EN 828 Com v47

SINUMERIK 828D
Commissioning Documentation
Sinumerik 828D
Edition 2016.06
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 4.7

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
B044 B038
B017 B007
Licensing and Network and
Data Electronic
Option Operator
Management Logbook
Management Panels
B010
NC
Connections &
Diagnostics
B008
B030 B051 B053 MCP & PP72/48 B026
Digital Inputs & Line and Motor Axis and Drive PN Connec- Creating a PLC
Outputs Modules Diagnostics tions and Program
Diagnostics
B019
S7-200 PLC
Instructions
B068 B058 B031 B037 B033

Commissioning PLC Onboard Alarms and Alarm PLC
Sequence Diagnostics Messages Structure Functions
B084
Encoder
Adjustments
B106 B016
B101 B020
Adaptive Additional B009
Servo Maintenance
Friction Axis Easy Extend
Optimization Planner
Compensation Installation
B029
Analogue
Spindle
B121 B120 B111 B110 B102

Technology Technology Technology Technology Tool
Setup Y Axis Setup Turning Setup Swivel Setup Milling Management
B122
Technology
Setup
Subspindle and
Tailstock
B035 B011 Appendix A Appendix B

Appendix C
Program Run Hardware Technology
PLC Interface
Handling MyScreens Differences Settings
End
SIEMENS TEST PROTOCOL
Machine Test Protocol Sinumerik 828D
Product / Version Company:
Address:
Sinumerik 828D SW4.7
Machine Range Machine Type - Features Spindle Config. MLFB KW Axis Conf MLFB N/M
Electrical Cabinet Protocol attached
Filename of Cabinet protocol
Distribution list
Name Company / e-mail Name Company / e-mail
Department Department
Title

Document no. Date
File name:
Protocol version 1.2
Copyright  Siemens AG 2016 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

2.2.1 Exception List ..................................................................................................................................................................................................................................................................... 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
5.2 Control ....................................................................................................................................................................................................................................................................................... 8

Doc-Nr Page 2/32 Protocol version 1.2

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  Ref ......................................................................................................................................................................................................................................................................... 11
8.1.2 Jog  MCP ...................................................................................................................................................................................................................................................................... 13
8.1.3 Jog  HMI Softkeys ........................................................................................................................................................................................................................................................ 17
8.1.4 MDA  Teachin .............................................................................................................................................................................................................................................................. 19
8.1.5 MDA  HMI Softkeys ..................................................................................................................................................................................................................................................... 20
8.1.6 MDA  MDA  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): ___________
2.2.1 Exception List

The machine has been released for sale with the following exceptions:
Function: Test Number Remark
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 Tested Responsible person Signature

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 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  Metric system of units

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

7 Functions tested
Confirm the functions as per the test plan
Test . Function Result / Accepted/To Do

8.1 Machine
8.1.1 Jog  Ref
8.1.2 Jog  MCP
8.1.3 Jog  HMI Softkeys
8.1.4 MDA  Teachin
8.1.5 MDA  HMI Softkeys
8.1.6 MDA  MDA  Teachin
8.1.7 AUTO  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 . 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  Ref
Technology Test Description Tested OEM Alternative / or Tested Reason for OEM To Do
No Comments / not 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  MCP
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.
T+M Repos
With interruption in Automatic, it
should be possible to switch to
Jog, move axis away from the
16
contour, subsequently return to
Automatic / Repos and Jog the
axis back to the previous
position.

8.1.3 Jog  HMI Softkeys

Technology Test Description Tested OEM Alternative / or Tested Reason for OEM Alternative To Do
No Comments / not
relevant
T+M T,S,M  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 
Set a spindle speed and activate
2 "Cycle Start" (together with
spindle M function) Repeat the
procedure with further spindles.
T+M Spindle gear change
3 Change gear, if a gear box is
available on the machine.
T+M Spindle direction 
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.

No Comments / not
relevant
T+M
5
T+M Measure Tool 

Manual 
Test with all types of possible
6 tools
Automatic 
Test with all types of possible
tools
T+M Position 
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 
8 Should change only the display
from MCS/WCS
T+M Hand wheel 
Test in both MCS and WCS
Syncron-actions.
show currently active
9
SYNACT
Settings 
Test and acknowledge
functionality of the Setting data’s

8.1.4 MDA  Teachin

No Comments / not
relevant
T+M Teach-in 
It should be possible to Jog the
1
axis in MDA - Teach-in
OPTION

8.1.5 MDA  HMI Softkeys

No Comments / not
relevant
T+M Program Control 
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

No Comments / not
relevant
SKP - When selected, the next
5 NC block with the Skip block
instruction will not be executed.
T+M G functions 
G - Functions for the reset state
of the machine - To be checked
6 for:
Turning
Milling
T+M Auxiliary functions 

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

All G functions
G - Functions for the reset
8 state of the machine - To be
checked for:
Turning
Milling
T+M > Extend menu 
Hand wheel 
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  MDA  Teachin

No Comments / not
relevant
T+M MDA 
Tool change in MDI window -
T01 + Cycle start for Turning
1 machines
T01 M06 + Cycle start for Milling
machines.
T+M MDA 
It should not be possible to Jog
2 the axis in MDA - exception :
Teach-in is active
T+M Teach-in 
Hand wheel 
Move axis using Hand wheel in
3 the machine axis interface or
using Geoax interface in
connection with Teach-in mode
OPTION

8.1.7 AUTO
No Comments / not
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 
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 
3
Cycle start
T+M AUTO 
4
Cycle Stop
T+M AUTO 
5
Cycle single block
T+M AUTO 
6
Program reset
T+M AUTO 
7
Feed Stop in Program effect
T+M AUTO 
8
Spindle stop in Program - effect
T+M AUTO 
9
Feed override = 0

T+M AUTO 
10
Spindle override = 50
T+M AUTO 
11
Effect of E-Stop
T+M Program control 
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 
M,S,T,H - Effect
17
Search to Tool

8.2 Parameter
8.2.1 Easy extend

No Comments / not
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

No Comments / not
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

No Comments / not
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
T+M L6 Optimised, Spindle Tool =
9
Pre-selected Tool

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

No Comments / not
relevant
T+M
1 Geometry axis
T+M
2 Thread boring
8.3.2 Renishaw circularity test

No Comments / not
relevant
T+M
1 Machine axis
T+M
2 Geometry axis
8.4 Safety Integrated
8.4.1 Safety related functions

No Comments / not
relevant
T+M
1 Function STO
T+M
2 Function SS1
T+M
3 Function SBR

8.5 Startup
8.5.1 Save data

No Comments / not
relevant
Save Data
1

8.6 Password protection
8.6.1 Securing data areas

No Comments / not
relevant
T+M Key switch 
Tools
1
Tool wear length and radius
Tool length and radius
T+M Key switch 
2
Create a tool
T+M Key switch 
3
Delete a tool
T+M Programming 
4
Open program
T+M Programming 
5
Edit program
T+M Programming 
6
Select program (NC)
T+M Offsets 
fine
7
coarse
T+M Password 
Delete SUNRISE after power on
8
All other power on retained
10
11

Not categorized
No Comments / not
relevant
T+M
1 Electrical Cabinet Protocol
T+M GSP iBase data input in

2
Prototype
T+M GSP iBase data Upload
3
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
T+M Axis 1 Axis utilisation value
9
in Comments column
10
in Comments column
11
in Comments column
12
in Comments column
13
in Comments column
T+M Adaptive Friction
14
compensation active

T+M ESR has been

15
commissioned
T+M ELG has been
16
commissioned

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
NX Modules
Drive-CLiQ Hub & Sensor Modules
PLC Periphery Modules
Hand-held Units
SINUMERIK 828D V4.7 Page 1 This document was produced for training purposes.
B060
B060
B060 Page 2 SINUMERIK 828D

System Overview B060
System Overview:
START
System
Overview
828D & PPU

Information
Machine
Control
Panels
PLC
Periphery
Modules
Drive
Components
NX Modules
Drive-CLiQ
Hub & Sen-
sor 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 Profinet MCP

PN/PN USB MCP
Coupler
To
other
828D
PN1 & PN2

Profinet
Interfaces
+24V DC Supply USB RS232 Mini
X1 PN2 PN1 Interface HHU
X135
Compact Flash Front

X140 Connection
ports
}
X145 Sinumerik X122 Sinamics kit
USB 2.0 828D & PPU X132 Digital I/O
X125
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
DMC20
X100 to X102 DriveCLiQ Interface DriveCLiQ
Hub
Teleservice
Modem
Filter
Sinamics S120 NX10/NX15 S120
Booksize
DMS
Scales/encoders
via SMx & DMC
modules
Reactor
Notes :

System Overview 828D Combi
PP72/48 PN PLC I/O
PN/PN USB MCP Profinet MCP
Coupler
To
other
828D
PN1 &
PN2
Profinet
+24V DC Supply Interfaces
Mini
RS232
X1 PN2 PN1 X135 HHU
Interface
Compact Flash Front
X140 Connection
ports
USB 2.0
X145
X125
Sinumerik
828D & PPU
X122
X132 } Sinamics
Digital I/O
kit
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
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 & PPU Information
828D Basic (PPU24x) & 828D (PPU28x) controllers with integrated PPU (Panel Processing Unit):
PPU240/280:
Vertical variant.
10.4” TFT colour
PPU241/281:
screen. Horizontal variant.
10.4” TFT colour screen.
828D (PPU290.3) controller:
PPU290.3 vertical variant.

16:9 screen ratio and 15,6’’ wide screen.
(Touch capable)
USB 2.0
X127 Ethernet DHCP server port.

Default address-192.168.215.1
Issues addresses up to 192.168.215.31.
Proximity
sensors for
display control
Notes :

General Information Software- (Current system software delivered on CF card):
Hardware Part Numbers: Part Numbers for PPU240.3/241.3:
The PPU model number gives information about the control- Milling 6FC5835-2GY40-4YA0 828D SW 24x
ler: Turning 6FC5835-1GY40-4YA0 828D SW 24x
PPU2xx.3
0 - Vertical
1 - Horizontal Part Numbers for PPU280.3/281.3/290.3:
4 - 828D Basic Milling 6FC5834-2GY40-4YA0 828D SW 26x

8 - 828D 6FC5833-2GY40-4YA0 828D SW 28x
9 - 828D OP15 6FC5836-2GY40-4YA0 828D SW 28xA
Turning 6FC5834-1GY40-4YA0 828D SW 26x

PPU Horizontal layout: 6FC5833-1GY40-4YA0 828D SW 28x
6FC5836-1GY40-4YA0 828D SW 28xA
6FC5370-3AA30-0AA0 PPU241.3 828D Basic
6FC5370-7AA30-0AA0 PPU281.3 828D
Blank Compact Flash Card 2GB:
PPU Vertical layout:
6FC5313-5AG00-0AA2
6FC5370-4AA30-0AA0 PPU240.3 828D Basic
6FC5370-8AA30-0AA0 PPU280.3 828D
6FC5370-8AA30-0BA0 PPU290.3 828D (15”)
828D Software/Hardware Compatibility Table:
Order Number 828D Technology 828D Basic 828D

Software PPU240.3/241.3 PPU280.3/281.3/290.3
6FC5835-2GY40-4YA0 24x Milling  
6FC5834-2GY40-4YA0 26x Milling  
6FC5833-2GY40-4YA0 28x Milling  
6FC5836-2GY40-4YA0 28xA (Advanced) Milling  
6FC5835-1GY40-4YA0 24x Turning  
6FC5834-1GY40-4YA0 26x Turning  
6FC5833-1GY40-4YA0 28x Turning  
6FC5836-1GY40-4YA0 28xA (Advanced) Turning  
Notes :

Specifications PPU24x/28x Front Interfaces and Status LEDs:
Input voltage- 24V DC +20% /-15% Ethernet DHCP server port.

Power Consumption 60W X127 Default address-192.168.215.1
Protection –Front operator panel IP65 Issues addresses up to
Rear of PPU IP20 192.168.215.31.
RDY
LED status indicators, see table
Operational temperature 0-45 °C NC
below.
Operational Relative humidity 5 to 90 % at 25°C (No CF
condensation)
X125 USB port for keyboard and
memory devices.
Horizontal model Vertical model
Width 310mm (12.2 in) 483mm (19 in)
Height 380mm (15 in) 220mm (8.66 in)
Depth 105mm (4.13 in) 105mm (4.13 in)
Compact Flash port for custom-
X145 er data storage and service/
commissioning tasks.
General information
The controller is available in vertical or horizontal formats.

The functionality of the two variants is identical. Name Colour Description
The PPU includes “Qwerty” and numerical keyboard inputs
and shortcut keys to specific machine areas. RDY Green System ready
The 828D encompasses the HMI, NC, PLC and CU logical
components. NC Orange NC ready (Flashes at approximately
1Hz)
CF Yellow CF card activity
PPU Rear interfaces and Status LEDs (All variants): Name Colour Description
X1-24V DC supply FAULT Red Fault present

SYNC Green Synchronisation OK
X100 to X102 -DriveCLiQ interface
Rx/Tx Yellow Network activity (1 each for PN1,
X130-Ethernet factory network-Configurable to receive an IP PN2 & X130 interfaces)
address automatically or a manually assigned fixed address
can be used. Link Green Network connected (1 each for
Do not use addresses in the following ranges: PN1, PN2 & X130 interfaces)
192.168.214.xxx and 192.168.215.xxx. These are reserved for
the system.
X135-USB interface X100 Fault PN

Sync
PN System CF-card
X140-RS232 interface X101 Fault
Sync
X102 Rx/Tx X130

X122 & X132-Digital I/O for Sinamics Link
X140 X135
X242 & X252-Digital I/O for NCK
X122
X143-Hand-wheels x 2 X132
PN1 & PN2 - Profinet interfaces. (Only PN1 available for X242
PPU240/PPU241) X252
X143
X1
M T1 T2 T3
Notes :

Schematic representation of the PPU
Factory network
Service Network
NX10 / NX15: Connection DRIVE CLiQ
PP72/48 PN
PPU 2xx
PROFINETBUS
3 12
DRIVE-CLiQ Sub-Topologie
Components NX10/15 (1)
the PPU
Regeln für die DRIVE CLiQ Verdrahtung

A NX10/15 components only about DRIVE-CLiQ X102 can be connected
to the Control-Unit
Notes :

The following tables highlight the technical specifications of the 828D controller.
Key:-
 In preparation
 Delivered as standard
 Option
- Not available 828D 828D
Basic
828D Software 24x 26x 28x 28xA
Technology (Turning/Milling) T M T M T M T M
System Performance
Number of axes with standard configuration 3 4 3 4 3 4 3 4
Maximum number axes/spindles/positioning axes 5 5 6 6 8 6 10 8
Each additional axis/spindle        
Each additional positioning axis        
Maximum number of interpolating axes 4 4 4 4 4 4 4 4
Maximum number of machining channels 1 1 1 1 1 1 2 1
Minimum block cycle time 9ms 9ms 6ms 6ms 6ms 3ms 6ms 3ms
CNC user memory (buffered) 3MB 3MB 3MB 3MB 5MB 5MB 10MB 10MB
CNC Functions
Tool management with tool life monitoring and workpiece
       
count
Replacement tools        
512/ 512/ 768/ 768/
Maximum number of tools/cutting edges 128/256 128/256 256/512 256/512
1024 1024 1536 1536
Number of settable zero offsets 50 50 100 100 100 100 100 100
Safety Integrated (Safe Torque Off, Safe Brake Control)        
Asynchronous subroutines (ASUP)        
Synchronised actions and high speed auxiliary function
       
output
Acceleration with jerk limitation        
Look Ahead (Number of blocks) 1 >150 1 >300 1 >450 1 >450
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 :

828D
828D
Basic
828D Software 24x 26x 28x 28xA
Technology (Turning/Milling) T M T M T M T M
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 cur-
       
rent 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 6ms 6ms
Maximum number of PLC ladder steps 32,000 32,000 32,000 32,000 32,000 32,000 32,000 32,000
Servo synchronous High Speed PLC Task        
Reaction time to process events (Terminal to terminal) 7,5ms 7,5ms 7,5ms 7,5ms 4,5ms 7,5ms 4,5ms 7,5ms
Maximum number of digital inputs/outputs 216/144 216/144 288/192 288/192 360/240 360/240 360/240 360/240
Maximum number of analogue inputs/outputs 6/6 6/6 8/8 8/8 10/10 10/10 10/10 10/10
PN/PN coupler        
Commissioning and Service Functions
Run MyScreens-easy creation of user screens
       
(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
Machine Control Panel MCP310 USB
Part Number: 6FC5303-0AF33-0AA0. The MCP310 is recommended for use with the vertical style PPU.
Part Number:
6FC5303-0AF33-0AA0.
Interfaces:
X10 USB Interface (rear side)
Features:
 39 membrane keys with LED
Indicators (22 user assignable)
 Feed override control(18 positions)
 Spindle override (15 positions)
 Dual 7-segment display for user specific
functions.
 Option for Emergency Stop button
 4 x Pre-drilled holes for hard wired user but-
tons/switches.
Machine Control Panel MCP483 USB
The MCP483 is recommended for use with the horizontal style PPU.
Part Number: Features:

6FC5303-0AF32-0AA0.  40 membrane keys with LED Indicators (24 user assignable)
 Feed override control(18 positions)
Interfaces:
X10 USB Interface (rear side)  Spindle override (15 positions)
 Optional Emergency Stop location.
 2 x Pre-drilled holes for hard wired user buttons.
Notes :

Machine Control Panel MCP310C PN
The MCP310 is recommended for use with the vertical style PPU.
Interfaces:- Hardware information

X10 24V DC supply
X20 Ethernet port 1 Part Number:
X21 Ethernet port 1 6FC5303-0AF23-0AA1
X30 Feed override switch input
X31 Spindle override switch input Features:
X51 User input connections  49 mechanical keys with LED
X52 User input connections Indicators (16 user assignable)
X55 User input connections  Feed override control(16 positions)
X53 User output connections
X54 User output connections  Key switch
 Emergency stop/Spindle override optional
H1 LED POWER OK  6 x Pre-drilled holes for hard wired user buttons
H2 LED BUSSYNC  1 x Hand-wheel connection
H3 LED BUSFAULT  Connections for 9 user Inputs & 6 outputs
S2 IP address selection switch
 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 :

Machine Control Panel MCP483C PN
The MCP483 is recommended for use with the horizontal style PPU.
Hardware information Interfaces:

X10 24V DC supply
Part Number: X20 Ethernet port 1
6FC5303-0AF22-0AA1 X21 Ethernet port 2
X30 Feed override switch input
Features: X31 Spindle override switch input
 50 mechanical keys with LED indicators (17 user X51 User input connections
assignable) X52 User input connections
 Spindle & feed override control. X55 User input connections
 Key switch
 Emergency stop button
 2 x Pre-drilled holes for hard wired user buttons LED Indicators:
 Connection via Ethernet H1 LED POWER OK LED
 1 x Hand-wheel connection H2 LED BUSSYNC (Bus ok & synchronised)
H3 LED BUSFAULT (Bus fault)
 Connections for 9 user Inputs & 6 outputs
S1 Hand-wheel type selection switch
 Connection via Profinet S2 IP address selection switch
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 :

PLC Periphery Modules Hardware Information
MCP Interface PN Part number: 6FC5303-0AF03-0AA0
The MCP Interface PN module is designed to enable customer Features:
specific Machine Control Panels to be connected via the
Profinet network..  80 single keys
 64 LEDs
 1 hand-wheel
 2 override switches
The following inputs/outputs are also available:

 9 digital inputs (5 V)
 6 digital inputs (24 V)
 15 digital outputs (24 V, each 0.15 A)
Additional items:
6FC5247-0AF13-1AA0 - Feed override, rotary switch incl.

6FC5247-0AF12-1AA0 - Spindle override rotary switch incl.

6FC5247-0AA35-0AA0 - cable set for additional control devic-

es. (60 units, 500mm)
Interface Description
X1 +24V Supply
X2 & X3 RJ45 Profinet Interface
X30 Feed override Interface
X31 Spindle override Interface
X40, X41 Digital inputs (24V)
X51, X52, X55 Digital inputs (TTL)
X53, X54, X56, Digital outputs (24V)
X57, X58
X60*) Hand-wheel 15 pin Sub-D socket.
X62*) Hand-wheel 12 pin strip connector.
X61 Not used
X111 to X114 PLC I/O for buttons/LEDs (5V)
S1 Addressing Switch
S2 Hand-wheel signal type. (Differential/TTL)
H500 to H502, Diagnostic LEDs
H505.
*) Only one hand-wheel can be connected to the MCP In-

terface PN. Choose X60 or X62.
Further information can be found in Module B008.
Notes :

PP72/48D PN Modules (Combined I/O module) PP72/48D PN modules are a compact component which con-
nect to the Profinet network (Ports PN1 or PN2 of the NCU).
A 24V DC supply is required.
There are two variants, one of which is all digital while the sec-
S1 ond offers both digital and analogue functionality (only for
PLC).
24 digital inputs and 16 digital outputs are available on each of
the 3 ribbon connectors giving a total of 72 inputs and 48 out-
X111 puts for each module.
The maximum number of allowed PP72/48 modules is deter-

mined by the software version:
X222
828D Software Maximum no. of PP72/48 modules
24x 3
26x 4
28x & 28xA 5
X2 X2
Port Port Interfaces:
2 1 X333 S1-Adressing switch-Default setting of 9
X1-24V DC Supply
X2-Profinet network ports 1 & 2
X111 digital inputs/outputs-ribbon connector
X1 X222 digital inputs/outputs-ribbon connector (first byte has
fast gating hardware)
X333 digital inputs/outputs- ribbon connector
Input information: The PN/PN coupler is used to link two Profinet networks so
X222, byte 1 - maximum delay time - 600μs. that data can be exchanged between them.
All other inputs, delay time - 0.5 to 3ms.
PP72/48D PN Part numbers:
One coupler is allowed per controller.
6FC5311-0AA00-0AA0 Digital only (PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue (PP72/48 2/2A PN) Part number:
6ES7158-3AD01-0AX0
PN/PN Coupler Interfaces:

X1 Port 1 & 2 Profinet 1 network
X2 Port 1 & 2 Profinet 2 network
PS1 & PS2 +24V DC supply
LEDs
SF1 Group fault for Profinet 1 network (Red)
SF2 Group fault for Profinet 2 network (Red)
BF1 Bus fault for Profinet 1 network (Red)
BF2 Bus fault for Profinet 2 network (Red)
MT1 Maintenance display Profinet 1 network (Yellow)
MT2 Maintenance display Profinet 2 network (Yellow)
ON Power supply +24V DC (Green)
LINK Connection on (Green) One per Profinet connection
RX/TX Data Exchange (Yellow) One per Profinet connection
PN/PN Coupler
Notes :

Drive Components General information
Line Modules Line modules are responsible for generating the DC link sup-
ply for the drive system.
They require 3-phase AC for the DC link and +24V DC for the
electronic supply.
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
network.
Modules of 16 Kw and above do connect to the DriveCLiQ.
Active Line Modules (ALM)

These modules are capable of mains regeneration and the
DC link is stabilised.
All ALM modules are connected to the DriveCLiQ network.
Smart Line Module Active Line Module
Interfaces: Part Numbers- ALM

SLM (5 & 10Kw variant) X21-Enable & temperature sensor input
X21-Enable, ready and fault signals X24-24V DC electronics supply
X22-Regeneration inhibit and fault reset signals U1, V1, W1-3-Phase supply
X24-24V DC electronics supply X200, X201, X202-DriveCliq connections
U1, V1, W1-3-Phase supply
6SL3130-7TE21-6AA3 16Kw Internal cooling
Part Numbers: 6SL3130-7TE23-6AA3 36Kw “ “
6SL3130-6AE15-0AB1 5Kw Internal cooling 6SL3130-7TE25-5AA3 55Kw “ “
6SL3130-6AE21-0AB1 10Kw “ “ 6SL3130-7TE28-0AA3 80Kw “ “
6SL3131-6AE15-0AA1 5Kw External cooling 6SL3130-7TE31-2AA3 120Kw “ “
6SL3131-6AE21-0AA1 10Kw “ “ 6SL3131-7TE21-6AA3 16Kw External cooling
6SL3131-7TE23-6AA3 36Kw “ “
6SL3131-7TE25-5AA3 55Kw “ “
SLM (16Kw and above) & ALM (all variants) 6SL3131-7TE28-0AA3 80Kw “ “
X21-Enable & temperature sensor input 6SL3131-7TE31-2AA3 120Kw “ “
X24-24V DC electronics supply
U1, V1, W1-3-Phase supply
X200, X201, X202-DriveCliq connections
Part Numbers:
6SL3130-6TE21-6AA3 16Kw Internal cooling
6SL3130-6TE23-6AA3 36Kw “ “
6SL3130-6TE25-5AA3 55Kw “ “
6SL3131-6TE21-6AA3 16Kw External cooling
6SL3131-6TE23-6AA3 36Kw “ “
6SL3131-6TE25-5AA3 55Kw “ “
Notes :

Motor Modules (MM) The motor modules convert the DC link voltage into a varia-
ble AC voltage which is then output to the servo
Motors.
Motor Modules are supplied with 24V DC via the ALM/SLM
All motor modules are connected to the DriveCLiQ network.
They are available in one or two axis variants and can be
internally or externally cooled.
Interfaces:
Single MM
X1-Output to Motor.
X21-Enable & temperature sensor input
X200, X201, X202-DriveCliq connections
Double MM
X1 & X2-Output to Motors
X21-Enable & temperature sensor input (Motor 1)
X200, X201, X202, X203-DriveCliq connections
Single MM Double MM
Part Numbers-single modules Part Numbers-double modules

6SL3120-1TE13-0AA4 1.6Kw Internal cooling 6SL3120-2TE13-0AA4 2 x 1.6Kw Internal cooling.
6SL3120-1TE15-0AA4 2.7Kw “ “ 6SL3120-2TE15-0AA4 2 x 2.7Kw “ “
6SL3120-1TE23-0AA4 16Kw “ “ 6SL3121-2TE13-0AA4 2 x 1.6Kw External cooling
6SL3120-1TE24-5AA3 24Kw “ “ 6SL3121-2TE15-0AA4 2 x 2.7Kw “ “
6SL3120-1TE31-3AA3 71Kw “ “
6SL3120-1TE32-0AA4 107Kw “ “
6SL3121-1TE13-0AA4 1.6Kw External cooling
6SL3121-1TE15-0AA4 2.7Kw “ “
6SL3121-1TE21-0AA4 4.8Kw “ “
6SL3121-1TE21-8AA4 9.7Kw “ “
6SL3121-1TE23-0AA3 16Kw “ “
6SL3121-1TE24-5AA3 24Kw “ “
6SL3121-1TE26-0AA3 32Kw “ “
6SL3121-1TE28-5AA3 46Kw “ “
6SL3121-1TE31-3AA3 71Kw “ “
6SL3121-1TE32-0AA4 107Kw “ “
Notes :

Motor Modules (MM) S120 Book-sized Compact
The S120 book sized compact motor modules are use to ex-
pand the number of drives the Sinamics Combi drive system
to the maximum of 6.
The modules are only available with internal cooling.
Interfaces:
Single MM
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- Single Modules

6SL3420-1TE13-0AA1 3/9 Amps
6SL3420-1TE15-0AA1 5/15 Amps
6SL3420-1TE21-0AA1 9/27 Amps
6SL3420-1TE21-8AA1 18/54 Amps
Part Numbers- Double Modules

6SL3420-2TE11-7AA1 2 x 1.7/5.1 Amps
6SL3420-2TE13-0AA1 2 x 3/9 Amps
6SL3420-2TE15-0AA1 2 x 5/15 Amps
Combi Drive (Combined Line and Motor Modules)
The Combi drive unit consists of a Line Module and either 3 or 4 Motor Mod-
ules, the first of which is dedicated to the Spindle.
They must always be connected to the DriveCLiQ network via controller inter-
face 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.
Part Numbers and Power ratings
Smart Line Spindle Axis 1 Axis 2 Axis 2

Module Motor Motor Motor Motor Part Number
Module 1 Module 2 Module 3 Module 4
3 Axes
16 Kw 18 A 5A 5A - 6SL3111-3VE21-6FA0
16 Kw 24 A 9A 9A - 6SL3111-3VE21-6EA0
20 Kw 30 A 9A 9A - 6SL3111-3VE22-0HA0
4 Axes
10 Kw 24 A 12A 12A 12A 6SL3111-4VE21-0EA0
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

If the regenerative capability of the line module is inadequate it
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.
Braking modules and resistors can also facilitate the controlled

shut down of the drives in the event of a power failure.
Another feature is the fast discharge of the DC link. This fea-

ture is used to quickly discharge the capacitors so that mainte-
nance tasks can be carried without having to await natural
discharge times. Fast discharging should only be carried out 1
to 2 times per week to avoid damaging the capacitors. Braking resistor:
6SN1113-1AA00-0DA0 0.3Kw
The braking module is connected to the DC link and 24V DC 6SL3100-1BE31-0AA0 1.5Kw
bus systems. 6ES7023-2SE87-2DC0 5kW
6ES7028-0SE87-2DC0 12.5kW
Connector X21 on the braking module is used for enable/fault/
ready signals.
Connector X1 is for connecting the external resistor.
Braking Module
6SL3100-1AE31-0AB1 1.5Kw
Control Supply Modules
The Control Supply Module is a 24V/20A DC Power Supply

Unit.
It is used to maintain the 24V DC in the event of a power fail-
ure.
The initial power to the module is taken from the line supply,
when a power failure occurs power is taken from the residual
voltage of the DC link.
Part Number:
6SL3100-1DE22-0AA1
Control Supply
Module
Notes :

NX Modules
General information
Since the integrated control unit (CU) can control only 6 axes, an NX module is required to achieve the
maximum number of 10 axes allowed by the system.
NX modules can also be used for reducing the drive cycle time from 125μs to 62.5μs, for example, in
the case of a high speed spindle application.
The modules are of the same design as the Sinamics S120 drives.
All modules have to be connected to the DriveCLiQ network.
NX10.3: Three additional axes

NX15.3: Six additional axes
The drive enable connections are not required to be physically connected, these signals are mirrored
with the CU connections:
X122.1 = OFF1
X122.2 = OFF3
Part Number:-
NX10.3: 6SL3040-1NC00-0AA0
NX15.3: 6SL3040-1NB00-0AA0
Interfaces:-
 X100 to X103 DriveCLiQ
 X122 4 x digital inputs & outputs
 X124 24V DC supply NX10/NX15
Notes :

Drive-CLiQ Hubs & Sensor Modules
DMC20 & DME 20 Drive-CLiQ Hubs
General information
The requirement for additional Drive-CLiQ ports is catered for

by the DMC20 (Cabinet mounted) & DME20 (Externally
mounted)
There are 6 Drive-CLiQ ports, 5 of these are available for ad-

ditional devices such as direct measuring systems.
The remaining port is used for connecting to the PPU/Drive-
CLiQ network.
Part Numbers:
DMC20: 6SL3055-0AA00-6AA1
DME20: 6SL3055-0AA00-6AB0
Interfaces:
 X500 - Drive-CLiQ, Connects to PPU/Drive-CLiQ network
 X501 to X505 - Drive-CLiQ, additional devices
 X524 - 24V DC supply
 RDY - LED indicator
DMC20 DME20
DMC20 & DME 20 Drive-CLiQ Hubs
displacement • Star-shaped distribution of a DRIVE-CLiQ line

• Extension of DRIVE-CLiQ Ports, e.g. for direct encoders
• Separating parts of the drives without errors in the remaining ones
• Parking of parts of the drives
Advantage • The DRIVE-CLiQ Hub Module allows individual DRIVE-CLiQ devices to be removed without inter r
upting the data exchange with the remaining devices in the DRIVE-CLiQ line ( Hot-Plugging ).
• Reducing the number of DRIVE-CLiQ cables in the cable carrier, because
signals from more than one encoder can be collected with one DRIVE-CLiQ Hub
Module and forwarded to the Control Unit through a single DRIVE-CLiQ cable.
Notes :

Sensor Modules (SMC & SME) SMC20
General information
Sensor modules are required to convert non-DriveCLiQ en-

coder signals into DriveCLiQ signals.
They are available for cabinet mounting (SMC) and external
mounting (SME).
Several variants of each are available:
SMC20
For the evaluation of the following measuring systems:-
Incremental sin/cos 1v pp
Absolute EnDat encoders
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
Part Number:-
6SL3055-0AA00-5BA3
SMC30 SMC30
For the evaluation of the following measuring systems:

 Incremental with TTL/HTL signals
 SSI with incremental TTL/HTL signals
 SSI without incremental signals
(Temperature evaluation-KTY84-130 can also be used)
Interfaces:-
 X500 DriveCLiQ
 X520 TTL measuring system input (15 pin D-type con-
nector)
 X521 HTL/TTL measuring system input (Screw type
connector)
 X531 “ measuring system input (Screw type
connector)
 Status LEDs
 X524 24V DC supply
Note-The extra measuring system interfaces offer more flexi-

bility for connecting the encoder, The device, however, can
only handle a single encoder.
Part Number:-
6SL3055-0AA00-5CA2
Notes :

SMC40 SMC40
SMC40 only supports measuring systems with the EnDat 2.2

interface and order designation EnDat 22 (without incremental
signals).
Two encoders can be handled.

Each encoder has it’s own channel.
When two encoders are used it is necessary that they each
have their own separate DRIVE CLiQ cable in X500/1 &
X500/2
Interfaces:
 X500/1: DRIVE-CLiQ channel 1 interface.
 X500/2: DRIVE-CLiQ channel 2 interface.
 X520/1: EnDat 2.2 encoder input - channel 1.
 X520/2: EnDat 2.2 encoder input - channel 2.
 X524: 24v electronics supply.
 2 x RDY LEDs (one for each channel)
Part Number:-
6SL3055-0AA00-5DA0
SME20/SME25 SME120/SME125
For the evaluation of the following measuring systems:- For the evaluation of the following measuring systems:-
Incremental sin/cos 1v pp with C and D tracks 5V supply- Incremental sin/cos 1v pp with C and D tracks 5V supply-
SME20 SME120
Absolute EnDat encoders 5V supply-SME25 Absolute EnDat encoders 5V supply-SME125
Absolute SSI with incremental signals 5V supply Sin/Cos 1V (Temperature evaluation-KTY84-130 can also be used)
pp-SME25
Interfaces:-
Interfaces:-  DriveCLiQ-Also supplies 24V DC
 DriveCLiQ-also supplies 24V DC  Measuring system input
 Measuring system input  Hall effect sensor input
 Temperature sensor input
Part Number:-
6SL3055-0AA00-5EA3-SME20
Part Number:-
6SL3055-0AA00-5HA5-SME25
6SL3055-0AA00-5JA3-SME120
6SL3055-0AA00-5KA5-SME125
SME20/SME25 SME120/SME125
Notes :

Hand-held Units The HHU offers manual axis movement via hand wheel or jog
buttons.
Hand Held Unit (HHU) A rotary switch is used to select the required axis, it is only
possible to select one axis at a time from the maximum of five
Hand held units allow the operator to manually control the axes.
machine remotely from the main operator panel. Safety is provided via a 2 channel emergency stop button and
a 3 position “Dead mans” enable button.
HHU with coiled cable, connector and mounting device:- The casing has magnets which are useful to attach the unit to
any suitable metallic surface, alternatively a holder can be
purchased for this purpose.
A terminating connector is available to facilitate the (Cold)
removal of the HHU without affecting the machine operation.
In addition to the +/- & Rapid jog buttons there are three user
assignable buttons.
The signals from the HHU are split into three categories.
1. The emergency and enabling buttons should be used
in the safety/enabling circuit of the machine.
2. The jog and axis selection should be done via the user
PLC program
3. The hand-wheel signals need to be taken to X143 of
the PPU
A connection kit that must be ordered separately is required

for connection of the mini HHU.
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.
6FX2006-1BG20 Pre assembled connection kit with termi-

nator.
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 27
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 END
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.
Software included in the toolbox:
 PLC Programming Tool (PLC user program)

 Configuration Data (rescue card image, examples e.g. for Easy Extend)
 Access MyMachine allows a remote operation between the 828D controller and a computer
running windows, but is also 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.

 Connect to the controller with each of the software packages.
Content:
Toolbox Installation.
Sinumerik
Network Settings.
Online Connection-Access MyMachine.
Online Connection-PLC Programming Tool.
B002
B002

Service and Commissioning Tools B002
Service and
Commissioning
Tools:
START
Toolbox
Installation
Network
Settings
Online
Connection:
Access
MyMachine
Online
Connection:
PLC
Programming
Tool
Service and
Commissioning
Tools:
END
Notes :

Toolbox Installation A series of dialogue boxes will appear which need to be

acknowledged.
Toolbox content:
 Configuration Data: Image for replacement card.
 PLC Programming Tool: For Creating/Loading/Editing
the PLC user program.
 Access MyMachine allows a remote operation between
the 828D controller and a computer running windows.
 SINUMERIK CNC-Lock Tool for configuring the disa-
bling of the control
 SINUMERIK Commissioning tool to perform offline
analysis of data e.g. BODE diagrams
 Start-up Tool:- For the configuration of the drives.
Double click the “Setup.exe”

file to start the toolbox
installation.
Software licence agreement: A selection of language options are available:
Notes :

Network Settings Select the “Network and Sharing Center” option.
X127 is a DHCP server with a fixed IP address of

192.168.215.1 and subnet mask of 255.255.255.224
IP addresses from 192.168.215.2 to 192.168.215.31 are auto-
matically issued to any PC connected to X127.
The name of the network adapter of the PC is required.
This can be found in the “Network connections” area of the
computer:
Select “Control
Panel” from the Select “Change
Start Menu of the adapter settings”
PC.
Notes :

Note the name of the network adapter associated with the Select the option “Internet Protocol Version 4 (TCP/IPv4)”
Local Area Connection. followed by the “Properties” button:
In the example below the network adapter is of the type:
Intel® 82579LM Gigabit Network.
Note: Network adapter may be different between PC makes

and types.
Double click the Local Area Connection icon:
Select the “Obtain an IP address automatically” option. Connect a suitable Ethernet cable between the PC and X127
of the controller. In some situations this may need to be a
cross-over cable.
The connection status can be checked via the “Details” option
of the Local Area Connection.
The PC is now set to receive an IP address from a DCHP

server, i.e. X127 of the 828D controller.
Notes :

The PC has been assigned the first available IP address of

192.168.215.2 by the DHCP server of X127.
Online Connection-Access MyMachine Set the privilege level to “Run the program as administrator“
Administrator Privilege Level

The Toolbox programs should always be run with privileges
set to Administrator.
Setting the Administrator Privilege:

Right click on the icon of the Access MyMachine program and
select “Properties“.
Notes :

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).
When the program is opened for the first time after the
Installation it is necessary to assign a password for encryption
purposes.
It is necessary to login with a password depending on the ac- The access level determines which data can be accessed via
cess level required: Access MyMachine.
The “Manufacturer” login grants the most access, the “User”
login is the most restrictive.
Select the login and enter the password.
Passwords:
Manufacturer-SUNRISE
Service-EVENING
User-CUSTOMER
Notes :

After a short delay the data folders of the controller will appear in the lower half of the Access MyMachine program, this indicates
that a successful connection was made.
Creating a "Project" within Access MyMachine Enter a name to identify the project.
Start the Access MyMachine program.
Under the pull down menus:

File --> New --> Project……..
Notes :

Loading files directly to the control system and from the control
The Project window will appear to the right-hand side.
system to the PC.
Managing the control system's NC data. You can copy files di-
rectly from the PC to the NC and from the NC to the PC.
Monitoring processes and remote control of the SINUMERIK via
a remote control function.
Saving the screenshot of the HMI on the PC.
Editing the following user files on the PC:
PLC alarm texts (oem_alarms_plc)
Cycle alarm texts (oem_alarms_cycles)
Part program messages (oem_partprogram_)
EasyScreen language strings
Tool management language strings
EasyExtend files (oem_aggregate)
Maintenance planner files (oem_maintenance)
Creating and loading an archive for the control system.
Managing user files with the following options:
Creating a project OFFLINE.
Copying individual files using the project dialog to the control
system or copying from the control system to the project.
Once a project has been created, AMM provides the following Deleting user files using the project dialog on the control sys-
functions: tem.
Viewer
The external viewer duplicates the controller display on the

external computer including menu and soft-key functionality.
When the viewer connects, access can be restricted on the
HMI or by the PLC interface.
To configure the HMI use the following soft-key sequence:
Viewing Rights-HMI
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. It may be necessary to Contact
the machine manufacturer if the PLC is restricting the viewer
access.
Notes :

Behaviour for remote access:
When a connection attempt is made a dialogue box will ap-

pear which requires acknowledgement, this determined how
long the dialogue box stays on the screen.
When set to “allowed”, then the controller will allow the con-
nection, even when the dialogue box has not been acknowl-
edged.
If set to “Denied” the connection will be blocked if the dialogue
box is not acknowledged.
The settings are saved by selecting the “OK” soft-key.
Connecting the Remote Viewer
To start this function select the following icon from the Access
MyMachine tool bar.
Alternatively select “Start” from the “Remote control” drop
down menu.
When the viewer attempts to connect, providing that the re-

mote viewer has not been blocked, the screen of the control-
ler will be displayed.
If an acknowledgement is required, a dialogue box will ap-
pear. The person at the controller should acknowledge with
the “Yes” soft-key.
This should be done within the time limit specified on the HMI
-set-up screen.
When the connection is successful the viewer will display the

same screen as the controller.
Notes :

The following keys are used to navigate the

controller from the remote PG/PC:
F1 to F8 - Horizontal soft-keys
Shift & F1 to F8 - Vertical soft-keys
F9 - Page Back/Up
F10 - Menu Select
Shift & F9 - Page right
F12 - Help function
Escape - Alarm Cancel
Select - Space Bar
Programs, machine data etc can be directly

changed from the remote computer, archives
can also be created.
Online Connection - PLC Programming Tool Set the privilege level to “Run the program as administrator“
Administrator Privilege Level

The Toolbox programs should always be run with privileges
set to Administrator.
Setting the Administrator Privilege:

Right click on the icon of the PLC Programming Tool program
and select “Properties“
Notes :

Start the PLC Programming Tool.
A communication protocol
is not active.
Double click the area
highlighted above.
When the Programming Tool has

started, locate and select the
“Communications” option found
in the “View” column on the left The correct adapter should be selected from the list and con-
side of the programming tool. firmed with the “OK” button.
Note: Adapter types will not necessarily be the one shown in

this example.
A list of network adaptors will be displayed: 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.
The correct
adapter should
be selected
from the list
and confirmed
with the “OK” Network adaptor.
button.
Note: Adapter types will not necessarily be the

one shown in this example.
Enter the IP address of the contoller:

X127 - 192.168.215.1
Notes :

B002 END Service and Commissioning Tools
After entering the IP address,

double click the “Double click
to Refresh” icon.
If the connection is successful an icon of the controller will

appear:
The PLC828 Programming

Tool is now connected to the
controller.
B002: END
Notes :

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
 Setup
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: Setup
Short Cut Keys
B061
B061

Menu Structure B061
Menu
Structure:
START
Menu Area:
Program
Manager
Menu Select
Button
Menu Area:
Diagnostics
Mode
Selection
Menu Area:
Setup
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.
The 5 vertical soft-keys can be used to change between the machine modes: This can also be
achieved via the Machine Control Panel.
Vertical Soft-key Functionality:
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 Setup 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: Setup
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 data class archive (.ARD) on an external data carrier

+ + S (USB-FlashDrive).
Creates a complete standard archive (.ARC) on an external data carrier

+ + C (USB-FlashDrive).
Note: For diagnostics purposes only.
Backs up the log files on the USB-FlashDrive. If a USB-FlashDrive 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 decreased 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:
The data of 828D sl controller is protected by using one of seven access levels, four of which
are set via a key-switch and three by password.
This module explains the different access levels, how to set these levels and how to protect
individual files.
It is also important that the system date and time are correct.
This is necessary for checking when an alarm occurred or when a file (Part program, archive etc)
was created or edited.
If at the time of installation, the time and date is not set correctly, the Guarantee period of the
controller could be effected.
Before the date and time displays can be edited, the password for the “User” or higher must be
entered.
Module Objective:
Upon completion of this module you will be able to set the different protection levels using a
password or key switch, you will also be able to change the protection levels of individual NC
programmes 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
Access Levels /
Time & Date:
START
Password
and
key-switch
information
Setting and
Deleting the
Password
Protection of
files
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
The following table shows the password/key-switch positions.

and associated protection levels/users.
Key switch Colour coded keys
Protection Access levels of the three keys:

Intended user:- Protected via:-
level
1 Manufacturer Password: SUNRISE Key colour Switch position Protection level
2 Service Password: EVENING No key required 0 7

Black 0&1 6-7
3 User Password: CUSTOMER
Green 0, 1 & 2 5-7
4 Programmer, Setter Key-switch position 3
Orange 0, 1, 2 & 3 4-7
5 Qualified operator Key-switch position 2
It is the responsibility of the OEM to ensure that the key-switch
signals are transferred to the PLC interface.
6 Trained operator Key-switch position 1
DB2600.DBB0 is used for the transfer of the key-switch signals.
7 Untrained operator Key-switch position 0
The key switch is located to the bottom right of the MCP and DB2600 Key-switch signals to NC (PLC  NC)
has four positions. Three colour coded keys are available,
each of which allow a different access level. This is from a Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
standard Siemens machine control panel. It is possible that a
manufacturer may use a different method to set the interface DBB0 Key- Key- Key- Key-
signal. switch switch switch switch
Pos.3 Pos.2 Pos.1 Pos. 0
Setting and Deleting the Password
Setting the password: A dialogue box is opened, this box shows the current access
The screen for entering the password is reached via the fol- level and allows a password to be entered using the key-
lowing key presses board.
After typing the password it is confirmed by pressing the “OK”

soft key.
Notes :

The dialogue box disappears and the current access level is Changing the password:
displayed above the left hand horizontal soft-keys.
It may be necessary to change the password from the default.
To change a password select the “Change password” soft
key.
Note: The password values are not saved in archive files.

Therefore, if a changed password is forgotten, you must:
 Load standard NC data (To reset the passwords to

default values)
 Read-in an archive. (To return the machine to a run-
ning condition)
Note: The password remains active after power off/on.

Module B033 explains how password deletion can be auto-
mated.
Protection of files
The properties of the file are found by paging right and select-
Certain files such as important cycles, programmes etc can be ing the properties Soft-key.
individually protected against accidental editing, deletion or
execution. They can also be hidden from view.
The file to be protected has to be located before the properties
can be edited. In this example, the part programme A dialogue box allows four properties to be changed.
“Example.MPF” is to have it’s properties changed.
In the following example, the program:
The “Part program” directory is located by selecting the
“Program manager” key.  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 2 or higher
is active
 Can only be read if the key switch position 3 or higher
is active
Example: TEST.MPF file has been selected in the Part Pro-
grams directory.
Notes :

B021 Access Levels / Time and Date Settings
Customising Soft-key Access Levels
It is possible to set the access levels for each soft-key.

The function must first be activated in the Setup area.
When the correct settings have been entered the “OK” soft
key has to be selected.
When the “OK” key is pressed the function will be activated. Use the mouse “Left click” to select the
This is confirmed by the message 150100 required access level.
The menu will automatically disappear when the selection is
made.
If an access level is already active the “Original setting” op-
tion will be available.
To set the access levels of the soft-keys it is necessary to con-

nect 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 “System data” soft-

key to Manufacturer.
Place the mouse pointer over

the soft-key and “Right click”
Notes :

A summary of any changes to access levels can be seen in

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.
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:-
If the date or time is changed, each element has to be con-

firmed using the “Input” key.
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.
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 are used in many ways to influence the operation of a machine.
During commissioning some of the machine data are automatically set while other machine data
have to be changed.
Over time, as the machine mechanically wears it may be necessary to edit certain machine data
such as compensation data.
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
Storing of Archives within AMM Project
B041
B041

Machine and Setting Data B041
Machine and
Setting Data:
START
Machine &
Setting Data
Overview
Data Classes
Editing
Machine &
Setting Data
User Views
Storing of
Archives
within AMM
Project
Machine and
Setting Data:
END
Notes :

Machine & Setting Data Overview Note:-

Machine Data is often referred to as “MD”.
General assignment Setting Data is often referred to as “SD”.
Editing of any type of data should only be undertaken by expe-
rienced personnel and in conjunction with the machine manu-
facturer. For everyone of these ranges an own listing exists, in which
machine data can be displayed and altered.
For a detailed description of each machine/setting data refer
to the “Function description” manual found on “DOC on DVD”. The following data ranges are used for the machine data:
The machine data are sub-divided into the following ranges:
$MM_ Display machine data
$MN_ General machine data
Range Description $MC_ Channel-specific machine data
9000 - 9999 Display machine data $MA_ Axis-specific machine data
10000 - 19999 General machine data $MNS_ General cycle machine data
20000 - 29999 Channel-specific machine data $MCS_ Channel-specific cycle machine data
30000 - 39999 Axis-specific machine data $MAS_ Axis-specific cycle machine data
41000 - 41999 General setting data
42000 - 42999 Channel-specific setting data Which mean:
43000 - 43999 Axis-specific setting data $ System variable
51000 - 51999 General cycle machine data M Machine data
52000 - 52999 Channel-specific cycle machine data
M, N, C, A, S Part range (second/third letter)
53000 - 53999 Axis-specific cycle machine data
54000 - 54999 General cycle setting data
55000 - 55999 Channel-specific cycle setting data
56000 - 56999 Axis-specific cycle setting data
By default, after power on the General Machine Data screen

The following data ranges are used for the setting data:
is displayed
$SN_ General setting data There are five components to each machine data which are
$SC_ Channel-specific setting data described below:
$SA_ Axis-specific setting data
1 2 3 4 5
$SNS_ General cycle setting data
$SCS_ Channel-specific cycle setting data
$SAS_ Axis-specific cycle setting data
Which mean:
$ System variable
D Setting data
N, C, A, S Part range (second/third letter)
Machine Data/Setting Data Location:
Machine data screens are found in the “Setup” area of the

controller
Machine Data Components:

 Machine Data Number
 Machine Data Name
 Machine Data Value/Unit
 Machine Data Activation Requirement
 Machine Data Class
Notes :

Activation of the MD/SD: Units for MD/SD

The function of the MD/SD determines the units in use.
There are four methods available for activating the MD/SD. The following table shows the abbreviations and descriptions of
The method depends on the MD/SD in question. the units.
The right hand column of the screen displays the required Unit Description
method. mm/sec Millimetres/second: Linear velocity/speed
rpm Revolutions/minute: rotational velocity/speed
Active via “Reset (po)” soft-key or controller m/s² Meters/second-squared: Linear acceleration
power off/on. rev/s² revolutions/second-squared: rotary acceleration
kgm² Kilogram/meter-squared: Moment of inertia
Active on selection of “Set MD active (cf)” soft s seconds: measurement of time.
key. Hz Cycles/second: Frequency.
deg Degrees: Angular measurement.
Active on selection of the appropriate PLC mm/rev millimetres/revolution: linear feed-rate determined
interface signal, usually via MCP “Reset” key. by a rotary axis.
m/s³ Meters/second-cubed: linear jerk
rev/s³ revolutions/second-cubed: rotary jerk
Active immediately the “Input” key is selected
to confirm the value. Kg Kilogram: Measurement of mass
mm millimetre: Linear measurement.
Nm Newton-Metre
mH milli-Henry: Measurement of inductivity
A Amperes (Amps): Electrical current
V Volts: Electrical potential
Some MD/SD have no units associated with them. In this case
use the “Help” function to determine the data type required.
Data Classes Individual (I) - The individual data is machine specific

(Compensations, reference points etc.). An archive of the
The 828D controller uses machine data which is divided into Individual type could typically be made prior to a software
data classes. update.
Data classes can be used to create archives which contain
only specific data of the controller, data according to its clas- User (U) - The user data is user specific (Part programs, tool
sification. Upgrades etc. can therefore be carried out while data, zero points etc.). An archive of the user type could be
leaving any existing unrelated data of the controller intact. used to transfer data to an identical machine cutting the same
component or in the case of a software update.
Types of Data Classes:-
The Data Classes are split into four categories:
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.
Notes :

When looking at the machine data area of the controller it is Editing Machine & Setting Data
possible to see which machine data belongs to which Data REMEMBER:- Create a data backup !
Class.
The machine data screens are restricted via the password
Example:-Axis specific machine data screen showing data and the display filter.
class identifiers: If the expected machine data is not present, first check the
access level (Module B021 Protection Levels) and then the
display filter.
The “Display options” soft-key accesses the display filter
mask. Here it is possible to select which machine data are
displayed.
Data Class Identifier
The Machine & Setting Data is separated into different groups. For further data the “Menu Extension” key must be selected.
This allows access to the Setting Data and also the Display
The default entry in the machine data screen gives the follow- Machine Data.
ing soft-keys:
General MD and general Cycle MD.
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.
Control Unit Parameter.
Infeed Parameter (ALM/SLM).
Drive Parameter.
Notes :

Setting Data and Display Machine Data:
General SD and general Cycle SD.
Channel-specific SD and channel-specific Cycle SD.
Axis-specific SD and axis-specific Cycle SD.

When the correct MD has been found, a value can be entered.
In this example Display MD 9900 is changed from 0 to 1. This
Display MD. will change the MD/SD description from system language to
plain text.
The correct machine data can be located by using either the

page/cursor keys or the search 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
name in text format.
The correct machine data has to be highlighted. The number REMEMBER:- Create a data backup !
1 is entered and confirmed with the “Input” key.
On pressing the “Input” key the text of the machine data

changes immediately (see below).
Notes :

User Views By default on the control there are two “User view” lists.
“Setup_Milling” and “Setup_Turning”
User views allows a customised list of machine data to be
made. These views list all MD/SD required for setting the technology
Milling or Turning.
Module B110 Setup Milling and B120 Setup Turning describe

the minimum setting for the respective MD and SD that should
be applied in each case.
When a bit pattern is described these bits MUST be set, in
addition to any that have been set by the OEM.
Select machine data list.
Edit existing machine data list or create new

machine data list.
The “SELECT” button can be to show the Setup_Turning view.
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.
Notes :

Insert new data in machine data list. The machine data list will be stored on the System CF card.
The location of the machine data list is:

System CF card/user/sinumerik/hmi/templates/user_views
Storing of Archives within an AMM Project To upload the Archive files from controller into the project, tick
all boxes in the bottom window.
Start the Access MyMachine program and make an online
connection to the controller.
Make sure the project, created previously in module B002,

appears on the right-hand side.
Followed by the "Upload" icon.
Notes :

The uploaded files can be seen in the upper window by using

the arrow icon to show the "Archives" pull down menu.
Use the "+" icon to the right of the OEM text, the contents of There are several tasks that can be performed from within
the Archives in the "project" can be seen. AMM software. An archive can be opened and the data looked
at.
Tick one of the Archive file and click the "Edit"
Notes :

This will open the file within "Create MyConfig Diff".

Select the menu , "Selective"
Two archives can be opened and the data compared with

each other.
Tick two Archive files and click the "Compare"
Notes :

B041 END Machine and Setting Data
This will open the two files within "Create MyConfig Diff".
Select the menu , "Selective", then open and tick the same areas within each file.
Data that is different will be highlighted in RED text.
B041: END
Notes :

B038 Network & Operator Panels
Module Description:
It is often a requirement to store machining programs off-line on an external computer.
Access MyMachine is a multi-functional software tool which connects via Ethernet (X127 & X130),
one of the functions offers the possibility to connect remotely to controllers in order to transfer
machining programs to and from an external computer.
It is also possible to configure and assign controller soft-keys to networked computers as another
method of Network & Operator Panels.
Module Objective:
Upon completion of this module you will be able to:
 Connect remotely via network to the controller using Access MyMachine and use copy and
paste functions to transfer machining programs.
 Configure soft-keys in the Program manager and assign these to networked computers.
Content:
Sinumerik
Access MyMachine connected via X130
Configuring a Network Drive
Set up logical drives
B038
B038

Network & Operator Panels B038
Network & Operator

Panels:
START
Access My-
Machine
via X130
Configuring
a
Network
Drive
Set up
logical
drives
Network & Operator

Panels:
END
Notes :

Access MyMachine connected via X130
Computer Network Settings
When using X130 in a manual set-up, the IP address and

subnet mask of the external 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 192.168.100.2 and subnet mask of 255.255.255.0.
The subnet mask must match the one entered on the
controller.
Select the ‘Use the following IP address” option and enter a

unique IP address, example 192.168.100.2 with a subnet
mask of 255.255.255.0
Configuring Interface X130
Ethernet interfaceX130 is configurable, the port can be as-

signed a fixed IP address or be set to automatically acquire
an IP address.
Interface X130 is primarily for connecting to the company
network. When configuring for connection to a company net-
work, certain information from the company network adminis-
trator is
required.
Firewall: X130 has a firewall which can inhibit the online

connection of certain software tools. It is possible to open
ports to allow connections to be made.
Change the firewall with the following key selection:
Notes :

X130 Controller Set-up An overview of the X127 and X130 interfaces is displayed.
X127 is a DHCP server with a fixed IP address of
The controller settings for X130 can now be entered. 192.168.215.1 and subnet mask of 255.255.255.224. This
interface cannot be configured.
Any existing X130 settings should be recorded before any X130 is the company network and is configurable.
changes are made.
IP address restrictions- IP addresses 192.168.215.xxx &

192.168.214.xxx. are reserved for use by the system.
Addresses within these ranges should not be used for X130.
The following example shows how to manually assign an IP

address to X130.
Push the SK
To obtain IP address automatically. Diagnostic network
To enter a defined IP address. Check that the settings for X130 are correct in the
“TCP/IP diagnostics” screen with the following key selec-
The following example shows X130 being manually configu- tion:
red with an IP address of 192.168.100.1 and a subnet mask
of 255.255.255.0
When the settings have been entered select the “OK” soft-key”
Switch the control off/on to activate the settings.
Notes :

The “Availability” of the network connection is shown. In the example below X127 has a green/white tick symbol with an
availability of 100%, this indicates that the connection has hardware attached and is healthy.
If X130 shows a red / white cross symbol, with an availability of 0%. Then it is due to the fact that no hardware connection
exists to X130 or this is disturbed.
The Display is not dynamic! She can be updated with the SK „Display new“ .
X127: Connection in
use
X130: Connection not

in use
Access MyMachine Connection
A default connection is available in Access MyMachine for

connecting to X127. If Ethernet port X130 is to be used a new
connection will have to be created.
Enter the IP address of X130 (192.168.100.1) also enter a

connection name and choose a login level (Manufacturer,
Service, User) and the correct password for the selected log-
in.
Notes :

Controller IP address
Connection name The new connection is now listed in the Available connec-
tions list:
Login: User
Password: CUSTOMER
Set the Transmission The new connection can now be tested

mode to LAN
A connection can also be made from the toolbar: A few moments later the connection will be made and the fold-
er structure of the controller will be displayed in the lower half
of the Access MyMachine program
From the drop down menu select the connection to be used

then press the “Connect” button.
Programs and files can now be copied and pasted between

the host PC and the controller.
It is also possible to create files/directories on the controller.
Notes :

Configuring a Network Drive
Create a user account "AUDUSER" with password protection "SUNRISE"
Add or remove user accounts
with accounts selecting and opening
Create a new account “AUDUSER“
Notes :

Entering as a password "SUNRISE"
Show the local User and Groups: start Lusrmgr.msc with
Setup Network Drive

A shared folder is required on the PC for the storage of files.
The transfer of programs can be achieved by mapping a soft- For reasons of security it is possible to restrict network access
key to a networked Computer. The soft-key will appear in the to the shared folder by setting “Permissions”.
Program Manager area of the controller.
The following example will show how to create a folder on the
The computer connected to the network must have been D drive and how to set up sharing and permissions.
logged in with a username and password. This information will
be required for inputting on the controller. The option “Use sharing Wizard” should be deselected via the
“Tools” menu in Windows® Explorer:
The computer log-in used in this example is:
Username: AUDUSER
Password: SUNRISE
Options:
In order for the required function to be achieved on your ma-

chine, the following software options must be available:
 "Network drive management"

Order Nr. 6FC5800-0AP01-0YB0
Notes :

Select the D drive, right click with the mouse pointer in the
right hand Window and create a new folder.
Deselect “Use sharing Wizard” Enter a suitable name for the new folder.
Right click on the folder and select “Properties”. The share permissions for the new folder can be set. The
folder access over the network can be restricted to certain
users. The following example sets the permissions for
Select the “AUDUSER” (Log-in name of the computer).
“Sharing” tab
Select “Share
Select this folder”.
“Advanced The “Share
Sharing” name” will auto-
matically take
the folder name
Notes :

A list of user is revealed when the “Find Now” button is

selected
The list of users authorised to use the computer is displayed.

It is possible to set up permissions for any user on the list.
Locate and select “AUDUSER” from the list.
The user named “AUDUSER” is now authorised to access the

shared folder. The type of access is determined next.
Notes :

The following settings allow the user “AUDUSER” to have full About Shared Folders:
control of the shared folder including editing/creating items.
Start Fmgmt.msc with:
Displays shared folders, current sessions, and open files
Notes :

Logical Drive Set-up
Mapping the Shared Folder
The folder previously set up for sharing now needs to be

mapped from the controller to allow programs to be trans-
ferred between the controller and PC.
The following procedure will create a soft-key in the Pro-

gram manager area which, when selected will display the
content of the shared folder and allow file transfer using
copy and paste functions.
Use the following key selection to reach the Logical Drives

configuration screen:
The USB port is configured as default, this should be left

untouched. The next available free area is position 2. Use
the cursor and select keys to navigate the screen.
In the following example, details of the external PC have attention: drive may not be setup !
been entered.
Information such as IP address, share name, log on details The new soft-key will now be available in the Program area:
etc. are required.
Ensure that a suitable network cable is connected and press
the “OK” soft-key.
following message will be displayed briefly above the hori-

zontal soft-keys
Files can be copied to/from the controller using the Copy/

Paste soft-keys.
Notes :

A not operating disk drive is represented with grayed SK! The new folder is also available in the “System data” area.
This provides a convenient method of saving files such as
archives to a safe storage location.
1. User „AUDUSER“ , password „SUNRISE“. folder „840D sl Progams“ share for „AUDUSER“ with permissions
„Full Control“. Folders inside the shared folder can directly be accesed using the Path!
User name (1)

+ Password (1)
Computer name Enabling name + Path HMI-Display
192.168.100.2 840D sl Programs
Mill 1
Milling
Mill 2
User1
Mill 3
Turning User1
Turn 1
Enabling name
Turn 2
User name (2)
+ Password (2) Turn 3
2. User „CUSTOMER“, password „TURNING“. folder „Turning User1“ share for „CUSTUMER“ with
permissions „Full Control“
Notes :

The following logical drives can be set up:
 USB-interface
USB Local Front USB
 CompactFlash Card of the PPU, NC Extend „Option 6FC5800-0AP77-0YB0“
 User CF Card
 Network drives
B038 : END
Notes :

B038 END Network & Operator Panels
Notes :

B044 License and Option Management
Module Description:
When a CF card with options is purchased, a software License key is required.
The license 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 can manage the licence key using the Sinumerik HMI.
Content:
Sinumerik
Licence and Option overview
Test Licences
Saving and Restoring the Licence Key
Retrieving a Lost Licence
Assigning New Licenses
B044
B044

License and Option Management B044
License and Option

Management:
START
Licence and
Option overview
Test Licences
Saving and
Restoring the
Licence Key
Retrieving a
Lost
Licence Key
Assigning New
Licenses
License and Option

Management:
END
Notes :

Licence and Option overview Option Management.
Use the following key selection to reach the licence screens: Options are used to expand the functionality of the Sinumerik
controller, for example, an additional axis.
The available options are displayed via the All options soft-
key
The licencing screen shows that the licence key is correct for
the System CF card.
The options that are licenced for that particular System CF The licenced options have now been set.
card are displayed in the right hand Licensed column. They are activated by an NCK Reset.
The Set column shows licences that have been set.
The options can be set individually. Alternatively, all the li-

cenced options can be set, automatically, by selecting the Set
option acc. Lic. Soft-key.
Notes :

Test Licences: 828D Sinumerik Operate Test Licence Periods:
A missing/incorrect license key will result in alarm number

8081 Control Period 1: Periods 2 to 6:
828D 150 hours 150 hours
Test Licence use and philosophy:
Test licence 1
Example: An unlicensed option and alarm 8081
 OEMs can freely activate and test options during the
commissioning stage. Once satisfied which options are
required, these can be officially purchased and licensed.
The complexity of the controller is reflected by the differ-
ent time periods.
Alarm active due to unlicensed option being set: Test licenses 2- 6

 Dealers/End users can demonstrate/test options.
 Service engineers can activate a test licence in the

Note: Cycle start is blocked if the licence key is not suffi- event of a faulty system CF card. This eliminates any
cient. production delays while awaiting the delivery of a new
licence from the Siemens Hotline.
In the event of an unlicensed option being set it is possible to
activate a Test licence.
Up to six time monitored test licences are available should a

licence key be unavailable/incorrect.
Additional test licence information: Alarm number 8084 will replace the 8081 alarm number.
This can be cleared with the cancel/clear button but will peri-
 A test licence is only required if the system has at least odically reappear as long as a test licence is active. The re-
one drive assigned to an axis. maining licence time will be seen in the alarm description.
The test licence period: Alarm 8084:
 starts with control power on and stops with power off.

 is paused when the correct licence key for the
activated options is entered.
 is paused if an unlicensed option is deactivated. The main licence screen also shows the status of the test
licence:
Activating the test licence:
By selecting the Activate test licence soft-key it is possible to

have full functionality of the option.
Notes :

Saving and Restoring the License Key:
Saving the Licence Key
It is possible to save the License number to a file so that it

can easily be restored.
A valid licence key must be already entered and active.
Choose the destination for the License key.
Create a new directory/workpiece if required:
The new folder now appears. Select OK to save the licence Restoring the License Key:
key to this folder.
Note: This function only works with alm type files.
Select the Read in License key soft-key:
A confirmation message is displayed, momentarily, above

horizontal soft-keys:
Highlight the License key file and press the OK soft-key:
The licence key is saved as an alm type file. The name of the
file is generated automatically and contains the serial number
of the CF card.
A shortcut to the Siemens licensing website is also created.
Notes :

The License key will now appear in the License key box. Retrieving a lost licence key
The CF card will arrive with documentation regarding the li-

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

prior to attempting any work where the NC data might be lost/
reloaded.
If the License key is lost it is possible to retrieve it via the inter-

net. The serial number of the internal CF card will be needed
to recover the License key.
The licensing website can be found at:

www.siemens.com/automation/license
To retrieve a lost key use the Show License Key option,

found in the left hand column.
From the Please select menu, choose Hardware serial num-
ber.
This is the serial number of the internal CF card taken from
the License screen shown on the controller.
The license key will now be displayed. A license report can be

requested and sent to an email address.
Notes :

The license key can be saved as a text file by right clicking on

the “Save license as a key file” link.
Example: Saving as a text file
Notes :

Entering the saved licence key: Assigning New Licenses
Unlike the alm type files, the txt file cannot be read in to the Activating an unlicensed option without a test licence being
controller. active results in alarm number 8081.
The licence number can be typed directly to the licence If a new option is required it can be licensed via the Web Li-
screen. cence Manager website.
Alternatively, the keys.txt file can be opened, on the control-
ler, and the licence key copied/pasted into the licence screen. Example of an unlicensed option that has been set:
Copy/paste from keys.txt:

Mark and copy the licence number section of the opened
keys.txt file:
The licencing screen also shows that the licence key is incor-
rect:
Locate the licence screen and paste the licence number using
the Ctrl + v key combination.
The assignment of a new Licence key is done via the Sie-

mens Web Licence Manager website:
www.siemens.com/automation/license
Each purchased option has a licence certificate. The certifi- Sequence:

cate contains the License and dispatch note numbers.
The licensing is achieved by a series of steps via the Sie-
Example licence certificate: mens Web License Manager website.
The hardware serial number (System CF card serial number)

and the hardware type are required. These can be seen on
the licensing screen.
Example:
Notes :

Web License Manager website default page: Enter the License number and the dispatch note number.
Example:
Step 1 of 5 - Login:
To login, select Direct Access on the Web License Manager
screen:
Continue to step 2 with the Next button. Step 3 of 5 - Selecting the option:
Any options not yet assigned are displayed. The additional
options can now be assigned to the hardware. Continue to
step 4 with the Next button.
Step 2 of 5 - Identify Product:

Enter the hardware serial number and select the product.
Continue to step 3 with the “Next“ button.
Notes :

Step 4 of 5 - Assigning the License:

The selected option is now ready for assigning.
Step 5 of 5 - Generate License Key:

The License Key includes all options assigned for the speci-
fied hardware.
The Licenses are assigned to the specified hardware by click-

ing the “Assign“ button.
There are three methods for saving the file. Two of these are The licence file can now be read directly into the controller:
in PDF or TXT format.
The remaining option is as an ALM file, this can be read di-
rectly into the controller.
Saving the License as an ALM file:
Download the License Key by double clicking the following

link:
It can be checked whether the License Key has been entered

successfully by pressing the All options soft-key and check-
ing that the missing option is licensed.
Save the file to a suitable place, e.g. USB stick, in order that it
can be loaded to the controller.
B044: END
Notes :

B044 END License and Option Management

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 GSP iBase database
via the identSNAPSHOT software.
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.
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 GSP iBase database via the identSNAPSHOT software.
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 GSP iBase
B007
B007

Electronic Logbook B007
Electronic Logbook:
START
Logbook
information
Importing/
Entering
Logbook
data
1st
Commission
ing Start-up
Complete
2nd
Commission
ing-Machine
Installed
Recording a
Service Visit
Saving the
Logbook
Data
Uploading to
GSP Ibase
Electronic Logbook:
END
Notes :

Logbook Information identSNAPSHOT
In the past, the validity of warranty claims was difficult to man- When the information has been entered it needs to be saved,
age and was the cause of delayed service response times. this is via a soft-key on the Logbook screen. This procedure
System/hardware faults were logged in paper logbooks which will create a log file.
were then usually left on the machine and often became dam-
aged or lost. This is known as the “identSNAPSHOT” function and is a
snapshot of the system including version data, cycle data,
By using GSP iBase and the Electronic Logbook system, the hardware components etc
warranty will automatically start, a record of the machine de-
tails and breakdowns will also be available on the controller. Each time a logbook entry is made, the log file should be
saved and uploaded to the GSP iBase database via the
The time and date of each entry is recorded; it is im- identSNAPSHOT software.
portant that the time and date settings of the controller are
correct. Incorrect time and date settings can lead to early The name of the file is made from a combination of the ma-
expiry of the warranty. chine name and system CF card serial number.
It is necessary to make entries at certain stages during the life

of the machine: Warranty
- Manufacturer information at OEM Every Sinumerik 828D package includes a 24 months of free
- Dealer information at delivery and installation of machine local service (On Site Service, OSS) by Siemens. When sup-
- End user information at delivery and installation of machine plied, the control package is automatically registered for the
- 1st Commissioning - End of start-up at Manufacturer first time in the GSP iBase final destination database, and the
- 2nd Commissioning Machine installed - End of start-up at OSS period is activated.
end user This can be extended free-of-charge from 12 months up to a
- All service visits maximum of 36 months trough online registration.
Importing/Entering the Logbook Data File Function
The OEM and Dealer information can be imported to the con- oem.xml Manufacturer information
troller in three ways: oemsubs.xml Manufacturer subsidiary information
 Import the XML file via the “Import” soft-key. dealer.xml Dealer information
(Preferred method) user.xml End user information
 Copy/paste the XML file in the “System data” area. ma_types.xml List of available machine types
The files are imported using the “Import” soft-key.
 Type the information directly on the controller. If the files are not available they can be created directly on the
(When the files are not available.) controller or offline on a computer.
Machine Identity File (identity.xml)

The preferred method is to obtain the correct xml files from
your Siemens contact partner. These are pre-populated files When the information has been imported the “identity.xml” file
containing the relevant OEM/machine information etc. Using is automatically created which contains all the information
this method guarantees the consistency between the data from the imported xml files.
stored in GSP iBase and the data stored on the machine.
If data is already present in the logbook area and needs to be
The following files can be imported: overwritten, then the identity.xml should first be deleted from
the system.
The machine name/number is stored in General Machine Data

17400. This is individual to the machine and needs to be en-
tered here.
Notes :

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

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

Load via “Import” soft-key.
*Country*
*Manufacturers name*
*Town*
Dealer Data Dealer Data (identity.xml)
dealer.xml: *Customer number* Export & upload

Load via “Import” soft-key.
*Country* Online
Registration
*Dealers name*
*Town* Configuration data:

components, machine identity,
licences, version information,
logbook entries etc.
User Data User Data (identity.xml)
user.xml: Not usually available

Load via “Import” soft-key. until point of sale.
Logbook entries
1st Commissioning
2nd Commissioning
Service visits
If the controller has existing machine identity data, it is necessary to delete the “identity.xml” file.
The location of the “identity.xml” file:
System CF card\individual\sinumerik\hmi\data\version\identity.xml
Notes :

Data Import function Ensure that the files to be imported are available on the control-
ler, network PC or USB memory device.
The Electronic Logbook is located in the Diagnostics area of the
controller:
Select the location of the file to be imported, e.g. USB.
Default Manufacturer screen with no data entered:
Select the file to be imported, e.g. oem.xml
A machine name/number is compulsory.
The information will now appear on the screen. In this example

the Manufacturer file (oem.xml) was loaded.
To see data for Dealer or End User select the relevant soft-key.
Enter the machine name and/or number, e.g. VMC123.

The value entered here is transferred to General MD 17400.
Notes :

Machine type
The machine type can be manually typed at the same time as

the name/number is entered. Alternatively a list of machine
types can be viewed if the “ma_types.xml” has been imported.
Example of an “ma_types.xml” file that has been edited to in-

clude three machine types.
Once the choice of machine type is made it cannot be undone

unless the “identity.xml” file is deleted.
When the file is imported, the machine types will appear in the
drop down list.
Copy and Paste function Locate the destination folder (Machine identity).
It is also possible to copy the files from USB/networked PC via

the “system data” area using the copy and paste functions.
Cursor to the source containing the file e.g. USB device.
The controller now needs to be powered off/on.
Notes :

Subsidiary files The default screen displays the manufacturer data.
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
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 “oem.xml” and “oemsubs.xml” files as

described previously.
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.
To return to the manufacturer details, select the “Reg. office of

manufact.” soft-key.
This is the original manufacturer soft-key with different text.
The text of the soft-key changes depending on the current
selected screen.
Select the branch/subsidiary name; in this case “ABC SUB” Templates for xml Files
Templates for the various xml files are available in the

“HMI data\Templates\Examples\Machine identity” folder.
The subsidiary details will be displayed.
Notes :

The templates can be used if the files cannot be obtained from

the Siemens partner. They should be copied and edited to
leave the original templates intact.
Example template for dealer.xml.
The file contains various

xml commands but no deal-
er data. Manually Entering Machine Identity Data
If the data has to be manually entered due to lack of an xml

file, the data can be typed directly into the controller.
Select which data is to be entered; Manufacturer, Dealer, End

user.
Example: A “dealer.xml” file with dealer information. The file
can be imported using the method described earlier.
Or Or A summary of the information can be seen.
Example: Manually entered “End user” data.
Notes :

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

turer the “Start-up Complete” soft-key is selected. This auto-
matically logs the current time and date.
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.
To confirm that 1st Commissioning is complete.
The information will appear on the main logbook page.
To confirm that 2nd Commissioning is complete.
The name and company/department of the engineer should

The information is now added to the main logbook page . be entered followed by a detailed description of the fault and
work carried out.
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.
Notes :

The details of the service visit are now shown on the Logbook The save procedure should be carried out after each data
page. 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

a standard procedure to ensure that a copy is locally available .
The file is to be uploaded to the online registration website via

an external PC, therefore it should also be saved to an external
USB/CF device.
Saving the Logbook data
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
entered on the logbook pages.
The file is given a default name using details from the machine
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- In this example, the files are saved in the “version” folder.
book entries. It is this file which needs to be uploaded to the
database via the internet. System CF card\user\sinumerik\hmi\ data\version
The information will now be saved.
Notes :

The file can be opened for viewing in the “System data” area: The information that was entered via the Logbook screen is
now stored in the xml file.
Service visits are found at the end of the file: Uploading to GSP iBase
Use the copy/paste function to transfer the xml file to a USB

stick 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 GSP iBase. This is
done using identSNAPSHOT software, which can be
downloaded via:
www.siemens.com/sinumerik/register
Once identSNAPSHOT has been downloaded, and the zip

The file is closed with the following soft-key selection. file has been extracted, a shortcut can be created of the
"Start_IdentSNAPSHOT.exe" onto the desktop of the
computer being used.
Notes :

Double click the desktop short cut to start the A language selection is available from the menu bar.
"identSNAPSHOT" software.
You must first register in order to upload data into the GSP
iBase Service Platform Industry database using
identSNAPSHOT. You only have to register once before the
first upload. All of the required data are saved locally on your
PC.
This is achieved by the pull down menu "Configuration" on
the right hand side at the top of identSNAPSHOT, then
selecting "My address".
Notes :

As response, you receive an e-mail from the identSNAPSHOT

registration with your user ID in the form of a graphic.
Select "New" The numerical sequence 82489503 is shown here as example
These digits must be entered in this sequence into the input

field "ID" and "Confirm ID“. The registration is completed with
"OK". If the registration was successful, the e-mail address
has a gray background. The user ID is then permanently
assigned to this e-mail address, and the e-mail address can
no longer be changed.
Enter your details that are heighted in RED* followed by.
To upload the "Logbook" XML file to GSP iBase, highlight

"Machine infos load" from the menu bar.
Use the "Open" window to locate the XML file on the memory
stick
Notes :

This will populate all relevant fields within identSNAPSHOT,

from the data of the "Logbook".
To upload the XML file to GSP iBase use the "Upload" -->
"Machine infos upload" from the menu bar.
If there is any problems, a window will appear advising you of

data to be checked
This will start the upload process.
Notes :

B007 END Electronic Logbook
When the "Logbook" file is uploaded successfully, a window

will appear.
B007: END
Notes :

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.
 Manage MD, SD, drive data and compensation data on the file level
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
Data admin
B017
B017

Data Management B017
Data Management:
START
Data
Management
Concept
Data
Classes
Easy
Archive
Save Data
Function
Creating
Archive With
Shortcut
Keys
System
Software
Backup and
Restore
System
CF Card
Replacement
Data
admin
Data Management:
END
Notes :

Data Management Concept
OEM
Change necessary to modification

Reproduce Machine at Manufacturer
and change in or Individual level - PLC or
Prototype Update change log in
Protokoll NC update necessary
Serial machines become

Prototype Individual Machines
1st TGZ File of Serial Maschine (1……..x)
Save Data
Commissioning Prototype (1………..x) Individual data (class)
Time and Date
OEM Logbook
Individual Machines
(1……..x)
Data save
TGZ File from Prototype into Local Archives
Serial machines TGZ with machine
and local to server
Updates
Daten
klassen Changes to machine E-Mail Incremental Machine at
Archiv with archive Update updates Customer
Update
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 classifica-
tion. 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 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 - The manufacturer data is common throughout a particular machine series. No individual or user data is included.
Individual - 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 - 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.
Data Classes for Machine Data Data Classes for PLC Data Blocks
When looking at the machine data area of the controller it is It is also possible to select the Data Class of certain Data
possible to see which machine data belongs to which Data Blocks in the User PLC program. When a Data Block is first
Class. created, the properties box is displayed.
Example: Axis specific machine data screen showing data The Data Class can be changed via the drop down menu. If
class identifiers: the Data Block already exists, the properties can be viewed by
right clicking on the Data Block and selecting properties.
Selection of the
Data Class.
Data Class Identifier
Notes :

Easy Archive Creating Non-Data Class Setup Archives:
Creating Setup Archives: A number of choices are available with regards to the type of
To create a Setup Archive, locate the correct area by using the data to be included in the archive you are about to create.
following key sequence. 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.
Ensure that the option “Create Setup Archive” is selected and

select “OK”.
Control Components:
NC data:- The NC data consists of:-

All machine and Setting data (except for drive machine data)
Tool data
Offsets
R parameters
Part Programs
User Data
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
Notes :

The example below shows the “All” option selected with the Information about the archive can be entered in the Comments
four control components also selected. This would create a section.
full backup of the controller.
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.
The archive is now created and stored in the specified destina-

tion.
Archives are created with an ”.ard”. extension.
A name for the archive needs to be entered, example-Milling A dialogue box indicates that the archive was successfully
Machine 123. created.
Notes :

Creating Data Class Setup Archives A selection of MANUFACTURER, INDIVIDUAL or USER data
can be made.
Data Class Setup Archives are created under the “Selection” A description of the data included with each selection is
option. shown below:
MANUFACTURER : This will create an archive containing all

manufacturer relevant data of the machine. This will not con-
tain any individual or user data.
INDIVIDUAL : This archive will save only machine specific

machine 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”
data Class type.
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 :

A suitable name for the archive should be entered.
A dialogue box indicates that the archive was successfully

created.
The archive is now created and stored in the destination speci-

fied earlier.
The archives are created with a default extension of “.ard”.
Reading in Archives
In the event of a hardware/software change it could be
necessary to read in archive files.
Loading Standard Data

Before reading in an archive it is recommended that the
controller is loaded with default data. The basic “Start-up” menu will be displayed, to display the
advanced “Start-up” menu select the keys indicated below in
Restart the controller, press the “select” key within 3 seconds the numerical order shown.
of the following screen appearing.
Press SELECT key to enter setup menu
1 2 3
Notes :

The advanced “Start-up” menu will be displayed. Cursor to the required option and press the “Input” key.
The menu contains many options.
The type of archive to be loaded will determine which option
should to be selected.
Example 1:-If a complete NCK archive is to be loaded, the

“NCK default data” option would be selected.
Example 2:-If a complete NCK, PLC, Drives & HMI archive is to

be loaded, the “Factory settings” option would be chosen.
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. Select the archive to be read-in, example- Milling Machine 123
Selecting the archive to be read-in
Use the following key combination to reach the area for read-
ing in archives:-
Information about the archive is displayed. It is possible to read

in all or part of the archive, depending upon the archive con-
Cursor to the “Read in Setup Archive” option and press “OK”. tents.
Notes :

When the archive has been successfully read-in the following

message box is displayed.
The reading in of the archive will begin, this is indicated by a

series of information boxes. When the process is complete the functionality of the machine
can be tested.
Note: It is important that the operator checks tool data, off-

sets, programs etc. as the archive could contain old data.
Save data function R parameters

Part Programs
The “Save Data” function is used to automatically save the NC User Data
data stored in the static ram memory (SRAM) of the 828D con-
troller to the system CF card. Performing the Save Data Function:
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
overwritten each time the save data function is performed.
The image cannot be retrieved from the CF card.
The saved data can be used in one of two ways:-
 Creation of series machines. Series machines are

produced by creating an image of the system CF card
of the prototype machine. When the image is
created it will include the “Save data” image which will
automatically be restored during 1st power on of the
series machine.
 Creation of backups during commissioning. The

saved data can be manually reloaded from the Start-up
menu. If the function has never been carried out, the
controller will be loaded with standard data.
Data saved by the “Save data” function:

All machine and setting data (Except for drive machine data)
Tool data
Offsets
Notes :

The start-up menu is selected during the start-up of the

controller:
Reboot the controller, within 3 seconds of the following screen

appearing, press the “select” key.
The data is now stored on the system CF card.
Restoring the data saved with the Save Data function
The data saved previously can be restored by one of two meth-

ods.
Creation of series machines:

When a system CF card, created using an image of the proto-
type machine, is inserted into a new controller for the first time, Press SELECT key to enter setup menu
the saved data will be automatically reloaded. This produces a
clone of the prototype machine.
Manually reloading the saved data:

The saved data can also be manually loaded. This is done
from the start-up menu. Message “4062 Backup data loaded”
will be displayed to warn the operator that the data was reload-
ed.
The Start-up menu will appear, cursor to the “Reload saved

user data” option and press the “Input” key.
Allow the procedure to continue, this could take about five

minutes.
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.
Cursor to the “Yes” button and press the “Input” key.
Notes :

Creating Archive with Shortcut keys
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.
+ +
The controller should be allowed plenty of time to create the
archive, a guide would be to allow 5 minutes.
If the procedure is used on a controller with an operational
A file with the .ard extension will be created and given a de-
screen, several dialogue boxes be will be shown, these will
fault name which includes time and date information.
clear when the archive has been created.
It should be checked that the file exists on the USB/CF device
If the screen has failed these boxes will obviously not be seen.
before commencing work. If there are any doubts it may be
better to do the procedure twice and compare the file sizes.
Example:
System Software Backup Completed prototype

machine
When the prototype of a particular machine is complete, series
production can begin. In order to do this a clone of the data of
the prototype machine is required.
The 828D controller uses an internal system CF card. This

card contains the system software from which the controller
operates. The card also contains other important data which is
essential for the machine to function.
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 Empty storage device Storage device containing
cards: (CF card/USB stick) system image (TGZ)
Notes :

Creating a system image
Before commencing it is necessary to perform the “Save data”

function described in Section 5.
Insert a FAT formatted CF card or USB stick of at least 1024MB

into the front of the controller (X125-USB, X145-CF card). Select the highlighted soft-keys in the numerical order indicat-
ed (not simultaneously):
Restart the controller, within 3 seconds of the following screen
appearing, press the “select” key.
1 2 3
The advanced menu will be shown, select the option “Create

software update/backup”.
Press the input key to continue.
Ensure that a USB or CF memory device is inserted.
Continue with the “Input” key.
Notes :

Enter a suitable name for the file, the “tgz” extension must
remain.
When the image has been created a confirmation message is

displayed. Remove the USB/CF storage device and power off/
on the controller.
The file will now be created. As the process continues the file
size, indicated in the brackets, will increase. The image should be stored in a safe place for future use.
Restoring a System Image
The previously created system image (TGZ file) is used for the starting up of series machines.
A licensed system CF card should be inserted into the rear CF card slot of the controller.
Location of rear CF card slot, insert the system CF in here:
Notes :

The following procedure will flash the backup image Insert the USB/CF device which contains the backup im-
saved earlier to the new system CF card. age and select “Yes” followed by the “Input” key.
The controller should be started and the advanced

“Start-up menu” selected.
Cursor to the “Install software update/backup” option

and press the “Input” key.
Select the backup image, e.g. 828D_image.tgz and press the The data backup is now written to the internal CF card. Allow
“Input” key. It is possible that more than one image is present the process to finish.
on the CF card/USB stick, ensure that the correct one is cho-
sen.
When the procedure is finished the controller needs to be

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

When the controller reboots, the alarm “4062 Back-up data Machine Functionality:
loaded” will be displayed. This data is the data saved in the
“Save data” procedure. Clear with the “Reset” key The machine functionality should now be checked. The opera-
tor should ensure that tool data, offsets etc. are correct.
If 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 GSP iBase system for register-
ing the machine.
The registration is very important with respect to the start of
the 2 year warranty period.
For this reason it is essential that the time and date be set
correctly.
System CF Card Replacement The software package “Access MyMachine” is required plus a
recovery file called “minsys.img”. This file is installed as part of
In the event of the internal CF card becoming damaged it is the toolbox and is found within the folder named “Recoverysys”
possible to write a previously saved system image to a new CF in the toolbox directory.
card.
It is necessary to obtain a replacement blank CF card from Start the “Access MyMachine” software:
Siemens. Part number for replacement 2GB card:
6FC5313-5AG00-0AA2.
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
performed prior to creating a system image.
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.
A connection to the controller is not necessary, cancel any
dialogue boxes.
Notes :

From the “View” menu select the “Expert view” option.
Highlight the drive letter of the CF card. Example “G:\”
Browse for the CF card:
Start the write procedure with the “Write” button. 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 start-up, the following

When the procedure is complete a confirmation box is dis- dialogue box will be displayed, select the “Input” key to contin-
played. ue.
Notes :

Insert the USB/CF device which contains the backup image

and select “Yes”.
The data backup is now written to the internal card. Allow the
process to finish.
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.
When the procedure is finished the controller needs to be pow- If alarms numbers 4060 & 400006, 120402 are present, this
ered off to allow the USB/CF device to be removed. 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
Switch off the controller, remove the front CF card/USB stick do not now correspond.
and then switch the controller on. Alarm number 8081 is generated because of this. The number
When the controller reboots, the alarm “4062 Back-up data of options not licensed will differ between machines.
loaded” will be displayed, this data is the data saved in the
“Save data” procedure. Clear with the “Reset” key.
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.
Notes :

Data admin
The "Data admin" function simplifies the commissioning and

permits the transfer, backup, loading and comparing of machi-
ne, setting, compensation and drive data at the file level. The
files are saved in the .tea ASCII format.
The "Data admin" softkey is visible as of access level

"Service" (= 2).
To find the "Machine data loaded" area:
 Transfer data within the controller

Only those controller objects are listed that are cur-
rently available in the controller.
 Save data to a file
Additional files with the extensions .acx and .log are
created for the SINAMICS parameters:
- Files with the extension .acx contain the parameter
descriptions for the selected drive object.
- The log file may also contain the warnings and errors
that occurred during the conversion from .acx to .tea.
 Load data from a file
 Compare data
Several files (.tea) and/or controller objects (axis, chan-
nel, servo, infeed, etc. ) can be compared at the same time.
An online comparison of constantly changing data is not
possible because the values are saved temporarily at the time
of the comparison. Up to eight elements can be taken into the
list of the data to be compared.
 Export SINAMICS lists
 Import SINAMICS lists
Save all DOs (drive parameters) individually in a file!
The drive data "DOs" saved in this way

can then be used for new topologies!
Notes :

The saved data is in the

following directory.
Use drive data modularly:

Optimized drive data "DOs" can be loaded to a new topology.
Prerequisite is that the drive objects comprising "power unit,
motor, encoder interface and encoder" are identical!
With the "Load data from a file" function, select a drive file
with the extension .TEA (source) and the servo (target). Con-
firm the selection with the "OK" softkey.
The source DOs must be loaded via the "Adapt" softkey

function!
Caution: Never direct Load "Actual topology will be over-
written"!
Notes :

B017 END Data Management
B017: END
Notes :

B010 NC Connections and Diagnostics
Module Description:
The 828D PPU can be diagnosed using status LEDs. 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

NC Connections and Diagnostics B010
NC Connections
and
Diagnostics:
START
PPU Status
LEDs and
Interfaces
(Front)
PPU Status
LEDs and
Interfaces
(Rear)
Input/Output
Terminal
Descriptions
NC Connections
and
Diagnostics:
END
Notes :

PPU Status LEDs and Interfaces (Front)
The interfaces are found on the front and the rear of the PPU. The front interfaces are found beneath a hinged cover to the left of
the screen.
Ethernet DHCP server port.

Default address-192.168.215.1
X127 Issues addresses up to
192.168.215.31.
RDY
LED status indicators, see table
NC
below.
CF
X125 USB port for keyboard and
memory devices.
Compact Flash port for custom-

X145 er data storage and service/
commissioning tasks.
Front LED Description:

PPU Status LEDs and Interfaces (Rear)
Red/
Interface locations:-
LED Green Orange Red
Orange
Rear view of PPU showing interfaces.
NC Ready
PLC in stop NC in stop Power-up
RDY and PLC in
mode mode (Alternating)
run mode
Internal (System) CF card location.
NC operation
NC
(Flashes cyclic)
Internal/External Fault
X100 Sync PN
CF card access
CF
(Flashes random- Fault PN
X101
ly) Sync
X102
Rx/Tx
Link
X130
Note: The CF card should not be removed while the CF LED
X140 X135
is flashing.
X122
X132
X242
X252
X143
X1
M T1 T2 T3
Notes :

Interfaces for 828D S120 Book-sized Drive Modules: Interfaces for 828D S120 Combi Drive System:
X1 +24V DC supply X1 +24V DC supply

X100 DriveCLiQ interface for line/motor/SM modules X100 DriveCLiQ interface for Combi Drive/SM module.
X101 DriveCLiQ interface for DMC/TM54/SM modules X101 DriveCLiQ interface for S120 Book-sized Compact
X102 DriveCLiQ interface for NX10/TM54/SM modules Motor Modules
X130 Ethernet-Factory network X102 DriveCLiQ interface for TM54 Terminal Module for
X135 USB interface Safety Integrated signals
X140 RS232 interface X130 Ethernet-Factory network
X143 Interface for two Hand-wheels X135 USB interface
X122 Digital I/O for Sinamics X140 RS232 interface
X132 Digital I/O for Sinamics X143 Interface for two Hand-wheels
X242 Digital I/O for NC X122 Digital I/O for Sinamics
X252 Digital I/O for NC and Analogue Spindle. X132 Digital I/O for Sinamics
PN Profinet interface X242 Digital I/O for NC and Analogue Spindle.
PN Profinet interface (Not on 828D Basic M/T) X252 Digital I/O for NC
T0 Analogue output measuring socket PN Profinet interface
T1 Analogue output measuring socket PN Profinet interface (Not on 828D Basic M/T)
T2 Analogue output measuring socket T0 Analogue output measuring socket
M Electronic ground for analogue measuring sockets T1 Analogue output measuring socket
T2 Analogue output measuring socket
NX10: Handling of more than 6 axes. M Electronic ground for analogue measuring sockets
SM: Sensor Module for non-DriveCLiQ encoders/scales.
DMC: DriveCLiQ hub for additional SM modules.
TM54: Terminal Module for Safety Integrated signals.
LED Indicators (all variants): Digital Input/Output Terminal Description
X122, X132, X242 & X252 Terminal Description

Name Colour Description
X122 & X132: BiCos are used to assign Sinamics inputs/
FAULT Red Fault present (Profinet interface)
outputs to a specific function e.g. enabling of drives, BERO’s,
SYNC Green Synchronisation OK (Profinet interface) automatic line contactor control etc.
Certain terminals are automatically assigned to a function by
Rx/Tx Yellow Network activity (X130 interface) default, these are the OFF1 and OFF3 drive enable signals
and the input for probe 1.
Link Green Network connected (X130 interface) 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.
X242 & X252: Functionality for digital NCK inputs/outputs and

one analogue spindle.
Notes :

X122-Sinamics I/O X122 Signal Function/Default Setting
Pin 1 Sinamics DI0 OFF1 (ALM, SLM >=16Kw), Pulses

enabled (SLM <16Kw)
Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop
Pin 3 Sinamics DI2 Safety Integrated SH/SBC 1 Group 1
input
Pin 4 Sinamics DI3 Safety Integrated SH/SBC 1 Group 2
input
Pin 5 Sinamics DI16 DI 16 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
X132-Sinamics I/O X132 Signal Function/Default Setting

Pin 4 Sinamics DI7 Line contactor check back signal
input
Pin 8 P24EXT1+24V DC +24V DC common
(P)
Pin 9 Sinamics DI/DO12 Infeed is ready output
Pin 10 Sinamics DI/DO13 Ready to power up output
Pin 12 Sinamics DI/DO14 Line module contactor control
output
Pin 13 Sinamics DI/DO15 Probe 2 de-centralised input
Notes :

X242-NCK Digital I/O X242 Signal Function/Default Setting

Pin 1 Not connected Not Connected
Pin 2 Not connected Not Connected
Pin 3 NCK DI1 (IN1) DI $A_IN[1]
Pin 8 P24EXT3 +24V DC +24V DC common
(P)
Pin 9 NCK D01 (OUT1) DO $A_OUT[1]
Pin 10 NCK DO2 (OUT2) DO $A_OUT[2]
X252 Signal Function/Default Setting

X252-NCK Digital I/O
Pin 1 AOUT Analogue output for spindle
Pin 2 AGND Analogue ground for spindle
Pin 8 P24EXT3 +24V DC +24V DC common
(P)
Pin 9 NCK DI9 (OUT9) DO $A_OUT[9]
Pin 10 NCK DI10 (OUT10) DO $A_OUT[10]
Pin 12 DO $A_OUT[11]
NCK DI11 (OUT11) (Note: If analogue spindle is declared, reserved
analogue spindle enable/direction)
Pin 13 DO $A_OUT[12]
NCK DI12 (OUT12) (Note: If analogue spindle is declared, reserved
for analogue spindle enable/direction)
Notes :

B010 END NC Connections and Diagnostics
X143-Hand-wheel connections X143 Signal Function/Default Setting

Pin 1 5V DC (P5) +5V DC common
Pin 2 0V DC (M) Ground
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
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 (X143) are pre-assigned, while the digital I/O and probes can
be assigned to any suitable connection by the user.
Connections used within the drive group components are known as BICOs (Binary Connectors)
Certain connections can be configured as an output or an input.
X252 has the possibility of analogue spindle functionality, this is described in Module B029
X122-Sinamics Digital I/O

X132-Sinamics Digital I/O
X252-NCK Digital I/O / Analogue Spindle 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.
Digital Input/Output Terminal Description
BICO Technology
BICO Assignment
NCK Inputs and Outputs
B030
B030

Digital I/O, hand-wheels and probes B030
Digital I/O,
Hand-Wheels and
Probes:
START
Terminal
Description
BICO
Technology
BiCo
Assignment
NCK Inputs
and
Outputs
Digital I/O,
Hand-Wheels and
Probes:
END
Notes :

B030 Digital I/O, hand-wheels and probes
Terminal Description
Interface locations:
Rear view of PPU showing interfaces.
Digital IO Interface connectors:

X122
X122 Digital I/O for Sinamics
X132 Digital I/O for Sinamics
X132 X242 Digital I/O for NC
X252 Digital I/O for NC / Analogue I/O for analogue spindle
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* OUT11 / Analog Spindle 12
14 MEXT1 MEXT3 14
Analogue spindle option
Enable / direction
Enable / direction
1* Fast inputs/outputs (Must be shielded). Can be parameterised as Inputs or outputs.
Functionality of X252 pins 12 & 13:
The functionality of X252 pins 12 & 13 changes depending on whether an analogue spindle is declared
X252 Analogue spindle is declared Analogue spindle is not declared

Pin 12 Controller enable/positive direction for Digital Output $A_OUT[11]
analogue spindle option
Pin 13 Controller enable/negative direction for Digital Output $A_OUT[12]
analogue spindle option
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)
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
Pin 10 SH/SBC 1 – Group 2 (Input) CU-p0739
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
Probe 1: Remote Measuring Each drive p0488,
Pin 13 Sinamics DI/O11 (Input) CU p680[0]=0 Index
(MD13210=1) encoder 1, 2, 3=3
Notes :

X132-Sinamics I/O

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 Digital Output $A_OUT[11] / Analogue spindle enable/direction
Pin 13 OUT12 NCK DO 12 Digital Output $A_OUT[12] / Analogue spindle enable/direction
Notes :

X143-Hand-wheel connections

Notes :

BICO technology:
Interconnecting signals
Every drive contains a large number of interconnectable input and output variables and internal control variables.
BICO technology (Binector Connector Technology) allows the drive to be adapted to a wide variety of requirements.
Digital and analog signals, which can be interconnected as required by means of BICO parameters, are identified by the
prefix BI, BO, CI, or CO in their parameter name.
Binectors, connectors
Binectors, BI: Binector Input, BO: Binector Output
A binector is a digital (binary) signal without a unit which can assume the value 0 or 1.
Binectors are subdivided into binector inputs (signal sink) and binector outputs (signal source).
Abbreviation Symbol Name Description

BI Binector input Can be interconnected to a binector output as
source.
(signal sink) The number of the binector output must be
entered as a parameter value.
BO Binector output Can be used as a source for a binector input.
(signal source)
Connectors, CI: Connector Input, CO: Connector Output
A connector is a digital signal, e.g. in 32-bit format. It can be used to emulate words (16 bits),
double words (32 bits) or analog signals. Connectors are subdivided into connector inputs
(signal sink) and connector outputs (signal source).
Abbreviation Symbol Name Description

CI Konnektoreingang Kann mit einem Konnektorausgang als Quelle
Connector Input verschaltet werden.
(Signalsenke) Die Nummer des Konnektorausgangs muss als
Parameterwert eingetragen werden.
CO Konnektorausgang Kann als Quelle für einen Konnektoreingang

Connector Output verwendet werden.
(Signalquelle)
Interconnecting signals using BICO technology
To interconnect two signals, a BICO input parameter (signal sink) must be assigned to the required BICO output parameter
(signal source). The following information is required for connecting a binector/connector input to a binector/connector output:
Connectors with no index: drive object ID and Parameter number
Binectors: Drive Object ID, Parameter number and Bitnumber z.B.: SERVO_3.3:3 P849[0] BICO 1:722.1
SERVO_3.3:3 P848[0] BICO 63:2090.2
Drive Object ID 63 = own drive object
Notes :

connection of OFF3 to several drives

The OFF3 signal is to be connected to two drives via terminal DI 2 on the Control Unit..
Each drive has the two binector inputs, "1. OFF3" and "2. OFF3". The two signals are processed via an AND gate
to STW1.2 (OFF3).
BO: Binector Output BI: Binector Input

signal source signal sink
signal flow
p 0848
X122.2
r0722.1 r 2090.2
p 0849
r 0722.1
p 0848
r 2090.2
p 0849
r 0722.1
The signal flows of the signal source now (digital input of the CU) to the target (on the function)
SINUMERIK
PLC NCK/CU
controller enable
DB38xx.DBX2.1
pulse enable
DB38xx.DBX4001.7
Logic Drive ready Logic
DB39xx.DBX4001.5
DB39xx.DBX4000.4
Pulses are enabled
DB39xx.DBX4001.7
ZSW 1+2
STW 1+2
MELDW
Statemachine
Infeed ready
Encoder-intf.
Controller
r863 p864
SERVO-
LineModul DO
MoMo
terminal EP on MoMO
only with Safety „STO“
Notes :

Telegramm 136 Telegramm 136

Appl.– Class 4 DSC Applikationsklasse 4 mit DSC
“Dynamic Servo Control" Lageregelung im Servotakt (0,125ms)
PZD1 STW1 ZSW1
PZD2
NSOLL_B NIST_B
PZD3
PZD4 STW2 ZSW2 STW1/2 = control word PB-telegram (NC → DO)
PZD5 MOMRED MELDW R 2090 / R 2094
ZSW1/2 = status word PB-telegram (DO → NC)
PZD6 G1_STW G1_ZSW
R 2053 [0/3]
PZD7 G2_STW MELDW = Message word PB-telegram (DO → NC)
G1_XIST1
PZD8 R 2053 [4]
XERR STWA = internal control word sequence control (DO)
PZD9 R 0898
G1_XIST2
PZD10 ZSWA = internal status word sequence control (DO)
KPC
PZD11 G2_ZSW R 0899
PZD12 M_VST
G2_XIST1
PZD13 DSC_STW
PZD14 res
G2_XIST2
PZD15 T_SYMM
PZD16 AIST_GLATT
PZD17 MSOLL_GLATT
PZD18 PIST_GLTT
PZD19 ITIST_GLATT
OFF 3 and Drive ready (schematic diagram)
1. AUS 3 Drive
NC p 0848
STW1.2 r 2090.2 STW A
2. AUS 3
p 0849
& OFF 3
X 122.2 r 0722.1 r 0898.2
2. AUS 2
p 0845 Drive
1 BICO
2. AUS 3
p 0849 ZSW A
r 0722.1
INF Betrieb = LM Bereit
p 0864
& Drive ready
p 2082.12 NC
r 0722.0 r 0899.7 r 2053[4].12 MELDW.12
AUS 1 DB31...62.DBX 93.5
AUS 2 ≥1 (Drive ready)
AUS 3
Freigabe intern fehlt!
Notes :

OFF1 and enable setpoint (schematic diagram)
DB38xx.DBX0002.1(controller enable)
STW1.0
(OFF1)
DB38xx.DBX4001.7(pulse enable)
&
STW1.7
DB38xx.DBX0001.5 (Acknowledge
(pos. measuring system 1) faults)
DB39xx.DBX5006.5
&
(measuring system 1 active)
≥1
DB38xx.DBX0001.6 STW1.6
(pos. measuring system 2) & (enable setpoint )
DB39xx.DBX5006.6 &
(measuring system 2 active)
DB39xx.DBX4001.5(Drive ready)
DB39xx.DBX 0001.3(follow-up active)
BiCo Assignment Use the “Select” key to give a more detailed view.
Assigning a BiCo to a function requires changing machine

data.
The default setting for OFF3 can be checked as an example.
The OFF3 signal is input on X122.2, the status of this signal The information regarding the source of the OFF3 signal
is displayed via CU r722.2. (X122.2) can be viewed.
In order for the signal to have any effect on the operation of
the drives It has to be referenced to each drive.
This is achieved through p0849 for each drive.
Parameter p849 Source of OFF3 signal:
Example: How the OFF3 signal is assigned to X axis p0849 CU parameter r722.1
Physical connection of the OFF3 signal:

CU X122 pin 2 = r722.1
By default, the OFF3 signal of each servo (p849) is assigned

to CU X122.2/r722.1.
Notes :

Checking the status of X122 and X132 via CU parameter In the following example it can be seen that r722.1 is checked.
r722: This indicates that X122 has +24V DC present on pin 2.
CU parameter r722 can be used to check the status of the Any un-checked bits indicate a 0V potential on the relevant
X122 and X132 interfaces. pins.
X122.2 = +24V DC,

therefore r722.1 = 1
The Hexadecimal value is displayed:
A more user friendly view is available by highlighting the ma-

chine data and pressing the “Select” key.
Assigning the probe inputs
In the following example, probes 1 & 2 will be assigned to

BICO connectors X122.13 and X132.13 respectively.
Probe 1 via X122.13 When the bits are un-
Probe 2 via X132.13 checked (Default setting)
the terminals are set as
Inputs.
Setting the functionality of the terminals This is the required setting
for probing functions.
X122/X132.9, 10, 12 & 13 can be used as either inputs or out-
puts.
This is determined by the setting of CU parameter p728: CU,
set input or output. Deactivating the Centralised Probe.
The 828D works with de-centralised probing.
Before continuing it must be ensured that CU. parameter
p680[0] = 0. (Default setting)
Notes :

Assigning the Probes to the Drives: Assigning probe 2 to X132.13
The system needs to know which terminal the probe input is Probe 2 is not assigned by default.
connected to, this is set with drive parameter p488. Drive parameter p489 needs to be parameterised in order for
probe 2 to function
All the drives that use the probe functions will need to be set.
Select the correct drive and cursor to the parameter p489[0]
There are two parameters, one for each probe, each with 3 then press the “Select” key
indexes (Indices).
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
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.
Saving the Changes:
The changed data needs to be saved to the system CF card

(Non-volatile memory).
The NC reset/power off/on methods do not save the drive
data.
Use the following soft-key sequence to save the drive data:
Repeat the procedure for p489[1] and p489[2]
The status of the save process is displayed directly above

the horizontal soft-keys:
It is also necessary to set p489[0], p489[1] & p489[2] for any

drive that is used with the probing functions e.g. X, Y & Z ax-
es for a standard milling machine
When the process is complete another message will be brief-
ly displayed:
Notes :

Probe Types:
The switching method of the probe has to be matched via Gen-

eral Machine Data 13200[0] (Probe 1) & 13200[1] (Probe 2)
MD13200 = 0 (Default), the probe signal is 0v in the non-

deflected state.
MD13200 = 1, the probe signal is 24v in the non-deflected
state. The status of the probes can also be seen via the PLC inter-
face:
DB2700.DBX1.0 = Probe 1
DB2700.DBX1.1 = Probe 2
Testing the Probe Signals:
The PLC interface signals indicate whether the probe has
The training equipment has two red buttons situated to the left been deflected.
of the MCP. These are connected to X122.13 (Left button) and The behaviour of the signal is influenced by MD13200
X132.13 (Right button) through normally open contacts
Pressing the red buttons will apply +24v to the relevant termi-
nals. The presences of the +24v is shown by a green tick sym- 13200[x] X122.13/X132.13 DB2700.DBX1.x
bol. (Bits 11 & 15). 0 0v 0
0 24v 1
1 0v 1
1 24v 0
The probes can be tested via a command in the part program After pressing the Cycle start button, the axis will move in the
using the following commands: programmed direction. The switch should be depressed be-
fore it reaches the specified position.
MEAS: Measurement with deletion of distance to go.
MEAS=1 Probe 1, detect rising signal.

MEAS=2 Probe 2, detect rising signal.
MEAS=-1 Probe 1, detect falling signal. X axis moving prior to the probe button being pressed.
MEAS=-2 Probe 2, detect falling signal.
Example for using probe 1 via part program:

G01 F300 X200 MEAS=1
Example program for testing probe 1:
Machine data 13200[0] = 0
Notes :

The position of the axis when the probe is triggered is read Assigning the Spindle BERO Connector:
into variables:
The training equipment has a proximity switch connected to
$AA_MM[x] - machine coordinate position. X122.12, this is for the spindle BERO (External zero mark)
$AA_MW[x] - workpiece coordinate position. signal.
To make this active the relevant Drive Machine Data, p495[0]
[x] = Axis name. or [1] 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 (X122.12).
Configuring the automatic line contactor.
The automatic line contactor function is used to ensure correct

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.
The feedback (Input) signal will be assigned to X132 pin 4
(Sinamics digital input 7).
The coil signal (Output) will be assigned to X132 pin 12
The assignment of the Drive Machine Data p495 and the (Sinamics digital Output 14).
BERO switch input is now complete.
Configuring the feedback signal:
The table of X132 shows information about the source and

The integrity of the wiring can be checked with the CU status destination. For the feedback signal, the source is CU param-
parameter r722.12. eter r722.7. The destination of this signal is LM parameter
p860.
Use the following soft-key selection to locate the set-up pages.
Notes :

For identification purposes, the LED of the module can be

made to flash.
The supply voltage can be manually entered or detected au-

tomatically.
The BICO connectors for line contactor operation are pre-

assigned.
X132.12 Output to line contactor coil.
X132.4 Input check back signal from line contactor.
Select the check box for SINAMICS-internal line contactor.
Notes :

A summary of the line supply data is displayed, this can be The data needs to be saved, select the “Yes” soft-key.
saved to a text file if required.
The following dialogue box indicates the state of save pro-

cess, when it has cleared the process is complete.
A summary of the line supply data is displayed, this can be

saved to a text file if required.
The status of the digital outputs can be checked using CU

parameter r747. The example below shows bit 14 (X132.12
Line contactor coil) is high.
Notes :

NCK Inputs and Outputs
X252 NCK Digital I/O - Interface X252 has NCK digital I/O signals.
There are four fixed digital inputs and four fixed outputs (Two outputs if analogue spindle is declared)
The addressing of the Inputs/outputs start at 9.
PLC variable byte DB2900.DBB1000 is assigned to the inputs, and byte DB2900.DBB1004 for the outputs.
This allows the PLC user program to be influenced from the part program.
X252 Signal Function Variable

Pin 1 AOUT Output for analogue axis. +/- 10V
Pin 2 AGND Ground for analogue output.
Pin 3 NCK DI 9 NCK Digital Input $A_IN[9] DB2900.DBX1000.0
Pin 8 P24EXT3 +24V DC (P) +24V DC common
Pin 9 NCK DO 9 NCK Digital Output $A_OUT[9] DB2900.DBX1004.0
Pin 10 NCK DO 10 NCK Digital Output $A_OUT[10] DB2900.DBX1004.1
NCK Digital Output $A_OUT[11] or DB2900.DBX1004.2
Pin 12 NCK DO 11
Analogue spindle enable/direction (If no analogue spindle)
NCK Digital Output $A_OUT[12] or DB2900.DBX1004.3
Pin 13 NCK DO 12
Analogue spindle enable/direction (If no analogue spindle)
Example: Setting an NCK output via a part program.
The NCK outputs can be set directly from a part program.
Select “MDA” mode.
The program will stop at the “M00” command, a message will

be displayed.
Type in the following text (Blue text):

Optional stop active.
$A_OUT[9] = 1 Set NCK output 9 to 1
Optional program stop, program will

M00
halt until Cycle Start is pressed.
$A_OUT[9] = 0 Set NCK output 9 to 0
M30 Program end
Press Cycle Start once.
Notes :

The status of the PLC variable can now be checked. 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-
plays a relevant message.
Type the following into the MDA screen (Blue text):

For the purpose of this exercise it is necessary to link X252 Setting NCK output 9 to 1
pin 3 to pin 9. $A_OUT[9] = 1 will also set NCK input 9
Type in the variables to be checked. If NCK input 9 = 1

IF $A_IN[9] == 1 GOTOF LABEL1 jump forward to LABEL1
When output 9 is set input 9 will also be set because of the
Message line showing that

MSG (“NCK INPUT 9 IS LOW”)
the input is low
Digital NCK output 9 M00 Program stops until

DB2900.DBX1004.1 M00 cycle start is pressed
M30 M30 Program end
LABEL1 used for the

LABEL1: jump command (GOTOF)
Digital NCK input 9 Message line for showing

MSG (“NCK INPUT 9 IS HIGH”)
Mirrors the status of that the input is high.
NCK output 9
M00 M00 Program stops until
cycle start is pressed
M30 M30 Program end
To test the run/test the program select the Cycle Start button. Edit the program so that NCK output 9 is set to 0.
Program message display
The Jump command is ignored and the message,

“NCK INPUT 9 IS LOW” is displayed.
B030: END
Notes :

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

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)
Combi Drive Module
Supply and Enabling Examples
B051
B051

Line and Motor Modules B051
Line and Motor

Modules:
START
Topology
Drive Object
Numbering
General
Information
Drive Module
power
Supply
Smart Line
Module (SLM)
Active Line
Module (ALM)
Motor Module
(MM)
Combi Drive
Module
Supply and En-

abling
Examples
Line and Motor

Modules:
END
Notes :

Topology
General information:
The Control Unit for the drives (CU) is contained within the PPU.
The CU has 3 DriveCLiQ interfaces:

X100: Line Modules (Not 5 & 10 Kw types) & Motor Modules
Motors, Encoders, Sensor Modules (SMCxx, SMExx) & Hubs (DMCxx, DMExx) via Line Modules/Motor Modules.
X101: Sensor Modules, DriveCLiQ Hubs.
X102: Numerical Extension Module. (NX10)
Sinamics drive hardware is classed as Drive Objects and Drive Components:

Drive Objects: CU, NX10, Line modules, Motor Modules.
Drive Components: Motors, Encoders, Sensor Modules, DriveCLiQ Hubs.
During the automatic topology recognition (fast commissioning) procedure, each drive object/component is automatically
assigned a number for identification purposes.
The CU is always Drive Object No1.
Drive Objects connected to the X100 DriveCLiQ bus are the first to be assigned numbers.
The numbers are assigned, sequentially, in the order that they are connected on the DriveCLiQ bus.
Drive components are then numbered, sequentially, in reverse order, continuing on from the last drive object.
Hardware connected to X101/X102 is also issued numbers which follow on from the last object/component connected to inter-
face X100.
Example: 5 Axis System (Spindle, X, Y, Z, A) “fast commissioning”
Objects are numbered in red.

Components are numbered in purple.
PPU Motor Motor Motor

Module Module Module
CU Spindle X Y Z A
Object No. Object No. Object No. Object No. Object No. Object No.
1 2 3 4 5 6
X203 X203
X102 X202 X202 X202
X101 X201 X201 X201
X100 X200 X200 X200
Sp X Y Z A X500
Motor Motor Motor Motor Motor SMC
SMI- 21 SMI- 18 SMI- 15 SMI- 12 SMI- 9 SMC- 7
ENC- 22 ENC- 19 ENC- 16 ENC- 13 ENC- 10 ENC- 8
MOT- 23 MOT- 20 MOT- 17 MOT- 14 MOT- 11 (6)
(2) (3) (4) (5) (6)
Notes :

Topology
NX10 modules can be used to increase the number of drives to beyond the six available with the CU.
Equipment connected to X100 & X101 is assigned to the CU and is numbered in the same manner described previously (Page 5)
The NX10 must always be connected to X102.

Like the CU, the NX10 is always Drive Object number 1. This is possible because they are classed as different drive devices.
Drive objects and components connected to the NX10 are issued numbers in the same way as with the CU.
Example- 7 axis system with NX10
Drive System
Drive Device 1: CU (PPU)

PPU Line Motor Motor Motor
Module Module Module Module
CU SLM/ALM Spindle X Y Z A
Object No. Object No. Object No. Object No. Object No. Object No. Object No.
1 2 3 4 5 6 7
DMC 23
X203 X203
X505
X102 X202 X202 X202 X202
X504
X101 X201 X201 X201 X201
X503
X100 X200 X200 X200 X200
X502
Spindle X Y Z A X500 X500
Motor Motor Motor Motor Motor X501 SMC SMC
SMI- 20 SMI- 17 SMI- 14 SMI- 11 SMI- 8 SMC- 24 SMC- 26
ENC- 21 ENC- 18 ENC- 15 ENC- 12 ENC- 9 ENC- 25 ENC- 27
X500
MOT- 22 MOT- 19 MOT- 16 MOT- 13 MOT- 10
(3) (4) (5) (6) (7)
Drive Device 2: NX10.3

NX Motor Module
NX10.3 B C
Object No. Object No. Object No.

