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SINUMERIK
SINUMERIK 840D sl / 828D
Basic Functions
Function Manual
Valid for
Control system SINUMERIK 840D sl /
 840DE sl SINUMERIK 828D
Software Version 
CNC software 4.4
09/2011
6FC5397-0BP40-2BA0
Preface
A2: Various NC/PLC interface
signals and functions
A3: Axis Monitoring, Protection
Zones
B1: Continuous­path Mode,
Exact Stop, LookAhead
B2: Acceleration
D1: Diagnostics tools
F1: Travel to fixed stop
G2: Velocities, setpoint / actual value
systems, closed-loop control
H2: Auxiliary function outputs to
PLC
K1: Mode group, channel, program
operation, reset response
K2: Axis Types, Coordinate
Systems, Frames
N2: Emergency stop
P1: Transverse axes
P3: Basic PLC Program for
SINUMERIK 840D sl
P4: PLC for SINUMERIK 828D
R1: Reference point approach
S1: Spindles
V1: Feedrates
W1: Tool offset
Z1: NC/PLC interface signals
Appendix
10 
11 
12 
13 
14 
15 
16 
17 
18 
19 

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   Summary of Contents for Siemens SINUMERIK 828D

  • Page 1 10  Systems, Frames 11  N2: Emergency stop 12  P1: Transverse axes P3: Basic PLC Program for 13  SINUMERIK 840D sl 14  P4: PLC for SINUMERIK 828D 15  R1: Reference point approach Valid for 16  S1: Spindles Control system SINUMERIK 840D sl / 17   840DE sl SINUMERIK 828D V1: Feedrates Software Version ...
  • Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
  • Page 3 Training For information about the range of training courses, refer under: • www.siemens.com/sitrain SITRAIN - Siemens training for products, systems and solutions in automation technology • www.siemens.com/sinutrain SinuTrain - training software for SINUMERIK FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support.
  • Page 4 Preface SINUMERIK You can find information on SINUMERIK under the following link: www.siemens.com/sinumerik Target group This publication is intended for: • Project engineers • Technologists (from machine manufacturers) • System startup engineers (Systems/Machines) • Programmers Benefits The function manual describes the functions so that the target group knows them and can select them. It provides the target group with the information required to implement the functions.
  • Page 5 The description of functions include as <signal address> of an NC/PLC interface signal, only the address valid for SINUMERIK 840D sl. The signal address for SINUMERIK 828D should be taken from the data lists "Signals to/from ..." at the end of the particular description of functions.
  • Page 6 Geometrical parameters for moving, rotating, scaling, and mirroring Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible. SINUMERIK 828D system performance (region) PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2...
  • Page 7 Preface PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2 BASIC T BASIC M Inclined Y axis ○ Synchronous spindle for counterspindle ○ Synchronous spindle for polygon ○ ○ ○ machining Gantry ○ ○ ○ ○ ○ ○ Temperature compensation ●...
  • Page 8 Preface Turning Milling ● Standard (basic scope) ○ Option Not available Basic Functions Function Manual, 09/2011, 6FC5397-0BP40-2BA0...
  • Page 9 Table of contents Preface.................................3 A2: Various NC/PLC interface signals and functions ................35 Brief description......................... 35 NC/PLC interface signals ......................36 1.2.1 General ............................36 1.2.2 Ready signal to PLC ........................38 1.2.3 Status signals to PLC ........................ 38 1.2.4 Signals to/from panel front ......................39 1.2.5 Signals to channel ........................
  • Page 10 Table of contents 2.1.2 Protection zones ........................77 Axis monitoring .......................... 78 2.2.1 Contour monitoring ........................78 2.2.1.1 Contour error ..........................78 2.2.1.2 Following Error Monitoring ......................78 2.2.2 Positioning, zero speed and clamping monitoring ..............81 2.2.2.1 Correlation between positioning, zero-speed and clamping monitoring ........81 2.2.2.2 Positioning monitoring .......................
  • Page 11 Table of contents B1: Continuous­path Mode, Exact Stop, LookAhead ................147 Brief Description ........................147 Exact stop mode........................150 Continuous-path mode ......................154 3.3.1 General functionality ........................ 154 3.3.2 Velocity reduction according to overload factor ............... 156 3.3.3 Blending ........................... 158 3.3.3.1 Rounding according to a path criterion (G641) ................
