 Qualified operator Key-switch position 2
6 Trained operator Key-switch position 1
7 Untrained operator Key-switch position 0

After typing the password it is confirmed by pressing the “OK”
The key switch is located to the bottom right of the MCP and soft key.
has four positions. Three colour coded keys are available,
each of which allow a different access level. This is from a
standard Siemens machine control panel. It is possible that a
manufacturer may use a different method to set the interface
signal. The dialogue box disappears and the current access level is
displayed above the left hand horizontal soft-keys.
Key switch Colour coded keys
Access levels of the three keys:-
Key colour Switch position Protection level
No key required 0 7
Black 0&1 6-7
Green 0, 1 & 2 5-7
Orange 0, 1, 2 & 3 4-7
The signals from the key switch are automatically set via the
MCP interface.
The higher the authorisation level the more data is available to

the user.
Example:- The machine data area is not available unless pro-
tection level 4 (Key position 3) or higher is released.
Notes :

Deleting the password: Protection of files
Before deleting a password the next highest password level Certain files such as important cycles, programmes etc can be
or higher should be set. Navigate to the screen where the individually protected against accidental editing, deletion or
password is entered, and select the “Delete password” soft execution. They can also be hidden from view.
key The desired file has to be located before the properties can be
edited. In this example, the part programme “828.MPF” is to
have it’s properties changed.
The “Part program” directory is located by selecting the
“Program manager” key.
A dialogue box is opened, this box shows the current access
level and asks if you really want to delete the current pass-
word, if yes select the “OK” soft-key to delete the password.
By highlighting the correct directory and opening it with the

“Input” key we can see the program “828D.MPF”. Ensure this
is highlighted.
The dialogue box will then disappear. The access level will be
now be determined by the key switch position.
The password remains active after power on.
Changing the password:

It may be necessary to change the password from the default.
To change a password the same level of access or higher
should be set. E.G to change the “Service” password, levels 2
or 1 must be active.
It should be noted that if the “Manufacturer” password is
changed and then forgotten, a re-load standard data is
required to set the passwords to default.
An archive would then have to loaded to return the ma-
chine to a running condition
Locate and select the “Change password” soft key.
The following dialogue box will be displayed. This allows a The properties of the file are found by paging right and select-
new password to be entered and confirmed. In this example ing the properties Soft-key.
the “Manufacturer” password is active, this allows the Manu-
facturer, Service & User passwords to be changed. Naviga-
tion of the dialogue box is achieved via the cursor and select
keys, confirmation is via the “OK” soft key.
A dialogue box allows four properties to be changed. In the
following example, the program:-
 Can only be executed if the “Service” password or
higher is active
 Can only be written to (Edited) if the “Manufacturer”
password or higher is active
 Will only be listed if the key switch position 0 or higher
In this example the “Manufacturer” password is active, this is active
allows the Manufacturer, Service & User passwords to be
changed.  Can only be read if the key switch position 1 or higher
is active
Notes :

B021 Access Levels / Time and Date settings
When the correct settings

have been entered the “OK”
soft key has to be selected.
Place the mouse pointer over the

soft-key and “Right click”
Customising Soft-key Access Levels
It is possible to set the access levels for each soft-key. Use the mouse “Left click” to select the
The function must first be activated in the Setup area. required access level.
The menu will automatically disappear when
the selection is made.
If an access level is already active the
“Original setting” option will be available.
When the “OK” key is pressed the function will be activated. A summary of any changes to access levels can be seen in
This is confirmed by the message 150100 the “Customize softkeys” area
The “Original setting” soft-key can be used to return the

access levels of all the soft-keys to their default state.
When customising is complete, select the “Close customizing”

soft-key.
To set the access levels of the soft-keys it is necessary to plug

a mouse into the USB socket of the controller.
Place the mouse pointer over the relevant soft-key and select
the “Right click” button.
Example: Changing the access level of the “Setup” soft-key to

Manufacturer.
Notes :

Setting the Date and Time
Before the date and time displays can be edited, the password
for the “User” or higher must be entered.
The Date/Time screen is reached with the following soft key
sequence:-
The time and date can now be checked and corrected if nec-
essary.
Use the cursor keys to move between the data fields.
The format can be changed by highlighting the required box
and using the “Select” key.
If the date or time is changed, each element has to be con-

firmed using the “Input” key.
Once the time & date are correct press the “OK” soft key.
B021: END
Notes :

B021 END Access Levels / Time and Date Settings

B041 Machine and Setting Data
Module Description:
Machine and Setting data's are used in many ways to influence the operation of a machine.
During commissioning some of the machine data is automatically set while other machine data has
to be changed.
Over time, as the machine mechanically wears it may be necessary to edit certain machine data
such as compensation data's.
This module shows the different machine data areas and other criteria such as how to activate the
machine data.
Module Objective:
Upon completion of this module you will be able to locate the different Machine/Setting data areas
and be able to carry out adjustments if required.
Content:
Sinumerik
Machine & Setting Data Overview
Data Classes
Editing Machine & Setting Data
User Views
B041
B041

Machine and Setting Data B041
Machine and Setting Data: Description

Machine and
Setting Data:
START
Machine and Setting data's are used in many ways to influ-
ence the operation of a machine.
During commissioning some of the machine data is automati-
cally set while other machine data has to be changed. Machine &
Over time, as the machine mechanically wears it may be nec- Setting Data
essary to edit certain machine data such as compensation Overview
data's.
This module shows the different machine data areas and
other criteria such as how to activate the machine data.
Data Classes
Editing
Machine &
Setting Data
User Views
Machine and
Setting Data:
END
Notes :

Machine & Setting Data Overview Menu „Machine data“
General assignment 1 2 3 4 5
The machine data are sub-divided into the following ranges:
Range Description
9000 - 9999 Display machine data
10000 - 19999 General machine data
20000 - 29999 Channel-specific machine data
30000 - 39999 Axis-specific machine data
41000 - 41999 General setting data
42000 - 42999 Channel-specific setting data
43000 - 43999 Axis-specific setting data
51000 - 51999 General cycle machine data
52000 - 52999 Channel-specific cycle machine data 1 Number of the machine data
53000 - 53999 Axis-specific cycle machine data
54000 - 54999 General cycle setting data 2 Denomination of the machine data
55000 - 55999 Channel-specific cycle setting data

Value and physical unit of the machine data
56000 - 56999 Axis-specific cycle setting data 3
m/s**2 m/s2 (Meter/second-squared): Accel-
For every one of these ranges an own listing exists, in which eration
machine data can be displayed and altered. U/s**3 U/s3 (Revolutions/second power 3):
rate of change of acceleration
for rotating axis
The following data ranges are used for the machine data:
kg/m**2 kgm2 (Kilogram-meter-squared): Mo-
$MM_ Display machine data ment of inertia
$MN_ General machine data mH mH (Milli-Henry): Inductivity
$MC_ Channel-specific machine data Nm Nm (Newton-Meter): Turning mo-
$MA_ Axis-specific machine data ment
us µs (Micro-seconds): Time
$MNS_ General cycle machine data
uA µA (Micro-Ampere): Electrical cur-
$MCS_ Channel-specific cycle machine data rent
$MAS_ Axis-specific cycle machine data uVs µVs (Micro-Volt-second): Magnetic
flux
Which mean: userdef User definition: The unit to be deter-
$ System variable mined by user.
M Machine data
4 Activation of the machine data:
M, N, C, A, S Part range (second/thierd letter) im = Active on selection of the “Input” key (immediate).
cf = Active on selection of “Set MD active (cf)” soft key.
The following data ranges are used for the setting data: re = Active on selection of the “Reset” key.
$SN_ General setting data po = Active on control power off/on or “Reset (po)” soft
$SC_ Channel-specific setting data key.
$SA_ Axis-specific setting data
5 Data class of the machine data:
$SNS_ General cycle setting data
S = System
$SCS_ Channel-specific cycle setting data
M = Manufacturer
$SAS_ Axis-specific cycle setting data I = Individual
U = User
Which mean:
$ System variable In case of machine data without a unit the units-column is empty. If
D Setting data the value terminates with an „H“, the value is in hexadecimal format.
N, C, A, S Part range (second/thierd letter)
Notes :

Data Classes Editing Machine & Setting Data
The 828D controller uses machine data which is divided into To locate the machine data screens first ensure that the rele-
data classes. vant access level is active (Module B021 Protection Levels)
Data classes can be used to create archives which contain then use the following key sequence:-
only specific data's of the controller, data according to it´s
classification. Upgrades etc. can therefore be carried out
while leaving any existing unrelated data of the controller
intact.
Types of Data Classes:-

The display should now show the machine data area with soft-
The Data Classes are split into four categories:- keys available to switch between the different machine data
areas.
System (S) - This data belongs to the system and cannot be
edited. The values are determined by the controller type and
standard data. Data belonging to this class is not saved in
any archive type.
Manufacturer (M) - The manufacturer data is common

throughout a particular machine series. No individual or user
data is included.
Individual (I) - The individual data is machine specific

(Compensations, reference points etc.). An archive of the
Individual type could typically be made prior to a software
update.
User (U) - The user data is user specific (Part programs, tool
data, zero points etc.). An archive of the user type could be
used to transfer data to an identical machine cutting the same
component or in the case of a software update. The machine data which are available for viewing is limited on
the activated display filters.
Data Classes for Machine and Setting Data
When looking at the machine data area of the controller it is

possible to see which machine data belongs to which Data
Class.
Example:-Axis specific machine data screen showing data

class identifiers:
Note:-
Machine Data is often referred to as “MD”.
Setting Data is often referred to as “SD”.
Data Class Identifier
Notes :

Editing Machine & Setting Data continued The correct machine data should first be located. This is
done by either using the page/cursor keys or the search
The Machine & Setting Data is separated into different groups. function.
The search function is activated with the “Search” soft key. If
the Machine Data number is known this can be typed into the
dialogue box. It is also possible to enter part or all of the MD
General MD and general Cycle MD.
name in text format.
Channel-specific MD and channel-specific Cycle MD.
Axis-specific MD and axis-specific Cycle MD.
User Views- Allows the user to create list of specific

machine data.
When the correct MD has been found, a value can be en-
Control Unit Parameter. tered. In this example we are going to change Display MD
9900 from 0 to 1. This will change the MD/SD description
Infeed Parameter (ALM/SLM). from system language to plain text.
Drive Parameter.
For further data the “Menu Extension” key must be selected.

This allows access to the Setting Data and also the Display
Machine Data.
The correct machine data has to be highlighted. The number

1 is entered and confirmed with the “Input” key.
On pressing the “Input” key the text of the machine data

changes immediately (see below).
General SD and general Cycle SD.
Channel-specific SD and channel-specific Cycle SD.
Axis-specific SD and axis-specific Cycle SD.
Display MD.
Notes :

Editing Machine & Setting Data continued
Insert new data in machine data list.
REMEMBER:- Create a data backup.
Editing of any type of data should only be undertaken by ex-

perienced personnel and in conjunction with the machine
manufacturer.
For a detailed description of each machine/setting data refer
to the “Function description” manual found on “DOConCD”
User Views
User views allows a customised list of machine data to be

made.
The machine data list will be stored on the System CF card.
Select machine data list.

The location of the machine data list is:
Edit existing machine data list or create new System CF card/user/templates
machine data list.
Create new machine data list.
The machine data list will be displayed in the machine data

area. Additional it will be displayed in the Parameter/Setting
data area.
B041: END
Notes :

B041 END Machine and Setting Data

B032 RCS Commander
Module Description:
It may be a requirement for service personnel to remotely diagnose problems with the controller or
machine.
This is achieved by using the RCS Commander software package installed on a PG/PC.
When connected, a viewer function is available so that the user can see and change the controller
data.
RCS Commander is also used for carrying out other service and commissioning tasks. These tasks
are explained in the relevant modules.
This module shows the installation of the RCS Commander software and how to make an online
connection using both the available ethernet ports X127 and X130.
Module Objective:
Upon completion of this module you will be able to connect remotely to the system using the Re-
mote Diagnosis function and the RCS Commander software tool.
Content:
Sinumerik
Network Settings
RCS Commander Online Connection
Bookmarks
External Viewer
B032
B032

RCS Commander B032
RCS Commander: Description

RCS
It may be a requirement for service personnel to remotely Commander:
diagnose problems with the controller or machine. START
This is achieved by using the RCS Commander software

package installed on a PG/PC.
When connected, a viewer function is available so that the Network
user can see and changes the controller data. Settings
RCS Commander is also used for carrying out other service

and commissioning tasks. These tasks are explained in the
RCS
relevant modules.
Commander
Online
This module shows the installation of the RCS Commander Connection
software and how to make an online connection using both
the available ethernet ports X127 and X130.
Bookmarks
External
Viewer
RCS
Commander:
END
Notes :

B032 RCS Commander
Network Settings The settings can now be changed to suit the network that the
controller is to be connected to.. Use the cursor and select
Network Settings keys to change the selections
RCS Commander can be connected to the controller via Address Type:-DHCP-To obtain IP address automatically.
Ethernet port X127 (Front) or X130 (Rear). Connection to Manual-To enter a defined IP address.
X127 (DHCP server) is straight forward and is tested during
the software installation Module B002. When the settings have been chosen select the “OK” soft-
key” and perform power off/on of the controller.
Ethernet port X130 is configurable, the port can be assigned a
fixed IP address or be set to automatically acquire an IP ad-
dress.
Port X130 is for connecting to the factory network. When con-
figuring for connection to a factory network, certain information
from the factory network administrator is required. Any existing
X130 settings should be recorded before attempting any
changes.
Configuring Port X130

IP address restrictions– Do not use IP addresses
192.168.215.xxx &192.168.214.xxx. These are reserved by
the system.
Locate the “TCP/IP diagnostics” screen with the following key

selection:-
In the following example the IP address of 192.168.100.1

and a sub-net mask of 255.255.255.0. have been manually
Basic Informa- assigned.
tion about the
two network
ports is
displayed.
X130 is not
configured.
X127 shows
the fixed IP
address of
192.168.215.1
To edit the settings select the “Details” and “Change” soft-

keys.
Notes :

RCS Commander B032
To activate the new setting the controller needs to be RCS Commander Online Connection
powered off/on.
Connection via X130
The TCP/IP diagnostics screen now will show the IP address
of port X130. A default connection is available in RCS Commander for con-
necting to X127. If ethernet port X130 is to be used a new
connection will have to be created.
Computer Network Settings

The IP address and subnet mask of the computer will also
have to be manually entered. If the controller is part of an
existing network this address must be unique.
The following example shows a manually assigned IP

address of 192.168.100.2 and subnet mask of
255.255.255.0. The subnet mask must match the one entered
on the controller.
Enter the IP address for X130 (192.168.100.1) also enter a
connection name and choose a login level (Manufacturer, Ser-
vice, User) and the correct password for the selected login.
Notes :

B032 RCS Commander
To make the connection select the “Connect” icon on the RCS The RCS Commander program can be used for copying and
Commander toolbar. pasting files between the controller to the external computer.
Files resident on the controller can be opened directly for edit-
ing.
In many cases it is easy to create files offline and then copy
them to the controller using RCS.
The function for writing images to CF cards is described in

Module B017.
Bookmarks
From the drop down menu select the connection to be used
then press the “Connect” button. Bookmarks are shortcuts directly to specific folders in the con-
troller. By default there are several bookmarks already set.
To add a personal bookmark the target folder has to be lo-
cated on the left hand side of the RCS Commander program.
Use the mouse “Right click” function on the folder and then
select “Add to bookmarks”
The following example shows the “hlp” folder, which is used

for user alarm help files, being given a bookmark.. The name
of the bookmark is to be “User alarm help files”
After a short delay the data folders of the controller will appear
in the bottom half of the RCS Commander program.
Give the bookmark a suitable name:
Notes :

RCS Commander B032
The bookmark will now be listed with any other bookmarks in Viewing Rights-HMI
the “Bookmark” menu. Rights for remote access - Selected in HMI
Do not allow remote access-Prevents remote connections.
Allow remote monitoring-The remote computer can monitor
the controller.
Allow remote operation-The remote computer can access the
various screens of the controller and changes can be per-
formed.
Viewing Rights-PLC
Rights for remote access, Specified by PLC (Not settable on
screen)
The access can be restricted/blocked via the user PLC with

interface signals. These signals have priority over the
“Selected in HMI” settings.
Behaviour for remote access

Confirmation dialog display time-When a connection attempt
is made a dialogue box will appear which requires acknowl-
edgement, this determined how long the
External Viewer dialogue box stays on the screen.
Afterwards remote access is allowed automatically-If this is
External Viewer set to “Allowed” the controller will allow the connection even
The external viewer duplicates the controller display on the when the dialogue box has not been acknowledged. If set to
external computer including menu and soft-key functionality. “Denied” the connection will be blocked if the dialogue box is
When the viewer connects, access can be restricted on the not acknowledged.
HMI or by the PLC interface.
To configure the HMI use the following soft-key sequence: When the settings are correct select the “OK” soft key.
Connection via modem

It is possible to connect to the controller using a Teleservice
adapter and modem. In this case the “Allow modem” soft-
To change the settings select the “Change” soft key. Use the
key is used to permit the connection.
cursor and select keys modify the settings:
Note: The “MC Information System RCS Host” option is re-

quired for connection via modem.
Notes :

B032 RCS Commander
Connecting the External Viewer The following keys are used to navigate the controller from
the remote PG/PC:
To start this function select the following icon from the RCS
Commander tool bar, Alternatively select “Start” from the
Remote control” drop down menu.
Keys Description
F1 to F8 Horizontal soft-keys
Shift & F1 to Vertical soft-keys
F8
F9 Page Back/Up
F10 Menu Select
Shift & F9 Page right
F12 Help function
Escape Alarm Cancel
Select Space Bar
When the viewer attempts to connect, providing that the re- Programs, machine data etc can be directly changed from the
mote viewer has not been blocked, the screen of the control- remote computer, archives can also be created.
ler will be displayed. If acknowledgement is required, the con-
troller “OK” soft-key will require selecting within the time limit
specified on the RCS set-up screen.
When the connection is successful the viewer will display the

same screen as the controller.
B032: END
Notes :

B044 Licensing of Options
Module Description:
When a controller with options is purchased a software licence key is issued. The licence key is
unique to the CF card supplied with the controller.
This module explains the licensing procedure and how to activate options.
Module Objective:
Upon completion of this module you will be able to check the control for the correct licence and
activate options.
Content:
Sinumerik
Entering and Checking Licences
Assigning Licences
B044
B044

Licensing of Options B044
Licensing of Options: Description

Licensing of
Options:
START
When a controller with options is purchased a software li-
cence key is issued. The licence key is unique to the CF card
supplied with the controller.
This module explains the licensing procedure and how to Entering and
activate options. Checking
Licences
Assigning
Licences
Licensing of
Options:
END
Notes :

Entering and Checking Licences
To check the licence number, use the following key com-

bination:-
Information regarding the licence and the CF card serial num-

ber is displayed.
The licence number is specific to the internal compact flash
card serial number.
For this reason a copied CF card cannot be used without gen-
erating an error message.
The licence key can be entered on this page. This is activated
by an NCK reset using the “Reset (po)” soft-key.
For retrieving a lost key use the “Display Licence Key ”option
from the left hand column.
From the “Please select” menu, choose “Hardware serial
number”.
This is the serial number of the internal CF card taken from
the licence screen shown on the controller.
Enter the CF card serial number and

then select “Get licence key”.
The control should arrive with documentation regarding the

licence key and options. This needs to be kept in a secure
place.
The licence key should be saved at first commissioning and

prior to attempting any work where the NC data might be lost/
reloaded. This is described on page 6.
If the licence key is lost it is usually possible to retrieve it via

the internet, the serial number of the internal CF card will be
needed to recover the licence key.
The licensing page can be found at::

www.siemens.com/automation/license
Notes :

The licence key should now be displayed. A full report can
be sent to an email address if desired.
Choose the destination for the licence key.
Create a new directory if required.
The new folder appears . Select “OK” to save the licence key
file to this folder.
The licence key can be sent in PDF format, which includes a
report of the options assigned to that particular licence num-
ber, to an email address of your choice.
It is also possible to save the licence key directly to a PC in a

text file format.
A message is displayed momentarily above horizontal soft-

keys.
To check that the licence save was successful select the “Exp.
Licence requirement” soft-key again.
The file is automatically given a name by the system.
Saving the licence key from the controller:
It is possible to save the licence number to a file so that in the

event of a hardware failure it can easily be restored.
Notes :

Restoring the licence number:- To select an option use the cursor keys and highlight the de-
sired option, then press the “Select” key to activate or enter a
Select the “Read in licence key” soft-key. number depending on the type of option being activated.
A “Reset (po)” is required to complete the procedure.
Highlight the licence key file and press the “OK” soft-key.
The licence key should now appear in the licence key box. All the licensed options can be set automatically via the “Set
option acc. lic.” soft-key
Setting the Licensed Options:

The “All options” soft-key reveals the options that are available If an non-licensed option is activated, the controller will issue
and those which are licensed. an alarm.
The NC/Cycle Start will also be inhibited.
To see all non-licensed options, select the “Missing licences”

soft-key.
The next section describes how to obtain a new licence key so

that a previously non-licenced option can be set.
Notes :

Assigning Licences Call up the “Web Licence Manager“ on a PC with Internet
access:
If a licence key is insufficient for a required option, it is possible http://www.siemens.com/automation/license
to assign a new licence key that includes the missing option.
The assignment of a new licence key is done via the internet.
Select “Direct Access“ of “Web Licence Manager“.
Each option is issued a Licence Certificate. The certificates are
delivered with the controller along with information about the
licence dispatch note numbers.
These are required for the Web Licence Manager.
Example: A licence certificate
Step 1 of 5 - Login:
Sequence: Enter the licence number resp. dispatch note number.
The licensing is achieved by a series of steps on the Siemens

licensing website.
Before commencing, take a note of the hardware serial num-

ber and the hardware type from the licensing manager
screen.
Notes :

Step 2 of 5 - Identify Product: The licences are assigned to the specified hardware by clicking
Enter the hardware serial number and select the product. the “Assign“ button.
Click “OK“ to confirm.
Step 5 of 5 - Generate Licence Key:

The Licence Key includes all options assigned for the hardware
specified.
Step 3 of 5 - Select licences:
The licences which have not yet been assigned on the dispatch
note selected are displayed. You can assign additional licences
to the hardware here.
A file containing the licence number can be downloaded. This

file can be then read0in to the controller:
Step 4 of 5 - Assign licence:

Overview of licences selected.
Notes :

Change to the licensing screen and enter the Licence Key by
pressing the “Read in licence key“ softkey.
The alarm caused by the unlicensed options is no longer dis-

played after assigning the Licence Key.
You can check whether the Licence Key has been entered
successfully by pressing the “All options“ soft-key. The option
should now be available in the “Licensed“ column.
B044: END
Notes :

B044 END Licensing of Options

B045 Network configuration
Module Description:
The 828D controller is equipped with a configurable ethernet interface (X130). This interface can
be used for service/commissioning work.
A soft-key can also be configured to facilitate the easy handling of data e.g. remote storage of part
programs.
This module shows how the ethernet connection is configured and the activation of a soft-key in
the program manager area.
Module Objective:
Upon completion of this module you will be able to configure ethernet connections on the control-
ler/external PC, create a shared folder on the PC and add a soft-key in the Program manager area.
Content:
Sinumerik
Activating the Network Option
Network Settings
Creating a Shared Folder
Configuring a Network Drive Soft-key
B045
B045

Network configuration B045
Network Configuration: Description

Network
Configuration:
The 828D controller is equipped with a configurable ethernet START
interface (X130). This interface can be used for service/
commissioning work.
A soft-key can also be configured to facilitate the easy han-
dling of data e.g. remote storage of part programs. Activating
the Network
Option
This module shows how the ethernet connection is configured
and the activation of a soft-key in the program manager area.
Network
Settings
Creating a
Shared
Folder
Configuring a
Network Drive
Soft-key
Network
Configuration:
END
Notes :

Activating the Network Option Configuring Port X130

A series of step are required to initialise and set up the net- IP address restrictions– Do not use IP addresses
work connection: 192.168.215.xxx & 192.168.214.xxx. These are reserved
by the system.
 Activation of the network drive option
 Configuring the network drive on the controller Locate the “TCP/IP diagnostics” screen with the following
key selection:
 Configuring the external PC
 Adding the soft-key in the Program Manager area
Activation of the Network Drive Option:
Use the following soft-key sequence to set access the licens-

ing/options screen.
Basic Information about the two network ports is displayed.

X130 is not configured.
X127 shows the fixed IP address of 192.168.215.1
To edit the settings select the “TCP/IP config” and “Change”

soft-keys.
Network drive management is enabled
Network Settings
Connection to X127 (DHCP server) is straight forward and is

tested during the software installation Module B002.
Ethernet port X130 is configurable, the port can be assigned a

fixed IP address or be set to automatically acquire an IP ad-
dress.
Port X130 is for connecting to the factory network.

When configuring for connection to a factory network, certain
information from the factory network administrators is required.
Any existing X130 settings should be recorded before attempt-
ing any changes.
Notes :

The settings can now be changed. Use the cursor and select
keys to change the selections
Address Type:-DHCP- To obtain IP address automatically.

Manual- To enter a defined IP address.
When the settings have been chosen select the “OK” soft-
key” and perform power off/on of the controller.
In the following example the IP address of 192.168.100.1 and

a sub-net mask of 255.255.255.0. have been manually
assigned.
Select “Control Panel”
Locate and double click the

Network Connections icon.
To activate the new setting the controller needs to be
powered off/on.
The TCP/IP diagnostics screen now will show the IP address

of port X130
Double click the Local Area Connection icon
Computer Network Settings
The IP address and subnet mask of the computer will also

have to be manually entered. If the controller is part of an
existing network this address must be unique.
The following example shows how to manually assign an IP

address of 192.215.100.2 and subnet mask of 255.255.255.0.
The subnet mask must match the one entered on the
controller.
Locate the “Control Panel” on the “Start” menu of the PC:
Notes :

Select “Properties” Creating a Shared Folder
A shared folder is required on the PC for storage of files etc.

The path to the folder and a soft-key are created in the next
section.
It should be first ensured that the “Simple file sharing” option

is deactivated on the computer to be connected to the con-
troller. This allows full access to the shared folder options.
Deselecting the “Simple file sharing” option:
Cursor to “Internet
Protocol (TCP/IP) and
select “Properties”
Select the ‘Use the following IP address” option and enter a

unique IP address. The subnet mask should match the subnet
mask set on the controller.
Notes :

On the PC select a suitable place for the shared folder. The

following example will show how to create a folder on the D Select the “Sharing” tab
drive.
Use explorer and select the D drive, right click with the
mouse in the right hand Window and select New/Folder. Select “Share this folder”
Select “Permissions”
Enter a suitable name for the new folder.
Select all options in the

Right click on the folder and select “Properties”. “Allow” column.
The folder should now have a Hand Symbol:
Sharing the folder makes it visible on the network. Networking

can be a problematic subject. In this example the security
settings are relaxed, security feature can be introduced once
a successful connection is made.
Problem with connecting can be caused by anti virus and
firewall setting.
Notes :

B045 END Network configuration
Configuring a Network Drive Soft-key The new soft-key should now be available in the Program
area:
To give the operator access to the remote folder a soft-key is
added to the Program Manager screen. The configuration
screen is found by using the following soft-key sequence.
Files can be copied to/from the controller using the Copy/

Paste soft-keys.
The USB port is configured as default, this should be left un- The new folder is also available in the “System data” area.
touched. The next available free area is position 2. Use the cursor This provides a convenient method of saving files such a s
and select keys to navigate the input fields. archives to a safe storage location.
The information of the external PC has been entered in the

following example.
Information such as IP address, shared folder name, log on
details etc. are required.
Ensure that a suitable network cable is connected and select
the “Activate drive” soft-key.
A message will be displayed briefly above the horizontal soft-

keys to show a connection was made. To continue press the
“OK” soft-key.
B045: END
Notes :

B007 Electronic Logbook
Module Description:
The electronic logbook function of the 828D controller is used to enter data such as manufacturer
(OEM), dealer and user information, 1st and 2nd commissioning dates as well as records of service
visits.
This data is then saved to a log file. The log file has to be uploaded into the EUNA database via the
Online Registration Website.
The function is not only necessary for warranty issues but also for service personnel (Records of new
and previous service visits) and also for quality control measures.
The warranty period of the controller can only be activated through EUNA.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
 Import/Enter Logbook Data

 Make logbook entries
 Save and load the log file using the Online Registration Website.
Content:
Sinumerik
Logbook information
Importing/Entering Logbook Data
1st Commissioning-Start-up Complete
2nd Commissioning-Machine Installed
Recording a Service Visit
Saving the Logbook Data - identSNAPSHOT
Uploading to the Online Registration Website
Siemens assumes no responsibility for its contents. B007
B007

Electronic Logbook B007
Electronic Logbook: Discription
Electronic Logbook:
The electronic logbook function of the 828D controller is used START
to enter data such as manufacturer (OEM), dealer and user
information, 1st and 2nd commissioning dates as well as
records of service visits.
This data is then saved to a log file. The log file has to be Logbook
uploaded into the EUNA database via the Online Registration Information
Website.
The function is not only necessary for warranty issues but also
for service personnel (Records of new and previous service Importing/
visits) and also for quality control measures. Entering
Logbook
The warranty period of the controller can only be activated Data
through EUNA.
1st
Commissioning:
Start-up
Complete
2nd
Commissioning:
Machine
Installed
Recording a
Service Visit
Saving the
Logbook Data -
identSNAPSHOT
Uploading
to the Online
Registration
Website
Electronic Logbook:
END
Notes :

Logbook Information Importing/Entering the Logbook Data
In the past, the validity of warranty claims was difficult to man- The OEM and Dealer information can be imported to the con-
age and was the cause of delayed service response times. troller in three ways:
System/hardware faults were logged in paper logbooks which
were then usually left on the machine and often became dam-  Import the XML file via the “Import” soft-key.
aged or lost. (Preferred method)
By using EUNA and the Electronic Logbook system, the war-

ranty will automatically start, a record of the machine details
 Copy/paste the XML file in the “System data” area.
(If the “Import” soft-key is not available)
and breakdowns will also be available on the controller.
The time and date of each entry is recorded; it is impor-  Type the information directly on the controller.
tant that the time and date settings of the controller are (When the files are not available)
correct. Incorrect time and date settings can lead to early
expiry of the warranty.
The preferred method is to obtain the correct xml files from
It is necessary to make entries at certain stages during the life your Siemens contact partner. These are pre-populated files
of the machine: containing the relevant OEM/machine information etc. Using
this method guarantees the consistency between the data
- Manufacturer information at OEM stored in EUNA and the data stored on the machine.
- Dealer information at delivery and installation of machine
- End user information at delivery and installation of machine The following files can be imported:
- 1st Commissioning - End of start-up at Manufacturer
- 2nd Commissioning Machine installed - End of start-up at
end user File Function
- All service visits
oem.xml Manufacturer information
oemsubs.xml Manufacturer subsidiary information
Note: If the procedures are not followed the warranty will
not be valid. dealer.xml Dealer information
user.xml End user information
identSNAPSHOT
ma_types.xml List of available machine types
When the “save” procedure is carried out, an xml file is cre-
ated. The files are imported using the “Import” soft-key, failing this,
This is known as the “identSNAPSHOT” function and is a the copy and paste option can be used.
snapshot of the system including version data, cycle data, If the files are not available they can be created directly on the
hardware components etc controller or offline on a computer.
Each time an entry is made, the log file should saved and up-
loaded to the EUNA database via the Online Registration
Website.
The file name is made from a combination of the machine Machine Identity File (identity.xml)
name and system CF card serial number.
When the information has been imported the “identity.xml” file
is automatically created which contains all the information
from the imported xml files.
If at any data is already present in the logbook area and needs

to be overwritten, then the identity.xml should first be deleted
from the system.
The machine name/number is also stored in General Machine

Data 17400.
Notes :

Concept for Electronic Logbook Data Import and Upload:
Offline preparation identSNAPSHOT-Controller

File upload & RSV activation
(identity.xml, MD17400)
OEM Data OEM Data (identity.xml)
oem.xml/oemsubs.xml: *Customer number*

Load via “Import” soft-key.
Or *Country*
OEM.xml:
No “Import” soft-key? *Manufacturers name*
Load via “Copy/paste” function.
Or *Town*
OEM.xml:
File not available?
Input data via controller keyboard.
Dealer Data Dealer Data (identity.xml)

Export & upload
dealer.xml: *Customer number*
Load via “Import” soft-key. Online
Or *Country* Registration
OEM.xml:
No “Import” soft-key? *Dealers name* Activation of RSV warranty
Load via “Copy/paste” function.
Or *Town* Configuration data:
OEM.xml: components, machine identity,
File not available? licence requirements,
Input data via controller keyboard. version information,
logbook entries etc.
User Data User Data (identity.xml)
No XML file available? Not usually available

Input data via controller keyboard. until point of sale.
Logbook entries
1st Commissioning
2nd Commissioning
Service visits
If the controller has existing machine identity data or a mistake is made when entering data manually, it is necessary to de-
lete the “identity.xml” file.
The location of the “identity.xml” file:
System CF card\individual\sinumerik\hmi\data\version\identity.xml
Should the machine name/number need to be deleted then this is done via General MD 17400[0]
Notes :

Data Import function (Preferred method) Locate the file(s) to be imported, e.g. via USB.
Select the files to be imported and press “OK”
The Electronic Logbook is located in the Diagnostics area of the In the following example two files, ma_types.xml and oem-
controller: subs.xml have been selected for importing to the controller:
The following screen shows no available information.
At this point the screen will not have any information displayed
Enter the machine name/number e.g. VMC123.
This information is stored in General MD 17400[0]
Select the “Change” soft-key.
The default Manufacturer screen is shown, again there is no

information available at present.
Machine Type:
Selection of the machine type. The list is only available if the

ma_types.xml file is present on the controller..
If this file is not present, the machine type can be manually
entered here.
Notes :

Selecting the “Insert” key will reveal a list. Jetzt erscheinen die Informationen auf dem Bildschirm. In
unserem Beispiel wurde die Hersteller-Datei (oem.xml)
geladen.
Um die Händler- oder Endkunden-Daten zu sehen, drücken Sie
The list will display the entries from the “ma_types.xml” file.
In this example the “Milling” option has been selected.
Address Selection:
The address of the OEM needs to be selected. It is possible The country selection needs to be made from the drop down
that the OEM has different manufacturing bases. list
The following example has two addresses listed
When the “OK” soft-key is pressed the Logbook entry screen

will be displayed and will show the basic information of the
machine.
Notes :

Copy and Paste Option The controller needs to be switched off/on to activate the new
file.
If the “Import” soft-key is not available it is possible to copy the
files from CF/USB/networked PC in the “system data” area The result of the copy/paste of the „dealer.xml“ can now be
using the copy and paste functions. seen on the controller.
The machine number and type do not need entering as they

were entered previously.
The address of the dealer needs to be selected from the list.
Cursor to the location the file e.g. USB device.
Locate the destination for the file (The files that were Imported
earlier will also be seen here) press the “Paste” soft-key:
The dealer information will now be displayed:
The file will now appear in the folder.
The content of the dealer.xml will now be displayed.
Notes :

OEM Subsidiary files Select the branch/subsidiary name; in this case-
“Test Subsidiary 1”
Subsidiary files are used to define the details of manufacturer
regional offices.
Example: A machine manufacturer has its head office in Ger-

many, and also has regional offices in other countries, e.g.
United Kingdom.
In this case, “oem.xml” would contain the details of the head
office; “oemsubs.xml” would contain the details of the regional The subsidiary details will be displayed.
office.
When an “oemsubs.xml” file is imported to the controller, the
“Manufacturer” soft-key is used to toggle between the OEM
and OEM subsidiary data.
Example: Import the “oemsubs.xml” files as described previ-

ously.
The default screen displays the manufacturer data. To return to the manufacturer details, select the “Reg. office of
manufact.” soft-key.
This the original manufacturer soft-key with different text. The
text of the soft-key changes depending on the current selected
screen.
Templates for xml Files
Templates for the various xml files are available in the

“HMI data\Templates\Examples\Machine identity” folder.
Select the “Manufacturer” soft-key to view the “oem subsidi-

ary” data
No data will be displayed until an “Address selection” has

been made. This is the name of the branch, i.e. the subsidiary.
Notes :

The templates can be used if the files cannot be obtained from Manually Entering Machine Identity Data
the Siemens partner. They should be copied and edited to
leave the original templates intact. If an xml file is not available the data can be typed directly into
Example template for dealer.xml. the controller.
Select which data is to be entered; Manufacturer, Dealer, End

user.
The file contains various xml commands but no dealer data.
Or Or
Example: Manually entered “End user” data.
Example: A “dealer.xml” file with dealer information. The file

can be imported using the method described earlier.
A summary of the information can be seen.
Notes :

1st Commissioning-Start-up Complete
When the machine has been commissioned at the manufac-

To confirm that 2nd Commissioning is complete.
turer the “Start-up Complete” soft-key is selected. This auto-
matically logs the current time and date.
The information is now added to the main logbook page .
!!This is the point when the warranty period begins, the

logfile must be saved then uploaded to the EUNA data-
base!!
To confirm that 1st Commissioning is complete.
The information will appear on the main logbook page. Recording a Service Visit
Whenever an engineer visits the machine to carry out mainte-

nance etc, a record of the visit and information about the
work carried out should be entered into the Logbook.
To do this select the “New Entry” soft key.
The name and company/department of the engineer should

be entered followed by a detailed description of the fault and
work carried out.
2nd Commissioning-Machine Installed
When the machine has been installed at the end-user (2nd

commissioning) the “Machine Installed” soft-key is pressed
This automatically logs the current time and date.
Notes :
SINUMERIK 828D Page 11

The details of the service visit are now shown on the Logbook The file is given a default name using details from the machine
page. information page. This can be changed. A comment can also
be added.
Two files are created by default, Version data and Configura-
tion data.
The “Version data (.TXT)” file is a text file and contains details
regarding the versions of the controller, drives etc.
The “Configuration data (XML)” file is an xml file and contains
more information about the whole system including the log-
book entries. It is this file which needs to be uploaded to the
database via the internet.
Saving the Logbook data - identSNAPSHOT
The following procedure shows how to save the newly entered

data to a file.
The file contains all information about the system (Controller,
drives, software and hardware etc) as well as the information The information will now be saved.
entered on the logbook pages.
The save procedure should be carried out after each data

entry in the logbook.
To save the data to a file first locate and select the “Save”
soft-key.
The file should be saved to the default “Version data” folder as In this example, the files are saved in the “version” folder.
a standard procedure to ensure that a copy is locally available .
The file is to be uploaded via an external PC, therefore it System CF card\user\sinumerik\hmi\data\version
should also be saved to an external USB/CF device.
Notes :

Uploading to the Online Registration Website The file is closed with the following soft-key selection.
The file can be opened for viewing in the “System data” area:
Use the copy/paste function to transfer the xml file to a

computer in preparation for uploading to the Online Registration
Website.
New Log Files

A new log file needs to be created when anything new is added
to the logbook.
The file must then be uploaded to the EUNA database.
The Online Registration website address is:

www.siemens.com/sinumerik/register
A language selection is available and an email address is

required. Notification emails will be sent to this address if the
“Enable email status notification“ option is selected.. To
continue use the “Next” key.
The information that was entered via the Logbook screen is

now stored in the xml file.
Service report entries are found et the end of the file:
Language selection.
Notes :

Entering the email address and enabling the “enable email

status notification” selection.
Continue with the “Next” button.
To upload the XML file select the “XML Upload” key.
The selected file is now ready to upload, select the “Upload”

key.
Use the “Browse” key to locate the file.
After a short delay an information box will indicate a successful

upload operation.
Notes :

The uploaded file will be seen in the “Assigned files list”
The “Action Bar” of the assigned files list is used for various
functions.
Refresh the page
Upload an XML file
View the file
Delete the file
Problems with uploading the XML files
In the event of an error during the upload process will be

necessary to email the xml file to:
service.euna.industry@siemens.com
B007: END
Notes :

B007 END Electronic Logbook

B017 Data Management
Module Description:
It is necessary to have procedures in place for saving and restoring the customers data stored in
the CNC.
The following cases have to be taken into consideration:
 Series machine production

 Individuality of machines
 Manufacturer changes to prototype machine
 Damage to the PPU
 Damage to the system CF card
Module Objective:
Upon completion of this module the course participant will know how to:
 Create and restore archives using the data class system of the 828D
 Create and restore a system image.
Content:
Sinumerik
Data Management Concept
Data Classes
Easy Archive
Save Data Function
System Software Backup and Restore
Creating Archive With Shortcut Key
System CF Card Replacement
B017
B017

Data Management B017
Data Management: Description
Data Management:
START
The 828D uses a data system in which data is separated into
Classes (data class structure).
Data classes allow backups to be created which contain only
the data which is belonging to the Manufacturer, individual Data
machine or end customer. Management
This enables upgrades etc. to be carried out while leaving Concept
other non-related data in the controller untouched.
The operating system of the 828D controller is stored on an

internal compact flash (CF) card, an image of this card can be
created for use in the event of a failure of this CF card. Data
Classes
It is necessary to have procedures in place for saving and re-
storing the customers data stored in the CNC.
The following cases have to be taken into consideration:

 Series machine production Easy
 Individuality of machines Archive
 Manufacturer changes to prototype machine
 Damage to the PPU
 Damage to the system CF card
Save Data
Function
Creating
Archive With
Shortcut Keys
System
Software
Backup and
Restore
System
CF Card
Replacement
Data Management:
END
Notes :

Data Management Concept B017 Data Management
Notes :

Data Classes
The 828D controller uses machine data which is divided into

data classes.
Data classes can be used to create archives which contain
only specific data's of the controller, data according to it´s clas-
sification. Upgrades etc. can therefore be carried out while
leaving any existing unrelated data of the controller intact.
Types of Data Classes:
The Data Classes are split into four categories:
System - This data belongs to the system and cannot be ed-

ited. The values are determined by the controller type and
standard data. Data belonging to this class is not saved in any
archive type.
Manufacturer - The manufacturer data is common throughout

a particular machine series. No individual or user data is in- Data Class Identifier
cluded.
Individual - The individual data is machine specific

(Compensations, reference points etc.). An archive of the Indi-
Data Classes for PLC Data Blocks
vidual type could typically be made prior to a software update.
User - The user data is user specific (Part programs, tool data, It is also possible to select the Data Class of certain Data
zero points etc.). An archive of the user type could be used to Blocks in the User PLC program. When a Data Block is first
transfer data to an identical machine created, the properties box is displayed.
cutting the same component or in the case of a software up- The Data Class can be changed via the drop down menu. If
date. the Data Block already exists, the properties can be viewed by
right clicking on the Data Block and selecting properties.
Data Classes for Machine Data
When looking at the machine data area of the controller it is

possible to see which machine data belongs to which Data
Class.
Example: Axis specific machine data screen showing data
class identifiers:
Selection of the
Data Class.
Notes :

Easy Archive Control Components:
Creating Setup Archives: NC data:- The NC data consists of:-

To create a Setup Archive, locate the correct area by using the All machine and Setting data (except for drive machine data)
following key sequence. Tool data
Offsets
R parameters
Part Programs
User Data
Ensure that the option “Create Setup Archive” is selected and
select “OK”. PLC data:- This will create an archive suited to restoring the
PLC user program in the event of a problem.
Drive data:- This will create an archive containing data for the
Sinamics drives.
The drive data can be taken out in two formats:
ACX is a binary file and is unreadable with text editors etc.
ASCII is a text file which can be opened with a text editor, this
can be useful in upgrade situations where new machine data
might prevent the binary file from reading in and/or the data
needs to be entered manually.
HMI data:- This saves data that is stored on the HMI.

The list comprises of:-
Cycle storage
Texts
Templates
Applications
Configurations
Help
Version data
Logs
User views
Dictionaries
Creating Non-Data Class Setup Archive:
The example below shows the “All” option selected with the
A number of choices are available with regards to the type of four control components also selected. This would create a full
data to be included in the archive you are about to create. backup of the controller.
The “All” option does not take into account the Data Classes.
Data from all data classes will be included.
Individual control components can be selected/deselected to
make a full or partial back-up of the controller.
Notes :

Information about the archive can be entered in the Comments
section.
A dialogue box indicates that the archive was successfully

created.
The destination of the archive needs to be selected next. this

can be on the controller itself in the “Archive” directory or ex-
ternally to a USB or CF device.
A new directory can be created if necessary.
Creating Data Class Setup Archives
Data Class Setup Archives are created under the “Selection”

option.
A name for the archive needs to be entered, example-Milling

Machine 123.
The archive is now created and stored in the specified destina-

tion.
Archives are created with an ”.ard”. extension.
Notes :

A selection of MANUFACTURER, INDIVIDUAL or USER data

can be made.
A description of the data included with each selection is shown
below:
A suitable name for the archive should be entered.
MANUFACTURER : This will create an archive containing all
manufacturer relevant data of the machine. This will not contain
any individual or user data.
INDIVIDUAL : This archive will save only machine specific ma-

chine data such as ball-screw compensations, reference point
offsets etc.
USER :This archive will save user specific data such as part
programs, tool and zero offsets.
The selections shown in the following example would create a

User Data Class archive containing user data from the NC
only.
Note that the Drive data option is not available for selection,
Drive data always belongs to the “Manufacturer” The archive is now created and stored in the destination speci-
data Class type. fied earlier.
The archives are created with a default extension of “.ard”.
A dialogue box indicates that the archive was successfully

created.
The destination of the archive is selected next. this can be on

the controller itself in the “Archives” directory or externally to a
USB or CF device. A new directory can be created if desired.
Notes :

Reading in Archives The advanced “Start-up” menu will be displayed.
In the event of a hardware/software change it could be The menu contains many options.
necessary to read in archive files. The type of archive to be loaded will determine which option
should to be selected.
Loading Standard Data
Before reading in an archive it is recommended that the Example 1:-If a complete NCK archive is to be loaded, the
controller is loaded with default data. “NCK default data” option would be selected.
Restart the controller, press the “select” key within 3 seconds Example 2:-If a complete NCK, PLC, Drives & HMI archive is to
of the following screen appearing. be loaded, the “Factory settings” option would be chosen.
Press SELECT key to enter setup menu
The basic “Start-up” menu will be displayed, to display the Cursor to the required option and press the “Input” key.
advanced “Start-up” menu select the keys indicated below in
the numerical order shown.
1 2 3
Notes :

Depending upon which option has been selected, a series of

dialogue boxes may appear, acknowledge these as required.
Allow the control to boot. This is indicated by the permanently
illuminated top green LED and the flashing orange middle LED
directly above the CF and USB sockets.
Alarms will be present (Alarm numbers 4060 & 400006, alarm
120402 will be present if the default drive data was loaded)
These alarms can be ignored.
Set the password to “service” or higher.
Selecting the archive to be read-in
Use the following key combination to reach the area for read- The reading in of the archive will begin, this is indicated by a
series of information boxes.
ing in archives:-
Cursor to the “Read in Setup Archive” option and press “OK”.
When the archive has been successfully read-in the following

message box is displayed.
Select the archive to be read-in, example- Milling Machine 123
When the process is complete the functionality of the machine

can be tested.
Information about the archive is displayed. It is possible to read
in all or part of the archive, depending upon the archive con- Note: It is important that the operator checks tool data, off-
tents. sets, programs etc. as the archive could contain old data.
Notes :

Save data function
The “Save Data” function is used to automatically save the NC

data stored in the static ram memory (SRAM) of the 828D con-
troller to the system CF card.
The “Save data” function stores an image of the data to the
internal CF card of the controller (the image is not accessible
via HMI explorer).
Only one copy of the image is stored, the previous image is The data is now stored on the system CF card.
overwritten each time the save data function is performed.
The image cannot be retrieved from the CF card. Restoring the data saved with the Save Data function
The saved data can be used in one of two ways:- The data saved previously can be restored by one of two meth-
ods.
 Creation of series machines. Series machines are pro-
duced by creating an image of the system CF card of Creation of series machines:
the prototype machine. When the image is When a system CF card, created using an image of the proto-
created it will include the “Save data” image which will type machine, is inserted into a new controller for the first time,
automatically be restored during 1st power on of the the saved data will be automatically reloaded. This produces a
series machine. clone of the prototype machine.
 Creation of backups during commissioning. The saved Manually reloading the saved data:
data can be manually reloaded from the Start-up menu. The saved data can also be manually loaded. This is done
If the function has never been carried out, the controller from the start-up menu. Message “4062 Backup data loaded”
will be loaded with standard data. will be displayed to warn the operator that the data was re-
loaded.
Data saved by the “Save data” function:-
All machine and setting data (Except for drive machine data) The start-up menu is selected during the start-up of the
Tool data controller:
Offsets
R parameters Reboot the controller, within 3 seconds of the following screen
Part Programs appearing, press the “select” key.
User Data
Performing the Save Data Function:
Notes :

The Start-up menu will appear, cursor to the “Reload saved Creating Archive with Shortcut keys
user data” option and press the “Input” key.
The screen of the 828D controller is integrated into the PPU
and cannot be changed. In the event of a screen failure it is
not possible to create an archive in the usual
manner prior to replacing the controller.
For this reason it is possible to create a complete archive by
simultaneously pressing three keys together.
The keys to be pressed are “CTRL” + “ALT” + “S”
This procedure will automatically create an archive to an exter-
nal USB or CF memory device.
Select the following keys simultaneously to produce the ar-

chive.
+ +
If the procedure is used on a controller with an operational

screen, several dialogue boxes be will be shown, these will
clear when the archive has been created.
If the screen has failed these boxes will obviously not be seen.
Cursor to the “Yes” button and press the “Input” key.
Allow the procedure to continue, this could take about five min-
utes.
When the process is complete a message is displayed warning

that the backup data has been loaded.
This message is cleared with the “Reset” key, however it
should be noted that the data that has been restored will possi-
bly be old data and may contain incorrect tool data etc.
The operator should be warned of this fact and be prepared to
check program data, offsets, tools etc. before operating the
machine. The controller should be allowed plenty of time to create the
archive, a guide would be to allow 5 minutes.
A file with the .arc extension will be created and given a de-
fault name which includes time and date information.
It should be checked that the file exists on the USB/CF device
before commencing work. If there are any doubts it may be
better to do the procedure twice and compare the file sizes.
Example:
Notes :

System Software Backup Creating a system image
When the prototype of a particular machine is complete, series Before commencing it is necessary to perform the “Save data”
production can begin. In order to do this a clone of the data of function described in Section 5.
the prototype machine is required.
Insert a FAT formatted CF card or USB stick of at least 1024MB
The 828D controller uses an internal system CF card. This into the front of the controller (X125-USB, X145-CF card).
card contains the system software from which the controller
operates. The card also contains other important data which is Restart the controller, within 3 seconds of the following screen
essential for the machine to function. appearing, press the “select” key.
The following procedure shows how to create an image of the

card. The image is of the type ”.tgz” and is saved to an exter-
nal USB or CF storage device.
Start-up of series machines is achieved quickly using USB/CF

cards:
Completed prototype
machine
Empty storage device Storage device containing Select the highlighted soft-keys in the numerical order indi-
(CF card/USB stick) system image (TGZ) cated (Not simultaneously):
1 2 3
Notes :

The advanced menu will be shown, select the option “Create Enter a suitable name for the file, the “tgz” extension must
software update/backup”. remain.
Press the input key to continue.
The file will now be created, as the process continues the file
size, indicated in the brackets, will increase.
When the image has been created a confirmation message is

displayed. Remove the USB/CF storage device and power off/
on the controller.
Ensure that a USB or CF memory device is inserted.

The image should be stored in a safe place for future use.
Continue with the “Input” key.
Notes :

Restoring a System Image The following procedure will flash the backup image
saved earlier to the new system CF card.
The previously created system image (TGZ file) is used for the
starting up of series machines.
The controller should be started and the advanced “Start
A licensed system CF card should be inserted into the rear CF -up menu” selected.
card slot of the Controller.
Cursor to the “Install software update/backup” option and
Location of rear CF card slot, insert the system CF in here: press the “Input” key.
Insert the USB/CF device which contains the backup

image and select “Yes” followed by the “Input” key.
Notes :

When the controller reboots, the alarm “4062 Back-up data

Select the backup image, e.g. 828D_image.tgz and press the loaded” will be displayed, this data is the data saved in the
“Input” key. It is possible that more than one image is present “Save data” procedure. Clear with the “Reset” key
on the card/USB stick, ensure that the correct one is chosen.
The machine functionality should now be checked. The opera-

tor should ensure that tool data, offsets etc are correct.
If alarm alarms numbers 4060 & 400006, 120402 are present,

this indicates that the “Save data” procedure was not carried
out before the system image was created.
In this case an archive will need to be loaded to get the
machine to an operational condition.
Time and Date Settings
The 828D controller uses the EUNA system for registering the
machine
The registration is very important with respect to the start of
the 2 year warranty
Period (2nd commissioning at End user).
The data backup is now written to the internal card. Allow the For this reason it is essential that the time and date be set
process to finish correctly.
When the procedure is finished the controller needs to be

powered off to allow the USB/CF device to be removed.
Notes :

System CF Card Replacement From the “View” menu select the “Expert view” option.
In the event of the internal CF card becoming damaged it is

possible to write a previously saved system image to a new CF
card.
It is necessary to obtain a replacement blank CF card from
Siemens. Part number for replacement 1GB card:
6FC5313-5AG00-0AA0.
The card will need to be licensed, this can only be done via the
Siemens Hotline.
The serial numbers of the faulty and replacement cards are
required by the Hotline before a new licence number can be
issued.
A system image (TGZ file) is a copy of the working system CF

card, creating a system image is described previously.
The “Save Data” function also described earlier, should be From the “NC commissioning” list, select the option “Creating
performed prior to creating a system image. SINUMERIK 828D boot system”.
Preparing the replacement System CF card:
This card needs to be made bootable using the following

procedure.
The replacement CF card should be inserted into a computer

using a suitable adaptor.
The software package “RCS Commander” is required plus a

recovery file called “minsys.img”. This file is installed as part of Browse for the CF card:
the toolbox and is found within the folder named “Recoverysys”
in the toolbox directory.
Start the “RCS Commander” software:
Highlight the drive letter of the CF card. Example “K:\”
A connection to the controller is not necessary, cancel any

dialogue boxes.
Notes :

Start the write procedure with the “Write” button. Insert the USB/CF device which contains the backup image
and select “Yes”.
When the procedure is complete a confirmation box is dis-

played. Select the backup image and press the “Input” key. It is possi-
ble that more than one image is present on the card/USB stick,
ensure that the correct one is chosen.
Writing the Image to the Replacement CF Card
The “Minsys” recovery file to the CF card makes the card boot-
able. The card needs to placed in the rear CF card slot of the
controller in place of the “damaged” card.
The following procedure will flash the backup image saved
earlier to the new system CF card.
Insert the replacement bootable system CF card in the rear

slot of the controller.
Switch the controller on and allow to startup, the following dia-

logue box will be displayed, select the “Input” key to continue.
The data backup is now written to the internal card. Allow the
process to finish.
Notes :

When the procedure is finished the controller needs to be pow-
ered off to allow the USB/CF device to be removed.
Switch off the controller, remove the front CF card/USB stick

and then switch the controller on.
When the controller reboots, the alarm “4062 Back-up data
loaded” will be displayed, this data is the data saved in the
“Save data” procedure. Clear with the “Reset” key.
If alarm alarms numbers 4060 & 400006, 120402 are present,

this indicates that the “Save data” procedure was not carried
out before the system image was created.
In this case an archive will need to be loaded to return the
machine to a running condition.
Licensing
The licence key number is matched to the System CF card

serial number, using a new CF card means that the numbers
do not now correspond.
Alarm number 8081 is generated because of this. The number
of options not licensed will differ between machines.
The new licence number obtained from the Siemens Hotline

will need entering, this is described in Module B044.
The data that was reloaded will need to be checked, tool data,
offsets etc will probably have changed since the image was
created.
The operator should verify this data before running the ma-
chine.
B017: END
Notes :

B017 END Data Management
Notes :

B010 PPU Connections and Diagnostics
Module Description:
The 828D PPU can be diagnosed using status LED’s. The status can be quickly assessed prior to
using more detailed diagnostic tools.
For the controller to function correctly the hardware has to be correctly connected, the location and
functionality of these interfaces is described in this module.
Module Objective:
Upon completion of this module you will be able to locate the status LED's and determine the
status of the CNC controller.
You will also be able to locate all the hardware connections and know their functionality.
Content:
Sinumerik
PPU Status LED’s and Interfaces (Front)
PPU Status LED’s and Interfaces (Rear)
Digital Input/Output Terminal Description
B010
B010

PPU Connections and Diagnostics B010
PPU Connections and Diagnostics : PPU Connections

Description and
Diagnostics:
START
The 828D PPU can be diagnosed using status LED’s. The
status can be quickly assessed prior to using more detailed
diagnostic tools. PPU Status
For the controller to function correctly the hardware has to be LED’s and
correctly connected, the location and functionality of these Interfaces
interfaces is described in this module. (Front)
PPU Status
LED’s and
Interfaces
(Rear)
Digital Input/
Output
Terminal
Description
PPU Connections
and
Diagnostics:
END
Notes :

B010 PPU Connections and Diagnostics
PPU Status LED’s and Interfaces (Front) PPU Status LED’s and Interfaces (Rear)
The interfaces are found on the front and the rear of the PPU. Interface locations:-
The front interfaces are found beneath a hinged cover to the
left of the screen. Rear view of PPU showing interfaces.
Internal (System) CF card location.
Fault
X100 Sync PN
X101 Fault PN
Sync
Rx/Tx X130
X102 Link
X140 X135
X122
Ethernet DHCP server port. X132
Default address-192.168.215.1
X127 Issues addresses up to X242
192.168.215.31. X252
RDY X143
LED status indicators, see table
NC X1
below. M T1 T2 T3
CF
X125 USB port for keyboard and
memory devices.
Interfaces for 828D S120 Book-sized Drive Modules:
X1 +24V DC supply
Compact Flash port for cus- X100 DriveCliq interface for line/motor/SM modules
X145 tomer data storage and service/ X101 DriveCliq interface for DMC/TM54/SM modules
commissioning tasks. X102 DriveCliq interface for NX10/TM54/SM modules
X130 Ethernet-Factory network
X135 USB interface
X140 RS232 interface
X143 Interface for two Hand-wheels
X122 Digital I/O for Sinamics
Red/ X242 Digital I/O for NC
LED Green Orange Red
Orange X252 Digital I/O for NC
NC Ready PN Profinet interface
PLC in stop NC in stop Power-up PN Profinet interface (Not on 828D Basic M/T)
RDY and PLC in
mode mode (Alternating)
run mode T0 Analogue output measuring socket
T1 Analogue output measuring socket
NC operation T2 Analogue output measuring socket
NC
(Flashes cyclic) M Electronic ground for analogue measuring sockets
Internal/External
CF card access NX10: Handling of more than 6 axes.
CF SM: Sensor Module for non-DriveCLiQ encoders/scales.
(Flashes ran-
domly) DMC: DriveCLiQ hub for additional SM modules.
TM54: Terminal Module for Safety Integrated signals.
Note: The CF card should not be removed while the CF LED
is flashing.
Notes :

PPU Connections and Diagnostics B010
Interfaces for 828D S120 Combi Drive System: Digital Input/Output Terminal Description
X1 +24V DC supply X122, X132, X242 & X252 Terminal Description

X100 DriveCliq interface for Combi Drive/SM module.
X101 DriveCliq interface for S120 Book-sized Compact X122 & X132: BiCo’s are used to assign Sinamics inputs/
Motor Modules outputs to a specific function e.g. Enabling of drives, BERO’s,
X102 DriveCliq interface for TM54 Terminal Module for automatic line contactor control etc
Safety Integrated signals Certain terminals are automatically assigned to a function by
X130 Ethernet-Factory network default, these are the OFF1 and OFF3 drive enable signals
X135 USB interface and the input for probe 1.
X140 RS232 interface The remaining terminals can be assigned to a function via
X143 Interface for two Hand-wheels machine data.
X122 Digital I/O for Sinamics The status of the terminals is transferred to CU parameter
X132 Digital I/O for Sinamics r0722 which is referred to when assigning a function.
X242 Digital I/O for NC
PN Profinet interface
PN Profinet interface (Not on 828D Basic M/T) X122-Sinamics I/O
M Electronic ground for analogue measuring sockets
X122 Signal Function/Default Setting
LED Indicators (All variants):
Pin 1 Sinamics DI0 OFF1 (ALM, SLM >=16Kw), Pulses
enabled (SLM <16Kw)
Name Colour Description
Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop
FAULT Red Fault present (Profinet interface)
Pin 3 Sinamics DI2 Safety Integrated SH/SBC 1 Group 1
SYNC Green Synchronisation OK (Profinet interface) input
Pin 4 Sinamics DI3 Safety Integrated SH/SBC 1 Group 2
Rx/Tx Yellow Network activity (X130 interface)
input
Link Green Network connected (X130 interface) Pin 5 Sinamics DI16 DI 16 Free to assign
Pin 6 Sinamics DI17 DI 17 Free to assign
Pin 7 MEXT2 Ground (M) Ground for pins 1 to 6
Pin 8 P24EXT1+24V DC (P) +24V DC common
Pin 9 Sinamics DI/DO8 Safety Integrated SH/SBC 1 Group 1
output
Pin 10 Sinamics DI/DO9 Safety Integrated SH/SBC 1 Group 2
output
Pin 11 MEXT1 Ground (M) P Ground for pins 9, 10, 12, 13
Pin 12 Sinamics DI/DO10 Bero 1 reference mark input
Pin 13 Sinamics DI/DO11 Probe 1 de-centralised input
Pin 14 MEXT1 Ground (M) Ground for pins 9, 10, 12, 13
Notes :

B010 END PPU Connections and Diagnostics
X132-Sinamics I/O X252-NCK Digital I/O
X132 Signal Function/Default Setting X252 Signal Function/Default Setting

Pin 1 Sinamics DI4 DI 4 Free to assign Pin 1 AOUT Analogue output for spindle
Pin 2 Sinamics DI5 DI 5 Free to assign Pin 2 AGND Analogue ground for spindle
Pin 3 Sinamics DI6 DI 6 Free to assign Pin 3 NCK DI9 (IN9) DI $A_IN[9]
Pin 4 Sinamics DI7 Line contactor check back signal Pin 4 NCK DI10 (IN10) DI $A_IN[10]
input
Pin 5 NCK DI11 (IN11) DI $A_IN[11]
Pin 8 P24EXT3 +24V DC +24V DC common
Pin 8 P24EXT1+24V DC +24V DC common (P)
(P)
Pin 9 NCK DI9 (OUT9) DO $A_OUT[9]
Pin 9 Sinamics DI/DO12 Infeed is ready output
Pin 10 NCK DI10 (OUT10) DO $A_OUT[10]
Pin 10 Sinamics DI/DO13 Ready to power up output
Pin 12 Reserved:
Pin 12 Sinamics DI/DO14 Line module contactor control NCK DI11 (OUT11)
Analogue spindle enable/direction
output
Pin 13 Reserved:
Pin 13 Sinamics DI/DO15 Probe 2 de-centralised input NCK DI12 (OUT12)
Analogue spindle enable/direction
Pin 14 MEXT1 Ground (M) Ground for pins 9, 10, 12, 13 Pin 14 MEXT3 Ground (M) Ground for pins 9, 10, 12, 13
X242-NCK Digital I/O

X143-Hand-wheel connections

Pin 1 5V DC (P5) +5V DC common
Pin 1 Not connected Not Connected
Pin 2 0V DC (M) Ground
Pin 2 Not connected Not Connected
Pin 3 1A Hand-wheel 1 signal A
Pin 4 –1A Hand-wheel 1 signal –A
Pin 5 1B Hand-wheel 1 signal B
Pin 6 –1B Hand-wheel 1 signal –B
Pin 8 P24EXT3 +24V DC +24V DC common
(P) Pin 9 2A Hand-wheel 2 signal A
Pin 9 NCK D01 (OUT1) DO $A_OUT[1] Pin 10 –2A Hand-wheel 2 signal –A
Pin 10 NCK DO2 (OUT2) DO $A_OUT[2] Pin 11 2B Hand-wheel 2 signal B
Pin 11 MEXT3 Ground (M) Ground for pins 9, 10, 12, 13 Pin 12 –2B Hand-wheel 2 signal –B
Pin 12 NCK DO3 (OUT3) DO $A_OUT[3]

Pin 13 NCK DO4 (OUT4) DO $A_OUT[4]
B010: END
Notes :

B030 Digital I/O, hand-wheels and probes
Module Description:
The 828D has interfaces for the connection of Digital I/O (Sinamics & NCK), Probes & Hand-
wheels. The hand-wheel connections are pre-determined (X143) while the digital I/O and probes
can be assigned to any suitable connection.
Connections used within the drive group components are known as BICOs (Binary Connectors)
Certain connections can be configured as an output or an input.
X122-Sinamics functionality
X132-Sinamics functionality
X242-NCK functionality
X143-Hand-wheel functionality
This module shows the pin assignment of each connector and shows several examples of how a
connector is assigned to a function, including probes and line contactors.
Module Objective:
Upon completion of this module you will be able to locate the interface connectors and configure
individual connections to perform certain functions.
Content:
Sinumerik
PPU Digital I/O Interfaces.
BICO Assignment
NCK Inputs and Outputs
B030
B030

Digital I/O, hand-wheels and probes B030
Digital I/O, hand-wheels and probes: Digital I/O,

Description hand-wheels and
probes:
The 828D has interfaces for the connection of Digital I/O START
(Sinamics & NCK), Probes & Hand-wheels. The hand-wheel
connections are pre-determined (X143) while the digital I/O
and probes can be assigned to any suitable connection. PPU:
Connections used within the drive group components are Digital Input/
known as BiCo’s (Binary Connectors) Output
Certain connections can be configured as an output or an Interfaces
input.
The connections use 4 screw type connectors, each with 12
terminals: Digital Input/
Output
X122-Sinamics functionality Terminal
X132-Sinamics functionality Description
X143-Hand-wheel functionality
This module shows the pin assignment of each connector BiCo

and shows several examples of how a connector is assigned Assignment
to a function, including probes and line contactors.
NCK Inputs
and
Outputs
Digital I/O,
hand-wheels and
probes:
END
Notes :

PPU Digital I/O Interfaces
Interface locations:
Rear view of PPU showing interfaces.
Digital IO Interface connectors:

X122
X132 X242 Digital I/O for NC
X143 Handwheel Interface
X242
X252
X143
Notes :

Connection diagram for X122, X132, X242, X252
PPU
X122 Drive NC X242

1 DI 0 Not used 1
2 DI 1 Not used 2
3 DI 2 IN1 3
4 DI 3 IN2 4 DC +24V
DC +24V 5 DI 16 IN3 5
6 DI 17 IN4 6
7 MEXT2 MEXT4 7
DC +24V DC +24V
8 P24EXT1 P24EXT3 8
9 DI/DO 8 1* OUT1 9
10 DI/DO 9 1* OUT2 10
11 MEXT1 MEXT3 11
12 DI/DO 10 1* OUT3 12
13 DI/DO 11 1* OUT4 13
14 MEXT1 MEXT3 14
X132 Drive NC X252

1 DI 4 +/- 10V AO Spindle 1
2 DI 5 AM Spindle 2
3 DI 6 IN9 3
4 DI 7 IN10 4
5 DI 20 IN11 5
6 DI 21 IN12 6
7 MEXT2 MEXT4 7
8 P24EXT1 P24EXT3 8
9 DI/DO 12 1* OUT9 9
10 DI/DO 13 1* OUT10 10
11 MEXT1 MEXT3 11
12 DI/DO 14 1* Analog Spindle 12 Enable/direction
13 DI/DO 15 1* Analog Spindle 13
Enable/direction
14 MEXT1 MEXT3 14
1* Fast inputs/outputs (Must be shielded). Can be parameterised as Inputs or outputs.
Notes :

X122, X132, X242, X252 & X143 Terminal Description
X122 & X132: BICO Connections are used to assign Sinamics inputs/outputs to a specific function e.g. Enabling of drives,
BERO’s, automatic line contactor control etc
Certain terminals are automatically assigned to a function by default, these are the OFF1 and OFF3 drive enable signals and the
input for probe 1.
The remaining terminals can be assigned to a function via machine data.
The status of the terminals is transferred to CU parameter r0722 which is referred to when assigning a function.
X122-Sinamics I/O:
X122 Signal Function/Default Setting BICO connection

Source Destination
ON/OFF1 for DriveCLiQ line
CU-r0722.0 Infeed p0840
modules (ALM, SLM >=16Kw)
Pin 1 Sinamics DI 0
Infeed ready for non DriveCLiQ
SLM X21.1 Drive p0864
SLM (SLM <16Kw)
Each drive 2nd OFF3,
Pin 2 Sinamics DI 1 OFF3 drive enable-Fast Stop CU-r0722.1
p0849
SH/SBC 1 – Group 1
p9620 (all drives in the
Pin 3 Sinamics DI 2 SINAMICS Safety Integrated CU-r0722.2
group)
(SH enable = p9601)
SH/SBC 1 – Group 2
p9620 (all drives in the
Pin 4 Sinamics DI 3 SINAMICS Safety Integrated CU-r0722.3
group)
(SH enable = p9601)
Pin 5 Sinamics DI 16 DI 16 Free to assign CU-r0722.4
Pin 8 P24EXT1 +24V DC common
SH/SBC 1 – Group 1 (Input) p9774 bit 1
Pin 9 Sinamics DI/O8 SINAMICS Safety Integrated CU-p0738 BICO from CU after the 1st
drive in the group
p9774 bit 1
SH/SBC 1 – Group 2 (Input) CU-p0739
Pin 10 Sinamics DI/O9 BICO from CU after the 1st
SINAMICS Safety Integrated
drive in the group
Pin 12 Sinamics DI/O10 Bero 1 - external zero mark (Input) CU-r0722.10 Drive p0495=2
Each drive p0488,
Probe 1: Remote Measuring (Input)
Pin 13 Sinamics DI/O11 CU p680[0]=0 Index
(MD13210=1)
encoder 1, 2, 3=3
Notes :

X132-Sinamics I/O
X132 Signal Function/Default Setting BICO connection

Source Destination

Pin 4 Sinamics DI 7 Line contactor feedback signal CU-r0722.7 LM-p0860

Infeed operation (Output)
Pin 9 Sinamics DI/O 12 LM-r0863.0 CU-p0742
(Line Module with DRIVE CliQ)
Infeed ready to start (Output)
Pin 10 Sinamics DI/O 13 LM-r0899.0 CU-p0743
(If Line Module with DRIVE CliQ)
Line contactor control (Output) LM-r0863.1 CU-p0744
Pin 12 Sinamics DI/O 14 Bero 2 - external zero mark(Input) CU-r0722.14 Drive p0495=5
2nd OFF 2 (Input) CU-r0722.14 Drive p0845
Each drive p0488,
Probe 2: Remote Measuring (Input) CU-p680[1]=0
Pin 13 Sinamics DI/O 15 Index
(MD13210=1) CU-p728 bit 15=0
encoder 1, 2, 3=6
Notes :


Pin 1 n/c n/c
Pin 2 n/c n/c
Pin 3 IN1 NCK DI 1 Digital Input $A_IN[1]
Pin 9 OUT1 NCK DO 1 Digital Output $A_OUT[1]

Pin 1 AOUT Output for analogue spindle +/- 10V
Pin 2 AGND Ground for analogue output
Pin 12 OUT11 NCK DO 11 Reserved: Analogue spindle enable/direction
Pin 13 OUT12 NCK DO 12 Reserved: Analogue spindle enable/direction
Notes :

X143-Hand-wheel connections

Notes :

BiCo Assignment Assigning the probe inputs.
Assigning a BiCo to a function requires changing machine In the following example, probes 1 & 2 will be assigned to
data. BICO connectors X122.13 and X132.13 respectively.
The default setting for OFF3 can be checked as an example. Probe 1 via X122.13 is used as the work-piece probe.
The OFF3 signal is input on X122.2, the status of this signal Probe 2 via X132.13 is used as the tool probe.
is displayed via CU r0722.2.
In order for the signal to have any effect on the operation of Setting the functionality of the terminals
the drives It has to be referenced to each drive.
This is achieved through p0849 for each drive. X132.9, 10, 12 & 13 can be used as either inputs or outputs.
This is determined by the setting of CU parameter p728: CU,
set input or output.
Example: Assigning the OFF3 signal to X axis p0849
The default setting for p728 is X132.9, X132.10, X132.12 &

X132.13 as outputs.
Use the “Select” key to give a more detailed view.
The information regarding the source of the OFF3 signal has

to be entered.
Bits 12, 13, 14, & 15 set as outputs.
Parameter name
and signal. Drive Object. To change X132.13 to an input, Bit 15 has to be de-selected.
P849, OFF3 CU = 1
Deselect and confirm with the “OK” soft-key.
Parameter in CU Bit number of

= r0722 Parameter = 1
Notes :

Assigning probe 2 to X132.13
Probe 2 is not assigned by default.

CU parameter p728 after assigning X132.13 as an input: Drive parameter 489 needs to be parameterised in order for
probe 2 to function
Select the correct drive and cursor to the parameter p489[0]

then press the “Select” key
Deactivating the Centralised Probe.

Before continuing it must be ensured that CU parameter p680
[0] = 0. (Default setting)
A list of permissible inputs is displayed, cursor to the correct

one i.e [6] DI/DO 15 (X132.13) and press the „Input“ key to
confirm.
Assigning the Probes to the Drives:
The system needs to know which terminal the probe input is

connected to, this is set with drive parameter p488.
All the axes that use the probe function will need to be set.
There are two parameters, one for each probe, each with 3
indexes (Indices). Repeat the procedure for p489[1] and p489[2]
p488 Measuring probe1 input terminal: Encoder 1..3
p489 Measuring probe2 input terminal: Encoder 1..3
Assigning probe 1 to X122.13:
The 1st probe is connected to X122.13 of the CU.

By default, probe 1 is already assigned to X122.13
It is also necessary to set p489[0], p489[1] & p489[2] for any
drive that is used when a probing function is used i.e X, Y & Z
axes for a standard milling machine
Notes :

Activation of Probe Soft-keys: Assigning the Spindle BERO Connector:

The soft-keys for the probing operation are not displayed as
standard. To display the soft-keys it is necessary to set The training equipment has a proximity switch connected to
General Setting Data 54780 bit 2 and 54782 bit 2. X122.10, this is for the spindle BERO (External zero mark)
signal.
To make this active the relevant Drive Machine Data (p495)
has to be set.
Ensure that the correct drive is selected, i.e. Spindle.
Select the input terminal to which the BERO switch is

connected (X122.10).
Setting the Probe Dimensions.