1 2 3
X203
X102 X202
B C X500
X101 X201 Motor Motor SMC
SMI- 7 SMI- 4 SMI- 10
ENC- 8 ENC- 5 ENC- 11
X100 X200 MOT– 9 MOT– 6
(2) (3)
Notes :

Topology
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.
Example – 5 axis system with Combi Drive:
Drive Device 1: CU (PPU)
4 Axis Combi Drive Booksize Compact

Motor Module
CU (PPU) Smart Spindle Sensor X Y Z 4th Axis

Line Motor Module Motor Motor Motor Motor
Module Module Internal Module Module Module Module
(SMI)
Comp. No.
Comp. No. Comp. No. Comp. No. Comp. No. Comp. No. 50
10 14 20 30 40
Object No.
Object No. Object No. Object No. Object No. Object No. Object No. 7
1 2 3 4 5 6
X202
X102
X201
X101 X200
X100 X200 X201 X220 X202 X203 X204
Spindle Spindle X Y Z M5
Motor DMS Motor Motor Motor SMI- 51
SMI- 11 SMI- 15 SMI- 21 SMI- 31 SMI- 41 ENC- 52
ENC- 12 ENC– 16 ENC- 22 ENC- 32 ENC- 42 MOT– 53
MOT– 13 (3) MOT– 23 MOT– 33 MOT– 43 (7)
(3) (4) (5) (6)
Notes :

General Information
Line and Motor Modules
Line and motor modules are responsible for supplying power

to the motors.
The Sinumerik 828D operates with the Sinamics S120
Booksize range of drive products. These are of a modular
design and are for use with the Drive-CLiQ drive bus system.
Line modules require a 3 phase AC supply, this is rectified

into a DC supply which is then supplied to the motor modules
via the DC link bus bars.
Motor modules convert the DC link back into a controllable AC

supply which is used to drive the servo motors.
By regulating the frequency and voltage of the AC supply to
the servo motors it is possible to precisely control the move-
ment of motors.
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-

plied by the user to the line module and then distributed to the
motor modules via a bus system.
Line-Modul Motor-Modul
(LM) (MM)
Example, Line module with two motor modules:-
Drive Module power Supply X24– Electronic Supply 24V DC
Power Requirements
The drive modules require two power supplies in order to op- “M” Terminal: Electronics ground
erate.
“+” Terminal: +24V DC
A 3 phase AC supply (380V to 480V +10% (-15% < 1 min) to (20.4V to 28.8V)
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
bar system on the front of the drive modules beneath a flip Location of the electronics supply and DC link bus bars:-
down cover
24V DC Electronics supply (X24) Bridging device for
The +24V DC electronics supply is obtained externally from continuity of the
the user on connector X24. This is also distributed by a bus bus between drive
bar system along the front of the drive modules. modules.
The electronic supply is used internally by the drive modules
for powering of the electronic circuitry etc. Externally it is used
for supplying the Drive-CLiQ encoders and fault, ready and
enable signals.
+24V DC Bus-bar
0V DC Bus-bar
+ DC Link Bus-bar
- DC Link Bus-bar
LM MM1 MM2
Notes :

Smart Line Modules (SLM) X22:

X21:
Various signals Various signals
The SLM is responsible for rectifying the AC mains supply into
the DC link voltage which is then utilised by the Motor Mod-
ules. X24:Electronics
supply
This DC link voltage is non-stabilised on all SLM types. Electronics/DC link
The SLM is also responsible for handling the regenerative cur- bus bars (below flip
rent caused by the braking of motors. The regenerative current down cover)
is fed back into the mains network. This eliminates the need for
braking resistors and complex measures for heat dissipation.
The SLM is available in 5, 10, 16 & 36Kw variants with internal
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- LED status
eration/deceleration rates are not severe. Indicators
Smart Line Modules- 5 & 10Kw
The 5 & 10Kw SLM’s are not used on the Drive-CLiQ network,
because of this there are slight differences with terminal func-
tionality compared to Drive-CLiQ type modules.
Example:-An internally cooled 10Kw SLM module showing

terminal locations etc.
X1: Mains supply
Protective earth (3-Phase AC)
connections
X22 Terminal description and functionality

Connector locations X21, X22 & X24
Terminal Function Description

+24V DC +24 V DC Supply for use with the func-
1 (Output) tions of X22.2 & 3 described below.
X21: X22: (SLM 5 & 10Kw
Enable, ready only) Disable Applying +24V DC will cause the regen-
and fault Regeneration and fault Regeneration eration function to be disabled.
signals reset signals (Input)
In some cases it may be necessary to
stop the regeneration of current caused
by braking motors. Example:- A poor
2
quality mains Network not able to han-
dle regeneration.
Note:-The fitting of resistor modules to
dissipate
excess energy will be required when
this function is used.
X24: Fault Reset Applying +24V DC will cause the reset-
24V DC (Input) ting of any drive faults.
Electronics
supply 3 A fault occurring on the drives system
will be latched, this can be reset with
this function providing the cause of the
original fault is no longer present.
0V DC Must be connected to the same 0V of
SLM 4 (Ground) the electronics supply (X24).
Notes :

1 Ready Signal Switches high (+24V DC) when the following conditions are true:
(Output)
 Electronics supply present (X24).
 DC Link is pre-charged.
 Pulses enabled (X21.3)
 No over-temperature
 No over-current
It is recommended that the signal is connected directly to the 828D controller via connector X122 pin 1. This is
the OFF1 enable signal.
2 Pre-warning Switches low when any of the following conditions arise:

(Output)
 Over-temperature threshold reached.
 I²t threshold reached.
 Mains fault making regenerative feedback impossible. If feedback is intentionally deactivated (X22.2 is
high) this warning is disabled.
This signal is for use by the manufacturer to set a user alarm and alert the operator to a problem.
3 Enable Puls- Applying +24V DC will cause the pulses to be enabled. (Current consumption:10mA)
es This signal must be removed at least 10ms prior to the 3-phase mains supply being removed.
(Input) Failure to do this can lead to damaged drive modules. This is especially important when the axes/spindles are
decelerating and causing regenerative currents. if the mains circuit is opened these 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).
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 suitable for an emergency stop situation.
4 Enable Puls- Must be connected to the 0V of the enable pulses supply.

es
(Ground)
LED Status Display (Non DriveCLiQ line module)
LED Colour Status Explanation Remedy
Green On Module is healthy and operational.
READY Orange On Pre charging of DC link active; Bypass

(Top) relay dropped out.
Red On Over temperature/current fault or elec- Diagnose fault (Output X21.2)

tronics power supply outside permitted Acknowledge fault (Input X22.3)
range.
Off Electronics power supply outside per-

mitted range.
DC LINK
(Bottom) Orange On DC link voltage within tolerance.
Red On DC link voltage outside tolerance. Check the mains supply
Notes :

X200/X201/
Smart Line Modules- 16Kw and above X21:Pulse X202:
enable Drive-CLiQ
These models are always required to be connected to the connectors
Drive-CLiQ drive bus network.
X24:Electronics
The functionality of certain terminals is therefore different from supply
the non-Drive-CLiQ SLM modules.
Electronics/DC
Regeneration can be deactivated by parameter P3533-Inhibit
link bus bars
regenerative operation. (below flip
down cover)
Terminal locations of an internally cooled 36Kw SLM:-
LED status
Indicators
X1: Mains supply

(3-Phase AC)
Protective
earth
terminals
Connector locations X21, X24, X200, X201 & X202 X21 Terminal description and functionality
1 Not used Not used
2 Not used Not used

X21:
Pulse enable 3 Enable Applying +24V DC enables the pulses.
Pulses (Current consumption:10mA)
(Input)
This signal must be removed at least 10ms prior
X202: to the 3-phase mains supply being removed.
Drive-CLiQ connector Failure to do this can lead to damaged drive mod-
ules. This is especially important when the axes/
spindles are regenerating. If the mains circuit is
opened in this state, regenerative currents remain
X201: within the drive system causing damage to the
Drive-CLiQ connector modules.
It is recommended that this terminal is connected
via an early break contact on the machine isolator
X200: switch and the line contactor (If used).
Drive-CLiQ connector 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
X24: switched off and mains regeneration halted, the
24V DC Electronics motors will then coast to a halt. This is not suita-
Supply ble for an emergency stop
situation.
4 Enable Must be connected to the 0V of the enable pulses

Pulses supply.
(Ground)
Notes :

LED Status Display

Off Electronics power supply outside permitted Check 24V DC supply to X24.
range.
Green On Module configured and ready, DriveCLiQ com-
munication is active.
Orange On DriveCLiQ communication is being estab- Check alarms on controller.
READY lished/module not configured.
(Top)
Red On At least one fault is present. Check alarms on controller.
Red Flashing Firmware download procedure is running.
@ 0.5Hz
Red Flashing Firmware download procedure is complete. Power off/on.

@ 4Hz
Green/ Flashing Component recognition is active (p0124 = 1)

Orange @ 2 Hz
or Red/
Orange
Off Electronics power supply outside permitted Check 24V DC supply to X24.
range.
DC LINK
Orange On DC link voltage within tolerance-Only if unit is
(Bottom)
configured and ready.
Red On DC link voltage outside tolerance-Only if unit is Check 3-phase supply.
configured and ready.
Active Line Modules (ALM) Terminal locations of ALM modules:-
The ALM is responsible for the rectification of the AC mains

supply into the DC link voltage which is then utilised by the
Motor Modules.
This DC link voltage is also stabilised unlike the SLM mod- X21: X200/X201/
Pulse enable, X202:
ules.
temperature Drive-CLiQ
The ALM is also responsible for handling regenerative current connectors
sensor
caused by the braking of motors.
The regenerative current is fed back into the mains network.
This eliminates the need for braking resistors and complex X24:Electroni Electronics/DC
measures for heat dissipation. cs supply. link bus bars
Regeneration can be deactivated by parameter P3533-Inhibit (below flip
regenerative operation. down cover)
The modules are available in 16, 36, 55, 80 & 120Kw variants LED status
with internal or external cooling capability. Indicators
The ALM is always connected to the DriveCLiQ bus and has
four DriveCLiQ connections.
The stabilised DC link makes the ALM suitable for high dy-
namic machinery where the acceleration and positioning of
axes/spindles is critical.
X1:
3-Phase AC
Protective Mains supply
earth
connections.
Notes :


Location of ALM connectors X21, X24, X200, X201 & X202
X21:
Enable and Terminal Function Description
Temperature sensor 1 + Temp Temperature sensor input from Active Interface
Connections (Input) Module (Observe the polarity)
2 - Temp Temperature sensor input from Active Interface
(Input) Module (Observe the polarity)
X203:
Drive-CLiQ connect- 3 Enable Applying +24V DC enables the pulses.
or Pulses (Current consumption:10mA)
(Input) This signal must be removed at least 10ms prior to
the 3-phase mains supply being removed.
X202: Failure to do this can lead to damaged drive mod-
Drive-CLiQ connect- ules. This is especially important when the axes/
or spindles are regenerating. If the mains circuit is
opened in this state, regenerative currents remain
X201: within the drive system causing damage to the mod-
Drive-CLiQ connect- ules.
or It is recommended that this terminal is connected via
an early break contact on the machine isolator
X200: switch and the line contactor (If used).
Drive-CLiQ connect- If the terminal is used by the manufacturer it must be
or ensured that it is controlled in the suggested man-
ner.
X24: When used in this way the transistors will be
24V DC Electronics switched off and mains regeneration halted; the
supply 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)
LED Status Display

Off Electronics power supply outside permitted Check 24V supply to X24.
range.
Green On Module configured and ready, DriveCLiQ
communication is active.
Orange On DriveCLiQ communication is being estab- Check alarms on controller.
READY
lished/module not configured.
(Top)
2Hz
Red Flashing Firmware download procedure is complete Power off/on.
8Hz
Orange 2 Hz
or Red/
Orange
Off Electronics power supply outside permitted Check 24V supply to X24.
range.
DC
LINK Orange On DC link voltage within tolerance-Only if unit is
(Botto configured and ready.
m)
Red On DC link voltage outside tolerance-Only if unit Check the mains input.
is configured and ready.
Notes :

Motor Modules (MM)
X200/X201/X202:
X21: DriveCLiQ
Motor Modules are responsible for converting the DC link Enables etc.
voltage into a variable AC voltage in order to drive the mo- Connectors
tors.
The modules have to be connected to the DriveCLiQ bus.
Single/double axis and internally/externally cooled versions
are available. Electronics/DC
Double axis modules are equipped with four DriveCLiQ con- link bus bars
nectors, one more than the single axis modules. (below flip down
cover)
Single Axis MM
Available in the following rated current output sizes:- LED Status
3, 5, 9, 18, 30, 45, 60, 85, 132 & 200A. Indicators
X11: Brake output
for MM of 45A and
Example:- A single axis MM showing connector locations etc. above
X1: Output to
Protective Motor, including
earth the brake output
terminals for MM less than
Double Axis MM X21: Motor 1 X22: Motor 2

Available in the following rated current output sizes:-3, 5, 9 & Enables etc. Enables etc.
18A
X200/X201/X202/ Electronics/DC
Example:-A double axis MM showing connector locations. link bus bars
These units will have two identical Motor/Brake connectors X203:
DriveCLiQ (below flip down
(X1 & X2) and two connectors cover)
identical enable connectors (X21 & X22).
LED Status
Indicators X1 & X2 Output
to Motor,
including the
brake output for
MM less than
45A
Protective
earth X11: Brake out-
put for MM of
connections
45A and above
Notes :

Connector X21 & X22 (X22 only for double axis mod-
Terminal descriptions ules).
X21: Pulse
Enable etc.
X21: Pulse 1 + Temp Positive temperature sensor input from non-
X22: Pulse (Input) DriveCLiQ temperature sensor.
Enable etc.
Enable etc.
Type:- KTY84-1C130/PTC
2 - Temp Negative temperature sensor input from non
X203: (Input) DriveCLiQ temperature sensor.
X202: DriveCLiQ Type:- KTY84-1C130/PTC
DriveCLiQ
3 Enable Applying +24V DC will cause the pulses of the
X202: Pulses individual axis to be enabled. (Current consump-
X201: DriveCLiQ (Input) tion:10mA)
DriveCLiQ When the signal is low, “Safe pulse suppression” is
X201: activated.
DriveCLiQ Note:-No electrical isolation occurs between the
X200: Motor module and the motor.
DriveCLiQ This enable signal is only operational if the Safety
X200: Integrated function “Safe Standstill (SH)” is ena-
DriveCLiQ bled.
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
Single axis Double axis do not match.
Module Module 4 Enable Must be connected to the 0V of the enable pulses
Pulses supply.
(Ground)
LED Status Display
Off Electronics power supply outside permitted Check 24V DC on X24.

range.
Orange On DriveCLiQ communication is being Check alarms on controller.
READY
established/module not configured.
(Top)
@ 0.5 Hz
Red Flashing Firmware download procedure is complete. Power drives OFF/ON.
@ 5 Hz
Orange or @ 2 Hz
Red/
Orange
Off Electronics power supply outside permitted Check 24V DC on X24.

range.
DC LINK
(Bottom) Orange On DC link voltage within tolerance-Only if unit
Red On DC link voltage outside tolerance-Only if unit Check mains input.
Notes :

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:

Connection Positive Con-
nection
Locating key Locating key
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 :

the new Motor Modules in the booksize format Single Motor Module Double Motor Module
These have been innovated in the range from 3 to 30 A, are

compatible regarding spare/replacement parts to existing
booksize products.
The Software does not have to be adapted for replacement
types.
There are the modules in two versions
C- Types: Continuous Motion 6SL3120-xxxxx-xxCx

200% overload, optimized for continuous load cycles
Typical for main spindle drives and continuous load cycles
Available in the following current:

SMM 18A, 30A
DMM 18A
D- Types: Discontinuous Motion 6SL3120-xxxxx-xxDx

300% overload, optimized for high-speed, intermittent load
cycles
Available in the following current:

SMM 3A, 5A, 9A, 18A, 30A
DMM 3A, 5A, 9A, 18A
Replacement types for the previous booksize Motor Modules
Order number Booksize today Booksize D-types Booksize C-types width
SMM 3A 6SL3120-1TE13-0AA4 6SL3120-1TE13-0AD0 50 mm

SMM18A 6SL3120-1TE21-8AA4 6SL3120-1TE21-8AD0 6SL3120-1TE21-8AC0 50 mm
DMM 3A 6SL3120-2TE13-0AA4 6SL3120-2TE13-0AD0 50 mm
DMM 18A 6SL3120-2TE21-8AA4 6SL3120-2TE21-8AD0 6SL3120-2TE21-8AC0 100 mm
SMM 30A 6SL3120-1TE23-0AA4 6SL3120-1TE23-0AD0 6SL3120-1TE23-0AC0 100 mm
Notes :

Integrated shield concept
Motor plug connectors

for Double Motor Modules
located next to one another
Shielding
integrated in the Motor Mod-
ule Shield connecting
terminal can be removed
You no longer require a hose Allows cable sheath diameters

clip when fabricating cables from 7mm to 19mm (up to 23mm
yourself Single Motor Modules)
Plug connectorwith latching

mechanism
PE is integrated
Fan can be replaced in the installed state
Fast, simple wiring
Can be removed
towards the front
Motor plug connectors that customers can fabricate/assemble
themselves from 1.5mm² (AWG16) to 6mm²
Prefabricated MOTION-CONNET power-cables to 10mm²
(AWG 8)
Push-in plug connector Plug connector screw Fan model Fan with
connection monitoring.-
supported from SINAMICS
firmware V4.8
6SL3162-2MB00-0AC0 6SL3162-2MB00-0AC0
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 al-
lowed by the system.
X21: Motor X12/X13: Fan Supply X224: +24V DC

Enables etc. and monitoring auxiliary 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 X21 Terminal description and functionality
Top view of Combi Drive Unit:
X21/X22 X12/X13 Terminal Function Description

Enables and tem- Fan supply and monitoring 1 Not used Not used
perature sensor. X224 +24V DC
auxiliary supply 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 re-
moved.
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 caus-
ing damage to the modules.
It is recommended that this terminal is connect-
ed 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
suitable for an emergency stop situation.
4 Enable Must be connected to the 0V of the enable
Pulses pulses supply.
(Ground)
X22 Terminal description and functionality X12/X13 Terminal description and functionality

Terminal Function Description Ground Ground connection for fan monitoring
1 + Temp Positive temperature sensor input from non- 1
circuit.
(Input) DriveCLiQ temperature sensor.
Type:- KTY84-1C130/PTC Fan Fan monitoring signal, input from fan.
2 - Temp Negative temperature sensor input from non 2 Monitoring.
(Input) DriveCLiQ temperature sensor. (Input)
Type:- KTY84-1C130/PTC +24 V DC +24V DC supply to fan.
3 Safety Applying +24V DC will cause the pulses of the 3
(Output) Maximum 2 A. (1 x 2 A or 2 x 1A)
Integrated. individual axis to be enabled. (Current consump-
Enable tion:10mA) 4 Ground Ground for fan supply.
Pulses When the signal is low, “Safe pulse suppres-
EP +24 V sion” is activated.
(Input) Note:-No electrical isolation occurs between the External Fan module
Motor module and the motor.
This enable signal is only operational if the Safe-
ty 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.
4 Safety Must be connected to the 0V of the enable puls-
Integrated. es supply. Non Siemens fans may be used without the monitoring. In
Enable this case terminals 1& 2 must be linked.
Pulses
EP M1
(Ground)
Notes :

X224 Terminal Description and functionality

X200 to X205 Terminal description and functionality
DriveCLiQ Interfaces:
X205 - DMS via SMCxx (If X220 not suitable)
X204 - Z axis motor feedback.

+ M
X203 - Y axis motor feedback.

Termi- Function Description
nal
+24 V +24V DC auxiliary supply to Combi drive module
X202 - X axis motor feedback.
+ DC
(Input)
X201 - Spindle axis motor feedback.
M Ground Ground for fan supply +24V DC auxiliary supply
X200 - DriveCLiQ drive bus (From X100 828D

Controller).
X220 Terminal description and functionality Interfaces X1 to X5

(5V TTL encoders)
X1 Mains Input-Terminal Description and Functionality:
Pin Signal Technical Information Terminal Function Description

Motor temperature sensor positive connection
1 + Temp U1 U Phase Line Phase U
(KTY 84-1C130)
2 Clock Clock Signal
V1 V Phase Line Phase V
3 Clock* Inverse Clock Signal
4 P-Encoder 5V W1 W Phase Line Phase W
+5V Encoder Power Supply
5 P-Encoder 5V
PE Earth Protective Earth
6 P-Sense +5V Sense Signal
M-Encoder
7 Encoder Power Supply 0V
(M) X2 to X5 Motor Supply-Terminal Description and
Motor temperature sensor negative connection Functionality:
8 - Temp
(KTY 84-1C130)
9 M-Sense 0V Sense Signal Terminal Function Description
10 R Reference Signal R
U2 U Phase Motor Phase U
11 R* Inverse Reference Signal R*
12 B* Inverse Incremental Signal B* V2 V Phase Motor Phase V
13 B Incremental Signal B
W2 W Phase Motor Phase W
14 A* Inverse Incremental Signal A*
15 A Incremental Signal A PE Earth Protective Earth
Notes :

Combi Drive LED Status:
Off Electronics power supply outside permitted Check +24V supply (X24).
range.
Orange On DriveCLiQ communication is being Check alarms on controller.
READY
established/module not configured.
(Top)
@ 0.5 Hz
Red Flashing Firmware download procedure is complete. Power drives OFF/ON.
@ 5 Hz
Orange or @ 2 Hz
Red/
Orange
Off Electronics power supply outside permitted Check +24V supply (X24).
range.
DC LINK
(Bottom) Orange On DC link voltage within tolerance-Only if unit
Red On DC link voltage outside tolerance-Only if unit Check mains input. (X1)
Supply and Enabling Examples

Minimum 10ms-
if supply disconnected
For trouble free operation it is essential that the drives are while drive is operational
powered on/off and enabled correctly.
If the mains supply switch/contactor is opened while the drive
pulses are enabled and the drive is in regeneration mode, the Mains supply
regenerative current which is normally fed back into the E Stop active
mains will have no where to go, except that is into the motor DB2700.DBX0.1
and line modules, this can result in damage to these mod- Input to ALM/SLM via line switch
ules. Enable Pulses
ALM/SLM
The solution is to use an auxiliary contact fitted to the mains X21.3
switch and drive line contactor.
Output/Input from/to 828D
This auxiliary contact must open at least 10ms before the In-feed ready.
From/to 828D
main contacts open. Link X132.10 to
The contact is wired to the Pulse Enable terminal of the SLM/ X122.1(OFF1)
ALM module. Output from 828D
Energize line
If the Main switch or contactor is operated while the drive is in contactor–
operation the pulses will be disabled and the motors will free 828D X132.12
wheel to a standstill. (Except when the Safety Integrated output
function “Safe Stop” is enabled) Line contactor
Input from N/O contact
Any potentially harmful current will be unable to enter the energised-
drive modules as the transistors are now switched off. 828D X132.4
Input
Input to ALM/SLM
OFF3 Enable
from user to
Below is the recommended timing diagram for the enabling of 828D X122.2
drives via the controller using a line Contactor.
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 DriveCLiQ
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
enabled
from 828D
X100 X132.10 to
828D
Early break X122.1
DriveCLiQ
contact X21 X132 (OFF1)
Main
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 :

B051 END Line and Motor Modules

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

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
personnel and help speed up the fault finding process.
Module Objective:
Upon completion of this 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:
START
Service
Overview
Screen
Axis
Diagnostics
Drive
Diagnostics
Axis and Drive

Diagnostics:
END
Notes :

Service Overview Screen The indicators change appearance depending on the condition
of the signal.
To navigate to the relevant diagnostics page please use the
following key presses. 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

The screen shows the status of various enable/monitoring only).
signals via indicators.
The signal is inactive/not in use.
Example: The diagnostics page showing a motor over tem-

perature problem on Axis 1. In this case the encoder cable
was not connected to the drive.
You can select the dislayed above the choice list.
Axis or drives to displayed about softkey or with the hook

select!
Or you can configure about the sotkey “extended selection“

new displayed.
Give the name for the displayed

and for the file
Notes :

Axis Diagnostics The selected axis is displayed at the top of the diagnostics
screen.
Axis specific information.
Each axis is displayed individually, changing to another axis

This detailed information can be very useful when a problem is done with the “Axis +” and “Axis -” soft keys.
occurs on the machine.
or
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.
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 :

Drive Diagnostics The drive diagnostics screen shows useful information regard-
ing the motor and drive states such as motor temperature, DC
Drive specific information link voltage etc.
For more detailed information regarding each individual drive,

select the “Service drive” soft key.
More diagnostics information is revealed by
using the page/cursor keys
Drive System.
Further drive diagnostic information, specifically Sinamics re-

lated, can be found by selecting the “Drive system” soft key.
The status of the Drive-CLiQ drive objects can be seen. The CU is the only drive object displayed, to view the other
drive objects press the “Input” key.
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.
Notes :

The following screen shows a healthy system, indicated by the Drives not ready or in a fault condition will display yellow or
green tick symbols. red symbols.
To see more information about the cause, cursor to the failed

axis and select the “Details” soft-key. Use the “Drive object +”
& “Drive object -” soft-keys to check the status of other axes.
or
Example: The “Status indicator” information indicates that axis

is in commissioning mode.
The lower half of the screen offers further information.
The screen will display information regarding the cause of

the problem.
A more serious situation is indicated by the appearance of

red/white cross symbol.
Example– MX1 (Servo 1) axis showing a fault with encoder 1
(SMI20).
Two further soft-keys are also available for displaying further
information.
Notes :

Selecting the “Warning” soft-key displays more infor- Selecting the “Faults” soft-key also displays more
mation which indicates a problem with encoder 1. information which indicates a problem with encoder
1, drive component 11.
It can be stored up to 8 faults. The fault cases can be exten-

ded with the key "INPUT" or be reduced!
The “Help” key, found to the lower right of the vertical soft- The alarms and warnings can also be seen on the alarm
keys can be used to get more information about Warnings/ screen.
Faults.
The alarms displayed can be filtered via machine data 13150

“SINAMICS_ALARM_MASK”.
Notes :

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 0909H this sets
bits 0, 3, 8 & 9. For service and commissioning work it maybe
necessary to view more alarms. Setting the machine data to
FFFFH will result in all alarms being displayed.
The default value should always be re-entered when the ser-
vice/commissioning work is complete.
Topology
The Component NCU_01 is connected via X100 to the
Component MM_SP1 socket X200.
The topology of the drive system can be
seen when the “Topology” soft-key is
selected.
Topology shows the Drive-CLiQ inter-

connections of the drive objects and
components.
When a drive object has a fault, the text

will be displayed in red or grey.
Notes :

Display options Automatic Firmware Update:

When replacement drive hardware is fitted it is important that
The topology display can be changed via the “Display op- the firmware version is correct. In normal circumstances the
tions” soft-key: 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.
Firmware:
Firmware is a software that is written to the internal flash
memory of the Drive-CLiQ components. Firmware updates
are used to keep the components up to date with the latest
technological advances. The firmware version is dependant
upon the current system software version.
Graphic Toplogydisplay
Set/act comparison NCU
The topology is displayed by the

NCU. To the display of the sin-
gle CU's!
or
Topology error
Notes :

To the alarms diagnosis the fields with Actual topology NCU

the cursor keys can be marked.
Target topology NCU
The topology of the complete drive

system is displayed!
Notes :

Configuration
The configuration shows the allocati-

on of the axes and the drive object/
component
Some of the information on the

screen can only be viewed by using
the cursor left/right keys.
Display Settings The “Sort” soft-key is used to view the components in a partic-
ular order according to Drive Object, Wiring, Component num-
The level of displayed information about the components can ber or Axis number:
be controlled with the “Display options” function.
Notes :

Electronic Rating Plates Example: Details of component Mot_SP1 SMI-Motor:

Useful information is displayed when the “Details” soft-key is
selected.
These are known as the ”Electronic Rating Plates”.
Example: Details of component MM_SP1 single motor module
Comparison Levels To the right of the screen, a column named “C.level” can be
seen.
This is used to set the comparison level for the Drive-CLiQ
components.
The system compares the stored details of the electronic rat-
ing plate of each object with the actual components connect-
ed to the Drive-CLiQ bus.
Once the drive system is configured it is continually moni-
Comparison Levels: tored. Alarms will be displayed if a fault occurs or an unknown
High-compares the complete electronic rating plate. object is detected.
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 system

to replace a faulty one it is not necessary to change the com-
parison level. The system should automatically load the cor-
rect 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.
Notes :

B053 END Axis and Drive Diagnostics
To change the level of comparison select the “Change”

soft-key and then the “OK” key.
B053: END
Notes :

B008 MCP & PP72/48 PN 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 and the physical inputs and
outputs of the machine.
Machine control panels (MCPs) :

MCPs handle signals such as axis selection, jog commands, cycle start etc.
There are two possibilities for connecting an MCP to the 828D controller; one is via USB, the second
is via Profinet.
It is possible to have a maximum of two MCPs per controller - one must be via USB & one must be
via Profinet.
There are two sizes of MCP supplied by Siemens:
MCP483 is 483mm in length and is recommended for use with the horizontal variant of 828D.
MCP310 is 310mm in length and is recommended for use with the vertical variant of the 828D.
A 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
Siemens machine control panels (MCPs) and PP72/48 periphery I/O modules.
Content:
Sinumerik
USB MCP: Description and Interface Signals
Profinet MCP: Description and Interface Signals
Profinet PP72/48: Description and Interface Signals
Profinet Configuration: MCP & PP72/48
Configuration of two MCPs
Siemens assumes no responsibility for its contents. B008
B008

MCP & PP72/48 PN Connections and Diagnostics B008
Profinet
Connections and
Diagnostics:
START
USB MCP:
Description and
Interface
Signals
Profinet MCP:
Description and
Interface
Signals
Profinet
PP72/48:
Description and
Interface
Signals
Profinet
Configuration:
MCP &
PP72/48
Configuration
of two MCPs
Profinet
Connections and
Diagnostics:
END
Notes :

B008 MCP & PP72/48 PN Connections and Diagnostics
USB MCP: Description and Interface Signals
USB type MCPs are suited to basic machine types.

They are available in two formats:
MCP483 USB - 483mm wide.
MCP310 USB - 310mm wide.
The MCPs have pre-determined buttons and switches (Cycle start, Jog selection, feed override etc.) for standard machine con-
trol as well as freely assignable custom keys and a twin 7-segment display.
A single USB interface is found on the rear side for connecting to the 828D.
Two 16mm diameter blanked holes are available on the MCP483 USB and four on the MCP310 USB.
Setup is achieved by a single machine data. No addressing is required.
MCP483 USB
MCP483 USB: Front Layout with Custom Key Identification (S10 - 24 & S31 - 39)
JOG REFP 88 S10 S11 S12 S31 S32 S33
Emergency Teach MCS Spindle Feed

Stop MDA
in WCS S13 S14 S15 S34 S35 S36 override override
RE-
AUTO
POS
VAR S16 S17 S18 S37 S38 S39
Single Cycle Cycle Spindle Spindle Feed Feed

RESET
block Stop Start S19 S20 S21 S22 S23 S24 stop start stop start
Notes :

MCP310 USB
MCP310 USB: Front Layout with Custom Key Identification (S10 - 18, S21 - 24 & S31 - 39)
S10 S11 S12 S31 S32 S33
Emergency
Stop S13 S14 S15 S34 S35 S36
S16 S17 S18 S37 S38 S39
JOG REFP S21 S22 S23 S24

Feed
override
Teach MCS
MDA
in WCS 88
Spindle Spindle
AUTO REPOS VAR Coolant
stop start
Cycle Cycle Single Feed Feed

RESET
Spindle Stop Start block stop start
override
Notes :

Input images (DB1000 & DB1001) for MCP483/MCP310 (USB & Profinet)
1st MCP = DB1000

2nd MCP =DB1001
Note: Further information regarding the use of a Profinet MCP via DB1000 & DB1001 interface is described in the last section of
this module.
DB1001/
User Data 1 [r/w]
DB1001
Spindle override JOG TEACH IN MDA AUTO

0000
D C B A
Machine function
0001
REPOS REF Var. INC
Spindle *Spindle Feed start *Feed stop 1) NC start *NC stop 1)
0002 start stop 1)
Reset Single block Feed override

0003
E D C B A
0004 S24 S22 S23 - S31 S34 S37 -
S32 S33 S35 Drive com- - S39 S38 S36

0005 mand in
MCS/WCS
Freely assignable customer keys Reserved
0006
S18 S40 (res.) 3) S7 2) S21 - - - -
Freely assignable customer keys
0007
S10 S11 S12 S13 S14 S15 S16 S17
1000 Version information of the MCP USB - byte 0
1) Signals marked with * are inverse signals.

2) MCP310 USB: Preassigned as Coolant. MCP483 USB: Freely assignable customer key.
3) Not available for MCP310 USB, for MCP483 USB freely assignable customer key.
Notes :

Ouput images (DB1100 & DB1101) for MCP483/MCP310 (USB & Profinet)
1st MCP = DB1100

2nd MCP =DB1101
Note: Further information regarding the use of a Profinet MCP via the DB1100 & DB1101 interfaces is described in the last sec-
tion of this module.
DB1100/
User Data 2 [r/w]
DB1101
Operating mode
0000
JOG Teach IN MDA AUTO
Feed start Feed stop NC start NC stop Machine function -

0001
REPOS REF Var. INC
S22 S31 S34 S37 - Single block Spindle Spindle
0002 start stop
S33 S35 Drive com- - S39 S38 S36 S24

0003 mand in
MCS/WCS
0004
S18 *S40 3) *S7 2) S21 - - - S32
0005
S10 S11 S12 S13 S14 S15 S16 S17
0006 - - - - - - - -
0007 - - - - - - - -
0008 7-segment display LED 1
0010 - - - - - - - -
0011 - - - - - - - -
DP
0012
- - - - - - DP2 DP1
0013
0014 User data
0015 User data
2) MCP310 USB: Preassigned as Coolant. MCP483 USB: Freely assignable customer key.
3) Not available for MCP310 USB, for MCP483 USB freely assignable customer key.
Notes :

7-Segment display.
The 7 segment display is controlled via DB1100.DBB8 (Left display) & DBB9 (Right display)
The following table shows the available 7-segment characters and the interface bits required to activate them.
Notes :

MCP USB Initialisation:
On machines where a single MCP of the USB type is to be

used, set the General Machine Data:
12950[0] = 1 Activates MCP1 for USB.
12950[1] = -1 Deactivates MCP2 for USB/Profinet.
The MCP USB LEDs will no longer flash following the NCK
reset.
Note: To configure a machine with two MCPs please refer

to the last section of this module.
Profinet MCP: Description and Interface Signals:
Profinet MCPs have extra functionality for advanced applications.

They are available in two formats:
MCP483 PN - 483mm wide.
MCP310 PN - 310mm wide.
The MCPs have pre-determined buttons and switches (Cycle start, Jog selection, feed override etc.) for standard machine con-
trol as well as freely assignable custom keys.
Various interfaces are found on the rear side.
Two 16mm diameter blanked holes are available on the MCP483 USB and six on the MCP310 USB.
Setup is achieved by machine data and dip switches.
MCP483 PN
S1
Notes :

MCP483 PN: Front Layout with Custom Key Identification (T1 - T16)
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.
MCP483 PN: Rear Layout
X10
X53
X54 X60 X61
X31 X51
X52
X55
X20
H3
X30 H2
H1 X21
X5
S2
X51 Digital inputs X60 Hand-wheel

Interface Description: X52 Digital inputs X61 Not used on 828D
S2 Addressing switch X53 Digital outputs
X5 Key-switch interface X54 Digital outputs
X10 24V DC supply X55 Digital inputs
X20 Port 1 Profinet connection in
X21 Port 2 Profinet connection out LED Indicators:
X30 Feedrate override interface H1 Power OK (Green)
X31 Spindle override interface H2 BUSSYNC
H3 BUSFAULT
Notes :

Machine Control Panel Interface Signals.
The following tables show the interface signals for an MCP483 PN with the recommended start address of 112.
MCP483 PN Input signals from machine control panel (keys)

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 Output 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 Rapid
QB119 KT6 KT5 KT4 KT3 KT2 KT1
Signals marked with * are inverse signals.
Notes :
SINUMERIK 828D Page 11

MCP310 PN
MCP310 PN: Front Layout with Custom Key Identification (T1 - T16)
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.
Notes :

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

S2 Addressing switch X52 Digital inputs X61 Not used on 828D
X5 Key-switch interface X53 Digital outputs
X10 24V DC supply X54 Digital outputs LED Indicators:
X20 Port 1 Profinet connection in X55 Digital inputs H1 Power OK (Green)
X21 Port 2 Profinet connection out H2 BUSSYNC
X30 Feedrate override interface H3 BUSFAULT
X31 Spindle override interface
Notes :

Machine Control Panel Interface Signals
The following tables show the interface signals for an MCP310 PN with the recommended start address of 112.
MCP310 PN Input signals from machine control panel (keys)
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 Output 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 :
B008 Page 14 SINUMERIK

Additional MCP PN I/O via Interfaces X51 to X55: Input Assignment (X51, X52 & X55):
Profinet MCP User I/O pin assignment

X51 X52
The 9 inputs and 6 outputs available on plugs X51 to X55 are I122.0 I122.3
designed for use with switches/buttons and indicator lamps 1 1
which can be installed in the blanked holes of the MCP. I122.1 I122.4
2 2
Below shows the I/O assignment of each individual plug.
I122.2 I122.5
3 3
The input terminals in the normally open state measure 5V DC M (0 volts) M (0 volts)
(Supplied by the MCP) 4 4
The inputs work by sinking the 5V DC signals to 0V (M).
The outputs terminals are supplied with +24Vdc from the MCP. X55
I122.6
No external voltages should be applied to the input and output 1
terminals. I122.7
2
I123.0
3
M (0 volts)
4
Output Assignment (X53 & X54):
X53 X54
Q119.0 Q119.3
1 1
Q119.1 Q119.4
2 2
Q119.2 Q119.5
3 3
M (0 volts) M (0 volts)
4 4
The outputs are capable of supplying 1.2 Watts per output, it is

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

PP72/48 PN Description and Interface Signals

S1 LEDs
PP72/48 PN modules are a compact component which con-
nect to the Profinet network (Ports PN1 or PN2 of the PPU).
There are two variants, one of which is all digital while the
second offers both digital and analogue functionality. X111

In total 72 digital inputs and 48 digital outputs are available on
each of the two variants.
The analogue module has an additional two analogue inputs
and two analogue outputs.
X222
828D Software Max. number of PP72/48 modules
24x 3
26x 4
28x & 28xA 5
X2 X2
Part numbers: 6FC5311-0AA00-0AA0 Digital only X333

(PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue
(PP72/48 2/2A PN)
X1
Interfaces:
S1: Addressing switches.

X1: 24V DC power supply.
X2: Profinet ports 1 & 2
X111, X222, X333: PLC I/O ribbon cable connectors (24 inputs and 16 outputs on each connector).
LED functionality:
Name Designation Colour Description
H1 Power Green On: Power OK

Off: One of the generated logic voltages is low.
H2 PNSync Green ON: Bus cycle clock is synchronised.
Off: Bus cycle clock is not synchronised
Flashing @ 0.5 Hz: Bus clock cycle is synchronised and cycli data exchange is running.
H3 PNFault Red Off: No errors present, data exchange with all configured
I/O devices is running.
On: Serious bus fault due to one the following:
 No physical connection to a subnet/switch.
 Incorrect transmission rate.
 Full duplex transmission is not activated.
H4 DIAG1 Green Reserved
H5 DIAG2 Green reserved
H6 OVTemp Red Over temperature Indication.
Notes :

Ribbon cable connections.
The following Tables show the pins and I/O addresses for ribbon connectors X111, X222, X333. This is assuming the PP72/48
PN is configured with a start address of 0 (Input bytes 0, 1, & 2 and output bytes 0 & 1).
Pin assignment X111 Pin assignment X222
Pin Signal Pin Signal Pin Signal Pin Signal Pin Signal Pin Signal
1 0V DC 19 I2.0 37 Q0.6 1 0V DC 19 I5.0 37 Q2.6
2 +24VDC O/P 20 I2.1 38 Q0.7 2 +24V DC O/P 20 I5.1 38 Q2.7
3 I0.0 21 I2.2 39 Q1.0 3 I3.0* 21 I5.2 39 Q3.0
4 I0.1 22 I2.3 40 Q1.1 4 I3.1* 22 I5.3 40 Q3.1
5 I0.2 23 I2.4 41 Q1.2 5 I3.2* 23 I5.4 41 Q3.2
6 I0.3 24 I2.5 42 Q1.3 6 I3.3* 24 I5.5 42 Q3.3
7 I0.4 25 I2.6 43 Q1.4 7 I3.4* 25 I5.6 43 Q3.4
8 I0.5 26 I2.7 44 Q1.5 8 I3.5* 26 I5.7 44 Q3.5
9 I0.6 27 Not used 45 Q1.6 9 I3.6* 27 Not used 45 Q3.6
10 I0.7 28 Not used 46 Q1.7 10 I3.7* 28 Not used 46 Q3.7
11 I1.0 29 Not used 47 +24V DC I/P 11 I4.0 29 Not used 47 +24V DC I/P
12 I1.1 30 Not used 48 +24V DC I/P 12 I4.1 30 Not used 48 +24V DC I/P
13 I1.2 31 Q0.0 49 +24V DC I/P 13 I4.2 31 Q2.0 49 +24V DC I/P
14 I1.3 32 Q0.1 50 +24V DC I/P 14 I4.3 32 Q2.1 50 +24V DC I/P
15 I1.4 33 Q0.2 15 I4.4 33 Q2.2
16 I1.5 34 Q0.3 16 I4.5 34 Q2.3
17 I1.6 35 Q0.4 17 I4.6 35 Q2.4
18 I1.7 36 Q0.5 18 I4.7 36 Q2.5
*Note: The first input byte of X222 has FAST gating hardware.
Input information:
X222, byte 1 - maximum delay time - 600μs.
All other inputs, delay time - 0.5 to 3ms.
Pin assignment X333

Pin Signal Pin Signal Pin Signal
1 0V DC 19 I8.0 37 Q4.6
2 +24V DC O/P 20 I8.1 38 Q4.7
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
6 I6.3 24 I8.5 42 Q5.3
7 I6.4 25 I8.6 43 Q5.4
8 I6.5 26 I8.7 44 Q5.5
9 I6.6 27 Not used 45 Q5.6
10 I6.7 28 Not used 46 Q5.7
11 I7.0 29 Not used 47 +24V DC I/P
12 I7.1 30 Not used 48 +24V DC I/P
13 I7.2 31 Q4.0 49 +24V DC I/P
14 I7.3 32 Q4.1 50 +24V DC I/P
15 I7.4 33 Q4.2
16 I7.5 34 Q4.3
17 I7.6 35 Q4.4
18 I7.7 36 Q4.5
Notes :

Profinet Configuration - MCP & PP72/48

Switch S1 - PP72/48
Each hardware item connected to the Profinet network needs Switch S1/S2 Binary Value Switch S2 - MCP483/MCP310
Position
a unique IP address.
This is determined by the setting of S2 on the MCP and S1 on 1 1
the PP72/48.
2 2
Each Profinet device has an IP address in the range
192.168.214.xxx . The switch setting determines the last part 3 4
of the IP address xxx.
4 8
The IP addresses are associated with general machine data
12986[0]….[6] which determines the input/output assignment. 5 16
6 32
Switch S1/S2
The selected IP address will determine the I/O that will be 7 64
assigned. This is seen in the following tables:
8 128
For all Profinet applications switch positions 9 and 10 need to
be set to on. 9 Profinet=ON
10 Profinet=ON
Machine Data 12986

Each index of MD12986 has a pre-set I/O range. To release a
particular I/O range the value of -1 has to be entered into the
necessary index.
Switch Default values of MD12986:

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 Compatibility
on
PN/PN
5
Coupler
96 to 111 96 to 111 - 20 *) To achieve compatibility between machines using the 828D
Controller, it is necessary to assign individual hardware with
7
6 MCP 112 to 125 112 to 121 64 the same I/O address range.
on
The 1st PP72/48 module should always start with I/O address
7 n/a n/a n/a n/a n/a 0 (MD12986[0] = -1). Further modules should be addressed in
Sentron numerical order i.e
8 132 to 143 132 to 143 - 21 *) 2nd PP72/48 (MD12986[1] = -1) I/O start address = 9
PAC 4200
Sentron 3rd PP72/48 (MD12986[2] = -1) I/O start address = 18
9 144 to 155 144 to 155 - 22 *)
PAC 3200 4th PP72/48 (MD12986[3] = -1) I/O start address = 27
10...15 n/a n/a n/a n/a n/a
5th PP72/48 (MD12986[4] = -1) I/O start address = 36
The MCP should always be assigned the start address of 112

*) The IP address of these components is configured by direct- (MD12986[6] = -1).
ly connecting to them using a PC and the relevant software.
Notes :

Recommended MD12986 use: Example: MD12986 for use with MCP and one PP72/48
module.
Machine data Device Start Address/ Activation
Default Setting Setting
12986[0] 1st PP72/48 0 -1
12986[1] 2nd PP72/48 9 -1
12986[2] 3rd PP72/48 18 -1
12986[3] 4th PP72/48 27 -1
12986[4] 5th PP72/48 36 -1
12986[5] PN/PN Coupler 96 -1
12986[6] MCP 112 -1
12986[7] Reserved
12986[8] Sentron PAC 132 -1 The machine data is activated by an NCK power off/on.
4200
12986[9] Sentron PAC 144 -1
3200
12986[10]... Reserved
[15]
Configuration of two MCPs Profinet MCP via Data Blocks
When two MCPs are to be connected, observe the following: It is possible to use the MCP Data Block interface for the
Profinet MCP rather than the PLC I/O interface.
 USB MCP always uses the DB interface.
Machine data to be set:
 Profinet MCP can use either PLC I/O or DB interface.
 If two MCPs are used, one must be the USB type and MD Profinet MCP via DB
one must be Profinet type.
19720 bit 0 1
Machine data is used to achieve the required configuration. 12986[6] -1
MCP MD Profinet USB Not used The PLC user program needs to be edited to ensure the cor-
rect transfer of signals between MCPs and the user interface.
1 12950[0] 0 1 -1 More information is found in Module B026.
2 12950[1] 0 1 -1
PLC Interface DBs for USB/Profinet MCPs
There are four PLC interface DBs to handle the two MCPs:
MD Inputs Outputs
MCP1 DB1000 DB1100
MCP2 DB1001 DB1101
Notes :

B008 END MCP & PP72/48 PN 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, described in the PLC Design document, is adhered to.
These requirements have been created so that the PLC program is easy to understand. This
simplifies 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
 Use the diagnostic functions of the Programming Tool
You will also know the recommended PLC design requirements.
Content: PLC Design
S7-200 PLC Cyclic Operation

Sinumerik
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
Comparing PLC Programs
Importing & Exporting PLC Archives.
B026
B026

Creating a PLC program B026
Creating a PLC
Program:
START
PLC Symbol
Design Tables
S7-200 PLC
Cyclic Cross
Operation Referencing
General PLC
Interface Data Blocks
Description
Creating a Comparing
PLC PLC Pro-
Project grams
(PLC Part 1)
Uploading & Importing &

Downloading Exporting
PLC PLC
Projects Archives
Editing PLC Creating a PLC

Programs Program:
(PLC Part 2) END
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.

 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 priority.
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
(Inputs) transferred 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 influ-

ence the Process Image Table (Outputs).
Process Image Table At the end of the scan the status of the outputs is
(Outputs) transferred 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 :

General PLC Interface Description
Operand identifiers Description Area

DB Data Blocks DB1000 to DB7999 System DBs
DB9000 to DB9063 User DBs
DB9900 to DB9999 Special DBs
T Timers 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 M999.7
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 Data Block 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 :

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 Ap-
pendix C.
DB1000/DB1001 User data (Area 1) /MCP USB

DB1100/DB1101 User data (Area 2) /MCP USB
DB1200...DB1207 PLC functions and PI services
DB1400 Retentive data area
DB1600 PLC user alarms
DB1700/DB1701 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/DB2501 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/DB3001 Operating mode signals (PLC to NCK)
DB3100/DB3101 Operating mode signals (NCK to PLC)
DB3200/DB3201 Signals to NCK channel, Signals to geometry axis
DB3300/DB3301 Signals from NCK channel, Signals from geometry axis
DB3400/DB3401 Signals for Asynchronous sub routines
DB3500/DB3501 G Functions from NCK channel
DB3700...DB3711 M/S Functions from axis/spindle
DB3800...DB3811 Signals to axis/spindle/drive/PLC axis & technology functions
DB3900...DB3911 Signals from axis/spindle/drive/PLC axis & technology functions
DB4000...DB4301 Signals to/from tool management
DB4500 PLC machine data and PLC user alarm configuration
DB4600...DB4700 Synchronised actions
DB4900 Reading/writing PLC variables
DB5300/DB5301 Tool management signals from NCK
DB5700...DB5711 Reading actual values/distance to go
DB6000...DB6011 Safety Integrated signals to axis
DB6100...DB6111 Safety Integrated signals from axis
DB9900...DB9902 Tool management-user interface
DB9903...DB9904 Maintenance planner user interface
DB9905 Easy Extend user interface
DB9906, DB9907 Control Energy function.
DB9908 Spindle temperature monitoring
DB9910...DB9912 NCvar selector
DB9913 Extended alarm messages
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)
Toolbox Examples
The PLC program is created using the PLC828 Programming

Tool software package which is part of the 828D toolbox.
The toolbox also contains examples of PLC projects
The following should be noted before using the examples from

the library:
The sample programs are freeware. Any user can use, Each example is a separate
copy and forward these programs free of charge. PLC828 project.
The authors and owners of these programs take no re- The Readme file gives a de-
sponsibility whatsoever for the functionality and compati- tailed description of the exam-
bility of this software. ples.
Use of the software is at the user's own risk.
Since this software is free of charge, there is no warranty The examples can be used to
nor entitlement to error correction and hotline support. easily achieve a running condi-
tion when commissioning a
Description of PLC examples: machine.
The examples are found in the examples folder created when Subroutines can be copied into
the toolbox “zip” file was extracted. the main PLC project from the
example projects.
Further projects relating to 2 channel machines and MCPs are Procedure:

found in the two additional folders
There are several MCP examples available:
Milling machine with (MCP310)

Readme and safety relay examples in pdf format are also
found in the examples folder.
Turning machine, turret behind the spindle (MCP310)
Turning machine, turret in front of the spindle (MCP310).

Creating a PLC Program from the example projects:
The PLC part of the commissioning procedure is in two parts.

Part one is intended to get the machine control panel and Milling machine with (MCP483).
hand-wheels functioning using example projects from the
toolbox.
PLC Project with Profinet MCP: Turning machine, turret behind the spindle (MCP483).
The training equipment is fitted with a Profinet MCP483, there-

fore the MCP483_M.ptp will be used along with the Hand-
wheel.ptp toolbox example.
Turning machine, turret in front of the spindle (MCP483).
Also included in PLC part 1 is the Prog_control.ptp example.
Notes :

Example for the training equipment using an MCP483 PN:
Select and open the MCP_483_M project.
It is advisable that the project is saved under a different 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.
The right hand window of the PLC828 programming tool con-

tains the ladder logic of the selected program block.
Network 1 has the comments “Important: see comment”
The comments are revealed by double clicking on the com-
ment.
Enter a suitable
name for the project.
Notes :

Double-clicking the net work title text will reveal the comments The other networks contain calls to subroutines. Additional
regarding the use of the example files. information about the subroutines can be seen when the net-
work comments are double-clicked.
Double-click Double-click
If the PLC project were to be loaded to the controller in it’s

Double-click
current state, the subroutines would not be called and the
logic within them would not be executed.
This is because of the logic written in network 2.
The “END” operation results in the PLC scan ending at this
point.
To delete the network, right-click on the network title area and

select “Delete” and then “Network(s)”.
Notes :

Deleting networks 1 & 2: Spindle assignment
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:
X =1
Y =2
Z =3
Sp = 4
A =5
The axis number of the Spindle has to be entered here.
The PLC project now has MCP functionality, however, as The Subroutine needs to be copied into the existing project
mentioned previously, there are two more example projects containing the MCP logic.
required (Hand-wheel.ptp & Program_control.ptp) for the PLC This is achieved by the right click/copy/paste functions of the
step 1 commissioning phase. mouse.
With the current PLC project open, also open the example
project Hand-wheel.ptp.
The example project contains only one subroutine. Comments

are also available as described previously.
In the Hand-wheel.ptp project, Right click on the Handwheel

subroutine and select “Copy”.
In the project containing the MCP subroutines, Right click on

the Program Block folder and select “Paste”.
Notes :

The properties dialogue box of the Subroutine is opened auto- The subroutine will now appear in the “Program Block” folder:
matically.
The properties can be edited if required.
The same procedure should be carried out for the Program-

control.ptp.
The project with the Prog_Control subroutine copied into it:
The comments for the Program-control.ptp, network 3, show The Data Block (DB9051) is located in the User Data Block
that Data Block DB9051 is also required. The DB needs to be folder. This needs to be copied and pasted using the same
copied to the new project. method that was used for the subroutines.
Viewing the comments: Copying the Data Block from the Program-control.ptp
Double-click
Into the current project:
DB9503 is part of the original MCP_483_M project.
Notes :

The properties dialogue box of the Subroutine is opened auto- Calling the subroutines.
matically.
The properties can be edited, however, the block number The newly added subroutines have to be called in Organisa-
should not changed. 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.
This should be pasted to an unused network e.g. Network 3 This subroutines are located in the Subroutines folder
Notes :

The target for the subroutine has to be selected by the mouse,

the selected area is indicated by a black rectangle.
The subroutine now

appears in the target
area.
The target for the sub- It is also possible to drag and drop the subroutines to the cor-
routine, indicated by rect place in the network.
the black rectangle.
The process should be repeated for the Prog_Control sub-

Double click on the subroutine to add it to the network in the routine.
target area.
Below: the call to the Prog_Control subroutine.
Double click the required subroutine e.g. Handwheel
The network comments/title can be modified by double click-

ing on the network title area.
The results of the compile

are displayed in the lower
half of the PLC828 Program-
ming Tool
When completed, the project needs to be compiled:
Notes :

PLC Part 1 is now complete. The call to the subroutines in PLC Project with USB MCP:
OB1 are shown below. The project is now ready for download-
ing to the controller. If a USB type MCP is to be used there are also PLC examples
in the toolbox.
There are only two example projects, one for milling, one for
turning.
No separate projects for MCP483/MCP310 types.
Milling machine with USB MCP483/MCP310
Milling machine with USB MCP483/MCP310
They can be integrated with the other projects in the same

way as the Profinet MCP.
OB1 containing the important comments/disclaimer and the Completed PLC step 1 for USB milling type MCP.
calls to the USB subroutines:
Notes :

Uploading and Downloading PLC projects The PLC type can be selected from the drop down list or, if
there is it can be read automatically via the Read PLC button.
The PLC project (Part 1) is now complete and can be down-
loaded to the controller.
The machine control panel will then be fully functional.
HMI functions such as Program Test (PRT), Mode selection
etc. will also be possible.
Uploading a PLC project to a computer:
It may be necessary to save the existing program from the

controller to a computer.
An online connection with the controller is necessary (Refer to

Module B002).
Open a new project in the PLC828D programming tool.
The Communications button can be used to check the con-

nectivity of the Programming Tool (As per Module B002).
New project
Button.
A warning is given regarding the use of older programs and Certain selections can be made with regards to what is to be
later software. included in the upload.
PLC type has automatically been automatically set.
Select the OK button to continue:
Select the Upload button:
Upload
Button.
Notes :

Confirmation of a successful upload:
Enter a file name and destination:
Downloading a PLC project to the controller
Save any changes with the Save button
Open the project to be downloaded.

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

gards to the types of blocks to be downloaded to the control-
ler.
Blocks of the Manufacturer/individual data class can be in-
cluded or excluded as well as the actual values of Data
Blocks.
Note- Actual values:
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, for example, 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 tak-
en when deciding whether to include the actual values of
the data blocks.
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- To start the PLC, select the Run button on the toolbar.
fered along with a warning about the dangers of downloaded
in run mode.
If in doubt always use the option “Place the PLC in STOP

mode.”
Run button.
PLC in Stop Mode
Allow the PLC to start - Green RDY LED on the controller.
The MCP will now be functioning, but no axis movement will

be possible. Axis movement is addressed in the PLC Part 2
section.
Editing PLC projects (PLC Part 2): The subroutine will be assigned the next available number.
The number and name can be changed if required.
Editing of the PLC project examples will be required to suit Comments and information about the author can also be
individual machine requirements. added.
It may also be necessary to create new subroutines.
Subroutines can be added via the Edit drop down menu. Example subroutine for axis enables:
Notes :

Calling the Axis Enables subroutine in OB1: Contacts and Coils
The Instructions folder of the programming tool includes sim-

ple and complex logic operations:
The contacts and coils are found in the Bit Logic folder Help Functionality:
By using the mouse Right click function it is possible to view

detailed information about each instruction.
Module B019 - S7 PLC Instructions also contains examples

of each PLC instruction.
Notes :

Adding the Logic: The contact needs to be assigned to an interface signal.

For the training simulator, input I0.0 is used. This is connected
Position the rectangle at the beginning of the network and to the top, right hand switch, directly below the hand-wheels.
double click the Normally open logic instruction.
Appendix C of the training documentation shows a full list of
interface signals.
Normally open contact..
Drive Enable - OFF3:
I0.0 is going to be used to switch an output (Coil)

The output to be used is Q0.0. This is connected to the
PP72/48 I/O periphery modules and will be used to control the
Sinamics OFF3 signal via X122 pin 2 of the 828D controller.
Instructions known as coils are used for switching outputs and Insert a coil and assign it to Q0.0.
interface signals. Network comments can also be added.
Select the area to the right of the contact:
Notes :

The toolbar contains shortcut keys which can also be used to Example - Input I0.1 is used to switch the controller enable for
add the most common instructions. the 1st NC axis (X axis) via DB3800.DBx2.1
Controller Enable
Network 2 can now be edited.

For the training this will be used to control the interface signal Further coils need to be added to for the other axes.
for the axis controller enable. The Branch function is used to achieve this.
Each axis has a Data Block, each which have interface sig-
nals . Three of these signals must be set to allow axis move-
ment.
Training equipment Controller Enable signal requirement:
Axis Interface signal

X DB3800.DBX2.1
Y DB3801.DBX2.1
Z DB3802.DBX2.1
Spindle DB3803.DBX2.1
A DB3804.DBX2.1
A branch will be inserted: Position the rectangle to the left of the 2nd coil and use the
branch key as described previously
A second coil is required for the 2nd NC axis (Y axis)
Notes :

Training equipment Pulse Enable signal requirement:
Axis Interface signal

X DB3800.DBX4001.7
Y DB3801.DBX4001.7
Z DB3802.DBX4001.7
Spindle DB3803.DBX4001.7
A DB3804.DBX4001.7
Example of X & Y Pulse Enable signals being controlled by

Input I0.2:
A coil needs to be added for each axis Controller Enable
interface signal.
Pulse Enable
A second requirement is for the Pulse Enable interface signal

to be set.
For training purposes, input I0.2 will be used to control this. A coil needs to be added for each axis Pulse Enable interface
signal.
Measuring Circuit Selection Example - 1st measuring circuit selection for X & Y axes:
The third requirement is for a measuring circuit interface signal

to be set.
There are two possibilities, depending on the number of encod-
ers assigned to an axis.
The first measuring circuit is, in most cases, the motor encoder.
The second measuring circuit is for an additional encoder/linear
scale.
The training equipment has 1 encoder each for the X, Y, Z, & A

axes. The spindle has a second encoder.
For training purposes it is useful to be able to switch between
For training purposes input I0.3/I0.4/I0.5 will be used to control 1st & 2nd measuring circuits.
this. For this reason the Spindle is handled differently.
Training equipment Measuring Circuit signal requirement:
Interface Signal
Axis Measuring Circuit 1 Measuring Circuit 2
X DB3800.DBX1.5 DB3800.DBX1.6
Y DB3801.DBX1.5 DB3801.DBX1.6
Z DB3802.DBX1.5 DB3802.DBX1.6
Spindle DB3803.DBX1.5 DB3803.DBX1.6 The project should be saved/compiled and downloaded to the
controller.
A DB3804.DBX1.5 DB3804.DBX1.6
Notes :

The status of the PLC ladder can be checked via the Program- The status of the bits can be monitored in various formats (Bit,
ming Tool. Byte, Word, Double Word, Timers, Counters)
Select the Program status button on the toolbar: Select the Chart status button on the toolbar:
Type in the signals to be monitored

The blue indicates that the
logic is true for that particu-
lar interface signal.
The example on the right
shows that I0.0 is switched
off, while I0.1 is switched
on and activates the coils
(interface signals)
Reselect Chart status. The current values will be dis-

played
The status of the drives can be viewed in the diagnostics area. Missing interface signals/fault conditions will result in some of
The status is dependant on the status of the interface signals, the green symbols being replaced by yellow or red symbols.
as well as other conditions such as an active fault.
Example - the result of missing the controller enable signal for
Example - A healthy system with the required interface bits each axis (DB380x.DBX2.1)
active. The axes are ready to be jogged etc.
Notes :

Symbol Tables Selecting the Symbol Table icon, found on the left
side, also displays the Symbol Tables:
The project contains predefined symbol tables which can be
edited.
A list of the symbol tables can be seen in the Symbol Table

folder.
The PP_1 (USR1) to PP_5( USR5) & the IS_MCP (USR31)

symbol tables are for the PP72/48 & MCP I/O. These can be
edited to suit.
The IF-Symbole (CMP1), POE-Symbole (SYS1) & DB-

Symbole (SYS2) symbol tables belong to the system and are
read-only. Further symbol tables can be selected via the tabs.
Editing the symbol tables
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
finding process.
The symbols used should match those of the electrical dia-
grams.
Double click the Symbol Tables to open them.
Example: Modified PP_1 symbol table
To see the effect of the symbol table, the options “Symbolic

Addressing” and “Symbol Information Tables” have to be
selected in the “View” menu.
Notes :

With both the Symbolic Information Table and the Symbolic New Symbol Tables
Addressing selected:
New Symbol Tables can be added by right clicking on the
Symbol Table folder and selecting Insert Symbol Table:
Symbolic
Addressing
Symbolic
Information
Table
Right click Insert Symbol table
A new symbol Table ready for editing:
Cross Referencing
Right click in the Symbol table to rename, if required:
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 :

Following the compile procedure the cross reference list will By using the mouse double click function it is possible to open
be displayed. up the subroutine where the instruction is used.
Symbol information will be displayed if selected.
Double click to Double click to

Cross reference selected with symbolic addressing: open the block open the block
at the exact Double click to at the exact
location of the open the block location of the
element at network 1 element
Cross reference selected without symbolic addressing:
Tabs for selecting Cross Reference, Byte Usage and Bit Us-
age formats.
Byte Usage Bit Usage
The Byte Usage table allows you to see which bytes, from The Bit Usage table allows you to see which memory address-
which memory areas, have been used in your program. It also es, down to the bit level, have been used in your program. It
helps you recognise duplicate-assignment errors. also helps you recognise duplicate-assignment errors.
b Indicates that a bit of memory has been assigned. b Indicates that a bit of memory has been assigned.
B Indicates that a byte 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. W Indicates that a word (16 bits) has been assigned.
D Indicates that a double word (32 bits) has been assigned. D Indicates that a double word (32 bits) has been assigned.
X Used for timers and counters. Byte Usage Example:
Byte Usage Example:
Notes :

Data Blocks Data Blocks - User Interface:
A Data Block is used for handling interface signals and data in There are many User Interface Data Blocks for interfacing
various formats. between the controller and the user PLC.
The system requires Data Blocks in order to interface between Their functionality is predetermined and include functionality,
the controller and the user PLC. for example, to control/monitor an axis.
The system data blocks are part of the PLC282 project, by
default, and can be found in the Data Block\User Interface
area. A selection of System Data Blocks, found in the User Interface
User Data Blocks can also be created . These are stored in folder, relating to axis functions:
the Data Block\User Data Blocks area.
Location of the two Data Block storage areas:
The contents of a Data Block can be viewed by double Clicking on it. DB3800 handles the signals from User PLC to the User
Interface.
Double click
It can be seen that the signals inside the Data

Block correspond to the interface signals
found in Appendix C and the ones set in the
Axis Enables subroutine.
Notes :

Data Blocks - User Data Blocks: The properties of the Data Block can be changed and infor-
mation added:
User Data Blocks, with a few exceptions, are created by the
user for many different purposes.
Some of the example PLC828 projects use User Data Blocks.
The PLC Project that was created earlier in this module con-
tains two User Data Blocks (DB9051 & DB9053).
These work in conjunction with the logic in the Subroutines to
ensure correct operation of the MCP & Program control func-
tions.
Adding a User Data Block
Right Click on the User Data Blocks folder and select Insert
Data Block:
Properties that can be changed:

 Name
 Author
 Block Number
 Data Class type
 Retentive/non-retentive
 Comments
The Data Block now appears in the User Data Blocks folder:
Double click on the Data block to enable data to be entered:
Notes :

Editing Data Blocks:

 The Address is automatically set, depending on the Data Type.
 The Name is entered by the user and must be unique. Underscores are automatically added in place of spaces.
 Data Types are selected via a drop down menu.
 Formats are selected via a drop down menu. (Available Formats are determined by the selected Data Type)
 An Initial Value can be set. This value can be transferred to the controller during the download procedure.
 Additional information can be added in the Comment column.
Various Data Types can be used in various Formats Data Types Format Drop Down Menu:
(Depending on the Data Type): Drop Down Menu: (Depends on the Data Type):
Data Type Format
Boolean Bit
Byte Unsigned, Hexadecimal, Binary, Ascii
Word Unsigned, Hexadecimal, Binary, Ascii
Double word Unsigned, Hexadecimal, Binary, Ascii
Integer Signed
Double Integer Signed
Real Floating point, Hexadecimal, Binary, Ascii
An example of a Data Block containing information, including Initial Values:
Initial Values:
If the Data Block requires Initial Values the values have to be

accepted. The values will then be contained in the PLC Pro-
ject.
When a project is uploaded or download it possible to choose
whether the actual values of Data Blocks are included.
Overwriting Data Block values on the controller could lead to
problems, it is therefor important that careful consideration is
given to this.
Accepting Initial Values:
The Data Block has to be active.

From the Edit menu select Accept Initial Values.
Notes :

Acknowledge the dialogue box:
The values are now saved within the PLC Project.

They will be transferred to the controller during download,
providing that the option is selected.
The complete PLC Project needs to be downloaded because

the Data Block has been added from new.
Also select the Data Blocks (only actual values) option.
Changes to Data Blocks requires that the PLC be in Stop

Mode for the download.
When the PLC has started, it will be possible to check the

values of the DB via the PLC828 Programming tool or on the
controller.
Diagnostics in the controller:
Place the PLC in Run mode:
The values are the same as the Initial Values that were set in
the PLC Project.
Notes :

Diagnostics on the PLC828 Programming Tool:
Select the Data Block Status button
The Current Value column displays the online value from the online PLC.
The Data Block online values can be changed using the New Value column.
Enter the new value and confirm with the Write All button.
Write All button:
The Current Value column will be updated.
Confirmation on the controller that the new value was accepted:
Online and offline differences.
If a value is written to the online PLC, the data will be different from the offline.
If the PLC Project were to be uploaded/downloaded one of the differences would be overwritten.
Careful consideration should be given when changing data in this way.
Notes :

Special data Blocks: Example: To add a Special Data Block to a project use the
mouse right click/copy function and paste into the Data
Special Data Blocks are part of the PLC828 Programming Block\User data Block folder:
Tool but, unlike the User Interface Data Blocks, they are not
automatically included in a project. Instead, they have to be
manually added to the project, depending on what functionality
is required.
There are nine Special Data Blocks located in the Instruc-

tions\Libraries folder:
Tool management
Tool management
Tool management
Service Planner
Service Planner
Easy Extend
Control Energy
Sentron PAC
Spindle temperature sensor
The Data Block properties will automatically be opened, some

of which can be edited:
Note:
The Special Data Blocks are described in more detail in
the relevant training module e.g. Tool management.
Notes :

Comparing PLC Programs
It is possible to compare the PLC program, loaded on the con-

troller, with the off-line project using the compare feature of
the programming tool.
The feature is found on the PLC menu:
The whole program can be compared, or a selection of blocks

can be made for comparing.
The compare results are displayed at the bottom of the Pro- The comparison indicates a difference in the Axis_Enables
gramming Tool. subroutine, network 6, row 1, column 1, operand: I0.6.
Example: Comparison with differences: The offline PLC - Axis enables, network 6:
The location of any differences is seen in the compare report.
The online PLC - Axis enables, network 6:
Notes :

Importing & Exporting PLC Archives Locate the setup archive to be loaded:
Importing Archives:
It is possible to import Setup archives (.ard extension) into
the Programming Tool.
Importing is done via the

File menu:
The archive doesn’t specifically have to be a PLC archive. It

can be an archive that also contains NC, Drive & HMI control
components.
Select the type of blocks to be imported: The blocks will be imported:
Notes :

Exporting Archives:
It is possible to export the PLC project in Setup archive (.ard
extension) format.
The archive can then be read into the controller using the Set-
up Archive area.
Exporting is done via the

File menu:
Select the type of blocks to be exported:
The archive can now be loaded into the controller.
B026：END
Notes :

B026 END Creating a PLC program

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:
START
Bit Logic And

Functions Functions
Compare Or
Functions Functions
Convert Move
Functions Functions
Program
Counter
Control
Functions
Functions
Floating
Point Shift/Rotate
Number Functions
Functions
Integer Timer
Functions Functions
Interrupt
Libraries
Functions
S7-200 PLC
Invert Instructions:
Functions END
Notes :

General Information A Word can only be addressed as 0 or an even number (IW0,

Address Formats: IW2, IW4 etc) odd numbers are not allowed.
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, As with the Byte format the numbering starts from the right.
M100.6, DB3804.DBX2.1. Example IW4
The Bit part is the number after the decimal point. The value of IB5 IB4
a bit is either 1 or 0. 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
Byte- A Byte is a collective of 8 bits of logic in the same
group. e.g. In this example I4.0, I4.1, I4.4, I4.5, I4.6, I5.1, I5.2, I5.5, I5.7.
Input Byte 4 (IB4) contains the bits I4.0, I4.1, I4.2, I4.3, I4.4, are equal to 1.
I4.5, I4.6, I4,7. Output Words (QW) and Marker Words (MB) can also be used
When working with bytes it must be remembered that the in the same way.
numbering counts up from the right as shown below.
IB4 Double Word- A Double Word is a collective of 32 bits of logic
Bit no 7 6 5 4 3 2 1 0 which encompasses two consecutive Words (Four consecu-
Value 1 0 1 0 0 1 0 1 tive Bytes).
In this example I4.0, I4.2, I4.5 & I4.7 are equal to 1. Another A Double Word can only be addressed as 0 or an even num-
term for being equal to 1 is that these bits are High. ber which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd
The bits equal to 0 are termed as being Low. numbers are not allowed.
Output Bytes (QB) and Marker Bytes (MB) can also be used in Example ID4
the same way. IB7 IB6 IB5 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
Word- A Word is a collective of 16 bits of logic which encom- 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
passes two consecutive Bytes.
Output Double Words (QD) and Marker Double Words (MD)
can also be used in the same way.
Bit Logic Function

The PLC program is built up of a series of blocks called sub-
Instruction Tree:-
routines. The blocks contain networks, the user PLC is written
The instructions are found in the menu tree to the left of the
into these networks.
main programming area.
The first instruction category in the list is Bit Logic. This group
is the simplest of the instructions.
The individual items in the Bit Logic area are referred to as
Operands.
These operands need to be addressed, the type of address
depends upon the
operand.
Terminology
Inputs:- Typically they are represent the physical state of the

machine i.e. Limit switches, buttons, pressure switches, door
switches etc. and are identified by the letter I e.g. I7.0. They
can also appear in Byte, Word and Double Word formats.
The instructions are divided into different sections, these are
expanded by clicking on the “+” symbol. Outputs:- Outputs are used to switch on relays, contactors,
solenoids, lamps etc. and are identified by the letter Q e.g.
Q4.1. They can be used as coils or contacts, they can also
appear in Byte, Word and Double Word formats.
Markers:- These are internal memory operands which can be

Mouse pointer placed Right clicking on the oper- used as contacts and coils. They are represented by the letter
on the operand and gives the chance to see M e.g. M20.0. They can also appear in Byte, Word and Dou-
reveals the type. a help file. Selecting Hide ble Word formats.
will make the whole instruc-
tion tree disappear.
Notes :

Program Status Contacts:

The status of an operand can be checked by selecting the
“Program status” Icon. The most commonly used operands are “contacts”. Combina-
The centre of the operand becomes highlighted with a colour tions of contacts are used to achieve the end result of activat-
when it is true. ing an output.
These contacts can be assigned to system/user variables,
markers, physical outputs or inputs and can be of the normal-
ly open or normally closed types.
Normally open contacts.

Program Q4.0 = 0 or Q4.0 = 1 or When the operand is high (Equal to one) the contact will be
Status Icon Low High closed and the logic will be true.
When the logic is true the centre of the contact will be col-
oured.
Coils: In the terms of an electrical device the contact will be closed
and current can flow.
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.
I6.0 = 0 or Low I6.0 = 1 or High
Output Q4.0 as a coil
Normally Closed Contacts. Immediate Contacts.

These operands are effective immediately upon activation,
In this situation when the status of the operand is high (Equal they are not subject to the Process Image Table (Inputs). They
to one) the logic will be false. are identified by the letter “I”.
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.
Normally Open Immediate Normally Closed Immediate
Not operands.
The Not operand is used to reverse the state of the logic. i.e.
A status of one will become a status of zero while a status of
I6.0 = 1 or (High) zero will become a status of one.
I6.0 = 0 (Low)
Set and Reset example:-
I6.2 = 1 but Q4.2 remains low because the not operand inverts
the signal.
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.
I6.2 = 0 but Q4.2 is high because the not operand inverts the
signal.
Notes :

Positive Transition operands.

No Operation Operand (NOP):-
The Positive Transition operand monitors the preced-
ing operand status for a rising edge (Signal state change from A network cannot be left in an unfinished state, this leads to
0 to 1) on seeing a rising edge the logic will become true for errors when the program is compiled and prevents the pro-
one scan of the PLC. gram from being loaded.
An unfinished network.
When I6.3 changes from 0 to 1, Q4.3 will become high for one If the program is in the development stages then a “No Oper-
scan of the PLC cycle ation” operand can be inserted, this prevents the network
from being operational and allows the program to be compiled
Negative Transition operands. and loaded to the controller.
The Negative Transition operand monitors the preceding oper-
and status for a falling edge (Signal state change from 1 to 0)
on seeing a falling edge the logic will become true for one
scan of the PLC.
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.
When I6.3 changes from 1 to 0, Q4.4 will become high for one
scan of the PLC cycle.
Immediate Outputs.
These operands are effective immediately upon activation.
The status is passed to both the physical output and the Pro-
cess Image Table (Outputs).
They are identified by the letter “I”. 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.
Output Immediate Set Immediate Reset Immediate Compare bytes for not being equal.
Compare functions are used to compare two values. The

compare values can be Byte, Integer (Single and double) or
Real format.
The available compare types are:-
Equal To IB6 = 14 and IB7 = 14, they IB6 = 15 and IB7 = 14, they
Not Equal To are equal so the status is are not equal so the status
Greater Than or Equal To low. Q5.1 = 1. is high. Q5.1 = 1.
Less Than or Equal To
Compare bytes for being greater than or equal.
Greater Than
Less Than
The following example is using the Compare Byte function to

compare Input
bytes 6 & 7.
IB6 = 15 and IB7 = 14, IB6 is
IB6 = 14 and IB7 = 15, IB6
greater than IB7 so the status
Compare Functions is less than IB7 so the sta-
is high. Q5.2 = 0.
Compare bytes for being equal tus is low. Q5.2 = 0
This would also be the case if
the values were equal.
Notes :

Compare bytes for being less than or equal. Compare bytes for being less than
IB6 = 14 and IB7 = 7, IB6 is IB6 = 6 and IB7 = 7, IB6 is IB6 = 15 and IB7 = 14, IB6 IB6 = 6 and IB7 = 7, IB6 is
greater than IB7 so the status less than IB7 so the status is greater than IB7 so the less than IB7 so the status
is low Q5.3 = 0. is high. Q5.3 = 1 status is low. Q5.5 = 0. is high. Q5.5 = 1.
This would also be the
case if the values were The same principle applies to the other number formats of Inte-
equal. ger, Double Integer and Real
Compare bytes for being greater than Convert Functions
Convert functions are used to change one number format into
another.
The functions available are:-
Double Integer to Real
Truncate
IB6 = 6 and IB7 = 7, IB6 is IB6 = 15 and IB7 = 14, IB6 Binary Coded Decimal to Integer
less than IB7 so the status is greater than IB7 so the Integer to Binary Coded Decimal
is false. Q5.4 = 0. status is high. Q5.4 = 1.
When the block is inserted into the network it needs to be pa-
rameterised. The input is the number that is to be converted, 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.
The source and destination of the input/output can be a System/
User Variable, Input, Output or Marker.
Converting Double Integer to Real.
Binary Coded Decimal to Integer.
This function will convert a value from BCD to an integer.

When I6.0 is true the integer value in MD0 will be converted Permitted ranges:
into a real number and the result placed into MD4.
It is also possible to extend the network via the “ENO” output BCD Decimal Hex
to other operands. The “ENO” output will be high if the convert Minimum 0000 0000 0000 0000 0 0
function was successful. Maximum 1001 1001 1001 1001 9999 9999
Truncate (Converts 32-bit real to 32 bit signed integer). Example:- When input I6.2 is true the value in MW0
(0000000001010100 = 54) will be converted into an integer
and the result placed in MW12. Output Q4.6 will become high
provided that the value in MW0 is within the ranges specified
above and I6.2 remains true.
The Truncate Function takes a 32 bit Real number and cov-
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.
Notes :

Integer to Binary Coded Decimal. 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
This function will convert a value from an integer to BCD .
count value will increment by one.
Permitted ranges:
The count can be reset at any time by setting the R input from
HEX BCD Decimal low to high.
When the counter is first selected in the user program it needs
Minimum 0000 0000 0000 0000 0 0 to be given a name (Available range C0 to C63).
A preset value is entered in the PV input field as an integer,
Maximum 1001 1001 1001 1001 9999 9999 when the count value is equal to or above this value the coun-
ter will be true. The counter operand (e.g. C1) can then be
Example: When input I6.3 is true the value in MW18 (96) will used elsewhere in the user PLC program.
be converted into an BCD and the result placed in MW16.(96
= 0000000010010110) Output Q4.6 will become high provided Below: A counter selected in the user program but not yet
that the value in MW0 is within the ranges specified above and parameterised.
I6.3 remains high. The name of the counter
needs to be entered here
e.g. C1
Counter functions
Count up counters
A preset value is
entered here e.g 10
Below: Network 19 count up counter C1. The count value Below: Network 19 count-up counter C1. The count value can
can be seen to be equal to six, this mean that the CU input be seen to be equal to ten, this means that the CU input (I6.4)
(I6.4) has detected a rising edge on 6 occasions since the has detected a rising edge on 10 occasions since the reset
reset (I6.4) was triggered. (I6.4) was triggered.
Network 20 is an example of how the counter can be used in Network 20 is an example of how the counter (C1) can be
the PLC logic. In this case the preset value (PV) of 10 has used in the PLC logic. In this case the preset value (PV) of 10
not been reached so the status is low. has been reached so the status is high, this results in output
Q4.7 being switched high.
Counter C1 with a The C1 operand will remain high until the reset input R (I6.5)
count value of 6. detects a rising edge. The count value stored in C1 will then
be set back to zero.
Preset value (PV) = 10 Preset value (PV) = 10
C1 count value = 10
Notes :

Below:-The reset input has been switched from low to high
resulting in the count value being reset to zero and the C1 Prior to using the countdown counter a value has to be en-
operand becoming false. No further counting can take place tered into the Preset Value PV input field.
until the reset signal is set to low. 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).
Below:-Count down counter C2 with a PV of two, this PV val-

Preset value (PV) = 10
ue 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
C1 count value = 0 detection of the CD input I7.0.
Countdown counters
Countdown counters are used to monitor the rising edge of 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.
Below:-Countdown counter C2 showing a count value of 4. Counter C2 with a

This means that the CD input has detected a rising edge from
I7.0 on 6 occasions since the preset value of 10 was entered.
Counter C2 with a
count value of 4.
Output Q5.6 set

high as a result of
countdown counter
Below:-Countdown counter C2 showing a count value of 0. C2 reaching zero.
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.
Notes :

Below:-Countdown counter C2 showing a count value of 10 A preset value (PV) can be entered. The counter operand will
after the LD input detected a rising edge from input I7.1. This become high if the actual count value matches or is above this
also results in the C2 operand becoming false as seen in net- preset value. As soon as the value less than the preset value
work 22. the counter operand will become low.
The stored count value can be
C2 count value = 10 reset at any time by setting the re- The counter C3 has
set input (R) to high a count value of 10
which is equal to the
preset value.
The C3 operand is high

due to the counter value
Countdown/count-up counters
and the preset value
Countdown/count-up counters are used to monitor the rising being equal. In this ex-
edge of two signals. One signal (CU) increases the count val- ample the output Q5.7 is
ue while the other signal (CD) decreases the count value. set by the C3 operand.
Below:- When the count value is less than the preset value Below:- When the count value is more than the preset value
the C3 operand will be low. In this example the count value is the C3 operand will be high. In this example the count value
9 after the countdown input I7.4 was switched from low to is 11 after the count-up input I7.3 was switched from low to
high. high.
The counter C3 has a count The counter C3 has a count value
value of 9 which is less than of 11 which is more than the pre-
set value.

The C3 operand is low The C3 operand is high
due to the counter due to the counter value
value being less than being more than the
the preset value. In preset value. In this
this example the out- example the output
put Q5.7 is not set by Q5.7 is set by the C3
the C3 operand. operand.
Notes :

Floating Point Number Functions
When input I9.0 goes high, the value in MD100 (IN1) in this
Addition of real numbers case 16, will be added to the value in MD104 (IN2) in this
case 2. The result will be placed in MD108 (OUT)
Below:- The function requires parameterisation on first selec-
tion.
Values to be added:
IN1 32 bit real number
IN2 32 bit real number added to IN1
Result:-
OUT 32 bit real number
MD100 has been assigned to IN1 and has a value of 16.0
Confirmation:- MD104 has been assigned to IN2 and has a value of 2.0
ENO Bit goes high if operation successful
Below:- The ADD function prior to parameterisation. 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-
Below:- Example of a parameterised ADD function before

being executed.
Subtraction of real numbers Multiplication of real numbers
The SUBTRACT function is parameterised in the same way as

The Multiply function is parameterised in the same way as the
the ADD function. When the function runs the IN2 value will be
ADD function.
subtracted from the IN1 value and the result placed in OUT. When the function runs the IN1 and IN2 values will be multi-
plied together and the result placed in OUT.
Below:- Example of the subtract function. MD100 - MD104 =

MD112 (16 - 2 = 14) Output Q6.1 is high.
Below:- Example of the multiply function. MD100 x MD104 =
MD112 (16 X 2 = 32)
Output Q6.2 is high.
Notes :

Division of real numbers Square root of real numbers
The Square Root function calculates the square root of a real

The Divide function is parameterised in the same way as the
number. The number to be calculated goes to the IN signal,
ADD function.
the result is output to the OUT signal.
When the function runs the IN1 value will be divided by the
IN2 value and the result placed in OUT.
Below:- Example of the Square function.

√MD100 = MD112 (√16 = 4)
Output Q6.4 is high.
Below:- Example of the divide function. MD100 ÷ MD104 =
MD112 (16 ÷ 2 = 8) Output Q6.3 is high.
MW200 + MW202 = 204

Integer Functions Adding Integers
(100) + (25) = (125)
Addition and Subtraction of integers.
Below:- The function requires parameterisation on first selec-

tion.
MD200 + MD202 = MD204
It is also possible to add/subtract/multiply/divide integers in Adding Double Integers (9000) + (3000) = (12000)
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 MW200 - MW202 = MW204
Subtracting Integers (100) - (25) = (75)
Result:-
OUT 16 bit integer or 32 bit double integer.
Confirmation:- MD100 has been

ENO Bit goes high if the operation was successful. assigned to IN1 and
has a value of 16.0 MD208 - MD212 = MD240
Subtracting Double Integers (9000) - (3000) = (6000)
Below:-Examples of adding/subtracting Integers and double
integers.
Notes :

Multiplication of integers.
This function multiplies two words and converts the result into
a double word.
MW200 ÷ MD204 = MD252

(100) ÷ (8) = (000C0004)
= 12 remainder 4
MW200 x MD202 = MD240

(100) x (25) = (2500)
Division of integers.
This function divides one word by another and converts the

result to a double word.
The result is in two parts, the high word section of the double Increment and Decrement Functions.
word represents the whole number while the low word repre-
sents the remainder. The format is hexadecimal. These functions allow a number to be incremented or decre-
In the example below the result of 100 ÷ 8 shows a value of mented by a value of one.
000C in hex format which is equal to 12 as an integer. The The formats can be Byte, Word or Double Word.
remainder is 0004 which is equal to 4 as an integer. 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.
The value in MB200

is incremented by one Decrementing Word
Incrementing Byte and the result sent to
MB232
The value in MD212

The value in MD208 is decremented by
is incremented by one Decrementing Byte one and the result
Incrementing Word and the result sent to sent to MD236
MD212
The value in MB200 is

decremented by one
Incrementing Double Word and the result sent to
MB201
The value in MW200

is decremented by
Decrementing Byte one and the result
sent to MW208
Notes :

Interrupt Functions Invert Functions

Interrupt Function The invert function inverts the bit pattern of a byte, word or
The interrupt function will freeze the processing of the PLC in double word. When viewed in the program status area this is
all networks after the network containing the interrupt. This is not very clear.
only effective in the Sub routine where the interrupt is used . It is better to look in the chart status area.
Examples:-
Invert Byte
With the interrupt active, the output Q8.1 is

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

remains set even though the proceeding
element, Input 11.2 is no longer true.
Invert Double Word
To locate the chart status area select the following icon on the
toolbar.
And Word
The addresses to be monitored need to be typed in the Ad-

dress column and the format set to binary. And Double Word
In the example below it can be seen that the status of the
inputs is the exact opposite of the output status.
This is better seen in the Chart Status area.
And Functions
I7.0 and I9.0 are high
which sets M238.0
The AND function compares two bytes, words or double
words. If two corresponding bits are high the relevant output This equivalent operation when written in ladder is seen be-
bit will be set. low:-
And Byte
Notes :

Or Functions
The OR function compares two bytes, words or double words.

If either one or both of the corresponding bits are high the
relevant output bit will be set.
If either input or both are
high M238.x will be set
OR Byte
This equivalent operation when written in ladder format is

seen below:-
OR Word
OR Double Word
Exclusive Or Functions
The Exclusive OR function compares two bytes, words or dou-
ble words. If either one but not both of the corresponding bits
are high the relevant output bit will be set. If either input but not both
are high M238.x will be set
Exclusive OR Byte This equivalent operation when written in ladder format is

seen below:-
Exclusive OR Byte
Exclusive OR Double Word
Notes :

Move Functions Immediate move functions as the name suggests, have an

Move functions are used for transferring data between from immediate effect on the PLC. They are only available for use
byte to byte, word to word, & double word to double word. with bytes.
The Immediate Read function is used to read physical inputs,
Below:-Standard Move examples 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
Move Byte
from Markers, Variables, Inputs, Outputs, Accumulators and
Load instructions.
Move Word Move Byte Immediate Read
Move Double Word

Move Byte Immediate Write
Move Real Number

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.
Swap Function Example of how a Jump/Label might be used.
Jump Instruction to Label 1 is not active.
MW68 prior to running the Swap function.

I7.2 switches Q8.7 in the expected manner.
MW68 after running the Swap function.
Program Control
Jump Instruction to Label 1 is active.
Jump Instruction & Labels
I7.2 does not switch Q8.7 because the
The Jump Instructions and labels are used together. When program jumps to Label 1.
the Jump is activated the program will skip to the Label spec-
ified by the Jump.
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.
Notes :

I7.2 does switch Q8.7 because it was high

before the program Jump Instruction was
activated. The Conditional Return Instruction is not
active.
I7.7 switches Q9.3 in the expected manner.

The Conditional Return Instruction is active.
Q8.7 remains high despite I7.2 being low

this because I7.2 was set low after the I7.7 does not switch Q9.3 as the subroutine
program Jump Instruction was activated. has been terminated by the Conditional
Return.
Conditional Return Instruction.

The Conditional Return Instruction is used to terminate a sub-
routine. Q9.3 remains high despite I7.7 being low.
This is
Example of how a Conditional Return Instruction might be because I7.7 was set low after the program
used:- Conditional Return was activated.
Q9.3 remains low despite I7.7 being high. The Conditional End Instruction is active.
This is
because I7.7 was set high after the Condi-
tional Return was activated.
I6.2 is high which but Q4.1 remains low. This
is because program end is now in the previ-
ous network.
Conditional End Instruction.
The Conditional End Instruction is used only in OB1 and re- When the Conditional End Instruction is active, no further pro-
sults in the program scan restarting at the beginning of OB1. cessing takes place.
No further operations after the Conditional End will be pro- Outputs, markers etc which were already high will remain so
cessed. until influenced from elsewhere in the program.
Example of how the Conditional End Instruction might be Shift Left Byte.
used.
The shift Left Byte function allows the bits within a byte to be
moved to the left by up to 8 places. In the example below the
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.
The Conditional End Instruction is not active.
I6.2 is high which switches Q4.1 high.
Notes :

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

Shift/Rotate Functions
shifted left by four places and the result placed in MB100.
Shift Left Word & Shift Right Word.
Below:-The Chart Status shows that status of IB9 has been The contents of a Word can be shifted left or right in the same
shifted left by four places and the result placed in MB100. way that the contents of a Byte can be shifted. The maximum
number of moves is 16.
Shift Right Byte.
Below:-Examples of shifting words.
The Shift Right Byte function operates in the same way as the
Shift Left Byte, except that the move is to the right. Shift Left:
Below:-Example of a Shift Right Byte by 2 places operation.
Shift Right: Shift Left:
The Results:
Shift Right:
The Results:
Shift Left Double Word & Shift Right Double Word
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 Timer Functions
shifted. The maximum number of moves is 32.
Timer are used to delay the effects of a signal when it switch-
Below: Examples of shifting Double Words. es. 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-
mum preset time (PT) value of 3276.7 seconds.
Notes :

On-Delay Timer
When a timer is selected it needs to be given a name (T0 to

T127) and a Preset Time value (PT).
Timer name - Txxx
Preset Time (PT)
Below: Input I7.0 is high and T1 has started to count. The T1

operand in network 8 is still low as the PT value of 50 has not
been reached.
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
T1 value has
I7.0 becomes high, T1 will start to count, when the PT value
reached 20
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
will continue to count and the T1 operand will remain high.
When I7.0 becomes low, the count value of T1 will reset to
zero and the T1 operand will go low.
Below:- The time value of T1 has gone beyond the PT value. Retentive On-Delay Timer
As a result the T1 operand in network 8 is high and has The Re-
switched output Q5.0 high. tentive On-Delay Timer works in the same way as the
ON-Delay Timer except that when the IN signal is re-
moved the Timer operand remains high. The Timer oper-
T1 value and will need to be reset by the user which also resets
has the time value to zero.
surpassed
the PT Below:- Retentive On-Delay timer T2 has been triggered
value of 50 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.
T1 operand is now
high, Q5.0 is also
high as result
Below: Input I7.0 has gone low and the T1 time value is reset
to zero. The T1 operand also goes low as a result.
Notes :

The Input I7.1 is now low, T2 has stopped counting but retains
the count value. The T2 operand remains high. If I7.1 be- Off-Delay Timer
comes high again the time value in T2 will continue.
The Off-Delay Timer T3 shown below monitors the IN input.
Timer retains the When this input is high, the T3 operand is also high as seen in
count value 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
zero.
Timer operand remains high Timer value sits at zero
The timer is reset using the Reset function which can be seen
in network 8 below.
Timer reset by I7.2

Timer operand T3 is high
Timer count value
reset to zero
Timer operand goes low
The Off-Delay Timer T3 shown below monitors the IN input. The Timer has counted up to the PT value, as a result the T3
When this input is high, the T3 operand is also high as seen in operand has been reset to zero. The timer value is reset to
network 12. zero when the IN input goes from low to high.
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
zero.
The time value has

reached the value
The IN signal has
set in PT
gone low, T3 starts
to count up
T3 operand is now zero
Timer operand T3 remains high
Notes :

Libraries Data Blocks
The Library contains system blocks for executing specific TM_CTS (DB9900 Constant transfer step table for tool
tasks. These blocks consist of Interrupt Routines and Data change
Blocks.
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 options.
CTRL_E (DB9906) Interface for energy saving.
SENTRON (DB9907) Interface for energy monitoring
ISM_TS (DB9908) Interface for spindle temperature

monitoring
Interrupt Routines The various data blocks are explained in the relevant modules.
INT_0 Executed synchronously with the servo cycle

INT_100 Executed immediately prior to the MAIN routine
(OB1)
INT_101 Executed immediately after to the MAIN routine
(OB1)
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:
START
PI Services
(Program
Invocation
Services)
Reading
Axis
Positions
Reading
and Writing
of NC Data
Data
Exchange
between
NC & PLC
PLC
controlled
axis
PLC
Functions:
END
Notes :

B033 PLC Functions
PI Services (Program Invocation Services)

PI Index Function Interrupt Priority
(DB1200.DBB4001)
PI Services 1 CH 2 CH
A PI Service is an NC task which can be initiated from the
user PLC program. Interface signals are used to select the 1 Initialization of ASUP1 1 1 to 4
required service, initialising, starting and monitoring the status 2 Initialization of ASUP2 2 1 to 4
of the service are available at the interface.
13 Initialization of ASUP3 — 1 to 4
PI Services that can be used:- 14 Initialization of ASUP4 — 1 to 4
 ASUP - Asynchronous User Program
Interrupt Priority:-
 LOGOUT - Password Reset
If ASUP1 & ASUP2 are called together, ASUP1 will run and
 _N_DASAVE - Saving of Data not ASUP2.
 TMMVTL - Tool Reloading via the PLC If ASUP2 is already running and ASUP1 is called, ASUP2
will be stopped and ASUP1 will run.
PI Service: ASUP - Asynchronous User Program If ASUP1 is running and ASUP2 is called, ASUP1 one will
A PLC ASUP is a program which can be initialised and started complete before ASUP2 starts.
from the user PLC independently of the normal NC operations.
Two ASUP are available (PLCASUP1.SPF and PI Parameters for ASUP1 - ASUP4:
PLCASUP2.SPF). These have to be created by the user and PI Parameter Address (Word) Signal Permitted values
stored in the “Manufacturer cycles” directory.
1 DB1200.DBW4004 LIFTFAST 0 or 1
The required ASUP is initialised by entering a value of 1 or 2
into the PI index interface. 2 DB1200.DBW4006 BLSYNC 0 or 1
Each ASUP first requires initialising before it can be run, this is
achieved by setting the “Start PI service” bit high when the 3 DB1200.DBW4008 Chan-No 0 to 2 *1)
relevant “PI index value” is active. The ASUP remains initial-
ised until the control is powered off/on. 4 DB1200.DBW4010 Priority 0 to 4 *2)
The multi channel 828D systems are able to process up to 4
*1) Value 0 is assigned to channel 1.
ASUP (PLCASUP1..4.SPF).
*2) Value 0 must be set with fixed priority.
ASUP behaviour: PI Services Start Bit Function

The behaviour of the ASUP when it is called is affected by
DB1200.DBX4000.0 Start PI Service
the following interface signals:
There are no PI parameters required for _N_DASAVE.
LIFTFAST: When the ASUP is requested, fast retraction of
the tool from the contour takes place prior to the ASUP run- PI Service: TMMVTL - Tool Reloading via the PLC
ning.
PI Index Function
(DB1200.DBB4001)
BLSYNC: When the ASUP is requested, the current program
block is processed prior to the ASUP running. 5 Initiate order for tool reloading
PI Services Start Bit Function PI Parameters for TMMVTL:

DB1200.DBX4000.0 Start PI Service PI Address Function Permitted
Parameter Values
PI Service: LOGOUT - Password Reset
1 DB1200.DBW4004 Tool Number 1 to 31999
PI Index (DB1200.DBB4001) Function
2 DB1200.DBW4006 Source Location 1 to 31999
3 Password Reset Number
3 DB1200.DBW4008 Source Maga- 1 to 31999
PI Services Start Bit Function
zine Number
4 DB1200.DBW4010 Target Location 1 to 31999
Number
There are no PI parameters required for LOGOUT.
5 DB1200.DBW4012 Target Maga- 1 to 32000
PI Service: _N_DASAVE - Saving of Data zine Number
PI Index (DB1200.DBB4001) Function
PI Services Start Bit Function
4 Save data automatically
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
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
to
4022 PI-Parameter 10
DB1200 NCK PLC [r]
5000 Fault Finished

5001
5002
DB3400-
PLC NCK [r/w]
3401

0000 Asup 1
start
0001 Asup 2
start
0002 Asup 3
Start
0003 Asup 4
start
DB3400-
NCK PLC [r]
3401
Asup 1 Asup 1 Asup 1 Asup 1

1000 start not number not running finished
possible possible
possible possible

1002 start not number not Running Finished
possible Possible
possible possible
Notes :

B033 PLC Functions
Example: Initialise and start an 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.
Path = NC data\Cycles\Manufacturer cycles.
The file will open automatically to allow the program com-

mands to be entered. In this example a 10 second dwell is
used with an operator message.
A subroutine should be created in which to write the PLC code to initialise and start the ASUP.
Select PI Service no. 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 sig-

nal” (DB3400.DBX0.0 high).
Notes :

PLC Functions B033
The ASUP will run in all modes. Any program running in automatic mode will be interrupted while the ASUP runs, this program
will then continue when the ASUP has finished.
Reset the “ASUP1 Start signal.
LED to indicate ASUP1 is running.
Notes :

B033 PLC Functions
Example: LOGOUT-Resetting the password
The following example can be used to reset the active password.
Select PI Service no. 3 by putting a value of 3

into B1200.DBB4001.
Start the PI service by switching

DB1200.DBX4000.0 high.
Reset the PI service start signal.
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 indication that a
data save function has been performed. Interface signals are available to indicate when a PI service is successful.
Select PI Service no. 4 by putting a value of

4 into DB1200.DBB4001.
Start the PI service by switching

DB1200.DBX4000.0 high.
Reset the PI service start signal.
Notes :

PLC Functions B033
PI Service complete signal used to set Q4.1.
MCP Reset key used to reset Q4.1.
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]

5711
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.
Notes :

B033 PLC Functions
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
The result of the example can be seen below:
Reading and Writing of NC Data The parameter values which are obtained from the NC Varia-
ble Editor point to the storage location within the NC which
During the manufacturing process it may be necessary to are required as destination or as source, determined by a
have data available to the NC program from the automation READ or WRITE function.
system in order to optimize the NC machining process.
This could take the form of a numerical value being trans- The NC Variable Editor is part of the 828D PLC Program-
ferred to an R Parameter or a machine setting data receiving ming Tool.
from the automation system an optimised value.
In the opposite direction it may be necessary to influence the
automation system dependent upon the current NC machining
process, positional data available in the automation system is
an example of this.
A user interface is available for the function of:
Reading NC data - DB1200-DB1207

Writing NC data - DB1200-DB1207
In addition to the user interface, a tool is available for the engi-

neering PC, this tool is required for generating the necessary
parameter values for the user interface.
The tool is called NC Variable Editor.
Notes :

PLC Functions B033
NCK/Drive PLC user interface NC Variable Editor
DB1200 Global Part DB9912 List 3

DBX0.0 Start Bit
DBX0.1 Read/Write DB9911 List 2
DBB1 Number of variables
DB9910 List 1
Writing NC Data - Var 1 Index
DB1207 Var 8 - Var 2 Index
…
etc. - Var 42 Index
DB1201 Var 2
Variable from
DB1200 Var 1 DB9910-9912
- Index DBB1000
- Data to NC
1016...1027.0
NC Data
Reading NC Data
Drive DB1207 Var 8
parameters
etc.
DB1201 Var 2
Variable from
DB1200 Var 1 DB9910-9912
- Index DBB1000
- Data from NC
3016...3027.0
Reading and Writing of NC Data Note
Up to eight variables can be addressed at any one time, iden- Channel-specific variables
tified by substituting a number (0 to 7) in place of the 4th digit When reading/writing channel-specific variables, only the
of the DB number. Example: variables of exactly one channel may be addressed in a job.
DB1200.DBB1000 - 1st variable
DB1201.DBB1000 - 2nd variable Drive-specific variables
DB1202.DBB1000 - 3rd variable etc. When reading/writing drive-specific variables, only the varia-
bles of exactly one SERVO drive object may be addressed in
a job. The SERVO drive object must be assigned to a ma-
chine axis of the NC. The line index corresponds to the logical
drive number.
Error case
In the event of an error, reading/writing variables from differ-
ent drive objects, or simultaneously from a channel and a
drive object, an error message is output:
DB1200.DBX3000.1 == 1 (error occurred)
Notes :

B033 PLC Functions
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 Start
Write:1
0001 Number of variables to be read/written
0002
0003
DB1200- PLC  NCK [r/w]

1207
1000 Variable Index
1001 Area Number
1002 Line index for NC variable x (Word)
1004 Column index for NC variable x (Word)
1006
1008 Writing data to NC variable x (1 to 4 bytes) *1)
1012
1016 Writing data to NC variable x (REAL) *2)
1020 Writing data to NC variable x (DWORD / DINT) *2)
1024 Writing data to NC variable x (WORD / INT) *2)
1026 Writing data to NC variable x (BYTE) *2)
1027 Writing data to

NC variable x
(BOOL) *2)
*1) Only for predefined variables of the "Read/write NC variable" user interface
*2) Only for variables from DB9910-9912 NC_DATA
DB1200 NCK  PLC [r]
Request
2000 Error in job
Complete
2001
Notes :

PLC Functions B033

1207
3000 Fault Valid Variable
3001 Access result

0: No error; 1:Illegal access to object; 5: Invalid address; 10: Object does not exist.
3002
3004 Reading data from NC variable x (1 to 4 bytes) *1)
3008
3012
3016 Reading data from NC variable x (REAL) *2)
3020 Reading data from NC variable x (DWORD / DINT) *2)
3024 Reading data from NC variable x (WORD / INT) *2)
3026 Reading data from NC variable x (BYTE) *2)
3027 Reading data

from NC varia-
ble x (BOOL)
*2)
*2) Only for variables from DB9910-9912 NC_DATA
Special data block (DB9910-9912) with selected NC data
DB9910-9912 Selected NC data [r]

0000 Variable index variable 1
0001 Syntax ID
0002 Area
0003 Unit
0004 Column index (WORD)
0006 Line index (WORD)
0008 Block
0009 Number of lines
0010 Type
0011 Length
etc
etc ...
0503 Length
Notes :

B033 PLC Functions
Predefined variables of the user interface
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)
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
Notes :

PLC Functions B033
Valid frame index numbers:
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 —
Type 5: R Parameters Type 8: Location status

R Parameters (Read/write)
DB120x.DBB1000 5 Location status $TC_MPP4 (Read)

DB120x.DBB1001 — DB120x.DBB1000 8
DB120x.DBW1002 R Number + 1 DB120x.DBB1001 —
DB120x.DBW1004 — DB120x.DBW1002 Location number
DB120x.DBD1008 Write data to NCK variable x (Real number) DB120x.DBW1004 Magazine number
DB120x.DBD3004 Read: data from NCK variable x (Real num- DB120x.DBD1008
ber)
Type 7: Magazine data-Location data
Meaning of the results in location status DB120x.DBW3004.
>0: Location type for virtual location
=0: “Match all” (Buffer) 1. Disabled
9999: Undefined (No virtual location) 2. Unassigned
4. Reserved for tool in buffer
Location type $TC_MPP2 (Read) 8. Reserved for tool to be loaded
DB120x.DBB1000 7 16. Assigned to the left half location
32. Assigned to the right half location
DB120x.DBB1001 — 64. Assigned to the upper half location
128. Assigned to the lower half location
DB120x.DBW1002 Location number
DB120x.DBW1004 Magazine number
DB120x.DBD1008
Notes :

B033 PLC Functions
Type 9: Tool number
Tool number $TC_MPP6 (Read)
DB120x.DBB1000 9
DB120x.DBB1001 —
DB120x.DBW1002 Location number
DB120x.DBW1004 Magazine number
DB120x.DBD1008
Variable from DB9910-9912 NC_DATA
Type 100 - 225: Variable from DB9910-9912 NC_DATA - The value of a variable can be read/written.
Selected NC data (Read/write)
DB120x.DBB1000 100 - 141: Variable 1 to 42 from DB9910 NC_DATA1

142 - 183: Variable 1 to 42 from DB9911 NC_DATA2
184 - 225: Variable 1 to 42 from DB9912 NC_DATA3
DB120x.DBB1001 Area Number of variable x *1)
DB120x.DBW1002 Line index of variable x *2)
DB120x.DBW1004 Column index of variable x *3)

DB120x.DBD1016 … Writing data to NCK variable x (REAL, ...)
DBX1027.0
DB120x.DBD3016 … Reading data from NCK variable x (REAL, ...)
DBX3027.0
*1) Only for variables from DB9910-9912 NC_DATA with parameter ”Unit” = 0
*2) Only for variables from DB9910-9912 NC_DATA with parameter ”Line index” = 0
*3) Only for variables from DB9910-9912 NC_DATA with parameter ”Column index” = 0
Notes :

PLC Functions B033
Example: Reading data from an R parameter
1. Predefined variable of the 2a. Variable from DB9910 NC_DATA 2b. Variable from DB9910 NC_DATA
user interface fixed addressing variable addressing
(Example: R-Parameter 10) (Example: R-Parameter 10, Chan 1) (Example: R-Parameter 10, Chan 1)
DB1200 PLC  NCK [r/w] DB1200 PLC  NCK [r/w] DB1200 PLC  NCK [r/w]
0000 Read:0 Bit1=0 0000 Read:0 Bit1=0 0000 Read:0 Bit1=0
0001 Number of variables 1 0001 Number of variables 1 0001 Number of variables 1
Variable declaration Variable declaration Variable declaration
1000 Variablenindex 5 1000 Variablenindex 100 1000 Variablenindex 101
1001 Bereichsnummer - 1001 Bereichsnummer - 1001 Bereichsnummer 1
1002 Line index 11 1002 Line index - 1002 Line index 11
1004 Column index - 1004 Column index - 1004 Column index -
Result NCK  PLC [r] Result NCK  PLC [r] Result NCK  PLC [r]
3004 Reading NC variable 25.0 3004 Reading NC variable - 3004 Reading NC variable -
3016 Reading NC variable - 3016 Reading NC variable 25.0 3016 Reading NC variable 25.0
DB9910 Selected NC data [r] DB9910 Selected NC data [r]
NC Variable 1 NC Variable 2
0000 Variable index 100 0012 Variable index 101
0001 Syntax ID 16#82 0013 Syntax ID 16#82
0002 Area 2 0014 Area 2
0003 Unit 1 0015 Unit 1
0004 Column index 1 0016 Column index 1
0006 Line index 11 0018 Line index 0
0008 Block 16#15 0020 Block 16#15
0009 Number of lines 1 0021 Number of lines 1
0010 Type 15 0022 Type 15
0011 Length 8 0023 Length 8
NC variables selection via 828D PLC Programming Tool
Notes :

B033 PLC Functions
Steps to achieve function Locate the NC Variables folder. The folder contains two lists,
one each for the NC variables and the drive parameters. R
Before parameterising the PLC user interface the address of parameters are found in the NC variables list.
the variable has to be known, and stored in a user Data
Block.
This is carried out with the NC Variable Editor tool.
In order to create the address data the following steps should
be followed:
Open the PLC Programming Tool:
All available NC variables are listed: To narrow down the list it is possible to apply a filter:
Notes :

PLC Functions B033
By default the filter is switched off: One type RP (R Parameter) is available:
Select the Block filter criteria and enter RP:
Detailed rpa variable information see help file: The required variables need to be selected, double-click on
the rpa row:
Notes :

B033 PLC Functions
The Row number for the first variable is set to 11. The chosen variable can now be seen in the lower half of the
(= Eleventh R parameter = R10). NC Variables selection area:
A second R variable now needs to be added. Double-click on

the rpa row:
The Row number for the second variable is set to 0. This of- The second variable can now be seen in the lower half of the
fers more flexibility by allowing the R parameter number to be NC Variables selection area:
selected via the user PLC Interface DB1200.DBW1002.
Notes :

PLC Functions B033
Compilation of the PLC project. Content of DB9910 (NC_DATA):
The data block DB9910 (NC_DATA) is generated.
The selected NC variables are specified via the DB9910 data

block (selected NC variable). The length of the data block
depends on the number of NC variables selected in the varia-
bles list. The variables list can contain maximum 42 selected
NC variables.
The DB9910 data block contains the data for variable ad-
dressing and data type conversion for each NC variable.
Notes :

B033 PLC Functions
Example: Reading data from an R parameter
Selection of the number of data sets to

be transferred. (In this case only one) Up
to eight can be transferred in the same
operation.
Selection of the Variable index 100

(1st variable defined in DB9910 = R pa-
rameter 10).
Start signal.
The read/write signal as be set to

Read. (0 = Read).
Reset Start signal.
Reset Read signal.
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:
Notes :

PLC Functions B033
R parameter 10 is used in the example, Cursor to R10 and When the start signal is set to high, the value in R10 will be
enter a value, confirm with the “Input” key. Example R10 = 99. transferred to DB1200.DBD3016.
Below: Status of target variable prior to the start signal.
The value from R10 will now appear in DB1200.DBD3016.

This value remains there only as long as the start signal is
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.DBD1016. Network 4 below shows how this can be done.
Selection of the number of data sets to

be transferred. (In this case only one) Up
to eight can be transferred in the same
operation.
Selection of the Variable index 101

(= 2nd variable defined in DB9910 = R
parameter [x]).
Selection of the Variable number 11

(= Eleventh R parameter = R10).
Value of 25 written to
DB1200.DBD1016.
Notes :

B033 PLC Functions
Start signal.
The read/write signal has to be set to

Write. (1 = Write).
Reset Start signal.
Reset Write signal.
The value from DB1200.DBD1016 will now appear in R10. This value remains there until the start signal is removed .
Data exchange between NC and PLC
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
between the user PLC and for example a part program.
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 When the cycle start button is pressed the value be copied
area of the Controller: $A_DBR[4]=R10. from R10 to the destination variable.
Notes :

PLC Functions B033
This can be checked in the Chart Status of the PLC828 pro- This can be checked in the R parameter area of the controller :
gramming tool:
To read data in the opposite direction is a similar operation.