  • Page 12 Table of contents Functions ..........................217 4.2.1 Acceleration and jerk for positioning motion to fixed points ............. 217 4.2.1.1 General Information ......................... 217 4.2.1.2 Parameterization ........................217 4.2.2 Acceleration without jerk limitation (BRISK/BRISKA) (channel-/axis-specific) ......218 4.2.2.1 General Information ......................... 218 4.2.2.2 Programmable maximum value (axis-specific) ................
  • Page 13 Table of contents 4.2.15.1 General Information ......................... 238 4.2.15.2 Programming ........................... 239 4.2.16 Jerk with programmed rapid traverse (G00) (axis-specific) ............. 240 4.2.16.1 General Information ......................... 240 4.2.16.2 Parameterization ........................240 4.2.17 Excessive jerk for block transitions without constant curvature (axis-specific) ......240 4.2.17.1 General Information .........................
  • Page 14 Table of contents 5.7.1.2 NC-specific machine data ......................296 5.7.1.3 Axis/spindle­specific machine data ..................297 5.7.2 Setting data ..........................297 5.7.2.1 Axis/spindle-specific setting data .................... 297 5.7.3 Signals ............................. 297 5.7.3.1 Signals to axis/spindle ......................297 5.7.3.2 Signals from axis/spindle ......................297 F1: Travel to fixed stop ..........................299 Product brief ..........................
  • Page 15 Table of contents Closed-loop control........................374 7.5.1 General ............................ 374 7.5.2 Parameter sets of the position controller ................. 377 Optimization of the control....................... 380 7.6.1 Position controller, position setpoint filter: Balancing filter ............380 7.6.2 Position controller, position setpoint filter: Jerk filter ..............383 7.6.3 Position control with proportional-plus-integral-action controller ..........
  • Page 16 Table of contents 8.13.4 Determining the output sequence .................... 442 8.13.5 Output suppression of spindle-specific auxiliary functions ............444 8.13.6 Auxiliary function output with a type 5 block search (SERUPRO) ........... 447 8.13.7 ASUB at the end of the SERUPRO ..................452 8.14 Implicitly output auxiliary functions ..................
  • Page 17 Table of contents 9.7.3 Automatic start of an ASUB after a block search ..............510 9.7.4 Cascaded block search ......................512 9.7.5 Examples of block search with calculation ................514 Block search Type 5 SERUPRO ..................... 518 9.8.1 REPOS ............................ 524 9.8.1.1 Continue machining after SERUPRO search target found ............
  • Page 18 Table of contents 9.9.13 Influencing the Stop events through Stop delay area .............. 588 9.10 Asynchronous subroutines (ASUBs), interrupt routines ............591 9.10.1 Function ........................... 591 9.10.1.1 General functionality ........................ 591 9.10.1.2 Sequence of an interrupt routine in program operation ............593 9.10.1.3 Interrupt routine with REPOSA ....................
  • Page 19 Table of contents 9.16 Program runtime / Part counter ....................661 9.16.1 Program runtime ........................661 9.16.2 Workpiece counter ........................668 9.17 Data lists..........................673 9.17.1 Machine data ........................... 673 9.17.1.1 General machine data ......................673 9.17.1.2 Channel­specific machine data ....................674 9.17.1.3 Axis/spindle­specific machine data ..................
  • Page 20 Table of contents 10.5.2 Frame components ........................723 10.5.2.1 Translation ..........................723 10.5.2.2 Fine offset ..........................724 10.5.2.3 Rotations for geometry axes ....................725 10.5.2.4 Scaling ............................. 729 10.5.2.5 Mirroring ........................... 729 10.5.2.6 Chain operator ......................... 730 10.5.2.7 Programmable axis identifiers ....................730 10.5.2.8 Coordinate transformation .......................
  • Page 21 Table of contents 10.6.3 Special reactions ........................802 10.7 Restrictions..........................804 10.8 Examples..........................804 10.8.1 Axes ............................804 10.8.2 Coordinate systems ......................... 807 10.8.3  Frames  ..........................808 10.9 Data lists..........................811 10.9.1 Machine data ........................... 811 10.9.1.1 Displaying machine data ......................811 10.9.1.2 NC-specific machine data ......................
  • Page 22 Table of contents 13.2 Key data of the PLC-CPUs for 840D sl and 840Di sl............... 839 13.3 Reserve resources (timers, counters, FC, FB, DB, I/O) ............846 13.4 Startup hardware configuration of the PLC-CPUs ..............847 13.5 Starting up the PLC program ....................852 13.5.1 Installation of the basic program ....................