The Tool Probe diameter has to be entered into General
Machine 51780.
This is for radius measurement of milling tools in “Measure in
Jog” mode. The assignment of the Drive Machine Data p495 and the
The following example shows the probe with a diameter of BERO switch input is now complete.
5mm.
Saving the Changes:
The changed data needs to be saved, use the following soft-

key sequence to save the drive data:
probes are now ready for testing.
Notes :

Configuring the automatic line contactor.
The status of the save process is displayed directly above the
The automatic line contactor function is used to ensure correct
horizontal soft-keys:
switching of the line supply to the line modules (DriveCLiQ
versions only)
The following example shows how to configure the line con-

tactor coil and line contactor feedback signals.
When the process is complete another message will be briefly The feedback (Input) signal will be assigned to X132 pin 4
displayed: (Sinamics digital input 7)
The coil signal (Output) will be assigned to X132 pin 12
(Sinamics digital Output 14)
Configuring the feedback signal:

Checking the status of X122 and X132 via CU parameter
The table of X132 shows information about the source and
r722
destination. For the feedback signal, the source is CU pa-
rameter r0722.7. The destination of this signal is LM parame-
The training equipment has two red buttons on the left off the
ter p0860.
MCP, these are connected to X122.13 (Left button) and
Use the following soft-key selection to locate the set-up pages.
X132.13 (Right button).
The status of the probe inputs and any other input can be
checked via CU parameter r722: CU digital inputs status.
The Hexadecimal value is displayed:
A more user friendly view is available by highlighting the ma-

chine data and selecting the “Select” key. It can be seen that
bits 0 & 1 are high (OFF1 & OFF3).
For identification purposes the LED of

the module can be made to flash.
By pressing the red buttons the status of the probes inputs will
go high. (Bits 11 & 15)
Notes :

A summary of the line supply data is displayed, this can be

saved to a text file if required.
The supply voltage can be manually entered or detected auto-
matically.
Select the check box for SINAMICS-internal line contactor. A summary of the line supply data is displayed, this can be
The data
saved to aneeds to ifbe
text file saved, select the “Yes” soft-key.
required.
The BICO connectors for line contactor operation are pre- The following dialogue box indicates the state of save proc-
assigned. ess, when it has cleared the process is complete.
X132.12 Output to line contactor coil.
X132.4 Input check back signal from line contactor.
Notes :

The status of the digital outputs can be checked using CU Example: Setting an NCK output via a part program.
parameter r747. The example below shows bit 14 (X132.12
Line contactor coil) is high. The NCK outputs can be set directly from a part program.
Select “MDA” mode.
Type in the following text:
$A_OUT[9] = 1 Set NCK output 9 to 1 Optional program

stop, program will
M00 halt until Cycle
Start is pressed.
NCK Inputs and Outputs $A_OUT[9] = 0 Set NCK output 9 to 0
M30 Program end

X252 NCK Digital I/O
Interface X252 has NCK digital I/O signals. Press Cycle Start once.
There are four fixed digital inputs and four fixed outputs. The
addressing of the Inputs/outputs start at 9.
PLC variable byte DB2900.DBB1000 is assigned to the in-

puts, and byte DB2900.DBB1004 for the outputs.
This allows the PLC user program to be influenced from the
part program.
X252 Signal Function Variable The program will stop at the “M00” command, a message will
be displayed.
Output for analogue
Pin 1 AOUT
axis. +/- 10V
Ground for Optional stop active.
Pin 2 AGND
analogue output.
NCK Digital Input
Pin 3 NCK DI 9 DB2900.DBX1000.0
$A_IN[9]
NCK Digital Input
$A_IN[10]
NCK Digital Input
$A_IN[11]
NCK Digital Input
$A_IN[12]
MEXT4
Pin 7 Ground for pins 3 to 6
Ground (M)
P24EXT3
Pin 8 +24V DC common
+24V DC (P)
NCK Digital Output
Pin 9 NCK DO 9 DB2900.DBX1004.0
$A_OUT[9]
NCK Digital Output
Pin 10 NCK DO 10 DB2900.DBX1004.1
$A_OUT[10]
MEXT3 Ground for pins 9, 10, The status of the PLC variable can now be checked.
Pin 11
Ground (M) 12, 13
Reserved: Analogue
Pin 12 NCK DO 11
spindle enable/direction
Reserved: Analogue
Pin 13 NCK DO 12
spindle enable/direction
Type in the variables to be checked.
MEXT3 Ground for pins 9, 10,
Pin 14
Ground (M) 12, 13
When the output is set the corresponding input is also set.
This is because, for the purpose of the next exercise, General
Machine Data 10361 has a value of 1020102.
Notes :

B030 END Digital I/O, hand-wheels and probes
Digital NCK output 9 Program message display

DB2900.DBX1004.1
Digital NCK input 9

Mirrors the status of
NCK output 9
Example: Using NCK inputs in a part program
The NCK inputs can also be used in the part program. The
following program checks the status of NCK input 9 and dis- Edit the program so that NCK output 9 is set to 0:
plays a relevant message.
Type the following into the MDA screen:
$A_OUT[9] = 1 Setting NCK output 9 to 1

will also set NCK input 9
If NCK input 9 = 1
IF $A_IN[9] == 1 GOTOF LABEL1
jump forward to LABEL1
Message line showing that The Jump command is ignored and the message,
MSG (“NCK INPUT 9 IS LOW”) the input is low “NCK INPUT 9 IS LOW” is displayed.
M00 Program stops until

M00
cycle start is pressed
M30 M30 Program end
LABEL1 used for the

LABEL1: jump command (GOTOF)
Message line for showing

MSG (“NCK INPUT 9 IS HIGH”) that the input is high.
M00 Program stops until

M00 cycle start is pressed
M30 M30 Program end
To test the run/test the program select the Cycle Start button.
B030: END
Notes :

B051 Line and Motor Modules
Module Description:
The Sinumerik 828D uses Sinamics drive components, these components must be powered on/off
in a certain sequence in order to operate correctly. This module shows how these components are
connected to the system and the required power on/off enabling sequence.
Module Objective:
Upon completion of this module you will know how the drive components of the Sinumerik 828D
system are integrated and how the power to these components should be applied and removed.
Content:
Sinumerik
Topology Drive Object Numbering
General Information
Drive Module power Supply
Smart Line Module (SLM)
Active Line Module (ALM)
Motor Module (MM)
Supply and Enabling Examples
B051
B051

Line and Motor Modules B051
Line and Motor modules: Description Line and Motor

Modules:
START
The Sinumerik 828D uses Sinamics drive components, these
components must be powered on/off in a certain sequence in
order to operate correctly. This module shows how these
components are
connected to the system and the required power on/off ena- Topology Drive
bling sequence. Object
Numbering
General
Information
Drive Module
power
Supply
Smart Line Module

(SLM)
Active Line Module

(ALM)
Motor Module (MM)
Supply and
Enabling
Examples
Line and Motor

Modules:
END
Notes :

Topology: Drive Object and Component Numbering
Example- 5 axis system (Spindle, X, Y, Z, A)
The system assigns the object/component numbers on the Drive-CLiQ Bus in the order they are connected.
CU is always object number 1.
The servo drives are classed as drive objects.
Motors, encoders etc are classed as drive components.
Components Motor, encoder etc. are then assigned in reverse order.
Objects are numbered in red.

Components are numbered in purple.
828D CU
Drive Object 1
X100 X101 X102

• • •
Single Motor Module Double Motor Module Double Motor Module SMC20
Drive Object 2 Drive Objects 3 & 4 Drive Objects 5 & 6 SMC- 7
ENC- 8
•X200 X201• •X200 X201• •X200 X201• •X500
X202 X202 X203 X202 X203

• • • •
•
Sp motor X motor Y motor Z motor A motor

SMI- 21 SMI- 18 SMI- 15 SMI- 12 SMI- 9
ENC- 22 ENC- 19 ENC- 16 ENC- 13 ENC- 10
MOT- 23 MOT- 20 MOT- 17 MOT- 14 MOT- 11
Notes :

Example- 7 axis system with NX10
The NX10 can only be connected to X102. The connected drives/motors are numbered in the same way as the CU.
The DriveCLiQ line module is always
assigned Object number 2.
Equipment connected to X101 is assigned to the CU, the numbering follows on from the last Component connected to X100.
CU Objects are numbered in red.

CU Components are numbered in purple.
NX Objects are numbered in green.
NX Components are numbered in blue.
Double Motor Module

NX10 Drive Objects 2 & 3
Drive Object 1
•X100 X101• •X200 X201•
X202 X203
• •
828D CU
Drive Object 1
Motor 6 Motor 7
SMI- 7 SMI- 4
X100 X101 X102
ENC- 8 ENC- 5
• • •
MOT- 9 MOT- 6
DMC20 25 SMC20
SMC- 26
ENC- 27
•X500 X502• •X500
SLM/ALM Single Motor Module Double Motor Module Double Motor Module SMC20
Drive Object 2 Drive Object 3 Drive Objects 4 & 5 Drive Objects 6 & 7 SMC- 8
ENC- 9
•X200 X201• •X200 X201• •X200 X201• •X200 X201• •X500
X202 X202 X203

X202 X203
• • •
• •
Motor 1 Motor 2 Motor 3 Motor 4 Motor 5

SMI- 22 SMI- 19 SMI- 16 SMI- 13 SMI- 10
ENC- 23 ENC- 20 ENC- 17 ENC- 14 ENC- 11
MOT- 24 MOT- 21 MOT- 18 MOT- 15 MOT- 12
Notes :

Example– 5 axis system with Combi Drive.
The Combi drive can only be connected to X100.

Additional axes are facilitated by the addition of Book-sized Compact Modules. These must always be connected to X101.
X102 is reserved for the connection of a Terminal Module (TM54) which is used for Safety Integrated functionality.
Drive Objects are numbered in red.

Drive Components are numbered in purple.
Book-sized
Compact Motor
Module
A Axis
Drive Object 7
Drive Component 50
•X200 X201•
X202
•
828D CU
Drive Object 1 Motor 5
SMI- 51
X100 X101 X102 ENC- 52
• • • MOT- 53
4 Axis Combi Drive
SLM/ALM Spindle Motor Integrated X Axis Motor Y Axis Motor Z Axis Motor
Drive Object 2 Module Sensor Module Module Module Module
Drive Object 3 (SMI) Drive Object 4 Drive Object 5 Drive Object 6
•X200 Drive Component 10 Drive Component 14 Drive Component 20 Drive Component 30 Drive Component 40
X201 X220 X202 X203 X204

• • • • •
Motor 1 Spindle Motor 2 Motor 3 Motor 4

SMI- 11 DMS SMI- 21 SMI- 31 SMI- 41
ENC- 12 Encoder ENC- 22 ENC- 32 ENC- 42
MOT- 13 ENC- 15 MOT- 23 MOT- 33 MOT- 43
Notes :

General Information Drive Module power Supply
Line and Motor Modules Power Requirements
Line and motor modules are responsible for supplying power The drive modules require two power supplies in order to op-
to the motors. erate.
The Sinumerik 828D operates with the Sinamics S120 Book-
size range of drive products. These are of a modular design A 3 phase AC supply (380V to 480V +10% (-15% < 1 min) to
and are for use with the Drive-CLiQ drive bus system. the bottom of the line module is used to produce the 600V DC
link. The DC link is distributed to the motor modules via a bus
Line modules require a 3 phase AC supply, this is rectified bar system on the front of the drive modules beneath a flip
into a DC supply which is then supplied to the motor modules down cover
via the DC link bus bars.
The +24V DC electronics supply is obtained externally from
Motor modules convert the DC link back into a controllable AC the user on connector X24. This is also distributed by a bus
supply which is used to drive the servo motors. bar system along the front of the drive modules.
By regulating the frequency and voltage of the AC supply to The electronic supply is used internally by the drive modules
the servo motors it is possible to precisely control the move- for powering of the electronic circuitry etc. Externally it is used
ment of motors. for supplying the Drive-CLiQ encoders and fault, ready and
enable signals.
Line and motor modules are available in different variants
depending on the machine requirements.
Each module requires a +24V DC control voltage, this is sup- X24– Electronic Supply 24V DC
plied by the user to the line module and then distributed to the
motor modules via a bus system.
“M” Terminal: Electronics ground
Example, Line module with two motor modules:-
“+” Terminal: +24V DC

(20.4V to 28.8V)
Location of the electronics supply and DC link bus bars:-
24V DC Electronics supply (X24) Bridging device for

continuity of the
bus between drive
modules.
+24V DC Bus-bar
0V DC Bus-bar
+ DC Link Bus-bar
- DC Link Bus-bar
LM MM1 MM2
Notes :

Line Mod- B051
Motor Mod-
ule ules
Smart Line Modules (SLM) Connector locations X21, X22 & X24
The SLM is responsible for rectifying the AC mains supply into

the DC link voltage which is then utilised by the Motor Mod-
ules.
This DC link voltage is non-stabilised on all SLM types
The SLM is also responsible for handling the regenerative cur-
rent caused by the
X21: X22: (SLM 5 & 10Kw
braking of motors. The regenerative current is fed back into the Enable, ready only)
mains network. This eliminates the need for braking resistors and fault sig- Regeneration and
and complex measures for heat dissipation. nals fault
The SLM is available in 5, 10, 16 & 36Kw variants with internal reset signals
or external cooling capability.
Due to the non-stabilised DC link voltage, the SLM would be
used on low dynamic machinery where the axis/spindle accel-
eration/deceleration rates are not severe.
Smart Line Modules- 5 & 10Kw
The 5 & 10Kw SLM’s are not used on the Drive-CLiQ network, X24:
24V DC Elec-
because of this there are slight differences with terminal func- tronics supply
tionality compared to Drive-CLiQ type modules.
Example:-An internally cooled 10Kw SLM module showing

terminal locations etc.
SLM
X21: X22:
Various signals Various signals X22 Terminal description and functionality
X24:Electronics
supply
Electronics/DC link
bus bars (below flip Terminal Function Description
down cover)
1 +24V DC +24 V DC Supply for use with the functions
(Output) of X22.2 & 3 described below.
2 Disable Applying +24V DC will cause the regenera-

Regeneration tion function to be disabled.
(Input)
In some cases it may be necessary to stop
the
LED status regeneration of current caused by braking
Indicators motors. Example:- A poor quality mains
Network not able to handle regeneration.
Note:-The fitting of resistor modules to
dissipate
excess energy will be required when this
function is used.
3 Fault Reset Applying +24V DC will cause the resetting of

(Input) any drive faults.
A fault occurring on the drives system will

be latched, this can be reset with this func-
tion providing the cause of the original fault
X1: Mains supply is no longer present.
Protective earth (3-Phase AC)
4 0V DC Must be connected to the same 0V of the
connections
(Ground) electronics supply (X24).
Notes :

X21 Terminal description and functionality LED Status Display
LED Colour Statu Explanation

s
Green On Module is healthy and operational.
READY Yellow On Pre charging of DC link active; Bypass relay

Terminal Function Description dropped out.
(Top)
1 Ready Switches high (+24V DC) when the following Red On Over temperature/current fault or electronics
Signal conditions are true:- power supply outside permitted range.
(Output)  Electronics supply present (X24).
Off Electronics power supply outside permitted
 DC Link is pre-charged. range.
 Pulses enabled (X21.3) DC LINK
Yellow On DC link voltage within tolerance.
(Bottom
 No over-temperature )
Red On DC link voltage outside tolerance.
 No over-current
It is recommended that the signal is connected di-

rectly to the 828D controller via connector X122 pin Smart Line Modules- 16Kw and above
1. This is the OFF1 enable signal.
2 Pre- Switches low when any of the following conditions These models are always required to be connected to the
warning arise:- Drive-CLiQ drive bus network.
(Output)
 Over-temperature threshold reached. The functionality of certain terminals is therefore different from
 I²t threshold reached. the non-Drive-CLiQ SLM modules.
 Mains fault making regenerative feedback Regeneration can be deactivated by parameter P3533-Inhibit
impossible. If feedback is intentionally regenerative operation.
deactivated (X22.2 is high) this warning is
disabled. Terminal locations of an internally cooled 36Kw SLM:-
This signal is for use by the manufacturer to set a
user alarm and alert the operator to a problem.
3 Enable Applying +24V DC will cause the pulses to be

X200/X201/
Pulses enabled. (Current consumption:10mA) X21:Pulse
(Input) X202:
enable Drive-CLiQ
This signal must be removed at least 10ms prior to
the 3-phase mains supply being removed. connectors
Failure to do this can lead to damaged drive mod-
ules. This is especially important when the axes/ X24:Electronic
spindles are decelerating and causing regenerative s supply
currents. if the mains circuit is opened these regen-
erative Electronics/DC
currents remain within the drive system causing link bus bars
damage to the modules. (below flip
down cover)
It is recommended that this terminal is connected via
an early break contact on the machine isolator switch
and the line contactor (If used).
If the terminal is used by the manufacturer it must be
ensured that it is controlled in the suggested manner.
When used in this way the transistors will be LED status

switched off and mains regeneration halted, the Indicators
motors will then coast to a halt. This is not suitable
for an emergency stop situation.
4 Enable Must be connected to the 0V of the enable pulses

Pulses supply.
(Ground)
Protective X1: Mains supply

earth (3-Phase AC)
terminals
Notes :

Connector locations X21, X24, X200, X201 & X202 LED Status Display
LED Colour Status Explanation

range.
Green On Module configured and ready, Drive-CLiQ

communication is active.
X21:
Pulse enable Orange On Drive-CLiQ communication is being estab-
READY
(Top) lished/module not configured.
Red On At least one fault is present.

X202: Green/ Flash- Firmware download procedure is running.
Drive-CLiQ connector Red ing
2Hz
X201: Green/ Flash- Component recognition is active (p0124 = 1)

Drive-CLiQ connector Orange ing
or Red/ 2 Hz
Orange
X200:
Drive-CLiQ connector range.
DC
LINK Orange On DC link voltage within tolerance-Only if unit is
X24: (Botto configured and ready.
24V DC Electronics m)
Red On DC link voltage outside tolerance-Only if unit
Supply is configured and ready.
X21 Terminal description and functionality
Termi- Function Description

nal
1 Not used Not used
2 Not used Not used
3 Enable Applying +24V DC enables the pulses.

Pulses (Current consumption:10mA)
(Input)
This signal must be removed at least 10ms prior to the 3
-phase mains supply being removed.
Failure to do this can lead to damaged drive modules.
This is especially important when the axes/spindles are
regenerating. If the mains circuit is opened in this state,
regenerative currents remain within the drive system
causing damage to the modules.
It is recommended that this terminal is connected via an
early break contact on the machine isolator switch and
the line contactor (If used).
When used in this way the transistors will be switched
off and mains regeneration halted, the motors will then
coast to a halt. This is not suitable for an emergency
stop
situation.

Pulses supply.
(Ground)
Notes :

Active Line Modules (ALM) Location of ALM connectors X21, X24, X200, X201 & X202
The ALM is responsible for the rectification of the AC mains

X21:
supply into the DC link voltage which is then utilised by the
Enable and
Motor Modules. Temperature sensor
This DC link voltage is also stabilised unlike the SLM mod- Connections
ules
The ALM is also responsible for handling regenerative current
X203:
caused by the braking of motors. Drive-CLiQ connec-
The regenerative current is fed back into the mains network. tor
This eliminates the need for braking resistors and complex
measures for heat dissipation. X202:
Regeneration can be deactivated by parameter P3533-Inhibit Drive-CLiQ connec-
regenerative operation. tor
The modules are available in 16, 36, 55, 80 & 120Kw variants
with internal or external cooling capability. X201:
The ALM is always connected to the Drive-CLiQ bus and has Drive-CLiQ connec-
four Drive-CLiQ connections. tor
The stabilised DC link makes the ALM suitable for high dy-
namic machinery where the acceleration and positioning of X200:
axes/spindles is critical. Drive-CLiQ connec-
tor
Terminal locations of ALM modules:-
X24:
24V DC Electronics
X21: X200/X201/ supply
Pulse enable, X202:
temperature Drive-CLiQ X21 Terminal description and functionality
sensor connectors
X24:Electroni Electronics/DC
cs supply. link bus bars
Terminal Function Description
(below flip
down cover) 1 + Temp Temperature sensor input from Active Interface
(Input) Module (Observe the polarity)
LED status
Indicators 2 - Temp Temperature sensor input from Active Interface
(Input) Module (Observe the polarity)
3 Enable Applying +24V DC enables the pulses.

Pulses (Current consumption:10mA)
(Input)
This signal must be removed at least 10ms prior to
the 3-phase mains supply being removed.
Failure to do this can lead to damaged drive mod-
ules. This is especially important when the axes/
X1: spindles are regenerating. If the mains circuit is
3-Phase AC opened in this state, regenerative currents remain
Protective Mains supply within the drive system causing damage to the mod-
earth ules.
connections. It is recommended that this terminal is connected via
an early break contact on the machine isolator switch
and the line contactor (If used).
When used in this way the transistors will be
switched off and mains regeneration halted, the
motors will then coast to a halt. This is not suitable
for an emergency stop
situation.

Pulses supply.
(Ground)
Notes :

LED Status Display Motor Modules (MM)
Motor Modules are responsible for converting the DC link

LED Colour Status Explanation voltage into a variable AC voltage in order to drive the mo-
tors.
Off Electronics power supply outside permitted The modules have to be connected to the Drive-CLiQ bus.
range. Single/double axis and internally/externally cooled versions
are available.
Green On Module configured and ready, Drive-CLiQ
communication is active. Double axis modules are equipped with four Drive-CLiQ con-
nectors, one more than the single axis modules.
READY Orange On Drive-CLiQ communication is being estab-
(Top) lished/module not configured.
Single Axis MM
Red On At least one fault is present. Available in the following rated current output sizes:-
Green/ Flashing Firmware download procedure is running. 3, 5, 9, 18, 30, 45, 60, 85, 132 & 200A.
Red 2Hz
Green/ Flashing Component recognition is active (p0124 = 1) Example:- A single axis MM showing connector locations etc.
Orange or 2 Hz
Red/
Orange

range. X200/X201/X202:
DC LINK X21: Drive-CLiQ
(Bottom) Orange On DC link voltage within tolerance-Only if unit is Enables etc. Connectors
configured and ready.
Red On DC link voltage outside tolerance-Only if unit is

Electronics/DC
link bus bars
(below flip down
cover)
LED Status
Indicators
X11: Brake output
for MM of 45A and
above
X1: Output to
Protective Motor, including
earth the brake output
terminals for MM less than
Notes :

Double Axis MM Terminal descriptions

Available in the following rated current output sizes:-3, 5, 9 &
18A
X21: Pulse
Enable etc.
Example:-A double axis MM showing connector locations.
These units will have two identical Motor/Brake connectors
X21: Pulse
(X1 & X2) and two X22: Pulse
Enable etc.
identical enable connectors (X21 & X22). Enable etc.
X203:
X202: Drive-CLiQ
Drive-CLiQ
X21:Motor 1 X22:Motor 2
X202:
Enables etc. Enables etc. X201: Drive-CLiQ
Drive-CLiQ
X201:
X200/X201/X202/ Electronics/DC
Drive-CLiQ
X203: link bus bars
(below flip down X200:
Drive-CLiQ
cover) Drive-CLiQ
connectors X200:
Drive-CLiQ
LED Status
Indicators X1 & X2 Output Single axis Double axis
to Motor, Module Module
including the
brake output for
MM less than
45A
Connector X21 & X22 (X22 only for double axis modules)
Protective
earth X11: Brake out-
connections put for MM of
45A and above
1 + Temp Positive temperature sensor input from non-Drive-CLiQ

(Input) temperature sensor.
Type:- KTY84-1C130/PTC
2 - Temp Negative temperature sensor input from non Drive-CLiQ

(Input) temperature sensor.
3 Enable Applying +24V DC will cause the pulses of the individual

Pulses axis to be enabled. (Current consumption:10mA)
(Input) When the signal is low, “Safe pulse suppression” is
activated.
Note:-No electrical isolation occurs between the Motor
module and the motor.
This enable signal is only operational if the Safety
Integrated function “Safe Standstill (SH)” is enabled.
This is a dual channel monitoring system of the Control
Unit and Motor Module. The status of the Enable Pulses
input is cross checked against the corresponding CU
input, an error is reported if they do not match.

Pulses supply.
(Ground)
Notes :

Motor Module (MM) continued
LED Status Display
LED Colour Status Explanation

range.
Green On Module configured and ready, Drive-CLiQ com-

munication is active.
READY Orange On Drive-CLiQ communication is being

(Top) established/module not configured.
Red On At least one fault is present.
Green/ Flashing Firmware download procedure is running.

Red 2Hz
Green/ Flashing Component recognition is active (p0124 = 1)

Orange 2 Hz
or Red/
Orange

range.
DC LINK
(Bottom) Orange On DC link voltage within tolerance-Only if unit is
Red On DC link voltage outside tolerance-Only if unit is

Motor connector (MM less than 45A)
Screw terminals. Not

Fixing screw on Crimped cable Metal connector
types housing, also used
for cable shield
Brake: Negative Brake: Posi-

Connection tive Connec-
tion
Locating key- Locating key-

Changeable
Motor: Motor: Motor:

Phase U Phase V Phase W
For MM modules of 45A and above, the brake is supplied by a

separate connector (X11).
The brake control circuit is isolated therefore it is not permissi-

ble to connect the –ve brake connector to the 0 volt common of
the machine.
Notes :

Combi Drive Modules
Combi Drive (Combined Line and Motor Modules).
The Combi drive unit consists of a Line Module and either 3 or 4 Motor Modules, the first of which is dedicated to the Spindle.
They must always be connected to the DriveCLiQ network via controller interface X100
The number of axes can be increased by adding Sinamics S120 Book-sized Compact
Motor Modules up to the maximum allowed by the system.
X21: Motor X12/X13: Fan Supply X224: +24V DC auxil-

Enables etc. and monitoring iary supply
X200 to X205:
Drive-CLiQ
connectors
X220: Interface
for TTL 5v DMS
encoder
LED Status
Indicators
X1: Line supply to

module
X2 to X5: Supply to
motors
Shielding and earth plate
X11: Connector for one

brake (Underneath)
Notes :

Detailed Terminal Description. X22 Terminal description and functionality.
Top view of Combi Drive Unit:
X21/X22 X12/X13
Enables and tem- Fan supply and monitoring
perature sensor. X224 +24V DC
auxiliary supply
1 + Temp Positive temperature sensor input from non-Drive-

(Input) CLiQ temperature sensor.
2 - Temp Negative temperature sensor input from non Drive

(Input) -CLiQ temperature sensor.
3 Safety Applying +24V DC will cause the pulses of the

Integrated. individual axis to be enabled. (Current consump-
Enable tion:10mA)
Pulses When the signal is low, “Safe pulse suppression”
EP +24 V is activated.
(Input) Note:-No electrical isolation occurs between the
Motor module and the motor.
This enable signal is only operational if the Safety
Integrated function “Safe Standstill (SH)” is en-
abled.
This is a dual channel monitoring system of the
Control Unit and Motor Module. The status of the
Enable Pulses input is cross checked against the
corresponding CU input, an error is reported if
they do not match.
4 Safety Must be connected to the 0V of the enable pulses

X21 Terminal description and functionality Integrated. supply.
Enable
Pulses
EP M1
(Ground)

X12/X13 Terminal description and functionality.
1 Not used Not used
2 Not used Not used
3 Enable Applying +24V DC enables the pulses. (Current 1 Ground Ground connection for fan monitoring circuit.
Pulses consumption:10mA)
(Input) 2 Fan Fan monitoring signal, input from fan.
This signal must be removed at least 10ms prior Monitoring.
to the (Input)
3-phase mains supply being removed.
Failure to do this can lead to damaged drive mod- 3 +24 V DC +24V DC supply to fan.
ules. This is especially important when the axes/ (Output) Maximum 2 A. (1 x 2 A or 2 x 1A)
spindles are regenerating. If the mains circuit is
opened in this state, regenerative currents remain 4 Ground Ground for fan supply.
within the drive system causing damage to the
modules.
It is recommended that this terminal is connected

via an early break contact on the machine isolator
switch and the line contactor (If used).
If the terminal is used by the manufacturer it must
be
ensured that it is controlled in the suggested
manner.
When used in this way the transistors will be

switched off and mains regeneration halted, the
motors will then coast to a halt. This is not suit-
able for an emergency stop situation.

Pulses supply.
(Ground)
Notes :

Non Siemens fans may be used without the monitoring. In Front View of Combi Drive and Interfaces.
this case terminals 1& 2 must be linked.
X224 Terminal Description and functionality.

X220 5V TTL DMS
encoder.
+ M
+24 V DC +24V DC auxiliary supply to Combi drive module

+
(Input)
M Ground Ground for fan supply +24V DC auxiliary supply
X22 Terminal description and functionality.
X200 to X205 Terminal description and functionality
DriveCLiQ Interfaces:
X205 - DMS via SMC (If X220 not suitable)
X204 - Z axis motor feedback.
X203 - Y axis motor feedback.
X202 - X axis motor feedback.
X201 - Spindle axis motor feedback.

X1 Line X2 to X5 Motor Supply Output
Supply
Input
X200 - DriveCLiQ drive bus (From X100 828D
Controller).
X220 Terminal description and functionality (for 5V TTL

encoders)
Notes :

Combi Drive Modules. Continued Supply and Enabling Examples
For trouble free operation it is essential that the drives are

Pin Signal Technical Information powered on/off and enabled correctly.
Motor temperature sensor positive connection (KTY If the mains supply switch/contactor is opened while the drive
1 + Temp
84-1C130) pulses are enabled and the drive is in regeneration mode,
the regenerative current which is normally fed back into the
2 Clock Clock Signal
mains will have no where to go, except that is into the motor
3 Clock* Inverse Clock Signal and line modules, this can result in damage to these mod-
4 P-Encoder 5V ules.
+5V Encoder Power Supply The solution is to use an auxiliary contact fitted to the mains
5 P-Encoder 5V switch and drive line contactor.
6 P-Sense +5V Sense Signal This auxiliary contact must open at least 10ms before the
main contacts open.
7 M-Encoder (M) Encoder Power Supply 0V
The contact is wired to the Pulse Enable terminal of the SLM/
- Temp
Motor temperature sensor negative connection (KTY ALM module.
8
84-1C130) If the Main switch or contactor is operated while the drive is
9 M-Sense 0V Sense Signal in operation the pulses will be disabled and the motors will
free wheel to a standstill. (Except when the Safety Integrated
10 R Reference Signal R function “Safe Stop” is enabled)
11 R* Inverse Reference Signal R* Any potentially harmful current will be unable to enter the
drive modules as the transistors are now switched off.
12 B* Inverse Incremental Signal B*
13 B Incremental Signal B
14 A* Inverse Incremental Signal A*

Below is the recommended timing diagram for the enabling
15 A Incremental Signal A of drives via the controller using a line Contactor.
Interfaces X1 to X5
Minimum 10ms-
if supply disconnected
while drive is operational
Mains supply
X1 Terminal Description and Functionality. E Stop active
DB2700.DBX0.1
Terminal Function Description Input to ALM/SLM via line switch
Enable Pulses
ALM/SLM
U1 U Phase Line Phase U X21.3
V1 V Phase Line Phase V Output/Input from/to 828D

In-feed ready.
From/to 828D
W1 W Phase Line Phase W Link X132.10 to
X122.1(OFF1)
PE Earth Protective Earth Output from 828D
Energise line
contactor–
X2 to X5 Terminal Description and Functionality. 828D X132.12
output
Input from N/O contact
Line contactor
Terminal Function Description energised-
828D X132.4
U2 U Phase Motor Phase U Input
Input to ALM/SLM
V2 V Phase Motor Phase V OFF3 Enable
from user to
W2 W Phase Motor Phase W 828D X122.2
PE Earth Protective Earth
Notes :

Mains Supply and Enabling Examples

SLM 5 & 10Kw, no line contactor, user controlled enable.
X122
I2t alarm from SLM
Main to user
supply
OFF1 Drive ready

Early break
SLM to 828D X132
contact
X21
Main Optional:
Switch Pulse enable
via user PLC
+24V 24V DC 0V
PSU
Supply to other
equipment
OFF3 Drive
enable from
user to 828D
Filter Reactor
Notes :


SLM 5 & 10Kw . User controlled line contactor (Early break contact) and 828D controlled enables.
X122
I2t alarm From SLM
to user
Mains
supply
OFF1 Drive ready

Early break SLM to 828D
contact X132
X21
Main
Switch Supply to other
equipment
Optional:-
Pulse enable
via user PLC
0V 24V
OFF3 Drive
enable from
Line Contactor user to 828D
with early break
contact Energise
Line
24V DC Line contactor
+24V 0V
PSU contactor from user
energised PLC
to user PLC
Filter Reactor
Notes :


ALM and SLM 16 & 36Kw-no line contactor, user controlled enables.
X122
Main
supply Drive
enable
from 828D
X100 X132.10 to
828D
Early break X122.1
contact X132 (OFF1)
X21
Main Drive-CLiQ
Optional:-
Switch Pulse enable
via user PLC
X200
+24V 24V DC 0V
PSU
Supply to other
equipment
OFF3
enable
(E stop)
from user
to 828D
X122.2
Filter Reactor
Notes :


ALM and SLM 16 & 36Kw. User controlled line contactor (Early break contact) and 828D controlled enables.
X122
Mains
supply Drive
enable
from 828D
X100 X132.10 to
828D
Early break X122.1
Drive-
contact X21 X132 (OFF1)
CLiQ
Main Supply to other

Switch equipment
X200
Optional:-
Pulse enable
via user PLC
0V 24V
OFF3 enable
Line Contactor (E stop)
with early break from user to
contact 828D X122.2
+24V 24V DC 0V
PSU
Line contactor
energised- Energise line
Filter Reactor to user PLC contactor-
from user PLC
Notes :


ALM & SLM 16 & 36Kw . 828D controlled line contactor (Early break contact) and enables.
X122
Mains
supply
Drive
enable
from 828D
X100 X132.10 to
828D
Early break X122.1
Drive- X132 (OFF1)
contact
X21
Main
Switch Supply to other
equipment Line Energise
X200 contactor Line
energised contactor-
Optional:- Pulse -to 828D from 828D
enable via user x132.4 X132.12
PLC or 828D
X122/X132
0V 24V
OFF3 enable
(E stop)
Line Contactor from user to
with early break 828D X122.2
contact
+24V 24V DC 0V
PSU
Filter Reactor
B051: END
Notes :

B051 END Line and Motor Modules

B053 Axis and Drive Diagnostics
Module Description:
In the event of a problem with the machine it may be necessary to check the status of an axis/
drive. The information obtained from these status screens can be very useful to technical person-
nel and help speed up the fault finding process.
Module Objective:
Upon completion of his module you will be able to use the Axis & Drive diagnostic functions.
Content:
Sinumerik
Service Overview Screen
Axis Diagnostics
Drive Diagnostics
B053
B053

Axis and Drive Diagnostics B053
Axis and Drive Diagnostics: Description

Axis and Drive
Diagnostics:
START
In the event of a problem with the machine it may be neces-
sary to check the status of an axis/drive. The information ob-
tained from these status screens can be very useful to techni-
cal personnel and help speed up the fault finding process.
Service
Overview
Screen
Axis
Diagnostics
Drive
Diagnostics
Axis and Drive

Diagnostics:
END
Notes :

Service Overview Screen The displayed axes can be changed to suit personal prefer-
ences.
To navigate to the relevant diagnostics page please use the
following key presses.
The “Active axes” soft-key will only display axes

that are currently active. Axes disabled via machine
data or parked axes will not be displayed.
The screen shows the status of various enable/monitoring
signals via indicators. The “All axes” soft-key will display any axes that are
currently configured as active or inactive.
The “Selected axis” soft-key allows selected axes to

be viewed.
Example below shows how to view axes 1 und 3
only.
The indicators change appearance depending on the condition

of the signal.
The signal is healthy, in the case of an enable, the

signal is high. For a monitoring signal there is no fault
present.
The signal is missing i.e. low (Enable signals only).
The signal is indicating a fault (Monitoring signals

only).
The signal is inactive/not in use.
Example:-The diagnostics page showing a motor over tem-

perature problem on Axis 1.
Notes :

Axis Diagnostics Drive Diagnostics
Axis specific information Drive specific information
For more detailed information regarding each individual axis For more detailed information regarding each individual drive,
select the “Service axis” soft key. select the “Service drive” soft key.
This detailed information is very useful when a problem oc-

curs on the machine.
Each axis is displayed separately, changing to another axis is

done with the “Axis +” and “Axis -” soft keys.
The selected axis is displayed at the top of the diagnostics

screen.
An alternative method of selecting the required axis is via the

“Axis selection” soft key.
This the quickest method on a machine with many axes.
The drive diagnostics screen shows useful information regard-
ing the motor and drive states such as motor temperature, DC
link voltage etc.
More diagnostics information is revealed by us-

ing the page/cursor keys
Further drive diagnostic information, specifically Sinamics re-

lated, can be found by selecting the “Drive system” soft key.
The status of the DriveCliQ drive objects can be seen.
A healthy drive object, fully enabled ready for

operation.
A drive object with a warning e.g. enable missing.
A drive object with a fault.

Useful information about the axis in question ranging from
positional data to current and torque readings is available.
Further information can be seen by using the page/cursor
keys.
Notes :

The CU is the only drive object displayed, to view the other The “Status indicator” information indicates that the OFF1
drive objects press the “Input” key. enable signal is not present.
The lower half of the screen offers further information.
Use the “Drive object +” & “Drive object -” soft-keys to check

the status of other axes
The following screen shows a healthy system, indicated by the

green tick symbols. A more serious situation is indicated by the appearance of
red cross symbol.
Example– MX1 (Servo 1) axis showing a fault with encoder 1
(SMI20).
The screen will display information regarding the cause of

the problem
Drives not ready or in a fault condition will display yellow or

red symbols.
The following example shows MSP1 exhibiting a problem.
To see more information about the cause, cursor to the failed
axis and select the “Details” soft-key.
Notes :

Two further soft-keys are also available for displaying further

information.
Selecting the “Warning” soft-key displays more

information which indicates a problem with
encoder 1.
The alarms and warnings can also be seen on the alarm

screen.
Selecting the “Faults” soft-key also displays more

information which indicates a problem with en-
coder 1 Drive component 15.
The alarms displayed can be filtered via machine data 13150

SINAMICS_ALARM_MASK.
The “Help” key, found to the lower right of the vertical soft-
keys can be used to get more information about Warnings/
Faults.
Many alarms are generated when the system detects a com-

ponent error. The machine data is used to filter out alarms
which may be confusing. The default value is 0909 this sets
bits 0, 3, 8 & 9. For service and commissioning work it maybe
necessary to view more alarms. Setting the machine data to
FFFF will result in all alarms being displayed.
The default value should always be re-entered when the ser-
vice/commissioning work is complete.
Notes :

Topology The component names can be changed to a more suitable

name
The topology of the drive system can be seen when the
“Topology” soft-key is selected.
Topology shows the DriveCLiQ interconnections of the drive
objects and components.
Example: Changing the name of SERVO 1 to X Axis.
Press the “OK” soft-key to confirm the changes, wait for the
dialogue box to clear.
The topology display can also be used to help identify faults.
CU (Drive object 1) is con-

nected via X100 to a motor
module (Drive object 2) socket
X200.
The topology display can be changed via the “Display op-

tions” soft-key:
When a drive object has a fault,

the text will be displayed in red
or grey.
Notes :

Firmware: When the process is running the Top LED of the drives will
flash red. Other DriveCLiQ components will also indicate the
Firmware is a small software program that is written to the process in a similar way.
internal flash memory of the DriveCLiQ components. Firm- When the update has finished a complete power off/on of the
ware updates are used to keep the hardware up to date with controller/drives is required.
the latest technological advances. It is important that the
DriveCLiQ components are all of the same firmware version.
The firmware version is dependant upon the current system
software version.
Automatic Firmware Update:

When replacement drive hardware is fitted it is important that
the firmware version is correct. In normal circumstances the
system automatically loads the firmware to any modules not
at the correct firmware level. If the firmware is not automati-
cally updated the “Load firmware” soft-key can be used.
The configuration area has several further functions:
Manual Firmware Update:

The “Load firmware” soft-key located in the Configuration
area which is accessed via the “Configuration” soft-key. The Drive Object and Component names can be changed via
the “Change” soft-key.
The system assigns names to the objects/components. It is
not always apparent from these names what the function of
each object/component is.
Using more suitable names can help with object identification
in the event of a problem.
The changes are accepted when the “OK” soft-key is pressed.
Notes :

Electronic Rating Plates Display Settings
Useful information is displayed when the “Details” soft-key is The level of displayed information about the components can
selected. be controlled with the “Display options” function.
These are known as the ”Electronic Rating Plates”.
Example: Details of MX1 axis Motor Module:
Comparison Levels:
Some of the information on the screen can only be viewed by

using the cursor left/right keys.
Example: Details of MX1 Servo Motor:
To the right of the screen a column named “C.level” can be

seen.
This is used to set the comparison level for the DriveCLiQ
components.
The “Sort” soft-key is used to view the components in a par- The system compares the stored details of the electronic
ticular order according to Drive Object, Wiring, Component rating plate of each object with the actual components con-
number or Axis number: nected to the DriveCLiQ bus.
Once the drive system is configured it is continually moni-
tored. Alarms will be displayed if a fault occurs or an un-
known object is detected.
Notes :

To change the level of comparison select the “Change” soft-
key and then the “Insert” key.
The comparison level can now be se-

lected, the “Input” key confirms the se-
lection.
Comparison Levels:
High-Compares the complete electronic rating plate

Medium– Compares the component type and order number
Low– compares the component type
Minimum– Compares the component class.
Service case 1: If a new component is to be fitted to a sys- Parameter r2 can also be used to view the status of the drives.
tem to replace a faulty one it is not necessary to change the
comparison level. The system should automatically load the
correct firmware to the new component.
Service case 2: If two existing components are to be inter-

changed to prove a fault e.g. Motor Module 1 & Motor Module
2, the system will detect this and issue alarms depending on
the setting of the comparison level.
In this case setting the comparison level to low would allow
the modules to be interchanged without alarms occurring.
Diagnostics Parameters
The status of the CU can be viewed via CU parameter r2.
When the parameter is highlighted and the select key is

pressed a list of operating status numbers and their meanings
is displayed.
B053: END
Notes :

B053 END Axis and Drive Diagnostics

B008 Profinet Connections and Diagnostics
Module Description:
The PLC periphery components of the 828D controller are connected to the Profinet network.
Periphery components are used to interface between the controller with the physical I/O of the ma-
chine.
Each periphery component needs to be configured, this is achieved with machine data and dip-
switches.
Periphery Components:
Machine control panels- The 828D controller uses one of three machine control panel variants for
handling signals such as mode selection, axis selection, federates, NC start etc.
- The MCP483 is 483mm in length and is recommended for use with the horizontal variant of 828D.
- The MCP310 is 310mm in length and is recommended for use with the vertical variant of the 828D.
- The 3rd variant is the OEM version (supplied/manufactured by OEM).
PP72/48 - The 828D controller uses up to five PP72/48 PN input/output modules for example, to
handle signals to coils and lamps, and signals from pressure switches, over-travel switches etc.
Module Objective:
Upon completion of this module the course participant will know how to configure and install a
Siemens machine control panel (MCP) and PP72/48 periphery I/O modules.
Content:
Sinumerik
Machine Control Panel Types
MCP483 PN Front and rear Layout
MCP310 PN Front and rear Layout
Machine Control Panel Interface Signals
PP72/48 PN Description and Interface Signals
Profinet Configuration - MCP & PP72/48
B008
B008

Profinet Connections and Diagnostics B008
Profinet Connections and Diagnostics: Description Profinet

Connections and
The PLC periphery components of the 828D controller are
Diagnostics:
connected to the Profinet network.
START
Periphery components are used to interface between the con-
troller with the physical I/O of the machine.
Each periphery component needs to be configured, this is
achieved with machine data and dip-switches. Machine
Control
Periphery Components: Panel Types
Machine control panels- The 828D controller uses one of three
machine control panel variants for handling signals such as
mode selection, axis selection, federates, NC start etc.
MCP483
The MCP483 is 483mm in length and is recommended for use Front and
with the horizontal variant of 828D. Rear layout
The MCP310 is 310mm in length and is recommended for use

with the vertical variant of the 828D.
MCP310
The 3rd variant is the OEM version (supplied/manufactured by Front and
OEM). Rear layout
PP72/48 - The 828D controller uses up to five PP72/48 PN

input/output modules for example, to handle signals to coils
and lamps, and signals from pressure switches, over-travel Machine
switches etc. Control Panel
Interface
Signals
PP72/48 PN
Description
and Interface
Signals
Profinet
Configuration
- MCP &
PP72/48
Profinet
Connections and
Diagnostics:
END
Notes :

Machine Control Panel Types
MCP483 PN
S1
MCP310 PN
Notes :

MCP483 PN Front Layout
SINUMERIK 828D
JOG REP REF T1 T2 T3 X Y Z
Teach 4th 5th 6th

VAR 1 T4 T5 T6
Emergency in Axis Axis axis Spindle Feed
Stop Override Override
7 th 8th
MDA 10 100 T7 T8 T9
Axis Axis
Profinet Connections and Diagnostics
MCS
Auto 1000 10000 T10 T11 T12
WCS
Page 5
Blank for Blank for Single Cycle Cycle Spindle Spindle Feed Feed Key
Reset T13 T14 T15 — Rapid + Switch
user user block Stop Start stop start Start Stop
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T15 are free for use by the manufacturer.
The two blanks can be removed to allow the user to add extra buttons/switches/lamps.
Notes :
B008
B008
MCP483 PN Rear Layout
B008
B008
X10
X53
X54 X60 X61
X31 X51
X52
X55
X20
H3
H2
X30 H1 X21
Page 6
X5
S2
Interface Description: X51 Digital inputs X60 Hand-wheel - Not used on 828D
S2 Addressing switch. X52 Digital inputs X61 Hand-wheel - Not used on 828D
X5 Key-switch interface X53 Digital outputs
X10 24V DC supply X54 Digital outputs
X20 Port 1 Profinet connection in. X55 Digital inputs

X21 Port 2 Profinet connection out.
X30 Feedrate override interface. LED Indicatots:
X31 Spindle override interface. H1 Power OK (Green)
H2 BUSSYNC
H3 BUSFAULT
Notes :
SINUMERIK 828D
MCP310 PN Front Layout
SINUMERIK 828D
Spindle Spindle
JOG REP REF VAR T1 T2 T3 100 %
Dec. Inc.
Blank for
spindle
Teach Spindle Spindle Spindle override/
MDA T13 1 T4 T5 T6
In right stop left E stop
Auto T14 T15 10 T7 T8 T9 X Y Z
Single 4th 5th 6th

Reset T16 100 T10 T11 T12
Block Axis Axis Axis Feed
Override
Page 7
Cycle Cycle WCS Feed Feed
1000 - Rapid +
Stop Start MCS Stop Start
Key Blank for Blank for Blank for Blank for Blank for Blank for
Switch user user user user user user
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T16 are free for use by the manufacturer.
The six blanks can be removed to allow the user to add extra buttons/switches/lamps.
Notes :
B008
B008
MCP310 PN Rear Layout
X10
X53
X54 X60 X61
X31 X51
X52
X55
X20
H3
H2
X30 H1
X21
X5
S2
Interface Description:- X51 Digital inputs X60 Hand-wheel - Not used on 828D
S2 Addressing switch X52 Digital inputs X61 Hand-wheel - Not used on 828D
X5 Key-switch interface X53 Digital outputs
X10 24V DC supply X54 Digital outputs
X20 Port 1 Profinet connection in. X55 Digital inputs
X21 Port 2 Profinet connection out.
X30 Feedrate override interface. LED Indicators:
X31 Spindle override interface H1 Power OK (Green)
H2 BUSSYNC
H3 BUSFAULT
Notes :

The following tables show the interface signals for an MCP483 PN with the recommended start address of 112.
MCP483 PN Signals from machine control panel (keys)
Spindle override JOG TEACH IN MDA AUTO

IB112
D C B A
IB113 REPOS REF INC var. 10000 INC INC 1000 INC 100 INC 10 INC 1
Key- Key- Spindle start *Spindle stop Feed *Feed NC Start *NC Stop
IB114 switch switch posi- start stop
position 0 tion 2
Reset Key- Single block Feedrate override
IB115 switch posi-
tion 1 E D C B A
Direction keys Key switch Axis selection keys
position 3
IB116 + - Rapid trav- X 4th axis 7th axis
R15 R13 erse R1 R4 R7
R14
Axis selection keys
IB117 Y Z 5th axis MCS/WCS R9 8th axis 6th axis
R2 R3 R5 R12 R8 R6
Unassigned customer keys
IB118
T9 T10 T11 T12 T13 T14 T15
IB119
T1 T2 T3 T4 T5 T6 T7 T8
IB122 KT8 KT7 KT6 KT5 KT4 KT3 KT2 KT1
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP483 PN Signals to machine control panel (LEDs)

Machine function Operating mode

QB112
INC 1000 INC 100 INC 10 INC 1 JOG TEACH IN MDA AUTO
QB113 Feed *Feed NC Start *NC Stop REPOS REF INC var. INC 10000
start stop
Direction X 4th axis 7th axis Single block Spindle start *Spindle stop
QB114 Minus R1 R4 R7 R10
R13
Z 5th axis MCS/WCS 8th axis 6th axis Direction Plus
QB115
R3 R5 R11 R9 R8 R6 R15
Unassigned customer keys Y
QB116
T9 T10 T11 T12 T13 T14 T15 R2
QB117
T1 T2 T3 T4 T5 T6 T7 T8
QB118 Reset R14
QB119 KT6 KT5 KT4 KT3 KT2 KT1
Signals marked with * are inverse signals.
Notes :

The following tables show the interface signals for an MCP310 PN with the recommended start address of 112.
IB112 *NC Stop Spindle - Spindle Spindle + Single block JOG MDA AUTO
100%
NC Start Spindle right *Spindle Spindle left Key-switch REF REPOS Teach IN
IB113 stop position 3
Feed start *Feed stop INC var. Key-switch

IB114 position 0 INC 1000 INC 100 INC 10 INC 1
Feedrate override
IB115 Reset Key-switch Key-switch E (16) D (8) C (4) B (2) A (1)
position 2 position 1
Direction keys Rapid
IB116 traverse KT5 (X52.2) KT4 (X52.1) KT3 (X51.3) KT2 (X51.2) KT1
+ - (X51.1)
Axis selection
IB117
T16 KT6(X52.3) 6th axis 5th axis 4th axis Z Y X
IB118 T9 T10 T11 T12 WCS MCS T13 T14 T15
IB119 T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP 310 PN Signals to machine control panel (LEDs)
QB112 *NC Stop Spindle Dec. Spindle Spindle Inc. Single Block JOG MDA AUTO
100%
NC Spindle *Spindle RESET REF REPOS Teach In
QB113 Spindle left
start right Stop
QB114 Feed Start *Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
QB115
QB116 Minus Plus Rapid trav- KT5 KT4 KT3 KT2 KT1
Direction Direction erse
QB117 T16 KT6 6th axis 5th axis 4th axis Z Y X
T9 T10 T11 T12 MCS/WCS T13 T14 T15
QB118
QB119 T1 T2 T3 T4 T5 T6 T7 T8
Notes :

Machine Control Panel Interface Signals PP72/48 PN Description and Interface Signals
User I/O pin assignment PP72/48 PN modules are a compact component which con-
nect to the Profinet network (Ports PN1 or PN2 of the PPU).
The 9 inputs and 6 outputs available on plugs X51 to X55 are
designed for use with switches/buttons and indicator lamps There are two variants, one of which is all digital while the
which can be installed in the blanked holes of the MCP. second offers both digital and analogue functionality.
Below shows the I/O assignment of each individual plug.
A 24V DC supply is required.
The input terminals in the normally open state measure 5V DC In total 72 digital inputs and 48 digital outputs are available on
(Supplied by the MCP) each of the two variants.
The inputs work by sinking the 5V DC signals to 0V (M). The analogue module has an additional two analogue inputs
and two analogue outputs.
The outputs terminals are supplied with +24Vdc from the MCP.
A maximum of 3 PP72/48 PN modules with the PPU240 and
No external voltages should be applied to the input and output PPU241 controllers.
terminals. A maximum of 4 PP72/48 PN modules with the PPU260 and
PPU261 controllers.
A maximum of 5 PP72/48 PN modules with the PPU280 and
Input Assignment (X51, X52 & X55): PPU281 controllers.
Part number:- 6FC5311-0AA00-0AA0 Digital only

I122.0 I122.3 (PP72/48D PN)
1 1
I122.1
6FC5311-0AA00-1AA0 Digital/analogue
I122.4
2 2 (PP72/48 2/2A PN)
I122.2 I122.5
3 3
M (0 volts) M (0 volts) S1
4 4
X51 X52
I122.6
1
I122.7 X111
2
I123.0
3
M (0 volts)
4
X55
Output Assignment (X53 & X54): X222
Q119.0 Q119.3
1 1
Q119.1 Q119.4
2 2
Q119.2 Q119.5
3 3
M (0 volts) M (0 volts) X2 X2
4 4
X53 X54 X333
The outputs are capable of supplying 1.2 Watts per output, it is

not permissible to connect relays, valves or other inductive
devices. X1
Notes :

Ribbon cable connections. Pin assignment X333
The following Tables show the pins and I/O addresses for con- Pin Signal Pin Signal Pin Signal
nectors X111, X222, X333 This is assuming the PP72/48 PN is
1 0V DC 19 I8.0 37 Q4.6
configured with a start address of 0 (Input bytes 0, 1, & 2 and
output bytes 0 & 1). 2 +24V DC O/P 20 I8.1 38 Q4.7
The first input byte of X222 has FAST gating hardware. 3 I6.0 21 I8.2 39 Q5.0
4 I6.1 22 I8.3 40 Q5.1
5 I6.2 23 I8.4 41 Q5.2
Pin assignment X111 6 I6.3 24 I8.5 42 Q5.3
7 I6.4 25 I8.6 43 Q5.4
Pin Signal Pin Signal Pin Signal
8 I6.5 26 I8.7 44 Q5.5
1 0V DC 19 I2.0 37 Q0.6 9 I6.6 27 Not used 45 Q5.6
2 +24VDC O/P 20 I2.1 38 Q0.7 10 I6.7 28 Not used 46 Q5.7
3 I0.0 21 I2.2 39 Q1.0 11 I7.0 29 Not used 47 +24V DC I/P
4 I0.1 22 I2.3 40 Q1.1 12 I7.1 30 Not used 48 +24V DC I/P
5 I0.2 23 I2.4 41 Q1.2 13 I7.2 31 Q4.0 49 +24V DC I/P
6 I0.3 24 I2.5 42 Q1.3 14 I7.3 32 Q4.1 50 +24V DC I/P
7 I0.4 25 I2.6 43 Q1.4 15 I7.4 33 Q4.2
8 I0.5 26 I2.7 44 Q1.5 16 I7.5 34 Q4.3
9 I0.6 27 Not used 45 Q1.6 17 I7.6 35 Q4.4
10 I0.7 28 Not used 46 Q1.7 18 I7.7 36 Q4.5
11 I1.0 29 Not used 47 +24V DC I/P
12 I1.1 30 Not used 48 +24V DC I/P
13 I1.2 31 Q0.0 49 +24V DC I/P
14 I1.3 32 Q0.1 50 +24V DC I/P
15 I1.4 33 Q0.2
16 I1.5 34 Q0.3
17 I1.6 35 Q0.4
18 I1.7 36 Q0.5
Pin assignment X222
Pin Signal Pin Signal Pin Signal

1 0V DC 19 I5.0 37 Q2.6
2 +24V DC O/P 20 I5.1 38 Q2.7
3 I3.0 21 I5.2 39 Q3.0
4 I3.1 22 I5.3 40 Q3.1
5 I3.2 23 I5.4 41 Q3.2
6 I3.3 24 I5.5 42 Q3.3
7 I3.4 25 I5.6 43 Q3.4
8 I3.5 26 I5.7 44 Q3.5
9 I3.6 27 Not used 45 Q3.6
10 I3.7 28 Not used 46 Q3.7
11 I4.0 29 Not used 47 +24V DC I/P
12 I4.1 30 Not used 48 +24V DC I/P
13 I4.2 31 Q2.0 49 +24V DC I/P
14 I4.3 32 Q2.1 50 +24V DC I/P
15 I4.4 33 Q2.2
16 I4.5 34 Q2.3
17 I4.6 35 Q2.4
18 I4.7 36 Q2.5
Notes :

Profinet Configuration - MCP & PP72/48 Default values of MD12986:
Each hardware item connected to the Profinet network needs

a unique IP address.
This is determined by the setting of S2 on the MCP and S1 on
the PP72/48.
Each profinet device has an IP address in the range
192.168.214.xxx . The switch setting determines the last part
of the IP address xxx.
The IP addresses are associated with general machine data
12986[0]….[6] which determines the input/output assignment.
Compatibility
Switch S1/S2
The selected IP address will determine the I/O that will be as- To achieve compatibility between machines using the 828D
signed. This is seen in the following tables: Controller, it is necessary to assign individual hardware with the
For all Profinet applications switch positions 9 and 10 need to same I/O address range.
be set to on. The 1st PP72/48 modules should always start with I/O address
0 (MD12986[0] = -1). Further modules should be addressed in
numerical order.
Switch S1 - PP72/48 The MCP should always be assigned the start address of 112
Switch S1/S2 Binary Value Switch S2 - MCP483/MCP310 (MD12986[6] = -1).
Position
Recommended MD12986 use:
1 1
2 2
Machine data Device Start Address/
3 4 default setting
4 8 12986[0] 1st PP72/48 0
5 16 12986[1] 2nd PP72/48 9
6 32
12986[2] 3rd PP72/48 18
7 64
12986[3] 4th PP72/48 27
8 128
12986[4] 5th PP72/48 36
9 Profinet=ON
12986[5] PN/PN Coupler 96
10 Profinet=ON
12986[6] MCP 112
Machine Data 12986
Each index of MD12986 has a preset I/O range. To release a 12986[7]…[15] Reserved
particular I/O range the value of -1 has to be entered into the
necessary index. Example: MD12986 for use with MCP and one PP72/48
module.
Switch
MD Profinet Input Output IP address
S1/S2
12986[x] Device Range Range 192.168.214.xxx
Setting
0 1&4
1. PP72/48 0 to 8 0 to 5 9
on
1 4
2. PP72/48 9 to 17 6 to 11 8
on
2 1, 2 & 3
3. PP72/48 18 to 26 12 to 17 7
on
3 2&3
4. PP72/48 27 to 35 18 to 23 6
on
4 1&3
5. PP72/48 36 to 44 24 to 29 5
on
PN/PN 3&5
5 96 to 111 96 to 111 20
Coupler on
7
6 MCP 112 to 129 112 to 119 64
on The machine data is activated by an NCK power off/on.
7 n/a n/a n/a n/a n/a
B008: END
Notes :

B008 END Profinet Connections and Diagnostics

B026 Creating a PLC program
Module Description:
The programming tool PLC828 is used to create the PLC program.

To maintain compatibility between machines fitted with the Sinumerik 828D controller it is essential
that the design criteria layed down in the PLC Design document is adhered to.
These requirements have been created so that the PLC program is easy to understand, this simpli-
fies the fault finding procedure, leading to minimal downtime in the event of a breakdown.
This module describes the PLC design requirements and shows how to use the PLC828
programming tool including uploading/downloading procedures.
Module Objective:
Upon completion of this module you will know how to use the PLC828 programming tool to:
 Create a PLC program
 Upload a PLC project from the controller to a computer
 Download a PLC project to the controller from a computer
You will also know the recommended PLC design requirements.
Content:
PLC Design
Sinumerik
S7-200 PLC Cyclic Operation
General PLC Interface Description
Creating a PLC Project (PLC Part1)
Uploading & Downloading PLC Projects
Editing PLC Programmes (PLC Part 2)
Symbol Tables
Cross Referencing
Data Blocks
B026
B026

Creating a PLC program B026
Creating a PLC Program: Description Creating

a PLC
Program:
The programming tool PLC828 is used to create the PLC pro- START
gram.
To maintain compatibility between machines fitted with the
Sinumerik 828D controller it is essential that the design criteria
laid down in the PLC Design document is adhered to. PLC Design Data Blocks
These requirements have been created so that the PLC pro-
gram is easy to understand, this simplifies the fault finding
procedure, leading to minimal downtime in the event of a
breakdown.
Creating
This module describes the PLC design requirements and
S7-200 PLC a PLC
shows how to use the PLC828 programming tool including
Cyclic Program:
uploading/downloading procedures.
Operation END
General PLC
Interface
Description
Creating a PLC
Project
(PLC Part 1)
Uploading &
Downloading
PLC
Projects
Editing PLC
programs
(PLC Part 2)
Symbol
Tables
Cross
Referencing
Notes :

PLC Design
PLC Design Requirements
The PLC design requirements have been put in place so that there is compatibility across machines fitted with the 828D control-
ler.
The design requirements are shown in the following table:-
Definition Description
1 Do not use Transfer Variables unless there is no alternative.

 It is not possible to status local variables
 Program blocks using transfer variables are difficult to understand for the customer and
the dealer.
2 Organisational block OB1 should perform organisational tasks only.

 Conditional subroutine calls
 Unconditional subroutine calls
3 The logic programmed should not exceed the width of the displayable area of the controller.
 The complete logic network should be displayable on the control.
4 Only use complex instructions when there is no alternative.

 Accumulator/Shift/Rotate
5 Network logic: Long and simple is better than short and complex
6 An output should only be “enabled/set/reset” once in the program.
7 A transitional marker should have only one function in the program.
8 Indirect addressing should not be used, only use absolute operand names in the program.
9 The servo-synchronous task should only be used when the absolutely necessary.
 The servo task is not called from OB! It is therefore difficult for the customer/dealer to
be aware of its presence.
10 All blocks and networks should have comments
11 Symbols should be available for all periphery signals, these should be the same as the elec-
trical diagram.
12 Interruptions and fault conditions should generate a user alarm/message.
13 Block naming should be unique across machine types.
14 Easy Extend should be used for the machine builder options.
15 Maintenance Planner should be used for the planning of service intervals on the machine.
Notes :

S7-200 PLC Cyclic Operation
The S7-200 PLC works cyclically, at the beginning of the scan the status of the inputs is copied to the Process Image Table
(Inputs).
This is then applied to the user PLC logic.
The Subroutines are processed in the order they appear in OB1.
This means that for example, an output set early in the scan might be reset later in the scan. It is the command that appears later
in the scan that takes precedent.
When the scan is complete the results are transferred to the Process Image Table (Outputs) which is then physically output to
the machine periphery devices.
The diagram below shows the position of the Interrupt Blocks INT_100 and INT_101.
Their position enables them to be used to influence the state of the inputs and outputs without making changes to the main user
programme.
Beginning
of
Scan
Process Image Table At the beginning of the scan, the status of the inputs is trans-
(Inputs) ferred to the Process Image Table.
The INT_100 interrupt block can be used to influence the
Interrupt INT_100 Process Image Table (Inputs).
Main Routine OB1

Subroutine
Subroutine
Subroutine Subroutines are processed in the

order they appear in OB1.
Subroutine
Subroutine
The INT_101 interrupt block can be used to influence the

Interrupt INT_101 Process Image Table (Outputs).
Process Image Table At the end of the scan, the status of the outputs is trans-
(Outputs) ferred to the Process Image Table.
End
of
Scan
The INT_0 interrupt block runs independently of

Interrupt INT_0
OB1.
It runs synchronously with the servo cycle. This
cycle time is very fast and could be used for ex-
ample with a fast turret where the signals need to
be decoded sooner than they can be achieved
with OB1.
it is recommended not to use it (see PLC design
document).
Notes :

General PLC Interface Description
The PLC interface Data Blocks are used for interfacing between the PLC, HMI, NC & Drives.
The following Table shows a brief description of the interface Data Blocks. For a more detailed description
please refer to Appendix C.
DB1000 User data (Area 1)
DB1100 User data (Area 2)
DB1200...DB1207 PLC functions and PI services
DB1400 Retentive data area
DB1600 PLC user alarms
DB1700 Program control (HMI to PLC) & SMS Messenger
DB1800 Mode signals (HMI to PLC), date/time (from PLC) & Maintenance Planner
DB1900 General status/selection signals to/from Operator Panel, RCS viewer inhibit
DB2500 Auxiliary functions M, T, S, D & H functions
DB2600 General signals to NCK
DB2700 General signals from NCK
DB2800 Signals to fast I/O
DB2900 Signals from fast I/O
DB3000 Operating mode signals (PLC to NCK)
DB3100 Operating mode signals (NCK to PLC)
DB3200 Signals to NCK channel, Signals to geometry axis
DB3300 Signals from NCK channel, Signals from geometry axis
DB3400 Signals for Asynchronous sub routines
DB3500 G Functions from NCK channel
DB3700...DB3707 M/S Functions from axis/spindle
DB3800...DB3807 Signals to axis/spindle/drive/PLC axis & technology functions
DB3900...DB3907 Signals from axis/spindle/drive/PLC axis & technology functions
DB4000...DB4300 Signals to/from tool management
DB4500 PLC machine data and PLC user alarm configuration
DB4600...DB4700 Synchronised actions
DB4900 Reading/writing PLC variables
DB5300 Tool management signals from NCK
DB5700...DB5707 Reading actual values/distance to go
DB9900...DB9902 Tool management-user interface
DB9903...DB9904 Maintenance planner user interface
DB9905 Easy Extend user interface
The Machine Control Panel is allocated to a certain Input/Output area.
IB112...IB125 Reserved for MCP 310/483 input signals

QB112...QB119 Reserved for MCP 310/483 output signals
Notes :

Creating a PLC Project (PLC Part1) Creating a PLC Program from the example projects:
Toolbox Examples The PLC part of the commissioning procedure is in two parts.
Part one is intended to get the machine control panel and hand
The PLC program is created using the PLC828 Programming -wheels functioning using the MCP_483_M.ptp and Hand-
Tool software package which is part of the 828D toolbox. wheel.ptp toolbox examples.
Also included in part 1 is the Prog_control.ptp example.
The toolbox also contains examples of PLC projects
Procedure:
The following should be noted before using the examples
from the library: There are several MCP examples available:
The sample programs are freeware. Any user can use,

Milling machine with (MCP310)
copy and forward these programs free of charge.
The authors and owners of these programs take no re- Turning machine, turret behind the spindle (MCP310)
sponsibility whatsoever for the functionality and com- Turning machine, turret in front of the spindle (MCP310)
patibility of this software. Milling machine with (MCP483)
Use of the software is at the user's own risk.
Turning machine, turret behind the spindle (MCP483)
Since this software is free of charge, there is no warranty
nor entitlement to error correction and hotline support. Turning machine, turret in front of the spindle (MCP483)
Description of PLC examples: Select and open the MCP_483_M project.
The examples are found in the examples folder created when It is advisable that the project is saved under a different and
the toolbox “zip” file was extracted. appropriate name. This will keep the example intact so that it
can be used again in the future.
To save the project select “Save as” from the drop down menu.
Each example is separate

PLC828 project.
The Readme file gives a detailed
description of the examples.
The examples can be used to

easily achieve a running condition
when commissioning a machine.
Subroutines can be copied into

the main PLC project from the
example projects.
Enter a suitable
name for the project.
Notes :

The right hand window of the PLC828 programming tool con- The other networks contain calls to subroutines, additional in-
tains the ladder logic of the selected program block. formation about the subroutines can be seen when the network
Network 1 has the comments “Important: see comment” comments are double-clicked.
The comments are revealed by double clicking on the com-
ment.
Double-click
Double-clicking the net work title text will reveal the comments
regarding the use of the example files.
Double-click
Double-click
Notes :

If the PLC project were to be loaded to the controller in it’s cur- The PLC project as it stands now is fine for the MCP to
rent state, the subroutines would not be called and the logic function.
within them would not be executed. However, as mentioned previously, there are two example pro-
This is because of the logic written in network 2. jects are required for the PLC Step 1 stage. (Hand-wheel.ptp &
The “END” operation results in the PLC scan ending at this Program_control.ptp)
point.
Keep the current PLC project open and open the example pro-
ject Hand-wheel.ptp.
The example project contains only one subroutine. Comments

are also available as described previously.
To delete the network, right-click on the network title area and

select the “Delete” and then “Network(s)” options
The Subroutine needs to be copied into the existing project

containing the MCP logic.
This is achieved by the right click and copy/paste function of
the mouse.
In the Hand-wheel.ptp
project, Right click on the
Spindle assignment Handwheel subroutine
and select “Copy”.
In order for the MCP to correctly process the spindle specific
signals it is necessary to declare the spindle axis number.
In this example the spindle is number 4
Typical axis numbers:

In the project containing the
X =1
MCP subroutines, Right
Y =2
click on the Program Block
Z =3
folder and select “Paste”.
Sp = 4
A =5
Axis number of the Spindle has to be entered here.
Notes :

The properties dialogue box of the Subroutine is opened auto- The Data Block (DB9051) is located in the Data Block folder,
matically. this is copied and pasted using the same method that was
The properties can be edited if required. used for the subroutines.
Copying the data block from the Program-control.ptp

example:
The subroutine will now appear in the “Program Block” folder:

Pasting the data block to the current project:
The same procedure should be carried out for the Program-

control.ptp.
The comments show that Data Block DB9051 is required. This
DB will also need to be copied to the new project.
Double-click
The block number should be left the same.
Notes :

Copy and paste the subroutine from the Program-control.ptp This should be pasted to an unused network e.g. Network 3
example to the current project.
Below: The current project with the Program-control.ptp data

block and subroutine added.
Data Block DB_9000 is a default data block which is present
when a new project is created.
Data Block DB_Common is part of the original MCP_483_M
project.
This subroutines are located in the “Subroutines” folder
Calling the subroutines.
The newly added subroutines have to be called in Organisa-

tion Block OB1.
OB1 should only be used for the calling of subroutines.
Below: OB1 containing calls to the MC P subroutines. Special

marker SM0.0 is always equal to 1 and is used to uncondition-
ally call the subroutines.
The SM0.0 marker can be copied with the right click/copy/

paste mouse functions.
The target for the subroutine has to be selected by the mouse,
the selected area is indicated by a black rectangle.
The target for the sub-

routine, indicated by
the black rectangle.
Notes :

Double click on the subroutine to add it to the network in the Uploading and Downloading PLC projects
target area.
The PLC project (Part 1) is now complete and can be
downloaded to the controller.
The machine control panel will be fully functional.
HMI functions such as Program Test (PRT), Mode selection
etc. will also be possible.
Part 2 of the PLC Project deals with user specific tasks

(Drive enables, PLC user alarms, maintenance tasks etc.)
Double click the These and other subjects are covered during the duration of
required subroutine the course.
e.g. Handwheel
Uploading a PLC project to a computer:
An online connection with the controller should be made be-

fore proceeding. (Refer to Module B002 for information with
regards to making a connection)
It may be necessary to save the existing program from the

controller to a computer.
The subroutine now If this is the case open a new project in the PLC828D pro-
appears in the target
gramming tool.
area.
Click on the “Upload” button found on the toolbar.
It is also possible to drag and drop the subroutines to the cor-
rect place in the network.
The process should be repeated for the Prog_Control subrou-

tine.
Below: OB1 with calls to the required subroutines.
New project Upload button

Button.
A choice can be made between which type of data class

blocks are to be included in the upload. All blocks should be
included for a full backup.
Notes :

Downloading a PLC project to the controller
The Project to be downloaded has to be open.

To start the download process select the “Download” button:
Acknowledge the dialogue box:
Download button
A dialogue box appears where choices can be made with re-

gards to the types of blocks to be downloaded to the controller.
Blocks of the Manufacturer/individual data class can be in-

cluded or excluded.
The program blocks uploaded from the controller will appear
in the “Program Block” folder. Note:
It is also possible to choose whether any actual values
stored in the offline project are downloaded to the control-
ler.
This is an important selection depending on the reason for
downloading the project in the first place.
Example: If an old PLC project containing actual values is

downloaded to a running machine it is possible that tool
management functionality will be affected.
Tool management and functions like Service Planner use

data blocks for storing data. This data is continually
changing which is why careful consideration should taken
when deciding whether to include the actual values of the
data blocks.
The uploaded file should be saved under a suitable name:
In the case of the PLC part 1, there will be no actual values
present.
Notes :

The option to download the project in stop or run mode is of- The subroutine will be assigned the next available number.
fered along with a warning about the dangers of downloaded in The number and name can be changed if required.
run mode. Comments and information about the author can also be
added.
If in doubt always use the option “Place the PLC in STOP
mode.”
Place PLC in STOP mode.
Calling a subroutine
A subroutine must be called otherwise the logic contained

within it will not be processed.
The “MAIN” (OB1)” program block is used to call Subroutines,
to open the block first open the “Program Block” folder and
double click the “MAIN (OB1) “ block.
PLC run button.

Example: An unconditional call to the “Handwheel” subrou-
Editing PLC projects (PLC Part 2): tine.
This is described in more detail in the section - “Toolbox Ex-
Editing of the PLC project examples will be required to suit amples”.
individual machine requirements.
It may also be necessary to create new subroutines.
Subroutines can be added via the “Edit” drop down menu
Notes :

Contacts and Coils Example: Input I112.3 as a normally open contact
Basic contacts and coil operands are found in the

“Instructions\Bit Logic” area
The required operand is selected by

the double clicking or drag and drop To add more instructions position the rectangle to the right of
functions. the normally open logic.
By hovering the mouse pointer over

a particular operand/instruction a
short description will be displayed.
There are many other mathematical

functions and logic operations avail-
able.
These are described in more detail Instructions known as coils are used for switching outputs and
in the module interface signals.
B019 S7-200 PLC Instructions.
Position the rectangle at the beginning of the network and

double click the “Normally open” logic instruction.
The instruction will appear in the network, an operand must

Coils are inserted in the same way as the contacts. They must
be entered.
also be given an operand name.
Example: Interface signal DB3000.DBX0.2 is assigned to a

coil and is switched by I112.3
The instruction will appear in the network, an operand must

be entered. Click on the ??.? to enable the inputting of the
operand name.
Notes :

The toolbar contains shortcut keys which can also be used to The branch will now appear, operands can the be added in
add operands. the usual way.
Entering Network Titles and Comments
Example: Click the contact button and select the To enter a network comment double click on the network title.
contact type from the list.
The network title can be changed and comments can be

added.
The shortcut keys are also used to create branches.
Example: Creating a branch after I112.3.

Place the rectangle on the operand and select one of the Line
up or Line down buttons
Notes :

Symbol Tables A list of the symbol tables can be seen in the “Symbol Table”
folder.
The project contains predefined symbol tables which can be The individual tables can be opened by double clicking them.
edited.
Select the “Symbol Table” icon found on the left side.
The symbol table opens and displays the symbols for the 1st
PP72/48 module.
Other symbol tables can be selected via the tabs.
Notes :

Editing the symbol tables Without symbolic information active:
A selection of symbol tables are concerned with Siemens inter-

face signals. These should not be edited if possible to ensure
conformity across the range of 828D controlled machines.
The symbol tables for the inputs and outputs, (PP_1, PP_2,
PP_3, PP_4, PP_5) should be edited to assist with the fault
With both symbolic information selections active:
finding process.
The symbols used should match those of the electrical dia-
grams.
Symbolic
Example: Modified PP_1 symbol table addressing
To see the effect of the symbol table, the options “Symbolic Symbolic
Addressing” and “Symbol Information Tables” have to be Information
selected in the “View” menu. Table
Cross Referencing.
A Cross Reference table can be created, this lists information

about individual operands such as which blocks they are used
in and can greatly assist maintenance personnel with the fault
finding process.
It may be necessary to compile the project before a cross

reference list can be displayed.
Compile
button
Notes :

Compiling will check the integrity of the PLC project and dis- Byte Usage
play the results in the bottom window of the programming tool.
The Byte Usage table allows you to see which bytes, from
which memory areas, have been used in your program. It also
helps you recognise duplicate-assignment errors.
b Indicates that a bit of memory has been assigned.
B Indicates that a byte of memory has been assigned.
W Indicates that a word (16 bits) has been assigned.
D Indicates that a double word (32 bits) has been assigned.
X Used for timers and counters.
Byte Usage Example:
The cross reference list will be displayed in Cross reference

format. Bit Usage
Symbol information will be displayed if selected. The Bit Usage table allows you to see which memory ad-
Byte Usage and Bit Usage formats are also available dresses, down to the bit level, have been used in your pro-
gram. It also helps you recognise duplicate-assignment errors.
Double click to Double click to b Indicates that a bit of memory has been assigned.
open the block open the block
at the exact Double click to at the exact B Indicates that a byte of memory has been assigned.
location of the open the block location of the
element at network 1 element W Indicates that a word (16 bits) has been assigned.
D Indicates that a double word (32 bits) has been assigned.
Byte Usage Example:
Tabs for selecting Cross Reference, Byte Usage and Bit Us-
age formats.
Notes :

B026 END Creating a PLC program
Data Blocks The online values of the Data Block can be viewed by select-
ing the Data Block Status button on the toolbar:
A Data Block is an area of memory used for handling data.
Certain Siemens functions rely on Data Blocks (Tool manage-
ment, Service Planner etc.)
These are present in the Library folder of the 828D Program-
ming Tool and have to be added to the project if required.
User Data Blocks are also possible and have to be created. Data Block Data Block
Current Status
The Data Block data types can be: values. Button
Boolean
Byte
Word
Double Word
Integer
Double Integer
Real
The format can be (Depending on the data type):

Signed
Unsigned
Floating Point
Bit, Hexadecimal
Binary
ASCII
To view the content of a Data Block select the “Data Block”

button:
The example shown is DB_Common and is part of the example

project created earlier. New values can
be written to the
data block.
Writing Data Block values:
Data Block status must be active.