In the MDA area type the line: R11=$A_DBR[4].
This will copy the contents of $A_DBR[4] into R11.
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).
3. A maximum of 3 sets of data can be written by the NC
in the same program block.
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]
DB3811
Activation signal
0008 Request PLC Request NC
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)
Notes :

B033 PLC Functions
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

DB3911

Positioning axis Position Error Axis
3000 active reached during travers- cannot be
ing started
3001
3002
3003 Error number
Prior to commissioning a PLC axis it is necessary to declare 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:
Variable positioning using the PLC interface
The following example shows how to position a PLC axis using a variable from the PLC interface.
Notes :

PLC Functions B033
Select the axis as a PLC axis by setting

I1.0 high.
Initiate the PLC axis by setting I1.1 high.
Select incremental moves by setting I1.2

high.
Command position of the axis (“real”

value).
Start the positioning procedure with I1.6.
General MD: 10910 $MN_INDEX_AX_POS_TAB_1

The PLC axis will now move to the position entered in
10930 $MN_INDEX_AX_POS_TAB_2
DB3805.DBD3004.
The index array to be used is selected via Axis machine da-
ta:
Axis MD: 30500 $MN_INDEX_AX_ASSIGN_POS TAB
The following example shows how to position a PLC axis

using the positions entered in an index table found in the
“General Machine Data” area.
By the changing the value of DB3805.DBD3004 it is possible to The 10 positions are divided equally into 36 degree incre-
move the axis to varying positions, For example, the value ments.
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:
General MD: 10900 $MN_INDEX_AX_LENGTH_POS_TAB_1

10920 $MN_INDEX_AX_LENGTH_POS_TAB_2
There are two index tables (Machine data arrays) available

where index positions can be entered:
Notes :

B033 PLC Functions
PLC controlled axis
PLC requirements:
Select the axis as a PLC axis by set-

ting 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 positioning 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 :

B037 Alarm Structure
Module Description:
The SINUMERIK 828D system offers various possibilities for diagnosis, one of which is displaying
alarms and messages.
Alarms and messages are generated to indicate the machine status and faults in the control unit,
drive system or machine. They are used to assist the user with identifying the cause of machine
stoppages.
Alarms/messages are sub-divided into the following ranges:

 NCK
 HMI
 SINAMICS
 PLC
Module Objective:
Upon completion of this module you will understand the alarm and message structure of the 828D
system.
Content:
Sinumerik
NCK Alarms and Messages Structure
Alarm Display Description
Alarm Acknowledgement
Alarm Log
Suppress Alarm Function
B037

Alarm Structure B037
NCK Alarms and

Messages:
START
NCK Alarms
and
Messages:
Structure
Alarm
Display
Description
Alarm
Acknowledg
ement
Alarm Log
Suppress
Alarm
Function
NCK Alarms and

Messages:
END
Notes

NCK Alarms and Messages: Structure 102000 - 102999 Services
The NCK alarm structure is divided into three areas. Each area 103000 - 103999 Machine
has been assigned a separate range of alarm/message num- 104000 - 104999 Parameter
bers.
105000 - 105999 Programming
Message/Alarm 106000 - 106999 Reserved
Function range
Nr.
107000 - 107999 OEM
NCK-Alarms/Messages
108000 - 108999 HiGraph
000000 - 009999 General alarms
109000 - 109999 Distributed systems (M to N)
010000 - 019999 Channel alarms
110000 - 110999 Cycles
020000 - 029999 Axis/spindle alarms
111000 - 111999 ShopMill, ShopTurn
060000 - 064999 Cycle alarms SIEMENS
113000 - 113999 Expanding User Interface (Easy screen)
065000 - 069999 Cycle alarms user
114000 - 114999 HT6
070000 - 079999 Compile cycles Manufacturer and OEM
119000 - 119999 OEM
HMI-alarms/messages
120000 - 129999 HMI advanced messages
100000 - 100999 Basic system
130000 - 139999 OEM
101000 - 101999 Diagnosis
142000 - 142099 RCS Host/Viewer
149000 - 149999 ePS
Message/Alarm Nr. Function range 231000 - 231999 DriveCLiQ component encoder 1

232000 - 232999 DriveCLiQ component encoder 2
SINAMICS-Alarms
233000 - 233999 DriveCLiQ component encoder 3
201000 - 203999 Control unit (CU)
234000 - 234999 Reserved
204000 - 204999 Reserved
235000 - 235999 Terminal Module 31 (TM31)
205000 - 205999 Power Unit
236000 - 236999 Reserved
206000 - 206999 Infeed
240000 - 240999 Controller extension (NX32)
207000 - 207999 Drive
241000 - 248999 Reserved
208000 - 208999 Option board
249000 - 249999 Sinamics GM7SM7GL
209000 - 209999 Reserved
250000 - 250999 Communication board (Comm Board)
213000 - 213002 Licence
250500 - 259999 Reserved
230000 - 230999 DriveCLiQ component power unit
Notes

Alarm Display Description Alarm No. Alarm acknowledge method.
When an alarm is activated it will be displayed on the top line

of the controller display.
More than Brief alarm description.

one alarm
present
If more than one alarm is present (Indicated by the arrow)

they can be made to rotate in turn by setting Display Machine
Data 9056.
With values of less than 500 there is no rotation cycle. Values

of 500 to 10000 (milliseconds) set the time that each alarm/
message is displayed for.
The machine data is activated with an NC reset.
To see extra information, highlight an alarm and select the

“Help” key.
A full list of alarms can be seen in the “Diagnostics” area.
Notes

The information will be displayed in a pop-up box. Help Screen Function Description:
Detailed display of the selected alarm when the “Help”

key is selected.
On board operating and programming manuals.
A list of key words is displayed, each is a shortcut to the

correct help-file.
The partial text of an alarm can be searched for.
The pop-up box will be displayed on the whole screen.
Used to open the link to the help-file from a keyword or

search item.
Returns to the keyword or search item.
Exits the help screens.
Alarm Acknowledgement
When an alarm has occurred and the cause rectified, the

alarm will have to be acknowledged.
The type of acknowledgement depends upon the type/ Acknowledgement is via the MCP “Reset” button.
seriousness of the alarm. This will also reset the machining program.
Some alarms needs a reset of the system while others re-
quire acknowledgement via a pushbutton.
Acknowledgement types:
Acknowledgement is via the NC keyboard “Alarm can-
cel” button.
The required acknowledgement is indicated to the right of the
This should not reset the machining program.
alarm number on the alarm display line.
Acknowledgement is via the “Delete HMI alarm” in the

“Diagnostic” area.
Requires action by the operator before continuing with

the Cycle Start. Alarm can also be cleared by the MCP
“Reset” button
This is specifically related to PLC user alarms.
A button/key/switch should be provided by the manu-
Controller needs to be powered off/on or an NCK pow- facturer to facilitate the acknowledgement of the
er on via the “Reset (po)” soft-key in the “Setup” area. alarms.
Notes

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.
The “Display new” 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-

ing the cursor and select keys and confirmed with the “OK”
soft key:
Number of entries:
This sets the maximum number of alarms displayed on the
alarm log page.
Write mode file: Off

The “Settings” soft key is used to configure the alarm log. No storing of the log file will take place to the internal flash
memory (Compact flash card)
At every event: Each time an alarm occurs this will be record-
ed to the compact flash memory.
When this option is selected, a warning is displayed. By leav-
ing this option permanently set, the life of the internal flash
card (PPU) will be reduced.
Notes

B037 END Alarm Structure
Write mode file: Time controlled:

The log will be saved at the interval entered in the Write inter-
val area (max. 32000 seconds).
This will cause less wear and tear of the CF card but still car-
ries similar risk of damage to the CF card.
The HMI will require restarting for the changes to become

effective
Suppress Alarm Function
Certain alarms can be suppressed via General Machine Data

11410 & 11415.
More detailed information is viewed with the “Help” key
The bit editor is viewed by pressing the “select” key.
B037: END
Notes

B031 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
machine.
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
PLC Alarm Configuration
Entering the Alarm Text
User Help Files
Alarm Log
Extended Alarm Configuration
Cycle Alarm Configuration
Program Messages Configuration
Text and Colour Configuration files
B031
B031

Alarms and Messages B031
Alarms
and
Messages:
START Messages
Configuration
General
Information Text and
Colour
Configuration
files
Alarm and
Message Alarms
Screens and
Messages:
END
PLC Alarm
Configuration
Entering the
Alarm Text
User Help
Files
Alarm Log
Extended
Alarm
Configaration
Cycle Alarm
Configuration
Notes :

General Information 1 2 3
The alarms/messages are sub-divided into the following ranges:
Range Description
0 - 9999 General alarms
10000 - 19999 Channel alarms
20000 - 29999 Axis/Spindle alarms
60000 - 64999 Cycles alarms Siemens
65000 - 69999 Cycle alarms Customer
100000 - 199999 HMI alarms
200000 - 299999 Sinamics alarms
300000 - 399999 General drive alarms
400000 - 499999 PLC alarms Siemens 1 Number of alarm
700000 - 700247 PLC alarms/messages Customer 2 Acknowlegement of alarm

Extended PLC alarms/messages Custo-
701000 - 701999 3 Alarm text
mer
As soon as a fault occurs on the machine, an alarm together A description of the system alarms, their cause and remedy is
with the alarm number, alarm text and the acknowledgement/ documented in the Online Help of the controller and in the
clearance will be shown on the screen. diagnosis manual on DOConCD.
Alarms and Message Screen When alarms and messages are triggered they are separated
and displayed on different screens. The time and date of the
The 828D controller allows 248 user PLC alarms/messages alarm/message occurrence is given.
to be configured (numbered 700000 to 700247).
A configurable alarm log is available to show past alarms/
Each alarm/message has an interface bit for activation messages including when they occurred and when they were
(DB1600.DBX0.0 to DB1600.DBX30.7). cleared. The log can be saved and forwarded to technical
personnel if necessary.
The alarms/messages can be displayed in red or black. Red
is traditionally used to indicate a more serious alarm and Select the following keys to locate the screen where the ac-
black is used for a message type situation. tive alarms and messages are displayed.
The effect an alarm/message has on the machine is configu-

rable via general machine data 14516. The same machine
data is used to determine how the alarm/message is acknowl-
edged.
The 828D controller allows 5000 Customer CYCLE alarms to

be configured (numbered 650000 to 69999).
The 828D controller allows the customer to create Program

messages, and assign text. Depending on the configuration, there are two areas where
an active alarm might be displayed.
The alarm/message text can be input via the controller or
created offline.
The extended alarm function allows the same alarm/message

number to be used for different situations by substituting part
of the text for a numerical variable. The following shows infor-
Notes :

The “Alarm list” screen displays serious alarms Alarms/messages are also displayed on the top line of the
which result in the machining process being halted. screen. When more than one alarm/message is present a
downwards pointing arrow appears to the right of the alarm/
message number.
The “Messages” screen displays less serious

alarms which may not necessarily result in the ma-
chining process being halted. The alarms can be made scroll in turn after a set time.
This is controlled by Display Machine Data 9056.
Below
With values of less than 500 there is no rotation cycle. Values

of 500 to 10000 set the time that each alarm/message is dis-
played for.
The units are milliseconds.
The machine data is activated with an NC reset.
PLC Alarm Configuration Below: An example of how Alarm 700000 is activated via input
I8.0.
The table below shows the alarm numbers and their associat-
ed interface signals and configuration machine data.
Alarm Activation bit Configuration Variable for

No. Machine Data Alarm text
function
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
700009 DB1600.DBX1.1 14516[9] DB1600.DBD1036
700010 DB1600.DBX1.2 14516[10] DB1600.DBD1040
... ... ... ...
700247 DB1600.DBX30.7 14516[247] DB1600.DBD1998
Notes :

Configuration machine data: Machine Data MD 14516 functionality:
The configuration machine data is used to determine how the Bits 0 to 4 determine how the controller reacts to that particu-
controller reacts to that particular alarm. Each alarm has a lar alarm, Bit 5 determine if the PLC message is shown in the
machine data assigned to it for this purpose. alarm log. Bits 6 & 7 determine how the alarm is acknowl-
edged.
The MD is in bit pattern format which is revealed when the

MD is highlighted and the “Select” key is pressed.
The bit is then activated with the “Select” or “Space” key and
confirmed with the “OK” soft-key.
Machine Data 14516 is also used to determine whether the

message/alarm appears on the alarm or message screens.
If neither bits 6 & 7 are used, then the message/alarm re-

quires no acknowledgement and will clear as soon as the
activation 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.
14516[xx] Effect/Acknowledgement Entering the Alarm Text

Bit 0 NC start inhibit Entering the Alarm Text with HMI
Bit 1 Read in disable
The PLC alarm text or existing text from AMM can be created
Bit 2 Feed disable or edited directly on the controller, the details are then saved
automatically to an XML file.
Bit 3 Emergency stop It is also possible to edit the xml file off the machine.
Bit 4 PLC stop
The alarm file determines the text that is displayed when a
Bit 5 Alarm log particular alarm is activated.
Bit 6 Acknowledged by DB1600.DBX3000.0
Creating the text on the controller
Bit 7 Acknowledged by Power off/on Locate the Alarm texts screen with the following key se-
quence.
The machine data is activated with via the “Reset (po)” soft
key.
In this window:
Manufacturer PLC alarm tex.
Manufacturer cycle alarm text.
Manufacturer part program message text.
Can be selected.
Notes :

Use the cursor key to highlight the User PLC alarm texts The colour of the alarm text can be either black or red. This
option alarm type and select “OK”. 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.
Up to 248 alarm numbers with text can now be typed in using Add further alarms in the same way. Select “OK” when all the
the key board. Existing alarms can also be edited here. alarms have been entered then reboot the HMI.
Allow the HMI to reboot.
The data is now saved to an xml file in the following location:

SystemCF card\oem\sinumerik\hmi\lng
The file name is dependant on the active language when the

file was created:
oem_alarms_plc_eng.ts. The “eng” part of the name is the
language identifier.
Language identifier examples:
eng = English
deu = German The alarm text entered earlier can be seen within the file.
fra = French
ita = Italian
esp = Spanish
chs = Chinese (Simplified)
cht = Chinese (Traditional)
kor = Korean
ptb = Portuguese (Brazil)
Viewing the oem_alarms_plc_eng.ts file:
Notes :

Creating additional language files using AMM-Project. Language files can be uploaded from the controller into the
project.
Access MyMachine can be used to the create language specif- To upload the language files, tick all boxes in the bottom win-
ic files. Start the Access MyMachine program and make an dow.
online connection to the controller.
Make sure the project, created previously in module B002,

appears on the right-hand side.
Followed by the "Upload" icon.
Example- Adding additional language specific files for the

alarm texts:
To add additional language files for the alarm texts, highlight
the "Alarm texts" menu, followed by "New target language"
Notes :

Select the file "oem_alarms_plc_deu.ts. and open it using the

"Edit" key.
Note:
Target lang: select from the remaining 8 standard

languages
Master copy: select the master language from the

control.
All languages: Allows you to pick the full remaining 21

languages.
In the Edit window, change the alarm number and required

text

text
Enter the required text for the second language.
Notes :


text
Select, with a tick, all the required boxes....

Download the two alarm text files, as shown, using the
"transfer" button.
German translation:
700000 Sicherheitstür geöffnet
700001 Hydrauliköldruck niedrig
700002 Hydraulikölstand niedrig
Note:
Export: Allows a CSV to be generated on PC/
PG, so that language text can be easily translated.
Import: Allows the translated CSV file to be im-
Once all the alarms have been transferred using AMM then
reboot the HMI.
English:
The respective files will be

transferred to the controller
Notes :

German: Entering the Alarm Text with TS-Editor.
Access MyMachine can be used for entering and editing

alarm text files, this is usually the better option when a large
number of alarms are to be used.
Start the Access MyMachine program and make an online
connection to the controller.
Locate the storage location of the alarm text files:
System CF card\oem\sinumerik\hmi\lng
Right click on the alarm text file oem_alarms_plc_eng.ts and Any alarms present in the alarm text file will be displayed.
select “Open with TS editor”
The text of the alarms can be easily edited, this is useful for
any translation requirements.
New alarms can also be added
Notes :

Variable Alarm text Function: In the Variable DB1600.DBD1012 the value of 2 is entered.
This is done by a move command.
It is possible to define a variable within the alarm text string. This variable is a Double Word and as such it has to use the
“MOVE_DW” instruction (Move Double Word).
Each alarm is assigned a Double Word variable for this pur-
pose. By selecting one of the following identifiers and enter- Below is an example of how a value 2 is moved into the varia-
ing it into the alarm text, the contents of the Double Word will ble DB1600.DBD1012 when input I8.3 is equal to one. This
appear in place of the identifier when the alarm is triggered. would display the number 2 in place of the “%d” and activate
alarm 700003.
%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 several
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.
Below is the alarm 700003 as displayed on the controller.
In the alarm text, “Axis %d in parked position” has been
typed.
By moving different values into DB1600.DBD1012 it is pos-

sible to use the same alarm number to display slightly differ-
ent messages.
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.
The HTML file name is fixed: sinumerik_alarm_oem_plc_pmc.html
File location for English language: System CF-Card\oem\sinumerik\hmi\hlp\eng\sinumerik_alarm_plc_pmc
The blue text indicates the folders that require creating. Separate folders are required for each language where the Help files are
a requirement.
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
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 Descriptions:
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 :

Creating the help files/directories on the controller

The folders can be created directly on the controller.
Locate the directory where the folders are to be created. Select the “Directory” soft-key, this is usually already selected
System CF-Card\oem\sinumerik\hmi\hlp by default.
Or
System CF-Card\user\sinumerik\hmi\hlp
Enter the directory name, this is the language directory.

Several will have to be created help files are to be available for
more than one language. See previous page for language spe-
cific folder names.
Below: Creating a folder for user help in the English language.
Highlight the new folder and select the “New” soft-key.
The new directory has to be named

“sinumerik_alarm_plc_pmc”
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:
Creating the help file:
Cursor to “sinumerik_alarm_plc_pmc” directory and select the
“New” soft-key followed by the “Any” soft-key.
Notes :

Example help file
Below is an example help file “sinumerik_alarm_oem_plc_pmc.html” for alarm 700001. The text is in different colours to assist with
understanding the contents.
It is important that the lines begin and end with a Tag open or Tag close instruction (< or />).
<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 :

Creating the help files/directories on an external PC: The alarm will appear in either the “Alarm list” or “Messages”
It is possible to create the directories/help files offline using screen depending how it has been configured.
an HTML or ASCII editor (e.g. Notepad®).
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 Ac-
cess MyMachine software. If several alarms exist cursor to the alarm correct one.
The “sinumerik_alarm_oem_plc_pmc.html” needs to be

placed in one of the following:
“System CF card\user\Sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
Or
“System CF card\oem\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
Testing the help file:
To test the Help file the alarm specified in the Help file should
be activated.
Alarm 700001 is activated by DB1600.DBX0.1
Active the 700001 alarm locate the “Alarms/Messages”

screen.
The HELP function is activated by the “HELP” key located to Alarm Log
the bottom right of the screen.
A log of alarms that have occurred can be seen by selecting
the “Alarm log” soft key.
This shows the time when the alarm occurred and when it
was cleared.
Notes :

The “Display new” soft key is used to refresh the list and dis- Number of entries:
play any alarms that have recently occurred. This sets the maximum number of alarms displayed on the
alarm log page.
Write mode file:
Off: No storing of the log file will take place to the internal
flash memory (Compact flash card)
At every event: Each time an alarm occurs this will be record-
ed to the compact flash memory.
The “Settings” soft key is used to refresh the list and display
any alarms that have recently occurred.
When this option is selected, a warning is displayed. By leav-

ing this option permanently set, the life of the internal flash
card will be reduced.
There are a number of options which can be selected by us-

ing the cursor and select keys and confirmed with the “OK”
soft key:
The controller needs to be restarted to make the changes

effective.
Time controlled: The log will be saved at the interval entered

in the Write interval area (max. 32000 seconds). Store log: This allows the log file to be manually saved in a
file which can be retrieved and used for diagnostic purposes.
The file destination is displayed at the bottom of the screen

for several moments after pressing the “Store log” soft key.
This option carries similar risk to the “At every event” option
and the same warning is displayed.
Use the following soft key sequence to locate the log file:-
Use the “Cursor” and “Input” to locate the “alarm log” directory.
The controller needs to be restarted to make the changes

effective.
Notes :

Extended Alarm Configuration
On a complex machine the need for more than 250 alarms

may be required, this can be achieved by using the “Extended
PLC Alarms”, thus giving an extra 1000 alarms.
To use the “Extended alarms” the relevant DB must be added

to the PLC program. First check the PLC type in the PLC pro-
gramming tool:
PLC -> Type…
The file can be viewed by using the “Open” soft key.
The file can be copied and pasted to other destina-

tions such as an external storage device.
This could then, for example be forwarded to tech- PLC Type -> 828D Step 2 07.01
nical personnel for assistance. Activate compatibility mode should be unticked.
As shown above.
Note: If the tick is removed from “Activate compatibility mode”

and acknowledged, the above window will be shown, also
acknowledge too.
DB9913 ALARM_INI should now be loaded into the project.

Located in the PLC libraries, in “Special Data Blocks”.
Double click on Data Block and acknowledge.
Notes :

The table below shows the extended alarm numbers and their Below: An example of how Alarm 701000 is activated via input
associated interface signals and configuration data. I8.7.
Alarm Activation bit Configuration Variable for

No. Data alarm text
function
701000 DB1600.DBX4000.0 DB9913.DBW0 DB1600.DBD5000

Configuration data:
701004 DB1600.DBX4000.4 DB9913.DBW8 DB1600.DBD5016 The configuration using the “Bit Editor” is used to determine
how the controller reacts to that particular alarm. Each alarm
701005 DB1600.DBX4000.5 DB9913.DBW10 DB1600.DBD5020 has a bit pattern assigned to it for this purpose, this Bit pattern
is configured via the PLC programming tool.
701007 DB1600.DBX4000.7 DB9913.DBW14 DB1600.DBD5028 Open the PLC program using the PLC programming tool.
Locate DB9913 in the “User Data Blocks” of the PLC program
and double click.
701009 DB1600.DBX4001.1 DB9913.DBW18 DB1600.DBD5036 Now double click the “Initial Value” for the required alarm num-
ber. The bit editor window will be shown.
... ... ... ...
Bit Editor functionality:
Bits 0 to 4 determine how the controller reacts to that particu-

lar alarm, Bit 5 determine if the PLC message is shown in the
alarm log. while Bits 6 & 7 determine how the alarm is
acknowledged.
The bit editor is also used to determine whether the message/

alarm appears on the alarm or message screens.
If neither bits 6 & 7 are used, then the message/alarm re-

quires no acknowledgement and will clear as soon as the
activation bit becomes zero.
The alarm/message will appear on the message page.
If bits 6 & 7 are used when the alarm/message appears on

the alarm page and an acknowledgement is required.
If bits 8 & 9 are used when the alarm/message appears on

the alarm page and an acknowledgement is required in
channel 1 or channel 2 or both.
Notes :

DB9913.DBWxx Alarm reaction/Acknowledgement - Cycle Alarm Configuration

channel
Alarms can be set from within an NC program. Alarms are
Bit 0 NC start inhibit
displayed in alarm window in either RED or BLACK text.
Bit 1 Read in disable
An example is shown using the SETAL command.
Bit 2 Feed disable …
Bit 3 Emergency stop N10 SETAL(65000)
…
Bit 4 PLC stop
Bit 5 Alarm log The valid range for alarm numbers lies between 60000 and
Bit 6 Acknowledged by DB1600.DBX3000.0 69999, 0f which 60000 to 64999 are reserved for SIEMENS
cycles and 65000 to 69999 are available to OEM / User.
Bit 7 Acknowledged by Power off/on
Bit 8 PLC user alarm for channel 1 The alarm text must be entered into the language specific files
Bit 9 PLC user alarm for channel 2 in the control via AMM or HMI alarm text editor, which is de-
scribed in this module.
When entering the alarm text string there are 4 parameters

that can be used.
Parameter Meaning
%1 Channel number
%2 Block number
%3 Text index for cycle alarm
%4 Additional alarm parameters
Example text entered into the language file via AMM or HMI
alarm text editor:
Chan%1,%2,OEM_CYCLE_ALARM,%4
The effect is shown below:
View's of the entered text using AMM and the HMI text editor.
Notes :

Program Messages Configuration The alarm text can also be entered into the language specific
files in the control via AMM or HMI alarm text editor, which is
Messages can be set from within an NC program. Messages described n this module.
are displayed in alarm window in GREEN text.
An example is shown using the MSG command. The text in the NC program is entered as a “text identifier”,
starting with the character “$”
…
N10 MSG(“MESSAGE”) Eg MSG(“$65000”) and text added into language specific file
… “PART PROGRAM MESSAGE”
The effect is shown below:
View's of the entered text using AMM and the HMI text editor.
Text and Colour Configuration files
The standard colours for the HMI alarms and messages are,
RED or BLACK for PLC and CYCLE alarms and GREEN for
MESSAGES. These colours can be chosen when using the
HMI alarm text editor and in AMM.
There is the ability to register an OEM file that is not restricted

by these basic colours.
The colour of :-
Alarm number
Alarm number background
Alarm text
Alarm text background
Can be changed. In the following example a “CYCLE ALARM”
background will be changed to “Yellow”
We must first declare a new OEM file in the configuration files

for the text and colour. The name of these file is going to be
“alarm_example”.
Notes :

Open the text configeration file slaesvcadapconf.xml in following directory: /oem/sinumerik/hmi/cfg, and add the line.
<AlarmTextEditor_oem_alarm_example type="QString" value="oem_alarm_example"/>
This is the edited content of the file.
<?xml version="1.0" encoding="UTF-8" standalone="yes"?>

<CONFIGURATION>
<AlarmTexts>
<BaseNames>
<AlarmTextEditor_oem_alarms_plc type="QString" value="oem_alarms_plc"/>
<AlarmTextEditor_oem_alarms_cycles type="QString" value="oem_alarms_cycles"/>
<AlarmTextEditor_oem_partprogram_messages type="QString" value="oem_partprogram_messages"/>
<AlarmTextEditor_oem_alarm_example type="QString" value="oem_alarm_example"/>
</BaseNames>
</AlarmTexts>
</CONFIGURATION>
Next create a file oem_alarm_example_eng.ts in the following directory: /oem/sinumerik/hmi/ing,
This is the content of the file.
<!DOCTYPE TS>
<TS>
<context>
<name>slaeconv</name>
<message><source>65200/NCK</source>
<translation>Chan%1,%2,alarm_example,%4</translation>
</message>
</context>
</TS>
Notes :

OEM Alarm text Configuration file location
siemens/sininumerik/hmi/cfg/ slaesvcadapconf.cfg Siemens default configeration file
oem/sinumerik/hmi
- hmi
- Ing
oem_alarms_cycles_eng.ts
The standard Alarm text files that are
oem_alarms_plc_eng.ts generated when text is entered via the HMI
editor or using AMM
oem_alarms_partprogram_messages_eng.ts
oem_alarms_alarm_example_eng.ts oem_alarms_alarm_example_eng.ts is dec-

lared in the slaesvcadapconf.xml
- cfg
OEM_Configuration file that is generated when

slaesvcadapconf.xml text is entered via the HMI editor or using AMM
Additional alarm text files must be declared in slaesvcadapconf. xml!

A sample-configuration file "oem_slaesvcadapconf. xml" is in following directory: /siemens/sinumerik/hmi/template/cfg.
But it must be renamed "slaesvcadapconf. xml" when transfered to its destination folder.
Notes :

Open the colour configeration file slaesvcconf.xml in following directory: /oem/sinumerik/hmi/cfg, and add the line.
<OEM_DataBase_05 type="QString" value="alarmtexteditor_db_oem_alarm_example"/>
This is edited content of the file.


<CONFIGURATION>
<DataBases>
<OEM_DataBase_01 type="QString" value="oem_slaedatabase"/>
<OEM_DataBase_02 type="QString" value="alarmtexteditor_db_oem_alarms_cycles"/>
<OEM_DataBase_03 type="QString" value="alarmtexteditor_db_oem_alarms_plc"/>
<OEM_DataBase_04 type="QString" value="alarmtexteditor_db_oem_partprogram_messages"/>
<OEM_DataBase_05 type="QString" value="alarmtexteditor_db_oem_alarm_example"/>
</DataBases>
</CONFIGURATION>
Next create a file alarmtexteditor_db_oem_alarm_example.xml in the following directory: /oem/sinumerik/hmi/cfg,
This is edited content of the file.
<?xml version="1.0" encoding="ISO-8859-1"?>

<!DOCTYPE SlAeAlarmAttributes>
<SlAeAlarmAttributes Version="01.00.00.00">
<Types></Types>
<Sources>
<Source CatLink="1" SourceID="0" SourceURL="/NCK">
<Alarms>
<Alarm AlarmID="65200"><DISPLOC>0</DISPLOC>
<MSGTEXT>slaeconv|65200/NCK</MSGTEXT>
<NUMBERBACKGROUNDCOLOR>#FF0000</NUMBERBACKGROUNDCOLOR>
<NUMBERCOLOR>#FFFFFF</NUMBERCOLOR>
<TEXTBACKGROUNDCOLOR>#FFFF00</TEXTBACKGROUNDCOLOR>
<TEXTCOLOR>#FF0000</TEXTCOLOR>
</Alarm></Alarms>
</Source></Sources>
</SlAeAlarmAttributes>
Notes :

OEM Color configuration file
siemens/sininumerik/hmi/cfg/ slaesvcconf.cfg Siemens default configeration file
oem/sinumerik/hmi
- hmi
- cfg
alarmtexteditor_db_oem_alarms_cycles.xml
Color files that are generated when colour
alarmtexteditor_db_oem_alarms_plc.xml is entered via the HMI editor or using AMM
alarmtexteditor_db_oem_alarms_partprogram_messages.xml
alarmtexteditor_db_oem_alarm_example.xml alarmtexteditor_db_oem_alarm_example.xml
is created by OEM so that non standard
colours can be used
slaesvcconf.xml OEM_Configuration file that is generated when

text is entered via the HMI editor or using AMM
Additional colour files must be declared in slaesvcconf. xml

A sample-configuration file "oem_slaesvcconf. xml" lies in following directory: /siemens/sinumerik/hmi/template/cfg.
But it must be renamed "slaesvcconf. xml" when transfered to its destination folder.
Notes :

There is a html colour code list which is Color Name HEX Crimson #DC143C
reprecented by a hexidecimal number.
AliceBlue #F0F8FF Cyan #00FFFF
HTML Codes format: AntiqueWhite #FAEBD7 DarkBlue #00008B
Each HTML code contains symbol "#"
Aqua #00FFFF DarkCyan #008B8B
and 6 letters or numbers. These numbers
are in hexadecimal numeral system. For Aquamarine #7FFFD4 DarkGoldenRod #B8860B
example "FF" in hexadecimal represents
Azure #F0FFFF DarkGray #A9A9A9
number 255 in Decimal.
Beige #F5F5DC DarkGreen #006400
Meaning of symbols: Bisque #FFE4C4 DarkKhaki #BDB76B
The first two symbols in HTML color code
represents the intensity of red color. 00 is Black #000000 DarkMagenta #8B008B
the least and FF is the most intense. The BlanchedAlmond #FFEBCD DarkOliveGreen #556B2F
third and fourth represents intensity of
green and fifth and sixth represents the Blue #0000FF DarkOrange #FF8C00
intensity of blue. So with combining the BlueViolet #8A2BE2 DarkOrchid #9932CC
intensity of red, green and blue an unlim-
ited colour pallet can be created;) Brown #A52A2A DarkRed #8B0000
BurlyWood #DEB887 DarkSalmon #E9967A
By defining the colour in the alarmtextedi-
CadetBlue #5F9EA0 DarkSeaGreen #8FBC8F
tor_db_oem_test.xml we can adjust:
Alarm number Chartreuse #7FFF00 DarkSlateBlue #483D8B
Alarm number background Chocolate #D2691E DarkSlateGray #2F4F4F
Alarm text
Alarm text background Coral #FF7F50 DarkTurquoise #00CED1
CornflowerBlue #6495ED DarkViolet #9400D3
Cornsilk #FFF8DC DeepPink #FF1493
DeepSkyBlue #00BFFF Lavender #E6E6FA Magenta #FF00FF

DimGray #696969 LavenderBlush #FFF0F5 Maroon #800000
DodgerBlue #1E90FF LawnGreen #7CFC00 MediumAquaMarine #66CDAA
FireBrick #B22222 LemonChiffon #FFFACD MediumBlue #0000CD
FloralWhite #FFFAF0 LightBlue #ADD8E6 MediumOrchid #BA55D3
ForestGreen #228B22 LightCoral #F08080 MediumPurple #9370DB
Fuchsia #FF00FF LightCyan #E0FFFF MediumSeaGreen #3CB371
Gainsboro #DCDCDC LightGoldenRodYellow #FAFAD2 MediumSlateBlue #7B68EE
GhostWhite #F8F8FF LightGray #D3D3D3 MediumSpringGreen #00FA9A
Gold #FFD700 LightGreen #90EE90 MediumTurquoise #48D1CC
GoldenRod #DAA520 LightPink #FFB6C1 MediumVioletRed #C71585
Gray #808080 LightSalmon #FFA07A MidnightBlue #191970
Green #008000 LightSeaGreen #20B2AA MintCream #F5FFFA
GreenYellow #ADFF2F LightSkyBlue #87CEFA MistyRose #FFE4E1
HoneyDew #F0FFF0 LightSlateGray #778899 Moccasin #FFE4B5
HotPink #FF69B4 LightSteelBlue #B0C4DE NavajoWhite #FFDEAD
IndianRed #CD5C5C LightYellow #FFFFE0 Navy #000080
Indigo #4B0082 Lime #00FF00 OldLace #FDF5E6
Ivory #FFFFF0 LimeGreen #32CD32 Olive #808000
Khaki #F0E68C Linen #FAF0E6 OliveDrab #6B8E23
Notes :

Orange #FFA500 SandyBrown #F4A460 Yellow #FFFF00

OrangeRed #FF4500 SeaGreen #2E8B57 YellowGreen #9ACD32
Orchid #DA70D6 SeaShell #FFF5EE
PaleGoldenRod #EEE8AA Sienna #A0522D
PaleGreen #98FB98 Silver #C0C0C0
PaleTurquoise #AFEEEE SkyBlue #87CEEB
PaleVioletRed #DB7093 SlateBlue #6A5ACD
PapayaWhip #FFEFD5 SlateGray #708090
PeachPuff #FFDAB9 Snow #FFFAFA
Peru #CD853F SpringGreen #00FF7F
Pink #FFC0CB SteelBlue #4682B4
Plum #DDA0DD Tan #D2B48C
PowderBlue #B0E0E6 Teal #008080
Purple #800080 Thistle #D8BFD8
RebeccaPurple #663399 Tomato #FF6347
Red #FF0000 Turquoise #40E0D0
RosyBrown #BC8F8F Violet #EE82EE
RoyalBlue #4169E1 Wheat #F5DEB3
SaddleBrown #8B4513 White #FFFFFF
Salmon #FA8072 WhiteSmoke #F5F5F5
oem_alarm_example_eng.ts, which states the text for the cyc- alarmtexteditor_db_oem_alarm_example.xml, which states
le alarm.This file is declared in slaesvcadapconf.xml confige- the text for the cycle alarm.This file is declared in slaes-
ration file. vcconf.xml configeration file.
Notes :

B031 END Alarms and Messages
Once all the files have been created and edited, reboot the This simple program when run will post this alarm.
HMI.
This method of creating alarm text and backgrounds with diffe-

rent coulours will not be affected by colour changes done by
the HMI editor or AMM.
B031: END
Notes :

B058 PLC On-board 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 editing of the user PLC program, and a rewire function,
which allows inputs or outputs to rewired while keeping the original PLC logic intact.
Module Objective:
Upon completion of this module you will be able to use the 828D PLC viewer to diagnose PLC
related problems. You will also be able to rewire inputs and outputs using the ladder editor
Content:
Sinumerik
PLC Diagnostics
PLC Editor
Interrupt Routines
B058
B058

PLC On-board Diagnostics B058
PLC On-board
Diagnostics:
START
PLC
Diagnostics
PLC
Editor
Interrupt
Routines
PLC On-board
Diagnostics:
END
Notes :

PLC Diagnostics A Word can only be addressed as 0 or an even number (IW0,

IW2, IW4 etc) odd numbers are not allowed.
Address Formats:
As with the Byte format the numbering starts from the right.
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, Example IW6:
M100.6, V38040002.1. IB7 IB6
The Bit portion is the number after the decimal point. The val- Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
ue of a bit is either 1 or 0. Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Byte- A Byte is a collective of 8 bits of logic in the same In this example I6.0, I6.1, I6.4, I6.5, I6.6, I7.1, I7.2, I7.5, I7.7.
group, e.g. Input Byte 4 (IB6) contains the bits I6.0, I6.1, I6.2, are equal to 1.
I6.3, I6.4, I6.5, I6.6, I6.7. Output Words (QW) and Marker Words (MB) can also be used
When working with bytes it must be remembered that the in the same way.
numbering counts up from the left as shown below.
Example IB6 Double Word- A Double Word is a collective of 32 bits of logic
IB6 which encompasses two consecutive Words (Four consecu-
Bit no 7 6 5 4 3 2 1 0 tive Bytes).
Value 1 0 1 0 0 1 0 1
A Double Word can only be addressed as 0 or an even num-
In this example I6.0, I6.2, I6.5 & I6.7 are equal to 1. Another ber which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd
term for being equal to 1 is that these bits are High. numbers are not allowed.
The bits equal to 0 are termed as being Low.
Example ID6
Output Bytes (QB) and Marker Bytes (MB) can also be used in IB9 IB8 IB7 IB6
the same way. 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
Word- A Word is a collective of 16 bits of logic which encom-
passes two consecutive Bytes. Output Double Words (QD) and Marker Double Words (MD)
can also be used in the same way.
Data Blocks (DB):

System Data Blocks are used for interfacing between the dif- Operating
ferent areas of the controller and the user PLC. Status
Module B034 describes this in more detail. Name: Taken from
The user can also create Data Blocks. the PLC828D pro-
ject name.
Last Changed: Last
Data Blocks can be written in different formats e.g.: time the project
was modified.
DB3804.DBX0.0 Data Block 3804 Bit 0.0
DB3801.DBX1000.7 Data Block 3801 Bit 1007.0 Version Information:
DB3801.DBB1000 Data Block 3801 Byte 1000 Supplied by the
system.
DB3804.DBW0 Data Block 3804 Word 0
DB3804.DBD0 Data Block 3804 Double Word 0
Cycle Time:
To locate the PLC status screens use the following soft key The cycle time of
sequence. PLC-CPU proces-
sor.
Processing Time:
The time taken to
process the PLC
logic.
By default, the first page displayed is the “PLC-CPU” screen.

This contains information regarding the PLC project and cy-
cle time information.
The processing time information display can be
reset by the “Reset pro. time” soft key
Notes :

Operating Status: NC/PLC Status

The operating status can be in Run or Stop mode. The status The status of the operands/variables used within the PLC
is indicated at the top of the screen. It is possible to change program can be checked via the “PLC Status” soft key.
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
and start the PLC to clear PLC related faults.
PLC Stop: 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
PLC Start: H = Hexadecimal
F = Floating point number (only for
Double Words)
By using the “Operand +” and ”Operand -” soft keys it is pos-

sible to quickly locate a different operand in a similar range.
The operand in question has to be highlighted and the new
value entered and confirmed with the “OK” soft key.
Or
The “Delete all” soft key will delete all entries on the list.
Changing M8.0 from 0 to 1.
Individual entries can be edited/deleted by using the Insert,

Delete and Cursor keys found on the keyboard.
The marker M8.0 should now have changed to a value of 1.

For test purposes it may be necessary to manually change
(Force) an operand. This is achieved with the “Change” soft
key.
Notes :

Caution should be taken when attempting to manually change Inserting Variables:

variables as unwanted movements may occur.
It is not possible to force operands which are being addressed The “Insert Variable” soft-key opens a list system variables
by the PLC program. which can be directly selected for monitoring.
The default screen shows all available variables.
The values stored in counters and timers can also be viewed.
This is best done in decimal format.
Adding and Displaying Comments:
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.
Variable Filter/Search: Variable Search

Ensure the “Search” tab is highlighted and type all or part of
To find a particular variable the “Filter/Search” function is avail- the variable name.
able. The search is automatic and as soon as the first letter is en-
tered the search will begin.
When the desired variable is found and highlighted, select
Filter: The variable will then appear in the NC/PLC Status List.
The Filter is available to narrow down the number of variables
on display. Cursor to the filter tab, the list is revealed by se-
lecting the “Insert” key.
Confirm the filter selection with the “Input” key.
Notes :

↑
1 is for the 1st NC axis
2 is for the 2nd NC axis etc.
Further information about the variable can be displayed by

selecting “Details” soft-key.
By selecting the “Operand +” & “Operand -” soft keys the vari-

able can be change to view different axes.
Or
Further functions are available when the following soft-key is Enter a suitable file name:
pressed:
Save mask: The list of operands that have been typed can be
saved to a file.
Confirmation of the file save is displayed above the horizontal

soft-keys for several seconds.
Load Mask: Previously saved files can be loaded using this

function.
Cursor to the preferred target area for the file:
Notes :

Status List: The default list of operands is shown in the above screen.
The “Set address” soft key allows this list to be configured.
A further method of checking the status of operands is via the
“Status list” soft key.
The value entered in box will become the first entry at the top
of the list.
Each of the three columns can be changed this way .
Select the columns using the cursor keys.
The operands can be manually changed via the ”Change” soft

key.
Notes :

The status of the PLC is shown by selecting “Program stat.”
PLC Program Status
soft key.
The PLC program ladder logic can be seen by selecting the
The operands which are true are highlighted in blue.
“Window 1 OB1” soft key.
It is recommended that the status be switched when not in use
to free more resources for the system.
Program status OFF:
Program status ON:
“Window 2 SBR0” is a second soft-key for looking at the lad-

der diagram.
This will open subroutine 0 by default.
The “Window 1” & “Window 2” soft-keys can be changed to The soft-key text changes to match the selected block:
open up different blocks within the program.
Protected Blocks:
A list of available blocks is displayed, by highlighting a block Protected blocks will be displayed with a yellow padlock sym-
and pressing the “Open” soft-key, the selected block will be bol.
opened.
Protection can be enabled via the PLC828D programming tool

or directly on the controller.
Selecting the “Open” or “Protected” soft-keys will result in a

password request.
Or
Notes :

The password, if known, can be entered and accepted. Symbolic and Absolute Addressing:
The status can be viewed with or without symbolic addressing

information.
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
The password, if known, can be entered and accepted. text description which is designed to assist the user to identify
the function of the operands without referring to additional
documentation
Example with “Symbolic addresses” selected:
The padlock symbol changes to green:
Confirmation that Symbolic

Addressing is active.
The block contents can now be viewed.
Example: with Symbolic addresses deselected, i.e. Absolute Due to space restrictions of the screen, it is not always pos-
addresses active: sible to see the whole symbolic/absolute description.
The cursor keys can be used to position the orange rectan-
gle around an operand.
This allows further information about the operand.
Pressing the “Select” key will reveal the full symbolic/
absolute information.
Further information can be displayed if the “Input” key is
pressed.
Confirmation that Absolute
addressing is active. An operand with absolute address view showing a truncated
number (Orange rectangle is in place):
Symbol Info
The symbol information for a whole network can be viewed by
selecting the network followed by the “Symbol info” soft key
Display after “Select” key is pressed:
Notes :

Display after “Input” key is pressed:
Example: The display at maximum magnification.
The display can be magnified via the “Zoom +” and “Zoom -”

soft keys.
Example: The display at minimum magnification.
Search Functions: After typing in the search target it is possible to choose be-
tween “Find all”, “Search downwards” or “Search upwards”.
The search function allows operands etc. to be located easily
in the program.
It is also possible to search in the current program block or all

program blocks.
By pressing the select key it is possible to choose between

“Find operand”, “Go to” or “Find subroutine command” in-
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.
When the search parameters are correct the “OK” key is se-
lected to start the search.
Notes :

After a successful search the target will be highlighted by an

orange rectangle.
The Find subroutine command option is used for searching

for a specific instruction within the program.
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.
Refer to the previous pages for examples of search options.
Symbol Info and Symbol tables
The Symbol table soft key allows different symbol tables to

be selected:
Notes :

Search: Cross Reference
On tables with a large number of entries it is possible to use The Cross ref. function allows the user to see which operands
the search function. are in use and in which blocks they are used.
The cursor and select keys are used to populate the search
dialogue box as described previously in the module.
Operands can be located with the Search function or the cur- If the search target appears in the cross reference list more
sor keys. than once, use the Continue search option.
When the correct place is located cancel the search function
and open the program block via the Open in window 1 or
Open in window 2 soft-keys.
OR
OR
Notes :

The cross reference list can be displayed with symbolic or PLC in stop mode:
absolute addresses.
The default is set to absolute as shown on the previous page. If the PLC goes into stop mode information is available on the
When the Symbolic addresses soft key is selected a text diagnostics screen. To locate the diagnostics screen, use the
description of the operand is displayed as seen below. This following soft-key sequence:
text description is taken from the symbols table. If no symbol
has been written for a particular operand the absolute ad-
dress remains.
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 :

PLC Editor Editing a Subroutine:
It is possible to edit the user PLC program directly on the Only existing subroutines (Blocks) can be edited. It is not
828D controller. possible to add new subroutines (with the exception of the
Interrupts 100 & 101 - see next section).
Machine Data 51232 needs to be set to 1 to enable the PLC
editing function: The editing is done the Setup menu:
The subroutine to be edited is selected via horizontal soft-

keys 5 or 6:
Or
Highlight and open the required block (subroutine):
Program status off:
The program status function needs to be off before editing

can commence. Editing is now possible:
The “Program status” soft-key is used to toggle between
program status on/off
Program status ON
Use the cursor keys to navigate through the subroutine:
Program status OFF
Notes :

A wide range of editing functions are available via the horizon- Saving the changes:
tal and vertical soft-keys:
Any changes must be saved in the CPU:
The changes have now been saved in the CPU.
Notes :

Interrupt Routines
Subroutines INT_100 and INT_101 (Rewire function)
Interrupt routines 100 & 101 can be used to influence the user PLC. This is known as the rewire function because it allows a
faulty input/output to be rewired to a spare location; the logic for the new input/output can then be added to the interrupts.
This means that the original user PLC program remains intact; this is important for compatibility reasons.
The interrupt routines belong to the individual data class type.
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 which was set early in the scan might then be reset later in the scan. It is the command
that appears later in the scan that takes priority.
When the scan is complete the results are transferred to the Process Image Table (Outputs). This the point at which the outputs
etc. are physically set.
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
(Inputs) transferred 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
(Outputs) transferred 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 example with a fast turret where the sig-
nals 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 The required interrupt can now be selected:
If the PLC program does not contain the Interrupt routines Or

they can be inserted using the PLC828D programming tool or
directly on the controller.
Interrupt Routine INT_100
Details can be added to identify the author and indicate the
Inserting the interrupt routines on the controller:
purpose of the block.
Use the “Accept” soft-key to complete the action.
Select horizontal soft-key 5 or 6 (note: the soft-key text might
display a different block/subroutine number)
Or
Interrupt 100/101 not present:
The interrupt will now appear in the list.
Use the cursor keys and soft-keys to add the required logic:
The interrupt can now be opened and logic entered.
Notes :

Example: rewiring I6.0 to I6.5. Example logic for INT100:
The table below shows that the PLC status for I6.0 is at 0.
This is despite there being a +24v signal present at the input
terminal. This indicates a problem with the PP72/48. All other
inputs are functioning correctly.
One solution would be to replace the PP72/48. Another possi-
bility would be to rewire the faulty input to an unused input.
Interrupt 100 could then be used to set I6.0, internally, via the
new input.
I6.5 is now controlling I6.0
Original wiring to faulty input:
Input 6.0 rewired to input 6.5:
PP72/48 PLC input/output module PP72/48 PLC input/output module
Function Signal Input PLC Status Function Signal Input PLC Status
Coolant on switch +24v I6.0 0 Faulty input 0v I6.0 1
Work light switch +24v I6.1 1 Work light switch +24v I6.1 1
Tool clamped switch 0v I6.2 0 Tool clamped switch 0v I6.2 0
Door closed switch 0v I6.3 0 Door closed switch 0v I6.3 0
Air pressure switch +24v I6.4 1 Air pressure switch +24v I6.4 1
Spare 0v I6.5 0 Coolant on switch +24v I6.5 1
Spare 0v I6.6 0 Spare 0v I6.6 0
Spare 0v I6.7 0 Spare 0v I6.7 0
Interrupt Routine INT_101 PP72/48 PLC input/output module

The Interrupt is added in the same way as INT_100.
Output PLC
Signal Function
Status
Q6.0 1 0v Machine light
Q6.1 1 +24v Unclamp tool
Q6.2 1 +24v Conveyor on
Q6.3 0 0v Lock door
Q6.4 1 +24v Hydraulics on
Q6.5 0 0v Spare
Q6.6 0 0v Spare
Q6.7 0 0v Spare
Example logic for INT101:
Example: rewiring Q6.0 to Q6.5.
The following table shows that the PLC status for Q6.0 is at 1,
but the +24v output is missing. This indicates a problem with
the PP72/48. All other outputs are functioning correctly. Q6.0 is now controlling Q6.5.
One solution would be to replace the PP72/48. Another possi-
bility would be to rewire the faulty output to an unused output. Any changes must be saved in the CPU:
Interrupt 101 can then be used to set Q6.5, internally, via the
existing output.
Notes :

B058 END PLC On-board Diagnostics
Output Q6.0 rewired to output 6.5:
PP72/48 PLC input/output module

Output PLC
Signal Function
Status
Q6.0 1 0v Faulty output
Q6.1 1 +24v Unclamp tool
Q6.2 1 +24v Conveyor on
Q6.3 0 0v Lock door
Q6.4 1 +24v Hydraulics on
Q6.5 1 +24v Machine light
Q6.6 0 0v Spare
Q6.7 0 0v Spare
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
Overall commissioning procedure for Sinumerik 828D
Preparing the controller
HMI Configuration
PLC Program
Drive configuration
DMS and NC Axis assignment
Machine data optimisation
Drive optimisation
B068
B068

Commissioning sequence B068
Commissioning
sequence:
START
NC Axis
Assignment
Preparing the
Controller
NC
Machine
Data
HMI:
Language
Password
Time/date
Alarm Text PLC part 2:
OEM
signals,
enables etc.
Machine
Configuration:
BAG/Channel/
Axis
Drive
Optimization
PLC Part 1:
Hardware
configuration
and MCP
Data
Management
Drives:
Firmware
Update &
Configuration
Commissioning
sequence:
START
DMS Encoder
Configuration
Notes :

Sinumerik 828D commissioning sequence
1. Tools/software installation (B002)
2. Preparing the controller
3. HMI Language - Password - Time and date -

Alarm Text
4. Machine configuration, BAG / Channel / Axis
5. PLC part 1, Hardware Configuration and

MCP
6. Drive firmware update and configuration
7. NC Axis assignment
8. NC machine data configuration
9a. PLC part 2, OEM signals, enables etc.
9b. Tool Management (B102)
10. Sinumerik Operate Technology (B110)
11. Drive optimization (B101)
12. Data management (B017)
Notes :

Preparing the controller
Factory settings
The controller should be loaded with default data this

will set default machine data with respect to the type of
machine technology (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

“Factory settings” option and press the “Input” key.
or
Acknowledge the dialogue box by selecting “Yes”.
The controller will now require powering off/on.
Allow the controller to fully start-up.

The green RDY LED at the front of the controller will be lit
Any manufacturer data can be deleted or left intact depending continually as confirmation.
on the next selection. This data includes any archives stored
on the controller.
Firmware update: Alarm 4060: Standard data for a milling machine has been
If the firmware of the drive components/objects is not at the loaded and the configuration is 3 axis and 1 spindle. This will
correct level for the software version an automatic firmware be expanded upon for our example.
update process will begin. Allow this to complete.
Alarm 40006: The user PLC has been cleared.
Expected Alarms:
The alarm list shows the following three alarms, this is normal Alarm 20402: The Sinamics drive system requires first com-
at this point in the procedure. missioning.
The request to commission the drives will appear several
times during the commissioning sequence, e.g. after each
NCK reset.
It is important only to commission the drives at a certain point
in the commissioning sequence.
Notes :

HMI Language - Password - Time and date - Alarm Text Password Setting
Language Selection Setting of the password is now necessary to enable machine

data etc. to be viewed and changed.
It is possible that the system is not in the desired language, if
this is the case the language can now be changed.
The password “SUNRISE” is recommended
The password will now be set to manufacturer level as

displayed just above the horizontal soft-keys.
Time and Date Setting

Configure alarms
The time and date should now be set, this is especially im-
portant for the GSP iBase online registration process. The customer will install the PLC during the commissioning
procedure, it could happen that customer alarms are present
at this time which requires that the alarm text exists prior to
the PLC program.
At this stage in the procedure you can choose to enter the
texts directly or read the alarm text file into the controller.
Notes :

Machine configuration, BAG / Channel / Axis
Licensing and Options
To activate the extra axis ensure that the option is available .
To check/activate the licence use the following key sequence:
Enter a value of 1 and select the Reset (po) soft-key to acti-

vate the change.
After performing an NCK reset, the controller may start-up

with the following screen, this screen indicates that an initial
start-up of the drive system is necessary.
The start-up of the drive system is carried out later in the com-
missioning sequence, therefore continue the process with the
Cancel Soft-key
Notes :

Machine Data An NCK reset is required to activate the machine data.
After the axis is licensed it can be configured in machine data.

Locate the Machine Data area:-
Following the reset it is necessary to cancel the drive system

commissioning request
The NC is only set for four axes/spindles (default data). To

activate an extra axis a value of 5 needs to be entered in Ma-
chine Data 20070[4].
The required axes are now available with default names:
Notes :

PLC part 1, Hardware configuration + MCP Default setting for MD12986:
Configuring the MCP and Periphery Devices
Machine Data 12986
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.
Each piece of hardware which is connected to the Profinet

network is identified by the setting of dip switches. These
switches give the hardware an IP address which corresponds
to General Machine Data 12986, this also defines the address
of the module in the interface.
The hardware is activated by entering a value of -1 in the rele-

vant machine data.
Item IP Address Machine Data Start Address (I/O)
PP72/48 No1 192.168.214.9 12986[0] 0 PP72/48
MCP 192.168.214.64 12986[6] 112
MCP
Assignment of the SDBs (System data blocks) The machine control panel subroutine needs to be called in
OB1:
Machine Data 11240
MD11240 Description
[0, 1, 2, 3]
0, -1, 0, 0 Telegram 136 and NX10.3
1, -1, 1, 1 Telegram 136 and NX15.3 (= Default)
2, -1, 2, 2 Telegram 136 and NX15.3, 1x CU320-2PN
The machine data are activated with a Reset (po).
PLC Program
The PLC program for the MCP can now be downloaded and
tested according to the machine test protocol.
It may be necessary at this point to jog the axis in simulation
mode. A temporary enable may have to be programmed in
order to make these tests.
Notes :

Drive firmware update and configuration
A system whose drives have not been configured 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.
A series of information boxes will be displayed: The drive components that are connected to the DriveCLiQ
bus are now displayed on the controller.
An NCK reset is required to complete the procedure:
Note: No axes have been assigned at this stage.
Notes :

Topology of S120 Training Simulator
PPU 1 MoMo 2 MoMo 3 4 MoMo 5 6
1 2 3 4 5 6
X203 X203
X102 X202 X202 X202
X101 X201 X201 X201
X100 X200 X200 X200
X500
SMI- 21 SMI- 18 SMI- 15 SMI- 12 SMI- 9 SMC
ENC- 22 ENC- 19 ENC- 16 ENC- 13 ENC- 10 SMC- 7
MOT- 23 MOT- 20 MOT- 17 MOT- 14 MOT- 11 ENC- 8
2 3 4 5 6 6
DMS Encoder Configuration

Use the “Drive +” or “Drive -” soft-keys to locate the drive
In certain situations it is not possible for the topology to assign which has been incorrectly assigned the DMS (Servo 3.3.6).
components according to the machine configuration.
In this case the assignment has to be changed manually.
or
Servo 3.3:6 is selected
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 of the encoder).
Deselecting the DMS encoder from Servo 3.3.6 (A axis):
To continue select the following soft-key sequence:
Notes :

By paging down to the bottom of the screen it can be seen The encoder has to be first deselected from Servo 3.3.6 (A
that this drive does in fact have a 2nd encoder assigned to it. axis) to free it up for assignment to the Servo 3.3.2 (spindle)
The encoder type is unknown at this stage and will be added Select the “Change” soft-key.
shortly.
Press the Next step soft-key (three times) until the Encoder
assignment screen is displayed, the page will show two en-
coders assigned to the axis.
Deselect Encoder 2:
Press the Next step soft-key
Drive Configuration will be read:
The unassigned encoder triggers expected alarm 201331:
Press the Next step soft-key (Three times) until the Summary
screen is displayed.
This now shows Servo 3.3.6 with only one encoder.
Notes :

A dialogue box shows that the configuration has changed and Assigning the DMS encoder to the Spindle:
that save be carried out.
This is not necessary at this stage because the encoder has Use the Drive + or Drive - soft-keys to locate Servo 3.3.2
still to be assigned to the Spindle.
or Servo 3.3.2 is selected
Press the Next step soft-key (Three times) until the Encoder Select the Encoder 2 checkbox.
assignment screen is displayed. From the list select the DMS encoder.
The top two encoders on the list are the ones available to the
The page will show one encoder assigned to the servo. spindle. The 1st one being the DMS (Motor_Module_6.X201-
SM_7-Encoder_8), the 2nd being the one already assigned
as the motor encoder.
The remaining items on the list are motor encoders which are
already assigned.
Below: Encoder 2 (Motor_Module_6.X201-SM_7-Encoder_8)

selected and assigned to the DMS.
Notes :

Press the “Next step” soft-key until the Encoder 2 configura- The details of the encoder need to be manually entered, select
tion screen appears. the “enter data” soft-key.
In this case the encoder is of the type: Rotary incremental

Sine/Cosine type with 1024 pulses and one zero mark per
revolution.
The position actual value needs to be inverted due to the
mounting method of the DMS encoder.
The screenshot below has had the encoder type and infor-
mation entered:
The bottom of the summary screen shows Encoder 2 details:
The encoder now appears in the list as a User-defined type:
Press the Next step soft-key (3 times) until the Summary

screen appears.
Notes :

The DMS assignment is now complete and needs to be NC Axis Assignment

saved, press the Yes soft-key.
At this point the NC axes and the Sinamics Drive objects are
configured but not logically assigned to each other.
The following describes how to make this connection.
The machine NC configuration shows no drives are as-

signed:
The new settings will now be saved.
End of DMS assignment.

Using the Drive system Softkey you can enter the area for
assigning the drive objects to the NC Axis.
Drive overview screen:
Axis assignment missing.
Notes :

Assignment Method:
Via Axis Machine Data - (NC Drive number) MD30110 - 828D Default.
Machine Axis Internal Axis Machine Data changed: Machine Data not changed:
Name name CTRL_OUT_MODULE_NR DRIVE_LOGIC_ADDRESS
MX1 AX1 30110 =2 13050[1] = 4140
MY1 AX2 30110 =3 13050[2] = 4180
MZ1 AX3 30110 =4 13050[3] = 4220
MSP1 AX4 30110 =1 13050[0] = 4100
MA1 AX5 30110 =5 13050[4] = 4260
The axis assignment procedure will automatically set various machine data including Axis MD 30110.
Assignment procedure:
SERVO_3_3_2
Training equipment axis/servo assignments:
SERVO 3.3.2 MSP1 Spindle

SERVO 3.3.3 MX1 X axis
SERVO 3.3.4 MY1 Y axis
SERVO 3.3.5 MZ1 Z axis
SERVO 3.3.6 MA1 A axis
(The MC1 axis is simulated)
Axis assignment is now achieved with the Axis Assignment

soft-key:
Check the top right of the screen for the currently selected
servo: e.g. SERVO_3_3_2
Notes :

From the Setpoint: axis - -> drive list, select the correct NC Any encoders associated with the axis will be automatically
axis for the servo. selected:
In this example SERVO 3.3.2 & AX4: MSP1
Use the Drive + or Drive - or Select a drive soft-keys to lo-

cate the next servo to be assigned e.g. SERVO 3.3.3. and
assign it to the correct NC axis e.g. MX1.
or or
Example: SERVO_3_3_3 assigned to NC axis MX1 Axis assignment confirmation:
The axis assignments can be seen on the machine configura-

tion screen:
SERVO_3_3_3
Repeat the process until all Servos have been assigned to the
correct NC axis.
Confirm the procedure with the OK soft-key:
Notes :

NC Machine Data Spindle Setting Data:
While the axis assignment procedure automatically sets cer- Spindle setting data can be set to limit the maximum spindle
tain machine data, it will be necessary to manually set addi- speed.
tional machine data according to the machine specifications The default maximum spindle speed is 1000rpm.
Machine data is used to set velocity/travel limitations, acceler- This needs to be changed to 3000rpm for the training simula-
ation, leadscrew pitches etc. tor.
For the training simulators the following spindle machine data

needs to be set.
Spindle MD
32000 3000
32010 100
32020 50
35100 3000
Unreferenced Axes:
35110[0] 3000
35110[1] 3000 By default, cycle start is inhibited until the axes are refer-
35120[0] 10 enced. This can be overcome by setting channel machine
data, 20700 REFP_NC_START_LOCK =0
35120[1] 10
35130[0] 3150 Warning: This should only be a temporary measure.
35130[1] 3150 Machine damage could result when running an axis that
hasn’t been referenced.
36200[0] 3300
36200[1] 3300
PLC part 2- OEM signals, enables etc. Example - X axis enable signals/measuring circuit 1 selection:
Axis Enables
The motors should only be allowed to rotate when the condi-

tions are safe to do so.
Interface signals are provided to allow the user to inhibit
movement of axes.
In the case of the simulator the on-board switches are used to
signal to the interface that the conditions to run are OK.
The system must also be informed which measuring system Example - CU parameter r722 showing bits 0 & 1 are set:
is in use. In the case of the simulator spindle, this is the 2nd
measuring system.
OEM signals should also be considered, example: reference

cams, over-travel switches, pressure switch monitoring, door
interlocks etc.
The axes can now be jogged.
Enable requirement Interface signal

OFF1 X122.1/r722.0
OFF3 X122.2/r722.1
Controller enable DB38xx.DBX2.1
Pulse enable DB38xx.DBX4001.7
Measuring circuit enable DB38xx.DBX1.5 or 1.6
Notes :

B068 END Commissioning sequence
Drive Optimisation Data Management
Drive optimisation is carried out to match the drive/controller to When the prototype of a machine is fully tested it is necessary
the mechanical characteristics of the axes. to create a backup of the data.
This is essential to achieve fast, accurate positioning, The backup data is in the form of a TGZ file (System image)
resulting in reduced cycle times and a superior surface finish. which includes all the information to restore the machine to its
Once a machine is optimised it should not require optimising original state.
again. This file is also used for the production of series machines as
Any mechanical problems should be repaired rather than it includes the Manufacturer data.
masked by re-optimisation.
See Module B017 Data Management for detailed information.
See Module B101 Servo Optimisation for detailed infor-
mation.
B068: END
Notes :

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 important 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
Automatic Referencing
Referencing Absolute Encoders
Machine Data Information
B084
B084

Encoder Adjustment B084
Encoder
Adjustment:
START
Referencing
Incremental
Encoders
Automatic
Referencing
Referencing
Absolute
Encoders
Machine Data
Information
Encoder
Adjustment:
END
Notes :

Referencing Incremental Encoders
General Information
Axes equipped with incremental encoders require referencing

each time that the NCK is reset or powered off/on.
This usually entails traversing the axis to a switch which then
initiates the referencing procedure.
Certain machine data are available to influence this procedure
and adjust it to individual requirements.
Some axes have a second encoder fitted for positioning oper-
ations. 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.
If it is uncertain whether an axis has an incremental or abso-

lute encoder fitted, this can be checked via axis machine data
Look for the “Measuring system 1 active” and “Measuring sys- 30240.
tem 2 active”. A green tick symbol indicates which measuring To check the machine data use the following soft key se-
system is active for each axis, typically the motor encoder. A quence.
2nd measuring circuit is typically a linear scale axes or an
encoder for a spindle.
Some manufacturers may also switch between measuring
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,
see below-
Machine data 30240[0] & [1] should be checked depending
upon the active measuring circuit. 1st axis - DB3800.1000.7
If the active measuring circuit is number 1 then machine data 2nd axis - DB3801.1000.7
30240[0] index 0 is active. If the active measuring circuit is 2, 3rd axis - DB3802.1000.7
the machine data 30240[1] index 1. etc.
Incremental encoders = 1
Absolute encoders =4
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.
Confirmation that the correct mode is selected can be seen

at the top of the screen.
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 Below: The symbol to the left of the axis name indicates that
machine control panel. the axis has been referenced, in this case axis MX1.
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 contin-
ually depressed throughout the reference cycle, it is more
common to find that the axis will continue to move even
when the jog direction button is released.
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 :

Automatic Referencing (Incremental Encoders) To initiate the automatic cycle the necessary interface bit has
to be set (DB3200.DBX1.0).
Automatic referencing cycle
Example of how the automatic referencing cycle can be initiat-
To set the automatic referencing function it has to be decided in ed.
what order you want the axes to referencing.
It is common for example that on a milling machine the Z axis
needs to be referenced first, this helps eliminate the chance of a
collision.
The order is set by axis machine data $MA_REFP_CYCLE_NR
Possible entries:
0 = no referencing cycle participation.
1 to 15 = allowable range for setting the sequence. Interface signal description:
-1 = no reference required for Cycle start.
DB3100.DBX1.2 Reference Mode Active.
Up to five axes can be referenced at the same time. DB3200.DBX7.1 NC Start Active.
DB3200.DBX1.0 Activate Automatic Referencing Procedure.
Example: Y Axis set as number 2 in the reference procedure. Interface signal DB3300.DBX1.0 (NC to PLC) changes to 1
while the referencing cycle is active.
Referencing Absolute Encoders Below: Example showing the 1st measuring system declared
as an absolute encoder. The 2nd measuring circuit is not ac-
General information:- tive in this case.
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
the case of an integrated motor encoder. Also checking with
the supplier of the encoder might help determine the correct
type.
Another method is to check the machine data.
upon the active measuring
circuit.

upon the active measuring circuit.
Machine data 30240[0] = 1st Measuring circuit

machine data 30240[1] = 2nd measuring circuit.
Incremental encoders…...30240[x] = 1
Absolute encoders……….30240[x] = 4
Simulation/no encoder.....30240[x] = 0
Notes :

The procedure requires that the axis be moved to a know

mechanical position e.g. 150 degrees. Locate machine data
34100 $MA_REFP_SET_POS and enter 150.
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
approach will be in the positive direction, a value of 1 will
make the approach negative.
Check that machine data 34200 ECN_REFP_MODE is set The feed rate when approaching this position should be re-
to 0 This enables the control to take over the value in ma- duced to avoid inaccuracies caused by backlash.
chine data 34100 $MA_REFP_SET_POS.
Check that machine data 34210 ENC_REFP_STATE is set
to 1. This is to enable encoder calibration to take place.
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.
Check whether machine data-

34010 REFP_CAM_DIR_IS_MINUS is set to 0 or 1.
Confirmation that the correct mode is selected can be seen at Select the axis to be referenced and then press the same di-
the top of the screen. rection key used to position the axis earlier.
The axis will not physically move but the position display will
change to show the axis is referenced symbol and the refer-
ence point set position will be shown as the position of the axis
(150 mm).
Machine data 34210 will have changed to 2 to indicate a suc-
cessful procedure.
Notes :

Machine Data Information

If the axis fails to reach the reference cam it is probably due
A list and brief description of the most common machine to machine data-
data. 34030 $MA_REFP_MAX_CAM_DIST (Default value 10000
mm) This is the maximum distance to the reference cam.
If a machine does not have reference switch cam it is possi- The controller will issue alarm:-20000 Channel %1 axis %2
ble to reference from the zero mark by changing machine reference cam not reached.
data-
34000 $MA_REFP_CAM_IS_ACTIVE (Default value 1) A When the reference switch is activated the axis reverses
value of 0 will deactivate the cam. This is used for example direction in search of the
on axes that have only one reference mark along the entire reference marker. This search speed is determined by ma-
traversing range and rotary axes that have only one refer- chine data-
ence mark per revolution. 34040 $MA_REFP_VELO_SEARCH_MARKER (Default
value 300.0 mm/min).
The direction that the axis approaches the reference switch
can be changed by machine data- The direction that the reference marker search direction is
34010 $MA_REFP_CAM_DIR_IS_MINUS (Default value 0) changed by machine data-
The default value will result in the reference point approach 34050 $MA_REFP_SEARCH_MARKER_REVERSE (Default
in a positive direction. To reverse the direction a value of 1 value 0) The default value cause the axis to search for the
has to be entered. reference cam in the opposite direction to the
direction specified in machine data 34010
The initial approach speed for referencing is determined by $MA_REFP_CAM_DIR_IS_MINUS.
machine data- Entering a value of 1 in machine data 34050 will reverse the
34020 $MA_REFP_VELO_SEARCH_CAM (Default value cam search direction.
5000.0 mm/min)
If the axis fails to reach the reference marker it is probably due

to machine data- 34090 $MA_REFP_MOVE_DIST_CORR (Default value 0.0
34060 $MA_REFP_MAX_MARKER_DIST (Default value 20 mm) This machine data is used to accurately set the position
mm) This is the maximum distance the axis can travel without and correct discrepancies caused by an encoder
finding the marker.. exchange or mechanical work.
The controller will issue alarm:-20002 Channel %1 axis %2 The values in machine data 34080 & 34090 are added togeth-
zero mark missing. er to determine how far
the axis moves.
When the marker is detected the axis will either stop or move
to a position determined by the values of two machine data Usually the position display shows zero after an axis has been
(34080 & 34090 see below for further explanation) referenced. This can be changed by machine data
The speed at which this position sought is determined by ma- 34100 $MA_REFP_SET_POS (Default value 0.0 mm)
chine data- The value entered in here will be displayed on the screen as
34070 $MA_REFP_VELO_POS (Default value 10000.0 mm/ soon as referencing is complete. This is used when the refer-
min). ence position is not the mechanical zero of the machine. The
machine data does not result in the axis physically moving.
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.
B084: END
Notes :

B084 END Encoder Adjustment

B101 Servo Optimisation
SINUMERIK
Operate
Module Description:
This module explains the step-by-step procedure for tuning the speed and position control loops
within the SINUMERIK 828D / SINAMICS S120.
The procedure is based on the onboard functions of the SINUMERIK Operate system.
Module Objective:
In order to ensure the required compatibility and consistency level between the machines
configured with the SINUMERIK 828D control, a defined tuning procedure should be observed.
This procedure is defined in this module.
Notice: This procedure causes the axis to move. All the required safety measures must be taken
into account. Before starting, you must read through the entire description and understand it.
SINUMERIK
Content:
Introduction
Automatic Servo Tuning
Acceleration
Axis jerk
Circularity test
Spindle tuning
Advanced surface
Applications
828D SINUMERIK Operate V4.7 Page 1 This document was produced for training purposes.
B101
B101
B101 Page 2 828D SINUMERIK Operate

Servo Optimisation B101
Servo
tuning:
START
Introduction
Circularity
test
Automatic
Servo
Tuning
Spindle
tuning
Interpolation
path
Advanced
Surface
Acceleration
Applications
Axis jerk
Servo tuning:
END
Notes
828D SINUMERIK Operate Page 3 B101

po The relevant machine data requires an "NCK reset" to take ef-

Introduction
fect.
General notes re The relevant machine data requires an activation through the
Since the drive tuning is a very complex topic within the com- "Reset" button.
missioning, it is recommended that you first read the docu- cf The relevant machine data requires an activation through the
ment to obtain an overview. The individual tuning steps can "Set MD active" softkey.
then be performed in the sequence described here.
The recommendations are summarized again for the most im The relevant machine data is active immediately.
common applications at the end of the module.
Saving the drive data
Note that the strategies described here apply to the majority of Each time the SINAMICS S120 is switched on or a "Drive
machines. Particularly for special-purpose machines or special reset" performed, the configuration data from a file saved on
requirements, it may be necessary to make expert settings. the SINUMERIK control is loaded to the appropriate drive. If
However, as this topic exceeds the scope of this module, drive parameters are changed, the drive data must be saved
which is only intended to explain the operation of AST under so that the changes are retained after the next power off/on or
"standard conditions", it is not considered in more detail. after a "Drive reset".
Please refer to the AST Intensive Training.
Note: An "NCK reset" has no effect on the drive data.
Activating the changed machine data
In this procedure of optimization, certain changes to the ma- To save the drive data:
chine data must be activated. How this change is activated is In the Drive parameters area, press the "Save/reset" softkey,
shown in the last column of the respective parameter value. then the "Save" softkey and finally the "Drive system" softkey.
The following list shows these specifications and their mean- Messages in the lower left-hand area of the screen show the
ing. status of the saving operation. When the saving operation is
finished, the message "All drive objects saved" is displayed.
Control block diagram Setup of basic parameters

828D / S120 control structure: The 828D CNC and the S120
drive control structure contain three cascaded, closed control In order to proceed the optimization successfully some axis
loops (current, speed and position). The individual control loops dependent parameters have to be set at the beginning.
must be tuned in succession: first the current controller, then Those are:
the speed controller and finally the position controller. The dy-
namic machine limits for velocity, acceleration and jerk are set
screw pitch MD31030
in the interpolator. The speed control loop is always closed via h
the motor encoder, whereas the position control loop can be led
back via the motor encoder or the direct measuring system. gear factor axis MD31050 (nload)
i = MD31060 / MD31050 MD31060 (nmotor)
encoder inversion p410
max. acceleration MD32300
SINUMERIK 828D PROFIBUS-DP DRIVE However it is difficult to determine the maximum acceleration
at this point in time because inertia and friction and holding
torques ore often not known. As they likewise the maximum
permitted jerk are irrelevant for the execution of Auto Servo
Tune, we will later come back to this topic.
Notes

Automatic Servo Tuning Notes

If available, the second measuring circuit should be enabled.
The Automatic Servo Tuning function is used to tune the cur-
rent, speed and position control loops, including the speed The (axis) MD32640 dynamic stiffness control is always
feedforward control. This can also be performed by users with- set to 1 by the Automatic Servo Tuning function; this enables
out extensive mechatronic knowledge. However, it is also pos- position control with a faster cycle time.
sible to make expert settings. When using the dynamic stiffness control, MD32110
ENC_FEEDBACK_POL must be set to 1. If the polarity has
Objective: Fine setting of a single axis or spindle using HMI to be reversed, this must be performed in the SINAMICS
SINUMERIK Operate. drive via p410.
 Performance of the frequency response measurements p410[0] & [1] Reverse actual encoder value:
Bit 0: Reverse actual velocity value
 Calculation of the speed control loop Bit 1: Reverse actual position value
 Setting of the current setpoint filters
 Calculation of the position control loop Example: To reverse the actual velocity and actual position
values of the second encoder, set p410[1] = 3.
 Verification of the actual response of the planned con-
trol loops If the automatic tuning is performed for a main spindle, a PLC
 Feedforward control mode: equivalent speed control servo enable signal may not be present. The machine manu-
time facturer should provide a method to enable this PLC interface
signal for the servo tuning, e.g. a special key combination or
 Interpolation paths by setting a special marker in the PLC status.
It is strongly recommended that you use the torque feedfor- Call of the tuning interface
ward control for the tuning. This ensures the greatest possible
contour accuracy.
By keeping the following error sufficiently small, the servo
gain factor has almost no effect on the path interpolation.
Therefore, different servo gain factors are now permitted in The Auto servo tuning screen is the standard screen. If this is
the axes for the path interpolation. not the case, press the "Auto servo tuning" softkey.
It is recommended that the setpoints of the position setpoint

filter "Jerk filter" (AX_JERK_TIME) be smoothed.
General procedure The screen shows whether an axis has been tuned or not.
If a machine or an axis is tuned for the first time, it is recom- The time and date of the tuning is shown for a tuned axis.
mended that this tuning is performed with a robust strategy
without further manual adaptations. This is to ensure that the
axis can be traversed correctly and the controllers can be set
correctly, even if they have not been tuned . The axis can
now be run in, aligned, etc.
In the second step, the tuning is performed again, but now
with realistic loading of the machine (e.g. with installed chuck
and possible a workpiece) with the desired strategy. Without
any load, the machine may be set well for no load, but is in-
stable later with the chuck and a workpiece.
Notes

Adapting the settings Tuning strategy

The tuning process should now be adapted to the require-
ments of the respective axis .
First select the axis to be tuned, and then the strategy can be
The default settings are for tuning at the simple press of a adapted.
button with minimum user interaction. The "Enable strategy
selection during tuning" checkbox is only for experts.
Note: The set strategy only applies for the selected axis!
The strategy settings are divided into three areas: axis

(general strategy settings), speed (speed controller) and posi-
tion (position controller).
Depending on the requirements, different strategies can be

selected in the axis settings (tune position controller and/or
speed controller, with/without verification, etc.). We are using
the strategy "102. Measure and retune speed and pos
ctrl" (the designation can vary slightly depending on the ver-
sion of the software; however the number of the strategy re-
mains the same). The speed and the position controller are
measured and tuned. Verification of the closed-loop will not be
performed due to the easier operation.
Speed controller settings
Selection of the tuning objective

We recommend that the "Moderate responsiveness" ob-
Different strategies can also be selected for the speed control-
jective is used for standard applications. It represents a com-
ler. The strategy "303. With reference model and reserve
promise between dynamic control response and robust set-
2000 Hz current setpoint filter" has proven itself here.
tings.
It is also possible to select a tuning objective. This affects the
The "Robust responsiveness" option should be used
closed-loop control. In this way, it is possible to adapt the
when high tolerances are to be expected in the components
open-loop control to the requirements of the machine.
used and later in the production, or when the masses, e.g.
for a rotary table, vary greatly. These settings increase the
controller stability (poor contour and surface
Notes

properties are achieved with an instable controller; the me-

chanical system is also subject to very heavy loads), but has a
negative effect on the dynamic response and the compensa-
tion of faults.
The last objective "Quick responsiveness" is particularly
suited for machines with high positioning accuracy or higher
machining speeds. However, the robustness of the control
usually decreases, and the axis becomes instable when
changes are made in the mechanical system or loading.
It may be that the preset objectives are not sufficient for the
desired axis behavior. The strategies can be adapted here
based on the specifications (press the "Adapt strategy" softkey
and confirm the prompt with "Yes"). However, these settings
should only be made with adequate background knowledge.
They are therefore not discussed in more detail in this module.
Note: The description of the tuning objectives applies in the
same way to the position controller. The set tuning objective As already shown with the speed controller, there are different
for the speed controller and the position controller is always strategies to adapt the position controller. The strategy "203.
identical. If the objectives are to be set differently, this must be Maximize Kv with NO speed setpoint filter and FFW" has
performed by adapting the strategy (see above). proved to return respectable results for most applications.
It is strongly recommended that the feedforward control (FFW)
be activated and the feedforward type be set to "Torque".
Position controller settings This greatly improves the positioning accuracy. This is already
preset in the above strategy.
Setting parameters  Kv upper limit: Absolute limitation of the Kv value. The

In order to be able to understand the settings better, the pa- gain is limited here in order to achieve a well damped
rameters used for the tuning are explained briefly here: responsiveness to positional faults and to be robust
against changes in the mechanical system.
Speed controller  Feedforward type: The feedforward control is used to
 Aggressiveness: Determines the settings of the control- reduce the contour deviation on finished components.
ler gain (Kp) and the integral time (Tn) depending on The setpoint is reached significantly quicker with the
the specified stability limits feedforward control. Two types of feedforward control
0: maximum stability can be selected:
1: maximum aggressiveness - Speed feedforward control and
 Minimum integral time: Prevents AST setting an inte- - Torque feedforward control
gral time that is too low. If the determined value is lower whereby the latter is recommended because the con-
than the minimum integral time, then this is used in- tour deviations are always very small here. The only
stead of the determined value. This provides more sta- restriction: the smallest moment of inertia (e.g. empty
bility, particularly when mass changes are expected table) should always be used for the tuning.
(e.g. for the main spindle of a turning machine). For directly driven axes only: note the moment of inertia
 Amplitude/phase reserve: Stability criteria for control at the first tuning with robust tuning objective and set it
loops. The higher the more stable. for the second tuning (with real loads).
 Maximum bandwidth: Limitation of the dynamic control-  Jerk filter: Recommended for mold-making applica-
ler response. tions. It is important to produce a surface as homoge-
nous as possible. Quick setpoint changes can be re-
Position controller duced by the filter and the induction of oscillations
 Kv factor reduction: The maximum Kv factor (= position avoided.
controller gain) calculated by the AST is reduced by the The filter time constant (AX_JERK_TIME) must be set
specified value. The maximum Kv factor is the value at manually by the user.
which the position control loop just does not overshoot
after a sudden excitation.
Notes

Note: The drive must support telegram 136 in order to be able Make sure that the axis to be tuned is in a safe position. If this
to use the torque feedforward control. It must also be activated is not the case, you can move the axis to a safe position with
in each drive in: the Jog keys on the MCP. Press "OK" to confirm.
 MD13060[x] = 136
 P922 = [136] SIEMENS telegram 136, PZD-15/19
Executing the Automatic Servo Tuning function:

The following dialog box then appears.
Various screens appear during the automatic tuning proce-

dure. "CYCLE START" must be pressed several times.
After completing the tuning, the following screen appears in

which the new values and the original values can be checked.
This example is from the position control.
The Automatic Servo Tuning function can now be executed.
The values of the speed controller can also be viewed and, if

required, adapted.
It is recommended that the jerk filter be set active in the axis

for mold and die applications. The "Jerk filter enable" check-
box must be activated. "Average" should be set as the jerk
filter type. A Power-On reset may have to be performed after
the tuning (of all axes). If this is the case, a corresponding
prompt is displayed.
The values can now be accepted and saved:
Notes

The dialog box that now appears indicates that the other axes
also have to be tuned for a good tuning result:
The time and date of the tuning now appear.
The other axes should then be tuned in the same way.
Notes

Tuning of the interpolation path
In order to achieve a contour error as small as possible in

multi-axis machining, all the relevant axes must have the
same following error.
After tuning the individual axes, the axes have different con-
troller settings which are the optimum for the respective axis. The interpolation path strategy can now be specified.
In order to ensure a uniform following error, the settings must
be changed to match the axis with the slowest response; this
includes the Kv factor and the feedforward control mode. (The Strategy "1105. Path optimization with dynamics matching
parameters selected for the interpolating axes are shown on element" is recommended.
the next page.)
Select the functions in the tuning menu in order to optimize
the path interpolation:
Select the channel that contains the axes to be tuned:
Description of the strategies: General settings for path interpolation

1105. Dynamics matching element (recommended) Note: The following specified parameters and adaptations
The equivalent time constants of the single axis tuning are re- only serve for better understanding. Manual adaptation is
tained. Parameter DESVAL_DELAY_TIME is used to adapt the normally not necessary.
following error.
Dynamic stiffness control: Is activated or deactivated in all
axes. If activated, it enables a higher position control gain (Kv
With speed feedforward control, a reduction of the Kp factor is factor).
possible, but not necessary in most cases. The noise suppres-
sion worsens when the Kp factor is reduced. The following Feedforward control: If all axes have been tuned with torque
strategies can be selected: feedforward control, this setting is also retained for the path
interpolation. If the feedforward control mode is mixed (3 or
1102. Moderate adaptation 4), FFW_MODE=3 is set for all axes.
Effective Kp factors are adapted. If an axis has been tuned without feedforward control,
Only relevant for speed feedforward control. FFW_MODE=0 is set for all axes.
Kp values can be reduced by up to 50% of the original value.
Kp factor of the main spindle is not reduced in order to corre- Speed setpoint filter: If setpoint filter 1 and DSC and feedfor-
spond to a lower effective Kp factor of a feed axis. ward control are used, this speed setpoint filter has no effect
on the following error (and therefore also no effect on the
1103. Without reduction path interpolation). The filter is recommended to stabilize the
Effective Kp factors are not adapted. position controller (increase of the Kv factor).
With torque feedforward control, an adaptation of the speed
controller gain (Kp) is not necessary. Jerk filter: Except for the "Dynamics matching element" strat-
egy, the settings for the jerk filter must be the same in all
1104. Custom adaptation axes.
Users can adapt the interpolation path strategy according to
their requirements in the lower selection field. DESVAL_DELAY_TIME is used to align different following
errors between the axes.
Notes

Speed feedforward control Performing the tuning

Tn is adapted in all axes.
Reference model (speed control) is adapted. Note: No measurements are required for this step.
Kv factor is recalculated and the lowest value is set for all
axes.
The actual tuning can now be performed:
Torque feedforward control (recommended)
Tn is not adapted. The axes that are to interpolate together can be selected.
Reference model (speed control) is not adapted. In the example, these are the X1, Y1, Z1 and A1 axes:
Kv factor is not adapted
→ The optimum axis values are retained.
Start the tuning:
After some calculations, the result of the tuning is displayed.

Press the "Accept" softkey to activate the settings.
The automatic servo tuning is now completed.
Further checks and settings are required for a complete tuning

of the drives. They are described in the following.
Notes

Maximum acceleration Basic calculations

The physical correlation will be explained briefly because of
In order to determine the maximum permitted acceleration for the need to do some calculations (please note that all calcula-
an axis, the following procedure is recommended: tions here are performed with respect to a rotary drive with a
gearbox and a lead screw).
1.) Determining the axis’ inertia The motor turns with the speed nM and delivers the torque MM.
That is transferred to the load side by the gear box with the
gear factor i = nL / nM = MM / ML. A lead screw with a pitch of h
2.) Determination of the torque maximum limit is transforms this rotary movement, which is applied to
through the slide to the workpiece: F‘L = ML * 2π/h resp.
v‘L = nL * h/2π.
3.) Determination of friction and holding torques
In order to convert the impact of masses use is made by the
mass moment of inertia. The equations are quite similar to the
4.) Determining of the inertia with maximum loading ones mentioned above; only the screw pitch and the gear fac-
tor are squared:
m‘L = JM / (h/2π * 1/i)2.
5.) Calculation of the maximum acceleration
The mass inertia of an axis will be determined during Automat-
ic Servo Tune an written in MD32650. If the task is to get the
6.) Check of the determined values inertia of a loaded axis, the additional mass must be converted
from the load to the motor side an added to this value.
Last but not least the acceleration is due to rearranging the

At the end of this section you will find an example calculation. formula F = m * a:
a = F‘L / m‘L
1. Determining the axis’ inertia 3. Determination of friction and hold torque

The inertia of an axis is automatically determined by AST. 0.9 As friction forces have to be overcome and in case of a sus-
times this value will be saved to the machine date MD32650. pended axis a constant torque (a so called holding torque) has
to be put against gravity acceleration, the permitted maximum
2. Determination of the maximum torque limit acceleration has to be again reduced. Both torques can easily
First of all the current limit of the drive (i.e. minimum out of be identified by a trace. For this purpose the axis has to be
current limit of motor and inverter) has to be identified. Multi- jogged slowly with constant speed and the consumed torque-
plied with the constant kT (p316) you get a maximum electric producing current iq has to be recorded:
torque. Depending on the planned torque reserve (in case
friction increases by the time of usage) one only calculates The following program can be used for this purpose (in case of
with about 80% of this value. a suspended axis it has necessarily to be jogged upwards!):
Now the torque limit of the mechanics is to be figured out:
 Gear box: output sided limitations have to be converted
to the motor side: MM = FL × h/(2π) × 1/i;
in the case of calculating with torque the factor h/(2π)
must be left out; an input sided limitation of the gear box
does not have to be converted
SOFT
 Forces on bearing and joining elements may serve as a
$AN_SLTRACE=0; Reset Start Trace-Trigger
limitation and therefore have to be taken into considera-
G0 X0
tion
$AN_SLTRACE=1; Start Trace-Trigger
G01 X20 F200; slow contant feed
The maximum torque limit is the smaller value of electrically
M30
available and mechanically permitted torque.
By conversion of the result onto the load side the maximum
Now open the trace environment:
permitted acceleration for both, drive and mechanics, can be
determined. This value should be put into MD32300 and acti-
vated with cf before continuing with the further steps.
Notes F‘L
In all calculations in this chapter, quantities that refer MM
to the motor side are marked with the index M, e.g. MM;
rotary quantities which refer to the load side with the
index L, e.g. ML and translational variables which refer
ML
to the load side are marked as primed quantities with
the index L, e.g. F‘L.

In order to find the signals you can make use of the search
filter function.
After that add the following variables:

 Nck/ServoData/nckServoDataActCurr64
(torque –producing current actual value)
 Nck/ServoData/nckServoDataCmdPos2ndEnc64
(position setpoint)
 Nck/ServoData/nckServoDataActVel1stEnc64
(velocity actual value).
The first signal we need is the actual value of the torque- Do as well with the two other variables.
producing current:
When all variables have been added, you must still perform
some settings:
Trace duration and starting conditions:

The axis must be chosen, e.g. X-axis:
The trace can be started manually or automatically. Further-
more the time recorded can be set:
In the following example the trace will be started by a com-

mand in the part program:
The trace start variable can be chosen easily by using the
“Quick list“ softkey:
The selected variable now appears in the list:
Notes

Chose the option $AN_SLTRACE==1.

Moreover it is possible if one of the selected signals (using
“Quick List“) or any other system variable (using “Choose
variable“) reaches the specified condition.
In this case $AN_SLTRACE == 1 is set:
Start/initialize trace:
The trace can be started/initialized by using the “Start trace”

softkey.
That depends on your selection in the “Settings“ screen.
In our example the trace is started by a command in the part
program.
Hit the “Start trace“ softkey, to initialize the trace:
The trace is now initialized and will be started as soon as the

trigger is set by the part program.
Now start the trace:
Current peaks when start- Current consumption dur-

ing out of static friction ing constant movement
The peak at the beginning shows the current during the start
out of static friction. This value is not relevant to these consid-
The three traces will be displayed together; the scaling can be
erations.
adjusted: Click “Zoom“ and choose “X-time axis“ and “Y-value
With the help of the cursor the maximum current of the area
axis“ (both softkeys are now highlighted in blue). Now choose
with constant velocity can be determined.
“Fit overlaid“.
The determined current can now be, again by means of the
Both range and the momentary current actual value will be
torque constant kT, converted into a torque value MM,FH.
displayed:
Notes

4. Determining the inertia with maximum loading 5. Calculation of the maximum acceleration
Until now only unloaded axes were taken into consideration. If Finally, the determined values have to be combined and con-
however a work piece is clamped, the motor need more cur- verted to the load side (the maximum axis acceleration is
rent to achieve the commanded acceleration. If we set up the saved with regard to the linear movement in the controller).
formerly determined values, the motor would quickly reach
current limitation when trying to provide the corresponding The maximum torque on the motor side is calculated as
torque. So, the maximum torque has to be adapted to the MM,max,tot = MM,max - MM,FH and can be converted to a maximum
maximum loading. force F‘L,max on the load side with help of the given formula.
The maximum total inertia is determined as
It is important to figure out realistic values of the loading and Jtot = Jempty + JmaxLoading and converted to a total mass m‘L,tot
possibly set up additional, loading dependent, datasets be- on the load side.
cause the maximum acceleration (depending on the mass of
the additional loading) can be very small. By this the desired The maximum acceleration can be determined by the interre-
acceleration for this machine can possibly not be reached any lationship F = m × a.
more. In the extreme case (madd.loading = Vprocessingarea × ρMaterial)
resulting masses will realistically never be reached on a real
machine. This heavy masses would lead to a very slow accel- This value should be put into MD32300 and confirmed with cf.
eration and by this to longer machining times.
Note: In order to keep the controller from limiting the current
further, the parameter p500 in the drive parameters has to be
set to “[101] Feed drive“ for feed drives!
6. Checking the determined values Add the following variables to the trace as described previous-
To make sure that the set maximum acceleration is not too ly:
high, it can be verified.  Nck/ServoData/nckServoDataActVel1stEnc64
(speed actual value)
For this purpose a new part program has to be generated.  Nck/ServoData/nckServoDataDrvLoad64
This program moves the axis within a given distance so that (Load (m_cmd / m_cmd,limit))
the programmed rapid traverse velocity can be reached, e.g.  Nck/ServoData/nckServoDataActCurr64
300 mm. (torque producing current act. value)
Now set the variable $AN_SLTRACE==1 as starting condition

for the trace and set the recording duration to 5 sec.
SOFT
$AN_SLTRACE=0; Reset Start Trace-Trigger Start the trace:
LAB:
G0 X0
$AN_SLTRACE=1; Start Trace-Trigger
X200 and adapt the display:
GOTOB LAB
M30
Now the maximum load can be measured out of the diagram

Then open the trace environment: with the help of the cursors. This value should not exceed
80%. If the value is higher the calculations have to be
checked.
Notes

Example
The cursor shows that the
Trace selection reached maximum load was at Relevant machine data
about 58.52%.
Imax, MoMo p67 Max. current of the
power module
Imax, motor p323 Max. motor current

kT p316 Torque constant
i (MD31060 / MD31050) Gear factor

h MD31030 Spindle pitch
Jempty MD32650 Mass moment of
inertia of the axis
determined by AST
- p500 Technological
application
amax MD32300 Maximum

acceleration
The example has been performed on the Z axis of a milling

machine.
Step 1: Determination of the axis inertia Now determine the maximum permissible linear force:
JMD = 0.0054 kg m2 (MD32650) F‘L, max = MM,max × (2π / h) × i = 29.1 Nm × (2π / 0.01 m) =
Jempty = 1.11 × JMD = 0.0060 kg m2 = 18275 N = 18.3 kN
(Notice: AST must have been performed for this axis before!)
Step 2: Determination of the torque upper limit Then determine the mass on the load side:
m‘L,empty = Jempty / (h/2π × 1/i)2 = 0.0060 kg m2 / 2.60 × 10-6 m2 =
Imax,MoMo = 36 Aeff (r67) = 2366 kg
Imax,motor = 52 Aeff (p323)
kT = 1.05 Nm / Aeff (p316) This yields the maximum permissible acceleration:
h = 10 mm (MD31030) amax = F‘L,max / m‘L,empty = 18.3 kN / 2366 kg = 7.72 m/s2
i=1 (MD31060 / MD31050)
Enter this value in MD32300 (to ensure that the maximum per-
Power module current limit (Imax,MoMo) ≤ motor current limit missible limit values for mechanics and electronics are not
(Imax,motor), that means, continue to use Imax,MoMo for your calcula- exceeded when performing further tests) and confirm with cf.
tion. Consequently, the maximum electrical torque ME (80% of
the available torque) results: Step 3: Determination of the friction and holding torque
As described in the theoretical part, perform the trace (which is
Mel,max = 0.8 × kT · Imax,MoMo = 0.8 × 1.05 Nm/A × 36 A = displayed here with the Z axis instead of the X axis ). The trace
= 30.24 Nm is displayed on the next page.
In this example, the mechanical limitation is defined via the You can now read off the maximum current from the diagram
gearbox. The machine specification stipulates that the maxi- during constant traversal and convert it into a torque value:
mum input torque Mme,max may not exceed 29.1 Nm. IM,RH = |- 8.6 A| = 8.6 A
MM,RH = kT × IM,RH = 9.0 Nm
Mme, max < Mel,max: The mechanics is limiting. MM,max = Mme,max
Notes

Step 5: Calculation of the maximum acceleration
Now, you must include the torques determined in your calcula-

tion:
MM,max,total = MM,max - MM,RH = 29.1 Nm - 9 Nm ≈ 20.0 Nm
Calculation of the resulting torque on the load side:
F‘L,max,total = MM,max,total × (2π / h) × i = 20.0 Nm × (2π / 0.01 m) =

= 12.44 kN
Together with the load mass, this yields the following accele-
ration:
amax,total = F‘L,max,total / m‘L,total = 12.44 kN / 2396 kg = 5.2 m/s2
Step 4: Determination of the maximum load This value is now entered in MD32300 and confirmed.
As, on the milling machine, the Z axis only comprises the tool, Step 6: Check of the values determined
we assume a maximum additional load of approx. 30 kg: Finally, check the settings. The trace is created, as declared in
the theoretical part. The result (see next page) shows that the
m‘L,load = 30 kg utilization is 76 % and thus close to the requested value of
80 %.
Together with the mass of the empty axis determined before,
this yields: The optimization process is thus completed.
m‘L,total = m‘L,empty + m‘L,load = 2366 kg + 30 kg = 2396 kg
Fault cases
If the utilization is permanently above the requested percenta-

ge value, you must reduce the acceleration.
As the friction value of the individual components changes in

the course of time, it may become necessary to determine the
friction torques anew. This is shown by a higher utilization as
requested, or, in an extreme case, by a trigger of the contour
monitoring. In this case, you must perform the calculation
anew, starting with step 3.
A larger workpiece mass than the one assumed during the

test might have been clamped. In this case, you must repeat
the calculation as from step 4.
Notes

Axis jerk
Example: Jerk effects on the acceleration curve
After completing the automatic servo tuning, the axis
acceleration should be set to meet the requirements of
the machine manufacturer (a check is made later during without jerk-
the torque utilization check). limited accelera-
tion
Large acceleration changes frequently occur with dynamic
axis movements. If these acceleration changes (generally with jerk-limited
called jerk, unit: m/s³) are very large, oscillations can occur on acceleration
the machine axis and thus result in an inexact workpiece con-
tour. In order to reduce this effect, the control can reduce the
jerk. This lengthens the time during which the acceleration
changes.
In the chart on the left, the active jerk filter is indicated by the
rounded corners of the velocity curve.
In the part program, the jerk limitation can be activated with

the "SOFT" command and deactivated with "BRISK". If nei-
ther of these commands is executed, the control uses the Preliminary consideration
default value. This is stored in the channel MD20150[20],
whereby 1 normally activates the jerk filter and 2 (delivery For an optimum setting of the jerk filter, the axis is traversed
state) deactivates it. using a part program and the positioning behavior monitored
with the trace function. If the oscillations are too large, the jerk
The following section explains how the jerk limitation is config- limitation must be adjusted. This procedure is repeated until
ured in the control. the curves have obtained the desired shape.
If the machine axis is using a direct measuring system then the FFWON
actual position value can be determined easily. However, if the SOFT
position control loop is closed via a motor encoder then it is $AN_SLTRACE=0; Reset Start trace trigger
much more difficult to display the position values (e.g. via an LAB:
external measuring system). In this case, the measured posi- G01 Y-110 F10000
tion curves serve as the minimum criterion: overshoot on the G04 F0.5
motor encoder must be avoided. $AN_SLTRACE=1; Start trace trigger
Y-160
Usually, jerk limitation values between 20 and 100 m/s 3 are set G04 F0.5
(corresponding values for rotary axes). GOTOB LAB
There is no need to reach the programmed feedrate. When

considering oscillations, short traversed distances (e.g. 3 to 10 Machine data:
mm) often have a greater effect on the mechanical excitation
than longer traversing distances and should therefore be con- To check the mechanical behavior without the influence of the
sidered as worst case. A dwell time (e.g. 0.5 s) should be position controller, the servo gain factor (position control gain)
maintained when the position setpoint is reached. and the equivalent time constant of the feedforward control
The first programmed feedrate should be set to half the maxi- should be set to 0.
mum axis feedrate. The response behavior for various override
levels (recommended: 10%, 20%, 50%) up to the programmed Position tolerances should also be expanded in order to avoid
velocity (i.e. 100%) can now be considered. Finally, the trace errors during the test.
should be traversed with maximum axis feedrate.
MD 32200 POSCTRL_GAIN = 0
MD 36012 STOP_LIMIT_FACTOR = 100
Part program for the jerk check MD 36400 CONTOUR_TOL = 20
Depending on the configuration of the machine used, the fol-
lowing NC program can be used in Automatic or MDA-
operation. The program contains commands for the activation/
deactivation of the trace trigger:
Notes

Selecting the trace signals: Starting/initializing the trace:

The characteristic curves of the position setpoints and actual
position values are required to set the jerk (see Utilization for The trace is started/initialized via the "Start trace” softkey.
the precise procedure): This depends on the selection in the "Settings" window.
 Position setpoint (64-bit) In our example, the trace is started via the command of a
nckServoDataCmdPos2ndEnc64 part program.
 Actual position value (64-bit) Press the "Start trace” softkey to initialize the trace:
nckServoDataActPos2ndEnc64
After inserting the variables, open the settings:
Start trace: Variable $AN_SLTRACE == 1

Stop trace: When the time has expired, 5.000 seconds
The trace has now been initialized and is started as soon as

the trigger has been set via the part program.
Viewing the trace results: Setting the trace scale:

The part of the trace in which the axis reaches the set position
Start the previously entered program: must be viewed. The trace scale must be adapted for this rea-
son:
The axis moves and the selected signals are monitored for five The following example shows the setting of the scale in order to
seconds. The result is then shown. view tha axis positioning at -110 mm.
The entered values result in a 100 micrometer window around
the target position of -110 mm.
A different scale may be required depending on the machine/
axis used.
The X minimum / X maximum values can also be adapted when
required.
Notes

Tuning the jerk setting:

The jerk must be set so that no oscillation is excited at the
actual position value. This is particularly the case when the
maximum jerk value has been set too high.
A jerk value that is set too low can also have negative effects;
the positioning of an axis takes a relatively long time in this
case.
Without the position controller, the axis is positioned without

overshoot by the control (overshoot must therefore come from
the mechanical system). However, a positioning error results
because the axis is only traversed with the feedrate signals.
An overshoot when the position is reached is caused by the

mechanical system and can be minimized by using the jerk
limitation.
The following examples show the effects of different maximum

jerk values on the positioning of an axis.
However, the following machine data must be checked (note

the old values first):
MD 32810 EQUIV_SPEEDCTRL_TIME = as tuned

MD 32200 POSCTRL_GAIN = 0
MD 32610 VELO_FFW_WEIGHT = 1.0
Set position (yellow) and actual position (green) do not match MD 32620 FFW_MODE = 3 or 4
because the position controller is not active.
Example - jerk too high: This chart shows the rise in jerk until overshoot occurs due to
the mechanical system.
Axis machine data 32431 is used to set the jerk.
Correct the oscillation of the actual position value by reducing
Example - jerk too high: the MAX_AX_JERK.
MD 32431 MAX_AX_JERK = 600
Restart the part program:
Start the trace:
Notes

Example - jerk too low: Positioning with feedforward control and active position
MD 32431 MAX_AX_JERK = 2 contoller:
The positioning contour is rounded when the jerk is too low. If the jerk has been tuned, the position controller and the feed-
forward control must be activated. Set the machine data as
required:
MD 32200 POSCTRL_GAIN = as noted previously

MD 32610 VELO_FFW_WEIGHT = 1.0
MD 32620 FFW_MODE = as noted previously
MD 32810 EQUIV_SPEEDCTRL_TIME = as noted previous-
ly
MD 32431 MAX_AX_JERK = 65
MD 20150[23] = 2 The feedforward control can then be ena-

bled as default setting.
Example - jerk tuned:
MD 32431 MAX_AX_JERK = 65 MD 36012 STOP_LIMIT_FACTOR = original value
MD 36400 CONTOUR_TOL = original value
When the jerk is tuned, there is little or no overshoot and the
positioning contour is sharp.
Example:
Good positioning without overshoot when the feedforward
control and jerk have been tuned correctly:
Notes

Circularity test Technically, the worst case scenario of circle radius and path
velocity must result in a radial acceleration of which the ma-
The circularity test of the controller is used to check the chine is capable.
interpolation of the axes working together. This function
measures a circle, either with the direct measuring system or A distinction is made between the following scenarios:
the motor measuring system. An alignment of the machine
mechanical system is not taken into account in the result. Standard circularity tests of machine manufacturers normally
This enables the commissioning engineer to clearly separate use a radius of 100 mm or 150 mm for feedrates that are
the problems of the controller tuning from the mechanical specified by the machine manufacturer. The machine manu-
problems. It is recommended to verify the machine geometry facturer defines the specifications or an acceptable result.
by using an inspection square (granite master square).
High-speed machining operations generally place high de-
The following position error compensations should be mands on precision at high speed. Therefore, for high-speed
switched off when this procedure is being performed: milling machines, the test circle radii should be in the range
 Backlash on reversal compensation MD32450 from 10 to 25 mm and the feedrates in the range from 5 to
10 m/min. The results for high-speed milling machines are
 Spindle compensation MD32700 generally acceptable when the p/p difference ≤ 0.010 mm and
 CEC compensation MD32710 the actual size of the circle is the same as the programmed
 Temperature compensation MD32750 radius.
 Friction compensation MD32500.
Paremeterizing the circularity test
Note: Backlash on reversal MD32450 must be adapted via an
Open the circularity test user interface:
external device, such as circularity test or dial gauge.
The best contour results are only achieved when the circulari-
ty test returns the correct actual size and shape as well as a
minimum p/p difference for all axis combinations (X-Y, X-Z, Y-
Z).
Generating the circle program

Since SW. 4.7, an NC program can be generated from the
circularity test. After setting the parameters:
The generated program is then displayed and must be con-

firmed:
Important: Make sure that the axes can be traversed ac-

cording to the program and that the paths are free.
The parameters can now be set: Starting the circularity test

The graphic window can now be opened:
Select the axes that are to be traversed in the circularity test
and the respective measuring system at "Measurement".
The required circle settings can be made at "Parameter".
The display options must be selected in the "Representation"

category. They can be adapted later in the chart.
Notes

After the machine axes have described a circle, the result is

displayed:
The NC program can now be executed. Make sure that the

control is in AUTO mode:
After tuning with AST, the circle shown here has a mean
radius that it 0.0019 mm too large.
Generally, the actual radius with tuned feedforward control is

mostly too large. This can be corrected through an additional
The circularty test can then be started. time constant (MD32895 DESVAL_ DELAY_TIME). This
may have to be activated (MD32890).
The machine data shown below is from a real machine that This results in the following figure:
has been used for the following circularity test examples.
Date Description X Y
32200 POSCTRL_GAIN 8.50 8.50
P1460 SPEEDCTRL_GAIN1 3.01 3.89
P1462 SPEEDCTRL_INTEGRATOR_TIME_1 6.18 6.18
P1433 SPEEDCTRL_REF_MODEL_FREQ 106.3 106.3
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 or 4 3 or 4
32810 EQUIV_SPEEDCTRL_TIME 0.0022 0.0022
32890 DESVAL_DELAY_ENABLE 1 1
32895 DESVAL_DELAY_TIME 0.0009 0.0009 The circle is now only 0.00021 mm too large.
Note:
The already existing value has been adapted by AST. Since SW 4.7, it is recommended that the adaptation only
To correct the circle radii, the time constant be performed in special cases via the AX_JERK_TIME
DESVAL_DELAY_TIME is increased in both axes by 0.0002 (MD 32410).
s to 0.0011 s, and activated by cf (whereby the channel must
be in Reset).
Notes

Different time constants

If the time constants of two axes are different, this effects the
following error and therefore the circularity. The circle be-
comes and ellipse or a figure eight. The following:
 AX_JERK_TIME (MD32410),
 DYN_MATCH_TIME (MD32910) and
 DESVAL_DELAY_TIME (MD32985)
mainly effect the differing circularity.
Adjustment of the time constsant

As already explained in the previous section, the adaptation
should normally be made with the DESVAL_DELAY_TIME.
The time constant in one or both axes can now be adapted.

In this way, it is possible to reduce the difference in the
shape.
Example:
In the following example, the X1 axis is too "slow" and cannot
follow the movement of the Y axis. The time constant of the X
axis must therefore be reduced or that of the Y axis in-
creased.
An improved circularity is shown after the adaptation.
Notes

Additional spindle tuning
Compare the preset MD with the MD shown below as well as all the relevant parameters for spindle/axis interpolation.
The example applies to a 8000 rpm spindle motor without mechanical gear stages.
The following parameters can be preset with the values proposed in the table. The values vary depending on 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 Maximum 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 tuned
MD 32200 POSCTRL_GAIN[1] x As tuned
MD 32620 FFW_MODE 3 or 4 3 = Velocity FFW, Torque FFW = 4
MD 32640 STIFFNESS_CONTROL_ENABLE 1 Dynamic Stiffness Control
MD 32810 EQUIV_SPEEDCTRL_TIME[0] x As tuned
MD 32810 EQUIV_SPEEDCTRL_TIME[1] x As tuned
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 tuned
MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL[1] X
MD 35210 GEAR_STEP_POSCTRL_ACCEL[0] X Acceleration in position control mode; to be tuned
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 coarse 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 tuned
MODEL_NATURAL_FREQUENCY
Notes

The speed controller acceleration should now be checked.

The acceleration should be determined first without the effect of the NC.
Set MD: 35200 [0] $MA_GEAR_STEP_SPEEDCTRL_ACCEL = 9999 (t=V/a t=9000/60s/9999 t=15 ms therefore no effect)
35200 [1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL = 9999
Now consider the motor data sheet. For example, 1PH8089-1VM02-0MG1 induction motor:
Acceleration/deceleration with the original motor data, corre-

sponds to the S1 curve.
P640 Current limit 17.7 A

(P305 rated motor current x 1.5)
P1520 Torque limit upper/motoring 4.8 Nm
P1521 Torque limit lower/regenerative -4.8 Nm
P1530 Power limit motoring 1.5 KW
P1531 Power limit regenerating -1.5 KW
Switch to the trace screen: Required variables:
Actual motor speed/velocity value

Active power
Torque-producing actual current value i(q)
Torque/force setpoint (limited)
Make sure that the spindle has been selected when you add
the variables:
The required variables can be selected:
Notes

After completing the trace function, press the "Fit all" softkey:
Enter the following program in MDA:
S8000 M03
G04 F5
M30
Initialize the trace and execute the program:
The acceleration time can be determined with the cursor: The power that is used/available for the acceleration of the
motor can be seen on trace 2:
Trace selection:
actual power
Time required for the acceler-

Trace selection: ation up to the
actual speed set speed = 2.5 seconds
Maximum available power

= 1.5 kW = S1 curve.
Cursor positioned at the start of the

trace and at the point at which the set
speed is reached.
Notes

The torque setpoint can be seen on trace 4: Based on the motor data sheet, the acceleration/deceleration
can be changed up to the maximum values. However, this
Trace selection: depends on the respective application.
torque setpoint
Enter suitable values for the application. In our example, a
short acceleration/deceleration time was required.
The maximum values from the motor data sheet are entered
in the appropriate drive data:
P640 Current limit 32 A

P1520 Upper torque limit / motoring 20.7 Nm
P1521 Lower torque limit / regenerative -20.7 Nm
P1530 Power limit motoring 13 KW
P1531 Power limit regenerating -13 KW
Torque setpoint
= 4.8 Nm = S1 curve.
Execute the spindle and trace function. Spindle position controller

The time required for the acceleration up to the set speed can
A test can now be performed to set the acceleration and jerk of
now be checked.
the position control. This test is performed through tapping
without a compensating chuck.
Trace selection:
actual speed Check MD 35550[0] & [1] DRILL_VELO_LIMIT; this is the
maximum tapping velocity.
Check SD 55484 $SCS_DRILL_TAPPING_SET_MC[0] = 1; it

keeps the spindle in positioning mode during the tapping.
The following program, which drills 10 holes in the same posi-
tion, can be used.
SUPA D0 G0 G90 Z-200

FFWON
Acceleration = 0.795 seconds M19
SOFT
Set the MD: LAB:
35200[0] & [1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL, G331 Z-214 S4000 K1
so that it corresponds to the requirements of the machine G332 Z-200 S4000 K1
manufacturer for the spindle acceleration. REPEAT LAB P=9
M30
Notes

The following variables can be selected in the trace window: Select the trace trigger, etc. via the "Settings" softkey.
Position setpoint (64-bit) The example shows a trace that is triggered as soon as the
Actual position value measuring system (64-bit) actual position exceeds 5 degrees. The trace is recorded for
Contour deviation (64-bit) 10 seconds.
Utilization (m_set/m_set,limit) (64-bit)
Note: Make sure that the correct signal is selected when moni-
toring measuring systems, e.g. measuring system 1 or 2.
Start the trace and press "CYCLE START" on the machine

control panel.
In the example below, the utilization reaches 64% and the posi-
tion control acceleration can be increased.
However, during tapping the spindle can operate above the S1
curve so that you must ensure that the utilization does not
reach 100% as otherwise "Contour monitoring” alarms are out-
put.
Tune 35210 $MA_GEAR_STEP_POSCTRL_ACCEL and Utilzation = 64%

32431 $MA_MAX_AX_JERK to obtain optimum results.
Also check the adaptable control range p1464, p1465 of the

spindle.
Notes

The following example shows the effect of an increase in the

position control acceleration from 120 to 160; the utilization
now increases from 64% to 88%.
If the application is a pure tapping machine, a test can be per-

formed during which 100 holes are tapped and then the servo
trace repeated to ensure that the utilization never reaches
100%.
Utilization = 88%
Notes

Advanced Surface
Background
The “High Speed Settings“ Cycle 832 supports the tooling of free-form surfaces in 3- or 5-axis programs. A good compromise
between machining time and surface quality. The softer the machine runs, the better the surface gets – i.e. a low jerk value has
to be chosen (e.g. between 20-50 m/s3). However, the machining time takes longer in this case. In order to save time, when
roughing the jerk and the acceleration can be set higher by the selection of DYNROUGH. Therefore index 2 of the appropriate
value has to be set to a reasonable value. Normally one will determine experimentally which jerk value is, despite the time
saved, not too hard for roughing, and when surface and accuracy of the part are ok within roughing.
Cycle 832 knows thee different types of machining: roughing, semi-finishing and finishing. For each of this modes there are, in
addition to the normal axis data (DYNNORM), a set of necessary settings. This additional parameters occur only in MD32431
and MD32300.
The dynamic G-code DYNPOS is used mainly for positioning purposes, as tapping.
Machining type dynamic G-Code (group 59) field index in axis-MD

Standard (normal machining) DYNNORM 0
Positioning DYNPOS 1
Roughing DYNROUGH 2
Semi-finishing DYNSEMIFIN 3
Finishing DYNFINISH 4
In order to prevent too many acceleration and stopping operations during milling, it is recommended to use a lower value, as
2 m/s2, while finishing. The acceleration during roughing can be set to the calculated maximal value.
The previously determined jerk value can be set for finishing. For roughing operations, it is recommended to put in a value that is
for times as high as the one for finishing.
Moreover the jerk of the path (MD20600[0…4]) should be set to 10,000 because the jerk values are set for every individual
axis.
In order to be able to determine the appropriate values all optimization steps mentioned before should be performed first of all.
To get approximate start values for an optimization, the set-up rules are summarized in the table below:
Roughing[2] Semi-finishing [3] Finishing [4]

MD32300 (acceleration) amax ≤2
maximum jerk
MD32431 (jerk) finishing x 4 finishing x 2 determined in jerk
optimization
Now the settings can be refined. Therefore it is recommended to create a part program for the verification of these settings. The
optimization is finished when the component properties (especially the surface quality) are as desired. If the surface does not
meet the specifications, the maximum jerk and acceleration values of the dynamic G-code must be further reduced.
Notes

Set-up rules (required setting values are highlighted in gray)
General machine data
Recommend-
MD Name Description Comment
ed value
10050 $MN_SYSLOCK_CYCLE_TIME Basic system cycle 0.002 - 0.004 HW dependent
10070 $MN_IPO_SYSLOCK_TIME_RATIO Factor IPO-cycle 1-2
10200 $MN_INT_INCR_PER_MM Internal calculation resolu- 100 000 100,000 for export version
tion linear axis
10210 $MN_INT_INCR_PER_DEG Internal calculation resolu- 100 000 100,000 for export version
tion rotary axis
10680 $MN_MIN_CONTOUR_ SAMP- Minimal contour sampling = MD 10200 100,000 for export version
LING_TIME time
10682 $MN_CONTOUR_ SAMP- Contour sampling factor 1 Default
LING_FACTOR
18360 $MN_MM_EXT_PROG_ BUF- Maximum reload memory 500 Against sticking, in some
FER_SIZE when xecution from exter- cases values like 2000 had
nal to be used.
18362 $MN_MM_EXT_PROG_NUM Number of ext. programs 2
that can be simultaneous-
ly processed
19330 $ON_IPO_FUNCTION_ MASK Compressor functionality If only the Bit 8 = 1 is acti-
Bit 8: 3-axis Bit 8 = 1 vated and a 5 axes program
Bit 2: 5-axis Bit 2 = 1 will be executed, only the
tool path will be compressed
not orientation.
NO ALARM!
Channel machine data
Recommend-
ed value
20150 $MC_GCODE_RESET_ VALUE[3] Initial setting G group 4 3 FIFOCTRL
20150 $MC_GCODE_RESET_ VALUE[20] Initial setting G group 21 2 SOFT
20150 $MC_GCODE_RESET_ VALUE[44] Initial setting G group 45 2 UPATH

(for 5-axis machining)
20150 $MC_GCODE_RESET_ VALUE[50] Initial setting G group 51 2 ORIAXES
(for 5-axis machining)
20170 $MC_COPRESS_BLOCK_ PATH_ Maximum length of 20
LIMIT POLYNOM generated by
the compressor
20172 $MC_COPRESS_VELO_TOL Max. deviation of the path 1000 Default
feed for COMPCAD
20442 $MC_LOOKAH_SYSTEM-PARAM System parameter for 0 Default
[0-19] extended Look Ahead
20443 $MC_LOOKAH_FFORM[0-1] Activate extended Look 0 Default
Ahead for selected tech-
nology-specific dynamic DYNNORM, DYNPOS
values
20443 $MC_LOOKAH_FFORM[2-4] Activate extended Look 1 See also Daimler machining
Ahead for selected tech- times
nology-specific dynamic 2 = LAHT
values 1 = LAHP (NCK83)
For =1 always the latest
LAH will be used.
Notes

Recommend-
ed value
20450 $MC_LOOAH_RELIEVE_BLOCK_ Relief factor for block 0 Deactivated
CYCLE cycle time
20455 $MC_ LOOKAH_FUNCTION_MASK Look Ahead special func- 0 Deactivated
tion related to safety inte-
grated
20460 $MC_LOOKAH_SMOOTH_FACTOR Smoothing factor for Look 0 Deactivated
Ahead
20465 $MC_ADAPT_PATH_ Reduction of Acceleration 1 Deactivated
DYNAMIC[0-1] BRISK/SOFT
20470 $MC_CPREC_WITH_FFW Programmable contour 3
accuracy CPRECON is
active if FFWON = 1
20476 $MC_ORISON_STEP_LENGH Path length for block 0.5 Default
division
20478 $MC_ORISON_MODE Mode of ORISON 100 100 = Chopper active
20480 $MC_SMOOTHING_MODE Behavior of smoothing x0x Default;
with G64x important: ten’s = 0
20482 $MC_COMPRESSOR_MODE Compressor mode 300 = Use 100
20484 $MC_COMPRESSOR_ Compressor behavior 9 Default

PERFORMANCE
20485 $MC_COMPRESS_SMOOTH_ Smoothing by compressor 0 Shall not have an effect
FACTOR[0-1]
20485 $MC_COMPRESS_SMOOTH_ Smoothing by compressor 0.0001 Shall not have an effect
FACTOR[2-4] or smaller value
20486 $MC_COMPRESS_SPLINE_ Compressor spline de- 3 Default
DEGREE[0-1] gree
20486 $MC_COMPRESS_SPLINE_ Compressor spline de- 5 3 = Default; 5 = COMPCAD
DEGREE[2-4] gree
20487 $MC_COMPRESS_SMOOTH_ Compressor smoothing 0 Default
FACTOR_2 [0-1] rotary axis
20487 $MC_COMPRESS_SMOOTH_ Compressor smoothing 0.5 Warning: At small path
FACTOR_2 [2-4] rotary axis length the smoothing has a
strong impact
20490 $MC_IGNORE_OVL_FACTOR_ Influence of G642 1
FOR_ADIS
20560 $MC_G0_TOLERANCE_FACTOR Tolerance factor with 3 Max. 5
COMPCAD, G645, OST,
ORISON
20600 $MC_MAX_PATH_JERK[0-1] Path jerk
20600 $MC_MAX_PATH_JERK[2-4] Path jerk 10 000 Deactivated
20602 $MC_CURV_EFFECT_ON_ Ratio, translator to cen- 0 Deactivated
PATH_ACCEL [0-1] tripetal acceleration
(DYNNORM, DYNPOS)
20602 $MC_CURV_EFFECT_ON_ Ratio, translator to cen- 0.65 (depends Limitation of the centripetal
PATH_ACCEL [2] tripetal acceleration on machine acceleration
(DYNROUGH) mechanic)
20602 $MC_CURV_EFFECT_ON_ Ratio, translator to cen- 0.6 (depends Limitation of the centripetal
PATH_ACCEL [3] tripetal acceleration on machine acceleration
(DYNSEMIFIN) mechanic)
20602 $MC_CURV_EFFECT_ON_ Ratio, translator to cen- 0.5 (determined Limitation of the centripetal
PATH_ACCEL [4] tripetal acceleration by circularity acceleration
(DYNFINISH) test)
Notes

Recommend-
ed value
20603 $MC_CURV_EFFECT_ON_ Effect path curvature on 0 Deactivated
PATH_JERK path jerk
20605 $MC_PREPDYN_SMOOTHING_ Factor for curve smooth- 1 Default
FACTOR [0-1] ing
20606 $MC_PREPDYN_SMOOTHING_ Activates curvature 0 Default
ON[0-1] smoothing for selected
technology-specific dy-
namic values
(DYNNORM, DYNPOS)
20606 $MC_PREPDYN_SMOOTHING_ Activates curvature 1 Function for Advanced Sur-

ON[2-4] smoothing for selected face
technology-specific dy-
namic values
(DYNROUGH, DYNSEMI-
FIN, DYNFINISH)
20607 $MC_PREPDYN_MAX_FILT_LENG Maximum filter length for 2 Default

TH_GEO [0-4] geometry axes
20608 $MC_PREPDYN_MAX_FILT_LENG Maximum filter length for 5 Default
TH_RD [0-4] rotary axes
28060 $MC_MM_IPO_BUFFER_SIZE Memory interpolator for 150
number of G1 blocks
28070 $MC_MM_NUM_BLOCKS_IN_ Memory preparation (pre- 80
PREP processing)
28520 $MC_MM_MAX_AXISPOLY_PER_ Maximum number of axis 5
BLOCK polynomials per block
28530 $MC_MM_PATH_VELO_ Number of memory ele- 5
SEGMENTS ments for limiting the path
velocity
28533 $MC_MM_LOOKAH_FFORM_ Memory for extended 18
UNITS Look Ahead
28540 $MC_MM_ARCLENGTH_ Number of memory ele- 10
SEGMENTS ments to display the arc
length function
28580 $MC_MM_ORIPATH_CONFIG Configuration for path 1
relative orientation ORI-
PATH with OST, OSD
28590 $MC_MM_ORISON_BLOCKS Number of blocks for ori- 100
entation smoothing
28610 $MC_MM_PREPDYN_BLOCKS Memory for curative 10

smoothing
29000 $OC_LOOKAH_NUM_CHECKED_ Number of Look Ahead 150 Must be the same than
BLOCKS blocks MD28060
Setting machine data

Recommend-
ed value
42470 $SC_CRIT_SPLINE_ANGLE COMP-criterion for target 36 Default
point analysis (should be
>30° )
42471 $SC_MIN_CURV_RADIUS Factor for coprocessor 1
tolerance
42500 $SC_SD_MAX_PATH_ACCEL Limits the path accelera- 10 000
tion vie Setting Data
Notes

Recommend-
ed value
42502 $SC_IS_SD_MAX_PATH_ACCEL Activates path accelera- 0 Deactivated
tion vie Setting data
42510 $SC_SD_MAX_PATH_JERK Limits the path jerk via 10 000
Setting data
42512 $SC_IS_SD_MAX_PATH_JERK Activates path jerk via 0 Deactivated
Setting data
42674 $SC_ORI_SMOOTH_DIST Maximum deviation for 5 For 5-axis application and
smoothing of tool orienta- OSD
tion with compressor with
OSD
42676 $SC_ORI_SMOOTH_TOL Tolerance for smoothing 1 For 5-axis application and
of tool orientation with OST
OST
42678 $SC_ORISON_TOL Tolerance for smoothing Side-milling: 0 For 5-axis application and
of tool orientation with Face-milling: ORISON
ORISON 0.1
Axis machine data

Recommend-
ed value
32300 $MA_MAX_AX_ACCEL[0-3] Axis acceleration Depends on
mechanic
32300 $MA_MAX_AX_ACCEL[4] Axis acceleration 1...3 To avoid machine reso-
(DYNFINISH) nance
32310 $MA_MAX_ACCEL_OVL_ Overload factor for axial 1.2 Default
FACTOR[0-4,AX] velocity steps (G64)
32400 $MA_AX_JERK_ENABLE[AX] Enable axes filter Determined by optimization
positioning / circle test
32402 $MA_AX_JERK_MODE[AX] Axes filter type 1 of 3 2 Same in all axes
32410 $MA_AX_JERK_TIME[AX] Filter time or filter se- Determined by optimization
quence positioning / circle test
32431 $MA_MAX_AX_JERK[AX] Axis jerk = MD 32410
32432 $MA_PATH_TRANS_JERK_ Axis jerk on block border = MD 32431
LIM[AX]
32640 $MA_STIFFNESS_CONTROL_ Dynamic stiffness control 1 Same in all axes
ENABLE[AX]
33000 $MA_FIPO_TYP[AX] Type of fine interpolator 3 Same in all axes
(only effective, if factor
IPO-cycle > 1)
33100 $MA_COMPRESS_POS_TOL[AX] Compressor smoothing 0.01 Value depending on machin-
tolerance for linear axes ing / cycle usually = 1,2 cor-
dial deviation CAM
33120 $MA_ PATH_TRANS_POS_ Maximum deviation when 0.005 Same in all axes
TOL[AX] smoothing with G645
Notes

Applications
Servo motor with gearbox / ball screw:

Selecting the tuning objective:
For axes on which very different loads are expected, "robust" or "moderate" is recommended as tuning objective.
One encoder: The limitation of the position control gain is active.