  • Page 23 Table of contents 13.12.2 NC VAR selector ........................914 13.12.2.1Overview ..........................914 13.12.2.2Description of functions ......................916 13.12.2.3Start­up, installation ......................... 924 13.13 Block descriptions........................925 13.13.1 FB 1: RUN_UP Basic program, start­up section ..............925 13.13.2 FB 2: Read GET NC variable ....................933 13.13.3 FB 3: PUT write NC variables ....................
  • Page 24 13.15.6 FB calls ..........................1084 13.16 Data lists ..........................1086 13.16.1 Machine data ......................... 1086 13.16.1.1NC-specific machine data ...................... 1086 13.16.1.2Channel­specific machine data ....................1086 P4: PLC for SINUMERIK 828D ......................1087 14.1 Overview..........................1087 14.1.1 PLC firmware ......................... 1087 14.1.2 PLC user interface .........................
  • Page 25 Table of contents 14.4.1.2 Preconditions of the status update ..................1132 14.4.1.3 Influence of the operating state on the target system ............1132 14.4.1.4 Communication and cycle ..................... 1132 14.4.1.5 Status update ........................1133 14.4.1.6 Simulating process conditions ....................1133 14.4.1.7 Checking cross references and the elements used ...............
  • Page 26 Table of contents 14.6.4.13Rotate spindle with constant cutting rate [feet/min] ............... 1192 14.6.4.14Error messages ........................1193 14.6.5 Starting ASUBs ........................1195 14.6.5.1 The ASUB UP interface ......................1196 14.6.5.2 Signal flow ..........................1197 R1: Reference point approach ......................1199 15.1 Brief Description ........................1199 15.2 Axis­specific referencing......................
  • Page 27 Table of contents 15.11.1.2Channel­specific machine data ..................... 1250 15.11.1.3Axis/spindle­specific machine data ..................1250 15.11.2 Signals ........................... 1251 15.11.2.1Signals to BAG ........................1251 15.11.2.2Signals from BAG ........................1251 15.11.2.3Signals to channel ......................... 1252 15.11.2.4Signals from channel ......................1252 15.11.2.5Signals to axis/spindle ......................1252 15.11.2.6Signals from axis/spindle .......................
  • Page 28 Table of contents 16.8.3 Spindle in setpoint range ....................... 1342 16.8.4 Minimum / maximum speed of the gear stage ............... 1344 16.8.5 Diagnosis of spindle speed limitation ..................1345 16.8.6 Maximum spindle speed ......................1347 16.8.7 Maximum encoder limit frequency ..................1348 16.8.8 End point monitoring ......................
  • Page 29 Table of contents 17.4.8 Feedrate for chamfer/rounding FRC, FRCM ................. 1404 17.4.9 Non-modal feedrate FB ......................1405 17.4.10 Programmable single­axis dynamic response ............... 1406 17.5 Supplementary conditions ..................... 1411 17.5.1 General boundary conditions ....................1411 17.5.2 Supplementary conditions for feedrate programming ............1411 17.6 Examples..........................
  • Page 30 Table of contents 18.4.9 Tool parameter 24: Undercut angle ..................1456 18.4.10 Tools with a relevant tool point direction ................1457 18.5 Tool radius compensation 2D (TRC) ..................1458 18.5.1 General ..........................1458 18.5.2 Selecting the TRC (G41/G42) ....................1459 18.5.3 Approach and retraction behavior (NORM/KONT/KONTC/KONTT) ........
  • Page 31 Table of contents 18.10.5 Tool type (SD42950 $SC_TOOL_LENGTH_TYPE) .............. 1549 18.10.6 Temperature offsets in tool direction (SD42960 $SC_TOOL_TEMP_COMP) ....... 1550 18.10.7 Tool lengths in the WCS, allowing for the orientation ............1550 18.10.8 Tool length offsets in tool direction ..................1551 18.11 Sum offsets and setup offsets ....................
  • Page 32 Table of contents 19.1.6 Signals to channel (DB21, ...) ....................1623 19.1.7 Signals from channel (DB21, ...) .................... 1624 19.1.8 Signals to axis/spindle (DB31, ...) ..................1625 19.1.9 Signals from axis/spindle (DB31, ...) ..................1637 19.2 Axis monitoring, protection zones (A3) .................. 1652 19.2.1 Signals to channel (DB21, ...) ....................
  • Page 33 Appendix ...............................1743 20.1 List of abbreviations....................... 1743 20.2 Overview..........................1751 Glossary..............................1753 Basic Functions Function Manual, 09/2011, 6FC5397-0BP40-2BA0...