Type in the new value and then select the “Write all” button.
Write all
button.
New value appears in the Current Value column.

Many values can be written at once.
Different Data Blocks are selected via the tabs.
Notes :

B019 S7-200 PLC Instructions
Module Description:
The Sinumerik 828D uses the in-built S7-200 PLC. Programming is performed with the software
package PLC828. This modules describes the instructions available to the user.
Module Objective:
Upon completion of this module you will know the PLC828 Programming Tool instruction list.
Content:
Sinumerik
Bit Logic Functions

Compare Functions
Convert Functions
Counter Functions
Floating Point Number Functions
Integer Functions
Interrupt Functions
Invert Functions
And Functions
Or Functions
Move Functions
Program Control Functions
Shift/Rotate Functions
Timer Functions
Libraries
B019
B019

S7-200 PLC Instructions B019
S7-200 PLC Instructions: Description

S7-200 PLC
Instructions
START
The Sinumerik 828D uses the in-built S7-200 PLC. Program- And
ming is performed with the software package PLC828. This Functions
modules describes the instructions available to the user.
Bit Logic
Functions
Or Functions
Compare
Functions
Move
Functions
Convert
Functions
Program
Control
Functions
Counter
Functions
Shift/Rotate
Functions
Floating Point
Number
Functions
Timer
Functions
Integer
Functions
Libraries
Interrupt
Functions
S7-200 PLC
Instructions
END
Invert
Functions
Notes :

General Information
Bit Logic Function
Address Formats:
Instruction Tree:-
The instructions are found in the menu tree to the left of the
Bit- This refers to a single element of logic e.g. I6.0, Q5.5,
main programming area.
M100.6, DB3804.DBX2.1.
The Bit part is the number after the decimal point. The value of
a bit is either 1 or 0.
Byte- A Byte is a collective of 8 bits of logic in the same

group. e.g.
Input Byte 4 (IB4) contains the bits I4.0, I4.1, I4.2, I4.3, I4.4,
I4.5, I4.6, I4,7.
When working with bytes it must be remembered that the
numbering counts up from the right as shown below.
IB4
Bit no 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1
In this example I4.0, I4.2, I4.5 & I4.7 are equal to 1. Another
term for being equal to 1 is that these bits are High. The instructions are divided into different sections, these are
The bits equal to 0 are termed as being Low. expanded by clicking on the “+” symbol.
Output Bytes (QB) and Marker Bytes (MB) can also be used in
the same way.
Word- A Word is a collective of 16 bits of logic which encom-

passes two consecutive Bytes. Mouse pointer placed Right clicking on the oper-
on the operand re- and gives the chance to see
A Word can only be addressed as 0 or an even number (IW0, veals the type. a help file. Selecting Hide
IW2, IW4 etc) odd numbers are not allowed. will make the whole instruc-
tion tree disappear.
As with the Byte format the numbering starts from the right.
Example IW4 The PLC program is built up of a series of blocks called
IB5 IB4 subroutines. The blocks contain networks, the user PLC is
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 written into these networks.
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
The first instruction category in the list is Bit Logic. This
In this example I4.0, I4.1, I4.4, I4.5, I4.6, I5.1, I5.2, I5.5, I5.7.
group is the simplest of the instructions.
are equal to 1.
The individual items in the Bit Logic area are referred to as
Output Words (QW) and Marker Words (MB) can also be used
Operands.
in the same way.
These operands need to be addressed, the type of address
depends upon the
Double Word- A Double Word is a collective of 32 bits of logic
operand.
which encompasses two consecutive Words (Four consecu-
tive Bytes).
Terminology
A Double Word can only be addressed as 0 or an even num-
Inputs:- Typically they are represent the physical state of
ber which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd
the machine i.e. Limit switches, buttons, pressure switches,
numbers are not allowed.
door switches etc. and are identified by the letter I e.g. I7.0.
They can also appear in Byte, Word and Double Word for-
Example ID4
mats.
IB7 B6 B5 IB4
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 Outputs:- Outputs are used to switch on relays, contactors,
solenoids, lamps etc. and are identified by the letter Q e.g.
Output Double Words (QD) and Marker Double Words (MD) Q4.1. They can be used as coils or contacts, they can also
can also be used in the same way. appear in Byte, Word and Double Word formats.
Markers:- These are internal memory operands which can

be used as contacts and coils. They are represented by the
letter M e.g. M20.0. They can also appear in Byte, Word
and Double Word formats.
Notes :

Program Status Normally Closed Contacts.

The status of an operand can be checked by selecting the
“Program status” Icon. In this situation when the status of the operand is high (Equal
The centre of the operand becomes highlighted with a colour to one) the logic will be false.
when it is true. In terms of an electrical circuit, the contact will be open and
current cannot flow through to the next operand.
This is the opposite of the Normally Open operand.
Program Q4.0 = 0 or Q4.0 = 1 or

Status Icon Low High
I6.0 = 0 (Low) I6.0 = 1 or (High)
Coils:
Set and Reset example:-
As the names suggests, “Coils” are switched on/off by
“Contacts”.
Typical coil operands are Outputs, Markers, Variables, Data
Blocks, Timer & Counters. It is also possible to have an input
as a coil but this can be deemed as bad
practice. I6.5= 0, however Q4.5 I6.6 = 1, this has the ef-
remains high because it is fect of resetting Q4.5 to 0.
a “Set” output.
Output Q4.0 as a coil Immediate Contacts.

These operands are effective immediately upon activation,
they are not subject to the Process Image Table (Inputs). They
are identified by the letter “I”.
Contacts:
The most commonly used operands are “contacts”. Combina-

tions of contacts are used to achieve the end result of activat-
ing an output. Normally Open Immediate Normally Closed Immediate
These contacts can be assigned to system/user variables,
markers, physical outputs or inputs and can be of the nor- Not operands.
mally open or normally closed types.
The Not operand is used to reverse the state of the logic. i.e.
Normally open contacts. A status of one will become a status of zero while a status of
zero will become a status of one.
When the operand is high (Equal to one) the contact will be
closed and the logic will be true.
When the logic is true the centre of the contact will be col-
oured.
In the terms of an electrical service the contact will be closed
and current can flow.
I6.2 = 1 but Q4.2 remains low because the not operand inverts
the signal.
I6.0 = 0 or Low I6.0 = 1 or High
I6.2 = 0 but Q4.2 is high because the not operand inverts the
signal.
Notes :

Positive Transition operands. Immediate Outputs.

These operands are effective immediately upon activation.
The Positive Transition operand monitors the preceding oper- The status is passed to both the physical output and the
and status for a rising edge (Signal state change from 0 to 1) Process Image Table (Outputs).
on seeing a rising edge the logic will become true for one scan They are identified by the letter “I”.
of the PLC.
Output Immediate Set Immediate Reset Immediate
Compare functions are used to compare two values. The

compare values can be Byte, Integer (Single and double) or
When I6.3 changes from 0 to 1, Q4.3 will become high for one Real format.
scan of the PLC cycle The available compare types are:-
Negative Transition operands. Equal To
Not Equal To
The Negative Transition operand monitors the preceding oper- Greater Than or Equal To
and status for a falling edge (Signal state change from 1 to 0) Less Than or Equal To
on seeing a falling edge the logic will become true for one Greater Than
scan of the PLC. Less Than
The following example is using the Compare Byte function to

compare Input
bytes 6 & 7.
Compare Functions
When I6.3 changes from 1 to 0, Q4.4 will become high for one Compare bytes for being equal
scan of the PLC cycle.
No Operation Operand (NOP):-
A network cannot be left in an unfinished state, this leads to

errors when the program is compiled and prevents the pro-
gram from being loaded.
IB6 = 14 and IB7 = 15, they IB6 = 14 and IB7 = 14,
are not equal so the status they are equal so the
is low. Q5.0 = 0. status is high. Q5.0 = 1.
Compare bytes for not being equal.

An unfinished network.
If the program is in the development stages then a “No Op-
eration” operand can be inserted, this prevents the network
from being operational and allows the program to be compiled
and loaded to the controller. IB6 = 14 and IB7 = 14, they IB6 = 15 and IB7 = 14, they
are equal so the status is are not equal so the status
low. Q5.1 = 1. is high. Q5.1 = 1.
Compare bytes for being greater than or equal.
An unfinished network with a NOP operand.
When a NOP operand is inserted it has to be given an numeri-

cal identifier.
This identifier can be selected from the range of 0-255. IB6 = 14 and IB7 = 15, IB6 IB6 = 15 and IB7 = 14, IB6
is less than IB7 so the is greater than IB7 so the
status is low. Q5.2 = 0 status is high. Q5.2 = 0.
This would also be the case
if the values were equal.
Notes :

Compare bytes for being less than or equal.
Converting Double Integer to Real.

IB6 = 14 and IB7 = 7, IB6 is IB6 = 6 and IB7 = 7, IB6 is
greater than IB7 so the status less than IB7 so the status
is low Q5.3 = 0. is high. Q5.3 = 1
This would also be the
case if the values were
equal.
Compare bytes for being greater than When I6.0 is true the integer value in MD0 will be converted
into a real number and the result placed into MD4.
It is also possible to extend the network via the “ENO” output
to other operands. The “ENO” output will be high if the convert
function was successful.
IB6 = 6 and IB7 = 7, IB6 is Truncate (Converts 32-bit real to 32 bit signed integer).
IB6 = 15 and IB7 = 14, IB6
less than IB7 so the status is greater than IB7 so the
is false. Q5.4 = 0. status is high. Q5.4 = 1.
The Truncate Function takes a 32 bit Real number and cov-
Compare bytes for being greater than erts it into a 32 bit Double Integer which is signed. In other
words only the whole number portion of the real number is
transferred. The fraction is discarded.
Example:-
When input I6.1 is true the value of –1.1 in MD0 was trans-
ferred to MD8 as a value of –1. Output Q4.5 was set high by
the ENO output.
IB6 = 15 and IB7 = 14, IB6 IB6 = 6 and IB7 = 7, IB6 is
is greater than IB7 so the less than IB7 so the status
status is low. Q5.5 = 0. is high.
Q5.5 = 1.
The same principle applies to the other number formats of

Integer, Double Integer and Real
Binary Coded Decimal to Inte-
This function will convert a value from BCD to an integer.

Permitted ranges:-
Convert Functions BCD Decimal

Hex
Convert functions are used to change one number format into Minimum 0000 0000 0000 0000 0
another. 0
The functions available are:- Maximum 1001 1001 1001 1001 9999 9999
Double Integer to Real
Truncate Example:- When input I6.2 is true the value in MW0
Binary Coded Decimal to Integer (0000000001010100 = 54) will be converted into an integer
Integer to Binary Coded Decimal and the result placed in MW12. Output Q4.6 will become high
provided that the value in MW0 is within the ranges specified
When the block is inserted into the network it needs to be above and I6.2 remains true.
parameterised. The input is the number that is to be con-
verted, the output is the result of the conversion.
The number format of the input and output is dependant on
the type of conversion i.e. word, double word, byte.
Notes :

Integer to Binary Coded Decimal. Below:-Network 19 count up counter C1. The count value
can be seen to be equal to six, this mean that the CU input
This function will convert a value from an integer to BCD . (I6.4) has detected a rising edge on 6 occasions since the
Permitted ranges: reset (I6.4) was triggered.
Network 20 is an example of how the counter can be used in
HEX BCD Decimal the PLC logic. In this case the preset value (PV) of 10 has
Minimum 0000 0000 0000 0000 0 0 not been reached so the status is low.
Maximum 1001 1001 1001 1001 9999 9999 Counter C1 with a

count value of 6.
Example:- When input I6.3 is true the value in MW18 (96) will
be converted into an BCD and the result placed in MW16.(96
= 0000000010010110) Output Q4.6 will become high provided
that the value in MW0 is within the ranges specified above and
I6.3 remains high.
Preset value (PV) = 10
Counter functions
Count up counters
Count up counters are used to monitor the rising edge of a
signal, each time a rising edge is detected on the CU input the Below:-Network 19 count-up counter C1. The count value
count value will increment by one. can be seen to be equal to ten, this means that the CU input
The count can be reset at any time by setting the R input from (I6.4) has detected a rising edge on 10 occasions since the
low to high. reset (I6.4) was triggered.
When the counter is first selected in the user program it needs Network 20 is an example of how the counter (C1) can be
to be given a name (Available range C0 to C63). used in the PLC logic. In this case the preset value (PV) of
A preset value is entered in the PV input field as an integer, 10 has been reached so the status is high, this results in
when the count value is equal to or above this value the output Q4.7 being switched high.
counter will be true. The counter operand (e.g. C1) can then The C1 operand will remain high until the reset input R (I6.5)
be used elsewhere in the user PLC program. detects a rising edge. The count value stored in C1 will then
be set back to zero.
Below:-A counter selected in the user program but not yet
parameterised.
The name of the counter

needs to be entered here
e.g. C1
C1 count value = 10
A preset value is
entered here e.g 10
Notes :

Below:-The reset input has been switched from low to high Below:-Countdown counter C2 showing a count value of 4.
resulting in the count value being reset to zero and the C1 This means that the CD input has detected a rising edge from
operand becoming false. No further counting can take place I7.0 on 6 occasions since the preset value of 10 was entered.
until the reset signal is set to low.
Counter C2 with a
count value of 4.
C1 count value = 0 Below:-Countdown counter C2 showing a count value of 0.

This means that the CD input has detected a rising edge from
I7.0 on 10 occasions since the preset value of 10 was en-
tered. The result of this is that the C2 operand is now true as
shown in network 22. In this case output Q5.6 is now high.
Countdown counters
Countdown counters are used to monitor the rising edge of a Counter C2 with a
signal, each time a rising edge is detected on the CD input
the count value will decrement by one.
When the count value reaches zero the counter operand be-
comes high.
Prior to using the countdown counter a value has to be en-
tered into the Preset Value PV input field.
This value has is then transferred into the counter when the
LD input (I7.1) changes from low to high.
The count value can be reloaded at any time by setting the
LD input from low to high.
When the counter is first selected in the user program it
needs to be given a unique name (Available range C0 to
C63).
Output Q5.6 set
high as a result of
countdown counter
Below:-Count down counter C2 with a PV of two, this PV C2 reaching zero.
value will be entered into the counter when the LD input I7.1
switches from low to high.
This count value will decrease by one on each positive edge
detection of the CD input I7.0.
Notes :

Below:-Countdown counter C2 showing a count value of 10 Below:- When the count value is less than the preset value
after the LD input detected a rising edge from input I7.1. This the C3 operand will be low. In this example the count value is
also results in the C2 operand becoming false as seen in net- 9 after the countdown input I7.4 was switched from low to
work 22. high.
The counter C3 has a count
C2 count value = 10 value of 9 which is less than

The C3 operand is low
due to the counter
value being less than
the preset value. In
Countdown/count-up counters this example the out-
put Q5.7 is not set by
Countdown/count-up counters are used to monitor the rising the C3 operand.
edge of two signals. One signal (CU) increases the count
value while the other signal (CD) decreases the count value.
Below:- When the count value is more than the preset value
A preset value (PV) can be entered. The counter operand will
the C3 operand will be high. In this example the count value
become high if the actual count value matches or is above this
is 11 after the count-up input I7.3 was switched from low to
preset value. As soon as the value less than the preset value
high.
the counter operand will become low.
The stored count value can be reset at any time by setting the
reset input (R) to high The counter C3 has a count value
of 11 which is more than the pre-
The counter C3 has set value.
a count value of 10
which is equal to the
preset value.
Preset value (PV) = 10 The C3 operand is

high due to the
The C3 operand is high counter value being
due to the counter value more than the
and the preset value preset value. In this
being equal. In this ex- example the output
ample the output Q5.7 is Q5.7 is set by the C3
set by the C3 operand. operand.
Notes :

Floating Point Number Functions Subtraction of real numbers
Addition of real numbers The SUBTRACT function is parameterised in the same way as
the ADD function. When the function runs the IN2 value will be
Below:- The function requires parameterisation on first selec- subtracted from the IN1 value and the result placed in OUT.
tion.
Values to be added:
IN1 32 bit real number
IN2 32 bit real number added to IN1
Result:-
OUT 32 bit real number
Confirmation:- Below:- Example of the subtract function. MD100 - MD104 =

ENO Bit goes high if operation successful MD112 (16 - 2 = 14) Output Q6.1 is high.
Below:- The ADD function prior to parameterisation.
Multiplication of real numbers
The Multiply function is parameterised in the same way as the

ADD function.
Below:- Example of a parameterised ADD function before When the function runs the IN1 and IN2 values will be multi-
being executed. plied together and the result placed in OUT.
When input I9.0 goes high, the value in MD100 (IN1) in this
case 16, will be added to the value in MD104 (IN2) in this
case 2. The result will be placed in MD108 (OUT)
Below:- Example of the multiply function. MD100 x MD104 =

MD112 (16 X 2 = 32)
Output Q6.2 is high.
MD100 has been assigned to IN1 and has a value of 16.0
MD104 has been assigned to IN2 and has a value of 2.0
Below:- Input I9.0 is high and the ADD function has been
performed. The result is placed in MD108. The ENO output is
high which sets output Q6.0 high, this indicates that the ADD
function was a success.
MD108 = 18 Result of the ADD func-
Notes :

Integer Functions
Division of real numbers Addition and Subtraction of integers.
Below:- The function requires parameterisation on first selec-

The Divide function is parameterised in the same way as the tion.
ADD function.
When the function runs the IN1 value will be divided by the It is also possible to add/subtract/multiply/divide integers in
IN2 value and the result placed in OUT. the same way as real numbers. The inputs and outputs act in
the same way, only the number format changes.
IN1 16 bit integer or 32 bit double integer

IN2 16 bit integer or 32 bit double integer
Result:-
OUT 16 bit integer or 32 bit double integer.
Confirmation:-
Below:- Example of the divide function. MD100 ÷ MD104 = ENO Bit goes high if the operation was successful.
MD112 (16 ÷ 2 = 8) Output Q6.3 is high.
Below:-Examples of adding/subtracting Integers and double
integers.
Adding Integers
Square root of real numbers MW200 + MW202 = 204

(100) + (25) =
(125)
The Square Root function calculates the square root of a real Adding Double Integers
number. The number to be calculated goes to the IN signal,
the result is output to the OUT signal.
MD200 + MD202 =
MD204
(9000) + (3000) =
Subtracting Integers (12000)
MD100 has been MW200 - MW202 =

assigned to IN1 and MW204
Below:- Example of the Square function. (100) - (25) = (75)
has a value of 16.0
√MD100 = MD112 (√16 = 4) Subtracting Double Integers
Output Q6.4 is high.
MD208 - MD212 =
MD240
(9000) - (3000) = (6000)
Notes :

Multiplication of integers. The value in MB100

is incremented by
Incrementing Byte one and the result
This function multiplies two words and converts the result into sent to MB232
a double word.
The value in MB100

is incremented by
Incrementing Word one and the result
sent to MB232
MW200 x MD202 = MD240 The value in MD208

(100) x (25) = (2500) is incremented by
Incrementing Double Word one and the result
Division of integers. sent to MD212
This function divides one word by another and converts the

result to a double word.
The value in MB200
The result is in two parts, the high word section of the double is decremented by
word represents the whole number while the low word repre- Decrementing Byte one and the result
sents the remainder. The format is hexadecimal. sent to MB201
In the example below the result of 100 ÷ 8 shows a value of
000C in hex format which is equal to 12 as an integer. The
remainder is 0004 which is equal to 4 as an integer.
The value in MW200
is decremented by
Decrementing Word one and the result
sent to MW208
The value in MD212

is decremented by
MW200 ÷ MD204 = MD252 Decrementing Byte one and the result
(100) ÷ (8) = (000C0004) sent to MD236
= 12 remainder 4
Increment and Decrement Functions.
These functions allow a number to be incremented or decre-

mented by a value of one.
The formats can be Byte, Word or Double Word.
This is a once only occurrence, further switching of the con-
trol bit does not result in further increments/decrements.
Below:- Examples of increment and decrement functions.
Notes :

Interrupt Functions The addresses to be monitored need to be typed in the Ad-

dress column and the format set to binary.
Interrupt Function
In the example below it can be seen that the status of the
The interrupt function will freeze the processing of the PLC in inputs is the exact opposite of the output status.
all networks after the network containing the interrupt. This is
only effective in the Sub routine where the interrupt is used .
Examples:-
With the interrupt active, the output Q8.1 is

not set even though the proceeding ele-
ment, Input 11.2 is true.
With the interrupt active, the output Q8.1

remains set even though the proceeding And Functions
element, Input 11.2 is no longer true.
The AND function compares two bytes, words or double
words. If two corresponding bits are high the relevant output
bit will be set.
And Byte
Invert Functions
The invert function inverts the bit pattern of a byte, word or
double word. When viewed in the program status area this is
not very clear.
It is better to look in the chart status area. And Word
Invert Byte
And Double Word
Invert Word
This is better seen in the Chart Status area.
Invert Double Word
I7.0 and I9.0 are high

which sets M238.0
This equivalent operation when written in ladder is seen be-

low:-
To locate the chart status area select the following icon on the
toolbar.
Notes :

Or Functions Exclusive Or Functions
The OR function compares two bytes, words or double words. The Exclusive OR function compares two bytes, words or dou-
If either one or both of the corresponding bits are high the ble words. If either one but not both of the corresponding bits
relevant output bit will be set. are high the relevant output bit will be set.
OR Byte
Exclusive OR Byte
OR Word
Exclusive OR Byte
OR Double Word
Exclusive OR Double Word

If either input or both are

high M238.x will be set
If either input but not both

This equivalent operation when written in ladder format is are high M238.x will be set
seen below:-
This equivalent operation when written in ladder format is
seen below:-
Notes :

Move Functions Swap Function
Move functions are used for transferring data between from

byte to byte, word to word, & double word to double word.
Below:-Standard Move examples
Move Byte MW68 prior to running the Swap function.
MW68 after running the Swap function.

Move Word
Program Control
Jump Instruction & Labels
Move Double Word
The Jump Instructions and labels are used together. When

the Jump is activated the program will skip to the Label
specified by the Jump.
Move Real Number The Jump Instruction needs to be parameterised with the
number of the label to be jumped to. The available range is
from 0 to 255.
The jump instruction has to be used in the same program-
ming block.
Immediate move functions as the name suggests, have an
immediate effect on the PLC. They are only available for use Example of how a Jump/Label might be used.
with bytes.
The Immediate Read function is used to read physical inputs,
these can then be read out to Markers, Variables, Inputs, Out-
puts, Accumulators and Load instructions.
The Immediate Write function writes only to an output byte Jump Instruction to Label 1 is not active.
from Markers, Variables, Inputs, Outputs, Accumulators and
Load instructions.
I7.2 switches Q8.7 in the expected manner.
Move Byte Immediate Read
Move Byte Immediate Write Jump Instruction to Label 1 is active.
I7.2 does not switch Q8.7 because the

program jumps to Label 1.
The Swap function takes the lower byte data and places it in
the higher byte and vice versa. The swap is initialised via the
EN input. The swapping continues every PLC cycle as long as
the input is high. A positive edge instruction can be used to
control the swapping of data more effectively.
Notes :

The Conditional Return Instruction is active.

Jump Instruction to Label 1 is active.
Q9.3 remains low despite I7.7 being high.

I7.2 does switch Q8.7 because it was high This is
before the program Jump Instruction was because I7.7 was set high after the Condi-
activated. tional Return was activated.
Conditional End Instruction.
The Conditional End Instruction is used only in OB1 and re-

Jump Instruction to Label 1 is active. sults in the program scan restarting at the beginning of OB1.
No further operations after the Conditional End will be proc-
essed.
Q8.7 remains high despite I7.2 being low
this because I7.2 was set low after the
program Jump Instruction was activated. Example of how the Conditional End Instruction might be
used.
Conditional Return Instruction.
The Conditional Return Instruction is used to terminate a sub-

routine.
The Conditional End Instruction is not active.
Example of how a Conditional Return Instruction might be
used:-
I6.2 is high which switches Q4.1 high.
The Conditional Return Instruction is not

active.
I7.7 switches Q9.3 in the expected manner.

The Conditional End Instruction is active.
The Conditional Return Instruction is active.

I6.2 is high which but Q4.1 remains low. This
is because program end is now in the previ-
ous network.
I7.7 does not switch Q9.3 as the subroutine
has been terminated by the Conditional
Return. When the Conditional End Instruction is active, no further
processing takes place.
Outputs, markers etc which were already high will remain so
The Conditional Return Instruction is active. until influenced from elsewhere in the program.
Shift Left Byte.

Q9.3 remains high despite I7.7 being low.
This is The shift Left Byte function allows the bits within a byte to be
because I7.2 was set low after the program
moved to the left by up to 8 places. In the example below the
Conditional Return was activated.
contents of IB9(IN) will be shifted left by 4 places (N). The
result will be placed in MB100 (OUT) The maximum number of
places that can be moved is eight. If a larger number is en-
tered the value will default to eight.
Notes :

Shift Right:
The example below shows the result when viewed in ladder
status, a better idea of this is seen in Chart Status.
Byte to be shifted (IB9) The result of the Shift

Byte Left instruction will The Results:
No of places to be be stored in MB100
shifted (4)
Below:-The Chart Status shows that status of IB9 has been

shifted left by four places and the result placed in MB100.
Shift Left Double Word & Shift Right Double Word
Below:-The Chart Status shows that status of IB9 has been

shifted left by four places and the result placed in MB100.
The contents of a Double Word can be shifted left or right in
the same way that the contents of a Byte or Word can be
Shift Right Byte. shifted. The maximum number of moves is 32.
The Shift Right Byte function operates in the same way as the
Below:-Examples of shifting Double Words.
Shift Left Byte, except that the move is to the right.
Below:-Example of a Shift Right Byte by 2 places operation.
Shift Left:
Shift Right:
The Results:
Shift/Rotate Functions
Shift Left Word & Shift Right Word.
The contents of a Word can be shifted left or right in the same

way that the contents of a Byte can be shifted. The maximum
number of moves is 16.
Below:-Examples of shifting words. Timer Functions
Shift Left: Timer are used to delay the effects of a signal when it
switches. There are a total of 128 timers available (T0 to
T127).
T0 to T15 have an input resolution of 100ms with a maximum
preset time (PT) value of 327.67 seconds.
T16 to T127 have an input resolution of 10ms with a maxi-
Notes :

On-Delay Timer Below:- The time value of T1 has gone beyond the PT value.
As a result the T1 operand in network 8 is high and has
When a timer is selected it needs to be given a name (T0 to switched output Q5.0 high.
T127) and a Preset Time value (PT).
Timer name - Txxx T1 value
has
surpassed
the PT
value of 50
Preset Time (PT)
T1 operand is now
high, Q5.0 is also
high as result
Below: On-Delay timer T1 has been a PT value of 50 this
equates to a delay of 5 seconds (50 x 100ms).When Input
I7.0 becomes high, T1 will start to count, when the PT value
is reached the T1 operand will switch high. As a result Q5.0
will be come high (Network 8) as long as I7.0 remains high T1 Below: Input I7.0 has gone low and the T1 time value is reset
will continue to count and the T1 operand will remain high. to zero. The T1 operand also goes low as a result.
When I7.0 becomes low, the count value of T1 will reset to
zero and the T1 operand will go low.
Retentive On-Delay Timer

The Re-
tentive On-Delay Timer works in the same way as the
ON-Delay Timer except that when the IN signal is re-
Below: Input I7.0 is high and T1 has started to count. The T1
moved the Timer operand remains high. The Timer oper-
operand in network 8 is still low as the PT value of 50 has not
and will need to be reset by the user which also resets
been reached.
the time value to zero.
T1 value has Below:- Retentive On-Delay timer T2 has been triggered

reached 20 by I7.1 and the time value has passed the 10 second PT
value (100 x 100ms = 10 seconds). The T2 operand is
high and has switched Q5.1 high.
Notes :

The Input I7.1 is now low, T2 has stopped counting but retains The Off-Delay Timer T3 shown below monitors the IN input.
the count value. The T2 operand remains high. If I7.1 be- When this input is high, the T3 operand is also high as seen in
comes high again the time value in T2 will continue. network 12.
When the timer detects a falling edge on the IN input the time
value in T3 will count up, when this value reaches the value of
PT (75 x 100ms = 7.5 seconds) the T3 operand will be set to
Timer retains the zero.
count value
The IN signal has

gone low, T3 starts
to count up
Timer operand remains high
The timer is reset using the Reset function which can be seen
in network 8 below. Timer operand T3 remains high
Timer reset by I7.2 The Timer has counted up to the PT value, as a result the
T3 operand has been reset to zero. The timer value is reset
to zero when the IN input goes from low to high.
Timer count value
reset to zero
The time value has

reached the value
set in PT
Timer operand goes low
Off-Delay Timer
T3 operand is now zero
The Off-Delay Timer T3 shown below monitors the IN input.
When this input is high, the T3 operand is also high as seen in
network 12. The Timer has counted up to the PT value, as a result the T3
When the timer detects a falling edge on the IN input the time operand has been reset to zero. The timer value is reset to
value in T3 will count up, when this value reaches the value of zero when the IN input goes from low to high.
PT (75 x 100ms = 7.5 seconds) the T3 operand will be set to
zero.
Timer value sits at zero
Timer operand T3 is high
Notes :

Libraries
The Library contains system blocks for executing specific

tasks. These blocks consist of Interrupt Routines and Data
Blocks.
Interrupt Routines
INT_0 Executed synchronously with the servo cycle

INT_100 Executed immediately prior to the MAIN routine
(OB1)
INT_101 Executed immediately after the MAIN routine
(OB1)
Data Blocks
TM_CTS (DB9900 Constant transfer step table for tool

change
TM_VTS (DB9901) Variable transfer step table for tool
change
TM_ACK (DB9902) Acknowledgement step table for tool
change
SP_INI (DB9903) Start data for service planner
SP_ACT (DB9904) Actual data for service planner
EE_IFC (DB9905) Interface for Easy Extend
The various data blocks are explained in the relevant mod-

ules.
B019: END
Notes :

B019 END S7-200 PLC Instructions
B019
B033 PLC Functions
Module Description:
The following functions are available in the PLC:
 Initialise ASUP
 Start ASUP
 Reset password
 Save data
 Tool reloading
 Read axis positions
 Read and write NC variables
 Exchange data between the NC and PLC
 Control an axis from the PLC
Module Objective:
Upon completion of this module you will be able to perform the above listed PLC tasks.
Content:
Sinumerik
PI Services (Program Invocation Services)
Reading Axis Positions
Reading and Writing of NC Data
Data Exchange between NC & PLC
PLC controlled axis
B033
B033

PLC Functions B033
PLC Functions: Description

PLC
Functions:
START
The following functions are available in the PLC:
 Initialise ASUP
PI Services
 Start ASUP (Program
 Reset password Invocation
 Save data Services)
 Tool reloading
 Read axis positions
 Read and write NC variables Reading Axis
 Exchange data between the NC and PLC Positions
 Control an axis from the PLC
Reading and
Writing of
NC Data
Data Ex-
change
between NC &
PLC
PLC con-
trolled
axis
PLC
Functions:
END
Notes :

B033 PLC Functions
PI Services (Program Invocation Services) ASUP behaviour:-

The behaviour of the ASUP when it is called is affected by
PI Services the following interface signals:
A PI Service is an NC task which can be initiated from the LIFTFAST: When the ASUP is requested, fast retraction of
user PLC program. Interface signals are used to select the the tool from the contour takes place prior to the ASUP run-
required service, initialising, starting and monitoring the status ning.
of the service are available at the interface.
BLSYNC: When the ASUP is requested, the current program
PI Services that can be used:- block is processed prior to the ASUP running.
 ASUP - Asynchronous User Program
PI Services Start Bit Function
 LOGOUT - Password Reset
 _N_DASAVE - Saving of Data DB1200.DBX4000.0 Start PI Service
 TMMVTL - Tool Reloading via the PLC PI Service: LOGOUT - Password Reset
PI Index (DB1200.DBB4001) Function
PI Service: ASUP - Asynchronous User Program
3 Password Reset
A PLC ASUP is a program which can be initialised and started
from the user PLC independently of the normal NC operations. PI Services Start Bit Function
Two ASUPS are available (PLCASUP1.SPF and DB1200.DBX4000.0 Start PI Service
PLCASUP2.SPF). These have to be created by the user and
stored in the “Manufacturer cycles” directory. There are no PI parameters required for LOGOUT.
The required ASUP is initialised by entering a value of 1 or 2
into the PI index PI Service: _N_DASAVE - Saving of Data
interface. PI Index (DB1200.DBB4001) Function
Each ASUP first requires initialising before it can be run, this is 4 Save data automatically
achieved by setting the “Start PI service” bit high when the
relevant “PI index value” is active. The ASUP remains initial- PI Services Start Bit Function
ised until the control is powered off/on:- DB1200.DBX4000.0 Start PI Service
There are no PI parameters required for _N_DASAVE.

PI Service: TMMVTL - Tool Reloading via the PLC
PI Index Function Interrupt Priority PI Index Function
(DB1200.DBB4001) (DB1200.DBB4001)
1 Initialization of ASUP1 1 5 Initiate order for tool reloading
2 Initialization of ASUP2 2
PI Parameters for TMMVTL:
Interrupt Priority:-
If ASUP1 & ASUP2 are called together, ASUP1 will run and
PI Address Function Permitted
not ASUP2. Parameter Values
If ASUP2 is already running and ASUP1 is called, ASUP2 will
be stopped and ASUP1 will run. 1 DB1200.DBW4004 Tool Number 1 to 31999
If ASUP1 is running and ASUP2 is called, ASUP1 one will
2 DB1200.DBW4006 Source Location 1 to 31999
complete before ASUP2 starts. Number
3 DB1200.DBW4008 Source Maga- 1 to 31999
zine Number
PI Parameters for ASUP1 & ASUP2:
4 DB1200.DBW4010 Target Location 1 to 31999
Number
PI Parameter Address (Word) Signal Permitted values 5 DB1200.DBW4012 Target Maga- 1 to 32000
(1 to enable) zine Number
1 DB1200.DBW4004 LIFTFAST 0 or 1 PI Services Start Bit Function

2 DB1200.DBW4006 BLSYNC 0 or 1 DB1200.DBX4000.0 Start PI Service
Notes :

PLC Functions B033
Interface signals for PI services
The following interface signals are reserved for use with the PI Services function.
DB1200 PLC NCK [r/w]

4000 Start
4001 PI-Index
1: ASUP1, 2: ASUP2, Password Reset, Saving of Data, Tool Reloading via the PLC
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
4008 PI-Parameter 3
4010 PI-Parameter 4
4012 PI-Parameter 5
4014 PI-Parameter 6
4016 PI-Parameter 7
4018 PI-Parameter 8
4020 PI-Parameter 9
4022 PI-Parameter 10
DB1200 NCK PLC [r]
5000 Fault Finished

5001
5002
DB3400 PLC NCK [r/w]

0000 Asup 1
start
0001 Asup 2
start
0002
0003
DB3400 NCK PLC [r]

Asup 1 start Asup 1 num- Asup 1 run- Asup 1
1000 not possi- ber not ning finished
ble possible
Asup 2 start Asup 2 num- Asup 2 run- Asup 2 finished
1001 not possi- ber not ning
ble possible
Notes :

B033 PLC Functions
Example: Initialise and start an ASUP A subroutine should be created in which to write the PLC
code to initialise and start the ASUP.
The ASUP has to be created either offline and loaded to the
controller or it can be created directly on the controller. To
create on the controller use the following soft-key sequence. Select PI Service no.
Path = NC data\Cycles\Manufacturer cycles. 1 (ASUP1) by putting
a value of 1 into
DB1200.DBB4001.
Initialise the ASUP with the

“Start PI Service signal”.
(DB1200.DBX4000.0 high).
Reset the “Start PI Service

signal”.
Start ASUP1 with the “ASUP1

Start signal” (DB3400.DBX0.0
high).
Reset the “ASUP1 Start signal.
LED to indicate ASUP1 is

running.
The ASUP will run in all modes. Any program running in

automatic mode will be interrupted while the ASUP runs, this
The file will open automatically to allow the program com-
program will then continue when the ASUP has finished.
mands to be entered. In this example a 10 second dwell is
used with an operator message.
Notes :

PLC Functions B033
Example: LOGOUT-Resetting the password
The following example can be used to reset the active pass- Select PI Service
word. no. 4 by putting a
value of 4 into
DB1200.DBB4001.
Start the PI service

by switching
Start the PI service
by switching
Select PI Service no.
DB1200.DBX4000.0
3 by putting a value of
high.
3 into
B1200.DBB4001.
Start the PI service Reset the PI service

by switching start signal.
PI service finished
DB1200.DBX4000.0
signal when
high.
Reset the PI service

PI Service complete signal used to set
start signal. PI service fault signal
when
MCP Reset key used to reset Q4.1.
The active password will be deleted and the access level will
be determined by the key-switch position.
Example: _N_DASAVE-Saving data

The following example can be used to automatically save
data to the internal flashcard. There is no on-screen indica-
tion that a data save function has been performed. Interface
signals are available to indicate when a PI service is success-
ful.
Notes :

B033 PLC Functions
Reading Axis Positions
Reading axis actual positions and distances to go
The actual position and distance to go of an axis can be read in the PLC.
The following PLC interface areas are reserved for this function.
DB5700- NCK PLC [r]

5707

0000 Axis actual value (Real)
0004 Axis distance to go (Real)

Request axis Request axis
0001 distances to go actual values
The following table shows the DB addresses for each axis when reading axis positions/distance to go.
Actual position Distance to go Axis

DB5700.DBD0 DB5700.DBD4 1
DB5704.DDD0 DB5704.DBD4 5
Example: Reading axis actual position and distance to go
Moving the 1st axis actual position into MD100 using the
MOV_R instruction.
The value is read only when DB2600.DBX1.1 is high.
Moving the 1st axis distance to go into MD200 using the

MOV_R instruction.
The value is read only when DB2600.DBX1.2 is high
Notes :

PLC Functions B033
The result of the example can be seen below:
Reading and Writing of NC Data
Up to eight variables can be addressed at any one time, identified by substituting a number (0 to 7) in place of the 4th digit of the
DB number. Example
DB1200.DBB1000 - 1st variable
DB1201.DBB1000 - 2nd variable
DB1202.DBB1000 - 3rd variable etc.
Variables that can be read/written:-

- Cutting edge (read/write)
- Number of cutting edges (read only)
- Settable work offsets (read only)
- Number of machine axes (read only)
- R parameters (read/write)
- Tool magazine location type (read only)
- Tool location status (read only)
- Tool number (read only)
Interface signals for read/write NC Data

The following interface signals are reserved for use with reading and writing NC data.
DB1200 PLC  NCK [r/w]

Read:0
0000 Write:1
Start
1200 0001 Number of variables to be read/written
DB1200-
PLC  NCK [r/w]
1207

Variable type:
1000 1: Tool data; 2: Tool edge Number; 3: Zero offset; 4: Number of axes, 5: R parameter
7: Location type; 8: Location status; 9: Tool number at a specific location
1001 Area Number
1002 Column Index number of NC variable x +1 (Word)
1004 Line Index of NC variable x (Word)
1006
1008 Writing data to NC variable
Notes :

B033 PLC Functions
DB1200 NCK  PLC [r]

Request com-
2000 Error in job
plete
2001
DB1200-
Line Index number of NC variable x +1 [r]
1207
3000 Valid variable
Access result
3001 0: No error; 1:Illegal access to object; 5: Invalid address; 10: Object does not exist.
3002
3004 Reading data from NCK variable
The following tables show the interface signals required for each of the variables.
Type 1: CuttEdgeParam - The cutting edge value of a tool can be read/written.
Cutting Edge Parameter (Read/write)
DB120x.DBB1000 1
DB120x.DBB1001 —
DB120x.DBW1002 (Cut. Edge No -1) * numCuttEdgeParams + Param. No (Word)
DB120x.DBW1004
DB120x.DBD1008 Write: Data to NCK variable x (Real number)
DB120x.DBD3004 Read: Data from NCK variable x (Real number)
Type 2: numCuttEdgeParams - The number of parameter elements of a cutting edge, up to 25 parameters are available.
Number of Cutting Edge Parameters (Read)
DB120x.DBB1000 2
DB120x.DBB1001 —
DB120x.DBW1002 —
DB120x.DBW1004 —
DB120x.DBD1008 —
DB120x.DBW3004 Read: Data from NCK variable x (Word)
Notes :

PLC Functions B033
Reading and Writing of NC Data continued
Type 3: linShift - Settable work offsets.

(only if MD18601MM_NUM_GLOBAL_USER_FRAMES > 0).
Settable work offsets (Read)
DB120x.DBB1000 3
DB120x.DBB1001 —
DB120x.DBW1002 Frame index * numMachAxes + AxisNumber
DB120x.DBW1004 —
DB120x.DBD1008 —
DB120x.DBD3004 Read: Data to NCK variable x (Real number)
Valid frame index numbers:
0: ACTFRAME = Current resulting work offset

1: IFRAME = Current settable work offset
2: PFRAME = Current programmable work offset
3: EXTFRAME = Current external work offset
4: TOTFRAME = Current total work offset (ACTFRAME + EXTFRAME)
5: ACTBFRAME = Current total base frame
6: SETFRAME = Current 1st system frame (PRESET, Scratching)
7: EXTSFRAME = Current 2nd system frame (PRESET, Scratching)
8: PARTFRAME = Current 3rd system frame (TCARR and PAROT with
Orientating tool carrier)
9: TOOLFRAME = Current 4th system frame (TAROT and TOFRAME)
10: MEASFRAME = Result frame for work piece and tool gauging
11: WPFRAME = Current 5th system frame (Work piece reference points)
12: WPFRAME = Current 6th system frame (Cycles)
Type 4: numMachAxes - The highest existing axis number.
Highest existing axis number (Read)
DB120x.DBB1000 4
DB120x.DBB1001 —
DB120x.DBW1002 —
DB120x.DBW1004 —
DB120x.DBD1008 —
Notes :

B033 PLC Functions
Type 5: R Parameters Type 9: Tool number
R Parameters (Read/write) Tool number $TC_MPP6 (Read)
DB120x.DBB1000 5 DB120x.DBB1000 9
DB120x.DBB1001 —
DB120x.DBB1001 —
DB120x.DBW1002 Location number
DB120x.DBW1002 R Number + 1
DB120x.DBW1004 Magazine number
DB120x.DBW1004 —
DB120x.DBD1008
DB120x.DBD1008 Write data to NCK variable x (Real number)
DB120x.DBD3004 Read: data from NCK variable x (Real number)
Example: Reading data from an R parameter
Type 7: Magazine data-Location data
>0: Location type for virtual location Selection of the number

=0: “Match all” (Buffer) of data sets to be trans-
ferred. (In this case only
9999: Undefined (No virtual location) one) Up to eight can be
transferred in the same
operation.
Location type $TC_MPP2 (Read)
DB120x.DBB1000 7 Selection of the
type of variable to
DB120x.DBB1001 — be transferred. (R
Parameter = 5).
DB120x.DBW1002 Location number
DB120x.DBW1004 Magazine number Selection of the

Variable number + 1
DB120x.DBD1008 (R parameter 10 +
1= 11).
Type 8: Location status

Start signal.
The read/write signal as be set to

Location status $TC_MPP4 (Read)
Read. (0 = Read).
DB120x.DBB1000 8
DB120x.DBB1001 — Reset Start signal.
DB120x.DBW1002 Location number Reset Read signal.

DB120x.DBW1004 Magazine number
DB120x.DBD1008 For the example it is better to have a value other than zero in
the selected R parameter. To locate the R Parameter screen
use the following key selection:
Meaning of the results in location status DB120x.DBW3004.
1. Disabled
2. Unassigned
4. Reserved for tool in buffer
8. Reserved for tool to be loaded
16. Assigned to the left half location
32. Assigned to the right half location
64. Assigned to the upper half location
128. Assigned to the lower half location
Notes :

PLC Functions B033
R parameter 10 is used in the example, Cursor to R10 and

enter a value, confirm with the “Input” key. Example R10 =
99.
Value of 25 written
to
DB1200.DBD1008
Start signal.
When the start signal is set to high, the value in R10 will be
transferred to DB1200.DBD3004. The read/write signal has to
Below: Status of target variable prior to the start signal. be set to Write.
(1 = Write).
Reset Start signal.
Reset Write signal.
The value from R10 will now appear in DB1200.DBD3004. The value from DB1200.DBD1008 will now appear in R10.
This value remains there only as long as the start signal is This value remains there until the start signal is removed.
present.
Example: Writing data to an R parameter

To write data to the NC variable it is necessary to first enter a
value in the area reserved for this function. This area is
DB1200.DBD1008. Network 4 below shows how this can be
done.
Notes :

B033 PLC Functions
Data exchange between NC and PLC This can be checked in the Chart Status of the PLC828 pro-
gramming tool:
The 828D controller has a 4095 byte memory area for use
with data exchange between the NC program and PLC.
The function is also available with SYNACT.
The memory available is from DB4900.DBB0 to

DB4900.DBB4095, allowing data to be exchanged directly To read data in the opposite direction is a similar operation.
between the user PLC and for example a part program. In the MDA area type the line: R11=$A_DBR[4].
This will copy the contents of $A_DBR[4] into R11.
It is possible to use Byte, Word, Double Word and floating
point numbers to be used as shown below:
$A_DBB[n] Byte format

$A_DBW[n] Word format
$A_DBD[n] Double Word format
$A_DBR[n] Real number
[n] should be substituted for the byte number.
To test the function, the value stored in R10 will be written

into $A_DBB[4] (the 4th byte of DB4900, i.e. DB4900.DBB4).
The following program code has to be typed into the MDA

area of the Controller: $A_DBR[4]=R10.
This can be checked in the R parameter area of the controller :
Notes:
1. The data structure in the data area is defined by the
user.
2. Data reading by the NC can activate a pre-read stop
(internal STOPRE).
When the cycle start button is pressed the value be copied 3. A maximum of 3 sets of data can be written by the NC
from R10 to the destination variable. in the same
program block.
Notes :

PLC Functions B033
PLC controlled axis
It is possible to control a servo axis using the PLC interface. Various interface signals are available for this task.
A tool magazine is an example of when a PLC controlled axis could be used.
There are 3 possibilities for positioning a PLC axis:
 Variable positioning using the PLC interface

 Pre-defined positioning from a table in the “General Machine Data” area.
 Equidistant positioning determined via “Axis Machine Data”
Interface signals are used to facilitate the movement of a PLC axis.
PLC interface signals:
DB3800- PLC NCK [r/w]

DB3807

Request PLC Activation signal Request NC
0008
axis/spindle for NC/PLC axis/spindle
axis
changeover
Start position-
3000 ing axis
Traversing Path Path

3002 dimension Condition: condition:
Inch Shortest path Incremental
(DC) (IC)
G function: G function:
3003 Indexing posi- Absolute posi- Absolute nega-
tion tive direction tive direction
(ACP) (ACN)
3004
3005
Position (Real number for variable positioning, double word when using fixed index positions)
3006
3007
3008
3009 Feedrate (Real number)
If = 0 value is taken from axis machine data POS_AX_VELO
3010
3011

DB3907
Positioning axis Position Error Axis
3000 active reached during travers- cannot be
ing started
3001
3002
3003 Error number
Notes :

B033 PLC Functions
The PLC axis will now move to the position entered in

Prior to commissioning a PLC axis it is necessary to declare DB3805.DBD3004.
the axis as a PLC axis.
It is possible to do this permanently via Axis machine data

30460 or using interface signals to switch between PLC/NC
control.
A geometry axis cannot be assigned as a PLC axis.
Firmly assigning the axis to the PLC via machine data:

By the changing the value of DB3805.DBD3004 it is possible to
move the axis to varying positions, For example, the value
entered here could be taken from the Tool Management inter-
face and used to position a tool carousel in preparation for a
tool change.
Positioning using an index table
The number of indexing positions is entered via machine data:

Variable positioning using the PLC interface
General MD: 10900 $MN_INDEX_AX_LENGTH_POS_TAB_1
The following example shows how to position a PLC axis 10920 $MN_INDEX_AX_LENGTH_POS_TAB_2
using a variable from the PLC interface.
There are two index tables (Machine data arrays) available
where index positions can be entered:
General MD: 10910 $MN_INDEX_AX_POS_TAB_1

Select the axis as a 10930 $MN_INDEX_AX_POS_TAB_2
PLC axis by setting
I1.0 high.
The index array to be used is selected via Axis machine data:
Axis MD: 30500 $MN_INDEX_AX_ASSIGN_POS TAB_1

Initiate the PLC axis
by setting I1.1 high.
The following example shows how to position a PLC axis using
the positions entered in an index table found in the “General
Select incremental Machine Data” area.
moves by setting
I1.2 high.
The 10 positions are divided equally into 36 degree incre-
ments.
Command position
of the axis (“real”
value).
Start the positioning

procedure with I1.6.
Notes :

PLC Functions B033
PLC controlled axis
PLC requirements:
Select the axis as a

PLC axis by setting
I1.0 high.
Initiate the PLC axis

by setting I1.1 high.
Select positioning
by index table. Bit
1.7 = high.
Selecting the
index position
e.g. 5.
Start the position-

ing sequence.
The axis will now move the position entered into the 5th value
(Index 4) of General Machine data 10910
$MN_INDEX_AX_POS_TAB_1.
B033: END
Notes :

B33 END PLC Functions

B031 PLC Alarms and Messages
Module Description:
Alarms and messages are essential to inform operators, maintenance personnel etc. of the state of
the machine.
Alarms and messages can be configured to have different behaviour on the operation of the ma-
chine.
User help files can be created to give a more detailed description of each alarm/message.
This module describes how the alarms and messages are activated.
The effect an alarm has on the system is described and how to acknowledge an alarm.
Module Objective:
Upon completion of this module you can configure, activate and set the attributes of
messages and alarms and create user help files.
Content:
Sinumerik
General Information
Alarm and Message Screens
Alarm Configuration
Entering the Alarm Text
User Help Files
Alarm Log
B031
B031

PLC Alarms and Messages B031
PLC Alarms and Messages: Description PLC Alarms

and
Messages:
START
Alarms and messages are essential to inform operators,
maintenance personnel etc. of the state of the machine.
Alarms and messages can be configured to have different
behaviour on the operation of the machine.
General
User help files can be created to give a more detailed de-
Information
scription of each alarm/message.
This module describes how the alarms and messages are
activated.
The effect an alarm has on the system is described and how
to acknowledge an alarm. Alarm and
Message
Screens
Alarm
Configura-
tion
Entering the
Alarm Text
User Help
Files
Alarm Log
PLC Alarms
and
Messages:
END
Notes :

General Information Alarms and Message Screen

The alarms/messages are sub-divided into the following ranges: The 828D controller allows 248 user PLC alarms/messages
to be configured (numbered 700000 to 700247).
Range Description Each alarm/message has an interface bit for activation
(DB1600.DBX0.0 to DB1600.DBX30.7).
0 - 9999 General alarms
10000 - 19999 Channel alarms The alarms/messages can be displayed in red or black. Red
is traditionally used to indicate a more serious alarm and
20000 - 29999 Axis/Spindle alarms black is used for a message type situation.
60000 - 64999 Cycles alarms Siemens The effect an alarm/message has on the machine is configur-
able via general machine data 14516. The same machine
65000 - 69999 Cycle alarms Customer data is used to determine how the alarm/message is acknowl-
edged.
100000 - 199999 HMI alarms
The alarm/message text can be input via the controller or
200000 - 299999 Sinamics alarms created offline.
300000 - 399999 General drive alarms
The extended alarm function allows the same alarm/message
number to be used for different situations by substituting part
400000 - 499999 PLC alarms Siemens
of the text for a numerical variable. The following shows infor-
700000 - 700247 PLC alarms/messages Customer mation required for setting and configuring alarms.
As soon as a fault occurs on the machine, an alarm together When alarms and messages are triggered they are separated
with the alarm number, alarm text and the acknowledgement/ and displayed on different screens. The time and date of the
clearance will be shown on the screen. alarm/message occurrence is given.
1 2 3 A configurable alarm log is available to show past alarms/

messages including when they occurred and when they were
cleared. The log can be saved and forwarded to technical
personnel if necessary.
Select the following keys to locate the screen where the ac-
tive alarms and messages are displayed.
Depending on the configuration, there are two areas where

an active alarm might be displayed.
The “Alarm list” screen displays serious alarms

1 Number of alarm which result in the machining process being halted.
2 Acknowlegement of alarm
3 Alarm text The “Messages” screen displays less serious
alarms which may not necessarily result in the ma-
chining process being halted.
A description of the system alarms, their cause and remedy is
documented in the Online Help of the controller and in the
diagnosis manual on DOConCD.
Notes :

Alarms and Message Screen Alarm Configuration
Below is an example of two alarms in the Alarm list. The table below shows the alarm numbers and their associ-
ated interface signals and configuration machine data.
Alarm Activation bit Configura- Variable for

No. tion extended alarm
Machine function
Data
700000 DB1600.DBX0.0 14516[0] DB1600.DBD1000
700001 DB1600.DBX0.1 14516[1] DB1600.DBD1004
700002 DB1600.DBX0.2 14516[2] DB1600.DBD1008
700003 DB1600.DBX0.3 14516[3] DB1600.DBD1012
700004 DB1600.DBX0.4 14516[4] DB1600.DBD1016
700005 DB1600.DBX0.5 14516[5] DB1600.DBD1020
700006 DB1600.DBX0.6 14516[6] DB1600.DBD1024
700007 DB1600.DBX0.7 14516[7] DB1600.DBD1028
700008 DB1600.DBX1.0 14516[8] DB1600.DBD1032

Alarms/messages are also displayed on the top line of the
700009 DB1600.DBX1.1 14516[9] DB1600.DBD1036
screen. When more than one alarm/message is present a
downwards pointing arrow appears to the right of the alarm/ 700010 DB1600.DBX1.2 14516[10] DB1600.DBD1040
message number.
...
700247 DB1600.DBX30.7 14516[247] DB1600.DBD1998
The alarms can be made to appear in turn after a set time.

This is controlled by Below:- An example of how Alarm 700000 might be activated
Display Machine Data 9056. via input I8.0.
Configuration machine data:-

The configuration machine data is used to determine how the
controller reacts to that particular alarm. Each alarm has a
machine data assigned to it for this purpose.
Machine Data MD 14516 functionality:-
14516[xx] Effect/Acknowledgement
Bit 0 NC start inhibit
Bit 1 Read in disable
Bit 2 Feed disable
With values of less than 500 there is no rotation cycle. Values Bit 3 Emergency stop
of 500 to 10000 set the time that each alarm/message is dis-
played for. Bit 4 PLC stop
The units are milliseconds. Bit 5
The machine data is activated with an NC reset.
Bit 6 Acknowledged by DB1600.DBX3000.0
Bit 7 Acknowledged by Power off/on
Notes :

Alarm Configuration continued Extended alarm function:-

It is possible to include a numerical variable within the alarm
text string. This is done using the variables shown in the
Bits 0 to 4 determine how the controller reacts to that particu-
“Variable for extended alarm function” column of the table
lar alarm, while Bits 6 & 7 determine how the alarm is ac-
on page 8.
knowledged.
The MD is set via a bit pattern which is revealed when the MD
Each alarm is assigned a Double Word variable for this pur-
is highlighted and the “Select” key is pressed.
pose. By selecting one of the following identifiers and enter-
The bit is then activated with the “Select” or “Space” key and
ing it into the alarm text, the contents of the Double Word
confirmed with the “OK” soft-key.
will appear in place of the identifier when the alarm is trig-
gered.
%d Decimal value
%x Hexadecimal
%b Binary
%o Octal
%u Unsigned integer
%f Floating point number
Example:-
The alarm number 700003 is to be used to signal that sev-
eral axes are in the parked position.
The bit to activate this alarm is DB1600.DBX0.3 and that the
extended function variable is DB1600.DBD1012.
In the alarm text type:-

“Axis %d in parked position”.
In the Variable DB1600.DBD1012 the value of 1 is entered.

This is done by a move command.
This variable is a Double Word and as such it has to use the
“MOVE_DW” instruction (Move Double Word).
Machine Data 14516 is also used to determine whether the
message/alarm appears on the alarm or message screens. Below is an example of how a value 2 is moved into the
variable DB1600.DBD1012 when input I8.3 is equal to one.
If neither bits 6 & 7 are used, then the message/alarm requires This would display the number 2 in place of the “%d” and
no acknowledgement and will clear as soon as the activation activate alarm 700003.
bit becomes zero.
The alarm/message will appear on the message page.
If bits 6 & 7 are used then the alarm/message appears on the

alarm page and an acknowledgement is required.
The machine data is activated with a power off/on via the

“Reset (po)” soft key.
Below is the alarm 700003 as displayed on the controller.
By moving different values into DB1600.DBD1012 it is pos-

sible to use the same alarm number to display slightly differ-
ent messages.
Notes :

Entering the Alarm Text
The PLC alarm text can be created directly on the controller,

the details are then saved automatically to an XML file.
It is also possible to edit the xml file off the machine, this is The data is now saved to an xml file in the following location:-
usually the better option when a large number of alarms are SystemCF card\oem\sinumerik\hmi\lng
to be used.
The file name is:-
The alarm file determines the text that is displayed when a oem_alarms_plc_eng.ts. The “eng” part of the name is the
particular alarm is activated. language identifier.
Creating the text on the controller Language identifier examples:-

Locate the Alarm texts screen with the following key se- eng = English
quence. deu = German
fra = French
ita = Italian
esp = Spanish
chs = Chinese (Simplified)
cht = Chinese (Traditional)
kor = Korean
Use the cursor key to highlight the User PLC alarm texts op-
ptb = Portuguese (Brazil)
tion alarm type and select “OK”.
Locate the file:-

SystemCF card\oem\sinumerik
\hmi\lng\oem_alarms_plc_eng.ts
The file can be edited on the controller or saved externally for
editing/forwarding elsewhere. Select the “Open” soft-key to
open the file.
Up to 248 alarm numbers with text can now be typed in using

the key board.
Existing alarms can also be edited here.
The text entered earlier can be seen within the file. When edit-
ing is important only to change the alarm number within the
<source> tag and the alarm description within the
<translation> tags. the rest of the file structure should be left
unchanged.
The file is automatically saved when the “Exit” soft-key is se-
lected.
The colour of the alarm text can be either black or red. This
is selected at the right of the text input field.
When an alarm text entry is complete press the “Input” key to

confirm the entry.
Add further alarms in the same way. Select “OK” when all the
alarms have been entered then reboot the HMI.
Notes :

Entering the Alarm Text continued When the search soft-key is selected further options are re-
vealed which can be used to locate alarms and text in the
The alarm text editing screen has search, copy, paste delete alarm list.
functionality. This is useful when editing exiting alarm texts.
Takes the user the beginning of the list.
Takes the user the end of the list.
Can be used to find a specific word and replace it

with another.
The search function can be used to search for text or alarm

numbers. Cancels the operation.
The option to search forward or backward is available as well
as a case sensitive option. Confirms data entry/starts the search function.
The cursor are used to navigate and the select key to toggle
between the choices.
The search is started when the “OK” soft key is pressed. The
“Continue search” soft key can be used to identify any further
matches.
The cursor and page up/down keys can also be used for find-
ing a particular alarm.
Example 1. Example 2.
The search function can be used to search for text or alarm

numbers.
The option to search forward or backward is available as well
as a case sensitive option.
The cursor are used to navigate and the select key to toggle
between the choices.
The search is started when the “OK” soft key is pressed. The
“Continue search” soft key can be used to identify any further
matches.
The cursor and page up/down keys can also be used for find-
ing a particular alarm.
Notes :

User Help Files
General Information
To further enhance the fault finding procedure it is possible to create a “Help” file.
When the HELP key is pressed the details of the selected alarm will be displayed on the screen.
Help file information and Rules:-

The help file is of the type HTML (HyperText Markup Language) and needs to be stored in a specific directory.
File location for English language:
System CF-Card\oem\sinumerik\hmi\hlp\eng\sinumerik_alarm_plc_pmc
The italicised text denotes folders that require creating. Separate folders are required for each language where the Help
file is to be utilised.
Examples:-
English - eng\sinumerik_alarm_plc_pmc
German - deu\sinumerik_alarm_plc_pmc
Chinese (Simplified) - chs\sinumerik_alarm_plc_pmc
Chinese (Traditional) - cht\sinumerik_alarm_plc_pmc
Portuguese - ptb\sinumerik_alarm_plc_pmc
Korean - kor\sinumerik_alarm_plc_pmc
The HTML file name is also fixed:

sinumerik_alarm_oem_plc_pmc.html
A separate file needs to be created and stored in each of the language folders.
HTML script language

Once the file is created the HTML code can be entered. HTML uses tags, each tag has a specific function.
Tags have to be opened and closed in the correct manner, example :-
<html> Opening the “html” tag

Information/more tags entered here
etc.
</html> Closing the “html” tag
Common HTML Tag

description TAG Description
html Root element-Main tag for the help file, contains all other tags, first to be
opened and last to be closed.
head Contains document information, opened immediately after the HTML tag,
closed directly before the BODY tag is opened.
body The main body of the HTML document, determines what will be displayed
on the screen. Opened immediately after the closing the HEAD tag.
Closed immediately before the HTML tag.
table Creates a table for the help file information.
tr Table row, creates a row within the table.
td Table data cell. Used within the tr tag, contains the text that is to be
displayed on the help screen. The tag is used with the width attribute to
determine the width of the cell and the valign attribute to align the text
within a cell.
p Used to begin a new paragraph.
b Text will be written in bold type.
i Text will be written in italic type.
br Starts a new line.
Notes :

User Help Files continued
Example help file

Below is an example help file for alarm 700001. the text has been coloured to assist with understanding the contents. Due to page
width restrictions, some of the entries are shown on two lines. In the HTML file these would normally be on a single line.
<html>
<head><meta http-equiv="Content-Type" content="text/html; charset="UTF-8"/><title></title></head>
<body>
<table>
<tr>
<td width="15%"><b><a name="700001">700001</a></b></td>
<td width="85%"><b>Hydraulic Oil Pressure Low</b></td>
</tr>
<tr>
<td valign="top" width="15%"><b>Parameter:</b></td>
<td width="85%">N/A</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Explanation:</b></td>
<td width="85%">I8.1 is low.</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Reaction:</b></td>
<td width="85%">Emergency Stop Initiated</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Remedy:</b></td>
<td width="85%">The hydraulic unit has indicated a fault. Check oil level. Check pressure switch. <br />Clean filter if necessary.</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Part number:</b></td>
<td width="85%">Hydraulic oil type: AAA. Pressure switch type: BBB <br /> Filter type CCC</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Program continuation:</b></td>
<td width="85%">Machine restart required</td>
</tr>
</table>
<p></p>
</body>
</html>
The system is able to cross reference the highlighted alarm with the entry under the “a” tag.
<td width="15%"><b><a name="700001">700001</a></b></td>
The contents of the table containing the correct anchor are now displayed.
Adding further alarms to the HTML file is simply a case of copying/pasting the existing Table tag and its contents and editing to
suit the individual alarm.
The contents of the “Head” tag should be left as it is. This determines the content type and text format.
Notes :

User Help Files continued Creating the help files/directories on the controller
The folders can be created directly on the controller or by using
Testing the help file on the controller the RCS Commander software package.
To test the Help file the alarm specified in the Help file should
be activated. Creating the help file folders on the controller:-
Alarm 700001 is activated by DB1600.DBX0.1
Locate the directory where the folders are to be created.
With the alarm active locate the “Alarms/Messages” screen. System CF-Card\oem\sinumerik\hmi\hlp
The alarm will appear in either the “Alarmlist” or “Messages”

screen depending how it has been configured.
If several alarms exist cursor to the alarm correct one.
Cursor to the “hlp” directory and select the “New” soft-key.
Select the “Directory” soft-key, this is usually already selected

The HELP function is activated by the “HELP” key located to by default.
the bottom right of the screen.
Enter the directory name, this is the language directory. Sev-

eral will have to be created help files are to be available for
more than one language. See previous page for language
specific folder names.
Below:-Creating a folder for English.
Notes :

User Help Files continued Creating the help files/directories on an external PC
Highlight the new folder and select the “New” soft-key. As mentioned previously it is possible to create the directo-
ries/help files directly on the controller or offline using an AS-
CII editor (e.g. Notepad®). This is usually a more comfortable
method than stood at the controller. These files have to be
transferred to the controller and placed in the correct folders.
This can be done via the USB /CF Interfaces or with the RCS
Commander software.
The files need to be placed in certain folders on the controller.

The new directory has to be named The “sinumerik_alarm_oem_plc_pmc.html” has to be
“sinumerik_alarm_plc_pmc”. placed in any of the following:-
“System CF card\user\Sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
“System CF card\oem\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
Creating the help file:-

Cursor to “sinumerik_alarm_plc_pmc” directory and select the
“New” soft-key followed by the “Any” soft-key. Alarm Log
A log of alarms that have occurred can be seen by selecting

the “Alarm protocol” soft key.
This shows the time when the alarm occurred and when it
was cleared.
Type in the help file name

“sinumerik_alarm_oem_plc_pmc.html“.
The file will automatically open in readiness for the HTML code
to be entered,
The file is closed with the following soft-keys:-
Notes :

Alarm Log continued Time controlled: The log will be saved at the interval entered
in the Write interval area (max. 32000 seconds).
The “Display new” soft key is used to refresh the list and dis-
play any alarms that have recently occurred.
This option carries similar risk to the “At every event” option
and the same warning is displayed.
The “Settings” soft key is used to refresh the list and display
any alarms that have recently occurred.
There are a number of options which can be selected by us- The controller needs to be restarted to make the changes
ing the cursor and select keys and confirmed with the “OK” effective.
soft key:-
Store log:-This allows the log file to be manually saved in a

file which can be retrieved and used for diagnostic purposes.
Number of entries:-
This sets the maximum number of alarms displayed on the
alarm log page.
Write mode file:-
The file destination is displayed at the bottom of the screen
Off: No storing of the log file will take place to the internal
for several moments after pressing the “Store log” soft key.
flash memory (Compact flash card)
At every event: Each time an alarm occurs this will be re-
corded to the compact flash memory.
Use the following soft key sequence to locate the log file:-
Use the “Cursor” and “Input” to locate the “alarm log” direc-
When this option is selected, a warning is displayed. By leav- tory.
ing this option permanently set, the life of the internal flash
card will be reduced.
The controller needs to be restarted to make the changes

effective.
Notes :

B031 END PLC Alarms and Messages
Alarm Log continued
The file can be viewed by using the “Open” soft

key.
The file can be copied and pasted to other desti-

nations such as an external storage device. This
could then, for example be forwarded to techni-
cal personnel for assistance.
B031: END
Notes :

B058 PLC Onboard Diagnostics
Module Description:
The 828D controller has on board PLC diagnostic capabilities to aid the user with the fault finding
process. It is possible to check the status of inputs, outputs etc, there is also a ladder editor which
allows faulty inputs or outputs to be software rewired.
Module Objective:
Upon completion of this module you will be able to use the 828D PLC viewer to diagnose PLC re-
lated problems. You will be able to rewire inputs and outputs using the ladder editor
Content:
Sinumerik
PLC Diagnostics
Interrupt Routines
B058
B058

PLC Onboard Diagnostics B058
PLC Onboard Diagnostics: Description

PLC Onboard
Diagnostics:
START
The 828D controller has on board PLC diagnostic capabilities
to aid the user with the fault finding process. It is possible to
check the status of inputs, outputs etc, there is also a ladder
editor which allows faulty inputs or outputs to be software
rewired. PLC
Diagnostics
Interrupt
Routines
PLC Onboard
Diagnostics:
END
Notes :

PLC Diagnostics Data Blocks (DB):-

System Data Blocks are used for interfacing between different
Address Formats:- areas of the controller and the user PLC.
Module B034 describes this in more detail.
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, The user can also create Data Blocks.
M100.6, V38040002.1.
The Bit part is the number after the decimal point. The value of Data Blocks can be written in different formats e.g.:
a bit is either 1 or 0.
DB3804.DBX0.0 Data Block 3804 Bit 0.0
Byte- A Byte is a collective of 8 bits of logic in the same DB3801.DBX1000.7 Data Block 3801 Bit 1007.0
group. e.g. DB3801.DBB1000 Data Block 3801 Byte 1000
Input Byte 4 (IB4) contains the bits I4.0, I4.1, I4.2, I4.3, I4.4, DB3804.DBW0 Data Block 3804 Word 0
I4.5, I4.6, I4,7. DB3804.DBD0 Data Block 3804 Double Word 0
When working with bytes it must be remembered that the
numbering counts up from the left as shown below. To locate the PLC status screens use the following soft key
IB4 sequence.
Bit no 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1
In this example I4.0, I4.2, I4.5 & I4.7 are equal to 1. Another
term for being equal to 1 is that these bits are High.
The bits equal to 0 are termed as being Low.
Output Bytes (QB) and Marker Bytes (MB) can also be used in By default the first page displayed is the “PLC-CPU” screen
the same way. contains information regarding the PLC project and cycle
time information.
Word- A Word is a collective of 16 bits of logic which encom-
passes two consecutive Bytes.
Operating Status
A Word can only be addressed as 0 or an even number (IW0,
IW2, IW4 etc) odd numbers are not allowed. Name: Taken from the
PLC828D project
As with the Byte format the numbering starts from the right. name. Last Changed:
Example IW4 Last time the project
was modified.
IB5 IB4
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 Version Information:
Supplied by the sys-
In this example I4.0, I4.1, I4.4, I4.5, I4.6, I5.1, I5.2, I5.5, I5.7. tem.
are equal to 1.
Output Words (QW) and Marker Words (MB) can also be used
in the same way. Cycle Time: The cycle
time of PLC-CPU
processor.
Double Word- A Double Word is a collective of 32 bits of logic
which encompasses two consecutive Words (Four consecutive Processing Time: The
Bytes). time taken to process
the PLC logic.
A Double Word can only be addressed as 0 or an even number
which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd num-
bers are not allowed. The processing time information display can be
reset by the “Reset pro. time” soft key
Example ID4
IB7 B6 B5 IB4
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Output Double Words (QD) and Marker Double Words (MD) can
also be used in the same way.
Notes :

Operating Status: The “Delete all” soft key will delete all entries on the list.
The operating status can be in Run or Stop mode. The status
is indicated at the top of the screen. It is possible to change
the operating state via soft-keys.
After certain procedures the PLC may be left in STOP mode
and require manually starting. It my also be necessary to stop Individual entries can be edited/deleted by using the Insert,
and start the PLC to clear PLC related faults. Delete and Cursor keys found on the keyboard.
PLC Stop:
For test purposes it may be necessary to manually change

(Force) an operand. This is achieved with the “Change” soft
key.
PLC Start:
The operand in question has to be highlighted and the new

value entered and confirmed with the “OK” soft key.
NC/PLC Status
The status of the operands/variables used within the PLC
program can be checked via the “PLC Status” soft key.
Changing M8.0 from 0 to 1.
The operands are typed into the left hand column. They can
be viewed in different formats. The format is changed by us-
ing the cursor key to highlight the letter in the “Format” col-
umn and then toggling with the “Select” key.
B = Binary
D = Decimal
H = Hexadecimal
F = Floating point number (only for The marker M8.0 should now have changed to a value of 1.
Double Words)
By using the “Operand +” and ”Operand -” soft keys it is pos-

sible to quickly locate a different operand in a similar range.
Notes :

It is useful to have this function in the commissioning stages. The default screen shows all available variables. To find a
Sometimes after data loss, it may also be necessary to enter particular variable the “Filter/Search” function is available.
values into Data Blocks using this method. This depends upon
the machine manufacturer. Caution should be taken when at-
tempting to manually enter data as unwanted movements may
occur. Filter
It is not possible to force operands which are being addressed The Filter is available to narrow down the number of vari-
by the PLC program. ables on display. Cursor to the filter tab, the list is revealed
by selecting the “Insert” key.
The values stored in counters and timers can also be viewed.
This is best done in decimal format.
By selecting the “Display comments” soft-key it is possible to

add comments to identify the function of each operand.
Confirm the entries with the “Input” key.
Confirm the filter selection with the “Input” key.
Insert Variable
Search
The “Insert Variable” soft-key opens a list system variables Ensure the “Search” tab is highlighted and type all or part of
which can be directly selected for monitoring. the variable name. The search is automatic and as soon as
the first letter is entered the search will begin.
When the desired variable is found and highlighted, select
the “OK” soft-key. The
variable will then appear in the NC/PLC Status List.
Notes :

Further functions are available when the following soft-key is

pressed:
Save mask: The list of operands that have been typed can be
saved to a file.
In the example shown the first axis is displayed by default,

this is seen determined by the values within the square brack-
ets.
[U1,1]
Cursor to the preferred target area for the file:
1 is for the 1st NC axis

2 is for the 2nd NC axis etc.
By selecting the “Operand +” & “Operand -” soft keys the vari-

able can be change to view different axes.
Enter a suitable file name:
Further information about the variable can be displayed by

selecting the “Display Comments” and “Details” soft-key.
Confirmation of the file save is displayed above the horizontal

soft-keys for several seconds.
Notes :

Load Mask: Previously saved files can be loaded using this The value entered in box will become the first entry at the top
function. of the list.
Each of the three columns can be changed this way .
Select the columns using the cursor keys.
The operands can also be forced via the

”Change” soft key.
A further method of checking the status of operands is via the
“Status list” soft key.
Viewing the Ladder Logic:

The PLC program ladder logic can be seen by selecting the
“Window 1 OB1” soft key.
The default list of operands is shown in the above screen.