The max. Kv can be set and is specified, for example, through the selection of the tuning objective.
Because of the measurement on the motor encoder, a higher controller gain would probably be
possible.
Two encoders: The limitation of the position control gain is active.
The max. Kv can be set and is specified, for example, through the selection of the tuning objective.
The mechanical frequency response is also measured. If low-frequency resonances are measured
here, this can lead to a further reduction of the position control gain so that the position on the load
side does not overshoot.
If the maximum possible position control gain is to be calculated, the "max. Kv" limit must be increased to a higher value (e.g. 20
m/mm/min).
Indirectly driven turning spindle:

The "Robust responsiveness" tuning objective is recommended.
If a higher dynamic response is required in the speed controller, select "Moderate responsiveness" increase the minimum inte-
gral time to at least 20 ms in the speed controller strategy. If different gear stages are used, they must be selected before
each tuning and then tuned with AST.
Milling spindle:
The robust or moderate tuning objective is recommended.
The tuning refers to the establishment of a stable speed controller and a stable position controller. The feedforward
control is also set.
If different gear stages are used, they must be selected before each tuning and then tuned with AST.
The ramp-up times are not tuned.
If third-party motors are used, they must be set up with the aid of the respective data sheets or SINAMICS MotID.
The current controller adaptation, etc. is not determined through AST.
Torque motor, linear motor and directly driven turning spindle:

"Moderate" is recommended for most applications.
"Quick" is recommended for high demands on accuracy and mold making.
The "Programmable AST for retune" option is recommended for very different clamping situations and load moments of inertia.
The axis can be retuned automatically (after a significant change in the load moment of inertia).
This must be supported by the machine manufacturer.
Because of the unknown mounting situation and greatly varying loads, it may be necessary to manually influence the measuring
parameters for the speed-controlled system.
You can do this after a measurement, or— if the required measuring parameters are already known — selected at "Strategy"
before starting the tuning.
Notes

Gantry:
The gantry grouping must be set up and synchronized in the SINUMERIK. AST recognizes which axes belong to the gantry
grouping and tunes all the associated axes automatically. Whereby, the gantry grouping is traversed with all axes and each axis
measured individually. The tuning results are checked for dynamic equivalence. All gantry axes are then set with the same
speed controller and position controller dynamic response. The current setpoint filters can be different (sutiable for the respective
axis).

"Moderate" is recommended for most applications.
"Quick" is recommended for high demands on accuracy and mold making.
The "AST for automatic retuning" option is recommended for very different clamping situations and load moments of inertia. The
axis can be retuned automatically (after a significant change in the load moment of inertia). This must be supported by the ma-
chine manufacturer.
Gantry with torque or linear motors:

Because of the unknown mounting situation and greatly varying loads, it may be necessary to manually influence the measuring
parameters for the speed-controlled system.
Requirement: In order to be able to ensure that all gantry axes have the same dynamic response, the axes must have
the same structure (same motor types, same encoders, same gear ratio).
Master-slave:
Must be tuned manually
If a clamping arrangement is required (torque difference), the clamping torque must first be selected and the torque compensato-
ry controller set.
The speed-controlled system, the speed controller reference frequency response and the position controller reference frequency
response can then be measured manually.
During this process, the master-slave grouping is always moved uniformly with all motors.
Notes

B101
B101 End Servo Optimisation
Notes

B106 Adaptive Friction Compensation
SINUMERIK
Operate
Module Description:
The "Adaptive Friction Compensation" option of the SINUMERIK 828D is described in this module.
This option enables acceleration-dependent friction effects at the reversal points of an axis to be
partly or totally eliminated.
The friction compensation is part of the Setup user interface.
Module Objective:
In order to be able to use the friction compensation with its new functionality, it is important to
understand the technical background and to know the individual input steps. This is explained in
the module.
SINUMERIK
Content:
Technical background
Requirements
Implementation in the control
Automatic optimization
Manual optimization
Expert settings
828D SINUMERIK Operate V4.7 Page 1 This document was produced for training purposes.
B106
B106

Adaptive Friction Compensation B106
Adaptive Friction
Compensation:
START
Technical
background
Requirements
Implemen-
tation
Automatic
optimization
Manual
optimization
Expert
settings
Adaptive Friction
Compensation:
END
Notes

Technical Background
"Stiction" from Debenben - Own publiction. licensed under Creative Commons Attribution-Share Alike
When starting an axis from standstill, stiction forces occur (F H)
that are opposite to the desired axis movement and keep the
axis stationary (see figures 1-3 on the right). Only when a criti-
cal friction force is overcome is the body released from standstill
http://commons.wikimedia.org/wiki/File:Stiction.svg#mediaviewer/File:Stiction.svg
and starts to move (figure 4). The stiction forces are caused
mainly by the guide mechanism and bearings of the axis. The
effect can often be reduced through sufficient lubrication. How-
ever, if suitable workpiece quality cannot be achieved at the
reversal points, the Adaptive Friction Compensation can be
used.
A value can be added to the feedrate to compensate for the

friction forces. Since the friction forces depend on the accelera-
tion, the SINUMERIK control can specify this addition, the ve-
locity injection pulse, for up to nine different acceleration values
as well as the active time and the decay time. The values are
interpolated linearly between these so-called interpolation
3.0 via Wikimedia Commons -

points.
Extensive mechatronic know-how is not required to program the

interpolation points. The user is assisted by an easy-to-use user
interface.
Of course, it is also possible to make expert settings directly in
the machine data.
Requirements The required softkey does not appear until the license has
been activated and the machine data has been set for at least
The license 6FC5800-0AS06-0YB0 must be purchased in or- one axis.
der to be able to use the Adaptive Friction Compensation func-
tion. The associated Friction compensation with adaptive
characteristics option must be activated in the License menu:
Before the function can be used, some machine data, which is

to be influenced by the Adaptive Friction Compensation must
be set in all axes:
 $MA_FRICT_COMP_MODE 32490[0] = 3
 $MA_FRICT_COMP_ENABLE 32500 = 1
The calculation accuracy

 MD10200 $MA_INT_INCR_PER_MM and
 MD10210 $MA_INT_INCR_PER_DEG
must also be set to at least 10000 for an automatic optimiza-

tion of the friction compensation. This step can be skipped if
optimization is only to be performed manually.
The changes to the MD must be activated via a po.
Notes

Implementation in the control Feedrate v
[mm/min]
B C
The characteristic (see figure on the right) of the acceleration
values is stored in the control as a data list. The values are in
the axis machine data of MD32490 — MD32588.
However, apart from the activation, a direct change of the ma-

chine data is not required for the setup via the setup wizard.
A
The values acceleration, amplitude (of the velocity injection
pulse), active time and decay time are relevant for the use of
the compensation.
Time t
The amplitude (A) describes the height of the velocity injection [s]
pulse at the reversal point.
The active time (B) is the time which the amplitude is added to The feedrate values for the interpolation points can be preset
the feedrate. individually. The control calculates the accelerations from
The amplitude is reduced during the decay time (C) in the form feedrate and travelled circle radius with a=v²/r and saves the
of a decaying exponential function. respective values as interpolation points in the machine data.
The required values for amplitude, active time and decay time
between the specified interpolation points are then interpolat-
ed linearly during operation.
The diagram above shows an example of a characteristic

curve for the active time, decay time and amplitude.
Notes

Automatic optimization
The automatic optimization of the Adaptive Friction Compen-

sation produces good results even without special knowledge
or much experience. The manual mode should therefore only
be used in special cases.
Open the user interface of the Adaptive Friction Compensa-

tion:
All axes for which the friction compensation is available are

shown on the start screen. Preparation
Already optimized axes are identified by the keyword To optimize an axis, it is important to specify possible
"Optimized" and the time stamp of the optimization. These feedrates for a circular path and a target tolerance band.
fields are empty before the optimization. This information is necessary because a machine cannot
arbitrarily be "well" optimized and a compromise has to be
found between speed and accuracy.
The values can now be entered in the control. To do this,

open the data list. Alternatively, you can accept the preset
values.
Note: During the optimization, the feedrates are processed in

a sequence determined according to an algorithm. This may
not correspond to the sequence of the values in the data list.
Axis selection
The axes on which the Adaptive Friction Compensation is to
be used can now be selected. It is recommended that you
optimize all of these axes. Each axis is traversed and opti-
mized separately.
The following parameters can be set:
Radius: $SCS_FRICT_OPT_RADIUS
Feed: $SCS_FRICT_OPT_FEED[i]
- i = 1 … 9 (interpolation points) Note: The channel must be in the AUTO mode and all select-
- Not all possible interpolation points have to be ed axes must be enabled.
assigned feedrate values; however, an entry of 0
cannot be followed by entries not equal to 0 After the required axes have been selected, press "Start".
The values of the rotary axes are in the respective variable
with the extension _ROT.
Complete the entries and back.
Notes

Adapting the program

The following window which contains the NC program ap-
pears:
Note: To insert a line break, press [Shift]+[Enter]. [Enter] alone

switches to the next input field.
CYCLE790 ensures that the axes traverse circularly.
Changing the program

It may be necessary to insert changes in the program, e.g. Starting the optimization
cancellation of a clamping for rotary axes.
The measuring cycle now starts. The measurement progress Information on the number
is displayed next to the axis being optimized. of steps and feedrate
Selected axis
The current results and the determined parameters can be
displayed. To do this, click in the graphic (see the figure on Determined comp.values
the right).
The cycle automatically runs through all selected axes.
After completion of the optimization, the result is displayed

next to the respective axis:
If the optimization does not provide any satisfactory results, a

manual optimization may be necessary subsequently. The
automatically determined compensation values are then used
as the starting point.
The interpolation points can also be changed subsequently

and the axis optimized again automatically. The algorithm Display of the resolution, the determined deviation from
the setpoint and the set radius.
takes the active compensation values into account, which
reduces the optimization duration.
Notes

Manual optimization  Use / to select the axis to be adapted
The manual mode is available for special applications or if the Method

results of the automatic optimization are not adequate. Note: Only the axis that has been selected with the above
The optimization is performed on the basis of the currently buttons is adapted.
active values (i.e. the optimization results if an automatic or a The measured values of the selected axis are displayed on
manual optimization has been performed previously). the vertical axis in the diagram.
Open the user interface of the manual optimization: 1 axis:

 Selected machine axis is traversed via a sine polyno-
mial
 Spindles, rotary axes or axes in general can also be
adapted in this way without coupling
 Diagram horizontal axis: Measured values of the ma-
chine axis rotated through 90°
2 axes:
 Traversing of two geometry axes in a circle
 This function is only relevant for special cases and is
not considered further here
Extended settings
The parameters to be set are identical to those of the auto-
matic optimization and are described in the relevant section.
Only the direction of rotation is also required
($SCS_FRICT_OPT_DIR_MINUS). However, this is only
active for two-axis traversing.
Strategy Starting the measurement and compensation values

Adaptation of the parameters until the measurements are The measurement is started in the same way as in automatic
within the required tolerance band (trial-and-error method). mode:
Before the adaptation: Determine the target tolerances and  Operating mode = AUTO and enables active
specify the possible feedrates for a circular path.  "Start" softkey
 If required, adaptation of the program
There is a plausibility check before the start of the measure-
ment. The following parameters are checked:  Confirmation of the program
- Observance of the maximum permissible feedrates  NC start
for the machine
- No 0 for the feedrates of the interpolation points The NC now performs the circle measuring program cyclically
(unless it is the last specified value) and displays the result in the circle diagram. Changes can
now be made to the compensation values. The current meas-
Recommendation for the setting of the feedrates: urement is terminated, the new parameters activated and the
1. Average feedrate measurement started again automatically.
2. High feedrate
3. Low feedrate
Now measure and adapt these three interpolation points. As an example, the X axis of a real machine is measured.
If required, interpolation points can be inserted one after the The circularity diagram shows the following result:
other and the compensation parameters set if the measured
values are not in an acceptable tolerance band. If the result is
satisfactory from the start, the relevant intermediate point can
be removed again.
Notes

Information on the number

of steps and feedrate
Resolution setting. If no value is entered, this parame-

ter is adapted after every measurement. If a value is
entered manually, this value is retained in all the sub-
sequent steps.
Performing a measurement with one axis

Separate parameters for the upper and lower reversal points.
Particularly with vertical axes, the force of gravity generates an  One axis (X1)
acceleration in the opposite direction to the motion at the lower  Resolution set to 1 µm/scl
reversal point. Different values must then be set for each rever-
sal point. Circularity outside the required tolerance (1 µm)
Equidirectional deviation
→ Reversal points do not have to be adapted separately
Setting of amplitude, decay

time and active time
Notes

B106 END Adaptive Friction Compensation
Note: The arrow and page up/down keys can be used to

make fine settings.
The deviation can already be reduced by adapting the ampli- Select the text field:
tude and the decay time.
The measured values are now within the tolerance band and
the measurement can be continued with the next step.
Amplitude +0.1 -0.1 +1.0 -1.0

Times +0.001 -0.001 +0.01 -0.01
Repeat this procedure for all

subsequent interpolation points.
Accepting changes Expert settings

After adapting the last step:
The control has further parameters for special application:
 Delay time before addition of the velocity injection

pulse
 Additional trigger delay
 Smoother rise of the curve
 Torque injection pulse (+ delay time and smoother rise
of the curve)
 Effect of the compensation on the actual value and not
on the setpoint (32490[0] = 4)
Important note
Determined and edited parameters are only kept temporari- The setting of these values requires greater knowledge of the
ly during the measurement and not saved and activated in mechanical system and the control, and should only be per-
the machine data until after the measurement is completed. formed by experts. These parameters are also not supported
by the Settings user interface.
This is performed through confirmation after the last step.
Parameters have only been completely saved when the Start

button is grayed-out.
If there is a power failure during this stage, all deter-

mined values are lost. It is therefore recommended that only
a few steps are adapted and then the changes saved before
continuing with the next step.
Notes

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. If the number of axes on the
NCU is not sufficient, the system must be retrofitted with a NX.
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 example.
An extension of an existing 5-axis system (spindle, X, Y, Z, A) on the NCU with a NX10
Module Objective:
At the end of this module, you will be able to add to a running system:
 An additional axis
 A NX
Content:
Sinumerik
Information
Options and Licensing
Adding the Additional Axis
Extension with NX
B016
B016

Additional Axis Installation B016
Additional Axis
Installation:
START
Information
Options and
Licensing
Adding the
Additional
Axis
Extension
with NX
Additional Axis
Installation:
END
Notes :

Informatiom
There are three scenarios that can take place when adding an
additional axis
Option 1 Option 2
Machine tool builder supplies: Machine tool builder supplies:
Line module ALM/SLM Line module ALM/SLM

Single Spindle module S1 Single Spindle module S1
Double motor module X1 Double motor module X1
Y1 Y1
Double motor module Z1 Single motor module Z1
A1 Single motor module A1
Line module sized correctly for all 4 axis plus spindle. Line module sized correctly for all 4 axis plus spindle.
All options commissioned with all enabling within the PLC for All options commissioned with all enabling within the PLC for
the A axis. the A axis.
Channel MD 20070 is set to 0 for the A axis Channel MD 20070 is set to 0 for the A axis
Drive MD p105 is set to 0 for the A axis Drive MD p105 is set to 0 for the A axis
The A axis motor and encoder cables are removed, and sold The A axis motor module, motor and encoder cables are re-
to the customer as an option, and setting the above MD and moved, and sold to the customer as an option, and setting the
parameter to 1 for additional axis use. above MD and parameter to 1 for additional axis use.
Option 3 In the case of option 3 there are many prerequisites to be

considered before adding an additional axis to the machine.
Machine tool builder supplies:
1. Will the Line module size be sufficient to power the
Line module ALM/SLM new motor module.
Single Spindle module S1 2. Will there be sufficient room around the additional
Double motor module X1 modules within the electrical cabinet (See module
Y1 C006) for air movement and proximity to other electri-
Single motor module Z1 cal components.
3. PLC program will have to modified for all enable sig-
Line module sized correctly for all 3 axis plus spindle. nals and safety features required for the additional axis.
All axis commissioned with all enabling within the PLC for a 3
axis plus 1 spindle. Once these prerequisites have been met, and it is possible to
The A axis being not supported. fit the additional axis. The following chapters will explain the
setting of machine data, changes to topology, and assigning
the new hardware to an NC axis
Notes :

To replicate a standard 3 axes + spindle milling machine, the Options and licensing
drive configuration has been changed so that only the double
axis modules are used. Any additional axes may need to be licensed. To check
The single axis module that was previously used for the spin- whether the licence already exists go to the licence screen:
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 Configuring the Additional Axis
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.
When the new hardware is connected and powered reapplied,

the system will detect the new hardware and issue an alarm.
The new axis can also be named accordingly.
In order to keep the original Sinamics drive settings (BICOs)

intact, the topology recognition process for the drives should
not be carried out. This action will reset the BICOs to factory
status.
Instead, the function is available where the extra hardware
To activate the machine data a “Reset (po)” procedure is re- can be manually added.
quired.
Notes :

When the new hardware is fitted and the controller powered To add the new component use the following procedure:
up, the system will detect the extra hardware and issue an
alarm.
Configuration with the additional axis can be seen below:
Ignore error 201416 which indicates that the system has

detected an additional component.
The new hardware is displayed in red:
The new components and component numbers are displayed
Notes :

or
A second encoder (SMC 20) has been assigned to DriveOb-

ject 3.3.6 by the system. In this case the encoder is of the type: Rotary incremental
Configure the second encoder. Sine/Cosine type with 1024 pulses and one zero mark
per revolution.
The new drive Drive- Objekt) has to be assigned to the

correct NC axis
Select the DO.
or or with
Select the axis from the “Setpoint” drop-down menu.
The axis will automatically be selected for the “Actual
Notes :

B016 END Additional Axis Installation
Axis Machine Data
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 spe-
cific machines.
Therefore other machine data will need to be checked. The

values of these machine data depend upon the application of
the newly installed axis.
Example of criteria which may need to be considered:-

 Linear or rotary axis
 Number & type of measuring circuits (Encoders/scales)
 Pulse count of the measuring circuits
 Maximum feed of the axis.
 Jog & referencing feed of the axis
 Direction of travel.
 Monitoring tolerances.
 Position lop optimization.
 Ball-screw pitch
 Gearbox ratios
The axis assignment function results in certain machine data Testing will only be possible if the PLC interface signals for the
for the axis being set. It is however necessary to check and new axis are set
adjust machine data to suit the individual requirements of
specific machines. Interface signals required for this example:
The follow machine data should be set to allow the axes to DB3804.DBX1.5 Activate 1st measuring system.
function as a rotary axis. DB3804.DBX2.1 Controller enable.
MA_IS_ROT_AX DB3804.DBX4001.7 Pulse enable.
With the following machine data should be checked for speed A full list of interface signals is available in Appendix C.
of the rotary axis.
Rotary Axis Optimisation procedures should also be carried out on the

MAX_AX_VELO 32000 3000 axis.
JOG_VELO_RAPID 32010 100
JOG_VELO 32020 50
SPIND_VELO_LIMIT 35100 3000
GEAR_STEP_MAX_VELO 35110[0] 3000
GEAR_STEP_MAX_VELO 35110[1] 3000
GEAR_STEP_MIN_VELO 35120[0] 10
GEAR_STEP_MIN_VELO 35120[1] 10
GEAR_STEP_MAX_VELO_LIMIT 35130[0] 3150
GEAR_STEP_MAX_VELO_LIMIT 35130[1] 3150
AX_VELO_LIMIT 36200[0] 3300
AX_VELO_LIMIT 36200[1] 3300
NOTE:
(Not recommended on actual machines)
Notes :

Extension with NX
The drive data must be saved before the extension! ( Module A17 chapter on data management)
The existing 5-axis system (spindle, X, Y, Z, A) on the NCU is extended with a NX10.
With the new topology, the X-axis and the Y-axis are on the NX10, the spindle, the Z-axis and the A-axis remain on the NCU!
NCU 1 MoMo 2 MoMo 3 4 NX 1 MoMo 2 3
X105 X105
1 2 3 4 1 2 3
X104 X104
X103 X203 X103 X203
X102 X202 X202 X102 X202
X101 X201 X201 X101 X201
X100 X200 X200 X100 X200
Sp Z A X500 X Y
SMI- 13 SMI- 10 SMI- 7 SMC SMI- 7 SMI- 4
ENC- 14 ENC- 11 ENC- 8 ENC- 5 ENC- 8 ENC- 5
MOT– 15 MOT– 12 MOT– 9 MOT- 6 MOT– 9 MOT– 6
2 3 4 2 2 3
The drive system must now be set to the factory settings!

This is how you reset the factory settings
If only the NCU is active (no NX), the SK
“Drive system“ is grayed out!
Notes :

The NC configuration of the machine shows the assigned DO:
Notes :

Delete all axis assignments via:
Configure the Drive Objects!

 Remove the second encoder of the system from DO 3.3.4
 Assign the second encoder to DO 3.3.2
 Configure the second encoder.
Encoder type: Rotary incremental Sine/Cosine with
1024 pulses and one zero mark per revolution.
After assigning the last DO, press the SK

and confirm the dialog with “Yes“!
The drive system overview now shows the new machine con-
figuration!
Now load the saved drive files ‚“DO“
With the "Load data from a file" function, select a drive file
with the extension .TEA (source) and the servo (target).
Confirm the selection with the "OK" softkey.
Notes :

B016 END Additional Axis Installation
The source DOs must be loaded via the "Adapt" softkey func-
tion!
Caution: Never direct Load "Actual topology will be over-
written"!
A016: END
Notes :

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:
 Spindle motor speed

 Tool change
 Spindle centre coolant
 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
Adding language files
B009
B009

Easy Extend B009
Easy Extend:
START
Tag
Descriptions:
Dialogue
Screens
General
Information
and Concept
Adding
language
files
Creating
XML scripts
Easy Extend:
END
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 <OPTION_MD name = $MN_USER_DATA_INT[0]"index"0"/>

<OPTION_MD name = "plc/9061.dbw0"index="0"/>
Agm.xml
<AGM>
<SET_ACTIVE>
</SET_ACTIVE>
<DEVICE> 1
<DEVICE> 2
<DEVICE> 3
<SET_INACTIVE>
<DEVICE> 4 </SET_INACTIVE>
<START_UP>
</START_UP>
<list_id> x </list_id> <name> "Device name" </name> <FORM>

</FORM>
</AGM>
<AMG>
<OPTION_MD name = "plc/db9061.dbw0" index = "0">
<!.....................................................................................................>
<DEVICE>
<list_id>1</list_id>
<name> "Basic Machine Settings"</name>
<password refvar - "plc/db9062.dbd0" />
<START_UP>
</START_UP>
<FORM>
..
</FORM>
<SET_ACTIVE>
..
</SET_ACTIVE>
<SET_INACTIVE>
..
</SET_INACTIVE>
</DEVICE>
PLC <!.....................................................................................................>
<DEVICE>
DB9905 <list_id>2</list_id>
<name> "Spindle Motor (Speed)"</name>
</DEVICE>
Byte Bit Description <!.....................................................................................................>
0 0 = = 1 - device has been commissioned (HMI feedback signal) <DEVICE>
1 = = 1 - device should be activated (HMI request) <list_id>3</list_id>
<name> "Tool Changer"</name>
2 = = 1 - device should be de-activated (HMI request) </DEVICE>
3-7 Reserved <!.....................................................................................................>
1 0-7 Reserved <DEVICE>
2 0 = = 1 - device is activated (PLC feedback signal) <list_id>4</list_id>
1 = = 1 - device has faulted <name> "Spindle Centre Coolant"</name>
</DEVICE>
2-7 Reserved <!.....................................................................................................>
3 0-7 Unique ID of the device </AMG>
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 The agm tag is the root element of the agm.xml.
All other tags are written inside this tag.
A unique file named “agm.xml” is required for Easy Extend.
This file has to be created by the user. Creation of the xml files can be done directly on the controller
or indirectly using AMM Access MyMachine or suitable editing
It is possible to configure all devices within the “agm.xml’. It is program such as Notepad ®.
also possible to use separate xml files for each individual de- Advanced xml editing software programmes are also commer-
vice. These files are called from within the agm.xml file. cially available.
The xml files use tags, which are required for code execution. The required directory is found under the following path:
Each tag performs a specific function. System CF card\oem\sinumerik\hmi\dvm
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
</name of tag> “close tag with / slash”
Short Version <name of tag...Enter script in here…/>
Use the following soft-key sequence to locate the system data

area of the controller
Type in the name-”agm.xml” (Lower case!) and confirm with
Editing agm files using AMM Access MyMachine
It is often more convenient to create and edit files remotely.

Editing the XML files offline and transferring them to the con-
troller is possible using AMM Access MyMachine.
Start AMM Access MyMachine:
Notes :

B009 Easy Extend
The following example shows how to configure Easy Extend

Device 1 using the agm.xml file and a separate file for the de-
vice itself.
Rather than have one file containing the code for many
devices, it makes sense to have one file for each device.
Locate the “dvm” folder .
These separate files can then be called from within the
agm.xml file.
The device is assigned the name of “Test Password” and will

be enabled via the PLC with a user defined password.
The following example is of an agm.xml file with the “include

src” command (Blue text is for information only; orange text is
to be typed into the “agm.xml”):
Below: The agm.xml file without descriptions:

<!Password Example for device 1->
<!Data block 9061 is required in the user PLC program-> <!Password Example for device 1->
<!Data block 9061 is required in the user PLC program->
<AGM> Open the AGM tag
<AGM>
<OPTION_MD name = "plc/db9061.dbw0" index="0" />
<!OPTION_MD name = "plc/db9061.dbw2" index="1" /> <OPTION_MD name = "plc/db9061.dbw0" index="0" />
<!OPTION_MD name = "plc/db9061.dbw4" index="2" /> <!OPTION_MD name = "plc/db9061.dbw2" index="1" />
<!OPTION_MD name = "plc/db9061.dbw6" index="3" /> <!OPTION_MD name = "plc/db9061.dbw4" index="2" />
<!OPTION_MD name = "plc/db9061.dbw6" index="3" />
OPTION_MD tag:
<?include src= "Password_test.xml" ?>
Declaring the PLC variable for enabling the devic-
es in user DB9061.
</AGM>
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
Notes :

Easy Extend B009
The individual xml files for each device should be placed in the
same directory as the agm.xml file.
Example: Password_test.xml (Blue text for information only;

orange text to be typed into the “password_test.xml”) :
<DEVICE> Open the DEVICE tag

<list_id> 1 </list_id> Device number e.g. 1
<name> "Test Password" </name> Device name
<password refvar = "plc/db9062.dbd0" />
password_refvar tag:
The password entered on the Easy Extend screen
will be stored here i.e. DB9062.DBD0
</DEVICE> Close the DEVICE tag
Power the controller off/on to activate the xml files
Below-The Password_test.xml file without descriptions:
<DEVICE>
<list_id> 1 </list_id>
<name> "Test Password" </name>
</DEVICE>
User PLC Program
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:
Notes :

B009 Easy Extend
Double clicking the DB will open up the properties and allow The Data Block will now appear in the Data Block folder of the
the Data Class to be selected, also the author can enter project. Other Data Blocks may also be present.
details if required.
Select the “OK” button:
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.
Enter a suitable name and select the required Data Block

number. Select “OK” to confirm.
User PLC requirements
The example will require a user Data Block to be created 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
HMI that the device is enabled. This is determined by the
“OPTION_MD” tag.
Right click on the Data Block folder and select “Insert Data
Block”.
Notes :

Easy Extend B009
The user DB will require certain information to be entered depending on the number of devices in use.
DB9061
DB9062
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 :

B009 Easy Extend
Enabling and Testing Devices
Device Enabling
Inputting the password:
To input the password, first locate the “Easy Extend” screen
via the following soft-key selection.
To enable the device select the “Enable function” soft-key.

The device created in the AGM file will be listed.
The device will now be enabled, this is indicated by a green

The password (123456) needs to be entered.
tick in the “Function” column.
Notes :

Easy Extend B009
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 :

B009 Easy Extend
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>
<name> "Messagebox" </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>
Notes :

Easy Extend B009
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
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 :

B009 Easy Extend
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 :

Easy Extend B009
The Test Tag
This tag is used to check that the requested actions have been successfully achieved. n the example below the test tag has been used
to check that the output Q4.7 is set to one.
<DEVICE>
<name> "Test 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> The condition of Q4.7 is
"PLC/Q4.7"==1 checked for a value of 1
</condition>
<THEN> If the above condition is true, a value of 1 is
<op> "$actionresult" = 1 </op> written to the system variable $actionresult
</THEN>
<ELSE>
<op> "$actionresult" = 0 </op> If the condition is false, a value of 0 is written
</ELSE> to system variable $actionresult
</IF>
</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 :

B009 Easy Extend
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 file has to be placed in the same folder as the agm.xml file.
<DEVICE>
<password refvar="plc/db9062.dbd0"></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 :

Easy Extend B009
System variables
The following examples shows how R parameters can be used:
<DEVICE>
<name> "R Parameters" </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 = "200" ypos = "150" name = "tiger.bmp" height="180" width="180"/>
</paint>
</FORM>
</DEVICE>
Notes :

B009 Easy Extend
The following screen shows the R parameters and the resized

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.
The “Undo” and “Repetition” soft-keys are available to switch

each single entry between its new and original value.
The “Last configuration” soft-key is available to restore all the

entries to their original values.
Values can be typed directly on the Easy Extend screen and

confirmed with the “OK” soft-key.
Creating and Restoring a “Rollback” Archive

These values can be checked in the “User variable” area.
It is possible to create a complete NC/PLC/Drives/HMI archive
from within Easy Extend\Setup area. This is achieved by se-
lecting the “Start setup” 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 sta-
tus.
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:
<DEVICE>
<name> "Rollback Archives" </name>
<START_UP>
</START_UP>
</DEVICE>
It is possible to write to other system variables, addressing

these variables is described in Section 9.
Notes :

Easy Extend B009
To create the archive:
The archive is created with the following soft-keys
Acknowledge the confirmation box with the “OK” soft-key.
When the archive has been created the „Back“ soft-key is se-
lected.
An archive file with the name of “Rollback.arc” will now be

created and stored in the “dvm_rb” folder.
Restoring a “Rollback” archive Additional Axis
In the event that the previously created archive needs to be Activating and deactivating axes
restored, the “Restore” soft-key can be selected and the dia-
logue box acknowledged. A common requirement is for an extra axis to be added.
A machine can be initially commissioned to include all axis
possibilities. The optional axis can then be deactivated until
required.
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 on the next page :
The dialogue box will clear when the read-in is complete.
Notes :

B009 Easy Extend
<DEVICE> After activation/deactivation, the system waits for drive

<list_id>1</list_id> parameter “p971 Save drive objects parameters” to become
<name> "switch drive active" </name> zero (condition), an NC and drive reset is then carried out to
<password refvar="plc/db9062.dbd0"/> activate the changed machine data.
<SET_ACTIVE> As can be seen in the example xml file, the drive parameter-
<data name = "drive/dc/p105[DO5]">1</data> “P105 Activate/deactivate drive object” is responsible for
<data name = "$MC_AXCONF_MACHAX_USED[4]">5</data> activating/de-activating the drive part of the system.
<data name = "drive/dc/p971[DO5]">1</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_ACTIVE>
<SET_INACTIVE>
<data name = "$MC_AXCONF_MACHAX_USED[4]">0</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_INACTIVE>
</DEVICE>
To activate/de-activate the axis in the NC part of the system,

channel machine data
“20070 MC_AXCONF_MACHAX_USED” is used.
The additional axis is the 5th axis therefore a value of 5 or 0 is
entered into 20070[4] to activate/deactivate.
The activated axis appears on The deactivated axis does not

the machine page: appear on the machine page:
Drive parameter “P971Save drive object parameters” is set to

1 to save the drive Parameters. When the data has been
saved the parameter automatically reverts to a value of 0.
Notes :

Easy Extend B009
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 :

B009 Easy Extend
PLC Addressing
x = variable numeric identifier, b = Bit number.
Inputs Outputs Markers Data Blocks

Mx.b MBx Mx.b DBx.DBx.b
IBx QBx MBx DBx.DBBx
IWx QWx MWx DBx.DBWx
IDx QDx MDx DBx.DBDx
Examples:
<data name = “plc/mb200”> 1 </data> Writing a value of 1 to MB200
<data name = “plc/db9905.dbx2.4”> 1 </data> Writing a value of 1 to db9905.dbx2.4
<data name = “plc/q0.5”> 0 </data> Writing a value of 0 to q0.5
NC Variables
<LET>name = “TempStatus”><LET Declaring a temporary variable with the LET tag.
<OP>TempStatus = “nck/channel/state/chanstatus” </OP> Writing the channel status in to the variable “TempStatus”.
Drive Addressing
The drive path starts with the component identifier (cu for the Control Unit, dc for a drive component)
The object number should be placed in square brackets.

The drive object number differs from the actual drive number because the CU, ALM, DriveCliq Hubs etc are all assigned an ob-
ject number.
Representation Example: Parameter 970 for drive object 2 = p0970[do2]
The drive index number can also be read from a local variable:
Example: Parameter p0970 with the drive object number obtained from the variable called “drive”. This would be written as
p0970[do$drive]
Examples:
<data name=“drive/cu/p0092”>1</data> Writing a value of 1 to the cu, p0092
<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 variable called “driveindex” and setting the value to 0.
<op>driveIndex = $ma_ctrlout_module_nr[0, AX1]</op> Reading the value of the NC variable (ctrlout_module_nr Axis 1) into
the temporary variable (driveindex)
<data name =“drive/dc[do$driveIndex]/p0092”>1<data> Using the temporary variable to determine the drive object number
and writing a value of 1 into p0092.
Notes :

Easy Extend B009
Special XML characters Operators
Some XML editors can incorrectly display certain characters. The following operations are available for use:
These have to be re-written.
The following characters are affected: Operator Significance

= Assignment
Character XML Notation
== Equal to
< < (Less than)
<, &lt Less than
> > (Greater than)
>, &gt Greater than
& & (Ampersand)
<=, <= Less than or equal to
“ " (Quotation) >=, >= Greater than or equal to
, ' (Apostrophe) I Logical OR operation (Bitwise)
II Logical OR operation
Operator Significance
&, & 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 :

B009 Easy Extend
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 $
symbol should be used immediately in front of the variable name.
DATA 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
DRIVE_VERSION
Device 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 :

Easy Extend B009
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 Individu-
al).
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 dia-
MSG logue 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 :

B009 Easy Extend
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 varia-
ble automatically takes the format of the NC/PLC variable.
Variables 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
SWITCH found 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 varia-
TEST ble. If the variable contains a value of one, then the device is functional. A value of zero indicates a faulty
device.
Notes :

Easy Extend B009
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 varia-
ble 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 DB9061.DBWx.
When only devices 1 to 16 are in use, no index is required:
<option_md name=“PLC/DB9061.DBW0”/>
When more than 16 devices are in use, the index must be specified:
<option_md name=“PLC/DB9061.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 (DB9061).
PASSWORD Attribute:
refvar - name of the reference variable.
Example: Declaring DB9062.DBD0 as the target for the entered password-
<password refvar=“plc/db9062.dbd0”/>
Notes :

B009 Easy Extend
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
POWER_OFF text is 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
condition 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.
DO_WHILE Providing that this is the case, again write a value of 15 into QB11. When the condition is false, stop the
loop.
<while>
<data name “plc/qb11> 15 </data>
<condition> “plc/ib9” ==0</condition>
</while>
?UP Update Agent Syntax -
Notes :

Easy Extend B009
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 ele-
INIT ments 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
values 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 :

B009 Easy Extend
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
variables 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 con-
trol and reference variables.
Notes :

Easy Extend B009
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 left-hand corner
ypos – Y position of the upper left-hand 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 left-hand corner
ypos – Y position of the upper left-hand 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 :

B009 Easy Extend
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 Attributes:
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 :

Easy Extend B009
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>
Notes :

B009 Easy Extend
Adding language files
Open the "Project" within AMM software, go "Online" to the

controller.
In the project window highlight the "EasyExtend" menu. Se-

lect the file "oem_aggregate_eng.ts.

text

text
Notes :

Easy Extend B009
Access MyMachine can be used to the create additional lan-

guage specific files for the Easy Extend function.
To add the files, select the "EasyExtend" tab followed by the
"New target language" button:
When all the required alarm text have been edited
Notes :

B009 Easy Extend
Select the file "oem_aggregate_deu.ts. and open with the

"Edit" key
Enter the required text for the second language.
Select, with a tick, all the required boxes, as shown.

Download the two files using the "transfer" button.
Editing the "agm.xml" and "oem_device_1.xml" files:
In the controller window, select the following path: System-CF

-card/oem/sinumrek/hmi/dvm
Notes :

Easy Extend B009
<AGM>
<DEVICE>
<name>$$Option_01</name>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
Open the agm.xml file and modify the text: <name>$$Option_04</name>
</DEVICE>
</AGM>
On the controller the HMI needs to be rebooted
When the language is changed on the controller, the respec-

tive text will be shown.
Notes :

B009 Easy Extend
English: German:
Explanation
In the file "oem_aggregate_eng.ts/oem_aggregate_deu.ts",

the language text is being assigned to a "source" name
(identifier).
In this example the "source" name is "Option_01"
In the file "agm.xml/oem_devive_1.xml" files, the control will

look for the source identier, by using the prefix $$ and the
stated source identifier used from the ts file eg. "$$Option_1",
The text associated with the source identifier will be

displayed.
Notes :

Easy Extend B009
<AGM>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
</AGM>
The active language of the controller determines which lan-

guage file is used.
Therefore:
A controller with English language selected uses the
"oem_aggregate_eng.ts" file.
A controller with German language selected uses the
"oem_aggregate_deu.ts" file.
The file name is: oem_aggregate_eng.ts. The “eng” part of

the name is the language identifier.
Language identifiers:
eng = English
deu = German
fra = French
ita = Italian
esp = Spanish
chs = Chinese (Simplified)
cht = Chinese (Traditional)
kor = Korean
ptb = Portuguese (Brazil)
B009: END
Notes :

B009 END Easy Extend

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
requirements 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
ts Language Files
PLC Interface Signals
Confirming/Resetting/Saving Tasks
Adding additional language files
B020
B020

Service Planner B020
Service
Planner:
START
Enabling the
Service
Planner
PLC
Programme
Example
Setting up
the
Maintenance
Tasks
ts Language
Files
PLC
Interface
Signals
Confirming/
Resetting/
Saving
Tasks
Adding
additional
language
files
Service
Planner:
END
Notes :

Enabling the Service Planner

The Data Block templates can be
In order for the Service planner to function the PLC user pro- found in the Libraries folder.
ject must contain DB9903 and DB9904. These are created Transferring them to the Data Block
with the PLC828 programming tool and then downloaded to folder is achieved by double clicking
the controller. the required template.
To create the Data Blocks first open up the correct project and
open the Data Block folder.
Double Click each Data Block
to add the PLC Project
In this example the required It is possible to change the Data Class of the Data Block and
Data Blocks (DB9903 & add the name of the author if needed.
DB9904) are not present. The box is closed by clicking the “OK” key.
Below: Data Blocks DB9903 & DB9904 are present in

the Data Block folder of the PLC Project.
Save the user project.
Download the project to the controller.
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
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.
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.
Notes :

Location of the Service Planner files:
The red clock symbol
Will be replaced with a green tick
ts Language Files
When a task is created the task names are stored in a lan-

guage dependent ts file. These files can be viewed and edited
on the controller or offline.
PLC Interface Signals

The information entered earlier via the screen can be seen in
the text of the file. It is possible to use an AMM software for The data entered on the screen is stored in the data blocks
creating or editing the offline file. created earlier. This can be seen in the PLC diagnosis area:-
Below is the “oem_maintenance_eng.ts” file containing the
text of the example used above.
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 7 Ackn 6 Ackn 5 Ackn 4 Ackn 3 Ackn 2 Ackn 1
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 7 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1
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 7 Deact 6 Deact 5 Deact 4 Deact 3 Deact 2 Deact 1
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

maintenance action has been completed. Simply resetting the
task without completing the task could result in damage to the
machinery.
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 Once the maintenance task is complete then it can be
screen, a red clock symbol should have appeared in the acknowledged by pressing the “Maintenance Completed” soft
“Status” column and the remaining time column will be zero. -key.
The red clock symbol
will be replaced with a green tick
This will reset the remaining time back to the original and the Saving Service Tasks:
interface bit will remain high for one PLC cycle. This can be All the Service Tasks can be saved/read-in to/from an external
used by the user PLC to acknowledge user alarms etc. USB/CF memory device.
It is possible to reset a maintenance task at any time prior to
the interval time expiring. Exporting tasks:
The “Exporting tasks” soft-key is used to save the tasks.
Tasks can be changed or deleted at any time with the
“Change task” & “Delete task” soft-keys.
The ‘Reset all” soft-key will reset the remaining times

for all the tasks.
Notes :

A warning appears that existing files on the USB/CF device will

Select the destination of the file e.g. USB and be overwritten, select “OK” to continue.
then select the “OK” soft-key.
Enter a suitable name for the file and then select the “OK” soft
-key.
Reading in Service Tasks: The procedure will overwrite any existing tasks on the control-
The “Importing tasks” soft-key is used to read in a task file. ler, select the “OK” soft-key to continue.
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.
Adding additional language files
Open the "Project" within AMM software, go "Online" to the

controller.
Notes :

Adding additional language specific files to "Maintenance

Planner".
Highlight the "Mainten. Planner" menu
Select the file "oem_maintenance_deu.ts.

Open with the "Edit" key.
Notes :


text

text
When the editing of the alarm text is complete, select the

"Save" button, followed by the "Exit" button.
Download the alarm text file by selecting it and using the

"transfer" button.
On the controller the HMI needs to be rebooted
When the language is changed on the controller, the respec-

tive text will be shown.
Notes :

In the project window, highlight the Alarm texts menu.

Select the "oem_alarms_plc_eng.ts" file, and open it with
the"Edit" key.
In the Edit window, change the alarm number and enter the
required text.
In the Edit window, change the alarm number and enter the
required text.
The second language can be edited in the same way by us-

ing the "oem_alarms_plc_deu.ts file.
When the editing of the alarm text is complete, select the

"Save" button, followed by the "Exit" button.
Notes :

Download the two alarm text files by selecting them and us-
ing the "transfer" button.

German: English:
B020: END
Notes :

B020 END Service Planner

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
interface 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:
START
Analogue
Servo
Control via
X252
Analogue Spindle:
END
Notes :

B029 Analogue Spindle
Analogue Servo Control via X252 X252 Terminal Description:

Interfaces: Rear view of PPU showing X252 interface.
Pin 1 AOUT Output for analogue axis +/- 10V

X122 Pin 9 OUT9 NCK DO 9 Digital Output $A_OUT[9]
X132 Pin 11 MEXT3 Ground (M) Ground for pins 9, 10, 12, 13
Digital Output $A_OUT[11] /
Pin 12 OUT11 NCK DO 11 Controller enable/positive direc-
X242 tion for analogue spindle option
Digital Output $A_OUT[12] /
X252 Pin 13 OUT12 NCK DO 12 Controller enable/negative direc-
tion for analogue spindle option
X143
Machine Data for Analogue axis. MD30134 $MA_IS_UNIPOLAR_OUTPUT:
X252 pins 1 & 2 are reserved for the analogue output MD30134 Signal Function
Signal which is used for controlling an analogue servo drive. =0 AOUT (X252.1) Analogue output +/- 10V
(Nominal +/- 10V, can be changed via machine data.) Bipolar
The functionality of the analogue signal can be influenced by spindle with AGND (X252.2) Analogue output 0V
Axis MD 30134 $MA_IS_UNIPOLAR_OUTPUT. enable
The resolution of the analogue output signal is 14bit. Controller enable (+24V
signal. DO11 (X252.12)
DC)
Sinamics digital outputs DO14 & DO15 (X132 pins 12 & 13)
=1 AOUT (X252.1) Analogue output +10V
are used for enabling and direction signals.
Unipolar
spindle,
Machine Data Descriptions. AGND (X252.2) Analogue output 0V
separate
MD30100 $MA_CTRLOUT_SEGMENT_NR: enable/
direction Controller enable (+24V
Activates the axis as an analogue axis when set to 0 DO11 (X252.12)
signals. DC)
(828D digital drive operation = 5)
Negative direction (+24V
DO12 (X252.13)
Note: MD30100 and X252 pins 12 & 13 DC)
X252 Axis MD 30100 = 0 Axis MD 30100 = 5 =2 AOUT (X252.1) Analogue output +10V
Unipolar
Pin 12 Controller enable/positive Digital Output spindle, AGND (X252.2) Analogue output 0V
direction for analogue spindle $A_OUT[11] direction
option dependant Controller enable and
DO11 (X252.12)
enable. positive direction (+24V DC)
Pin 13 Controller enable/negative Digital Output
direction for analogue spindle $A_OUT[12] Controller enable and
option DO12 (X252.13) negative direction (+24V
DC)
Notes :

Analogue Spindle B029
MD32250 $MA_RATED_OUTVAL : MD30240 $MA_ENC_TYP :

Sets the analogue output value (X252 pins 1 & 2) Sets the actual value encoder type.
up to a maximum of +/- 10 volts for maximum speed. Permitted values: 1 = Incremental, 4 = Absolute.
The value entered is a percentage of 10 volts.
Example: MD32250 = 80  80% of 10 volts  8 volts. MD36700 $MA_DRIFT_ENABLE[0] :
When the maximum speed is requested, 8 volts will be present Activation of automatic drift compensation
on X252 pins 1 & 2. Permitted values: 0 = Inactive , 1 = active.
MD32260 $MA_RATED_VELO : MD36710 $MA_DRIFT_LIMIT[0] :

Sets the maximum speed of the axis in rpm. A this speed the Limit for automatic drift compensation, if active.
voltage determined by MD32250 will be present on X252 pins
1 & 2. MD36720 $MA_DRIFT_VALUE[0] :
A basic drift value can be entered as an additional speed set-
MD30200 $MA_NUM_ENCS : point. Works with or without the presence of an actual value
Sets the number of actual value encoders used with the axis, if encoder.
no encoder used, must be set to 0.
MD30220 $MA_ENC_MODULE_NR[0] :
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
MD30220[0] of the axis that the encoder is connected to.
MD30230 $MA_ENC_INPUT_NR[0] :
As previously explained, the encoder is connected as the 2nd
encoder of an existing Sinamics axis, therefore a value of 2
must be entered in MD30230[0].
Example: Notes:
Machine data configuration for a system with 3 digital axes The analogue axis is restricted in the following areas:
and an analogue spindle. The spindle encoder is connected
via SMC to the Y axis Sinamics drive module.  Dynamic Stiffness Control - unavailable.
Machine
X Y Z SP  Torque Feed Forward control - unavailable.
Data
30100 5 5 5 0  The “Drive Ready” signal is simulated and set by the

drive software.
30110 1 2 3 1
 The drive parameters cannot be accessed, utilisation
30120 1 1 1 1 and other drive related functionality will not be seen on
the Service Display screens.
30130 1 1 1 1
30134 0 0 0 0, 1 or 2  Automatic speed and position controller optimisation is

not possible.
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

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
User Interface PLC - NCK
Machine data for Tool Management
Magazine Configuration
Tool load / unload
Tool change sequence
HMI customization
Tool change with a turret
B102
B102

Tool Management B102
Tool Management:
START
Fundamentals
User
Interface
PLC - NCK
Machine data
for Tool
Management
Magazine
Configuration
Load / Unload
Tool change
sequence
Customizing
the Tool
Management
HMI
Tool change
with turret
Tool Management:
END
Notes :

Fundamentals
Requirements
 Sinumerik 828D SW 4.7

 Toolbox 828D SW 4.7
Scope of delivery
Tool management is included in the scope of delivery for all 828D controls (M/T version).
Licensing
 “Replacement tools for tool management“ (Duplo tools)

Order Nr. 6FC5800-0AM78-0YB0
Tool Management Start up sequence
1. Tools/Software installation
2. Load the machine data
3. Magazine configuration
4. Tool load/unload
5. Tool change sequence
6. HMI modifications
Notes :

Tool Management Checklist
Tool management functions Remarks
Define new tool
Tool load
Tool unload
Tool relocate
Position Magazine
Define a new tool directly in the magazine
Define a new tool directly in the spindle
Delete a tool in the magazine
Delete a tool in the spindle
Relocate the tool in the spindle
Prepare tool change
Tool change
Do tool change with a fixed location tool
Do tool change with a hand tool
Reset during tool change
E Stop during tool change
Main switch during tool change
Tool recovery functions

Tool change after block search
Tool change in Simulation
Tool change in Program Test
Tool change in Inch und metric
Tool change in T,S,M
Tool change in *Measure Tool* function
Notes :

Tool management
Magazine configuration
Magazine (9999)
Location (2)
Magazin (2)
LP2
Location (1...n)
Reference (2, 1) etc.
CL
Magazine (9998) Gr2

Location (3) Magazine (1)
Sp Location (1...n)
Reference (1, 1) etc.
Location (1) Gr1
Location (2)
LP1
Magazine (9999)
Location (1)
Magazine 1, 2 Real magazines CL Change Location

e.g chain, turret, box magazine LP1 Loading Position 1 (Spindle/Manual)
Magazine 9998 Buffer magazine LP2 Loading Position 2 (Magazine)
Magazine 9999 Loading magazine Sp Spindle
Gr1 Gripper 1
Gr2 Gripper 2
Notes :

Tool change process for milling machines
programGUIDE
Block search
Destination N100 T=“Face_Mill_20” Tool preparation -> PLC
Move magazine/Tool
N100 to change position
PROG_EVENT -> After BLS
Block search Cycle

=1
ShopMill MD52212.3
M06 L6.SPF
N5...
=0 N150 N10...
.. Program test active?
..
.. Simulation active?
..
ISFILE -> CYCPE_MA .. Block search active?
..
.. Tool in Spindle?
..
.. Hand tool?
Hand tool permitted
..
MD22562.1=1
..
..
..
N85 M206 Toolchange order -> PLC

..
..
M17
M30
Notes :

Tool change process for milling machines
ShopMill
Tool preparation
ShopMill SD55212.0=1
HEADER
Tool preparation -> PLC

MILLING
Tool change -> L6
Block Search
Destination DRILLING
CENTERING
Move magazine/Tool
to change position
CENTERING Tool change -> L6


DRILLING
Block Search Cycle

ShopMill MD52212.3 =1
DRILLING Tool change -> L6

=0 TAPPING
L6.SPF
N5...
ISFILE -> CYCPE_MA N10...
Toolchange .. Program test active?
TAPPING
-> L6 ..
..
.. Block search active?
..
.. Tool in Spindle?
..
.. Hand tool?
Hand tool permitted
..
MD22562.1=1
..
..
END ..
N85 M206 Toolchange order -> PLC

..
..
M17
Notes :

Tool change process for turning machines
programGUIDE
Block Search
Destination N100 T=“Turning_Tool_1” TCHANGE.SPF
N5...
N10...
.. Program test active?
..
N100 .. Simulation active?
..
..
PROG_EVENT -> After BLS ..
..
..
..
..
..
Block Search Cycle ..
=1
ShopTurn MD52212.3
N85 Txx Tool change order -> PLC
..
..
M17
=0
T=“Turning_Tool_2”
ISFILE -> CYCPE_MA
M30
Notes :

Tool change process for turning machines
ShopTurn
HEADER
ROUGHING Tool change -> TCHANGE

Block Search
Destination DRILLING
CENTERING Tool change -> TCHANGE

Block Search Cycle

ShopTurn MD52212.3 =1
DRILLING
Tool change -> TCHANGE
=0
TCHANGE.SPF
N5...
ISFILE -> CYCPE_MA N10...
TAPPING Tool change .. Program test active?
-> TCHANGE ..
..
..
..
..
..
..
..
..
END ..
N85 Txx Tool change order -> PLC

..
..
M17
Notes :

Structure of Tool Management
HMI
Tool list
Tool wear list
OEM-Tool list
Magazine list
NCK
Manage tool data

- State
- Monitoring (cutting time/ pieces)
- Offsets
Manage magazine data

- Magazine
- Magazine locations
Tool Management
- Tool search
- Empty location search
- Tool change
- Load, unload
PLC
Magazine control
Gripper control
Spindle control
Safety interlocks
Notes :

User Interface PLC - NCK
The interface is set up for Tool Management functions: Load/Unload and tool change. The PLC functions DB9900, DB9901 and
DB9902 are used to communicate changes in the current positions of tools.
NCK PLC
PLC-Firmware PLC machine pro-

gram
Machine data
Machine functions for
Load/Unload
DB41xx
...
DB40xx
Acknowledgment for
Load/unload/
the transfer steps
relocate
Tool manage-
ment Machine functions for
Tool change
DB43xx ...
DB42xx Acknowledgment for
Tool change the transfer steps
Magazine data
DB9902
Acknowledg-
ment steps
DB9900 Variable transfer

DB9901 steps / positions
Transfer steps
Notes :

Example: Transfer- and acknowledgment tables
DB4200 Acknowledgement signals for tool change

PLC NCK Signals to TM [r/w]
Acknowledgement step
0000 7 6 5 4 3 2 1 ALL
NC 0001 15 14 13 12 11 10 9 8 PLC
0002 23 22 21 20 19 18 17 16
0003 Res 30 29 28 27 26 25 24
DB9902 Acknowledgement step table [r]

Acknowledgement step 1
0000 Transfer step for new tool 0
0001 Transfer step for old tool 0
0002 Acknowledgement status 1
0003 Reserved
0011 Reserved
0015 Reserved
DB9900 Constant transfer step table [r] DB9901 Variable transfer step table [r/w]
Transfer step 1 Transfer step 101
0000 Source magazine no. 0 0000 Source magazine no. 1
0002 Source location no. 1 0002 Source location no. 0
0004 Target magazine no. 9998 0004 Target magazine no. 9998
0006 Target location no. 2 0006 Target location no. 1
Transfer step 2
0008 Source magazine no. 9998
0010 Source location no. 1
0012 Target magazine no. 9998
0014 Target location no. 3
Notes :

Overview of the interface data blocks
Data block no. Responsible for:
DB4000- Load/unload signals to tool management [PLC NCK]

DB4001 Per loading point there is one interface DB40xx for 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
DB4100- Load/unload signals from tool management [NCK PLC]
DB4101 Per loading point there is one interface DB41xx for jobs for loading, unloading, relocat-
ing a tool (MVTOOL) and for magazine positioning (POSM).
The jobs appear on the interface of the loading point from which the tool is to be ex-
changed
DB4200- Tool change signals to tool management [PLC NCK]
DB4201 Per tool holder/spindle there is one interface DB42xx for 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.
DB4300- Tool change signals from tool management [NCK PLC]
DB4301 Per tool holder/spindle there is one interface DB43xx for jobs for preparing and execut-
ing the tool change.
The jobs appear in the tool holder interface (of the spindle) where a tool is to be
exchanged.
DB9900 Constant transfer-step table [r]
The individual tool movements are defined as transfer steps – tool from magazine loca-
tion 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).
DB9901 Variable transfer-step table [r/w]
The individual tool movements are defined as transfer steps – tool from magazine loca-
tion x/y to magazine location m/n. Acknowledgment steps can be defined with these
transfer steps.
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).
DB9902 Acknowledgement-step table [r]
Each entry indexes two transfer steps (for the new and old tool) and gives the corre-
sponding 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.
Note:
The data blocks DB40xx, DB41xx, DB42xx and DB43xx are system blocks and are created automatically by the
control.
The data blocks DB9900, DB9901 and DB9902 are made available by the PLC Programming Tool under Librar-
ies / 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.
Notes :

Tool Management
User interface loading, unloading, relocating
Acknowledgement signals for loading, unloading, relocating, positioning the magazine
DB4000- PLC NCK Signals to TM [r/w]

DB40xx (*1)
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Total

y000 ment step 7 ment step 6 ment step 5 ment step 4 edgement edgement ment step 1 acknowl-
step 3 step 2 edgement
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Acknowl-
y001 ment step 15 ment step 14 ment step 13 ment step 12 edgement edgement ment step 9 edgement
step 11 step 10 step 8
Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Acknowl-

y003 Reserved ment step 30 ment step 29 ment step 28 edgement edgement ment step 25 edgement
y004 Multitool: Location number (Int)
y006 to
y008 Reserved
Status3 for total Acknowledg

y009 acknowledge- e error reset
ment
(*1) xx = Loading position, y = TO unit
Jobs for loading, unloading, relocating, positioning the magazine
DB4100- NCK PLC Signals from TM [r]

DB41xx (*1)
y000 Multitool: Job
Data in the
multitool range
Multitool: Multitool: Job from NC Positioning Relocating Unloading Loading
y001 Job from NC Positioning program
program
y002 Reserved
y004 Reserved
y006 Source magazine no. (Integer)
y008 Source location no. (Integer)
y010 Target magazine no. (Integer)
y012 Target location no. (Integer)
Load/unload
y014 without mov-
HMI to PLC ing magazine
Notes :


DB41xx (*1)
y016 to
y054 Reserved
y056 Multitool: Distance coding (Int)
y058 Multitool: Number of locations (Int)
y060 Multitool: Tool distance (Real)
y064 Multitool: Number (Int)
y068 Multitool: Spindle/tool number (Int)
Feedback signal

DB41xx (*1)
Acknowl- Acknowl-
y100 edgement edgement OK
error
y102 Reserved
y104 Error status (Word)
y106 Reserved
y108 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Total

ment step 7 ment step 6 ment step 5 ment step 4 ment step 3 edgement edgement acknowledge-
step 2 step 1 ment
y109 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl-
ment step 15 ment step 14 ment step 13 ment step 12 ment step 11 edgement edgement edgement

y111 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl-
Reserved ment step 30 ment step 29 ment step 28 ment step 27 edgement edgement edgement
Notes :

Job status

DB41xx (*1)

y120 Reserved
y122 Reserved
y124 Current magazine number of the tool (Integer)
y126 Current location number of the tool (Integer)
y128 Target magazine number of the tool (Integer)
y130 Target location number of the tool (Integer)
y132 to
y138 Reserved
User interface tool change
Acknowledgement signals for tool change preparing and execute

DB42xx (*1)
Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl- Total
y000 ment step 7 ment step 6 ment step 5 edgement edgement edgement edgement acknowl-
step 4 step 3 step 2 step 1 edgement
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl-
y001 ment step 15 ment step 14 ment step 13 ment step 12 edgement edgement edgement edgement
step 11 step 10 step 9 step 8
Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowledge- Acknowl-
y002 ment step 23 ment step 22 ment step 21 edgement edgement edgement ment step 17 edgement
Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowledge- Acknowl-
y003 Reserved ment step 30 ment step 29 edgement edgement edgement ment step 25 edgement
y004 to
y008 Reserved
Status3 for Acknowledg

total e error reset
y009
acknowledge-
ment
y010 to Reserved
y024
(*1) xx = Tool holder, y = TO unit
Notes :

Jobs for tool change preparing and execute

DB43xx (*1)
Multitool: Job
y000 Data in the
multitool range
Tool Manual tool Manual tool No old tool T0 Prepare Change tool Fixed location
y001 remains in unload load change (Initiated by coded
spindle M06)
y002 Reserved
y004 Reserved
y006 Source magazine no. for new tool (Integer)
y008 Source location no. for new tool (Integer)
y010 Reserved
y012 Reserved
y014 Reserved
y016 Reserved
y018 Target magazine no. for old tool (Integer)
y020 Target location number for old tool (Integer)
y022 Location type (Integer)
y024 Size, left (Integer)
y026 Size, right (Integer)
y028 Reserved
y030 Reserved
Tool status for new tool
y032 Tool has been Tool is fixed Tool being Pre warning Measuring tools Tool Tool Active tool
in use location coded changed limit reached disabled enabled
y033 Manual tool 1:1 change Master tool To be loaded To be Blocked Identifier for
unloaded tool
y034 New tool: Internal T no. of NCK (Integer)
y036 Reserved (Double word)
y044 User defined parameter 1 (Double word)
Notes :

Feedback signal
DB43xx (*1)
Acknowl- Acknowl-
y100 edgement edgement
error OK
y102 Reserved
y106 Reserved
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Total

y108 ment step 7 ment step 6 ment step 5 ment step 4 edgement edgement edgement acknowl-
step 3 step 2 step 1 edgement

Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl-
y111 Reserved ment step 30 ment step 29 ment step 28 edgement edgement edgement edgement
Job status
DB4300- NCK PLC Job status [r]

DB43xx (*1)
y120 Reserved
y122 Reserved
y124 Current magazine no. for new tool (Integer)
y126 Current location no. for new tool (Integer)
y128 Target magazine no. for new tool (Integer)
y130 Target location no. for new tool (Integer)
y132 Current magazine no. for old tool (Integer)
y134 Current location no. for old tool (Integer)
y138 Target location no. for old tool (Integer)
Notes :

Transfer data blocks for status and position changes
Constant transfer step table (DB9900)
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 :

Variable transfer step table (DB9901)
DB9901 Variable transfer step table [r/w]

Transfer step 101
0000
Transfer step 101

0002
Transfer step 101
0004
Transfer step 101

0006
Transfer step 102
0008
Transfer step 102

0010
Transfer step 102

0012
Transfer step 102
0014
etc
Transfer step 164
0504
Transfer step 164
0506
Transfer step 164
0508
Transfer step 164
0510
Notes :

Acknowledgement step table (DB9902)

0000
Transfer step for new tool. (Byte)
0001
Transfer step for old tool. (Byte)
0002
Acknowledgement status. (Byte)
0003
Reserved
0004
0005
0006
0007
Reserved
etc
0116
0117
0118
0119
Reserved
Notes :

Acknowledgment status
Acknowledgment Status Meaning
Synchronous end ac- 1 Job finished at the specified position:

knowledgment
The tools are in the positions specified. The part program can be continued.
3 Job cancelled:
The job is cancelled, previously acknowledged tool position changes will be kept.
The cancel command itself does not trigger any position acknowledgements 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.
Further 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 Interme- 105 Intermediate position for tool:
diate acknowledgment
The tools are moved from the source position specified in the 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.
204 Communicate magazine position:
The magazine location is in the change/load/unload point of the specified target

location.
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.
Notes :

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
- 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 acknowl-
edgment reserves the source location for this tool ($TC_MPP4 bit 1 and bit 2). The behaviour 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.
- States 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.
Coding for position from a job:
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.
Notes :

Machine data for Tool Management
Tool Management requires that changes are made to the machine data for memory configuration. The TO block
need to be assigned to the channel etc. These machine data are set by default in the system.
NC TM
TO Block 2
TO Block 1
Magazine data
$TC_MAP...
NC Channels
One magazine configurati-

on for each TO Block Channel 2
Channel 1
Multitool data Machine
$TC_MTP... data
Tool Management
Tool data
$TC_TP...
Cutting edge data

$TC_DP...
Note:
- The cutting edge data are available by default.

- The tool data are only available when tool monitoring is active (default on 828D).
- The magazine data are only available when the magazine management is active (default on 828D).
Notes :

Default settings on tool magazines Default settings on tool magazines
The number of magazines, which the NCK can manage, is Magazine 1

permanently set by the 828D Software:
828D 24x 26x 28x 28xA

Software (Advanced)
Magazine 2 (828D 28x only)
Number of 128 256 512 768
tools
Number of 3 3 4 4
magazines
Buffer magazine (9998)
Number of 84 84 260 260
magazine loca-
tions
Number of 256 512 1024 1536
cutting edges Load magazine (9999)
Note:
Since at least one buffer and one loading point must be availa-
ble, maximum two real magazines can be managed.
When the control powers up, depending on the technology,
the following tool magazines are pre-selected and created:
Milling: Chain magazine with 20 locations and double gripper Turning: Turret with 12 locations

- Location 1 Spindle
- Location 2 Gripper 1
Magazine 1 (Turret)
Location 1
Magazine 1 (Chain) ...
- Location 1 Location 12
...
- Location 30
Notes :

Overview of the Machine data
MD Identifier Settings Comment Description
10715 $MN_M_NO_FCT_CYCLE 6 M function to be replaced by a subroutine
10716 $MN_M_NO_FCT_CYCLE_NAME L6 Subroutine name for M function replacement
10717 $MN_T_NO_FCT_CYCLE_NAME ““ Name of tool-changing cycle for T function replacement
10718 $MN_M_NO_FCT_CYCLE_PAR -1 M function replacement with parameters
Setting of T function substitution

- Bit 0: Substitution of the D or DL number
10719 $MN_T_NO_FCT_CYCLE_MODE 0H
- Bit 1: Call time for block start or block end
- Bit 2: Call time for block start and block end
Masking of alarm outputs
11415 $MN_SUPPRESS_ALARM_MASK_2 Bit 16 = 0
- Bit 16: Alarm 17212, 17214, 17215, 17216 (Manual tools)
Parameterization for search run
Bit 0 = 1
Bit 0: Alarm 10208 after action blocks
11450 $MN_SEARCH_RUN_MODE Bit 1 = 1
Bit 1: Automatic PROG_EVENT start after block search
Bit 2 = 1
Bit 2: The output of the spindle functions is suppressed
15710 $MN_TCA_CYCLE_NAME ““ Name of tool-changing cycle for TCA function replacement
$MN_MAXNUM_REPLACEMENT_TOO
17500 1 Maximum number of replacement tools
LS
$MN_TOOL_DATA_CHANGE_COUNT
17530 1FH Mark tool data change for HMI
ER
Memory reservation for tool management (SRAM)
- Bit 0: Provide magazine management data
- Bit 1: Provide monitoring data
- Bit 2: Provide OEM/CC data
- Bit 3: Consider adj. location
Bit 0 = 1
$MN_MM_TOOL_MANAGEMENT_MA - Bit 4: Complex search for tools in magazine
18080 Bit 1 = 1
SK - Bit 5: Wear monitoring
Bit 3 = 1
- Bit 6: Classification of magazines in wear groupings
- Bit 7: Adapter of magazine locations
- Bit 8: Additive and/or set-up offsets
- Bit 9: Handling a turret
- Bit 10: The multitool function is available
18082 $MN_MM_NUM_TOOL 512 *) Number of tools the NCK can manage (SRAM)
18084 $MN_MM_NUM_MAGAZINE 4 *) Number of magazines the NCK can manage (SRAM)

$MN_MM_NUM_MAGAZINE_LOCATIO
18086 260 *) Number of magazine locations the NCK can manage (SRAM)
N
$MN_MM_NUM_CUTTING_EDGES_IN
18100 1024 *) Tool offsets in the TO range (SRAM)
_TOA
18105 $MN_MM_MAX_CUTTING_EDGE_NO 9 Maximum value of D number
$MN_MM_MAX_CUTTING_EDGE_PE
18106 9 Maximum number of D numbers per tool
RTOOL
Activation of tool management
19320 $ON_TECHNO_FUNCTION_MASK Bit 4 = 1
- Bit 4: Tool monitoring and Magazine management
*) Settings for 828D software 28x.
Notes :

Overview of the Machine data
Definition of basic control settings after reset/part program end

Bit 0 = 1
20110 $MC_RESET_MODE_MASK - Bit 0: RESET mode
Bit 6 = 1
- Bit 6: Active tool length compensation
20120 $MC_TOOL_RESET_VALUE 0 Tool length compens. during run-up (reset/part program end)
$MC_TOOL_MANAGEMENT_TOOLH
20124 1 Tool holder number
OLDER
20128 $MC_COLLECT_TOOL_CHANGE 0 System Tool change commands to PLC after block search
$MC_CUTTING_EDGE_RESET_VAL Tool edge length compens. during run-up (reset/part program
20130 0 System
UE end)
20270 $MC_CUTTING_EDGE_DEFAULT 1 Initial position of tool cutting edge without programming
Activation of tool management functions
- Bit 0: Magazine management active
- Bit 1: Monitoring functions active
- Bit 2: OEM-/CC- functions active
- Bit 3: Adjacent location treatment
- Bit 4: Requirement Tool change preparation
- Bit 5: HL/PLC sync. for main spindle on transport ack.
- Bit 6: HL/PLC sync. for second. spindle on transport ack.
- Bit 7: HL/PLC Sync. for main spindle during PLC ack.
- Bit 8: HL/PLC sync. for second. spindle during PLC ack.
Bit 0 = 1 - Bit 9: Simulation on PLC acknowledgements
Bit 1 = 1 - Bit 10: Tool change command only after PLC prep. ack.
Bit 3 = 1 - Bit 11: Preparation command with same tool
20310 $MC_TOOL_MANAGEMENT_MASK
Bit 14 = 1 - Bit 12: Preparation command when tool already in spindle
Bit 23 = 1 - Bit 13: Trace of tool sequences
Bit 24 = 1 - Bit 14: Automatic tool change during RESET and Start
- Bit 15: No return transport with multiple preparation cmd.
- Bit 16: Programming T=“Location number“
- Bit 17: Control of time monitoring via PLC
- Bit 18: Message to PLC with last replacement tool
- Bit 19: Synchronization behaviour (Bits 5-8)
- Bit 20: Behaviour during program test
- Bit 21: Response to tool state “W“
- Bit 22: T=“Location number“+ tool sub-group ($TC_TP11)
- Bit 23: On offset selection no synchronization with HL
- Bit 24: Command number 8 and 9 ignore location reservation
Time monitoring for tool in tool holder
20320 $MC_TOOL_TIME_MONITOR_MASK Bit 0 = 1
- Bit 0: Monitoring tool in tool holder 1
22550 $MC_TOOL_CHANGE_MODE 1 New tool offset with M function
22560 $MC_TOOL_CHANGE_M_CODE 206 M function for tool change

$MC_TOOL_CHANGE_ERROR_MO Response to tool change errors
22562 Bit 1 = 1
DE - Bit 1: Manual tools permitted
28085 $MC_MM_LINK_TOA_UNIT 1 System Assignment of a TO unit to a channel (SRAM)

$MC_MM_TOOL_DATA_CHG_BUFF
28450 400 System Buffer for tool data changes (DRAM)
_SIZE
Notes :

Overview of the Technology settings
51200 $MNS_ACCESS_WRITE_TM_GEO 5 Write tool offset geometry data protection level

51201 $MNS_ACCESS_WRITE_TM_WEAR 6 Write tool offset wear data protection level
$MNS_ACCESS_WRITE_TM_WEAR_
51202 7 Protection level for tool offset restricted writing of wear data
DELTA
51203 $MNS_ACCESS_WRITE_TM_SC 7 Write tool offset total offsets protection level
51204 $MNS_ACCESS_WRITE_TM_EC 7 Write tool offset use offsets protection level
51205 $MNS_ACCESS_WRITE_TM_SUPVIS 7 Write tool offset monitoring data protection level

$MNS_ACCESS_WRITE_TM_ASSDN
51206 7 Write tool offset unique D number protection level
O
$MNS_ACCESS_WRITE_TM_WGROU
51207 7 Write tool offset wear groups protection level
P
51208 $MNS_ACCESS_WRITE_TM_ADAPT 7 Write tool offset adapter data protection level
51209 $MNS_ACCESS_WRITE_TM_NAME 4 Write tool offset tool name protection level
51210 $MNS_ACCESS_WRITE_TM_TYPE 4 Write tool offset tool type protection level
51211 $MNS_ACCESS_READ_TM 7 Read tool offset data protection level
51212 $MNS_TM_WRITE_WEAR_ABS_LIMIT 0.999 Maximum tool wear value

$MNS_TM_WRITE_WEAR_DELTA_LI
51213 0 Maximum difference value restricted tool wear input
MIT
Validity of the restricted tool wear input
- Bit 0: Use for cutting edge data, wear
51214 $MNS_TM_WRITE_LIMIT_MASK 7H
- Bit 1: Use for SC data, total offsets
- Bit 2: Use for EC data, use offsets
$MNS_ACCESS_WRITE_TM_ALL_PA
51215 4 Protection level TM details - write all parameters
RAM
$MNS_ACCESS_WRITE_TM_TOOL_C
51216 4 Protection level TM create tool
REATE
$MNS_ACCESS_WRITE_TM_TOOL_D
51217 4 Protection level TM delete tool
ELETE
$MNS_ACCESS_WRITE_TM_TOOL_L
51218 4 Protection level TM load tool
OAD
$MNS_ACCESS_WRITE_TM_TOOL_U
51219 4 Protection level TM unload tool
NLOAD
$MNS_ACCESS_WRITE_TM_TOOL_M
51220 4 Protection level TM relocate tool
OVE
$MNS_ACCESS_WRITE_TM_TOOL_R
51221 4 Protection level TM reactivate tool
EACTIVATE
$MNS_ACCESS_WRITE_TM_TOOL_M
51222 4 Protection level TM measure tool
EASURE
$MNS_ACCESS_WRITE_TM_TOOL_C
51223 4 Protection level TM create tool cutting edge
REATE
$MNS_ACCESS_WRITE_TM_TOOL_D
51224 4 Protection level TM delete tool cutting edge
ELETE
$MNS_ACCESS_WRITE_TM_MAGAZI
51225 4 Protection level TM position magazine
NE_POS
Notes :

Overview of the Technology settings
Function mask Display

52210 $MCS_FUNCTION_MASK_DISP Bit 4 = 1
- Bit 4: Show follow-on tool in T,F,S window
Function mask Cross-technology
52212 $MCS_FUNCTION_MASK_TECH Bit 3 = 1
- Bit 3: Call block search cycle for ShopMill/ShopTurn
Enable fast M functions (for ShopMill/ShopTurn)
- Bit 0: Enable fast M functions: coolant OFF
52229 $MCS_ENABLE_QUICK_M_CODES 0H - Bit 1: Enable fast M functions: coolant 1 ON
- Bit 2: Enable fast M functions: coolant 2 ON
- Bit 3: Enable fast M functions: coolant 1 and 2 ON
$MCS_M_CODE_ALL_COOLANTS_O
52230 9 M code for all coolants OFF (for ShopMill/ShopTurn)
FF
52231 $MCS_M_CODE_COOLANT_1_ON 8 M code for coolant 1 ON (for ShopMill/ShopTurn)
52232 $MCS_M_CODE_COOLANT_2_ON 7 M code for coolant 2 ON (for ShopMill/ShopTurn)
$MCS_M_CODE_COOLANT_1_AND_2
52233 -1 M code for coolant 1 and 2 ON (for ShopMill/ShopTurn)
_ON
52240 $MCS_NAME_TOOL_CHANGE_PROG ““ Tool change program for G code steps
Function mask Tool management
- Bit 0: Do not permit Create tool on magazine location
- Bit 1: Load/unload disable when machine is not in reset
- Bit 2: Load/unload disable for emergency stop
- Bit 3: Load/unload tool to/from spindle disabled
- Bit 4: Load directly in spindle
52270 $MCS_TM_FUNCTION_MASK 0H
- Bit 7: Create tool using the T number
- Bit 8: Hide Relocate tool
- Bit 9: Hide Position magazine
- Bit 10: Reactivate tool using Position magazine
- Bit 11: Reactivate tool in all monitoring modes
- Bit 12: Hide Reactivate tool
52271 $MCS_TM_MAG_PLACE_DISTANCE 70 Distance between individual magazine locations
52274 $MCS_TM_LOAD_STATION 2 Number of Loading stations
52281 $MCS_TOOL_MCODE_FUNC_ON -1 M code for tool-specific function ON (for ShopMill)
52282 $MCS_TOOL_MCODE_FUNC_OFF -1 M code for tool-specific function OFF (for ShopMill)
- Bit 0: Diameter display for rotating tools
- Bit 1: Default direction of rotation for all turning tools is M4
- Bit 2: Create tool without name proposal
- Bit 3: Input disable for tool name and tool type of loaded
tools
- Bit 4: Input disable for loaded tools, if the channel is not in
Reset
54215 $SNS_TM_FUNCTION_MASK_SET 0H - Bit 5: Calculate tool wear inputs additively
- Bit 6: Numerical input of the tool ident
- Bit 7: Fade out tool monitoring parameter
- Bit 8: Diameter display for transverse axis - Geometry
- Bit 9: Diameter display for transverse axis - Wear
- Bit 10: Enable loading/relocating of tools on buffer locations
- Bit 11: Creation of new tools in gripper locations is disabled
- Bit 12: Do not unload measuring tools if ”Unload all” function
is executed.
55212 $SCS_FUNCTION_MASK_TECH_SET Bit 0 = 1
- Bit 0: Tool preselection active (for ShopMill)
Notes :

Overview of the Magazine data and Tool data
Magazine data
Description:
MLSR - MAP: Magazine description data
MAMP - MPAC: Magazine user data
MDP - MPP: Magazine location data
MPTH - MPPC: Magazine location user data

- MPTH: Magazine location type hierarchy
MPPC
- MDP: Distance to change location
MPP
- MAMP: Magazine block data
MAPC
- MLSR: Magazine location assignment to spindle
MAP
The magazine data are only available when the magazine
management is active.
Multitool data Description:

- MTP: Multitool description data
MTPPC
- MTPC: Multitool user data
MTPP
- MTPP: Multitool location data
MTPC
- MTPPC: Multitool location user data
MTP
The Multitool data are only available when the magazine
management is active.
Tool data
Description:
TPC
- TP: Tool related data
TPG - TPG: Tool related grinding data
TP
- TPC: Tool related user data
Note: The Tool data are only available when tool monitoring
is active.
Cutting edge data

Description:
ECP
- DP: Cutting edge data
SCP - DPC: Cutting edge user data
MOPC - MPO: Cutting edge monitoring
MOP - MOPC: User cutting edge monitoring
DPC - SCP: Location dependent offsets fine

- ECP: Location dependent offsets course
DP
Notes :

Description of the Magazine and Tool Data
Magazine data
Parameter Default Description
Magazine block data (MAMP)

$TC_MAMP1 ““ Identifier of the configuration magazine
$TC_MAMP2 0 Type of tool search (Bit 0-7) and Art type of empty location search (Bit 8-15)
- Bit 0: active tool/ lowest Duplo
- Bit 1: shortest distance
- Bit 2: active tool/ min. $TC_TP10
- Bit 3: monitor for lowest actual value
- Bit 4: monitor for largest actual value
- Bit 5: monitor for $AC_MONMIN
- Bit 6: first current magazine (Bit 7=1)
- Bit 7: complex search in magazines
- Bit 8: first location forward
- Bit 9: current location forward
- Bit 10: last location backward
- Bit 11: current location backward
- Bit 12: symmetric actual location
- Bit 13: 1:1 Change
- Bit 14: Hierarchies
- Bit 15: Location type hierarchies
$TC_MAMP3 0 Procedure for tools in a wear group
Magazine description data (MAP)
$TC_MAP1 0 Type of magazine (1: Chain, 3: Turret, 5: Box magazine, 7: Buffer magazine,
9: Loading magazine)
$TC_MAP2 ““ Identifier of magazine
$TC_MAP3 2 Status of magazine
- Bit 0: active magazine
- Bit 1: disabled
- Bit 2: magazine is at load position
- Bit 3: Tool motion is active
- Bit 4: Magazine may be moved
- Bit 5: Reserved
- Bit 6: Magazine is fixed location coded
- Bit 7: Reserved
- Bit 8: Edge location must not be overlapped left
- Bit 9: Edge location must not be overlapped right
- Bit 10: Edge location must not be overlapped top
- Bit 11: Edge location must not be overlapped bottom
$TC_MAP6 1 Number of tiers (box magazine only)
$TC_MAP7 0 Number of columns
$TC_MAP8 0 Current magazine position relative to change position
$TC_MAP9 0 Current wear group number
$TC_MAP10 0 Current tool search strategies of magazine, see MAMP2.
Magazine user data (MAPC)

$TC_MAPC1 0 Magazine user data 1..10
to
$TC_MAPC10
Notes :

Magazine data
Magazine location data (MPP)
$TC_MPP1 0 Location type (1: Magazine location, 2: Spindle/tool holder, 3: Gripper,

4: Loader, 5: Transfer location, 6: Loading station, 7: Loading point)
$TC_MPP2 9999 Location type (0: every tool fits in this location)
$TC_MPP3 FALSE Consider adjacent location(1=on, 0=off)
$TC_MPP4 1 Location state
- Bit 0: Disabled
- Bit 1: Free to accept a tool
- Bit 2: Reserved for tool from buffer
- Bit 3: Reserved for new tool to be loaded
- Bit 4: Occupied in left half location
- Bit 5: Occupied in right half location
- Bit 6: Occupied in upper half location
- Bit 7: Occupied in lower half location
- Bit 8: left half location reserved
- Bit 9: right half location reserved
- Bit 10: top half location reserved
- Bit 11: lower half location reserved
- Bit 12: Wear group disabled
- Bit 13: Overlapping permitted
$TC_MPP5 0 Location type index

$TC_MPP6 0 T No. of tool at this location
$TC_MPP7 0 No. of adapter in magazine location
$TC_MPP_SP 0 For tool speed and acceleration monitoring
$TC_MPP66 0 No. of the tool, for which the identification “reserved for tool in buffer“ is set
Magazine location user data (MPPC)
$TC_MPPC1 0 Magazine location user data 1..10

to
$TC_MPPC10
Magazine location type hierarchy (MPTH)
$TC_MPTH1 9999 Magazine location type hierarchy 1..7

to
$TC_MPTH7
Distance to change location (MDP)
$TC_MDP1 9999 Distance between tool change position of magazine and location of first inter-
nal magazine (loading magazine 9999)
$TC_MDP2 9999 Distance between tool change position of magazine and location of second
internal magazine (buffer magazine 9998)
Magazine location assignment to spindle (MLSR)
$TC_MLSR 9999 System variable for assigning magazine locations of the buffer magazine to
the spindle
Notes :

Multitool data
Multitool description data (MTP)
$TC_MTPN 0 Number of locations
$TC_MTP2 “MT-Nr.“ Multitool identifier

$TC_MTP3 1 Size on left
$TC_MTP4 1 Size on right
$TC_MTP5 1 Size on above
$TC_MTP6 1 Size on below
$TC_MTP7 9999 Magazine location type
$TC_MTP8 0 Multitool status
- Bit 0: active tool
- Bit 1: enabled
- Bit 2: disabled
- Bit 3: measure
- Bit 4: prewarning limit reached
- Bit 5: Multitool being changed
- Bit 6: fixed location coded
- Bit 7: tool was in use
- Bit 8: identifier for tools in buffer
- Bit 9: ignore disabled state
- Bit 10: to be unloaded
- Bit 11: to be loaded
- Bit 12: master tool
- Bit 13: reserved
- Bit 15: hand tool
$TC_MTP_POS 0 Multitool position
$TC_MTP_KD Type of distance coding (1: Location number, 2: Distance, 3: Angle)
Multitool user data (MTPC)
$TC_MTPC1 0 Multitool user data 1..10
to
$TC_MTPC10
Multitool location data (MTPP)
$TC_MTPP2 0 Multitool location type

$TC_MTPP4 0 Multitool location state
$TC_MTPP6 0 T number of tool at this location
$TC_MTPP7 0 Adapter number of adapter at this location
$TC_MTPPL 0 Distance from reference location, distance “length“
$TC_MTPPA 0 Distance from reference location, distance “angle“
Multitool location user data (MTPPC)
$TC_MTPPC1 0 Multitool location user data 1..10
to
$TC_MTPPC10
Notes :

Tool data

Tool related data (TP)
$TC_TP1 T-Nr. Duplo number
$TC_TP2 “T-Nr.“ Tool identifier

$TC_TP3 1 Size on left
$TC_TP4 1 Size on right
$TC_TP5 1 Size on above
$TC_TP6 1 Size on below
$TC_TP7 9999 Magazine location type
$TC_TP8 0 Tool status
- Bit 0: active tool
- Bit 1: enabled
- Bit 2: disabled
- Bit 3: measure
- Bit 4: prewarning limit reached
- Bit 5: tool being changed
- Bit 6: fixed location coded
- Bit 7: tool was in use
- Bit 8: identifier for tools in buffer
- Bit 9: ignore disabled state
- Bit 10: to be unloaded
- Bit 11: to be loaded
- Bit 12: master tool
- Bit 13: reserved
- Bit 15: hand tool
$TC_TP9 0 Tool monitoring method
- Bit 0: tool life
- Bit 1: workpiece count
- Bit 2: wear monitoring active
- Bit 3: wear monitoring, location dependent offset fine active
$TC_TP10 0 Replacement change strategy
$TC_TP11 0 Tool information
Tool related user data (TPC)
$TC_TPC1 0 Tool related user data 1..10

to
$TC_TC10
Notes :

Cutting edge data

Cutting edge data (DP)
$TC_DP1 9999 Tool type

$TC_DP2 0 Cutting edge position
$TC_DP3 0 Geometry length 1
$TC_DP6 0 Geometry radius
$TC_DP7 0 Geometry corner radius (tool type 700 slotting saw)
$TC_DP8 0 Geometry length 4 (tool type 700 slotting saw)
$TC_DP10 0 Geometry angle 1
$TC_DP11 0 Geometry angle 2 for conical milling tools
$TC_DP12 0 Wear length 1
$TC_DP15 0 Wear radius
$TC_DP16 0 Wear slot width/rounding radius
$TC_DP19 0 Wear angle 1
$TC_DP20 0 Wear angle 2 for conical milling tools
$TC_DP21 0 Adapter length 1
$TC_DP24 0 Clearance angle
$TC_DP25 0 For ShopMill/ShopTurn:

A bit-coded value for various states of tools is stored here for ShopMill and
ShopTurn (turning direction, coolant 1/2, number of teeth)
Cutting edge user data (DPC)
$TC_DPC1 0 Cutting edge user data 1..10

to
$TC_DPC10
Notes :

Magazine Configuration Magazine configuration: how to create, how to load
The magazine configuration can be accomplished with the Example: Chain magazine 30 locations and double gripper
operating software “HMI Operate“.
The magazine configuration contains:
Magazine 1
(Chain) 30 locations
- Definition of the magazines
- Definition of the magazine locations
- Definition of the buffer locations Buffer magazine
- Definition of the load locations 3 locations (Spindle and
(9998)
- Definition of the search strategy two Grippers)
Load magazine
Procedure: (9999) 2 locations (load location
for Spindle and magazine)
- Create the magazine configuration
- Load magazine data into the NC Load magazine

data
NC
(INI file)
Configure the chain magazine
Example: Chain magazine 30 locations and double gripper
L2
9999,2
L1 G1
9999,1 9998,2 M1 Magazine 1
Sp Spindle
M1 G1 Gripper 1
G2 Gripper 2
Sp L1 Loading point 1
G2 L2 Loading point 2
9998,1
9998,3
Notes :

Start the magazine configuration Create a new magazine configuration
Position the cursor on the "Tool unit (Chan1)" folder and press
the "Delete element" softkey.
Confirm deleting with "OK" softkey.
The Tool management menu contains the following areas: The default magazine configuration of the 828D controller is
Active data contains the tool management of the NC deleted.
Examples contains examples for the tool management
Network / USB contains the connections
Position the cursor on the "Active data" folder and press the A magazine configuration is created that consists of a maga-
"New element" softkey. zine with 5 locations, as well as a tool spindle and a loading
point.
Configure the TO unit
Set the search strategy and accept with "OK".
Name optional
Channel number input a value of “1”
Tool search select “Active tool”
Location search select “1:1 replacement”
This magazine configuration can now be adapted to the
conditions on the machine.
Notes :

Configure the tool spindle / grippers Two new locations of the Gripper type are added to the buffer.
Position the cursor on the "Tool spindle / gripper" folder and

open the element with the "Input" key.
Set the number of locations and accept with "OK".
Name optional
Magazine no. 9998 (not changeable)
Locations input a value of “3”
The location type can be defined by the OEM, e.g. to spindle

or transfer location. To do this, the cursor must be positioned
on the appropriate location and the element opened.
Configure the load magazine A new location of the Loading point type is added to the load
magazine.
Position the cursor on the "Load magazine" folder and open
the element with the "Input" key.
Name optional
Magazine no. 9999 (not changeable)
The location type can be defined by the OEM, e.g. to loading

station. To do this, the cursor must be positioned on the ap-
propriate location and the element opened.
Notes :

Configure Magazine 1 Accept the preassignments for the new magazine locations
for Location type and Consider adjacent location with "OK".
Position the cursor on the "Magazine 1" folder and open the
element with the "Input" key.
The new locations are added to the magazine.
Name optional
The location type can be defined by the OEM. To do this, the

cursor must be positioned on the appropriate location and the
element opened.
Configure the assignments Specify the assignments of the magazine and accept with
"OK".
Position the cursor on the "Assignments" folder and open the
The adaption of the magazine configuration is now com-

pleted.
Notes :

Back up the data Enter the name for Initialization program INI and accept with
"OK".
Position the cursor on the "Active data" folder and press the
"Copy" softkey.
The INI file is created and saved to the USB stick.
Position the cursor on the "USB" folder and press the "Paste"
softkey.
Notes :

Configuration file (INI file)
CHANDATA(1) $TC_MPP1[9999,1]=7
$TC_MPP2[9999,1]=0 Loading point 1
$TC_MPP3[9999,1]=0
; delete old data $TC_MPP4[9999,1]=2
$TC_MAP1[0]=0 Delete old data $TC_MPP5[9999,1]=1
$TC_DP1[0,0]=0 $TC_MPP1[9999,2]=7
$TC_MAMP1="" $TC_MPP3[9999,2]=0
TO area $TC_MPP4[9999,2]=2
$TC_MAMP2=8193 $TC_MPP5[9999,2]=2
$TC_MAP1[1]=1 Assignments
$TC_MAP2[1]="" Magazine 1 $TC_MLSR[2,1]=0
$TC_MLSR[3,1]=0 Grippers to spindle
$TC_MAP3[1]=17
$TC_MAP6[1]=1 $TC_MDP1[1,1]=0 Loading points to
$TC_MAP7[1]=30 $TC_MDP1[1,2]=4 magazine
$TC_MAP10[1]=8193
$TC_MDP2[1,1]=0 Spindle/grippers to
$TC_MPP1[1,1]=1 $TC_MDP2[1,2]=0
$TC_MDP2[1,3]=0 magazine
$TC_MPP2[1,1]=1 Location 1
$TC_MPP3[1,1]=1 M17
$TC_MPP4[1,1]=2
$TC_MPP5[1,1]=0 to
...
$TC_MPP1[1,30]=1 Variables in the configuration file (INI file)
$TC_MPP3[1,30]=1
Parameter Meaning
$TC_MPP4[1,30]=2
$TC_MPP5[1,30]=0 $TC_MAMP1 Configuration magazine identifier
$TC_MAMP2 Tool search (bit 0-7) and location search (bit 8-15)
$TC_MAP1[9998]=7 - Bit 0=1: Active tool / min. duplo
$TC_MAP2[9998]="" - Bit 13=1: 1:1 replacement of old tool on location
Buffer magazine of new tool
$TC_MAP3[9998]=17
$TC_MAP1 Magazine type (1=chain, 7=tool buffer magazine,
$TC_MAP6[9998]=1
9=load magazine)
$TC_MAP7[9998]=3
$TC_MAP10[9998]=0 $TC_MAP2 Magazine identifier
$TC_MAP3 Magazine state
$TC_MPP1[9998,1]=2 - Bit 0=1: Active magazine
$TC_MPP2[9998,1]=0 Spindle - Bit 4=1: Magazine can be moved
$TC_MPP3[9998,1]=0 $TC_MAP6 Number of lines (box magazine only)
$TC_MPP4[9998,1]=2
$TC_MAP7 Number of columns
$TC_MPP5[9998,1]=1
$TC_MPP1[9998,2]=3 $TC_MAP10 Magazine tool search strategies, see MAMP2
$TC_MPP2[9998,2]=0 Gripper 1 $TC_MPP1 Location category (1=magazine location,
$TC_MPP3[9998,2]=0 2=Spindle /tool holder, 3=gripper, 7=loading point)
$TC_MPP4[9998,2]=2 $TC_MPP2 Location type (0=compatible with each tool location
$TC_MPP5[9998,2]=1 type)
$TC_MPP1[9998,3]=3 $TC_MPP3 Consider adjacent location (1=On, 0=Off)
$TC_MPP2[9998,3]=0 Gripper 2 $TC_MPP4 Location state
$TC_MPP3[9998,3]=0 - Bit 1=1: Free to receive a tool
$TC_MPP4[9998,3]=2
$TC_MPP5 Location type index
$TC_MPP5[9998,3]=2
$TC_MLSR Assignment of locations of the buffer magazine to
$TC_MAP1[9999]=9 the spindle
$TC_MAP2[9999]="" $TC_MDP1 Distance from the magazine change position to the
$TC_MAP3[9999]=17 Load magazine
location of the first internal magazine (9999)
$TC_MAP6[9999]=1
$TC_MAP7[9999]=2 $TC_MDP2 Distance from the magazine change position to the
$TC_MAP10[9999]=0 location of the second internal magazine (9998)
Notes :

Activate the data After successfully reading in the definition files, the "*" symbol
goes away.
"Activate data" softkey.
The definition files are read in.
Display on the controller
After successfully loading the configuration file, all magazines

and buffers in the tool list are displayed in the Parameters
area.

- Location 1 Spindle
Magazine 1 (Chain)
- Location 1
...
- Location 30
Notes :

Load / Unload Example: Chain magazine 30 locations and double gripper
Load loc. 2
Tool load/unload is done via the loading location defined in
the machine configuration. L2
Load loc. 1 9999,2
Each loading location has it own interface area in
DB41xx/40xx .
G1
L1 9998,2 M1 Magazine 1
The interfaces are set up to handle the tool management 9999,1 Sp Spindle
commands: *Tool load*, *unload*, *Relocate* and *position M1 G1 Gripper 1
magazine*. G2 Gripper 2
Sp L1 Load loc. 1
G2 L2 Load loc. 2
The PLC functions DB9900, DB9901 und DB9902 are used 9998,1
9998,3
to communicate the current positions of tools.
Procedure:
Load location 1 is permanently assigned to the Spindle.
- Assign loading locations.
Load location 2 is assigned to the magazine via machine data
- PLC program to handle the acknowledgments for the tool 52274 = 2.
management commands.
Assign loading locations Display on the controller
Load station Tool management
MD52274
Load station Tool manage-
$MCS_TM_TOOL_LOAD_
ment
STATION
Change to: 2
Description:
1
If only one loading station is configured: The setting = 0
= 0: No query window appears on the surface
2
If more than 1 loading station is configured, you can select
between
= 0: A query window appears on the surface to select the
loading point.
= 1: fixed loading station 1, the window does not appear
= 2: fixed loading station 2, the window does not appear 1. Magazine location on change position
2. Magazine location on loading point
Notes :

Loading into the magazine
Using the dialogue for *Load*, either a completely new tool

can be created and loaded to the magazine or a tool out of the
tool list can be transferred to a location in the magazine.
1. Enter the desired location and confirm with OK -> Job to

PLC (DB4101.DBX1.0=1).
1. Select the tool.

2. Press the softkey “Load“.
Job: Load magazine DB4101 Acknowledgement for load the magazine DB4001
DB4101 NCK PLC Signals from TM [r] DB4001 PLC NCK Signals to TM [r/w]
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 Job Ack Ack Ack Ack Ack Ack Ack Total
DBB0
7 6 5 4 3 2 1 Ack
Job Posi- Relo- Un- Load- Ack Ack Ack Ack Ack Ack Ack Ack
from tionin cate loadin ing DBB1
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram Example: Load tool to magazine location 9
Source magazine no. (INT)
DB4101.DBW6 =0
DBW6
DB4101.DBW8 =0
DBW8 Source location no. (INT) DB4101.DBW10 =1
DB4101.DBW12 =9
DBW10 Target magazine no. (INT)
DBW12 Target location no. (INT)
PLC Programming example with Total acknowledgement
Notes :

Unloading from the magazine
A tool can be removed from a location in the magazine with

the „Unload“ dialogue.
2
1
1. Select the magazine location.

2. Press the softkey “Unload“ -> Job to PLC
(DB4101.DBX1.1=1).
Job: Unload magazine DB4101 Acknowledgement for unload the magazine DB4001
DBB0
7 6 5 4 3 2 1 Ack
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram Example: Unload tool from magazine location 9
DB4101.DBW6 =1
DBW6
DB4101.DBW8 =9
DB4101.DBW12 =0
Notes :

Loading to the spindle
Using the dialogue for *Load *, either a completely new tool

can be created and loaded to the spindle or a tool out of the
tool list can be transferred to the spindle.
1. Press softkey “Spindle“ -> Job to PLC (DB4100.DBX1.0=1).
1. Select the tool.

2. Press the softkey “Load“.
DBB0
7 6 5 4 3 2 1 Ack
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram Example: Load tool to the spindle
DB4100.DBW6 =0
DBW6
DB4100.DBW8 =0
DB4100.DBW12 =1
Notes :

Unloading the spindle
The „Unload“ dialogue can be used to unload the tool in the

spindle.
1. Select the spindle.

2. Press the softkey “Unload“ -> Job to PLC
(DB4100.DBX1.1=1).
Job: Unload magazine DB4100 Acknowledgement for unload the magazine DB4000
DBB0
7 6 5 4 3 2 1 Ack
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram Example: Unload tool from spindle
DB4100.DBW6 =9998
DBW6
DB4100.DBW8 =1
DB4100.DBW12 =0
Notes :

Relocate tool
A magazine tool can be moved from one location to another

with the „Relocate“ dialogue.
2
1
1. Enter the desired location and confirm with OK -> Job to

PLC (DB4100.DBX1.2=1).
1. Select the tool to be relocated.

2. Press softkey „Relocate“.
Job: Relocate tool DB4100 Acknowledgement for relocate tool DB4000
DBB0
7 6 5 4 3 2 1 Ack
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram Example: Relocate tool from location 9 to 5
DB4100.DBW6 =1
DBW6
DB4100.DBW8 =9
DB4100.DBW12 =5
Notes :

Position magazine
The „Position magazine“ dialogue is used to position a partic-

ular magazine pocket to the load position.
1. Select the magazine pocket.

2. Press the softkey “Position magazine“ -> Job to PLC
(DB4101.DBX1.3=1).
Job: Position magazine DB4101 Acknowledgement for position magazine DB4001
DBB0
7 6 5 4 3 2 1 Ack
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram Example: Bring magazine pocket 5 to the load position
DB4101.DBW6 =1
DBW6
DB4101.DBW8 =5
DB4101.DBW12 =2
Notes :

Interruption to the loading/unloading sequence
Examples of what can cause the loading sequence to be aborted

- Reset
- E-Stop
- Power failure
Job: Load magazine DB4101 Reset Acknowledgement for load the magazine DB4001
DBB0
7 6 5 4 3 2 1 Ack
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram ...
DBW6 Source magazine no. (INT) Sta- Ack

tus 3 error
DBW8 Source location no. (INT) DBB9 for reset
Total
Ack
PLC Programming example with Total acknowledgement and Status 3 for “cancel job”
Note:
By directly writing to parameter $TC_MPP6[magazine No.,location No.] = 0, a tool can be removed from this magazine location
(whether it is a real magazine, buffer or loading magazine).
All reservations of the removed tool are automatically deleted. This does not involve an associated command output to the PLC.
Notes :

Sequence for Tool Change Procedure:
- Set up the machine data for the tool change

The tool change is done at the change location, which is
specified in the magazine configuration.
- Generate the tool change program L6
DB43xx/42xx contains an interface area for each change
- Write the PLC program for acknowledgment of the tool
location which has been configured.
change commands
- Prepare tool change

Each interface is set up to handle these following Tool Man-
- Tool change sequence
agement situations:
- Interruption to the tool change
- Recovery functions after an interruption
- Prepare tool change
- Execute tool change (triggered via M06)
The PLC functions DB9900, DB9901 und DB9902 are used

Set up the machine data for the tool change Programming the tool change
TEST_PROGRAM.MPF
Tool change with M function N10
N20
MD22550 = 1 An M function is used to start the „Tool N30 T=“FRAESER1” Prepare for change (PLC)
Change“ phase, Which M function is speci- N40
fied by MD 22560. N50
Tool change program
The T command starts the „Prepare Tool“ N60 M06
L6 is called
phase. N70
MD22560 = 206 M Function for Tool Change N80
This M function triggers the start of the tool N90
change process. N100 M30 Program end
Tool change program L6
MD10715 = 6 This is the M function which calls a subpro-

gram to be called. The name of the subpro-
gram is given in MD10716.
MD10716 = L6 The name of the subprogram which is
called when the M function specified in
MD10715 is programmed.
The tool change program, L6 is called whenever M6 is pro-

grammed.
Notes :

Allow hand tools Suppress alarm output for hand tools
MD22562 Response to tool change errors MD11415 Suppression of alarm output

Standard behaviour: During the tool change
preparation only those tools are recognized Bit 16 = 0 Alarms 17212, 17214, 17215, 17216 for
whose data are assigned to a magazine. hand tools are not masked out
Bit 1 = 1 Manual tools permitted
Bit16=0 No masked out alarms for hand tools
Bit16=1 Masked out alarms for hand tools
Hand tools
- 17212 ”Load hand tool to spindle/tool holder”
- 17214 ”Remove hand tool from spindle/tool holder”
The NC part program can also call tools which are not as-
- 17215 ”Remove hand tool from buffer location”
signed to a magazine. Such tools need to be manually loaded
- 17216 ”Remove hand tool from tool holder and load hand
into the machine (e.g. directly into the spindle) for the dura-
tool”
tion of their use. When the program has finished with the
hand tool, it has to be manually removed from the machine.
Ignore location reservation with asynchronous Transfer
Tool Management uses DB4300.DBX1.5 and DBX1.6 to in-
form the PLC program that a hand tool is involved in the
change. The machine operator gets one of these alarms MD20310 Activation of Tool Management
17212, 17214, 17215 ,17216 to warn that manual action is
needed to make the tool change. The alarms are reset when Bit 24 = 1 Asynchronous transfer command no. 8 and
9: Ignore location reservation
The location reservation of the tool in the magazine will be

ignored. Thus it is possible to move a tool to this location (e.g.
via asynchronous transfer).
Notes :

Generate the tool change program L6
The L6 tool change program has to take the machine layout into consideration. The L6 program is stored in the manufacturer
cycles or the user cycles directory of the control.
There is a template is located on the 828D toolbox in this directory “examples/Tool_management“.
PROC L6 SAVE DISPLOF

;VERSION: 04.7.2.1 February 19, 2015
;CHANGE : 04.7.0 June 04, 2014
DEF INT _WZ_IN_SP,_WZ_VOR
;
IF $P_MC == TRUE ;MCALL ist activ
IF $AC_ASUP <> 0 ;tool call during block search or overstore
;dont cancel MCALL
ELSE
MCALL ;cancel MCALL
ENDIF
ENDIF Read which tool is
IF(NOT $P_SEARCH) ; no block search coming and which tool
_WZ_IN_SP=$TC_MPP6[9998,1] ; read tool number from spindle is in the spindle right
GETSELT(_WZ_VOR) ; read tool number preselected tool
; now .
IF(_WZ_IN_SP<>_WZ_VOR) ; if new tool
SPOSA[1]= 0 ; spindle positioning
G0 ; go to change position Position axes/
G75 Z=0 spindle
WAITS(1) ; wait for spindle
ENDIF
ELSE
ENDIF M206
; Tool change -> PLC
M206 ; change tool, tool management and PLC
;
;SETPIECE(1) ; if the number of workpieces machined by the tool is monitored
; (Tool Wear, column TC = C) counter of main toolholder
; is decremented by 1
M17
TCA program
The TCA program is used for the replacement tools (duplo tools) function. With selection of a replacement tool on the HMI sur-
face or programming of a TCA command in the NC program the TCA cycle is automatically called.
The TCA program is stored in the manufacturer cycles or the user cycles directory of the control.
PROC TCA(STRING[64] _TOOL_NAME,INT _DUPLO,INT _TH_NO)

;VERSION: 04.7.2.1 February 19, 2015
;CHANGE : 02.07.01. Mai 14, 2012
;
_TCA(_TOOL_NAME,_DUPLO,_TH_NO) ; Tool call to NC
;
; insert here machine function for tool change
M17
Notes :

Example: Transfer- and acknowledgment tables
Example: Tool change Chain magazine with double gripper
L1
9999,1
G1
9998,2
3 1 M1 Magazine 1
T=“FRAESER1“ Sp Spindle
M1 G1 Gripper 1
2 4 G2 Gripper 2
Sp L1 Load loc. 1
9998,1
G2
9998,3
Example: Constant transfer step table (DB9900)
Acknowledg- from to Comment

ment step
Magazine Location Magazine Location
1 1 0 1 9998 2 Tool change: Tool from magazine to gripper 1
2 9998 1 9998 3 Tool change: Tool from spindle to gripper 2

2
3 9998 2 9998 1 Tool change: Tool from gripper 1 to spindle

3
4 9998 3 0 2 Tool change: Tool from gripper 2 to magazine

4
5 9999 1 9998 1 Tool change: Tool from load location to spin-

dle
6 9998 1 9999 1 Tool change: Tool from spindle to load loca-

tion
Example: Variable transfer step table (DB9901)
Acknowledg- from to Comment

ment step
Magazine Location Magazine Location
101 1 0 9998 1 "Prepare tool change": The magazine is posi-

DB9901.DBW0 tioned at the changing point.
The source position must be entered by the
PLC user program.
102 0 0 0 0 Recovery function: The tool is positioned from

DB9901.DBW8 the source position to the specified target
position.
The source and target position must be en-
tered by the PLC user program.
Notes :

Example: Acknowledgment table (DB9902)
Acknowledg- Transfer step Acknowledg- Comment

ment step ment status
New tool Old tool
1 0 0 1 Final acknowledgment without tool movement.

(prepare change)
2 0 0 1 Final acknowledgment without tool movement.