  • Page 34 Basic Functions Function Manual, 09/2011, 6FC5397-0BP40-2BA0...
  • Page 35 A2: Various NC/PLC interface signals and functions Brief description Content The PLC/NCK interface comprises a data interface on one side and a function interface on the other. The data interface contains status and control signals, auxiliary functions and G functions, while the function interface is used to transfer jobs from the PLC to the NCK.
  • Page 36 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals NC/PLC interface signals 1.2.1 General NC/PLC interface The NC/PLC interface comprises the following parts: • Data interface • Function interface Data interface The data interface is used for component coordination: •...
  • Page 37 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals Channel-specific signals (DB21, ...) PLC to NC: • Control signal "Delete distance­to­go" NC to PLC: • NC status signals (NCK alarm active) Axis/spindle-specific signals (DB31, etc.) PLC to NC: •...
  • Page 38 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals 1.2.2 Ready signal to PLC DB10 DBX104.7 (NC CPU Ready) The NC CPU is ready and registers itself cyclically with the PLC. DB10 DBX108.3 (HMI Ready) SINUMERIK Operate is ready and registers itself cyclically with the NC. DB10 DBX108.5 (drives in cyclic operation) Precondition: For all machine axes of the NC, the corresponding drives are in the cyclic operation, i.e.
  • Page 39 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals DB21, ... DBX36.6 (channel­specific NCK alarm pending) The NC sends this signal to the PLC to indicate that at least one NC alarm is pending for the affected channel. See also: DB21, ...
  • Page 40 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals DB19 DBX 0.3 / 0.4 (Delete cancel alarms / Delete recall alarms) (HMI Advanced) Request to delete all currently pending alarms with Cancel or Recall delete criterion. Deletion of the alarms is acknowledged via the following interface signals.
  • Page 41 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals 1.2.5 Signals to channel DB21, ... DBX6.2 (delete distance-to-go) The rising edge on the interface signal generates a stop on the programmed path in the corresponding NC channel with the currently active path acceleration. The path distance-to-go is then deleted and the block change to the next part-program block is enabled.
  • Page 42 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals DB31, ... DBX1.4 (follow-up mode) "Follow-up mode" is only effective in conjunction with the NC/PLC interface signal: DB31, ... DBX2.1 (controller enable) DB31, ... DBX2.1 DB31, ... DBX1.4 Function Ineffective Normal operation (machine axis in closed-loop control mode)
  • Page 43 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals Application example Positioning response of machine axis Y following clamping when "controller enable" set. Clamping pushed the machine axis from the actual position Y to the clamping position Y Figure 1-1 Effect of controller enable and follow-up mode Figure 1-2...
  • Page 44 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals Figure 1-3 Trajectory for clamping and "follow-up" Drives with analog setpoint interface A drive with an analog setpoint interface is capable of traversing the machine axis with an external setpoint. If "follow-up mode"...
  • Page 45 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals Canceling follow­up mode Once follow-up mode has been canceled, the machine axis does not have to be homed again if the maximum permissible encoder limit frequency of the active measuring system was not exceeded during follow-up mode. If the encoder limit frequency is exceeded, the controller will detect this: •...
  • Page 46 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals The table below shows the functionality of the interface signals in conjunction with the "controller enable". DB31, ... DBX1.5 DB31, ... DBX1.6 DB31, ... DBX2.1 Function 0 (or 1) Position measuring system 1 active Position measuring system 2 active "Parking"...
  • Page 47 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals Canceling the controller enable when the machine axis is in motion: If a machine axis is part of an interpolatory path movement or coupling and the controller enable for this is canceled, all axes involved are stopped with a fast stop (speed setpoint = 0) and an alarm is displayed: Alarm: "21612 Controller enable reset during movement"...
  • Page 48 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals Synchronizing the actual value (homing) Once the controller enable has been set, the actual position of the machine axis does not need to be synchronized again (homing) if the maximum permissible limit frequency of the measuring system was not exceeded during the time in which the machine axis was not in position-control mode.
  • Page 49 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals DB31, ... DBX9.0 / 9.1 / 9.2 (controller parameter set) Request for activation of the specified controller parameter set. Controller parameter set DBX9.2 DBX9.1 DBX9.0 Parameter-set changeover must be enabled via the machine data (not required for spindles): MD35590 $MA_PARAMSET_CHANGE_ENABLE = 1 or 2 More information about parameter set changeover can be found in: References:...