The “Set address” soft key allows this list to be configured.
Notes :

This opens up OB1 of the user PLC. The status of the PLC is Symbolic and Absolute Addressing:
shown by selecting “Program stat. ON” soft key.
The operands which are true are highlighted in blue. The status can be viewed with or without symbolic addressing
It is recommended that the status be switched when not in information.
use to free more resources for the system. By selecting the “Symbolic” option, the operands will be dis-
played with information taken from the Symbols Table.
The symbols table is where the operands are given a short
text description which is designed to assist the user to identify
the function of the operands without referring to additional
documentation
Example with “Absolute” viewing selected i.e not “Symbolic”
“Window 2 SBR0” is a second soft-key for looking

at the ladder diagram. Confirmation that “Absolute”
This will open subroutine 0 by default. Addressing is active.
Example: with “Symbolic” viewing selected:

The “Window 1” & “Window 2” soft-keys can be
changed to open up different blocks within the pro-
gram.
A list of available blocks is displayed, by highlighting a block

and pressing the “Open” soft-key, the selected block will be
opened.
Confirmation that “Symbolic”
Addressing is active.
Symbol Info
The symbol information for a whole network can be viewed by
selecting the network followed by the “Symbol info” soft key
The text of the soft key will now display the selected subrou-
tine number e.g. SBR6 A table will appear containing the symbol information for that
particular network.
Notes :

Due to space restrictions of the screen, it is not always possi-

ble to see the whole symbolic/absolute description.
The cursor keys can be used to position the orange rectangle
around an operand.
This allows further information about the operand. Example: The display at maximum magnification.
Pressing the “Select” key will reveal the full symbolic/absolute
information.
Further information can be displayed if the “Input” key is
pressed.
An operand in absolute address view showing a truncated

number (Orange rectangle is in place):
Display after “Select” key is pressed

Search Functions:
The search function allows operands etc to be located easily

in the program.
Display after “Input” key is pressed:
By pressing the select key it is possible to choose between

The display can be magnified via the “Zoom +” and “Zoom -” “Find operand”, “Go to” or “Find subroutine command” in-
soft keys. structions. Use the cursor keys to highlight the option re-
quired.
The “Select” key is used to expand the menu and reveal the
choices which are confirmed by the “Enter” key.
Example: The display at minimum magnification.
After typing in the search target it is possible to choose be-

tween “Find all”, “Search downwards” or “Search upwards”.
Notes :

It is also possible to search in the current program block or all Refer to the previous
program blocks. pages for examples of
search options.
Symbol table
The “Symbol table” soft key allows different symbol tables to

be selected, the tables can also be edited here.
When the search parameters are correct the “OK” key is se-
lected to start the search.
After a successful search the target will be highlighted by an

orange rectangle.
To search for further occurrences of the target the

“Continue search” soft key is available.
When all occurrences have been found a message
will be displayed above the horizontal soft keys.
The “Go to” option is used for searching for a network within
the open program block.
The “Edit” softkey allows the table to be changed.
Extra lines can be added.
Unwanted lines can be deleted.
Confirmation of the changes is with the “OK” soft-

key.
The “Find subroutine command” option is used for searching A combination of these soft-keys and the “Insert” key
for a specific instruction within the program. is used to edit the symbol table
Notes :

Saving the changes
The changes now need to be loaded into the CPU:- The new entry should be visible when the symbol table is
viewed.
The changes can be saved while the PLC is in RUN or

STOP. A warning message is displayed. Loading in RUN can
be dangerous and damaging and should be carried out by
trained personnel
Different symbol tables can be selected via the “Select sym.

table” soft-key.
Make the choice between “Loading in STOP” or “Loading in

RUN”
A dialogue box is displayed momentarily and the PLC oper-

ating status is now in STOP.
The ere are two types of symbol table available, the system
symbol tables are not available for editing. these are named
“SYS_SYM0”,” SYS_SYM1” etc.
The “USER_SYM0”,”SYS_SYM1” tables etc, are for the user
and can be created & edited.
To insert a new symbol table select the “Insert symbol table”

soft-key. A name for the table needs to be entered and con-
firmed with the “OK” soft-key.
When the dialogue box clears the PLC has to be placed in

RUN.
After approximately 30 sec. the Operating Status of the PLC The “Delete” soft-key” is used to remove any unwanted sym-
should change to run. bol tables. The table is deleted immediately the soft-key is
pressed, no confirmation dialogue box is shown.
Notes :

To rename the symbol table use the “Change symbol table”
soft-key.
On tables with a large number of entries it is possible to use If the search target appears in the cross reference list more
the search function. than once, use the “Continue search” option.
The cursor and select keys are used to populate the search When the correct place is located cancel the search function
dialogue box as described previously in the module. and open the program block via the “Open in window 1” or
“Open in window 2” soft-keys.
OR
OR
Cross Reference
The “Cross ref.” function allows the user to see what operands
are in use and in which blocks they are used.
The cross reference list can be displayed with symbolic or

absolute addresses.
The default is set to absolute as shown on the previous page.
When the “Symbolic addresses soft key is selected a text
description of the operand is displayed as seen below. This
text description is taken from the symbols table. If no symbol
has been written for a particular operand the absolute address
remains.
Operands can be located with the “Search” function or the

cursor keys.
Notes :

PLC in stop mode:
If the PLC goes into stop mode further information is available

on the diagnostics screen. To locate the diagnostics screen,
use the following soft-key sequence.
Several alarms will occur, some are as a result of the PLC

going into stop. The
important alarm is the one that indicates the cause of the
PLC going into stop In this case it is alarm “400010 Arithmetic
error in user program: Type 1 SBR3 network 1”.
This tells us that we need to examine network 1 of SBR3

(Subroutine number 3).
When SBR3 is opened and network 1 examined it can be

seen that the “Divide” operation is attempting to divide 200
by 0, this is not permitted and so the PLC is put into stop
mode.
The program needs to be corrected and then loaded to the
controller.
Notes :

Interrupt Routines
Subroutines INT_100 and INT_101
While it is not possible to edit the PLC program on the controller, there is the possibility of influencing the PLC program by using
Interrupt Blocks 100 & 101 (INT_100 & INT_101).
The S7-200 PLC works cyclically, at the beginning of the scan the status of the inputs is copied to the Process Image Table
(Inputs).
This is then applied to the user PLC logic.
The Subroutines are processed in the order they appear in OB1.
This means that for example, an output set early in the scan might be reset later in the scan. It is the command that appears later
in the scan that takes precedent.
When the scan is complete the results are transferred to the Process Image Table (Outputs) which is then physically output to
the machine periphery devices.
The diagram below shows the position of the Interrupt Blocks INT_100 and INT_101.
Their position enables them to be used to influence the state of the inputs and outputs without making changes to the main user
programme.
Beginning of Scan
Process Image Table At the beginning of the scan, the status of the inputs is trans-
(Inputs) ferred to the Process Image Table.
Interrupt INT_100 The INT_100 interrupt block can be used to influence the
Process Image Table (Inputs).
Main Routine OB1 Subroutine
Subroutine
Subroutine Subroutines are processed in the

order they appear in OB1.
Subroutine
Subroutine
Interrupt INT_101 The INT_101 interrupt block can be used to influence the
Process Image Table (Outputs).
Process Image Table At the end of the scan, the status of the outputs is trans-
(Outputs) ferred to the Process Image Table.
End of Scan
Interrupt INT_0 The INT_0 interrupt block runs independently of

OB1.
It runs synchronously with the servo cycle. This
cycle time is very fast and could be used for ex-
ample with a fast turret where the signals need to
be decoded sooner than they can be achieved
with OB1.
it is recommended not to use it (see PLC design
document).
Notes :

Inserting the Subroutines
It is possible that the user PLC program does not contain the
interrupt blocks.
The blocks can be added via the controller providing General
Machine Data 19730[0] bit 25 is selected. To check the ma-
chine data use the following key selection:
Interrupt Routine INT_100

To display the individual bits use the “Select” key.
Locate option bit 25, if the “Check mark” is not present as The option to add interrupt block INT100 is given. Details can
seen below, use the “Select” key to enable the bit. be added to identify the author and indicate the purpose of
Press the “OK” soft-key to confirm. the block.
The machine data is activated with an NCK reset. Use the “OK” soft-key to complete the action.
The interrupt should now appear in the list.
To check/install the interrupt blocks use the following soft-

keys:-
OR
The list shows that the blocks are not loaded. To load the To add interrupt INT_101 the same procedure is followed.
blocks select the “Add” soft-key.
Use the “Insert” key to reveal the list under the ‘Number of
interrupt program” heading.
Select the number “101” with the mouse and press the “OK”
soft-key.
Notes :

A number of choices are available:-
OR
For inserting or deleting networks.

Insert: A network is added after the network that is high-
lighted.
Deleting: The highlighted network is deleted.
The interrupt should now be shown in the “Program block” Networks are automatically re-numbered.
list.
To add logic to the block the “Line” in the network has to be
highlighted and the “Insert operation” soft-key selected.
To open a block first highlight it and then select the “Open”

soft-key. A choice of a Normally Closed or Normally Open operation is
available (revealed by the “Select” key).
For this example a normally open operation is to be used.
Confirm this with the “OK” soft-key.
The selected block will open in readiness for editing. The operation now appears in the network.
The “Operand” soft-key should be pressed to assign the op-

eration an operand.
Type the name of the operand in to the box, in this example

I6.0 is used.
Select the “Edit” soft-key.
Notes :

B058 END PLC Onboard Diagnostics
The value is confirmed with the “Input” key. Loading the changes to the CPU:
To add the next operation the next part of the network should When loading in CPU is complete, the PLC must be re-
be selected with the cursor key and the “Insert Operation” soft- started.
key.
This function can be used in the event of a hardware failure of

the periphery components.
Example:
I7.0 fails to change state when the +24V signal is applied/
removed. I6.0 is an unused input, remove wire from I7.0 and
connect to I6.0. Use the interrupt INT_100 as shown so that
The available operations are limited to:- I7.0 is the same state as I6.0.
NOT
Positive Edge The position of interrupt INT100 in the PLC scan means that
Negative Edge the logic contained within takes precedence over the PII table.
Standard Coil
Set Coil
Reset Coil.
Interrupt Routine INT_101
This example is using a standard coil.
Editing of the INT101 interrupt routine is exactly the same as
for INT100.
This function can also be used in the event of a hardware fail-

ure of the periphery components.
The operation should be assigned an operand e.g. I7.0.
Example:
Physical output Q4.0 fails to change state in line with the PLC
logic. Q5.0 is an unused input, remove wire from Q4.0 and
connect to Q5.0. Use the interrupt INT_101 as shown so that
Q5.0 is always the same state as Q4.0.
When the editing is complete, select “Accept”. The position of interrupt INT101 in the PLC scan means that
the logic contained within takes precedent over the logic in the
standard program blocks and writes directly to the PIQ table.
This solution can save time waiting for replacement hardware

and unnecessary editing of the PLC.
The save procedure should be carried out as with INT_100.
B058: END
Notes :

B068 Commissioning sequence
Module Description:
The Sinumerik 828D CNC controller has been developed for the mid-range machine tool market,
where programming at the machine is necessary, in addition to programming using external
CAD/CAM type systems.
These machines are sold in high volume and should exhibit similar operating characteristics.
In order to ensure similarities, a defined start-up procedure is used by the commissioning engineer.
Module Objective:
Upon completion of this module you will be able to configure and commission a 3 axis
milling machine with spindle and additional 4th axis according to the defined commissioning
procedure.
This procedure is necessary to ensure compatibility and quality of the installation.
Content:
Sinumerik
Hardware and Software Requirements/Commissioning Sequence

Preparing the Controller
Configuring the MCP and Periphery Devices
Drives: Firmware Update & Configuration
Combi Drives: Drive Configuration (Start-up Tool)
Combi Drives: NC Axis Assignment
S120 Drives: Drive Configuration (Start-up Tool)
S120 Drives: NC Axis Assignment
NC Machine Data
Axis Enables
Drive Optimization
Data Management
B068
B068

Commissioning sequence B068
Commissioning sequence: Description Commissioning

sequence:
START
The Sinumerik 828D CNC controller has been developed for S120 Drives:
the mid-range machine tool market, where programming at Drive
the machine is necessary, in addition to programming using Configuration
external CAD/CAM type systems. (Start-up Tool)
Hardware and
These machines are sold in high volume and should exhibit
Software
similar operating characteristics.
Requirements/
In order to ensure similarities, a defined start-up procedure is
Commissioning
used by the commissioning engineer
Sequence
S120 Drives:
NC Axis
Assignment
Preparing
the
Controller
NC Machine
Data
Configuring
the MCP and
Periphery
Devices
Axis Enables
Drives:
Firmware Update
& Configuration
Drive Optimization
Combi Drives:
Drive Configuration
(Start-up Tool)
Data Management
Combi Drives:
NC Axis Assign-
ment Commissioning
sequence:
END
Notes :

Hardware and Software Requirements/Commissioning Sequence
Hardware and Software Requirements
 Certain software tools and a computer are required in order to carry out the commissioning.
 The software tools are obtained fro the Toolbox DVD which is included in the scope of delivery.
 Before commissioning a machine it is essential to check that the hardware has been installed to the required specification.
Sinumerik 828D commissioning sequence
1. Tools/software installation
2. Loading of standard data
3. PLC part 1, Machine control panel
4. Drive firmware update and configuration
5. NC Axis assignment
6. NC machine data configuration
7. PLC part 2, OEM signals, enables etc.
8. Drive optimization
9. Data management
Notes :

Preparing the Controller
1. Tools/software installation
The installation of the tools/software required to commission the Sinumerik 828D controller is described in Module B002.
2. Loading of Standard Data-Factory Settings
The controller should be loaded with default data this will set default machine data with respect to the type of machine technol-
ogy (Milling/Turning)
In order to load the default data the Setup menu has to be selected during start-up.
Switch on the controller and wait until the screen below is displayed and then press the “Select” key within 3 seconds .
The basic “Set-up” menu will be displayed, to display the advanced “Start-up” menu select the keys indicated below in the nu-
merical order shown.
1 2
Notes :

The advanced setup menu will be displayed. Cursor to the The alarm list shows the following three alarms, this is nor-
“Factory settings” option and press the “Input” key. mal at this point in the procedure.
It is possible that the system is not in the desired language, if

Any manufacturer data can be deleted or left intact depending this is the case the language can now be changed.
on the next selection. This data includes any archives stored
on the controller.
Or
Acknowledge the dialogue box by selecting “Yes”.
Setting of the password is now necessary to enable machine

data etc to be viewed and changed.
The controller will now require powering off/on.
Allow the controller to fully start-up, this can take up to five

minutes. The green LED at the front of the controller will be lit
continually as confirmation.
If the firmware of the drive components/objects is not at the

correct level for the software version an automatic firmware
update process will begin. Allow this to complete, the screen
will automatically clear on completion of the update.
Notes :

The password - “SUNRISE” is recommended Activate the option by entering the value 1 and select the
“Reset (po)” soft-key for activation.
The password will now be set to manufacturer level as
displayed just above the horizontal soft-keys.
The time and date should now be set, this is especially impor-
tant for the EUNA online registration process.
The control should be allowed start-up fully (green LED)
After the axis is licensed it can be configured in machine data.

Locate the Machine Data area:-
Alarm number 120402 can be acknowledged with the “Alarm
Cancel” key.
Standard data for a milling machine has been loaded and the
configuration is 3 axis and 1 spindle. This will be expanded
upon for our example.
The NC is only set for four axes/spindles (default data). To
To activate the extra axis ensure that the option is available .
activate an extra axis a value of 5 needs to be entered in Ma-
chine Data 20070[4]
To check/activate the licence use the following key sequence:
An NCK reset is required to activate the machine data.
Notes :

Configuring the MCP and Periphery Devices The machine control panel subroutine needs to be called in
OB1:
3. PLC Part 1 -Configuring the MCP/Periphery Devices.
The machine control panel is connected via the Profinet net-

work. The signals are transferred to the control via the user
PLC program/interface.
PLC periphery devices (PP72/48) are also part of the Profinet
network.
The PLC program for the MCP can now be downloaded and
Each piece of hardware which is connected to the Profinet tested according to the machine test protocol. It may be nec-
network is identified by the setting of dip switches. These essary at this point to jog the axis in simulation mode. A tem-
switches give the hardware an IP address which corresponds porary enable may have to be programmed in order to make
to General Machine Data 12986, which also defines the ad- these tests.
dress of the module in the interface.
Item IP Address Machine Data Start Address (I/O)
PP72/48 No1 192.168.214.9 12986[0] 0

Drives: Firmware Update and Configuration
MCP 192.168.214.64 12986[6] 112
4. Drive firmware update and configuration
Default setting for MD12986:
An un-configured system will boot by default to the following
screen.
When the “OK” soft-key is selected the system will check the
equipment connected to the DriveCLiQ bus.
The firmware will be loaded to any hardware not at the latest
version.
The configuration of the connected drive hardware will be
saved to the controller as part of the drive configuration
procedure.
The hardware is activated by entering a value of –1 in the

relevant machine data.
PP72/48
MCP
A series of information boxes will be displayed, allow the
process to complete.
The machine data are activated with a NCK power off.om.
Notes :

The firmware will be updated if necessary. Combi Drives: Drive Configuration (Start-up Tool)
5. Drive Configuration
The drives are configured externally with the HMI Start-up

Tool.
Run the Start-up Tool.
Switch the power off/on.

The drive objects that were recognised during the configura-
The drive components that are connected to the DriveCLiQ tion can be seen in the start up area of the controller.
bus are now displayed on the controller.
DMS Encoder-Combi Drive System
The Spindle DMS encoder is not of the DriveCLiQ type, be-

cause of this the system cannot acquire any information from
it. The encoder details have to be entered manually using the
following procedure.
Note: No axes have been
assigned at this stage.
Notes :

Use the “Drive +” , “Drive -” or “Select a drive” soft-keys to

locate the spindle drive.
Or Or
The drive required in this case is servo 2.
When the encoder type has been chosen, the pulse count etc
needs to be entered.
Select the “Change” soft-key and then continue with the “Next”
soft-key until the following screen is displayed.
When the encoder details have been entered select the “OK”
soft-key.
For this example the actual position value has to be inverted,

this is due to the mounting method on this particular equip-
ment. Select the “Details” soft-key.
Select the “Enter data” soft-key.
The DMS encoder in this case is an Incremental HTL/TTL

(TTL 5 Volt signals 1024 pulses/rev and 1 zero mark/rev).
Notes :

Select the “Invert position act. Val” option and then select the Combi Drives: NC Axis Assignment
“OK” soft-key.
6. NC Axis Assignment
The drives now have to be assigned to the correct NC axis.
As can be seen below the drive objects have no axes as-

A summary of the data entered for the DMS encoder can be signed to them.
viewed.
Continue selecting the “Next” soft-key until the “Ready” soft- Axis assignment missing.
key is displayed.
Assignment is carried with the following sequence:
When the “Ready” soft-key is selected, a dialogue box will

be displayed. Select “Yes” to save the changed data.
Select the drive to be assigned.
Or Or
The example below shows the spindle drive with no set-point/

actual value assignments.
The reassignment of the encoder is completed when the sys-

tem has restarted.
Use the mouse to select the correct axis for the spindle drive
(AX4:MSP1).
Notes :

A dialogue box warns of the necessity to set certain machine When all axes/drives have been assigned, the changes are
data after the assignment is complete. saved selecting “Yes” when the dialogue box below is dis-
The axis assignment procedure automatically sets certain played.
machine data using information taken from the motor elec-
tronic rating plate. Onto
Information such as ball screw pitches, feed rates etc. should
be entered manually.
Allow the control to complete the NCK power on reset.
The assigned axes can be seen on the Machine configuration

page.
Axes assigned to the servos.

The same selection is automatically entered into the other
fields. It is not necessary to change these on a standard instal- S120 Drives: Drive Configuration (Start-up Tool)
lation. Confirm the selection by pressing the “Accept” key.
5. Drive Configuration
The drives are configured externally with the HMI Start-up

Tool.
The remaining axes still have to be assigned, therefore select

“No”.
The drive objects that were recognised during the configura-

Select the next drive to be assigned and repeat the process. tion (Page 8/9) can be seen in the setup area of the control-
ler.
Or Or
Notes :

By paging down to the bottom it can be seen that this drive
does in fact have two encoders assigned to it.
Servo 6
with
2nd
encoder
Direct Measuring system (DMS)
In certain situations it is not possible for the topology to as- The encoder has to be first deselected from Servo 6 to free it
sign components according to the machine configuration. up for assignment to the spindle (Servo 2) Select the
In this case the assignment has to be changed manually. “Change” soft-key.
The following example is necessary because the spindle Di-
rect Measuring System (DMS) is connected to another axis
(A axis).
The system needs to be configured so that it associates this
encoder with the spindle (physical location).
To continue select the “Drives” soft-key. Press the “Next” soft-key until the following screen is dis-
played, the page should show two encoders assigned to the
axis.
Use the “Drive +” / “Drive -” soft-keys to locate the drive which

has been incorrectly assigned the DMS.
Or
The drive required in this case is Servo 6. The “Identify via

LED” function can be used to aid the identification of the cor-
rect module.
Servo 6 is
selected
Notes :

Deselect the encoder.
Continue with the following sequence, a series of dialogue

boxes will be displayed.
The configuration process is not finished therefore select “No”.
The second encoder now needs to be assigned to the correct

axis.
In this case, Servo 2 (Spindle) is the correct axis.
The system detects the removal of the encoder and issues an

alarm which can be ignored.
Continue with the following sequence, a series of dialogue Servo 2

boxes will be displayed. is
selected.
Press the “Next” soft-key until the “Ready” soft-key appears. Paging to the bottom shows that only one encoder is as-
signed to this axis at the moment. Select the “Change” soft-
key.
Servo 2
When the “Ready” soft-key is selected the following dialogue with
box will be displayed. encoder.
Notes :

A similar procedure is carried out to assign the encoder to Continue with the “Next” soft-key.
the correct axis.
Press the “Next” soft-key until the following message box

appears.
Narrows
down the
list of When the above information box has closed select the “Next”
encoders to soft-key.
choose
from
No 2nd
encoder
assigned The details of the encoder have to be manually entered, select
the “enter data” soft-key.
Use the mouse to select the second encoder check box and
to highlight the correct encoder from the list.
Two encoders are available, one is already assigned to the
motor so the spare one should be highlighted and confirmed
with the “Input” key followed by the sequence of soft-key
presses.
In this case the encoder is a rotary incremental Sine/Cosine

type with 1024 pulses and one zero mark per revolution.
Only 2 encoders are available for selection:

The DriveCLiQ motor encoder (SMI20_21) and the DMS en-
coder (SM_7). Select the DMS encoder.
Notes :

S120 Drives: NC Axis Assignment
6. NC Axis Assignment
The drives now have to be assigned to the correct NC axis.
At present, as can be seen below, the drive objects have no

axes assigned to them.
The encoder position actual value needs to be inverted due to

the mounting method on the spindle motor, select the “Details”
soft-key.
Axis assignment missing.

Select the “invert position act. value” option.
Axis assignment is carried with the following sequence:
Select the drive to be assigned.
The example below shows the Spindle without any set-point

or actual value components assigned.
Press the “Next” soft-key until the “Ready” soft-key appears.
When the “Ready” soft-key is selected, the chance to save/

discard the changes is available. The changes need to be
saved, to save the changes select the “Yes” soft-key.
The reassignment of the encoder is completed when the sys-

tem has restarted.
Notes :

A dialogue box warns of the necessity to set certain machine
data after the assignment is complete.
The axis assignment procedure automatically sets certain
machine data using information taken from the motor elec-
If more axes are to be assigned select “No”, otherwise select
tronic rating plate.
“Yes”.
Information such as ball screw pitches, feed rates etc. should
be entered manually.
Select the next drive to be assigned and continue as previously.

Use the mouse to reveal the list of axes and highlight the
correct axis for the selected motor module, confirm with the
“Input/enter” key.
When all axes have been assigned the changes need to be
activated with an NCK reset, select “Yes” .
The assigned axes can now be seen below in the drive set-up
screen.
The same selection is automatically entered into the other

fields. It is not necessary to change these on a standard in-
stallation. Confirm the selection by pressing the “Accept” key.
Axes assigned to the servos.
The spindle motor module set-point and actual values

have been assigned to nc axis MSP1.
Notes :

NC Machine Data
7. NC machine data configuration
NC Machine Data needs adjusting to match the controller to the machine.

The machine data can be used to set velocity limitations, acceleration, number/type of encoders etc.
The following machine data are for the simulators only. Careful consideration should be given the values entered on an actual
machine.
AXIS MD X Y Z Spindle A
30110 2 3 4 1 5
30220 2 3 4 1 5
30130 1 1 1 1 1
30240[0] 1 1 1 1 4
30240[1] 0 0 0 1 0
31020[0] 2048 2048 2048 2048 512
31020[1] 1024
34200 1 1 1 1 0
Axis MD Spindle only

32000 3000
32010 100
32020 50
35100 3000
35110[0] 3000
35110[1] 3000
35120[0] 10
35120[1] 10
35130[0] 3150
35130[1] 3150
36200[0] 3300
36200[1] 3300
CHANNEL MD
20700 =0 NC start possible without referencing (not recommended on actual machines).
Notes :

Axis Enables
Once the signals for the axes are complete the changes can
be downloaded to the controller.
8. PLC part 2- OEM signals, enables etc.
The Sinamics OFF1 and OFF3 enable signals are also re-
The motors should only be allowed to rotate when the condi-
quired. This is carried out by connecting +24V DC to terminals
tions are safe to do so.
X122.1 & X122.2 respectively of the 828D controller.
Interface signals are provided to allow the user to inhibit
These signals should be controlled in the recommended man-
movement of axes.
ner to ensure correct start-up/shutdown of the drives.
In the case of the simulator the on-board switches are used to
signal to the interface that the conditions to run are OK.
OEM signals should also be considered, example: reference
The system must also be informed which measuring system
cams, over-travel switches, pressure switch monitoring, door
is in use. In the case of the simulator spindle, this the 2nd
interlocks etc.
measuring system.
Below is a method used to enable the X axis via inputs Drive Optimisation
straight to the Interface signals.
9. Drive optimisation
Drive optimisation is carried out to match the drive/controller to

the mechanical characteristics of the axes.
This is essential to achieve fast, accurate positioning,
resulting in reduced cycle times and a superior surface finish.
Once a machine is optimised it should not require optimising
again. Any mechanical problems should be repaired rather
than masked by re-optimisation.
Data Management
10. Data Management
When the prototype of a machine is fully tested it is nec-

essary to create a backup of the data.
The backup data is in the form of a TGZ file (System
image) which includes all the information to restore the
machine to its original state. This file is also used for the
production of series machines as it includes only Manu-
facturer data.
Enable signals explanation:

DB380x.DBX2.1 - Controller enable
DB380x.DBX4001.7 - Pulse enable
DB380x.DBX1.5 - Activate 1st measuring circuit
DB380x.DBX1.6 - Activate 2nd measuring circuit
The letter x is the axis identifier and has to be substituted for a

valid axis number.
0 = 1st axis
1 = 2nd axis
2 = 3rd axis
3 = 4th axis
etc.
The 1st axis is X, this is the 1st NC axis, the other axes follow
in the same pattern.
Example: DB3802.DBX2.1 is the third axis and therefore this

will be the controller enable for the Z axis.
B068: END
Notes :

B068 END Commissioning sequence

B084 Encoder Adjustment
Module Description:
All positioning axes require referencing in order for the controller to position them. The procedures
for the referencing of incremental and absolute encoders is described along with the most impor-
tant machine data.
Module Objective:
Upon completion of this module you will be able to synchronise/adjust the measuring system for
the Sinumerik 828D controller.
Content:
Sinumerik
Referencing Incremental Encoders
Referencing Absolute Encoders
Machine Data Information
Automatic Referencing
B084
B084

Encoder Adjustment B084
Encoder Adjustment: Description

Encoder
Adjustment:
START
All positioning axes require referencing in order for the con-
troller to position them. The procedures for the referencing of
incremental and absolute encoders is described along with
the most important machine data. Referencing
Incremental
Encoders
Referencing
Absolute
Encoders
Machine
Data Infor-
mation
Automatic
Referencing
Encoder
Adjustment:
END
Notes :

Referencing Incremental Encoders
General Information
Axes equipped with incremental encoders require referencing

each time that the NCK is powered off/on or reset.
This usually entails traversing the axis to a switch which then
initiates the referencing
Procedure. Certain machine data's are available to influence
this procedure and adjust it to individual requirements.
Some axes have a second encoder fitted for positioning op-
erations. It needs to be checked which measuring system is
active, as that will be the one which requires
referencing.
To check which measuring system is active we can look at the
“Axis diagnostics” area.
Machine data 30240[0] & [1] should be checked depending

Look for the “Measuring system 1 active” and “Measuring sys- upon the active measuring circuit.
tem 2 active”. A green tick symbol indicates which measuring If the active measuring circuit is number 1 then machine data
system is active for each axis., typically the motor encoder. A 30240[0] index 0 is active. If the active measuring circuit is 2,
2nd measuring circuit is typically a linear scale axes or an the machine data 30240[1] index 1.
encoder for a spindle. Incremental encoders = 1
Some manufacturers may also switch between measuring Absolute encoders =4
systems. If there is uncertainty about this please contact the
manufacturer for information. To reference an axis having an incremental encoder, an in-
terface signal needs to be switched high in the user PLC
program. This is usually done with a switch connected to the
axes. The axis will traverse towards the switch and activate
it. This will then start the reference procedure for that axis.
Example of an axis reference switch input activating a refer-

ence point approach variable.
Variable DB380x.DBX1000.7 “Delay Ref. Pt approach” inter-

face signal needs to be set to high to initiate the referencing
procedure.
Each axis has its own variable which is identified by chang-
ing the x for a numerical value which represents the axis,
If it is uncertain whether an axis has an incremental or abso- see below-
lute encoder fitted, this can be checked via axis machine data
30240. 1st axis - DB3800.1000.7
To check the machine data use the following soft key se- 2nd axis - DB3801.1000.7
quence. 3rd axis - DB3802.1000.7
etc.
Notes :

Before referencing can be initiated the controller needs to be

placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
The axis must now be jogged in the direction of the refer-

ence switch. The direction is set up via machine data. .
The axis should now continue towards the reference switch.
Some systems require that the jog direction button is con-
Confirmation that the correct mode is selected can be seen tinually depressed throughout the reference cycle, it is more
at the top of the screen. common to find that the axis will continue to move even
when the jog direction button is released.
Below: The symbol to the left of the axis name indicates that
the axis has been referenced, in this case axis MX1.
Each axis can be referenced individually. It is also possible

to reference the axes automatically. This usually set up by
the machine builder and will be explained in more detail later
in the module.
To reference an individual axis select the correct axis via the

machine control panel.
Notes :

Example: Referencing diagram for incremental encoder
In the event of the values of machine data 34080 & 34090 equalling less than the stopping distance of the axis, the controller will
automatically readjust to the correct position.
34040 $MA_REFP_VELO_SEARCH_MARKER = 0
34080 $MA_REFP_MOVE_DIST + 34090 $MA_REFP_MOVE_DIST_CORR = > 0
Velocity
Reference point cam
switch activated
0 1
MD34020 Ref. point approach velocity
34070 Ref. point position velocity
MD34040 Ref. point search marker velocity
Position
Cam switch 1 0
Axis referenced. Marker pulse detected Reverse direction
The control receives a reference axis command, the axis accelerates to the feed-rate in machine data
34020 $MA_REFP_VELO_SEARCH_CAM then searches for the reference switch input to become high.
The reference switch is operated and the axis decelerates.
The axis reverses direction at the feed-rate set in machine data.

34040 $MA_REFP_VELO_SEARCH_MARKER.
Feed-rate as machine data 34040 $MA_REFP_VELO_SEARCH_MARKER.

Search for next reference marker
Reference marker is detected. The axis accelerates to the feed-rate set in

machine data 34070 $MA_REFP_VELO_POS to a position which is the sum of machine data 34080
$MA_REFP_MOVE_DIST and
34090 $MA_REFP_MOVE_DIST_CORR.
Once the axis is referenced the controller issues interface signals.

1st axis - DB3900.DBX0.4 1st measuring circuit is referenced
1st axis - DB3900 DBX0.5 2nd measuring circuit is referenced
2nd axis - DB3901 DBX0.4 1st measuring circuit is referenced
2nd axis - DB3901 DBX0.5 2nd measuring circuit is referenced
etc.
The position display will indicate the axis is referenced and display any values stored in machine data :
34100 $MA_REFP_SET_POS
Notes :

Referencing Absolute Encoders
The procedure requires that the axis be moved to a know
mechanical position e.g. 150mm. Locate machine data
General information:-
34100 $MA_REFP_SET_POS and enter 150.
Absolute encoders need referencing on first commissioning
and remain referenced until a problem occurs with encoder or
the NCK. Re loading of an archive will also necessitate the
referencing of the encoder.
Procedure:
First it must be ascertained that the encoder is of the absolute
type. This can be done checking the motor data rating plate in
Check that machine data 34200 ECN_REFP_MODE is set
the case of an integrated motor encoder. Also checking with
to 0 This enables the control to take over the value in ma-
the supplier of the encoder might help determine the correct
chine data 34100 $MA_REFP_SET_POS.
type.
Check that machine data 34210 ENC_REFP_STATE is set
Another method is to check the machine data.
to 1. This is to enable encoder calibration to take place.
upon the active measuring
circuit.

upon the active measuring circuit.
If the active measuring circuit is number 1 then machine data
30240[0] (Index 0) is active. If the active measuring circuit is
2, the machine data 30240[1] (Index 1) is active.
Incremental encoders =1 Check whether machine data 34010
Absolute encoders =4 REFP_CAM_DIR_IS_MINUS is set to 0 or 1.
The axis to be referenced should be moved to the known

mechanical position using “Jog” mode in the direction deter-
mined by the value of machine data 34010
REFP_CAM_DIR_IS_MINUS. A value of 0 and the ap-
proach will be in the positive direction, a value of 1 will make
the approach negative.
The feed rate when approaching this position should be re-
duced to avoid inaccuracies caused by backlash.
Before referencing can be initiated the controller needs to be

placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
Notes :

Confirmation that the correct mode is selected can be seen at Machine Data Information
the top of the screen.
A list and brief description of the most common machine
data.
If a machine does not have reference switch cam it is possi-

ble to reference from the zero mark by changing machine
data-
34000 $MA_REFP_CAM_IS_ACTIVE (Default value 1) A
value of 0 will deactivate the cam. This is used for example
on axes that have only one reference mark along the entire
traversing range and rotary axes that have only one refer-
ence mark per revolution.
The direction that the axis approaches the reference switch

can be changed by machine data-
34010 $MA_REFP_CAM_DIR_IS_MINUS (Default value 0)
The default value will result in the reference point approach
in a positive direction. To reverse the direction a value of 1
has to be entered.
The initial approach speed for referencing is determined by

machine data-
34020 $MA_REFP_VELO_SEARCH_CAM (Default value
5000.0 mm/min)
If the axis fails to reach the reference cam it is probably due

to machine data-
34030 $MA_REFP_MAX_CAM_DIST (Default value 10000
mm) This is the maximum distance to the reference cam.
Select the axis to be referenced and then press the same di- The controller will issue alarm:-20000 Channel %1 axis %2
rection key used to position the axis earlier.
reference cam not reached.
The axis will not physically move but the position display will
change to show the axis is referenced symbol and the refer- When the reference switch is activated the axis reverses
ence point set position will be shown as the position of the axis direction in search of the
(150 mm). reference marker. This search speed is determined by ma-
Machine data 34210 will have changed to 2 to indicate a suc-
chine data-
cessful procedure. 34040 $MA_REFP_VELO_SEARCH_MARKER (Default
value 300.0 mm/min).
The direction that the reference marker search direction is

changed by machine data-
34050 $MA_REFP_SEARCH_MARKER_REVERSE (Default
value 0) The default value cause the axis to search for the
reference cam in the opposite direction to the
direction specified in machine data 34010
$MA_REFP_CAM_DIR_IS_MINUS.
Entering a value of 1 in machine data 34050 will reverse the
cam search direction.
Notes :

Automatic Referencing
If the axis fails to reach the reference marker it is probably due
to machine data-
Automatic referencing cycle
34060 $MA_REFP_MAX_MARKER_DIST (Default value 20
To set the automatic referencing function it has to be decided
mm) This is the maximum distance the axis can travel without
in what order you want the axes to referencing. It is common
finding the marker..
for example that on a milling machine the Z axis needs to be
The controller will issue alarm:-20002 Channel %1 axis %2
referenced first, this helps eliminate the chance of a collision.
zero mark missing.
The order is set by axis machine data
$MA_REFP_CYCLE_NR (Default 1)
When the marker is detected the axis will either stop or move
Possible entries:-
to a position determined by the values of two machine data
0 = no referencing cycle participation.
(34080 & 34090 see below for further explanation)
1 to 15 = allowable range for setting the sequence.
The speed at which this position sought is determined by ma-
-1 = no reference required for Cycle start.
chine data-
34070 $MA_REFP_VELO_POS (Default value 10000.0 mm/
Up to five axes can be referenced at the same time.
min).
34080 $MA_REFP_MOVE_DIST (Default value -2.0 mm).

Once the marker has been detected it is advisable to move
the axis away from the marker (Into the machining area). This
is achieved by putting a value in machine data 34080.
If the axis was asked to reference again while still on the
marker this could result in the axis going toward the end of the
slide.
34090 $MA_REFP_MOVE_DIST_CORR (Default value 0.0

mm) This machine data is used to accurately set the position
and correct discrepancies caused by an encoder
exchange or mechanical work.
The values in machine data 34080 & 34090 are added to-
gether to determine how far
the axis moves.
Usually the position display shows zero after an axis has been
referenced. This can be changed by machine data
34100 $MA_REFP_SET_POS (Default value 0.0 mm)
The value entered in here will be displayed on the screen as
soon as referencing is complete. This is used when the refer- To initiate the automatic cycle the necessary interface bit has
ence position is not the mechanical zero of the machine. The to be set. This is
machine data does not result in the axis physically moving. variable DB3200.DBX1.0 which is channel related.
Example of how the automatic referencing cycle could be

initiated.
Interface signal DB3300.DBX1.0 changes to 1 while the ref-

erencing cycle is active.
B084: END
Notes :

B084 END Encoder Adjustment

B101 Servo Optimisation
Module Description:
This module explains the step by step procedure to optimise the current, speed and position con-
troller loops within the Sinumerik 828D/ Sinamics S120.
The procedure uses the on-board functionality of the Sinumerik Operate system.
This procedure is valid from SW 2.7/4.4.
Module Objective:
To ensure the necessary level of compatibility and consistency between machines configured with
the Sinumerik 828D controller. A defined Optimisation procedure should be adhered to and this
procedure is defined in this module.
Caution: These procedures result in axis movement. All necessary safety precautions must be
taken into account. Make sure that that you read through and understand the entire procedure be-
fore beginning.
Content:
Sinumerik
Introduction
Auto Servo Tuning
Axis Jerk
Acceleration
Circularity Test
Additional Spindle Optimisation
B101
B101

Servo Optimisation B101
Servo Optimisation: Description

Servo
Optimisation:
START
This module explains the step by step procedure to optimize
the current, speed and position controller loops within the
Sinumerik 828D/ Sinamics S120.
The procedure uses the on-board functionality of the Introduction

Sinumerik Operate system.
This procedure is valid from SW 2.7/4.4.
Auto Servo
Tuning
Axis Jerk
Acceleration
Circularity
Test
Additional
Spindle
Optimisation
Servo
Optimisation:
END
Notes :

Introduction Auto Servo Tuning
Activating Machine Data changes Using the Automatic Servo Tuning feature we can optimize the
current, speed and position controller loops, including velocity
Throughout this procedure, certain machine data changes need feed forward.
to be activated. To the right of each parameter value there is an
indication of how the particular change takes effect. The follow-
Aim: to tune a single axis or spindle using HMI Operate
ing is a list of these indications and their meaning.
- Performing frequency response measurements
po The relevant machine data requires an “NCK Reset” to
take effect - Calculation of speed control loop
re The relevant machine data requires activation of the - Setting current setpoint filters
“Reset” key to take effect
cf The relevant machine data requires activation of the - Calculation of position control loop
“Set MD active” softkey to take effect.
- Checking the actual response of the proposed control loops
im The relevant machine data is immediately active.
- Feed forward control : equivalent speed control time
Saving Drive settings
- Interpolation paths
Every time the S120 drive is powered on or a “Drive Reset” is
performed, the S120 drive data is loaded to the relevant drive
Before auto servo tuning: MD32640 Dynamic stiffness control
from a stored file. Therefore when drive machine data are
should be set = 1, this enables position control in a faster cycle
altered, the drive data must be saved so that the change is
time.
retained after the next power off/on or “Drive Reset”.
NOTE: An “NCK Reset” does not affect the drive data. When using dynamic stiffness control, MD32110
ENC_FEEDBACK_POL must be = 1. If the feedback polarity
In order to save drive data: needs to be inverted it must be done in the Sinamics drive with
In the “Drive MD” area, press the “Save/Reset” then the p410.
“Save” then the “Drive System” softkeys. Messages at the A second measuring circuit should be enabled if available.
bottom left of the screen indicate the status of the save proc-
ess. When the save process is complete, the message “All If Auto Tuning a main spindle it is possible that the PLC servo
drive objects backed up” appears. enable signal is missing. The OEM should provide a method of
switching this PLC interface signal on for servo tuning. E.g spe-
cial key combination or forcing of special marker in PLC status.
Controller Block Diagram
828D/S120 controller structure: The 828D CNC and S120 Checking the Machine Data:
drive controller structure contains three cascaded closed loop
controllers (current, speed and position). Each controller must
be optimized in succession starting with the innermost current
controller, then the speed controller and finally the position
controller. The machine dynamic limits for velocity, accelera-
tion and jerk are set in the interpolator. The speed control loop
is always closed via the motor encoder while the position con-
trol loop can be closed via the motor encoder or direct meas-
uring system.
SINUMERIK 828D PROFIBUS –DP
Notes :

To get to the Auto Servo Tuning feature press the “Menu Use the cursor/select keys to highlight and select the axis to
Select” key followed by the “Setup” key. Then press be tuned
“Optim./test”.
The following example shows the X axis has been selected.
The default screen is the Auto Servo Tuning screen, if the is

not the case select the “Auto servo tuning” soft-key.
Select “Options” to check defaults.
The screen shows whether an axis has been tuned or not. A

tuned axis will have a time and date of the tuning displayed.
Ensure that all the options are selected.
NOTE: Reading in a setup archive, taken from a tuned ma- This will give Single Pushbutton Tune with minimum user in-
chine e.g. prototype, will result in the axes being displayed as teraction
untuned on the target machine.
The axes will however still be in the tuned state and retuning
is not necessary.
Notes :

Tuning Strategy: Tuning Objective Description:
Select the “Tune” soft-key, the tuning strategy now needs to Disturbance optimal aggressive
be decided.
The speed controller gain and position controller gain (Kv fac-
tor) will be optimised with maximum values and minimum ro-
bustness.
Application:
High speed cutting with maximum suppression of any distur-
The Axis, Speed and Position strategies should be set as seen bance forces such as: friction, teeth of drive belt, heavy cutting
below (Strategies 102, 303 & 203). forces e.g. machining titanium.
Recommended for high speed cutting with linear motors.
Precondition:
Machine must be of a rigid construction, moved masses do not
change significantly.
Disturbance optimal moderate
The speed and position controller will be optimised with 80%

of maximum gain and a good robustness.
Application:
Many types of applications.
Precondition:
No high expectations of machine structure,
recommended for general purpose use.
Damping optimal
The speed controller will be optimised to achieve maximum

The Tuning Objective can also be selected, the default is damping in order to prevent vibration and to be able to get a
“Disturbance optimal moderate” good position controller value.
The choice is dependant on the mechanical properties of the Application:

machine/axis. The “Disturbance optimal aggressive” option Large machines with large moved masses.
should not be used for a “weak” axis.
Precondition:
Weak machine structure because of high masses/ inertias.
Dynamics are low because of the size of machine.
Recommended e.g. for moving columns, where operators
cabin is travelling with the column.
Can be used if the “Disturbance optimal” test results in a very
low position control gain.
Notes :

Custom Selections: Position Controller Settings:
It is possible to further influence the optimisation procedure by

making certain selections via the “Custom”soft-key.
Speed Controller Settings:
The important setting is: Kv (Position controller) reduction fac-

tor
Kv reduction factor:
This parameter is like the aggressiveness of the position con-

troller.
It applies specific reduction to the maximum Kv computed by
AST.
The maximum Kv is the largest Kv that would result in zero
position overshoot (with feedforward disabled).
The important settings are: Tuning Aggressiveness and Mini- Default = 0.8
mum integral time Tn Min = 0.1
Max = 1.0
Tuning Aggressiveness:
This parameter determines the selection of Kp and Tn based

on stability margins.
Default = 0.6
Min = 0 [most robust]
Max = 1 [most aggressive]
Minimum integral time Tn:
This parameter prevents AST from setting the speed loop inte-
grator time too low.
When AST would otherwise have selected a value lower than
this parameter, the actual value used is limited to the value set
by the Minimum integral time Tn.
Default = 5.0 Ms
Min = 0.5 ms
Max = 100 ms
Notes :

Check that the axis to be tuned is in a safe position, if it is not When the tuning is complete the following screen will be dis-
“Jog” axis to the middle of its travel. Press “OK” to accept. played allowing the new and original values to reviewed.
This example is of the Position Controller.
After pressing “OK” the dialogue box shown next will appear, Other values can also be viewed
requesting the user to press cycle start on the machine control
panel.
Example: Speed controller settings for review.
Various screens will be displayed as the Auto Tune procedure

continues. Cycle start will be required on several occasions.
The new values will be used if the “Accept” soft-key is se-

lected.
Notes :

The dialogue box warns that the remaining axes must be Use the select key to select “Channel 1 path”
tuned in order to achieve proper interpolation results.
Press the “Edit and tune” soft-key.

The time and date of the tuning will now be shown:
The remaining axes should now be tuned in the same way
Select the axes that can interpolate together.

The following example shows X, Y, Z and the Spindle having
being selected.
Interpolating Axes:
Now the axis selection can be made for the tuning of the inter-
polation paths. Select the “Interp. path” soft-key.
The axes that will be interpolating together now have to be

assigned to the Channel 1 path
Notes :

The interpolation path strategy can now be decided, the default Axis Jerk
is “1103 Reduce stand alone optimal regulators with partial
matching” Jerk limited acceleration can now be optimized using the HMI
Advanced Start-up tool.
Jerk is used to smooth the acceleration response by applying a
time for the change in acceleration.
Jerk is defined in units/sec3, i.e. acceleration ([units/sec2 / time
[sec]). The time it takes for the acceleration change to take
place, [sec] = acceleration [units/s 2] / jerk [units/s3].
Axes do not have to have the same Jerk value.
The result of jerk-limited acceleration is rounded corners at the

start and end of the acceleration phase of the velocity profile
and smoothed motion.
Jerk limiting is active when “SOFT” is programmed and de-
activated when “BRISK” is programmed.
“SOFT” mode is set as the default reset state via channel
MD 20150[20] = 2.
The new setting will now be calculated and the offered for re- It is recommended to use “SOFT” as the default reset value.
view. Press the “Accept” soft-key.
If channel MD 20150[20] = 1, "BRISK" mode is active as a
default on power up, (acceleration without jerk limit).
If channel MD 20150[20] = 2, "SOFT" mode is active as a de-
fault on power up, (acceleration with jerk limit).
The positioning response of the axis can be checked using the

servo trace tool and a commanded position step via part pro-
gram at different feedrates.
In cases where a direct scale is used, the actual slide re-
sponse can easily be viewed.
In cases where the motor encoder is used to close the position
loop, (indirect feedback), the actual response of the slide is not
visible to the closed loop or the servo trace tool.
On machines with 828D in general jerk values will be between
20 and 100.
The test part program should traverse the axis a sufficient dis-
tance that allows the programmed velocity to be reached, e.g.
50 mm.
A dwell time should be used after the velocity is reached and
after the setpoint position is reached, e.g. 0.5 second.
The initial programmed velocity can be approximately ½ of the
maximum axis velocity and the response should be checked at
all of the feedrate override increments as well as the maximum
speed.
Machine Data:
To check the positioning behaviour without the influence of the

position controller, the Servo Gain Factor (Position Control
Auto Servo Tuning is now complete. Gain) should be set to 0.
Positioning tolerances should opened up to prevent errors dur-

ing the test.
MD 32200 POSCTRL_GAIN = 0
MD 36012 STOP_LIMIT_FACTOR = 100
MD 36400 CONTOUR_TOL = 20
Notes :

Selecting the Trace Signals: The first signal required is the position set-point:
A trace of the Set and Actual Position values is required to.

Use the following key sequence to reach the trace screen:.
The axis needs to be selected, e.g. Y axis:
The required variables can now be selected:
The selected variable will now appear in the list:
The second signal required is the position actual value of the

active measuring system:
The filter search function can be used to find the signal:
Notes :

Trace Duration and Trigger Conditions:

Starting/Initialising the Trace:
The trace can be started manually or automatically. The du-
ration of the trace can also be set: The trace is started/initialised via the “Start trace” soft-key.
This will depend on the selection made on the “Settings”
screen.
In our example the trace will be started via a command from the
part program.
Select the “Start trace” soft-key to initialise the trace:
In the following example the trace will be started via a com-
mand from a part program:
The trigger variable can be easily selected via the “Quick list”
soft-key:
Select th $AN_SLTRACE==1 option.

It is also possible to trigger the trace from a value taken from
the previously selected signals or from one of the many sys-
tem variables available via the “Choose variable” soft-key.
The trace is now initialised and will be started when the trigger
is set via the part program.
Notes :

Part Program For Jerk Test: Scaling the Trace:
The following NC program can be used in Automatic or MDA It is necessary to view the part of the trace where the axis ar-
mode. This may be different depending on the configuration rives at the set position. In order to see this in detail it is neces-
of the actual machine. sary to scale the trace:
The program contains commands for activating/deactivating
the trace trigger::
FFWON
SOFT The following example shows the scaling set up to view the axis
$AN_SLTRACE=0; Reset start servo trace trigger positioning at -110mm.
LAB: The values entered will give a 100 micron window around the
G01 Y210 F10000 target position of -110mm.
G04 F0.5 Individual machines/axes may require different scaling.
$AN_SLTRACE=1; Start servo trace trigger The X minimum/X maximum values can also be adjusted if re-
Y260 quired.
G04 F0.5
GOTOB LAB
M30
Viewing the Trace Results:
Return to the trace screens and press Cycle start”:
The axis will move and the selected signals will be monitored
for 5 seconds, the results will then be displayed:
The set position (Yellow) and the actual position (Green) do not
match, this is because the position controller is not active.
Notes :

Optimising the Jerk setting: This diagram shows how the jerk is increased until there is an
overshoot in the response of the mechanics.
It is necessary to set the Jerk so that there is no overshoot of
the actual position. This caused by a jerk value that is too Remove the overshoot by decreasing the MAX_AX_JERK.
high.
Having a Jerk value that is too low can also be detrimental to
the machine as this effects the time it takes to position an
axis.
Without the position controller the axis positions with no over-

shoot.
The remaining positioning error exists because the position
controller is switched off and the axis is moving with just feed
forward signals.
Any overshoot when coming into position comes from the
mechanics and can be eliminated using jerk limitation.
The following examples show the effect that different Jerk

values have on the positioning of an axis.
It is first necessary to check/set the following Machine Data:
MD 32200 POSCTRL_GAIN = 0
MD 32610 VELO_FFW_WEIGHT = 1.0
MD 32620 FFW_MODE = 3
MD 32810 EQUIV_SPEEDCTRL_TIME = As optimised
To adjust the Jerk, Axis Machine Data 32431 is used.
Example: Jerk too high: Example: Jerk too low

MD 32431 MAX_AX_JERK = 600 MD 32431 MAX_AX_JERK = 2
With the Jerk too low the positioning contour will be rounded.
Restart the trace and then run the part program:
Example: Jerk optimised

MD 32431 MAX_AX_JERK = 65
With the Jerk optimised there is little or no overshoot and the

positioning contour is sharp.
Notes :

Positioning with feed forward and position controller ac- Acceleration
tive:
Maximum axis acceleration: Axis MD 32300 defines the
When the Jerk has been optimised the position controller maximum axis acceleration. The default value is [1 m/sec 2
needs to be activated as well as Feed Forward. (metric), 39.37 in/sec2 (inch) and 2.77 rev/sec2 (rotary)]. Each
axis can have a different acceleration setting.
Adjust the Machine Data where necessary:
Important! Machine mechanics limit the maximum axis accel-
MD 32200 POSCTRL_GAIN = As optimised eration. The machine builder must define the required setting
MD 32610 VELO_FFW_WEIGHT = 1.0 value! If not defined, the default value should be used unless
MD 32620 FFW_MODE = 3 the machine builder authorizes an increase.
MD 32810 EQUIV_SPEEDCTRL_TIME = As optimised
MD 32431 MAX_AX_JERK = 65 Checking the maximum axis acceleration:
The torque utilization under worst-case load and velocity con-
MD 20150[23] =2 Feed Forward can then be enabled as a ditions should be checked after the Kv factor and Feed For-
default. ward have been optimized to be sure that the torque limit is
not reached.
MD 36012 STOP_LIMIT_FACTOR = original value
MD 36400 CONTOUR_TOL = original value The "Servo trace" start up tool is used to measure the velocity
actual value of the relevant active measuring system and the
Example: torque utilization percentage via the “Utilization (m_set/
Good positioning without overshoot when feed forward and m_set_limit)” trace signal. When the “Utilization (m_set/
jerk are correctly optimized: m_set_limit)” trace signal =100%, the drive is on current limit!
If allowed by the machine builder, MD 32300 can be set so

that the torque utilization during the acceleration phase of the
worst case load and velocity lies between 80% and 90% of the
limit depending on how much safety factor is desired.
A test part program should traverse the axis a sufficient dis-

tance that allows the programmed rapid velocity to be
reached, e.g. 300 mm.
Change the trace measuring parameters to view the load

torque utilization and change the part program as shown.
SOFT
$AN_SLTRACE=0; Reset start servo trace trigger
LAB:
G0 X10
$AN_SLTRACE=1; Start servo trace trigger
X310
GOTOB LAB
M30
Select the following signals for monitoring:
Velocity actual value meas. System 2

Utilization (m_set/m_set_limit)
Torque prod curr. Act val. i(q)
Notes :

It is necessary to know the maximum values of the 3 traces.

Select the “Cursors” soft-key and position them on each of the
traces in order to read the maximum values..
The three traces will be displayed together, select the “Fit all”
soft-key.
Velocity:
Cursor positioned at the top of

Trace selection the trace shows that the
maximum velocity reached was
36 m/min.
Utilisation:
Cursor positioned at the top of

Trace selection the trace shows that the
utilisation maximum reached
was 58.52%
It is necessary to know the maximum values of the 3 traces.

Select the “Cursors” soft-key and position them on each of the
traces in order to read the maximum values..
Notes :

Current: Circularity Test
Cursor positioned at the top of The “built-in” circularity test of HMI Operate is used to
Trace selection the trace shows that the check the interpolation of axes that will work together. The
maximum current reached was tool measures a circle with reference to the motor or direct
10.53A measuring system. Machine mechanical alignment is not
considered in the result. This gives the commissioning engi-
neer the ability to clearly separate controller Optimisation
issues from mechanical issues.
Axis MD32200, MD32400, MD32402, MD32410, MD32490,

MD32500, MD32510, MD32520, MD32540, MD32620,
MD32640, MD32810, MD32900, MD32910, MD32930,
MD32940 and drive P1421 to P1426, P1400, P1433, P1434
are checked via this procedure.
The following positional error compensations should be

switched off when this procedure is carried out. Backlash
Comp MD32450, Encoder Comp MD32700, CEC Comp
MD32710, Temperature Comp MD32750, Friction Comp
MD32500.
Note: Backlash MD32450 must be adjusted using an external
device e.g ballbar or dial gauge.
The best overall contouring results are achieved when the

circle test results in the correct actual size, shape and mini-
mum p/p deviation between combinations of interpolating
axis, (X-Y, X-Z, Y-Z).
A circle test part program and the circularity test start up tool
Summary: can be used to measure and evaluate these results. The
“worst case” test circle radius and path feedrate must result in
The maximum velocity of 36 m/min is reached with a utilization a realistic radial acceleration that the machine is capable of.
of 58.52%. Machine builders typically have specifications for test
circle radius and feedrate.
The “Utilization (m_set/m_set_limit)” signal selection displays
the utilized percentage of the active current limit. Standard machine builder circle tests typically use a radius of
100 mm or 150 mm at feedrates determined by the machine
The active current limit is: builder. The machine builder defines the acceptable result
P0640 = [RMS amps]. specifications.
P0640 is limited to whichever is the lower of P0338 Motor High speed cutting requirements are usually more stringent
Limit Current/ Mot I Max [RMS amps] or r0209 Power Unit and test circles for high speed cutting machines might be in
Maximum Current/ PU I Max [RMS amps] the range of 10 to 25 mm radius at feedrates of 5 m/min to 10
m/min. For high speed cutting machines, the results are nor-
In this example P0640 was 18A, therefore utilization is: mally acceptable when the p/p deviation </= 0.010 mm, and
18A x 58.52/100 = 10.53A. the actual size is equal to the programmed radius at the worst
case path feedrate.
Note:
Example of an X-Y circle part program –
This test was done on a milling machine Y axis with a dividing Position, feedrate and active plane must be adapted to
head on the table. the machine!
The 58% utilisation allows for additional weight to be added
without causing problems. FFWON
Utilisation should be kept to 85% maximum. SOFT
The acceleration can be changed to affect the utilisation. G90 G01 F3000 X150 Y50 Z-100
LAB:
G91 G64 G02 X0 Y0 I10
GOTOB LAB
M30
Notes :

Setting the “Circularity test” parameters:

Set the desired measuring parameters to match the pro-
grammed circle:
Measurement: Select the relevant axes and the “active”

measuring system.
Parameter: Enter the programmed radius and feedrate. The

multiplier should remain at 1
Resolution: Set the resolution as desired, e.g. 0.010 mm/grad
Representation: Select “Mean radius”.
Select “Optim./test”.
The example program should first be modified to fit the ma-

chine positions, feed-rates and plane if necessary. The ex-
ample program uses circular interpolation and runs the pro-
grammed circle continuously. Follow the specific machine
procedures to run the test part program.
Select the “Circular. Test” soft-key.
Important: The circularity test must be activated manually by
pressing the "Start" soft-key after the test program is started.
Notes :

The machine data below are from an actual machine which The circle size is now corrected using MD32410 AX_JERK_TIME
was used for the following circularity test examples The Jerk Time should be enabled and the mode selected:
Data Description X Y Data Description X Y

32200 POSCTRL_GAIN 8.50 8.50
32200 POSCTRL_GAIN 8.50 8.50
P1460 SPEEDCTRL_GAIN1 3.01 3.89
P1460 SPEEDCTRL_GAIN1 3.01 3.89
P1462 SPEEDCTRL_INTEGRATOR_TIME_1 6.18 6.18
P1462 SPEEDCTRL_INTEGRATOR_TIME_1 6.18 6.18
P1433 SPEEDCTRL_REF_MODEL_FREQ 106.3 106.3
P1433 SPEEDCTRL_REF_MODEL_FREQ 106.3 106.3
P1440 NUM_SPEED_FILTERS 0 0
P1440 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0022 0.0022
32810 EQUIV_SPEEDCTRL_TIME 0.0022 0.0022 32400 AX_JERK_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0 32402 AX_JERK_MODE 2 2
32410 AX_JERK_TIME 0.012 0.012
As a general rule, with feed forward optimised, the actual radius The circle is now just 0.00021 mm oversize.
will be too large.
This can be corrected using a time constant
(MD32410 AX_JERK_TIME)
If necessary enable the time constant in all axes.
The circle below shows the results after feed forward has been
optimized however the mean radius is 0.0019mm too large.
Notes :

If the Jerk Time of interpolating axes is different, the circle

shape will be affected.
Data Description X Y
32400 AX_JERK_ENABLE 1 1
32402 AX_JERK_MODE 2 2
32410 AX_JERK_TIME 0.015 0.012
In some situations different jerk values can be used correct

circle errors
Data Description X Y
32400 AX_JERK_ENABLE 1 1
32402 AX_JERK_MODE 2 2
32410 AX_JERK_TIME 0.012 0.0125
Notes :

Additional Spindle Optimisation
Check Preset MD as below also any relevant parameter for spindle/axis interpolation.
Example is for 8000 rpm Spindle Motor with no mechanical gear ranges.
The following parameters can be pre-set to the suggested values in the charts below. The values will vary depending upon the
application.
Machine Machine Data Name Value Explanation
Data
MD 30300 IS_ROT_AX 1 Rotary axis/spindle
MD 30310 ROT_IS_MODULO 1 Modulo conversion for rotary axis/spindle
MD 30320 DISPLAY_IS_MODULO 1 Modulo 360 degree display for rotary axis/spindle
MD 32000 MAX_AX_VELO[0] 8000 Max axis velocity
MD 32010 JOG_VELO_RAPID 60 Traverse rate in rapid jog
MD 32020 JOG_VELO 10 Traverse rate in jog
MD 32040 JOG_REV_VELO_RAPID 60 Rotary traverse rate in rapid jog
MD 32050 JOG_REV_VELO 10 Rotary traverse rate in jog
MD 32200 POSCTRL_GAIN[0] x As optimized
MD 32200 POSCTRL_GAIN[1] x As optimized
MD 32620 FFW_MODE 3 3 for Velocity Feed Forward
MD 32640 STIFFNESS_CONTROL_ENABLE 1 Dynamic Stiffness Control
MD 32810 EQUIV_SPEEDCTRL_TIME[0] x As optimized
MD 32810 EQUIV_SPEEDCTRL_TIME[1] x As optimized
MD 34000 REFP_CAM_IS_ACTIVE 0 If no bero switch
MD 34020 REFP_VELO_SEARCH_CAM 30 Reference point approach velocity
MD 34040 REFP_VELO_SEARCH_MARKER[0] 30 Creep velocity
MD 34040 REFP_VELO_SEARCH_MARKER[1] 30
MD 34060 REFP_MAX_MARKER_DIST[0] 370 Maximum distance to reference mark
MD 34060 REFP_MAX_MARKER_DIST[1] 370
MD 33000 FIPO_TYPE 3 Type of interpolator
MD 35000 SPIND_ASSIGN_TO_MACHAX 1 Assignment of spindle to machine axis
MD 35100 SPIN_VELO_LIMIT 8000 Maximum spindle speed
MD 35110 GEAR_STEP_MAX_VELO[0] 8000 Maximum spindle speed for gear change
MD 35110 GEAR_STEP_MAX_VELO[1] 8000
MD 35130 GEAR_STEP_MAX_VELO_LIMIT[0] 8000 Maximum spindle speed for gear stage
MD 35130 GEAR_STEP_MAX_VELO_LIMIT[1] 8000
MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL[0] X Acceleration in speed control mode ;to be optimized
MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL[1] X
MD 35210 GEAR_STEP_POSCTRL_ACCEL[0] X Acceleration in position control mode ;to be optimized
MD 35210 GEAR_STEP_POSCTRL_ACCEL[1] X
MD 35500 SPIND_ON_SPEED_AT_IPO_START 2 Feedrate enable for spindle in the set range
MD 35550 DRILL_VELO_LIMIT[0] 4000 Maximum spindle speed for tapping
MD 35550 DRILL_VELO_LIMIT[1] 4000
MD 36000 STOP_LIMIT_COARSE 0.4 In position course limit
MD 36010 STOP_LIMIT_FINE 0.1 In position fine limit
MD 36030 STANDSTILL_POS_TOL 5 Standstill tolerance
MD 36040 STANDSTILL_DELAY_TIME 1 Delay for standstill monitoring
MD 36050 CLAMP_POS_TOL 1 Clamping tolerance
MD 36060 STANDSTILL_VELO_TOL 2 Tolerance for “Axis/spindle” stopped
MD 36200 AX_VELO_LIMIT[0] 8800 Threshold for velocity monitoring
MD 36200 AX_VELO_LIMIT[1] 8800
MD 36300 ENC_FREQ_LIMIT[0] 1000000 Encoder limit frequency
MD 36300 ENC_FREQ_LIMIT[1] 1000000
MD 36400 CONTOUR_TOL 30 Tolerance band for contour monitoring
P 1433 SPEED_CONTROLLER_REFERENCE x As optimised
_MODEL_NATURAL_FREQUENCY
Notes :

A check should now be made of the speed control accel- Acceleration/deceleration with the original motor data equates to
eration. the S1 curve.
Firstly identify the acceleration time without any influence by

the NC. P640 Current limit 17.7 A
(P305 rated motor current x1,5)
Set MD: P1520 Torque limit upper/motoring 4.8 Nm
35200 [0] & [1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL = P1521 Torque limit lower/regenerative -4.8 Nm
9999 P1530 Power limit motoring 1.5 KW
P1531 Power limit regenerating -1.5 KW
( t=V/a t=9000/60s/9999 t=15ms therefore no influence).
Now look at the motor data sheet.

E.g. 1PH8089-1VM02-0MG1 asynchronous motor: Locate the trace screen:
The required variables can now be selected:
Required Variables:
Speed actual value motor

Active power
Torque prod curr. Act. Val i(q)
Torque setpoint (Limited)
Ensure that the Spindle is selected when adding the variables:
Notes :

When the trace function is complete select the “Fit all” soft-
key:
Select the “Settings” soft-key.
The trace is to be triggered when the spindle actual value = 5

rpm (Rising edge). The trace will last for 4 seconds.
The cursors are used to determine the acceleration time:
Time taken to accelerate to

Trace selection: commanded speed
Actual speed = 2.5 seconds
Enter a program in MDA.
S8000 M03
G04 F5
M30
Initialize the trace and then run the part program:

Cursors positioned at
beginning of trace and at the
point where the commanded
speed is reached.
Notes :

The power taken/available to accelerate the motor can be Acceleration/deceleration can now be modified by using the
viewed on trace 2: motor data sheet, up to the maximum values, however this
depends upon the application.
Trace selection:
Active power Enter the values to suit the application. In this case short accel-
eration/deceleration time was the requirement.
The maximum values from the motor data sheet are entered
into the relevant Drive Data:
P640 Current limit 32 A

P1520 Torque limit upper/motoring 20.7 Nm
P1521 Torque limit lower/regenerative -20.7 Nm
P1530 Power limit motoring 13 KW
P1531 Power limit regenerating -13 KW
Maximum available power

=1.5Kw = S1 curve.
The torque set-point can be viewed on trace 4:
Trace selection:
Torque set-point
Run the spindle and trace function.

The time taken to accelerate to the commanded speed can
now be checked.
Trace selection:
Actual speed
Acceleration = 0.795 seconds

Torque set-point
=4.8 Nm = S1 curve. Adjust MD:
35200[0] & [1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL to
give the machine tool builders requirement for spindle accel-
eration.
Notes :

Spindle Position Controller
A test can now also be made to set up the position control ac-
celeration and jerk by doing a test with solid tapping.
Check MD 35550 [0] & [1] DRILL_VELO_LIMIT, this is the

maximum speed for tapping.
Check SD 55484 $SCS_DRILL_TAPPING_SET_MC[0]=1, this
keeps the spindle in positioning mode during tapping.
The following program can be used which will tap 10 holes in

the same position.
SUPA D0 G0 G90 Z-200 Start the trace and press “Cycle Start” on the machine control
FFWON panel.
M19
SOFT
LAB:
G331 Z-214 S4000 K1
G332 Z-200 S4000 K1
REPEAT LAB P=9 In the example below, utilization is reaching 64% and therefore
M30 the position control acceleration can be increased. However
during tapping the spindle maybe operating above the S1 curve
and so it must be ensured that utilization does not reach 100%
The following singles need to be selected on the Trace screen:
otherwise “Contour monitoring” alarms will appear.
Position setpoint (64 bit)
Position actual value meas. System (64 bit) Optimize 35210 $MA_GEAR_STEP_POSCTRL_ACCEL and
Contour deviation (64 bit) 32431 $MA_MAX_AX_JERK for optimum results
Load (m_set/m_set, limit) (64 bit)
Also check p1464, p1465 adaptive control range for spindle.
Note: When monitoring measuring systems, ensure that the
correct signal is selected i.e. measuring system 1 or 2.
Select the trace trigger etc, via the “Settings” soft-key.

The example shows the trace triggered when the actual posi-
tion goes above 5 degrees. The trace will record for 10 sec-
onds.
Acceleration = 64%
Notes :

B101 END Servo Optimisation
The following example shows the effect of increasing the posi-

tion control acceleration from 120 to 160, the utilisation then
increased from 64% to 88%.
If the application is purely a tapping machine a test can be

made to tap 100 holes and then servo trace can be repeated
to make sure utilisation never reaches 100%.
Acceleration = 88%
B101: END
Notes :

B102 Tool Management
Module Description:
This module explains the step by step procedure to setup the Tool management on a milling and
on a Turning machine.
Module Objective:
Upon completion of this module, you will be able to setup the Tool management for a milling and
also a Turning machine.
Content:
Sinumerik
Fundamentals
PLC - NCK user interface
Machine data for the tool management
PLC Program Blocks
Example: Loading/unloading
Example: Change manual tools
Application example for turning machine
Application example for milling machine
B102
B102

Tool Management B102
Tool Management: Description Tool

Management:
START
This module explains the step by step procedure to setup the
Tool management on a milling and on a Turning machine.
Fundamen-
tals
PLC - NCK
user inter-
face
Machine data
for the tool
management
PLC Program
Blocks
Example:
Loading/
unloading
Example:
Change
manual tools
Application
example for
turning
machine
Application
example for
milling
machine
Tool
Management:
END
Notes :

B102 Tool Management
Notes :

Tool management
Fundamentals
Tool management (TM)

The tool management (TM) function ensures that the right tool is in the right place on the
machine at all times.
Machines, magazines, loading positions and tool buffers (e.g. spindles, grippers) form a
specific system in which the tools are stored and transported. The tool management
continually informs the NCK of the current location of the tools and logs it using NC part
programs, PLC or HMI initiated tool movements.
During tool management commissioning the specific machine system architecture is mapped
in the control. For example, one or more magazines are set up that are able to pick up tools
at their locations. The "workplace" of a tool is described in the control in the form of value
pairs (magazine number and location number).
Note
Scope of delivery
Tool management is included in the scope of delivery for all controls (M/T version).
The function "Spare tools for tool management" (duplo tools) is an option.
See also
Additional references:
● SINUMERIK 828D Parameter Manual
● A comprehensive description of the tool and magazine parameters and the internal data
structure is to be found in:
→ Description of Functions Tool Management of the SINUMERIK 840D sl
As far as the range of functions is concerned, the NCK part of this documentation is also
valid for the SINUMERIK 828D.
The description of the PLC functions and the communication between NC and PLC in this
documentation is not valid for the SINUMERIK 828D.
● The settings of the tool management user interface are described in:
→ Commissioning Manual Base Software and Operating Software (IM9)

0BTool management
Structure of the tool management
Function structure
The software components of the control have the following tasks in the tool management:
● HMI:
– Tool data display, input/output
– Magazine data display, input/output
– Load/Unload relocation dialog
● NCK:
The tool management administrates the magazine locations. These locations might be
empty, loaded with tools or assigned to oversized tools in adjacent locations. Empty
locations can be loaded with other tools. The tool management provides the machine
manufacturer with optimized management of tools and magazine locations. Magazine
management provides extended functions such as load, unload or position tools. It also
includes searches for tools, magazine locations and search strategies for replacement
tools.
For the tool monitoring functions, while the active monitoring is running, tools are disabled
and no longer used. To continue machining, an equivalent tool (duplo tool) that is not
disabled is used, if available.
● PLC:
– Execute tool change
– Move tools in the magazine
– Gripper control
– Magazine control if applicable
– Safety interlocks
– Providing the structure of tool movements in transfer step tables
– Acknowledgment of the tool movements with acknowledgment step tables
PLC user program

The PLC user program executes the tool management jobs and acknowledges all position
changes of the tools (and magazines). The monitoring and prevention of collisions is the task
of the PLC user program alone, for example:
● Multiple spindles are using the same magazine.
● The paths of simultaneous jobs cross.
● As long as a large tool is located in the shifter, the chain must not be moved.

Tool management
PLC-Firmware
Functions of the PLC firmware:
● Assignment of tool management jobs to the PLC user program
● Communication of PLC user program acknowledgments to the tool management
● Transfer feedback signals for each acknowledgment (acknowledgment incorrect with
error number of acknowledgment OK) to PLC user program.
● In addition: Register order status
Components of the tool management
Tool list, magazines, magazine list

Circular and chain magazines can be managed. Other types of magazines are mapped on
these. Loading points or loading stations shall be used as the magazine type for loading and
unloading.
A magazine buffer combines all other locations in which tools can be placed (spindle,
gripper, ...).
Note
Default settings for tool magazines
The number of magazines, which the NCK can manage, is permanently set by the system:
• PPU24x.2: Number of magazines = 3
Since at least one buffer and one loading point must be available, the PPU24x.2/PPU26x.2
can manage one real magazine and the PPU28x.2 can manage two real magazines.
When the control powers up, depending on the technology, the following tool magazines are
pre-selected and created:
• Milling: one chain magazine with 20 locations, double gripper and a tool carrier
• Turning: one revolver with 8 locations, a tool carrier
Magazines
Information is provided by the system for all locations in the magazine, describing the
content and status of the locations.
The position of a tool is described by an identifier for the magazine and an identifier for the
location. Magazines have an identifier and a number, magazine locations only a number. In
a real magazine (chain, turret, etc.), the position of the tool is identified by the magazine
number assigned during start-up and the location within the magazine.
Example:
The T number of the tool in magazine location 7 in magazine 1: $TC_MPP6[1,7]

0BTool management
Tool list
The tool list contains all the tools known to the NC. These are the tools in the magazine and
unloaded tools whose data is to be retained. The tool management works with loaded tools
from the tool list.
Magazine list
The magazine list is a location-oriented map of the tool magazine, gripper and spindle. The
tool management only works with the tools from the magazine list. Additional tools without a
magazine assignment can also be selected for tool changes. The tool must be inserted in the
machine manually and removed again manually after machining (manual tool).
Loading magazine
The loading magazine is the 1st internal magazine and is assigned magazine number 9999.
The loading magazine has loading points for loading and unloading tools.
For the allocation of locations, one is fixed, all other locations can be assigned freely.
Location 1 in the loading magazine is used for the fixed assignment. Location 1 is reserved
for loading/unloading to all spindles/tool holders.
All positioning and relocation jobs to any locations (not loading points) are still handled via
location 1. The stated jobs, which refer to a particular loading point, are output at the
interface of this loading point. The loading points are assigned to magazines during start-up
($TC_MDP1). A loading point is an open access point to the magazine, where a tool is
manually loaded and unloaded from the magazine.
Buffer
Buffers are located in the 2nd internal magazine. The buffer includes the spindle, tool holder,
gripper, loader and transfer location. The buffers are managed under magazine number
9998. Each buffer element is assigned a unique location. Any location numbers may be
assigned. It is recommended that all spindles or tool holders be numbered in ascending
order, starting at number 1. The assignment to real magazines or of spindles/tool holders to
other buffers is made during start-up ($TC_MDP2, $TC_MLSR).
Chain magazine
The setting in MD22550: $MC_TOOL_CHANGE_MODE may only have the value 1 for these
magazine types.
Chain magazines do not as a rule have any additional buffer available for transportation
between magazine and spindle. These additional buffers can contain tools temporarily.
Description of the buffers and loading points:
Magazine Location Meaning

1 xx Real magazine 1 (chain, plate, box), position xx
9998 1 Spindle
9998 2 Gripper
9998 3 Gripper
9998 4 Toolboy

Tool management

9998 5 Shifter
9999 1 Loading point for spindle, manual tool
9999 2 Magazine loading point
Circular magazine
The setting of MD22550: $MC_TOOL_CHANGE_MODE normally has the value 0.
Circular magazines do not have any additional buffer with which tools can be transported
from the magazine to the spindle. The tools on circular magazines are not physically
transported into the spindle, but are moved into a defined position through rotation of the
turret so that machining can take place with one particular tool. The tool is only transported
to the spindle or tool holder in the software. Transporting the tool to the buffer 9998/1
(spindle) serves to inform the tool management that the turret holding the requested tool has
been turned to the machining position.
The programming command T = identifier initiates the tool change. T = location can be
programmed as an alternative. If T = location, no tool need actually be stored in the location.