(change tool)
3 101 0 204 Message: Variable magazine location moved

to the change location.
4 1 2 105 Intermediate acknowledgment: New tool from

specified magazine location to gripper 1, old
tool from spindle to gripper 2.

gripper 1 to spindle, old tool from gripper 2 to
specified magazine location.
6 0 2 105 Intermediate acknowledgment: Old tool from

spindle to gripper 2.

gripper 2 to specified magazine location.

specified magazine location to gripper 1.

gripper 1 to spindle.
10 102 0 201 Message: Variable magazine location moved

to the change location.

spindle to load location.

load location to spindle.
13 0 0 3 "Cancel order" command.
Notes :

Prepare tool change Example: Prepare tool change
L2
Programming 9999,2
G1 T=“CUTTER1“
9998,2
TEST_PROGRAM.MPF
N10 L1 M1 Magazine 1
N20 9999,1 1 Sp Spindle
N30 M1 G1 Gripper 1
N40 G2 Gripper 2
N50 T=“CUTTER1” Prepare tool -> PLC Sp L1 Load loc. 1
N60 9998,1 L2 Load loc. 2
N70 2
N80 G2
9998,3
N90
N100 M06 Call L6, do tool change Update Tool list
N110
N120
N130
N140
N150
N160 M30 Program end
Prepare for tool change -> Job to PLC (DB4300.DBX1.2=1).
Sequence for prepare tool change Note
For a 1:1 change the new and old tool must satisfy all these
conditions:
Job “Prepare change“
- Neither tool is fixed location
- Both tools have the same size
- Both tools have the same location type
Position the magazine to the location

(DB4300.DBW6/8) for the new tool
Acknowledge the “Prepare

change “ job
Update magazine position

-> Asynchronous transfer
Notes :

Job: Prepare tool change DB4300 Acknowledgement for prepare tool change DB4200
DBB0
7 6 5 4 3 2 1 Ack
Tool Manu- Manu- No old T0 Pre- Chang Fixed
Ack Ack Ack Ack Ack Ack Ack Ack
real tool al tool tool pare e tool loca- DBB1
mains unload chang (Initiat tion 15 14 13 12 11 10 9 8
DBB1 in load e ed by coded
spin- M06)
dle Example: 1:1 change Example: Not 1:1 change
DB4300.DBW6 =1 DB4300.DBW6 =1
DBW6 Source magazine no. for new tool (Int) DB4300.DBW8 =10 DB4300.DBW8 =10
DBW8 Source location no. for new tool (Int) DB4300.DBW18 =1 DB4300.DBW18 =1
DB4300.DBW20 =10 DB4300.DBW20 =4
DBW18 Target magazine no. for old tool (Int )
DBW20 Target location number for old tool (Int )
Acknowledgment table DB9902 Variable transfer step table DB9901
Address Name Data type Format Value Address Name Data type Format Value
0.0 TsNewT_1 BYTE Unsigned 0 0.0 SrcMag_101 INT Signed 1

1.0 TsOldT_1 BYTE Unsigned 0 2.0 SrcPos_101 INT Signed 0
2.0 State_1 BYTE Unsigned 1 4.0 DstMag_101 INT Signed 9998
3.0 Res_1 BYTE Unsigned 0 6.0 DstPos_101 INT Signed 1
4.0 TsNewT_2 BYTE Unsigned 0

5.0 TsOldT_2 BYTE Unsigned 0
6.0 State_2 BYTE Unsigned 1
7.0 Res_2 BYTE Unsigned 0

Notes :

PLC Programming example with acknowledgement signals for prepare tool change
Final acknowledgement for prepare change with Status 1
Ack 1
Update Magazine position with Status 204
Ack 3
Notes :

Sequence for tool change Example: Tool change with 1:1 change
L2
Programming 9999,2
G1 T=“CUTTER1“
9998,2
TEST_PROGRAM.MPF
N10 L1 2 1 M1 Magazin 1
9999,1 Sp Spindle
N20
N30 M1 G1 Gripper 1
N40 1 2 G2 Gripper 2
N50 T=“CUTTER1” Prepare tool -> PLC Sp L1 Load Location 1
9998,1 L2 Load Location 2
N60
N70
G2
N80 9998,3
N90
N100 M06 Call L6, do tool change
N110
N120
N130
N140
N150
Tool change -> Job to PLC (DB4300.DBX1.1=1).
Sequence: Tool change with 1:1 change Note:
For a 1:1 change the new and old tool must satisfy all these
conditions:
Job “Execute tool change“
- Neither tool is fixed location
- Both tools have the same size
1 2 - Both tools have the same location type
Old tool from spindle to gripper 2 and

new tool from magazine to gripper 1
-> intermediate acknowledgment
(Mag -> Gr1, Sp -> Gr2)
Ack 4
3 4
Old tool from gripper 2 to magazine

and new tool from gripper 1 to spindle
-> intermediate acknowledgment
(Gr 1 -> Sp, Gr 2 -> Mag)
Ack 5
Acknowledge “Execute tool

change “ job Ack 2
Notes :

Job: Execute tool change DB4300 Acknowledgement for execute tool change DB4200
DBB0
7 6 5 4 3 2 1 Ack
spin- M06)
Example: Tool change with 1:1 change
dle
DB4300.DBW6 =1
DBW6 Source magazine no. for new tool (Int) DB4300.DBW8 =10
Source location no. for new tool (Int) DB4300.DBW18 =1
DBW8
DB4300.DBW20 =10
The job remains unchanged, the tools are still in their re-
spective starting positions.
Acknowledgment table DB9902 Constant transfer step table DB9900


Notes :

PLC Programming example with acknowledgement signals for execute tool change (1:1 change)
Intermediate acknowledgement M1 -> Gr1, Sp -> Gr2 with Status 105
Ack 4
Intermediate acknowledgement Gr1 -> Sp, Gr2 -> M1 with Status 105
Ack 5
Final acknowledgement for execute tool change with Status 1
Ack 2
Notes :

Example: Tool change not 1:1 change Job: Execute tool change DB4300
L2
DB4300 NCK PLC Signals from TM [r]
9999,2
G1 T=“CUTTER1“
9998,2 Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 Job
L1 5 4 3 M1 Magazine 1
9999,1 Sp Spindle Tool Manu- Manu- No old T0 Pre- Chang Fixed
M1 G1 Gripper 1 real tool al tool tool pare e tool loca-
1 2 G2 Gripper 2 mains unload chang (Initiat tion
L1 Load loc. 1 DBB1 in load e ed by coded
Sp
L2 Load loc. 2 spin- M06)
9998,1 dle
G2 DBW6 Source magazine no. for new tool (Int)
9998,3
DBW8 Source location no. for new tool (Int)
Acknowledgement for execute tool change DB4200
DB4200 PLC NCK Signals to TM [r/w]

Ack Ack Ack Ack Ack Ack Ack Total
DBB0
7 6 5 4 3 2 1 Ack
DBB1
15 14 13 12 11 10 9 8
Sequence for non-1:1 tool change
1 4
Old tool from spindle to gripper 2 New tool from magazine to gripper 1
-> Intermediate acknowledgement -> Intermediate acknowledgement
(Sp -> Gr 2) Ack 6 (Mag -> Gr 1) Ack 8
2 5
Old tool from gripper 2 to magazine New tool from gripper 1 to spindle
-> Intermediate acknowledgement -> Intermediate acknowledgement
(Gr 2 -> Mag) Ack 7 (Gr 1 -> Sp) Ack 9
Position magazine to new tool location Acknowledge “Execute tool

(DB4300.DBW6/8) change “ job Ack 2
->Update magazine position Ack 3
Notes :

Acknowledgment table DB9902 Constant transfer step table DB9900


PLC Programming example with acknowledgement signals for execute tool change (not 1:1 change)
Final acknowledgement for prepare tool change with Status 1
Ack 1
Update Magazine position old tool with Status 204
Ack 3
Notes :

Intermediate acknowledgement Sp -> Gr2 with Status 105
Quitt 6
Intermediate acknowledgement Gr2 -> M1 with Status 105
Ack 7
Update Magazine position new tool with Status 204
Ack 3
Intermediate acknowledgement M1 -> Gr1 with Status 105
Ack 8
Intermediate acknowledgement Gr1 -> Sp with Status 105
Ack 9
Final acknowledgement for execute tool change with Status 1
Ack 2
Notes :

Interruption to the tool change Sequence: Abort tool change
Example: Abort 1:1 tool change

Interrupt L1
9999,1
G1 1
9998,2
T=“FRAESER1“
1 M1 Magazine 1 Old tool from spindle to gripper 2 und
Sp Spindle New tool from magazine to gripper 1
M1 G1 Gripper 1 -> Intermediate acknowledgement
2 G2 Gripper 2 (Mag -> Gr 1, Sp -> Gr 2)
Sp L1 Load loc. 1
9998,1
G2
9998,3
“Reset“ acknowledge
DB4300 Ack 13
Interruption to the tool change 2
Examples of what can cause the tool change to be aborted Old tool from gripper 2 to magazine
and new tool von gripper 1 to spindle
- Reset -> Intermediate acknowledgement
- E-Stop (Gr 1 -> Sp, Gr 2 -> Mag)
- Power failure
Interruption to the tool change
Acknowledgement for cancel job DB4200

Acknowledgment table DB9902
Address Name Data type Format Value
DBB0 49.0 TsOldT_13 BYTE Unsigned 0
7 6 5 4 3 2 1 Ack
Ack Ack Ack Ack Ack Ack Ack Ack 51.0 Res_13 BYTE Unsigned 0
DBB1
15 14 13 12 11 10 9 8
PLC Programming example with acknowledgement for “cancel job”
Ack 13
Notes :

Recovery Functions Sequence: Tool changer recovery
Example: Tool changer recovery 1
New tool from gripper 1 to spindle

L1 -> Asynchronous transfer (Gr 1 -> Sp)
Recovery
9999,1 Ack 10
G1
9998,2
2
1 M1 Magazine 1
Sp Spindle Old tool from gripper 2 to magazine
T=“FRAESER1“
M1 G1 Gripper 1 -> Asynchronous transfer (Gr 2 ->
2 G2 Gripper 2
Mag) Ack 10
Sp L1 Load loc. 1
9998,1
G2
9998,3
Note:
Asynchronous transfers are used to inform the Tool Man-

agement of tool movements which have been initiated by
the PLC without a specific job request from Tool Manage-
ment in the NC.
Acknowledgement for recovery function DB4200

DBB0
7 6 5 4 3 2 1 Ack
DBB1
15 14 13 12 11 10 9 8
Acknowledgment table DB9902 Variable transfer step table DB9901

Notes :

PLC Programming example with acknowledgement signals for recovery function
The specific data from a job of tool management are not available after Power-On.
In the following example these data are saved in a user data block.
User data block DB9040
Save data for recovery function
Acknowledgement for recovery function (asynchronous transfers)
Asynchronous transfer Gr1 -> Sp
Ack 10
Asynchronous transfer Gr2 -> M1
Ack 10
Notes :

Asynchronous transfer Gr1 -> M1
Ack 10
Asynchronous transfer Gr2 -> Sp
Ack 10
Notes :

Customizing the Tool Management HMI The customization of the HMI is accomplished by making
changes to these configuration files.
- Technology Milling - sltmlistconfig.xml

The following screen areas of tool management can be cus- - Technology Turning - sltmturninglistconfig.xml
tomized to suit particular machine configurations.
- Reconfigure the tool list Template:

- Modify the list parameters
- Reconfigure a screen “Details“ There is a template located on the controller in this directory
- Reconfigure a screen “New tool - favourites“
- Reconfigure tool types Configuration file “oem_sltmlistconfig.xml“
- Give names to magazine locations “System CF Card\siemens\sinumerik\hmi\template\cfg“
- Generate custom texts
Custom text file “oem_sltmlistdialog_xxx.ts“
“System CF Card\siemens\sinumerik\hmi\template\lng“
Procedure:
- Create the configuration file

- Create the custom text file
Customize the HMI via configuration file Tooltip
Example for OEM tool list
3
The configured tool tip text “OEM 1 Tooltip“ will be displayed.
2 Longtext
1. New softkey “OEM Tool“ is displayed

2. New column for OEM parameter 1 is displayed The descriptive text “OEM 1 Longtext“ will be displayed.
3. Column heading is “OEM 1“
Notes :

Create the configuration file
Example: OEM tool list
In this example the OEM Tool list will be enabled and the user parameter “ToolUser_1“ will be displayed in an new column. The
parameter “ToolUser_1“ refers to the OEM tool parameter $TC_TPC1.
The OEM tool parameters are activated via these NC machine data (default on 828D):
- MD18080 Bit 2=1 OEM-/CC- data available

- MD20310 Bit 2=1 OEM-/CC- functions active
- MD18094 = 2 Number of OEM tool parameters
Filename of configuration file:
- sltmlistconfig.xml for Technology Milling

- sltmturnlistconfig.xml for Technology Turning
Copy the configuration file “sltmlistconfig.xml“ into the user or oem directory.
OEM directory
“System CF Card\oem\sinumerik\hmi\cfg“
User directory
“System CF Card\user\sinumerik\hmi\cfg“
Example: Configuration file “sltmlistconfig.xml“
<CONFIGURATION>








<LISTCONFIGURATION>
<SlTmTooloemForm> Enable OEM tool list
<Enabled value="true" type="bool" />
</SlTmTooloemForm>
</LISTCONFIGURATION>




<LISTCONFIGURATION>
<SlTmTooloemForm> Define column for user parameter
<INSERT_COLUMN>
<COLUMN6> “ToolUser_1“
<TOOLTYPE_ALL>
<Item value="ToolUser_1" type="QString" />
</TOOLTYPE_ALL>
</COLUMN6>
</INSERT_COLUMN>
</SlTmTooloemForm>
</LISTCONFIGURATION>
</CONFIGURATION>
Notes :

Create the custom text file
Example: Custom texts for OEM tool list
Filename of Custom text file “sltmlistdialog_xxx.ts“ (xxx language code):
- sltmlistdialog_deu.ts for german custom texts

- sltmlistdialog_eng.ts for english custom texts
Copy the custom text file “sltmlistdialog_xxx.ts“ into the user or oem directory
OEM directory
“System CF Card\oem\sinumerik\hmi\lng“
User directory
“System CF Card\user\sinumerik\hmi\lng“
Example: Custom text file “sltmlistdialog_eng.ts“
<?xml version="1.0" encoding="utf-8"?>

<!DOCTYPE TS><TS>




<context>
<name>SlTmListForm</name>




<message>
<source>TM_HL_TOOL_USER_1</source> Headline
<translation>OEM 1</translation>
<chars>30</chars>
</message>
<message>
<source>TM_TT_TOOL_USER_1</source> Tooltip
<translation>OEM 1 Tooltip</translation>
<chars>30</chars>
</message>
<message>
<source>TM_HL_TOOL_USER_1_LONG</source> Longtext
<translation>OEM 1 Longtext</translation>
<chars>30</chars>
</message>
</context>
</TS>
Notes :

Tool change on a lathe with turret Example: Turret with 12 locations
On a lathe, the tool change is handled by the turret which is

configured in the magazine configuration.
L1
DB43xx/42xx contains an interface area for each turret which 9999,1 M1 Magazine 1
has been configured. H1 Tool holder 1
M1 L1 Load loc. 1
H1
All interfaces are set up for the „Execute tool change“ com- 9998,1
mand, which is triggered by the NC instruction “T-number“.
The PLC functions DB9900, DB9901 und DB9902 are used

Procedure:
- Activate Tool Management
- Configure the turret magazine
- Tool load / unload
- Generate the TCHANGE program
- Tool change with turret
Notes :

Activate Tool Management
Overview of the machine data for Turning
TCHANG
10717 $MN_T_NO_FCT_CYCLE_NAME Name of tool-changing cycle for T function replacement
E
15710 $MN_TCA_CYCLE_NAME ““ Name of tool-changing cycle for TCA function replacement
$MN_MAXNUM_REPLACEMENT_TOO
17500 1 Maximum number of replacement tools
LS
$MN_TOOL_DATA_CHANGE_COUNT
17530 1FH Mark tool data change for HMI
ER
Memory reservation for tool management (SRAM)
Bit 0 = 1
- Bit 0: Provide magazine management data
$MN_MM_TOOL_MANAGEMENT_MA Bit 1 = 1
18080 - Bit 1: Provide monitoring data
SK Bit 3 = 1
- Bit 3: Consider adj. Location
Bit 10 = 1
- Bit 10: The multitool function is available
18082 $MN_MM_NUM_TOOL 512 *) Number of tools the NCK can manage (SRAM)
18084 $MN_MM_NUM_MAGAZINE 4 *) Number of magazines the NCK can manage (SRAM)
$MN_MM_NUM_MAGAZINE_LOCATIO
18086 260 *) Number of magazine locations the NCK can manage (SRAM)
N
$MN_MM_NUM_CUTTING_EDGES_IN
18100 1024 *) Tool offsets in the TO range (SRAM)
_TOA
19320 $ON_TECHNO_FUNCTION_MASK Bit 4 = 1
- Bit 4: Tool monitoring and Magazine management
Definition of basic control settings after reset/part program end
Bit 0 = 1
20110 $MC_RESET_MODE_MASK - Bit 0: RESET mode
Bit 6 = 1
- Bit 6: Active tool length compensation
$MC_TOOL_MANAGEMENT_TOOLHO
20124 1 Tool holder number
LDER
Bit 0 = 1
- Bit 0: Magazine management active
Bit 1 = 1
- Bit 1: Monitoring functions active
Bit 3 = 1
20310 $MC_TOOL_MANAGEMENT_MASK - Bit 3: Adjacent location treatment
Bit 14 = 1
- Bit 14: Automatic tool change during RESET and Start
Bit 16 = 1
- Bit 16: Programming T=“Location number“
Bit 23 = 1
- Bit 23: On offset selection no synchronization with HL
Time monitoring for tool in tool holder
20320 $MC_TOOL_TIME_MONITOR_MASK Bit 0 = 1
- Bit 0: Monitoring tool in tool holder 1
22550 $MC_TOOL_CHANGE_MODE 0 New tool offset with T function

$MC_MM_TOOL_DATA_CHG_BUFF_
28450 400 Buffer for tool data changes (DRAM)
SIZE
*) Settings for 828D software 28x.
Notes :

Machine data for the tool change with turret Tool change program, TCHANGE
MD10717 = Name of the subprogram which is called

TCHANGE when a T command is programmed.
Tool change triggered by T function
MD22550 = 0 The „tool change“ phase is activated by the The TCHANGE program is called whenever a T command is
T function for the new tool. programmed in the part program.
Programming the tool change
TEST_PROGRAM.MPF
N10
N20
N30 T=“ROUGHING1” Tool change program
N40 TCHANGE is called
N50
N60
N70
N80
N90
Define tool holder Activation of “T=Location number“
MD20124 = 1 Tool holder number MD20310 Tool Management Mask
Bit 16 = 1 Programming T=Location number
If a tool holder number is defined, then the number in

$TC_MPP5 is interpreted as the tool holder number, and not If “T=Location number“ is active, then tools can be pro-
as the spindle number. The automatic address extension for grammed via “T=Location number“.
T is then also the tool holder number and no longer the spin-
dle number.
Example: Tool change with turret
The tool holder must be defined if the lathe has more than one
spindle .
T=“ROUGHING1“
T3
Example: Tool change with turret
T2
L1
9999,1 M1 Magazine 1
H1 Tool holder 1
M1/T1 L1 Load loc. 1
L1 H1
9999,1 M1 Magazine 1 9998,1
T8
H1 Tool holder 1
M1 L1 Load loc. 1 T7
H1
9998,1
Notes :

Magazine Configuration Magazine configuration: how to create, how to load
The magazine configuration can be accomplished with the Example: Turret with 12 locations
operating software “HMI Operate“.
The magazine configuration contains:
Magazine 1
(turret) 12 locations
- Definition of the magazines
- Definition of the magazine locations
- Definition of the buffer locations Buffer magazine
- Definition of the load locations (9998) 1 location (tool holder)
- Definition of the search strategy
Load magazine
Procedure: (9999) 1 location ((load location
for turret)
- Create the magazine configuration
- Load magazine data into the NC Load magazine

data
NC
(INI file)
Configure the turret magazine
Example: Turret with 12 locations
L1
9999,1 M1 Magazine 1
H1 Toolholder 1
M1 L1 Load loc. 1
H1
9998,1
Notes :

Start the magazine configuration Create a new magazine configuration
Position the cursor on the "Tool unit (Chan1)" folder and press
the "Delete element" softkey.
Confirm deleting with "OK" softkey.
The Tool management menu contains the following areas: The default magazine configuration of the 828D controller is
Active data contains the tool management of the NC deleted.
Examples contains examples for the tool management
Network / USB contains the connections
Position the cursor on the "Active data" folder and press the A magazine configuration is created that consists of a maga-
"New element" softkey. zine with 5 locations, as well as a tool spindle and a loading
point.
Configure the TO unit
Set the search strategy and accept with "OK".
Name optional
Channel number input a value of “1”
Tool search select “Active tool”
Location search select “First location forward“ This magazine configuration can now be adapted to the
conditions on the machine.
Notes :

Configure Magazine 1 Accept the preassignments for the new magazine locations
for Location type and Consider adjacent location with "OK".
Position the cursor on the "Magazine 1" folder and open the
The new locations are added to magazine.
Set the number of locations, the magazine type and type of

location coding and accept with "OK".
Magazine type select “Tool turret”

Location coding select “Fixed-location coded“
The location type can be defined by the OEM. To do this, the

cursor must be positioned on the appropriate location and the
element opened.
Configure the assignments Specify the assignments of the magazine and accept with
"OK".
Position the cursor on the "Assignments" folder and open the
The creation of the magazine configuration is now com-

pleted.
Notes :

Back up the data Enter the name for Initialization program INI and accept with
"OK".
"Copy" softkey.
The INI file is created and saved to the USB stick.
Position the cursor on the "USB" folder and press the "Paste"
softkey.
Notes :

Configuration file (INI file) Variables in the configuration file (INI file)
Parameter Meaning
CHANDATA(1) $TC_MAMP1 Configuration magazine identifier
$TC_MAMP2 Tool search (bit 0-7) and location search (bit 8-15)
; delete old data - Bit 0=1: Active tool / min. duplo
$TC_MAP1[0]=0 Delete old data - Bit 8=1: First location forward
$TC_DP1[0,0]=0 $TC_MAP1 Magazine type (1=chain, 7=tool buffer magazine,
9=load magazine)
$TC_MAMP1="" TO area $TC_MAP2 Magazine identifier
$TC_MAMP2=257
$TC_MAP3 Magazine state
- Bit 0=1: Active magazine
$TC_MAP1[1]=3 - Bit 4=1: Magazine can be moved
$TC_MAP2[1]="" Magazine 1 - Bit 6=1: Fixed-location coded
$TC_MAP3[1]=81 $TC_MAP6 Number of lines (box magazine only)
$TC_MAP6[1]=1
$TC_MAP7 Number of columns
$TC_MAP7[1]=12
$TC_MAP10[1]=257 $TC_MAP10 Magazine tool search strategies, see MAMP2
$TC_MPP1 Location category (1=magazine location,
$TC_MPP1[1,1]=1 2=Spindle /tool holder, 3=gripper, 7=loading point)
$TC_MPP2 Location type (0=compatible with each tool location
$TC_MPP3[1,1]=1 type)
$TC_MPP4[1,1]=2 $TC_MPP3 Consider adjacent location (1=On, 0=Off)
$TC_MPP5[1,1]=0 to
... $TC_MPP4 Location state
$TC_MPP1[1,12]=1 - Bit 1=1: Free to receive a tool
$TC_MPP2[1,12]=1 $TC_MPP5 Location type index
$TC_MPP4[1,12]=2 $TC_MLSR Assignment of locations of the buffer magazine to
$TC_MPP5[1,12]=0 the spindle
$TC_MDP1 Distance from the magazine change position to the
$TC_MAP1[9998]=7 location of the first internal magazine (9999)
$TC_MAP2[9998]="" $TC_MDP2 Distance from the magazine change position to the
$TC_MAP3[9998]=17 location of the second internal magazine (9998)
Buffer magazine
$TC_MAP6[9998]=1
$TC_MAP7[9998]=1
$TC_MAP10[9998]=0
$TC_MPP1[9998,1]=2
$TC_MPP2[9998,1]=0
$TC_MPP3[9998,1]=0 Spindle/holder
$TC_MPP4[9998,1]=2
$TC_MPP5[9998,1]=1
$TC_MAP1[9999]=9
$TC_MAP2[9999]="" Load magazine
$TC_MAP3[9999]=17
$TC_MAP6[9999]=1
$TC_MAP7[9999]=1
$TC_MAP10[9999]=0
$TC_MPP2[9999,1]=0
$TC_MPP3[9999,1]=0
$TC_MPP4[9999,1]=2
$TC_MPP5[9999,1]=1
Assignments
$TC_MDP1[1,1]=0 Loading point to
magazine
$TC_MDP2[1,1]=0
Spindle/holder to
M17 magazine
Notes :

Activate the data After successfully reading in the definition files, the "*" symbol
goes away.
"Activate data" softkey.
The definition files are read in.
Display on the controller
After successfully loading the configuration file, all magazines

and buffers in the tool list are displayed in the Parameters
area.
Magazine 1 (Turret)
- Location 1
...
- Location 12
Notes :

Tool load / unload Sequence load magazine (turret)
Example: Load a tool into the magazine

Job “Load“ (DB4100 Interface
1)
T=“ROUGHING1“
2 1
1
L1 Position the correct magazine location
9999,1 M1 Magazine 1 (DB4100.DBW10/12) to the load loca-
H1 Tool holder 1
M1 tion
L1 Load loc. 1
H1
9998,1
2
Place the tool into the magazine by

hand
Acknowledge the “Load“ job
DBB0
7 6 5 4 3 2 1 Ack
15 14 13 12 11 10 9 8
DBB1 NC g g
pro-
gram Example: Load tool to magazine location 9
DB4100.DBW6 =0
DBW6
DB4100.DBW8 =0
DB4100.DBW12 =9
Notes :

Generate the TCHANGE program
The TCHANGE, tool change program has to take the machine layout into consideration. The TCHANGE program is stored in the
manufacturer cycles or the user cycles directory of the control.
PROC TCHANGE SAVE SBLOF DISPLOF

;VERSION: 02.15 May 02, 2015
;CHANGE : 02.07.01. May 14, 2012
;
DEF INT _LANGUAGE
IF $P_GG[47]==2
_LANGUAGE=1
ELSE
_LANGUAGE=0
ENDIF
IF _LANGUAGE==1 ; CALL IN ISO-MODE

$C_MACPAR[1] = $C_T_VALUE
G291
T$1
G290
ELSE
IF $C_T_PROG==1 ; T is numeric
IF $C_T==0 ; T=0
T=0
ENDIF
IF $C_T > 0
T=$C_T ; T-programming location number T=Location number
IF $C_D_PROG==TRUE
D=$C_D ; call Cutting edge number if programmed Tool change -> PLC
ENDIF
ENDIF
ENDIF
;
IF $C_TS_PROG==1 ; T is string
T=$C_TS ; T-programming without address expansion
IF $C_D_PROG==TRUE
D=$C_D ; call Cutting edge number if programmed T=“Identifier“
ENDIF Tool change -> PLC
ENDIF
ENDIF
;
;SETPIECE(1) ; if the number of workpieces machined by the tool is monitored
; (Tool Wear, column TC = C) counter of main toolholder
; is decremented by 1
M17
TCA program
The TCA program is used for the replacement tools (duplo tools) function. With selection of a replacement tool on the HMI sur-
face or programming of a TCA command in the NC program the TCA cycle is automatically called.
The TCA program is stored in the manufacturer cycles or the user cycles directory of the control.

PROC TCA(STRING[64] _TOOL_NAME,INT _DUPLO,INT _TH_NO)
;VERSION: 02.15 May 02, 2015
;CHANGE : 02.07.01. May 14, 2012
;
_TCA(_TOOL_NAME,_DUPLO,_TH_NO) ; Tool call to NC
;
M17
Notes :

Tool change with turret Programming examples
T=“Identifier“
Programming -> T=“ROUGHING1“
TEST_PROGRAM.MPF T=Location number

N10 -> T3 or T=3
N20
N30 TCA (“Tool identifier“, Duplo no., Tool holder no.)
N40 -> TCA(“ROUGHING1“, 1, 1)
N50 T=“ROUGHING1” Tool change program
N60 TCHANGE is called The TCA command forces the tool change to take place, re-
N70 gardless of the status of the tool. It is used ,for example with
N80 the “Measure Tool “ feature.
N90
N100
N110
N120
N130
N140
N150
Tool change -> Job from PLC (DB4300.DBX1.1=1).
Example: Tool change with turret Sequence: Tool change with turret
T=“ROUGHING1“ Job “Execute tool change“
1
L1
9999,1 M1 Magazine 1 1
H1 Toolholder 1
M1 L1 Load loc. 1
H1
Position turret to new tool location
9998,1 (DB4300.DBW6 and 8)
Acknowledge “Execute tool

change“ job
Notes :

Job: Execute tool change DB4300 Acknowledgement for “Execute tool change” DB4200
DBB0
7 6 5 4 3 2 1 Ack
spin- T-No)
dle Example: Change to turret position 3
DB4300.DBW6 =1
DBW6 Source magazine no. for new tool (Int)
DB4300.DBW8 =3
DBW8 Source location no. for new tool (Int) DB4300.DBW18 =0
DB4300.DBW20 =0
B102: END
Notes :

B102 END Tool Management

B110 Setup Milling
Sinumerik
Operate
Module Description:
In this module a simple milling machine with the axes X, Y and Z, the rotary axes A, C and the
main spindle SP1 is to be setup for milling. The individual commissioning steps are to be checked
from time to time to show the result of the parameterization.
The preparation of the tool list, the cycle selections, the block search and various basic settings
are also part of the training scope. There will be a detailed description of the selections to be made
for JOG-TSM.
Module Objective:
By means of this module you will learn and get to know the meaning of the Machine and Setting
data to be used as well as the various means available in order to configure the machine to suit the
particular requirements.
The functions will be parameterized in several blocks and subsequently tested to check correct
working.
Content:
Menu and Technology settings
Sinumerik
Manufacturer Cycles
Setup for Milling
Cycle settings
Tool List Setup
Basic Settings
JOG-TSM
Block Search
Simulation
828D/840D sl SINUMERIK Operate V4.7 Page 1

B110
B110 Page 2 828D/840D sl SINUMERIK Operate

Setup Milling B110
Setup Milling:
START
Simulation
Overview
MD and SD
Machining
example
Manufacturer
Cycles
Menu and
Technology
settings
Setup for
Milling
Setup Milling:
END
Cycle
Settings
Tool List
Setup
Basic
Settings
JOG-TSM
Block search
Notes
828D/840D sl SINUMERIK Operate Page 3 B110

B110 Setup Milling
Overview Machine data and setting data
Basic settings Machine data/setting data
10260 $MN_CONVERT_SCALING_SYSTEM 1 Exact Enable basic system conversion

$MN_FRAME_GEOAX_CHANGE_MO
10602 1 Exact Frames when changing geometry axes
DE
10714 $MN_M_NO_FCT_EOP 32 Variable M function for spindle active after reset
10715 $MN_M_NO_FCT_CYCLE[0] 6 Variable M function to be replaced by a subroutine
10716 $MN_M_NO_FCT_CYCLE_NAME[0] L6 Variable Subroutine name for M function replacement
10722 $MN_AXCHANGE_MASK Bit 2 = 1 Exact Parameters for axis replacement behavior

Bit 0: 15110: REORG not possible
Bit 0 = 1
Bit 1: 10763 The path component of the block in the con-
Bit 1 = 1
11410 $MN_SUPPRESS_ALARM_MASK Variable tour plane is zero
Bit 15 =1
Bit 15: 5000 Communication order cannot be executed
Bit 20 =1
Bit 20: 2900 Reboot is delayed
Bit 0: Machining is stopped with the loading of the last
Bit 0 = 1 Exact action block after search run
11450 $MN_SEARCH_RUN_MODE Bit 1 = 1 Exact Bit 1: Automatic ASUP start after output of action blocks
Bit 2 = 1 Exact Bit 2: The output of the auxiliary functions in the action
blocks is suppressed
$MN_TOOL_DATA_CHANGE_COUN
17530 1FH Exact Mark tool data change for HMI
TER
Bit 0 = 1 Exact Bit 0: Memory for TM-specific data is provided
$MN_MM_TOOL_MANAGEMENT_M
18080 Bit 1 = 1 Exact Bit 1: Memory for monitoring data (WZMO) is provided
ASK
Bit 3 = 1 Exact Bit 3: Memory to consider adjacent location is provided
19320 $ON_TECHNO_FUNCTION_MASK Bit 4 = 1 Exact Tool management with magazine data enabled
Bit 0 = 1 G codes acc. to $MC_GCODE_RESET_VALUE

Bit 0 = 1 Exact
Bit 6 = 1 Current setting for active tool length offset is re-
20110 $MC_RESET_MODE_MASK Bit 6 = 1 Exact
tained after reset/end-of-part-program
Bit 14 =1 Exact
Bit 14= 1 The current setting of the basic frame is retained
20128 $MC_COLLECT_TOOL_CHANGE 0 Exact No tool change commands after search run

$MC_CUTTING_EDGE_RESET_VAL
20130 1 Exact Tool and cutting edge remain activated
UE
Group 16: Feedrate override 3 = CFIN
[15] = 3 Variable Group 22: Tool offset type 2 = CUT2DF
[21] = 2 Variable Group 42: Toolholder 1 = TCOABS (for swivel)
20150 $MC_G_CODE_RESET_VALUE [41] = 1 Exact Group 52: Frame rotation in relation to workpiece 1 = PA-
[51] = 1 Exact ROTOF (2 = PAROT, for swivel)
[52] = 1 Variable Group 53: Frame rotation in relation to tool 1 = TOROTOF
(for swivel)
Group 6: Plane selection remains active after Reset
[5] = 1 Exact
Group 8: Zero point offset remains active after Reset
[7] = 1 Exact
20152 $MC_G_CODE_RESET_MODE Group 13: Work piece dimensioning inch/metric default
[12] = 0 Exact
after reset
[21] = 0 Variable
Group 22: Tool correction type default after reset
$MC_WAB_MAXNUM_DUMMY_BLO maximum number of blocks w/o traversing movement with
20202 10 Minimum
CKS SAR
$MC_CUTCOM_MAXNUM_CHECK_
20240 4 Minimum Blocks for look-ahead contour calculation with TRC
BLOCKS
$MC_CUTCOM_MAXNUM_DUMMY_ maximum number of blocks without traversing motion in
20250 5 Minimum
BLOCKS TRC
Notes

Setup Milling B110
Bit 0 = 1 Exact Bit 0: Tool management active

Bit 1 = 1 Exact Bit 1: Tool monitoring function active
20310 $MC_TOOL_MANAGEMENT_MASK Bit 3 = 1 Exact Bit 3: Consider adjacent location active
Bit 14 =1 Exact Bit 14: automatic tool change during RESET and Start
Bit 23 =1 Variable Bit 23: On offset selection no synchronization with HL
20320 $MC_TOOL_TIME_MONITOR_MASK Bit 0 = 1 Variable Time monitoring for tool in tool holder 1
Errors in ISO scanner are not output, the block is trans-
20734 $MC_EXTERN_FUNCTION_MASK Bit 3 = 1 Variable
ferred to the Siemens translator.
22550 $MC_TOOL_CHANGE_MODE 1 Exact Tool change with M function
22560 $MC_TOOL_CHANGE_M_CODE 206 Variable M function for tool change

Active system frames after reset
24006 $MC_CHSFRAME_RESET_MASK Bit 0 = 1 Exact Bit 0 = 1 Actual value setting and scratching remains active
Bit 5 = 0 Exact Bit 5 = 0 System frame for cycles is deleted
Deletion of system frames after reset
$MC_CHSFRAME_RESET_CLEAR_
24007 Bit 0 = 0 Exact Bit 0 = 0 Actual value setting and scratching not delete
MASK
Bit 5 = 1 Exact Bit 5 = 1 System frame for cycles delete
Reset channel system frames after power on
$MC_CHSFRAME_POWERON_MAS
24008 Bit 0 = 0 Exact Bit 0 = 0 Actual value setting and scratching not reset
K
Bit 5 = 0 Exact Bit 5 = 0 System frame for cycles not reset
24030 $MC_FRAME_ACS_SET 1 Exact Adjustment of SZS coordinate system
Bit 0: Measurement of total operating time is active for all
Bit 0 = 1 part programs
Bit 1 = 1 Bit 1: Measurement of current program runtime is active
Bit 4 = 1 Bit 4: Measurement also with active dry run feed
27860 $MC_PROCESSTIMER_MODE Variable
Bit 5 = 1 Bit 5: Measurement also with program test
Bit 6 = 1 Bit 6: $AC_CYCLE_TIME is not deleted on start by ASUP
Bit 8 = 1 and PROG_EVENT
Bit 8: AC_CYCLE_TIME will be deleted with GOTOS
Bit 0 = 1 Bit 0: Counter $AC_REQUIRED_PARTS is activated
27880 $MC_PART_COUNTER Bit 8 = 1 Variable Bit 8: Counter $AC_ACTUAL_PARTS is active
Bit 11 =1 Bit 11: Increment $AC_ACTUAL_PARTS with GOTOS
28000 $MC_MM_REORG_LOG_FILE_MEM 75 Minimum Memory space for REORG (DRAM)

$MC_MM_NUM_REORG_LUD_MOD Number of blocks for local user variables in REORG
28010 20 Minimum
ULES (DRAM)
Setting up system frames (SRAM)
28082 $MC_MM_SYSTEM_FRAME_MASK Bit 0 = 1 Exact Bit 0 = 1 System frame for actual value and scratching
Bit 5 = 1 Exact Bit 5 = 1 System frame for cycles
Setting up data management system frames (SRAM)
$MC_MM_SYSTEM_DATAFRAME_M
28083 Bit 0 = 1 Exact Bit 0 = 1 System frame for actual value and scratching
ASK
Bit 5 = 0 Exact Bit 5 = 0 System frame for cycles
28450 400 Exact Buffer for tool data changes (DRAM)
_SIZE
35040 $MA_SPIND_ACTIV_AFTER_RESET 2 Exact Own spindle RESET
42440 $SC_FRAME_OFFSET_INCR_PROG 0 Exact Zero offsets in frames
42442 $SC_TOOL_OFFSET_INCR_PROG 0 Exact Tool length offsets
42528 $SC_CUTCOM_DECEL_LIMIT 1 Exact Feed lowering on circles with tool radius compensation
Change of tool length components with change of active
42940 $SC_TOOL_LENGTH_CONST 0 Exact
plane
Assignment of tool length compensation independent of tool
42950 $SC_TOOL_LENGTH_TYPE 0 Exact
type
Notes

B110 Setup Milling
Basic settings Technology data
Bit mask for available search modes (ShopMill/ShopTurn)

Bit 0: Block search with calculation without approach
$MNS_BLOCK_SEARCH_MODE_MA
51024 Bit 0 = 1 Bit 1: Block search with calculation with approach
SK_JS
Bit 3: Skip EXTCALL programs
Bit 5: Block search with test run
Bit mask for available block search modes
Bit 0 = 1 Bit 0: Block search with calculation without approach
$MNS_BLOCK_SEARCH_MODE_MA Bit 1 = 1 Bit 1: Block search with calculation with approach
51028
SK Bit 4 = 1 Bit 3: Skip EXTCALL programs
Bit 5 = 1 Bit 4: Block search without calculation
Set actual value selection
0 = Set actual value is not offered.
51038 $MNS_SET_ACT_VALUE 1 1 = If a user frame (settable work offset e.g. G54) is active,
it will be used. In G500 Set actual values is not offered
(system frame is no longer used).
$MNS_PROGRAM_CONTROL_MOD Options for machine - program influence:
51039 Bit 0 = 1
E_MASK Bit 0: Program test function available
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,
$MNS_SWITCH_TO_MACHINE_MAS
51040 0H the operating area is not automatically switched
K
over to Machine.
Bit 2: Do not switch automatically in Programs during
program selection.
Bit 3: No auto. Start of block search on selection / execu-
tion under Programs.
Function mask Simulation
Bit 0: No automatic start on simulation selection
Bit 1: Deactivate simulation
Bit 4: Ignore frame components in X and Y (compatibility)
51226 $MNS_FUNCTION_MASK_SIM 0H Bit 5: Turning tool can rotate in the tool spindle
Bit 6: Enable handwheel as simulation override
Bit 7: Interpretation of handwheel values as absolute
values
Bit 10: Hide zero point symbol
Bit 0: G code programming without multi-channel data
51228 $MNS_FUNCTION_MASK_TECH 0H
Bit 1: Enable print function of editor
Bit 2: With external program selection, test program
$MCS_DISP_COORDINATE_SYSTE
52000 0 0: Vertical milling machine
M
0: Plane selection on the operator panel
17: always G17
52005 $MCS_DISP_PLANE_MILL 0
18: always G18
19: always G19
Technology
0: no specific configuration
52200 $MCS_TECHNOLOGY 2 Exact
1: turning
2: milling
Extended technology
52201 $MCS_TECHNOLOGY_EXTENSION 0 1: turning: extended technology Turning has not yet been
implemented for Milling
2: milling
Notes

Setup Milling B110
Meaning of the axes

0 = no special meaning; 1 = tool spindle (driven tool); 2 = C
axis of the tool spindle (driven tool); 3 = main spindle
(turning); 4 = C axis of the main spindle (turning); 5 = coun-
52206 $MCS_AXIS_USAGE 0 terspindle (turning); 6 = C axis of the counterspindle
(turning); 7 = linear axis of the counterspindle (turning);
tailstock (turning); 9 = steady rest (turning); 10 = B axis
(turning), 12 = B axis of the counter spindle (turning),
13 = Traverse travel X of the counter spindle (turning)
Axis attributes
Bit 0: Rotates around the 1st geometry axis (applies to
rotary axes)
Bit 1: Rotates around the 2nd geometry axis (applies to
rotary axes)
Bit 2: Rotates around the 3rd geometry axis (applies to
rotary axes)
Bit 3: Positive direction of rotation is counter-clockwise
(applies to rotary axes)
Bit 4: Displayed direction of rotation for M3 is counter-
clockwise (applies to spindles)
Bit 5: Direction of rotation M3 corresponds to rotary axis
minus (applies to spindles)
This bit must be set in the same way as a PLC bit.
For 840D sl: PLC bit DBnn.DBX17.6, nn = 31 +
52207 $MCS_AXIS_USAGE_ATTRIB 0H machine axis index
For 828D: PLC bit DB38xx.DBX2001.6, xx is ma-
chine axis index
Bit 6: Show rotary axis as offset target for measuring
Bit 7: Offer rotation axis in position pattern
Bit 8: Offer rotation axis to accept blank (at milling ma-
chines)
Bit 9: Spindle is not SPOS-capable
Bit 10: Rotary axis rotates around 1st geometry axis (for
position pattern only)
Bit 11: Rotary axis rotates around 2nd geometry axis (for
Bit 12: Rotary axis rotates around 3rd geometry axis (for
Bit 13: Position of the axis for blank selection from active
WO (for rotary axes)
Bit 0: Measuring system for programs always in the base
system
Bit 1: Front view for turning in school coordinate system
Bit 2: Hide “T,S,M” soft key in JOG area
Bit 3: Generate automatic end-of-program in MDI (with
the “Delete blocks” soft key)
Bit 4: Show follow-on tool in T,F,S window
Bit 5: Hide softkey “Actual machine values“
Bit 0 = 1
Bit 6: Hide tool radius/diameter in T,F,S window
Bit 7: Hide tool length in T,F,S window
Bit 4 = 1
Bit 8: Hide tool icon in T,F,S window
Bit 9: Display selection ”Simple input”
Bit 10: Do not offer channel in job lists
Bit 11: For Work activate the display of the logical spindles
Bit 12: Hide mold making view for G code
Bit 13: Hide channel axes which are currently located in
another channel
Bit 14: Display overlay of DRF under machine
Bit 15: Display overlay of tool ($AA_TOFF) under machine
Notes

B110 Setup Milling
Function screen for displaying overview of work offsets

Bit 0: Show machine position
Bit 2: Display DRF offset
Bit 3: Display $AA_OFF position offset
Bit 4: Display $P_PARTFRAME
Bit 5: Display $P_SETFRAME
Bit 6: Display $P_EXTSFRAME
Bit 7: Display $P_ISO1FRAME
Bit10: Display $P_ACTBFRAME
Bit 11: Display $P_IFRAME
$MCS_FUNCTION_MASK_DISP_ZO
52211 1FFFF5H Bit 12: Display $P_TOOLFRAME
A
Bit 13: Display $P_WPFRAME
Bit 14: Display $P_TRAFRAME
Bit 15: Display $P_PFRAME
Bit 17: Display $P_CYCFRAME
Bit 18: Display sum of work offsets
Bit 19: Display offset of active tool
Bit 20: Display Work position
Bit 21: Display BCS position
Bit 22: Display $P_GFRAME
Bit 23: Display TOFF
Bit 24: Display overlay $AA_TOFF
Bit 0: Enable swivel plane/align tool with tool carrier
Bit 1: Optimized travel along software limit switches
(ShopMill/ShopTurn)
Bit 2: Special 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 ZV cannot be entered as an absolute
value (ShopTurn)
52212 $MCS_FUNCTION_MASK_TECH Bit 3 = 1 Exact Bit 7: Detect the expiry of tool lives (ShopMill/ShopTurn)
Bit 8: Manual machine (ShopMill/ShopTurn)
Bit 9: Selection/deselection of work offset via softkey
Bit 10: Enable swivel plane/align tool using kinematic
transformation
Bit 11: Switch off layer check for drilling and milling tools
(ShopTurn)
Bit 13: Approach tool change point Y in Machine
(ShopTurn)
Bit 14: With approach logic only check tool position with
cutting edge (ShopTurn)
Function mask Milling
Bit 0: Enable cylinder surface transformation (ShopMill)
Bit 1: Offer fixed table for blank clamping (at milling ma-
chines)
Bit 2: Special handling of slide mill/saw for polyhedron
52214 $MCS_FUNCTION_MASK_MILL 0H
Bit 3: Enable inside/rear machining (ShopTurn)
Bit 4: Enable spindle clamping (C axis) (ShopTurn)
Bit 5: Enable spindle control of tool spindle via surface
Bit 6: Enable spindle control of turning spindle via surface
Bit 7: Offer fixed table for blank clamping (on boring mills)
Notes

Setup Milling B110

Function mask Drilling
Bit 0: CYCLE84 Unhide technology fields
52216 $MCS_FUNCTION_MASK_DRILL 0H Bit 2: Thread tapping also without encoder (ShopMill/
ShopTurn)
Bit 3: Constant cutting speed in rel. to diameter of center-
ing (ShopMill/ShopTurn)
Enable fast M functions
Bit 0: Coolant OFF
52229 $MCS_ENABLE_QUICK_M_CODES 0H Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
Bit 3: Coolant 1 and 2 ON
$MCS_M_CODE_ALL_COOLANTS_
52230 9 M-code for all coolants OFF
OFF
52231 $MCS_M_CODE_COOLANT_1_ON 8 M-code for coolant 1 ON
52232 $MCS_M_CODE_COOLANT_2_ON 7 M-code for coolant 2 ON
$MCS_M_CODE_COOLANT_1_AND
52233 -1 M-code for coolant 1 + 2 ON
_2_ON
$MCS_NAME_TOOL_CHANGE_PRO
52240 M6 Tool change program for G code steps
G
Bit 0: Do not permit Create tool on magazine location
Bit 1: Load/unload disable, if machine is not in reset
Bit 2: Load/unload disable for emergency stop
Bit 3: Load/unload tool or relocate tool to/from spindle
disabled
Bit 4: Load directly in spindle
Bit 5: Use grinding configuration file
Bit 6: Permit relocating to/from spindle despite a block
(Bit 3)
Bit 7: Create tool using the T number
Bit 8: Hide Relocate tool
Bit 9: Hide Position magazine
Bit 10: Reactivate tool using Position magazine
Bit 11: Reactivate tool in all monitoring modes
Bit 12: Fade out Reactivate tool
Distance between individual magazine locations.
52271 $MCS_TM_MAG_PLACE_DISTANCE 70 Is used for graphical display of magazine and tools in tool
management.
Number of load station
= 0: If a query window is on the surface or if only one load-
52274 $MCS_TM_LOAD_STATION 0 ing station is available there will be no pop-up window
= 1: fixed loading station 1
= 2: fixed loading station 2
ShopMill only:
52281 $MCS_TOOL_MCODE_FUNC_ON -1
M-code for tool-specific function ON
M-code for tool-specific function OFF
52282 $MCS_TOOL_MCODE_FUNC_OFF -1 If both M commands of a function equal -1, the correspond-
ing field will not be displayed
X=0
Axis position at start of simulation
53230 $MAS_SIM_START_POSITION Y=0
Only adjust with geometry axes
Z=300
Notes

B110 Setup Milling

Bit 0: Diameter display for rotating tools
Bit 1: Default direction of rotation for all turning tools is M4
Bit 2: Create tool without name suggestion
Bit 3: Input disable for tool name and tool type in loaded
tools
Bit 4: Input disable for loaded tools, if the channel is not in
Reset
Bit 5: Calculate tool wear inputs additively
Bit 6: Numerical input of the tool ident.
Bit 7: Fade out tool monitoring parameters
54215 $SNS_TM_FUNCTION_MASK_SET 0H
Bit 8: Diameter display for transverse axis - Geometry
Bit 9: Diameter display for transverse axis - Wear
Bit 10: Enable loading/relocating of tools on buffer loca-
tions
Bit 11: Creating of new tools in gripper locations is disabled
Bit 12: Do not unload measuring tools if ”Unload all” func-
tion is executed
Bit 13: Do not delete tool wear when inputting the geome-
try value
Bit 14: Load/relocate tool. Search without pre-assignment
of the magazine
$SCS_MAX_INPUT_FEED_PER_RE
55200 1 Feedrate input upper limit for mm/rev
V
$SCS_MAX_INPUT_FEED_PER_TIM
55201 10000 Feedrate input upper limit for mm/min
E
$SCS_MAX_INPUT_FEED_PER_TO
55202 1 Feedrate input upper limit for mm/tooth
OTH
Bit 0 = 1 Bit 0: Tool preselection active
$SCS_FUNCTION_MASK_TECH_SE
55212 Bit 1 = 1 Bit 1: Calculate thread depth from metric thread lead
T
Bit 2 = 1 Bit 2: Refer to the table for thread diameter and depth
Bit 3: Delete programs generated by contour cycles
Bit 0: Default setting - milling cycles with synchronous
operation
Bit 2: Depth calculation in milling cycles without parameter
SC
= 0: Depth calculation in milling cycles is carried out
Bit 0 = 1 between reference plane + safety clearance and
55214 $SCS_FUNCTION_MASK_MILL_SET
Bit 2 = 1 depth
without inclusion of the safety clearance
Note: Bit 2 is active with the following milling cycles: CY-
CLE61, CYCLE71, CYCLE76, CYCLE77, CYCLE79, CY-
CLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCK-
ET4
Bit 0: reserved
Bit 1: Consider rotation of the tool plane (CYCLE86)
Bit 2: Consider swivelled table kinematics (CYCLE86)
Bit 3: Monitoring spindle MD 31050/31060 (CYCLE84)
$SCS_FUNCTION_MASK_DRILL_SE Bit 3 = 1
55216 Bit 4: Monitoring spindle MD 31050/31060 (CYCLE840)
T Bit 4 = 1
Bit 5: reserved
Bit 6: Adapt spindle position to the tool orientation
(CYCLE86)
Bit 7: Adapt direction of retraction path in the plane to
active mirroring (CYCLE86)
Notes

Setup Milling B110
55300 $SCS_EASY_SAFETY_CLEARANCE 1 Simple input: Safety clearance
55301 $SCS_EASY_DWELL_TIME 0.6 Simple input: dwell time
55305 $SCS_EASY_DRILL_DEEP_FD1 90 Simple input: percentage 1st federate deep - hole drilling
55306 $SCS_EASY_DRILL_DEEP_DF 90 Simple input: percentage infeed deep - hole drilling
55307 $SCS_EASY_DRILL_DEEP_V1 1.2 Simple input: min. depth infeed deep - hole drilling
55308 $SCS_EASY_DRILL_DEEP_V2 1.4 Simple input: absolute retraction value deep - hole drilling
$SCS_EASY_THREAD_RETURN_DI
55309 2 Simple input: return distance thread tapping
ST
Engraving cycle CYCLE60: Circ. path radius for generating
55400 $SCS_MILL_ENGRAVE_POINT_RAD 0
the char. ”point”
Notes

B110 Setup Milling
Setup Milling Configuration of the axes and spindle
Pre-requisite: Machine axis name
Sinumerik Operate is already installed, PLC commissioning MD10000

has been carried out, the tool management set-up has been $MN_AXCONF_MACHAX_ Machine axis name
completed. NAME_TAB
Licensing: Change to:

chine, the following software options must be available: MD10000[0] = MX1
MD10000[1] = MY1
 "ShopMill/ShopTurn" MD10000[2] = MZ1
Order Nr. 6FC5800-0AP17-0YB0 MD10000[3] = MSP1
MD10000[4] = MA1
 "Residual material detection and machining"
MD10000[5] = MC1
 "Simultaneous recording (real-time simulation)"

 "3D simulation 1 (finished part)"

Assignment of geometry axis to channel axis Machine axis number valid in channel
MD20070
MD20050 Machine axis number valid in
Assignment of geometry axis $MC_AXCONF_MACHAX_
$MC_AXCONF_GEOAX_ channel
to channel axis USED
ASSIGN_TAB
Change to:
Change to:
MD20070[0] = 1
MD20050[0] = 1 MD20070[1] = 2
MD20050[1] = 2 MD20070[2] = 3
MD20050[2] = 3 MD20070[3] = 4
MD20070[4] = 5
MD20070[5] = 6
Geometry axis name in channel

Channel axis name in channel
MD20060 MD20080
Geometry axis name in chan- $MC_AXCONF_CHANAX_ Channel axis name in channel
$MC_AXCONF_GEOAX_
nel NAME_TAB
NAME_TAB
Change to:
Change to:
MD20080[0] = X1
MD20080[1] = Y1
MD20060[0] = X MD20080[2] = Z1
MD20060[1] = Y MD20080[3] = SP1
MD20060[2] = Z MD20080[4] = A
MD20080[5] = C
Notes

Setup Milling B110
Rotary axis / spindle AX4: MSP1

MD30310 = 1 Modulo-transformation for rotary axis
AX5: MA1
MD30300 $MA_IS_ROT_AX Rotary axis / spindle MD30310 = 0 Modulo-transformation for rotary axis
AX6: MC1
Change to: MD30310 = 1 Modulo-transformation for rotary axis
AX4: MSP1
MD30300 = 1 axis is a rotary axis
Modulo 360 degrees displayed for rotary axis or spindle
AX5: MA1
AX6: MC1 MD30320 Modulo 360 degrees displayed
MD30300 = 1 axis is a rotary axis $MA_DISPLAY_IS_MODULO for rotary axis or spindle
Change to:
Modulo conversion for rotary axis / spindle AX4: MSP1

MD30320 = 1 Actual value display Modulo
AX5: MA1
MD30310 Modulo conversion for rotary
$MA_ROT_IS_MODULO axis / spindle
AX6: MC1
Change to: MD30320 = 1 Actual value display Modulo
Assignment of spindle to machine axis Check of the set axes and spindles:
MD35000
Assignment of spindle to ma-
$MA_SPIND_ASSIGN_TO_
chine axis
MACHAX
Change to:
Description:
Definition of the spindle. The spindle is defined if the spindle
number is entered into this MD.
AX4: MSP1
MD35000 = 1 Assignment of spindle to the machine axis
(spindle S1)
Notes

B110 Setup Milling
Manufacturer cycles Note:
For the individual matching the following cycles are included The cycle PROG_EVENT.SPF is a standard Siemens cycle
in the standard cycle package: and should not be changed by the manufacturer. For the
manufacturer cycles CYCPE1MA.SPF or CYCPE_MA.SPF,
the corresponding jump-out markers are prepared at the
Manufacturer‘s cycle for matching to the technological beginning and at the end of PROG_EVENT.SPF.
CUST_TECHCYC.SPF
cycles.
Manufacturer‘s cycle for matching to the functions At the beginning of the cycle PROG_EVENT
CUST_800.SPF
swivelling plane and orienting tool (CYCLE800).  CYCPE1MA in the directory CMA
Manufacturer‘s cycle for matching to the function High
CUST_832.SPF
Speed Settings (CYCLE832). At the end of the cycle PROG_EVENT
CUST_CLAMP.SPF
Manufacturer’s cycle for matching to the function multi-  CYCPE_MA.SPF in the directory CMA
ple workpiece clamping
Standard cycle for the support of the functionality of: For these cycles templates are not available. If the
 Block search when milling or turning is activated CYCPE1MA.SPF and CYCPE_MA.SPF manufacturer cycles
PROG_EVENT.SPF are loaded in the NC, the program branches from
 Block search and swivelling plane
PROG_EVENT to the manufacturer cycles as appropriate.
 Block search and tool indexing
Copying the Manufacturer cycles Setting-up for milling
Matching of the coordinate systems to the user interface

1. Select the Setup mode for "Commissioning"
2. Press the Softkey "System data". Coordinate system position
3. Open the directory NC-data / Cycles / Stand- MD52000

ard cycles and select the required cycle. $MCS_DISP_COORDINATE_ Coordinate system position
SYSTEM
4. Press the Softkey "Copy" and open the direc-
Default: 0 Change to:
tory NC-data / Cycles / Manufacturer's cycles.
5. Press the Softkey "Paste". Description:

Now this cycle is available for individual
matching This MD is used to match the coordinate system of the user
interface to the coordinate system of the machine. In the user
interface all help images, the animated graphics, the simula-
tion as well as the input fields with circular direction indica-
Note:
tion.
The cycles intended for the machine matching commencing The coordinate system can take on any of the shown posi-
with CUST_.*.SPF can be copied into the manufacturer or tions.
user directory when using the access level "Manufacturer".
The cycle "PROG_EVENT.SPF is a standard cycle that may The typical selection for vertical milling machine is 0 = Pre-
neither be copied nor altered. It is listed here only to indicate setting
the scope for manufacturer-specific matching.
Notes

Setup Milling B110
Selection table of the possible coordinate systems
Plane selection Milling The machining planes are specified as shown:
MD52005
$MCS_DISP_PLANE_MILL Plane selection Milling Plane Tool axis
Default: 0 Change to: Z

X/Y
G17
Description: Y
Z/X
0: Plane selection in the user interface G18
This setting makes sense only if the machining plane on X
the machine can be switched, e.g. by the use of angular Y/Z
G19
milling heads.
17: always G17
18: always G18
19: always G19
Note:
Typical vertical function = G17
Notes

B110 Setup Milling
Continuation MD52005
Example planar milling:
Plane selection by means of the toggle key:

G17 (XY), G18 (ZX), G19 (YZ) or no plane
Technology Extended technology
MD52200 MD52201
Technology $MCS_TECHNOLOGY_EXTE Extended technology
$MCS_TECHNOLOGY
NSION
Change to: 2 Default: 0 Change to:
Description: Meaning of the axes in the channel
0: No specific configuration
1: Turning
2: Milling MD52206[x] Meaning of the axes in the
$MCS_AXIS_USAGE channel
Please also note MD 52201
$MCS_TECHNOLOGY_EXTENSION. Default: 0 Change to:
Selection of 2 specifies milling as the main technology. This

means, the Softkeys for drilling and milling will be shown Description:
along the lower edge of the screen.
No matching specification of the machine datum is required
for the sample machine being described here.
Note:
If high-speed extension spindles are used, a 2 must be en-
tered into the respective machine datum of the extension
spindle. An extension spindle is not included in the axis con-
figuration used here.
Notes

Setup Milling B110
Axis attributes Description:

In case of machines with rotary axes it is possible - in conjunc-
MD52207[x] tion with the function:
Axis attributes "work piece measuring - edge alignment” - to determine the
$MCS_AXIS_USAGE_ATTRIB
angular correction
Default: 0H Change to: For this the following settings are necessary for the rotary ax-
es:
Description:
MD52207[5] C axis
Bit 0: Rotates around the 1st geometry axis (applies to rotary Bit 2 = 1: rotates around the 3rd geometry axis
axes) Bit 6 = 1: Show rotary axis as correction destina-
tion for measuring
Bit 1: Rotates around the 2nd geometry axis (applies to rotary
axes)
Bit 2: Rotates around the 3rd geometry axis (applies to rotary Example: Measuring zero-point work piece - align edge
axes)
Note:
The Bits 3, 4 and 5 have no meaning in conjunction with

ShopMill.
Number of actual values with large font Only display spindles in actual values window when in
axis mode
MD52010
Number of actual values with
$MCS_DISP_NUM_AXIS_BIG MD51023 Only display spindles in actual
large font
_FONT $MNS_ACT_VALUE_SPIND_ values window when in axis
MODE mode
Description: Description:
Number of actual values with large font, Max. value 31. The display of the spindles in the actual value windows can
be influenced by means of this. If the datum is set to 1 the
spindles will be shown in the actual value window only while
they are in the axis mode. The axes are displayed below the
geometry and auxiliary axes. Axes that are not in the axis
mode are shown as gaps.
If set to 0 the spindles will be displayed at all times.
Notes

B110 Setup Milling
Function mask display Bit 0 = 0:

In a ShopMill program it is
possible to select "mm dimen-
MD52210 sions" or "inch dimensions" in
$MCS_FUNCTION_MASK_ Function mask display the program header.
DISP
Default: Bit 0 = 1 Bit 0 = 1:
Change to: The selection field “Unit of
Bit 1 = 1
meas.” is hidden. The measur-
ing system for programs is
Description:
always in the base system.
Bit 0: Meas. sys. for programs always in the base system
Bit 1: Face view when turning in the school coordinate sys-
tem
Bit 2: Hide "T,S,M" softkey in Jog area
Bit 3: Generate automatic end-of-program in MDI (with Soft- Bit 1: Takes no effect in the Milling technology.
key "Delete blocks")
Bit 2=0: The Softkey "T,S,M" is shown in the mode JOG . Bit 4=0: The follow-up tool is not shown in the T;F;S-window
This setting is in line with the basic setting of Shop-
Mill.
Bit 2=1: The Softkey "T,S,M" is hidden in the mode JOG. Bit 4 = 1 The follow-up tool is shown in the T;F;S-window.
This setting makes sense only in conjunction with
tool prepare on a machine featuring a double grip-
per.
Bit 3=0: Under MDA the command End-of-program will not

be generated automatically after "Block delete".
Note: Also see the setting of SD 55210

$SCS_FUNCTION_MASK_TECH_SET, Bit 0
"Tool pre-selection activated"
Bit 3=1: Under MDA the M-command entered in MD 10714
$M_NO_FCT_EOP will automatically be generated
as end-of-program command after "block delete". In
this example configuration it is M32.
Notes

Setup Milling B110
Function mask Cross-technology Bit 0 and Bit 1 make sense only in conjunction with swivelling.
A more detailed description will be found in Module "Setup
Swivelling".
MD52212
Function mask Cross-
$MCS_FUNCTION_MASK_
technology
TECH
Change to: Bit 3 = 1
Bit 5 = 0 Bit 2: This Bit is not relevant in the technology Milling . In the
ShopMill cycles the longest cutting edge is taken into
account when retracting (retraction to the safety level).
Description:
(ShopMill/ShopTurn) Bit 3 = 0 Bit 3 = 1
Bit 3: Call block search cycle for ShopMill/ShopTurn The ShopMill cycle The ShopMill cycle
Bit 4: Approach logic through cycle (ShopTurn) E_S_ASUP is not carried E_S_ASUP will be carried
Bit 5: Call block search cycle for SERUPRO out after block search. out after block search. De-
Bit 6: Work offset ZV cannot be entered as an absolute value tails regarding this setting
(ShopTurn) are contained in the section
"Block search"
Bit 5 = 0 Bit 5 = 1 Cycle Settings-Drilling

Block search cycle for The standard cycle CY-
SERUPRO will not be CLE207 will be called up after
MD52216
called up. Block search with SERUPRO.
$MCS_FUNCTION_MASK_ Function mask Drilling
DRILL
The setting of Bit 3 is not ef-
fective in this case. The Default: 0H Change to:
E_S_ASUP will not be called
The setting = 0 is neces- up.
sary for single-channel
ShopMill machines. Description:
This setting must be used only
for multi-channel machines. Bit 0 = 0 Hide input fields Technology
1 Show input fields Technology
CYCLE84 (without compensating chuck)
Bit 1 = 0 Hide input fields Technology
1 Show input fields Technology
CYCLE840 (with compensating chuck) valid only for
ShopMill.
Notes

B110 Setup Milling
Continued MD52216 MD52216 Bit 0 = 1 MD52216 Bit 1 = 1

Technology fields will be Technology fields will be
shown with the selection shown with the selection
Bit 0 = 0 Bit 1 = 0 "without compensating "with compensating chuck
Technology fields will not be shown in either case: chuck (Cycle84) (Cycle840)
"with compensating chuck" "without compensating chuck
Function mask Cross-technology Bit 1 = 0 The thread depth will not be evaluated automatically
The value for the thread depth "H1" must be entered manual-
SD55212 ly from a table.
$SCS_FUNCTION_MASK_
technology
TECH_SET Bit 1 = 1 The thread depth will be evaluated from the metric
Change to: Bit 0 = 1 thread pitch.
Bit 1 = 1
Bit 2 = 1
Description:
Bit 0: Tool pre-selection activated
Bit 1: Evaluate thread depth from metric pitch
Bit 2: Transfer thread diameter and thread depth from table

Directly after the exchange has been completed, the
tool will be prepared.
The generation of the follow-up tool occurs only with
JobShop cycles.
Bit 1: Automatic evaluation of the thread depth for metric
threads
Bit 2: Transfer thread diameter and thread depth from table.
Notes

Setup Milling B110
SD55212 Continued Bit 2 = 1 Thread diameter and depth from a table
Only if in the table the column "without" is selected and for P

the unit "mm/rev" will the thread depth "H1" in the yellow-
backed fields be calculated automatically. These automatical-
ly obtained values can be overwritten by the operator. If the
thread pitch is entered again, the thread depth will be calcu-
lated once more automatically.
Different factors are stored for the internal and external

threads:
- Internal threads: 0,5413
- External threads: 0,6134
As soon as the line ”Table ISO metric" is selected, the table is

activated for the various threads.
The yellow-backed fields for nominal diameters and thread

depth H1 will be filled in with tabular values depending on the
chosen thread.
Notes

B110 Setup Milling
Cycle Settings-Milling Bit 0 = 1
SD55214
$SCS_FUNCTION_MASK_ Function mask Milling
MILL_SET
Default: Bit 0 = 1
Change to:
Bit 2 = 1
Description:
Bit 0: Default setting for milling with synchronous operation
Bit 1: not assigned
SC
Bit 0 The machining sense (Up-cut/down-cut) can be fixed

or selectable via the “toggle” key.
Bit 2 = 0 Bit 2 = 1 Function mask Drilling

The subdivision of cuts in The subdivision of cuts in
direction of infeed is cal- direction of infeed is ob-
culated including the safe- tained without the safety SD55216
ty gap SC for the path gap SC for the path from $SCS_FUNCTION_MASK_ Function mask Drilling
from Z0+SC to Z1 Z0 to Z1 DRILL_SET
Default: Bit 3 = 1
Change to:
Bit 4 = 1
Description:
Bit 0: Reserved
Bit 1: Boring CYCLE86: Taking into account the rotation of
the work piece plane when positioning the spindle
Bit 2: Boring CYCLE86: Taking into account the indexed
table kinematics (tool carrier) when positioning the
spindle
Bit 3: Tapping CYCLE84: (without compensating chuck).
Note:
Monitoring the machine data 31050[x] and 31060[x] of
The safety gap is specified in the program header.
the spindle
Notes

Setup Milling B110
SD55216 Continued Description:
Bit 4: Tapping CYCLE840: (with compensating chuck). Moni- Bit 0: Reserved

toring the machine data 31050[x] and 31060[x] of the
spindle Bit 1 = 1: Taking into account the rotation of the tool plane
(CYCLE 86)
Bit 5: Reserved In the boring cycle,CYCLE86 the spindle is po-
sitioned on the parameter SPOS when reaching
The denominator of the gearbox is contained in MD31050[x] the boring depth. If SPOS=0 the tool cutting
while MD31060[x] contains the numerator. Together the two edge points in the positive direction of the 1st
provide the gear ratio for the spindle. This is required for mon- axis of the plane (G17 towards X+).
itoring the feed obtained from the speed x the pitch.
If the setting is varied by using Bit 1 = 1, a rota-
tion about the tool axis (e.g. ROT Z180) will be
taken into account for the spindle positioning.
Bit 2 = 1: Taking into account indexed table kinematics

(CYCLE 86)
See description Bit 1
With the selection of Bit 2 = 1 an indexed kine-
matics will be taken into account when position-
ing the spindle.
Description: Cycle Settings
Bit 3 = 1: Tapping CYCLE84: Monitoring the machine data

Upper limit feedrate/rev
31050 $MA_DRIVE_AX_RATIO_DENOM (divider
of gearbox ratio) and 31060
$MA_DRIVE_AX_RATIO_NUMERA (numerator of SD55200
gearbox ratio) of the spindle for the boring axis $SCS_MAX_INP_FEED_PER_ Upper limit feedrate/rev
REV
The monitoring is activated only if MD35590
Default: 1 mm/U Change to:
$MA_PARAMSET_CHANGE_ENABLE = 2.
This setting permits a parameter block change by
Description:
the PLC-interface or by the command SCPARA
(servo parameter block programming). Upper limit for the selection of the federate/rev
If the monitoring is activated the alarm 61127
[Channel %1: ] Block %2 (gear ratio of the tapping
axis incorrectly defined) will be set:
Upper limit feedrate/min
Bit 4 = 1: Similar to Bit 3, however, for the cycle CYCLE840
SD55201
Bit 5: Reserved $SCS_MAX_INP_FEED_PER_ Upper limit feedrate/min
TIME
Default: 10000 mm/min Change to:
Description:
Upper limit for the input of the feedrate in mm/min
Notes

B110 Setup Milling
Upper limit feedrate/tooth Setting up the tool list
SD55202 These settings are applicable only to JobShop programs

$SCS_MAX_INP_FEED_PER_ Upper limit feedrate/tooth
TOOTH Enable fast M functions
Default: 1 mm Change to:
MD52229
$MCS_ENABLE_QUICK_M_ Enable fast M functions
Description: CODES
Upper limit for the selection of the feedrate/tooth
Default: 0H Change to:
Description:
Bit 0: Coolant OFF
Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
This MD is used to declare the commands used for the cool-

ant control (see MD52230 - MD52233) as being fast M-
commands (M=QU…). In case of fast commands the program
progress continues without waiting for the acknowledgement
of the M-command by the PLC.
In the tool list there are input fields for coolant 1 and coolant 2 M-code for all coolants OFF
for each tool. The select key can be used to toggle the func-
tion "coolant ON/OFF". The respective M-functions are put MD52230
out if the tool is changed by means of the part-program. The $MCS_M_CODE_ALL_ M-code for all coolants OFF
M-commands will not be put out if the tool is exchanged by COOLANTS_OFF
means of the T,S,M mask.
Description:
M-Code for all coolant OFF
M-code for coolant 1 ON
MD52231
$MCS_M_CODE_COOLANT_1 M-code for coolant 1 ON
_ON
Description:
M-Code for coolant 1 ON
Notes

Setup Milling B110
M-code for coolant 2 ON M-code for both coolants ON
MD52232
$MCS_M_CODE_COOLANT_2 M-code for coolant 2 ON MD52233
_ON $MCS_M_CODE_COOLANT_ M-code for both coolants ON
1_AND_2_ON
Default: -1 Change to:
Description:
M-Code for coolant 2 ON Description:
M-Code for coolant 1 + 2 ON
Already defined: M8 = Coolant 1 ON

M7 = Coolant 2 ON
If in the JobShop tool list both coolants (coolant 1 and coolant

2) have been selected, the following M-command is generat-
ed:
-1: M-command for coolant 1 on (setting of MD52231) and
M-command for coolant 2 on (setting of MD52232)
>0: the M-command selected in this MD.

A separate M-command for both coolants is to be used if
the M-commands for coolant 1 and coolant 2 are grouped
in one M-commands group, however both coolants are to
be activated after a block search.
M-code for tool-specific function ON
MD52281[x]
M-code for tool-specific func-
$MCS_TOL_MCODE_FUNC_
tion ON
ON
Description:
In MD52281[0] - [3] ON and
in MD52282[0] - [3] OFF up to 4 additional columns for tool-
specific functions can be activated in the tool list. These can
then be selected in the columns M1- M4 (see screenshot
"Tool list" on the following page).
Description:
M-Code for tool-specific function ON
The value -1 means that the M-function will not be put out. If
both M-commands of a function = -1, the associated field in
the surface will not be shown.
Notes

B110 Setup Milling
M-code for tool specific function OFF Function mask Tool management
MD52282[x] MD52270 Function mask Tool manage-

M-code for tool-specific func-
$MCS_TOOL_MCODE_FUNC $MCS_TM_FUNKTION_MASK ment
tion OFF
_OFF
Description:
Description: Bit 0: Create tool on a magazine location not permitted.
M-Code for tool-specific function ON Tools can only be created outside the magazine.
The value -1 means that the M-function will not be put out. If
both M-commands of a function = -1, the associated field in Bit 1: Loading/unloading is not possible while the machine is
the surface will not be shown. not in Reset.
Tools can only be loaded or unloaded if the respective
channel is at rest.
Bit 2: Loading/unloading locked during emergency OFF

Tools can only be loaded or unloaded if the Emergency
OFF is not activated.
Bit 3: Loading/unloading tools to/from spindle disabled.

Tools cannot be loaded to or unloaded from the
spindle.
Bit 4: Loading takes place in the spindle directly. Bit 10: Re-activation of tool using magazine positioning
The tools are only loaded exclusively in the spindle. Before re-activation the tool is located on the loading
position.
Bit 5: Use grinding configuration file for creating the tool list.
Only grinding tools are offered. Bit 11: Re-activating the tool in all monitoring modes.
When re-activating a tool, all monitoring modes for this
Bit 6: Relocating a tool to/from the buffer (spindle/gripper) is tool released in the NC will also be re-activated; i.e.
permitted desoite a block (see bit3) also those monitoring modes that are not selected for
the respective tool, but which are dormant in the back-
Bit 7: Create tool using the tool number. Specify the tool's ground.
T-number when creating the tool.
Note: This function is intended for machines with tool Bit 12: Hide 'Tool re-activation'
management but without magazine configuration. The The function "Tool re-activating" is suppressed on the
default setting must not be changed. user interface.
Bit 8: Hide 'Re-locate tool' Note:

The function 'Re-locate tool' is suppressed on the user
This MD must be matched to the circumstances of the ma-
interface.
chine. By hiding those functions on the user interface that are
not applicable to the machine, the PLC can be spared unnec-
Bit 9: Hide 'Magazine positioning'
essary actions to prevent operation errors.
The function 'magazine positioning' is suppressed on
the user interface.
Notes

Setup Milling B110
Load station Tool management The following screenshots show a configuration with two
loading stations and the setting MD52274 = 0.
MD52274 Load station Tool manage-

$MCS_TM_TOOL_LOAD_ ment
Description:
If only one loading station is configured: The setting = 0

If more than 1 loading station is configured, you can select
between
= 0: A query window appears on the surface to select the

loading point.
Acknowledge the selection made with OK
Function mask Tool management Bit 5: Evaluation of tool wear inputs additively
The input of wear data will be added to any existing
SD54215 wear values.
Function mask Tool manage-
$SNS_TM_FUNCTION_MASK
ment Bit 6: Numeric input of the tool identification
_SET
No name will be assigned to a new tool being created.
Default: 0H Change to: Only numerical characters are permitted .
Description: Bit 7: Hiding the tool monitoring parameter
Bit 0: Diameter readout for rotating tools The tool monitoring parameter will not be shown on the
It is not the radius value, but the diameter value that is user interface.
shown for rotating tools.
Bit 1: Default direction of rotation for all turning tools is M4

When turning tools are created, the direction of rotation
is preset to M4.
Bit 2: Creating tools without assigning a name

When creating a new tool the input field for the tool
name remains empty.
Bit 3: Input interlock for tool name and tool type for loaded
tools
Tool name and tool type cannot be changed for loaded
tools.
Notes

B110 Setup Milling
Continued SD54215 Bit 0 = 0 permanent radius readout for all tools
Description:
Bit 8: Diameter readout for transverse axis - geometry

The geometry value of the transverse axis is shown as
a diameter value.
Bit 9: Diameter readout for transverse axis - wear

The wear value of the transverse axis is shown as
diameter value.
Bit 10: Release of Tool loading / Tool re-location to buffer

station
The magazine number can be entered in the loading
dialog. This permits access to the buffer station using
the magazine number 9998.
Bit 11: The creation of new tools in the gripper locations is

blocked.
Bit 0 = 1 Diameter readout for rotating tools Bit10 = 1 Release of Tool relocation to buffer station
Notes

Setup Milling B110
Continued SD54215 Checking the tool management
The locations 1 = spindle, 2 = gripper 1 and 3 = gripper 2 can

be loaded directly by means of the magazine number 9998.
In the tool list these are the uppermost three lines without
numbering.
Marked tools can be unloaded. As soon as the cursor is
In the shown example the "TWIST_DRILL_8" is loaded in the
moved to a free magazine location the Softkey "New tool"
spindle.
appears for the creation of a new tool.
By horizontal scrolling the fields for all tool-specific M-

functions M1 … M4 appear.
The various types of tools are shown in the selection list.
Notes

B110 Setup Milling
Basic settings Description:

The Bits 4 and 16 are only evaluated if Bit 0 = 1.
Reset-defiant settings
Meaning of the individual Bits:
Definition of basic control settings after reset/PP end Bit 0 = 0:
Initial setting after booting:
- G-Codes as per $MC_GCODE_RESET_VALUES
- Tool length offset not active
MD20110 Definition of basic control set- - Transformation not active
$MC_RESET_MODE_MASK tings after reset/PP end - no coupled axes groupings active
- no tangential correction active
Change to: Bit 0 = 1 - no axial rotational feed active
Bit 6 = 1 - path rotational feed with master spindle
Bit 14 = 1 (Default)
Initial setting after Reset or after end-of-part-program :

Description:
The current settings will be retained.
Determination of the basic control settings after booting and With the next part-program Start the following Initial settings
reset/end-of-part-program with respect to the G-codes will become active:
(especially the current plane and selectable zero-point offset),
tool length and transformation by the setting of the following
bits:
Bit 0: Reset mode

Bit 6: Reset response "Active tool length offset"
Bit 14: Reset response "Initial frames"
Bit 16: Reset response "Master spindle"
- G-Codes as per $MC_GCODE_RESET_VALUES Description:

- Transformation not active Initial setting after Reset or after End-of-part program:
- No coupled-motion groupings active Depending on $MC_RESET_MODE_MASK Bit 6 to 7 the
- No tangential offsets active current settings for
- No master value couplings active - Tool length offset
- No axial rotational feedrate active - Transformation
- Path rotational feedrate with master spindle will either be retained or changed to the initial settings as
(Default) stored in the MDs.
Bit 0 = 1: Depending on Bit 8 and 9 the current settings of coupled mo-

Initial setting after booting: tion axes or tangentially corrected axes will either be retained
- G-Codes as per $MC_GCODE_RESET_VALUES or switched OFF.
- Tool length offset active as per
$MC_TOOL_RESET_VALUE, Projected synchronous spindle coupling:
$MC_CUTTING_EDGE_RESET_VALUE and The coupling will be un-selected depending on the setting of
$MC_SUMCORR_RESET_VALUE $MC_COUPLE_RESET_MODE_1.
- Transformation active per $MC_TRAFO_RESET_VALUE
- Geo axis replacement as per Non-projected synchronous spindle coupling:
$MC_GEOAX_CHANGE_RESET Depending on Bit 10 the coupling will either be switched OFF
- No coupled-motion groupings active or retained.
- No tangential correction active Depending on Bit 14 the initial frame will be retained or un-
selected.
Initial setting after reset or after end-of-part-program:
Depending on the setting of $MC_GCODE_RESET_MODE Note:
the current settings for the G-groups will be retained or set to The setting of Bit 0 = 1 must be set for JobShop-uses,
the initial values stored in $MC_GCODE_RESET_VALUES. such that the settings of the Bits 4 and 16 can be evaluat-
ed.
Notes

Setup Milling B110
Continued MD20110 Description:

However, it must be remembered that after the end of pro-
Bit 6 = 0:
gram or a program interruption either the last programmed
Initial setting for the active tool length offset after Reset/End-
value for the master spindle or master tool holder, or the val-
of-part program as per $MC_TOOL_RESET_VALUE,
ue specified by $MC_SPIND_DEF_MASTER_SPIND or
$MC_CUTTING_EDGE_RESET_VALUE,
$MC_TOOL_MANAGEMENT_TOOLHOLDER will determine
$MC_USEKT_RESET_VALUE and
the master spindle or the master tool holder.
$MC_SUMCORR_RESET_VALUE.
(The selection is made by Bit 16 or Bit 17.)
Is $MC_TOOL_CHANGE_MODE = 1, the tool specified by
$MC_TOOL_PRESEL_RESET_VALUE is additionally pre-
A special case is $MC_CUTTING_EDGE_DEFAULT = -2:
selected.
If a tool has been changed on the spindle, but no new correc-
If the tool and/or magazine management is active, it is not the
tion D has been programmed, then the previous tool is still
datum $MC_TOOL_RESET_VALUE that is used, instead
active in the NCK.
$MC_TOOL_RESET_NAME will be used.
If an interruption takes place in this state, - e.g. by pressing
the reset key, the correction will be specified by the lowest D-
Bit 6 = 1:
number of the tool in the master spindle.
The current setting for the active tool length offset remains in
force after reset/End-of-part-program.
Note:
If the tool and/or magazine management is active, that tool
The setting Bit 6=1 is necessary to ensure that after a
will be selected which is presently loaded in the master spin-
reset/End-of-part-program the previously programmed
dle (generally = master tool holder).
tool and the previously programmed cutting edge re-
If the tool in the master spindle happens to be blocked, the
mains activated (for instance, if the tool was changed via
"blocked"-status will be ignored. .
the T,S,M-mask) and if for example the JobShop-
functions in the mode of operation JOG "Zero point work
piece" or "Tool measurement" can be carried out with
this tool.
Bit 14 = 0: Description:
The basic frame is cancelled
Bit 16 = 0:
Bit 14 = 1: Initial setting for the master spindle as per
The current setting for the basic frame is retained. $MC_SPIND_DEF_MASTER_SPIND.
Note: Bit 16 = 1:
The setting Bit 14 = 1 is necessary to retain the channel- The current setting of the master spindle (SETMS) is re-
specific basic work offset (WO), which was activated with tained. This Bit in case of
G500, after a Reset/End-of-part-program. $MC_TOOL_MANAGEMENT_TOOLHOLDER = 0 has also
After activation of the basic WO (JOG-T,S,M-mask - Work an effect on the response of Bit 6.
offset - basic reference) the values in the Work offset
base are transferred to the Total basic WO and then from Note:
there to be transferred for activation also to the Total The setting of Bit 16 is not applicable to ShopMill.
WO.
The previously described settings in MD20110
correspond to the further MD-settings in:
MD20120 $MC_TOOL_RESET_VALUE
MD20130 $MC_CUTTING_EDGE_RESET_VALUE
MD20150 $MC_GCODE_RESET_VALUES
MD20152 $MC_GCODE_RESET_MODE
MD20140 $MC_TRAFO_RESET_VALUE
MD20112 $MC_START_MODE_MASK
MD20121 $MC_TOOL_PRESEL_RESET_VALUE
MD20118 $MC_GEOAX_CHANGE_RESET
Notes

B110 Setup Milling
Tool edge with length compensation during runup (reset/ Corresponds to:
end of part program) MD20110 $MC_RESET_MODE_MASK
MD20130 Tool edge with length com- Note:

$MC_CUTTING_EDGE_ pens. during runup (reset/end
RESET_VALUE of pp) This setting is necessary to ensure that after a reset/End
-of-part-program the previously programmed tool and
Change to: 1 the previously programmed cutting edge remains acti-
vated (for instance, if the tool was changed via the T,S,M
-mask) and if for example the JobShop-functions in the
Description: mode of operation JOG "Zero point work piece" or "Tool
measurement" can be carried out with this tool.
Specification of the cutting edge, which depending on
MD20110 $MC_RESET_MODE_MASK and after part pro-
gram Start depending on MD20112
$MC_START_MODE_MASK is used to select the tool length
offset after booting and after Reset /End-of-part-program.
With active tool management and with Bit 0 and Bit 6 set in
MD20110 $MC_RESET_MODE_MASK at selection, the last
offset of the tool active at power OFF (as a rule the tool in the
spindle) is effective after booting.
Notes

Setup Milling B110
Initial setting of G groups Note:

(exact) means that this setting is necessary in conjunction
with JobShop; (variable) means that this should be seen as a
MD20150[x] suggestion and that another setting is permissible.
$MC_GCODE_RESET_ Initial setting of G groups
VALUES
Change to: [15] = 3 MD20150[15] = 3 (variable)
[21] = 2 Group 16: Feedrate correction on internal and external
[41] = 1 curves
[51] = 1 Value: 3 = CFIN
[52] = 1 This setting provokes a constant feedrate on
internal curves and acceleration on external
curves
MD20150[15] = 3 (CFIN)
MD20150[21] = 2 (CUT2DF) MD20150[21] = 2 (variable)
MD20150[41] = 1 (TCOABS) Group 22: Tool correction type
MD20150[51] = 1 (PAROTOF) Value: 2 = CUT2DF
MD20150[52] = 1 (TOROTOF) 2½-D-tool correction caused by Frame
The tool correction acts relative to the current
Description: Frame (oblique plane)
Specification of the G-Codes, which after booting and Reset/
End-of-part program are activated depending on MD20150[41] = 1 (exact)
MD20110 $MC_RESET_MODE_MASK and Group 42: Tool carrier
MD20152 $MC_GCODE_RESET_MODE as well as after part Value: 1 = TCOABS
program Start depending on Determination of the tool length components
MD20112 $MC_START_MODE_MASK. from the current tool orientation
MD20150[51] = 1 (exact)
Group 52: Tool-related Frame rotation
Value: 1 = PAROTOF
The tool related Frame rotation is deactivated.
The work piece coordinate system is not aligned
to the work piece.
MD20150[52] = 1 (variable)
Group 52: Tool-related Frame rotation
Value: 1 = TOROTOF
The tool related Frame rotation is de-activated.
Notes

B110 Setup Milling
Reset response of G groups Note:

Reset response of G groups
$MC_GCODE_RESET_MODE
Change to: [5] = 1 MD20152[5] = 1 (exact)

[7] = 1 Group 6: Plane selection
[12] = 0 Value: 1
[21] = 0 A plane switch (e.g. G17 for facing) programmed
in the part-program remains active after Reset/
Description: End-of-part-program.
This machine datum is evaluated only if in MD20110 MD20152[7] = 1 (exact)

$MC_RESET_MODE_MASK the Bit 0 is set. For each entry Group 8: Selectable zero point offset
in MD20150 $MN_GCODE_RESET_VALUES (that is for Value: 1
each G group) this MD is used to specify whether A zero point offset (e.g. G54) programmed in the
part program remains active after Reset/End-of-
= 0: in case of a Reset/End-of-part-program the setting as part-program. This permits for example the acti-
per $MC_GCODE_RESET_VALUES is used again vation of a zero point offset in the mode-of-
or operation JOG_T,S,M-mask Parameter zero
= 1: the current setting is retained after Reset/End-of-part- point offset.
program
Description: Maximum number of blocks w/o traversing movement

with SAR
MD20152[12] = 0 (exact)
Group 13: Work piece dimensioning inch/metric MD20202 Maximum number of blocks
Value: 0 $MC_WAB_MAXNUM_ w/o traversing movement with
In the user interface it is possible in the mode-of- DUMMY_BLOCKS SAR
operation JOG Basic softkey line ">" Settings per
Softkey "Switching Inch" to toggle the measuring Change to: 10
system from metric to inch and vice versa.
Description:
MD20152[21] = 0 (variable)
Group 22: Tool correction type Maximum number of blocks that can appear between the
Value: 0 SAR (soft approach and retraction) block and the traversing
After Reset/End-of-part-program the tool correc- block which determines the direction of the approach or re-
tion defined in MD20150[15] is activated once traction tangent.
more. CUT2DF in this configuration example.
This setting is required in conjunction with the JobShop-
cycles. A typical use is illustrated by the screenshot below
taken from a continuous path milling operation on a contour
using the approach and leaving strategy "Semi-circle".
Notes

Setup Milling B110
Continued MD20202 Blocks for look-ahead contour calculation with TRC
MD20240
Blocks for look-ahead contour
$MC_CUTCOM_MAXNUM_
calculation with TRC
CHECK_BLOCKS
Description:
Indicates the maximum number of blocks with traversing in-
formation at the offset plane that are considered simultane-
ously for collision detection with active TRC (tool radius com-
pensation).
Note:
The Standard setting should not be undercut.
Maximum number of blocks without traversing motion in Time monitoring for tool in tool holder
TRC
MD20320
Time monitoring for tool in tool
MD20250 Maximum number of blocks $MC_TOOL_TIME_MONITOR
holder
$MC_CUTCOM_MAXNUM_ without traversing motion in _MASK
DUMMY_BLOCKS TRC
Change to: 5
Description:
Note: The setting Bit 0 = 1 is required for the life-time monitoring of
The value 5 represents a value based on experience for the tool in the tool holder 1. The machine configuration used
JobShop installations. here only uses one tool holder.
Notes

B110 Setup Milling
Active system frames after reset Deletion of system frames after reset
MD24006 MD24007
Active system frames after Deletion of system frames
$MC_CHSFRAME_RESET_ $MC_CHSFRAME_RESET_
reset after reset
MASK CLEAR_MASK
Change to: Bit 0 = 1 Change to: Bit 0 = 0
Bit 5 = 0 Bit 5 = 1
Bit-mask for the reset setting of the channel-specific system Bit-mask for deleting channel-specific system frames in the
frames, which will be evaluated with the channel. data management on Reset..
Bit 0: System frame active for preset. actual value/ scratching Bit 0 = 0: The system frame for setting actual values and
scratching (basic reference) will not be deleted with Reset/
Bit 5: System frame for cycles End-of-part-program.
Bit 5 = 1: The system frame for cycles will be deleted with

Reset/End-of-part-program.
Reset channel system frames after power ON Activation and impact of program runtime measurement
MD24008
Reset channel system frames
$MC_CHSFRAME_ MD27860
after power ON Activation and impact of pro-
POWERON_MASK $MC_PROCESSTIMER_
gram runtime measurement
Change to: Bit 0 = 0 MODE
Bit 5 = 0
Bit 1 = 1
Description: Bit 4 = 1
This machine data defines whether channel-specific system Bit 5 = 1
frames are reset in the data management on Power On. That Bit 6 = 1
is offsets and rotations are set to 0, scalings to 1. Mirroring is Bit 8 = 1
disabled.
Description:
The selection can be made separately for individual system
frames. Under the function program runtime timers are provided as
system variables. While the NCK-specific timers are always
Bit 0: System frame for set actual value and scratching is activated (for timings since the last control unit boot), the
deleted after Power On. channel-specific timers must be started by means of this da-
tum.
Bit 5: System frame for cycles retained after Power On.
Meaning:
Bit 0 = 0
No timing of the total runtime for all part programs
Notes

Setup Milling B110
Bit 0 = 1 Bit 5 = 0 No timing during program test

The timing of the total runtime for all part programs is
Bit 5 = 1 Timing also during program test
active ($AC_OPERATING_TIME)
Bit 6 only if Bit 1 = 1:
Bit 1 = 0
No timing of the current program runtime Bit 6 = 0
Delete $AC_CYCLE_TIME also after Start by ASUP and
Bit 1 = 1
PROG_EVENTs.
The measurement of the current program run-time is active
($AC_CYCLE_TIME) Bit 6 = 1
$AC_CYCLE_TIME will not be deleted after Start by ASUP
Bit 2 = 0
and PROG_EVENTs.
No timing of the tool cutting time
Bit 2 = 1
Timing of the tool cutting time is active Bit 7 = 0 $AC_CUTTING_TIME counts only with active tool.
($AC_CUTTING_TIME)
Bit 7 = 1 $AC_CUTTING_TIME counts independently of tool.
Bit 3
Reserved
Bit 8 = 0
Bits 4 only if Bit 0 and 1= 1:
$AC_CYCLE_TIME will not be deleted in case of a jump with
Bit 4 = 0 No timing during active test run feed motion GOTOS to the program start.
Bit 4 = 1 Timing also during active test run feed motion
Description: Work piece counters
Bit 8 = 1 A difference is made between the following work piece coun-

$AC_CYCLE_TIME will be deleted in case of a jump with ters:
GOTOS to the program start.  Number of the command work pieces
System variable $AC_REQURED_PARTS
Bit 9 only if Bit 0, 1 = 1:
Setting by means of Bit 0 and 1
Bit 9 = 0  Total number of work pieces (actual work pieces) fin-
$AC_OPERATING_TIME, $AC_CYCLE_TIME: No timing ished since the Start
when Override = 0. System variable $AC_TOTAL_PARTS
Bit 9 = 1 Setting by means of Bit 4, 5 and 7
$AC_OPERATING_TIME, $AC_CYCLE_TIME: Timing also if  Number of all work pieces (actual work pieces) finished
Override = 0. since the Start
Bit 10 to 31 System variable $AC_ACTUAL_PARTS
Reserved Setting by means of Bit 8, 9 and 11
 Number of work pieces finished as per the own strate-
gy
System variable $AC_SPECIAL_PARTS
Setting by means of Bit 12, 13 and 15
Notes

B110 Setup Milling
Continued Work piece counters Activation of workpiece counter
In the user interface of the MD27880 Activation of workpiece coun-

mode-of-operation AUTO the $MC_PART_COUNTER ter
mask shown alongside can be
opened by selecting Time/ Change to: Bit 0 = 1
Counter Bit 8 = 1
Bit 11 = 1
Bit 0 = 1: Counter $AC_REQUIRED_PARTS is activated

Further meaning of Bit 1-3 only if Bit 0 =1 and
The following assignment applies: $AC_REQUIRED_PARTS > 0:
- Parameter "Workpieces, setpoint":
$AC_REQUIRED_PARTS Further meaning of Bit 1 - 3 only if Bit 0 = 1 and
- Parameter "Workpieces, actual": $AC_REQUIRED_PARTS > 0:
$AC_ACTUAL_PARTS
Bit 1 = 0: Alarm/VDI-output if $AC_ACTUAL_PARTS corre-
sponds to $AC_REQUIRED_PARTS
Bit 1 = 1: Alarm/VDI-output if $AC_SPECIAL_PARTS corre-

sponds to $AC_REQUIRED_PARTS
Bit 2: reserved Bit 9 = 0: Counter $AC_ACTUAL_PARTS is increased by the

value 1 after a VDI-output of M02/M30
Bit 3: reserved
Bit 9 = 1: Counter $AC_ACTUAL_PARTS is increased by the
Bit 4 = 1: Counter $AC_TOTAL_PARTS is active value 1 after the output of the M-command from MD
PART_COUNTER_MCODE[1]
Further meaning of Bit 5 - 7 only if Bit 4 = 1 and
$AC_TOTAL_PARTS > 0: Bit 10: reserved
Bit 5 = 0: Counter $AC_TOTAL_PARTS is increased by the Bit 11 = 1: Counter $AC_ACTUAL_PARTS is increased by

value 1 after a VDI-output of M02/M30. the value 1 after a jump back with GOTOS.
Bit 5 = 1: Counter $AC_TOTAL_PARTS is increased by the Bit 12 = 1: Counter $AC_SPECIAL_PARTS is active

value 1 after the output of the M-command from MD
PART_COUNTER_MCODE[0] Further meaning of Bit 13-15 only if Bit 12 =1 and
$AC_REQUIRED_PARTS > 0:
Bit 6 : reserved
Bit 13 = 0: Counter $AC_SPECIAL_PARTS is increased by
Bit 7 = 1: Counter $AC_TOTAL_PARTS is increased by the the value 1 after a VDI-output of M02/M30
value 1 after a jump back with GOTOS
Bit 8 = 1: Counter $AC_ACTUAL_PARTS is active the value 1 after output of the M-command from
MD PART_COUNTER_MCODE[2]
$AC_REQUIRED_PARTS > 0: Bit 14: reserved
Notes

Setup Milling B110
Continued MD27880 In a G code part program the program repetition can be done
by:
the value 1 after a jump back with GOTOS. G-Code-Program_1: G-Code-Program_2:
… ...
M33; Repeat GOTOS; Repeat
Application example: M30 M30
MD27880 PART_COUNTER = 101H The number of work pieces is to be set in the mode-of-
Bit 0 = 1: Counter $AC_REQUIRED_PARTS "Work pieces operation AUTO in the mask “Time/Counter” by the parame-
Command" activate ter “Workpieces, setpoint”.
Bit 8 = 1: Counter $AC_ACTUAL_PARTS "Work pieces Actu-
al" activate Relevant PLC interface signals:
MD 27882[1] PART_COUNTER_MCODE = 33 Activating the part program repetition is done by setting the
PLC interface signal "Program branches control" to 1.
Part program: - For 840D sl: PLC bit DB21.DBX384.0
In such a JobShop-Program the program repeat can be - For 828D: PLC bit DB3200.DBX16.0
switched ON in the automatically generated End-of-program
block by means of the parameter "Repetition". In this case the When the actual number of workpieces matches the number
command GOTOS will be generated. of setpoint the PLC interface signal "Workpiece setpoint
reached" is set to 1.
- For 840D sl: PLC bit DB21.DBX317.1
- For 828D: PLC bit DB3300.DBX4001.1
Memory space for REORG (DRAM)
MD28000
Memory space for REORG
$MC_MM_REORG_LOG_
(DRAM)
FILE_MEM
Change to: 75
Number of blocks for local user variables in

REORG (DRAM)
MD28010 Number of blocks for local

$MC_MM_NUM_REORG_ user variables in REORG
LUD_ MODULES (DRAM)
Change to: 20
Notes

B110 Setup Milling
Projecting of channel-specific system frames Projecting of channel-specific system frames in the data
management
MD28082
$MC_MM_SYSTEM_FRAME_ System frames (SRAM)
MASK MD28083
$MC_MM_SYSTEM_ System frames (SRAM)
Change to: Bit 0 = 1 DATAFRAME_MASK
Bit 5 = 1
Bit 5 = 0
Description:
Bit mask for configuring channel-specific system frames in- Description:
cluded in the channel. Bit mask for configuring channel-specific system frames in
the data storage (SRAM).
Bit 0: System frame for setting actual value and scratching
Bit 0: System frame for setting actual value and scratching
Bit 5: System frame for cycles
Bit 5: System frame for cycles
Note:
The system frames for actual value set and scratching
(basic reference) and for cycles are required for JobShop
installations.
Notes

Setup Milling B110
Work offsets in frames Feed reduction on circles with tool radius compensation
SD42440
$SC_FRAME_OFFSET_INCR_ Work offsets in frames SD42528 Feed reduction on circles with
PROG $SC_CUTCOM_DECEL_LIMIT tool radius compensation
Change to: 0
Change to: 1
Note:
Note:
This setting is required for JobShop installations.
This setting is required for JobShop installations. It avoids the
"stopping" of the axes in such circular sections if the diameter
of the milling cutter is only marginally smaller than the ma-
chining radius.
Tool length compensations
SD42442
$SC_TOOL_OFFSET_INCR_ Tool length compensations
PROG
Change to: 0
Note:
Change of tool length components with change of active Assignment of tool length compensation independent of
plane tool type
Assignment of tool length com-

Change of tool length compo- SD42950
SD42940 pensation independent of tool
nents with change of active $SC_TOOL_LENGTH_TYPE
$SC_TOOL_LENGTH_CONST type
plane
Change to: 0
Change to: 0
If this setting data is not equal to 0, the assignment of tool This setting data defines the assignment of the tool length
length components (length, wear, base dimensions) to geom- components to the geometry axes independently of the tool
etry axes is not changed when the machining plane (G17 - type. It can assume any value between 0 and 2. Any other
G19) is changed. value is interpreted as 0..
Notes

B110 Setup Milling
JOG-TSM Tool change
Definition of basic control settings after Reset/PP end

In the operation mode JOG the input masks for "T,S,M",
"Position" and "Face milling" are available. These permit sim-
ple functions to be carried out such:
- T,S,M: Tool changes, spindle functions, ZPO-selections MD20110 Definition of basic control
- Position: axes and spindles positioning $MC_RESET_MODE_MASK settings after reset/PP end
- Face milling: roughing of a corner with chamfers and/or ra-
dii. Change to: Bit 6 = 1
After the data have been entered and NC-Start initiated the Bit 0 = 1 Reset mode
file MA_JOG_STEP1.MPF will be generated in the directory Bit 6 = 1 Active tool length compensation
"Workpieces - TEMP " in the program-manager and execut- Bit 14 = 1 Base frame
ed.
Description:
To ensure that such functions as e.g. tool selection and spin-
dle Start will remain activated also after Reset and End-of Bit 6 = 1:
program, respective machine data are required, which will be The current setting for the active tool length correction re-
described below. mains active also after Reset/End-of-part program.
If the tool or magazine management is active, that tool is
The settings will be described with the T,S,M-Mask; the input selected which happens to be in the master spindle
masks Position and Roughing do not require special settings. (generally referred to as master-tool holder).
If the tool in the master spindle is locked, the "locked" status
will be ignored.
It must be borne in mind that after end-of-program, program Activation of tool management functions
abort either the last programmed value for the master spindle
respectively the master tool holder or else the value specified MD20310
by $MC_SPIND_DEF_MASTER_SPIND respectively Activation of tool management
$MC_TOOL_MANAGEMENT_
$MC_TOOL_MANAGEMENT_TOOLHOLDER for the master functions
MASK
spindle respectively the master-tool holder will be used.
Bit 0 - 3 must be set as in MD18080

$MN_MM_TOOL_MANAGEMENT_MASK
Bit 0 = 1 Magazine management active

Bit 1 = 1 Monitoring functions active
Bit 3 = 1 Adjacent location treatment
Bit 14 = 1 autom. tool change during Reset and Start
Bit 23 = 1 On offset selection no synchronization
with HL
Description:
Bit 14 = 1: Reset-Mode
Tool and correction selection as per the settings of MD20110
$MC_RESET_MODE_MASK and
MD20112 $MC_START_MODE_MASK.
Bit 14 = 0: No Reset mode
Notes

Setup Milling B110
Spindle Own spindle RESET
These settings are required to enable spindles to be started MD35040

from the T,S,M mask. $MA_SPIND_ACTIVE_AFTER Own spindle RESET
_RESET
Change to: 2
M function for spindle active after reset
AX4: MSP1
MD10714 M function for spindle active MD35040 = 2 Own spindle reset
$MN_M_NO_FCT_EOP after reset
Description:
Change to: 32 This machine data defines the response of the spindle after
Reset and program end (M2, M30).
Suggestion M32
This MD is only active in the spindle mode open-loop control
mode. In the positioning or oscillation mode, the spindle is
Description:
always stopped.
With Start in the manual mode-of-operation (T,S,M-mask,
position) the part-program MA_JOG_STEP1 will be generat-
ed and executed.
This part-program will be finished with the M-function in
MD10714. The setting of MD35040 = 2 ensures that the spin-
dle remains active also after the end-of-program.
Limitations see MD10715 $MN_M_NO_FCT_CYCLE
MD35040 $MA_SPIND_ACTIVE_AFTER_RESET = 0: Start main spindle via the T,S,M-mask

 Spindle stops (with M2/M30 and channel and mode group
reset) T,S,M-mask with inputs for spindle speed and direction of
 Program is aborted rotation of the main spindle S1
MD35040 $MA_SPIND_ACTIVE_AFTER_RESET= 1:
 Spindle does not stop
 Program is aborted Enter speed and direction of
rotation
 Spindle does not stop at the M function configured via and actuate NC-Start
MD10714 $MN_M_NO_FCT_EOP (e.g. M32).
 However, the spindle stops at channel or mode group re-
set.
Not relevant to:

MA_JOG_STEP1 is generat-
 Spindle modes other than open-loop control mode. ed
Notes

B110 Setup Milling
Continued Start main spindle via the T,S,M-mask Monitoring the tool change
Description:
 M3 G972 S1=1000
Starting of the spindle
Note:
In case of a ShopMill installation there will be no
CUST_TECHCYC call-ups for the spindle control from the
T,S,M-mask and during program execution.
Note on spindle direction of rotation:

The assignment of the direction arrow for the spindle
M-function M3/M4 is effected via the MD52207
$MCS_AXIS_USAGE_ATTRIB.
Shown in the T,F,S-field is the tool currently loaded in the

spindle. Use the cursor keys to select the required tool and
thereafter transfer it by means of the Soft-Key "In
manual" .
Notes

Setup Milling B110
Loading the new tool
The tool will be loaded into the T,F,S mask with Cycle Start.
The PLC-tool change functions provided by the machine man-
The selected tool "Finisher" is now displayed in the T,S,M ufacturer are executed in the background for this process.
mask.
Gear step
Parameterize gear stage change
MD35010
Parameterize gear stage
$MA_GEAR_STEP_CHANGE_
change
ENABLE
Change to: Bit 0 = 1 With NC-Start the program
MA_JOG_STEP1 will be gen-
erated - in this example for
Description:
the selection of the gear
The selection field Gear stage appears only if in MD35010 for stage 2 = M42.
the spindle Bit 0 = 1 is set.
Number of gear stages
MD35090
$MA_NUM_GEAR_STEPS
Description:
Number of prepared gear stages.
Notes

B110 Setup Milling
Inch/Metric-switching Selection of Inch/Metric-switching:
Below once again a summation of the machine data settings

required for Inch/metric switching.
Enable basic system conversion
MD10260
Enable basic system conver-
$MN_CONVERT_SCALING_
sion
SYSTEM
Change to: 1
Description: Note:
Switching the measuring systems with HMI-Softkey MD 20152[12] = 0 must be set for the position readouts to be
0. Hide Softkey inch/metric switching converted.
1. Display Softkey inch/metric switching
Selection of Inch/metric switching. :
Block search Function mask Cross-technology
Parameterization for search run MD52212

$MCS_FUNCTION_MASK_
technology
TECH
MD11450 Parameterization for search
$MN_SEARCH_RUN_MODE run Change to: Bit 3 = 1

Bit 1 = 1 Description:
Bit 2 = 1 Bit 3: Call block search cycle for ShopMill/ShopTurn
Note:
Description:
Bit 0: Response to output of alarm 10208 The setting of Bit 3=1 ensures that the tool programmed after
the block search is duly changed and that the spindle rotates
Bit 1: Automatic ASUP start after action blocks in the tool-assigned direction at the speed programmed in the
destination block. For installations without ShopMill this Bit
Bit 2: Response to Auxf output (spindle) needs not to be set, however, the machine manufacturer
must ensure that the tool and spindle functions are gathered
and put out during the block search.
Notes

Setup Milling B110
Tool change commands to PLC after search run 1: Tool changing commands and tool preparation commands
are gathered and passed on to the PLC with program Start
when the search run has attained the destination block.
MD20128
Tool change commands to 0: all tool and/or magazine specific commands that were
$MC_COLLECT_TOOL_
PLC after search run gathered during the block search will not be put out to the
CHANGE
PLC with the next program Start! That means that also pro-
Change to: 0 grammed POSM, TCI, TCA will not be passed on to the PLC.
Note 1:
Description:
Without an active magazine management the tool change-M-
This MD is of any meaning only with activated magazine
code will not be gathered, if it is not assigned to an auxiliary
management (MD18080
function group. With an active magazine management this
$MN_MM_TOOL_MANAGEMENT_MASK, MD20310
corresponds to an MD-value = 0.
$MC_TOOL_MANAGEMENT_MASK).
It specifies whether after block search with evaluation tool
Note 2:
changing commands, tool preparation commands (generally
tool changing commands) are put out to the PLC or not put The value = 0 is sensible for instance if after reaching the
out to the PLC. search destination the gathered tool change commands are
transferred to the PLC in an ASUP-program with the aid of
Note: the commands GETSELT, GETEXET.
This setting is necessary for ShopMill/ShopTurn.
Simulation
Adjustment of SZS Coordinate system
MD24030 Adjustment of SZS Coordinate

$MC_FRAME_ACS_SET system
Change to: 1
Description:
0: SZS results from the WCS transformed with
$P_CYCFRAME and $P_PFRAME.