  • Page 50 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals 1.2.7 Signals from axis/spindle DB31, ... DBX61.0 (drive test travel request) If machine axes are traversed by special test functions such as "function generator", an explicit drive-test-specific enable is requested for the movement: DB31, ...
  • Page 51 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals DB31, ... DBX76.0 (lubrication pulse) Following a control POWER ON/RESET, the signal status is 0 (FALSE). The "lubrication pulse" is inverted (edge change), as soon as the machine axis has covered the parameterized traversing distance for lubrication: MD33050 $MA_LUBRICATION_DIST (distance for lubrication by PLC) 1.2.8...
  • Page 52 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals DB31, ... DBX21.5 (Motor selection done) The PLC user program sends this signal to the drive to indicate successful motor selection. For example, in the case of star/delta switchover on the SIMODRIVE 611D or 611U, a message or signal must be provided when the motor contactor has switched.
  • Page 53 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals 1.2.9 Signals from axis/spindle (digital drives) DB31, ... DBX92.1 (ramp-function generator disable active) The drive signals back to the PLC that ramp-function-generator fast stop is active. The drive is thus brought to a standstill without the ramp function (with speed setpoint 0).
  • Page 54 A2: Various NC/PLC interface signals and functions 1.2 NC/PLC interface signals DB31, ... DBX94.2 (ramp-up completed) The signal indicates that the actual speed value has reached the new setpoint allowing for the tolerance band set in the drive machine data. The acceleration procedure is thus completed.
  • Page 55 A2: Various NC/PLC interface signals and functions 1.3 Functions Functions 1.3.1 Screen settings Contrast, monitor type, foreground language, and display resolution to take effect after system startup can be set in the operator panel front machine data. Contrast MD9000 $MM_LCD_CONTRAST (contrast) For slimline operator panel fronts with a monochrome LCD, the contrast to be applied following system startup can be set.
  • Page 56 A2: Various NC/PLC interface signals and functions 1.3 Functions REFRESH suppression MD10131 $MN_SUPPRESS_SCREEN_REFRESH (screen refresh in case of overload) Default setting for screen-refresh strategy with high NC utilization: • Value 0: Refresh of current values is suppressed in all channels. •...
  • Page 57 A2: Various NC/PLC interface signals and functions 1.3 Functions References: /PG/Programming Manual Fundamentals In addition to the programmed parameters, machine data are relevant in two instances of involute interpolation; these data may need to be set by the machine manufacturer/end user. Accuracy If the programmed end point does not lie exactly on the involute defined by the starting point, interpolation takes place between the two involutes defined by the starting and end points (see illustration below).
  • Page 58 A2: Various NC/PLC interface signals and functions 1.3 Functions Limit angle If AR is used to program an involute leading to the base circle with an angle of rotation that is greater than the maximum possible value, an alarm is output and program execution aborted. Figure 1-8 Limited angle of rotation towards base circle The alarm display can be suppressed using the following parameter settings:...
  • Page 59 A2: Various NC/PLC interface signals and functions 1.3 Functions 1.3.3 Activate DEFAULT memory GUD start values The DEF... / REDEF... NC commands can be used to assign default settings to global user data (GUD). These default settings must be permanently stored in the system if they are to be available after certain system states (e.g.
  • Page 60 A2: Various NC/PLC interface signals and functions 1.3 Functions Access from NC To allow the NC to access PLC variables (from a part program) quickly, $ variables are provided in the NCK. The PLC uses a function call (FC) to read and write $ variables. Data are transferred to and from the NCK immediately.
  • Page 61 A2: Various NC/PLC interface signals and functions 1.3 Functions Supplementary conditions • The user's programming engineer (NCK and PLC) is responsible for organizing the DPR memory area. No checks are made for inconsistencies in the configuration. • A total of 1024 bytes are available in the input and output directions. •...
  • Page 62 A2: Various NC/PLC interface signals and functions 1.3 Functions Example A WORD is to be transferred from the PLC to the NC. The position offset within the NCK input (PLC output area) should be the fourth byte. The position offset must be a whole-number multiple of the data width.
  • Page 63 Access authorization Access to functions, programs and data is user­oriented and controlled via 8 hierarchical protection levels. These are subdivided into: • Password levels for Siemens, machine manufacturer and end user • Keyswitch positions for end user Multi-level security concept A multi-level security concept to regulate access rights is available in the form of password levels and keyswitch settings.