1 xx Real magazine 1 (circular), position xx
9998 1 Tool holder
9999 1 Loading point for tool holder, manual tool
If the value 1 is also set for the revolver in MD22550: $MC_TOOL_CHANGE_MODE, the
statement made for the chain magazines also applies here.
Consider adjacent location

Consider adjacent location is used for oversized tools. When searching for empty locations
(loading, tool change) the bits 4 ... 11 are then evaluated in the magazine location parameter
$TC_MPP4 (half location occupied/reserved).
See also
You can find additional information in the "Machine data for the tool management (Page 27)"
section.
Loading and unloading tools manually
Manual tools
Bit 1 of MD22562: $MC_TOOL_CHANGE_ERROR_MODE decides whether additional tools
without magazine allocation can be selected during tool change. The automatically selected
tool must be inserted in the machine manually and removed again manually after machining.

0BTool management
Responsibility of the operator

The operator must ensure that the data block for the tool on the spindle is in the NCK, or that
he/she puts the appropriate tool onto the spindle for the data block stored in the NCK. Tools
which are loaded manually during machining are referred to as "manual tools".
Note
The responsibility is on the user to comply with the safety regulations via the PLC program.
An alarm (17212, 17214 or 17216) is always output to indicate that a tool change involving a
manual tool has been executed. The alarm is reset by the tool change acknowledgment of
the PLC user program.
The following types of tools are manual tools:

● Oversized tools
● Tools that cannot be stored in the magazine.
● Tools that may not be handled by the gripper system.

Tool management
PLC - NCK user interface
Overview
The tool management receives tasks for preparing and carrying out a tool change (T
command, M06), a tool movement (MVTOOL) or magazine positioning (POSM) from the part
program or from the HMI. From these tasks the TM defines the location change needed for
the tool and assigns this to the PLC.
Program components and interfaces:
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Figure 1-1 Interfaces of the tool management
The user interface provides separate data blocks for loading, unloading, relocating and
magazine positioning on the one hand and tool change on the other hand.

0BTool management
Relocating, unloading, loading tool, positioning magazine
Tool and magazine movements

Per loading point there is one interface for:
● Jobs for loading, unloading, relocating a tool (MVTOOL) and for magazine positioning
(POSM).
Message to the PLC user program:
– Job active
– Job specification
– Job description
The jobs appear on the interface of the loading point from which the tool is to be
exchanged.
● Acknowledgments of the PLC user program
All acknowledgments for a job must take place in the interface of the same loading point.
Acknowledgment errors should also be reset in this interface.
● Feedback from the tool management to the PLC user program
Message to the PLC user program:
– Status of acknowedgment
– Error status
– Map of the acknowledgment bits
● Job status
Selected data from the last intermediate or end acknowledgment is saved. This data is
needed by the PLC firmware for the next acknowledgment to the tool management and is
readable for diagnostic purposes. This data can be used by the user program to restart
after an abort (e.g. reset during a tool change).
Rule
The distribution of jobs to the interfaces takes place according to the following rule:
If the job contains a loading point (9999/x), that interface will be used.
Otherwise, the interface of the first loading point (9999/1) will be used.
All acknowledgments for a job must take place in the interface of the same loading point.
Interface signal Meaning

xx: Load location
DB40xx.DBX0.0 – DBX 3.6 PLC user program:
Acknowledgments for loading/unloading/relocating or
positioning the magazine

Tool management

DB40xx.DBX9.0 PLC user program:
Resetting the message "Acknowledgment error"
/DB41xx.DBX100.1) and the diagnostic information in the
feedback interface
DB41xx.DBX0.0 Tool management:
Job for loading/unloading/relocating or positioning the
magazine
DB41xx.DBB1 Tool management: Job specification
DB41xx.DBW 6 – DBW34 Job description
DB41xx.DBX100:0 Positive feedback: Acknowledgment status, acknowledgment
OK, 1 PLC cycle pending
DB41xx.DBX100.1 Negative feedback: Acknowledgment status, acknowledgment
error, static pending
DB41xx.DBB104 Tool management: Feedback error status
DB41xx.DBX108.0 - Map of acknowledgments for load, unload, relocate or position
DB41xx.DBX111.6 magazine. This map belongs to the positive or negative
feedback and remains valid for the same time.
DB41xx.DBW124 – DBW130 Job status
Jobs
DB4100...41xx Signals from tool management [r]

xx: Load location
DBB0 Job
DBB1 Job from NC Positioning Relocating Unloading Loading
program
DBB2 Reserved
DBB3 Reserved
DBB4 Reserved
DBB5 Reserved
DBW6 Source magazine number (INT)
DBW8 Source location number (INT)
DBW10 Target magazine number (INT)
DBW12 Target location number (INT)
DBW14: Load/unload
HMI → PLC without moving
magazine
Signal description:

0BTool management
● Job:
The interface contains a job. Job processing has not yet been completed with an end
acknowledgment. This signal is reset after transmission of the end acknowledgment to
the tool management.
● Loading:
The "target location" parameter's magazine location should be loaded with a tool via the
"source location" parameter's loading station.
● Unloading:
The tool in the "source location" parameter's magazine location should be unloaded to
the "target location" parameter's unloading station.
● Relocating:
The tool in the "source location" parameter's magazine location should be relocated to
the "target location" parameter's magazine location.
● Positioning:
The "source location" parameter's magazine location should be positioned at the "target
location" parameter's change/loading/unloading station. The tool remains in its magazine
location.
● NC program positions magazine:
The positioning job comes from the part program.
● Loading/unloading without moving magazine:
HMI sets/deletes this signal when requested by the operator. If the bit is active, there
must be no traversing motion of the magazine, only a mechanical unlocking/locking of the
location. The load/unload command must be acknowledged after the action. For a
position and relocate request, this signal is not valid for a traversing motion.
● Source location:
Magazine and location number of a tool that traverses or should be positioned at a
change or loading station.
● Target location:
Magazine and location number to where a tool is moving or to where a magazine location
should be positioned.
Acknowledgments
DB4000...40xx Signals to tool management [r/w]

xx: Load location
DBB0 Acknowle Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Total
dgment gment gment gment gment gment gment acknowled
step 7 step 6 step 5 step 4 step 3 step 2 step 1 gment
DBB1 Acknowle Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
dgment gment gment gment gment gment gment gment
step 15 step 14 step 13 step 12 step 11 step 10 step 9 step 8

Tool management
DB4000...40xx Signals to tool management [r/w]

DBB2 Acknowle Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
dgment gment gment gment gment gment gment gment
DBB3 Reserved Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
gment gment gment gment gment gment gment
step 30 step 29 step 28 step 27 step 26 step 25 step 24
DBB4 Reserved
DBB5 Reserved
DBB6 Reserved
DBB7 Reserved
DBB8 Reserved
DBB9 Resetting the
acknowledgme
nt error
Signal description:
● Total acknowledgment:
At a 0/1 edge the end acknowledgment, with status 99, is sent to the current job (job
complete, all target positions have been reached). As long as the signal is present, no
changes may be made to the data of this interface!
This signal is reset by the PLC firmware after the acknowledgment has been transferred
to the tool management.
● Acknowledgment step 1…30:
At a 0/1 edge, the appropriate acknowledgment step from the acknowledgment step table
is sent to the tool management. As long as the signal is present, no changes may be
made to the data of this interface and the variable transfer-step table!
● Resetting the acknowledgment error:
Resetting the message "Acknowledgment error" /DB41xx.DBX100.1) and the diagnostic
information in the feedback interface.
Feedback reports

xx: Load location
DBB100 Acknowled Acknowled
gment gment OK
error
DBB101 Reserved
DBB102 Reserved
DBB103 Reserved

0BTool management

DBW104 Error status (WORD)
DBB106 Reserved
DBB107 Reserved
DBB108 Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
gment gment gment gment gment gment gment gment
Signal description:
● Acknowledgment OK (DB41xx.DBX100.0):
The acknowledgment of the PLC user program (area DB40xx.DBB0 to DBB3) was
transferred without error to the tool management. This signal is reset after one PLC cycle.
● Acknowledgment error (DB41xx.DBX100.1):
Negative feedback of acknowledgment status. There is an error in the acknowledgment
of the PLC user program (area DB40xx.DBB0 to DBB3). The cause of the error is
displayed in "Error status."
The "acknowledgment error" bit is only set if the acknowledgment from the PLC firmware
is accepted as error free and the tool management detects and signals an error in the
acknowledged tool transfer (for example, when the target location for tool transfer is
occupied).
Errors that are detected directly by the tool management in the NC before an
acknowledgment is sent by the PLC user program, do not result in the setting of bit 100.1.
If an error is present that prevents transfer of the acknowledgment to the tool
management (error status 1 to 7), the error is only output on the interface of the tool
management and not by the NC (no NC alarm!).
If necessary, signal such errors with a user PLC alarm in the PLC user program.
This signal remains pending statically until the error has been acknowledged (set the bit
"Reset acknowledgment error" DB40xx.DBX9.0) by the user. The interface in
DB40xx.DBB0 to DBB3 is disabled if bit "acknowledgment error" is pending. Incoming
acknowledgment bits are not evaluated by the PLC firmware and are cleared when bit
"Reset acknowledgment error" is set.
Error status:
If there is an error, the error status (DB41xx.DBB104) contains a diagnostic number unequal
to zero.

Tool management
Status Meaning
0 No error
1 Multiple acknowledgment signals at the same time
2 Acknowledgment without job
3 Invalid transfer step number
4 There is no job for a position specification
5 The status does not permit a location change (acknowledgment status 0 is
used)
7 An impermissible acknowledgment status has been used
Other values: The number corresponds to the error message of the tool management in the
NCK caused by this transfer
The error status is reset by acknowledgment of the error by the user.
Map of acknowledgments (DB41xx.DBB108 to DBB111)

The acknowledgments last set by the PLC user program (DB40xx.DBB0 to DBB3) are set
and reset by the PLC firmware together with the bits "Acknowledgment OK" or
"Acknowledgment error". If there is an error, the user uses these statically pending bits to
see which acknowledgment step triggered the error. If the PLC user program incorrectly sets
multiple acknowledgment bits, these are also entered one-to-one in the map.
Job status

xx: Load location
DBW124 Current magazine number of the tool (INT)
DBW126 Current location number of the tool (INT)
DBW128 Target magazine number of the tool (INT)
DBW130 Target location number of the tool (INT)

0BTool management
Tool change
Interface description
Per tool holder/spindle there is one interface for:
● Jobs for preparing and executing the tool change.
Message to the PLC user program: Job active; job specification and job description.
The jobs appear in the toolholder interface (of the spindle) where a tool is to be
exchanged.
● Acknowledgments of the PLC user program
All acknowledgments for a job must take place in the interface of the same tool holder (of
the same spindle). Acknowledgment errors should also be reset in this interface.
● Feedback from the tool management to the PLC user program
Message to the PLC user program: Acknowledgment status, error status, map of the
acknowledgment bits.
● Job status
Selected data from the last intermediate or end acknowledgment is saved. This data is
needed by the PLC firmware for the next acknowledgment to the tool management and is
readable for diagnostic purposes. This data can be used by the user program to restart
after an abort (e.g. reset during a tool change).
End acknowledgment for tool change

A common end acknowledgment (tool change via T command using turret) or separate end
acknowledgment (Txx and M206 in separate blocks, default milling) is possible for "Prepare
tool change" and "Implement tool change." With the appropriate MD setting, the end
acknowledgment for the job to prepare for a tool change permits the NCK preprocessing to
continue.
The machine data with which the response of block preprocessing, main run, and the various
acknowledgment responses are defined are described in Chapter Machine data for the tool
management (Page 27).
The main NCK run can be continued with the end acknowledgment to the job "Carry out tool
change". Therefore, these end acknowledgments should take place as early as possible.
This can mean that the end acknowledgment can take place before the old tool is in the
magazine (e.g. the new tool is in the spindle, the old tool in the toolboy). The rest of the
steps to bring the old tool into the magazine must then be communicated asynchronously.
The same interface should be used as for synchronous acknowledgments.

xx: Spindle index / tool holder
DB42xx.DBX0.0 – DBX 3.6 PLC user program:
Preparing and carrying out acknowledgments for tool change
DB42xx.DBX9.0 PLC user program:
Resetting the message "Acknowledgment error"
(DB43xx.DBX100.1) and the diagnostic information in the
feedback interface

Tool management

DB43xx.DBX0.0 Tool management: Job for "Prepare tool change" and "Execute
tool change"
DB43xx.DBB1 Tool management job specification
DB43xx.DBW 6 – DBW34 Job description
DB43xx.DBX100.0 Positive feedback: Acknowledgment status, acknowledgment OK,
one PLC cycle pending
DB43xx.DBX100.1 Negative feedback: Acknowledgment status, acknowledgment
error, static pending
DB43xx.DBX100:0 Positive feedback: Acknowledgment status, one PLC cycle
pending
DB43xx.DBX100:1 Negative feedback: Acknowledgment status, static pending.
DB43xx.DBX100:0 Tool management feedback: Acknowledgment status
DB43xx.DBB104 Tool management feedback: Error status
DB43xx.DBX108.0 - Map of acknowledgments for tool change: This map belongs to the
DB43xx.DBX111.6 positive or negative feedback and remains valid for the same time.
DB43xx.DBW124 – DBW138 Job status
Jobs

xx: Tool holder
DBB0 -- -- -- -- -- -- -- Job
DBB1 Tool Unload Load No old T0 Prepare Change fixed-
remains in manual manual tool change tool location
the tool tool (initiated coded
spindle by: M06)
DBB2 Reserved
DBB3 Reserved
DBB4 Reserved
DBB5 Reserved
DBW6 Source magazine number for new tool (INT)
DBW8 Source location number for new tool (INT)
DBW10 Reserved
DBW12 Reserved
DBW14 Reserved
DBW16 Reserved
DBW18 Target magazine number for old tool (INT)
DBW20 Target location number for old tool (INT)
DBW22 Location type (INT)
DBW24 Size left (INT)
DBW26 Size right (INT)
DBW28 Reserved
DBW30 Reserved

0BTool management

DBB32 Tool status for new tool
-- -- -- Master To be To be Blocked Identifier
tool loaded unloaded for tool
DBB33 Tool status for new tool
Tool has Tool fixed- Tool being Prewarnin Measuring Tool Tool Active tool
been in location- changed g limit tools disabled enabled
use coded reached
DBW34 New tool: Internal T number of NCK (INT)
DBW36 Reserved
DBW38 Reserved
DBW40 Reserved
DBW42 Reserved
DBW44 Free parameter 1 (DWORD)
Signal description:
● Job:
The interface contains a job. Job processing has not yet been completed with an end
acknowledgment. This signal is reset after transmission of the end acknowledgment to
● Fixed-location coded: The new tool is fixed-location-coded.
● Execute tool change:
The new tool is to be loaded into the tool holder / the spindle. The old tool is to be brought
back to a magazine location. This job always requires an end acknowledgment.
● Prepare a tool change:
Initialize new tools. If necessary, position magazine location for old tool at the changing
point. This job requires an individual end acknowledgment. If there is a parallel job
"Execute change," end acknowledgment for the preparation is not necessary.
● T0: T0 has been programmed (empty tool holder / spindle).
● No old tool:
Tool change into the previously empty tool holder / spindle.
● Load manual tool:
A manual tool is to be loaded. The HMI displays the tool which is to be loaded.
● Unload manual tool:
The tool is to be changed via manual operation.
● Tool remains in spindle:
The bit is set at a change from tool holder → spindle to tool holder → spindle. Triggers can
be, for example, reset start mode or block search.

Tool management
● Source location for the new tool:

Magazine and location number from where the new tool comes (mostly a location in a
real magazine).
● Target location for the old tool:
Magazine and location number to where the old tool is to be transported (mostly a
location in a real magazine).
● Origin of the new tool:
– Internal T number: Internal T number of the new tool
– Tool status: Tool status of the new tool
– Location type: Location type of the new tool
– Size: Size (right, left, up, down) of the new tool
– User-definable parameters: Three user-definable parameters which are transferred by
the part program to the PLC user program.
Acknowledgments
DB4200 ... 42xx Signals to tool management [r/w]

xx: Tool holder
DBB0 Acknowledg Acknowle Acknowled Acknowled Acknowled Acknowled Acknowled Total
ment step 7 dgment gment gment gment gment gment acknowled
step 6 step 5 step 4 step 3 step 2 step 1 gment
DBB1 Acknowledg Acknowle Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
ment step dgment gment gment gment gment gment gment
15 step 14 step 13 step 12 step 11 step 10 step 9 step 8
DBB2 Acknowledg Acknowle Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
ment step dgment gment gment gment gment gment gment
23 step 22 step 21 step 20 step 19 step 18 step 17 step 16
DBB3 Reserved Acknowle Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
dgment gment gment gment gment gment gment
DBB4 Reserved
DBB5 Reserved
DBB6 Reserved
DBB7 Reserved
DBB8 Reserved
DBB9 Resetting the
acknowledg
ment error
Signal description:

0BTool management
● Total acknowledgment:
At a 0/1 edge the end acknowledgment, with status 99, is sent to the current job (job
complete, all target positions have been reached). As long as the signal is present, no
changes may be made to the data of this interface!
● Acknowledgment step 1…30:
At a 0/1 edge, the appropriate acknowledgment step from the acknowledgment step table
is sent to the tool management. As long as the signal is present, no changes may be
made to the data of this interface and the variable transfer-step table!
● Resetting the acknowledgment error:
Resetting the message Acknowledgment error (DB43xx.DBX100.1) and the diagnostic
information in the feedback interface.
Feedback reports

xx: Load location
DBB100 Acknowled Acknowled
gment gment OK
error
DBB101 Reserved
DBB102 Reserved
DBB103 Reserved
DBW104 Error status (WORD)
DBB106 Reserved
DBB107 Reserved
Signal description:

Tool management
● Acknowledgment OK (DB43xx.DBX100.0): Positive feedback of acknowledgment status.

The acknowledgment of the PLC user program (area DB42xx.DBB0 to DBB3) was
transferred without error to the tool management. This signal is reset after one PLC cycle.
● Acknowledgment error (DB43xx.DBX100.1): Negative feedback of acknowledgment
status.
There is an error in the acknowledgment of the PLC user program (area DB42xx.DBB0 to
DBB3). The cause of the error is displayed in "Error status."
The "acknowledgment error" bit is only set if the acknowledgment from the PLC firmware
is accepted as error free and the tool management detects and signals an error in the
acknowledged tool transfer (for example, when the target location for tool transfer is
occupied).
Errors that are detected directly by the tool management in the NC before an
acknowledgment is sent by the PLC user program, do not result in the setting of bit 100.1.
If an error is present that prevents transfer of the acknowledgment to the tool
management (error status 1 to 7), the error is only output on the interface of the tool
management and not by the NC (no NC alarm!).
If necessary, signal such errors with a user PLC alarm in the PLC user program.
This signal remains pending statically until the error has been acknowledged (set the bit
"Reset acknowledgment error" DB4200.DBX9.0) by the user. The interface in
DB42xx.DBB0 to DBB3 is disabled if bit "acknowledgment error" is pending. Incoming
acknowledgment bits are not evaluated by the PLC firmware and are also cleared when
bit "Reset acknowledgment error" is set.
Error status:
If there is an error, the error status (DB43xx.DBB104) contains a diagnostic number unequal
to zero.
Status Meaning
0 No error
1 Multiple acknowledgment signals at the same time
2 Acknowledgment without job
3 Invalid transfer step number
4 There is no job for a position specification
5 The status does not permit a location change (acknowledgment status 0 is
used)
7 An impermissible acknowledgment status has been used
Other values: The number corresponds to the error message of the tool management in the
NCK caused by this transfer.
The error status is reset by acknowledgment of the error by the user.

0BTool management
Map of acknowledgments (DB43xx.DBB108 to DBB111)

The acknowledgments last set by the PLC user program (DB42xx.DBB0 to DBB3) are set
and reset by the PLC firmware together with the bits "Acknowledgment OK" or
"Acknowledgment error." If there is an error, the user uses these statically pending bits to
see which acknowledgment step triggered the error. If the PLC user program incorrectly set
multiple acknowledgment bits, these are also entered one-to-one in the map.
Job status
DB4300 ... 43xx Signals from tool management [r]

xx: Tool holder
DBW124 Current magazine number for new tool (INT)
DBW126 Current location number for new tool (INT)
DBW128 Target magazine number for new tool (INT)
DBW130 Target location number for new tool (INT)
DBW132 Current magazine number for old tool (INT)
DBW134 Current location number for old tool (INT)
DBW136 Target magazine number for old tool (INT)
DBW138 Target location number for old tool (INT)
Transfer-step and acknowledgment-step tables
Configurable step tables

There are configurable tables available in the data blocks TM_CTS (DB9900), TM_VTS
(DB9901) and TM_ACK (DB9902), which are used to describe the tool movement
sequences.
Interface signal Name Meaning

DB9900 TM_CTS Constant transfer-step table (configurable)
DB9901 TM_VTS Variable transfer-step table (can be configured and written
to from PLC user program)
DB9902 TM_ACK Acknowledgment-step table (configurable)
The data blocks DB40xx, 41xx, 42xx and 43xx are system blocks and are created
automatically by the control.
The data blocks DB9900, DB9901 and DB9902 are made available by the Programming
Tool under Libraries / Special data blocks. The blocks are not yet filled with the necessary
data. The user must copy them into the PLC project and edit them.

Tool management
Transfer-step tables
The individual tool movements are defined as transfer steps – tool from magazine location
x/y to magazine location m/n. Acknowledgment steps can be defined with these transfer
steps. DB9900 contains permanently configured transfer steps (constant transfer-step table).
DB 9901 can be changed by the PLC user program; for example, for acknowledging
intermediate steps like magazine locations for tool change preparation (variable transfer-step
table).
DB9900 Constant transfer-step table [r]

DBW0 Transfer step 1 Source magazine number (INT)
DBW2 Transfer step 1 Source location number (INT)
DBW4 Transfer step 1 Target magazine number (INT)
DBW6 Transfer step 1 Target location number (INT)
…
DB9901 Variable transfer-step table [rw]

DBB 8 Transfer step 102 Source magazine number (INT)
…

0BTool management
Acknowledgment step table

Each entry indexes two transfer steps (for the new and old tool) and gives the corresponding
status reached. The acknowledgment-step table in DB9902 is used jointly for
acknowledgments on the interface of the loading point and on the interface of the tool holder.
DB9902 Acknowledgment-step table [r]

DBB0 Acknowledgment step 1 Transfer step for new tool (BYTE)
DBB1 Acknowledgment step 1 Transfer step for old tool (BYTE)
DBB2 Acknowledgment step 1 Acknowledgment status (BYTE)
DBB3 Acknowledgment step 1 reserved
…
See also
PLC Program Blocks (Page 33)

Tool management
Machine data for the tool management
Machine data (default setting)

The following machine data has already been preset for tool management or will be set with
"default data" during booting: These settings can be changed as necessary.
MD number Designation Value

10715[0] M_NO_FCT_CYLE 6 (M version)
10716[0] M_NO_FCT_CYLCLE_NAME L6 (M version)
10717 T_NO_FCT_CYLCLE_NAME TCHANGE (T version)
17500 MAXNUM_REPLACEMENT_TOOLS 0
20124 TOOL_MANAGEMENT_TOOLHOLDER 1
20270 CUTTING_EDGE_DEFAULT 1
20310 TOOL_MANAGEMENT_MASK 181400F (T version)
180400F (M version)
22550 TOOL_CHANGE_MODE 0 (T version)
1 (M version)
22560 TOOL_CHANGE_MCODE 206
22562 TOOL_CHANGE_ERROR_MODE 0 (for manual tool)
MD20270: $MC_CUTTING_EDGE_DEFAULT
If no cutting edge is programmed after a tool change, the cutting edge number set in
$MC_CUTTING_EDGE_DEFAULT is used.
MD20270: $MC_CUTTING_EDGE_DEFAULT
Basic setting of tool cutting edge without programming (DWORD)
>0 Number of the cutting edge that is selected with M206 Cutting edge selection is also
active if followed by D programming.
=1 Default setting
=0 No cutting edge is initially active after a tool change. Any tool offset active before tool
change is deselected (corresponds to D0!). Cutting edge selection only active with D
programming.
= -1 Tool edge number of old tool also applies to new tool.
= -2 Tool edge offset of old tool remains active until D is programmed.
The setting in MD20270 affects the block preparation of the NC. To prevent preprocessing
stop from occurring when tool change command is called until it is acknowledged again,
perform NC functions without tool offset in the tool change subprogram, for example,
traversing axes or output of auxiliary functions.
Example:
Requirement: MD20270: $MC_CUTTING_EDGE_DEFAULT= 0 or = -2

0BTool management
After the tool change command M206 the axes can continue travel without having to wait for
the tool change acknowledgment and execute traversing blocks without tool compensation.
Travel only stops in a block with compensation selected (D no.) until end of tool change is
signaled by the PLC.
Sequence in the part program:
N10 T="Drill18" ; Tool change preparation

N20 M6 ; Tool change subprogram called
Tool change subprogram L6:
N10 M206 ; Tool change
N20 D0 : Compensation deselected
N40 Y150 M79 ; Traverse machine axes
N50 G01 D1 X10 ; Activate tool compensation.
; Check whether tool has been changed.
; Preprocessing stop is maintained until tool change
preparation is completed. The main run waits at N50 (D1)
until tool change has been executed and acknowledged.
MD20310: $MC_TOOL_MANAGEMENT_MASK
Settings:
Activating the tool management functions
T and M version:
Bit 0 =1 Tool management active:
The functions of tool management are enabled for the current channel.
Bit 1 =1 Monitoring functions of tool management active:
The functions for monitoring tools (tool life and workpiece count) are enabled.
Bit 2 =1 OEM functions active
Bit 3 =1 Adjacent location consideration active
Bit 14 =1 Tool and offset selection according to the settings in:
MD20110 $MC_RESET_MODE_MASK
MD20112 $MC_START_MODE_MASK
Bit 23 =1 With offset selection no synchronization with main run.
Bit 24 =1 Using an asynchronous transfer with acknowledgment status 201, you can move
a tool to a location reserved for another tool with "reserved for tool from buffer".
This location reservation is then removed before the movement is executed
("Reserved for new tool to be loaded" (bit value="H8") remains effective).
Additionally only for T version:
Bit 16 =1 T location number is active.

Tool management
If a locked tool is at the programmed location, the location of a replacement tool (if available)
is output as job from the tool management when the option "Spare tools for tool
management" option is set.
Channel MD52270: $MCS_TM_FUNCTION_MASK

Settings:
SD52270: $MCS_TM_FUNCTION_MASK
Tool management function mask
Bit 0: Creating tool at the magazine location is not permitted.
Tools can only be created outside of the magazine.
Bit 1: Load/unload lock, if the machine is not in the reset state.
Tools can only be loaded/unloaded when the relevant channel is in the reset state.
Bit 2: Load/unload lock for EMERGENCY STOP.
Tools can only be loaded/unloaded when EMERGENCY STOP is not active.
Bit 3: Tool in/out of spindle load/unload locked.
Tools cannot be loaded to or unloaded from the spindle.
Bit 4: Loading is performed directly into the spindle.
Tools are only loaded directly into the spindle.
Bit 5: Reserved
Bit 6: Reserved
Bit 7: Create tool using the T number.
The T number of the tool must be entered when creating a tool.
Bit 8: Hide tool relocation.
The "Relocate tool" function is hidden in the user interface.
Bit 9: Hide magazine positioning.
The "Position magazine" function is hidden in the user interface.
Bit 10: Reactivate tool with magazine positioning.
Before Reactivate, the tool is positioned at the loading point.
Bit 11: Reactivate tool in all monitoring types.
When reactivating a tool, all the monitoring types for this tool enabled in the NC are
reactivated. I.e. also the monitoring types that are not set for the relevant tool, but are
only in the background.
Bit 12: Hide reactivating tool.
The "Reactivate tool" function is hidden in the user interface.

0BTool management
Settings at the user interface

The settings for dialogs of the tool management at the user interface are generally made
using SD54215: $SNS_TM_FUNCTION_MASK_SET:
SD54215: $SNS_TM_FUNCTION_MASK_SET
Tool management function mask
Bit 0: Diameter display for rotating tools.
For rotating tools, the diameter is displayed and not the radius.
Bit 1: M4 is the default direction of rotation for all turning tools.
When creating turning tools, the direction of rotation is pre-assigned with M4.
Bit 2: Create tool without name suggestion.
Bit 3: Input lock, tool name and tool type for loaded tools.
For loaded tools, the tool name and the tool type can no longer be changed.
Bit 4: Input lock for loaded tools if the channel is not in the reset state.
Bit 5: Calculate by adding tool wear entries.
Wear data is entered in addition to the already existing wear value.
Bit 6: Numerical input of the tool identification.
Only numbers are permitted for the input of the tool identification.
Bit 7: Hide tool monitoring parameters.
The tool monitoring parameters are hidden in the user interface.
Bit 8: Diameter display for face axis → Geometry.
The geometry value of the face axis is displayed as diameter value.
Bit 9: Diameter display for face axis → Wear.
The wear value of the face axis is displayed as diameter value.
Bit 10: Enable tool load/relocate to buffer storage locations.
The magazine number can be entered into the "Load" dialog. It is therefore possible to
access the buffer storage via magazine number 9998.
Tool call for tool measuring in JOG

For special applications (e.g. measuring cycles in JOG), it is necessary to load a specific tool
(e.g. miller_15, duplo number 2) - independent of its status - onto the spindle or the
toolholder; this can be the case, for example, if a tool was being used but was locked by the
tool monitoring function. For the new release, it should now be measured.
The NC command TCA is available to call a tool independent of the status and by selecting
duplo and tool holder number; this is used when measuring tools in JOG.
TCA ("Tool name", duplo No., toolholder No.)

TCA behaves like the T command with respect to alarm and command output to the PLC.
Boundary conditions:
The following boundary conditions must be observed for an active T function replacement
(default setting for turning):

Tool management
● TCA cannot be substituted (T replacement cycle).

● The cycle defined in MD10717: $MN_T_NO_FCT_CYCLE_NAME and which is executed
for a T call, is not started by the TCA command.
To ensure that a tool change cycle also starts when TCA is programmed, the language
command TCA must be redefined in _TCA (default setting NC).
● The machine functions of the TCHANGE.SPF must be transferred into the TCA.SPF
cycle. The TCA.SPF cycle is in the Toolbox CD.
Example:
The following example describes the sequence:
PROC TCA(STRING[64] _TOOL_NAME,INT _DUPLO,INT _TH_NO)

;VERSION: 01.00.07. Oct 22, 2009
;CHANGE: 01.00.07. Oct 22, 2009
TCA(_TOOL_NAME,_DUPLO,_TH_NO) ;Tool call to NC
; here, insert the machine functions for the change
M17
Note
The offset selection corresponding to MD20270: $MC_CUTTING_EDGE_DEFAULT acts in
the same way as for the T command.
TCA and D must not be programmed in the same block.
Default setting for turning technology

Two machine data items determine the function for turning technology:
● MD22550: $MC_TOOL_CHANGE_MODE = 0
Setting for a revolver magazine: The new tool is changed immediately with the T function.
No additional M command is used. No distinction is made between Prepare tool change
and Execute tool change.
The function "Manual tools" is not enabled for this case.
● MD20310: $MC_TOOL_MANAGEMENT_MASK = 81400F (bit 16=1)
Bit 16 is used to set the tool programming type:
T = "x" with x as tool identifier
Tx, with x as location number of the magazine containing the tool used for machining.
When the function is active, T1 selects the tool in location number 1 instead of the tool
with identifier "1". Then the identifier of the tool in this location is ascertained (e.g.
"FINISHING TOOL") The procedure is as if T="FINISHING_TOOL" had been
programmed.
If T = location number, no tool need actually be stored in the location.

0BTool management
● MD10717: $MN_T_NO_FCT_CYCLE_NAME = TCHANGE

Name of tool change cycle for T function replacement.
For a description, refer to the Chapter Example: Tool change cycle for turning machine
(Page 60)
● ISO dialects
Default setting for programming the tool offset:
MD10888 $MN_EXTERN_DIGITS_TOOL_NO = 0
MD10889 $MN_EXTERN_DIGITS_OFFSET_NO = 2
MD10890 $MN_EXTERN_TOOLPROG_MODE = 4
Programming T101 and T0101 leads to the same result: T1 H01
Configuring the magazine

The magazine configuration can be created either with the start-up tool or with a
configuration program. The configuration program is selected and started as a normal part
program.
An NC POWER ON is needed after changing the magazine configuration. The changed
configuration is only displayed after restarting the NC.
See also
Examples:
● Configuration of a chain magazine with a dual gripper (Page 65)
● Configuration of a revolver magazine (Page 54)
The program is also to be found on the Toolbox CD.
References
Further information:
● SINUMERIK 828D List Manual: Machine data and interface signals
● SINUMERIK 802D sl/828D/840D sl: Function Manual: ISO dialects
– The description "Substitution by a replacement cycle for a tool selection block" is valid
for the ISO mode (G291).
– The description "Tool change and tool offsets" is valid when programming the tool
offset.

Tool management
PLC Program Blocks
Acknowledgment process
Information to tool management

The tool management expects acknowledgment of its orders in order to track and carry the
actual tool positions. At least one acknowledgment is required for each order. This is
sufficient for many applications.
Acknowledgment takes place either via the table defined in DB9902, or in one step with the
total acknowledgment (DB40xx/42xx DBX0.0) after a completely finished tool management
order using a 0/1 edge (set) of the corresponding bits in the user interface.
As long as the acknowledgment signal is present, no changes may be made to the data of
this interface! This signal is reset by the PLC firmware after the acknowledgment has been
transmitted to the tool management. In certain circumstances resetting may take place after
several PLC cycles.
There are further advantages if the tool management is also informed of intermediate
positions:
● Information about intermediate positions:
If the intermediate tool positions are known in the tool management, the allocation of the
buffer magazine may be queried. This makes powering up easier after switching off and
on again or after canceling a command (e.g. via reset). If the tool currently being changed
is needed again immediately, it can be loaded back into the spindle from a buffer location
without loading it into the magazine first.
● Information about magazine positions:
If the tool management knows at which magazine location there is a transfer point
(changing point for the spindle, loading point), it can determine the shortest paths in the
magazine for finding an empty location or for selecting a new tool. During orders the tool
management can usually recognize the magazine position from intermediate
acknowledgments (e.g. tool transfer between the real magazine and the buffer) or from
the end acknowledgment (e.g. "magazine positioning" order complete). If the magazine is
positioned by the PLC user program itself (e.g. by means of HMI or machine keys)
without a tool management order, this must be communicated to the tool management
via synchronous signals.
Types of acknowledgment
Tool and magazine movements

The tool management distinguishes between synchronous acknowledgment and an
asynchronous job-independent message.
Synchronous acknowledgment

0BTool management
● Acknowledgment of the intermediate steps of a job (tool management registers the

current position changes of tools, part program must wait).
The tool management is informed of intermediate steps of a job by an intermediate
acknowledgment. In intermediate acknowledgments, only the target position of the
intermediate step is relevant. The source position is known from the job or the last
intermediate acknowledgment. During a tool change, two tools (new and old) can also be
acknowledged simultaneously. Intermediate acknowledgments are only possible before
the end acknowledgment.
● End acknowledgment of a job (part program can be continued)
An end acknowledgment is necessary for every job. The end acknowledgment allows the
part program to continue and frees up the job interface for new jobs. It should take place
as soon as possible (e.g. as soon as the new tool is in the spindle and a collision is no
longer expected). The tool management can be informed asynchronously of further steps
after the end acknowledgment of a job (e.g. the return path of the old tool into the
magazine).
Asynchronous job-independent message
Position change of a tool or magazine ("asynchronous message", e.g. when the PLC
changes a tool position via machine control panel operation without tool change job).
An asynchronous message can be used to inform the tool management of a tool or
magazine movement, independently of a job. An asynchronous message must always
contain a source position (from) and target position (to).
Tool movements within a magazine (relocate tool) can only be carried out with magazine
locations which are actually occupied. Empty transfers are not permissible. Two
asynchronous transfers can be implemented in a single message. In this case the interface
must be used for tool change DB42xx.
Effect of acknowledgments
Effect of acknowledgments on the job and the part program:
● Intermediate and end acknowledgment take place synchronously with the job.
– The part program must wait.
– No new job can come yet.
● Message of an asynchronous transfer:
– The part program continues to run.
– The message is completely independent of any job.

Tool management
Acknowledgment states
Acknowledgment states and their meaning:

The status indicated by the respective type of acknowledgment is shown in the following
table:
Acknowledgment Meaning
Synchronous end 1 Job finished at the specified position:
acknowledgment The tools are in the positions specified. The part program can be
continued.
3 Job canceled:
The job is canceled, previously acknowledged tool position
changes will be kept. The cancel command itself does not
trigger any position acknowledgments or changes in the tool
management.
6 End acknowledgment for "Move tool" from the real magazine to
a buffer (gripper, spindle) with reservation of the old location in
the magazine for this tool. Same meaning as status 1.
7 Repeat "prepare tool change" job:
The tool change was informed of a new tool position in advance.
The "prepare tool change" job is to be recalculated with this
position. This is permissible only for preparation commands
which have not yet been acknowledged.
99 Total acknowledgment: Job complete, all positions reached.
All the tools concerned are in the positions specified in the job.
The part program can be continued. All target positions from the
job have been reached.
Synchronous 105 Intermediate position for tool:
intermediate The tools are moved from the source position specified in the
acknowledgment job, or from the last acknowledged intermediate position, to the
specified target position.
Communicating an 201 Communicate tool movement:
asynchronous transfer The tool is moved from the source position to the specified
target position. When moving from a location in a real magazine
to an intermediate buffer location, the source location is
reserved for the tool.
Also observe MD20310, bit 24 (Page 27).
204 Communicate magazine position:
The magazine location is in the change/load/unload point of the
specified target location.
Overview of evaluated table parameters
Acknowledgment status 1 3 6 7 99 105 201 204

New tool Transfer step x - x - - x x x
• from magazine - - - - - - xx xx

0BTool management
Acknowledgment status 1 3 6 7 99 105 201 204

• from location - - - - - - xx xx
• to magazine xx - xx - - xx xx zz
• to location xx - xx - - xx xx zz
Old tool Transfer step x - - - - x x -
• from magazine - - - - - - xx -
• from location - - - - - - xx -
• to magazine xx - - - - xx xx -
• to location xx - - - - xx xx -
Legend:
- Date not relevant
x Number (1…n) of the transfer step from the transfer-step table
xx Magazine number, location number of the tool
zz Magazine number, location number of the load / unload or changing point
The status overview issues the following information:

● Depending on their meaning, the states 1, 6, 105, 201 and 204 should be combined in
the acknowledgment table with the transfer steps to make useful acknowledgment steps.
● If status 1 is coded with both transfer step numbers = 0, this acknowledgment step serves
as an end acknowledgment of the current status reached via intermediate
acknowledgments.
● If a tool has been moved for a real magazine to a buffer (relocate, MVTOOL),
acknowledgment with status 6 or total acknowledgment reserves the source location for
this tool ($TC_MPP4 bit 1 and bit 2). The behavior is the same as for the removal of a
tool from the magazine during tool change. With status 1, there is no reservation of the
source location during relocation or MVTOOL.
● Statuses 3 and 7 need only to be coded once in the acknowledgment-step table, as no
transfers steps are evaluated.
● Status 99 does not need to be coded, it is specified by the "total acknowledgment" bit.

Tool management
Typical sequence of any job with total acknowledgment
2UGHU

7RWDODFNQRZOHGJPHQW

$FNQRZOHGJPHQW2.
Signal description:
① The PLC user program recognizes from the 0/1 edge of the signal DB43xx.DBX0.0 (job) that a
new job has been assigned by the tool management.
② The PLC user program sets the acknowledgment signal in DB42xx.DBX0.0 (total
acknowledgment). With activation of the 0/1 edge, the PLC firmware starts transferring the
acknowledgment to the tool management.
③ After successful transmission of the acknowledgment to the tool management, the PLC
firmware sets a PLC cycle to 1 for the signal "acknowledgment OK" and at the same time the
job signal and the acknowledgment bit are reset to 0.
Typical sequence of any job with total acknowledgment and end acknowledgment
2UGHU
,QWHUPHGLDWHDFNQRZOHGJPHQW

(QGDFNQRZOHGJPHQW
$FNQRZOHGJPHQW2.
Signal description:
① The PLC user program recognizes from the 0/1 edge of the signal DB43xx.DBX0.0 (job) that a
new job has been assigned by the tool management.
② The PLC user program acknowledges the transfer steps, configured in DB9900, DB9901 and
DB9902, with acknowledgment status 105. The tool management updates the tool positions
using the transfer steps of the acknowledgments.
③ The execution of the job is acknowledged by the PLC user program with acknowledgment
status 1. After successful transmission of the acknowledgment to the tool management, the
PLC firmware sets a PLC cycle to 1 for the signal "acknowledgment OK" and at the same time
the job signal and the acknowledgment bit are reset to 0.
Sequence of the tool management with block splitting (machine data setting milling)
Txx M6 ;
Program L6 is called with M6 (basic setting)

0BTool management
2UGHU

([HFXWHWRROFKDQJH
3UHSDUHDWRROFKDQJH


(QGDFNQRZOHGJPHQW
$FNQRZOHGJPHQW2.
Signal description:
① The PLC user program receives a new job. The job "prepare tool change" and the job "execute
tool change" are issued one after the other. Txx and M206 have been programmed in separate
NC blocks. Only the job "prepare tool change" is present in the interface in DB43xx. The job
"execute tool change" is output only after the end acknowledgment for the job for tool
preparation.
② Bit DB43xx.DBX0.0 (job) is reset with acknowledgment of the "prepare tool change" job. If the
change command (M206) has already run through the NC main run, the new job is immediately
output at the interface.
③ The "execute tool change" job is acknowledged as a normal job. The end acknowledgment OK
is returned and the bit for the job is simultaneously reset.
The description of the job ("execute tool change" and "prepare tool change") is not reset. Byte
1 of DB43xx is not overwritten until the next job.
Note
MD20270, MD20310:
The response of the interface in DB43xx.DBB1 and of NC block processing is affected by the
setting in MD20270: $MC_CUTTING_EDGE_DEFAULT and MD20310:
$MC_TOOL_MANAGEMENT_MASK bit 5, 6, 7, and 8.
This sequence described here corresponds to the presetting of the machine data.
Sequence of the tool management without block splitting (machine data setting milling)
Txx Myy ;
Myy is the setting from MD22560: $MC_TOOL_CHANGE_M_CODE
This type of programming is not recommended!

Tool management
2UGHU
([HFXWHWRROFKDQJH
3UHSDUHDWRROFKDQJH


(QGDFNQRZOHGJPHQW
$FNQRZOHGJPHQW2.
Signal description:
① The PLC user program receives a new job. The job "prepare tool change" and the job "execute
tool change" are issued simultaneously. Txx and M206 have been programmed in one NC
block.
② Several intermediate steps are acknowledged. The state of the job remains unchanged. The
positions of the tools are updated using the transfer steps of the acknowledgments from the
tool management.
③ The end acknowledgment OK is returned and the bit for the job is simultaneously reset.
The description of the job ("execute tool change" and "prepare tool change") is not reset. Byte
1 of DB43xx is not overwritten until the next job.
Note
The response of the interface in DB43xx.DBB1 is affected by the setting in MD20310 bit 10.
This sequence described here corresponds to the presetting of the machine data.
Configuring step tables
Configuring step tables

You can find the transfer-step tables (TM_CTS, DB9900 and TM_VTS, DB9901) and the
acknowledgment-step table (TM_ACK, DB9902) in the Programming Tool under "Libraries"
→ "Special data blocks". The blocks are copied into a project with a double-click.
The structure of the data blocks is permanently fixed.
The blocks are not yet filled with the necessary data. The user must edit them in the
Programming Tool, via the menu "View" → "Data block". The constant tables (TM_CTS,
DB9900 and TM_ACK, DB9902) are configured by writing the initial data block values in the
Programming Tool.
The initial data block values are loaded into the control, along with the PLC user program.
Changed initial values are not activated until the PLC is restarted!

0BTool management
Configuring the transfer steps

Any changes to the tool and magazine positions must be communicated to the tool
management by the PLC user program. A table of all mechanical single movements which
should be acknowledged / communicated helps with this. For each tool transfer, the table
contains the corresponding tool start and target position, or for positioning a magazine
location at a transfer point (change, load, unload point), the magazine position and the name
of the transfer point.
● The transfer steps 1 … 64 are permanently configured in TM_CTS (DB9900) and can be
changed only by reloading.
● The transfer steps 101 … 164 in TM_VTS (DB9901) can be completely or partially
overwritten by the PLC user program (e.g. by entering the current magazine location).
Coding for position from a job

In the constant transfer-step table, the locations of real magazines are not identified by their
actual values (e. g. 1/14 for magazine 1 location 14) but with symbolic values (0/1) or (0/2).
Otherwise the transfer-step table would be huge for large magazines.
These symbolic values have the following meaning:
Magazine / Location Meaning

(0/1) The source position of the only or new tool from the job should be used.
(0/2) The target position of the old tool from the job should be used.
(0/3) The target position of the only tool or new tool from the job should be used.
This symbolic notation form can only be used for synchronous intermediate and end
acknowledgments, since asynchronous messages do not have a job as a reference.
Example: Constant transfer-step table
Transfer step Address Name Start value Comment

DB9900
1 0.0 SrcMag_1 0 Source magazine number of the
transfer step
2.0 SrcPos_1 1 Source position number of the
transfer step
4.0 DstMag_1 0 Target magazine number of the
transfer step
6.0 DstPos_1 1 Target position number of the
transfer step
transfer step
transfer step
transfer step

Tool management
Transfer step Address Name Start value Comment

DB9900
transfer step
Example as a complete step
Transfer of to Comment
step
Magazine Location Magazine Location
1 0 1 0 1 Prepare Tool: The magazine is
positioned at the changing point of the
new tool.
2 0 1 9998 2 Tool change: Tool from magazine to
gripper 1
3 9998 1 9998 3 Tool change: Tool from spindle to
gripper 2
4 9998 2 9998 1 Tool change: Tool from gripper 1 to
spindle
5 9998 3 0 2 Tool change: Tool from gripper 2 to
magazine
Example: Variable transfer-step table
Transfer Address Name Start value Comment

step DB9901
transfer step
transfer step
transfer step
transfer step
transfer step
transfer step
transfer step
transfer step

0BTool management
Transfer of to Comment
step
Magazine Location Magazine Location
101 1 0 9998 1 "Prepare tool change": The magazine
is positioned at the changing point.
The source position must be entered
by the PLC user program.
102 1 0 9998 2 "Prepare tool change": Tool from
magazine to buffer. The source
position must be entered by the PLC
user program.
Configuring acknowledgment steps
Configuring the acknowledgment steps

The PLC 31 provides acknowledgment steps to acknowledge tool and magazine
movements. These are activated via the corresponding bits on the user interface. The data
of these acknowledgment steps (with the exception of special case acknowledgment step 9:
total acknowledgment) are stored in acknowledgment step table TM_ACK (DB9902). The
transfer steps (number of the transfer step from the transfer step table) for the old and new
tool and an acknowledgment status are combined in one acknowledgment status.
It is important to include an acknowledgment step with the status 3 in this table, so that
potential errors can be reset. The numbers for the transfer in this acknowledgment step are
0.
Special meaning of transfer step 0

Only the transfer steps assigned to the acknowledgment step are executed. If only one or no
transfer step is assigned, no tool transfer will be carried out for the tool with transfer step = 0.
The tool is not available or remains at its original location.
Example: Acknowledgment step table
Acknowledg Address Name Start value Comment

ment step DB9902
1 0.0 TsNewT_1 0 Transfer step number of the new tool
1.0 TsOldT_1 0 Transfer step number of the old tool
2.0 State_1 3 Status to NCK
2 4.0 TsNewT_2 1 Transfer step number of the new tool
5.0 TsOldT_2 0 Transfer step number of the old tool
6.0 State_2 1 Status to NCK

Tool management
Acknowledg Transfer step Acknowledg Comment

ment step ment status
New tool old tool
1 0 0 3 "Cancel order" command.
2 2 0 1 Prepare Tool: The tool is taken from the
magazine (changing point) and placed
into gripper 1.
Acknowledgment is given by setting the corresponding bits in the user interface:

● DB40xx for loading/unloading / relocating or positioning the magazine
● DB42xx for "prepare tool change" and "execute tool change"
After processing, the acknowledgment bit is reset one PLC cycle by the PLC firmware.
In the same data block where the acknowledgments have taken place, for a PLC cycle the
feedback message is output in bit 100.0 (acknowledgment OK), or as a static signal in bit
100.1 (acknowledgment error); the error status is output in byte 104 for an acknowledgment
error, and in bytes DBB108 to DBB111 the acknowledgment bits last set are output. The
user can use these bits to see which acknowledgment step triggered the error. If the PLC
user program incorrectly set multiple acknowledgment bits, these are also entered one-to-
one in the map. Resetting of the error status occurs when the user acknowledges the error in
DB40xx.DBX9.0 or DB42xx.DBX9.0.
Adjust the PLC user program
Adjust the PLC user program

The control of mechanical processes, monitoring and prevention of potential collisions and
the acknowledgment of tool position changes are the task of the PLC user program.
See also
In the PLC project on the Toolbox CD you can find examples of transfer steps and their
acknowledgments, for a turning machine with a circular magazine and a milling machine with
a chain magazine and dual gripper:
● Application example for milling machine (Page 65)
● Application example for turning machine (Page 54)
These blocks are function examples for the acknowledgment of different tool management
jobs.
Acknowledging jobs
Many tool movements or tool management jobs can be directly acknowledged using total
acknowledgment at bit 0.0 of the interface, without previous intermediate acknowledgment.
For example:

0BTool management
● Turns of a circular magazine

● Loading/unloading (only for systems without additional buffers such as handling systems,
loaders, etc.)
● Changing manual tools
● Positioning a magazine
Rules for acknowledgment

If intermediate steps are useful, several rules must be observed during acknowledgment:
The PLC user program must ensure that all acknowledgments are transferred correctly to
● Only one acknowledgment signal at a time may be sent to the tool management.
● Synchronous acknowledgments are permissible only for the pending job
● Only valid transfer-step numbers may be used (1 - 64, 100 - 164). For asynchronous
messages, at least one transfer step must be input for status 201, for status 204 a
transfer step for the new tool must be input.
● Coded positions in the transfer steps may only be used for synchronous
acknowledgments and only with the values 0/1, 0/2 or 0/3.
● No illegal acknowledgment states may be used.
● Magazine positioning with a job may only receive a synchronous acknowledgment (end
acknowledgment). Intermediate positions must be reported to the tool management with
asynchronous messages.
● Acknowledgment signals must be reset by the PLC basic program. After an
acknowledgment bit is set, the user interface may not be changed until the feedback
message in DB41xx/DB43xx DBB100!
● Asynchronous messages with two transfer steps must be acknowledged on the tool
change interface (DB42xx).
Information on magazine location
Overview
It is possible to read up to eight NC variables in one job using the existing NC services
interface (DB1200).
Variable $TC_MPP2 with index 7: Location type

Parameter assignment:
Read variable from Address Signal Valid values

the NCK
Job DB1200.DBX0.0 Start 0/1
DB1200.DBX0.1 Write variable 0

Tool management

the NCK
DB1200.DBB1 Number of variables 1…8
Parameter DB120x.DBW1000 Variables index 7
DB120x.DBW1002 Location number 1 … 31999
DB120x.DBW1004 Magazine number 1 … 9999
Result DB1200.DBX2000.0 Job completed 0/1
DB1200.DBX2000.1 Error in job 0/1
DB120x.DBX3000.0 Variable is valid 0/1
DB120x.DBB3001 Access result 0/3/5/10
DB120x.DBW3004 Data from NCK variable n
Legend:
n > 0: Location type for virtual location
n = 0: "match all" (buffer)
n = 9999: undefined (no virtual location)
Variable I$TC_MPP4 with index 8: Location state


the NCK
Legend:
n=1 locked
n=2 free (<> occupied)
n=4 reserved for tool in buffer
n=8 reserved for tool to be loaded
n = 16 occupied in left half location
n = 32 occupied in right half location

0BTool management
n = 64 occupied in upper half location

n = 128 occupied in lower half location
Variable $TC_MPP6 with index 9: T number of the tool at this location


the NCK
n = T number of the tool on the parameterized location
Error (for all variables)

In case of error, DB120x.DBX3000.0 = 0 and an entry is made in the access result:
Values in DB120x.DBB3001
0 No error
3 Illegal access to object
5 Invalid address
10 Object does not exist
PI service: TMMVTL
Function
With PI service TMMVTL, it is possible to initiate a job to relocate a tool from the PLC. After
an error-free "PI Start," the tool management performs an empty location search in the target
magazine for the tool on the defined source location. Subsequently the PLC receives a job
for relocating the tool (user interface DB41xx.DBB0).

Tool management
Parameter assignment
Starting program instance services in the NCK area:
PI service Address Signal Valid values

DB1200.DBB4001 PI index 5
Parameter DB1200.DBW4004 Tool number 1 ... 31999
(internal T number)
DB1200.DBW4006 Source location number 1 ... 31999
DB1200.DBW4008 Source magazine number 1 ... 31999
DB1200.DBW4010 Target location number -1
DB1200.DBW4012 Target magazine number 1 ... 32000
The tool can be specified either via a T number or by means of the location and magazine
numbers. The value -1 is entered at unused specification points.
With the parameter, target location number =-1, a search is made in the complete magazine
for an empty location for the tool according to the search strategy that has been selected. If a
target location is specified, then a check is made as to whether the location with the
specified target location number is free and suitable for the particular tool.
For a target magazine number = -1, a search is made in a buffer for the tool corresponding
to the assignment obtained from $TC_MDP2.
Application
Examples:
● When using buffers to return the tool (for example Toolboy and/or shifter), an explicit
empty location search in the magazine may be needed during the asynchronous return
transport. In this case the PLC does not have to note the original location, the PI service
searches for a suitable location.
● A tool is to be moved from a background magazine to the front magazine.

0BTool management
Example: Loading/unloading
Programming
For loading, tools are placed directly in the magazine or the spindle; for unloading, they are
removed directly from the magazine. Normally, a single acknowledgment from the operator
or the PLC user program (tool holder is closed again) is sufficient as a message that the
process is complete. There is no need to configure a transfer step. The total
acknowledgment can be set in DB40xx.DBX0.0.
Acknowledgment to tool management:
Acknowledgment Acknowledgment bit Transfer step new Transfer step old Status
step tool tool
xxx DB4000.DBX0.0 -- -- (99)
Figure 1-2 Programming in PLC user program
Loading procedures using handling systems or transporting the tool from the spindle into the
magazine can be performed using further asynchronous messages.
Different loading sequences are described below:
Loading via the spindle with preselection of a magazine location

You can create a new tool directly on the chosen free magazine location or, using the "load"
dialog, move a tool from the tool list, which is not located in the magazine, to a magazine
location.
1. A job from the tool management is always output at the interface for the loading point.
You must acknowledge this job.
2. Then move this tool, which is not yet positioned in the magazine, into the spindle with Txx
M6 or via an asynchronous transfer.
3. Then manually place the tool into the spindle and deposit it in the magazine with T0 M6.
The procedure is always possible irrespective of whether manual tools are allowed. If
manual tools are permitted, this sequence of operations must always be observed when
loading via the spindle.
The tools can be oversized or fixed-location coded.

Tool management
Loading via the spindle with preselection of a magazine location

You can create a new tool directly on the spindle or, using the "load" dialog, move a tool
from the tool list, which is not located in the magazine, to the spindle.
2. Then manually place the tool into the spindle and deposit it in the magazine with T0 M6.
A free location is selected by the tool management in which the tool can be deposited.
This sequence is only possible if the manual tools function is not set MD22562:
$MC_TOOL_CHANGE_ERROR_MODE Bit 1=0 (default setting).
The tools can be oversized or fixed-location coded.
Loading directly into the magazine

Position the relevant magazine location next to the loading position. You can create a new
tool directly on the chosen free magazine location or, using the "load" dialog, move a tool
from the tool list, which is not located in the magazine, to the selected magazine location.
2. Now place the tool in the magazine.
This sequence is not subject to any restrictions or constraints.

0BTool management
Example: Change manual tools
Programming
In MD22562: $MC_TOOL_CHANGE_ERROR_MODE Bit 1=1, additional tools without
magazine allocation have been selected by the NC part program. The selected tool must be
inserted in the machine manually and removed again manually after machining ("manual
tools").
The operator must ensure that the data block for the tool on the spindle is in the NCK, or that
he/she puts the appropriate tool onto the spindle for the data block stored in the NCK.
Note
The responsibility is on the user to comply with the safety regulations via the PLC user
program.
The PLC user program is informed with DB43xx.DBX1.5 and DBX1.6 whether a manual tool
is involved in a tool change job. With alarm 17212: "Channel %1, Manual tool %2, Duplo No.
%3, Load to toolholder %4" or Alarm 17214. "Remove manual tool from spindle/tool holder,"
the operator is requested to execute the tool change.
The alarms are reset after a tool change by the acknowledgment from the PLC.
Starting position 1
The manual tool in the spindle should be exchanged for another manual tool
Job from tool management to the PLC user program (tool change):
DB4300.DBX0.0, DBX1.2, DBX1.5 and DBX1.6 ("Prepare tool change")
DB43xx.DBW6 Source magazine number 9999

DB43xx.DBW8 Source location number 1
DB43xx.DBW10 Target magazine number 9999
DB43xx.DBW12 Target location number 1
Acknowledgment "Prepare tool change":
Acknowledgment Acknowledgment bit Transfer step for Transfer step for Status
step the new tool the old tool
xxx DB4200.DBXx.x 0 0 1
Displayed on the interface:

DB4300.DBX0.0 /1.1, DBX1.5 and DBX1.6 ("Execute")
The job remains otherwise unchanged, the tools are still at the starting positions.
An intermediate step can be inserted for acknowledging the removal of the old tool:
Synchronous acknowledgment: The tool is no longer in the spindle:

Tool management
Transfer step From to Comment

Magazine Locati Magazine Locati
on on
6 9998 1 9999 1 Tool removed from the spindle
DB9900.DBW40
After intermediate acknowledgment of the empty spindle and insertion of the new tool in the
spindle, the tool change is terminated with a total acknowledgment:
DB4200.DBX0.0 (99)
Starting position 2
A manual tool is in the spindle and is to be replaced by a tool from the magazine
Job from tool management to the PLC user program (tool change):
DB4300.DBX0.0, DBX1.2 and DBX1.6 ("Prepare tool change")
DB43xx.DBW6 Source magazine number 1

DB43xx.DBW8 Source location number 6
DB43xx.DBW10 Target magazine number 9999
DB43xx.DBW12 Target location number 1
Acknowledgment "Prepare tool change":
Acknowledgm Acknowledgment bit Transfer step for the Transfer step for the Status
ent step new tool old tool
Displayed on the interface:

DB4300.DBX0.0 /1.1 and 1.6 ("Execute tool change")
The job remains otherwise unchanged, the tools are still at the starting positions.
Synchronous acknowledgment: The old tool is no longer in the spindle:

0BTool management

on on
6 9998 1 9999 1 Asynchronous message, unload
DB9900.DBW40 the tool from the spindle
Acknowledgm Acknowledgment bit Transfer step for the Transfer step for the Status
ent step new tool old tool
The spindle is now empty, the old tool is outside the magazine.
Next step: Synchronous acknowledgment, new tool to gripper 1
Transfer step of to Comment

on on
3 0 1 9998 2 New tool to gripper 1
DB9900.DBW16
Acknowledg Acknowledgment bit Transfer step for the Transfer step for the Status
ment step new tool old tool
The job is unchanged.

Next step: Synchronous acknowledgment, new tool from gripper 1 to spindle:

on on
4 9998 2 9998 1 New tool from gripper 1 to spindle
DB9900.DBW24
This completes the tool movement.

End acknowledgment:

Tool management
The step New tool from gripper 1 to spindle can be omitted and replaced by a total
acknowledgment. This also informs the tool management that all tools are in their target
positions.
DB4200.DBX0.0 (99)

0BTool management
Application example for turning machine
Example: Turning machine with revolver magazine (MAGKONF_MPF)
Example file
You can find the program for configuring the magazine in the Toolbox.
The program can be read into the control and should be adjusted for the specific machine
concerned.
Configuration
0DJD]LQH UHYROYHU
7RROKROGHU
6SLQGOH &KDQJLQJSRLQW

/RDGDQGXQORDG

1 ... 4 Transfer steps

Figure 1-3 Turning machine with revolver magazine
Description of the program

To start with, all the old magazine definitions and tools are deleted. As the program
sequence continues, all magazines and buffers are newly created and assigned by writing
the magazine parameters.
Search strategies for tools and magazine locations can be defined in N70.
For revolver magazines it is advisable to define all locations as fixed-location coded. For
magazine type 3 N320 $TC_MAP3[NUM_MAG] = 81 (Bit6 = 1) is set.
The chain magazine locations are set up from N430 to N500. Magazine location type = 0
means that the magazine location can be loaded with tools of different location types.
The buffers are set up from N520 onwards.
From N920, the buffers are assigned to the spindle / tool holder and the magazine.
After the magazine configuration program has finished running, restart the NC using (NCK
reset).

Tool management
See also
You will find a precise description of the parameters used in the Tool Management Function
Manual of SINUMERIK 840D sl.
Example MAG_CONF_MPF
1. Plant configuration:
– 1 revolver magazine with 8 locations (can be set up in N40)
– 1 loading point
– 3 buffer locations (can be set up in N50, assignments from N540)
2. Part program:
;MAG_CONF_MPF
N10 def int NUM_MAG,MAG_TYPE, LOCATIONS,
PLACE, NUM_BUFFER, NUM_LOAD, PLACE_SEARCH
;
N20 NUM_MAG = 1 ;Number of the magazine
N30 MAG_TYPE = 3 ;Magazine type (1: chain,
3: revolver, 5: box magazine)
N40 LOCATIONS = 8 ;Number of magazine locations
N50 NUM_BUFFER = 1 ;Number of buffers (spindle,
gripper)
N60 NUM_LOAD = 1 ; Number of loading points
N70 PLACE_SEARCH = 257 ; Type of search strategy
;= 257 Bit13=0 no exchange of the old tool on the location of the new tool
;Setting for pickup magazine
;=12289 Bit13=1 exchange old tool on the location of the new tool
;Setting for chain magazine
N80;
N90;
;Check parameters
N100 STOPRE
N110 if ((NUM_MAG==0)or(LOCATIONS==0))
N120 Err1:STOPRE
N130 MSG("Wrong Parameter --> Cancel")
N140 G04 F4
N150 STOPRE
N160 M0
N170 GOTOB Err1
N180 endif
N190; Magazine configuration
N200;
N210;

0BTool management
N220; Delete old data when magazine 1 is set up

N230 if NUM_MAG ==1
N240 $TC_MAP1[0]=0 ; Delete magazine
N250 $TC_DP1[0,0]=0 ; Delete Tools
N260 STOPRE
N270 endif
; Configuration
;
N280 $TC_MAMP2= PLACE_SEARCH ; Type of search strategy
;
; Magazine
; Set up magazine
N290 $TC_MAP1[NUM_MAG]= MAG_TYPE
N300 $TC_MAP2[NUM_MAG]="MAGAZINE"<<NUM_MAG
N310 if MAG_TYPE == 3
N320 $TC_MAP3[NUM_MAG]=81 ; Magazine status, all locations
fixed-location coded for revolver
magazine
N330 else
N340 $TC_MAP3[NUM_MAG]=17 ; Magazine status
N350 endif
N360 $TC_MAP4[NUM_MAG]=-1
N380 $TC_MAP6[NUM_MAG]=1 ; Number of lines in magazine
N390 $TC_MAP8[NUM_MAG]=0
N410 $TC_MAP7[NUM_MAG]=LOCATIONS ; Number of magazine locations
N420 $TC_MAP10[NUM_MAG]=PLACE_SEARCH
;
; Magazine locations
N430 for PLACE=1 to LOCATIONS
N440 STOPRE
N450 $TC_MPP1[NUM_MAG,PLACE]=1 ; Location type
N460 $TC_MPP2[NUM_MAG,PLACE]=0 ; Location type, 0 compatible with
every tool location type
N470 $TC_MPP3[NUM_MAG,PLACE]=1 ; Consider adjacent location On (Off
would be 0)
N480 $TC_MPP4[NUM_MAG,PLACE]=2 ; Location status
N490 $TC_MPP5[NUM_MAG,PLACE]=PLACE ; Location type index
N500 endfor
N510 STOPRE
;
N520; Definition of buffer magazine (always number 9998)
;
N530 $TC_MAP1[9998]=7 ; Magazine type 7: Buffer

Tool management
N540 $TC_MAP2[9998]="BUFFER"<<NUM_MAG
N550 $TC_MAP3[9998]=17 ; Magazine status
N560 $TC_MAP6[9998]=1 ; Number of lines
N570 $TC_MAP7[9998]=NUM_BUFFER ; Number of locations
;
; Locations in the buffer
;Spindle
N580 $TC_MPP1[9998,1]=2 ; Location type (here spindle)
N590 $TC_MPP2[9998,1]=0 ; Location type (here always 0)
N600 $TC_MPP3[9998,1]=0 ; Consider adjacent location Off
N610 $TC_MPP4[9998,1]=2 ; Location status
N620 $TC_MPP5[9998,1]=1 ; Location type index
;
N630; Gripper
N640 FOR PLACE=2 to NUM_BUFFER
N650 STOPRE
N660 $TC_MPP1[9998,PLACE]=3 ;(here gripper)
N670 $TC_MPP2[9998,PLACE]=0 ;(here always 0)
N680 $TC_MPP3[9998,PLACE]=0 ; Consider adjacent location Off
N690 $TC_MPP4[9998,PLACE]=2 ; Location status
N700 $TC_MPP5[9998,PLACE]=PLACE ; Location type index
N710 endfor
N720 STOPRE
;
;
N730; Definition of loading magazine (always number 9999)
;
N740 $TC_MAP1[9999]=9 ; Magazine type 9: Loading magazine
N750 $TC_MAP2[9999]="LOADING
MAGAZINE"<<NUM_MAG
N770 $TC_MAP4[9999]=-1
N780 $TC_MAP5[9999]=-1
N800 $TC_MAP7[9999]=NUM_LOAD ; Number of locations
N810 STOPRE;
;
N820; Loading magazine locations
;
N830 for PLACE=1 to NUM_LOAD
N840 STOPRE
N850 $TC_MPP1[9999,PLACE]=7 ; Location type Loading point
N860 $TC_MPP2[9999,PLACE]=0 ; Location type (here always 0)

0BTool management

N900 endfor
N910 STOPRE
;
;
N920; Offsets (clearances) ; Clearances to magazine
;
; Buffer
N930 for PLACE=1 to NUM_BUFFER
N940 $TC_MDP2[1,PLACE]=0
N950 endfor
N960 STOPRE
;
;Loading points
N980 stopre
N1000 endfor
N1010 M30 ; End

Tool management
Display in operating software
Figure 1-4 Turning machine tool list
Example: Acknowledgment steps (turning machine)
Acknowledgment steps
Generally, the mechanical sequences on a turning machine are simpler than those for a
milling machine. In the configuration described in the previous chapter without additional
buffer, tool changes can be acknowledged after the mechanical movements without transfer
steps. The PLC user program must detect incoming jobs in the job interfaces and execute
the mechanical movements.
Total acknowledgment to tool management:
step tool tool
-- DB4000.DBX0.0 -- -- (99)
-- DB4200.DBX0.0 -- -- (99)

0BTool management
Figure 1-5 Programming in PLC user program
An asynchronous message can be used for magazine movements without a job from the tool
management.
step tool tool
xxx DB4000.DBXx.x 101 0 204
Transfer step Source Objective Comment

Magazin Location Magazin Location
e e
101 1 n 9998 1 The variable location in Magazine
DB9901.DBW0 1 is positioned at the changing
point to the spindle.
n is the actual location number (n ≠ 0) to be entered by the PLC user program in the variable transfer
table.
Example: Tool change cycle for turning machine
Transfer variables
With MD10717: $MN_T_NO_FCT_CYCLE_NAME (name of cycle to be executed instead of
the T function, e.g. "TCHANGE"), you can set that a cycle is run when the T command is
called. The cycle is run through at every T call, irrespective of whether a new tool or the
already active tool is called. The position of the revolver can be set on the programmed tool
in this cycle (POSM). This is necessary when the revolver has been positioned manually
after a tool selection and the tool has not been deselected. In this case, the NC does not
issue a new job for tool change at the interface.
Sample program
Prerequisite is that the tool management has been informed of each magazine movement.
The example has been created for machine data with the turning technology default setting.
The "Spare tools for tool management" option is not active.
Transfer variables of the T replacement cycle:
Tag Description
$SC_T T number of the tool (numerical)
$SC_T_Prog Bool variable that shows whether a T word is available in $C_T.

Tool management
Tag Description
$C_TS Identifier for tool (string)
$C_TS_Prog Bool variable that shows whether an identifier is available in $C_TS.
$C_TE Address extension of the T word
$C_D Programmed D number
$C_D_Prog Bool variable that shows whether an offset number is available in $C_D.
$C_DL Programmed additive/setup offset
$C_DL_Prog Bool variable that shows whether an offset number is available in $C_DL.
In the following example, a job for positioning the magazine with POSM is output at the
interface. During the magazine positioning, the block processing of the NC must be
controlled by the PLC user program. In most cases, it is useful to set the load or feed disable
during this time. As soon as the position setpoint specified in the job is reached
(asynchronous message of the magazine position), the job is terminated with total
acknowledgment.
PROC L6 SAVE SBLOF DISPLOF

IF $C_T_PROG==1 ; T is numeric
IF $C_T==0 ; T=0
T=0
ENDIF
IF $C_T>0
IF $C_T<=$TC_MAP7[1] ; Does the magazine location exist?
POSM($C_T) ; Position magazine
ENDIF
T=$C_T ; T programming of location number
ENDIF
ENDIF
IF $C_TS_PROG==1 ; T is an identifier
_TNO_NEW=GETT($C_TS,1) ; Querying of T number
IF _TNO_NEW>0 ; Does the T number exist?
_TL_NEW=$A_MYMLN[_TNO_NEW] ; Querying of location number
ENDIF
IF _TL_NEW>0 ; Is the tool in the magazine?
POSM(_TL_NEW) ; Position magazine
ENDIF
T=$C_TS ; T programming without address extension
ENDIF
M17

0BTool management
See also
The function is available irrespective of tool management and is described in full in: Function
Manual, Basic Functions, "Mode Group, Channel, Program Operation, Reset Behavior (K1)."
Example: Turning machine with counterspindle
Magazine configuration
In the magazine configuration the magazine is assigned twice as many locations as actually
exist, e.g. in the case of revolver with 12 locations, 24 locations are set up. Location 1-12 for
the main spindle, location 13-24 for the counterspindle.
The user program positions the magazine in such a way that, for example, the same position
is approached for location 1 and location 13. So each real magazine location corresponds to
a virtual magazine location for the main spindle and a virtual magazine location for the
counterspindle.
Example: Test for empty buffer
Procedure
Read the T number of a tool in gripper 1 and 2:
1. In the PLC user program, enter the parameters in DB1200.
2. In DB1200.DBX0.0, set the start for reading the location states.
Once the order has been successfully executed, the results are entered starting from
DB1200.DBB3000:
Read variable from the Address Signal Values

NCK
Parameters DB1200.DBW1000 Variables index 9
DB1200.DBW1002 Location number 2
DB1200.DBW1004 Magazine number 9998
DB1201.DBW1000 Variables index 9
DB1201.DBW1002 Location number 3
DB1201.DBW1004 Magazine number 9998
Order DB1200.DBX0.1 Write variable 0
DB1200.DBX0.2 PI service 0
DB1200.DBB1 Number of variables 2
DB1200.DBX0.0 Start →1
Result DB1200.DBB2000.0 Order completed 1
DB1200.DBX2000.1 Error in order 0
DB1200.DBX3000.0 Variable is valid 1
DB1200.DBB3001 Access result 0

Tool management
Read variable from the Address Signal Values

NCK
DB1200.DBW3004 Data from NCK variable n
DB1201.DBX3000.0 Variable is valid 1
DB1201.DBB3001 Access result n
DB1201.DBW3004 Data from NCK variable 0
Example: Transporting a tool from a buffer into the magazine
Procedure
A tool is to be moved from a buffer (for example, of a gripper) into the magazine. The empty
location search for the tool from gripper 1 (magazine 9998, location 2) is executed with PI
Service TMMVTL and an order to relocate the tool is generated.
In the PLC user program, enter the parameters in DB1200, and in DB1200.DBX4000.0, set
the start to read the PI service.
Start PI Services in the Address Signal Values

NCK area
Parameter DB1200.DBW4004 Tool number 0
DB1200.DBW4006 Source location number 2
DB1200.DBW4008 Source magazine number 9998
DB1201.DBW4010 Target location number -1
DB1201.DBW4012 Target magazine number 1
Job DB1200.DBB4001 PI index 5
DB1200.DBX4000.0 Start →1
Result DB1200.DBB5000.0 Job completed 1
DB1200.DBX5000.1 Error in job 0
DB410x.DBX0.0 delivers an order to relocate the tool from the buffer. The target location in
magazine 1 is in DB4100.DBW12. With it, the PLC user program can execute the necessary
sequence.