$P_CYCFRAME.
The position readouts show the SZS-Coordinate system if

"WCS" is selected.
Depiction of the Coordinate systems and the Frame chain
Notes

B110 Setup Milling
Description: Axis position at start of simulation
The SZS-Coordinate system is different to the WCS Coordi- MD53230

nate system by Axis position at start of simula-
$MAS_SIM_START_
tion
 Cycle frame POSITION
 Programmable frames (G54, …) Change to:
 Transformation (TRANS, ROT, SCALE)
With the setting of MD24030 $MC_FRAME_ACS_SET = 1 AX1: MX1

the programmable frames are taken into account in the posi- MD53230 = e.g. 0 mm
tion readouts.
AX1: MY1
MD53230 = e.g. 0 mm
AX2: MZ1
MD53230 = e.g. 300 mm
Description:
Axis position at the Start of the simulation.
Note:
For the further axes and spindles this MD should be left on 0.
Simulation depiction Tipp:

To permit better observation of the simulation it is advisable
to reduce the rapid traverse rate by means of the override
switch. The percentage settings do not represent a linear
function. A setting of about 60 - 80% are practicable.
Alternatively to the vertical Softkeys the override setting can

also be obtained using the following keys:
Override increase: and
Override reduction: and
Override maximum: and M
Notes

Setup Milling B110
Machining example Machining program: Face milling
Machining example (part program)
The following describes a programming example which

demonstrates a subsequent machining operation with planar
milling and drilling.
Program head with workpiece definition:
Tool list
Preparation:
The tools used in this example must be created.
Face milling and technology data: Deep hole drilling and technology data:
Notes

B110 Setup Milling
Continuation Machining example (part program)
Position circle for deep hole drilling: Program end and repetition:
Simulation depiction: Note:

For better representation in the 3D view the function
"Section" was used.
Selection of the simulation: Details - Section
Using the softkeys "X +" to "Z -" the section axes can be set.
Under "Details - rotate view" the work piece can be rotated

into the required position.
Notes

Setup Milling B110
Machine —> JOG
MD52010 BIG_FONT = 3
depending on MD52011
MD20098[X] Bit 0 = MCS actual

value window
MD52210 FUNCTION_MASK_DISP
Bit 4 = 1 Show follow-on tool in T,F,S window
MD51040 SD55212 FUNCTION_MASK_ TECH_SET
SWITCH_TO_MACHINE_MASK Bit 0 = 1 Tool pre-selection active
MD52206 AXIS_USAGE, Meaning of the axes in the channel

MD52200 TECHNOLOGY = 2
MD52207 AXIS_USAGE_ATTRIB, Axis attributes
Softkey Description
selection
MD52210 FUNKTION_MASK Bit 2 = 1
MD52200 = 2 =2: Technology Milling
MD51040 SWITCH_TO_MACHINE_MASK, Automatic operating area switchover to machine

Bit 0: When selecting a program in the program manager not automatically switch over
Bit 1: When switching the operating mode via the MCP not automatically switch over
Bit 2: When program selection in program not automatically switch over MD52200 = 2 =2: Technology Milling
Bit 3: When selection / execution under program not automatically start of block search
MD52210 Bit 2 = 0 Show Softkey “T,S,M“ in JOG

Bit 2 = 0 area
Notes

B110 Setup Milling
Softkey Description
Machine —> JOG —> WCS selection
MD20098[X] Bit 16 = WCS actual

value window
Switchover Switchover Softkey from MCS to WCS via

MCS/WCS PLC
Softkey Description
Machine —> JOG —>MCS selection
MD51023 ACT_VALUE_SPIND = 1
Spindles are displayed only if in axis
mode, MSP1 not displayed
(Default setting)

MCS/WCS PLC
Spindles are always displayed (Scroll bar
on the right, down)
alternative
Notes

Setup Milling B110
Machine —> JOG —> T,S,M
MD20110 RESET_MODE_MASK
Bit 6 = 1 Tool length compensa-
tion is retained even after RESET
MD20130 = 1 Tool and tool edge
number retain active
MD17500
MAX_NUM_REPLACEMENT_TOOLS
>1 Maximum number of tools in a tool group
For 828D the Replacement tools for tool
management option is required.
Bit 6 = 1 Active tool length offset is retained after reset
and
MD20310 TOOL_MANAGEMENT_MASK
Bit 14 = 1 Automatic Tool change during Reset and Start
MD35040
SPIND_ACTIV_AFTER_RESET
= 2 Own spindle reset
MD35000 AX4:MSP1 = 1
The spindle must be configured
MD35010 GEAR_STEP_CHANGE_ENABLE
of AX4:MSP1 Bit 1 = 1
and
MD35090 NUM_GEAR_STEPS of MSP1
Number of gear steps = 5
Notes

B110 Setup Milling
MD20152[7] G_CODE_RESET_MODE = 1 Work

Work offset is retained even after Reset
Bit 0 = 0 Selection of the meas. unit on
the operator panel
MD20152[5] G_CODE_RESET_MODE = 1
Switch over machining plane
and
MD52005 DISP_PLANE_MILL = 0 Plane
selection on the operator panel
Notes

Setup Milling B110
Machine —> JOG —> Set WO
The softkey is highlighted if no G500 is active

and MCS is not selected
Softkey Description
Machine —> JOG —> Measure workpiece selection
SD54780 Bit 2 = 1 Activate calibration for electronic

Bit 2 = 1 workpiece probe
Example:
Choice for the 5 free assign-
able vertical softkeys
The 5 marked softkeys are free assignable

For 828D: These softkeys are free assignable with
Extended operating functions option only.
Notes

B110 Setup Milling
Machine —> JOG —> Measure workpiece
SD54780 Bit 3 = 1
Select probe calibration data field
MD52207[X] AXIS_USAGE_ATTRIB, Axis attributes

Bit 6 = 1 Show rotary axis as offset target for measuring
Example:
MD52207[5] AXIS_USAGE_ATTRIB = 44H
Bit 6 = 1 Show rotary axis as correction
destination for measuring in addition to
coordinate rotation
Selection
Notes

Setup Milling B110
Softkey Description
Machine —> JOG —> Measure tool selection
SD54782 Bit 2 = 1 Enable automatic tool measure-

Bit 2 = 1 ment

Bit 2 = 1 ment

Bit 2 = 1 ment
SD54782 Bit 2 = 0
SD54782 Bit 2 = 1
Machine —> JOG —> Measure tool
SD54782 Bit 3 = 1
Select tool probe calibration data field
Notes

B110 Setup Milling
Machine —> JOG —> Position
MD20098[3] Bit 20 = 0 Fade out spindle SP1
not displayed
Machine —> JOG —> Face milling
SD55200 MAX_INP_FEED_PER_REV, Upper limit feedrate/rev

SD55201 MAX_INP_FEED_PER_TIME, Upper limit feedrate/min
SD55202 MAX_INP_FEED_PER_TOOTH, Upper limit feedrate/tooth
SD43220 SPIND_MAX_VELO_G26, Programmable upper spindle limitation G26

SD43230 SPIND_MAX_VELO_LIMS, Spindle speed limitation with G96
Notes

Setup Milling B110
Softkey Description
Machine —> JOG —> Settings selection
MD10260 = 1 =1: Enable basic system conversion
MD10260 CONVERT_SCALING = 1
Softkey Description
selection
Option Extended operating functions

(828D only)
MD51067=1 =1: Show handwheel window

(Handwheel must be configured in
MD11350)
Notes

B110 Setup Milling
Parameter —> Tool list
SD54215 TM_FUNCTION_MASK
Bit 0 = 0 Always radius
Bit 0 = 1 Diameter display for rotating tools
MD52281[X] TOOL_MCODE_FUNC_ON e.g. 51, 53, 55, 57

MD52282[X] TOOL_MCODE_FUNC_OFF e.g. 52, 54, 56, 58
These columns are displayed with Shop-

Mill/ShopTurn option only
Softkey Description
selection
MD52270 TM_FUNCTION_MASK
Bit 0 = 1 Create tool on magazine location not allowed
Bit 7 = 1 Create tool using the tool number
SD54215 TM_FUNCTION_MASK_SET
Bit 2 = 1 Create tool without name suggestion
Bit 3 = 1 Input disable for tool name and tool type in loaded tools
Bit 4 = 1 Input disable for loaded tools, if the channel is not in Reset
Bit 11 = 1 Creating tool in gripper disabled
MD19320 Bit 4 = 1 Enable Tool Management

Bit 4 = 1
Notes

Setup Milling B110
SD54215 TM_FUNCTION_MASK Bit 1 = 0 M3 right

SD54215 TM_FUNCTION_MASK Bit 1 = 1 M4 left
Default direction of rotation for new created tools
MD52229 ENABLE_QUICK_M_CODES
MD52230 M_CODE_ALL_COOLANTS_OFF
MD52231 M_CODE_COOLANT_1_ON
MD52233 M_CODE_COOLANT_1_AND_2_ON

Softkey Description
Parameter —> Tool wear selection
Bit 5 = 1 Calculate tool wear inputs additively
SD54215 TM_FUNCTION_MASK_SET MD52270 Bit 12 = 0 Enable Reactivate tool

Bit 7 = 1 Fade out tool monitoring parameters Bit 12 = 0
These columns are displayed with active tool time

monitoring only MD20320 Bit 0 = 1
Notes

B110 Setup Milling
Softkey Description
Parameter —> Magazine selection
MD17500 MAX_NUM_REPLACEMENT_TOOLS
MD52270 Bit 8 = 0 Enable Relocate tool

Bit 8 = 0
MD52270 Bit 9 = 0 Enable Position magazine

Bit 9 = 0
Bit 8 = 1 Fade out Relocate tool
Bit 9 = 1 Fade out Position magazine
For 828D the “Replacement tools for tool management”

option is required
Parameter —> Load tool
Bit 1 = 1 Load/unload disable, if machine is not in reset
Bit 2 = 1 Load/unload disable on Emergency stop
Bit 3 = 1 Load/unload tool to/from spindle is disabled
Bit 4 = 1 Loading is executed directly in the spindle
MD52274 TM_TOOL_LOAD_STATION
Default setting = 0 All configured stations are taken into account
Notes

Setup Milling B110
Parameter —> Load tool
SD54215 TM_FUNCTION_MASK_SET Bit 10 = 1

Enable load/relocate tool on buffer locations
Magazine 9998 Location 1 = Spindle
Magazine 9998 Location 2 = Gripper 1
Magazine 9998 Location 3 = Gripper 2
Parameter —> Setting data
MD35000 AX4:MSP1 = 1
Assignment of spindle to machine axis,
otherwise this field is not displayed
Notes

B110 Setup Milling
Machine —> MDA
Bit 3 = 1 The M-code entered in MD10714 M_NO_FCT_EOP is
generated automatically after pressing the “Delete blocks“ softkey
Softkey Description
selection

(828D only)

(828D only)
Notes

Setup Milling B110
Machine —> TEACH IN —> Teach program
The “Teach prog.“ softkey is displayed when

selecting TEACH IN at the MCP
Softkey Description
selection

(828D only)

(828D only)

(828D only)
Notes

B110 Setup Milling
Softkey Description
Machine —> AUTO —> Time / Counter selection
MD27860 PROCESSTIMER_MODE
Bit 0 = 1 Measuring total runtime for all part programs
Bit 1 = 1 Measuring current program runtime
Bit 4 = 1 Measuring during active dry run feedrate
Bit 5 = 1 Measuring during program test
Bit 6 = 1 $AC_CYCLE_TIME is not deleted on start by ASUP
and PROG_EVENTs
Bit 8 = 1 Delete $AC_CYCLE_TIME with GOTOS
MD27860 Bit 0 =1: Softkey Time/Counter

MD27880 PART_COUNTER or Bit 8 = 1 =0: Softkey Times (Default setting)
Bit 0 or 8 or both =1
MD27880 PART_COUNTER
Bit 0 = 1 Counter $AC_REQUIRED_PARTS
Bit 8 = 1 Counter $AC_ACTUAL_PARTS
Bit 11 = 1 Increment AC_ACTUAL_PARTS
with GOTOS
Softkey Description
selection
Option Simultan. recording (real-time simulation)

(828D only)
Notes

Setup Milling B110
Machine —> AUTO —> Overstore
Bit 3 = 1 The M-code entered in MD10714 M_NO_FCT_EOP is
Machine —> AUTO —> Program control

The marked selection is
displayed here
MD51039 PROGRAM_CONTROL_MODE_MASK
Bit 0 = 1 Program test function available
Selection
Notes

B110 Setup Milling
Softkey Description
Machine —> AUTO —> Block search (ShopMill) selection
MD51024 Bit 0 Bit mask for available search modes in

MD51024 BLOCK_SEARCH_MODE_MASK_JS and Bit 1 = 1 ShopMill program
Bit 0 and 1 =1
MD51024 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
(Default setting Bit 0 = 1)

(828D only)
Softkey Description
Machine —> AUTO —> Block search (G Code program) selection

MD51028 BLOCK_SEARCH_MODE_MASK and Bit 1 = 1 G code program
Bit 0 and 1 =1
MD51028 BLOCK_SEARCH_MODE_MASK 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 4 = Block search without calculation
Bit 5 = Block search with test run

(828D only)
Notes

Setup Milling B110
Softkey Description
Machine —> AUTO —> Simultaneous recording selection
Option 3D simulation 1 (finished part)

Softkey bar with 3D-
Simulation option
Softkey Description
Program manager —> New program selection
Option ShopMill/ShopTurn
PROGRAM MANAGER, New
Notes

B110 Setup Milling
Program —> Edit
ShopMill/ShopTurn option required
The same program shown as G code

w/o ShopMill/ShopTurn option
MD52200 TECHNOLOGY = 2 Milling
Softkey Description
selection
Notes

Setup Milling B110
Program —> Edit —> Program header
Bit 0 = 0 Unhides input field for mm/
inch
Selection
MD52005 DISP_PLANE_MILL
= 0 plane selection on the operator panel
SC = Safety distance
Selection
SD55214 FUNCTION_MASK_MILL_SET
Bit 2 = 1 Depth calculation in milling cycles w/o SC
Default setting = 1
Bit 0 = 1 Milling cycles with synchronous operation
Default setting = 1
Notes

B110 Setup Milling
Program —> Drilling
MD52216 FUNCTION_MASK_DRILL
Bit 0 CYCLE 84 (w/o compensat. chuck)
Bit 1 CYCLE 840 (with compensat. chuck)
CYCLE 840 for ShopMill only
Bit 0 = 1 Unhide input fields Technology
SD55216 FUNCTION_MASK_DRILL_SET
Bit 1 = Boring (CYCLE86) Consider rotation of the tool plane
Bit 2 = Boring (CYCLE86) Consider swiveled table kinematics
Bit 3 = Tapping (CYCLE84) Monitoring spindle MD 31050/31060
Bit 6 = Boring (CYCLE86) Adapt spindle position to the tool orientation
Bit 7 = Boring (CYCLE86) Adapt direction of retraction path in the plane to active mirroring
Notes

Setup Milling B110
Program —> Milling
SD55212 FUNCTION_MASK_TECH_SET
Bit 1 = 1 Calculate thread depth from metric
thread lead
Note: As soon as the line table "None" is
selected, the parameter H1 can be overwritten
Selection Table
Bit 2 = 1 Refer to the table for thread diameter and depth
Note: As soon as the line table "ISO metric" is selected, the table is
activated for the various threads
Notes

B110 Setup Milling
Softkey Description
Program —> Contour milling selection
Softkey bar with Residual Option Residual material detection and machining
material detection and
machining option
Option Residual material detection and machining
Softkey Description
Program —> Simulation selection
MD51226 FUNCTION_MASK_SIM
Bit 0 = 1 No automatic start on simulation selection
MD53230 SIM_START_POSITION
Axis position at start of simulation
for AX1:MX1 e.g. 500mm
for AX2:MY1 e.g. 500mm
for AX3:MZ1 e.g. 200mm
Notes

Setup Milling B110
Program —> Measure workpiece
Softkey bar with Meas-

urement cycles option
Program —> Measure tool
Softkey bar with Meas-

urement cycles option
B110: END
Notes

B110 END Setup Milling

B111 Setup Swivelling
Sinumerik
Operate
Module Description:
In this module a milling machine with the axes X, Y and Z, a tool spindle SP1, well as a swivel
table A and C is to be set up. The individual setup steps will be checked at times in order to show
the result of the parameterization.
The setting up of a swivelling block follows in a further step.
The functionality of the manufacturer cycle CUST_800.SPF will be explained.
At the end the swivelling function will be tested under JOG and in the part program by means of an
example.
Module Objective:
With the aid of this module you will learn know the meaning of the MDs and SDs that must be
addressed as well as the various means to configure the machine according to the requirements.
The functions will be parameterized in blocks and in the end tested for correct function.
Content:
Sinumerik
Machine data set-up
Swivelling data block set-up
Set up the CUST_800.SPF
Application in JOG and part program

B111

Setup Swivelling B111
Swivelling
set up:
START
Overview
Machine and
setting data
Machine data
set-up
Swivelling
data block
set-up
Set up the
CUST_800.SPF
Application in
JOG and
part program
Swivelling
set up:
END
Notes

$MN_FRAME_GEOAX_CHANGE_
MODE
18088 $MN_MM_NUM_TOOL_ CARRIER 1 Minimum Maximum number of definable tool carriers
18114 $MN_MM_ENABLE_TOOL_ ORIENT 0 Variable Assign tool cutting edge orientation
Group 42: Tool carrier = 1 (TCOABS)

Group 52: Work piece related frame rotation = 2
[41] = 1 Exact
(PAROTOF)
[51] = 2 Exact
20150 $MC_G_CODE_RESET_VALUE Group 53: Tool related frame rotation = 1 (TOROTOF)
[52] = 1 Exact
Group 54: Vector rotation for polynomial programming =
[53] = 1 Variable
>1 in cases of rotary axes with Hirth tooth sys-
tem or angled tools are used
[41] = 0 Exact
20152 $MC_G_CODE_RESET_MODE [51] = 0 Exact Reset response of G groups
[52] = 0 Exact
Tool carrier: rotary axis setting with axis positions not
20196 $MC_TOCARR_ROTAX_ MODE Bit 1 = 1 Variable
defined
$MC_TOOL_PARAMETER_DEF_
20360 Bit 10 = 1 Variable Definition of tool parameters
MASK
21100 $MC_ORIENTATION_IS_ EULER 0 Variable Angle definition for orientation programming
$MC_TOCARR_ROT_OFFSET_
21186 1 Variable Offset of TOCARR rotary axes from WO
FROM_FR
22530 $MC_TOCARR_CHANGE_M_CODE 0 Variable M code at change of tool carrier

24006 $MC_CHSFRAME_RESET_ MASK
Bit 4 = 1 Exact Bit 4: System frame for work piece reference is active
$MC_CHSFRAME_RESET_CLEAR_ Bit 2 = 0 Exact Bit 2 = 0 rotary table reference (PAROT) not delete
24007
MASK Bit 3 = 0 Exact Bit 3 = 0 tool reference (TOROT,..) not delete
Bit 4 = 0 Exact Bit 4 = 0 Workpiece reference not delete
$MC_CHSFRAME_POWERON_ Bit 2 = 0 Exact Bit 2 = 0 rotary table reference (PAROT) not reset
24008
MASK Bit 3 = 0 Exact Bit 3 = 0 tool reference (TOROT,..) not reset
Bit 4 = 0 Exact Bit 4 = 0 Workpiece reference not reset
$MC_USER_FRAME_POWERON_ Parameterize properties for settable frame
24080 Bit 0 = 0 Exact
MASK Bit 0 = 0 Settable zero offset via power on not active
Bit 2 = 1 Exact Bit 2: rotary table reference ($P_PARTFRAME)
28082 $MC_MM_SYSTEM_FRAME_MASK
Bit 3 = 1 Exact Bit 3: tool reference ($P_TOOLFRAME)
Bit 4 = 1 Exact Bit 4: Workpiece reference ($P_WPFRAME)
$MC_MM_SYSTEM_ DATAFRAME_ Bit 2 = 1 Exact Bit 2: rotary table reference ($P_PARTFRAME)
28083
MASK Bit 3 = 1 Exact Bit 3: tool reference ($P_TOOLFRAME)
Bit 4 = 1 Exact Bit 4: Workpiece reference ($P_WPFRAME)
Bit 0 = 1 Bit 0: Modulo rotary axis programming
30455 $MA_MISC_FUNKTION_ MASK Variable
Bit 2 = 1 Bit 2: Positioning response at modulo rotary axis
Notes


plane
Assignment of tool length compensation independent of
tool type
$SC_TOCARR_FINE_
42974 0 Variable Fine offset TCARR ON / OFF
CORRECTION
42980 $SC_TOFRAME_MODE 2000 Exact Frame definition at TOFRAME, TOROT and PAROT

52212 $MCS_FUNCTION_MASK_ TECH Bit 0 = 1 Exact
(ShopMill/ShopTurn)
Function mask Swivel CYCLE800
Bit 0: Unhide 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: Show swivel data block "Deselection"
Bit 3: Display active swivel plane in JOG
Bit 4: Positioning in basic position (pole position) of the
kinematics
Bit 5: Align tool, absolute (TCOABS)
Bit 6: Do not offer swivel mode “directly” under swivel in
$SCS_FUNCTION_MASK_SWIVEL_ Bit 2 = 1 JOG
55221
SET Bit 3 = 1 Bit 7: Swivel plane: Direction selection in initial setting of
kinematics
Bit 8: Take into account work offset of rotary axes, swivel
data set in Work
Bit 9: Swivel data set TC permanently assigned to the
tool
Bit 10: Swivel plane: Display input field “positioning direc-
tion”
Bit 11: Swivel plane: Positioning of both solutions AB -
display kinematics
Bit 12: Reset behaviour taking into account the rotary axis
position
Hide and unhide cycle alarms CYCLE800
$SCS_MILL_SWIVEL_ALARM_
55410 0H = 0: Cycle alarms are hidden
MASK
= 1: Cycle alarms are displayed
Initial setting swivel: retract
= 0: no change
= 1: no
$SCS_MILL_SWIVEL_RESET_RET
55420 0 = 2: Z
RACT
= 3: Z XY
= 4: Tool direction max.
= 5: Tool direction inc.
Initial setting swivel: tool correction
$SCS_MILL_SWIVEL_RESET_TRA = 0: no change
55421 0
CK = 1: do not correct
= 2: correct
Initial setting swivel: swivel mode
$SCS_MILL_SWIVEL_RESET_MOD
55422 0 = 0: axis by axis
E
= 1: direct
Notes

Swivelling
The function swivelling permits with the help of swivel heads

or swivel tables to machine oblique faces. The swivelling is
possible both in the mode-of-operation JOG and also in AU-
TOMATIC.
For this you can program the swivelling axes (A, B, C) of the
machine or else you can simply state the rotations about the
swivelling axes (X, Y, Z) of the work piece coordinate system
as shown on the respective work piece drawing. The rotation
of the work piece coordinate system in the program are then
automatically converted during the machining of the work
piece into rotations of the respective swivelling axes of the
machine.
The swivel axes are always rotated to place the machining

plane perpendicular to the tool axis for machining. During
machining, the machining plane is permanently set.
When the coordinate system is swivelled, the previously set
work offset is automatically converted for the swivelled state.
Machine data set-up Description:
Function mask Cross-technology Bit 0 = 0 Swivelling plane/aligning tool with tool carrier is not
enabled
MD52212 Bit 0 = 1 Swivelling plane/aligning tool with tool carrier is
Function mask Cross- enabled
$MCS_FUNCTION_MASK_
technology
TECH
The following functions are available:
In JOG:
Bit 0 and 1 are meaningful for swivelling. In Program - Various:
Description:
Bit 1: Optimized travel along software limit switches For details see section "Application in JOG and part program"
(ShopMill/ShopTurn) in this module.
Bit 1 = 0 No optimized travelling along software limit switch-

es in ShopMill/ShopTurn program
Bit 1 = 1 Optimized travelling along software limit switches in
ShopMill/ShopTurn program
The function "Optimized travelling along Software limit switch-

es" is only important for machines with swivel head or mixed
kinematics and will be clarified by means of the following dia-
grams.
Notes

The first diagram shows the axis motion if the coordinate sys- The second diagram shows the axis motion in case of a swiv-
tem is not swivelled. elled coordinate system.
1. Retraction from the work piece to the retraction plane RP 1. Retraction from the work piece to the retraction plane RP
2. Travelling along the retraction plane to the next machining 2. Travelling along the retraction plane to the next machining
position position. Here the machining space at the machine would
3. Infeed to the work piece be exceeded and from this a software limit switch alarm
would be raised as a result. This alarm will be avoided by
optimized travelling along the software limit switch.
3. Travelling along the Software limit switch.
4. Infeed to the work piece.
Function mask Swivel CYCLE800 Bit 10: Swivel plane: Display input field “positioning direction”
Bit 11: Swivel plane: Positioning of both solutions AB - display
kinematics
SD55221
Function mask Swivel Bit 12: Reset behaviour taking into account the rotary axis
$SCS_FUNCTION_MASK_
CYCLE800 position
SWIVEL_SET
Bit 3 = 1
Description:
Description: Bit 0: Input field "Swivel":
Bit 1: Retraction variant Z; Z XY or fixed position In the editor mask
Bit 2: Show swivel data block "Deselection" “Swivel plane” is the
Bit 3: Display active swivel plane in JOG selection "Swivel yes/no"
Bit 4: Positioning in basic position (pole position) of the kine-
matics = 0 not released
Bit 6: Do not offer swivel mode “directly” under swivel in JOG = 1 released
Bit 7: Swivel plane: Direction selection in initial setting of
kinematics
Bit 8: Take into account work offset of rotary axes, swivel
data set in Work
Bit 9: Swivel data set TC permanently assigned to the tool
Notes

Continuation of SD55221 =1 with fixed points
Bit 1: Retraction variant: Note:

Instead of “Z” and “Z XY” the
In the editor mask parameters “Fixed point 1” and
“Swivel plane“ is the “Fixed point 2” are displayed.
selection "Retract"
The positions for X, Y and Z
= 0 without fixed point. axis are defined in the param-
eters $TC_CARR38[n] …
Note: $TC_CARR40[n].
The further selections of Z, Z
XY, Max. tool direction, etc.
in the parameter "Retract" are
set in the swivelling block by
means of the parameter
$TC_CARR37[n].
Bit 2: De-selection swivelling Bit 3: Display active swivel plane in JOG:

block: In the mask “Swivel“ in JOG the active swivelling plane
In the editor mask = 0 not displayed
“Swivel plane” and in = 1 displayed
swivelling-JOG is the de
-selection of the swivel-
ling block
= 0 not released
The parameter "TC" is
hidden.
= 1 released
The parameter "TC" with
the selection "TABLE"
for the selection or “0“
for the de-selection ap-
pears.
Notes

Hide and unhide cycle alarms for CYCLE800 Initial setting swivel: Retract
SD55410 SD55420
Hide and unhide cycle alarms
$SCS_MILL_SWIVEL_ALARM $SCS_MILL_SWIVEL_RESET Initial setting swivel: Retract
for CYCLE800
_MASK _RETRACT
Default: 0H Change to: Default: 0 Change to:
= 0: Cycle alarms are hidden Description:

= 1: Cycle alarms are displayed
With this setting data, the state
of the toggler “Retract” in the
Description:
editor mask “Swivel plane” and
Swivelling in JOG: the cycle alarms 62186 and 62187 can be in swivelling-JOG can be set
hidden or displayed. with the “Initial setting” softkey.
Bit 0: Display alarm 62186: Active work offset G54 ff. and = 0: no change
base (base reference) contain rotations = 1: no
= 2: Z
Bit 1: Display alarm 62187: Active base and basic reference = 3: Z XY
(G500) contain rotations = 4: Tool direction max.
Initial setting swivel: Tool correction Initial setting swivel: Swivel mode
SD55421 SD55422
Initial setting swivel: Tool cor- Initial setting swivel: Swivel
$SCS_MILL_SWIVEL_RESET $SCS_MILL_SWIVEL_RESET
rection mode
_TRACK _MODE
Default: 0 Change to: Default: 0 Change to:
With this setting data, the state With this setting data, the state
of the toggler “Tool” in the editor of the toggler “Swivel mode” in
mask “Swivel plane” and in swiv- the editor mask “Swivel plane”
elling-JOG can be set with the and in swivelling-JOG can be
“Initial setting” softkey. set with the “Initial setting” soft-
key.
= 0: no change
= 1: do not correct = 0: axis by axis
= 2: correct = 1: directly
Note:
The tracking of the tool tip when
swivelling requires the option
"Machining package 5-axes”.
This option is not available with
the NCK-Export-Version.
Notes

Frames when changing geometry axes Number of swivelling data sets
MD10602 Maximum number of definable tool carriers

Frames when changing geom-
$MN_FRAME_GEOAX_
etry axes
CHANGE_MODE
MD18088
Maximum number of definable
Change to: 1 $MN_MM_NUM_TOOL_
tool carriers
CARRIER
Description: Change to: 1
Geometry axes can be switched over in the following states:
Description:
 Selection and de-selection of transformations Maximum number of definable tool carriers for orientable
 Switchable geometry axes GEOAX() tools in the TO area. The value is divided by the number of
active TO units. The integer result states how many tool carri-
The current total frame is then defined as follows: ers can be defined for each TO unit. The data for defining a
tool carrier are set with the system variables
= 0: The current total frame is cancelled. $TC_CARR1, ... $TC_CARR65
= 1: The current total frame is recalculated when geometry The data are stored in battery-backed memory.
axes are switched over. Translations, scaling and mirror-
ing for the new geometry axes become active. The rota- Application example(s):
tions of the old geometry axes still apply.
2 channels are taken to be active, with one TO-unit (= default)
in each channel. Three carriers are to be defined in channel
1 , one carrier in channel 2. The value to be set is 6, because
6 / 2 = 3. I.e. in each TO-unit there are a max of 3 carrier defi-
nitions.
Assign tool cutting edge orientation Value = 2:

Not only the system parameter $TC_DPV[n, m] but also the
additional three system parameters $TC_DPV3[n, m],
MD18114 $TC_DPV4[n, m] and $TC_DPV5[n, m] are assigned to each
Assign tool cutting edge orien-
$MN_MM_ENABLE_TOOL_ tool cutting edge D=m of the tool T=n, with the aid of which
tation
ORIENT any spatial tool orientation can be defined. T, D are the NC
Default: 0 Change to: addresses T and D with which the tool change or the tool
selection and the offset selection are programmed.
Note: Value = 3:
This machine data is used only in conjunction with angled Not only the system parameters $TC_DPV[n, m] and
tools. $TC_DPV3 - $TC_DPV5 but also the additional three system
parameters $TC_DPVN3[n, m], $TC_DPVN4[n, m] and
Description: $TC_DPVN5[n, m] are assigned to each tool cutting edge
D=m of the tool T=n, with the aid of which a vector (normal
The function allows an orientation deviating from the default vector) can be defined that is preferably perpendicular to the
value to be assigned to each tool cutting edge. tool orientation. The normal vector may be modified so that it
lies in the plane formed by the orientation and the pro-
Value = 0: grammed normal vector but perpendicular to the orientation.
The tool orientation function is inactive.
The orientation and the possibly modified normal vector
Value = 1: together define a complete orientation coordinate system.
The system parameter $TC_DPV[n, m] is assigned to each The machine data affects the requirement for battery-backed
tool cutting edge D=m of the tool T=n, with the aid of which memory.
one of 6 possible tool orientations in positive or negative co-
ordinate direction can be defined.
Notes

Initial setting of G groups Reset response of G groups
MD20150[x] MD20152[x]
$MC_GCODE_RESET_ Initial setting of G groups Reset response of G groups
VALUES
Change to: [41] = 1 Change to: [41] = 0
[51] = 2 [51] = 0
[52] = 1 [52] = 0
[53] = 1
Description:
Group 42: Tool carrier This MD is only evaluated if bit 0 is set in MD20110
MD20150[41] = 1 (TCOABS) $MC_RESET_MODE_MASK.
Group 52: Work piece related frame rotation
MD20150[51] = 2 (PAROTOF) Setting this MD equal to 0 specifies that for each entry in
Group 53: Tool related frame rotation MD20150 $MC_GCODE_RESET_VALUES the setting after
MD20150[52] = 1 (TOROTOF) a reset/end of part-program is once more the setting as per
Group 54: Vector rotation for polynomial programming MD20150 $MC_GCODE_RESET_VALUES.
MD20150[53] = >1 in cases of rotary axes with Hirth tooth
system or angled tools are used
Description:
Definition of the G codes which become active on run-up and
reset or at part program end depending on MD20152
$MC_GCODE_RESET_MODE and at part program start
depending on MD20112 $MC_START_MODE_MASK.
Tool carrier: If the relevant bit is 0, the position of the rotary axis will be 0;
Rotary axis setting with axis positions not defined a possibly necessary rotation is performed through the speci-
fied frame.
MD20196
Tool carrier: rotary axis setting If the relevant bit is 1, the rotation is performed by means of
$MC_TOCARR_ROTAX_
with axis positions not defined the rotary axis of the orientable tool carrier. The resulting
MODE
frame will no longer include a rotation.
Default: Bit 1 = 1 Change to:
Example:
Bit 0: Rotary axis mode for ToolCarrier with 1 axis A tool in its basic position points into the Z direction, and an
Bit 1: Rotary axis mode for ToolCarrier with 1 axis axis of the orientable tool carrier rotates the work piece
around Z (C-Axis). If the tool shall be oriented in parallel with
Description: the Z axis of a rotating frame, and if the frame only rotates
The MD is bit-coded. Bit 0 applies to orientable tool carriers around the Z axis, the tool orientation will not be changed, if
with one axis, bit 1 for those with 2 axes. the C axis is rotated. The condition saying that the tool is to
point in the direction of the Z axis defined by the frame is
When the axis positions of an orientable tool carrier are deter- therefore fulfilled for any position of the Z axis.
mined from a specified frame, it might happen that the re-
quired orientation is achieved at any position of a rotary axis.
This MD specifies how the rotary axis position is defined in

these cases:
Notes

Definition of tool parameters Angle definition for orientation programming
MD20360 MD21100
Angle definition for orientation
$MC_TOOL_PARAMETER_ Definition of tool parameters $MC_ORIENTATION_IS_
programming
DEF_MASK EULER
Change to: Bit 10 = 1 Change to: 0
The Bits 10 and 19 are meaningful for swivelling. Description:

= 0: The values programmed with A2, B2, C2 during orienta-
Description: tion programming are interpreted as an RPY angle (in
Bit 10: degrees). The orientation vector is produced by rotating a
Activate the tool component of an active, orientable tool carri- vector in direction Z first by C2 around the Z axis, then by
er even if no tool is active. B2 around the new Y axis and finally by A2 around the
new X axis. In contrast to Euler angle programming, all
Bit 19: three values influence the orientation vector in this case.
The tool orientation change caused by an orientable tool
holder becomes effective even if no tool is active. This bit is = 1: The values programmed with A2, B2, C2 during orienta-
only effective if bit 10 is also set. tion programming are interpreted as Euler angles (in de-
grees). The orientation vector is produced by rotating a
vector in direction Z first by A2 around the Z axis, then by
B2 around the new X axis and finally by C2 around the
new Z axis. This means that the value of C2 is meaning-
less.
Offset of TOCARR rotary axes from WO (Work offset) M code at change of tool carrier
MD21186 MD22530
Offset of TOCARR rotary axes M code at change of tool carri-
$MC_TOCARR_ROT_ $MC_TOCARR_CHANGE_M_
from WO er
OFFSET_FROM_FR CODE
Change to: 1 Default: 0 Change to:
Rotary axes offset for the orientable tool carrier is automati- The absolute value of this machine data indicates the number
cally accepted from the work offset activated on activation of of the M code, which is output at the VDI interface when a
the orientable tool carrier for the rotary axes. tool carrier is activated.
= 0: In CYCLE800, the WCS is recalculated when there is a  If the MD is positive, the unchanged M code is always
value in the zero offset (ZO) of the rotary axes. output.
If values are entered in the zero offset of the rotary axes
of the active swivel data set, the basic position of the  If the MD is negative, the number of the tool carrier is add-
swivel data set and therefore also the basic position if the ed to the absolute value of the machine data and the num-
WCS can be changed. ber is output.
= 1: A value in the zero offset (ZO) of the rotary axes acts as Special cases:
an offset of the orientable tool carrier. The WCS remains If the number of the M code to be output or the absolute value
unchanged. of this MD is set to one of the values 0 to 6, 17 or 30. It is not
monitored whether an M code created in this way will conflict
with other functions.
Notes

MD24006 MD24007
Active system frames after Deletion of system frames after
reset reset
MASK CLEAR_ MASK

Bit 3 = 0
Description: Bit 4 = 0
Bit mask used for the reset setting of the channel-specific Description:
system frames included in the channel.
Bit mask used to delete channel-specific system frames from
Bit 4: System frame for work piece reference points is active the data management on reset.
after reset.
Bit 2: Reserved, for TCARR and PAROT, see MD20150
Related to: $MC_GCODE_RESET_VALUES[].
MD28082 $MC_MM_SYSTEM_FRAME_MASK
Bit 3: Reserved, for TOROT and TOFRAME, see MD20150
$MC_GCODE_RESET_VALUES[].
Bit 4: System frame for work piece reference points is delet-

ed on reset.
Reset channel system frames after power on Parameterize properties for settable frame
MD24008 MD24080
Reset channel system frames Parameterize properties for
$MC_CHSFRAME_ $MC_USER_FRAME_
after power on settable frame
POWERON_ MASK POWERON_ MASK
Bit 3 = 0
Bit 4 = 0
Description:
Description: Setting the following bits activates certain properties of the
This machine data defines whether channel-specific system settable frame:
frames are reset in the data management on Power On. That
is offsets and rotations are set to 0, scalings to 1. Mirroring is Bit 0 = 0: default behaviour.
disabled.
Bit 0 = 1: if MD20152 $MC_GCODE_RESET_MODE[7] = 1,
Bit 2: System frame for TCARR and PAROT is deleted after the last active settable frame is selected again ac-
Power On. cording to G code group 8 after power up of the con-
trol.
Bit 3: System frame for TOROT and TOFRAME is deleted
after Power On.
Bit 4: System frame for work piece reference points deleted

after Power On.
Related to:
MD28082 $MC_MM_SYSTEM_FRAME_MASK
Notes

System frames (SRAM) System frames (SRAM)
MD28082 MD28083
$MC_MM_SYSTEM_FRAME_ System frames (SRAM) $MC_MM_SYSTEM_ System frames (SRAM)
MASK DATAFRAME_MASK
Bit 3 = 1 Bit 3 = 1
Bit 4 = 1 Bit 4 = 1
Bit mask for configuring channel-specific system frames in- Bit mask for configuring channel-specific system frames in
cluded in the channel. the data storage (SRAM).
Bit 2: System frame for TCARR and PAROT Bit 2: System frame for TCARR and PAROT
Bit 3: System frame for TOROT and TOFRAME Bit 3: System frame for TOROT and TOFRAME
Bit 4: System frame for work piece reference points Bit 4: System frame for work piece reference points
Axis functions Description:

Bit 0 = 0:
MD30455 Modulo rotary axis/spindle: Programmed positions must be
$MA_MISC_FUNKTION_ Axis functions within the modulo range. Otherwise, an alarm is output.
MASK
Bit 0 = 1:
If positions outside the modulo range are programmed, no
Bit 2 = 1
alarm is output. The position is modulo-converted internally.
Example: B-5 is equivalent to B355, POS[A]=730 is identical
AX4: MSP1 to POS[A]=10, and SPOS=-360 behaves like SPOS=0
MD30455 Bit 0 = 1 (modulo range 360 degrees).
MD30455 Bit 2 = 1
Bit 2 = 0:
AX6: MC1 Modulo rotary axis positioned at G90 with AC by default
MD30455 Bit 0 = 1
MD30455 Bit 2 = 1 Bit 2 = 1:
Modulo rotary axis positioned at G90 with DC by default
This setting must be done for those axes which are declared (shortest path)
as modulo axes, in this example the C axis and the spindle.
Notes

plane tool type
Assignment of tool length com-

Change of tool length compo- SD42950
SD42940 pensation independent of tool
nents with change of active $SC_TOOL_LENGTH_TYPE
$SC_TOOL_LENGTH_CONST type
plane
Change to: 0
Change to: 0
If this setting data is not equal to 0, the assignment of tool This setting data defines the assignment of the tool length
length components (length, wear, base dimensions) to geom- components to the geometry axes independently of the tool
etry axes is not changed when the machining plane (G17 - type. It can assume any value between 0 and 2. Any other
G19) is changed. value is interpreted as 0..
Fine offset TCARR ON / OFF Frame definition at TOFRAME, TOROT and PAROT
SD42974
SD42980 Frame definition at TOFRAME,
$SC_TOCARR_FINE_ Fine offset TCARR ON / OFF
$SC_TOFRAME_MODE TOROT and PAROT
CORRECTION
Change to: 0 Change to: 2000
= 0: no fine offset of the vectors of the swivelling block This setting data defines the direction of the geometry axes
on the machining plane (XY in the case of G17), in the case
= 1: Fine offset of the vectors of the swivelling block. The of the frame definition by means of TOFRAME, TOROT
parameters of the swivelling block $TC_CARR41[n] ... (TOROTY, TOROTX) or for PAROT.
$TC_CARR65[n] take effect.
= 2000: Rotation around the Z axis is selected so that the
angle between the new X axis and the old X-Z plane
has the same absolute value as the angle between
the new Y axis and the old Y-Z plane.
Notes

Swivel data block set-up
For every swivel head, swivel table or combination of both, a swivel data a set has to be compiled.
Swivel data sets may be assigned to several channels (refer to machine data).
A swivel data set consists of parameters $TC_CARR1[n] to $TC_CARR65[n], n = number of swivel data set.
In the operating area Setup, the swivel data set parameters ($TC_CARR1[n] to $TC_CARR65[n]) can be read in/out . Program-
ming with relevant value assignment is also possible in a NC program (manufacturer cycle). After program start, swivel data set
parameters are immediately active.
Offset vectors I1 to I4
The vectors always contain three components, which represent the reference to the X, Y and Z machine axes. The positions in
the kinematic chain are measured by the machine manufacturer; they are always relevant with respect to a swivel head / swivel
table (swivel data set). Offset vectors I1 to I4 refer to the non-swiveled state of the rotary axes (machine kinematics basic set-
ting).
I1 $TC_CARR1…...3[n]
I2 $TC_CARR4…...6[n]
I3 $TC_CARR15...17[n]
I4 $TC_CARR18...20[n]
Rotary axis vectors V1 and V2

V1 $TC_CARR7…...9[n]
V2 $TC_CARR10...12[n]
Kinematic types
Kinematic selection with $TC_CARR23[n]=“T“ (type T)

$TC_CARR23[n]=“P“ (type P)
$TC_CARR23[n]=“M“ (type M)
Swivel head (type T) Swivel table (type P) Swivel head + swivel table (type M)
Offset vector I1 Offset vector I2 Offset vector I1

Rotary axis vector V1 Rotary axis vector V1 Rotary axis vector V1
Offset vector I2 Offset vector I3 Offset vector I2
Rotary axis vector V2 Rotary axis vector V2 Offset vector I3
Offset vector I3 Offset vector I4 Rotary axis vector V2
Offset vector I4
Notes

Swivel head Swivelling tool carrier

The swivelling axes are on the swivel head. The kinematics type is "T".
I3 distance from the tool adapter to the pivot point/intersection of the 2nd rotary axis
I2 distance from the pivot point/intersection of the 2nd rotary axis to the pivot point/intersection of the 1st rotary axis
I1 closure of the I1=-(I2+I3) vector chain, if the swivel head cannot be changed
Swivel table Swivelling work piece carrier (swivel table)

The swivelling axes are on the work piece table. The kinematics type is "P".
I2 distance from the machine reference point to the pivot point/intersection of the 1st rotary axis
I3 distance from the pivot point/intersection of the 1st rotary axis to the pivot point/intersection of the 2nd rotary axis (or to
the reference point of the tool adapter)
I4 closure of the I4=-(I2+I3) vector chain, if the swivel table cannot be changed
Swivel head / Swivel table Mixed kinematics: (swivel head and swivel table
Of the swivelling axes one is on the spindle head and one on the work piece table. The kinematics type is "M".
I2 distance from the tool adapter to the pivot point/intersection of the 1st rotary axis
I1 closure of the I1=-I2 vector chain, if the swivel head cannot be changed..
I3 distance from the machine reference point to the pivot point/intersection of the 2nd rotary axis (or to
the reference point of the tool adapter)
I4 closure of the I4=-I3 vector chain, if the swivel table cannot be changed.
Swivel data block set-up
● Which kinematics type is it?

Swivel head, swivel table or mixed kinematics of swivel head and swivel table.
● What are the names of the rotary axes of the kinematics?

Manual rotary axes are permitted and don't have to be determined in the NC.
● What is the 1st or 2nd rotary axis of a swivel data set?

Rule: Rotary axis 2 is based on rotary axis 1. With mixed kinematics, rotary axis 1 is always the axis for the tool
orientation.
● Is the traversing direction of the linear axes and the rotary axes correct?
Right-hand rule: If the linear axis or the rotary axis moves the workpiece, the direction of motion of the axis and also
the sign of the rotary axis vector change.
● Which rotary axis rotates around which axis of the coordinate system or the machine axis (axes)?
This defines the rotary axis vectors of the kinematics.
Example 1:
Head kinematics. Rotary axis 2 rotates around axis Y → rotary axis vector V2xyz = 0,1,0
Example 2:
Table kinematics. Rotary axis 1 rotates around axis X → rotary axis vector V1xyz = -1,0,0
Notes

Example : Swivel table "TABLE"
Vectors relate to the basic setting of the kinematics.
Rotary axis vector V1: Rotary axis A rotates around X.
Rotary axis vector V2: Rotary axis C rotates around Z.
Offset vector I2: Distance from the reference point of the

machine to the pivot point/intersection of
rotary axis 1
Offset vector I3: Distance from the pivot point of rotary axis 1
to the pivot point/intersection of
rotary axis 2
Offset vector I4: Closure of vector chain I4=-(I2+I3)
Side view of the machine from the X direction
Spindle (tool adapter) is positioned on a block

dimension above the top edge of the table (rotary axis
C) or the center of the table.
A measuring rod in the spindle is used to

determine the turning center of rotary
axis C.
Notes

Side view of the machine from the Y direction
Kinematik Schwenktisch TABLE
X Y Z
Offset vector 260.000 200.000 0.000

I2
Rotary axis vector V1 -1.000 0.000 0.000
Offset vector I3 0.000 0.020 20.400
Rotary axis vector V2 0.000 0.000 -1.000
Offset vector I4 -260.000 -200.020 -20.400
Rotary axes A
Rotary axis 1
Angular range -100.000 100.000
Rotary axis 2 C
Angular range 0.000 360.000
Select Swivel data with
Notes

Retract settings
The settings in the "Selection fields Retraction" corresponds to SD55221 $SCS_FUNCTION_MASK_SWIVEL_SET, Bit 1 Re-
traction variant.
Notes

The configuration described is one of mixed kinematics
with the rotary axes type „P“ with the rotary axes. Offset Kinematics 24 0
Angular offset *) 26 0
A: in the tool heads with a swivelling range of +100 .. –100
degrees Angle grid *) 28 0
C: in the work piece table with a swivelling range of 0 .. 360 Name of rotary axis 2 36 “C“
degrees
Range of angles 31, 33 0 360
Parameter Offset Kinematics 25 0
$TC_CARR
Angular offset *) 27 0
Name 34 “TABLE“
Angle grid *) 29 0
Kinematics 23 “P“
*) for Hirth-toothing
X Y Z
Offset vector I1 41 - 43 0 0 0
Retraction position 38 - 40 0 0 300
Rotary axis vector V1 4-6 260 200 0
Offset vector I2 7-9 -1 0 0
Offset vector I3 15 - 17 0 0.02 20.4
Offset kinematics 64 0
Rotary axis vector V2 10 - 12 0 0 -1 rotary axis 1
Offset vector I4 18 - 20 -260 -200.02 -20.4 Offset kinematics 65 0
rotary axis 2
Name of rotary axis 1 35 “A“
Range of angles 30, 32 -100 +100 $TC_CARR41[n] to $TC_CARR65[n] are envisaged for the
fine offset of the rotary axis and offset vectors.
Notes

1 Manually
$TC_CARR37[n]
In the swivelling block parameter $TC_CARR37[n] the display 2 Semi-automatically
variants are shown decoded in ones; tens, etc.
Thousands Selection field Direction: Direction reference of
rotary axes
In the used data block the parameter $TC_CARR37[1] =
415008004 is assumed. In the table the settings are high- 0 No display of direction reference,
lighted. CYCLE800(_DIR) = -
3 Direction reference Rotary axis 1 optimized
Decimal place Meaning (selection - in basic position)
Ones Selection of swivelling mode 4 Direction reference Rotary axis 2 optimized
(selection - in basic position)
0 Axis by axis
5 No display Direction reference
1 Axis by axis + projection angle
CYCLE800(_DIR) = +
2 Axis by axis
8 Direction reference Rotary axis 1 opti-
+ projection angle + space angle
mized (selection + in basic position)
3 Axis by axis + directly
9 Direction reference Rotary axis 2 optimized
4 Axis by axis + projection angle + directly (selection + in basic position)
5 A.by axis + proj. angle + space angle + direct. Ten-thousands Selection field tracking / B-axis kinematics
Tens Rotary axis 1 0 No, no selection of tracking

0 Automatically 1 Selection Tracking (TRAORI)
1 Manually 2 No Tracking, B-axis kinematics
2 Semi-automatically 3 Selection Tracking + B-axis kinematics
Hundreds Rotary axis 2
Hundred thou- 0 reserved
0 Automatically sands
Decimal place Meaning Hundred mil- Release of swivelling block, swivelling block change
lions and tool change
Hundred- 0 reserved
thousands
0 No release of swivelling block
One million and Selection field retraction
4 Swivelling block released
ten millions
swivelling block- and tool change auto-
00 No retraction matically
01 Retraction Z Swivelling block change automatically and
tool change manually
02 Retraction Z XY
03 Retraction Z or Z XY swivelling block change manually and tool
change automatically
04 Retraction in tool direction max.
08 Retraction in tool direction inc. Swivelling block- and tool change manual-
ly
15 Retraction in Z, Z XY or Tool direction

max. or Tool direction inc
Note:
The tracking of the tool tip when swivelling requires the commissioning of the function TRAORI. For this the option "Machining
package 5-axes” is required. This option is not available with the NCK-Export-Version.
Interrelation of TOOLCARRIER ⇔ 5-axis transformation (transformer type 24, 40, 56):
For 5-axis transformation, transformer type 72 in MD24100: $MC_TRAFO_TYPE_1 can be used.
In the case of transformer type 72, the vectors of the TOOLCARRIER in MD24582: $MC_TRAFO5_TCARR_NO_1 are used.
Notes

Set up the CUST_800.SPF Copying manufacturer cycles
Adaptations 1. Select the "Start-up" operating area.
During swivelling, all axis positions are approached using the

CUST_800.SPF cycle. The call is exclusively made by the
swivel cycle CYCLE800 respectively by the cycles 2. Press the "System data" softkey.
E_TCARR (ShopMill) or F_TCARR (ShopTurn).
In cycle CUST_800.SPF, the function markers (_M2: to 3. Open the directory NC data/Cycles/Standard
_M59) are prepared and documented. Also refer to the follow- cycles and select the manufacturer cycles.
ing diagram “Call-up structure for swivelling”.
If you modify the cycle CUST_800.SPF, proceed as follows: 4. Press the "Copy" softkey and open the NC
data/Cycles/Manufacturer cycles directory.
1. Copy cycle CUST_800.SPF from the directory
/NC data/Cycles/Standard cycles
5. Press the "Paste" softkey.
2. Insert cycle CUST_800.SPF into directory The cycles are available for you to individual-
/NC data/Cycles/Manufacturer cycles. ly adapt them.
Note:
By means of the access stage "Manufacturer" it is only possi-
ble to copy into the manufacturer or user directory those cy-
cles starting with CUST_.*.SPF and which are envisaged for
the machine matching.
CUST_800.SPF _A1 Angle of rotary axis 1

Copying and in pasting into manufacturer cycles. _A2 Angle of rotary axis 2
1. Feed evaluation in percent (%) for swivelling in
JOG mode
_TC2
2. Number of the new swivel head/table replacement
under ShopMill
Incremental position during retraction in the incre-
_T_POS
mental tool direction (see marker)
Retraction before swivelling
If the cycle CUST_800.SPF is not modified, the axis Z

(marker _M41) or the axis Z will during retraction be trav-
ersed to the positions first followed by the axes X, Y (marker
_M42) in the MCS system (Machine coordinate System).
Parameter of the manufacturer cycle CUST_800.SPF Specified in the system variables $TC_CARR38[n] to
$TC_CARR40[n] are the freely available position values. Dur-
ing retraction the active cutting edge (D0) is de-selected and
CUST_800 (INT _MODE, INT _TC1, REAL _A1, REAL _A2, re-selected after the retraction.
INT _TC2, REAL _T_POS) SBLOF DISPLOF
If retraction in direction of the tool is agreed, the tool axis will
be retracted as far as the software end position (in the tool
_MODE Es werden die Marken _M2 bis _M59 angesprungen. direction by the maximum amount) or else it will be retracted
by an incremental amount away from the work piece in the
_TC1 Nummer des Schwenkkopfes/-tisches(CYCLE800). direction of the tool. The tool lengths will be taken into ac-
count accordingly.
Notes

Call-up structure for swivelling
The diagram below shows the call-up structure from a
ShopMill part program: programGuide program:
Description:
The cycle E_TCARR is used for milling machines (ShopMill) and the cycle F_TCARR for turning machines (ShopTurn).
Notes

CYCLE800 structured chart

Sequence in AUTOMATIC mode
Structure: CYCLE800.SPF / CUST_800.SPF
Notes

Structure: E_TCARR.SPF
Notes

Call-up sequences of the manufacturer cycle Mode-of-operation AUTO:

CUST_800.SPF
Part program with selection of the swivelling block with swiv-
The following description shows a couple of call-up sequenc-
elling and without retraction:
es of the customers cycle CUST_800.SPF.
 _M4: Load new swivel head automatically
Mode-of-operation JOG:  _M40: User Init
Selection of the swivelling block, with or without swivelling:  _M20: Automatic swivelling of the rotary axes 1 and 2
 _M40: User Init  _M14: Retraction after swivelling
 _M20: Automatic swivelling of the rotary axes 1 and 2
Part program with de-selection of the swivelling block:
De-selection of the swivelling block:
 _M11: Initializing the swivelling angle on program start
 _M40: User Init
 _M6: Change swivel head automatically
Swivelling with retraction:  _M40: User Init
 _M40: User Init  _M14: Retraction after swivelling:
 _M41: with retraction mode "Z"
_M42: with retraction mode "Z, XY"
_M44: with retraction mode "Tool direction max."
_M45: with retraction mode "Tool direction inc."
There will be no call-up of CUST_800 in case of a tool
change from the T,S,M-mask, no matter whether a swivelling
block is selected or not.
Mode-of-operation AUTO:
Part program without Swivelling with tool change, no swivel-

ling block activated, without retraction:
 _M2: Magazine tool change
 _M12: Swivelling after tool change (AUTO)
Part program without Swivelling with tool change, swivelling

block activated, without retraction:
 _M11: Initializing the swivelling angle on program start
 _M2: Magazine tool change
 _M12: Swivelling after tool change (AUTO)
Notes

Variable used in CUST_800: _TC_N_WZ: = 0: tool tracking not activated

= 1: tool tracking activated
_A1: contains the angular position evaluated in _TC1: Number of the swivelling block
CYCLE800 of the first rotary axis; is used
also as transfer parameter for the _TC2: Only for JobShop: Number of the new swiv-
E_SWIV_H for positioning the first rotary elling block for swivelling block change,
axis. otherwise: Override value for swivelling in
JOG
_A2: contains the angular position evaluated in
CYCLE800 of the second rotary axis; is used _T_POS: Transfer parameter evaluated by CYCLE800
also as transfer parameter for the for the retraction in tool direction :
E_SWIV_H for positioning the second rotary max.: as far as Software limit switch
axis. inc.: The value entered in the swivelling
mask for incremental retraction is re-
_SC_NO_VAL: Used as indicator that the rotary axis position calculated by CYCLE800 to a new absolute
is not defined. position taking into account the Software
limit switch.
_TC_FR: Retraction mode:
= 0: No retraction $P_EP[_AX1]: The system variable provides the current
= 1: Z or fixed point 1 WCS command position of the first rotary
= 2: Z XY or fixed point 2 axis.
= 5: Tool direction max. $P_EP[_AX2]: The system variable provides the current
WCS command position of the second rotary
Note: axis.
By means of the command MOD10 the tens-
place of this variable, which has no meaning
for the retraction mode, is hidden.
Note on markers _M2 to _M13 Note on markers _M14 to _M15

If the swivel data set (SDS) or tool is changed, the linear axes Depending on the values of the retraction plane and the pro-
are retracted using the last retraction mode (modal). grammed swivel plane, it is possible that the linear axes now
If this behaviour is not desired in milling/turning, the corre- also travel the swivelled retraction plane while running up
sponding calls must be commented out with a semicolon (;). from the current position to the software limit switches after a
The E_SWIV_H or F_SWIV_H cycle is called in milling/ block search. To avoid this problem, marker _M14 in the
turning (see markers _M2 to _M9) in the CUST_800.SPF CUST_800.SPF is called after swivelling. The E_SP_RP(30)
manufacturer cycle. cycle preset there runs up to the milling retraction plane,
whereby travel may be along the software limit switches. An
Parameter E_SWIV_H (Par1, Par2, Par3) appropriate retraction after block search can be set at marker
_M15.
 Par1: Number of swivel data set (_TC1)
 Par2: Angle of 1st rotary axis Note on markers _M20 to _M31
 Par3: Angle of 2nd rotary axis
Markers _M20 to _M31 are distinguished by machine kine-
matics with two rotary axes or one rotary axis. A distinction is
Modification examples also made between automatic rotary axes (known to the
NCU) and manual (semi-automatic) rotary axes. There is only
If the rotary axes (swivel head/table) are not to be positioned ever one valid marker for swivelling with the active swivel
during swivel data change / tool change, the call of the data set.
E_SWIV_H cycle can be commented out at the relevant
markers. If the rotary axes are to move to a certain position,
an angle value can be transferred to parameters Par 2, Par 3. Note on marker _M35
Run through _M35 for block search and a swivel data set with
manual rotary axes.
Notes

Note on marker _M40 _M42: retraction in Z XY or fixed point 2

The retraction positions are determined by the swivelling
This marker is envisaged for user applications such as swiv- block parameter:
elling without active tool correction - $TC_CARR38[n] for the X-axis
- $TC_CARR39[n] for the Y-axis
If the swivelling of the rotary axes without active tool cutting - $TC_CARR40[n] for the Z-axis
edges (D0) is not possible, then this can be rectified in the The retraction positions are approached in the machine coor-
cycle CUST_800.SPF: dinate system (departure block with SUPA D0).
_M40: _M43: not used

IF ((NOT $P_TOOL) AND _TC1)
LOOP _M44: Retraction in tool direction max.
MSG ("no tool cutting edge active") The retraction position is evaluated from the Software limit
M0 switch position. The approach takes place in the work piece
STOPRE coordinate system (departure block with G90).
ENDLOOP
ENDIF _M45: Retraction in tool direction inc.
GOTOF_MEND The retraction position is defined incrementally to the current
position in the swivelling mask. The input value is converted
internally into an absolute position taking into account the
Note on markers _M41 to _M45 Software limit switch. The approach takes place in the work
piece coordinate system (departure block with G90).
_M41: retraction in Z or fixed point 1
The retraction position of the Z-axis is determined by the
swivelling block parameter $TC_CARR40[n] for the Z-axis.
The retraction position is approached in the machine coordi-
nate system (departure block with SUPA D0).
Note on marker _M46 Note on tool change + swivelling

The retraction before the swivelling after a block search can As a rule the functions Swivelling (CYCLE800) and the tool
be set with the marker _M46. The variable _E_VER is 1, if it change on a machine are independent of one another. Hence
is a milling program. in case of a technological sequence involving several tools
e.g. centring, drilling, tapping etc. the swivelled working plane
can be maintained.
Note on markers _M57 to _M59 If for the mechanical operation of the tool changes the rotary
axes of the activated swivelling block are involved or if these
The markers _M57 to _M59 are used for swivelling in JOG
must be retracted, then this must be taken into account in the
and active 5-axis transformation (TRAORI).
tool changing program. After the tool change the same rotary
axis positions as before the tool change will be approached. If
linear axes (geo axes) are involved with the tool change, the
Note on "Tracking tool"
rotations in the NC (swivelling frame) do not need to be
The tracking of the tool requires that the 5-axis transformation cleared, instead the linear axes can be positioned as machine
has been arranged, which is equivalent to the respective axes by means of the commands G153 or SUPA.
swivelling block. The programming part for tool tracking is
included in the markers _M20, _M21, _M22 and _M30. The
first 5-axis transformation will be called up with TRAORI(1).
Note:
The function "Tracking tool" is not available with the NCK

Export version that is subject of this module.
Notes

Application in JOG and part program
Swivelling in JOG
Shown below is how the swivelling configuration can be test-

ed.
Basic setting:
The axes are positioned by means of the mask "Position":
X = 0, Y = 0, Z = 100, A = 0 and C = 0
A tool is selected, the tool length is 80mm, no values are en-
tered in the zero point offset.
Before swivelling there is the following outset position:
Thereafter follows by means of JOG-swivelling a swivelling by

90 degree about the X-axis.
From this result the following axis positions:
Description:
The coordinate system is being tracked with the rotation

about the X-axis, in this example it is rotated by 90 degrees.
The following new axis positions result:
A = 90: A rotation about the A-axis by 90 degrees corre-

sponds to an A-axis position of 90 degrees.
Notes

Swivelling in AUTO (part program) Machining program: Swivel
The following describes a programming example which

demonstrates the swivelling and a subsequent machining
operation with planar milling and drilling on the swilled face.
Program head with workpiece definition:

Tool list
Preparation:
The tools used in this example must be created.
Swivel the machining plane: Face milling and technology data:
Notes

B111 END Setup Swivelling
Continuation Swivelling in AUTO (part program)
Deep hole drilling and technology data: Position circle for deep hole drilling:
Simulation depiction: Note:

For better representation in the 3D view the function
"Section" was used.
Selection of the simulation: Details - Section
Using the softkeys "X +" to "Z -" the section axes can be set.
Under "Details - rotate view" the work piece can be rotated

into the required position.
B111: END
Notes

B120 Setup Turning
Sinumerik
Operate
Module Description:
In this module a simple turning machine with the axes X and Z, a main spindle C as well as a
driven tool CS3 is to be set up for turning and the subtechnology milling. The individual setup steps
are to be checked from time to time to show the result of the parameterization.
The preparation of the tool list, the cycle selections, the search run and various basic settings are
also part of the training scope. There will be a detailed description of the selections to be made for
JOG-TSM, TRANSMIT/TRACYL and for the main .
Module Objective:
By means of this module you will get to know the meaning of the Machine and Setting data to be
used as well as the various means available in order to configure the machine to suit the particular
requirements.
The functions will be parameterized in several blocks and subsequently tested regarding the
function.
Content:
Manufacturer Cycles
Setup for Turning

Sinumerik
Cycle settings
Tool list setup
Basic settings
JOG-TSM
Block search
Simulation
TRANSMIT/TRACYL
Clamping jaws, cut-off and parts gripper

B120

Setup Turning B120
Setup Turning:
START
Simulation
Overview
MD and SD
Machining
example
Manufacturer
Cycles
TRANSMIT
TRACYL
Setup for
Turning
Clamping jaws,
cut-off and parts
gripper
Cycle
Settings
Menu and
Technology
settings
Tool List
Setup
Setup Turning:
END
Basic
Settings
JOG-TSM
Block search
Notes

B120 Setup Turning
10260 $MN_CONVERT_SCALING_SYSTEM 1 Exact Enable basic system conversion

$MN_FRAME_GEOAX_CHANGE_MO
DE
10610 $MN_MIRROR_REF_AX 0 Exact Reference axis for mirroring
10714 $MN_M_NO_FCT_EOP 32 Variable M function for spindle active after reset
10722 $MN_AXCHANGE_MASK Bit 2 = 1 Exact Parameters for axis replacement behaviour
Bit 0: 15110: REORG not possible
Bit 0 = 1
Bit 1: 10763 The path component of the block in the con-
Bit 1 = 1
11410 $MN_SUPPRESS_ALARM_MASK Variable tour plane is zero
Bit 15 =1
Bit 15: 5000 Communication order cannot be executed
Bit 20 =1
Bit 20: 2900 Reboot is delayed
Bit 0: Machining is stopped with the loading of the last
Bit 0 = 1 Exact action block after search run
11450 $MN_SEARCH_RUN_MODE Bit 1 = 1 Exact Bit 1: Automatic ASUP start after output of action blocks
Bit 2 = 1 Exact Bit 2: The output of the auxiliary functions in the action
blocks is suppressed
11470 $MN_REPOS_MODE_MASK Bit 3 = 1 Exact Mask for support of special alarm outputs
$MN_TOOL_DATA_CHANGE_COUN
17530 1FH Exact Mark tool data change for HMI
TER
Bit 0 = 1 Exact Bit 0: Memory for TM-specific data is provided
$MN_MM_TOOL_MANAGEMENT_M
18080 Bit 1 = 1 Exact Bit 1: Memory for monitoring data (WZMO) is provided
ASK
Bit 3 = 1 Exact Bit 3: Memory to consider adjacent location is provided
19320 $ON_TECHNO_FUNCTION_MASK Bit 4 = 1 Exact Tool management with magazine data
20100 $MC_DIAMETER_AX_DEF X Variable Geometry axis with transverse axis function
Bit 0 = 1 G codes acc. to MD20150
Bit 0 = 1 Exact
Bit 6 = 1 Current setting for active tool length offset is
Bit 6 = 1 Exact
20110 $MC_RESET_MODE_MASK retained after reset/end-of-part-program
Bit 14 =1 Exact
Bit 14 = 1 The current setting of the basic frame is retained
Bit 16 =0 Variable
Bit 16 = 0 Initial setting for master spindle acc. to MD20090
$MC_TOOL_MANAGEMENT_TOOLH
20124 1 Exact Tool holder number
OLDER
20128 $MC_COLLECT_TOOL_CHANGE 0 Exact No tool change commands after search run
$MC_CUTTING_EDGE_RESET_VAL
20130 1 Exact Tool and cutting edge remain activated
UE
[5] = 2 Exact Group 6: Plane selection 2 = 18
[15] = 3 Variable Group 16: Feedrate override 3 = CFIN
20150 $MC_G_CODE_RESET_VALUE [21] = 2 Variable Group 22: Tool offset type 2 = CUT2DF
[28] = 2 Exact Group 29: Radius/diameter programming 2 = DIAMON
[48] = 3 Variable Group 49: Point-to-point motion 3 = PTPG0
Group 6: Plane selection remains active after Reset
[5] = 0 Exact
Group 8: Zero point offset remains active after Reset
[7] = 1 Exact
Group 13: Work piece dimensioning inch/metric default
[12] = 0 Exact
20152 $MC_G_CODE_RESET_MODE after reset
[14] = 1 Exact
Group 15: Type of feed remains active after Reset
[15] = 0 Exact
Group 16: Feed correction remains active after Reset
[21] = 0 Variable
Group 22: Tool correction type default after reset
$MC_WAB_MAXNUM_DUMMY_BLO maximum number of blocks w/o traversing movement with
20202 10 Minimum
CKS SAR
$MC_CUTCOM_MAXNUM_CHECK_
20240 4 Minimum Blocks for look-ahead contour calculation with TRC
BLOCKS
$MC_CUTCOM_MAXNUM_DUMMY_ maximum number of blocks without traversing motion in
20250 5 Minimum
BLOCKS TRC
Notes

Setup Turning B120
Bit 0 = 1 Exact Bit 0: Tool management active

Bit 1 = 1 Exact Bit 1: Tool monitoring function active
Bit 3 = 1 Exact Bit 3: Consider adjacent location active
20310 $MC_TOOL_MANAGEMENT_MASK
Bit 14 =1 Exact Bit 14: automatic tool change during RESET and Start
Bit 16 =1 Exact Bit 16: Programming T=’Location number’
Bit 23 =1 Variable Bit 23: On offset selection no synchronization with HL
20320 $MC_TOOL_TIME_MONITOR_MASK Bit 0 = 1 Variable Time monitoring for tool in tool holder 1
$MC_TOOL_PARAMETER_DEF_
20360 Bit 0 = 1 Variable Definition of tool parameters
MASK
Errors in ISO scanner are not output, the block is trans-
20734 $MC_EXTERN_FUNCTION_MASK Bit 3 = 1 Variable
ferred to the Siemens translator.
22550 $MC_TOOL_CHANGE_MODE 0 Exact Tool change with T function
Bit 0 = 1
24006 $MC_CHSFRAME_RESET_MASK Exact Bit 0 = 1 Actual value setting and scratching remains active
Bit 5 = 0
Exact Bit 5 = 0 System frame for cycles is deleted
$MC_CHSFRAME_RESET_CLEAR_ Bit 0 = 0
24007 Exact Bit 0 = 0 Actual value setting and scratching not delete
MASK Bit 5 = 1
Exact Bit 5 = 1 System frame for cycles delete
$MC_CHSFRAME_POWERON_MAS Bit 0 = 0
24008 Exact Bit 0 = 0 Actual value setting and scratching not reset
K Bit 5 = 0
Exact Bit 5 = 0 System frame for cycles not reset
24030 $MC_FRAME_ACS_SET 1 Exact Adjustment of SZS coordinate system
24040 $MC_FRAME_ADAPT_MODE 7H Exact Adaptation of active frames
Bit 0: Measurement of total operating time is active for all
Bit 0 = 1 part programs
Bit 1 = 1 Bit 1: Measurement of current program runtime is active
Bit 4 = 1 Bit 4: Measurement also with active dry run feed
27860 $MC_PROCESSTIMER_MODE Variable
Bit 5 = 1 Bit 5: Measurement also with program test
Bit 6 = 1 Bit 6: $AC_CYCLE_TIME is not deleted on start by
Bit 8 = 1 ASUP and PROG_EVENT
Bit 8: AC_CYCLE_TIME will be deleted with GOTOS
Bit 0 = 1 Bit 0: Counter $AC_REQUIRED_PARTS is activated
27880 $MC_PART_COUNTER Bit 8 = 1 Variable Bit 8: Counter $AC_ACTUAL_PARTS is active
Bit 11 =1 Bit 11: Increment $AC_ACTUAL_PARTS with GOTOS
28000 $MC_MM_REORG_LOG_FILE_MEM 75 Minimum Memory space for REORG (DRAM)
$MC_MM_NUM_REORG_LUD_MOD Number of blocks for local user variables in REORG
28010 20 Minimum
ULES (DRAM)
Bit 0 = 1
28082 $MC_MM_SYSTEM_FRAME_MASK Exact Bit 0 = 1 System frame for actual value and scratching
Bit 5 = 1
Exact Bit 5 = 1 System frame for cycles
$MC_MM_SYSTEM_DATAFRAME_M Bit 0 = 1
28083 Exact Bit 0 = 1 System frame for actual value and scratching
ASK Bit 5 = 0
Exact Bit 5 = 0 System frame for cycles
28450 400 Exact Buffer for tool data changes (DRAM)
_SIZE
35040 $MA_SPIND_ACTIV_AFTER_RESET 2 Exact Own spindle RESET
42440 $SC_FRAME_OFFSET_INCR_PROG 0 Exact Zero offsets in frames
42442 $SC_TOOL_OFFSET_INCR_PROG 0 Exact Tool length offsets
42528 $SC_CUTCOM_DECEL_LIMIT 1 Variable Feed lowering on circles with tool radius compensation
plane
Assignment of tool length compensation independent of
tool type
Notes

B120 Setup Turning
Bit mask for available search modes (ShopMill/ShopTurn)

$MNS_BLOCK_SEARCH_MODE_MA
51024 Bit 0 = 1 Bit 1: Block search with calculation with approach
SK_JS
Bit mask for available block search modes
Bit 0 = 1 Bit 0: Block search with calculation without approach
$MNS_BLOCK_SEARCH_MODE_MA Bit 1 = 1 Bit 1: Block search with calculation with approach
51028
SK Bit 4 = 1 Bit 3: Skip EXTCALL programs
Bit 5 = 1 Bit 4: Block search without calculation
Set actual value selection
51038 $MNS_SET_ACT_VALUE 1 1 = If a user frame (settable work offset e.g. G54) is active,
it will be used. In G500 Set actual values is not offered
(system frame is no longer used).
$MNS_PROGRAM_CONTROL_MOD Options for machine - program influence:
51039 Bit 0 = 1
E_MASK Bit 0: Program test function available
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,
$MNS_SWITCH_TO_MACHINE_MAS
51040 0H the operating area is not automatically switched
K
over to Machine.
Bit 2: Do not switch automatically in Programs during
program selection.
Bit 3: No auto. Start of block search on selection / execu-
tion under Programs.
Function mask Simulation
51226 $MNS_FUNCTION_MASK_SIM 0H Bit 5: Turning tool can rotate in the tool spindle
Bit 7: Interpretation of handwheel values as absolute
values
51228 $MNS_FUNCTION_MASK_TECH 0H
0: Vertical lathe, right hand head
6: Vertical lathe, left hand head
$MCS_DISP_COORDINATE_SYSTE 33: Horizontal lathe with machining in front of the turning
52000 34
M centre
34: Horizontal lathe with machining behind the turning cen-
tre
52005 $MCS_DISP_PLANE_MILL 0 Milling: 0: Plane selection on the operator panel
52006 $MCS_DISP_PLANE_TURN 18 Turning: Always G18

Technology
52200 $MCS_TECHNOLOGY 1 Exact
1: turning
2: milling
Extended technology
52201 $MCS_TECHNOLOGY_EXTENSION 2
1: turning: extended technology Turning for Milling
2: milling
Notes

Setup Turning B120
Meaning of the axes

0 = no special meaning; 1 = tool spindle (driven tool); 2 = C
axis of the tool spindle (driven tool); 3 = main spindle
(turning); 4 = C axis of the main spindle (turning); 5 = coun-
$MCS_AXIS_USAGE [2]=3
52206 ter spindle (turning); 6 = C axis of the counter spindle
[3]=1
(turning); 7 = linear axis of the counter spindle (turning);
tailstock (turning); 9 = steady rest (turning); 10 = B axis
(turning), 12 = B axis of the counter spindle (turning),
Axis attributes
Bit 0: Rotates around the 1st geometry axis (applies to
rotary axes)
Bit 1: Rotates around the 2nd geometry axis (applies to
rotary axes)
Bit 2: Rotates around the 3rd geometry axis (applies to
rotary axes)
Bit 3: Positive direction of rotation is counter-clockwise
(applies to rotary axes)
clockwise (applies to spindles)
Bit 5: Direction of rotation M3 corresponds to rotary axis
minus (applies to spindles)
For 840D sl: PLC bit DBnn.DBX17.6, nn = 31 +
52207 $MCS_AXIS_USAGE_ATTRIB 0H machine axis index
For 828D: PLC bit DB38xx.DBX2001.6, xx is ma-
chine axis index
Bit 8: Offer rotation axis to accept blank (at milling ma-
chines)
Bit 10: Rotary axis rotates around 1st geometry axis (for
Bit 11: Rotary axis rotates around 2nd geometry axis (for
Bit 12: Rotary axis rotates around 3rd geometry axis (for
Bit 13: Position of the axis for blank selection from active
WO (for rotary axes)
Bit 0: Measuring system for programs always in the base
system
Bit 1: Front view for turning in school coordinate system
Bit 3: Generate automatic end-of-program in MDI (with
the “Delete blocks” soft key)
Bit 0 = 1
Bit 3 = 1
Bit 13: Hide channel axes which are currently located in
another channel
Notes

B120 Setup Turning
Function screen for displaying overview of work offsets

$MCS_FUNCTION_MASK_DISP_ZO
52211 1FFFF5H Bit 12: Display $P_TOOLFRAME
A
(ShopMill/ShopTurn)
Bit 6: Work offset ZV cannot be entered as an absolute
value (ShopTurn)
52212 $MCS_FUNCTION_MASK_TECH Bit 3 = 1 Exact Bit 7: Detect the expiry of tool lives (ShopMill/ShopTurn)
Bit 10: Enable swivel plane/align tool using kinematic
transformation
Bit 11: Switch off layer check for drilling and milling tools
(ShopTurn)
Bit 13: Approach tool change point Y in Machine
(ShopTurn)
Bit 14: With approach logic only check tool position with
cutting edge (ShopTurn)
chines)
52214 $MCS_FUNCTION_MASK_MILL 0H
Notes

Setup Turning B120

52216 $MCS_FUNCTION_MASK_DRILL 0H Bit 2: Thread tapping also without encoder (ShopMill/
ShopTurn)
Bit 3: Constant cutting speed in rel. to diameter of center-
ing (ShopMill/ShopTurn)
Function mask Turning
Bit 0: Enable zoom under manual for tool measurement
Bit 1: Enable parts gripper for cut-off
Bit 2: Enable tailstock
Bit 3: Enable spindle control of main spindle via surface
Bit 4: Enable spindle control of counterspindle via surface
Bit 6: Enable balance cutting for dual-channel stock re-
moval
52218 $MCS_FUNCTION_MASK_TURN 0H
Bit 7: Retraction during stock removal along contour with
G1
Bit 8: Input spindle chuck data in the program
Bit 9: Additional entry of tailstock data in the program
Bit 10: Enable convex thread
Bit 11: Reserved
Bit 12: Deactivate thread synchronization
Bit 13: Stock rem. contour with CYCLE95 (828D program-
GUIDE without Advanced Technology)
Enable fast M functions
Bit 0: Coolant OFF
52229 $MCS_ENABLE_QUICK_M_CODES 0H Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
$MCS_M_CODE_ALL_COOLANTS_
52230 9 M code for all coolants OFF
OFF
52231 $MCS_M_CODE_COOLANT_1_ON 8 M code for coolant 1 ON
52232 $MCS_M_CODE_COOLANT_2_ON 7 M code for coolant 2 ON
$MCS_M_CODE_COOLANT_1_AND
52233 -1 M code for coolant 1 + 2 ON
_2_ON
[0]: M code for Open chuck with non-rotating main spindle
52250 $MCS_M_CODE_CHUCK_OPEN ““ [1]: M code for Open chuck with non-rotating counter spin-
dle
$MCS_M_CODE_CHUCK_OPEN_RO [0]: M code for Open chuck with rotating main spindle
52251 ““
T [1]: M code for Open chuck with rotating counter spindle
[0]: M code for Close chuck main spindle

52252 $MCS_M_CODE_CHUCK_CLOSE ““
[1]: M code for Close chuck counter spindle
Notes

B120 Setup Turning

Bit 0: Do not permit Create tool on magazine location
Bit 1: Load/unload disable, if machine is not in reset
Bit 2: Load/unload disable for emergency stop
Bit 3: Load/unload tool or relocate tool to/from spindle
disabled
Bit 4: Load directly in spindle
Bit 6: Permit relocating to/from spindle despite a block
(Bit 3)
53220 $MAS_AXIS_MCS_POSITION 0 Position of axis in the Machine
X=400 Axis position at start of simulation
53230 $MAS_SIM_START_POSITION
Z=0 Only adjust with geometry axes
[0]: Spindle chuck: Chuck dimension ZC1
[1]: Spindle chuck: Stop dimension ZS1
53240 $MAS_SPINDLE_PARAMETER 0 [2]: Spindle chuck: Jaw dimension ZE2 (counter spindle
only)
in the data set of the main spindle and the counter spindle
Spindle jaw type only for counter spindle
53241 $MAS_SPINDLE_CHUCK_TYPE 0 = 0: Jaw type 1
= 1: Jaw type 2
[0] Tailstock diameter
53242 $MAS_TAILSTOCK_PARAMETER 0
[1] Tailstock length
Bit 0: Diameter display for rotating tools
Bit 1: Default direction of rotation for all turning tools is
M4
Bit 3: Input disable for tool name and tool type in loaded
tools
Bit 4: Input disable for loaded tools, if the channel is not
in Reset
Bit 5: Calculate tool wear inputs additively
Bit 6: Numerical input of the tool ident.
54215 $SNS_TM_FUNCTION_MASK_SET Bit 0 = 1
Bit 8: Diameter display for transverse axis - Geometry
Bit 10: Enable loading/relocating of tools on buffer loca-
tions
Bit 11: Creating of new tools in gripper locations is disa-
bled
Bit 12: Do not unload measuring tools if ”Unload all” func-
tion is executed
Bit 13: Do not delete tool wear when inputting the geome-
try value
Bit 14: Load/relocate tool. Search without pre-assignment
of the magazine
$SCS_MAX_INPUT_FEED_PER_RE
55200 1 Feedrate input upper limit for mm/rev
V
$SCS_MAX_INPUT_FEED_PER_TIM
55201 10000 Feedrate input upper limit for mm/min
E
$SCS_MAX_INPUT_FEED_PER_TO
55202 1 Feedrate input upper limit for mm/tooth
OTH
Notes

Setup Turning B120

Bit 0: Tool preselection active
$SCS_FUNCTION_MASK_TECH_SE Bit 1 = 1
55212 Bit 1: Calculate thread depth from metric thread lead
T Bit 2 = 1
Bit 2: Refer to the table for thread diameter and depth
Bit 0: Default setting - milling cycles with synchronous
operation
SC
Bit 0 = 1 between reference plane + safety clearance and
55214 $SCS_FUNCTION_MASK_MILL_SET
Bit 2 = 1 depth
without inclusion of the safety clearance
Note: Bit 2 is active with the following milling cycles: CY-
CLE61, CYCLE71, CYCLE76, CYCLE77, CYCLE79, CY-
CLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCK-
ET4
Bit 0: reserved
Bit 2: Consider swiveled table kinematics (CYCLE86)
$SCS_FUNCTION_MASK_DRILL_SE Bit 3 = 1
55216 Bit 4: Monitoring spindle MD 31050/31060 (CYCLE840)
T Bit 4 = 1
Bit 5: reserved
Bit 6: Adapt spindle position to the tool orientation
(CYCLE86)
Bit 7: Adapt direction of retraction path in the plane to
active mirroring (CYCLE86)
Bit 0: New thread table during thread cutting
$SCS_FUNCTION_MASK_TURN_SE Bit 1: Reserved (CYCLE93)
55218 Bit 0 = 1
T Bit 2: Reserved (CYCLE93)
Bit 3: Chamfer in CYCLE930 as chamfer length (CHF)
Bit 4: Retraction from the inside machining (CYCLE951)
55300 $SCS_EASY_SAFETY_CLEARANCE 1 Simple input: Safety clearance
55301 $SCS_EASY_DWELL_TIME 0.6 Simple input: dwell time
55305 $SCS_EASY_DRILL_DEEP_FD1 90 Simple input: percentage 1st federate deep - hole drilling
55306 $SCS_EASY_DRILL_DEEP_DF 90 Simple input: percentage infeed deep - hole drilling
55307 $SCS_EASY_DRILL_DEEP_V1 1.2 Simple input: min. depth infeed deep - hole drilling
55308 $SCS_EASY_DRILL_DEEP_V2 1.4 Simple input: absolute retraction value deep - hole drilling
$SCS_EASY_THREAD_RETURN_DI
55309 2 Simple input: return distance thread tapping
ST
Engraving cycle CYCLE60: Circ. path radius for generating

55400 $SCS_MILL_ENGRAVE_POINT_RAD 0
the char. ”point”
Notes

B120 Setup Turning
Only for ShopTurn cycles with complete machining rough-

ing and finishing
55500 $SCS_TURN_FIN_FEED_PERCENT 100 - Grooving cycles : all
- Undercut cycles : “Thread DIN” and “Thread”
- Thread cycles : all
$SCS_TURN_ROUGH_O_RELEASE_
55505 1 Return distance stock removal for external machining
DIST
$SCS_TURN_ROUGH_I_RELEASE_
55506 0,5 Return distance stock removal for internal machining
DIST
$SCS_TURN_GROOVE_DWELL_TIM negative value in spindle revolutions
55510 -1
E positive value in seconds
$SCS_TURN_PART_OFF_CTRL_DIS
55540 0,1 Path for cut-off check
T
$SCS_TURN_PART_OFF_CTRL_FE
55541 0 Feedrate for cut-off check
ED
$SCS_TURN_PART_OFF_CTRL_FO
55542 10 Force in percent for cut-off check, in %
RCE
$SCS_TURN_CONT_RELEASE_ANG
55580 45 Contour turning: retraction angle
LE
$SCS_TURN_CONT_RELEASE_DIS
55581 1 Contour turning: retraction value
T
55582 $SCS_TURN_CONT_TRACE_ANGLE 5 Contour turning: minimum angle for rounding along contour
$SCS_TURN_CONT_VARIABLE_DE
55583 20 Contour turning: percentage for variable cutting depth
PTH
$SCS_TURN_CONT_BLANK_OFFSE
55584 1 Contour turning: blank allowance
T
Contour turning: feed interrupt time
$SCS_TURN_CONT_INTERRUPT_TI
55585 -1 negative value in spindle revolutions
ME
positive value in seconds
$SCS_TURN_CONT_INTER_RETRA
55586 1 Contour turning: retraction path after feed interrupt
CTION
$SCS_TURN_CONT_MIN_REST_MA Contour turning: minimum difference dimension residual
55587 50
T_AX1 machining axis 1
$SCS_TURN_CONT_MIN_REST_MA Contour turning: minimum difference dimension residual
55588 50
T_AX2 machining axis 2
$SCS_TURN_CONT_TOOL_BEND_R
55595 0,1 Contour plunge turning: retraction path due to tool bending
ETR
$SCS_TURN_CONT_TURN_RETRA
55596 0,1 Contour plunge turning: retraction depth prior to turning
CTION
Notes

Setup Turning B120
Setup Turning Configuration of the axes and spindles
Pre-requisite: Machine axis name

Sinumerik Operate is already installed, PLC commissioning
has been carried out, the tool management set-up has been MD10000
completed. $MN_AXCONF_MACHAX_ Machine axis name
NAME_TAB
Licencing: Change to:
chine, the following software options must be available: MD10000[0] = MX1
MD10000[1] = MZ1
 "ShopMill/ShopTurn" MD10000[2] = MCS1
Order No. 6FC5800-0AP17-0YB0 MD10000[3] = MCS3
MD10000[4] = MQ1
 "Residual material detection and machining"
Order No. 6FC5800-0AP13-0YB0
 "Simultaneous recording (real-time simulation)"

 "3D simulation 1 (finished part)"

 "TRANSMIT and peripheral surface transformation"

Order No. 6FC5800-0AM27-0YB0
Assignment of geometry axis to channel axis Machine axis number valid in channel
MD20050 MD20070
Assignment of geometry axis Machine axis number valid in
$MC_AXCONF_GEOAX_ $MC_AXCONF_MACHAX_
to channel axis channel
ASSIGN_TAB USED
Change to: Change to:
MD20050[0] = 1 MD20070[0] = 1
MD20050[1] = 0 MD20070[1] = 2
MD20050[2] = 2 MD20070[2] = 3
MD20070[3] = 4
MD20070[4] = 5
Geometry axis name in channel

Channel axis name in channel
MD20060 MD20080
Geometry axis name in chan-
$MC_AXCONF_GEOAX_ $MC_AXCONF_CHANAX_ Channel axis name in channel
nel
NAME_TAB NAME_TAB
Change to:
Change to:
MD20080[0] = X1
MD20060[0] = X MD20080[1] = Z1
MD20060[1] = Y MD20080[2] = C
MD20060[2] = Z MD20080[3] = CS3
MD20080[4] = Q
Notes

B120 Setup Turning
Rotary axis / spindle AX3: MCS1

MD30310 = 1 Modulo-transformation for rotary axis
AX4: MCS3
MD30300 $MA_IS_ROT_AX Rotary axis / spindle MD30310 = 1 Modulo-transformation for rotary axis
AX5: MQ1
Change to: MD30310 = 1 Modulo-transformation for rotary axis
AX3: MCS1
MD30300 = 1 axis is a rotary axis Modulo 360 degrees displayed for rotary axis or spindle
AX4: MCS3
MD30300 = 1 axis is a rotary axis MD30320 Modulo 360 degrees displayed
$MA_DISPLAY_IS_MODULO for rotary axis or spindle
AX5: MQ1
Change to:
AX3: MCS1
Modulo conversion for rotary axis / spindle
AX4: MCS3
MD30310 Modulo conversion for rotary MD30320 = 1 Actual value display Modulo
$MA_ROT_IS_MODULO axis / spindle
AX5: MQ1
Change to:
Assignment of spindle to machine axis Check of the set axes and spindles:
MD35000
Assignment of spindle to ma-
$MA_SPIND_ASSIGN_TO_
chine axis
MACHAX
Change to:
Description:
Definition of the spindle. The spindle is defined if the spindle
number is entered into this MD.
AX3: MCS1
(spindle S1)
AX4: MCS3
(spindle S3)
Notes

Setup Turning B120
Manufacturer Cycles Note:
The cycle PROG_EVENT.SPF is a standard Siemens cycle

For the individual matching the following cycles are included and should not be changed by the manufacturer. For the
in the standard cycle package: manufacturer cycles CYCPE1MA.SPF or CYCPE_MA.SPF,
the corresponding jump-out markers are prepared at the be-
ginning and at the end of PROG_EVENT.SPF.
CUST_TECHCYC.SPF For matching to the technological cycles.
At the beginning of the cycle PROG_EVENT
Standard cycle for the support of the functionality of: -  CYCPE1MA in the directory CMA
PROG_EVENT.SPF
• Block search when milling is activated At the end of the cycle PROG_EVENT
• Turning and indexing plane  CYCPE_MA.SPF in the directory CMA
• Tool indexing
For these cycles templates are not available. If the
CYCPE1MA.SPF and CYCPE_MA.SPF manufacturer cycles
are loaded in the NC, the program branches from
PROG_EVENT to the manufacturer cycles as appropriate.
Manufacturer cycle CUST_TECHCYC.SPF
The manufacturer‘s cycle CUST_TECHCYC.SPF is called up

by the
 ShopTurn cycles
 Standard cycle CYCLE92 (roughing)
Jump markers (_M1 to _M142), some of them already pre-

pared with entries, have been provided in the cycle
CUST_TECHCYC.SPF. These entries must be made to suit
the machine by the manufacturer. A listing of the jump mark-
ers together with a brief description will be found on the next
page. Further details can be found in the sections "JOG-
TSM", "Block search" and "Clamping jaws, chucks, part grip-
per and tailstock".
1. Copy the cycle CUST_TECHCYC.SPF from the directory /

NC-Data / Cycles / Standard cycles.
2. Paste in the Cycle CUST_TECHCYC.SPF in to following
directory: /NC-Data/Cycles/Manufacturer cycles
Notes

B120 Setup Turning
Extract from the CUST_TECHCYC.SPF Implementation of the matching
In the manufacturer‘s cycle CUST_TECHCYC.SPF the fol-

lowing jump-to markers have been prepared.
 Switching between spindle and C-axis mode of the

main spindle: _M1, _M2
Tool spindle: _M11, _M12
Counter spindle: _M21, _M22
 Spindle clamping and unclamping:

Main spindle: _M3, _M4
Tool spindle: _M13, _M14
Counter spindle: _M23, _M24
 Chuck flushing, opening and closing:

Main spindle: _M5, _M6, _M7, _M8
Counter spindle: _M25, _M26, _M27, M28, _M29
 Axis of the counter spindle after block search:

_M30
 Coupling and un-coupling of the driven tool

(engaging / disengaging the drive):
_M41, _M42
 Configuration of special functions when switching be- Setting-up for turning

tween the machining planes (no settings are neces-
Matching of the Coordinate systems to the user interface
sary here for TRACYL or TRANSMIT with the C–axis.)
_M61 to _M68
 Positioning the part receptacle for cut-off operations,

moving it in and out. Coordinate system position
_M100, _M101, _M102
MD52000
$MCS_DISP_COORDINATE_ Coordinate system position
 Configuration of special functions for tool changing SYSTEM
(these special functions will be called up after the
T-command has been put out.) Change to: 34
_M110, _M111, _M112, _M113, _M114
Description:
 Settings for coupling of the main and counter spindle
With this MD you adapt the operator panel of the coordinate
_M120
system
to the machine's coordinate system. Depending on the select-
 Setting of specific aspects for starting and ending the ed
program position, all help screens, the simulation graphics, the simula-
_M131, _M135, _M136 tion and the input fields with the circular direction specified
will change automatically.
 Setting of specific aspects for the tool change after
block search:
_M140, _M141, _M142
Notes

Setup Turning B120
The Coordinate system can take one from the shown posi-
tions.
Typical settings are:

34: Horizontal lathe with machining behind the turning centre
(sloping bed turning machine)
33: Horizontal lathe with machining in front of the turning cen-
tre (flat bed turning machine)
0 = Vertical lathe (round-about turning machine) right hand
head
6 = Vertical lathe (round-about turning machine) left hand
head
Selection table of the possible Coordinate systems
Plane selection Milling and Turning The machining planes are specified as shown:
MD52005
Plane selection Milling
$MCS_DISP_PLANE_MILL Plane Machining
Change to: 0 Boring/milling

X/Y
front G17
Turning
MD52006 Z/X
Plane selection Turning G18
$MCS_DISP_PLANE_TURN
Boring/milling
Change to: 18 Y/Z
mantle G19
Description:
Turning operation: The machining plane is set permanently to
G18.
Boring and milling operations: In the standard cycles the ma-
chining plane can be set by means of the parameter PL. In
the ShopTurn cycles the setting of the MD52005 has no ef-
fect.
Notes

B120 Setup Turning
Technology Extended technology
MD52200 MD52201
Technology $MCS_TECHNOLOGY_EXTE Extended technology
$MCS_TECHNOLOGY
NSION
Description: If driven tools are available, it is at this stage possible to also

activate the milling technology in addition to turning..
0: No specific configuration
1: Turning
Description:
2: Milling
Please also note MD 52201 0: no specific configuration
$MCS_TECHNOLOGY_EXTENSION. 1: Turning
2: Milling by means of driven tools with
The selection of 1 specifies turning as the main technology. TRANSMIT/TRACYL
This means, the Softkeys for turning will be shown along the
lower edge of the screen. Example:
Turning machine with milling technology
MD 52200 $MCS_TECHNOLOGY = 1
MD 52201 $MCS_TECHNOLOGY_EXTENSION = 2
The Softkey "milling" will be shown as well.

The Softkey boring is also shown if there are no driven tools.
In this case, however, only concentric drilling with a fixed drill
is possible.
Meaning of the axes in the channel Axis attributes
MD52206[x] Meaning of the axes in the MD52207[x]

Axis attributes
$MCS_AXIS_USAGE channel $MCS_AXIS_USAGE_ATTRIB
Change to: [2] = 3 Change to: Bit 3 = 0

[3] = 1 Bit 4 = 0
Bit 5 = 0
MD52206[2] = 3 Main spindle C
MD52206[3] = 1 Tool spindle CS3 MD52207[2] C
Description: Bit 3 = 0: C+ Direction of rotation clockwise when looking

towards the spindle head.
0 = no specific meaning
1 = Tool spindle (driven tool) Bit 4 = 0: M3 is clockwise when looking towards the spindle
2 = C-axis of the Tool spindle (driven tool) head
3 = Main spindle (turning)
4 = C-axis of the main spindle (turning) Bit 5 = 0: M3 means C+ direction
5 = Counter spindle (turning)
6 = C-axis of the counter spindle (turning) Note:
7 = Linear axis of the counter spindle (turning)
8 = Tailstock (turning) If there is a separate C-axis drive, the entry for Bit 3 must be
9 = Steady (turning) made in the data set of that drive.
10 = B-axis (Turning)
12 = B axis of the counter spindle (turning)
Notes

Setup Turning B120
Description: Specifying the direction of rotation

Bit 3: Positive direction of rotation is counter-clockwise (for
In order for the direction of rotation of the spindle and the C-
rotary axes)
axis to be shown correctly in the ShopTurn user interface and
to ensure that the correct direction of rotation is carried out
when programming ShopTurn functions, some settings must
clockwise (for spindles)
be made that correspond with one another. In this case the
settings must be chosen according to the actual direction of
Bit 5: Direction of rotation M3 corresponds to rotary axis mi-
rotation of the spindle/C-axis of the machine.
nus (for spindles).
This Bit must be set in the same way as PLC interface
In case of C-axis operation with the main spindle
signal “Invert M3/M4”.
For 840D sl: PLC bit DBnn.DBX17.6, nn = 31 + ma- The assignment of the direction of spindle rotation (M3/ M4)
chine axis index to the positive direction of rotation of the C-axis is obtained
For 828D: PLC bit DB38xx.DBX2001.6, xx is machine from the PLC interface signal “Invert M3/M4” of the respective
axis index C-axis.
Bit 4 determines, whether M3 and C+ rotate in the same di-
rection (= 0) or in opposition (= 1). It must be ensured under
all circumstances that Bit 5 is identical to PLC interface signal
“Invert M3/M4”!
2 possible configurations: Our example machine:
 spindle and C-axis with a drive The machine features no separate drives for the spindle and
for the C-axis. This means that the settings in machine datum
 Separate C-axis drive 52207 must be entered according to the axis index for the
main spindle (Index [2]).
Notes

B120 Setup Turning
From this derive the following setting possibilities for the main spindle. The settings for the machine data, however, depend on
the direction of viewing the coordinate axis.
No matter as to which of the four combinations of MD52207[2] Bit 3 und Bit 4 shown below the machine manufacturer selects, it
is imperative that the settings shown in one line for PLC interface signal “Invert M3/M4” and MD52207[2] Bit 5 are used.
52207[2] C 52207[2] C PLC bit C 52207[2] C

Rotation dir. of the main spindle Bit 3 Bit 4 “Invert M3/M4“ Bit 5
0 0 0 0
0 1 1 1
1 1 0 0
1 0 1 1
The setting of the machine datum MD52207 Bit 3 requires that viewing takes place in the direction of the negative Z axis. If, how-
ever, you prefer to view in the positive Z axis direction, the values must be reversed; i.e. "0" and "1" must be exchanged.
Note:
The MD52207[2] of the main spindle is relevant for
 the readout of the spindle direction in the T,F,S window
 the readout within simulation simultaneous recording
 the rotation direction of the spindle after tool change according to the direction given in the tool list
Notes

Setup Turning B120
Function mask display Bit 0 = 0:

In a ShopTurn program it is
possible to select "mm dimen-
MD52210 sions" or "inch dimensions" in
$MCS_FUNCTION_MASK_ Function mask display the program header.
DISP
Default: Bit 0 = 1 Bit 0 = 1:
Change to: The selection field “Unit of
Bit 1 = 1
meas.” is hidden. The measur-
ing system for programs is
Description: always in the base system.
Bit 0: Meas. system for programs always in the base system
Bit 1: Face view when turning in the school coordinate sys-
tem
Bit 2: Hide "T,S,M" softkey in the JOG area
Bit 3: Generate automatic end-of-program in MDI (with Soft-
key "Delete blocks")
Bit 4: Show follow-on-tool in T,F,S-window
Bit 1=0: Display of the coordinate system when machining the Bit 1=1: Display of the coordinate system during face machin-
front face (G17) ing (G17) in the ordinary Coordinate system
The display of the axis directions depends on the set- The axis direction are always displayed in the ordinary
ting for the position of the coordinate system in MD coordinate system independently of the setting of the
52000 $MCS_DISP_COORDINATE_SYSTEM; in this machine datum 52000
example = 34 for a horizontal lathe with machining be- $MCS_DISP_COORDINATE_SYSTEM.
hind the turning centre.
Notes

B120 Setup Turning
Continuation MD52210 Bit 4=0: The follow-up tool is not shown in the T,F,S-window
Bit 2=0: The Softkey "T,S,M" is shown in the mode JOG .

This setting is in line with the basic setting of Shop-
Turn
Bit 2=1: The Softkey "T,S,M" is hidden in the mode JOG. Bit 4=1: The follow-up tool is shown in the T,F,S-window.
This setting makes sense only in conjunction with
tool prepare on a machine featuring a double grasp-
er. In the configuration chosen for this example the
display of the follow-up tool is not possible.
Bit 3=0: Under MDA the command End-of-program will not

be generated automatically after "Block delete".
Bit 3=1: Under MDA the M-command entered in MD 10714

$M_NO_FCT_EOP will automatically be generated
as End-of-program command after "block delete". In
this example configuration it is M32.
Function mask Cross-technology Bit 0 and Bit 1 are meaningless for the machine configuration
used here. These Bits are used in the technology Turning in
conjunction with a B-axis kinematics.
MD52212
$MCS_FUNCTION_MASK_
technology
TECH
Bit 5 = 0 Bit 2 = 0 Bit 2 = 1 (Step drill)
Description:
(ShopMill/ShopTurn) D2
Bit 3: Call block search cycle for ShopMill/ShopTurn D1
The current cutting edge The longest cutting edge in
will be taken into account direction of the active cutting
Bit 6: Work offset ZV cannot be entered as an absolute value
when retracting. edge is taken into account
(ShopTurn)
when retracting.
Notes

Setup Turning B120
Continuation MD52212 Bit 5 = 0 Bit 5 = 1

Block search cycle for The standard cycle CY-
SERUPRO will not be CLE207 will be called up
called up. after Block search with SE-
RUPRO.
The setting of Bit 3 is not

effective in this case. The
The setting = 0 is provided F_S-ASUP will not be called
for single-channel Shop- up.
Turn machines.
This setting must be used
only for multi-channel ma-
Bit 3 = 0 Bit 3 = 1 chines.
The ShopTurn cycle The ShopTurn cycle

F_S_ASUP is not carried F_S_ASUP will be carried out
out after block search. after block search. Details
Bit 6 = 0 Bit 6 = 1
regarding this setting are
contained in the section
"Block search". In the program header of a In the program header of a
ShopTurn program the param- ShopTurn program the pa-
eters "Description of zero rameters "Description of
point offsets" and "ZV" appear zero point offsets" and "ZV"
and the operator can choose will not appear.
Bit 4 = 0 Fixed value (ShopTurn only) whether the zero point offset
is to be described.
MD52214
$MCS_FUNCTION_MASK_ Function mask Milling
MILL
Description:
chines)
Notes

B120 Setup Turning
Continuation MD52214 Usage
Bit 3 = 1 Release of machining internally/at the rear 1. Machining at the rear refers to the face of the work piece
opposite the front face. The work piece must be clamped
in such a manner that machining on the rear using the
Machining at rear Machining internal required tool is possible on the rear of the work piece. The
infeed along the Z-axis (e.g. drilling depth) is in the positive
direction.
HSP HSP
2. Internal machining is possible on large internal work piece
diameters using a suitable tool. The infeed along the X-
axis (e.g. drilling depth) takes place in the positive direc-
tion.
With the release of "machining internally/at rear" an additional Boring: Clamping OFF
input parameter appears in the boring, milling and position
masks depending on the face to be machined.
Axial face: front / rear Boring: Clamping ON
Milling: Plunging with

clamping OFF
Mantle: external / internal
Bit 4 = 1: Enable spindle clamp (C-axis)
With the release of the spindle clamping an additional input

parameter will appear in the boring and milling masks
"clamping OFF / clamping ON" .
Milling: Plunging with

clamping ON
Notes

Setup Turning B120
Function mask Drilling MD52216 Bit 0 = 0 Technology fields will not be shown
MD52216
$MCS_FUNCTION_MASK_ Function mask Drilling
DRILL
Description:
Bit 0: CYCLE84 Show technology fields (without compensat-
ing chuck)
Bit 1: CYCLE840 Show technology fields
The selection "with compensating chuck (CYCLE840)"
is not available for ShopTurn.
Note: The release of the technology requires an axis

optimization!
MD52216 Bit 0 = 1 Technology fields are being shown Function mask Turning
MD52218
$MCS_FUNCTION_MASK_ Function mask Turning
TURN
Description:
Bit 0: Enable zoom under manual for tool measurement
Bit 1: Enable parts gripper for cut-off
Bit 2: Enable Tailstock
Bit 3: Enable spindle control of main spindle via surface (only
Manual machine)
Bit 4: Enable spindle control of tool spindle via surface (only
Manual machine)
Bit 5: Enable spindle control of counter spindle via surface
(only Manual machine)
These settings for bit 3 to 5 are reserved for the Manual ma-
chine function, MD52212 bit 8 = 1.
Notes

B120 Setup Turning
Continuation MD52218 When "Yes" a further param-

eter "XM" (Depth parts grip-
per extend) appears.
Bit 1 = 0 Bit 1 = 1
In the mask "Cut-off" the In the mask "Cut-off" the pa-
parameter "Parts gripper" rameter "Parts gripper" is
is not shown". being shown".
When the parts gripper is released, there will be jumps from Extract from the Manufacturer‘s cycle CUST_TECHCYC.SPF
the machining cycles for the cut-off to the Manufacturer‘s with the modes 100 - 102, which have been provided for the
cycle CUST_TECHCYC.SPF parts gripper. At this point the machine manufacturer can
- ShopTurn program: Mode 100, 101 and 102 undertake the machine-specific matching.
- ProgramGuide program. Mode 101 and 102
 Mode 100. Positioning the parts gripper before the cut-off

This call-up occurs only with a ShopTurn-Program, if prior
to the cut-off the tool has been positioned (the axis is still at
the retraction level).
 Mode 101. Extending the parts gripper before the cut-off

This jump occurs if the X-axis has attained the position de-
fined under XM for the cut-off.
 Mode 102. Closing the parts gripper after the cut-off.

This jump occurs when the X-axis during the cut-off has
attained the end-position as defined under X2.
Notes

Setup Turning B120
Continuation MD52218 Bit 2 = 1 Tailstock released
Bit 2 = 0 Tailstock not released
Description:
Bit 0: Tool pre-selection active
Bit 1: Calculate thread depth from metric thread lead

Directly after the exchange has been completed, the
tool will be prepared
The generation of the follow-up tool occurs only with
JobShop cycles
Bit 1: Automatic evaluation of the thread depth for metric
threads
Bit 2: Transfer thread diameter and thread depth from table.
SD55212
$SCS_FUNCTION_MASK_
technology
TECH_SET
Default Bit 1 = 1
Change to:
Bit 2 = 1
Notes

B120 Setup Turning
Continuation SD55212
Bit 1 = 0 The thread depth will not be evaluated automatically

The value for the thread depth "H1" must be entered manual-
ly from a table.
Bit 1 = 1 The thread depth will be evaluated from the metric

thread pitch.
Only if in the table the column "without" is selected and for P

the unit "mm/rev" will the thread depth "H1" in the yellow-
backed fields be evaluated automatically. These automatical-
ly obtained values can be overwritten by the operator. If the
thread pitch is entered again, the thread depth will be evaluat-
ed once more automatically.
Different factors are stored for the internal and external

threads:
- Internal threads: 0,5413
- External threads: 0,6134
Bit 2 = 1 Thread diameter and depth from a table
As soon as the line table "ISO metric" is selected, the table is


chosen thread.
Notes

Setup Turning B120
Continuation SD55212
Bit 2 = 1 Thread diameter and depth from a table
As soon as the line table "ISO metric" is selected, the table is


chosen thread, the value H1 being the thread depth.
Function mask Milling Bit 0 = 1 Default setting for milling down-cut
SD55214
$SCS_FUNCTION_MASK_ Function mask Milling
MILL_SET
Default: Bit 0 = 1
Change to:
Bit 2 = 1
Description:
Bit 0: Default setting for milling with synchronous operation
Bit 1: Not assigned
SC
Bit 0 is used as setting for the initial commissioning. If there-

after the program header for milling is opened, the
toggle key can be used to select between climb milling
and conventional milling. The selection made here
remains activated.
Notes

B120 Setup Turning
Continuation SD55214 Note:

The safety gap is specified in the program header.
Bit 2 = 0 Bit 2 = 1
The subdivision of cuts in The subdivision of cuts in
direction of infeed is ob- direction of infeed is ob-
tained including the safety tained without the safety
gap SC for mantle and gap SC for mantle and Function mask Drilling
face milling for the path face milling for the path
from Z0+SC to Z1. from Z0 to Z1.
SD55216
$SCS_FUNCTION_MASK_ Function mask Drilling
DRILL_SET
Default: Bit 3 = 1
Change to:
Bit 4 = 1
Description:
Bit 0: Reserved
Bit 1: Boring CYCLE86: Taking into account the rotation of
the work piece plane when positioning the spindle
Bit 2: Boring CYCLE86: Taking into account the indexed
table kinematics (tool carrier) when positioning the
spindle
Bit 3: Tapping CYCLE84: (without compensating chuck).
Bit 0: Reserved
Monitoring the machine data 31050[x] and 31060[x] of
the spindle
Bit 1 = 1: Taking into account the rotation of the tool plane
Bit 4: Tapping CYCLE840: (with compensating chuck). Moni- (CYCLE 86)
toring the machine data 31050[x] and 31060[x] of the In the cycle CYCLE86 Boring the spindle is po-
spindle sitioned on the parameter SPOS when reaching
the boring depth. If SPOS=0 the tool cutting
Bit 5: Reserved
edge points in the positive direction of the 1st
axis of the plane (G17 towards X+).
The denominator of the gearbox is contained in MD31050[x]
while MD31060[x] contains the numerator. Together the two
If the setting is varied by using Bit 1 = 1, a rota-
provide the gear ratio for the spindle. This is required for
tion about the tool axis (e.g. ROT Z180) will be
monitoring the feed obtained from the speed x the pitch.
taken into account for the spindle positioning.
Bit 2 = 1: Taking into account indexed table kinematics

(CYCLE 86)
See description Bit 1
With the selection of Bit 2 = 1 an indexed kine-
matics will be taken into account when position-
ing the spindle.
Notes

Setup Turning B120
Continuation SD55216 Function mask Turning
Description: SD55218
$SCS_FUNCTION_MASK_ Function mask Turning
Bit 3 = 1: Tapping CYCLE84: Monitoring the machine data TURN_SET
31050 $MA_DRIVE_AX_RATIO_DENOM (divider
of gearbox ratio) and 31060 Default: Bit 0 = 1 Change to:
$MA_DRIVE_AX_RATIO_NUMERA (numerator of
gearbox ratio) of the spindle for the boring axis.
Description:
The monitoring is activated only if MD35590
$MA_PARAMSET_CHANGE_ENABLE = 2 Bit 0: New thread table for thread cutting
This setting permits a parameter block change by Bit 1: Reserved (CYCLE93)
the PLC-interface or by the command SCPARA
(servo parameter block programming). Bit 2: Reserved (CYCLE93)
If the monitoring is activated the alarm 61127
[Channel %1: ] Block %2 (gear ratio of the tapping Bit 0: For the types of thread ISO metric, Whitworth BSW,
axis incorrectly defined) will be set: Whitworth BSP and UNC a table is included, which will
be used when this Bit is activated.
Bit 4 = 1: Similar to Bit 3, however, for the cycle CYCLE840
Bit 5: Reserved
Cycle settings Return distance stock removal for external machining
Roughing feedrate for complete machining in % SD55505

Return distance stock removal
$SCS_TURN_ROUGH_O_
for external machining
RELEASE_DIST
SD55500
Roughing feedrate for com- Default: 1mm Change to:
$SCS_TURN_FIN_FEED_
plete machining in %
PERCENT
Description:
Default: 100% Change to:
This setting datum states the
distance parallel to the axis by
Description: which the tool will be retracted
When complete machining has been selected (roughing and during machining. If the safety
finishing) the percentage specified in this datum will be used distance specified in the pro-
for the finishing feedrate F . gram is less than this setting
datum, then the safety dis-
The selection complete machining (roughing in finishing) is tance will be applicable.
only available in technology turning:
 Grooving cycles “Groove 1”, “Groove 2” and “Groove 3” -1: Retraction will always take
place by the safety distance
 Undercut cycles “Thread DIN” and “Thread” SC specified in the program
 Thread cycles “longitudinal”, “taper”, “face” and “chain” header.
This setting datum is effective

only for the roughing cycles
1-3 and not during contouring.
Notes

B120 Setup Turning
Return distance stock removal for internal machining Description:

This setting datum states
SD55506 the distance parallel to the
Return distance stock removal axis by which the tool will
$SCS_TURN_ROUGH_I_
for internal machining be retracted during ma-
RELEASE_DIST
chining. If the safety dis-
Default: 0,5mm Change to: tance specified in the pro-
gram is less than this set-
ting datum, then the safety
distance will be applicable.
-1: Retraction will always

take place by the safety
distance SC specified in
the program header.
This setting datum is effec-

tive only for the roughing
cycles 1-3 and not during
contouring.
Tool clearance time for grooving at the base (neg. val- Contour turning: Retraction angle
ue=rotations)
SD55580
Contour turning: retraction
$SCS_TURN_CONT_
SD55510 Tool clearance time for groov- angle
RELEASE_ANGLE
$SCS_TURN_GROOVE_ ing at the base (neg. val-
DWELL_TIME ue=rotations) Default: 45Grad Change to:
Default: -1s Change to:
Description:
Description: This setting datum specifies
If in the course of a cycle, e.g. plunging and extended rough- the angle at which the tool is
ing (CYCLE952) a dwell period is included, then the value of lifted off the surface when
this setting datum will be used. roughing during contouring.
 negative Value: Dwell in spindle revolutions
 positive Value: Dwell in seconds
Notes

Setup Turning B120
Contour turning: retraction value Contour turning: minimum angle for rounding along con-
tour
SD55581
Contour turning: retraction
$SCS_TURN_CONT_ SD55582 Contour turning: minimum
value $SCS_TURN_CONT_TRACE_ angle for rounding along con-
RELEASE_DIST
ANGLE tour
Default: 1mm Change to:
Default: 5Grad Change to:
Description:
Description:
This setting datum specifies
the distance, by which the tool This setting datum specifies
is lifted off the surface in both the angle between cutting
directions when contouring. edge and the contour as from
which the cutting depth is var-
ied such as to remove any
remaining material.
Contour turning: percentage for variable cutting depth Contour turning: Blank allowance
SD55583 SD55584
Contour turning: percentage Contour turning: blank allow-
$SCS_TURN_CONT_ $SCS_TURN_CONT_BLANK_
for variable cutting depth ance
VARIABLE_DEPTH OFFSET
Default: 20% Change to: Default: 1mm Change to:
Percentage for variable cut- This setting datum states the distance (machining allowance)
ting depth when contouring. of the raw material as from which switching from G0 to G1
The variable cutting depth can takes place during contouring, in order to compensate for
be selected for roughing and possible blank allowances.
residual material removal.
Notes

B120 Setup Turning
Contour turning: Feed interrupt time (neg. values = revo- Contour turning:
lutions) Retraction after feed interrupt
SD55585 Contour turning: feed interrupt SD55586

$SCS_TURN_CONT_ time (neg. values = revolu- Contour turning: Retraction
$SCS_TURN_CONT_
INTERRUPT_TIME tions) path after feed interrupt
INTER_RETRACTION
Default: -1s Change to: Default: 1mm Change to:
Feed interruption times during Retraction path feed interrupt during contour turning, contour
contouring, contour grooving grooving and plunge turning:
and plunging
R>0: retraction path after feed interrupt (the setting datum
 Negative Value: feed inter- 55585 $SCS_TURN_CONT_INTERRUPT_TIME is now inef-
ruption in revolutions fective!)
 Positive Value: feed inter- =0: no retraction path
ruption in seconds
This setting datum is effective
only if the setting datum
55586
$SCS_TURN_CONT_INTER_
RETRACTION equals 0.
Contour turning: minimum difference dimension residual Contour turning: minimum difference dimension residual
machining axis 1 machining axis 2
SD55587 Contour turning: minimum SD55588 Contour turning: minimum

$SCS_TURN_CONT_MIN_ difference dimension residual $SCS_TURN_CONT_MIN_ difference dimension residual
REST_MAT_AX1 machining axis 1 REST_MAT_AX2 machining axis 2
Default: 50% Change to: Default: 50% Change to:
This MD defines the limit value for stock removal of residual This MD specifies the limiting value for the removal of residu-
material in the direction of the 1st axis. al material in the direction of the 2nd axis.
Example: Example:
If the MD is set to 50% and the finishing allowance is 0,5 mm, If this MD is set to 50% and the finishing allowance is 0.5mm,
the residual material, which is thinner than 0.25mm, will not any residual material thinner than 0.25mm will not be re-
be machined in a separate pass, instead it will be removed moved by means of an extra pass, instead it will be removed
with the finishing pass. together with the finishing pass.
Note: Note:
If residue machining is programmed and the residual material If residue machining is programmed and the residual material
is less than defined in the setting data 55587 and 55588, in is less than specified in the setting data 55587 and 55588, in
other words there is no residual material, the alarm 61732 "no other words there is no residual material during roughing, the
residual material" will appear.. alarm 61732 "no material to be machined" will appear.
Notes

Setup Turning B120
Contour plunge turning: Retraction path due to tool

bending
SD55595
Contour plunge turning: retrac-
$SCS_TURN_CONT_TOOL_
tion path due to tool bending
BEND_RETR
Default: 0,1mm Change to:
Description:
Due to the bending of the tool when grooving it is not possible
to traverse right up to the contour during roughing. This SD
specifies the lateral distance to the previous cut, by which the
successive cut will be shortened each time.
The sketch right illustrates the settings for the setting data
55595 and 55596.
a: Bending of the tool = Distance to the previous cut =

SD55595
b: Tool length difference due to the bending of the tool = Re-

traction between grooving (plunging to the next depth) and
roughing (turning operation) = SD55596
Contour plunge turning: Retraction depth prior to turning Upper limit feedrate/min
SD55201
SD55596 $SCS_MAX_INP_FEED_PER_ Upper limit feedrate/min
Contour plunge turning: retrac- TIME
$SCS_TURN_CONT_TURN_
tion depth prior to turning
RETRACTION
Default: 0,1mm Change to:
Description:
Description: Feedrate input upper limit for mm/min
Retraction between grooving and turning in order to compen-
sate for the difference in tool length caused by deflection of
the tool (see sketch under SD55595).
Upper limit feedrate/tooth
Upper limit feedrate/rev SD55202

$SCS_MAX_INP_FEED_PER_ Upper limit feedrate/tooth
SD55200 TOOTH
$SCS_MAX_INP_FEED_PER_ Upper limit feedrate/rev
REV Default: 1 mm Change to:
Default: 1 mm/U Change to:

Description:
Description: Feedrate input upper limit for mm/tooth
Feedrate input upper limit for mm/rev
Notes

B120 Setup Turning
Setting up the tool list In the JobShop tool list there are input fields for coolant 1 and
coolant 2 for each tool. The select key can be used to toggle
the function "Coolant ON/OFF". The respective M-functions
These settings are applicable only to JobShop programs.
are put out if the tool is changed by means of the part-
program, The M-commands will not be put out if the tool is
Enable fast M functions exchanged by means of the T,S,M mask.
MD52229
$MCS_ENABLE_QUICK_M_ Enable fast M functions
CODES
Description:
Bit 0: Enable fast M functions: coolant OFF
Bit 1: Enable fast M functions: coolant 1 ON
Bit 2: Enable fast M functions: coolant 2 ON
Bit 3: Enable fast M functions: coolants 1 and 2 ON
This MD is used to declare the commands used for the cool-

ant control (see MD52230 - MD52233) as being fast M-
commands (M=QU…). In case of fast commands the program
progress continues without waiting for the acknowledgement
of the M-command by the PLC.
M code for all coolants OFF M code for coolant 2 ON
MD52230 MD52232
$MCS_M_CODE_ALL_ M code for all coolants OFF $MCS_M_CODE_COOLANT_2 M code for coolant 2 ON
COOLANTS_OFF _ON
Default: 9 Change to: Default: 7 Change to:
M-Code for all coolants OFF M-Code for coolant 2 ON
M code for coolant 1 ON
MD52231
$MCS_M_CODE_COOLANT_1 M code for coolant 1 ON
_ON
Description:
M-Code for coolant 1 ON
Notes

Setup Turning B120
M code for both coolants ON Function mask Tool management
MD52233 MD52270 Function mask Tool manage-

$MCS_M_CODE_COOLANT_ M code for both coolants ON $MCS_TM_FUNKTION_MASK ment
1_AND_2_ON
Description:
Description: Bit 0: Create tool on a magazine location not permitted. Tools
M-Code for Coolant 1 + 2 ON can only be created outside the magazine.
Already defined: M8 = Coolant 1 ON Bit 1: Loading/unloading is not possible while the machine is
M7 = Coolant 2 ON not in Reset.
Tools can only be loaded or unloaded if the respective
If in the JobShop tool list both coolants have been selected, channel is at rest.
the following M-command will be put out.
Bit 2: Loading/unloading locked during emergency OFF
-1: M-command for coolant 1 OFF is MD52231 and M- Tools can only be loaded or unloaded if the Emergency
command for coolant 2 OFF is MD52232 OFF is not activated.
>0: the M-command selected in this MD. Bit 3: Loading/unloading tools to/from spindle disabled.
A separate M-command for both coolants is to be used if Tools cannot be loaded to or unloaded from the
the M-commands for coolant 1 and coolant 2 are grouped spindle.
in an M-commands group, however both coolants are to
be activated after a block search.
Bit 4: Loading takes place in the spindle directly. Bit 10: Reactivate tool using Position magazine. Prior to re-
The tools are only loaded exclusively in the spindle. activating the tool is positioned at the loading position.
Bit 5: Use grinding configuration file for creating the tool list. Bit 11: Reactivate tool in all monitoring modes. When re-
Only grinding tools are offered. activating a tool, all monitoring modes enabled in the
NC are reactivated for this tool, even the monitoring
Bit 6: Relocating a tool to/from the buffer (spindle/gripper) is modes, which have not been set for the relevant tool,
permitted desoite a block (see bit3) but are available in the background only.
Bit 7: Create tool using the tool number. Specify the tool's Bit 12: Hide 'Tool re-activation'
T-number when creating the tool. The function "Tool re-activating" is suppressed on the
Note: This function is intended for machines with tool user interface.
management but without magazine configuration. The
default setting must not be changed. Note:
This MD must be matched to the circumstances of the ma-
Bit 8: Hide 'Re-locate tool'
chine. By hiding those functions on the user interface that are
The function 'Re-locate tool' is suppressed on the user
not applicable to the machine, the PLC can be spared unnec-
interface.
essary actions to prevent operation errors..
Bit 9: Hide 'Magazine positioning'
The function 'magazine positioning' is suppressed on
the user interface.
Notes

B120 Setup Turning
Load station Tool management Function mask tool management
MD52274 SD54215
Load station Tool manage- Function mask Tool manage-
$MCS_TM_TOOL_LOAD_ $SNS_TM_FUNCTION_MASK
ment ment
STATION _SET
Default: 0 Change to: Default: 0H Change to: Bit 0 = 1
If more than 1 loading station is configured, a pop-up window Bit 0: Diameter display for rotating tools
appears when a tool is created with a query in which station It is not the radius value, but the diameter value that is
the tool is to be loaded. shown for rotating tools.
= 0: If a query window is on the user interface or if only one Bit 1: Default direction of rotation for all turning tools is M4
loading station is available there will be no pop-up win- When turning tools are created, the direction of rotation
dow is preset to M4.
= 1: fixed loading station 1, the window does not appear Bit 2: Create tool without name proposal
When creating a new tool the input field for the tool
= 2: fixed loading station 2, the window does not appear name remains empty.
If only one loading station is configured: The setting = 0 Bit 3: Input disable for tool name and tool type of loaded
In the turning machine configuration described here there is tools.
only one loading station is configured. The query on the right Tool name and tool type cannot be changed for loaded
regarding the selection of the loading station does not ap- tools.
pear.
Description: Bit 8: Diameter display for transverse axis - Geometry

Bit 4: Input disable for loaded tools, if the channel is not in The geometry value of the transverse axis is shown as
Reset. a diameter value.
While the program is in progress the data for loaded
tools cannot be changed. Bit 9: Diameter display for transverse axis - Wear
The wear value of the transverse axis is shown as
Bit 5: Calculate tool wear inputs additively diameter value.
The input of wear data will be added to any existing
wear values. Bit 10: Enable loading/ relocating of tools on buffer location
The magazine number can be entered in the loading
Bit 6: Numerical input of the tool ident dialog. This permits access to the buffer station using
No name will be assigned to a new tool being created. the magazine number 9998.
Only numerical characters are permitted .
Bit 11: Creation of new tools in gripper location is disabled.
Bit 7: Fade out tool monitoring parameter
The tool monitoring parameter will not be shown on the
user interface.
Notes

Setup Turning B120
Continued SD54215 Bit 0 = 1 Diameter readout for rotating tools
Bit 0 = 0 permanent radius readout for all tools
Description:
As soon as the cursor is moved to a line with a rotating tool,
the term 'Radius' in the header line will be replaced by a di-
ameter symbol.
Bit 1 = 1 M4 Tool 14 has been newly created Checking the tool management
Bit 1 = 0 M3 Tool 15 has been newly created
Marked tools can be off-loaded. As soon as the cursor beam

is moved to a free magazine location or below the magazine
the Softkey "New tool" appears for the creation of a new tool.
Notes

B120 Setup Turning
By horizontal scrolling the fields for the direction of rotation of

the tools and the selection of Coolant 1 ON/OFF and
Coolant 2 ON/OFF, appear.
The function Multitool, as selected with MD18080 Bit 10 is

also included in the selection list for the various types of tools
with cutting directions.
Basic settings Description:

Bit 0: Reset mode
Reset-resistant settings Bit 6: Active tool length compensation
Bit 14: Base frame
Bit 16: Master spindle
Definition of basic control settings after reset/PP end
The Bits 4 and 16 are only evaluated if Bit 0 = 1.
Meaning of the individual Bits:

MD20110 Definition of basic control set-
$MC_RESET_MODE_MASK tings after reset/PP end Bit 0 = 0:
Change to: Bit 0 = 1 - G-Codes as per $MC_GCODE_RESET_VALUES
Bit 6 = 1 - Tool length offset not active
Bit 14 = 1 - Transformation not active
- no coupled axes groupings active
- no tangential correction active
Description: - no axial rotational feed active
Determination of the basic control settings after booting and - path rotational feed with master spindle
Reset/End-of-part-program with respect to the G-codes (Default)
(especially the current plane and selectable zero-point offset),
tool length and transformation by the setting of the following Initial setting after Reset or after end-of-part-program :
bits: The current settings will be retained.
With the next part-program Start the following initial settings
will become active:
Notes

Setup Turning B120

Initial setting after Reset or after end-of-part program:
Depending on $MC_RESET_MODE_MASK Bit 6 to 7 the
- Transformation not active
current settings for
- No coupled-motion groupings active
- Tool length offset
- No tangential offsets active
- Transformation
- No master value couplings active
will either be retained or changed to the initial settings as
- No axial rotational feedrate active
stored in the MDs.
- Path rotational feedrate with master spindle
(Default)
Depending on Bit 8 and 9 the current settings of coupled mo-
tion axes or tangentially corrected axes will either be retained
Bit 0 = 1:
or switched OFF.
Projected synchronous spindle coupling:
- Tool length offset active as per
The coupling will be de-selected depending on the setting of
$MC_TOOL_RESET_VALUE,
$MC_COUPLE_RESET_MODE_1.
$MC_CUTTING_EDGE_RESET_VALUE and
$MC_SUMCORR_RESET_VALUE
Non-projected synchronous spindle coupling:
- Transformation active per $MC_TRAFO_RESET_VALUE
Depending on Bit 10 the coupling will either be switched OFF
- Geo axis replacement as per
or retained.
$MC_GEOAX_CHANGE_RESET
Depending on Bit 14 the initial frame will be retained or de-
- No coupled-motion groupings active
selected.
- No tangential correction active
Note:
Initial setting after reset or after end-of-part-program:
The setting of Bit 0 = 1 must be set for JobShop-uses,
Depending on the setting of $MC_GCODE_RESET_MODE
such that the settings of the Bits 4 and 16 can be evaluat-
the current settings for the G-groups will be retained or set to
ed.
the initial values stored in $MC_GCODE_RESET_VALUES.
Continued MD20110 However, it must be remembered that after the end of pro-
gram or a program interruption either the last programmed
Bit 6 = 0: value for the master spindle or master tool holder, or the val-
Initial setting for the active tool length offset after Reset/End- ue specified by $MC_SPIND_DEF_MASTER_SPIND or
of-part program as per $MC_TOOL_RESET_VALUE, $MC_TOOL_MANAGEMENT_TOOLHOLDER will determine
$MC_CUTTING_EDGE_RESET_VALUE, the master spindle or the master tool holder.
$MC_USEKT_RESET_VALUE and (The selection is made by Bit 16 or Bit 17.)
$MC_SUMCORR_RESET_VALUE.
Ist $MC_TOOL_CHANGE_MODE = 1, the tool specified by A special case is $MC_CUTTING_EDGE_DEFAULT = -2:
by $MC_TOOL_PRESEL_RESET_VALUE is additionally pre- If a tool has been changed on the spindle, but no new correc-
selected. tion D has been programmed, then the previous tool is still
If the tool and/or magazine management is active, it is not the active in the NCK.
datum $MC_TOOL_RESET_VALUE that is used, instead If an interruption takes place in this state, - e.g. by pressing
$MC_TOOL_RESET_NAME will be used. the reset key, the correction will be specified by the lowest D-
number of the tool in the master spindle.
Bit 6 = 1:
The current setting for the active tool length offset remains in Note:
force after reset/End-of-part-program. The setting Bit 6=1 is necessary to ensure that after a
If the tool and/or magazine management is active, that tool reset/End-of-part-program the previously programmed
will be selected which is presently loaded in the master spin- tool and the previously programmed cutting edge re-
dle (generally = master tool holder). mains activated (for instance, if the tool was changed via
If the tool in the master spindle happens to be blocked, the the T,S,M-mask) and if for example the JobShop-
"blocked"-status will be ignored. . functions in the mode of operation JOG "Zero point work
piece" or "Tool measurement" can be carried out with
this tool.
Notes

B120 Setup Turning
Continued MD20110 Note:

The setting of Bit 16 = 0 is important for ShopTurn-
Bit 14 = 0: machines. The following spindles are used on the ma-
The basic frame is cancelled chine as configured here:
- Main spindle
Bit 14 = 1: - Tool spindle
The current setting for the basic frame is retained. and in a further module
- Counter spindle
Note: The command SETMS(..) is used within cycles for ad-
The setting Bit 14 = 1 is necessary to retain the channel- dressing the spindles (M and S-command).
specific basic offset, which was activated with G500, af-
ter a Reset/End-of-part-program.
After activation of the basic offset (JOG-T,S,M-mask - The previously described settings in MD20110
zero point offset - basic reference) the values in the zero correspond to the further MD-settings in:
point offset base are transferred to the overall base Total
WO and then from there to be transferred for activation MD20120 $MC_TOOL_RESET_VALUE
also to the overall Total WO. MD20130 $MC_CUTTING_EDGE_RESET_VALUE
MD20150 $MC_GCODE_RESET_VALUES
Bit 16 = 0: MD20152 $MC_GCODE_RESET_MODE
Initial setting for the master spindle as per MD20140 $MC_TRAFO_RESET_VALUE
$MC_SPIND_DEF_MASTER_SPIND. MD20112 $MC_START_MODE_MASK
MD20121 $MC_TOOL_PRESEL_RESET_VALUE
Bit 16 = 1: MD20118 $MC_GEOAX_CHANGE_RESET
The current setting of the master spindle (SETMS) is re-
tained. This Bit in case of
$MC_TOOL_MANAGEMENT_TOOLHOLDER = 0 has also
an effect on the response of Bit 6.
Tool edge with length compensation during run-up Corresponds to:

(reset/end of pp) MD20110 $MC_RESET_MODE_MASK
MD20130 Tool edge with length com- Note:

$MC_CUTTING_EDGE_ pens. during runup (reset/end
RESET_VALUE of pp) This setting is necessary to ensure that after a reset/End-
of-part-program the previously programmed tool and the
Change to: 1 previously programmed cutting edge remains activated
(for instance, if the tool was changed via the T,S,M-mask)
and if for example the JobShop-functions in the mode of
Description: operation JOG "Zero point work piece" or "Tool measure-
ment" can be carried out with this tool.
Specification of the cutting edge, which depending on
MD20110 $MC_RESET_MODE_MASK and after part pro-
gram Start depending on MD20112
$MC_START_MODE_MASK is used to select the tool length
offset after booting and after Reset /End-of-part-program.
With active tool management and with Bit 0 and Bit 6 set in
MD20110 $MC_RESET_MODE_MASK at selection, the last
offset of the tool active at power OFF (as a rule the tool in the
spindle) is effective after booting.
Notes

Setup Turning B120
Initial setting of G groups Note:

$MC_GCODE_RESET_ Initial setting of G groups
VALUES
Change to: [5] = 2 MD20150[5] = 2 (exact)
[15] = 3 Group 6: Plane selection
[21] = 2 Value: 2 = G18
[28] = 2 The is the basic setting for turning.
[48] = 3
MD20150[15] = 3 (variable)
Group 16: Feedrate correction on internal and external
MD20150[5] = 2 (G18) curves
MD20150[15] = 3 (CFIN) Value: 3 = CFIN
MD20150[21] = 2 (CUT2DF) This setting provokes a constant feedrate on
MD20150[28] = 2 (DAIMON) internal curves and acceleration on external
MD20150[48] = 3 (PTPG0) curves.
Description: MD20150[21] = 2 (variable)
Specification of the G-Codes, which after booting and Reset/ Group 22: Tool correction type
End-of-part program are activated depending on Value: 2 = CUT2DF
MD20110 $MC_RESET_MODE_MASK and 2½-D-tool correction caused by Frame
MD20152 $MC_GCODE_RESET_MODE The tool correction acts relative to the current
as well as after part program Start depending on Frame (oblique plane)
MD20112 $MC_START_MODE_MASK.
MD20150[28] = 2 (exact)
Group 29: Radius/diameter programming
Value: 2 = DIAMON
Modal diameter programming ON
The effect is independent of the programmed
measuring mode (G90/G91).
The diameter programming is shown on the
user interface by means of a diameter symbol in
front of the X-axis readout.
MD20150[48] = 3 (variable)
Group 49: Point-to-point-motion
Value: 3 = PTPG0
Point-to-point-motion only with G0, otherwise
continuous path motion
Notes

B120 Setup Turning
Continued MD20150
Description:
The sketch below illustrates the setting PTPG0.
In the course of a facing operation travelling from one Point 1
to another Point 2 is intended.
When travelling at feedrate (G1) an interpolation between the
X-axis and the C-axis takes place. This results in the behav-
iour of the X-axis as shown in the lower sketch in that the axis
firstly travels from the starting point X1 in the minus-direction
(the distance towards the centre point reduces) to the point
XP and then from there in the plus-direction to the destination
Point X2. In conjunction with the interpolation with the C-axis
in effect a straight line is being traversed from Point 1 to Point
2. This behaviour corresponds to the programming of CP
(continuous path).
When travelling at rapid traverse rate (G0) the motion of the X

-axis first in the negative and then in the positive direction is
not very sensible. By the setting of PTPG0 the axis will move
directly from the starting point X1 to the destination point X2.
When projected onto the front face of the work piece this rep-
resents a spiral-like motion.
Notes

Setup Turning B120
Reset response of G groups Note:

Reset response of G groups
Change to: [5] = 0
MD20152[5] = 0 (exact)
[7] = 1
Group 6: Plane selection
[12] = 0
Value: 0
[14] = 1
A plane switch (e.g. G17 for facing) programmed
[15] = 0
in the part-program remains active after Reset/
[21] = 0
End-of-part-program.
Description: MD20152[7] = 1 (exact)

Group 8: Selectable zero point offset
This machine datum is evaluated only if in MD20110 Value: 1
$MC_RESET_MODE_MASK the Bit 0 is set. For each entry A zero point offset (e.g. G54) programmed in the
in MD20150 $MN_GCODE_RESET_VALUES (that is for part program remains active after Reset/End-of-
each G group) this MD is used to specify whether part-program. This permits for example the acti-
vation of a zero point offset in the mode-of-
= 0: in case of a Reset/End-of-part-program the setting as operation JOG_T,S,M-mask Parameter zero
per $MC_GCODE_RESET_VALUES is used again point offset.
or
= 1: the current setting is retained after Reset/End-of-part-
program
Description: MD20152[15] = 0 (exact)

Group 16: Feed correction on internal or external curves
MD20152[12] = 0 (exact) Value: 0
Group 13: Work piece dimensioning inch/metric After Reset/End-of-part-program the feed correc-
Value: 0 tion defined in MD20150[15] is activated once
In the user interface it is possible in the mode-of- more.
operation JOG Basic strip ">" Settings per Soft-
key "Switching Inch" to toggle the measuring MD20152[21] = 0 (variable)
system from metric to inch and vice versa. Group 22: Tool correction type
Value: 0
MD20152[14] = 1 (exact) After Reset/End-of-part-program the tool correc-
Group 15: Type of feed tion defined in MD20150[15] is activated once
Value: 1 more. CUT2DF in this configuration example.
The last type of feed G93 to G97 to be pro-
grammed remains active after Reset/End-of-part
-program.
In the user interface it is possible in the mode-of-
operation JOG - Position to position the axes
with rapid traverse or at feedrate in mm/min or
mm/rev. The type of feed programmed in this
mask remains active.
Notes

B120 Setup Turning
Definition of tool parameters Bit 3: Zero point offsets of Frames in the transverse axis will
be evaluated as diameter values.
MD20360
Bit 4: PRESET value is evaluated as diameter value.
$MC_TOOL_PARAMETER_ Definition of tool parameters
DEF_MASK Bit 5: Evaluate external zero point offsets in the transverse
axis as diameter values.
Bit 6: Read actual values of the transverse axis as diameter
value (AA_IW, AA_IEN, AA_COMM, AA_IB, Caution:
Description:
but not AA_IM)
Definition of the effect of tool parameters.
Bit 7: Readout of all actual values of the transverse axis as
Bit Nr. Meaning when the Bit is set.
diameter values independently of the G-Code of the
----------------------------------------------------------------------------------
Group 29 (DIAMON / DIAMOF)
Bit 0: For turning and grinding tools, the wear parameter of
the transverse axis is included in the calculation as a Bit 8: Display of the distance to go in WCS always as a radi-
diameter value. us.
Bit 1: For turning and grinding tools, the tool length compo- Bit 9: During DRF-handwheel traverse of an axis only half of
nent of the transverse axis is included in the calcula- the specified increment is actually travelled. (providing
tion as a diameter value. MD11346 $MN_HANDWH_TRUE_DISTANCE = 1)
Bit 2: If a wear component or a length component is included Bit 10: Permit activation of the tool component of an active
in the calculation as a diameter value, the tool may indexable tool carrier even if no tool is active..
only be used in the plane that was active when the tool
was selected. If the bit is set, a plane change raises an
alarm
Maximum number of blocks w/o traversing movement

Bit 11: The tool parameter $TC_DP6 is not interpreted as tool
with SAR
radius, but as a tool diameter.
Bit 12: The tool parameter $TC_DP15 is not interpreted as
wear on the tool radius, but as wear of the tool diame- MD20202 Maximum number of blocks
ter. $MC_WAB_MAXNUM_ w/o traversing movement with
DUMMY_BLOCKS SAR
Bit 13: During JOG of circles, the circle centre Coordinate is
always a radius value, see SD42690 Change to: 10
SC_JOG_CIRCLE_CENTRE.
Bit 14: Absolute values of the transverse axis for cycle masks
as a radius Description:
Bit 15: Incremental values of the transverse axis for cycle Maximum number of blocks that can appear between the
masks as diameters. SAR (soft approach and retraction) block and the traversing
block which determines the direction of the approach or re-
Note: traction tangent.
For turning machines it is sensible to enter and evaluate This setting is required in conjunction with the JobShop-
the tool wear correction value for turning tools in the X- cycles. A typical use is illustrated by the screenshot below
axis as a diameter, since the wear is determined on the taken from a continuous path milling operation on a contour
work piece diameter. using the approach and leaving strategy "Semi-circle".
Notes

Setup Turning B120
Continued MD20202 Blocks for look-ahead contour calculation with TRC
MD20240
Blocks for look-ahead contour
$MC_CUTCOM_MAXNUM_
calculation with TRC
CHECK_BLOCKS
Description:
Indicates the maximum number of blocks with traversing in-
formation at the offset plane that are considered simultane-
ously for collision detection with active TRC (tool radius com-
pensation).
Note:
The Standard setting should not be undercut.
Maximum number of blocks without traversing motion in Time monitoring for tool in tool holder
TRC
MD20320
Time monitoring for tool in tool
MD20250 Maximum number of blocks $MC_TOOL_TIME_MONITOR
holder
$MC_CUTCOM_MAXNUM_ without traversing motion in _MASK
DUMMY_BLOCKS TRC
Change to: 5
Description:
Note: The setting Bit 0 = 1 is required for the life-time monitoring of
The value 5 represents a value based on experience for the tool in the tool holder 1. The machine configuration used
JobShop installations. here only uses one tool holder.
Notes

B120 Setup Turning
MD24006 MD24007
Active system frames after Deletion of system frames
reset after reset
MASK CLEAR_MASK
Bit 5 = 0 Bit 5 = 1
Bit-mask for the reset setting of the channel-specific system Bit-mask for deleting channel-specific system frames in the
frames, which will be evaluated with the channel. data management on Reset..
Bit 0: System frame active for preset. actual value/ scratching Bit 0 = 0: The system frame for setting actual values and
scratching (basic reference) will not be deleted with Reset/
Bit 5: System frame for cycles End-of-part-program.
Bit 5 = 1: The system frame for cycles will be deleted with

Reset/End-of-part-program.
Reset channel system frames after power ON Adaptation of active frames
MD24008
Reset channel system frames MD24040
$MC_CHSFRAME_ Adaptation of active frames
after power ON $MC_FRAME_ADAPT_MODE
POWERON_MASK
Bit 5 = 0 Bit 1 = 1
Bit 2 = 1
Description:
Description:
This machine data defines whether channel-specific system
frames are reset in the data management on Power On. That Bit-mask for matching the active frame to the axis constella-
is offsets and rotations are set to 0, scalings to 1. Mirroring is tion
disabled.
Bit 0: Adjustment of rotations.
The selection can be made separately for individual system
frames. Bit 1: Rectangular shear angle
Bit 0: System frame for set actual value and scratching is Bit 2: Geo axes are not scaled
deleted after Power On.
Note:
Bit 5: System frame for cycles retained after Power On.
This setting is absolutely necessary for the function the
ShopTurn cycles in conjunction with TRANSMIT/
TRACYL.
Notes

Setup Turning B120
Activation and impact of program runtime measurement Bit 0 = 1

The timing of the total runtime for all part programs is
active ($AC_OPERATING_TIME)
MD27860 Bit 1 = 0
Activation and impact of pro- No timing of the current program runtime
$MC_PROCESSTIMER_
gram runtime measurement
MODE Bit 1 = 1
The measurement of the current program run-time is active
Change to: Bit 0 = 1 ($AC_CYCLE_TIME)
Bit 1 = 1
Bit 4 = 1 Bit 2 = 0
Bit 5 = 1 No timing of the tool cutting time
Bit 6 = 1 Bit 2 = 1
Bit 8 = 1 Timing of the tool cutting time is active
($AC_CUTTING_TIME)
Description: Bit 3
Under the function program runtime timers are provided as Reserved
system variables. While the NCK-specific timers are always Bits 4,5 only if Bit 0, 1 = 1:
activated (for timings since the last control unit boot), the
channel-specific timers must be started by means of this da- Bit 4 = 0 No timing during active test run feed motion
tum. Bit 4 = 1 Timing also during active test run feed motion
Meaning: Bit 5 = 0 No timing during program test
Bit 0 = 0 Bit 5 = 1 Timing also during program test
No timing of the total runtime for all part programs Bit 6 only if Bit 1 = 1:
Description: Bit 9 only if Bit 0, 1 = 1:

Bit 6 = 0 Bit 9 = 0
Delete $AC_CYCLE_TIME also after Start by ASUP and $AC_OPERATING_TIME, $AC_CYCLE_TIME: No timing
PROG_EVENTs. when Override = 0.
Bit 6 = 1 Bit 9 = 1
$AC_CYCLE_TIME will not be deleted after Start by ASUP $AC_OPERATING_TIME, $AC_CYCLE_TIME: Timing also if
and PROG_EVENTs. Override = 0.
Bit 7 only if Bit 2 = 1: Bit 10 to 31
Reserved
Bit 7 = 0 $AC_CUTTING_TIME counts only with active tool.
Bit 7 = 1 $AC_CUTTING_TIME counts independently of tool.
Bit 8 = 0
$AC_CYCLE_TIME will not be deleted in case of a jump with
GOTOS to the program start.
Bit 8 = 1
$AC_CYCLE_TIME will be deleted in case of a jump with
GOTOS to the program start.
Notes

B120 Setup Turning
Work piece counters In the user interface of the

mode-of-operation AUTO the
A difference is made between the following work piece coun- mask shown alongside can be
ters: opened by selecting Time/
 Number of the command work pieces Counter
System variable $AC_REQURED_PARTS
Setting by means of Bit 0 and 1
 Total number of work pieces (actual work pieces) fin-
ished since the Start
System variable $AC_TOTAL_PARTS
Setting by means of Bit 4, 5 and 7
The following attribution applies:
 Number of all work pieces (actual work pieces) fin- - Param "Workpiece Command" = $AC_REQUIRED_PARTS
ished since the Start - Param "Work pieces Actual" = $AC_ACTUAL_PARTS
System variable $AC_ACTUAL_PARTS
Setting by means of Bit 8, 9 und 11
 Number of work pieces finished as per the own strate- Activation of workpiece counter
gy
System variable $AC_SPECIAL_PARTS
Setting by means of Bit 12, 13 and 15 MD27880 Activation of workpiece coun-
$MC_PART_COUNTER ter

Bit 8 = 1
Bit 11 = 1
Bit 0 = 1: Counter $AC_REQUIRED_PARTS is activated Bit 6 : reserved

Further meaning of Bit 1-3 only if Bit 0 =1 and
$AC_REQUIRED_PARTS > 0: Bit 7 = 1: Counter $AC_TOTAL_PARTS is increased by the
value 1 after a jump back with GOTOS
$AC_REQUIRED_PARTS > 0: Bit 8 = 1: Counter $AC_ACTUAL_PARTS is active
Bit 1 = 0: Alarm/VDI-output if $AC_ACTUAL_PARTS corre- Further meaning of Bit 9 - 11 only if Bit 8 = 1 and
sponds to $AC_REQUIRED_PARTS $AC_REQUIRED_PARTS > 0:
Bit 1 = 1: Alarm/VDI-output if $AC_SPECIAL_PARTS corre- Bit 9 = 0: Counter $AC_ACTUAL_PARTS is increased by the
sponds to $AC_REQUIRED_PARTS value 1 after a VDI-output of M02/M30
Bit 2: reserved Bit 9 = 1: Counter $AC_ACTUAL_PARTS is increased by the
Bit 3: reserved PART_COUNTER_MCODE[1]
Bit 4 = 1: Counter $AC_TOTAL_PARTS is active Bit 10: reserved
Further meaning of Bit 5 - 7 only if Bit 4 = 1 and Bit 11 = 1: Counter $AC_ACTUAL_PARTS is increased by
$AC_TOTAL_PARTS > 0: the value 1 after a jump back with GOTOS.
Bit 5 = 0: Counter $AC_TOTAL_PARTS is increased by the
value 1 after a VDI-output of M02/M30.
Bit 5 = 1: Counter $AC_TOTAL_PARTS is increased by the

PART_COUNTER_MCODE[0]
Notes

Setup Turning B120
Continued MD27880 Part program:
Bit 12 = 1: Counter $AC_SPECIAL_PARTS is active In such a JobShop-Program the program repeat can be
switched ON in the automatically generated End-of-program
Further meaning of Bit 13-15 only if Bit 12 =1 and block by means of the parameter "Repeat". In this case the
$AC_REQUIRED_PARTS > 0: command GOTOS will be generated.
Bit 13 = 0: Counter $AC_SPECIAL_PARTS is increased by G-Code-Program_1: G-Code-Program_2:

the value 1 after a VDI-output of M02/M30 … ...
M33; Repeat GOTOS; Repeat
Bit 13 = 1: Counter $AC_SPECIAL_PARTS is increased by M30 M30
the value 1 after output of the M-command from MD
PART_COUNTER_MCODE[2] The number of work pieces is to be set in the mode-of-
operation AUTO in the mask “Time/Counter” by the parame-
Bit 14: reserved ter “Workpieces, setpoint”.
Bit 15 = 1: Counter $AC_SPECIAL_PARTS is increased by Relevant PLC interface signals:

the value 1 after a jump back with GOTOS.
Activating the part program repetition is done by setting the
PLC interface signal "Program branches control" to 1.
Application example: - For 840D sl: PLC bit DB21.DBX384.0
MD27880 PART_COUNTER = 101H
Bit 0 = 1: Counter $AC_REQUIRED_PARTS "Work pieces
When the actual number of workpieces matches the number
Command" activate
of setpoint the PLC interface signal "Workpiece setpoint
Bit 8 = 1: Counter $AC_ACTUAL_PARTS "Work pieces Actu-
reached" is set to 1.
al" activate
- For 840D sl: PLC bit DB21.DBX317.1
MD 27882[1] PART_COUNTER_MCODE = 33
Memory space for REORG (DRAM) Description:

Bit-mask for the projecting of channel-specific system frames,
MD28000 which are evaluated in the channel.
Memory space for REORG
$MC_MM_REORG_LOG_
(DRAM) Bit 0 = 1 System frame for actual value set and scratching
FILE_MEM
Bit 5 = 1 System frame for cycles
Change to: 75
Note:
The system frames for actual value set and scratching
Number of blocks for local user variables in REORG (basic reference) and for cycles are required for JobShop
(DRAM) installations.
MD28010 Number of blocks for local

$MC_MM_NUM_REORG_ user variables in REORG
LUD_ MODULES (DRAM)
Projecting of channel-specific system frames in the data
Change to: 20 management
Projecting of channel-specific system frames

MD28083
$MC_MM_SYSTEM_ System frames (SRAM)
MD28082 DATAFRAME_MASK
$MC_MM_SYSTEM_FRAME_ System frames (SRAM)
MASK Change to: Bit 0 = 1
Bit 5 = 0
Bit 5 = 1
Notes

B120 Setup Turning
Work offsets in frames Feed reduction on circles with tool radius compensation
SD42440
$SC_FRAME_OFFSET_INCR_ Work offsets in frames SD42528 Feed reduction on circles with
PROG $SC_CUTCOM_DECEL_LIMIT tool radius compensation
Change to: 0
Change to: 1
Note:
Note:
This setting is required for JobShop installations. It avoids the
"stopping" of the axes in such circular sections if the diameter
of the milling cutter is only marginally smaller than the ma-
chining radius.
Tool length compensations
SD42442
$SC_TOOL_OFFSET_INCR_ Tool length compensations
PROG
Change to: 0
Note:
plane tool type
Change of tool length compo- Assignment of tool length com-

SD42940 SD42950
nents with change of active pensation independent of tool
$SC_TOOL_LENGTH_CONST $SC_TOOL_LENGTH_TYPE
plane type
Note: Note:
The setting = 18 is required for ShopTurn installations, see The setting = 2 is required for ShopTurn installations,
also SD42950 $SC_TOOL_LENGTH_TYPE. see also SD42940 $SC_TOOL_LENGTH_CONST.
With the setting the setting data

SD42940 $SC_TOOL_LENGTH_CONST and
SD42950 $SC_TOOL_LENGTH_TYPE
the tool lengths are rigidly assigned to the geometry axes
independently of the tool type:
Length 1 = X
Length 2 = Z
Lange 3 = Y
Notes

Setup Turning B120
JOG-TSM Tool changes

Definition of basic control settings after reset/PP end
In the operation mode JOG the input masks for "T,S,M",
"Position" and "Roughing" are available. These permit simple
functions to be carried out such
- T,S,M: Tool changes, spindle functions, zero point offset- MD20110 Definition of basic control set-
selections $MC_RESET_MODE_MASK tings after reset/PP end
- Position: axes and spindles positioning
- Roughing: roughing of a corner with chamfers and/or radii. Change to: Bit 6 = 1
After the data have been entered and NC-Start initiated the
file MA_JOG_STEP1.MPF will be generated in the directory Bit 0 = 1 Reset mode
"Workpieces - TEMP" and carried out in the program- Bit 6 = 1 Active tool length compensation
manager. Bit 14 = 1 Base frame
To ensure that such functions as e. g. tool selection and spin- Description:

dle Start will remain activated also after reset and end-of, Bit 6 = 1:
respective machine data are required, which will be described
below. The current setting for the active tool length correction re-
The settings will be described with the T,S,M-Mask; the input mains active also after Reset/end-of-part program.
masks Position and Roughing do not require special settings. If the tool or magazine management is active, that tool is se-
lected which happens to be in the master spindle (generally
referred to as master-tool holder).
If the tool in the master spindle is locked, the "locked" status
will be ignored.
It must be borne in mind that after end-of-program, program Description:

abort either the last programmed value for the master spindle
respectively the master tool holder or else the value specified Bit 14 = 1: Reset-Mode
by $MC_SPIND_DEF_MASTER_SPIND respectively Tool and correction selection as per the settings of MD20110
$MC_TOOL_MANAGEMENT_TOOLHOLDER for the master $MC_RESET_MODE_MASK and
spindle respectively the master-tool holder will be used. MD20112 $MC_START_MODE_MASK.
Bit 14 = 0: No Reset mode
MD20310 Note:
$MC_TOOL_MANAGEMENT_
functions In case of turning machines featuring a turret the setting with
MASK
Bit 16=1 "Programming T=Location number" the program-
Change to: Bit 14 = 1 ming of the turret place can be selected in addition to the tool
name. In the T,S,M-mask appears the following selection
means:
Bit 0 - 3 must be set as in MD18080
$MN_MM_TOOL_MANAGEMENT_MASK
Bit 0 = 1 Magazine management active

Bit 1 = 1 Monitoring functions active
Bit 3 = 1 Adjacent location treatment
Bit 14 = 1 autom. tool change during Reset and Start
Bit 16 = 1 Programming T = "Location number"
Bit 23 = 1 On offset selection no synchronization with
HL
Notes

B120 Setup Turning
Continuation of tool change The cycle CYCLE206 called up with the tool change in turn
calls the manufacturer cycle CUST_TECHCYC in the mode
110 and 111.
Selection and transfer of a
tool from the list of tools in the
T,S,M-mask (the direct input Extract from the CUST_TECHCYC.SPF:
of the name is also possible)
With NC-Start the part-

program MA_JOG_STEP1 is
generated in directory Work
pieces - TEMP and the tool
change is carried out.
Description:
 CYCLE210(0)
checks the configuration settings for ShopTurn, as for
instance axis and spindle assignment.
 CYCLE206
obtains the tool name and the cutting edge number as
transfer parameters.
 M32
The M-command defined under MD10714
_M110: This mode is called up after the tool change. No en- _M112: Is called up before the tool change when the retrac-
tries are prepared. tion plane is reached (the retraction plane is defined
for the X and Z-axis in the part program)
_M111:This jump is provided in case the tool change takes
place from a ShopTurn-program and the tool change _M113: Is called up if just a cutting edge, but no tool, has
is set up with the M-command (MD22550 been programmed.
$MC_TOOL_CHANGE_MODE = 1). The ShopTurn- Here a special case is being considered where on
cycle F_HOME.SPF for the approach of the tool one tool there is a cutting edge for external and an-
changing position will be called up. other or internal machining. If now a change between
these two cutting edges is programmed (together with
Further jump accesses in the CUST_TECHCYC are provided a simultaneous change from external to internal ma-
for the tool change, which, however, are called up only during chining) there will be no approach of the tool changing
the program execution. point from the ShopTurn cycles. The change of the
cutting edge takes place close to the work piece and
the starting point of the internal machining will be ap-
proached along the shortest possible path. In order to
avoid collisions with the work piece the ShopTurn
cycle F_HOME for the approach of the tool changing
point is called up.
_M114: Is called up after the tool change.
Notes

Setup Turning B120

_RESET
Change to: 2
AX3: MCS1
MD35040 = 2 Own spindle-RESET (Main spindle)
MD10714 M function for spindle active
$MN_M_NO_FCT_EOP after reset AX4: MCS3
MD35040 = 2 Own spindle-RESET (Tool spindle)
Change to: 32 Description:
Suggestion M32 This machine data defines the response of the spindle after
Reset and program end (M2, M30).
Description:
This MD is only active in the spindle mode open-loop control
With Start in the manual mode-of-operation (T,S,M-mask, mode. In the positioning or oscillation mode, the spindle is
position) the part-program MA_JOG_STEP1 will be generat- always stopped.
ed and executed.
This part-program will be finished with the M-function in
MD10714. The setting of MD35040 = 2 ensures that the spin-
MD35040 $MA_SPIND_ACTIVE_AFTER_RESET = 0:
reset)
 Program is aborted
 Spindle does not stop at the M function configured via
 However, the spindle stops at channel or mode group
reset.
Not relevant to:

 Spindle modes other than open-loop control mode.
Notes

B120 Setup Turning
Start main spindle via the T,S,M-mask MA_JOG_STEP1 is generat-

ed
T,S,M-mask with inputs for spindle speed and direction of
rotation of the main spindle S1
Main spindle S1 select
Description:
 SETMS(1)
declares the main spindle S1 as master spindle
Enter speed and direction of
 CUST_TECHCYC(4)
rotation
Call-up of CUST_TECHCYC in mode 4 "Main spindle C-
axis clamping release"
and actuate NC-Start
 CUST_TECHCYC(2)
Call-up of CUST_TECHCYC in mode 2 "Main spindle
switch to spindle mode-of-operation"
 M1=4 G972 S1=1000
Starting of the spindle
Note on spindle direction of rotation:

The assignment of the direction arrow for the spindle
M-function M3/M4 is effected via the MD52207
$MCS_AXIS_USAGE_ATTRIB.
Listed here are all the CUST_TECHCYC jump accesses en- Description:
visaged for the main spindle.
For the switching of the main spindle into the C-axis mode or
Extract from the CUST_TECHCYC.SPF: spindle mode and for clamping or unclamping of the main
spindle the following jump accesses into the manufacturer
cycle CUST_TECHCYC.SPF are prepared:
_M1: Switching the main spindle into the C-axis mode.
_M2: Switching from the C-axis mode into the spindle mode
_M3: Main spindle clamp
_M4: Main spindle unclamp
Notes

Setup Turning B120
Continued, Start main spindle via the T,S,M-mask From this derives the following logic:
The IF-query is fulfilled, if the main spindle is not in the mode-
of-operation 2 = positioning and not in the mode-of-operation
4 = axis mode-of-operation or the Prog_Event is in the mode
Description: 5 = block search.
_M1: Switching to the C-axis mode The subsequent line positions the main spindle to 0 degrees:
When switching into the C-axis mode there is a difference SPOS[_F_S_NR[0]]=0
whether in the C-axis mode the main spindle is driven by the The query ensures that the main spindle is not positioned
spindle drive or by a separate feed drive motor. again, if it had already been switched into the axis mode be-
forehand.
1. No separate feed drive available:
The following entry is prepared: 2. Separate feed drive fitted:
IF (($P_SMODE[_F_S_NR[0]]<>2)AND($P_SMODE The IF-query described above and the subsequent ENDIF-
[_F_S_NR[0]]<>4))OR($P_PROG_EVENT==5) command must be invalidated and replaced by the logic for
the engaging of the separate feed drive. This should prefera-
Variable _F_S_NR: The spindle index of the main, the tool bly be done in a separate manufacturer cycle, e.g. AX-
and the counter spindle can be freely defined by the machine IS_C_ON.SPF.
manufacturer. In order to permit the CUST_TECHCYC to be
generally valid for all applications, the spindle index will be _M1: Main spindle: Change to C axis mode
determined via the variable _F_S_NR from the given axis AXIS_C_ON
configurations (set by means of MD52206 GOTOF _MEND
$MCS_AXIS_USAGE). The following applies:
_F_S_NR[0] holds the spindle index of the main spindle
_F_S_NR[1] holds the spindle index of the tool spindle
_F_S_NR[2] holds the spindle index of the counter spindle
Example for the manufacturer cycle AXIS_C_ON.SPF: _M2: Switching of the main spindle to the spindle mode:
1. No separate feed drive available:
PROC AXIS_C_ON The following entry is prepared :
IF $P_SEARCH==1 GOTOF _END IF($SP_MODE[_F_S_NR[0]]<>1
IF $P_SIM==1 GOTOF _END ;N20 M[_F_S_NR[0]]=
; Do not execute cycle during block search and simulation ENDIF
IF $A_IN[24]==1 The line N20 will be executed only if the main spindle is not in
;If feedback from the PLC, that the drive is already coupled, the spindle mode and can be supplemented by "5". By means
;do not execute cycle; of the command M5 the counter spindle is switched back to
; Release digital inputs and outputs via MD10350/MD10360 the spindle mode.
GOTOF _END
ENDIF
M[_F_S_NR[0]]=41 ;Select gearbox stage 1 for main spindle
SPOSA[[_F_S_NR[0]]=0 ;Position main spindle
WAITS(1) ;wait until the spindle position is reached
STOPRE
G0 C0 ;C-axis positioning
STOPRE
M64 ;M-command for engaging the C-axis
MARK1:
IF $A_IN[24]==1 GOTOF MARK2
;Query whether the engaging has been completed
GOTOB MARK1 ; Jump back to engaging completed
MARK2:
_END:
IF $P_SIM==1 ;Simulation active
M[_F_S_NR[0]]=70 ;Switch main spindle into the axis mode
ENDIF
M17
Notes

B120 Setup Turning
Continued: Extract from the CUST_TECHCYC.SPF _M3: Main spindle: C axis clamping
The following entry is prepared:
2. Separate feed drive available: ;N30 M[_F_S_NR[0]]=
As described for the previous mode a further manufacturer ;N35 $AC_PRTIME_A_INC=1.5
cycle should be used for disengaging the separate feed drive:
AXIS_C_OFF.SPF and this is called up in the mode _M2. Enter the M-command for clamping the main spindle in the
line N30. The line N35 is prepared for matching the machin-
_M2: ; Main spindle: Change to spindle mode ing time evaluated during the simulation to the real machining
AXIS_C_OFF time (delay caused by the activation of the clamping must be
GOTOF _MEND taken into account).
Example for the manufacturer cycle AXIS_C_OFF.SPF: _M4: Main spindle: Release C axis clamping
PROC AXIS_C_OFF ;N40 M[_F_S_NR[0]]=
IF $P_SEARCH==1 GOTOF _END ;N45 $AC_PRTIME_A_INC=1.5
IF $P_SIM==1 GOTOF _END
; Do not carry out cycle during block search and simulation Enter the M-command for the clamping of the counter spindle
M65 ;M-command for disengaging C-axis in line N40. The line N45 is prepared for matching the ma-
MARK1: chining time evaluated during the simulation to the real ma-
IF $A_IN[23]==1 GOTOF MARK2 chining time (delay caused by the un-clamping must be taken
;Query, whether the disengaging has been completed into account).
GOTOB MARK1
MARK2:
ENDIF
_END:
M17
Monitoring the tool change
Use the cursor keys to select the required tool and

Shown in the T,F,S-field is the tool currently loaded in the thereafter transfer it by means of the Soft-Key "OK".
spindle.
Notes

Setup Turning B120
Loading the new tool
The tool will be loaded into the T,F,S mask with Cycle Start.
The PLC-tool change functions provided by the machine
The selected tool "Finisher" is now displayed in the T,S,M manufacturer are executed in the background for this pro-
mask. cess.
Gear step
Parameterize gear stage change
MD35010
Parameterize gear stage
$MA_GEAR_STEP_CHANGE_
change
ENABLE
With NC-Start the program
Description: MA_JOG_STEP1 will be gen-
erated - in this example for the
The selection field Gear stage appears only if in MD35010 for selection of the gear stage 2
the spindle Bit 0 = 1 is set. of the main spindle M1=42.
MD35090
$MA_NUM_GEAR_STEPS
Description:
Number of prepared gear stages.
Notes

B120 Setup Turning
T,S,M-mask: Zero point offset Machining level
In the T,S,M-mask to select a The initial setting of the machining level of a turning machine
zero point offset by means of is G18 as per MD20150[5] = 2.
the parameter Zero point off-
set (G54,…) or it can be de-
selected by means of the se-
lection "Basic setting". Depending on the setting of MD20152[5] the switching of the
plane remains operative after a reset/end-of-program.
MD20152[5]=0 MD20152[5]=1
In order for the selection and de-selection of the Zero point

offset remains activated also after reset/end of part-program,
the setting of MD20152[7]=1 is required.
Inch/Metric-switching Selection of Inch/Metric-switching:
Below follows once more a summation of the machine data

settings required for Inch/Metric-switching. The details to
these MDs can be found in section "Basic settings".
Enable basic system conversion
MD10260
Enable basic system conver-
$MN_CONVERT_SCALING_
sion
SYSTEM
Change to: 1
Description:
Switching the measuring systems with HMI-Softkey

0. Hide Softkey inch/metric switching Note:
1. Display Softkey inch/metric switching MD 20152[12] = 0 must be set for the position readouts to be
converted.
Notes

Setup Turning B120
Manufacturer cycle CUST_TECHCYC.SPF Overview of the CUST_TECHCYC-jump accesses
In the cycle CUST_TECHCYC.SPF function marks (_M1 to Description:

_M142) are prepared and documented. Match the cycle if
necessary under manufacturer cycle. This section provides an overview of the CUST_TECHCYC-
jump accesses, including a note where the description can be
found.
 Main spindle:
1-2 Switching axis/spindle mode:
Section JOG-TSM
3-4 Clamping ON/OFF:
Section JOG-TSM
5-9 Chuck open/close, chuck flushing:
Section Jaws, chuck, …
 Tool spindle:
11 - 12 Switching axis/spindle mode:
Section JOG-TSM
13 - 14 Clamping ON/OFF:
Section JOG-TSM
 Counter spindle:
21 - 22 Switching axis/spindle mode:
Module Sub spindle
23 - 24 Clamping ON/OFF:
Module Sub spindle
25 - 29 Chuck open/close, chuck flushing
Module Sub spindle
 30: Positioning the 4th axis after block search: Note:

Section Block search In order to clarify the call-ups of the CUST_TECHCYC it is
possible to display the call-up mode by adding a message
 41 - 42: Engaging/disengaging a driven tool: during commissioning:
Section JOG-TSM, CUST_TECHCYC
; MODE:
 61 - 68: Switching turning/milling, mantle-front face C, MSG ("CUST_TECHCYC-Mode = "<<_MODE)
mantle-front face Y, B-axis and block search: M0
Section JOG-TSM, CUST_TECHCYC STOPRE
MSG()
 100 - 103: Part receptacle:
Section Jaws, chuck, ...
 110 - 118: Tool change:

Section JOG-TSM, CUST_TECHCYC
 120 - 126: Engaging of main/counter spindle:

Module Sub spindle
 131 - 136: ShopTurn program-control:

Section: JOG-TSM, CUST_TECHCYC
 140 - 142: Block search:

Section Block search
Notes

B120 Setup Turning
Tool spindle
After the selection of the tool

spindle S3, input of the speed,
selection of the direction of
rotation and NC-Start the pro-
gram shown alongside is gen-
erated.
The CUST_TECHCYC (42) is

called up after tool spindle
Stop.
Extract from the CUST_TECHCYC.SPF
Description: Note:
In the program sequence the CUST_TECHCYC call-ups are
_M11 - _M14
obtained from the ShopTurn cycles depending on the pro-
These jump accesses for the tool spindle relate to the jump
grammed technology - in case of driven tools by the boring
accesses _M1 - _M4 for the main spindle and have already
and milling cycles. For this all shown jump accesses are pos-
been described there. The entries differ only with respect to
sible..
the spindle index in the variable _F_S_NR.
The call-ups in mode 11 (switching the tool spindle into the C
-axis mode) and mode 13 (tool spindle clamp) are not possi-
_M41: Engaging a driven tool
ble in the T,S,M-mask.
_M41: ; Engage driven tool
;N410 M[_F_S_NR[1]]=
GOTOF _MEND
The line N410 must be completed with the M-command for
engaging the driven tool.
_M42: Disengaging a driven tool

_M42: ; Disengage driven tool
N420 M[_F_S_NR[1]]=5 ; Stop spindle
;N425 M[_F_S_NR[1]]=
GOTOF _MEND
In block N420 the tool spindle is stopped. The line N425 must
be completed with the M-command for disengaging the driven
tool.
Notes

Setup Turning B120
Program control
Description: _M135: at the end of a program loop of a ShopTurn pro-

gram
The modes 131 - 136 will be called up only by a ShopTurn No entry is prepared.
program.
_M136: at the end-of-program of a ShopTurn program
_M131: At the beginning of a program The following entry is prepared:
The following entry is prepared: _I=0
_TC_N_WZ=0 IF($P_TOOL>0)
_TC_A_WZ=0 _I=$P_AD[1]
GOTOF _MEND ENDIF
The variables _TC_N_WZ and _TC_A_WZ are meaningful IF(_I<>731)AND(_I<>732)
only in conjunction with a B-axis. _N1360 F_HOME
ENDIF
_M132: at the end of the program header GOTOF _MEND
The following entry is prepared: Block N1360 calls up the ShopTurn-cycle F_HOME for the
_I=0 approach of the tool changing position defined in the program
IF($P_TOOL>0) header.
_I=$P_AD[1]
ENDIF
IF(_I<>731)AND(_I<>732)
_N1320 F_HOME
ENDIF
GOTOF _MEND
Block N1320 calls up the ShopTurn-cycle F_HOME for the
approach of the tool changing position defined in the program
header.
Notes

B120 Setup Turning
Block search Function mask Cross-technology
Parameterization for search run MD52212

$MCS_FUNCTION_MASK_
technology
TECH
MD11450 Parameterization for search
$MN_SEARCH_RUN_MODE run Change to: Bit 3 = 1

Bit 1 = 1 Description:
Bit 2 = 1 Bit 3: Call block search cycle for ShopMill/ShopTurn
Note:
Description:
Bit 0: Response to output of alarm 10208 The setting of Bit 3=1 ensures that the tool programmed after
the block search is duly changed and that the spindle rotates
Bit 1: Automatic ASUP start after action blocks in the tool-assigned direction at the speed programmed in the
destination block. For installations without ShopMill this Bit
Bit 2: Response to Auxf output (spindle) needs not to be set, however, the machine manufacturer
must ensure that the tool and spindle functions are gathered
and put out during the block search.
Tool change commands to PLC after search run 1: Tool changing commands and tool preparation commands
are gathered and passed on to the PLC with program Start
when the search run has attained the destination block.
MD20128
Tool change commands to 0: all tool and/or magazine specific commands that were
$MC_COLLECT_TOOL_
PLC after search run gathered during the block search will not be put out to the
CHANGE
PLC with the next program Start! That means that also pro-
Change to: 0 grammed POSM, TCI, TCA will not be passed on to the PLC.
Note 1:
Description:
Without an active magazine management the tool change-M-
This MD is of any meaning only with activated magazine
code will not be gathered, if it is not assigned to an auxiliary
management (MD18080
function group. With an active magazine management this
$MN_MM_TOOL_MANAGEMENT_MASK, MD20310
corresponds to an MD-value = 0.
$MC_TOOL_MANAGEMENT_MASK).
It specifies whether after block search with evaluation tool
Note 2:
changing commands, tool preparation commands (generally
tool changing commands) are put out to the PLC or not put The value = 0 is sensible for instance if after reaching the
out to the PLC. search destination the gathered tool change commands are
transferred to the PLC in an ASUP-program with the aid of
Note: the commands GETSELT, GETEXET.
This setting is necessary for ShopMill/ShopTurn.
Notes

Setup Turning B120
Simulation
Adjustment of SZS Coordinate system
MD24030 Adjustment of SZS Coordinate

$MC_FRAME_ACS_SET system
Change to: 1
Description:
$P_CYCFRAME and $P_PFRAME.

$P_CYCFRAME.
The position readouts show the SZS-Coordinate system if

"WCS" is selected.
Depiction of the Coordinate systems and the Frame chain
Description: Axis position at start of simulation
The SZS-Coordinate system is different to the WCS Coordi-

MD53230
nate system by Axis position at start of simula-
$MAS_SIM_START_
 Cycle frame POSITION
tion
 Programmable frames (G54, …)
Change to:
 Transformation (TRANS, ROT, SCALE)
With the setting of MD24030 $MC_FRAME_ACS_SET = 1 AX1: MX1

the programmable frames are taken into account in the posi- MD53230 = e.g. 400 mm
tion readouts.
AX2: MZ1
MD53230 = e.g. 0 mm
Description:
Axis position at the Start of the simulation.
The simulation is possible only, if for at least one geo-axis a
value not equal to 0 has been set.
Note:
For the further axes and spindles this MD should be left on 0.
Notes

B120 Setup Turning
Simulation depiction Tipp:

To permit better observation of the simulation it is advisable
to reduce the rapid traverse rate by means of the override
switch. The percentage settings do not represent a linear
function. A setting of about 60 - 80% are practicable.
Alternatively to the vertical Softkeys the override setting can

also be obtained using the following keys:
Override increase: and
Override reduction: and
Override maximum: and M
Machining program: Roughing

Machining example
Machining example Main spindle
Example:
By means of a simple machining example with the main spin-
dle the sequence is to be tested. Program head with workpiece definition:
Tool list
Preparation:
The tools used in this example must have been edited and
must have the correct cutting edge orientation.
Notes

Setup Turning B120
Stock removal and technology data: Program end and repetition:
Test of the machining Start, work piece in the main spindle
A check of the machining sequences can be made having

completed the inputs and selecting simulation.
Alteration of the speed to about 60%.
The machining progress is illustrated below in several stages.
Notes

B120 Setup Turning
Cut main spindle End of the machining
TRANSMIT/TRACYL for the main spindle There are 2 differing sets of data, both of which must be set
up; - one for TRANSMIT and one for TRACYL:
General aspects
 Front face machining main spindle: Transformation 1
By means of the functions cylinder mantle transformation and MD 24100 $MC_TRAFO_TYPE_1=256 (with C–axis)
front face machining both the mantle as well as the front face
of the work piece can be machined.  Cylinder mantle transformation main spindle: Transfor-
mation 3 without slot side face correction (with C–axis):
The functions cylinder mantle transformation (TRACYL) and MD 24300 $MC_TRAFO_TYPE_3=512
front face machining (TRANSMIT) are a Software-Option.
The functions must be set up additionally by means of the

machine data.
_________________________________________________
Note:
There is a difference between the set-ups of TRANSMIT and
TRACYL depending on whether a Y-axis is available or not.
Described here is the set-up as applicable when no Y-axis is
available.
_________________________________________________
Notes

Setup Turning B120
Note: These MDs were already set up and described.
With the function TRANSMIT/TRACYL a non-existent Y-axis MD10602 $MN_FRAME_GEOAX_CHANGE_MODE = 1

is simulated by means of an interpolation between X/C (in MD24040 $MC_FRAME_ADAPT_MODE = 7H
case of TRANSMIT) respectively Z/C (in case of TRACYL). In
this configuration example there is, apart from the main spin-
dle, no separate C-axis as feed drive for the C-axis mode. The data blocks for TRANSMIT and TRACYL described be-
Therefore, the channel index of the main spindle must be low are conceived for the configured horizontal lathe with
entered for the C-axis into the configuration data for TRANS- machining behind the turning centre and with the axis config-
MIT/TRACYL. uration as shown above. Nevertheless such requirements as
the direction of rotation of the C-axis in case of the transfor-
mation or the input of an offset might require an adaptation
As a reminder; this is how the machine is already config- this set of data.
ured:
Index
20080[0] $MC_AXCONF_CHANAX_NAME_TAB = X1 1 The tables on the next pages gives an overview of the data
20080[1] $MC_AXCONF_CHANAX_NAME_TAB = Z1 2 blocks for TRANSMIT and TRACYL.
20080[2] $MC_AXCONF_CHANAX_NAME_TAB = C 3
20080[3] $MC_AXCONF_CHANAX_NAME_TAB = CS3 4
20080[4] $MC_AXCONF_CHANAX_NAME_TAB = Q 5
Front face machining (TRANSMIT)
 Front face machining main spindle: Transformation 1 (with C–axis)
Set-
MD Identifier Comment Description
tings
24100 $MC_TRAFO_TYPE_1 256 Definition of the 1st transformation in the channel
[0]=1 (X)
[1]=3 (C)
24110 $MC_TRAFO_TYPE_IN_1 [2]=2 (Z) Axis assignment for transformation 1
[3]=0
[4]=0
[0]=1 (X)
$MC_TRAFO_GEOAX_ASSIGN_TAB Assignment of geometry axes to channel axes for transfor-
24120 [1]=3 (C)
_1 mation 1
[2]=2 (Z)
$MC_TRANSMIT_ROT_AX_OFFSET
24900 0 Offset of rotary axis for the 1st TRANSMIT transformation
_1
$MC_TRANSMIT_ROT_AX_FRAME_
24905 2 Rotary axis offset TRANSMIT 1
1
$MC_TRANSMIT_ROT_SIGN_IS_PL
24910 0 Sign of rotary axis for 1st TRANSMIT transformation
US_1
Restriction of working range in front of / behind the pole, 1.
24911 $MC_TRANSMIT_POLE_SIDE_FIX_1 1
TRANSMIT
24920 $MC_TRANSMIT_BASE_TOOL_1 0 Vector of base tool for 1st TRANSMIT transformation
Notes

B120 Setup Turning
Front face machining with TRANSMIT Rotary axis offset TRANSMIT 1
Offset of rotary axis for the 1st TRANSMIT transformation MD24905

Rotary axis offset TRANSMIT
$MC_TRANSMIT_ROT_AX_
1
FRAME_1
MD24900 Change to: 2
Offset of rotary axis for the 1st
TRANSMIT transformation
OFFSET_1
Default: 0 Grad Change to: Description:
0: the axial offset of the rotary axis is not taken into account.
Description: 1: the axial offset of the rotary axis will be taken into account.
Indicates the offset of the rotary axis for the first agreed
TRANSMIT transformation in degrees in relation to the neu- 2: the axial offset of the rotary axis will be taken into account
tral position while TRANSMIT is active. up to the SZS.
The rotary position of the XY-plane of the Cartesian Coordi- If the work piece is to be rotated during machining with
nate system in relation to the defined zero position of the ro- TRANSMIT, then this cannot be achieved by programming
tary axis C can be entered here. the rotary axis in the channel, since this is occupied by a ge-
ometry axis (Y). An offset of the rotary axis in the transfor-
mation frame (TRANS, ROT, SCALE) will be taken into ac-
count during TRANSMIT if the setting is = 1.
Corresponds to:
MD24030 $MC_FRAME_ACS_SET
Sign of rotary axis for 1st TRANSMIT transformation Restriction of working range in front of / behind the pole,
1st TRANSMIT
MD24910
Sign of rotary axis for 1st MD24911 Restriction of working range in
$MC_TRANSMIT_ROT_SIGN
TRANSMIT transformation $MC_TRANSMIT_POLE_SIDE front of / behind the pole, 1st
_IS_PLUS_1
_FIX_1 TRANSMIT
Change to: 0
Change to: 1
Indicates the sign with which the rotary axis is taken into Restriction of the working range in front of/behind the pole or
account in the TRANSMIT transformation for the first agreed no restriction, i.e. travelling through the pole.
TRANSMIT transformation for each channel.
The assigned values have the following meaning:
Corresponds to:
0: No restriction of the working range. Travelling through the
MD24960 $MC_TRANSMIT_ROT_SIGN_IS_PLUS_2
pole.
Note:
1: Working range of the linear axis for positions >= 0,
The requirements at the machine such as direction of rotation (if the tool length correction parallel to the linear axis = 0)
of the spindle/C-axis might necessitate different settings to If on the turning machine travelling in the X-axis beyond
the ones shown here. the turning centre (-X) is not possible.
2: Working range of the linear axis for positions <=0,
(if the tool length correction parallel to the linear axis = 0)
Notes

Setup Turning B120
Continuation of Restriction of the working range in Vector of base tool for 1st TRANSMIT transformation
front of / behind the pole, 1st TRANSMIT
The sketch below shows the behaviour with the setting of

MD24911 = 1. MD24920[x]
Vector of base tool for 1st
$MC_TRANSMIT_BASE_
This setting is usual, since normally no or very little traverse is TOOL_1
available in the X-axis beyond the turning centre.
Default: 0, 0, 0 mm Change to:
Machining takes place in the following steps:
 Traverse along the X-axis to the pole MD24920[0] =0
 Rotation of the rotary axis by 180 degrees. During this MD24920[1] =0
motion the X-axis remains stationary MD24920[2] =0
 Machining of the remainder of the block. The X-axis
Description:
motion is now away from the centre in the positive
direction. This states a basic offset of the tool zero point for the 1st
TRANSMIT-transformation. Only if there is an offset from the
turning centre will this MD be required. For the standard ma-
chining the default applies.
The index i takes on the values 0, 1, 2 for the 1st to the 3rd
geometry axis.
Corresponds to:
MD24970 $MC_TRANSMIT_BASE_TOOL_2
Creating a machining program for front face machining Program head with workpiece definition:
with the main spindle.
Notes

B120 Setup Turning
Create contour description:  Straight X=-15 abs

 Front face, Starting point X=25 abs, Y =10 abs
 Straight Y=0 abs  End point
Notes

Setup Turning B120
Continuous path milling on front face and technology data: Starting the simulation:
Note:
In order for the depiction of the simulation to correspond to
the depiction of the contour programming, the transformation
has been deactivated (TRAFOOF) following the continuous
path milling and the C-axis positioned into the basic position
(G0 C0). Otherwise the depiction would be shown in the last
C-axis position to be approached =180 degrees; in other
words rotated by 180 degrees.
Cylinder mantle transformation (TRACYL)
 Cylinder mantle transformation main spindle: Transformation 3 (without slot side face correction with C–axis)
Set-
tings
24300 $MC_TRAFO_TYPE_3 512 Definition of the 3rd transformation in the channel
[0]=1 (X)
[1]=3 (C)
[3]=0
[4]=0
[0]=1 (X)
24320 [1]=3 (C)
_3 mation 3
[2]=2 (Z)
24800 $MC_TRACYL_ROT_AX_OFFSET_1 0 Offset of rotary axis for the 1st TRACYL transformation
24805 $MC_TRACYL_ROT_AX_FRAME_1 2 Rotary axis offset TRACYL 1
$MC_TRACYL_ROT_SIGN_IS_PLUS
24810 1 Sign of rotary axis for 1st TRACYL transformation
_1
24820 $MC_TRACYL_BASE_TOOL_1 0 Vector of base tool for 1st TRACYL transformation
Notes

B120 Setup Turning
Mantle machining with TRACYL (without slot side face

correction)
Offset of rotary axis for the 1st TRACYL transformation
MD24800
Offset of rotary axis for the 1st
$MC_TRACYL_ROT_AX_
TRACYL transformation
OFFSET_1
Default: 0 Grad Change to:
Description:
Indicates the offset of the rotary axis for the first agreed
TRACYL transformation in degrees in relation to the neutral
position while TRACYL is active.
The rotary position of the mantle plane in relation to the rotary

axis C can be entered here.
Rotary axis offset TRACYL 1 Sign of rotary axis for 1st TRACYL transformation
MD24805
$MC_TRACYL_ROT_AX_ Rotary axis offset TRACYL 1
FRAME_1 MD24810
Sign of rotary axis for 1st
$MC_TRACYL_ROT_SIGN_
Change to: 2 TRACYL transformation
IS_PLUS_1
Change to: 1
Description:
0: the axial offset of the rotary axis will not be taken into ac-
count. Description:
Indicates the sign with which the
1: the axial offset of the rotary axis will be taken into ac-
rotary axis is taken into account in
count.
the TRACYL transformation for
the first agreed TRACYL transfor-
2: the axial offset of the rotary axis will be taken into account
mation.
up to the SZS.
If the work piece is to be rotated during machining with

Corresponds to:
TRANSMIT, then this cannot be achieved by programming
MD24860
the rotary axis in the channel, since this is occupied by a ge-
$MC_TRACYL_ROT_SIGN_IS_PLUS_2
ometry axis (Y). An offset of the rotary axis in the transfor-
mation frame (TRANS, ROT, SCALE) will be taken into ac-
count during TRANSMIT if the setting is = 1.
Corresponds to:
MD24030 $MC_FRAME_ACS_SET
Notes

Setup Turning B120
Vector of base tool for 1st TRACYL transformation Creating a machining program for mantle machining with
the main spindle.
MD24820[x]
Vector of base tool for 1st
$MC_TRACYL_BASE_
TRACYL transformation
TOOL_1
MD24820[0] =0
MD24820[1] =0
MD24820[2] =0
Description:
Indicates a basic offset of the tools zero for the 1st TRACYL
transformation. The offset is referenced to the geometry axes
valid when TRACYL is active. The basic offset is included
with and without selection of the tool length compensation.
Programmed length corrections have an additive effect with
respect to the basic tool.
The index i takes on the values 0, 1, 2 for the 1st to 3rd ge-
ometry axes.
Corresponds to:
MD24870 $MC_TRACYL_BASE_TOOL_2
Notes

B120 Setup Turning
Testing the machining
Chuck, jaws, part receptacle and tailstock
This section describes

 the functions for opening closing and flushing of the chuck
for the main spindle
 The setting and dimensions of the jaws for the main spin-
dle
 The settings for part receptacle and
 The settings of the tailstock
Chuck
Machine data for the definition of M-commands
Notes

Setup Turning B120
M code for open chuck with non-rotating spindle M code for open chuck with rotating spindle
MD52250[x] MD52251[x]
M code for Open chuck with M code for Open chuck with
$MCS_M_CODE_CHUCK_ $MCS_M_CODE_CHUCK_
non-rotating spindle rotating spindle
OPEN OPEN_ROT
Default: - Change to: Default: - Change to:
e.g.: "M34" or "M1=34" e.g.: "M35" or "M1=35"
Elements: Elements:
MD52250[0] = Main spindle MD52251[0] = Main spindle
MD52250[1] = Counter spindle MD52251[1] = Counter spindle
M-code for Close chuck Chuck flushing, close, open
MD52252[x] For the control of the chuck functions there are jump exits
$MCS_M_CODE_CHUCK_ M- code for Close chuck from the ShopTurn cycles into the manufacturer-cycle
CLOSE CUST_TECHCYC.SPF.
Default: - Change to:

Description:
e.g.: "M36" or "M1=36"
Elements:
MD52251[0] = Main spindle
MD52251[1] = counter spindle
Notes

B120 Setup Turning
Continuation of Chuck flushing, close, open Note:

The definition of the M-commands for opening and closing
the chuck of the main and counter spindle does not occur in
CUST_TECHCYC.SPF but by way of machine data. This is
necessary in order for the opening and closing of the chuck
and the associated work piece movement to be shown cor-
rectly in the simulation also with G-programs. The M-
command for flushing the chuck occurs directly in Mode 5
since this is not necessary for the simulation.
Description:
The machine data are evaluated in the modes _M6, _M7 and
_M8. If the machine data contain a numerical value only, then
this will be put out as M-function without an extension. If the
machine datum contains an auxiliary function with an exten-
sion, e.g. M1=34, then this will be executed out as a string.
Jaws for the main spindle
Spindle chuck data
MD53240[x] ZC1: The parameter ZC1 is

$MAS_SPINDLE_ Spindle chuck data used for manual meas-
PARAMETER uring of tools if the
Default: 0, 0, 0 Change to: chuck of the main spin-
dle is used as reference.
Description: Furthermore for the sim-
ulation of the faceplate.
for AX3: MCS1
ZS1: The parameter ZS1 is
MD53240[0] =0 → e.g. 200 mm only used in the simula-
Chuck dimensions = ZC1 in the mask Spindle chuck data tion for the depiction of
MD53240[1] =0 → e.g. 120 mm the jaws.
Stop dimensions = ZS1 in the mask Spindle chuck data
MD53240[2] =0
Jaws dimensions = ZE2 in the mask Spindle chuck data
The inputs for the parameters "ZC1" for chuck dimensions
In case of the main spindle the selection for the type of jaws and "ZS1" for the dead stop dimensions are written into the
is not available. This machine datum 53240[2] is meaning- machine data MD53240[0] and MD53240[1] of the data block
less. of the C-axis. These entries are then transferred to the data
block of the spindle if there exists a separate C-axis as feed
The dimensions depend on the used jaws and can be drive for the C-axis mode apart from the main spindle.
changed by the machine operator.
Notes

Setup Turning B120
Check of the entries made in the window "Spindle chuck

data"
The entries for the parameters "ZC1" chuck dimension and

"ZS1 stop dimension for the counter spindle are identical in
MD53240.
_________________________________________________
Note:
The input field ZE1 for the jaw dimensions be shown only if
the jaw type 2 has been selected.
_________________________________________________
Spindle chuck data

Z1
MD53241
Spindle jaw type
$MAS_SPINDLE_CHUCK_TYPE
Default: 0 Change to: Z1
Description:
for AX3: MCS1
0 = Jaw type 1 = Clamping from outside

1 = Jaw type 2 = Clamping from inside
Jaw type 1:
Jaw type 1: Z1 lies in the WKS on the front edge of the
clamping jaws; so if for instance Z1 = -10, the work piece will
be inserted by 10 mm.
Jaw type 2:
Jaw type 2: Z1 lies on the inner jaw step; so for Z1 = 0, the
work piece will be inserted right up to the jaw step.
Notes

B120 Setup Turning
Part receptacle
MD52218
$MCS_FUNKTION_MASK_TURN
Description:
Bit 1: Release of the part receptacle
Example:
In case of a work piece ZI = 150mm long, ZB is theoretically
120mm, since 30mm were entered in ZS1 as the dead stop
dimension. For safety reasons, however, a further allowance
must be made to ensure that the tools do not damage the
surface of the chuck jaws.
MD52218 Bit 1 = 0 MD52218 Bit 1 = 1
Notes

Setup Turning B120
Continuation of Part receptacle
Description: Program mask Cutting-off cycle
No entries are prepared in the CUST_TECHCYC-jump ac- ShopTurn program: programGuide program:
cesses for the part receptacle.
_M100: This mode is used only in a ShopTurn-program, The

call-up occurs when the tool in the X-axis is on the
retraction level at the height of the cut-off position.
_M101: This mode is used both in ShopTurn programs as

also in a programGuide program. It is called up when
during the cut-off the position XM defined in the input
mask for the extension of the part receptacle has
been reached.
_M102: This mode is used both in ShopTurn programs as

also in a programGuide program. It is called up when
the destination depth of the cut-off is reached; it can
be used for swivelling the part receptacle into posi-
tion. Description:
The parameter ”Parts gripper” appears in the input masks
with the release of the part receptacle in MD52218 Bit 1 = 1.
If this is set to "yes" a further parameter XM appears for the
definition of the position for the extension of the part recepta-
cle. The destination depth, defined in parameter X2, is at the
same time the position for positioning the part receptacle.
Notes

B120 Setup Turning
Tailstock activation
Software-Option
For the depiction of the tailstock the option "ShopMill/
ShopTurn" is required.
MD52218
$MCS_FUNKTION_MASK_TURN
Description:
Bit 2: Release of tailstock
The tailstock dimensions are set up in the mask "Spindle

chuck data".
Tailstock data Tailstock programming
After release of the tailstock in MD52218 the parameter

MD53242[x]
Tailstock data "Tailstock" appears additionally in the program header of a
$MAS_TAILSTOCK_PARAMETER
ShopTurn-Program.
AX3: MCS1
MD53242[0] = XR1 Tailstock diameter
MD53242[1] = ZR1 Tailstock length
Description:
The inputs into the parameters "XR1" for tailstock diameter
and "ZR1" for tailstock length must be entered into the ma-
chine data MD53242[0] and MD53242[1] of the data set for
the C-axis. These entries are then transferred to the data set
of the spindle. The tailstock dimensions are used in the simu-
lation for the depiction of the tailstock.
With tailstock "yes" a further

parameter XRR for the defini-
tion of the retraction level in
the X-axis for the prevention of
collisions with the tailstock.
Notes

Setup Turning B120
Machine —> JOG
MD52010 BIG_FONT = 2
depending on MD52011
MD20098[X] Bit 0 = MCS actual

value window SD55212 FUNCTION_MASK_ TECH_SET
Bit 0 = 0 Tool preselection not active
MD51040
SWITCH_TO_MACHINE_MASK MD52206 AXIS_USAGE, Meaning of the axes in the channel
MD52207 AXIS_USAGE_ATTRIB, Axis attributes
MD52200 TECHNOLOGY = 1
Softkey Description
selection
MD52210 FUNKTION_MASK Bit 2 = 1
MD52200 = 1 =1: Technology Turning
MD51040 SWITCH_TO_MACHINE_MASK, Automatic operating area switchover to machine

Bit 0: When selecting a program in the program manager not automatically switch over
Bit 1: When switching the operating mode via the MCP not automatically switch over MD52200 = 1 =1: Technology Turning
Bit 2: When program selection in program not automatically switch over
Bit 3: When selection / execution under program not automatically start of block search
MD52210 Bit 2 = 0 Show Softkey “T,S,M“ in JOG

Bit 2 = 0 area
Notes

B120 Setup Turning
Softkey Description
Machine —> JOG —> WCS selection
MD20098[X] Bit 16 = WCS actual

value window
MD20100 DIAMETER_AX = X
and MD52200 TECHNOLOGY = 1
and no DIAMOF or MCS active Switchover Switchover Softkey from MCS to WCS via
MD20150[28] = 2 DIAMON PLC
MCS/WCS
Softkey Description
Machine —> JOG —> MCS selection
Spindles are displayed only if in axis
mode, MCS1 and MCS3 not displayed
(Default setting)

MD51023 ACT_VALUE_SPIND = 0 PLC
Spindles are always displayed MCS/WCS
alternative
Notes

Setup Turning B120

Bit 6 = 1 Tool length compensa-
tion is retained even after RESET
MD20130 = 1 Tool and tool edge
number retain active
Bit 16 = 1 Tool name or location number
MD17500
MAX_NUM_REPLACEMENT_TOOLS
For 828D the Replacement tools for tool
management option is required.
Bit 6 = 1 Active tool length offset is retained after reset
and
Bit 14 = 1 Automatic Tool change during Reset and Start
MD35040
SPIND_ACTIV_AFTER_RESET
= 2 Own spindle reset
MD35000 AX3:MCS1 = 1
MD35000 AX4:MCS3 = 3
These selection fields are displayed
for the configured spindles only
MD35010 GEAR_STEP_CHANGE_ENABLE
of AX3:MCS1 Bit 1 = 1
and
MD35090 NUM_GEAR_STEPS of C1 Number
of gear steps = 5
Notes

B120 Setup Turning
MD20152[7] G_CODE_RESET_MODE = 1
Work offset is retained even after Reset
Bit 0 = 0 Selection of the meas. unit on
the operator panel
Machine —> JOG —> Set WO
The softkey is highlighted if no G500 is active

and MCS is not selected
Notes

Setup Turning B120
MD52000 DISP_COORDINATE_SYSTEM = 34, Coordinate system position

33: Horizontal lathe with machining in front of the turning centre, 34: Horizontal lathe with machin-
ing behind the turning centre
Selection
Depending on the selection different

softkeys are displayed
Softkey Description
Machine —> JOG —> Measure tool selection

Bit 2 = 1 ment
MD52218 Bit 0 =1 Enable zoom under manual for tool

Bit 0 = 1 measurement

Bit 2 = 1 ment
Selection
Notes

B120 Setup Turning
MD52218 Bit 0 = 1
Enable Magnifying glass
SD54782 Bit 3 = 1
Select tool probe calibration data field
Notes

Setup Turning B120
Machine —> JOG —> Position
MD20098[2] Bit 20 = 0 Fade out spindle C

MD20098[3] Bit 20 = 0 Fade out spindle CS3
not displayed
Machine —> JOG —> Stock removal
SD55200 MAX_INP_FEED_PER_REV, Upper limit feedrate/rev

SD55201 MAX_INP_FEED_PER_TIME, Upper limit feedrate/min
SD55202 MAX_INP_FEED_PER_TOOTH, Upper limit feedrate/tooth
SD43220 SPIND_MAX_VELO_G26, Programmable upper spindle limitation G26

SD43230 SPIND_MAX_VELO_LIMS, Spindle speed limitation with G96
Notes

B120 Setup Turning
Softkey Description
Machine —> JOG —> Settings selection
MD35000 AX3:MCS1 = 1
MD35000 AX4:MCS3 = 3
These selection fields are displayed
for the configured spindles only
MD10260 = 1 1: Enable basic system conversion
MD10260 CONVERT_SCALING = 1
Softkey Description
selection

(828D only)
MD51067 = 1 =1: Show handwheel window

(Handwheel must be configured in
MD11350)
Notes

Setup Turning B120

MD18080 SD54215 TM_FUNCTION_MASK_SET
TOOL_MANAGEMENT_MASK Bit 0 = 1 Diameter display for rotating tools
Bit 10 = 1 (Multitool)
Bit 8 = 1 Diameter display for transverse axis - Geometry
Softkey Description
selection
Bit 0 = 1 Create tool on magazine location not allowed
Bit 7 = 1 Create tool using the tool number
Bit 2 = 1 Create tool without name suggestion
Bit 3 = 1 Input disable for tool name and tool type in loaded tools
Bit 4 = 1 Input disable for loaded tools, if the channel is not in Reset
Bit 11 = 1 Creating tool in gripper disabled
MD19320 Bit 4 = 1 Enable Tool Mamagement

Bit 4 = 1
Notes

B120 Setup Turning
SD54215 TM_FUNCTION_MASK Bit 1 = 0 M3 right

SD54215 TM_FUNCTION_MASK Bit 1 = 1 M4 left
Default direction of rotation for new created tools
MD52229 ENABLE_QUICK_M_CODES
MD52230 M_CODE_ALL_COOLANTS_OFF
MD52233 M_CODE_COOLANT_1_AND_2_ON

Softkey Description
Parameter —> Tool wear selection
Bit 5 = 1 Calculate tool wear inputs additively
Bit 9 = 1 Diameter display for transverse axis - Wear
Turning tools
ΔRadius
MD52270 Bit 12 = 0 Enable Reactivate tool

SD54215 TM_FUNCTION_MASK_SET Bit 12 = 0
Bit 7 = 1 Fade out tool monitoring parameters
These columns are displayed with active tool time

monitoring only MD20320 Bit 0 = 1
Notes

Setup Turning B120
Softkey Description
Parameter —> Magazine selection
MD17500 MAX_NUM_REPLACEMENT_TOOLS
MD52270 Bit 8 = 0 Enable Relocate tool

Bit 8 = 0
MD52270 Bit 9 = 0 Enable Position magazine

Bit 9 = 0
Bit 8 = 1 Fade out Relocate tool
Bit 9 = 1 Fade out Position magazine
For 828D the “Replacement tools for tool management”

option is required
Parameter —> Tool load
Bit 1 = 1 Load/unload disable, if machine is not in reset
Bit 2 = 1 Load/unload disable on Emergency stop
Bit 3 = 1 Load/unload tool to/from spindle is disabled
Bit 4 = 1 Loading is executed directly in the spindle
MD52274 TM_TOOL_LOAD_STATION
Default setting = 0 All configured stations are taken into account
Notes

B120 Setup Turning
Softkey Description
Parameter —> Setting data selection
MD35000 AX3:MCS1 = 1 MD52200 = 1 =1: Technology Turning

MD35000 AX4:MCS3 = 3
Assignment of spindles to machine axes,
otherwise this fields are not displayed
Softkey Description
Parameter —> Setting data selection
MD53241 AX3:MCS1 = X The input fields for the

0 = Clamp from outside tailstock data are dis- =1: Technology Turning
MD52200 = 1
= Jaw type 1 played only, if MD52218
1 = Clamp from inside Bit 2 = 1 and the ShopMill/
= Jaw type 2 ShopTurn option is set
MD53240[0] AX3:MCS1 = 40 Tailstock

MD35240[1] AX3:MC1S = 30 MD53242[0] AX3:C1 = 41
MD35242[1] AX3:C1 = 71
Notes

Setup Turning B120
Machine —> MDA
Bit 3 = 1 The M code entered in MD10714 M_NO_FCT_EOP is
Softkey Description
selection

(828D only)

(828D only)
Notes

B120 Setup Turning
Machine —> TEACH IN —> Teach program
The “Teach prog.“ softkey is displayed when

selecting TEACH IN at the MCP
Softkey Description
selection

(828D only)

(828D only)

(828D only)
Notes

Setup Turning B120
Softkey Description
Machine —> AUTO —> Time / Counter selection
MD27860 PROCESSTIMER_MODE
Bit 0 = 1 Measuring total runtime for all part programs
Bit 1 = 1 Measuring current program runtime
Bit 4 = 1 Measuring during active dry run feedrate
Bit 5 = 1 Measuring during program test
Bit 6 = 1 $AC_CYCLE_TIME is not deleted on start by ASUP
and PROG_EVENTs
Bit 8 = 1 Delete $AC_CYCLE_TIME with GOTOS
MD27880 Bit 0 =1: Sotkey Time/Counter

MD27880 PART_COUNTER oder Bit 8 = 1 =0: Softkey Times (Default setting)
Bit 0 or 8 or both =1
MD27880 PART_COUNTER
Bit 0 = 1 Counter $AC_REQUIRED_PARTS
Bit 8 = 1 Counter $AC_ACTUAL_PARTS
Bit 11 = 1 Increment AC_ACTUAL_PARTS
with GOTOS
Softkey Description
selection
Option Simultan. recording (real-time simulation)

(828D only)
Notes

B120 Setup Turning
Machine —> AUTO —> Overstore
Bit 3 = 1 The M code entered in MD10714 M_NO_FCT_EOP is
Machine —> AUTO —> Program control

The marked selection is
displayed here
MD51039 PROGRAM_CONTROL_MODE_MASK
Bit 0 = 1 Program test function available
Selection
Notes

Setup Turning B120
Softkey Description
Machine —> AUTO —> Block search (ShopTurn) selection

MD51024 BLOCK_SEARCH_MODE_MASK_JS and Bit 1 = 1 ShopTurn program
Bit 0 and 1 =1
MD51024 BLOCK_SEARCH_MODE_MASK_JS, Bit mask for available search modes

Bit 1: Block search with calculation with approach
(Default setting Bit 0 = 1)

(828D only)
Softkey Description
Machine —> AUTO —> Block search (G Code program) selection

MD51028 BLOCK_SEARCH_MODE_MASK and Bit 1 = 1 G code program
Bit 0 and 1 =1
MD51028 BLOCK_SEARCH_MODE_MASK Bit mask for available search modes

Bit 4: Block search without calculation

(828D only)
Notes

B120 Setup Turning
Softkey Description
Machine —> AUTO —> Simultaneous recording selection

Softkey bar with 3D
simulation option
Notes

Setup Turning B120
Softkey Beschreibung
Program manager —> New program Anwahl
Option ShopMill/ShopTurn
PROGRAM MANAGER, New
Program —> Edit

Notes

B120 Setup Turning
Program —> Edit

MD52200 TECHNOLOGY = 1 Turning
Softkey Description
selection
MD52201 TECHNOLOGY_EXT = 2
Subtechnology Milling

MD52201 = 2 =2: Subtechnology Milling
Notes

Setup Turning B120
Bit 0 = 0 Unhides input filed for mm/
inch
Selection
MD52212 FUNCTION_MASK_TECH
Bit 6 = 0, if 1 the Work offset value ZV
cannot be entered
Notes

B120 Setup Turning
Selection
MD52218 FUNCTION_MASK_TURN
Bit 2 = 1 Enable tailstock
SC = Safety distance
Bit 2 = 1 Depth calculation in milling cycles w/o SC
Selection
Bit 0 = 1 Milling cycles with synchronous operation
Notes

Setup Turning B120
MD52214 FUNCTION_MASK_MILL
Bit 4 = 1 Enable spindle clamping
MD52214 FUNCTION_MASK_MILL
Bit 3 = 1 Enable inside/rear machining
Milling: Longitudinal slot insertion

with closed clamping
Bit 0 CYCLE84
Bit 0 = 1 Unhide input fields Technology
Bit 1 CYCLE840 not relevant for ShopTurn
Notes

B120 Setup Turning
SD55216 FUNCTION_MASK_DRILL_SET
Bit 1 = Boring (CYCLE86) Consider rotation of the tool plane
Bit 2 = Boring (CYCLE86) Consider swiveled table kinematics
Bit 6 = Boring (CYCLE86) Adapt spindle position to the tool orientation
Bit 7 = Boring (CYCLE86) Adapt direction of retraction path in the plane to active mirroring
Notes

Setup Turning B120
Program —> Turning
MD52218 FUNCTION_MASK_TURN
Bit 1 = 1 Enable parts gripper for cut-off
All grooving cycles, undercut thread and thread cycles

SD55500 TURN_FIN_FEED_PERCENT, Roughing feedrate for
complete machining in %
- Grooving cycles: all
- Undercut: Undercut thread DIN und Undercut thread
- Thread cycles: all
Stock removal:
SD55505 TURN_ROUGH_O_RELEASE_DIST, Return distance stock removal for external machining
SD55506 TURN_ROUGH_I_RELEASE_DIST, Return distance stock removal for internal machining
Groove:
SD55510 TURN_GROOVE_DWELL_TIME, Negative value = clearance time in spindle revolutions
Positive value = clearance time in seconds
Notes

B120 Setup Turning
Bit 1 = 1 Calculate thread depth from metric
thread lead
Note: As soon as the line table "None" is select-
ed, the parameter H1 can be overwritten
Table
Selection
Bit 2 = 1 Refer to the table for thread diameter
and depth
Note: As soon as the line table "ISO metric" is
selected, the table is activated for the various
threads
Notes

Setup Turning B120
Softkey Description
Program —> Contour turning selection

Contour turning:
SD55580 TURN_CONT_RELEASE_ANGLE, Retraction angle
SD55581 TURN_CONT_RELEASE_DIST, Retraction value
SD55582 TURN_CONT_TRACE_ANGLE, Minimum angle for rounding along contour
SD55583 TURN_CONT_VARIABLE_DEPTH, Percentage for variable cutting depth
SD55584 TURN_CONT_BLANK_OFFSET, Blank allowance
SD55585 TURN_CONT_INTERRUPT_TIME, Feed interrupt time (neg. values = revolutions)
SD55586 TURN_CONT_INTER_RETRACTION, Retraction path after feed interrupt Option Residual material detection and machining
SD55587 TURN_CONT_MIN_REST_MAT_AX1, Min. difference dimension res. machining axis 1
SD55588 TURN_CONT_MIN_REST_MAT_AX2, Min. difference dimension res. machining axis 2
Plunge turning:
SD55595 TURN_CONT_TOOL_BEND_RETR, Retraction path due to tool bending
SD55596 TURN_CONT_TURN_RETRACTION, Retraction depth prior to turning
MD52210 FUNCTION_MASK
Bit 1 = 1 Front view for turning in
school coordinate system (Default)
TRANSMIT and TRACYL

must be configured
MD52210 FUNCTION_MASK
Bit 1 = 0 Front view in coordi-
nate system of the machine
Notes

B120 Setup Turning
Selection
Selection of the machining plane for Subtechnology

milling (MD52201 = 2)
Bit 2 = 1 Refer to the table for thread diameter
and depth
Note: As soon as the line table "ISO metric" is Table
selected, the table is activated for the various
threads
Selection
Notes

Setup Turning B120
Softkey Description
Program —> Simulation selection
MD51226 FUNCTION_MASK_SIM
Bit 0 = 1 No automatic start on simulation selection
MD53230 SIM_START_POSITION
for AX1:MX1 e.g. 500mm, for AX2:MZ1 e.g. 200mm.
The simulation is possible only, if for at least one geo-
axis a value not equal to 0 has been set.
MD52200 TECH-
NOLOGY = 0
MD52200 TECH-
Notes

B120 END Setup Turning
Program —> Measure workpiece
MD52201 = 0
no Subtechnology
MD52201 = 2
Measurement cycles option
Program —> Measure tool
MD52201 = 0
no Subtechnology
MD52201 = 2
Measurement cycles option
B120: END
Notes

B121 Setup Y-axis
Sinumerik
Operate
Module Description:
A turning machine with the linear axes X and Z as well as a main spindle C and a driven tool CS3,
now an additional Y-axis is to be added and tested.
The way of checking the undertaken parameterization is shown by means of examples and
illustrations.
Module Objective:
By means of this module you will learn which MD's must be adapted in order to retrofit a Y-axis to
an operative machine and at the end check it's function. In case of the transformations the special
aspects regarding the slot-wall correction will be pointed out.
Content:
Sinumerik
Setting up the Y-axis
TRANSMIT/TRACYL
Machining examples

B121

Setup Y-axis B121
Extension
Y-axis:
START
Setting up
the Y-axis
TRANSMIT/
TRACYL
Machining
examples
Extension
Y-axis:
END
Notes

B121 Setup Y-axis
Setting up the Y-axis
MD10000[x] MD20050[x]
Assignment of geometry axis
$MN_AXCONF_MACHAX_ Machine axis name $MC_AXCONF_GEOAX_
to channel axis
NAME_TAB ASSIGN_TAB
MD10000[0] = MX1 MD20050[0] = 1

MD10000[1] = MZ1 MD20050[1] = 6
MD10000[2] = MCS1 MD20050[2] = 2
MD10000[3] = MCS3
MD10000[4] = MQ1 New:
MD10000[5] = MY1 MD20050[1] = 6
New:
MD10000[5] = MY1 MD20060[x]
$MC_AXCONF_GEOAX_ Geometry axis to channel
NAME_TAB
Change to:
MD20060[0] = X
MD20060[1] = Y
MD20060[2] = Z
MD20070[x] MD20080[x]
Machine axis number valid in
$MC_AXCONF_MACHAX_ $MC_AXCONF_CHANAX_ Channel axis name in channel
channel
USED NAME_TAB
MD20070[0] = 1 MD20080[0] = X1
MD20070[1] = 2 MD20080[1] = Z1
MD20070[2] = 3 MD20080[2] = C
MD20070[3] = 4 MD20080[3] = CS3
MD20070[4] = 5 MD20080[4] = Q
MD20070[5] = 6 MD20080[5] = Y1
New: New:
MD20070[5] = 6 MD20080[5] = Y1
Notes

Setup Y-axis B121
Meaning of the axes in the channel Description:

0 = No special meaning
1 = Tool spindle (driven tool)
MD52206[x] Meaning of the axes in the
2 = Extension spindle (driven tool)
$MCS_AXIS_USAGE channel
3 = Main spindle (Turning)
4 = C-axis of the main spindle (Turning)
Change to:
5 = Counter spindle (Turning)
6 = C-axis of the counter spindle (Turning)
MD52206[0] = 0 7 = Linear axis of the counter spindle (Turning)
MD52206[1] = 0 8 = Tailstock (Turning)
MD52206[2] = 3 9 = Steady (Turning)
MD52206[3] = 1 10 = B-axis (Turning)
MD52206[4] = 0
MD52206[5] = 0
Validation of the changed MD's
New:
MD52206[5] = 0
Matching the MD's for the Y-axis AX6: MY1

MD30130 = 0 for simulation (command value)
MD30240 = 0 Simulation (actual value encoder)
MD30300 = 0
MD30310 = 0
MD30320 = 0
MD30350 = 1 for axis simulation
MD34000 = 0 axis without a reference point stop
Text in Italics mark entries for simulated axes.
Some of the undertaken changes will be activated only after

renewed Power ON (Softkey “Reset (po) )“ valid.
Scrolling the axes with Softkey Axis +/-)
The axis “Y1“ is now also visible in the machine configuration.
All axes, spindles and rotary axes can be traversed in both

directions by means of the operating elements.
Notes

B121 Setup Y-axis
Check of the installed axes and spindles:
The Y-axis is now available.
As a reminder:
MD52010 $MCS_DISP_NUM_AXIS_BIG_FONT is set to 3,
hence the 3 geo-axes are shown in large type.
The axis MY1 is now available.
Setting up the oblique Y-axis
_________________________________________________
Note:
The "Oblique Y-axis“ must be regarded as a special case. In

order to be able to use this function, the option “Oblique axis“
is required - Order Nr. 6FC5800-0AM28-0YB0.
The "Oblique Y-axis“ is not part of this documentation.
Function
If your turning machine features an oblique axis (i.e. an axis
that is not perpendicular to the axes X and Z) you can still
programme the entire machining operation in Cartesian co-
ordinates. The control unit transforms the Cartesian co-
ordinates into the motions of the oblique axis using the func-
tion oblique axis (TRAANG).
Notes

Setup Y-axis B121
TRANSMIT/TRACYL  Cylinder mantle transformation main spindle: Transfor-

mation 3 with slot side wall correction and Y–correction:
General aspects MD 24300 $MC_TRAFO_TYPE_3=514
The basic information and machine data settings have al-

ready been described in module “Setup Turning”. Only the The following axes are being assumed for the configuration of
differences and specialities regarding the transformations TRANSMIT/TRACYL:
TRANSMIT and TRACYL in conjunction with the Y-axis. Index
20080[0] $MC_AXCONF_CHANAX_NAME_TAB = X1 1
_________________________________________________ 20080[1] $MC_AXCONF_CHANAX_NAME_TAB = Z1 2
Note: 20080[3] $MC_AXCONF_CHANAX_NAME_TAB = CS3 4
There is a difference between the set-ups of TRANSMIT and 20080[4] $MC_AXCONF_CHANAX_NAME_TAB = Q 5
TRACYL depending on whether a Y-axis is available or not. 20080[5] $MC_AXCONF_CHANAX_NAME_TAB = Y1 6
Described here is the set-up as applicable when an Y-axis is
available.
_________________________________________________
The tables on the next pages gives an overview of the data
There are 2 differing sets of data, both of which must be set blocks for TRANSMIT and TRACYL.
 Front face machining main spindle: Transformation 1

MD 24100 $MC_TRAFO_TYPE_1=257 (with Y–axis)
Slot side wall correction
Description:
If the machine features a real Y-axis, an extended TRACYL-
variant "Type 514“ can be projected. This permits the machin-
ing of slots with side wall correction: Slot side wall and bottom
are perpendicular to one another - even if the cutter diameter
is less than the slot width. This under other circumstances is
possible only if the diameter is the same as the slot width.
The following sketches show the machining of a slot The slot side wall correction is available only for
 without slot side wall correction: By rotation of the  longitudinal slots
C-axis the slot walls are not parallel
 transverse slots
 With slot side wall correction: The slot width is ob-
tained by the displacement of the Y-axis - the slot
 slots in any direction (contours)
walls are now parallel to one another
The transformation of the type 514 in case of a machine with
a further linear axis makes use of the redundancy in order to
obtain a better tool correction. Applicable for the second line-
ar axis (Y-axis) is now:
● a reduced working range and
● that the second linear axis should not be used for exe-
cution of the part-program.
A programming example will be found on the following pages.
Notes

B121 Setup Y-axis
TRANSMIT/TRACYL
 Front face machining main spindle: Transformation 1 (with Y–axis)

 Cylinder mantle transformation main spindle: Transformation 3 (with slot side face correction and Y-correction)
Set-
tings
24100 $MC_TRAFO_TYPE_1 257 Definition of the 1st transformation in the channel
[0]=1 (X)
[1]=3 (C)
[3]=6 (Y)
[4]=0
[0]=1 (X)
24120 [1]=3 (C)
_1 mation 1
[2]=2 (Z)
24300 $MC_TRAFO_TYPE_3 514 Definition of the 3rd transformation in the channel
[0]=1 (X)
[1]=3 (C)
[3]=6 (Y)
[4]=0
[0]=1 (X)
24320 [1]=3 (C)
_3 mation 3
[2]=2 (Z)
Validation of the changed MD's
After all parameters have been entered they

must be validated by means of the Soft-Key
“Set MD active (cf)“.
Furthermore a re-boot is required for the simu-

lation and the graphical simulation. This can be
achieved either by means of the Softkey "HMI
Reboot“ or by switching the machine OFF and
back ON again.
Notes

Setup Y-axis B121
Machining examples Create contour description:

 Front face C, Starting point X=25 abs, Y =10 abs
In the drilling and milling cycles and in the contour descrip-  Straight X=-15 abs
tions the following machining faces can be selected in case of  Straight Y=0 abs
a real Y-axis:
 Mantle C
 Mantle Y
 Front face C
 Front face Y
Tool list
1st Machining example on the front face C
Continuous path milling on front face C and technology data: Starting the simulation:
Note:
In order for the depiction of the simulation to correspond to
the depiction of the contour programming, the transformation
has been deactivated (TRAFOOF) following the continuous
path milling and the C-axis positioned into the basic position
(G0 C0). Otherwise the depiction would be shown in the last
C-axis position to be approached =180 degrees; in other
words rotated by 180 degrees.
Notes

B121 Setup Y-axis
2nd machining example front face Y Create contour description:

 Front face Y, Starting point X=25 abs, Y =10 abs
 Straight X=-15 abs
 Straight Y=0 abs
Continuous path milling front face Y and technology data: Start simulation:
The depiction in the simulation corresponds to the depiction

in contour input mask.
Notes

Setup Y-axis B121
3rd programming example for mantle face machining Program header with blank definition:
with slot side wall correction
Create contour description: Contour description:
A slot with parallel walls is to be milled. For this it is not the

contour of the slot that is to be programmed, instead it is an
imaginative central path of a bolt being moved along the slot
that has to be programmed.
 Mantle C, starting point Y=0 abs, Z=10 abs

 Straight Z=-40 abs
 Straight Z=0 abs
For the slot side wall correction it is most important, that the
contour is programmed back to the starting point since the
slot mill traverses along this contour with the necessary Y-
axis offset.
Notes

B121 END Setup Y-axis
Continuous path milling and technology data: Machining sequence:
Note: Tool "END_MILL_D8_M“, diameter = 8 mm

Offset to the programmed contour D = 6 mm
The slot side wall correction must be used only in conjunction Resulting slot width: 12 mm (= 2x D)
with the radius correction. The input parameter D determines
the width of the slot = offset to the programmed path. In case of cylinder mantle curve transformation with slot side
wall correction the axis used for the correction (Y-axis) should
be set to 0 (y=0) such that the slot will be machined centrally
to the programmed slot centre line.
Travelling paths:
The entry into the slot takes place at a position of -2 mm
(D - tool diameter), the return path takes place at a Y-position
of +2 mm (-D + tool diameter).
The difference in the Y-axis is therefore 4mm. If the slot-mill
diameter of 8 mm is added the slot width of 12mm is ob-
tained.
The simulation below shows the retraction from the slot.
Simulation depiction:
Note:
In the mask "Path milling “ the radius correction "to the left of
the contour“ is selected. Alternatively it is also possible to
select the radius correction "to the right of the contour“. The
only difference is the direction of traverse in the slot, i.e. when
entering the slot the Y-axis is positioned on +2 mm, on the
way back on -2 mm. The result on the work piece is identical.
B121: END
Notes

B122 Setup Counter spindle/Tailstock
Sinumerik
Operate
Module Description:
In this module a counter spindle will first of all be set up and shown as to which settings are
required for the axis ZS2 and the spindle CS2. In a subsequent step the technologies TRANSMIT
will be set up for the counter spindle and the technology TRACYL for the available axes/spindles.
After that follows the configuration for "Traverse to fixed stop" as well as for cutting-off. Lastly the
setting up of the counter spindle tailstock will be described.
A simple machining example using the main and the counter spindle, supported by illustrations, will
be used to thoroughly check the functionality.
A more complex machining example for facing with the main spindle, followed by circumferential
machining using the counter spindle and finally a facing operation with the counter spindle will be
used to check the functionality of TRANSMIT and TRACYL. This example, too, will be illustrated by
pictures showing the machining progress.
Module Objective:
With the aid of this module you will learn matching of general MD, channel MD and axis MD, in
order to extend the functionality of the machine and to equip the counter spindle with the technolo-
gy TRANSMIT/TRACYL. The travelling to a fixed stop as well as the cutting-off and the setting-up
of a tail stock for the counter spindle complete the functionality of the machine.
Content:
Sinumerik
Counter spindle set-up
TRANSMIT TRACYL for the counter spindle set-up
Travelling to a fixed stop
Tailstock for the counter spindle set-up
Machining example MSp - CSp
Machining example MSp - CSp TRANSMIT TRACYL

B122

Setup Counter spindle/Tailstock B122
Machining
Counter spindle/ example
Tailstock set-up: MSp - CSp
START TRANSMIT
TRACYL
Counter Counter spindle/

spindle Tailstock set-up:
set-up END
TRANSMIT
TRACYL for
the counter
spindle
set-up
Travelling to
a fixed stop
Tailstock for
the counter
spindle
set-up
Machining
example
MSp - CSp
Notes

Counter spindle set-up Before machining the rear face, the counter spindle must
grab the work piece, pull it away from the main spindle and
If your machine features a counter spindle, you will be able to move it to the new machining location.
machine work pieces using turning, drilling and milling opera-
tions on all faces without having to re-load the work piece
manually.
Setting-up the axis and spindle Meaning of the axes in the channel
_________________________________________________
Note: MD52206[x] Meaning of the axes in the
The spindle denominations C2 and C3 are not permissible, $MCS_AXIS_USAGE channel
since these denominations are already used in the numerical
range of MD10620 – MD10640. Change to: [6] = 7
[7] = 5
If these abbreviations are used, the error message 4020
"Denomination C2 used repeatedly in the machine datum MD52206[6] = 7 Linear axis of the counter spindle ZS2
$MN_AXCONF_MACHAX_NAME_TAB“ MD52206[7] = 5 Counter spindle CS2
_________________________________________________
Description:
0 = No special meaning
MD10000[6] = MZS2 1 = Tool spindle (driven tool)
MD10000[7] = MCS2 2 = Extension spindle (driven tool)
3 = Main spindle (turning)
MD20070[6] = 7 4 = C-axis of the main spindle (turning)
MD20070[7] = 8 5 = Counter spindle (turning)
6 = C-axis of the counter spindle (turning)
MD20080[6] = ZS2 7 = Linear axis of the counter spindle (turning)
MD20080[7] = CS2 8 = Tailstock (turning)
9 = Steady (turning)
10 = B-axis (turning)
Notes

Matching of the axis MD for rotary axis/spindle AX7: MZ2 (Linear axis of the counter spindle)
MD30130 = 0 for simulation (command value)
MD30240 = 0 Simulation (actual value Encoder)
MD30300 = 0
MD30310 = 0
MD30320 = 0
MD34000 = 0 axis without reference cam
Text in italics shows entries for simulated axes.

________________________________________________
Note:
In the axis MD's 32000, 32010, 32020, 35100, 35110, 35120,
35130, 36200 the speeds of the - possibly - available gearbox
steps and their minimum and maximum limits must be en-
tered depending on the machine execution.
(Scrolling of axes using Softkey axis +/-) ________________________________________________
AX8: MCS2 (Counter spindle)
MD30130 = 0 for Simulation (com. value)
MD30240 = 0 Simulation (actual value encoder)
MD30300 = 1 axis is rotary axis
MD30310 = 1 Modulo transformation for rotary axis
MD30320 = 1 actual value readout Modulo
MD34000 = 0 axis without reference cam
MD35000 = 2 Assignment spindle to machine axis
(spindle S2)
Check of the installed axes and spindles:
The ZS2-axis is now available.
As a reminder:
MD52010 $MCS_DISP_NUM_AXIS_BIG_FONT is set to 3,
hence the 3 geo-axes are shown in large type.
The axis MZS2 and the spindle MCS2 is now available.
Notes


_RESET
Change to: 2
AX3: MCS1
MD35040 = 2 Own spindle-RESET (Main spindle)
MD10714 M function for spindle active
$MN_M_NO_FCT_EOP after reset AX4: MCS3
MD35040 = 2 Own spindle-RESET (Tool spindle)
Change to: 32 AX8: MCS2
MD35040 = 2 Own spindle reset (Counter spindle)
Suggestion M32
Description:
Description:
This machine data defines the response of the spindle after
With Start in the manual mode-of-operation (T,S,M-mask, Reset and program end (M2, M30).
position) the part-program MA_JOG_STEP1 will be generat-
ed and executed. This MD is only active in the spindle mode open-loop control
This part-program will be finished with the M-function in mode. In the positioning or oscillation mode, the spindle is
MD10714. The setting of MD35040 = 2 ensures that the spin- always stopped.
MD35040 $MA_SPIND_ACTIVE_AFTER_RESET = 0:
reset)
 Spindle does not stop at the M function configured via
 However, the spindle stops at channel or mode group
reset.
Not relevant to:

 Spindle modes other than open-loop control mode.
Notes

Travelling direction Description:

By means of this MD the direction of motion of the machine
The following settings must be made to inform the user inter- can be reversed. The conventions, however, will not be lifted
face and the cycles in which direction the spindles and rotary in this case; i.e. the rules will be upheld.
axes are rotating.
The direction of rotation of an NC-rotary axis is specified via _________________________________________________
the MD32100 $MA_AX_MOTION_DIR.
Note:
For SINAMICS-Drives it is recommended to utilise the direc-
These settings are: tion reversal in the drive. See P1821 under the control Unit
Specific to machine manufacturers. MD (Drive MD).
With reference to the work piece the main and the counter
spindle must have the same direction-of-rotation and speed in
MD32100 Traversing direction (not con- order to enable the transfer of the work piece from the main
$MA_AX_MOTION_DIR trol direction) to the counter spindle under synchronous running conditions.
Default: 1 ändern auf: The machine manufacturer cycle CUST_TECHCYC.SPF is

called up in the ShopTurn cycles.
Here the default for the coupling of the main and counter
0, 1: Direction reversal spindle can be changed Mark _M120.
-1: No direction reversal _________________________________________________
Specifying the direction of rotation As a reminder: Here once more the axis indexes
MD52206[6] = 7 Linear axis of the counter spindle ZS2

MD52207[x] MD52206[7] = 5 Counter spindle CS2
Axis attributes
$MCS_AXIS_USAGE_ATTRIB

Bit 4 = 1
Bit 5 = 0
Note:
MD52207[7] CS2 In order to be able to use the counter spindle on your ma-
Bit 3 = 1: C+ Direction of rotation is counter-clockwise (for chine, the following software-options will be required:
rotary axes).
 "Travelling to a fixed stop with Force Control"
Bit 4 = 1: M3 Indicated direction of rotation for M3 is counter Order Nr. 6FC5800-0AM01-0YB0
-clockwise (for spindles) Is required if cutting-off in the counter spindle is envis-
aged.
Bit 5 = 0: M3 Direction of rotation M3 means rotary axis mi-
nus (for spindles).
 “Generic coupling "CP-STATIC“
Order Nr. 6FC5800-0AM75-0YB0
Note:
If there is a separate C-axis drive, the entry for Bit 3 must be
made in the data set of that drive.
Notes

From this derive the following setting possibilities for the counter spindle. The settings of the machine data, however, depend on
the direction of viewing the co-ordinate axis.
No matter as to which of the four combinations of MD52207[6] Bit 3 und Bit 4 shown below the machine manufacturer selects, it
is imperative that the settings shown in one line for PLC interface signal “Invert M3/M4” and MD52207[6] Bit 5 are used.
52207[7] CS2 52207[7] CS2 PLC bit CS2 52207[7] CS2

Direction of rotation counter spindle Bit 3 Bit 4 “Invert M3/M4“ Bit 5
1 1 0 0
1 0 1 1
0 0 0 0
0 1 1 1
The setting of the machine datum MD52207 Bit 3 assumes that the direction of viewing is in direction of the negative Z-axis . If,
however, you are looking in the positive direction of the co-ordinate axis, the values must be reversed; i.e. "0" and "1" must be
interchanged.
Note:
The MD52207[6] of the counter spindle affects
 the readout of the spindle direction in the user interface
 the depiction in the simulation and for sketching
 the direction of rotation of the spindle after a tool change according to the direction of rotation from the tool.
Notes

TRANSMIT and TRACYL for the counter spindle set-up There are 2 differing sets of data, both of which must be set
General aspects
 Front face machining counter spindle: Transformation 2
The basic information and machine data settings have al- MD 24200 $MC_TRAFO_TYPE_2=257 (with Y–axis)
ready been described in module “Setup Turning”. Only the
differences and specialities regarding the transformations  Cylinder mantle transformation counter spindle: Transfor-
TRANSMIT and TRACYL in conjunction with the counter mation 4 With slot side face correction and Y–correction:
spindle. MD 24400 $MC_TRAFO_TYPE_4=514
_________________________________________________
Note:
The tables on the next pages gives an overview of the data
There is a difference between the set-ups of TRANSMIT and blocks for TRANSMIT and TRACYL.
TRACYL depending on whether a Y-axis is available or not.
Described here is the set-up as applicable when an Y-axis is
available.
_________________________________________________
Note: These MD's were already configured in the module

“Setup Turning” in section TRANSMIT/TRACYL for the
With the function TRANSMIT/TRACYL a non-existent Y-axis main spindle.
will be simulated by an interpolation between X/C (in case of
TRANSMIT) or Z/C (in case of TRACYL). In this configuration MD10602 $MN_FRAME_GEOAX_CHANGE_MODE = 1
example there is beside the counter spindle no separate C- MD24040 $MC_FRAME_ADAPT_MODE = 7H
axis as feed drive for the C-axis mode-of-operation. For this
reason the channel index of the counter spindle must be en- The sets of data for TRANSMIT and TRACYL described be-
tered for the CS2-axis into the configuration data for TRANS- low are as required for the horizontal lathe with machining
MIT/TRACYL.. behind the turning centre as configured here and the axis
configuration as described above. Nevertheless the condi-
tions on the machine might require matching of this set of
As a reminder: the machine is already configured thus: data, such as for instance the direction of rotation of the
C-axis in case of the transformation or the input of an offset.
Index
20080[0] $MC_AXCONF_CHANAX_NAME_TAB = X1 1
20080[1] $MC_AXCONF_CHANAX_NAME_TAB = Z1 2
20080[4] $MC_AXCONF_CHANAX_NAME_TAB = Q 5
20080[5] $MC_AXCONF_CHANAX_NAME_TAB = Y1 6
20080[6] $MC_AXCONF_CHANAX_NAME_TAB = ZS2 7
Notes

Front face machining (TRANSMIT)
 Front face machining counter spindle: Transformation 2 (with Y–axis)
24200 $MC_TRAFO_TYPE_2 257 Definition of the 2nd transformation in the channel
[0]=1 (X)
[1]=8 (CS2)
[3]=6 (Y)
[4]=0
[0]=1 (X)
$MC_TRAFO_GEOAX_ASSIGN_TAB Assignment of geometry axes to channel axes for trans-
24220 [1]=8 (CS2)
_2 formation 2
[2]=2 (Z)
$MC_TRANSMIT_ROT_AX_OFFSET Offset of rotary axis for the 2nd TRANSMIT transfor-
24950 0
_2 mation
$MC_TRANSMIT_ROT_AX_FRAME_
24955 2 Rotary axis offset TRANSMIT 2
2
$MC_TRANSMIT_ROT_SIGN_IS_PL
24960 0 Sign of rotary axis for 2nd TRANSMIT transformation
US_2
Restriction of working range in front of / behind the pole,
24961 $MC_TRANSMIT_POLE_SIDE_FIX_2 1
2. TRANSMIT
24970 $MC_TRANSMIT_BASE_TOOL_2 0 Vector of base tool for 2nd TRANSMIT transformation
Front face machining (TRANSMIT) Rotary axis offset TRANSMIT 2
Offset of rotary axis for the 2nd TRANSMIT transfor- MD24955

mation $MC_TRANSMIT_ROT_AX_ Rotary axis offset TRANSMIT 2
FRAME_2
MD24950 Change to: 2

Offset of rotary axis for the 2nd
OFFSET_2
Description:
Default: 0 Grad Change to: 0: axial rotary axis offset is not considered
Description: 1: axial rotary axis offset is considered
States the offset of the rotary axis in degrees in relation to the 2: axial rotary axis offset is considered until SZS.
zero position while TRANSMIT is active for the second
agreed TRANSMIT-transformation. The SZS-frames include transformed rotations around the
rotary axis.
Corresponds to:
MD24900 $MC_TRANSMIT_ROT_AX_OFFSET_1 Note:
This setting is necessary in conjunction with JobShop.
Notes

Sign of rotary axis for 2nd TRANSMIT transformation Restriction of working range before/behind the pole, 2.
TRANSMIT
MD24960 MD24961 Restriction of working range

Sign of rotary axis for 2nd
$MC_TRANSMIT_ROT_ $MC_TRANSMIT_POLE_ before/behind the pole, 2.
SIGN_IS_PLUS_2 SIDE_FIX_2 TRANSMIT
Indicates the sign with which the rotary axis is taken into Restriction of the working range before/behind the pole or
account in the TRACYL transformation for the 2nd agreed else no restriction; i.e. travelling through the pole.
TRACYL transformation for each channel. The sign of the
virtual Y-axis is meant in this context. The assigned values have the following meaning:
Corresponds to: 1: Working area of linear axis for positions >= 0,

MD24910 $MC_TRANSMIT_ROT_SIGN_IS_PLUS_1 (if tool length correction parallel to the linear axis = 0)
Note: 2: Working area of linear axis for positions <=0,

(if tool length correction parallel to the linear axis = 0)
Match to the machine conditions.
0: No restriction of working area. Traversal through pole.
Vector of base tool for 2nd TRANSMIT transformation
MD24970[x]
Vector of base tool for 2nd
$MC_TRANSMIT_BASE_
TOOL_2
MD24970[0] = 0
MD24970[1] = 0
MD24970[2] = 0
Description:
States a basic offset for the tool zero point offset for the 2nd
TRANSMIT-transformation. This MD will only be required. For
the standard application the default is applicable.
The index i takes the values 0, 1, 2 for the 1st to the 3rd ge-
ometry axis.
Corresponds to:
MD24920 $MC_TRANSMIT_BASE_TOOL_1
Notes

Cylinder mantle transformation (TRACYL)
 Cylinder mantle transformation main spindle: Transformation 4 (with slot side face correction and Y-correction)
24400 $MC_TRAFO_TYPE_4 514 Definition of the 4th transformation in the channel
[0]=1 (X)
[1]=8 (CS2)
[3]=6 (Y)
[4]=0
[0]=1 (X)
$MC_TRAFO_GEOAX_ASSIGN_TAB Assignment of geometry axes to channel axes for trans-
24420 [1]=8 (CS2)
_4 formation 4
[2]=2 (Z)
24850 $MC_TRACYL_ROT_AX_OFFSET_2 0 Offset of rotary axis for the 2nd TRACYL transformation
24855 $MC_TRACYL_ROT_AX_FRAME_2 2 Rotary axis offset TRACYL 2
$MC_TRACYL_ROT_SIGN_IS_PLUS
24860 1 Sign of rotary axis for 2nd TRACYL transformation
_2
24870 $MC_TRACYL_BASE_TOOL_2 0 Vector of base tool for 2nd TRACYL transformation
Mantle machining with TRACYL for the counter spindle Rotary axis offset TRACYL 2
(without correction of slot side edge )
MD24855
$MC_TRACYL_ROT_AX_ Rotary axis offset TRACYL 2
FRAME_2
Offset of rotary axis for the 2nd TRACYL transformation
Change to: 2
MD24850 Description:
Offset of rotary axis for the 2nd
$MC_TRACYL_ROT_AX_
TRACYL transformation 0: axial rotary axis offset is not considered.
OFFSET_2
Default: 0 Grad Change to: 1: axial rotary axis offset is considered.
2: axial rotary axis offset is considered until SZS.

Description:
Indicates the offset of the rotary axis in degrees in relation to The SZS frames include transformed axial rotary axis offsets.
the neutral position for the 2nd agreed TRACYL transfor-
mation for each channel.
Irrelevant:
if no TRACYL is active
Notes

Sign of rotary axis for 2nd TRACYL transformation Vector of base tool for 2nd TRACYL transformation
MD24860 MD24870[x]
Sign of rotary axis for 2nd Vector of base tool for 2nd
$MC_TRACYL_ROT_SIGN_ $MC_TRACYL_BASE_
TRACYL transformation TRACYL transformation
IS_PLUS_2 TOOL_2
Change to: 1 Default: 0, 0, 0 mm Change to:
Description: MD24870[0] = 0
MD24870[1] = 0
Indicates the sign with which the rotary axis is taken into MD24870[2] = 0
account in the TRACYL transformation for the 2nd agreed
TRACYL transformation for each channel. Description:
Corresponds to: Indicates a basic offset of the tools zero for the 2ndTRACYL
MD24810 $MC_TRACYL_ROT_SIGN_IS_PLUS_1 transformation. The offset is referenced to the geometry axes
valid when TRACYL is active. The basic offset is included
Note: with and without selection of the tool length compensation.
Programmed length corrections have an additive effect with
Match to the machine conditions.
respect to the basic tool.
The index i takes the values 0, 1, 2 for the 1st to 3rd geome-
try axes.
Corresponds to:
MD24820 $MC_TRACYL_BASE_TOOL_1
Activation of the undertaken alterations Switching between axis mode and clamping
After all parameters have been entered and validated by Extract from the CUST_TECHCYC.SPF
means of the softkey “Set MD active (cf)“ one further step is
necessary.
Turn the main switch OFF once and turn it back ON again to
cause the control to re-boot. By this the control unit is
matched to the undertaken alterations.
Notes

Continue: Switching between axis mode and clamping Description:

For the switching of the counter spindle into the C-axis mode-
of-operation and for clamping or unclamping of the counter
spindle the following jumps into the manufacturer cycle
CUST_TECHCYC.SPF have been prepared:
_M21: Switching of the counter spindle into the C-axis mode-
of-operation.
_M22: Switching of the C-axis mode to the spindle mode
_M23: Counter spindle clamping
_M24: Counter spindle release clamping
Description: The following line positions the counter spindle to 0 degrees:

SPOS[_F_S_NR[2]]=0
_M21: Switching to the C-axis mode This query ensures that the counter spindle is not positioned
When switching to the C-axis mode there is a difference, again if it was switched into the axis mode beforehand.
whether the C-axis mode is carried out with the drive of the
counter spindle or by means of a separate feed drive. 2. Separate feed drive fitted:
The IF-query described above and the subsequent ENDIF-
1.No separate feed drive fitted: command must be replaced by the logic for the coupling of
The following entry is provided : the separate feed drive. This should preferably be effected in
IF (($P_SMODE[_F_S_NR[2]]<>2)AND($P_SMODE a separate manufacturer cycle, e.g. AXIS_CS2_ON.SPF.
[_F_S_NR[2]]<>4))OR($P_PROG_EVENT==5) _M21: Sub spindle: Change to C axis mode
AXIS_CS2_ON
Variable _F_S_NR: The spindle index of the main, the tool GOTOF _MEND
and the counter spindle.
In order to enable the CUST_TECHCYC-draft to be generally Example for the manufacturer cycle AXIS_CS2_ON.SPF:
valid for all applications the spindle index is determined by PROC AXIS_CS2_ON
means of the variable _F_S_NR from the existing axis config- IF $P_SEARCH==1 GOTOF _END
urations (setting via MD52206 $MCS_AXIS_USAGE. IF $P_SIM==1 GOTOF _END
The following applies: ; Cycle not to be carried out during block search and
_F_S_NR[0] contains the spindle index of the main spindle ; simulation
_F_S_NR[1] contains spindle index of the tool spindle IF $A_IN[24]==1
_F_S_NR[2] contains spindle index of the counter spindle ;Cycle not to be carried out on report by the PLC, that the
feed drive is already coupled
From this derives the following logic: GOTOF _END
The IF-query is fulfilled, if the counter spindle is not in the ENDIF
mode-of-operation 2 = positioning and not in the mode-of- M[_F_S_NR[2]]=41 ;Select counter spindle gear stage 1
operation 4 = axis mode or the program event is in the mode SPOSA[[_F_S_NR[2]]=0 ;Positioning of counter spindle
5 = block search. WAITS(1) ;Wait until spindle position is reached
Notes

Continuation of extract from CUST_TECHCYC.SPF

2. Separate feed drive fitted:
As described in the previous mode a further manufacturer
STOPRE cycle for un-coupling the separate feed drive is used: AX-
G0 CS2=0 ;CS2-axis positioning IS_CS2_OFF.SPF and this is called up in _M22.
STOPRE
M66 ;M-command for coupling the CS2-axis _M22: ; Sub spindle: Change to spindle mode
MARK1: AXIS_CS2_OFF
IF $A_IN[24]==1 GOTOF MARK2 GOTOF _MEND
;Query whether coupling has taken place
GOTOB MARK1 ; Jump back until coupling is completed Example for manufacturer cycle AXIS_CS2_OFF.SPF:
MARK2:
_END: PROC AXIS_CS2_OFF
IF $P_SIM==1 ;Simulation active IF $P_SEARCH==1 GOTOF _END
M[_F_S_NR[2]]=70 ;Switch counter spindle to the axis mode IF $P_SIM==1 GOTOF _END
ENDIF ; Cycle not to be carried out with block search and simulation
M17 M67 ;M-command for un-coupling the CS2-axis
MARK1:
_M22: Switching the counter spindle to the spindle IF $A_IN[24]==0 GOTOF MARK2
mode: ;Query, whether un-coupling is completed
1. no separate feed drive : GOTOB MARK1
The following entry has been prepared: MARK2:
IF($SP_MODE[_F_S_NR[2]]<>1 ENDIF
;N220 M[_F_S_NR[2]]= _END:
ENDIF M17
Line N220 can be extended by „5“. The counter spindle will
be switched back to the spindle mode with the command M5
_M23: Sub spindle: C axis clamping Coupling

The following entry has been prepared:
;N230 M[_F_S_NR[2]]=
Extract from CUST_TECHCYC.SPF
;N235 $AC_PRTIME_A_INC=1.5
In line N230 enter the M-command for clamping the counter

spindle. Line N235 has been prepared for matching the time
evaluated in the simulation to the real machining time.
_M24: Sub spindle: Release C axis clamping

The following entry has been prepared:
;N240 M[_F_S_NR[2]]=
;N245 $AC_PRTIME_A_INC=1.5
In line N240 enter the M-command for clamping the counter

spindle. Line N235 has been prepared for matching the time
evaluated in the simulation to the real machining time.
Notes

Continued: Coupling Description:
Definition of coupling counter spindle/main spindle

_M120: Definition of the coupling of spindle [2], spindle [0]
_M121: End of C-axis mode-of-operation after COUPOF
_M122: Definition of the coupling spindle [0], spindle [2]
_M123: Switch of C axis mode after CUPOF
_M125: Change to main spindle
_M126: Change to counter spindle
_M120: Definition: Coupling counter spindle/main spindle

N1200 COUPOF(SPI(_F_S_NR[0]),SPI(_F_S_NR[2]))
N1201 COUPDEL(SPI(_F_S_NR[0]),SPI(_F_S_NR[2]))
N1202 COUPDEF(SPI(_F_S_NR[2]),SPI(_F_S_NR[0]),1,1,
”NOC”,”DV”)
The prepared COUPDEF-command for coupling the main
and counter spindle can be made to suit by the machine man-
ufacturer, for example to change the direction of rotation be-
tween the two spindles.
_M125 and _M126:

No entries prepared here.
Chuck MD52251[0] Main spindle

MD52251[1] Counter spindle
Machine data for definition of the M-commands
Description:
M code for Open chuck with non-rotating spindle
M-Code for open chuck with rotating spindle.
e.g.: "M35" or "M1=35"
MD52250[x]
M code for opening chuck with
$MCS_M_CODE_CHUCK_
non-rotating spindle
OPEN
Default: Change to:

M code for Close chuck
MD52250[0] Main spindle MD52252[x]

MD52250[1] Counter spindle $MCS_M_CODE_CHUCK_ M code for closing the chuck
CLOSE
Description:
Default: Change to:
M-Code for opening chuck with non-rotating spindle.
e.g.: "M34" or "M1=34"
MD52252[0] Main spindle
M code for Open chuck with rotating spindle MD52252[1] Counter spindle
Description:
MD52251[x]
M code for opening chuck with M-Code for Close chuck
$MCS_M_CODE_CHUCK_
rotating spindle e.g.: "M36" or "M1=36"
OPEN_ROT
Default: Change to:
Notes

Chuck flushing, closing, opening
Description: Note:
Chuck of the counter spindle opening, closing and flushing The M-commands for opening and closing the chucks of the
main and the counter spindle are not defined by
_M26: Counter spindle chuck closing
CUST_TECHCYC.SPF. but by the machine data. This is nec-
if chuck [1] not closed, then closing
essary for the opening and closing of the chucks and the as-
sociated work piece motions to be correctly shown in the sim-
_M27: Counter spindle, chuck opening while stationary
ulation of G-code programmes.
if chuck [1] not open, then opening
Description:
_M28: Counter spindle, chuck opening while rotating
if chuck [1] not open while rotating, then opening The machine data are evaluated in the modes _M26, _M27
and _M28 . If the machine data contain only a numerical val-
_M29: Counter spindle, de-selection of chuck flushing ue then this will be put out as an M-function without an exten-
sion. If the machine datum contains an auxiliary function
with extension, e.g.. M1=34, then this will be carried out as a
string.
Notes

Clamping jaws counter spindle Note 1

Alteration to the machine data will automatically be trans-
Spindle chuck data ferred to the menu display Spindle chuck data and vice versa.
_________________________________________________
MD53240[x] In case of machines that feature a Y-axis, a parking position

Spindle chuck data must be created for this spindle to ensure collision-free work-
$MAS_SPINDLE_PARAMETER
ing. The default 0 is usually adequate.
_________________________________________________
Description: Note 2
for AX8: MCS2 In order to show the counter spindle firstly without tailstocks,
it is sensible to temporarily take out a setting of the basic ma-
MD53240[0] = e.g. 50 mm chine!
Chuck dimension = ZC2 in the mask Spindle chuck data _________________________________________________
MD53240[1] = e.g. 40 mm
Stop dimension = ZS2 in the mask Spindle chuck data MD52218 Bit 2 = 0
MD53240[2] = e.g. 22 mm AX3: MCS1

MD53242[0] = 0
Jaw dimension = ZE2 in the mask Spindle chuck data
MD53242[1] = 0
The dimension for ZE2 takes effect only when the jaw type 2
is selected; Z1 would be shifted by this amount.
Check of the entries made in the window "Spindle chuck

data"
The entries for the parameters "ZC2" chuck dimension and

"ZS2 stop dimension for the counter spindle are identical in
MD53240.
_________________________________________________
Note:
The input field ZE2 for the jaw dimensions be shown only if
the jaw type 2 has been selected.
_________________________________________________
Notes

Spindle chuck data

Z1
MD53241
Spindle jaw type
$MAS_SPINDLE_CHUCK_TYPE
Default: 0 Change to: Z1
Description:
for AX8: MCS2
0 = Jaw type 1 = Clamping from outside

1 = Jaw type 2 = Clamping from inside
Jaw type 1:
Jaw type 1: Z1 lies in the WKS on the front edge of the
clamping jaws; so if for instance Z1 = -10, the work piece will
be inserted by 10 mm.
Jaw type 2:
Jaw type 2: Z1 lies on the inner jaw step; so for Z1 = 0, the
work piece will be inserted right up to the jaw step.
Travelling to a fixed stop Description:

Activation of sub functions of "Travel to fixed stop".
Travelling to a fixed stop is required to enable the controlled
transfer of a work piece, that was being machined in the main Release of Travelling to a fixed stop
spindle, to the counter spindle for continued machining.
Bit 0: Reserved
Release of the safe brake test

Travel to fixed stop mode Bit 1 = 0: Safe brake test not available
Bit 1 = 1: Safe brake test can be executed under the control
of the PLC.
MD37000
Travel to fixed stop mode
$MA_FIXED_STOP_MODE _________________________________________________
Note:
When enabling these functions the user must ensure that
Travelling to a fixed stop and Safe brake test are not called
up simultaneously.
_________________________________________________
Notes

Retract position Z for counter spindle Description:

In this example Z2 is the linear axis of the counter spindle.
Hence the parameter list for AX7: MZS2 must be selected
SD55232 Retract position Z for coun- and there MD37050 = 2 must be set. .
$SCS_SUB_SPINDLE_REL_POS ter spindle
The machine datum determines whether the alarms:
Change to: e.g. 700mm 20091 "Fixed stop not reached",
20094 "Fixed stop aborted" and
Description: 25042 "FOC: Standstill monitoring" are output.
Z-retract position for the counter spindle (ZS2). MD = 0

Suppresses alarm 20091 "Fixed stop not reached"
MD = 2
Suppression of alarms
Enable of the fixed stop alarms
20091 "Fixed stop not reached" and
20094 "Fixed stop aborted"
MD37050 MD = 3
Enable of the fixed stop
$MA_FIXED_STOP_ALARM_ Suppression of alarm 20094 "Fixed stop aborted"
alarms
MASK Add value 8
Suppression of alarm 25042 "FOC: Standstill monitoring"
Change to: 2
Note:
for AX7: MZS2
Independently of the setting of the alarm mask it is possible to
MD37050 = 2 (Linear axis of the counter spindle) read errors during approach of the fixed stop from the status
variable $AA_FXS.
MD = 1 (Default) 1. Work piece reception by counter spindle

Alarms 20091, 20094 and 25042 will be raised
In setting data described below the paths, the feedrate, and
the force for the travelling to a fixed stop will be defined.
The alarms 20091 "Fixed stop not reached" and 20094 "Fixed
stop aborted" will be suppressed, since the function Travelling
to a fixed stop is also used for checking cutting-off operations
(see description below).
In order to recognise erroneous behaviour all the same when Counter spindle: path for travel to fixed stop
travelling to a fixed stop, these alarms are replaced by a cycle
alarm:
SD55550 Counter spindle: path for
61254 [channel %1: ] block %2: Error while travelling to a $SCS_TURN_FIXED_STOP_DIST travel to fixed stop
fixed stop
Counter spindle: Feedrate for travel to fixed stop
SD55551
Counter spindle: feedrate
$SCS_TURN_FIXED_STOP_
for travel to fixed stop
FEED
Notes

Counter spindle: Force for travel to fixed stop in %

Fixed stop
MSp CSp
SD55552
Counter spindle: force for 10mm
$SCS_TURN_FIXED_STOP_
travel to fixed stop in % Rap-trav.
FORCE
Default: 10 % Change to:
-X
Between the travelling to a fixed stop and the chucking the 0,1mm
counter spindle can retract a small amount in order to relieve
pressure on the work piece.
SD55550
Counter spindle: Retraction path prior to chucking after e.g. 10mm
fixed stop SD55551
e.g. 10mm/min
SD55553 Counter spindle: retraction SD55552
$SCS_TURN_FIXED_STOP_ RE- path prior to chucking after e.g. 10%
TRACTION fixed stop SD55553
e.g. 0,1mm
Change to: e.g. 0,1
Sequence: Retraction path prior to cut-off with counter spindle

1. The counter spindle travels with G0 to the work piece in
the main spindle until the distance specified in SD55550 SD55543 Retraction path prior to
has been reached. $SCS_TURN_PART_OFF_RETRACT cut-off with counter
ION spindle
2. The remaining distance will be travelled at the feedrate
defined in SD55551 and with the reduced force as defined
in SD55552 right up to the work piece.
3. The counter spindle retracts by the amount defined in SD

55553 in order to relieve the work piece. Chucking and pulling
4. Chucking the work piece in the counter spindle.