  • Page 64 • Conversely, protection rights for a certain protection level can only be altered from a higher protection level. • Access rights for protection levels 0 to 3 are permanently assigned by Siemens and cannot be altered (default). • Access rights can be set by querying the current keyswitch positions and comparing the passwords entered.
  • Page 65 A2: Various NC/PLC interface signals and functions 1.3 Functions Defaults The following default passwords are defined for protection levels 1 to 3: • Protection level 1: SUNRISE • Protection level 2: EVENING • Protection level 3: CUSTOMER Note Following NC-CPU ramp-up in commissioning mode (NCK commissioning switch: position 1) the passwords for protection levels 1 –...
  • Page 66 A2: Various NC/PLC interface signals and functions 1.3 Functions Default settings via the PLC user program The keyswitch switch positions are transferred to the NC/PLC interface via the basic PLC program. The corresponding interface signals can be modified via the PLC user program. In this context, from the point of view of the NC, only one switch position should ever be active, i.e,.
  • Page 67 A2: Various NC/PLC interface signals and functions 1.4 Examples Examples Parameter set changeover A parameter-set changeover is performed to change the position-control gain (servo gain factor) for machine axis X1 from v = 4.0 to Kv = 0.5. Preconditions The parameter set changeover must be enabled by the machine data: MD35590 $MA_PARAMSET_CHANGE_ENABLE [AX1] = 1 or 2 (parameter set change possible) The 1st parameter set for machine axis X1 is set, in accordance with machine data with index "0"...
  • Page 68 A2: Various NC/PLC interface signals and functions 1.4 Examples Changeover In order to switch over the position-control gain, the PLC user program selects the 4th parameter set for machine axis X1. • Request by PLC user program: DB31, … DBX9.0 – DBX9.2 = 3 (parameter set servo) A request to change over to the 4th parameter set is sent for machine axis AX1.
  • Page 69 A2: Various NC/PLC interface signals and functions 1.5 Data lists Data lists 1.5.1 Machine data 1.5.1.1 Display machine data Number Identifier: $MM_ Description SINUMERIK Operate 9000 LCD_CONTRAST Contrast 9001 DISPLAY_TYPE Monitor type 9004 DISPLAY_RESOLUTION Display resolution 9008 KEYBOARD_TYPE Keyboard type (0: OP, 1: MFII/QWERTY) 9009 KEYBOARD_STATE Shift behavior of keyboard during booting...
  • Page 70 A2: Various NC/PLC interface signals and functions 1.5 Data lists Number Identifier: $MM_ Description SINUMERIK Operate 9232 USER_BEGIN_WRITE_RPA_1 Start of the first RPA area 9233 USER_END_WRITE_RPA_1 End of the first RPA area 9234 USER_CLASS_WRITE_RPA_2 Write protection for second RPA area 9235 USER_BEGIN_WRITE_RPA_2 Start of the second RPA area...
  • Page 71 A2: Various NC/PLC interface signals and functions 1.5 Data lists Number Identifier: $MC_ Description 27800 TECHNOLOGY_MODE Technology in channel 28150 MM_NUM_VDIVAR_ELEMENTS Number of write elements for PLC variables 28530 MM_PATH_VELO_SEGMENTS Number of storage elements for limiting path velocity in block 1.5.1.4 Axis/spindle­specific machine data Number...
  • Page 72 Data on PLC (DWORD type data) $A_DBR[n] Data on PLC (REAL type data) 1.5.3 Signals 1.5.3.1 Signals to NC Signal name SINUMERIK 840D sl SINUMERIK 828D Keyswitch setting 0 to 3 DB10.DBX56.4-7 DB2600.DBX0.4-7 1.5.3.2 Signals from NC Signal name SINUMERIK 840D sl SINUMERIK 828D Remote diagnostics active (HMI alarm is pending) DB10.DBX103.0...
  • Page 73 A2: Various NC/PLC interface signals and functions 1.5 Data lists 1.5.3.3 Signals to operator panel front Signal name SINUMERIK 840D sl SINUMERIK 828D Screen bright DB19.DBX0.0 Screen dark DB19.DBX0.1 Key disable DB19.DBX0.2 DB1900.DBX5000.2 Delete Cancel alarms (HMI Advanced only) DB19.DBX0.3 Delete Recall alarms (HMI Advanced only) DB19.DBX0.4...