0BTool management
Example: Repeat "Prepare tool change" order
Sequence: Repeat the command

For a milling machine with toolboy and shifter, the asynchronous transfer message and order
can cross:
● The toolboy was acknowledged to the tool management as the target position for the old
tool with the end acknowledgment.
● The part program is continued with the new tool and after a very short time needs the
previous (old) tool once more.
● The tool management generates the next preparation order for the tool change with the
toolboy as the source position for what will then be the new tool.
● At the same time the PLC user program transfered the tool from the toolboy into the
shifter.
● The PLC user progamm communicates the tool movement from the toolboy to the shifter
asynchronously and starts onward transport to the magazine.
● In the next cycle the AWP recognizes the new order to relocate the tool from the toolboy
to the spindle.
But the tool is no longer in the toolboy! The PLC user program must detect such a condition
(monitoring: does toolboy or shifter contain a tool?). It can now cancel the return of the tool
into the magazine. A repeat order (Status 7) can then be requested from the tool
management:
● Meanwhile, the tool management has received the message that the tool is in the shifter.
● It generates a new preparation order with the source position shifter for the new tool.
NOTICE
The acknowledgment to repeat the order "Prepare tool change" may only be issued
before the end acknowledgment of the "Prepare tool change" order!
step tool tool

Tool management
Application example for milling machine
Example: Milling machine with chain magazine and dual gripper

(MAGKONF_EXAMPLE_MPF)
Example file
You can find the program for configuring the magazine in the Toolbox.
The program can be read into the control and should be adjusted for the specific machine
concerned.
Configuration
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6SLQGOH

&KDQJLQJSRLQW

*ULSSHU

0DJD]LQHORDGLQJSRLQW
/RDGDQGXQORDG
PDJD]LQH
1 ... 11 Transfer steps

Figure 1-6 Milling machine with chain magazine

1 xx Real magazine (chain, plate, box), position xx
9998 1 Spindle
9998 2 Gripper 1
9998 3 Gripper 2
9999 1 Magazine loading point

0BTool management
Description of the program

To start with, all the old magazine definitions and tools are deleted. As the program
sequence continues, all magazines and buffers are newly created and assigned by writing
the magazine parameters.
Search strategies for tools and magazine locations can be selected in N70. Here it is
determined whether the tool can be placed directly in the new tool location, when changing
out of the spindle. This makes the tool change possible in a single mechanical sequence, so
shorter changeover times can be achieved. This sequence is not possible for pickup
magazines.
The chain magazine locations are set up from N430 to N500. Magazine location type = 0
means that the magazine location can be loaded with tools of different location types.
The buffers are set up from N520 onwards. If additional buffers are available (toolboy,
shifter...), the number should be changed in N50.
Additionally available loading points should be dealt with in the same way in N60.
From N920, the buffers are assigned to the spindle / tool holder and the magazine.
After the magazine configuration program has finished running, restart the NC (NCK reset).
See also
Further information:
● The configuration of a disk-type magazine with fixed-location coding is performed as for
the configuration of a revolver magazine: Example: Turning machine with revolver
magazine (MAGKONF_MPF) (Page 54)
● You will find a precise description of the parameters used in the Tool Management
Function Manual of SINUMERIK 840D sl.
Example MAG_CONF_MPF
1. Plant configuration:
– 1 chain magazine with 8 locations (can be set up in N40)
– 1 loading point
– 3 buffer locations (can be set up in N50, assignments from N540)
2. Part program:
;MAG_CONF_MPF
N10 def int NUM_MAG,MAG_TYPE, LOCATIONS,
PLACE, NUM_BUFFER, NUM_LOAD, PLACE_SEARCH
;
N20 NUM_MAG = 1 ;Number of the magazine
N30 MAG_TYPE = 1 ;Magazine type (1: chain,
3: revolver, 5: box magazine)
N40 LOCATIONS = 8 ;Number of magazine locations
N50 NUM_BUFFER = 3 ;Number of buffers (spindle,
gripper)

Tool management
N60 NUM_LOAD = 1 ; Number of loading points

N70 PLACE_SEARCH = 12289 ; Type of search strategy
;= 257 Bit13=0 no exchange of the old tool on the location of the new tool
;Setting for pickup magazine
;=12289 Bit13=1 exchange old tool on the location of the new tool
;Setting for chain magazine
N80;
N90;
;Check parameters
N100 STOPRE
N110 if ((NUM_MAG==0)or(LOCATIONS==0))
N120 Err1:STOPRE
N130 MSG("Wrong Parameter --> Cancel")
N140 G04 F4
N150 STOPRE
N160 M0
N170 GOTOB Err1
N180 endif
N190; Magazine configuration
N200;
N210;
N220; Delete old data when magazine 1 is set up
N230 if NUM_MAG ==1
N240 $TC_MAP1[0]=0 ; Delete magazine
N250 $TC_DP1[0,0]=0 ; Delete Tools
N260 STOPRE
N270 endif
; Configuration
;
N280 $TC_MAMP2= PLACE_SEARCH ; Type of search strategy
;
; Magazine
; Set up magazine
N290 $TC_MAP1[NUM_MAG]= MAG_TYPE
N300 $TC_MAP2[NUM_MAG]="MAGAZINE"<<NUM_MAG
N310 if MAG_TYPE == 3
N320 $TC_MAP3[NUM_MAG]=81 ; Magazine status, all locations
fixed-location coded for revolver
magazine
N330 else
N340 $TC_MAP3[NUM_MAG]=17 ; Magazine status
N350 endif

0BTool management
N380 $TC_MAP6[NUM_MAG]=1 ; Number of lines in magazine

N410 $TC_MAP7[NUM_MAG]=LOCATIONS ; Number of magazine locations
N420 $TC_MAP10[NUM_MAG]=PLACE_SEARCH
;
; Magazine locations
N430 for PLACE=1 to LOCATIONS
N440 STOPRE
N450 $TC_MPP1[NUM_MAG,PLACE]=1 ; Location type
N460 $TC_MPP2[NUM_MAG,PLACE]=0 ; Location type, 0 compatible with
every tool location type
N470 $TC_MPP3[NUM_MAG,PLACE]=1 ; Consider adjacent location On (Off
would be 0)
N480 $TC_MPP4[NUM_MAG,PLACE]=2 ; Location status
N490 $TC_MPP5[NUM_MAG,PLACE]=PLACE ; Location type index
N500 endfor
N510 STOPRE
;
N520; Definition of buffer magazine (always number 9998)
;
N530 $TC_MAP1[9998]=7 ; Magazine type 7: Buffer
N540 $TC_MAP2[9998]="BUFFER"<<NUM_MAG
N570 $TC_MAP7[9998]=NUM_BUFFER ; Number of locations
;
; Locations in the buffer
;Spindle
N580 $TC_MPP1[9998,1]=2 ; Location type (here spindle)
N590 $TC_MPP2[9998,1]=0 ; Location type (here always 0)
N600 $TC_MPP3[9998,1]=0 ; Consider adjacent location Off
N610 $TC_MPP4[9998,1]=2 ; Location status
N620 $TC_MPP5[9998,1]=1 ; Location type index
;
N630; Gripper
N640 FOR PLACE=2 to NUM_BUFFER
N650 STOPRE
N660 $TC_MPP1[9998,PLACE]=3 ;(here gripper)
N670 $TC_MPP2[9998,PLACE]=0 ;(here always 0)
N710 endfor

Tool management
N720 STOPRE
;
;
N730; Definition of loading magazine (always number 9999)
;
N740 $TC_MAP1[9999]=9 ; Magazine type 9: Loading magazine
N750 $TC_MAP2[9999]="LOADING
MAGAZINE"<<NUM_MAG
N770 $TC_MAP4[9999]=-1
N780 $TC_MAP5[9999]=-1
N800 $TC_MAP7[9999]=NUM_LOAD ; Number of locations
N810 STOPRE;
;
N820; Loading magazine locations
;
N840 STOPRE
N850 $TC_MPP1[9999,PLACE]=7 ; Location type Loading point
N860 $TC_MPP2[9999,PLACE]=0 ; Location type (here always 0)
N900 endfor
N910 STOPRE
;
;
N920; Offsets (clearances) ; Clearances to magazine
;
; Buffer
N930 for PLACE=1 to NUM_BUFFER
N950 endfor
N960 STOPRE
;
;Loading points
N980 stopre
N1000 endfor
N1010 M30 ; End

0BTool management
Display in operating software
Figure 1-7 Tool list Milling machine
Flow chart: Tool change
Tool change program sequence (PLC)

The sequence described here describes the change between magazine and spindle. The
changing of manual tools as well as loading and unloading are not taken into account.
Both procedures are described in Chapter:
The machine data default setting is selected such that the job for "Prepare tool change" is
triggered with the T command on the interface:
N10 T = "Tool name" M6
The block preprocessing is not interrupted. M6 is used to start the tool change subprogram
(L6) at the same time. As soon as the job for "Prepare tool change" has been acknowledged
and in the tool change subprogram the M code for tool change output has been reached, the
"Execute tool change" job is output to the interface (block splitting).
A tool change command (M206) must always precede a prepare tool change command. A
change command without a previous "Prepare tool change" job will not initiate a job from the
tool management.

Tool management
You will find the expression 1:1 change in the program sequence. This means that the tool
change will be carried out in a single cycle. The tool from the spindle (old tool) will be set
down at the magazine location of the new tool. No additional magazine positioning is
required. In this case, the target location of the old tool in the tool management job is the
same as the source location of the new tool (DB43xx.DBW6 and DBW8 are equal to DBW18
and DBW20).
A 1:1 change is not possible for:
● Tools with different location types
● Different tool sizes
● Fixed-location tools
By programming T0 in the NC program, a tool change is initiated without a new tool. Only the
spindle tool is transported to the magazine (empty the spindle).
① ... ⑭ refer to the steps in the flow chart below.
You can see the different acknowledgment options from the steps. Job-related
acknowledgments and asynchronous messages are used.
Please take the transfer steps used from the table in Chapter Example: Acknowledgment
steps (milling machine) (Page 79)

0BTool management
"Tool change" flow chart
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1: 1 change: The old tool is deposited in the location of the new tool.
Figure 1-8 Flow Diagram

Tool management
Description of the Procedure

● NC program:
T command or T command with simultaneous tool change call (M6)
● Interface signals:
Job from TM: DB43xx.DBX0.0 (job bit) and
DB43xx.DBB1 (command bits): Prepare change (DB43xx.DBX1.2)
● Magazine and location number of the tools to be moved:
DB43xx.DBW6 to DBW20: Source location of the new tool, target location of the old tool
Step 1 Change requested

Request: Source location of the new tool == Target location of the old tool, Normal case:
There is a tool in the tool holder and a new tool is being requested. Both tools have the same
location type and the same tool size in the magazine list, the tools are not fixed-location
coded.
The old tool is set down on the magazine location of the new tool, in a direct exchange (1:1
change). If there is no old tool in the tool holder (DB4300.DBX1.4), the same sequence takes
place. In this case, the magazine positions the new tool to the changing point.
→ continue with Step 2
Request: Source location of new tool >< Target location of old tool, Special cases:
The TM is informed by DB43xx.DBX1.3 whether the active tool from the tool holder should
be removed (T0). In this case, the magazine positions the storage location of the old tool
(that is currently in the spindle) to the changing point.
The magazine location for the old tool is also positioned to the changing point if the old tool
cannot be stored on the new tool location (1:1 change not possible). The cause could be
different location types or tool sizes, or that a fixed-location coded tool is involved. In this
case, the tool change is carried out in two steps. First the old tool in the magazine is set
down and then the new tool is transported to the spindle.
Step 2: Position magazine, location from new tool to changing point.

← Previous step: Step 1
For example, the magazine movement can be executed via an NC rotary axis controlled by a
PLC. The movement should be notified to the tool management. The magazine position is
thus updated at the user interface, in the views of the tool and magazine lists.
The target position is read from DB4300.DBW8 (location number for new tool – source) and
written to DB9901.DBW2 (transfer step 101). If there is magazine coincidence at the target
position, the step is acknowledged asynchronously:
Acknowledg Acknowledgment bit Transfer step new Transfer step old Status
ment step tool tool
4 DB4200.DBX0.4 101 0 204

0BTool management
Acknowledgment to TM:

on on
101 1 n 9998 1 The variable location in magazine 1
DB9901.DBW0 is positioned at the changing point to
the spindle.
n: is here the actual location number (n ≠ 0) to be entered by the PLC user program in the variable
transfer table.
Step 3: Positioning the magazine; location from the old tool to the changing point.
Same as Step 2, however, the magazine target location is obtained from DB4300.DBW20
(location number for old tool - target).
ment step tool tool
4 DB4200.DBX0.4 101 0 204
Transfer step from to Comment

on on
the spindle.
transfer table.
Step 4: Acknowledge prepare tool change job

← Previous step: Step 2 or Step 3
With this, the preparation for the tool change is complete for many systems.
ment step tool tool
1 DB4200.DBX0.1 0 0 1

Tool management

● NC program:
M206 initiates the job for execute tool change
● Interface signals:
Job from TM: DB43xx.DBX0.0 (job bit)
DB43xx.DBB1 (command bits): Execute change (DB43xx.DBX1.1)
● Magazine and location number of the tools to be moved:
DB43xx.DBW6 to DBW20: Source location of the new tool, target location of the old tool
Step 5 change requested

← Previous step: No previous step, entry point in the sequence for "Execute tool change" job
Similarly to Step 1, it is checked whether a direct change or a change in two steps is to be
executed:
● 1:1 change possible: → continue with Step 6
● 1:1 change not possible: → continue with Step 9
Step 6: Old tool from the spindle to gripper 2 and new tool from the magazine to gripper 1
The PLC program controls the machine functions with which the gripper movements, tool
clamping, etc. are performed. As soon as the mechanical movements are completed and
acknowledged in the PLC user program, the tool movements are acknowledged to the tool
management.
ment step tool tool
5 DB4200.DBX0.5 1 2 105

on on
1 0 1 9998 2 New tool from magazine to gripper 1
DB9900.DBW0 Step 6 or Step 13
2 9998 1 9998 3 Old tool from spindle to gripper 2
→ continue with Step 7.

0BTool management
Step 7: Old tool from gripper 2 to magazine and new tool from gripper 1 to spindle
The PLC program controls the machine functions for the gripper movements, tool clamping,
etc. As soon as the mechanical movements are completed and acknowledged in the PLC
user program, the tool movements are acknowledged to the tool management.
Acknowledgm Acknowledgment bit Transfer step new Transfer step old Status
ent step tool tool
7 DB4200.DBX0.7 3 4 105

on on
4 9998 3 0 2 Old tool from gripper 2 to magazine
Step 8: End acknowledgment

← Previous step: Step 7 or Step 14
End acknowledgment takes place with tool changeover in the initial setting, or in a state
where the machine can continue machining. Here it is possible that there are still mechanical
movements to be executed before the tool change can be completed.
ent step tool tool
1 DB4200.DBX0.1 0 0 1
Step 9: Old tool from spindle to gripper 2

management.

Tool management
ent step tool tool
8 DB4200.DBX1.0 0 2 105

on on
2 9998 1 9998 3 Old tool from spindle to gripper 2
Step 10: Old tool from gripper 2 to magazine

management.
ent step tool tool
9 DB4200.DBX1.1 0 4 105

on on
4 9998 3 0 2 Old tool from gripper 2 to magazine
Step 11: T0 ?
Request: Is T0 set in the tool change job?
DB43xx.DBX1.3
If only the tool holder should be emptied, the tool change can be completed:

0BTool management

Do you want to place a new tool in the tool holder?
Step 12: Magazine position location from new tool to changing point
Sequence as in Step 2
ment step tool tool
4 DB4200.DBX0.4 101 0 204

on on
the spindle.
transfer table.
Step 13: New tool from magazine to gripper 1

The PLC program controls the machine functions used to execute gripper movements, tool
clamping etc.
ent step tool tool
10 DB4200.DBX1.2 1 0 105

on on
1 0 1 9998 2 New tool from magazine to gripper 1

Tool management
Step 14: New tool from gripper 1 to spindle

The PLC user program controls the machine functions with which the gripper movements,
tool clamping, etc. are performed. As soon as the mechanical movements are completed
and acknowledged in the PLC user program, the tool movements are acknowledged to the
tool management.
The tool change can be ended:
ent step tool tool
11 DB4200.DBX1.3 3 0 105

on on
Example: Acknowledgment steps (milling machine)
Constant transfer step table

on on
1 0 1 9998 2 New tool from magazine to gripper
DB9900.DBW0 1
Step ⑥ or ⑬
2 9998 9998 3
DB9900.DBW8 Step ⑥ or ⑨
3 9998 9998 1
DB9900.DBW16 Step ⑦ or ⑩
4 9998 3 0 2
DB9900.DBW24 Step ⑦ or ⑭

0BTool management

on on
5 0 2 9998 1 Storage location of the old tool
DB9900.DBW32
6 0 1 9998 1 Magazine location with the new tool
DB9900.DBW40 to the changing point
Step ② or ⑫
7 -- -- -- --
DB9900.DBW48
Variable transfer step table

on on
101 1 n 9998 1 The variable location in Magazine 1
DB9901.DBW0 is positioned at the changing point
to the spindle.
102 -- -- -- --
DB9901.DBW8
n : here is the actual location number (n ≠ 0) to be entered by the PLC user program in the variable
transfer table.
Acknowledgment step table
Acknowledgment Transfer step Acknowledgm Comment

step ent status
Old tool New tool
1 0 0 1 End acknowledgment,
DB9902.DBW0 Step ④ and ⑧
2 0 0 3 Cancel order
DB9902.DBW4
3 0 0 105 Intermediate acknowledgment
DB9902.DBW8 for subsequent order, Step ④
4 101 0 204 Variable magazine location to
DB9902.DBW12 changing point
DB9902.DBW16 Step ⑥
DB9902.DBW20 Step ③
DB9902.DBW24 Step ⑦

Tool management
Acknowledgment Transfer step Acknowledgm Comment

step ent status
Old tool New tool
DB9902.DBW28 Step ⑨
DB9902.DBW32 Step ⑩
DB9902.DBW36 Step ⑬
DB9902.DBW40 Step ⑭
12 -- -- --
DB9902.DBW44
Note: The step numbers ① ... ⑭ refer to the flow chart in Chapter Flow chart: Tool change
(Page 70)
Example: Tool change cycle for milling machine
Sample program
PROC L6 SAVE DISPLOF

;----------------------------------------------------------------
; Example of a tool change cycle for machine manufacturers
;----------------------------------------------------------------
DEF INT _WZ_IN_SP,_WZ_VOR
DEF REAL _SPP= ... ; spindle position
;
IF(NOT $P_SEARCH) ; if no block search
_WZ_IN_SP=$TC_MPP6[9998,1] ; tool in spindle
GETSELT(_WZ_VOR) ; previously selected tool
;
IF(_WZ_IN_SP<>_WZ_VOR) ; if another tool
SPOS=_SPP ; position spindle
G0 ; approach tool change position:
G75 Z=0
WAITS(1)
ENDIF
ELSE
ENDIF
;
; Load tool: Tool management and PLC
M206

0BTool management
M17
;----------------------------------------------------------------
; END
;----------------------------------------------------------------

B009 Easy Extend
Module Description:
Easy extend is a system which gives the seller of the machine a mechanism to enable the hardware
options which are offered by the machine tool builder, without the necessity for service intervention.
A machine option could typically be a:
 Tailstock
 Parts catcher
 Barfeed
 Coolant filter
Module Objective:
Upon completion of this module you will be able write Easy extend scripts to enable and activate
machine builder options.
Content:
Sinumerik
General Information and Concept

Creating XML scripts
User PLC Program
Enabling and Testing Devices
Example of XML Scripts
Creating and Restoring Rollback Archives
Additional Axis
Addressing of variables.
General Tag Descriptions
Tag Descriptions - Dialogue Screens
B009
B009

Easy Extend B009
Easy Extend: Discription
Easy extend is a system which gives the seller of the Easy Extend:
START
machine a mechanism to enable the hardware options Tag
which are offered by the machine tool builder, without Descriptions:
the necessity for service intervention. Dialogue
Screens
A machine option could typically be a: General
Information
and Concept
 Tailstock
Easy Extend:
 Parts catcher END
 Barfeed
 Coolant filter
Creating
XML scripts
User PLC
Program
Enabling and
Testing
Devices
Creating and
Restoring a
“rollback“
archive
Additional
Axis
Addressing
of Variables
General Tag
Descriptions
Notes :

B009 Easy Extend
General Information
 Each OEM option is assigned to an Easy Extend device.

 A maximum of 64 devices can be configured.
 The dealer can enable activate an option when it is purchased.
XML Files
Easy Extend uses Extended Mark-up Language.
The agm.xml file is the main file and entry point for Easy Extend.
All Easy Extend devices originate from the agm.xml file, this can include calls to other xml files to simplify the programming
structure.
The XML language used in the 828D is none standard and has been extended to allow the following data processing and high-
level language elements:-
 Archiving of NC/PLC data

 Reading and writing of NC/PLC/Drive data
 Conditional jumps within an xml block
 Execution of program loops
 Execution of arithmetic operations
 Creation of local variables
 Loading/creating archives
 Displaying messages
User PLC
Data Block EE_IFC (DB9905) is located in the PLC828D library and has to be integrated into the OEM´s PLC project.
Interface signals for activating and deactivating devices are to be found in the Data Block.
A user Data Block is required for password protecting devices.
Device Enabling
Devices first need to be enabled, this can be done using one of two methods.
Enabling by PLC variable: A PLC variable is declared in the agm.xml file, the status of the variable is checked. This method is
used if the device is to be password protected.
Enabling by machine data: A user machine data is declared in the agm.xml file. If the corresponding bit of the machine data is
set the device will be enabled.
Device Activation
Once a device has been enabled it can be activated. Activation is done with a soft-key on the Easy Extend screen and with PLC
interface signals for acknowledgement.
Toolbox Examples
The 828D toolbox supplied with the controller contains various Easy Extend and PLC project examples which can be used to
supplement the information supplied in this module.
Notes :

Easy Extend B009
Easy extend Concept
Notes :

B009 Easy Extend
An example of the Easy Extend screen from an actual machine showing some of the types of options which can be handled us-
ing the Easy Extend function.
Possible sequence to follow in order to use a builder option.
ENABLE Device - with or without Password
STARTUP Device - 1st Startup of Device. With or without input parameters
ACTIVATE Device - To enable device useage
DEACTIVATE Device - To remove device
Notes :

Easy Extend B009
Creating XML Scripts
A unique file named “agm.xml” is required for Easy Extend.

Type in the name-”agm.xml” (Lower case!) and confirm with
This file has to be created by the user.
the “OK” soft-key.
It is possible to configure all devices within the “agm.xml’. It is
also possible to use separate xml files for each individual de-
vice. These files are called from within the agm.xml file.
The xml files use tags, which are required for code execution.
Each tag performs a specific function.
Executing script is written between tags, the script is written

after the “open tag” and finishes at the “Close tag”.
Example:
<name of tag> “open tag”
Enter script in here Editing agm files using RCS Commander
</name of tag> “close tag with / slash”
It is often more convenient to create and edit files remotely.
Short Version <name of tag...Enter script in here…/> Editing the XML files offline and transferring them to the con-
troller is possible using RCS commander.
The agm tag is the root element of the agm.xml.
All other tags are written inside this tag. Start RCS commander:
Creation of the xml files can be done directly on the controller

or indirectly using RCS commander or suitable editing program
such as Notepad (r)
Advanced xml editing software programmes are also commer-
cially available.
The required directory is found under the following path:

System CF card\oem\sinumerik\hmi\dvm Locate the “dvm” folder .
Use the following soft-key sequence to locate the system data

area of the controller
Notes :

B009 Easy Extend
The following example shows how to configure Easy Extend The individual xml files for each device should be placed in the
Device 1 using the agm.xml file and a separate file for the de- same directory as the agm.xml file.
vice itself.
Example: Password_test.xml (Blue text for information only;
Rather than have one file containing the code for many green text to be typed into the “password_test.xml”) :
devices, it makes sense to have one file for each device.
These separate files can then be called from within the <DEVICE> Open the DEVICE tag
agm.xml file. <list_id> 1 </list_id> Device number e.g. 1
<name> "Password Test" </name> Device name
The device is assigned the name off “Test Password” and will <password refvar = "plc/db9030.dbd4" />
be enabled via the PLC with a user defined password.
password_refvar tag:
Example of an agm.xml file with “include src” command (Blue The password entered on the Easy Extend screen
text for information only; orange text to be typed into the will be stored here i.e. DB9030.DBD4
“agm.xml”):
</DEVICE> Close the DEVICE tag
<!Example agm.xml for Password test>
<!Data block 9030 is required in the user PLC program/> Power the controller off/on to activate the xml files
<AGM> Open the AGM tag

Below-The Password_test.xml file without descriptions:
<OPTION_MD name = "plc/db9030.dbw0" index="0" />
<DEVICE>
<!OPTION_MD name = "plc/db9030.dbw2" index="1" />
<list_id> 1 </list_id>
<name> "Password Test" </name>
<password refvar = "plc/db9030.dbd4" />
</DEVICE>
OPTION_MD tag:
Declaring the PLC variable for enabling the
devices in user DB9030.
Index 0 - Devices 1 to 16 Bits 0 - 15
Index 1 - Devices 17 to 32 “ 0 - 15
<?include src= "Password_test.xml" ?>
“Include src” tag:

Call to the individual device xml files eg
“Password_test.xml”
</AGM> Close the AGM tag
Below- The agm.xml file without descriptions:
<!Password example for device 1/>

<!Data block 9030 is required in the user PLC program/>
<AGM>

<?include src= "Password_test.xml" ?>
</AGM>
Notes :

Easy Extend B009
User PLC Program The Data Block will now appear in the Data Block folder of the
project. Other Data Blocks may also be present.
Adding system data block DB9905 to the user PLC
For “Easy Extend” to work a system Data Block (DB9905) is

required. The Data Block is found in the Library of the Pro-
gramming Tool and is used for the communication between
PLC and the HMI.
Data Block in the library of the PLC828 programming tool:
By double clicking the DB, the contents can be viewed. Up to

64 devices can be handled by the DB. A set of signals are
assigned to each device which are to be used in the user PLC
for activating, deactivating and device status.
User PLC requirements
The example will require a user Data Block (DB9030) to be cre-

ated so that the defined and entered passwords can be compared.
The DB to be used is defined in the xml file with the “password
refvar” tag. It is also possible to use the same DB to signal the
Double clicking the DB will open up the properties and allow HMI that the device is enabled. This is determined by the
the Data Class to be selected, also the author can enter “OPTION_MD” tag.
details if required.
Right click on the Data Block folder and select “Insert Data Block”.
Select the “OK” button:
Enter a suitable name and select the required Data Block

number. Select “OK” to confirm.
The Data Block will now appear in the Data Block folder of the
project. Other Data Blocks may also be present.
Notes :

B009 Easy Extend
The user DB will require certain information to be entered depending on the number of devices in use.
The following PLC example can be used for enabling and activating devices using the PLC interface signals and the previously
created user Data Block.
Defining the required password as 123456
Comparing the password entered by the

user with the defined password.
If true the enable signal is then set.
Fault reset on first power on.
Password reset on deactivation of the device.
Notes :

Easy Extend B009
Enabling and Testing Devices
Device Enabling
Inputting the password:
To input the password, first locate the “Easy Extend” screen The device will now be enabled, this is indicated by a green
via the following soft-key selection. tick in the “Function” column.
The device created in the AGM file will be listed.
To enable the device select the “Enable function” soft-key.
The password (123456)needs to be entered.
Notes :

B009 Easy Extend
The device is enabled but it is not operational until it is activated. This is achieved by pressing the “Activate” button.
A green tick symbol will appear in the “Activated” column to confirm this.
When the activation is successful the “Activate” interface signal will be high for one PLC cycle. This should be used in the PLC
logic to set the “Activated” interface signal.
Defining the required

password:123456
Device enabled:
Entered password matches required
password, enable signal is then set.
Device activated:
Activation interface signal is set.
When the “Deactivate” soft-key is pressed the “Deactivate” interface signal is high for one PLC cycle. This should be used in the
PLC logic to reset the “Activate” signal
Device disabled:
Password no longer matches, enable signal = 0
Activation interface
signal is reset
Password is reset to zero by deactivate

interface signal
Notes :

Easy Extend B009
Message Box Test:
The agm.xml file has to be modified to include the new file:
<AGM>

<?include src= "MessageBox_test.xml" ?>


</AGM>
The “Set_Active” tag:
The script within the Set_Active tag is run when the “Activate” soft-key is pressed. Likewise, the “Deactivate” soft-key runs the
script included in the Set_Inactive tag.
“MessageBox_test.xml”
<DEVICE>
<list_id>1</list_id>
<name> "Message box" </name>
<SET_ACTIVE>
<LET name = "var_return"> 0</LET>
<MSGBOX text="Activate Option 1. %n Press OK" caption="Activation of Option" retvalue="var_return" type="BTN_OK" />
</SET_ACTIVE>
<SET_INACTIVE>
<LET name = "var_return"> 0 </LET>

<MSGBOX text="Deactivate Option 1. %n Press OK" caption="Deactivation of Option" retvalue="var_return" type="BTN_OK" />
</SET_INACTIVE>
</DEVICE>
Message Box Attributes:
text - The text to be displayed in the message box. Using the characters “%n” results in a new line.
caption - The header of the text box.
retvalue - Defines the variable where the return value is copied. (Return values– OK = 1, CANCEL = 0.)
type - Acknowledgement possibilities:

“BTN_OK” - OK button.
“BTN_CANCEL - CANCEL button.
“BTN_OKCANCEL” - OK & CANCEL buttons
Notes :

B009 Easy Extend
When the “Activate” soft-key is pressed a message box will appear containing the specified text. To activate the device select the
“OK” soft-key. The device will then be activated in the usual way.
Notes :

Easy Extend B009
Switching on an output using the “Write_PLC_output.xml”
Modify the agm.xml to include the new file:- <?include src= "Write_PLC_output.xml" ?>
Create the device file containing the function for switching a PLC output. This example has also been configured with a cancel
soft-key. The functions IF, THEN & ELSE are used to evaluate whether the OK or Cancel key was pressed. If the cancel key is
pressed the system variable “$actionresult” is set to 0. This interrupts the processing of the function.
<DEVICE>
<name> "Write PLC output" </name>
<SET_ACTIVE>
<MSGBOX text="Activate Option 1 %n Press OK%n%nAbort press Cancel" caption="Activation of Option" retvalue="var_return" type="BTN_OKCANCEL" />
<IF>
<condition> var_return==1 </condition>
<THEN>
<DATA name = "PLC/Q4.7"> 1</DATA>
</THEN>
<ELSE>
<OP>"$actionresult" = 0</OP>
</ELSE>
</IF>
</SET_ACTIVE>
<SET_INACTIVE>
<MSGBOX text="Deactivate Option 1 %n Press OK%n%nAbort press Cancel" caption="Deactivation of Option" retvalue="var_return" type="BTN_OKCANCEL"/>
<IF>
<THEN>
<DATA name = "PLC/Q4.7"> 0</DATA>
</THEN>
<ELSE>
<OP> "$actionresult" = 0 </OP>
</ELSE>
</IF>
</SET_INACTIVE>
</DEVICE>
When the device is activated the option to cancel is now available:
Notes :

B009 Easy Extend
The Test Tag

This tag is used to check that the requested actions have been successfully achieved. In the example below the test tag has been
used to check that the output Q4.7 is set to one.
<DEVICE>
<name> "Write PLC output" </name>

<SET_ACTIVE>
<MSGBOX text="Activate Option 1 %n Press OK%n%nAbort press Cancel" caption="Activation of Option" retvalue="var_return" type="BTN_OKCANCEL" />
<IF>
<THEN>
<DATA name = "PLC/Q4.7"> 1 </DATA>
</THEN>
<ELSE>
<OP>"$actionresult" = 0</OP>
</ELSE>
</IF>
</SET_ACTIVE>
<SET_INACTIVE>
<MSGBOX text="Deactivate Option 1 %n Press OK%n%nAbort press Cancel" caption="Deactivation of Option" retvalue="var_return" type="BTN_OKCANCEL"/>
<IF>
<THEN>
<DATA name = "PLC/Q4.7"> 0 </DATA>
</THEN>
<ELSE>
<OP> "$actionresult" = 0 </OP>
</ELSE>
</IF>
</SET_INACTIVE>
<TEST>
<IF>
<condition>
<"PLC/Q4.7" == 1 The condition of Q4.7 is
</condition> checked for a value of 1
<THEN>
<op> "$actionresult" = 1 </op> If the above condition is true, a value of 1 is
</THEN> written to the system variable $actionresult
<ELSE>
<op> "$actionresult" = 0 </op>
If the condition is false, a value of 0 is written
</ELSE>
</IF> to system variable $actionresult
</TEST>
</DEVICE>
To run the Test function first enter the “Start up” area of the Easy Extend area. The “Function test device” soft-key should be pressed
to initiate the test. A dialogue box will display the result of the test.
Q4.7 = 1 Q4.7 = 0
Notes :

Easy Extend B009
The Form Tag
One custom screen can be defined for each device, this is done using the form tag. The custom screen can include texts and
bitmaps. Input fields can be linked to machine variables allowing the operator to set machine parameters.
The “Addition. parameter” soft-key is reserved for the instructions contained in the Form tag.
Within the Form tag the following tags can be utilised:-
LET
INIT
PAINT
TIMER
CLOSE
CAPTION
SOFTKEY_OK
SOFTKEY_CANCEL
Creating the picture_test.xml:
The following example shows how a bitmap is selected and positioned on the screen:
The bitmap has to be placed in the same folder as the agm.xml file.
<DEVICE>
<password refvar="plc/db9030.dbd4"></password>
<name> "Picture Test" </name>
<FORM>
<init>
<caption>Easy Extend Picture Test</caption>
</init>
<paint>
<img xpos = "155" ypos = "90" name = "tiger.bmp" height="250" width="250"/>
</paint>
</FORM>
</DEVICE>
The script will result in a device named “Picture Test”

When the device is enabled and the “Addition. parameter” soft-key is selected, the “tiger.bmp” picture will appear on the screen in
the position specified by the IMG tag. The caption “Easy Extend Picture Test” will be displayed in the title bar.
Notes :

B009 Easy Extend
System variables
The following examples shows how R parameters can be used:
<DEVICE>
<name> "Picture Test" </name>
<FORM>
<init>
<caption>Easy Extend Picture Test</caption>
<control name = "r_param_0" xpos = "100" ypos = "30" refVar = "nck/channel/parameter/r[0]" />
</init>
<paint>
<text xpos = "40" ypos = "30">R0</text>
<img xpos = "190" ypos = "120" name = "tiger.bmp" height="180" width="180"/>
</paint>
</FORM>
</DEVICE>
Notes :

Easy Extend B009
The following screen shows the R parameters and the resized These values can be checked in the “User variable” area.
image.
The values are written to the variables when the “OK” soft-key
is pressed or can be set to be immediately written.
For information on this see the “Hotlink” element under the
“Control” tag description.
It is possible to write to other system variables, addressing

these variables is described in Section 9.
Values can be typed directly on the Easy Extend screen and

confirmed with the “OK” soft-key.
Creating and Restoring a “Rollback” Archive
It is possible to create a complete NC/PLC/Drives/HMI archive

from within Easy Extend\IBN Start up area. This is achieved by
selecting the “Start-up” soft-key.
The fixed name for the archive is “rollback.arc”.
If an error occurs while initialising a device, the “rollback”
archive can be used to return the controller to its original
status.
The “Start-up” soft-key is only available if the “START_UP” tag
is used within each individual device.
The “START_UP” tag does not need to contain any instruc-
tions.
Example:
The “Undo” and “Repetition” soft-keys are available to switch
each single entry between its new and original value. <DEVICE>
<name> "Archives" </name>
<START_UP>
</START_UP>
</DEVICE>
The “Last configuration” soft-key is available to restore all the
entries to their original values.
Notes :

B009 Easy Extend
To create the archive: Restoring a “Rollback” archive
The archive is created with the following soft-keys In the event that the previously created archive needs to be
restored, the “Restore” soft-key can be selected and the dia-
logue box acknowledged.
Acknowledge the confirmation box with the “OK” soft-key.
An archive file with the name of “Rollback.arc” will now be

created and stored in the “dvm_rb” folder.
The dialogue box will clear when the read-in is complete.
When the archive has been created the following dialogue box
will be displayed, the device will be activated when the „OK“
soft-key is selected.
Notes :

Easy Extend B009
Additional Axis
Activating and deactivating axes

To activate/de-activate the axis in the NC part of the system,
A common requirement is for an extra axis to be added. channel machine data
A machine can be initially commissioned to include all axis “20070 MC_AXCONF_MACHAX_USED” is used.
possibilities. The optional axis can then be deactivated until The additional axis is the 5th axis therefore a value of 5 or 0 is
required. entered into 20070[4] to activate/deactivate.
Note: When changing certain types of drive parameter it is
necessary to disable the drives.
An example of how axis number five is activated/deactivated is

shown below :
<refvar="plc/db9030.dbd4"></password>
<SET_ACTIVE>DEVICE>
<name> "switch drive active" </name> Drive parameter “P971Save drive object parameters” is set to
<password 1 to save the drive Parameters. When the data has been
<data name = "drive/dc/p105[DO5]">1</data> saved the parameter automatically reverts to a value of 0.
<data name = "$MC_AXCONF_MACHAX_USED[4]">5</data>
<data name = "drive/dc/p971[DO5]">1</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_ACTIVE>
<SET_INACTIVE>
<data name = "$MC_AXCONF_MACHAX_USED[4]">0</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/> The deactivated axis does not The deactivated axis does not
</SET_INACTIVE> appear on the machine page: appear on the machine page:
After activation/deactivation, the system waits for drive

parameter “p971 Save drive objects parameters” to become
zero (condition), an NC and drive reset is then carried out to
activate the changed machine data.
As can be seen in the example xml file, the drive parameter-

“P105 Activate/deactivate drive object” is responsible for
activating/de-activating the drive part of the system.
Notes :

B009 Easy Extend
Addressing of Variables
Machine and Setting Data
The $ character must be used before the name of the data.
Machine data addresses:
$MX_<Name[index, AXyy]>
MN - General machine data

MC - Channel machine data
MA - Axis machine data
Setting data addresses:
$SX_<Name[index, AXyy]>
SN - General setting data

SC - Channel setting data
SA - Axis setting data
Index - Specifies the index number of the variable.

AXyy - Specifies the axis number in the case of axis specific data.
The axis index number can also be read from a local variable:
Example:-
Axis index with the index number obtained from the variable called “axis”. This would be written as AX$axis.
Examples:-
<data name=“$MN_AXCONF_MACHAX_NAME_TAB[0]”>X1</data> Writing a value of X1 to general machine data
$MN_AXCONF_MACHAX_NAME_TAB[0]
<data name=“$MA_CTRLOUT_MODULE_NR[0, AX1]”>1</data> Writing a value of 1 to axis1 machine data

$MA_CTRLOUT_MODULE_NR, index 0.
Indirect addressing:-
<let name=“axisindex”>1</let> Declaring a temporary variable called “axisindex” and setting the value to 1.
<data name=“$MA_CTRLOUT_MODULE_NR[0, AX$axisindex]”>1</data> Using the temporary variable to determine the axis
index number and writing a value of 1 into axis1 machine data $MA_CTRLOUT_MODULE_NR, index 0.
Addressing user data
The GUD path is first specified followed by the specific area. If a field is to be used, this follows next and is contained in square
brackets.
The following GUDS can be addressed:-

SGUD Siemens GUDS.
MGUD Manufacturer (OEM) GUDS.
UGUD User GUDS.
Examples:-
<data name=“gud/channel/mgud/syg_rm[0]”>1</data> Defining the channel
manufacturer gud - syg_rm, index 0 and writing a value of 1 to it.
<op>“gud/channel/mgud/syg_rm[0]” = 5*2</op> The result of the multiplication of two numbers (5 x 2) is written to the
syg_rm[0] gud.
Notes :

Easy Extend B009
PLC Addressing Drive Addressing
x = variable numeric identifier, b = Bit number. The drive path starts with the component identifier.
CU for the Control Unit.
DC for a drive component.
Inputs Outputs Markers Data Blocks The object number should be placed in square brackets.
The drive object number differs from the actual drive number
Mx.b MBx Mx.b DBx.DBx.b because the CU, ALM DriveCliq Hubs etc are all assigned an
object number.
IBx QBx MBx DBx.DBBx
Representation Example: Parameter 970 for drive object 2 =
IWx QWx MWx DBx.DBWx
p0970[do2]
IDx QDx MDx DBx.DBDx
The drive index number can also be read from a local vari-
able:-
Example: Parameter p0970 with the drive object number ob-

Examples: tained from the variable called “drive”.
<data name = “plc/mb200”> 1 </data> Writing a value of 1 This would be written as p0970[do$drive]
to MB200
<data name = “plc/db9905.dbx2.4”> 1 </data> Writing a Examples:-

value of 1 to db9905.dbx2.4 <data name=“drive/cu/p0092”>1</data> Writing a value of
1 to the cu, p0092
<data name = “plc/q0.5”> 0 </data> Writing a value of 0 to
q0.5 <data name=“drive/dc/p0092[do1]”>1</data> Writing a
value of 1 to do1 p0092[do1]
Indirect Addressing:-
<let name=“driveIndex”>0</let> Declaring a temporary
NC Variables variable called “driveindex” and setting the value to 0.
<LET>name = “TempStatus”><LET Declaring a temporary <op>driveIndex = $ma_ctrlout_module_nr[0, AX1]</op>

variable with the LET tag. Reading the value of the NC variable (ctrlout_module_nr Axis
1) into the temporary variable (driveindex)
<OP>TempStatus = “nck/channel/state/chanstatus” </OP>
Writing the channel status in to the variable “TempStatus”. <data name =“drive/dc[do$driveIndex]/p0092”>1<data>
Using the temporary variable to determine the drive object
number and writing a value of 1 into p0092.
Notes :

B009 Easy Extend
Special XML characters
Some XML editors can incorrectly display certain characters.

These have to be re-written.
The following characters are affected:-
Character XML Notation
< < (Less than)
> > (Greater than)
& & (Ampersand)
“ " (Quotation)
, ' (Apostrophe)
Operators
The following operations are available for use:
Operator Significance
= Assignment
== Equal to
<, &lt Less than
>, &gt Greater than
<=, <= Less than or equal to
>=, >= Greater than or equal to
I Logical OR operation (Bitwise)
II Logical OR operation
&, & Logical AND operation (Bitwise)
&&, Logical AND opertaion

&&amp
+ Addition
— Subtraction
* Multiplication
/ Division
! Not
!= Not equal to
Operations are executed from left to right. Brackets can be

used to define the priority of expressions.
Notes :

Easy Extend B009
General TAG Descriptions
Tag Function
AGM Main Tag, defines the device. All other tags are contained within this tag.
BREAK Conditional Interrupt.
For reboot of the NC (resetnc) or Drive (resetdrive)

CONTROL_RESET Eg <control_reset resetnc=“true” />
<control_reset resetdrive=“true”/>
For writing directly to the NC, PLC, GUD and Drive areas.
Attributes: name variable address
All alphanumeric values can be used as tag values. When writing directly from a local variable the $ sym-
DATA bol should be used immediately in front of the variable name.
Examples:
<data name=“plc/mb160”>1</data> (Writing a value of 1 into mb160.
<let name= “tempvar”>7</let> (Declaring a variable named “tempvar” and loading a value of 7 into it.)
<data name= “plc/mb170”>$tempvar</data> (Writing the contents of the variable into marker byte 170.
For saving/restoring the listed drive and machine data. Up to 20
addresses can be listed line by line.
Attributes:
Action=“read” - saves the value of the variable into temporary memory.
Action=“append” - Attaches the value of the listed variable to an existing list.
Action=“write” - writes the saved values into the machine data
Id=“name” - Label given to the temporary memory
DATA_LIST Examples: Reading the values of R200, R201 & R202 into the temporary memory called “name”:-
<data_list action=“read” id=“<name>”>
nck/channel/parameter/r[200]
</data_list>
Writing the values back into the listed machine variables:-
<data_list action=“write” id=“<name>”>
DEVICE Used to describe the device.
The version number of the drive is copied into the $driveversion variable that is valid within the Device
DRIVE_VERSION
tag
ELSE A condition used if the instruction was not fulfilled.(Used in conjunction with IF, THEN)
The Form tag contains the user dialogue description. One dialogue is permitted per device. The “Addition.
Parameter” soft-key displays the user dialogue that is entered under this tag.
Attributes:
color - Background colour of the dialogue screen.
label - Optional name for the form.
FORM xpos - X Position of the upper left-hand corner of the dialogue box
ypos - Y Position of the upper left-hand corner of the dialogue box.
width - Extension in the X direction (Pixels).
height - Extension in the Y direction (Pixels).
Example:- <FORM name=“dialog name” color=“#ff000”/>

Function call-Executes the functions within the “name” attribute.
Attribute:
FUNCTION
Name - “Name of the function body”.
Example: <FUNCTION name=“function name”/>
Notes :

B009 Easy Extend
Tag Function
For the creation and restoring of archive files.
Attributes:
Create=“true” - Command to create an archive
Name=“filename.arc” or “filename.ard”- Filename
specified by user (.arc = complete archive, .ard = dataclass archive)
Class - Specifies that the archive will be a “Data class” archive.(Choice of User, Manufacturer or Individual)
If a class is not specified a standard archive containing NC, PLC, HMI & Drive data will be created.
Group - Specifies the data groups to be included in the archive.(Choice of NC, PLC, HMI & Drive data)
FILE Examples:-
Read in a standard archive called “complete.arc”-
<file name=”complete.arc/>
Read in a data class archive called “dataclass.ard”-
<file name=”dataclass.ard/>
Create a standard archive called “user.arc”-
<file name=”user.arc create=“true” />
Create a data class archive called “user.ard”-
<file name=”user.ard” create=“true” class=“manufacturer individual user” group=“nc plc hmi drv”>
The archives are stored in the following path:- System CF card\OEM\Sinumerik\HMI\DVM\Archives.
Contains the function body of a sub-function. This should be programmed within the AGM or DEVICE tags.
Globally used functions should be set up in the AGM tag.
Attribute:
name = “Name of the function body”
FUNCTION_ BODY Example:
<FUNCTION_BODY name=“function name”>
…
…
</FUNCTION_BODY>
ID Dialogue screen index of the device.
Conditional instruction (IF, THEN, ELSE)
Used with the THEN and ELSE tags.

Following the IF tag, a condition is declared. If this condition is true, the THEN tag is executed. Should the
condition be false the ELSE tag will be executed.
Example:
The following example checks IF MB120 has a value not equal to 5. If this id true, the THEN tag contains the
instruction to load a value of five to MB120.
IF MB120 was already had a value of 5, the THEN tag would be ignored and the code in the ELSE tag would
be auctioned.
IF
<IF>
<CONDITION> “plcmb120” !=5 </CONDITION>
<THEN>
<OP> “plc/mb120” =5 </OP>
</THEN>
<ELSE>
…
…
</ELSE>
</IF>
This tag is used to call other XML files from within the AGM.XML.
INCLUDE Example: <?include src=“name of xml file to be included”?>
For displaying a message specified in the tag. This can be used in the case of alarm numbers, the dialogue
MSG box would display the text associated with the alarm number.
NAME The NAME instruction defines the name of a device to be displayed in the dialogue screen.
Notes :

Easy Extend B009
Tag Function
Setting up of a local variable with a user specified name.
Attribute:
name - variable name
type - The format of the variable can be integer (INT),
double (DOUBLE) or string (STRING). The default of INT is
assumed if no format is specified.
Examples:
LET <LET name=“variable_name” type=“STRING”/>
It is possible to assign a value to the variable eg 99:
<LET name=“variable_name” type=“STRING”>99</LET>
NC and PLC variables can be saved in a local variable using the “=“ operation. The format of the local vari-
able automatically takes the format of the NC/PLC variable.
Variable that are required to be globally available should be set up directly after the AGM tag.
When used with a dialogue box, processing of the message opens up the corresponding DEVICE tag, this
tag is closed after the message is executed and as such deletes all variables within the DEVICE tag.
A message box is opened with this tag, the return value can be used to make a branch.
Attributes:
text - The text to be displayed in the message box. Using the characters “%n” results in a new line.
caption - The header of the text box.
MSGBOX retvalue - Defines the variable when/where the return value is copied. 0 - CANCEL, 1- OK,
type - Acknowledgement possibilities.
“BTN_OK” - OK button.
“BTN_CANCEL - CANCEL button.
“BTN_OKCANCEL” - OK or CANCEL buttons.
Execute instruction. For carrying out mathematical Operations with system and temporary variables.
Examples:
Setting a temporary variable equal to PLC system variable MB100
<op> tmpVar=“plc/mb100” </op>
OP Multiplying a variable by 2.
<op> tmpVar= tmpvar * 2 </op>
Setting PLC system variable MB100 equal to a temporary variable.
<op> “plc/mb100”=tmpVar </op>
Text can be output in the dialogue line or copied into a variable.
Attributes:
name - Name of the variable where the text is to be saved (optional)
text - The text to be output.
PRINT Values:- Number of variables whose values should be inserted in the text.
Format:- d Integer
f Floating point value
s String
Example: <print name=“variable name” text=“text” %formatting”> variable..</print>
SET_ACTIVE Data within this tag is used to activate the device.
SET_INACTIVE Data within this tag is used to de-activate the device.

START_UP Data within this tag is used to commission the device.
STOP Stops a sequence at this position

The switch tag allows the value of a variable to be compared with a number of constants. If a match is found
SWITCH the value will be written into the variable specified in the DATA tag.
Used for testing that a device is functional.. The test result should be entered into the $actionresult variable.
TEST If the variable contains a value of one, then the device is functional. A value of zero indicates a faulty device.
Notes :

B009 Easy Extend
Tag Function
THEN Used with the IF, & ELSE commands. See the description for IF
VERSION Version Information
For Loop – This tag checks for a condition, if the condition is false, the loop will end.
Example:- Declaring a local variable as “count” with an initial value of 0. Set the condition to check that the
variable is less than or equal to 7. Increment the count by increments of one. When the value of the variable
is more than 7 (False) add 1 to the count value and place the result in output byte 10.
<let name=“count=0”</op>
<for>
<init>
FOR <op> count=0 </op>
</init>
<condition> count <= 7 </condition>
<increment>
<op count = count +1</op>
</increment>
<op “plc/qb10” = 1+count</op>
</for>
This tag is used for the enabling of the device.
Enabling via PLC machine data:
14510 $MN_USER_DATA_INT[0] to $MN_USER_DATA_INT[3]
The devices are assigned to the machine data in logical order, each machine data handles 16 devices-
$MN_USER_DATA_INT[0] Devices 1 to 16 (Bits 0 to 15)
“ “ “ “ [1] “ 17 to 32 (Bits 0 to 15)
“ “ “ “ [2] “ 33 to 48 (Bits 0 to 15)
“ “ “ “ [3] “ 49 to 64 (Bits 0 to 15)
Bit assignment examples:
$MN_USER_DATA_INT[0] bit 15 = device 16
OPTION_MD Attributes:
name - machine data address - $MN_USER_DATA_INT
Index - index of machine data - [x]
Example:- <option_md name=“$MN_USER_DATA_INT0[0]/>
Enabling via PLC variable:
Example DB9030.DBWx.
When only devices 1 to 16 are in use, no index is required:
<option_md name=“PLC/DB9030.DBW0”/>
When more than 16 devices are in use, the index must be specified:
<option_md name=“PLC/DB9030.DBW0” index=“0”/>
When this tag is used for a device and the option is not set, a soft-key is available which allows the entry of
a password. The entered password is placed in the specified variable and should be verified by the user
PLC. Acknowledgement of this to the HMI is required using the relevant interface bit (DB9030).
PASSWORD Attribute:
refvar - name of the reference variable.
Example: Declaring DB9030.DBD4 as the target for the entered password-
<password refvar=“plc/db9030.dbd4”/>
Notes :

Easy Extend B009
Tag Function
The interface signals are handled as standard by DB9905. This tag allows the interface to be re-defined.
Attribute:
PLC_INTERFACE Name - Address of the new interface.
Example: <plc_interface name=“address of the new interface”/>
With this tag a message will appear instructing the operator to power down the system. The message text is
POWER_OFF fixed by the System.
While Loop - This tag executes a sequence of instructions for a multiple number of times providing that a
certain condition is true. The sequence is halted when the condition becomes false.
Example:- Set the condition that IB9 should be equal to 0. Providing that this is the case, write a value of 15
into QB11 using the data tag.
WHILE <while>
<condition> “plc/ib9” ==0</condition>
<data name “plc/qb11> 15 </data>
</while>
Do-While Loop - This tag executes a sequence for instructions and then checks for a condition, if the condi-
tion is true, the instructions will be processed again. The processing stops when the condition is false.
Example:- Write a value of 15 into QB11 using the data tag. Then check the condition that IB9 should be
equal to 0.
Providing that this is the case, again write a value of 15 into QB11. When the condition is false, stop the
DO_WHILE loop.
<while>
<data name “plc/qb11> 15 </data>
<condition> “plc/ib9” ==0</condition>
</while>
?UP Update Agent Syntax -
Notes :

B009 Easy Extend
TAG Descriptions - Dialogue Screens
Tag Function
The Form tag contains the user dialogue description. One dialogue is permitted per device. The “Addition.
Parameter” soft-key displays the user dialogue that is entered under this tag.
The following tags are processed by the Form tag:-
LET
INIT
PAINT
TIMER
CLOSE
CAPTION
SOFTKEY_OK
SOFTKEY_CANCEL
FORM Attributes:
color - Background colour of the dialogue screen.
name - Optional name for the form.
xpos - X Position of the upper left-hand corner of the dialogue box
ypos - Y Position of the upper left-hand corner of the dialogue box.
width - Extension in the X direction (Pixels).
height - Extension in the Y direction (Pixels).
Example:- <FORM name=“dialog name” color=“#ff000”/>

The INIT tag is executed immediately after the generation of the dialogue box. All the screen input elements
INIT and hotlinks should be written in here.
The PAINT tag is executed when the dialogue box is displayed.
PAINT All texts and graphics for the dialogue box should be written in here.
The CAPTION tag contains the title of the dialogue box and should be used within the INIT tag.
CAPTION Example: <caption> Title of Dialogue box </caption>
The tag controls the behavior of the dialog screens when saving user entries.
The behavior should be defined within the INIT tag.
If the tag is not used then the entries are always buffered.
Exception: The hotlink attribute is set to true.

DATA_ACCESS Attribute:
type = "TRUE" – values that have been entered are not buffered. The dialog screen directly copies the val-
ues that have been entered into the reference variables.
type = "FALSE" – the values are only copied into the reference variable when tag UPDATA_DATA type =
"FALSE"
Notes :

Easy Extend B009
Tag Function
The CONTROL tag generates the control elements.
Attributes:
name:- label of the field. The label also represents a local variable.
xpos:- X position of the upper left hand corner.
zpos:- Y position of the upper left hand corner.
fieldtype:- Field type (Optional).
“edit” - Data can be changed
“readonly” - Data cannot be changed.
“combobox” - A drop down list with text that can accept a value or be used for selection purposes.
If no type is specified, the default is set to “edit”.
refvar – label of the reference variable that can be linked to the field. (optional)
hotlink – “TRUE“ the field is automatically updated when data is changed (optional)
format – formatting data, refer to the print tag (optional)
time – specifies the refresh rate of the data (optional). The following refresh rates are possible:
“super fast“ - refresh time < 100ms
“fast“ - refresh time, approx. 100ms
“normal“ - refresh time, approx 200ms
“slow“ - refresh time, approx. 500ms
If the combo box field type is selected then the expressions to be displayed also have to be defined. The tag
<item> should be used for this purpose. The combo box saves the index of the currently selected text in the vari-
ables belonging to the control (variable name). Indexing starts with the value 1.
CONTROL Syntax:
<item>Expression</item>
Example:
<control name = "button1" xpos = "10" ypos = "10" fieldtype=” combobox “>
<item>text1</item>
<item>text2</item>
<item>text3</item>
<item>text4</item>
</control>
If any integer value should be assigned to an expression then the value=“value“ attribute must be added to the
tag. Instead of the consecutive numbering - the control variable now contains the assigned value of the item.
Example:
<control name = "button1" xpos = "10" ypos = "10" fieldtype=” combobox “>
<item value = “10” >text1</item>
</control>
Note: The hotlink attribute results in the appropriate control being cyclically updated. This means that if a value is
entered, then the next update cycle overwrites the value that has been entered. In order to avoid this, use the
DATA_ACCESS tag to activate the function where entered data is immediately saved.
An additional possibility is to include the SOFTKEY_OK tag in the form. This tag is then run before the dialog box
is closed. In this block - using the UPATE_CONTROLS instruction - data can be aligned between the control and
reference variables.
Notes :

B009 Easy Extend
Tag Function
The tag is used to display a text at the specified position on the screen. If the text is to be read from a text file,
then the “$$” character string should be placed in front of the label.
If the contents of a string variable are to be displayed, then the “$$$” character string should be located in front
of the variable.
Syntax: <text xpos = "X position" ypos = "Y position"> Text </text>
Attributes:
xpos - X position of the upper lefthand corner
ypos – Y position of the upper lefthand corner
color – text color
Value: Text to be displayed
Example: Direct text output: <text xpos=“10“ ypos=“20“> Hello World </text>
Example: Indirect text output with text from a file:

The text to be output should be set-up in the oem_aggregate_eng.ts file, “eng” specifies that the file is the eng-
lish version. The German version would be “deu”. This should be changed to suit the language of the controller.
The file has to exist in the following directory: System CF card\oem\sinumerik\hmi\lng

Example of the file:
TEXT
<TS>
<context>
<name>EASY_EXTEND</name>
<message>
<source>MY_TEXT_SYMBOL</source>
<translation>R2</translation>
<chars>20</chars>
</message>
<message>
<source>R3</source>
<translation>RPAR3</translation>
<chars>20</chars>
</message>
</context>
</TS>
Example tag to be placed in the relevant xml file: <text xpos=“10” ypos=“20”>$$MY_TEXT_SYMBOL </text>
Example: Indirect text output with text form a variable:

<LET name=“TextVar” type=“string”> Hello World </text><text xpos=“10” ypos=“20“>$$$TextVar </text>
The tag is used to display an image/graphic at the specified position.
The bit maps in the BMP or PNG format should be saved in the directory CF-Card/oem/sinumerik/hmi/dvm.
Linux: Lower case letters should be used for all file names.
Syntax: <img xpos = "X position" ypos = "Y position" name=“name“ />
Attributes:
IMG xpos - X position of the upper lefthand corner
ypos – Y position of the upper lefthand corner
name – bit map name
Optional: If the display of an image/graphic deviates from the original size then the dimensions can be defined
using the width and height attributes.
width – width in pixels
height - height in pixels
Notes :

Easy Extend B009
Tag Function
The tag draws a solid square at the specified position in the specified color.
Syntax:
<box xpos="X position" ypos = "Y position" width=“X extension“ height=“Y extension“ color=“color code“ />
BOX Attribute:
xpos – X position of the upper left hand corner
ypos – Y position of the upper left hand corner
width – extension in the X direction (in pixels)
height – extension in the Y direction (in pixels)
color – color coding
TIMER Dialog box message. Tag is cyclically executed.
CLOSE Dialog box message. Tag is executed before the dialog box is closed.
Using the tag, a variable is included in the cyclic read utility (hotlink).
This tag is only valid within the INIT instruction of a form.
Attribute:
REQUEST
name - address label
Syntax: <REQUEST name = “NC Variable“ />

The tag synchronises data between the operator elements and the reference variables.
Attribute:
type – the attribute defines the direction of the data
alignment.
TRUE – data is read out of the reference variables and
copied into the operator elements.
FALSE – data is copied from the operator elements into the reference variables.
UDATE_CONTROLS
Syntax:
<update_controls type="<direction>"/>
Example:
<softkey_ok>
<update_controls type="false"/>
</softkey_ok>
This tag overwrites the standard behavior when a dialog box is closed using the "Cancel" softkey.
The tag should be programmed in the first sub-level of a form tag.
The following functions can be executed in this tag:
 Data manipulation
 Conditional processing
 Loop processing
SOFTKEY_ CANCEL
Example:
<form>
<softkey_cancel>
<data name=”plc/mb170”>2</data>
</softkey_cancel>
</form>
Notes :

B009 END Easy Extend
Tag Function
This tag overwrites the standard behavior when closing a dialog box using the "OK" softkey.
The tag should be programmed in the first sub-level of a form tag.
The following functions can be executed in this tag:

 Data manipulation
 Conditional processing
 Loop processing
Syntax:
<SOFTKEY_OK>
…
…
</SOFTKEY_OK>
Example:
SOFTKEY_OK
<form>
….
….
<softkey_ok>
<update_controls type="false"/>
<let name="msgbox_result">0</let>
<MsgBox text="Execute NCK Reset!! " caption= "NCK Reset" retvalue= "msgbox_result" type=
"BTN_OKCANCEL" />
<if>
<condition> " msgbox_result " == 1 </condition>
<then>
<CONTROL_RESET resetnc="TRUE"/>
</then>
</if>
</softkey_ok>
</form>
B009: END

B011 Easy Screen
Module Description:
Easy Screen is a function of the Sinumerik 828D which allows the manufacturer to write custom
screens.
The screens are intended as an interface to the specific functions offered by the OEM.
Module Objective:
Upon completion of this module the course participant will be able to create Easy Screens.
Content:
Sinumerik
General Information
Basic Configuration Information
Creating Easy Screen User Files
Language Dependent Texts
Parameters and Variable Description
B011
B011

Easy Screen B011
Easy Screen: Description

Easy Screen:
START
Easy Screen is a function of the Sinumerik 828D which allows
the manufacturer to write custom screens.
The screens are intended as an interface to the specific func-
tions offered by the OEM
General
Information
Basic
Configuration
Information
Creating
Easy Screen
User Files
Language
Dependant
Texts
Parameters
and
Variable
Descriptions
Easy Screen:
END
Notes :

B011 Easy Screen
General Information Basic Configuration Information
The Easy Screen function is configured using ASCII files. Configuration files are used to create the screens.
These files contain the descriptions of the user interface. These configuration files are automatically interpreted by the
controller.
As standard, up to 5 screens can be configured. The files are not available as standard and have to be cre-
Further screens are available via a licensed option (Not 828D ated by the user using an ASCII editor (e.g. Notepad® or
Basic) directly on the controller).
Sinumerik Operate Runtime OA Easy Screen, order No:
6FC5800-0AP64-0YB0. The “easyscreen.ini“ file is a master file which is required to
specify which other files are to be used to create a user
In order to create images for the screens, a graphic pro- screen.
gramme is required. Paint Shop Pro® and Paint® are pro- These files contain the information which determine what is
grammes which are compatible with the 828D controller. displayed on a particular screen.
The screen is split into different areas:
Easy Screen can be used for the following functions:
1. Display of dialogs and provision of:
 Soft-keys
 Variables, (tables This function will be available with a
later level of implementation.)
 Text and help text
 Graphic displays and help displays
2. Calling up dialogs by means of:
 The (entry) soft-keys
 PLC selection
3. Dynamic re-structuring of dialogs:
 Changing or deleting soft-keys
 Defining and designing variable fields
 Showing, replacing and deleting (language-dependent/ 1 Main dialog area
independent) display texts 2 Title bar containing screen name (Left) and
 Showing, replacing and deleting display texts “Long text” description of the selected
variable (Right)
(Language dependent/individual)
3 Variable input/output field
4. Initiating actions when:
4 Variable name “Short text”
 Showing dialogs 5 Graphics related text
 Entering values (variables) 6 Unit text
 Pressing soft-keys
Operating areas overview
Closing dialogues
5.. Exchange of data between dialogs. Operating area Permissible position for start softkeys
6. Variables
 Reading (NC, PLC, user variables)
Machine JOG HSK6
 Writing (NC, PLC, user variables) Machine MDA HSK6

 Linking with mathematical, comparative or logic Machine AUTO HSK6
operators
7. Executing functions: Parameter HSK7
 Subroutines Program HSK6
 File functions
Program-Manager HSK2-8, 12-16, if not used for networked
 PI Services drives
8. Taking into account levels of protection defined for user
groups. Diagnostics HSK7
Commissioning HSK7
Notes :

Easy Screen B011
To enable custom screens in other area of the controller, the Creating Easy Screen User Files
“easyscreen.ini” file has to be modified.
There are eight areas in total:- The files required for the Easy Screen function need to be
created. This can be done directly on the controller by navigat-
Machine Area-Sub divided into:- ing to the relevant folders. Use the following key sequence to
Jog locate the “System data” area.
MDA
Auto
Parameter Area
Program Edit Area
Program Manager Area
Diagnosis Area
Start-up Area
The three Machine Areas are specified by the by “Screen”

entry.
SlMaJogScreen = Jog screen
SlMaAutoScreen = Auto screen
SlMaMdaScreen = MDA screen
Each area should have a “com” file specified.
Example of how all the areas are specified within the

“easyscreen.ini” file:- Creating the “easyscreen.ini” file on the controller
[STARTFILES] This file sets up the links to the files which are to be used to
StartFile01 = area := AreaMachine, dialog := SlMachine, create the user screens, it also determine which operating
screen := SlMaJogScreen, startfile := ma_jog.com areas these files are available in. The file has to be located in
any of the following paths/directories:-
StartFile02 = area := AreaMachine, dialog := SlMachine, “System CF card\oem\sinumerik\hmi\cfg”
screen := SlMaAutoScreen, startfile := ma_auto.com “System CF card\user\sinumerik\hmi\cfg”
StartFile03 = area := AreaMachine, dialog := SlMachine, Use the cursor keys to locate and open this directory.
screen := SlMaMdaScreen, startfile := ma_mda.com
StartFile04 = area := AreaParameter, dialog := SlParame-

ter, startfile := param.com
StartFile05 = area := AreaProgramEdit, dialog := SlPro-

gramEdit, screen := EditorScreen , startfile := aeditor.com
StartFile06 = area := AreaProgramManager, dialog :=

SlPmDialog, startfile := progman.com
StartFile07 = area := AreaDiagnosis, dialog:=SlDgDialog,

startfile := diag.com
StartFile08 = area := AreaStartup, dialog:=SlSuDialog,

startfile := startup.com
Notes :

B011 Easy Screen
To create the file select the “New” soft-key and ensure that the “Any” soft-key is selected.
The “Any” soft-key allows the file type to be determined by the user. In the dialogue box type in the name of the file and confirm
with the “OK” soft-key.
The file name must be in lowercase due to the LINUX operating system.
The newly created file will be automatically opened in preparation for editing.
Example: easyscreen.ini file

The following example will show how the “easyscreen.ini” file is used to specify the “Parameter” area of the controller as the area
from where the “Easy Screens” are to be accessed.
(area := Area Parameter)
The “com” file, the content of which will determine what appears on the Easy Screen screens, is also declared here.
(startfile := param.com)
The first step is to enter the header ([STARTFILES])

The code for specifying the controller area and “com” file is then entered on a new line as shown below.
[STARTFILES]
StartFile01 = area := AreaParameter, dialog := SlParameter, startfile := param.com
Creating the User Files on an external PC
As mentioned previously it is possible to create the Easy Screen files directly on the controller or offline using an ASCII editor
(e.g. Notepad®).
These files have to be transferred to the controller and placed in the correct folders using the USB/CF Interfaces or with RCS
Commander software.
Below: The easyscreen.ini file located in the cfg directory
Notes :

Easy Screen B011
Creating the “param.com” file Storage path for the image files:
“System CF card\oem\sinumerik\hmi\ico\ico640”
The param.com file has been declared in the “easyscreen.ini” “System CF card\user\sinumerik\hmi\ico\ico640”
file and now needs to be created.
To see the results of the example we have to locate the
Code contained within the param.com file is used to create “parameter” area of the control.
soft keys and display texts and graphics etc.
The file needs to be created and placed in one of the following

folders:
“System CF card\oem\sinumerik\hmi\proj”
“System CF card\user\sinumerik\hmi\proj” The 7th horizontal soft-key contains the text specified in the
“param.com” file: HS7=("Easy %nScreen").
Below: The param.com file located in the proj directory.
Example: param.com file
It is necessary to specify a soft-key to be used as the entry

point to the Easy Screens.
Further soft-keys can be assigned within the Easy Screens if
required. Screen title/name tiger.bmp image
The example defines the 7th horizontal soft-key as the entry
point, the soft-key will have the text “Easy Screen” (on 2 lines).
HS7=("Easy %nScreen")
When the soft-key is pressed a Mask (mask1) will be loaded:

PRESS(HS7)
LM("mask1")
END_PRESS
//END
The Mask contains the code which determines the content of

the Easy Screens.
The first line of the mask (Mask header) contains the mask
name, text and graphic information.
The following example shows mask1 with the title of Picture

Test. An image named tiger.bmp, will be displayed when HS7 is
pressed. The image will be positioned 110 pixels from the left
and 25 pixels from the top of the screen.
//M(mask1/ "Picture Test" / "tiger.bmp" / / / 110, 25)
Notes :

B011 Easy Screen
Mask header information: Adding Dialogue Elements:
The various parameters are separated by the “Forward slash” Dialogue Elements refer to long and short texts, graphics texts,
character (/). unit texts and I/O fields. Additional soft-keys can also be added.
//M(Identifier/header/Graphic/Dimension/Variable/Graphic The dialogue elements are added below the mask header.
position/Attributes)
In the following example (Shown in red text) the a soft-key with
Parameter descriptions: the label “Variable Test” is added. When the soft-key is pressed
the screen will display a list of four variables. The four variables
are defined under a new mask (Mask2-Workpiece Dimensions)
Parameter Description
Identifier Label of dialogue/mask. //S(START)
Header Name of the screen. HS7=("Easy %nScreen")

Graphics Name of image to be displayed. PRESS(HS7)
Dimension Position and size of the dialogue. (Distance from LM("mask1")
the left hand side, right hand side, width, height) END_PRESS
Values in pixels and separated by commas
//END
Variable The cursor can be assigned to a variable. The
first variable has an index of 1, the remaining //M(mask1/"Picture Test"/"tiger.bmp"///110,25)
variables are indexed in the order that they were
configured. HS1=("Variable %nTest")
Graphic The position of the graphic in pixels. Distances PRESS(HS1)
Position Position are from the left and top of the dialogue
LM("mask2")
screen and are separated by a comma.
END_PRESS
Attributes CM (Column Mode) Column alignment.
//END
CM0: Default, the column distribution is carried
out separately for each line. //M(mask2/"Workpiece Dimensions"/)
CM1: The column distribution is of the ling with Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")
the most columns applies to all lines. Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]")
CB: (Change Block) Response when the dialogue Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")
is opened. The CB attribute can also be used on
individual variables, in this case the individual VS8=("EXIT")
setting has priority over the CB setting in the
Mask Header. PRESS(VS8)
EXIT
CB0: All change blocks associated with the dia- END_PRESS
logue are processed when it is opened.
//END
CB1: Change blocks are only processed if the
relevant value changes. The parameters of the variables defined in mask2 are separated
by the forward slash character (/).
A detailed description of the Dialogue Element parameters can

be found in chapter ”Parameters and Variable Descriptions”.
Notes :

Easy Screen B011
The additional soft-key can now be seen. Detailed Analysis:
//M(Mask1/"Workpiece Dimensions") Name of Mask1:
HS1=("Variable %nTest") Determines the text for horizontal

soft-key 1 as “Variable Test”:
When the soft-key is pressed mask2 will be loaded.
PRESS(HS1)
LM("mask2")
END_PRESS
Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")

R parameter 0 as a real number to 2 decimal places, sets the
component length:
When the soft-key is pressed the defined variable will be dis-

played.
Screen title/name Long text of the selected variable.

Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")
component width:
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]")

component height:
Short text Input field
Values entered in the input field will be transferred to relevant Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")
variable. R parameter 3 as an integer, sets the spindle speed:
Notes :

B011 Easy Screen
VS8=("EXIT") Determines the text for vertical soft-key 8 as Language Dependant Texts
“EXIT”:
It is possible to configure the Easy Screen configuration files
so that that the easy Screen language matches that of the
system.
Checking the entered values In order to do this it is necessary to create one text file for
each required language.
Values can be entered directly on the custom screen. These The text that is to be displayed is contained within the text
values are transferred directly to the variables. files.
They can be checked by viewing the variables on the standard The Easy Screen configuration files use identifiers to ensure
screen by pressing the “User variable” soft-key. that the correct text is displayed.
The files containing the text can be placed in in the following

locations:
“System CF card\oem\sinumerik\hmi\lng”
“System CF card\user\sinumerik\hmi\lng”
“System CF card\addon\sinumerik\hmi\lng”
Example Text File:
;VERSION:SLP.02.05.QJM Otc 16, 2010

;CHANGE :SLP.02.04.QJM Jun 30, 2010
85100 0 0 "English%nEasy Screen"

85101 0 0 "English Mask Header"
85102 0 0 "English Long Text"
85103 0 0 "English Short Text"
Identifier Not used Required text
Allowable range of identifiers 85000 to 89899
Part of the file name can be assigned by the user but must
also contain the correct 3 letter language coding. This is so
that the system can display the contents of the correct file.
Filename Examples:
easyscr_eng.txt English filename example

easyscr_deu.txt German filename example
User part File

of extension
filename
Language
coding
Example of a second text file:
85100 0 0 "Deutsch%nEasy Screen"

85101 0 0 "Deutsch Mask Header"
85102 0 0 "Deutsch Long Text"
85103 0 0 "Deutsch Short Text"
Notes :

Easy Screen B011
The files for English and German can be seen located in the The language file needs to be declared in the “easyscreen.ini”
OEM area. file. No language coding is required.
Declarations of other text files may also be present.
;VERSION:SLP.02.01.H56 Nov 10, 2009

;CHANGE :
[STARTFILES]
StartFile04 = area := AreaParameter, dialog := SlParameter,

startfile := param.com
[LANGUAGEFILES]
LngFile01 = almc.txt
LngFile02 = alsc.txt
LngFile03 = aluc.txt
LngFile04 = easyscr.txt
The identifier is used in place of the text in the param.com file. [SYSTEM]
The identifier has to be prefixed by the $ symbol. System = 0
The text associated with the identifier will be displayed.
Setting the controller language:
Example param.com file for language dependent text.
The controller language is selected via the “Start-up” menu.
//S(START)
HS7=($85100)
PRESS(HS7)
LM("mask1")
END_PRESS
//END
//M(mask1/$85101/"tiger.bmp"///110,25)
HS1=("Variable %nTest")
PRESS(HS1)
LM("mask2")
END_PRESS When using the examples shown earlier it can be seen that the
text displays change with the selected language.
//END
//M(mask2/"Workpiece Dimensions"/)
Or
Def Var1=(R2///$85102, $85103///"$R[0]")
VS8=("EXIT")
English long and short texts:
PRESS(VS8)
EXIT
END_PRESS
German long and short texts:
//END
Notes :

B011 Easy Screen
Parameters and Variables Descriptions 4. Texts-

Text possibilities are-
When a variable is assigned certain properties can be set.  Long text = text displayed when each element is high-
These properties are contained rounded brackets, each prop- lighted.
erty is separated by a forward slash (/)
If a property is not used, the slash still needs be present.  Short text = name of the element
 Graphics text = text relating to the graphics, if used.
Basic description:  Unit text = unit of the variable e.g. mm, rpm etc
DEF Var1=(1/2/3/4/5/6/7/8/9/10) The texts types are separated by commas and need enclosing
in speech marks:- /”Long”, “Short”, “Graphics”, “Unit”/
1. Variable type
2. Limit values, toggle field or table identifier 5. Attributes-
3. Default The following properties can be influenced by the attributes
4. Texts Input mode
5. Attributes  Access level
6. Help display  Alignment of short text
7. System or user variable
 Font size
8. Position of short text
9. Position of I/O field (Left, top, width, height)  Handling limit values
10. Colours  Response when screen is opened (Change block)
Detailed description: The attributes are separated by commas, and are not valid for
toggle fields.
1. Variable type
R[x] Real number, “x” indicates the number of decimal Input mode:-
places displayed Attribute Effect
I Integer. wr0 I/O field invisible, short text visible.
S[x] String,”x” indicates the string length. wr1 Read only, no inputting of data, short text visible.
C Character (Individual character) (Default setting)
B Boolean number wr2 Read & write possible, long and short text visible.
V Variant type wr3 As with wr1 but with I/O field visible, long and short
text visible.
2a. Limit values- wr4 All elements invisible.
A minimum and a maximum value can be specified. The values wr5 As wr2 except entries are immediately active.
are separated by a comma, the minimum value is specified first. with wr2 the entry becomes active exiting the field
Values can be in I, C and R decimal formats or as characters in or pressing enter/input/return.
the format “A” , “F”
The limit value also works in conjunction with the limit attrib- Access level:-
ute, see the attribute property for more information. Attribute Level Password/Key position
ac7 7 Not released
2b. Toggle field- ac6 6 SUNRISE
Creates a list of predefined entries in the I/O field. The list is ac5 5 EVENING
initiated by the “*” character. ac4 4 CUSTOMER
The entries can be assigned a value. ac3 3 Key switch pos 3
The Limit value is interpreted as a list for the Toggle field. ac2 2 Key switch pos 2
If only a “*” is used, a variable Toggle field is generated. ac1 1 Key switch pos 1
ac0 0 Key switch pos 0
2c. Table Identifiers-
Identifiers can be assigned to tables containing NCK/PLC val- Alignment of short text:-
ues of the same type. The “%” character is used to differentiate Attribute Effect
an identifier from a toggle field or limit value. al0 Left justified (Default)
A comma is required after the identifier, the file name containing al1 Right justified
the table information is then typed. al2 Centred
3. Default setting-
The value in the assigned variable can take on various states.
This depends on whether a default value, system or user vari-
able (Or both) has been assigned to the variable field (I/O or
toggle field)
Toggling is not possible until a valid value is assigned to the
variable.
Notes :

Easy Screen B011
5. Attributes continued- Setting Data Syntax
Font size:- Global setting data $SN_...