MSp CSp
2. Cut-off
After chucking there is the possibility to cut off the work piece.
Prior to this the counter spindle can be retracted a small
amount together with the work piece to create a tensile force
in the work piece. This relieves the tool a little bit during the
parting.
SD55543
e.g. 1mm
Notes

Cut-off check Feedrate for cut-of check
After the cut-off a check can be carried out and during turning SD55541
the function "Travelling to a fixed stop" can be used. The cut- Feedrate for cut-off
$SCS_TURN_PART_OFF_CTRL_
off check can either be set up by means of the following check
FEED
channel specific setting data or it can be deactivated:
Path for cut-off check Force for cut-off check in %
SD55540 SD55542
$SCS_TURN_PART_OFF_CTRL_ Path for cut-off check Force for cut-off check
$SCS_TURN_PART_OFF_CTRL_FO
DIST in %
RCE
Default: 0.1 mm Change to: Default: 10 % Change to:
MSp Cut-off CSp Sequence:

1. The counter spindle travels by the amount defined in
SD55543 to obtain a tensile force.
2. Cutting-off
3. For cut-off check the counter spindle retracts at the

feedrate defined in SD55541 with reduced force as per
SD55540 SD55542 the distance from SD55540.
e.g. 1mm
SD55541
e.g. 1mm/min
SD55542
e.g. 10%
Notes

Note: Setting up the counter spindle tailstock
The function „Travelling to a fixed stop“ is also used for the

On machines that feature a counter spindle, the counter spin-
cutting-off check. The cutting off is taken to be successful, if
dle can be used as a tailstock by clamping a quill-point in the
the travelling to a fixed stop fails.
chuck. The mask „Spindle chuck data“ is laid out for both the
definition of the tailstock dimensions (diameter and length) of
The alarms 20091 and 20094 are suppressed by changing
the main and also of the counter spindle.
the configuration of MD37050 to 2.
Alarm Alarm Text Opening the input mask Spindle chuck data
20091 The axis %1 has not reached the fixed stop

20094 Axis %1 end stop has been aborted.
In order to recognise a mal-function during the cut-off check, Depiction of the spindle chuck data for “Tailstock release“
these alarms are replaced by the cycle alarm 61255:
[channel %1: ] Block %2: Error on cut-off: Tool breakage?
Release of tailstock depiction
MD52218 Funktionsmaske Dre-

$MCS_FUNKTION_MASK_TURN hen
ändern auf: Bit 2 = 1
Bit 2: Enable tailstock
The tailstock is displayed when in the "program" tailstock is

selected.
Notes

Depiction of the spindles after “Tailstock release“ and Cursor Depiction of the tailstock after “Tailstock release“, cursor on
position on ZC1. The fields for XR1, ZR1, XR2 and ZR2 have position XR2 and the tailstock data have been entered manu-
not yet been filled in. ally.
The mechanical dimensions must be entered in the input

fields XR1, ZR1, XR2 and ZR2.
Tailstock data for the counter spindle ________________________________________________

Note:
MD53242[x] The entries in the mask Spindle chuck data correspond di-
Tailstock data rectly to the entries in MD53242[0] and MD53242[1] of AX3:
MCS1 and AX8: MCS2.
Default: 0 mm Change to: ________________________________________________
AX8: MCS2
Tailstock data for the main spindle
MD53242[x]
Tailstock data
AX3: MCS1
Notes

Machining program: Counter spindle

Machining example Main spindle - Counter spindle
Example:
By means of a simple machining example with the main spin-
dle followed by the counter spindle the sequence is to be
tested.
The programming of the operations with the counter spindle Program head with workpiece definition:
is carried out in the same manner as for the main spindle, for
instance the location of cutting. For the machining with the
counter spindle the Z-axis is mirrored (within the cycles). Only
the cutting edge position must suit the actual cutting direction.
This way of programming permits part programmes to be run
both with the main spindle and also with the counter spindle.
Tool list
Preparation:
The tools used in this example must have been edited and
Stock removal and technology data main spindle: Transfer to the counter spindle:
Notes

Stock removal and technology data counter spindle: Test of the machining
A check of the machining sequences can be made having

completed the inputs and selecting simulation.
Alteration of the speed to about 60%.
Cut main spindle Transfer to the counter spindle
Notes

Cut counter spindle Machining completed
Machining example main spindle with TRANSMIT and Machining program: MSp and CSp
counter spindle with TRACYL and TRANSMIT
Example:
By means of a simple machining program for facing with the
main spindle followed by turning and facing with the counter
spindle the sequence is to be tested.
Tool list Note:

In the last two program steps the symbol for the front face
Preparation: machining with the counter spindle is the same as that for
machining on the main spindle. For the machining with the
The tools used in this example must have been edified and counter spindle the Z-axis is mirrored.
Reason:
The programming is generally speaking the same as for ma-
chining with the main spindle. Hence these programs can be
run on the main as well as on the counter spindle.
Machining time:
At the end of the graphic simulation the established machin-
ing time will be entered In the bottom program line.
Notes

Program head with workpiece definition: Create contour description:

Continuous path milling front face C main spindle: Transfer to the counter spindle:
Notes

Create contour description: Continuous path milling front face C counter spindle:
Longitudinal slot Per. surface C counter spindle: Start simulation:
Start, work piece in the main spindle
Notes

B122 END Setup Counter spindle/Tailstock
Transfer of the work piece to the counter spindle Retraction of the counter spindle
Work piece in the counter spindle End of the machining
B122: END
Notes

B035 Program Handling Using External Storage
Module Description:
It is often a requirement to store machining programs externally to the controller.
The EES (Execute from External Storage) feature can then be used to execute the programs, from
the external source, as if they were stored in the NC memory.
The external storage can be on the System CF card, USB memory, or a networked PC.
Examples reason for storing programs externally:

 The size of the program.
 The number of programs on the controller is at the limit.
 Centrally stored programs can be accessed by many networked machines.
 Ensures that the programs can be recovered in the event of data loss.
Module Objective:
Upon completion of this module you will know how to:
 Setup a networked logical drive

 Activate the Execute from an External Source command
 Activate the NC Extend memory.
 Use main programs and subprograms with the above features.
Content:
Sinumerik
Program handling - General information
Setting up a Networked Logical Drive
Execute from an External Source Function
NC Extend Function
Program Use With EES & NC EXTEND
B035
B035

Program Handling B035
Program
Handling:
START
Program
Handling -
General
information
Setting up a
Networked
Logical
Drive
Execute
from an
External
Source
Function
NC Extend
Function
Program
Use With
EES & NC
EXTEND
Program
Handling:
END
Notes :

B035 Program Handling
Program Handling - General information. NC Extend: Releases 100MB of System CF card memory.
(Option number: 6FC5800-0AP77-0YB0)
Logical Drives
Execute from External Source (EES): Suitable for connect-
The logical drive features allows storage of machining pro- ing via Ethernet to an external PC for unlimited storage capaci-
grams in addition to the standard NC memory. ty. (Option number: 6FC5800-0AP75-0YB0)
.
The additional storage can be: Global Part Program Memory:
 On the controller (System CF card). The Global Part Program Memory feature behaves like stand-
ard NC memory and has no restrictions on program jumps,
 A USB device. block search etc.
 A user CF card. The feature can be activated for one of the following memory
 A networked computer. types:
 System CF card (NC Extend).
By default, the User CF card and USB features are already  USB.
active.
 User CF card.
Programs can be easily copied and pasted between the con-  Networked computer (EES).
troller and a logical drive.
It is also possible to execute a program from a logical drive Standard NC memory allocation and availability of EES/NC
however, there are limitations with program jumps and block Extend functions:
search, for example.
828D NC Memory NC Extend EES
NC Extend, EES, and Global Part Program Memory. Software
24x 3MB  
Options are available which allow full program functionality for 26x 5MB  
programs stored externally of the controller.
28x 8MB  
28xA 10MB  
Setting up a Networked Logical Drive. The following example shows how to connect to a Win-
dows7® computer via the X130 (Factory network) interface of
Option: The following software option is required.: the controller (Direct connection without DHCP)
X130 will be configured with an IP address of 192.168.100.1.
 Network drive management - 6FC5800-0AP01-0YB0 The computer will be configured with an IP address of
192.168.100.2
Both will have the subnet mask of 255.255.255.0
Note:
There are certain IP addresses that must be avoided as they
are reserved for use by the system.
IP addresses in the 192.168.214.xxx range must be avoided.
IP addresses in the 192.168.215.1 to 31 range must also be
avoided.
Configuring Interface X130:

Activate the option with an NCK Reset.
Connect a suitable Ethernet cable between the computer and
the X130 interface of the controller.
X130
Notes :

Locate the network settings screen: Setting the X130 IP Address:
Deselect the DHCP client option and enter the required IP

address and subnet mask (192.168.100.1/255.255.255.0):
Note: The control needs to be switched off/on to activate

the new settings
Setting up the Logical Drive: Select a free soft-key. Further soft-keys, 24 in total, are ac-
cessed via the >>Level soft-key.
Locate the logical drives set-up area:
Example - Soft-key 8:
Default Logical drives screen:
Choose the NW Windows option:
Notes :

For this example the following data is required (the external The relevant data has to be entered:
computer settings will be changed later):
Computer name: 192.168.100.2

(IP address of the PC)
Enabling name: 828D Programs

(Name of the shared folder on the PC).
User name: AUDUSER

(Login name of the PC)
Password: SUNRISE
(Login password of the PC, for example)
Soft-key text: 828D Programs

(the text that will appear on the soft-key in the Program
manager area).
The remaining parameters are to be left unchanged for this

example.
Computer Network Set-up.
The computer must now be given an IP address that is in the

same subnet mask.
The IP address for this example is: 192.168.100.2 with a sub-
net mask of 255.255.255.0.
Locate and open the Network and Sharing Center of the

computer to be connected to the controller.
This can be found in the Control Panel:
Double click the connection in

use and then choose Properties.
Notes :

The IP address and the subnet mask can now be entered:
Double click the Internet Protocol Version 4(TCP/IPv4)

option.
Computer- Shared Folder Select View:
A shared folder allows it to be accessed via the network.

The folder is required for the storage of programs which will be
accessible from the controller.
For reasons of security it is possible to restrict access to the

shared folder by setting permissions.
The following example will show how to create a folder on the

D drive and how to set up sharing and permissions.
The option - Use sharing Wizard - can be deselected, via the

Tools menu in Windows® Explorer, to ease setup:
From Windows® Explorer, select the Tools menu, followed by

Folder options:
Notes :

Deselect the Use Sharing Wizard option:
Creating a New Folder
Example:
In Windows® Explorer:
 Select the D drive.
 With the mouse pointer In the right hand window, right
click and create a new folder.
 Give a suitable name to the folder.
Example 828D Programs.
Sharing the New Folder  Select the Sharing tab.

 Select the Advanced sharing tab.
 Right click with the mouse pointer on the 828D Pro-
grams folder.
 Select the Properties option from the list
Notes :

 Select Share this folder.  Select Permissions.
The default setting is for everyone to have read only access It is possible to restrict access to the shared folder by other
to the folder. users of the PC.
If restrictions are required, the Everyone user can be re-
moved or the permissions deselected.
Users can than be added via the Add button.
The required users of the computer can be searched for in the

Check Names field.
Notes :

In the following example, the user AUDUSER is going to be If the user exists, it will be displayed.
given permission to access the shared folder.
Enter AUDUSER in the Check Names field, then select the

Check Names button.
Example: AUDUSER has been granted full access to the It should now be possible to access the shared folder from the
shared 828D Programs folder. Program manager area of the controller.
The Share permission for Everyone has been removed.
Notes :

The shared folder being accessed from the controller. Accessing individual sub-folders.
If a folder is created within the shared folder it will inherit the

share properties of the host folder.
It is possible to directly access a subfolder by entering a path

on the Logical drive set-up screen.
Example:
The 828D Programs folder has been shared.
Two folders, Share 1 & Share 2, have been added within the
shared folder.
There is no need to share these new folders.
Note: If the Soft-key for accessing the shared folder is

grey, this indicates a problem with the network set up or
possibly the security of the computer hosting the shared Access the Program manager screens:
folder.
Firewall settings should be checked and temporarily disa-
bled to see if this is causing problems.
The new folders can be seen inside the original shared folder:
Accessing individual folders.
By entering a path in the logical drives set-up screen it is pos-

sible to access individual folders contained within the main
shared folder.
Example:
The following example shows two additional soft-keys which
have been set-up to give access to one each of the new fold-
ers.
Notes :

The path to Share 1 has been included. The path to Share 2 has been included.
Access soft-keys 9 & 10 in the Program manager area: Execute from an External Source Function
The EES (Execute from External Source) function allows a

networked logical drive to be used with the Global part pro-
gram memory setting. The size of available memory is limited
only by the space available on the networked PC.
It is also possible to use the EES function on a USB memory
device or user CF card.
When the option is used in conjunction with the Global part

program memory setting, it behaves exactly like standard NC
memory. i.e. there are no restrictions on block search, long
program jumps etc., that are found with other methods of exe-
cuting programs from an external source. It is also possible to
edit the program in NC stop.
Activating the EES Function:
The option, 6FC5800-0AP75-0YB0, needs to be set.
The two sub-folders can now be accessed:
Activate the option with an NCK Reset.
Notes :

Once the option is set and activated it can be decided which Example - Setting the Global part program memory for a net-
logical drive is to be used. worked computer.
This can be:
 USB memory device For the example a new networked logical drive (EES SHARE)
has been assigned to soft-key 6:
 User CF card
 Networked computer.
Setting the Global part program memory
Locate the Logical drives area:
The global part program memory setting can be applied to

either:
 A USB device
 A user CF card
 The NC Extend memory
 A networked computer. The EES SHARE folder has been created and shared on the
networked computer:
From within the Logical drives area, select the EES logical The EES SHARE Logical drive will now be activated for Global
drive, followed by the Change and then Details soft-keys. part program memory.
The Global part program memory can now be set.
Confirmation the Global part program memory is active is

seen on the Logical drive page for that particular logical drive:
Notes :

The result of activating the Global part program memory is the

creation of three folders which match the default NC memory
folders, also this drive whether a local drive, USB or a net-
worked drive will become the “MASTER NC MEMORY”.
Navigate to the Program manager screen:
The folder structure that was created by the Global part pro-
gram memory.
This is the same as the folder structure in the NC memory

area.
The available space, in this case the networked computer’s

hard disk, can be seen at the bottom right of the screen.
NC Extend Function. The settings for the NC Extend can be viewed in the Logical
drives area.
The NC Extend function releases 100MB of System CF card
memory which, when used with the Global part program
memory feature, behaves exactly like standard NC memory.
i.e. there are no restrictions on block search, long program
jumps etc. that are found with other methods of executing pro-
grams from external storage.
The option - 6FC5800-0AP77-0YB0 - needs to be set.
Activate the option with an NCK reset:

After the reset it will be possible to the NC Extend soft-key in
the Program Manager area The default settings, e.g. soft-key text can be changed if re-
quired.
Notes :

Setting the Global part program memory:
The NC Extend area has 100MB of additional memory for

storage of part programs/sub-programs/workpieces.
Only one Global Part Program Memory can be active, there-

fore, If it was already active on another logical drive it will be
automatically deactivated for that drive.
The result of the Global part program memory being set is the
creation of the folder structure on the NC Extend drive: The available space, in this case on the System CF card, can
be seen at the bottom right of the screen.
The result of activating the Global part program memory is the Program Use With EES & NC EXTEND
creation of three folders which match the default NC memory
folders. Part programs, subprograms etc. can now be stored on the
external source and used in the same way as the ones in the
Navigate to the Program manager screen: NC memory.
If, for example, the programs and subprograms are in different

memory areas it is necessary to call the subprogram in a cer-
tain way, depending on its and the part program’s location.
The folder structure that was created by the Global part pro- Example 1: Main program and subprogram in the standard
gram memory. NC memory:
This is the same as the folder structure in the NC memory

area. Example: MAIN_PROGRAM.MPF calling the
SUB_PROGRAM.SPF.
In this instance, only the name of the subprogram needs to
typed in order to execute it from the part program.
Notes :

B035 END Program Handling
The contents of the SUB_PROGRAM.SPF : The SUB_PROGRAM.SPF will be called and will run for 10
A program message (Sub_Program has been called) will be seconds:
displayed for 10 seconds (G04 F10) when the program is exe-
cuted.
Execute the MAIN_PROGRAM.MPF program:
Example 2: The subprogram is called:
Main program in the EES memory, subprogram in the EES

memory:
Note:
If a subprogram exists in both the NC and EES/NC Extend

memory, the one in the NC memory will be called unless the
path is specified.
The call to the SUB_PROGRAM.SPF can be seen below:
B035 : END
Notes :

B011 Run MyScreens
Module Description:
Run MyScreens 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 Run MyScreens
display screens.
Content:
Sinumerik
General Information
Basic Configuration Information
Creating Run MyScreens User Files
Language Dependent Texts
Parameters and Variable Description
B011
B011

Run MyScreens B011
Run MyScreens:
START
General
Information
Basic
Configuration
Information
Creating
Run
MyScreens
User Files
Language
Dependant
Texts
Parameters
and
Variable
Descriptions
Run MyScreens:
END
Notes :

B011 Run MyScreens
General Information
The Run MyScreens function is configured using ASCII files. These files contain the descriptions of the user interface.
As standard, up to 5 screens can be configured. Further screens are available via a licensed option Sinumerik Integrate Run
MyScreens, order No: 6FC5800-0AP64-0YB0.
In order to create images for the screens, a graphic programme is required, e.g. Paint Shop Pro® and Paint® are programmes
which are compatible with the 828D controller.
Run MyScreens 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/independent) display texts
 Showing, replacing and deleting display texts (language dependent/individual)
4. Initiating actions when:

 Showing dialogs
 Entering values (variables)
 Pressing soft-keys
 Closing dialogues
5.. Exchange of data between dialogs.
6. Variables
 Reading (NC, PLC, user variables)
 Writing (NC, PLC, user variables)
 Linking with mathematical, comparative or logic
operators
7. Executing functions:
 Subroutines
 File functions
 PI Services
8. Taking into account levels of protection defined for use groups.
Notes :

Run MyScreens B011
Basic Configuration Information
Configuration files are used to create the screens.

These configuration files are automatically interpreted by the
controller.
The files are not available as standard and have to be creat-
ed by the user using an ASCII editor (e.g. Notepad® or di-
rectly on the controller).
The “easyscreen.ini“ file is a master file which is required to

specify which other files are to be used to create a user
screen.
These files contain the information which determine what is
displayed on a particular screen.
The screen is split into different areas:
1 Main dialog area

2 Title bar containing screen name (Left) and
“Long text” description of the selected
variable (Right)
3 Variable input/output field
4 Variable name “Short text”
5 Graphics related text
6 Unit text
Operating areas overview To enable custom screens in other area of the controller, the
“easyscreen.ini” file has to be modified.
Operating area Permissible position for start soft-keys
There are eight areas in total:-
Machine JOG HSK6
Machine Area-Sub divided into:-
Machine MDA HSK6 Jog
MDA
Machine AUTO HSK6 Auto
Parameter HSK7
Parameter Area
Program HSK6
Program Edit Area
Program-Manager HSK2-8, 12-16, if not used for networked
drives Program Manager Area
Diagnostics HSK7 Diagnosis Area

Commissioning HSK7 Start-up Area
Notes :

B011 Run MyScreens
The three Machine Areas are specified by the “Menu” entry.

SlMaJogMillMenuHU, SlMaJogTurnMenuHU = Jog screen
SlMaAutoMenuHU = Auto screen
SlMaMdaMenuHU = MDA screen
Each area should have a “com” file specified.
Example of how all the areas are specified within the “easyscreen.ini” file:-
[STARTFILES]
StartFile01 = area := AreaMachine, dialog := SlMachine, menu := SlMaJogMillMenuHU, startfile := ma_jog.com
StartFile02 = area := AreaMachine, dialog := SlMachine, menu := SlMaAutoMenuHU, startfile := ma_auto.com
StartFile03 = area := AreaMachine, dialog := SlMachine, menu := SlMaMdaMenuHU, startfile := ma_mda.com
StartFile04 = area := AreaParameter, dialog := SlParameter, startfile := param.com
StartFile05 = area := AreaProgramEdit, dialog := SlProgramEdit, 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
Creating Run MyScreens User Files Creating the “easyscreen.ini” file on the controller
The files required for the Run MyScreens function need to be This file sets up the links to the files which are to be used to
created. This can be done directly on the controller by navi- create the user screens, it also determine which operating
gating to the relevant folders. Use the following key sequence areas these files are available in. The file has to be located in
to locate the “System data” area. any of the following paths/directories:-
“System CF card\oem\sinumerik\hmi\cfg”
“System CF card\user\sinumerik\hmi\cfg”
Use the cursor keys to locate and open this directory.
Notes :

Run MyScreens B011
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 “Run MyScreens” are to be accessed.
(area := Area Parameter)
The “com” file, the content of which will determine what appears on the Run MyScreens 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 Run MyScreens 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 Ac-
cess MyMachine software.
Below: The easyscreen.ini file located in the cfg directory
Notes :

B011 Run MyScreens
Creating the “param.com” file Below: The param.com file located in the proj directory.
The param.com file has been declared in the “easyscreen.ini”

file and now needs to be created.
Code contained within the param.com file is used to create

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”
Example: param.com file

Storage path for the image files:
It is necessary to specify a soft-key to be used as the entry “System CF card\oem\sinumerik\hmi\ico\ico640”
point to the Run MyScreens. “System CF card\user\sinumerik\hmi\ico\ico640”
Further soft-keys can be assigned within the Run MyScreens if
required. To see the results of the example we have to locate the
The example defines the 7th horizontal soft-key as the entry “parameter” area of the control.
point, the soft-key will have the text “Run MyScreens” (on 2
lines).
//S(START)
HS7=("Run %nMyScreens")
The 7th horizontal soft-key contains the text specified in the
When the soft-key is pressed a Mask (mask1) will be loaded:
“param.com” file: HS7=("Run %nMyScreens").
PRESS(HS7)
LM("mask1")
END_PRESS
//END
The Mask contains the code which determines the content of

the Run MyScreens.
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 :

Run MyScreens B011
Screen title/name tiger.bmp image
Mask header information: Parameter Description
The various parameters are separated by the “Forward slash” Graphic The position of the graphic in pixels. Distances
character (/). Position Position are from the left and top of the dialogue
screen and are separated by a comma.
//M(Identifier/header/Graphic/Dimension/Variable/Graphic Attributes CM (Column Mode) Column alignment.
position/Attributes)
CM0: Default, the column distribution is carried
Parameter descriptions: out separately for each line.
CM1: The column distribution is of the ling with

the most columns applies to all lines.
Parameter Description
CB: (Change Block) Response when the dialogue
Identifier Label of dialogue/mask.
is opened. The CB attribute can also be used on
Header Name of the screen. individual variables, in this case the individual
setting has priority over the CB setting in the
Graphics Name of image to be displayed. Mask Header.
Dimension Position and size of the dialogue. (Distance from CB0: All change blocks associated with the dia-
the left hand side, right hand side, width, height) logue are processed when it is opened.
Values in pixels and separated by commas
Variable The cursor can be assigned to a variable. The CB1: Change blocks are only processed if the
first variable has an index of 1, the remaining relevant value changes.
variables are indexed in the order that they were
configured.
Notes :

B011 Run MyScreens
Adding Dialogue Elements: //S(START)
Dialogue Elements refer to long and short texts, graphics texts, HS7=("Run %nMyScreens")
unit texts and I/O fields. Additional soft-keys can also be added. PRESS(HS7)
LM("mask1")
The dialogue elements are added below the mask header. END_PRESS
//END
In the following example (Shown in red text) a soft-key with the
label “Variable Test” is added. When the soft-key is pressed the //M(mask1/"Picture Test"/"tiger.bmp"///110,25)
screen will display a list of four variables. The four variables are
defined under a new mask (mask2-Workpiece Dimensions). HS1=("Variable %nTest")
PRESS(HS1)
The parameters of the variables defined in mask2 are separated LM("mask2")
by the forward slash character (/). END_PRESS
//END
A detailed description of the Dialogue Element parameters can
be found in chapter ”Parameters and Variable Descriptions”. //M(mask2/"Workpiece Dimensions"/)
Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")
Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]")
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")
VS8=("EXIT")
PRESS(VS8)
EXIT
END_PRESS
//END
The additional soft-key can now be seen. Screen title/name Long text of the selected variable.
Short text Input field
Values entered in the input field will be transferred to relevant

When the soft-key is pressed the defined variable will be dis-
variable.
played.
Notes :

Run MyScreens B011
Detailed Analysis: Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")

R parameter 0 as a real number to 2 decimal places, sets the
//M(Mask1/"Workpiece Dimensions") Name of Mask1: component length:
HS1=("Variable %nTest") Determines the text for horizontal

soft-key 1 as “Variable Test”:
Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")

R parameter 1 as a real number to 2 decimal places, sets the
When the soft-key is pressed mask2 will be loaded. component width:
PRESS(HS1)
LM("mask2")
END_PRESS
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]") VS8=("EXIT") Determines the text for vertical soft-key 8 as
R parameter 2 as a real number to 3 decimal places, sets the “EXIT”:
component height:
Checking the entered values
Values can be entered directly on the custom screen. These

values are transferred directly to the variables.
They can be checked by viewing the variables on the standard
screen by pressing the “User variable” soft-key.
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")
R parameter 3 as an integer, sets the spindle speed:
Notes :

B011 Run MyScreens
Language Dependant Texts Example Text File:

It is possible to configure the Run MyScreens configuration VERSION:SLP.02.05.QJM Otc 16, 2010
files so that the Run MyScreens language matches that of CHANGE :SLP.02.04.QJM Jun 30, 2010
the system.
In order to do this it is necessary to create one text file for 85100 0 0 "English%nMyScreens"
each required language. 85101 0 0 "English Mask Header"
The text that is to be displayed is contained within the text 85102 0 0 "English Long Text"
files. 85103 0 0 "English Short Text"
The Run MyScreens configuration files use identifiers to en-
sure that the correct text is displayed.
The files containing the text can be placed in the following

locations: Identifier Not used Required text
“System CF card\oem\sinumerik\hmi\lng” Allowable range of identifiers 85000 to 89899

“System CF card\user\sinumerik\hmi\lng”
“System CF card\addon\sinumerik\hmi\lng” 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: The files for English and German can be seen located in the
OEM area.
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 for the German language
85100 0 0 "Deutsch%nMyScreens" The identifier is used in place of the text in the param.com file.
85101 0 0 "Deutsch Mask Header" The identifier has to be prefixed by the $ symbol.
85102 0 0 "Deutsch Long Text" The text associated with the identifier will be displayed.
85103 0 0 "Deutsch Short Text"
Notes :

Run MyScreens B011
Example param.com file for language dependent text. The language file needs to be declared in the “easyscreen.ini”
file. No language coding is required.
//S(START) Declarations of other text files may also be present.
HS7=($85100)
PRESS(HS7) ;VERSION:SLP.02.01.H56 Nov 10, 2009

LM("mask1") ;CHANGE :
END_PRESS
//END [STARTFILES]
//M(mask1/$85101/"tiger.bmp"///110,25) StartFile04 = area := AreaParameter, dialog := SlParameter,

HS1=("Variable %nTest") startfile := param.com
PRESS(HS1)
LM("mask2") [LANGUAGEFILES]
END_PRESS LngFile01 = almc.txt
//END LngFile02 = alsc.txt
LngFile03 = aluc.txt
//M(mask2/"Workpiece Dimensions"/) LngFile04 = easyscr.txt
Def Var1=(R2///$85102, $85103///"$R[0]") [SYSTEM]

System = 0
VS8=("EXIT")
PRESS(VS8)
EXIT
END_PRESS
//END
Setting the controller language: When using the examples shown earlier it can be seen that the
text displays change with the selected language.
The controller language is selected via the “Start-up” menu.
Or
English long and short texts:
German long and short texts:
Notes :

B011 Run MyScreens
Parameters and Variables Descriptions Detailed description:
When a variable is assigned certain properties can be set. 1. Variable type

These properties are contained rounded brackets, each proper- R[x] Real number, “x” indicates the number of decimal
ty is separated by a forward slash (/) places displayed
If a property is not used, the slash still needs to be present. I Integer.
S[x] String,”x” indicates the string length.
Basic description: C Character (Individual character)
B Boolean number
DEF Var1=(1/2/3/4/5/6/7/8/9/10) V Variant type
1. Variable type 2a. Limit values-

2. Limit values, toggle field or table identifier A minimum and a maximum value can be specified. The values
3. Default are separated by a comma, the minimum value is specified first.
4. Texts Values can be in I, C and R decimal formats or as characters in
5. Attributes the format “A” , “F”
6. Help display The limit value also works in conjunction with the limit attrib-
7. System or user variable ute, see the attribute property for more information.
8. Position of short text
9. Position of I/O field (Left, top, width, height) 2b. Toggle field-
10. Colours Creates a list of predefined entries in the I/O field. The list is
initiated by the “*” character.
The entries can be assigned a value.
The Limit value is interpreted as a list for the Toggle field.
If only a “*” is used, a variable Toggle field is generated.
2c. Table Identifiers- 5. Attributes-

Identifiers can be assigned to tables containing NCK/PLC val- The following properties can be influenced by the attributes
ues of the same type. The “%” character is used to differentiate  Input mode
an identifier from a toggle field or limit value.
 Access level
A comma is required after the identifier, the file name containing
the table information is then typed.  Alignment of short text
 Font size
3. Default setting-  Handling limit values
The value in the assigned variable can take on various states.  Response when screen is opened (Change block)
This depends on whether a default value, system or user varia-
ble (Or both) has been assigned to the variable field (I/O or tog- The attributes are separated by commas, and are not valid for
gle field) toggle fields.
Toggling is not possible until a valid value is assigned to the
variable. Input mode:-
Attribute Effect
4. Texts- wr0 I/O field invisible, short text visible.
Text possibilities are- wr1 Read only, no inputting of data, short text visible.
 Long text = text displayed when each element is high- (Default setting)
lighted. wr2 Read & write possible, long and short text visible.
 Short text = name of the element wr3 As with wr1 but with I/O field visible, long and short
 Graphics text = text relating to the graphics, if used. text visible.
wr4 All elements invisible.
 Unit text = unit of the variable e.g. mm, rpm etc
wr5 As wr2 except entries are immediately active.
with wr2 the entry becomes active exiting the field
The text types are separated by commas and need enclosing in
or pressing enter/input/return.
speech marks:- /”Long”, “Short”, “Graphics”, “Unit”/
Notes :

Run MyScreens B011
Access level:- Limits:

Attribute Level Password/Key position Checking whether the value of the variable is within the limits
ac0 0 Not released specified by the limit values.
ac1 1 SUNRISE Attribute Effect
ac2 2 EVENING li0 No check.
ac3 3 CUSTOMER li1 Check with respect to minimum
ac4 4 Key switch pos 3 li2 Check with respect to maximum.
ac5 5 Key switch pos 2 li3 Check with respect to minimum and maximum.
ac6 6 Key switch pos 1
ac7 7 Key switch pos 0
Behaviour when opening (Change block):
Alignment of short text:-
Attribute Effect
Attribute Effect
cb0 The change block defined for this variable is
al0 Left justified (Default)
processed when the screen opens (Default).
al1 Right justified
cb1 The change block defined for this variable is
al2 Centred
processed if there is a change in the value of the
variables.
Font size:
Attribute Effect
The “cb” attributes, specified in the variables definition, take
fs1 8pt. font size (Default)
precedence over the globally specified attributes in the “screen
fs2 16pt font size
form” definition.
The clearance between lines is defined. The default font size
allows 16 lines. The graphics and unit text can only be 6. Help Display-
configured in the default font size.
The name of the HTML file containing the help text needs to be
typed in speech marks. The display appears automatically if the
cursor is positioned on the variable.
Notes :

B011 Run MyScreens
7. System or user variables- PLC Data Syntax
The variable to be viewed is entered here, these have to be Byte y of bit z of data block x DBx.DBXy.z
contained within speech marks. The variable must be
addressed in the correct way. Byte y of data block x DBx.DBBy
Word y of data block x DBx.DBWy

Addressing Variables:
Double word y v. of data block x DBx.DBDy
Machine Data Syntax String y with length z from data block x DBx.DBSy.z
Global machine data $MN_... Real y of data block x DBx.DBRy
Axis specific machine data $MA_... Flag byte x bit y Mx.y
Channel specific machine data $MC_... Flag byte x MBx
Flag word x MWx

Setting Data Syntax
Flag double word x MDx
Global setting data $SN_...
Axis specific setting data $SA_...
Channel specific setting data $SC_...
System variable Syntax
R parameter 1 $R[1]
PLC Data Syntax 8. Position of short text
Input byte x bit y Ix.y The Short Text defined in attribute No.4 is positioned using
parameter No.8.
Input byte x IBx The measurements are in pixels and relate to the top left
corner of the main dialogue body.
Input word x IWx
Three values can be entered to define the position from the left,
Input double word x IDx
the position from the top and the width of the short text.
Output byte x bit y Qx.y Each entry has to be separated by a comma.
Output byte x QBx The following example would position the text “Short text” 200
pixels from the left and 100 pixels from the top with a width of
Output word x QWx 250 pixels:
Output double word QDx
Def Var1=(R2///" ","Short text"///"$R[0]"/200, 100, 250//)
Soft-key Status Syntax
Visible (Default) Se1
Disabled (Grey text) Se2
Displayed(Last soft-key used) Se3
Notes :

Run MyScreens B011
9. Position of I/O field 10. Colours
The I/O field can be positioned and sized using parameter The foreground and background colours of the I/O field can be
No.9. chosen by using parameter No.10.
The measurements are in pixels and relate to the top left The default colours are foreground: Black, background: White.
corner of the main dialogue body. These are determined by the “Write mode” (See parameter 5)
The following table shows index numbers to be used to achieve

Four values can be entered to define the position from the left, the required colour.
the position from the top and the width and height of the I/O The foreground colour is defined first, followed by a comma then
field. the background colour:
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 Index Colour
the top with a width of 100 pixels and a height of 150 pixels: 1 Black
2 Red/brown
Def Var1=(R2///" "," "///"$R[0]"//600, 400, 100, 150/) 3 Dark green
4 Light grey
5 Dark grey
6 Blue
7 Red
8 Brown
9 Yellow
10 White
B011: END
Notes :

B011 END Run MyScreens

Appendix A Hardware Differences
Hardware
Differences:
START
PPU
Differences
Digital I/O
Hardware
Differences:
END
Sinumerik
Appendix A
PPU2xx.2 / PPU2xx.3: X122, X132, X242 & X252 Interface Description

The Binary Connectors (BiCo’s) of X122 and X132 are used to

Fault assign Sinamics inputs/outputs to a specific function e.g. Ena-
X100 Sync PN
bling of drives, BERO’s, automatic line contactor control etc
X101 Fault PN X242 and X252 is used for NC digital inputs and outputs.
Sync
X102
Rx/Tx
Link
X130 Certain terminals are automatically assigned to a function by
default, remaining terminals can be assigned to a function via
X140 X135 machine data.
X122
X132 r0722 which is referred to when assigning a function.
X242
X252
X143
X1
M T1 T2 T3
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
14 MEXT1 MEXT3 14
1* Fast inputs/outputs (Must be shielded).
Notes :
Appendix A Page 2 SINUMERIK 828D

Hardware Differences Appendix A
X122-Sinamics I/O

Source Destination
ON/OFF1 for DriveCLiQ line

CU-r0722.0 Infeed p0840
modules (ALM, SLM >=16Kw)
Pin 1 Sinamics DI0
Infeed ready for non DriveCLiQ
SLM X21.1 Drive p0864
SLM (SLM <16Kw)
Each drive 2nd OFF3,

Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop CU-r0722.1
p0849
Pin 3 Sinamics DI2 SINAMICS Safety Integrated CU-r0722.2
group)
(SH enable = p9601)
Pin 4 Sinamics DI3 SINAMICS Safety Integrated CU-r0722.3
group)
(SH enable = p9601)
SH/SBC 1 – Group 1 (Input) p9774 bit 1
Pin 9 Sinamics DI/DO8 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/DO9 BICO from CU after the
SINAMICS Safety Integrated
Pin 12 Sinamics DI/DO10 Bero 1 - external zero mark (Input) CU-r0722.10 Drive p0495=2
Each drive p0488,

Probe 1: Remote Measuring (Input)
Pin 13 Sinamics DI/DO11 CU-p680[0]=0 Index
(MD13210=1)
encoder 1, 2, 3=3
Notes :
SINUMERIK 828D Page 3 Appendix A

X132-Sinamics I/O
Source Destination
Pin 1 Sinamics DI4 DI 4 Free to assign CU-r0722.4
Pin 4 Sinamics DI7 Line contactor feedback signal CU-r0722.7 LM-p0860

Infeed operation (Output) LM-r0863.0 CU-p0742

Pin 9 Sinamics DI/DO12
(Line Module with DRIVE CliQ)
Infeed ready to start (Output) LM-r0899.0 CU-p0743
(If Line Module with DRIVE CliQ)
Line contactor control (Output) LM-r0863.1 CU-p0744

Pin 12 Sinamics DI/DO14 Bero 2 - external zero mark(Input) CU-r0722.14 Drive p0495=5
2nd OFF 2 (Input) CU-r0722.14 Drive p0845
Probe 2: Remote Measuring (Input) CU-p680[1]=0 Each drive p0488,
Pin 13 Sinamics DI/DO15 (MD13210=1) CU-p728 Bit 15=0 Index
encoder 1, 2, 3=6
Notes :


Pin 1 n/c n/c
Pin 2 n/c n/c
Pin 3 NCK DI1 (IN1) Digital Input $A_IN[1]
Pin 9 NCK DO1 (OUT1) Digital Output $A_OUT[1]

Pin 1 AOUT Output for analogue spindle +/- 10V
Pin 12 NCK DO11 (OUT11) Digital Output $A_OUT[11] / Analogue spindle enable/direction
Pin 13 NCK DO12 (OUT12) Digital Output $A_OUT[12] / Analogue spindle enable/direction
Notes :

PPU2xx.1: X122, X132 & X142 Interface Description

The Binary Connectors (BiCos) of X122 and X132 are used to

assign Sinamics inputs/outputs to a specific function e.g. Ena-
bling of drives, BERO’s, automatic line contactor control etc.
X142 is used for NC digital inputs and outputs.
Certain terminals are automatically assigned to a function by

default, remaining terminals can be assigned to a function via
machine data.

r0722 which is referred to when assigning a function.
PPU
X122 Drive NC X142

1 DI 0 DI0 1
2 DI 1 DI1 2 DC +24V
DC +24V 3 DI 2 DI2 3
4 DI 3 DI3 4
5 MEXT MEXT 5
DC +24V DC +24V
6 P24EXT1 P24EXT3 6
7 DI/DO 8 1* DO4 7
8 DI/DO 9 1* DO5 8
9 MEXT1 MEXT3 9
10 DI/DO 10 1* DO6 10
11 DI/DO 11 1* DO7 11
12 MEXT1 MEXT3 12
X132 Drive
1 DI 4
2 DI 5
3 DI 6
4 DI 7
5 MEXT
6 P24EXT2
7 DI/DO 12 1*
8 DI/DO 13 1*
9 MEXT2
10 DI/DO 14 1*
11 DI/DO 15 1*
12 MEXT2
1* Fast inputs/outputs (Must be shielded).
Notes :

X122-Sinamics I/O
X122 Signal Function/Default Setting BiCo connection

Source Destination
ON/OFF1 for DriveCLiQ line modules CU-r0722.0 Infeed p0840
(ALM, SLM >=16Kw)
Pin 1 Sinamics DI0
Infeed ready for non DriveCLiQ SLM SLM X21.1 Drive p0864
(SLM <16Kw)
Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop CU-r0722.1 Each drive 2nd OFF3,
p0849
Pin 3 Sinamics DI2 SH/SBC 1 – Group 1 CU-r0722.2 p9620 (all drives in the
SINAMICS Safety Integrated group)
(SH enable = p9601)
Pin 4 Sinamics DI3 SH/SBC 1 – Group 2 CU-r0722.3 p9620 (all drives in the
SINAMICS Safety Integrated group)
(SH enable = p9601)
Pin 5 0V Ground (M) Ground for pins 1 to 4
Pin 6 +24V DC +24V DC common
Pin 7 Sinamics DI/DO8 SH/SBC 1 – Group 1 CU-p0738 p9774 bit 1

SINAMICS Safety Integrated BICO from CU after the
Pin 8 Sinamics DI/DO9 SH/SBC 1 – Group 2 CU-p0739 p9774 bit 1

SINAMICS Safety Integrated BICO from CU after the
Pin 9 0V Ground (M) Ground for pins 7, 8, 10, 11
Pin 10 Sinamics DI/DO10 Bero 1 - external zero mark CU-r0722.10 Drive p0495=2
Pin 11 Sinamics DI/DO11 Probe 1: Remote Measuring CU-p680[0]=0 Each drive p0488,
(MD13210=1) Index
encoder 1, 2, 3=3
Notes :

X132-Sinamics I/O
X132 Signal Function/Default Setting BiCo connection
Source Destination
Pin 1 Sinamics DI4 Digital Input $A_IN[1] CU-r0722.4 CU-p2082[0]
Digital Input $A_IN[4] CU-r0722.7 CU-p2082[3]
Pin 4 Sinamics DI7

Line contactor feedback signal CU-r0722.7 LM-p0860
Pin 6 +24V DC +24V DC common
Digital Output $A_OUT[4] CU-p2091.3 CU-p0742

Infeed operation LM-r0863.0 CU-p0742
(Line Module with DriveCLiQ connec-
tion)

Infeed ready to start LM-r0899.0 CU-p0743
(if Line Module with DriveCLiQ con-
nection)
Line contactor control LM-r0863.1 CU-p0744

Bero 2 - external zero mark CU-r0722.14 Drive p0495=5
2nd OFF 2 CU-r0722.14 Drive p0845

Probe 2: Remote Measuring CU-p680[1]=0 Each drive p0489,
(MD13210=1) CU-p728 Bit 15=0 Index
encoder 1, 2, 3=6
Notes :


Pin 1 NCK DI 0 Digital Input $A_IN[9]
Pin 6 +24V DC (P) +24V DC common
Pin 7 NCK DI/O 4 Digital Output $A_OUT[9]
Appendix A: END
Notes :


Appendix B
Sinumerik
Operate
Technology
Settings:
START
General
Machine Data
51000-51999
Channel
Machine Data
52000-52999
Axis
Machine Data
53000-53999
General Setting
Data
54000-54999
Sinumerik
Channel Setting
Data
55000-55999
Technology
Settings:
END
828D/840D sl SINUMERIK Operate V4.7 Page 1 This document was produced for training purposes.
Appendix B
General Machine Data
828D/840D sl SINUMERIK Operate
Technology Settings
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
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
51019 $MNS_DISP_RES_ROT_AX Display resolution of rotary axis
51020 $MNS_DISP_RES_ANGLE Display resolution of angle
Page 2
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 (ShopMill/ShopTurn single-channel)
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
Appendix B
51027 $MNS_ONLY_MKS_DIST_TO_GO Distance-to-go display in work window 9420
Appendix B
51028 $MNS_BLOCK_SEARCH_MODE_MASK Bit mask for available block search modes

Bit 4: Block search without calculation
Appendix B
Appendix B
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
Technology Settings
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.
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.
- 840D sl: PLC bit DB19.DBX13.0 Disable teach transfer
- 828D: PLC bit DB1700.DBX1000.0 Disable teach transfer
Bit 2: Block selection only explicitly
Page 3
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
1 = REL coordinate system can be selected as an alternative of the WCS/SZS coordinate
system
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)
Technology Settings
51038 $MNS_SET_ACT_VALUE Set actual value selection 9422
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
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 4
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
Appendix B
51052 $MNS_ACCESS_WRITE_SEA Protection level write setting data 9215
Appendix B
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
Appendix B
Appendix B
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
Technology Settings
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
51066 $MNS_ORDER_DISPLAYED_CHANNELS Channel numbers of the channels displayed

Page 5
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
51073 $MNS_ACCESS_SET_SOFTKEY_ACCESS Protection level of ”Adapt softkeys”

51074 $MNS_ACCESS_WRITE_WPC_COUNTER Write protection level of workpiece counter
51160 $MNS_ACCESS_WRITE_CA_MACH_JOG Write protection level collision monitoring machine jog
51161 $MNS_ACCESS_WRITE_CA_MACH_AUTO Write protection level collision monitoring machine automatic

51162 $MNS_ACCESS_WRITE_CA_TOOL Write protection level collision monitoring tool
51198 $MNS_ACCESS_READ_TM_ALL_PARAM Protection level TM details - read all parameters
51199 $MNS_ACCESS_WRITE_TM_GRIND Protection level of tool management for writing grinding data
Technology Settings
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
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 6
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-
Appendix B
formed. incremental wear limitation can be combined, i.e. the wear can be changed up
to the absolute limit, see MD 51212.
Appendix B
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
Appendix B
Appendix B
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
Technology Settings
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 7
51225 $MNS_ACCESS_TM_MAGAZINE_POS Protection level TM position magazine
51226 $MNS_FUNCTION_MASK_SIM Function mask Simulation

Bit 5: Turning tool can rotate in the tool spindle
Bit 7: Interpretation of handwheel values as absolute values
51228 $MNS_FUNCTION_MASK_TECH Function mask Cross-technology
51230 $MNS_ENABLE_LADDER_DB_ADDRESSES Activation of DB addresses in PLC Ladder Viewer
51231 $MNS_ENABLE_LADDER_EDITOR Activation of PLC ladder add-on tool for INT100/101
51232 $MNS_ENABLE_LADDER_EDITOR_ADV Activation of PLC ladder editor for the complete PLC project
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
51300 $MNS_MAXNUM_WAITM_USER Number of wait marks available to the end user

Technology Settings
51600 $MNS_MEA_CAL_WP_NUM Number of calibration data fields for workpiece probes
51601 $MNS_MEA_CAL_EDGE_NUM Number of geometry data fields of gauging block for workpiece probes
51602 $MNS_MEA_CAL_TP_NUM Number of calibration data fields for tool probes
51603 $MNS_MEA_CAL_TPW_NUM Number of calibration data fields for tool probes
51618 $MNS_MEA_CM_ROT_AX_POS_TOL Entries in parameter $MN_MEA_CM_ROT_AX_POS_TOL are effective only if MD51740

$MNS_MEA_FUNCTION_MASK Bit 2 or Bit 16 is set.
The real angle position of the rotary axes can deviate from the programmed one (exact stop fine
window).
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, workpiece and tool measuring
Bit 0: Workpiece, monitoring of the calibration status
Page 8
Bit 1: Workpiece, length ref. of probe in infeed axis at the ball circumference
Bit 2: Workpiece, correction in the tool, taking into account toolholders
Bit 3: Reserved
Bit 4: Workpiece, probe fixed in the machine (not in a spindle)
Bit 5: Workpiece, correction in WO course, if no WO fine is set up
Bit 6: Measuring blocks in measuring cycles with feedrate override 100%
Bit 15: Workpiece, traverse measuring block with path behaviour G60 exact stop
Bit 16: Tool, turning technology, taking into account toolholders
51742 $MNS_MEA_FUNCTION_MASK Meas. cycles: Limitation of protection levels when writing system variables
51750 $MNS_J_MEA_M_DIST This parameter defines the measuring path in front of and behind the measuring setpoint. 9752
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
Appendix B
51757 $MNS_J_MEA_COLL_MONIT_FEED Feedrate in the working plane with active collision detection. 9757
Appendix B
51758 $MNS_J_MEA_COLL_MONIT_POS_FEED Feedrate of the infeed axis with active collision detection, for "Measure in JOG". 9758
Appendix B
Appendix B
51770 $MNS_J_MEA_CAL_RING_DIAM Calibration ring diameter for Measure in JOG
51772 $MNS_J_MEA_CAL_HEIGHT_FEEDAX Calibration height in the infeed axis for probe length calibration
51780 $MNS_J_MEA_T_PROBE_DIAM_RAD Diameter of the tool probe for radius measurement for Measure in JOG 9766
51781 $MNS_MEA_T_PROBE_THICKNESS Tool probe thickness
Technology Settings
51784 $MNS_J_MEA_T_PROBE_APPR_AX_DIR Approach direction in the plane on the tool probe for Measure in JOG 9768
51786 $MNS_J_MEA_T_PROBE_MEASURE_DIST Measuring path for tool measurement with stationary spindle for Measure in JOG 9772
51840 $MNS_GRIND_FUNCTION_MASK Function mask for grinding cycles

Bit 0: Reference point for recording dresser/grinding wheel is a work offset
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.
Page 9
52001 $MCS_DISP_COORDINATE_SYSTEM_2 Coordinate system for turning on milling machines
52004 $MCS_PROG_COORDINATE_SYS_CHAN Coordinate system during programming as described in the specific channel
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
Channel Machine Data
Technology Settings
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.
52020 $MCS_ORIAXES_EULER_ANGLE_NAME Axis identifier of the orientation axes: Euler angle or geometry axis name
52032 $MCS_STAT_DISPLAY_BASE Number basis for display of articulated joint STAT
52033 $MCS_TU_DISPLAY_BASE Number basis for display of rotary axis position TU
52200 $MCS_TECHNOLOGY Technology 9020

1: turning
2: milling
Page 10
Also note MD 52201 $MCS_TECHNOLOGY_EXTENSION.

52201 $MCS_TECHNOLOGY_EXTENSION Extended technology
1: turning
2: milling
Also note MD 52200 $MCS_TECHNOLOGY.
Example:
Turning machine with milling technology
MD 52200 $MCS_TECHNOLOGY = 1
MD 52201 $MCS_TECHNOLOGY_EXTENSION = 2
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.
Appendix B
5 = counter spindle (turning)
6 = C axis of the counter spindle (turning)
Appendix B
7 = linear axis of the counter spindle (turning)

8 = tailstock (turning)
9 = steady rest (turning)
10 = B axis (turning)
11 = reserved
Appendix B
Appendix B
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: Positive direction of rotation is counter-clockwise (applies to rotary axes) 9822, 9823,
Bit 4: Displayed direction of rotation for M3 is counter-clockwise (applies to spindles) 9824, 9825.
Bit 5: Direction of rotation M3 corresponds to rotary axis minus (applies to spindles)
Technology Settings
- 840D sl: PLC bit DBnn.DBX17.6, nn = 31 + machine axis index
- 828D: PLC bit DB38xx.DBX2001.6, xx is machine axis index
Bit 7: Offer rotation axis in position pattern 9727
Bit 8: Offer rotation axis to accept blank (at milling machines)
Bit 10: Rotary axis rotates around 1st geometry axis (for position pattern only)
Bit 11: Rotary axis rotates around 2nd geometry axis (for position pattern only)
Bit 12: Rotary axis rotates around 3rd geometry axis (for position pattern only)
Bit 13: Position of the axis for blank selection from active WO (for rotary axes)
Page 11
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 3: Generate automatic end-of-program in MDI (with the “Delete blocks” soft key)
Bit 13: Hide channel axes which are currently located in another channel

Technology Settings
52211 $MCS_FUNCTION_MASK_DISP _ZOA Function screen for displaying overview of work offsets
Bit 1: reserved
Bit 12: Display $P_TOOLFRAME
Page 12

52212 $MCS_FUNCTION_MASK_TECH Function mask Cross-technology
Bit 0: Enable swivel plane/align tool with tool carrier 9723
Bit 1: Optimized travel along software limit switches (ShopMill/ShopTurn)
Bit 6: Work offset ZV cannot be entered as an absolute value (ShopTurn)
Bit 7: Detect the expiry of tool lives (ShopMill/ShopTurn)
Appendix B
Bit 10: Enable swivel plane/align tool using kinematic transformation
Appendix B
Bit 11: Switch off layer check for drilling and milling tools (ShopTurn)
Bit 12: reserved
Bit 13: Approach tool change point Y in Machine (ShopTurn)
Bit 14: With approach logic only check tool position with cutting edge (ShopTurn)
Appendix B
Appendix B
52214 $MCS_FUNCTION_MASK_MILL Function mask Milling

Bit 0: Enable cylinder surface transformation (ShopMill) 9721
Bit 1: Offer fixed table for blank clamping (at milling machines)
Bit 4: Enable spindle clamping (C axis) (ShopTurn) 9843
Technology Settings
52216 $MCS_FUNCTION_MASK_DRILL Function mask Drilling
Bit 2: Thread tapping also without encoder (ShopMill/ShopTurn)
Bit 3: Constant cutting speed in rel. to diameter of centering (ShopMill/ShopTurn)
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
Page 13
Bit 2: Enable tailstock 9842

Bit 3: Enable spindle control of main spindle via surface 9897Bit 0
Bit 4: Enable spindle control of counterspindle via surface 9897Bit 1
Bit 5: Enable spindle control of tool spindle via surface 9897Bit 2
Bit 6: Enable balance cutting for dual-channel stock removal
Bit 7: Retraction during stock removal along contour with G1
Bit 8: Input spindle chuck data in the program
Bit 9: Additional entry of tailstock data in the program
Bit 10: Enable convex thread
Bit 11: Reserved
Bit 12: Deactivate thread synchronization
Bit 13: Stock rem. contour with CYCLE95 (828D programGUIDE without Advanced Technology)
52229 $MCS_ENABLE_QUICK_M_CODES Enable fast M functions
Bit 0: Coolant OFF
Bit 1: Coolant 1 ON
Bit 2: Coolant 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

Technology Settings
52240 $MCS_NAME_TOOL_CHANGE_PROG Tool change program for G code steps
52241 $MCS_TOOL_CHANGE_POS_Y Tool change position Y in the Machine (ShopTurn)
52242 $MCS_TURN_TOOL_FIXING Tool adapter for turning tools
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
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]: Counterspindle
Page 14
52251 $MCS_M_CODE_CHUCK_CLOSE_OPEN_ M code for Open chuck with rotating spindle.

ROT Example: "M35" or "M1=35"
Elements:
[0]: Main spindle
[1]: Counterspindle
52252 $MCS_M_CODE_CHUCK_CLOSE M code for Close chuck
Elements:
[0]: Main spindle
[1]: Counterspindle
52253 $MCS_M_CODE_TAILSTOCK_FORWARD M code for quill forward
Elements:
[0]: Quill opposite main spindle
[1]: Quill opposite counterspindle
Appendix B
52254 $MCS_M_CODE_TAILSTOCK_BACKWARD M code for quill backward
Appendix B
Elements:
[0]: Quill opposite main spindle
[1]: Quill opposite counterspindle
52260 $MCS_MACHINE_JOG_INTERRUPT_PRIO Priory for start ASUP under machine JOG
Appendix B
Appendix B
52270 $MCS_TM_FUNCTION_MASK Function mask Tool management

Bit 0: Do not permit Create tool on magazine location 9478 Bit 3
Bit 1: Load/unload disable, if machine is not in reset 9478 Bit 9
Bit 2: Load/unload disable for emergency stop 9478 Bit 12
Bit 3: Load/unload tool or relocate tool to/from spindle disabled 9478 Bit 15
Bit 4: Load directly in spindle 9478 Bit 20
Technology Settings
Bit 6: Permit relocating to/from spindle despite a block (Bit 3)
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
Page 15
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
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.
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.
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, workpiece and tool measuring 9750, 9751
Bit 0: Workpiece probe connected at probe input 2 _CHBIT[0]
Bit 1: Workpiece, turning technology, measuring in the third geometry axis (Y) _CHBIT[19]
Bit 2: Calc. of correction angle with/without active orientation transformation
Bit 16: Tool probe connected at probe input 2 _CHBIT[1]
Bit 17: Tool measurement turning, recording the cutting edge position
Technology Settings
52750 $MCS_J_MEA_FIXPOINT Z value for measuring 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
52780 $MCS_J_MEA_T_PROBE_APPR_MODE Approach mode tool measurement in JOG
52800 $MCS_ISO_M_ENABLE_POLAR_COORD Polar coordinates

0: OFF
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
Page 16
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
52818 $MCS_ISO_M_FUNCTION_MASK Function mask for ISO milling mode
Bit 0: Reserved
52819 $MCS_ISO_T_FUNCTION_MASK Function mask for ISO turning mode
Bit 0: Reserved
Appendix B
52840 $MCS_GRIND_FUNCTION_MASK Function mask for grinding
Bit 7: Retraction while profiling with G1
Appendix B
52842 $MCS_GRIND_DIAMETER_LENGTH Number of diameter length
52843 $MCS_GRIND_WIDTH_LENGTH Number of grinding wheel with

Axis Machine Data
Appendix B
Appendix B
53220 $MAS_AXIS_MCS_POSITION Position of axis in the Machine
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
Technology Settings
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
53250 $MAS_CLAMPING_TOLERANCE Permissible tolerance when an axis jams
Page 17
General Setting Data

54215 $SNS_TM_FUNCTION_MASK_SET Function mask Tool management
Bit 0: Diameter display for rotating tools 9663
Bit 1: Default direction of rotation for all turning tools is M4 9826
Bit 3: Input disable for tool name and tool type in loaded tools 9478 Bit 4
Bit 4: Input disable for loaded tools, if the channel is not in Reset 9478 Bit 7
Bit 5: Calculate tool wear inputs additively 9478 Bit 6
Bit 6: Numerical input of the tool ident. 9478 Bit 10
Bit 8: Diameter display for transverse axis - Geometry 9478 Bit 11
Bit 10: Enable loading/relocating of tools on buffer locations 9478 Bit 25

Bit 11: Creating of new tools in gripper locations is disabled
Bit 12: Do not unload measuring tools if ”Unload all” function is executed
Bit 13: Do not delete tool wear when inputting the geometry value
Bit 14: Load/relocate tool. Search without pre-assignment of the magazine
54480 $SNS_AST_MMC_HANDLER_NAME Zuordnung einer HMI-Operate-Instanz für AST-Kommandos
54481 $SNS_AST_MMC_DEFAULT_IS_PCU Auswahl HMI-Operate intern (NCU) / extern (PCU) für AST
Technology Settings
54600 $SNS_MEA_WP_BALL_DIAM Effective diameter of the probe sphere for the workpiece probe _WP[x,0]
54601 $SNS_MEA_WP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction _WP[x,1]
54602 $SNS_MEA_WP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction _WP[x,2]
54603 $SNS_MEA_WP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction _WP[x,3]
54604 $SNS_MEA_WP_TRIG_PLUS_DIR_AX2 Trigger point of the 2ns measuring axis in positive direction _WP[x,4]
54605 $SNS_MEA_WP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction _WP[x,5]
54606 $SNS_MEA_WP_TRIG_PLUS_DIR_AX3 Trigger point of the 3d measuring axis in positive direction _WP[x,6]
54607 $SNS_MEA_WP_POS_DEV_AX1 Position deviation of the probe sphere in the 1st measuring axis _WP[x,7]
Page 18
54608 $SNS_MEA_WP_POS_DEV_AX2 Position deviation of the probe sphere in the 2nd measuring axis _WP[x,8]
54609 $SNS_MEA_WP_STATUS_RT Calibration status 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]
54611 $SNS_MEA_WP_FEED Measuring feed for calibration
54615 $SNS_MEA_CAL_EDGE_BASE_AX1 Calibration groove base of the 1st measuring axis _KB[x,2]
54617 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX1 Calibration groove edge in positive direction of the 1st measuring axis _KB[x,3]
54618 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX1 Calibration groove edge in negative direction of the 1st measuring axis _KB[x,4]
Appendix B
54619 $SNS_MEA_CAL_EDGE_BASE_AX2 Calibration groove base of the 2nd measuring axis _KB[x,6]
Appendix B
Appendix B
Appendix B
54620 $SNS_MEA_CAL_EDGE_UPPER_AX2 Calibration groove upper edge of the 2nd measuring axis _KB[x,5]
54621 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX2 Calibration groove edge in positive direction of the 2nd measuring axis _KB[x,0]
54622 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX2 Calibration groove edge in negative direction of the 2nd measuring axis _KB[x,1]
54625 $SNS_MEA_TP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction _TP[x,0]
Technology Settings
54626 $SNS_MEA_TP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction _TP[x,1]
54627 $SNS_MEA_TP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction _TP[x,2]
54628 $SNS_MEA_TP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction _TP[x,3]
54629 $SNS_MEA_TP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction _TP[x,4]
Page 19
54630 $SNS_MEA_TP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction _TP[x,5]
54631 $SNS_MEA_TP_EDGE_DISK_SIZE Tool probe edge length/wheel diameter _TP[x,6]

9765
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
calibration 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
Technology Settings
54633 $SNS_MEA_TP_TYPE Tool probe type cube / wheel _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]
9767
54635 $SNS_MEA_TP_STATUS_GEN Calibration status in general, reserved for internal use!
54636 $SNS_MEA_TP_FEED Measuring feed for tool probe calibration in MCS
54640 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction _TPW[x,0]
54641 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction _TPW[x,1]
Page 20
54642 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction _TPW[x,2]
54643 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction _TPW[x,3]
54644 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction _TPW[x,4]
54645 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction _TPW[x,5]
54646 $SNS_MEA_TPW_EDGE_DISK_SIZE Tool probe edge length/wheel diameter _TPW[x,6]
Appendix B
Appendix B
Appendix B
Appendix B
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)!
Technology Settings
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
54648 $SNS_MEA_TPW_TYPE Tool probe type cube / wheel _TPW[x,8]
Page 21
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]
54650 $SNS_MEA_TPW_STATUS_GEN Calibration status in general, reserved for internal use!
54651 $SNS_MEA_TPW_FEED Measuring feed for tool probe calibration in WCS
54652 $SNS_MEA_INPUT_TOOL_PROBE_SUB CNC measurement input for tool probe with reference to the counterspindle 9828
=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
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
Technology Settings
54670 $SNS_MEA_CM_MAX_PERI_SPEED Max. permissible peripheral speed of the tool to be measured _CM[0]
9759
54671 $SNS_MEA_CM_MAX_REVOLUTIONS Maximum tool speed for tool measuring _CM[1]
9760
54672 $SNS_MEA_CM_MAX_FEEDRATE Maximum feed for contact of the tool with the probe _CM[4]
9771
54673 $SNS_MEA_CM_MIN_FEEDRATE Minimum feed for 1st contact of the tool with the probe _CM[4]
9761
54674 $SNS_MEA_CM_SPIND_ROT_DIR Direction of spindle rotation for tool measuring _CM[5]
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).
Page 22
Monitoring parameter for tool measuring with rotating spindle.
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
$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!
Monitoring parameter for tool measuring with rotating spindle.
54677 $SNS_MEA_CM_MEASURING_ACCURAC Required measuring accuracy for tool measuring _CM[3]

Y 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
Appendix B
=1: TT130 (Heidenhain)
=2: TS27R (Renishaw)
Appendix B
Appendix B
Appendix B
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 SD54689
$SNS_MEA_T_PROBE_MANUFACTURER<>0)
=2: Offset through user-defined offset table
54692 $SNS_MEA_T_CIRCULAR_ARC_DIST Arc distance for single cutting edge measuring from the radius
Technology Settings
54693 $SNS_MEA_T_MAX_STEPS Max. number of contacts for single cutting edge measuring from the radius
54695 $SNS_MEA_RESULT_OFFSET_TAB_RAD1 Offset table (measure tool radius with rotating spindle)
54696 $SNS_MEA_RESULT_OFFSET_TAB_RAD2 Offset table 1st peripheral speed (radius)
54697 $SNS_MEA_RESULT_OFFSET_TAB_RAD3 Offset table 2nd peripheral speed (radius)
54698 $SNS_MEA_RESULT_OFFSET_TAB_RAD4 Offset table 3rd peripheral speed (radius)

Page 23
54699 $SNS_MEA_RESULT_OFFSET_TAB_RAD5 Offset table 4th peripheral speed (radius)
54700 $SNS_MEA_RESULT_OFFSET_TAB_RAD6 Offset table 5th peripheral speed (radius)
54705 $SNS_MEA_RESULT_OFFSET_TAB_LEN1 Offset table (measure tool length with rotating spindle)
54706 $SNS_MEA_RESULT_OFFSET_TAB_LEN2 Offset table 1st peripheral speed (length)
54707 $SNS_MEA_RESULT_OFFSET_TAB_LEN3 Offset table 2nd peripheral speed (length)

54708 $SNS_MEA_RESULT_OFFSET_TAB_LEN4 Offset table 3rd peripheral speed (length)
54709 $SNS_MEA_RESULT_OFFSET_TAB_LEN5 Offset table 4th peripheral speed (length)
54710 $SNS_MEA_RESULT_OFFSET_TAB_LEN6 Offset table 5th peripheral speed (length)

Technology Settings
54740 $SNS_MEA_FUNCTION_MASK Function mask for measuring cycles, workpiece and tool measuring
Bit 0: Workpiece, measurement repeated if TSA, TDIF are exceeded _CBIT[0]
Bit 1: Workpiece, repeat measurement with M0 if TSA, TDIF are exceeded _CBIT[1]
Bit 2: Workpiece, stop at M0 if TUL, TLL are exceeded _CBIT[2]
Bit 3: Workpiece, accept calibrated probe ball radius in tool data _CBIT[15]
Bit 4: Workpiece , plane between calibration and measurement can be different
Bit 16: Tool, repeat measurement if TDIF, TSA are exceeded _CBIT[0]
Bit 17: Tool, repeat measurement with stop at M0 if TDIF, TSA are exceeded _CBIT[1]
Bit 19: Tool milling, reduction of the spindle speed at the last probing _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
Bit 1: Selection of display softkey 3D measurement
Page 24
Bit 3: Select probe calibration data field, 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, length L1, L2, L3
Bit 14: Enable selection of tool offset work offset
Bit 15: Enable selection of tool offset dimensional difference check
Bit 16: Selection of workpiece measurement with spindle reversal
Bit 17: Selection align workpiece probe in switching direction
Bit 18: Select Number of measurements
Bit 19: Select Offset with averaging
Bit 20: Select Empirical values
Appendix B
Bit 21: Select Additive setup offset
Bit 22: Select Calibrate to unknown or known center point
Bit 24: Select Calibrate with or without positional deviation
Appendix B
Bit 25: Selection zero offset when measuring the angularity of the spindle
Bit 26: Tool offset selection not enabled
Bit 27: Select tolerance of linear vectors with kinematics measurement
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 10: Select measuring function ”Check teeth individually”
Technology Settings
Bit 11: Selection spindle reversal when calibrating on the plane
Bit 12: Select Number of measurements
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, Workpiece measurement in JOG 9747
Bit 2: Activate calibration for electronic workpiece probe
Bit 5: Select WO as measuring basis
Page 25
Bit 6: Select WO compensation in basic reference, enable

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
Bit 16: Selection of workpiece measurement with spindle reversal
Bit 17: Selection align workpiece probe in switching direction
54782 $SNS_J_MEA_FUNCTION_MASK_TOOL Setting for input screen, Tool measuring in JOG 9749
Bit 2: Enable automatic tool measurement
Bit 3: Select tool probe calibration data field, enable
Bit 10: Select measuring function ”Check teeth individually”
Bit 11: Selection spindle reversal when calibrating on the plane
Channel Setting Data
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
55214 $SCS_FUNCTION_MASK_MILL_SET Function mask Milling
Bit 0: Default setting - milling cycles with synchronous operation 9827
Bit 2: Depth calculation in milling cycles without parameter SC _ZSD[9]
= 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
Page 26
Note: Bit 2 is active with the following milling cycles: CYCLE61, CYCLE71, CYCLE76, CYCLE77, _ZSD[1]
CYCLE79, CYCLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCKET4
55216 $SCS_FUNCTION_MASK_DRILL_SET Function mask Drilling
Bit 0: reserved
Bit 2: Consider swivelled table kinematics (CYCLE86)
Bit 5: reserved
Bit 6: Adapt spindle position to the tool orientation (CYCLE86)
Bit 7: Adapt direction of retraction path in the plane to active mirroring (CYCLE86)
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)
Bit 3: Chamfer in CYCLE930 as chamfer length (CHF)
Appendix B
Bit 4: Retraction from the inside machining (CYCLE951)
55220 $SCS_FUNCTION_MASK_MILL_TOL_SET Function mask High Speed Settings CYCLE832
Bit 0: Unhide technology fields
Appendix B
Bit 1: Orientation tolerance (OTOL) as a tolerance factor, enter it directly

Bit 2: Mould-making function can be selected in High Speed Settings mask
Bit 3: High Speed Settings mask with Advanced Surface option
Appendix B
Appendix B
55221 $SCS_FUNCTION_MASK_SWIVEL_SET Function mask Swivel CYCLE800
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: Show swivel data block "Deselection"
Bit 3: Display active swivel plane in JOG
Bit 4: Positioning in basic position (pole position) of the kinematics
Technology Settings
Bit 6: Do not offer swivel mode “directly” under swivel in JOG
Bit 7: Swivel plane: Direction selection in initial setting of kinematics
Bit 8: Take into account work offset of rotary axes, swivel data set in Work
Bit 9: Swivel data set TC permanently assigned to the tool
Bit 10: Swivel plane: Display input field “positioning direction”
Bit 11: Swivel plane: Positioning of both solutions AB - display kinematics
Bit 12: Reset behaviour taking into account the rotary axis position
55230 $SCS_CIRCLE_RAPID_FEED Positional feed on circular path 9724
Page 27
55232 $SCS_SUB_SPINDLE_REL_POS Z retraction position for the counter spindle 9851
55260 $SCS_MAJOG_SAFETY_CLEARANCE Safety clearance for machine JOG
55261 $SCS_MAJOG_RELEASE_PLANE Retraction plane for machine JOG
55300 $SCS_EASY_SAFETY_CLEARANCE Simple input: Safety clearance
55301 $SCS_EASY_DWELL_TIME Simple input: dwell time
55305 $SCS_EASY_DRILL_DEEP_FD1 Simple input: percentage 1st federate deep - hole drilling
55306 $SCS_EASY_DRILL_DEEP_DF Simple input: percentage infeed deep - hole drilling

55307 $SCS_EASY_DRILL_DEEP_V1 Simple input: min. depth infeed deep - hole drilling
55308 $SCS_EASY_DRILL_DEEP_V2 Simple input: absolute retraction value deep - hole drilling
55309 $SCS_EASY_THREAD_RETURN_DIST Simple input: return distance thread tapping
55400 $SCS_MILL_ENGRAVE_POINT_RAD Engraving cycle CYCLE60: Circ. path radius for generating the char. ”point”
Technology Settings
55410 $SCS_MILL_SWIVEL_ALARM_MASK Hide and unhide cycle alarms
Bit 0: Display alarm 62186: Active work offset G54 ff. and base (basic reference) contain rotations
Bit 1: Display alarm 62187: Active base and basic reference (G500) contain rotations
Bit 2: Display alarm 61148: Swivel plane not possible with active turning tool
Bit 3: Display alarm 61426: Kinematics measurement with CYCLE9960/996
55420 $SCS_MILL_SWIVEL_RESET_RETRACT Initial setting swivel: retract
= 0: no change
= 1: no
= 2: Z
= 3: Z XY
55421 $SCS_MILL_SWIVEL_RESET_TRACK Initial setting swivel: tool correction
= 0: no change
= 1: do not correct
= 2: correct
55422 $SCS_MILL_SWIVEL_RESET_MODE Initial setting swivel: swivel mode
Page 28
= 0: axis by axis
= 1: direct
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]
Appendix B
Appendix B
Appendix B
Appendix B
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.
55481 $SCS_DRILL_TAPPING_SET_GG12 Settings for tapping G group 12 cycle CYCLE84 and CYCLE840: 9855[0]
Technology Settings
G group 12: Block change behaviour at exact stop (G60) 9856[1]
0 = Exact stop behaviour, 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 behaviour, same as before the cycle call
1 = SOFT
Page 29
2 = BRISK
3 = DRIVE
55483 $SCS_DRILL_TAPPING_SET_GG24 Settings for tapping G group 24 cycle CYCLE84 and CYCLE840: 9855[0]
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
Technology Settings
55500 $SCS_TURN_FIN_FEED_PERCENT Roughing feedrate for complete machining in % 9630
55505 $SCS_TURN_ROUGH_O_RELEASE_DIST Return distance stock removal for external machining 9648
-1: The distance is specified internally.
55506 $SCS_TURN_ROUGH_I_RELEASE_DIST Return distance stock removal for internal machining 9649
-1: The distance is specified internally.
55510 $SCS_TURN_GROOVE_DWELL_TIME Tool clearance time for grooving at the base (neg. value=revolutions) 9621
- 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
55542 $SCS_TURN_PART_OFF_CTRL_FORCE Force for cut-off check, in % 9861

Page 30
55543 $SCS_TURN_PART_OFF_RETRACTION Retraction path prior to cut-off with counter spindle
55550 $SCS_TURN_FIXED_STOP_DIST Counterspindle: path for travel to fixed stop 9852

(see setting data 55551 $SCS_TURN_FIXED_STOP_FEED).
55551 $SCS_TURN_FIXED_STOP_FEED Counterspindle: feedrate for travel to 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 Counterspindle: force for travel to fixed stop, in % 9854
55553 $SCS_TURN_FIXED_STOP_RETRACTION Counterspindle: retraction path prior to chucking after fixed stop 9857
55580 $SCS_TURN_CONT_RELEASE_ANGLE Counter turning: retraction angle
55581 $SCS_TURN_CONT_RELEASE_DIST Counter turning: retraction value 9550
55582 $SCS_TURN_CONT_TRACE_ANGLE Counter turning: minimum angle for rounding along contour 9553
Appendix B
Appendix B
Appendix B
Appendix B
55583 $SCS_TURN_CONT_VARIABLE_DEPTH Counter turning: percentage for variable cutting depth 9556
55584 $SCS_TURN_CONT_BLANK_OFFSET Counter turning: blank allowance 9552
55585 $SCS_TURN_CONT_INTERRUPT_TIME Counter turning: feed interrupt time (neg. value=revolutions) 9557
- Negative value in spindle revolutions
- Positive value in seconds
Technology Settings
This setting data is effective only if setting data 55586 is 55586
$SCS_TURN_CONT_INTER_RETRACTION = 0.
55586 $SCS_TURN_CONT_INTER_RETRACTION Counter turning: retraction path after feed interrupt 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 Counter turning: minimum difference dimension residual machining axis 1 9554
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.
Page 31
55588 $SCS_TURN_CONT_MIN_REST_MAT_AX2 Counter turning: minimum difference dimension residual machining axis 2 9555
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 Counter plunge turning: retraction path due to tool bending 9560
In this setting data you specify the lateral distance to the last cut, by which each next cut will be
shortened.
55596 $SCS_TURN_CONT_TURN_RETRACTION Counter plunge turning: retraction path prior to turning 9561
Technology Settings
55613 $SCS_MEA_RESULT_DISPLAY Selection of 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!
55614 $SCS_MEA_RESULT_MRD Program control of the display of the measurement result display MRD
=0: Hide measurement result display
=1: Show measurement result display
55618 $SCS_MEA_SIM_ENABLE Setting measuring cycles under 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,
Page 32
the travel is performed without collision detection.

55619 $SCS_MEA_SIM_MEASURE_DIFF Value for simulated error of measurement _MC_SIMDIFF
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 Empirical value memory _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!
Appendix B
55624 $SCS_MEA_AVERAGE_VALUE_NUM Number of mean values _EVMVNUM[1]
Appendix B
Appendix B
Appendix B
55625 $SCS_MEA_AVERAGE_VALUE Mean value memory _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 calibrating a tool probe 9773
Technology Settings
55630 $SCS_MEA_FEED_MEASURE Feed for calibrating a workpiece probe 9756
55631 $SCS_MEA_FEED_MEASURE_DEG Measurement feedrate of workpiece probe during positioning of a rotary axis
55632 $SCS_MEA_FEED_RAPID IN_PERCENT Rapid traverse velocity in per cent for intermediate positioning _SPEED[0]
55634 $SCS_MEA_FEED_PLANE_VALUE Traverse velocity for intermediate positioning in the plane _SPEED[1]
Page 33
55636 $SCS_MEA_FEED_FEEDAX_VALUE Positioning velocity in the infeed axis _SPEED[2]
55637 $SCS_MEA_FEED_POS_DEG Feedrate when positioning a rotary axis between individual measurements
55638 $SCS_MEA_FEED_FAST_MEASURE Rapid measuring feed _SPEED[3]

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.
Technology Settings
55644 $SCS_MEA_KIN_DM_TOL Measure kinematics: Tolerance of diameter of calibration ball
55645 $SCS_MEA_KIN_MODE Free component of the linear vector
55646 $SCS_MEA_KIN_VALUE Measure kinematics completely: value of the linear vector
55647 $SCS_MEA_KIN_MIN_ANG_TRIANGLE Minimum interior angle of the measurement triangle
55648 $SCS_MEA_KIN_MIN_ANG_POS Minimum angle when positioning a rotary axis
55649 $SCS_MEA_KIN_BALL_VEC Perform complete kinematics measurement: Vector of the ball mounting
55730 $SCS_MEA_PROTOCOL_USER_EXT File extension for application protocol
55740 $SCS_MEA_FUNCTION_MASK Function mask for measuring cycles, workpiece and tool measuring
Bit 0: Workpiece, collision monitoring for intermediate positioning _CHBIT[2]
Page 34
Bit 1: Workpiece, coupling spindle with coordinate rotation around infeed axis _CHBIT[13]
Bit 2: Workpiece, for coupling of spindle pos., reverse positioning direction _CHBIT[14]
Bit 3: Workpiece, do not repeat if the probe does not switch _CHBIT[15]
Bit 4: Workpiece, 1st probing for each measurement with fast measuring feedrate _CHBIT[17]
Bit 5: Workpiece, fast retraction after measurement _CHBIT[16]
Bit 6: Workpiece, deactivate probe during spindle positioning
Bit 7: Kinematics, normalization based on the input values of rotary axis vectors
Bit 8: Kinematics, measurement with active swivel (TCARR) or active TRAORI
Bit 9: Kinematics, user-specific scaling of rotary axis vectors
Bit 10: Complete kinematics measurement with reference
Bit 11: Kinematics, number of measuring points for measuring the calibration ball
Bit 15: Workpiece, calib. Radius with start point at venter of ring, only in JOG E_MESS_SETT[1]
Bit 16: Tool, collision monitoring for intermediate positioning _CHBIT[2]
Bit 17: Tool, do not repeat if the probe does not switch _CHBIT[15]
Bit 19: Tool, fast retraction after measuring _CHBIT[16]
Bit 28: Continuous standard protocol for measurement in JOG (append)
Bit 29: Table format for standard protocol for measurement in JOG
Appendix B
55774 $SCS_J_MEA_PROTOCOL_FILE Name and path of protocol file for measurement in JOG
Appendix B
Appendix B
Appendix B
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
55802 $SCS_ISO_M_DRILLING_TYPE Tapping type
0: Tapping without compensating chuck
1: Tapping with compensating chuck
Technology Settings
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)
Page 35
55807 $SCS_ISO_M_TAPPING_SET_MC Setting tapping G84: Spindle mode/position control
55808 $SCS_ISO_T_RETRACTION_FACTOR Factor (1-200%) for retraction speed at tapping G84/G88
55810 $SCS_ISO_T_DWELL_TIME_UNIT Dwell time evaluation for deep hole drilling G83/G87
0: Seconds
1: Revolutions
55818 $SCS_ISO_M_FUNCTION_MASK Function mask for ISO milling mode

Bit 0: Reserved
55819 $SCS_ISO_T_FUNCTION_MASK Function mask for ISO turning mode
Bit 0: Without complete residual corner cut
Bit 1: Stock removal roughing without tool nose radius compensation
Technology Settings
55820 $SCS_FRICT_OPT_RADIUS Circle radius for optimizing friction compensation
55821 $SCS_FRICT_OPT_RADIUS_ROT Circle radius for optimizing friction compensation for rotary axes
55822 $SCS_FRICT_OPT_FEED Feedrates for optimizing friction compensation
55823 $SCS_FRICT_OPT_FEED_ROT Feedrates for optimizing friction compensation for rotary axes
55824 $SCS_FRICT_OPT_STEP Step number for optimizing friction compensation
55826 $SCS_FRICT_OPT_ACT_STEP Current step number for optimizing friction compensation
55828 $SCS_FRICT_OPT_DIR_MINUS Direction of rotation for optimizing friction compensation
55844 $SCS_GRIND_MEA_KIN_TOL Kinematic measurement: Tolerance of kinematic vectors

Page 36
55880 $SCS_GRIND_CONT_RELEASE_ANGL Grinding - profiling: retraction angle

E
55881 $SCS_GRIND_CONT_RELEASE_DIST Grinding - profiling: retraction value
55884 $SCS_GRIND_CONT_BLANK_OFFSET Grinding - profiling: blank allowance
Appendix B
Appendix B
Appendix B: END
B034
Appendix C PLC Interface Structure
PLC Interface
Structure:
START 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
Sinumerik
AUX
Functions
DB9900
User
DB2600 Interface
DB2700
NCK
Signals
PLC Interface
Structure:
END
DB2800
DB2900
Fast NC I/O
Appendix C
Machine Control Panel
Machine Control Panel MCP483 PN

During commissioning the MCP address range is set to start at Input and output Bytes 112.
MCP483 PN Signals from machine control panel (keys)

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
1 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 :
Appendix C Page 2 SINUMERIK 828D

PLC Interface Structure Appendix C
Machine Control Panel MCP310 PN
During commissioning the MCP address range is set to start at Input and output Bytes 112.
MCP310 PN Signals from machine control panel (keys)

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
+ -
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
Notes :
SINUMERIK 828D Page 3 Appendix C

Interface Description
User Data Areas

There are two areas set aside for free use within the user PLC or MCP Data Block interface.
DB1000-
User Data 1 [r/w]
DB1001
0000
User Data
up to
0019 User Data
Input image for MCP483 USB and MCP310 USB
DB1000-
User Data 1 [r/w]
DB1001

0000
D C B A
Machine function
0001
REPOS REF Var. INC
Spindle *Spindle Feed start *Feed stop 1) NC start *NC stop 1)
0002 start stop 1)
Reset Single block Feed override

0003
E D C B A
0004 S24 S22 S23 - S31 S34 S37 -
S32 S33 S35 Drive com- - S39 S38 S36

0005 mand in
MCS/WCS
Freely assignable customer keys Reserved
0006
S18 S40 (res.) 3) S7 2) S21 - - - -
0007
S10 S11 S12 S13 S14 S15 S16 S17

2) For MCP310USB, preassigned with ”Coolant”, for MCP483 USB freely assignable customer key.
3) Key not available for MCP310 USB, for MCP483 USB freely assignable customer key.
Notes :

User Data Areas-continued
DB1100- User Data 2 [r/w]

DB1101
0000
User Data
up to
0007
User Data
Output image for MCP483 USB and MCP310 USB
DB1100-
User Data 2 [r/w]
DB1101
Operating mode
0000
JOG Teach IN MDA AUTO
Feed start *Feed stop 1) NC start *NC stop 1) Machine function -

0001
REPOS REF Var. INC
S22 S31 S34 S37 - Single block Spindle *Spindle
0002 start stop 1)
S33 S35 Drive com- - S39 S38 S36 S24

0003 mand in
MCS/WCS
0004
S18 S40 (res.) S7 S21 - - - S32
0005
S10 S11 S12 S13 S14 S15 S16 S17
0006 - - - - - - - -
0007 - - - - - - - -
0010 - - - - - - - -
0011 - - - - - - - -
DP
0012
- - - - - - DP2 DP1
0013
0014 User data
0015 User data

2) For MCP310 USB, preassigned with ”Coolant”, for MCP483 USB freely assignable customer key.
3) Key not available for MCP310 USB, for MCP483 USB freely assignable customer key.
Notes :

7-Segment display
The 7 segment display is controlled via DB1100.DBB8 (Left display) & DBB9 (Right display).
The following table shows the available 7-segment characters and the interface bits required to activate them.
DB1100.DBB8/9 bits:
7 Segment
Hex Decimal
Display
7 6 5 4 3 2 1 0
0 - - x x - - - - 30 48
1 - - x x - - - x 31 49
2 - - x x - - x 32 50
3 - - x x - - x x 33 51
4 - - x x - x - - 34 52
5 - - x x - x - x 35 53
6 - - x x - x x - 36 54
7 - - x x - x x x 37 55
8 - - x x x - - - 38 56
9 - - x x x - - x 39 57
A - x - - - - - x 41 65
b - x - - - - x - 42 66
C - x - - - - x x 43 67
d - x - - - x - - 44 68
E - x - - - x - x 45 69
F - x - - - x x - 46 70
H - x - - x - - - 48 72
j - x - - x - x - 4A 74
H - x - - x x - - 4C 76
n - x - - x x x - 4E 78
o - x - - x x x x 4F 79
p - x - x - - - - 50 80
q - x - x - - - x 51 81
r - x - x - - x - 52 82
t - x - x - x - - 53 83
u - x - x - x - x 55 85
y - x - x x - - - 59 89
Notes :

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
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]

DB1207
1000 Variable Index
1001 Area Number
1002 Line index for NC variable x (Word)
1004 Column index for NC variable x (Word)
1006
1008 Writing data to NC variable x (1 to 4 bytes) *1)
1012
1016 Writing data to NC variable x (REAL) *2)
1020 Writing data to NC variable x (DWORD / DINT) *2)
1024 Writing data to NC variable x (WORD / INT) *2)
1026 Writing data to NC variable x (BYTE) *2)
1027 Writing data

to NC varia-
ble x (BOOL)
*2)
*2) Only for variables from DB9910, DB9911, DB9912 NC_DATA
Notes :

Results:-The results of the task are output to the following areas:-

2000 Error in job Request

Complete
2001

DB1207
3000 Fault Valid Variable
3001 Access result

0: No error, 3: Access to object is not permitted, 5: Invalid address, 10: Object does not exist
3002
3004 Reading data from NC variable x (1 to 4 bytes) *1)
3008
3012
3016 Reading data from NC variable x (REAL) *2)
3020 Reading data from NC variable x (DWORD / DINT) *2)
3024 Reading data from NC variable x (WORD / INT) *2)
3026 Reading data from NC variable x (BYTE) *2)
3027 Reading data

from NC
variable x
(BOOL) *2)
*2) Only for variables from DB9910, DB9911, DB9912 NC_DATA
PI Services
4000 Start
4001 PI-Index
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
etc
4022 PI-Parameter 10
Notes :

PI Services:- Result
5000 Fault Finished
5001
5002
Retentive Data Area
DB1400 Retentive Data [r/w]
User area
0000
User area
0001
etc
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]
Channel 1
2000 Acknowledge Acknowledge PLC Stop Em. Stop Feed disa- Read-in NC start
with power ON with DB1600. ble disable disable
DBX3000.0
Channel 2
2001 Feed disa- Read-in NC start

ble disable disable
DB1600 Alarm acknowledgement PLC HMI [r/w]
3000 Acknowledg
e
Extended User Alarms

DB1600 Activating alarms (Alarm number range 701000 to 701247) PLC HMI [r/w]
4000 701007 701006 701005 701004 701003 701002 701001 701000
4001 701015 701014 701013 701012 701011 701010 701009 701008
4002 701023 701022 701021 701020 701019 701018 701017 701016
4003 701031 701030 701029 701028 701027 701026 701025 701024
etc
4124 701999 701998 701997 701996 701995 701994 701993 701992
DB1600 Variable for alarm PLC HMI [r/w]
etc
Notes :

Program Control Signals

DB1700- HMI signals HMI PLC [r]
DB1701
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
Program selection
DB1700- Interface PLC HMI [r/w]
DB1701
1000 Part program Disable teach
selection transfer
1001 Always 1 Part program handling: Number of the control data base for user file names
1002 Part program handling: Index of the file to be transferred from the user list
DB1700- Interface HMI PLC [r]

DB1701
Part program handling status

2000
Selection Loading Unloading Active Error OK
2001 Error program handling
SMS Messenger
DB1700- Interface SMS messenger PLC [r]
DB1701
3000 Variable-Settable via SMS
Notes :

Signals from HMI
DB1800 HMI PLC [r]
0000 Reset JOG mode MDA mode AUTO

mode
0001 Machine Machine Machine

function:- function:- function:-
REF REPOS TEACH IN
Note:- Signals present for only one plc cycle.
Signals from PLC

DB1800 Signals from PLC [r]
1000 Start-up ar- Power up Power up

chive was with saved with default
read in data values
1002
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
1016 Configured number of mode groups
1018 Maximum channel number
1020 Maximum axis number
1022 Current channel distribution
Channel 2 Channel 1
1023 Reserved
1024 Current axis distribution
Axis 8 Axis 7 Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
1025 Current axis distribution
Axis 12 Axis 11 Axis 10 Axis 9
1026 Reserved
Notes :

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
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
4003
32 31 30 29 28 27 26 25
Notes :

Maintenance Planner-continued
DB1800 PLC HMI Disable Maintenance task acknowledgement [r/w]
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 Channel number displayed by the HMI software
0003 Screen Data transfer Keyboard

change active has been
active used
0004 Active JobShop area
0006 up to Reserved
0010
0011 Error code for function selection number
Function selection from DBB5021
0012 up to Reserved
0019
0020 Simulation state
0022 up to Reserved
0023
Error code for function selection number:

0 No error
1 Function selection number is missing (DBB5021 Bit 0 … 5)
2 Invalid parameter
3 Internal error
10 Channel does not exist
Notes :

General selection/status signals from HMI (retentive area)
1000
1002
Axis number for hand-wheel 1

1003
Machine axis Hand-wheel C B A
selected
1004
selected
1005
selected
General selection/status signals to HMI (retentive area)

DB1900 PLC HMI [r/w]
5000 Actual values OP key Screen dark

in 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 up to Reserved
5020
5021 Busy Strobe Function selection number from PLC (Bit 0 … 5)

function function
5022 Parameter 1 for function selection number,
function selection from DBB5021


5025 Reserved
Notes :

Auxiliary functions from NCK channel (read only)

DB2501
0000 up to
0003
0004 M fcts.5 M fcts.4 M fcts.3 M fcts.2 M fcts.1

change change change 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 H fcts.1

change change change
0013 up to
0019
Decoded M signals (M0-M99)

DB2501
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 :

Transferred T functions

DB2501
2000 T function 1 (DINT)
2004
up to
2007
Transferred M functions

DB2501
3000 M function 1 (DINT)
3004 Extended address of M function 1 (Byte)
Transferred S functions
DB2501
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

DB2501
5000 D function 1 (DINT)
5004
Notes :

Transferred H functions
DB2500- NCK interface PLC [r]

DB2501
6000 H function 1 (REAL)
6004 Extended address of H function 1 (Byte)
NCK Signals-General Signals to NCK
Protection level: Key-operated switch position 0 to 3 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 DB5707.
Signals from the roboter

1000 Roboter status byte 0
Notes :

Signals from NCK


0000 Emergency
Stop active
0001 INCH measur- Probe 2 Probe 1

ing system actuated actuated
0002 NC Ready Drive ready Drives in HMI ready

cyclic opera-
tion
0003 Air temp. NCK alarm is

alarm active
0004
0005
0006
Signals from NCK-continued
0007
0008
0009
0010
0011
0012 Change counter for motions of hand-wheel 1
0015 Change counter, inch metric unit system.
0016
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
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
0005
Values from the PLC for digital NCK outputs
0006
Setting mask for digital NCK outputs
0007
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
1010
Setting mask for external digital NCK outputs
1011
Notes :

Signals From Fast Inputs & Outputs

DB2900 PLC NCK [r]
Actual values for digital NCK inputs
0000
Set-points for digital NCK outputs
0004

Actual values of external digital NCK inputs
1000
Set-points of external digital NCK outputs
1004
Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Operating Mode Signals

DB3001

Reset Mode group Operating mode
changeover
0000 disable
JOG MDA Auto
Machine function
0001
REF REPOS 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

DB3101
Active mode
0000 828D Ready
JOG MDA Auto
Active Machine function

0001
REF REPOS 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

DB3201

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

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 Handwheel
commands ated M01 sim. contour contour hand wheel 3 2 1
0014 h/wheel ON
Activate skip Activate skip

0015 block 9 block 8
0016 Program
branches
(GOTOS)
control
0017 Value from PLC for NC grinding inputs $AC_IN_KEY_G[1…8]
0018 Blocking the digital NCK grinding inputs from the PLC
0019 Status of the digital NCK grinding outputs from the PLC $AC_IN_KEY_G_RUN_IN[1…8]
(*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)

DB3201
Geometry axis 1 (Axis 1 in WCS)

1000
Traversing keys Rapid trav- Traversing key Feedrate stop Activate handwheel (*1)
erse override lock
+ - 3 2 1
1001
Machine function (*2)
Continuous Inc var INC10000 INC1000 INC100 INC10 INC1
travel
1002
1003

1004
erse override lock
+ - 3 2 1

1005
travel
1006
1007

1008
erse override lock
+ - 3 2 1

1009
travel
1010
1011 Invert hand-

wheel direc-
tion of rot.
(*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

DB3301

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 Transfor- M2/M30 Block search Hand-Wheel Rev. Referencing

0001 active mation 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 H-wheel
3 2 1
Protection
zones no long-
0007 er guaranteed
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]
DB3301
1000 Motion Command Travel request Active Hand-wheel (*1)
Plus Minus Plus Minus 3 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
1011 Invert hand-

wheel direc-
tion of rot.
(*1) The type of numbering for the hand-wheel is determined by machine data 11234 (0=bit coded, 1=binary coded).
Additional status signals from NC channel

DB3301
4000 G00 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 Retract data JOG Retract Stop condition StopbyColl
available active Danger
4006 Dormant ASUP Any ASUP

active Active
4008 Active Transformation Number
4010 ´Status of the enable for the digital NCK grinding inputs to the PLC $AC_IN_KEY_G_ISENABLE[1...8]
4011 ´Status of the function of the digital NCK grinding inputs to the PLC $AC_IN_KEY_G_RUN_OUT[1...8]
Notes :

Asynchronous sub routines

DB3401
0000 Asup 1 start
0001 Asup 2 start
0002 Asup 3 start
0003 Asup 4 start
ASUP result

DB3401
Asup 1 start Asup 1 num- Asup 1 run- Asup 1
1000 not possible ber not possi- ning finished
ble
ble
1002 not possible ber not possi- ning Finished
ble
ble
G functions from NC channel

DB3501

0000 Active G function of group 1 (8 bit Integer)
etc
M/S functions, axis specific-spindle specific

DB3711

0000 M function for spindle (Double Integer)
0004 S function for spindle (Real)
Signals from operating software
DB3700- HMI PLC [r]

DB3711
1000 Activate pro- Suppress

gram test program test
Notes :

Signals to axis/spindle
DB3811
Feedrate override
Override active Measuring Measuring Follow up mode Axis/spindle disa- Sensor for fixed Acknowledge
system 2 system 1 ble 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 3 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
DB3811

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

DB3811
Start position- Start spindle Start spindle Start spindle

3000 ing axis positioning turning oscillating
3001 Stop spindle Stop spindle

turning oscillating
Automatic Constant cut- Direction of Hand-wheel Traversing Path Path

3002 gear ting speed rotation-same override dimension Condition: condition:
selection as M4 on Inch Shortest path Incremental
(DC) (IC)
G function: G function:
3003 Indexing posi- Absolute Absolute
tion positive direc- negative
tion direction
(ACP) (ACN)
3004 Position (Real number, with indexing axis, Double word)
3008 Feedrate (Real number)

If = 0 value is taken from machine data POS_AX_VELO
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
DB3811
Open manual
4000
brake
Pulse enable Speed control- Parameter set selection
4001 ler integrator
disable C B A
4002
4003
Notes :

Signals to technology functions

DB3811
Master/slave ON Torque equalisa-
5000 tion controller ON
Activate
dynamic
5001 backlash
compensation
Enable following
5002 axis overlay
Stop HIAxMove Stopp corr Stop DEPBCS Stop DEPMCS Resume HIAx- Resume corr Resume DEP- Resume
5003 Move BCS DEPMCS
PLC controlled Stop along Stop at next Change reversal Set reversal point Continue Reset External
5004 axis braking ramp reversal point point oscillation
reversal
Disable auto- Start gantry

5005 matic synchro- synchronisation
nisation
Positioning the Automatic gear Specified direc- Specified direc- Spindle

5006 spindle stage change tion of rotation tion of rotation STOP
CCW CW
Delete synchronism Track synchro- Disable syn- Resynchroniza-

5007 correction nism chronization tion
General signals from axis/spindle

DB3911

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

DB3911

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

DB3911
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

DB3911
Positioning axis Position reached Error Axis

3000 active during travers- cannot be
ing started
3001 Reserved
3002 Reserved
3003 Error number
Notes :

Signals from drive

DB3911

Holding brake Drive autonom
4000 open motion active
4001 Pulses enabled Speed control- Motor being Active motor / parameter set
ler integrator selected
disabled E D C B A
nact = nset nact < nx nact < nmin Md < Mdx Ramp up com- Temperature pre-warning
4002 pleted
Heat Sink Motor
4003 Generator op Vdclink <

min speed Vdclinkx
undershot
4004 Reserved
4006 Reserved
Interface as- Active motor / parameter set

4008 signment valid
(Bit 0-4) E D C B A
Signals from technology functions

DB3911

Master/slave Torque compen- Master/slave Master/
5000 active satory controller coarse slave fine
on
5001
ESR Acceleration Velocity Superimposed Actual Synchronism Synchronism
reaction initiat- warning warning motion coupling coarse fine
5002 ed threshold threshold
reached reached
Maximum Maximum Synchronisation Axis is Synchro- Following Leading spin-
5003 acceleration velocity running accelerating nism over- spindle active dle active
reached reached ride travel
Oscillation ac- Oscillation Sparking out Error during Oscillation Oscillation

5004 tive movement active oscillation cannot start reversal is
active movement active
Gantry axis Gantry lead- Gantry group- Synchronisation Gantry warning Gantry shut-
5005 ing axis ing is syn- ready threshold down limit
chronising reached reached
Position Position Clamping Dynamic
measuring measuring tolerance backlash
5006
system 2 system 1 exceeded compensation
activated activated active
Synchronism Synchronism 2 Synchronism
2 coarse fine correction is
5007
taken into
account
Active infeed axis
5008
Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
Notes :

Signale von SMI24 Spindel

DB3907
Sensor configuration
Sensor S6 Sensor S5 Sensor S4 Sensor S1 Sensor avail-
available available available available able
7000 (angular (piston end (clamped
position of position) state)
the motor
shaft)
Sensor configuration
Status value
7001 is generated
7002 Status of the clamping system (sensor S1)
7004 Analog measured value of the clamping system (sensor S1)
Status digital sensors
Sensor S5 Sensor S4
7006 available available
(angular (piston end
position, position)
motor shaft)
7007
Tool Management
User interface loading, unloading, relocating

DB40xx (*1)
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Total

y000 ment step 7 ment step 6 ment step 5 ment step 4 edgement edgement ment step 1 acknowl-
step 3 step 2 edgement
Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Acknowl-
y003 Reserved ment step 30 ment step 29 ment step 28 edgement edgement ment step 25 edgement
Status3 for total Acknowledg

y009 acknowledge- e error reset
ment
Notes :


DB41xx (*1)
y000 Multitool: Job
Data in the
multitool range
Multitool: Multitool: Job from NC Positioning Relocating Unloading Loading
y001 Job from NC Positioning program
program
y006 Source magazine no. (Integer)
y008 Source location no. (Integer)
y010 Target magazine no. (Integer)
y012 Target location no. (Integer)
Load/unload
y014
without mov-
HMI to PLC
ing magazine

y064 Multitool: Number (Int)
y068 Multitool: Spindle/tool number (Int)
Feedback signal

DB41xx (*1)
Acknowl- Acknowl-
y100 edgement edgement OK
error
y102 Reserved
y106 Reserved
y108 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Total
ment step 7 ment step 6 ment step 5 ment step 4 ment step 3 edgement edgement acknowledge-
step 2 step 1 ment
y111 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl-
Reserved ment step 30 ment step 29 ment step 28 ment step 27 edgement edgement edgement
Notes :

Job status

DB41xx (*1)
y120 Reserved
y122 Reserved
y124 Current magazine number of the tool (Integer)
y126 Current location number of the tool (Integer)
y128 Target magazine number of the tool (Integer)
y130 Target location number of the tool (Integer)
y132 to
y138 Reserved
User interface tool change

DB42xx (*1)

Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl- Total
y000 ment step 7 ment step 6 ment step 5 edgement edgement edgement edgement acknowl-
step 4 step 3 step 2 step 1 edgement
Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowledge- Acknowl-
y002 ment step 23 ment step 22 ment step 21 edgement edgement edgement ment step 17 edgement
Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowledge- Acknowl-

y003 Reserved ment step 30 ment step 29 edgement edgement edgement ment step 25 edgement
y004 to
y008 Reserved
Status3 for Acknowledg

total e error reset
y009
acknowledge-
ment
y010 to Reserved
y024
Notes :

Jobs for tool change preparing and execute

DB43xx (*1)

y000 Multitool: Job
Data in the
multitool range
Tool Manual tool Manual tool No old tool T0 Prepare Change tool Fixed location
y001 remains in unload load change (Initiated by coded
spindle M06)
y002 Reserved
y004 Reserved
y006 Source magazine no. for new tool (Integer)
y008 Source location no. for new tool (Integer)
y010 Reserved
y012 Reserved
y014 Reserved
y016 Reserved
y020 Target location number for old tool (Integer)
y022 Location type (Integer)
y024 Size, left (Integer)
y026 Size, right (Integer)
y028 Reserved
y030 Reserved
y032 Tool has been Tool is fixed Tool being Pre warning Measuring tools Tool Tool Active tool
in use location coded changed limit reached disabled enabled
y033 Manual tool 1:1 change Master tool To be loaded To be Blocked Identifier for
unloaded tool
y034 New tool: Internal T no. of NCK (Integer)
Notes :

Feedback signal
DB43xx (*1)
Acknowl- Acknowl-
y100 edgement edgement
error OK
y102 Reserved
y106 Reserved
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Total

y108 ment step 7 ment step 6 ment step 5 ment step 4 edgement edgement edgement acknowl-
step 3 step 2 step 1 edgement

Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl-
y111 Reserved ment step 30 ment step 29 ment step 28 edgement edgement edgement edgement
Job status
DB4300- NCK PLC Job status [r]

DB43xx (*1)
y120 Reserved
y122 Reserved
y124 Current magazine no. for new tool (Integer)
y126 Current location no. for new tool (Integer)
y128 Target magazine no. for new tool (Integer)
y130 Target location no. for new tool (Integer)
y132 Current magazine no. for old tool (Integer)
y134 Current location no. for old tool (Integer)
y138 Target location no. for old tool (Integer)
Notes :

PLC machine data

INT values (MD14510 USER_DATA_INT)
0000 Int values (Word/2 bytes)
Up to
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
DB4600- PLC  HMI [r/w] Deactivate synchronised action with ID...

DB4601
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
DB4701
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
DB5301

Tool limit Tool
value warning
0000
reached limit
reached
Transferred tool management functions

DB5301
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

DB5711
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
Safety Integrated
Safety Control Channel (SCC)
DB6000- PLC NCK Signals to axis [r/w]

DB6011

Test stops for
0000 extended func-
tions
0001
0002
External Torque 1 or 2 Direction of Test with Start Select
0003 brake closed rotation brake 1 or 2 brake test safe brake test
Safety Info Channel (SIC)

DB6100- NCK PLC Signals from axis [r]
DB6111
Safety error ESR requested Bit 1 Bit 0
active Safety limited Safety limited
0000
speed limit speed limit
value value
Safety error Safe limited Safe operat- Safe limited Safe operat- Safe stop 2 Safe stop 1 Safe torque of
0001 with Stop A speed selected ing stop select- speed active ing stop active
ed
Test stop re- Test stop active Safe direction Safe direction
0002
quested negative positive
Safety limited Bit 0
position is for Safety lim-
0003
selected ited position
area
0004 Velocity limit
Acceptance Acceptance
test Safety test Safety
0008
limited position limited position
active selected
Load torque Close external Brake test
negative sign brake
0009 Completed OK active With brake 2 Setpoint specifi- Safe Brake
cation during Test (SBT)
SBT in the drive
Notes :

Tool management user interface
DB9900 Constant transfer step table [r]

0000 Transfer step 1 Source magazine no. (Integer)
0002 Transfer step 1 Source location no. (Integer)
0004 Transfer step 1 Target magazine no. (Integer)
0006 Transfer step 1 Target location no. (Integer)
etc
DB9901 Variable transfer step table [r/w]

etc
Notes :

Tool management user interface-continued

0000 Acknowledgement step 1 Transfer step for new tool. (Byte)
0001 Acknowledgement step 1 Transfer step for old tool. (Byte)
0002 Acknowledgement step 1 Acknowledgement status. (Byte)
0003 Acknowledgement step 1 Reserved
etc
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

0252
64 64 64
0253
Error Activated
0254
64 64
0255 Device ID_64
Notes :

Ctrl Energy user interface
DB9906 Energy saving profiles

Control signals
n+0
Set time to Immediately
prewarning limit activate energy
saving profile
Control signals (HMI PLC)
n+1
Immediately
activate energy
saving profile
Signals to check energy saving profile

n+2
PLC user signal Master com-
puter signal
n+3 Reserved
Control signals
n+4
Activation time energy saving
T1 has expired profile active
n+5 Reserved
n+6 Actual value: Actual value T1
n+8 Actual value: Actual value T2
Effectiveness profile
n+10
Disable energy Energy saving
saving profile profile config-
ured
State conditions (HMI PLC)
n+11
Screen change Data transfer Operator panel
active active

n+12
Machine
control panel
used
n+13
NC Channel
1 in reset
n+14

n+15
PLC user Master com-
signal puter signal
n+16 State conditions (HMI PLC) Activation time T1
n+18 State conditions (HMI PLC) Prewarning time T2
Profile instances: Energy profile 1 (n=0): DB9906.DBB0 … DBB19

Energy profile 2 (n=20): DB9906.DBB20 … DBB39
etc
Energy profile 8 (n=140): DB9906.DBB140 … DBB159
Notes :

Ctrl Energy user interface-continued
DB9907 SENTRON PAC

PLC HMI
0000 Regenerative Infeed energy SENTRON PAC Display manu-
energy is read is read from represents the al value
from SEN- SENTRON machine
TRON PAC PAC
0001 PLC FW
should perform
measurement
HMI PLC
0002
Measurement
in progress
0004 Manual value (REAL) to HMI
0008 Total active power (REAL) to HMI
0012 Measured drawn active energy in kWh (REAL) to HMI
0016 Measured supplied active energy in kWh (REAL) to HMI
0020 Total active power in watts (REAL) from SENTRON
0024 Drawn active energy at taritf1 (F) in Wh (REAL) from SENTRON
0028 Supplied active energy at tariff1 (F) in Wh (REAL) from SENTRON
0032 Drawn active energy in kWh per day (REAL) to HMI
0036 Supplied active energy in kWh per day (REAL) to HMI
0040 Drawn active energy in kWh per previous day (REAL) to HMI
0044 Supplied active energy in kWh per previous day (REAL) to HMI
0048 Drawn active energy in kWh per month (REAL) to HMI
0052 Supplied active energy in kWh per month (REAL) to HMI
0056 Drawn active energy in kWh per previous month (REAL) to HMI
0060 Supplied active energy in kWh per previous month (REAL) to HMI
0064 Drawn active energy in kWh per annum (REAL) to HMI
0068 Supplied active energy in kWh per annum (REAL) to HMI
0072 Drawn active energy in kWh per previous year (REAL) to HMI
0076 Supplied active energy in kWh per previous year (REAL) to HMI
0096 Production Act (PLC HMI)
0097 Value invalid Value invalid Value invalid

DBD0028 DBD0024 DBD0020
0098 Value invalid Value invalid Value invalid Value invalid Value invalid Value invalid Value invalid Value invalid
DBD0384 DBD0344 DBD0304 DBD0264 DBD0224 DBD0184 DBD0144 DBD0104
0099 Value invalid Value invalid

DBD0464 DBD0424
Notes :

Ctrl Energy user interface-continued
DB9907 SENTRON PAC

Control/Command bits
n+100
Resetting data Input-Mode: Determining Energy meas- Reading energy Editing compo-
(Energy or differential urement in Updating actual nent
power) values progress value
n+101 Reserved
n+102 Reserved
n+104 Active power or active energy of the ancillary component in kW or kWh
n+108 Consumed active energy of the ancillary component in kWh
n+112 Supplied active energy of the ancillary component in kWh
n+116 Consumed active energy of the ancillary component at beginning of measurement in kWh
n+120 Supplied active energy of the ancillary component at beginning of measurement in kWh
n+124 Consumed active energy of the ancillary component at end of measurement in kWh
n+128 Supplied active energy of the ancillary component at end of measurement in kWh
n+132 Reserved
n+136 Reserved
Ancillary component instances:
Ancillary component 1 (n=0): DB9907.DBB100 … DBB139

etc
Notes :

Spindle temperature sensors user interface
DB9908 ISM_TS
n+0 Sensor installation location
n+2 Reserved
n+4 Temperature sensor actual value [C]
n+8 Temperature sensor warning threshold value [C]
n+12 Number of alarm limit value violations
n+14 Last alarm limit value violation: Year
n+15 Last alarm limit value violation: Month
n+16 Last alarm limit value violation: Day
n+17 Last alarm limit value violation: Hour
n+18 Last alarm limit value violation: Minute
n+19 Last alarm limit value violation: Seconds
n+20 Duration of the warning limit value violations
n+24 Temperature sensor fault threshold value [C]
n+28 Number of fault limit value violations
n+30 Last fault limit value violation: Year
n+31 Last fault limit value violation: Month
n+32 Last fault limit value violation: Tag
n+33 Last fault limit value violation: Day
n+34 Last fault limit value violation: Minute
n+35 Last fault limit value violation: Seconds
n+36 Duration of the fault limit value violation
Spindle/temperature sensor instances:
Spindle 1, temperature sensor 1 (n=0): DB9908.DBB0000 … DBB0039

Notes :

Special data block (DB9910, DB9911, DB9912) with selected NC data
DB9910- Selected NC data [r]

DB9912
0001 Syntax ID
0002 Area
0003 Unit
0008 Block
0010 Type
0011 Length
0013 Syntax ID
0014 Area
0015 Unit
0020 Block
0022 Type
0023 Length
etc
0493 Syntax ID
0494 Area
0495 Unit
0500 Block
0502 Type
0503 Length
Notes :

Special data block (DB9913) for Extended PLC Alarms
DB9913 Alarm acknowledgement [r]
0000 Alarm response / cancel criterion, channel assignment alarm 701000
etc
Appendix C: END
Notes :

EN 828 Com v47

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SINUMERIK 828D

This document was produced for training purposes.

Commissioning Manual for

Sinumerik 828D Software 4.7

B068 B058 B031 B037 B033

B121 B120 B111 B110 B102

B035 B011 Appendix A Appendix B

Sinumerik 828D SW4.7

Electrical Cabinet Protocol attached

Filename of Cabinet protocol

Machine Test Protocol Sinumerik 828D

Copyright  Siemens AG 2016 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

5.2 Control ....................................................................................................................................................................................................................................................................................... 8

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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

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Test carried out at (OEM Name):

1.2 Participants carrying-out the test

Name Company / Department

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2 Summary and result

2.2.1 Exception List

2.3 Release Siemens

2.4 Release from Machine Tool Builder

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3.2 Data Backup

- ____________ (NCPLC Archive)

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4.1 Changes to the machine.

Date Change Reason Tested Responsible person Signature

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The test plan extends the commissioning documentation of 828D.

The test plan is valid for the current Software version

1) Siemens Code(DIN) and ShopMill/ShopTurn with  Metric system of units

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