  • Page 74 A2: Various NC/PLC interface signals and functions 1.5 Data lists 1.5.3.6 Signals from channel Signal name SINUMERIK 840D sl SINUMERIK 828D Channel­specific NCK alarm is active DB21, ..DBX36.6 DB3300.DBX4.6 NCK alarm with processing stop present DB21, … .DBX36.7 DB3300.DBX4.7 Overstore active DB21, ...
  • Page 75 A2: Various NC/PLC interface signals and functions 1.5 Data lists Signal name SINUMERIK 840D sl SINUMERIK 828D | < n DB31, ..DBX94.4 DB390x.DBX4002.4 | < n DB31, ..DBX94.5 DB390x.DBX4002.5 DB31, ..DBX94.6 DB390x.DBX4002.6 Basic Functions Function Manual, 09/2011, 6FC5397-0BP40-2BA0...
  • Page 76 A2: Various NC/PLC interface signals and functions 1.5 Data lists Basic Functions Function Manual, 09/2011, 6FC5397-0BP40-2BA0...
  • Page 77 A3: Axis Monitoring, Protection Zones Brief Description 2.1.1 Axis monitoring functions Function Comprehensive monitoring functions are present in the control for protection of people and machines: • Contour monitoring • Position monitoring • Zero-speed monitoring • Clamping monitoring • Speed-setpoint monitoring •...
  • Page 78 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Axis monitoring 2.2.1 Contour monitoring 2.2.1.1 Contour error Contour errors are caused by signal distortions in the position control loop. Signal distortions can be linear or nonlinear. Linear signal distortions Linear signal distortions are caused by: •...
  • Page 79 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring • Position control loop gain MD32200 $MA_POSCTRL_GAIN (servo gain factor) • Maximum acceleration MD32300 $MA_MAX_AX_ACCEL (Maximum axis acceleration) • Maximum velocity MD32000 $MA_MAX_AX_VELO (maximum axis velocity) • With activated feedforward control: Precision of the path model and the parameters: MD32610 $MA_VELO_FFW_WEIGHT (factor for the velocity feedforward control) MD32800 $MA_EQUIV_CURRCTRL_TIME (Equivalent time constant current control loop for feedforward control)
  • Page 80 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Fault If the configured tolerance limit is exceeded, the following alarm appears: 25050 "Axis <Axis identifier> Contour monitoring" The affected axis/spindle is stopped via the configured braking ramp in follow-up mode: MD36610 $MA_AX_EMERGENCY_STOP_TIME (Maximum time for braking ramp when an error occurs) Basic Functions Function Manual, 09/2011, 6FC5397-0BP40-2BA0...
  • Page 81 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring 2.2.2 Positioning, zero speed and clamping monitoring 2.2.2.1 Correlation between positioning, zero-speed and clamping monitoring Overview The following overview shows the correlation between the positioning, zero speed and clamping monitoring functions: 2.2.2.2 Positioning monitoring Function At the end of a positioning operation:...
  • Page 82 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring After reaching "Exact stop fine", the position monitoring is deactivated. Note The smaller the exact stop fine tolerance is, the longer the positioning operation takes and the longer the time until block change. Rules for MD setting MD36010 $MA_STOP_LIMIT_FINE MD36020 $MA_POSITIONING_TIME...
  • Page 83 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring 2.2.2.3 Zero speed monitoring Function At the end of a positioning operation: • Set velocity = 0 AND • DB31, ... DBX64.6/64.7 (motion command minus/plus) = 0 checks the zero-speed monitoring to ensure that the following error of every participating machine axis is smaller than the standstill tolerance during the delay time.
  • Page 84 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring 2.2.2.4 Exact stop and standstill tolerance dependent on the parameter set Common factor for position tolerances For adaptation to different machining situations and/or axis dynamics, e.g.,: • Operating state A: High precision, long machining time •...
  • Page 85 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Fault If the clamping tolerance is exceeded, the following alarm appears: 26000 "Clamping monitoring" The affected axis is stopped via the configured braking ramp in follow-up mode: MD36610 $MA_AX_EMERGENCY_STOP_TIME (Maximum time for braking ramp when an error occurs) Automatic stopping for removal of the clamp If a clamped axis must be traversed again in continuous-path mode, the NC stops the path motion for Look Ahead at the start of the motion block of the clamped axis until the clamped axis can once again be traversed.
  • Page 86 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Figure 2-2 Release axis clamp if MD36052 $MA_STOP_ON_CLAMPING = 'H01' The part-program blocks N310 and N410 refer to the following programming example: N100 G0 X0 Y0 Z0 A0 G90 G54 F500 N101 G641 ADIS=.1 ADISPOS=5 N210 G1 X10...