Attribute Effect
fs1 8pt. font size (Default) Axis specific setting data $SA_...
fs2 16pt font size
Channel specific setting data $SC_...
The Clearance between lines is defined. The default font size
allows 16 lines. The graphics and unit text can only be System variable Syntax
configured in the default font size.
R parameter 1 $R[1]
Limits:
PLC Data Syntax
Checking whether the value of the variable are is within the lim-
Byte y of bit z of data block x DBx.DBXy.z
its specified by the limit values.
Byte y of data block x DBx.DBBy
Attribute Effect
li0 No check. Word y of data block x DBx.DBWy
li1 Check with respect to minimum
li2 Check with respect to maximum. Double word y v. of data block x DBx.DBDy
li3 Check with respect to minimum and maximum.
String y with length z from data block x DBx.DBSy.z
Behaviour when opening (Change block): Real y of data block x DBx.DBRy
Attribute Effect Flag byte x bit y Mx.y
cb0 The change block defined for this variable is
processed when the screen opens (Default). Flag byte x MBx
cb1 The change block defined for this variable is
processed if there is a change in the value of the Flag word x MWx
variables. Flag double word x MDx
The “cb” attributes, specified in the variables definition, take Input byte x bit y IBx.y
precedence over the globally specified attributes in the “screen
form” definition. Input byte x IBx
6. Help Display- Input word x IWx
Input double word x IDx

The name of the HTML file containing the help text needs to be
typed in speech marks. The display appears automatically if the Output byte x bit y QBx.y
cursor is positioned on the variable.
Output byte x QBx
7. System or user variables-
Output word x QWx
The variable to be viewed is entered here, these have to be
Output double word QDx
contained within speech marks. The variable must be
addressed in the correct way.
Soft-key Status Syntax
Addressing Variables.
Visible (Default) Se1
Disabled (Grey text) Se2

Machine Data Syntax
Displayed(Last soft-key used) Se3
Global machine data $MN_...
Axis specific machine data $MA_...
Channel specific machine data $MC_...
Notes :

B011 END Easy Screen
8. Position of short text
The Short Text defined in attribute No.4 is positioned using

parameter No.8.
The measurements are in pixels and relate to the top left
corner of the main dialogue body.
Three values can be entered to define the position from the left,
the position from the top and the width of the short text.
Each entry has to be separated by a comma.
The following example would position the text “Short text” 200
pixels from the left and 100 pixels from the top with a width of
250 pixels:
Def Var1=(R2///" ","Short text"///"$R[0]"/200, 100, 250//)
9. Position of I/O field
The I/O field can be positioned and sized using parameter No.9.
The measurements are in pixels and relate to the top left
corner of the main dialogue body.
Four values can be entered to define the position from the left,
the position from the top and the width and height of the I/O field.
Each entry has to be separated by a comma.
The following example would position the I/O field for the
defined variable, 600 pixels from the left and 100 pixels from the
top with a width of 100 pixels and a height of 150 pixels:
Def Var1=(R2///" "," "///"$R[0]"//600, 400, 100, 150/)
10. Colours
The foreground and background colours of the I/O field can be

chosen by using parameter No.10.
The default colours are foreground: Black, background: White.
These are determined by the “Write mode” (See parameter 5)
The following table shows index number to be used to achieve

the required colour.
The foreground colour is defined first, followed by a comma then
the background colour:
Index Colour
1 Black
2 Red/brown
3 Dark green
4 Light grey
5 Dark grey
6 Blue
7 Red
8 Brown
9 Yellow
10 White
B011: END
Notes :

B020 Service Planner
Module Description:
The 828D controller has a Service Planner function which allows the user to set up maintenance
tasks. The tasks require an acknowledgement to confirm that the task has been completed, the
tasks are based on timed intervals. Each task has to be parameterised to suit the individual re-
quirements of that task.
Module Objective:
Upon completion of this module you will be able to set up maintenance tasks using the Service
Planner function.
Content:
Sinumerik
Enabling the Service Planner
PLC Programme Example
Setting up the Maintenance Tasks
XML Data Files
PLC Interface Signals
Confirming/Resetting/Saving Tasks
B020
B020

Service Planner B020
Service Planner: Description Service

Planner:
START
The 828D controller has a Service Planner function which
allows the user to set up maintenance tasks.
The tasks require an acknowledgement to confirm that the Enabling the

task has been completed, the tasks are based on timed inter- Service
vals. Planner
Each task needs to be parameterised to suit the individual

requirements of that task.
PLC
Programme
Example
Setting up
the Mainte-
nance Tasks
XML Data
Files
PLC Interface
Signals
Confirming/
Resetting/
Saving Tasks
Service
Planner:
END
Notes :

Enabling the Service Planner Below: Data Blocks DB9903 & DB9904 are present in
the Data Block folder of the PLC Project.
In order for the Service planner to function the PLC user pro-
ject must contain DB9903 and DB9904. These are created
with the PLC828 programming tool and then downloaded to
the controller.
To create the Data Blocks first open up the correct project and
open the Data Block folder.
In this example the required

Data Blocks (DB9903 &
DB9904) are not present.
Save the user project.
Download the project to the controller.
The Data Block templates can be

found in the Libraries folder.
Transferring them to the Data Block
folder is achieved by double clicking
the required template.
Double Click each Data Block

to add the PLC Project
It is possible to change the Data Class of the Data Block and

add the name of the author if needed.
The box is closed by clicking the “OK” key.
Notes :

PLC Programme Example
Below is an example of how to activate and reset messages using the Service Planner.
Setting the
alarm
Setting the
message
Resetting the
alarm
Resetting the
message
Deactivating the
service interval
Notes :

Setting up the Maintenance Tasks
To set up a Maintenance task the password level needs to be

set to Manufacturer.
To locate the Service Planner screen use the following key

sequence.
To create a new task use the “New task” soft-key
Task information now needs to be entered
Input Field Explanation:- (All time values are in hours)
Maintenance Task: A brief description of the task

Interval:
1st warning: Interval at which a pre-warning is issued
Quantity: Determines the number and interval of pre-warning.
Remaining time:- Indicates the time remaining to the alarm
being triggered.
Example:-
In the following example, the interval is 168 hours. The 1st
warning will appear after 144 hours and then every 3 hours
until the alarm is triggered after 168 hours.
The interval for between the warning is obtained by the follow-
ing:-
“Interval” minus the “1st warning” divided by the “Quantity”.
(168 - 144) ÷ 8 = 3
To confirm the data, use the “Input” key, to navigate the dia-
logue boxes use the cursor keys. When the data required fields
have been entered press the “Enter” key.
Notes :

The information entered earlier via the screen can be seen in
the text of the file. It is possible to use an XML editor for
creating an offline file.
Below is the “oem_maintenance_data.xml” file containing the
data of the example used in Section 3.
The red clock symbol
Will be replaced with a green tick
XML Data Files PLC Interface Signals
When a task is created the interval details are stored in an xml The data entered on the screen is stored in the data blocks
file, the task names are stored in a language dependent ts file. created earlier. This can be seen in the PLC diagnosis area:-
These files can be viewed and edited on the controller or off-
line.
Location of the Service Planner files:
For a task to have an effect on the controller the interface

signals have to be evaluated in the user PLC program.
When a first warning or interval is reached a message must
be generated to warn/advise the operator of any action re-
quired.
Data Blocks and variables are available to assist with this.
When values are entered via the HMI they are transferred
into DB9903 (Initial Data Table) The system uses these val-
ues to determine when the interface bits need
setting.
DB9903 uses four data words per maintenance task.
Notes :

DB9903 Initial Data Table for Service Planner [r]
Word Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Task 1: Interval (Hours)

2 Task 1: 1st warning
4 Task 1: Quantity
6 Reserved
12 Task 2: Quantity
14 Reserved
20 Task 3: Quantity
22 Reserved
The sequence is continued up to Task 32.

252 Task 32: Quantity
254 Reserved
Data Block 9904 is used to report the status of the maintenance tasks.
DB9904 Actual Data Table for Service Planner [r]
Word Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Task 1 Residual time (Hours)

2 Task 1: Number of warnings issued
4 Reserved
6 Reserved
8 Task 2: Residual time (Hours)
12 Reserved
14 Reserved
The sequence is continued up to Task 32.
248 Task 32: Residual time (Hours)

252 Reserved
254 Reserved
Notes :

User interface warning signals.

When the maintenance task is acknowledged the relevant interface bit will be set for one PLC cycle.
DB1800 Acknowledgement signals PLC -> HMI [r/w]

4000 Ackn 8 Ackn 6 Ackn 5 Ackn 4 Ackn 3 Ackn 2 Ackn 1 Ackn 0
The following interface signals are used for signalling that an alarm or message has been activated. Example: by checking that
the remaining time is not zero then the user PLC can be written to produce a message can be issued. If the remaining time is
zero then an alarm can be issued in the same way. The signal is active for one PLC cycle.
DB1800 Warning/Alarm signals HMI -> PLC [r]

3000 Alarm 8 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1 Alarm 0
It may be necessary to deactivate a task, switching the signal high will result in the task being frozen.
DB1800 Deactivation signals PLC -> HMI [r/w]

2000 Deact 8 Deact 6 Deact 5 Deact 4 Deact 3 Deact 2 Deact 1 Deact 0
Notes :

Confirming/Resetting/Saving Tasks
When a task has reached the time limit, it requires, depend-

ing on the task type, some kind of action is to be completed.
Once this is complete then the task can be acknowledged
and the time limits reset.
Only qualified personnel should reset the task after the main-
tenance action has been completed. Simply resetting the task
without completing the task could result in damage to the
machinery. The ‘Reset all” soft-key will reset the remaining times
for all the tasks.
The user PLC program should trigger a PLC user alarm when
a task has reached a time limit. If it is a pre-warning the mes-
sage response can usually acknowledged by the “Alarm Can-
cel” key with no interference to the machine operation.
When the Interval time has expired completely the PLC user
message should be configured to match the importance of
the maintenance task.
When the status of the task is checked in the Service Planner
screen, a red clock symbol should have appeared in the
“Status” column and the remaining time column will be zero. This will reset the interval time back to the original and the
interface bit will remain high for one PLC cycle. This can be
used by the user PLC to acknowledge user alarms etc.
It is possible to reset a maintenance task at ant time prior to
the interval time expiring.
Saving Service Tasks:

All the Service Tasks can be saved/read-in to/from an external
USB/CF memory device.
Exporting tasks:
The “Exporting tasks” soft-key is used to save the tasks.
Select the destination of the file e.g. USB and

then select the “OK” soft-key.
Once the maintenance task is complete then it can be ac-

knowledged by pressing the “Maintenance Completed” soft-
key.
The red clock symbol Enter a suitable name for the file and then select the “OK” soft
-key.
will be replaced with a green tick
This will reset the remaining time back to the original and the
interface bit will remain high for one PLC cycle. This can be
used by the user PLC to acknowledge user alarms etc.
It is possible to reset a maintenance task at any time prior to
the interval time expiring.
Tasks can be changed or deleted at any time with the

“Change task” & “Delete task” soft-keys.
Notes :

A warning that existing files on the USB/CF device will be
overwritten, select “OK” to continue.
Reading in Service Tasks:

The “Importing tasks” soft-key is used to read in a task file.
The save procedure creates two files, one file is of the “xml”
type, while the second file is of the “ts” type. The “xml” has to
be selected for the import procedure, followed by the “OK” soft
-key.
The procedure will overwrite any existing tasks on the control-

ler, select the “OK” soft-key to continue.
B020: END
Notes :

B020 END Service Planner

B018 Easy Messenger
Module Description:
It is possible to send SMS messages from the controller to report certain events that occur on the
machine.
It is also possible to send and receive an SMS message to the controller which can be used to
influence the machine by means of changing PLC variables.
Module Objective:
Upon completion of this module you will be able to set up the modem and controller so that the
SMS messaging function can be used.
Content:
Sinumerik
Activating the Modem
Configuring the Modem
Testing the Modem
Setting PLC variables via SMS
B018
B0018

Easy Messenger B018
Easy Messenger: Description

Easy
It is possible to send SMS messages from the controller to Messenger:
report certain events that occur on the machine. START
It is also possible to send and receive an SMS message to
the controller which can be used to
influence the machine by means of changing PLC variables.
Activating
the Modem
Configuring
the Modem
Testing the
Modem
Setting PLC
variables via
SMS
Easy
Messenger:
END
Notes :

B018 Easy Messenger
Activating the Modem Configuring the Modem
A SIM card is required which has to be fitted inside the Mo- The modem setup screens are reached through the following
dem. To dismantle the modem two clips have to be released. key combination:-
When the “Easy Msg active” soft key is selected the control
will start to communicate with the modem.
The SIM card slot can be seen below, once inserted the mo-
dem can be clipped back together.
Slide the top part of the SIM

card holder in the direction of
the arrow and lift up.
The Modem should be connected to the controller with a 9-pin

modem cable. The cable should be connected to Port X140 of
the controller and X1 of the modem. Port X140 is a female
connector. Port X1 is a male connector.
There is a connection for an antenna, three status LED’s and

a switch for changing the functionality.
Type: Sinaut MD720-3
Modem part number:- 6NH9720-3AA00
Cable part number:-6NH7701-5AN
The modem is set to a default transmis-

sion mode known as Terminal Mode. The
“SET” switch should not be pressed as
this can change the modem settings and
cause it to stop functioning.
LED information:-
S (Status)
The status of the connection will be displayed.
Q (Quality
C (Connection)
During normal operation:-

S - Off
Q - On
C - Flashes every 2 seconds (Terminal
mode active)
To activate the modem machine data

51233 needs to be set to 1.
Notes :

Easy Messenger B018
To identify the controller to the SMS recipient a name can be
added in the settings screen.
A limit on the number of SMS messages sent can also be
entered. When the limit has been exceeded a message box
will be displayed.
The counter will then have to be reset to zero with the “Reset A user profile must now be added.
SMS counter” soft key.
Details about the recipient of the SMS messages should be

entered as well as the events which result in a message be-
ing sent.
The screen is navigated using the cursor and select keys.
The following example shows the user name of Fred Bloggs

has been entered with a phone number of +49123456789.
The User ID is a 5 digit number which is selected by the user
and is necessary for the setting of PLC variables by SMS.
The user will receive SMS messages when programmed
messages from the part program are initiated.
More information about some of the events can be seen by

pressing the “Details” soft key.
If the SIM card has a pin number active, it can be deleted with
the “Delete PIN” soft-key.
Notes :

B018 Easy Messenger
Testing the Modem
A test message can be sent to test the connection. “Send test

SMS” soft key.
The telephone number specified in the user profile will receive

a test message.
The user must now be activated, select the “User active” soft-
key and then the “OK” soft-key.
The newly created user will appear on the screen.

A green tick appears before the name to indicate the user is
active.
The user profile can be edited or deleted, further profiles can

also be added. Sending a message from a part program
Example:
To send a message from part program first ensure that this
option is set in the user profile.
Select MDA mode and type in the following text:-

A list of text messages that have been sent and received can
be seen when the “SMS Protocol” soft key is selected. MSG (“SMS: TYPE YOUR TEXT IN HERE”)
Then press “CYCLE START”
Notes :

Easy Messenger B018
The text should then be displayed at the very top of the The variable should also have changed to the requested set-
screen. ting.
A message containing the same text should then be re-
ceived by the designated phone.
It is also possible to activate and deactivate users in the

same way:-
12345 deactivate or 12345 activate.
The controller sends out confirmation that the task was suc-
cessful.
A record of these texts can be found in the alarm log page.
Setting PLC variables via SMS
The possibility is available to set a variable in the PLC via

SMS. This function could be used for example to activate a
user message. Variable DB1700.DBB3000 is reserved for
this function.
The format can be in Binary, Hexadecimal or Decimal.

Format required for writing to the variable
Binary 2#00000000
Hexadecimal 16#00
Decimal 10#00
In the text editing area of the SMS device the ID of a user has
to be input followed by the value to be sent to the variable.
Example:-DB1700.DBX3000.4 is to be set to a 1, the profile

to be used has the ID of 12345.
Text to be typed in the SMS device:- 12345 plc 2#00010000
Now send the message. Providing that the user exists and is
active the SMS protocol screen of the controller will display
the received message, a few moments later the controller will
send a message to the sender to inform them that the task
was successful..
B018: END
Notes :

B018 END Easy Messenger

B016 Additional Axis Installation
Module Description:
A common requirement is for a standard machine to be fitted with an additional axis.

This requirement usually arises after the machine has left the factory.
Reconfiguring the drives will result in any user settings of the existing drives being overwritten by
default
data.
This module describes the procedure for adding an additional axis to a 3 axis + spindle milling ma-
chine while keeping the original settings intact and takes the form of a running example.
Module Objective:
Upon completion of this module you will be able to retrofit an axis to a running system.
Content:
Sinumerik
Options and Licensing
Adding the Additional Axis
B016
B016

Additional Axis Installation B016
Additional Axis Installation: Description Additional Axis

Installation:
A common requirement is for a standard machine to be fitted START
with an additional axis.
This requirement usually arises after the machine has left the
factory.
Prior to adding an additional axis it must be ensured that Options and

power and space requirements can be met. Licensing
This module describes the procedure for adding an additional

axis to a 3 axis + spindle milling machine while keeping the
original settings intact and takes the form of a running exam-
ple.
Adding the
Additional
Axis
Additional Axis
Installation:
END
Notes :

B016 Additional Axis Installation
Options and licensing Configuring the Additional Axis
Any additional axes may need to be licensed to check whether To replicate a standard 3 axes + spindle milling machine, the
the licence already exists go to the licence screen: drive configuration has been changed so that the only the
double axis modules are used.
The single axis module that was previously used for the spin-
dle will now become the additional axis.
The 3 axis + spindle DriveCLiQ configuration can be seen
below:
It may be necessary to obtain a new licence if the current one
does not allow further axis expansion.
The new axis also needs to be added in the channel machine

data area.
The axes have been assigned to the drives in the following

way:
X axis Double motor module 1, 1st drive.

Y axis Double motor module 1, 2nd drive
Z axis Double motor module 2, 1st drive.
Spindle Double motor module 2, 2nd drive.
The new axis can also be named accordingly. When the new hardware is connected and powered reapplied,
the system will detect the new hardware and issue an alarm.
In order to keep the original Sinamics drive settings (Bico’s)

intact, the topology recognition process for the drives should
To activate the machine data a “Reset (po)” procedure is re- not be carried out. This action will reset the Bico’s to factory
quired. status.
Instead, the function is available where the extra hardware
can be manually added.
Notes :

Additional Axis Installation B016
When the new hardware is fitted and the controller powered
up, the system will detect the extra hardware and issue an
alarm.
Configuration with the additional axis can be seen below:
The new components and component numbers are displayed
The procedure is carried out using the Start-up Tool.
Run the Start-up tool:
Ignore error 201416 which indicates that the system has

detected an additional component.
To add the new component use the following procedure:
The new hardware is displayed in red:
Notes :

B016 END Additional Axis Installation
A message box confirms that the transfer of the new hardware The axis will automatically be selected for the “Actual value”.
was successful:
The new drive has to be assigned to the correct NC axis
Select the new axis
Or
To complete the assignment an NCK power off/on is required.
The axis assignment function results in certain machine data

for the axis being set. It is however necessary to check and
adjust machine data to suit the individual requirements of
specific machines.
Testing will only be possible if the PLC interface signals for

the new axis are set
Select the axis from the “Set-point” drop-down menu.
Interface signals required for this example:
DB3804.DBX1.5 Activate 1st measuring system.

DB3804.DBX2.1 Controller enable.
DB3804.DBX21.7 Pulse enable.
A full list of interface signals is available in Appendix C.
Optimisation procedures should also be carried out on the

axis.
B016: END
Notes :

B029 Analogue Spindle
Module Description:
The 828D system offers the possibility for the connection of an analogue Spindle
Analogue output functionality is available for controlling a single analogue servo drive. The inter-
face for this is located on X252 of the 828D controller.
The analogue controlled axis must be declared as a spindle.
Module Objective:
Upon completion of this module you will be able to locate and configure the analogue interfaces.
Content:
Sinumerik
Analogue Servo Control via X252
B029
B029

Analogue Spindle B029
Analogue Spindle: Description

Analogue Spindle:
The 828D system offers the possibility for the connection of START
an analogue Spindle
Analogue output functionality is available for controlling a

single analogue servo drive. The interface for this is located Analogue
on X252 of the 828D controller. Servo
Control via
The analogue controlled axis must be declared as a spindle. X252
Analogue Spindle:
END
Notes :

B029 Analogue Spindle
Analogue Servo Control via X252 Machine Data for Analogue axis.
Interfaces: Rear view of PPU showing X252 interface. X252 pins 1 & 2 are reserved for the analogue output
Signal which is used for controlling an analogue servo drive.
(Nominal +/- 10V, can be changed via machine data.)
The functionality of the analogue signal can be influenced by
Axis MD 30134 $MA_IS_UNIPOLAR_OUTPUT.
The resolution of the analogue output signal is 14bit.
Sinamics digital outputs DO14 & DO15 (X132 pins 12 & 13)
are used for enabling and direction signals.
Machine Data Descriptions.
MD30100 $MA_CTRLOUT_SEGMENT_NR:
Activates the axis as an analogue axis when set to 0
X122 MD30134 $MA_IS_UNIPOLAR_OUTPUT:
X132
MD30134 Signal Function
X242 =0 AOUT (X252.1) Analogue output +/- 10V

Bipolar
spindle with AGND (X252.2) Analogue output 0v
X252 enable
signal. DO11 (X252.12) Controller enable (+24V DC)
=1 AOUT (X252.1) Analogue output +10V

X143 Unipolar
spindle,
separate AGND (X252.2) Analogue output 0v
enable/
direction DO11 (X252.12) Controller enable (+24V DC)
signals.
DO12 (X252.13) Negative direction (+24V DC)
X252 Signal Function/Default Setting =2 AOUT (X252.1) Analogue output +10V

Unipolar
Pin 1 AOUT Output for analogue axis +/- 10V spindle, AGND (X252.2) Analogue output 0v
Pin 2 AGND Ground for analogue output
direction
Pin 3 IN9 NCK DI 9 Digital Input $A_IN[9] Controller enable and
dependant DO11 (X252.12)
Pin 4 IN10 NCK DI 10 Digital Input $A_IN[10] positive direction (+24V DC)
enable.
Pin 6 IN12 NCK DI 12 Digital Input $A_IN[12] Controller enable and
Pin 7 MEXT4 Ground (M) Ground for pins 3 to 6 DO12 (X252.13)
negative direction (+24V DC)
Pin 11 MEXT3 Ground (M) Ground for pins 9, 10, 12, 13 MD32250 $MA_RATED_OUTVAL :
Controller enable/positive direction Sets the analogue output value (X252 pins 1 & 2)
Pin 12 OUT11 NCK DO 11 up to a maximum of +/- 10 volts for maximum speed.
for analogue spindle option
Controller enable/negative direc- The value entered is a percentage of 10 volts.
Pin 13 OUT12 NCK DO 12
tion for analogue spindle option Example: MD32250 = 80  80% of 10 volts  8 volts.
Pin 14 MEXT3 Ground (M) Ground for pins 9, 10, 12, 13 When the maximum speed is requested, 8 volts will be present
on X252 pins 1 & 2.
MD32260 $MA_RATED_VELO :
Sets the maximum speed of the axis in rpm. A this speed the
voltage determined by MD32250 will be present on X252 pins
1 & 2.
Notes :

Analogue Spindle B029
MD30200 $MA_NUM_ENCS : Notes:
Sets the number of actual value encoders used with the axis, if
no encoder used, must be set to 0. The analogue axis is restricted in the following areas:
MD30220 $MA_ENC_MODULE_NR[0] :  Dynamic Stiffness Control-unavailable.

The encoder should be connected as the 2nd encoder of an
existing Sinamics axis via an SMC module.
MD30220[0] of the analogue axis should be set the same as  Torque Feed Forward control-unavailable.
MD30220[0] of the axis that the encoder is connected to.
 The “Drive Ready” signal is simulated and set by the
MD30230 $MA_ENC_INPUT_NR[0] : drive software.
As previously explained, the encoder is connected as the 2nd
encoder of an existing Sinamics axis, therefore a value of 2  The drive parameters cannot be accessed, utilisation
must be entered in MD30230[0]. and other drive related functionality will not be seen on
the Service Display screens.
MD30240 $MA_ENC_TYP :
Sets the actual value encoder type.
Permitted values: 1 = Incremental, 4 = Absolute.
 Automatic speed and position controller optimisation is
not possible.
MD36700 $MA_DRIFT_ENABLE[0] :
Activation of automatic drift compensation
Permitted values: 0 = Inactive , 1 = active.
MD36710 $MA_DRIFT_LIMIT[0] :
Limit for automatic drift compensation, if active.
MD36720 $MA_DRIFT_VALUE[0] :
A basic drift value can be entered as an additional speed set-
point. Works with or without the presence of an actual value
encoder.
Example:
Machine data configuration for a system with 3 digital axes

and an analogue spindle. The spindle encoder is connected
via SMC to the Y axis Sinamics drive module.
Machine
X Y Z SP
Data
30100 5 5 5 0
30110 1 2 3 1
30120 1 1 1 1
30130 1 1 1 1
30134 0 0 0 0, 1 or 2
30200 1 1 1 1
30220[0] 1 2 3 2
30230[0] 1 1 1 2
30240 1 or 4 1 or 4 1 or 4 1 or 4
B029: END
Notes :

B029 END Analogue Spindle
Notes :

B006 Electrical Cabinet Design
Module Description:
Technological advances have resulted in the reduction in size of electronic equipment. The result
being that the equipment is more prone to heat, dust and moisture damage.
By calculating the power loss of the components and therefore ensuring the correct cooling
requirements of a particular cabinet, it is possible to reduce the failure rate of these and other compo-
nents.
It is also essential that the cabinets are designed to prevent/minimise the ingress of contaminants.
Module Objective:
Upon completion of this module you will know the design criteria of electrical cabinets.
Content:
Sinumerik
Choosing a Cabinet
Arrhenius’ Law
Cabinet Cooling
Equipment Mounting
Cables, plugs and sockets
Cabinet Sealing
Miscellaneous
Siemens assumes no responsibility for its contents. B006
B006

Electrical Cabinet Design B006
Electrical Cabinet Design: Description
Electrical Cabinet
Failure to construct an electrical cabinet to the Design:
requirements set out in this module will result in START
premature failure of electronic components.
This could be due to heat, dust moisture etc.
The following list shows the Seven Deadly Sins which Choosing a
must be avoided. Cabinet
Seven Deadly sins
The key to building a good electrical cabinet is avoiding

Arrhenius’
certain “Sins” which will cause
Law
premature equipment failure and sporadic faults.
 Sin 1 Cooling units must be able to handle the

heat generated by the electrical equipment. Cabinet
Cooling
 Sin 2 Air circulation must be controlled in a man-
ner which will prevent condensation forming and
must make use of the natural convection of warm
air.
Equipment
 Sin 3 Shielding of cables should be done with pur- Mounting
posely made clamps and not with a wire tail.
 Sin 4 Cabinets should be fully sealed including

unused cable entries.
Cables, plugs
and sockets
 Sin 5 Electrical equipment must be installed in
such a way that the air can flow freely,
recommended air gaps around the equipment
must be adhered to.
Cabinet
 Sin 6 Electrical cables must be routed so that Sealing
sensitive signal cables are kept separate from the
power cables.
 Sin 7 DC link bus-bar connections must be

tightened to the recommended torque. Miscellaneous
Electrical Cabinet
Design:
END
Notes :

Choosing a Cabinet Cabinet Ambient Temperature
Most of the heat within an electrical control cabinet is produced The ideal ambient temperature for the cabinet is 35°C.
by the drive The cooling unit should be set to achieve this temperature.
components. If the temperature is allowed to get too high the lifetime of the
components will be reduced.
Sinamics drives are available in internally or externally cooled If the temperature is set too low there is a risk of condensation
variants. forming on the electronic components which can also be
The internally cooled drive types dissipate heat within the detrimental to the equipment.
cabinet and will usually require a cooling unit to remove this
heat.
The externally cooled drive types dissipate heat to the outside
of the cabinet and may not require cooling units.
It may be preferable to always use cooler units as this allows

the cabinet to be sealed which is the best option for stopping
the entry of contaminants. Within the cabinets it may also be
necessary to install fans to ensure the air is circulated and
prevent “Hot spots” from forming.
The technical specifications of the individual hardware compo-

nent will provide details of the power loss measured in Watts.
Calculations are made to see if the cabinet can dissipate the
heat naturally.
The cabinet manufacturer can supply details of the heat-loss of
the cabinet.
Natural heat dissipation occurs through the cabinet walls
providing the wall is in free air and not against a wall for
example.
A general rule is that the energy dissipated is approximately
50Watts/m² of free cabinet wall assuming a 10° temperature
difference between the cabinet and the outside air.
Example 1:- A cabinet with a width of 3 m, a height of 2 m and

a depth of 1 m sited with its back to a wall has an effective
surface area of approximately 13 m².
2m x 3m = 6m² (Front)
2m x 1m = 2m² (left side)
2m x 1m = 2m² (Right side)
3m x 1m = 3m² (Top)
Total = 13m²
Therefore this cabinet is able to dissipate approximately 650 W.

(50W x 13m²)
If the actual losses of the cabinet equipment are higher than
this, other cooling measures have to be implemented.
Example 2:-
Internally cooled 36Kw Active Line Module-Power loss = 630W
Internally cooled 18A Single Motor Module-Power loss = 165 W
Internally cooled 30A Single Motor Module-Power loss = 630 W
These few items alone add up to 1425 W which would require

extra cooling if fitted into the cabinet described in example 1.
Notes :

Arrhenius Law
The following graph demonstrates Arrhenius Law and shows the effects that increased temperature has on the lifetime of elec-
tronic components.
It can be seen that an increase in temperature by 10 will result a 50% increase in the failure rate (50% reduction in life time).
Expected
Life Defect
Time Rate
120% — 9.00
— 8.00
100%
— 7.00
80% — 6.00
— 5.00
60%
— 4.00
40% — 3.00
— 2.00
20%
— 1.00
0% — 0.00
-10K -5K 0K 5K 10K 15K 20K 25K 30K
Temperature Change
Notes :

Cabinet Cooling Cabinets with cooling units

Cabinet cooling is usually accomplished using fans and filters Correct installation of cooling units.
or cooling units.
The cool air should be directed to the bottom of the drive. The
The fans and filter option would normally be used on low internal drive fans and natural convection will draw the air
power installations or where the drive units are of the through the drives.
externally cooled type.
A drawback of this method is that the fans pull air from outside The cool air from the cooling unit should not be directed
the cabinet via filters. Even if the filters are serviced regularly it straight onto/into the drives, it should be allowed to mix with
is impossible to keep all contaminants out of the cabinet. the warmer air already in the cabinet, This will minimise the
risk of condensation forming.
Cooling units allow the cabinets to be air-tight as the air within
the cabinet is re-circulated through the cooling unit. Cabinet top mounted cooling units require a method of direct-
A thermostat should be employed to regulate the temperature ing the cool air from the cooling unit to the bottom of the
to the recommended 35°C. drives.
If a higher temperature is unavoidable (max 50°C) the drive
units have to be de-regulated. In the case of a door mounted unit it may be necessary to
direct the cool air with the use of baffles.
It is important to position the cabinet and cooling devices to
ensure correct operation. Example of cabinet cooling with roof mounted cooling units:
A cabinet placed in such a position where it restricts the venti-
lation inlet/outlet can prevent the cabinet from being cooled
correctly or result in the cooling unit becoming damaged due
to excessive work cycles.
The cooling device should also be positioned to ensure the Outlet Cooling
cool air is reaching the desired areas and that the warm air is unit
extracted and not allowed to cause hot spots within the cabi- Inlet
net.
The inlets and outlets of the cooling units must have a

clearance of at least 200mm.
Example:
≥ 200mm
Ducting
Roof mounted
cooling units
Outlet
m
≥ 200mm 0m
20
≥
Drive
t
t
le
le
In
In
Potential
equipment
obstruction
Electrical cabinet Electrical cabinet
Temperature
Measuring point
The use of baffles is recommended to prevent ventilation short

circuits where the exhaust air is taken directly into the cooling
units.
Cabinet top mounted cooling unit.
Notes :

Example of cabinet cooling with door mounted cooling units: Cabinet cooling sins
The following diagrams are examples of cabinet cooling sins:
Outlet Cooling
unit
Inlet
Outlet
≥ 200mm Cooling
unit Air short circuit due
Drive to lack of ducting
equipment
Baffle
Temp.
Meas. Drive
point Inlet equipment
Cabinet door mounted cooling unit.
It is advisable that the cooling units are switched off

automatically when the cabinet door is opened.
Large differences between the outside air temperature and the

cabinet temperature can lead to condensation forming when
the cabinet doors are opened. This should be taken into
Cabinet top mounted cooling unit with-
consideration when the cabinet thermostat is set. out ducting
A by-product of cooling units is water. For obvious reasons it

must be ensured that this water is not allowed to enter the
electrical cabinet . This is particularly important for roof
mounted cooling units as any leaking water could drip directly
onto the drive equipment.
The outside of the cooling unit must be protected from any

possible contamination such as coolant, machine waste etc.
Notes :

Cabinet cooling sins continued. Cabinet cooling sins continued.
Air intake restricted due to

narrow gap due between
cooling unit and drive equip- Cold air outlet at the
ment. top of the cooling
unit.
< 200mm
Drive Drive
equipment equipment
Cold air directed straight

onto drive equipment will Warm air intake at the
cause condensation prob- bottom of the cooling
lems. unit.
Wrong type of cooling unit used.

Air short circuit/contamination
due to cabinet sealing problems
≥ 200mm
Drive
equipment
Baffle
Temp.
Meas.
point
Air short circuit/contamination due to

cabinet sealing problems
Notes :

Cabinets Without Cooling Units
For cabinets with externally cooled drive units it is possible that

the cooling can be achieved with fans drawing air from the
outside via a filter.
Natural convection causes the warm air to exit via a filter.
The fact that air is being drawn directly from the outside means
that this system can never be airtight.
Having a fan for the inlet side only ensures that the cabinet is
positively pressurised which helps keep contaminants from
entering.
It is extremely important that the filters are service regularly to
avoid ingress of contaminants and to maintain the efficiency of
the cooling process.
Example: Cabinet with externally cooled drive units.
Outlet
via filter
Drive
equipment
Temperature
Measuring points
Inlet via
Fan &
filter unit
Fan & filter type cooling system
Notes :

Equipment Mounting
Example:- Externally cooled
The correct mounting of equipment is important with respect drive module heat-sinks
to the cooling process and for Electromagnetic compatibility protruding from the rear of a
measures. cabinet with a cut-out ready to
accept another module.
Air flow to drive units:-
It is essential that the air flow to the drive units is unrestricted.

Other electrical
equipment, including cable ducting and cables, must be
mounted a suitable distance away from the top and bottom
sides of the drive units. The minimum distance for
Sinamics S120 drives is 80mm.
Examples: Correct mounting methods for drive equipment.
Cable
ducting Example:- Externally cooled
drive modules with heat-sink
≥ 80mm cover and fan/filter.
The fan takes air in at the
bottom and the cover creates
a chimney effect to give a
good cooling effect.
Drive
equipment
≥ 80mm
Cable
ducting
Diagram showing minimum Photograph of correctly

distance between drive units installed drive units. Cables
and other cabinet components. and ducting are not causing
restrictions to the air flow.
Notes :

Electromagnetic Compatibility (EMC) Example of a filter, reactor and line module installation.
To cut down on the interference effects caused by the high
frequency drive equipment certain measures can be taken.
One of these includes the positioning of the
equipment within the cabinet. By positioning the line module,
reactor and filter in close proximity to each other, cables
lengths can be kept to a minimum thus cutting down on emis-
Filter
sions.
Further reductions in emissions can be achieved by screening
the cables.
The mounting plate for the equipment should be one of bare
metal, this acts as a central earth point and also improves the
EMC.
Cable screen
Example: A bare metal backplane ready for the drive modules ground point
to be mounted, note the earth bonding cables, one for each
drive module.
Reactor
Line Module
Example: How shielded cable can be grounded.
Notes :

A typical cabinet layout demonstrating the close proximity of the filter, reactor and line module in order to reduce the interference
effects of the high frequency drive current.
The use of shielded cables is also necessary to further eliminate this Interference.
Shielding plates offer the best method for grounding the shields.
The power cables and the signal cables should also be run separately from each other throughout the machine and not just in
the electrical cabinet.
It is not permissible to connect any other equipment between the line module and the filter and reactor.
Remaining
Equipment
Filter
Shielded DriveCliq
Cables
Shielded Power Cables
Comb Power Module Add.

Axis
Line Module and Module
Main
4 Motor Modules
Switch
Filter Reactor
Protection
Shield plate for

≥ 100mm grounding the shields
Shielded Power Cables

Shielded Motor Cables
Notes :

Cables, Plugs and Sockets Example: An Incorrectly shielded cable
Shielding
Shielded power cables are recommended between the Sinam-

ics line filter, reactor and line module. If the cable length is 1m
or less the cables can be twisted and not shielded.
Signal cables and power cables should be kept separate by a

distance of at least 0.2m.
Cables should be kept as close as possible to objects with a

ground potential, this reduces crosstalk between cables.
Where the cable shield is grounded it should be done with the

use of grounding plates, this allows a large surface area of the
shield to be connected. The use of a wire to connect the shield
to ground is not permitted as the wire then becomes an aerial
which can introduce problems. Shielding that is connected via a plug & socket housing must
use a metallic housing with a continuous metallic contact.
Failure to observe all of the above can lead to intermittent Metalized housings are not permitted, over a period of time the
faults. metalized coating becomes worn and fails to be conductive to
the levels required.
The shielding of cables has a downside in that it causes addi- To maintain the airtight properties of the cabinet, cable outlets
tional losses in the line filter, reactor, in-feed and motor mod- should use methods
ules. This becomes worse the longer the cable length and can which form a seal and any unused openings blanked off.
cause overheating of the drive components.
A maximum of 50m is allowed for each motor module and a
maximum of 150m for each drive system.
Examples of cabinet cable entries:

Example: Correctly shielded cables
With plugs and sockets
Notes :

Cables, Plugs and Sockets Cabinet Sealing
Cabling Sins A cabinet that isn’t sealed correctly can lead to a multiple of
problems. Poor Sealing can be caused by cable entries, poorly
fitting doors, etc.
Encoder and power cables in close proximity:
A poorly sealed cabinet can:-
 Influence the air circulation and cause overheating due

to hotspots forming and air short circuits.
 Lead to a high moisture content which can in turn lead

to component failure.
 Emit electrical interference, causing problems with

other nearby equipment.
 Allow harmful, conductive contaminants to enter

causing component failure.
The cabinet door should always be closed and locked during

normal running operation, access should only be with a key or
tool and by authorised personnel.
Below:-An example of a poorly fitting cabinet door.
Top
Encoder and motor cables in close proximity.
Bottom
Notes :

Miscellaneous
Coil Suppression
Poor Electromagnetic compatibility can also affect other

cabinet mounted components.
To deal with this suppressing devices can be used on any item
with a coil. (Except servo motors)
AC components use RC networks for suppression while DC
components use diodes.
Below:-Example of 3 phase AC suppressors
AC Suppressor
B006: END
Notes :

B006 END Electrical Cabinet Design

Appendix A Hardware Differences
Module Description:
This module shows hardware differences of the Sinumerik 828D.
Module Objective:
Upon completion of this module you will understand the Sinumerik 828D hardware differences be-
tween Version 2.7 and 4.4
Contents:
Sinumerik
PPU Differences (IDC & SOC2 Drive Controllers)
SINUMERIK 828D Page 1 This document was produced for training purposes.
Appendix A
Notes
Appendix A Page 2 SINUMERIK 828D

Hardware Differences Appendix A
Appendix A: Description
Appendix A:
START
This module shows hardware differences of the Sinumerik
828D.
PPU
Differences
Appendix A:
END
Notes :
SINUMERIK 828D Page 3 Appendix A

Basic Information 828D controller with integrated PPU
Sinamics Drive Controller Types: PPU260/280 Vertical variant 10.4” TFT Colour Screen.
The IDC type drive controller has been superseded by the SOC2
drive controller.
This has made it necessary to change the design of the 828D.
The IDC controller is for use only with software version 2.x
The SOC2 controller is for use only with software version 4.x
Version Information:
PPU26x.1 and PPU28x.1:

Compatible only for version 2.x software.
PPU24x.2, PPU26x.2 and PPU28x.2:

Compatible only for version 4.x Software. PPU261/281 Horizontal variant 10.4” TFT Colour Screen.
Technology:
PPU26x.x and PPU28x.x: Technology is determined by the soft-

ware contained on the system CF card.
The milling and turning variants are identical when viewed from
the front and rear.
PPU24x.2: Technology determined by the controller hardware

type and the software contained on the system CF card.
The milling and turning variants are labelled on the top right cor-
PPU240 Horizontal variant 8.4” TFT Colour Screen:
ner of the front face of the controller (BASIC M or BASIC T).
Sinamics Drive Component Compatibility:
It is important that the drive component versions are compatible

with the software version.
Version 4.x can only be used with the following drive component
versions (Numbers relate to the last four digits of the Siemens
part number e.g. 6SL3120-2TE13-0AA3):
S120 Booksize Motor and Infeed modules: xxA3

PPU241 Vertical variant 8.4” TFT Colour Screen:
SME2x Sensor Module External: xxA3
SMC30: Sensor Module Cabinet: xxA2
All other components (e.g. SMC20) are not affected.
Notes :

Hardware Differences Appendix A
Interface locations: Interface locations:
Version 2.xx IDC Hardware. Version 4.xx SOC2 Hardware.

(PPU26x.1 & PPU28x.1) (PPU24x.2, PPU26x.2 & PPU28x.2)
Internal (System) CF card location. Internal (System) CF card location.
Fault
X100 Sync PN
X101 Fault PN
Sync
Rx/Tx X130
X102 Link
X140 X135
X122
X132
X242
X252
X143
X1
M T1 T2 T3
Interfaces for 828D V2.x: Interfaces for 828D V4.x:
X1 +24V DC supply X1 +24V DC supply

X100 DriveCliQ interface for line/motor modules
X101 DriveCliQ interface for DMC module X100 DriveCliQ interface for line/motor modules
X102 DriveCliQ interface for NX10 module DriveCliQ interface for Combi Dive
X120 Profinet interface
X121 Profinet interface X101 DriveCliQ interface for DMC module
X130 Ethernet-Factory network DriveCliQ interface for Compact Motor Modules
X135 USB interface (When used with Combi drive)
X140 RS232 interface for modem only
X122 Digital I/O for Sinamics X102 DriveCliQ interface for NX10 module
X132 Digital I/O for Sinamics (Not Combi or Basic versions)
X142 Digital I/O for NC DriveCliQ interface for TM54 Terminal Module for
X143 Interface for two Hand-wheels Safety Integrated signals.
T1 Analogue output measuring socket X130 Ethernet-Factory network
T2 Analogue output measuring socket X135 USB interface
M Electronic ground for analogue measuring sockets X140 RS232 interface
X143 Interface for two Hand-wheels
PN Profinet interface
PN Profinet interface (Not on 828D Basic M/T)
M Electronic ground for analogue measuring sockets
Notes :
SINUMERIK 828D Page 5 Appendix A

Digital I/O Interfaces
The interfaces for the digital I/O functionality has changed. The
v4.x interfaces now have 14 terminals compared with the v2.x
which have 12 pins.
An extra interface (X252) for digital NC I/O is present on V4.x
hardware.
V2.x Digital I/O Interfaces:
X122, X132 and X142
V4.x: Digital I/O Interfaces:
X122, X132, X242 and X252
Please refer to modules B010 & B030 for a detailed description

of the terminal functionality.
Appendix A: END
Notes :

Appendix B Technology Settings
Module Description:
The Technology settings for Milling and Turning are located in Machine Data. This module shows the differ-
ent areas.
The Machine Data areas are within the following ranges:-

51xxx General Machine Data
52xxx Channel Machine Data
53xxx Axis Machine Data
54xxx General Setting Data
55xxx Channel Setting Data
56xxx Axis Setting Data
Module Objective:
Upon completion of this module you will know the 840D sl Sinumerik Operate Technology machine data and
be able to carry out adjustments if required.
Content:
Sinumerik
General Machine Data
Channel Machine Data
Axis Machine Data
General Setting Data
Channel Setting Data
Appendix B
Appendix B
Appendix B Page 2 SINUMERIK 828D

Technology Settings Appendix B
Technology Settings: Description Technology

Settings:
START
The Technology settings for Milling and Turning are located in
Machine Data. This module shows the different areas.
The Machine Data areas are within the following ranges:-

51xxx General Machine Data
General
52xxx Channel Machine Data
Machine Data
53xxx Axis Machine Data
54xxx General Setting Data
55xxx Channel Setting Data
56xxx Axis Setting Data
Channel
Machine
Data
Axis Ma-
chine Data
General Setting
Data
Channel Setting
Data
Technology
Settings:
END
Notizen
SINUMERIK 828D Page 3 Appendix B

Appendix B
Appendix B
MD Identifier Description Old MD/GUD
51000 $MNS_DISP_RES_MM Display resolution in mm

51001 $MNS_DISP_RES_MM_FEED_PER_REV Display resolution in mm feedrate/rev
51002 $MNS_DISP_RES_MM_FEED_PER_TIME Display resolution in mm feedrate/min
51003 $MNS_DISP_RES_MM_FEED_PER_TOOTH Display resolution in mm feedrate/tooth
51004 $MNS_DISP_RES_MM_CONST_CUT_RATE Display resolution constant cutting speed m/min
Technology Settings
51010 $MNS_DISP_RES_INCH Display resolution in inch 9011
51011 $MNS_DISP_RES_INCH_FEED_P_REV Display resolution in inch feedrate/rev
51012 $MNS_DISP_RES_INCH_FEED_P_TIME Display resolution in inch feedrate/min
51013 $MNS_DISP_RES_INCH_FEED_P_TOOTH Display resolution in inch feedrate/tooth
51014 $MNS_DISP_RES_INCH_CUT_RATE Display resolution constant cutting speed ft/min
51020 $MNS_DISP_RES_ANGLE Display resolution of angle
Page 4
51021 $MNS_DISP_RES_SPINDLE Decimal places in speed entry field 9010, 9664

51022 $MNS_DISP_RES_ROT_AX_FEED Display resolution of rotary axis feedrate
51023 $MNS_ACT_VALUE_SPIND_MODE Only display spindles in actual values window
This affects the display of the spindles in the axis actual values window.
0 = Spindles are always displayed
1 = Spindles are displayed only if in axis mode
51024 $MNS_BLOCK_SEARCH_MODE_MASK_JS Bit mask for available search modes
Bit 0: Block search with calculation without approach
Bit 1: Block search with calculation with approach
Bit 3: Skip EXTCALL programs
Bit 5: Block search with test run
51025 $MNS_FRAMES_ACT_IMMEDIATELY Active data (frames) are activated immediately after change 9440
51026 $MNS_AXES_SHOW_GEO_FIRST When the machine data value is 1, the geometry axes of the channel are displayed first. 9421
51027 $MNS_ONLY_MKS_DIST_TO_GO Distance-to-go display in work window 9420

51028 $MNS_BLOCK_SEARCH_MODE_MASK Bit mask for available block search modes
SINUMERIK 828D
Bit 0: Block search with calculation without approach

Bit 1: Block search with calculation with approach
Bit 3: Skip EXTCALL programs
Bit 4: Block search without calculation
Bit 5: Block search with test run
SINUMERIK 828D
Technology Settings
51029 $MNS_MAX_SKP_LEVEL The machine data defines how many skip levels are made available for operation. 9423
51030 $MNS_SPIND_MAX_POWER Maximum value of the permissible spindle power rating in percent; the display bar in the 9428
machine image is shown in green within the range between 0 and the value stored in
SPIND_MAX_POWER.
51031 $MNS_SPIND_POWER_RANGE Scale end value for spindle power rating in percent; value must be equal to or greater than 9429
SPIND_MAX_POWER.
The display bar in the machine image is shown in red in the range between the values of
SPIND_MAX_POWER and SPIND_POWER_RANGE.
51032 $MNS_STAT_DISPLAY_BASE Number basis for display of articulated joint STAT 9042
00: no display
02: binary value display
10: decimal value display
16: hexadecimal value display
Page 5
51033 $MNS_TU_DISPLAY_BASE Number basis for display of rotary axis position TU 9243
00: no display
02: binary value display
10: decimal value display
16: hexadecimal value display
51034 $MNS_TEACH_MODE Teach mode to be activated 9026
Bit 0: Default teach-in
Taught-in block is transferred to the program using the Accept softkey.
Bit 1: Acceptance of teach block can be blocked by the PLC.
DB19.DBX13.0 = 0 block is accepted.
DB19.DBX13.0 = 1 block is not accepted.
Bit 2: Block selection only explicitly
Bits 16-31 are reserved for OEM.
51035 $MNS_WRITE_FRAMES_FINE_LIMIT Input limit for all work offsets fine
51036 $MNS_ENABLE_COORDINATE_REL Display REL coordinate system
0 = no relative coordinate system selectable
Appendix B
1 = REL coordinate system can be selected as an alternative of the WCS/SZS coordinate
system
Appendix B
51037 $MNS_ENABLE_COORDINATE_ACS Activate settable coordinate system 9424

0 = WCS coordinate system is displayed.
1 = SZS coordinate system is displayed.
(SZS is WCS reduced by the offset components defined in MD24030)
Appendix B
Appendix B
51038 $MNS_SET_ACT_VALUE Set actual value selection 9422
0 = Set actual value is not offered.
1 = If a user frame (settable work offset e.g. G54) is active, it will be used. In G500 Set ac-
tual values is not offered (system frame is no longer used).
51039 $MNS_PROGRAM_CONTROL_MODE_MASK Options for machine - program influence:
Bit 0: Program test function available
Technology Settings
51040 $MNS_SWITCH_TO_MACHINE_MASK Automatic operating area switchover to machine
Bit 0: When selecting a program in the program manager, the operating area does not
automatically switch over to Machine.
Bit 1: When switching the type of operation via the MCP, the operating area is not auto-
matically switched over to Machine.
Bit 2: Do not switch automatically in Programs during program selection.
Bit 3: No auto. Start of block search on selection / execution under Programs.
51041 $MNS_ENABLE_PROGLIST_USER Activates the PLC program list of the USER area. The programs entered there can be se-
lected by the PLC for processing.
51042 $MNS_ENABLE_PROGLIST_INDIVIDUAL Activates the PLC program list of the INDIVIDUAL area. The programs entered here can be
Page 6
selected by the PLC for processing.

51043 $MNS_ENABLE_PROGLIST_MANUFACT Activates the PLC program list of the MANUFACTURER area. The programs entered here
can be selected by the PLC for processing.
51044 $MNS_ACCESS_SHOW_SBL2 Display protection level SBL2 9227
51045 $MNS_ACCESS_TEACH_IN Protection level TEACH IN 9219
51046 $MNS_ACCESS_CLEAR_RPA Protection level delete R variables 9221
51047 $MNS_ACCESS_READ_GUD_LUD Read user variable protection level 9211
51048 $MNS_ACCESS_WRITE_GUD_LUD Write protection level of user variables
51049 $MNS_ACCESS_WRITE_PRG_COND Write program control protection level 9214
51050 $MNS_ACCESS_WRITE_PROGRAM Write part program protection level 9217
51051 $MNS_ACCESS_WRITE_RPA Protection level write R variables 9222
51052 $MNS_ACCESS_WRITE_SEA Protection level write setting data 9215

SINUMERIK 828D
51053 $MNS_ACCESS_WRITE_BASEFRAME Write basic work offset (basic frame) protection level
51054 $MNS_ACCESS_WRITE_CYCFRAME Write cycle frame protection level 9186

51055 $MNS_ACCESS_WRITE_EXTFRAME Write external work offset protection level 9188
SINUMERIK 828D
Technology Settings
51056 $MNS_ACCESS_WRITE_PARTFRAME Write table reference protection level 9184
51057 $MNS_ACCESS_WRITE_SETFRAME Write basic reference protection level
51058 $MNS_ACCESS_WRITE_TOOLFRAME Write basic tool reference protection level 9183

51059 $MNS_ACCESS_WRITE_TRAFRAME Write transformation frame protec. level 9187
51060 $MNS_ACCESS_WRITE_USERFRAME Write settable work offset (G54 ... G599) protection level
51061 $MNS_ACCESS_WRITE_WPFRAME Write workpiece reference protection level 9185
51062 $MNS_ACCESS_WRITE_FINE Write protection level for fine offset of all work offsets 9203
51063 $MNS_ACCESS_SET_ACT_VALUE Set actual value protection level 9220

51064 $MNS_ACCESS_WRITE_PROGLIST Write protection level of program list in USER area
51065 $MNS_NUM_DISPLAYED_CHANNELS Number of channels displayed simultaneously 9034
Page 7
51066 $MNS_ORDER_DISPLAYED_CHANNELS Channel numbers of the channels displayed
Contains the numbers of the channels to be displayed under machine in the multi-
channel view, in the desired order and separated by commas, semicolons or spaces.
51067 $MNS_ENABLE_HANDWHEEL_WINDOW Show handwheel window.
If the machine data is set to 0, the window for handwheel assignment is hidden.
51068 $MNS_SPIND_DRIVELOAD_FROM_PLC1 Machine axis index of spindle 1 utilization display from PLC
51069 $MNS_SPIND_DRIVELOAD_FROM_PLC2 Machine axis index of spindle 2 utilization display from PLC
51070 $MNS_ACCESS_CAL_TOOL_PROBE Protection level for calibration of the tool probe (ShopTurn)
51071 $MNS_ACCESS_ACTIVATE_CTRL_E Protection level of CTRL-Energy
51072 $MNS_ACCESS_EDIT_CTRL_E Protection level of CTRL-Energy for changing profiles
Appendix B
51073 $MNS_ACCESS_SET_SOFTKEY_ACCESS Protection level of ”Adapt softkeys”
51198 $MNS_ACCESS_READ_TM_ALL_PARAM Protection level TM details - read all parameters
Appendix B
51199 $MNS_ACCESS_WRITE_TM_GRIND Protection level of tool management for writing grinding data
Appendix B
Appendix B
51200 $MNS_ACCESS_WRITE_TM_GEO Write tool offset geometry data protection level 9201
51201 $MNS_ACCESS_WRITE_TM_WEAR Write tool offset wear data protection level 9202
51202 $MNS_ACCESS_WRITE_TM_WEAR_DELTA Protection level for restricted writing of tool wear values, 9203
s. SD 54213: TM_WRITE_DELTA_LIMIT
51203 $MNS_ACCESS_WRITE_TM_SC Write tool offset sum offset protection level 9204
Technology Settings
51204 $MNS_ACCESS_WRITE_TM_EC Write tool offset use offsets protection level 9205
51205 $MNS_ACCESS_WRITE_TM_SUPVIS Write tool offset monitoring data protection level 9206
One authorization applies to all limit values: quantity, service life, wear and the monitor-
ing type.
51206 $MNS_ACCESS_WRITE_TM_ASSDNO Write tool offset unique D number protection level 9207
51207 $MNS_ACCESS_WRITE_TM_WGROUP Write tool offset wear groups (magazine location / magazine) protection level 9208
51208 $MNS_ACCESS_WRITE_TM_ADAPT Write tool offset tool adapter geometry data protection level 9209
Page 8
51209 $MNS_ACCESS_WRITE_TM_NAME Write tool offset tool name and duplo data protection level 9240
51210 $MNS_ACCESS_WRITE_TM_TYPE Write tool offset tool type protection level 9241
51211 $MNS_ACCESS_READ_TM Read tool offset data protection level 9200
51212 $MNS_TM_WRITE_WEAR_ABS_LIMIT With TM_WRITE_WEAR_ABS_LIMIT, the max. possible value of a tool wear is limited 9639
absolutely, independently of the current protection level (keyswitch position), i.e. also
independently of ACCESS_WRITE_TM_WEAR. Absolute and incremental wear limita-
tion can be combined, i.e. the wear can be changed incrementally up to the absolute
limit, see MD 51213.
51213 $MNS_TM_WRITE_WEAR_DELTA_LIMIT When entering tool offsets, the value of the change from the previous value to the new 9450
value cannot exceed the value set here.
With TM_WRITE_WEAR_DELTA_LIMIT, the change to a tool wear can be limited incre-
mentally, if the current protection level is the same as or higher than the one set in AC-
CESS_WRITE_TM_WEAR_DELTA. With the current protection level being the same or
higher than ACCESS_WRITE_TM_WEAR, an incremental limitation is no longer per-
formed. incremental wear limitation can be combined, i.e. the wear can be changed up
to the absolute limit, see MD 51212.
SINUMERIK 828D
51214 $MNS_TM_WRITE_LIMIT_MASK Validity of the restricted tool wear input 9449

Bit 0: Use for cutting edge data, wear
Bit 1: Use for SC data, sum offsets
Bit 2: Use for EC data, use offsets
Bit 0+1+2: Use for all data, wear, SC, EC
SINUMERIK 828D
Technology Settings
51215 $MNS_ACCESS_WRITE_TM_ALL_PARAM Protection level TM details - write all parameters
51216 $MNS_ACCESS_TM_TOOL_CREATE Protection level TM create tool
51217 $MNS_ACCESS_TM_TOOL_DELETE Protection level TM delete tool
51218 $MNS_ACCESS_TM_TOOL_LOAD Protection level TM load tool
51219 $MNS_ACCESS_TM_TOOL_UNLOAD Protection level TM unload tool
51220 $MNS_ACCESS_TM_TOOL_MOVE Protection level TM relocate tool
51221 $MNS_ACCESS_TM_TOOL_REACTIVATE Protection level TM reactivate tool
51222 $MNS_ACCESS_TM_TOOL_MEASURE Protection level TM measure tool
51223 $MNS_ACCESS_TM_TOOLEDGE_CREATE Protection level TM create tool cutting edge
51224 $MNS_ACCESS_TM_TOOLEDGE_DELETE Protection level TM delete tool cutting edge

Page 9
51225 $MNS_ACCESS_TM_MAGAZINE_POS Protection level TM position magazine
51226 $MNS_FUNCTION_MASK_SIM Function mask Simulation

Bit 0: No automatic start on simulation selection
51228 $MNS_FUNCTION_MASK_TECH Function mask Cross-technology
Bit 0: G code programming without multi-channel data
Bit 1: Enable print function of editor
51230 $MNS_ENABLE_LADDER_DB_ADDRESSES Activation of DB addresses in PLC Ladder Viewer
51231 $MNS_ENABLE_LADDER_EDITOR Activation of PLC Ladder Editor
51233 $MNS_ENABLE_GSM_MODEM Activation of GSM Modem for Easy Message
51235 $MNS_ACCESS_RESET_SERV_PLANNER Protection level for acknowledgement of maintenance tasks
51600 $MNS_MEA_CAL_WP_NUM The workpiece probe calibration data refer to the workpiece coordinate system (WCS)!
Appendix B
In the data fields, the workpiece probe calibration data of the technologies Milling and
Turning are stored!
Appendix B
51601 $MNS_MEA_CAL_EDGE_NUM The gauging block is exclusively used to calibrate the workpiece probe of the Turning
technology!
51602 $MNS_MEA_CAL_TP_NUM The geometry data and calibration data of the tool probe refer to the machine coordinate
system (MCS)!
Appendix B
Appendix B
51603 $MNS_MEA_CAL_TPW_NUM The geometry data and calibration data of the tool probe refer to the workpiece coordinate sys-
tem (WCS)!
51618 $MNS_MEA_CM_ROT_AX_POS_TOL Entries in parameter $MN_MEA_CM_ROT_AX_POS_TOL are effective only if

$MN_MEA_TOOLCARR_ENABLE=1
The real angle position of the rotary axes can deviate from the programmed one (exact stop fine
window).
Technology Settings
This deviation depends on the position control features of the axis. The maximum deviation ex-
pected on the concrete axis must be entered in this parameter. When the tolerance is exceeded,
alarm 61442 "Toolholder not in parallel with the geometry axes" is displayed.
51740 $MNS_MEA_FUNCTION_MASK Function mask for measuring cycles
Bit 0: Workpiece measurement, calibration status monitoring, measuring in automatic
Bit 1: Workpiece measurement, lenght reference of probe in infeed axis, for milling
Bit 2: Workpiece measurement, support of orientable toolholders
Bit 3: Workpiece measurement, correction angle for mono probe
Bit 16: Tool measurement, support of orientable toolholders
51750 $MNS_J_MEA_M_DIST This parameter defines the measuring path in front of and behind the measuring setpoint. 9752
Page 10
51751 $MNS_J_MEA_M_DIST_MANUELL Measuring path, manual measurement ((for "Measure in JOG")) [mm] (in front of and behind the 9753
measuring setpoint)
51752 $MNS_J_MEA_M_DIST_TOOL_LENGTH Measuring path for tool length measuring. 9754
51753 $MNS_J_MEA_M_DIST_TOOL_RADIUS Measuring path for tool radius measuring. 9755
51757 $MNS_J_MEA_COLL_MONIT_FEED Feedrate in the working plane with active collision detection. 9757
51758 $MNS_J_MEA_COLL_MONIT_POS_FEED Feedrate of the infeed axis with active collision detection, for "Measure in JOG". 9758
51770 $MNS_J_MEA_CAL_RING_DIAM Calibration ring diameter, for probe sphere calibration in the plane, for "Measure in JOG"
51772 $MNS_J_MEA_CAL_HEIGHT_FEEDAX Calibration height in the infeed axis for probe length calibration, for "Measure in JOG"
The calibration height must be entered with reference to the the workpiece coordinate system
(WCS)!
51780 $MNS_J_MEA_T_PROBE_DIAM_RAD Effective grinding wheel diameter of the tool probe for radius measurement on milling tools, for 9766
"Measure in JOG"
51784 $MNS_J_MEA_T_PROBE_APPR_AX_DIR Effective grinding wheel diameter of the tool probe for length measurement on milling tools, for 9768
SINUMERIK 828D
"Measure in JOG"
51786 $MNS_J_MEA_T_PROBE_MEASURE_DIST Measuring path for tool probe calibration and tool measuring with stationary spindle, in front of 9772
and behind the expected switching position.
SINUMERIK 828D
Technology Settings
52000 $MCS_DISP_COORDINATE_SYSTEM With this MD you adapt the operator panel of the coordinate system to the machine's coordinate 9650
system. Depending on the selected position, all help screens, the sequence graphic, the simula-
tion and the input fields with the circular direction specified will change automatically.
Also note MD 52210 $MCS_FUNCTION_MASK_DISP, bit 1.
52005 $MCS_DISP_PLANE_MILL Plane selection Milling 9660
0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52006 $MCS_DISP_PLANE_TURN Plane selection Turning
0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52010 $MCS_DISP_NUM_AXIS_BIG_FONT Number of actual values with large font
Page 11
52011 $MCS_ADJUST_NUM_AXIS_BIG_FONT Adapt the number of actual values with large font if the number of geometry axes changes, e.g.
due to transformations like TRANSMIT or TRACYL.
0 = Only MD 52010 "DISP_NUM_AXIS_BIG_FONT" is valid. The number is assigned as a fixed
value.
1 = Only the geometry axes are displayed in large font. MD 52010
"DISP_NUM_AXIS_BIG_FONT" is ignored.
2 = The number of geometry axes plus the content of MD 52010 "DISP_NUM_AXIS_BIG_FONT"
are displayed in large font.
52200 $MCS_TECHNOLOGY Technology 9020
0: no specific configuration
1: turning
2: milling
Also note MD 52201 $MCS_TECHNOLOGY_EXTENSION.
52201 $MCS_TECHNOLOGY_EXTENSION Extended technology
0: no specific configuration
1: turning
2: milling
Appendix B
Also note MD 52200 $MCS_TECHNOLOGY.
Example:
Appendix B
Turning machine with milling technology

MD 52200 $MCS_TECHNOLOGY = 1
MD 52201 $MCS_TECHNOLOGY_EXTENSION = 2
Appendix B
Appendix B
52206 $MCS_AXIS_USAGE Meaning of the axes in the channel
0 = no special meaning 9705, 9708,
1 = tool spindle (driven tool) 9802, 9803,
2 = auxiliary spindle (driven tool) 9804, 9805,
3 = main spindle (turning) 9806, 9807,
4 = C axis of the main spindle (turning) 9808.
5 = counter spindle (turning)
6 = C axis of the counter spindle (turning)
Technology Settings
7 = linear axis of the counter spindle (turning)
8 = tailstock (turning)
9 = steady rest (turning)
10 = B axis (turning)
52207 $MCS_AXIS_USAGE_ATTRIB Axis attributes
Bit 0: Rotates around the 1st geometry axis (applies to rotary axes) 9653, 9720,
Bit 1: Rotates around the 2nd geometry axis (applies to rotary axes) 9703, 9704,
Bit 2: Rotates around the 3rd geometry axis (applies to rotary axes) 9706, 9707,
Bit 3: Displayed positive direction of rotation is counterclockwise (applies to rotary axes) 9822, 9823,
Bit 4: Displayed direction of rotation for M3 is counterclockwise (applies to spindles) 9824, 9825.
Page 12
Bit 5: Direction of rotation M3 corresponds to rotary axis minus (applies to spindles)

This bit must be set analog to PLC bit DBnn.DBX17.6!
(nn = 31 + machine data index)
Bit 6: Show rotary axis as offset target for measruning
Bit 7: Offer rotation axis in position pattern 9727
52210 $MCS_FUNCTION_MASK_DISP Function mask Display
Bit 0: Measuring system for programs always in the base system 9626 Bit 9
Bit 1: Front view for turning in school coordinate system 9719
Bit 2: Hide “T,S,M” soft key in JOG area
Bit 3: Generate automatic end-of-program in MDI (with the “Delete blocks” soft key)
Bit 4: Show follow-on tool in T,F,S window
52212 $MCS_FUNCTION_MASK_TECH Function mask Cross-technology
Bit 0: Enable Swivel 9723
Bit 1: No optimized travel along software limit switches
Bit 2: Approach logic for step drill (ShopTurn)
Bit 3: Call block search cycle for ShopMill/ShopTurn
Bit 4: Approach logic through cycle (ShopTurn)
Bit 5: Call block search cycle for SERUPRO
Bit 6: Work offset value ZV cannot be entered (ShopTurn)
SINUMERIK 828D
Bit 7: Detect the expiry of tool lives (ShopMill/ShopTurn)

Bit 11: Switch off layer check for drilling and milling tools (ShopTurn)
SINUMERIK 828D
Technology Settings
52214 $MCS_FUNCTION_MASK_MILL Function mask Milling

Bit 0: Enable cylinder surface transformation (ShopMill) 9721
Bit 1: Reserved
Bit 2: Reserved
Bit 3: Enable inside/rear machining
Bit 4: Enable spindle clamping (C axis) 9843
52216 $MCS_FUNCTION_MASK_DRILL Function mask Drilling
Bit 0: CYCLE84 Unhide input fields Technology
Bit 1: CYCLE840 Unhide input fields Technology
52218 $MCS_FUNCTION_MASK_TURN Function mask Turning
Bit 0: Enable zoom under manual for tool measurement 9840
Bit 1: Enable parts gripper for cut-off 9841
Bit 2: Enable tailstock 9842
Bit 3: Reserved
Bit 4: Enable spindle control of main spindle above surface 9897Bit 0
Bit 5: Enable spindle control of tool spindle above surface 9897Bit 1
Bit 6: Enable balance cutting for dual-channel stock removal 9897Bit 2
Page 13
52229 $MCS_ENABLE_QUICK_M_CODES Enable fast M functions

Bit 0: Coolant OFF
Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
Bit 3: Coolant 1 and 2 ON
52230 $MCS_M_CODE_ALL_COOLANTS_OFF M code for all coolants OFF 9686
52231 $MCS_M_CODE_COOLANT_1_ON M code for coolant 1 ON 9680
52232 $MCS_M_CODE_COOLANT_2_ON M code for coolant 2 ON 9681
52233 $MCS_M_CODE_COOLANT_1_AND_2_ON M code for coolant 1 + 2 ON 9668
52240 $MCS_NAME_TOOL_CHANGE_PROG Tool change program for G code steps
Appendix B
Appendix B
Appendix B
Appendix B
52244 $MCS_SUB_SPINDLE_PARK_POS_Y Parking position of the Y axis with counter spindle 9849
52248 $MCS_REV_2_BORDER_TOOL_LENGTH Limit value of tool length X for 2nd revolver: 9838
Limit value = 0: There is only one revolver
Tool length < limit value: Tool belongs to 1st revolver/multifix
Tool length >= limit value: Tool belongs to 2nd revolver/multifix
Technology Settings
52250 $MCS_M_CODE_CHUCK_OPEN M code for Open chuck with non-rotating spindle.
Example: "M34" or "M1=34"
Elements:
[0]: Main spindle
[1]: Counter spindle
52251 $MCS_M_CODE_CHUCK_CLOSE_OPEN_ M code for Open chuck with rotating spindle.
ROT Example: "M34" or "M1=34"
Elements:
[0]: Main spindle
Page 14
52252 $MCS_M_CODE_CHUCK_CLOSE M code for Close chuck

Elements:
[0]: Main spindle
52253 $MCS_M_CODE_TAILSTOCK_FORWARD M code for tailstock forward
Elements:
[0]: Main spindle
52254 $MCS_M_CODE_TAILSTOCK_BACKWARD M code for tailstock backward
Elements:
[0]: Main spindle
52260 $MCS_MACHINE_JOG_INTERRUPT_PRIO Priory for start ASUP under machine JOG
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
52270 $MCS_TM_FUNCTION_MASK Function mask Tool management

Bit 0: Create tool on magazine location not allowed. Tools can only be created outside the maga- 9478 Bit 3
zine.
Bit 1: Load/unload disable, if machine is not in reset. Tools can only be loaded/unloaded, if the 9478 Bit 9
appropriate channel is in reset state.
Bit 2: Load/unload disable on Emergency stop. Tools can only be loaded/unloaded, if Emer- 9478 Bit 12
gency stop is not active.
Bit 3: Load/unload tool to/from spindle is disabled. Tools cannot be loaded to or unloaded from 9478 Bit 15
the spindle.
Bit 4: Loading is executed directly in the spindle. Tools are loaded exclusively directly in the spin- 9478 Bit 20
dle.
Bit 5: Use grinding configuration file.
Bit 6: Reserved
Bit 7: Create tool using the tool number. Specify the tool's T number when creating the tool.
Bit 8: Fade out Relocate tool. The function 'Relocate tool" is faded out on the user interface.
Bit 9: Fade out Position magazine. The function 'Position magazine' is faded out on the user in-
terface.
Bit 10: Reactivate tool using Position magazine. Prior to reactivating the tool is positioned on the
Page 15
loading position.
Bit 11: Reactivate tool in all monitoring modes. When reactivating a tool, all monitoring modes
enabled in the NC are reactivated for this tool, even the monitoring modes, which have not
been set for the relevant tool, but are available in the background only.
Bit 12: Fade out Reactivate tool. The function 'Reactivate tool' is faded out on the user interface.
52271 $MCS_TM_MAG_PLACE_DISTANCE Distance between individual magazine locations. 9479

Is used for graphical display of magazine and tools in tool management.
52272 $MCS_TM_TOOL_LOAD_DEFAULT_MAG Default magazine for tool loading 9671

0 = No default magazine
52273 $MCS_TM_TOOL_MOVE_DEFAULT_MAG Default magazine for tool relocation 9687
0 = No default magazine
52274 $MCS_TM_TOOL_LOAD_STATION Number of load station 9673
0 = All configured stations are taken into account
Appendix B
52281 $MCS_TOOL_MCODE_FUNC_ON M code for tool-specific function ON 9739, 9741,
Value -1 means that the M function is not output. If both M commands of a function equal -1, the 9743, 9745.
Appendix B
corresponding field will not be displayed in the user interface.

52282 $MCS_TOOL_MCODE_FUNC_OFF M code for tool-specific function OFF 9740, 9742,
Value -1 means that the M function is not output. If both M commands of a function equal -1, the 9744, 9746.
corresponding field will not be displayed in the user interface.
Appendix B
Appendix B
52290 $MCS_SIM_DISPLAY_CONFIG Location of status display of the channel in the simulation (OP019 only)
Bit 0: Corner left/top
Bit 1: Corner right/top
Bit 2: Corner left/bott
Bit 3: Corner right/bott
52740 $MCS_MEA_FUNCTION_MASK Function mask for measuring cycles 9750, 9751
Bit 0: Workpiece measurement, CNC probe input _CHBIT[0]
Technology Settings
Bit 1: Workpiece measurement, measurement in third geometry axis (Y), for turning _CHBIT[19]
Bit 16: Tool measurement, CNC probe input _CHBIT[1]
52750 $MCS_J_MEA_FIXPOINT Z value for measuring against fixed point 9748
52751 $MCS_J_MEA_MAGN_GLAS_POS Zoom position for tool measurement 9820, 9821
[0] = Position in 1st axis
[1] = Position in 2nd axis
52800 $MCS_ISO_M_ENABLE_POLAR_COORD Polar coordinates
0: OFF
Page 16
1: ON
52802 $MCS_ISO_ENABLE_INTERRUPTS Interrupt process
0: OFF
1: ON
52804 $MCS_ISO_ENABLE_DRYRUN Machining skipped during tapping G74/G84 at DRY RUN
0: OFF
1: ON
52806 $MCS_ISO_SCALING_SYSTEM Basic system
0: not defined
1: METRIC
2: INCH
52808 $MCS_ISO_SIMULTAN_AXES_START Simultaneous approach to the boring position on all programmed axes
0: OFF
1: ON
52810 $MCS_ISO_T_DEEPHOLE_DRILL_MODE Select the type of deep hole drilling
0: deep hole drilling with chip breaking
1: deep hole drilling with stock removal
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
Axis Machine Data

53230 $MAS_SIM_START_POSITION Axis position at start of simulation
53240 $MAS_SPINDLE_PARAMETER Spindle chuck data

[0]: Chuck dimension
[1]: Stop dimension
[2]: Jaw dimension
53241 $MAS_SPINDLE_CHUCK_TYPE Spindle jaw type
0 = Clamp from outside 9829
1 = Clamp from inside
53242 $MAS_TAILSTOCK_PARAMETER Tailstock data
[0]: Tailstock diameter 9836
[1]: Tailstock length 9837

Page 17

54215 $SNS_TM_FUNCTION_MASK_SET Function mask Tool management
Bit 0: Diameter display for rotating tools. For rotating tools the diameter is displayed instead of
the radius value. 9663
Bit 1: Default direction of rotation for all turning tools is M4. When creating turning tools the direc- 9826
tion of rotation is defaulted with M4.
Bit 2: Create tool without name suggestion. 9478 Bit 4
Bit 3: Input disable for tool name and tool type in loaded tools. When tools are loaded, the tool 9478 Bit 7
name and tool type can no longer be changed. 9478 Bit 6
Bit 4: Input disable for loaded tools, if the channel is not in Reset. 9478 Bit 10
Bit 5: Calculate tool wear inputs additively. Wear data are input additively to the already existing
wear value. 9478 Bit 11
Bit 6: Numerical input of the tool ident. Only numbers are permissible for tool ident input.
Bit 7: Fade out tool monitoring parameters. The tool monitoring parameters are faded out on the
user interface.
Appendix B
Bit 8: Diameter display for transverse axis - Geometry. The geometry value of the transverse axis
is displayed as diameter value.
Bit 9: Diameter display for transverse axis - Wear. The wear value of the transverse axis is dis-
Appendix B
played as diameter value.