  • Page 87 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Parameter assignment: MD36052 $MA_STOP_ON_CLAMPING = 'H03' (Special function for clamped axis) Prerequisites regarding the PLC Application programs • The axis is removed from the clamp as soon as a travel command is pending. •...
  • Page 88 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring • The axis is always clamped when no travel command is pending. • The axis does not have to be clamped during positioning of the other axes. It can be seen whether the axes are being positioned depending on whether rapid traverse (G0) is programmed.
  • Page 89 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Constraints Continuous-path mode For the above-mentioned functions: • Automatic stopping for releasing the clamps • Optimized release of the axis clamp through traverse command • Automatic stopping for setting the clamps the "Look Ahead" function must be active. Part-program blocks without path motion (e.g.
  • Page 90 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring The function behaves as follows: • MD36052 $MA_STOP_ON_CLAMPING = 'H03' No longer has an effect. The travel command is set in Look Ahead mode only for blocks with active continuous­path mode. M82 generates a stop and thus interrupts the continuous­path mode.
  • Page 91 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring See also interface signal: DB31, ... DBX1.4 (follow-up mode) Note The following interface signals can be evaluated by the PLC user program as the criterion for activation of the "Follow-up mode": DB31, ... DBX60.6 / 60.7 (position reached with exact stop coarse / fine) 2.2.3 Speed-setpoint monitoring Function...
  • Page 92 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Figure 2-6 Speed setpoint limitation Speed-setpoint monitoring delay To prevent an error reaction from occurring in every speed-limitation instance, a delay time can be configured: MD36220 $MA_CTRLOUT_LIMIT_TIME (Speed-setpoint monitoring delay) Only if the speed limitation is required for longer than the configured time does the corresponding error reaction occur.
  • Page 93 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring 2.2.4 Actual velocity monitoring Function The actual-velocity monitoring checks that the current actual velocity of a machine axis/spindle does not exceed the configured threshold: MD36200 $MA_AX_VELO_LIMIT (velocity-monitoring threshold) The threshold should be 10-15% above the configured maximum velocity. •...
  • Page 94 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring 2.2.5 Measuring-system monitoring (systems with PROFIBUS drives) The NC has no direct access to the measuring-system hardware for systems with PROFIBUS drives and therefore measuring-system monitoring is mainly performed by the drive software. References: Drive Functions SINAMICS S120 /FBU/SIMODRIVE 611 universal Function Manual...
  • Page 95 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring 2.2.6 Limit switches-monitoring Overview of the end stops and possible limit switch monitoring: 2.2.6.1 Hardware limit switches Function A hardware limit switch is normally installed at the end of the traversing range of a machine axis. It serves to protect against accidental overtravelling of the maximum traversing range of the machine axis while the machine axis is not yet referenced.
  • Page 96 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Effectivity The hardware limit-switch monitoring is active after the control has ramped up in all modes. Effect Upon reaching the hardware limit switch, the following occurs: • Alarm 21614 "Channel <Channel number> Axis <Axis identifier> Hardware limit switch <Direction>" •...
  • Page 97 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring • PRESET After use of the function PRESET, the software limit-switch monitoring is no longer active. The machine must first be re-referenced. • Endlessly rotating rotary axes No software limit-switch monitoring takes place for endlessly rotating rotary axes: MD30310 $MA_ROT_IS_MODULO == 1 (Modulo conversion for rotary axis and spindle) Exception: Setup-rotary axes Effects...
  • Page 98 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring • Changing of the software limit switch (1st ↔ 2nd software limit switch) If the actual position of the machine axis after changing lies behind the software limit switch, it is stopped with the maximum permissible acceleration.
  • Page 99 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Reference point at the tool Taking into account the tool data (tool length and tool radius) and therefore the reference point at the tool when monitoring the working area limitation depends on the status of the transformation in the channel: •...
  • Page 100 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring Manual operating modes • JOG with / without transformation The axis is positioned at the working area limitation and then stopped. Power­up response If an axis moves outside the permissible working area when activating the working area limits, it will be immediately stopped with the maximum permissible acceleration.
  • Page 101 A3: Axis Monitoring, Protection Zones 2.2 Axis monitoring lower working area limitation G25 X… Y… Z… upper working area limitation G26 X… Y… Z… Figure 2-7 Programmed working area limitation The programmed working area limitation has priority and overwrites the values entered in SD43420 and SD43430.