Bit 10: Enable load/relocate tool on buffer locations. In the load dialog the magazine number can 9478 Bit 25
be entered. Thus it is possible to access the buffer using magazine number 9998.
Bit 11: Creating tool in gripper disabled.
Appendix B
Appendix B
54600 $SNS_MEA_WP_BALL_DIAM Effective sphere diameter of the probe sphere for the workpiece probe. _WP[x,0]
The value of this parameter is created by the operation "Calibrate workpiece probe"!
54601 $SNS_MEA_WP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in negative traversing direction (X at G17) of the _WP[x,1]
workpiece probe.
The term "negative traversing direction" refers to the currently active workpiece zero point refer-
ence!
Technology Settings
54602 $SNS_MEA_WP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in positive traversing direction (X at G17) of the _WP[x,2]
workpiece probe.
The term "positive traversing direction" refers to the currently active workpiece zero point refer-
ence!
54603 $SNS_MEA_WP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in negative traversing direction (Y at G17) of the _WP[x,3]
workpiece probe.
ence!
Page 18
54604 $SNS_MEA_WP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in positive traversing direction (Y at G17) of the _WP[x,4]
workpiece probe.
ence!
54605 $SNS_MEA_WP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in negative traversing direction (Z at G17) of the _WP[x,5]
workpiece probe.
ence!
54606 $SNS_MEA_WP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in positive traversing direction (Z at G17) of the _WP[x,6]
workpiece probe.
ence!
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
54607 $SNS_MEA_WP_POS_DEV_AX1 The position deviation in the 1st measuring axis represents a geometrical offset of the centre _WP[x,7]
point of the probe sphere related to the electrical centre point of the probe in this axis!
54608 $SNS_MEA_WP_POS_DEV_AX2 The position deviation in the 2nd measuring axis represents a geometrical offset of the centre _WP[x,8]
point of the probe sphere related to the electrical centre point of the probe in this axis!
54609 $SNS_MEA_WP_STATUS_RT Calibration status of the axis positions reserved for internal use! _WP[x,9]
54610 $SNS_MEA_WP_STATUS_GEN Calibration status in general reserved for internal use! _WP[x,10]
Page 19
54611 $SNS_MEA_WP_FEED Measure workpiece measuring feed for calibration.

This measuring feed is used for all subsequent workpiece measuring programs in conjunction
with the probe field.
54615 $SNS_MEA_CAL_EDGE_BASE_AX1 Calibration groove base of the 1st measuring axis (abscissa, Z at G18) _KB[x,2]
This parameter is a geometrical component of the calibration groove and must be supplied by the
user!
54617 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX1 Calibration groove edge in positive direction of the 1st measuring axis (abscissa, Z at G18) _KB[x,3]
user!
54618 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX1 Calibration groove edge in negative direction of the 1st measuring axis (abscissa, Z at G18) _KB[x,4]
Appendix B
user!
Appendix B
Appendix B
Appendix B
54619 $SNS_MEA_CAL_EDGE_BASE_AX2 Calibration groove base of the 2nd measuring axis (ordinate, X at G18) _KB[x,6]
This parameter is a geometrical component of the calibration groove and must be supplied by
the user!
54620 $SNS_MEA_CAL_EDGE_UPPER_AX2 Calibration groove upper edge of the 2nd measuring axis (ordinate, X at G18) _KB[x,5]
the user!
54621 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX2 Calibration groove edge in positive direction of the 2nd measuring axis (ordinate, X at G18) _KB[x,0]
Technology Settings
the user!
54622 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX2 Calibration groove edge in negative direction of the 2nd measuring axis (ordinate, X at G18) _KB[x,1]
the user!
54625 $SNS_MEA_TP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) _TP[x,0]
The trigger point refers to the machine coordinate system (MCS).
Prior to calibration the approximate trigger point must be entered in the machine coordinate sys-
tem!
Page 20
The exact value of this parameter is created by the operation "Calibrate tool probe"!
54626 $SNS_MEA_TP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) _TP[x,1]
tem!
54627 $SNS_MEA_TP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) _TP[x,2]
tem!
54628 $SNS_MEA_TP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) _TP[x,3]
tem!
54629 $SNS_MEA_TP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) _TP[x,4]
SINUMERIK 828D
tem!
SINUMERIK 828D
Technology Settings
54630 $SNS_MEA_TP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) _TP[x,5]
tem!
54631 $SNS_MEA_TP_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. _TP[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured 9765
with square probes.
54632 $SNS_MEA_TP_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. _TP[x,7]
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the 9764
minus direction.
The parameter is divided into three components the functions of which are to be assigned to cali-
bration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components
Decimal position:
Page 21
Ones: 1st geometry axis (X)

Tens: 2nd geometry axis (Y)
Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not enabled
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
54633 $SNS_MEA_TP_TYPE Tool probe type _TP[x,8]
0: Cube 9763
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54634 $SNS_MEA_TP_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. _TP[x,9]
For tool probe calibration this distance defines the calibration depth and for milling tool measuring 9767
the measuring depth!
Appendix B
This parameter does not apply to turning tool measuring!
54635 $SNS_MEA_TP_STATUS_GEN Calibration status general, reserved for intermal use!
Appendix B
The value ot this parameter is assigned when the “Calibrate tool probe“ procedure is executed!
54636 $SNS_MEA_TP_FEED Measuring feed for tool probe calibration in WMCS
This measuring feed is used for all subsequent tool measuring programs in conjunction with the
probe filed!
Appendix B
Appendix B
54640 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) _TPW[x,0]
The trigger point refers to the workpiece coordinate system (WCS).
Prior to calibration the approximate trigger point must be entered in the workpiece coordinate sys-
tem!
54641 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) _TPW[x,1]
Technology Settings
tem!
54642 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) _TPW[x,2]
tem!
54643 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) _TPW[x,3]
Page 22

tem!
54644 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) _TPW[x,4]
tem!
54645 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) _TPW[x,5]
tem!
54646 $SNS_MEA_TPW_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. _TPW[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured
with square probes.
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
54647 $SNS_MEA_TPW_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. _TPW[x,7]
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
minus direction.
The parameter is divided into three components the functions of which are to be assigned to cali-
bration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components
Decimal position:
Ones: 1st geometry axis (X)
Tens: 2nd geometry axis (Y)
Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not enabled
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
Page 23
54648 $SNS_MEA_TPW_TYPE Tool probe type _TPW[x,8]

0: Cube
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54649 $SNS_MEA_TPW_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. _TPW[x,9]
For tool probe calibration this distance defines the calibration depth and for milling tool measur-
ing the measuring depth!
This parameter does not apply to turning tool measuring!
54650 $SNS_MEA_TPW_STATUS_GEN Calibration status general, reserved for intermal use!
The value ot this parameter is assigned when the “Calibrate tool probe“ procedure is executed!
54651 $SNS_MEA_TPW_FEED Measuring feed for tool probe calibration in WCS
This measuring feed is used for all subsequent tool measuring programs in conjunction with the
probe filed!
54652 $SNS_MEA_INPUT_TOOL_PROBE_SUB CNC measurement input for tool probe with reference to the counterspindle 9828
Appendix B
=0: Toolsetter no.=n+1, with reference to the main spindle
CNC measurement input corresponds to the value of $MCS_MEA_FUNCTION_MASK, bit16
=10: Toolsetter no.=n+1, with reference to the counterspindle
Appendix B
units digit =0, corresponds to CNC measurement input 1

=11: Toolsetter no.=n+1, with reference to the counterspindle
units digit =1, corresponds to CNC measurement input 2
Appendix B
Appendix B
54670 $SNS_MEA_CM_MAX_PERI_SPEED Max. permissible peripheral speed of the tool to be measured when the spindle rotates. _CM[0]
Monitoring parameter for tool measuring with rotating spindle only effective with 9759
SD54749 $SNS_MEA_FUNCTION_MASK_TOOL, Bit 10 = 0!
54671 $SNS_MEA_CM_MAX_REVOLUTIONS Max. permissible tool speed for tool measuring with rotating spindle. _CM[1]
The speed is automatically reduced when this value is exceeded. 9760
Monitoring parameter for tool measuring with rotating spindle only effective with
Technology Settings
54672 $SNS_MEA_CM_MAX_FEEDRATE Max. permissible feed for contact of the tool to be measured with the probe when the spindle ro- _CM[4]
tates. 9771
54673 $SNS_MEA_CM_MIN_FEEDRATE Min. feed for first contact of the tool to be measured with the probe when the spindle rotates. _CM[4]
Too small feeds for large tool radii are thus avoided! 9761
Page 24
54674 $SNS_MEA_CM_SPIND_ROT_DIR Direction of spindle rotation for tool measuring with rotating spindle (default: 4 = M4) _CM[5]
Notice: If the spindle is already rotating when the measuring cycle is called, the direction of rota-
tion is maintained independently of $SNS_MEA_CM_SPIND_ROT_DIR!
54675 $SNS_MEA_CM_FEEDFACTOR_1 Feedrate factor 1, for tool measuring with rotating spindle _CM[6]
=0: Single probing with the feedrate calculated by the cycle (but at least with the value of 9769
$SNS_MEA_CM_MIN_FEEDRATE)
>=1: First probing with calculated feedrate (but at least with the value of
$SNS_MEA_CM_MIN_FEEDRATE).
54676 $SNS_MEA_CM_FEEDFACTOR_2 Feedrate factor 2, for tool measuring with rotating spindle _CM[7]
=0:Second probing with the feedrate calculated by the cycle (only effective with 9770
MEA_CM_FEEDFACTOR_1 > 0)
>=1: Second probing with calculated feedrate, feedrate factor 2
Third probing with calculated feedrate (tool speed is influenced by SD54749
SINUMERIK 828D
$SNS_MEA_FUNCTION_MASK_TOOL, Bit 12)

Notice: - Feedrate factor 2 should be smaller than feedrate factor 1!
- If the value of feedrate factor 2 is 0, a third probing will not be not performed!
SINUMERIK 828D
Technology Settings
54677 $SNS_MEA_CM_MEASURING_ACCURACY Required measuring accuracy for tool measuring _CM[3]
The value of this parameter always refers to the last contact of the tool with the probe! 9762
54689 $SNS_MEA_T_PROBE_MANUFACTURER Tool probe type (manufacturer) _TP_CF
These indications are required for tool measuring with rotating spindle. 9774
=0: No indication
=1: TT130 (Heidenhain)
=2: TS27R (Renishaw)
54691 $SNS_MEA_T_PROBE_OFFSET Measurement result offset for tool measuring with rotating spindle. _MT_COMP
=0: No offset 9775

=1: Cycle-internal offset (only effective with SD54690
$SNS_MEA_T_PROBE_MANUFACTURER<>0)
=2: Offset through user-defined offset table
Page 25
54695 $SNS_MEA_RESULT_OFFSET_TAB_RAD1 Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[0] ... this element always has value ZERO
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[1] ... 1st tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[2] ... 2nd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[3] ... 3rd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[4] ... 4th tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[0] ... 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[1] ... offset value for radius regarding 1st ra-
dius and 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[2] ... offset value for radius regarding 2nd ra-
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[3] ... offset value for radius regarding 3rd ra-
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[4] ... offset value for radius regarding 4th ra-
Appendix B
Appendix B
Appendix B
Appendix B
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[0] ... 2nd peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[1] ... offset value for radius regarding 1st radius
and 2nd peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[2] ... offset value for radius regarding 2nd radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[3] ... offset value for radius regarding 3rd radius
Technology Settings
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[4] ... offset value for radius regarding 4th radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[0] ... 3rd peripheral speed
and 3rd peripheral speed
Page 26

$SNS_MEA_RESULT_OFFSET_TAB_RAD5[0] ... 4th peripheral speed
and 4th peripheral speed
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
$SNS_MEA_RESULT_OFFSET_TAB_RAD6[0] ... 5th peripheral speed
54705 $SNS_MEA_RESULT_OFFSET_TAB_LEN1 Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[0] ... this element always has value ZERO
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[1] ... 1st tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[2] ... 2nd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[3] ... 3rd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[4] ... 4th tool radius
Page 27
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[0] ... 1st peripheral speed

$SNS_MEA_RESULT_OFFSET_TAB_LEN2[1] ... offset value for radius regarding 1st radius
and 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[2] ... offset value for radius regarding 2nd radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[3] ... offset value for radius regarding 3rd radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[4] ... offset value for radius regarding 4th radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN3[0] ... 2nd peripheral speed
Appendix B
Appendix B
Appendix B
Appendix B
$SNS_MEA_RESULT_OFFSET_TAB_LEN4[0] ... 3rd peripheral speed
Technology Settings
$SNS_MEA_RESULT_OFFSET_TAB_LEN5[0] ... 4th peripheral speed
Page 28

$SNS_MEA_RESULT_OFFSET_TAB_LEN6[0] ... 5th peripheral speed
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
54740 $SNS_MEA_FUNCTION_MASK Function mask for measuring cycles
Bit 0: Workpiece measurement, repeat measurement if _TDIF and _TSA are exceeded _CBIT[0]
Bit 1: Workpiece measurement, repeat measurement with alarm output and cycles stop at M0 _CBIT[1]
Bit 2: Workpiece measurement, exceeding _TUL, _TLL, _TDIF, cycles stop at M0 _CBIT[2]
Bit 3: Workpiece measurement, accept calibrated probe radius in the tool data _CBIT[15]
Bit 16: Tool measurement, repeat measurement if _TDIF and _TSA are exceeded _CBIT[0]
Bit 17: Tool measurement, repeat measurement with alarm output and cycles stop at M0 _CBIT[1]
Bit 18: Tool measurement, exceeding _TDIF, cycles stop at M0 _CBIT[2]
Bit 19: Tool meas. milling machine, spindle speed reduction during last touching _CHBIT[22]
54750 $SNS_MEA_ALARM_MASK Expert mode for cycle alarms
Bit 0 - 7 Workpiece measurement
Bit 0 =1 Alarms with cycle-internal states and coding are displayed (expert mode)!
Bit 1 - 7 Reserved
Bit 8 -16 Tool measuring
Bit 0 - 7 Reserved
54760 $SNS_MEA_FUNCTION_MASK_PIECE Setting for input screen, measuring cycles in Automatic, workpiece measuring
Page 29
Bit 1: Display softkey 3D measurement

Bit 3: Select probe calibration data fileld, enable
Bit 4: Select Calibrate Input measuring feed
Bit 6: Enable selection of WO compensation in basic reference
Bit 7: Enable selection of WO compensation in channel-specific basic WO
Bit 8: Enable selection of WO compensation in global basic WO
Bit 9: Enable selection of WO compensation in work offset
Bit 10: Enable selection of WO compensation in course and fine
Bit 11: Enable selection of tool offset wear and geometry
Bit 12: Enable selection of tool offset not inverted and inverted
Bit 13: Enable selection of tool offset radius, lenght L1, L2, L3
Bit 14: Enable selection of tool offset work offset
Bit 15: Enable selection of tool offset dimensional difference check
Bit 18: Select Number of measurements
Bit 19: Select Offset with averaging
Bit 20: Select Empirical values
Bit 21: Select Additive setup offset
Appendix B
Bit 22: Select Calibrate to unknown or known center point
Bit 24: Select Calibrate with or without positional deviation
Appendix B
Appendix B
Appendix B
54762 $SNS_MEA_FUNCTION_MASK_TOOL Setting for input screen, measuring cycles in Automatic, tool measuring
Bit 4: Select Calibrate Input measuring feed
Bit 5: Select Input feed and spindle speeds for contacting
Bit 7: Select Measure in MCS and WCS
Bit 8: Select Measure absolute and incremental
Bit 9: Select Tool offset Geometry and wear
Bit 12: Select Number of measurements
Technology Settings
Bit 13: Select Empirical values
54764 $SNS_MEA_FUNCTION_MASK_TURN Setting for input mask, Measuring cycles in Automatic, Workpiece turning
Bit 0: Measure Diameter inside/outside with reversal
Bit 1: Measure Diameter inside/outside “Travel under turning center“?
54780 $SNS_J_MEA_FUNCTION_MASK_PIECE Setting for input screen, Measure in JOG, workpiece measurement 9747
Bit 2: Activate calibration for electronic workpiece probe
Bit 5: Select WO as measuring basis
Bit 6: Select WO compensation in basic reference, enable
Page 30
Bit 7: Select WO compensation in channel basic frame, enable

Bit 8: Select WO compensation in global basic frame, enable
Bit 9: Select WO compensation in settable frame, enable
54782 $SNS_J_MEA_FUNCTION_MASK_TOOL Setting for input screen, Measure in JOG, tool measurement 9749
Bit 2: Enable automatic tool measurement
Bit 3: Select tool probe calibration data fileld, enable
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
55200 $SCS_MAX_INP_FEED_PER_REV Feedrate input upper limit for mm/rev 9665
55201 $SCS_MAX_INP_FEED_PER_TIME Feedrate input upper limit for mm/min 9664

55202 $SCS_MAX_INP_FEED_PER_TOOTH Feedrate input upper limit for mm/tooth 9666
55212 $SCS_FUNCTION_MASK_TECH_SET Function mask Cross-technology
Bit 0: Tool preselection active 9667
Bit 1: Calculate thread depth from metric thread lead 9640
Bit 2: Refer to the table for thread diameter and depth
55214 $SCS_FUNCTION_MASK_MILL_SET Function mask Milling
Bit 0: Default setting - milling cycles with synchronous operation 9827
Bit 1: Reserved _ZSD[9]
Bit 2: Depth calculation in milling cycles without parameter SC
= 0: Depth calculation in milling cycles is carried out between reference plane + safety
clearance and depth
= 1: Depth calculation in milling cycles is carried out without inclusion of the safety clear-
ance _ZSD[1]
Page 31
Note: Bit 2 is active with the following milling cycles: CYCLE61, CYCLE71, CYCLE76, CYCLE77,
CYCLE79, CYCLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCKET4
55216 $SCS_FUNCTION_MASK_DRILL_SET Function mask Drilling
Bit 0: Reverse the direction of spindle rotation during tapping
Bit 1: Consider rotation of the tool plane (CYCLE86)
Bit 2: Consider swiveled table kinematics (CYCLE86)
Bit 3: Monitoring spindle MD 31050/31060 (CYCLE84)
Bit 4: Monitoring spindle MD 31050/31060 (CYCLE840)
Bit 5: Calculation of the break point at G33 (CYCLE840)
55218 $SCS_FUNCTION_MASK_TURN_SET Function mask Turning
Bit 0: New thread table during thread cutting
Bit 1: Reserved (CYCLE93)
Bit 2: Reserved (CYCLE93)
55220 $SCS_FUNCTION_MASK_MILL_TOL_SET Function mask High Speed Settings CYCLE832
Bit 0: Unhide technology fields CYCLE832
Bit 1: Orientation tolerance (OTOL) as a tolerance factor, enter it directly
Appendix B
Appendix B
Appendix B
Appendix B
55221 $SCS_FUNCTION_MASK_SWIVEL_SET Function mask Swivel CYCLE800
Bit 0: Display input field "No swivel"
Bit 1: Retraction variant Z, Z XY or fixed position
= 0: Retract Z or retract Z XY
= 1: Retract to fixed position 1 or 2
Bit 2: Allow selection "Deselection" of the swivel data block
Bit 3: Show active swivel plane under Swivel in JOG
Bit 4: Optimized positioning in basic position (pole position) of the kinematics
Technology Settings
The settings of the Swivel function mask affect all swivel data records.
55230 $SCS_CIRCLE_RAPID_FEED Rapid traverse feedrate in mm/min for positioning on circle path between circumferential grooves 9724
and contour elements
55231 $SCS_MAX_INP_RANGE_GAMMA Maximum input area alignment angle gamma 9863
55232 $SCS_SUB_SPINDLE_REL_POS Z retraction position for the counter spindle 9851
55260 $SCS_MAJOG_SAFETY_CLEARANCE Safety clearence for machine JOG
55261 $SCS_MAJOG_RELEASE PLANE Retraction plane for machine JOG

Page 32
55410 $SCS_MILL_SWIVEL_ALARM_MASK Hide and unhide cycle alarms CYCLE800

Bit 0: Error analysis 62186 - active work offset G%4 and base (base relation) include rotations
Bit 1: Error analysis 62187 - active base and base relation (G500) include rotations
55441 $SCS_MILL_TOL_TECHNO_ROUGH Settings for roughing High Speed Settings cycle CYCLE832 of G group 59 _TOLT[1]
55442 $SCS_MILL_TOL_TECHNO_SEMIFIN Settings for pre-finishing High Speed Settings cycle CYCLE832 of G group 59 _TOLT[2]
55443 $SCS_MILL_TOL_TECHNO_FINISH Settings for finishing High Speed Settings cycle CYCLE832 of G group 59 _TOLT[3]
55446 $SCS_MILL_TOL_VALUE_ROUGH Tolerance value for roughing High Speed Settings cycle CYCLE832 _TOLV[1]
55447 $SCS_MILL_TOL_VALUE_SEMIFIN Tolerance value for pre-finishing High Speed Settings cycle CYCLE832 _TOLV[2]
55448 $SCS_MILL_TOL_VALUE_FINISH Tolerance value for finishing High Speed Settings cycle CYCLE832 _TOLV[3]
55460 $SCS_MILL_CONT_INITIAL_RAD_FIN This data affects the radius of the approach circle during contour pocket finishing. 9670
-1: The radius is selected to maintain a safety clearance to the finishing allowance in the starting
point.
>0: The radius is selected to maintain the value of this setting data to the finishing allowance in the
starting point.
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
55481 $SCS_DRILL_TAPPING_SET_GG12 Settings for tapping G group 12 cycle CYCLE84 and CYCLE840: 9855[0]
G group 12: Block change behavior at exact stop (G60) 9856[1]
0 = Exact stop behavior, same as before the cycle call
1 = G601
2 = G602
3 = G603
Index[0]: for tool spindle
Index[1]: for main spindle - for drilling in centre
55482 $SCS_DRILL_TAPPING_SET_GG21 Settings for tapping G group 21 cycle CYCLE84: 9855[0]
G group 21: Acceleration profile (SOFT, BRISK, ..) 9856[1]
0 = Acceleration behavior, same as before the cycle call
1 = SOFT
2 = BRISK
3 = DRIVE
55483 $SCS_DRILL_TAPPING_SET_GG24 Settings for tapping G group 24 cycle CYCLE84 and CYCLE840: 9855[0]
Page 33
G group 24: Feedforward control (FFWON, FFWOF ) 9856[1]

0 = Feedforward control, same as before the cycle call
1 = FFWON
2 = FFWOF
55484 $SCS_DRILL_TAPPING_SET_MC Setting for tapping cycle CYCLE84 spindle operation at MCALL 9855[0]
0= Reactivate spindle operation at MCALL 9856[1]
1= Maintain position-controlled spindle operation at MCALL
55489 $SCS_DRILL_MID_MAX_ECCENT Maximum centre offset for centre drilling 9862

55490 $SCS_DRILL_SPOT_DIST Rough drilling depth for drill and thread milling 9682
Appendix B
Appendix B
Appendix B
Appendix B
55500 $SCS_TURN_FIN_FEED_PERCENT When selecting Complete machining (roughing and finishing), the percentage of the entered 9630
feedrate F as specified in this setting data is used for finishing.
55505 $SCS_TURN_ROUGH_O_RELEASE_DIST This setting data defines the distance by which the tool is returned from the contour during stock 9648
removal of an outer corner. This does not apply to stock removal of a contour.
-1: The distance is specified internally.
55506 $SCS_TURN_ROUGH_I_RELEASE_DIST This setting data defines the distance by which the tool is returned from the contour during stock 9649
Technology Settings
removal of an inner corner. This does not apply to stock removal of a contour.
-1: The distance is specified internally.
55510 $SCS_TURN_GROOVE_DWELL_TIME If a tool clearance time occurs in a cycle, e.g. deep hole drilling, grooving, the value of this setting 9621
data is used
- Negative value in spindle revolutions
- Positive value in seconds
55540 $SCS_TURN_PART_OFF_CTRL_DIST Path for cut-off check 9859
55541 $SCS_TURN_PART_OFF_CTRL_FEED Feedrate for cut-off check 9860
Page 34
55542 $SCS_TURN_PART_OFF_CTRL_FORCE Force in percent for cut-off check 9861

55543 $SCS_TURN_PART_OFF_RETRACTION Retraction path prior to cut-off with counter spindle
55550 $SCS_TURN_FIXED_STOP_DIST In this setting data you specify the distance to the programmed target position, after which the 9852
counter spindle travels with a special feedrate during travel to fixed stop (see setting data 55551
$SCS_TURN_FIXED_STOP_FEED).
55551 $SCS_TURN_FIXED_STOP_FEED In this setting data you specify the feedrate with which the counter spindle travels to a fixed stop. 9853
In setting data 55550 $SCS_TURN_FIXED_STOP_DIST you specify the distance after which the
tool travels in this feedrate.
55552 $SCS_TURN_FIXED_STOP_FORCE In this setting data you specify at which percentage of the driving force the counter spindle is to 9854
stop during travel to fixed stop.
55553 $SCS_TURN_FIXED_STOP_RETRACTION Retraction path prior to chucking after travel to fixed stop 9857
55580 $SCS_TURN_CONT_RELEASE_ANGLE This setting data defines the angle by which the tool is retracted from the contour during contour
turning roughing.
55581 $SCS_TURN_CONT_RELEASE_DIST This setting data defines the value by which the tool is retracted in both axes during contour turn- 9550
ing roughing. This applies to cutting, plunge-cutting and plunge turning.
SINUMERIK 828D
55582 $SCS_TURN_CONT_TRACE_ANGLE This setting data specifies the angle between the cutting edge and the contour, at which the con- 9553
tour is rounded in order to remove residual material.
SINUMERIK 828D
Technology Settings
55583 $SCS_TURN_CONT_VARIABLE_DEPTH Percentage for variable cutting depth during contour turning 9556
55584 $SCS_TURN_CONT_BLANK_OFFSET This setting data specifies the distance to the blank, after which contour turning is switched from 9552
G0 to G1 in order to adjust any possible blank allowances. This applies to cutting, plunge cutting
and plunge turning.
55585 $SCS_TURN_CONT_INTERRUPT_TIME Feed interrupt time during contour turning, contour grooving and plunge turning 9557
- Negative value in spindle revolutions
- Positive value in seconds
This setting data is effective only if setting data 55586 is 55586
$SCS_TURN_CONT_INTER_RETRACTION = 0.
55586 $SCS_TURN_CONT_INTER_RETRACTION Retraction path feed interrupt during contour turning, contour grooving and plunge turning: 9558
>0: Retraction path after feed interrupt (setting data 55585
$SCS_TURN_CONT_INTERRUPT_TIME is ineffective!)
=0: No retraction path
55587 $SCS_TURN_CONT_MIN_REST_MAT_AX1 This MD defines the limit value for stock removal of residual material in the direction of the 1st 9554
axis.
Page 35
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
55588 $SCS_TURN_CONT_MIN_REST_MAT_AX2 This MD defines the limit value for stock removal of residual material in the direction of the 2nd 9555
axis.
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
55595 $SCS_TURN_CONT_TOOL_BEND_RETR Retraction due to tool bending during plunge turning. In this setting data you specify the lateral 9560
distance to the last cut, by which each next cut will be shortened.
55596 $SCS_TURN_CONT_TURN_RETRACTION Retraction depth prior to plunge turning 9561
Appendix B
Appendix B
Appendix B
Appendix B
55613 $SCS_MEA_RESULT_DISPLAY Measurement result display _CHBIT[10]

=0: No measurement result display _CHBIT[11]
=1: The measurement result is displayed until cycle end _CHBIT[18]
=2: The measurement result is displayed until the start/call of the next cycle
=3: With the measurement result display, the cycle is stopped by an internal M0, with NC start,
the measuring cycle is continued and the measurement result display is deselected
=4: The measurement result display is only shown for cycle alarms 61303, 61304, 61305, 61306
Same behavior as with setting 3!
Technology Settings
55618 $SCS_MEA_SIM_ENABLE Selection of measuring cycle response in a simulated environment
= 0: Measuring cycles are not executed (measuring cycle is skipped internally)
= 1: Measuring cycles are executed; real axes are required!
During calibration no values are entered in the probe data fields,
no measurement result is displayed,
the measuring cycle is not logged,
the travel is performed without collision detection.
55619 $SCS_MEA_SIM_MEASURE_DIFF With this parameter simulated measurement errors can be specified on the measuring points. _MC_SIMDIFF
Page 36
Provided that SD55618 $SCS_MEA_SIM_ENABLE=1 is used and that the measuring cycles are
executed in a simulated environment of HMI Advanced or ShopMill / ShopTurn, a measurement
difference can be entered in this parameter. The value of the measurement difference must be
smaller than the measuring path in parameter _FA!
Otherwise cycle alarm 61301 "Probe does not switch" is output during active simulation.
55622 $SCS_MEA_EMPIRIC_VALUE_NUM Number of empirical values _EVMVNUM[0]
55623 $SCS_MEA_EMPIRIC_VALUE In its default setting the empirical value memory consists of 20 memory elements. _EV[n]
Using parameter $SCS_MEA_EMPIRIC_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the empirical value memory, empirical values can be stored which are cleared with the currently
calculated difference between the setpoint and the actual value.
Using parameter _EVNUM the empirical value element to be cleared is addressed!
55624 $SCS_MEA_AVERAGE_VALUE_NUM Number of mean values _EVMVNUM[1]

SINUMERIK 828D
SINUMERIK 828D
Technology Settings
55625 $SCS_MEA_AVERAGE_VALUE In its default setting the mean value memory consists of 20 memory elements. _MV[n
Using parameter $SCS_MEA_AVERAGE_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the mean value memory, the mean values calculated in connection with functionality "Automatic
tool offset with mean value creation" are stored.
Using parameter _EVNUM the mean value element to be used is addressed!
55628 $SCS_MEA_TP_FEED_MEASURE Feed for calebrating a tool probe with stationary spindle in AUTO and JOG 9773
55630 $SCS_MEA_FEED_MEASURE Measure measuring feed of workpiece in Automatic and JOG 9756
55632 $SCS_MEA_FEED_RAPID IN_PERCENT Traverse velocities for positioning in the measuring cycle between the measuring positions, with _SPEED[0]
rapid traverse velocity in per cent, with collision detection not active
Note:
If necessary, adapt the value of the rapid traverse velocity in per cent to the probe type used and to
the machine characteristics! This means that the maximum deflection of the actual probe type must
be considered!!
Page 37
Explanations:
In the measuring cycles any intermediate positions are calculated prior to the actual set of meas-
urements. These positions can be approached
- with collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1) or
- without collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0).
Depending on this setting different velocities are used for the approach:
- with collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1):
With SD55634 $SCS_MEA_FEED_PLAN_VALUE the traversing feed is performed in the plane
and with SD55636 $SCS_MEA_FEED_FEEDAX_VALUE during traversing in the feed axis
(applicate).
If the probe switches when these intermediate positions are approached, the movement is stopped
and the alarm "Probe collision" is output.
- without collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0):
The intermediate positions are approached with the maximum axis velocity (rapid traverse) in per-
cent as specified in SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT.
With SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT=0 and SD55632
$SCS_MEA_FEED_RAPID_IN_PERCENT=100 the maximum axis velocity is effective.
Appendix B
55634 $SCS_MEA_FEED_PLANE_VALUE Traverse velocity for intermediate positioning in the plane _SPEED[1]
Appendix B
Appendix B
Appendix B
55636 $SCS_MEA_FEED_FEEDAX_VALUE Traverse velocities for intermediate positioning in the measuring cycle in the infeed axis, with and _SPEED[2]
without collision detection.
Note:
If necessary, adapt the value of the velocity in the infeed axis to the probe type used and to the
machine characteristics! This means that the maximum deflection of the actual probe type must be
considered!!
Technology Settings
Explanations:
In the measuring cycles any intermediate positions are calculated prior to the actual set of meas-
urements. These positions can be approached
- with collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1) or
- without collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0).
Depending on this setting different velocities are used for the approach:
- with collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1):
With SD55636 $SCS_MEA_FEED_FEEDAX_VALUE the traversing feed is performed in the infeed
axis (applicate).
Page 38
If the probe switches when these intermediate positions are approached, the movement is stopped
and the alarm "Probe collision" is output.
- without collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0):
The intermediate positions are approached with the maximum axis velocity (rapid traverse) in per-
cent as specified in SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT.
With SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT=0 and SD55632
$SCS_MEA_FEED_RAPID_IN_PERCENT=100 the maximum axis velocity is effective.
55638 $SCS_MEA_FEED_FAST_MEASURE Rapid measuring feed _SPEED[3]
Note:
If necessary, adjust the value of the velocity to the probe type used and to the machine characteris-
tics!
This means that the maximum deflection of the actual probe type must be considered!!
The use of "Rapid measuring feed" depends of SD55740 $SCS_MEA_FUNCTION_MASK Bit4!
55640 $SCS_MEA_FEED_CIRCLE Circular feed for measuring circle segment
55642 $SCS_MEA_EDGE_SAVE_ANG Additional safe angle for measuring corner

Set $SCS_MEA_EDGE_SAVE_ANG=10 for compatibility programs.
SINUMERIK 828D
SINUMERIK 828D
Technology Settings
55740 $SCS_MEA_FUNCTION_MASK Function mask for measuring cycles

Bit 0: Workpiece measurement, collision monitoring _CHBIT[2]
Bit 1: Workpiece measurement, coupling spinlde with coordinate rotation around Z in automatic _CHBIT[13]
Bit 2: Workpiece measurement, coupling spinlde , positioning direction of spindle _CHBIT[14]
Bit 3: Workpiece measurement, no. of meas. attempts with non-switching of probe _CHBIT[15]
Bit 4: Workpiece measurement, approach velocity to the measuring point _CHBIT[17]
Bit 5: Workpiece measurement, retration velocity from the measuring point _CHBIT[16]
Bit 6: Workpiece measurement, probe activation/deactivation with spindle motions
Bit 14: Workpiece measurement, coupling spindle with coordinate rotation around Z in JOG E_MESS_SETT[0]
Bit 15: Workpiece measurement, known/unknown reference ring center point in JOG E_MESS_SETT[1]
Bit 16: Tool measurement, collision monitoring _CHBIT[2]
Bit 17: Tool measurement, no. of meas. attempts with non-switching of probe _CHBIT[15]
Bit 18: Tool measurement, approach velocity to the measuring point _CHBIT[17]
Bit 19: Tool measurement, retration velocity from the measuring point _CHBIT[16]
55800 $SCS_ISO_M_DRILLING_AXIS_IS_Z Selection of the drilling axis
0: Drilling axis is vertical to the active plane
1: Drilling axis is always "Z", independently of the active plane
Page 39
55802 $SCS_ISO_M_DRILLING_TYPE Tapping type

0: Tapping without compensating chuck
1: Tapping with compensating chuck
2: Deep hole tapping with chip breakage
3: Deep hole tapping with stock removal
55804 $SCS_ISO_M_RETRACTION_FACTOR Factor for retraction speed (0...200%)
55806 $SCS_ISO_M_RETRACTION_DIR Retraction direction for precision drilling and reverse counter-sinking G76/G87
0: G17(-X) G18(-Z) G19(-Y)
1: G17(+X) G18(+Z) G19(+Y)
2: G17(-X) G18(-Z) G19(-Y)
3: G17(+Y) G18(+X) G19(+Z)
4: G17(-Y) G18(-X) G19(-Z)
55808 $SCS_ISO_T_RETRACTION_FACTOR Factor (1-200%) for retraction speed at tapping G84/G88
Appendix B
55810 $SCS_ISO_T_DWELL_TIME_UNIT Dwell time evaluation for deep hole drilling G83/G87
0: Seconds
Appendix B
1: Revolutions
Appendix B: END
Appendix B Technology Settings
Appendix B Page 40 SINUMERIK 828D
B034
Appendix C PLC Interface Structure
Module Description:
Information to and from the different system areas of the controller is handled by interfaces. This
module shows how the different areas communicate .
Module Objective:
Upon completion of this module you will be know the Sinumerik 828D PLC interface structure and
use it to help write the PLC program and diagnose PLC faults.
Content:
Sinumerik
Interface Structure Overview
Operand Description and Ranges
Interface Description
Appendix C
Appendix C
Appendix C Page 2 SINUMERIK 828D

PLC Interface Structure Appendix C
PLC Interface Structure: Description

PLC Interface
Structure:
START DB2800
Information to and from the different system areas of the
DB2900
controller is handled by interfaces. This module shows how
the different areas communicate . Fast NC I/O
Operand
Description
and Range DB3000
DB3100
Operating
Mode Signals
Machine
Control
Panel DB3200
DB3300
NCK
Channel
DB1000
DB1100
User Area
DB3400
ASUP
Signals
DB1200
DB1400
PI Services
DB3700
DB3800
DB3900
Axis/Spindle
DB1600
PLS User
Alarms
DB4000
Tool
Management
DB1700
DB1800
DB1900
HMI Signals DB4500
PLC
Machine
Data
DB2500
AUX
Functions
DB9900
User
Interface
DB2600
DB2700
NCK
Signals
PLC Interface
Structure:
END
Notes :
SINUMERIK 828D Page 3 Appendix C

Operand Description and Ranges
Operand identifiers Description Area

DB Data Blocks DB1000 to DB7999
DB9000 to DB9036
DB9900 to DB9905
T Timers T128
T0 - T15 = 100ms
T16 - T127 = 10ms
C Counters C0 to C63
I Digital Inputs I0.0 to I256.3
Q Digital Outputs Q0.0 to Q256.3
M Marker M0.0 to M511.7
SM Special Marker SM0.0 to SM0.6 (see below)
A ACCU AC0 to AC3 (DWord)
Structure of Data Blocks

The 8-Digit Data Block made up of different sections.
DB3801.DBX1000.7
Bit Number (0 to 7)
Offset (000 to 999)
Section (0 to 9)
Area Number (00 to 99)
User Area (10 to 99)
The format of the can be written in different ways.

Type Format No of bits
Bit DB3801.DBX1000.7 1
Byte DB3801.DBB0 8
Word DB3801.DBW2 16
Double Word DB3801.DBD3004 32
Special Markers
The interface structure also consists of “Special Markers” (Flags) which are a set of operands to be used at the convenience of
the user throughout the PLC program
SM bits Description
SM0.0 Flag with defined ONE signal
SM0.1 Initial setting: first PLC cycle ’1’, following cycles ’0’
SM0.2 Buffered data lost - only valid in first PLC cycle (’0’ data ok, ’1’ data lost)
SM0.3 Power On: first PLC cycle ’1’, following cycles ’0’
SM0.4 60 s cycle (alternating ’0’ for 30 s, then ’1’ for 30 s)
SM0.5 1 s cycle (alternating ’0’ for 0.5 s, then ’1’ for 0.5 s
SM0.6 PLC cycle (alternating one cycle ’0’, then one cycle ’1’)
General
Variables that can only be read are identified with [r]
Variables that can be read and written to are identified with [r/w]
Notes :

Interface Description
Machine Control Panel MCP483 PN

During commissioning the MCP address range is set to start at Input and output Bytes 112.

Spindle override JOG TEACH IN MDA AUTO
IB112
D C B A
IB113 REPOS REF INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
Key- Key- Spindle start *Spindle stop Feed *Feed NC Start *NC Stop
IB114 switch switch position 2 start stop
position 0
Reset Key- Single block Feedrate override
IB115 switch position
E D C B A
Direction keys Key switch Axis selection keys
IB116 + - Rapid traverse position 3 X 4th axis 7th axis
R15 R13 R14 R1 R4 R7
Axis selection keys
IB117 Y Z 5th axis MCS/WCS R9 8th axis 6th axis
R2 R3 R5 R12 R8 R6
IB118
T9 T10 T11 T12 T13 T14 T15
IB119
T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP483 PN Signals to machine control panel (LEDs)
Machine function Operating mode

QB112
INC 1000 INC 100 INC 10 INC 1 JOG TEACH IN MDA AUTO
QB113 Feed *Feed NC Start *NC Stop REPOS REF INC var. INC 10000
start stop
Direction X 4th axis 7th axis Single Spindle start *Spindle stop
QB114 Minus R1 R4 R7 R10 block
R13
Z 5th axis MCS/WCS 8th axis 6th axis Direction

QB115 R3 R5 R11 R9 R8 R6 Plus
R15
Unassigned customer keys Y
QB116
T9 T10 T11 T12 T13 T14 T15 R2
QB117
T1 T2 T3 T4 T5 T6 T7 T8
QB118 Reset R14
QB119 KT6 KT5 KT4 KT3 KT2 KT1
Notes :

Machine Control Panel MCP310 PN

During commissioning the MCP address range is set to start at Input and output Bytes 112.

IB112 *NC Stop Spindle - Spindle 100% Spindle + Single block JOG MDA AUTO
IB113 NC Start Spindle right *Spindle stop Spindle left Key-switch REF REP Teach IN
position 3
Feed start *Feed stop INC var. Key-switch posi-
IB114 tion 0
INC 1000 INC 100 INC 10 INC 1
Feedrate override
IB115 Reset Key- Key-switch E (16) D (8) C (4) B (2) A (1)
switch position position 1
2
Direction keys
IB116
+ - Rapid traverse KT5 (X52.2) KT4 (X52.1) KT3 (X51.3) KT2 (X51.2) KT1(X51.1)
Axis selection
IB117 6th axis 5th axis 4th axis Z Y X
T16 KT6(X52.3)
IB118 T9 T10 T11 T12 WCS MCS T13 T14 T15

IB119 T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP 310 PN Signals to machine control panel (LEDs)

QB112 *NC Stop Spindle Dec. Spindle 100% Spindle Inc. Single Block JOG MDA AUTO
NC *Spindle RESET REF REPOS Teach In
QB113 Spindle right Spindle left
start Stop
QB114 Feed Start *Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
QB115
QB116 Minus Plus Rapid trav- KT5 KT4 KT3 KT2 KT1
Direction Direction erse
QB117 T16 KT6 6th axis 5th axis 4th axis Z Y X
QB118 T9 T10 T11 T12 MCS/WCS T13 T14 T15
QB119 T1 T2 T3 T4 T5 T6 T7 T8
User Data Areas

There are two areas set aside for free use within the user PLC.
DB1000 User Data 1 [r/w]

0000
User Data
up to
User Data
Notes :

User Data Areas-continued
DB1100 User Data 2 [r/w]
0000
User Data
up to
0007
User Data
Reading/Writing of NC data
It is possible to read/write data too/from the NC &PLC. Variables are available to facilitate this function.
Below:- Defining read or write, how many variables and setting the start Signal.
DB1200 PLC interface NCK [r/w]

0000 Read:0 Start
Write:1
0001 Number of variables to be read/written
0002
0003
Below:-Information regarding the variable has to be written to the following areas. Up to eight sets of data can be moved in one
go.
DB1200 PLC interface NCK [r/w]

-1207
1000 Variable Index
1: Tool data; 2: Tool edge Number; 3: Zero offset; 4: Number of axes, 5: R parameter
7: Location type; 8: Location status; 9: Tool number at a specific location
1001 Area Number
1002 Column index for NCK variable x (Word)
1004 Line index for NCK variable x (Word)
1006
1008 Data to be written to NCK
Results:-The results of the task are output to the following areas:-

2000 Error in job Request
Complete
2001
2002
Notes :


DB1207
3000 Fault Valid Variable
3001 Access result

0: No error, 1: Illegal access, 5: Invalid address, 10: Object does not exist
3002
3004 Data that was read from the NC variable (1 to 4 bytes)
PI Services

4000 Start
4001 PI-Index
1: ASUP1, 2: ASUP2, Password Reset, Saving of Data, Tool Reloading via the PLC
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
4008 PI-Parameter 3
4010 PI-Parameter 4
4012 PI-Parameter 5
4014 PI-Parameter 6
4016 PI-Parameter 7
4018 PI-Parameter 8
4020 PI-Parameter 9
4022 PI-Parameter 10
PI Services:- Result
5000 Fault Finished
5001
5002
Notes :

Retentive Data Area
DB1400 Retentive Data [r/w]
User area
0000
User area
0001
User area
0002
User area
0004
etc
User area
0126
User area
0127
User Alarms
DB1600 Activating alarms (Alarm number range 700000 to 700247) PLC HMI [r/w]
0000 700007 700006 700005 700004 700003 700002 700001 700000
0001 700015 700014 700013 700012 700011 700010 700009 700008
0002 700023 700022 700021 700020 700019 700018 700017 700016
0003 700031 700030 700029 700028 700027 700026 700025 700024
etc
0030 700247 700246 700245 700244 700243 700242 700241 700240
DB1600 Variable for alarm. PLC HMI [r/w]
1000 Variable for alarm 700000 (4 bytes)
etc
Notes :

DB1600 Active alarm response HMI PLC [r]
2000 Acknowledge Acknowledge PLC Stop Em. Stop Feed disable Read-in NC start
with power ON with DB1600. disable disable
DBX3000.0
DB1600 Alarm acknowledgement PLC HMI [r/w]
3000 Acknowl-
edge
Program Control Signals

DB1700 HMI signals HMI PLC [r]
0000 Test run M01 DRF

Feedrate Selected Selected
selected
0001 Program test Feedrate over-
selected ride
(Rapid) selected
0002 Skip Skip block 6 Skip block 5 Skip block 4 Skip block 3 Skip block 2 Skip Skip block
block 7 selected selected selected selected selected block 1 0
selected selected selected
0003 Skip Skip
block 9 block 8
selected selected
0007 Reset NC stop NC start
SMS Messenger
DB1700 Interface SMS messenger PLC [r]
3000 Variable-Settable via SMS
3001
3002
3003
Signals from HMI

DB1800 HMI PLC [r]
0000 Reset JOG mode MDA mode AUTO

mode
0001 Machine Machine

function:- function:-
REF TEACH IN
0002
0003
Note:- Signals present for only one plc cycle.
Notes :

Signals from PLC

DB1800 Signals from PLC [r]
1000 Start-up archive Power up with Power up

was read in saved data with default
values
1001
1002
1003
1004 PLC cycle time in micro seconds (Double Integer)
1008 Year (Tens) BCD Year (Units) BCD
1009 Month (Tens) BCD Month (Units) BCD
1010 Day (Tens) BCD Day (Units) BCD
1011 Hour (Tens) BCD Hour (Units) BCD
1012 Minute (Tens) BCD Minute (Units) BCD
1013 Second (Tens) BCD Second (Units) BCD
1014 Millisecond (Hundreds) BCD Millisecond (Tens) BCD
1015 Millisecond (Units) BCD Weekday BCD (1, 2…….7) 1 = Sunday
Maintenance Planner
DB1800 PLC HMI Deactivate Maintenance Task [r/w]
Deactivate Maintenance Task

2000
8 7 6 5 4 3 2 1

2001
16 15 14 13 12 11 10 9

2002
24 23 22 21 20 19 18 17

2003
32 31 30 29 28 27 26 25
DB1800 HMI PLC Alarm for Maintenance Task [r]
Alarm for Maintenance Task

3000
8 7 6 5 4 3 2 1

3001
16 15 14 13 12 11 10 9

3002
24 23 22 21 20 19 18 17

3003
32 31 30 29 28 27 26 25
Notes :

Maintenance Planner-continued
DB1800 PLC HMI Maintenance task acknowledgement [r/w]

Maintenance Task acknowledgement
4000
8 7 6 5 4 3 2 1

4001
16 15 14 13 12 11 10 9

4002
24 23 22 21 20 19 18 17

4004
32 31 30 29 28 27 26 25
DB1800 PLC HMI Disable Maintenance task acknowledgement [r]
Disable Maintenance task acknowledgement

5000
8 7 6 5 4 3 2 1

5001
16 15 14 13 12 11 10 9

5002
24 23 22 21 20 19 18 17

5003
32 31 30 29 28 27 26 25
Signals from operator panel (retentive area)

0000 MCS/WCS Simulation Cancel

selection active
0001 Active HMI area
0002
0003
0004 Active JobShop area
0006
0007
Notes :

General selection/status signals from HMI (retentive area)

1000
1001
1002
Axis number for hand-wheel 1
1003 Machine axis Hand-wheel Contour hand- C B A
selected wheel
Axis number for hand-wheel 2

1004 Machine axis Hand-wheel Contour hand- C B A
selected wheel
General selection/status signals to HMI (retentive area)

DB1900 PLC HMI [r/w]
5000 Actual values in OP key
WCS disable
(0=MCS)
5001 External viewer- External

Monitoring only viewer
not
permitted
5002
5003 PLC Hardkeys (Range of values 1….255, 0 is start position
5004
5005
5006
5007
5008
5009
5010
5011
5012
5013
5014
5015
5016
5017
5018
5019
5020
Notes :

Auxiliary functions from NCK channel (read only)
0000 up to
0003
0004 M fcts.5 M fcts.4 change M fcts.3 change M fcts.2 change M fcts.1 change
change
0005
0006 S fcts.1 change
0007
0008 T fcts.1
change
0009
0010 D fcts.1 change
0011
0012 H fcts.3 H fcts.2 change H fcts.1 change

change
0013 up to
0019
Decoded M signals (M0-M99)
DB2500 NCK PLC

1000 Dynamic M functions
M1=5 M1=4 M1=3
M7 M6 M5 M4 M3 M2 M1 M0

M15 M14 M13 M12 M11 M10 M09 M08

M23 M22 M21 M20 M19 M18 M17 M16
etc
Dynamic M functions
1012 M99 M98 M97 M96
1013 up
to 1015
Note:- Signals present for only one plc cycle.
Notes :

Interface Description continued
Transferred T functions
DB2500 NCK interface PLC

2000 T function 1 (DINT)
2004
up to
2007
Transferred M functions
DB2500 M functions from NCK channel NCK PLC

3000 M function 1 (DINT)
3004 Extended address of M function 1 (Byte)
Transferred S functions
DB2500 NCK PLC
4000 S function 1 (REAL)
4004 Extended address of S function 1 (Byte)
4008 S function 2 (REAL)
4012 Extended address of S function 2 (Byte)
4016
4020
Transferred D functions
DB2500 NCK PLC

5000 D function 1 (DINT)
5004
Notes :

Transferred H functions
DB2500 NCK interface PLC [r]

6000 H function 1 (REAL)
6004 Extended address of H function 1 (Byte)
NCK Signals-General Signals to NCK

Protection level Ackn. emerg. Emerg. stop Braking along
stop contour in
0000 event of
4 5 6 7 Emerg. stop
Request axis Request INC Inputs
distances to Actual values in Mode
0001 go (*1) (*1) Group range
active
0002
0003
(*1) Used in conjunction with Data blocks DB5700 to 5707.
0000 Emergency
Stop active
0001 INCH measur- Probe 2 actu- Probe 1 actu-

ing system ated ated
0002 NC Ready Drive ready Drives in HMI ready

cyclic opera-
tion
0003 Air temp. NCK alarm is

alarm active
0004
0005
0006
Notes :

NCK Signals-continued
0007
0008
0009
0010
0011
0012 Change counter for motions of hand-wheel 1
0013 Change counter for motions of hand-wheel 2
0014
0015 Change counter, inch metric unit system.
etc
0019
Notes :

Signals to fast inputs and outputs

Disable digital NCK inputs
0000 Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
Values from the PLC for digital NCK inputs
0001 Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
Disable digital NCK outputs
0004 Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1
Overwrite mask for digital NCK outputs
Values from the PLC for digital NCK outputs
Setting mask for digital NCK outputs
Disable external digital NCK inputs
1000 Input16 Input15 Input14 Input13 Input 12 Input11 Intput10 Input 9
Values from the PLC for the external digital NCK inputs
1001 Input16 Input15 Input14 Input13 Input12 Input11 Input10 Input 9
Disable external digital NCK outputs
1008 Ouput16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Overwrite mask for external digital NCK outputs
1009 Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output 9
Values from PLC for the external digital NCK outputs
Setting mask for external digital NCK outputs
Notes :

Signals From Fast Inputs & Outputs

DB2900 PLC NCK [r]
Actual values for digital NCK inputs
0000
Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
Set-points for digital NCK outputs
0004
Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1

Actual values of external digital NCK inputs
1000
Input 16 Input 15 Input 14 Input 13 Input 12 Input 11 Input 10 Input 9
Set-points of external digital NCK outputs
1004
Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Operating Mode Signals

Reset Mode group Operating mode
changeover
0000 disable
JOG MDA Auto
Machine function
0001
REF Teach in
Machine function (to use the INC function DB2600.DBX1.0 must be set to 1)
0002 Continuous INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
travel
0003

Active mode
0000 828D Ready
JOG MDA Auto
Active Machine function
0001
REF Teach in
0002 Continuous INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
travel
0003
Notes :

Channel Signals/Signals to NC channel

Activate dry run Activate M01 Activate single Activate DRF Activate feed Activate re-
0000 feedrate block (*1) forward verse travel
Activate program Enable protec- Activate

0001 test tion zones referencing
Activate skip Activate skip Activate skip Activate skip Activate skip block Activate skip Activate skip Activate skip
0002 block 7 block 6 block 5 block 4 3 block 2 block 1 block 0
Feed-rate override (31 position gray code)

0004 H G F E D C B A
Rapid traverse override (31 position gray code)

Feed-rate Rapid traverse Limited path Program level Delete number of Delete dis- Read-in disable Feed-rate
0006 override override active velocity abort subroutine cycles tance to go disable
active (*2)
Suppress NC stop axis plus NC stop NC stop at NC start NC start lock

0007 Start Lock spindle block limit
Activate machine related protection zone

0008 Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Activate machine related protection zone

0009 Area 10 Area 9
Activate channel Activate channel Activate chan- Activate channel Activate channel Activate Activate chan- Activate
0010 specific protec- specific protec- nel specific specific protec- specific protection channel nel specific channel
tion zone tion zone protection zone tion zone zone specific pro- protection zone specific pro-
tection zone tection zone
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Activate channel Activate channel Activate chan- Activate channel Activate channel Activate Activate chan- Activate
0011 specific protec- specific protec- nel specific specific protec- specific protection channel nel specific channel
tion zone tion zone protection zone tion zone zone specific pro- protection zone specific pro-
tection zone tection zone
Area 10 Area 9
0012
Do not disable Deactivate
0013 tool workpiece
counter
No tool change Circle Jog Activate associ- Neg. direction for Sim. Handwheel Handwheel
commands ated M01 sim. contour contour hand wheel 2 1
0014 h/wheel ON
Activate skip Activate skip

0015 block 9 block 8
0016 Program
branches
(GOTOS)
control
0017
0018
0019
(*1) Select single block type (SBL1, SBL2) via soft-key.

(*2) Even if feed-rate override is not active (=100%) the 0% is still effective.
Notes :

Control signals to geometry axis (Axis in WCS)
DB3200. PLC NCK [r/w]

Geometry axis 1 (Axis 1 in WCS)
1000 Traversing keys Rapid trav- Traversing key Feedrate stop Activate handwheel (*1)
erse override lock
+ - 2 1
1001 Machine function (*2)
Continuous Inc var INC10000 INC1000 INC100 INC10 INC1
travel
1002
1003
1004 Traversing keys
+ - Rapid trav- Traversing key Feedrate stop 2 1
erse override lock
travel
1006
1007
1008 Traversing keys
+ - Rapid trav- Traversing key Feedrate stop 2 1
erse override lock
travel
1010
1011
(*1) The type of numbering for the hand-wheel is determined by machine data
11234 HANDWH_VDI_REPRESENTATION (0=bit coded, 1=binary coded).
(*2) Machine function:- Only if DB2600.DBX1.0 is not set.
Notes :

Signals from NC channel

DB3300. NCK PLC [r]
Last action M0/M01 Approach Action block Forward Reverse travel Program
block active Active block activate Travel active active execution
active from
0000
external ac-
tive
Program test Transforma- M2/M30 Block search Hand-Wheel Rev. Referencing

0001 active tion active active active override feed-rate active
active active
0002
Channel status Program status
0003 Reset Interrupted Active Aborted Interrupted Stopped Wait Running
NCK alarm Specific NCK All axes sta- All axes ref- Stop Start
with alarm is ac- tionary erenced Request request
0004
processing tive
stop present
Contour hand - wheel active
(Bit/binary coded)
0005 H-wheel H-wheel
1 2
Protection
zones no
0007 longer guaran-
teed
Machine related protection zones pre-activated
0008
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Machine related protection zones pre-activated
0009 Area 10 Area 9
Channel specific protection zones pre-activated
Channel specific protection zones pre-activated
0011
Area 10 Area 9
Machine related protection zones violated
Machine related protection zones violated
0013 Area 10 Area 9
Channel specific protection zones violated
Channel specific protection zones violated
0015 Area 10 Area 9
Notes :

Status signals from geometry axis (Axis in WCS)

DB3300. NCK  PLC [r]
1000 Motion Command Travel request Active Hand-wheel (*1)
Plus Minus Plus Minus 2 1
Active machine function

1001 Continuous Inc var INC10000 INC1000 INC100 INC10 INC1
travel

Motion Command Travel request Active Hand-wheel (*1)
1004

travel

1008 Motion Command Travel request Active Hand-wheel (*1)

travel
(*1) The type of numbering for the hand-wheel is determined by machine data
11234 HANDWH_VDI_REPRESENTATION (0=bit coded, 1=binary coded).
Additional status signals from NC channel

DB3300. NCK PLC [r]
G00
4000 active
Travel request Work-piece set- External

4001 for drive test point reached language
present mode active
4002 Dry run feedrate Associated M01/ Stop ASUP is

is active M00 active delayed stopped
No tool manage- Delay Delay

4003 ment commands FST suppress FST
active
Prog Event Display
4004 Start after Boot Operator panel Part program Part program
search run reset end start from
reset
4005 Jog Circle active Stop condition StopbyColl

Danger
4006 Dormant ASUP Any ASUP

active Active
4007
4008 Active Transformation Number
4008-4011 Reserved
Notes :

Asynchronous sub routines

0000 Asup 1
start
0001 Asup 2
start
0002
0003
ASUP result

Asup 1 start not Asup 1 num- Asup 1 running Asup 1
possible ber not finished
1000 possible
Asup 2 start not Asup 2 num- Asup 2 running Asup 2 finished

possible ber not
1001 possible
G functions from NC channel

0000 Active G function of group 1 (8 bit Integer)
etc
M/S functions, axis specific-spindle specific

DB3707
0000 M function for spindle (Double Integer)
0004 S function for spindle (Real)
Notes :

Signals to axis/spindle

DB3807
Feedrate override
Override active Measuring Measuring Follow up mode Axis/spindle dis- Sensor for fixed Acknowledge
system 2 system 1 able stop fixed stop
0001 reached
Reference point value Clamping in pro- Distance to go/ Controller

gress spindle reset enable
0002 4 3 2 1
Axis/spindle enable Velocity/spindle Enable

0003 program test speed limiting approach to
fixed stop
Traversing keys Rapid traverse Traverse key lock Feedrate stop/ Activate Hand-wheel
0004 override spindle stop
Plus Minus 2 1
Machine function (only if DB2600.DBX1.0 = 0)

travel
Request PLC axis/ Activation signal Request NC

0008 spindle when signal when this axis/spindle
byte is changed
Parameter set-Servo
0009
C B A
Delay reference Modulo Limit 2nd software limit switch Hardware limit switch
point approach Reached
1000 Plus Minus Plus Minus
Jogging to position Jog fix-point Jog fix-point Jog fixpoint

1001 position 2 position 1 position 0
Activate Suppress
1002 program test program test
Signals to spindle
DB3807
Clear S value Spindle:-No Spindle resynchro- Spindle resynchro- Gear changed Actual gear stage
speed moni- nise 2 nise 1
2000 toring for gear C B A
change.
Invert M3/M4 Resynchronise spin- Feedrate

2001 dle during override valid
positioning for spindle
Setpoint direction of rotation Oscillation speed Oscillation via PLC

2002
CCW CW
Spindle override
2003
H G F E D C B A
Notes :

Signals to PLC axis

DB3807
Start positioning Start spindle Start spindle Start spindle
3000 axis positioning turning oscillating
3001 Stop spindle Stop spindle

turning oscillating
Automatic gear Constant cutting Direction of rota- Hand-wheel Traversing Path Path
selection speed tion-same as M4 override dimension Condition: condition:
3002 on Inch Shortest path Incremental
(DC) (IC)
G function: G function:
Indexing position Absolute posi- Absolute nega-
3003 tive direction tive direction
(ACP) (ACN)
3004
3005
Position (Real number, with indexing axis, Double word)
3006
3007
3008
3009 Feedrate (Real number)
If = 0 value is taken from machine data POS_AX_VELO
3010
3011
Note:- IC, DC, ACP, ACN only one signal can be selected at any one time. If no signal is selected AC is active by default.
Signals to drive

DB3807
Open manual
4000 brake
Pulse enable Speed controller Parameter set selection

4001 integrator disable
C B A
4002
4003
Notes :

Signals to technology functions

DB3807
Master/slave ON Torque equalisa-
5000 tion controller ON
5001
5002
Stop HIAxMove Stopp corr Stop DEPBCS Stop DEPMCS Resume HIAx- Resume corr Resume Resume
5003 Move DEPBCS DEPMCS
5004
Disable auto- Start gantry
5005 matic synchro- synchronisation
nisation
5006 Positioning the Automatic gear Specified direc- Specified direc- Spindle
spindle stage change tion of rotation tion of rotation STOP
(Spindle) CCW CW
5007 Delete synchronism

override
(Couplings)
5008
(SISITECH)
5009
(SISITECH)
General signals from axis/spindle

DB3907

Position reached Referenced/ Referenced/ Encoder limit Spindle/no
0000 synchronised 2 synchronised 1 frequency ex- axis
With exact stop- With exact stop- ceeded
fine coarse
Current controller Speed controller Position con- Axis/spindle sta- Follow up mode Axis ready Axis alarm
0001 active active troller active tionary active For
(n < nmin) operation
Power fixed stop Fixed stop Activate travel to Measurement Rotational feder- Hand-wheel
0002 limited reached fixed stop active ate overlay active
active
Axis stop
0003 Ready for opera-
tion
Travel command Travel request Active hand-wheel

0004

travel
PLC axis/spindle Neutral axis/ Exchange New type from NX axis/

0008 spindle possible PLC requested spindle
Servo parameter set

0009
C B A
PLC axis Position re- Position restored

0011 permanently stored 1 2
assigned
Notes :

Signals from axis

DB3907
Modulo limit
1000 enabled
Active
Jog position Indexing axis in Jog fix point posi- Jog fix point posi- Jog fix point posi- Act jog fix Act jog fix point Act jog fix point
1001 reached position tion reached 2 tion reached 1 tion reached 0 point position position1 position 0
2
Rotary axis in Indexing axis in Positioning axis Path axis Lubrication

1002 position position pulse
Velocity re-
1003 duced by Colli-
sion check
Signals from spindle

DB3907
Gearbox Set gear stage
2000 changeover
C B A
Actual Speed monitoring Spindle in Set- Supporting Geometry moni- Set-point Set-point speed Speed limit
2001 direction is clock- point range range limit vio- toring speed in- limited exceeded
wise lated creased
Active spindle mode Rigid tapping GWPS active Constant cut-

ting velocity
2002 Control mode Oscillation mode Positioning mode Synchronous active
mode
Spindle in posi- Tool with dy-

2003 tion namic limiting
Signals from PLC axis

DB3907
Positioning axis Position reached Error Axis

3000 active during travers- cannot be
ing started
3001
3002
3003 Error number
Signals from drive

DB3907
Holding brake
4000 open
Pulses enabled Speed controller Drive ready Active parameter set

4001 integrator disabled
C B A
Variable signal- nact = nset nact < nx nact < nmin Md < Mdx Ramp up Temperature pre-warning
4002 ling function 1 completed
Heat Sink Motor
Vdclink <
4003 Vdclinkx
Notes :

Signals from technology functions

DB3907
Master/slave Master/slave equali- Master/slave Master/slave
5000 active sation controller coarse fine
active
5001
ESR Acceleration Velocity warn- Superimposed
reaction initiated warning thresh- ing threshold motion
5002 old reached reached
Maximum Maximum Synchronisation Axis is Synchronism

5003 acceleration velocity running accelerating override
reached reached travel
Gantry axis Gantry leading Gantry group- Synchronisation Gantry warning Gantry shut-
5005
axis ing is synchro- ready threshold reached down limit
(Gantry) nising reached
5006
Synchronisa-
tion
5007 Override
Is factored in
5008 Active special axis

(Grinding) Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
Tool Management
User interface loading, unloading, reloading
DB4000- PLC NCK Signals to TM [r/w]

DB40xx (*1)
Acknowledge- Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Total ac-

0000 ment step 7 ment step 6 ment step 5 step 4 step 3 edgement ment step 1 knowledgeme
step 2 nt
Acknowledge- Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Acknowl-

0001 ment step 15 ment step 14 ment step 13 step 12 step 11 edgement ment step 9 edgement
step 10 step 8
Acknowledge- Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Acknowl-

0002 ment step 23 ment step 22 ment step 21 step 20 step 19 edgement ment step 17 edgement
step 18 step 16
Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Acknowl-

0003 Reserved ment step 30 ment step 29 step 28 step 27 edgement ment step 25 edgement
step 26 step 24
0004 to
0016 Reserved
Notes :

Jobs for loading, unloading, reloading, positioning the magazine
DB4100- NCK PLC Signals from TM [r]

DB41xx (*1)

0000 Job
Job from NC pro- Positioning Relocating Unloading Loading

0001 gram
0002 Reserved
0003 Reserved
0004 Reserved
0005 Reserved
0006 Source magazine no. (Integer)
0008 Source location no. (Integer)
0010 Target magazine no. (Integer)
0012 Target location no. (Integer)
Load unload
0014 without mov-
HMI to PLC ing magazine
Feedback signal

DB41xx (*1)
Acknowledge- Acknowledge-
0100 ment error ment OK
0101 Reserved
0102 Reserved
0104 Fault status (Word)
(*1) xx = Loading position
Job status

DB41xx (*1)

0120 Reserved
0121 Reserved
0122 Reserved
0124 Current magazine number of the tool (Integer)
0126 Current location number of the tool (Integer)
0128 Target magazine number of the tool (Integer)
0130 Target location number of the tool (Integer)
(*1) xx = Loading position
Notes :

User interface tool change
DB4200- PLC NCK Signals to TM [r/w]

DB42xx (*2)

Acknowledge- Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Total ac-
0000 ment step 7 step 6 ment step 5 ment step 4 ment step 3 ment step 2 ment step 1 knowledgeme
nt
Acknowledge- Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl-

0001 ment step 15 step 14 ment step 13 ment step 12 ment step 11 ment step 10 ment step 9 edgement
step 8
Acknowledge- Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl-

0002 ment step 23 step 22 ment step 21 ment step 20 ment step 19 ment step 18 ment step 17 edgement
step 16
Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl-

0003 Reserved step 30 ment step 29 ment step 28 ment step 27 ment step 26 ment step 25 edgement
step 24
0004 to
0024 Reserved
(*2) xx = Tool holder
Notes :

Jobs for tool change preparing and execute

DB43xx (*1)
0000 Job
Tool Manual tool Manual tool No old tool T0 Prepare Change tool Fixed location
0001 remains in spin- unload load change (Initiated by coded
dle M06)
0002 Reserved
0004 Reserved
0005 Reserved
0006 Source magazine no. for new tool (Integer)
0008 Source location no. for new tool (Integer)
0010 Reserved
0012 Reserved
0014 Reserved
0016 Reserved
0018 Target magazine no. for old tool (Integer)
0020 Target location number for old tool (Integer)
0022 Location type (Integer)
0024 Size, left (Integer)
0026 Size, right (Integer)
0028 Reserved
0030 Reserved
Tool status for new tool

0032 Master tool To be loaded To be Blocked Identifier for
unloaded tool
Tool status for new tool

0033 Tool has been in Tool is fixed Tool being Pre warning limit Measuring tools Tool Tool Active tool
use location coded changed reached disabled enabled
0034 New tool: Internal T no. of NCK (Integer)
0036 Reserved (Double word)
0040 Reserved (Double word)
0044 User defined parameter 1 (Double word)
Notes :

Feedback signal
DB43xx
(*1)

0100 Acknowledge- Acknowledge-
ment error ment OK
0101 Reserved
0102 Reserved
0104 Fault status acknowledgement (Word)
Job status
DB4300- NCK PLC Job status [r]

DB43xx
(*1)

0120 Reserved
0121 Reserved
0122 Reserved
0124 Current magazine no. for new tool (Integer)
0126 Current location no. for new tool (Integer)
0128 Target magazine no. for new tool (Integer)
0130 Target location no. for new tool (Integer)
0132 Current magazine no. for old tool (Integer)
0134 Current location no. for old tool (Integer)
0136 Target magazine no. for old tool (Integer)
0138 Target location no. for old tool (Integer)
PLC machine data

INT values (MD14510 USER_DATA_INT)
0000 Int values (Word/2 bytes)
Up to
Notes :

HEX values (MD14512 USER_DATA_HEX)

1000 Hex value (Byte)
Up to
FLOAT values (MD14514 USER_DATA_FLOAT)

2000 Float value (Real/4 bytes)
Up to
User alarm Configuration (MD14516 USER_DATA_PLC_ALARM)

3000 Alarm reaction/cancellation criterion-Alarm 700000
Up to
Synchronised actions
Signals to channel
DB4600 PLC  HMI [r/w] Deactivate synchronised action with ID...
0000 ID8 ID7 ID6 ID5 ID4 ID3 ID2 ID1
Notes :

Signals from channel

DB4700 NCK  PLC [r] Synchronised action with ID... can be blocked from the PLC
Reading and writing PLC variables
DB4900 PLC interface [r/w]

0000 Offset 0
0001 Offset 1
0002 Offset 2
Up to Offset 4095
4095
Tool management functions from NC channel

Change signals for tool management functions
Tool limit value Tool
0000 reached warning limit
reached
Transferred tool management functions

1000 T number for tool warning limit (Double integer)
1004 T number for tool limit value (Double integer)
1008
1012
Notes :

Axis actual values and distances to go

Signals from axis/spindle
5705

0000 Axis actual value (Real)
0004 Axis distance to go (Real)
Used in with:- DB2600.DBX1.1 Request axis actual value

DB2600.DBX1.2 Request axis distance to go
Tool management user interface
DB9900 Constant transfer step table [r]

0000 Transfer step 1
Source magazine no. (Integer)

Source location no. (Integer)

Target magazine no. (Integer)

Target location no. (Integer)




etc



Notes :

Tool management user interface-continued
DB9901 Variable transfer step table [r/w]

Transfer step 101
Transfer step 101

Transfer step 101

Transfer step 101

Transfer step 102

Transfer step 102

Transfer step 102

Transfer step 102

etc
Transfer step 164
Transfer step 164

Transfer step 164

Transfer step 164

Notes :

Tool management user interface-continued
DB9902 Acknowledgement step table [r]

Acknowledgement step 1
0000 Transfer step for new tool. (Byte)
0001 Transfer step for old tool. (Byte)
0002 Acknowledgement status. (Byte)
0003 Reserved
0007 Reserved
etc
0119 Reserved
Maintenance planner user interface
DB9903 Initial data table [r]

0000 Interval 1 [Hours]
0002 Time of first warning 1 [Hours]
0004 Number of warnings to be output 1
0006 Reserved 1
0014 Reserved 2
etc
0254 Reserved
Notes :

Maintenance planner user interface-continued
DB9904 Actual data table [r]

0002 Number of warnings output 1
0004 Reserved_1 1
0006 Reserved_2 1

0012 Reserved_1 2
0014 Reserved_2 2
etc

0252 Reserved_1 32
0254 Reserved_2 32
Easy Extend user interface
DB9905 HMI PLC [r/w]
Deactivate Activate Enable

0000
1 1 1
0001
Error Activated
0002
1 1
0003 Device ID_1

0004
2 2 2
0005
Error Activated
0006
2 2
0007 Device ID_2
etc

0248
64 64 64
0250
Error Activated
0252
64 64
0254 Device ID_64
Appendix C: END
Notes :

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SINUMERIK 828D

This document was produced for training purposes.

Commissioning Manual for

Sinumerik 828D Software 4.4

B010 B051 B053 B008

B101 B102 B020

Copyright © Siemens AG 2008 All Rights Reserved.

1 RESPONSIBLE PERSONS: ................................................................................................................................................................................4

1.1 Schedule .....................................................................................................................................................................................................................................................................................4

1.2 Participants carrying-out the test............................................................................................................................................................................................................................................4

2 SUMMARY AND RESULT ...................................................................................................................................................................................5

2.1 Summary ...................................................................................................................................................................................................................................................................................5

2.2 Result .........................................................................................................................................................................................................................................................................................5

2.3 Release Siemens ........................................................................................................................................................................................................................................................................5

2.4 Release from Machine Tool Builder........................................................................................................................................................................................................................................5

3.1 Modified data ............................................................................................................................................................................................................................................................................6

3.2 Data Backup..............................................................................................................................................................................................................................................................................6

4 CHANGE LOG .....................................................................................................................................................................................................7

4.1 Changes to the machine............................................................................................................................................................................................................................................................7

5 SYSTEM DESCRIPTION .....................................................................................................................................................................................8

5.1 Machine .....................................................................................................................................................................................................................................................................................8

Doc-Nr.:xx.yy Page 2/32 Date: 11.04.2012 Protocol version 1.0

Copyright © Siemens AG 2009 All Rights Reserved.

6 TEST OBJECTIVE ...............................................................................................................................................................................................9

6.1 Note ............................................................................................................................................................................................................................................................................................9

8.1 Machine area...........................................................................................................................................................................................................................................................................11

8.2 Parameter ................................................................................................................................................................................................................................................................................25

8.3 Geometry .................................................................................................................................................................................................................................................................................28

8.4 Safety Integrated.....................................................................................................................................................................................................................................................................28

8.5 Startup .....................................................................................................................................................................................................................................................................................29

8.6 Password protection ...............................................................................................................................................................................................................................................................30

Copyright © Siemens AG 2009 All Rights Reserved.

8.6.1 Securing data areas ...........................................................................................................................................................................................................................................................30

Test carried out at (OEM Name):

1.2 Participants carrying-out the test

Name Company / Department

Doc-Nr.:xx.yy Page 4/32 Date: 11.04.2012 Protocol version 1.0

Copyright © Siemens AG 2009 All Rights Reserved.

2 Summary and result

2.3 Release Siemens

2.4 Release from Machine Tool Builder

Doc-Nr.:xx.yy Page 5/32 Date: 11.04.2012 Protocol version 1.0

Copyright © Siemens AG 2009 All Rights Reserved.

3.2 Data Backup

- ____________ (NCPLC Archive)

Doc-Nr.:xx.yy Page 6/32 Date: 11.04.2012 Protocol version 1.0

Copyright © Siemens AG 2009 All Rights Reserved.

4.1 Changes to the machine.

Date Change Reason Teste Responsible person Signature

Doc-Nr.:xx.yy Page 7/32 Date: 11.04.2012 Protocol version 1.0

Copyright © Siemens AG 2009 All Rights Reserved.

Doc-Nr.:xx.yy Page 8/32 Date: 11.04.2012 Protocol version 1.0

Copyright © Siemens AG 2009 All Rights Reserved.

The test plan extends the commissioning documentation of 828D.

The necessary programs are to be created directly at the machine.

The test plan is valid for the current Software version

1) Siemens Code(DIN) and ShopMill/ShopTurn with Æ Metric system of units

Doc-Nr.:xx.yy Page 9/32 Date: 11.04.2012 Protocol version 1.0