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Instruction Manual 05/2005 Edition

sinumerik
SINUMERIK 802D sl
System Overview 1
Component Description 2

Operator Controls
and Displays 3
SINUMERIK 802D sl
Interfaces 4
Instruction Manual Dimensional Drawings
and Drill Patterns 5

Installation 6

Connection 7

Technical Data 8

Start-Up 9

Creating a Drive Project 10

Valid for Starting Up the PLC 11


Control system Software version
SINUMERIK 802D sl 1 Data Backup and
Series Machine Start-Up 12

Machine/Setting Data A

Standards and Approvals B

ESD Directive C
05/2005 Edition
Terms of License D
Safety Notes
This Manual contains information which you should carefully observe to ensure your own personal safety
and the prevention of material damage. The notices are highlighted by a warning triangle and, depending on
the degree of hazard, represented as shown below:

Danger
! indicates that death or severe personal injury will result if proper precautions are not taken.

Warning
! indicates that death or severe personal injury may result if proper precautions are not taken.

Caution
! with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.

Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

Attention
indicates that an undesirable event or state may arise if the relevant note is not observed.

If several hazards of different degrees occur, the hazard with the highest degree must always be given
preference. If a warning note with a warning triangle warns of personal injury, the same warning note can
also contain a warning of material damage.

Qualified personnel
Start-up and operation of the device/equipment/system in question must only be performed using this
documentation. Commissioning and operation of a device/system may only be performed by qualified
personnel. Qualified personnel as referred to in the safety guidelines in this documentation are those who
are authorized to start up, ground and label units, systems and circuits in accordance with the relevant safety
standards.

Use as intended
Please note the following:

Warning
! The equipment may only be used for single purpose applications explicitly described in the catalog and in
the technical description and it may only be used along with third-party devices and components
recommended by Siemens. It is assumed that this product be transported, stored and installed as intended
and maintained and operated with care to ensure that the product functions correctly and properly.

Trademarks
All designations with the trademark symbol  are registered trademarks of Siemens AG. Other designations
in this documentation may be trademarks whose use by third parties for their own purposes may infringe the
rights of the owner.

Disclaimer of Liability
We have checked that the contents of this document correspond to the hardware and software described.
Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical.
The information given in this publication is reviewed at regular intervals and any corrections that might be
necessary are made in the subsequent editions.

Siemens AG Copyright (E) Siemens AG 2005.


Automation and Drives 6FC5397–0CP10–1BA0
Postfach 4848
D–90437 NÜRNBERG Siemens AG 2005
GERMANY Subject to change without prior notice.
Preface
SINUMERIK Documentation
The SINUMERIK documentation is organized in 3 parts:
S General Documentation
S User Documentation
S Manufacturer/Service Documentation
More detailed information about other publications concerning SINUMERIK 810D and 840D
and publications that apply to all SINUMERIK control systems (e.g., Universal Interface,
Measuring Cycles, etc.) can be obtained from your local Siemens branch office.
A list of documents, updated on a monthly basis, is available on the Internet for the available
languages at:
http://www.siemens.com/motioncontrol
Select “Support”/“Technical Documentation”/“Overview of Documents”.
The Internet version of the DOConCD (DOConWEB) is available at:
http://www.automation.siemens.com/doconweb

Target readership of this documentation


This document is designed for machine tool manufacturers. This publication provides detai-
led information that the user requires for operating the SINUMERIK 810D sl.

Standard version
This Instruction Manual describes the functionality of the standard scope. Extensions or
changes made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.

Hotline
If you have any questions, please contact the following hotline:
A&D Technical Support
Phone: +49 (0) 180 / 5050 – 222
Fax: +49 (0) 180 / 5050 – 223
Internet: http://www.siemens.com/automation/support–request
If you have any comments, suggestions, or corrections regarding this documentation, please
fax or e-mail them to:
Fax: +49 (0) 9131 / 98 – 63315
E-mail: motioncontrol.docu@siemens.com
Fax form: See the reply form at the end of the brochure.

SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition


6FC5 397-0CP10-1BA0 iii
Preface

Internet address
http://www.siemens.com/motioncontrol

SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition


iv 6FC5 397-0CP10-1BA0
Table of Contents

Table of Contents
1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
3 Operator Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.1 Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.2 Error and status displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
4 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.1 CNC operator panel (PCU) interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.1.1 Compact flash card (CF card) slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.1.2 Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.3 USB port (available soon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.4 RS232 COM interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.1.5 PROFIBUS DP interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.1.6 DRIVE CLiQ interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.1.7 Handwheel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.1.8 Digital inputs/digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.2 MCPA module interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.3 PP 72/48 I/O module interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
5 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.1 Dimension drawing and drilling pattern for the CNC operator panel (PCU) . . . . . . . . . . . . . 5-40
5.2 Dimension drawing and drilling pattern for the machine control panel (MCP) . . . . . . . . . . . 5-42
5.3 Dimension drawings and drilling patterns for the NC full keyboard . . . . . . . . . . . . . . . . . . . . 5-44
5.4 Dimension drawing for the PP72/48 I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
7 Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
7.1 General rules for operation of a SINUMERIK 802D sl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
7.2 Rules regarding current consumption and power loss of a cubicle arrangement . . . . . . . . 7-53
7.3 Overall design of the SINUMERIK 802D sl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7.4 Connecting the protective conductor for the individual components . . . . . . . . . . . . . . . . . . . 7-55
7.5 Connection overview for the SINUMERIK 802D sl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
7.6 Connecting the MCPA module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
7.7 Connecting the analog spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
7.8 Connecting the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
7.9 Connecting the full keyboard to the CNC operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
7.10 Connecting the Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
7.11 Connecting the RS232 COM port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
7.12 Connecting the PP72/48 I/O module and the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
7.13 Connecting the SINAMICS drive to the DRIVE-CLiQ interface . . . . . . . . . . . . . . . . . . . . . . . 7-70
7.14 Connecting the digital inputs/outputs to the PCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
7.15 Connecting the digital inputs/digital outputs to the PP72/48 I/O module . . . . . . . . . . . . . . . . 7-72
7.16 Connecting the machine control panel to the PP72/48 I/O module . . . . . . . . . . . . . . . . . . . . 7-73

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6FC5 397-0CP10-1BA0 v
Table of Contents

7.17 Connecting shielded lines via the shield connection (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
8 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
9 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-79
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-79
9.1.1 Access levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-80
9.1.2 Structure of machine data (MD) and setting data (SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-81
9.1.3 RCS802D Commissioning and Diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
9.2 Turning on and booting the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
9.3 Language setting and file management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-84
9.3.1 Creating a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-84
9.3.2 Help, language and alarm files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-85
9.3.3 Transmitting data to the 802D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-85
9.4 Setting the technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88
9.5 Entering the machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90
9.6 Setting the Profibus address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-91
9.7 Starting Up the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-92
9.8 Configuring SINAMICS S120 with 802D sl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-93
9.8.1 Commissioning using predefined macros without the STARTER commissioning tool . . . . 9-93
9.8.2 Starting up motors without SMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-97
9.8.3 Faults and warnings when starting up the SINAMICS S120 drive . . . . . . . . . . . . . . . . . . . . . 9-97
9.8.4 Setpoint/actual-value assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98
9.8.5 Default settings of the axis machine data for feed axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-99
9.8.6 Default settings of the axis machine data for the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-101
9.9 STARTER start-up tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-105
9.9.1 Explanations regarding the STARTER user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-105
9.9.2 Operating philosophy of the STARTER commissioning tool for SINAMICS S120 . . . . . . . . 9-106
9.10 Start-up sequence when working with STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109
9.10.1 Creating a drive object OFFLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109
9.10.2 Operating the STARTER control panel (motor rotating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110
9.10.3 Creating a drive project ONLINE (recommended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110
9.11 Diagnosis via STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-111
9.11.1 Function generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-112
9.11.2 Trace function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-115
9.11.3 Measuring function (SERVO) (available soon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-116
9.11.4 Measuring sockets (available soon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-119
9.12 Completing the start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-120
9.13 Service display of the axis drive behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-121
10 Creating a Drive Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
10.1 Creating a drive project OFFLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
10.1.1 Creating a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
10.1.2 Configuring a drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131
10.2 Operating the control panel in STARTER (with the motor rotating) . . . . . . . . . . . . . . . . . . . . 10-140
10.2.1 Loading the project into the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
10.2.2 Operating the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143
10.3 Creating a drive project ONLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
10.3.1 Creating a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
10.3.2 Acquiring the component topology and configuring the drive unit automatically . . . . . . . . . 10-153
10.3.3 Configuring and checking the topology of the drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157

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11 Starting Up the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-163


11.1 Commissioning the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-164
11.2 Start-up modes of the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-164
11.3 PLC alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-166
11.3.1 General PLC alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-167
11.3.2 User alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-167
11.4 PLC programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-170
11.4.1 Command overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-171
11.4.2 Explanation of the stack operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-174
11.4.3 Program organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-181
11.4.4 Data organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-181
11.4.5 Interface to the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-181
11.4.6 Testing and monitoring your program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-182
11.5 PLC applications Download/Upload/Copy/Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-183
11.6 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-185
12 Data Backup and Series Machine Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-187
12.1 Data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-187
12.1.1 Internal data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-187
12.1.2 External data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-188
12.1.3 Data backup via V24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-189
12.1.4 External data backup via CF Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-189
12.2 Series machine start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-190
12.3 Data backup in case of backlight failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-193
A Machine and Setting Data 802D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-195
A.1 List of machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-196
A.1.1 Display machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-196
A.1.2 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-201
A.1.3 Channelspecific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-206
A.1.4 Axisspecific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-214
A.2 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-226
A.3 SINAMICS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-230
B Standards and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-231
B.1 Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-232
B.2 Transport and storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-234
B.3 Mechanical and climatic ambient conditions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . B-234
B.4 Information on insulation tests, safety class, and degree of protection . . . . . . . . . . . . . . . . . B-236
B.5 Safety of electronic control systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-237
C Directive for handling electrostatically sensitive devices (ESD) . . . . . . . . . . . . C-239
C.1 What does ESD mean? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-239
C.2 Electrostatic charging of persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-240
C.3 Basic protective measures against discharge of static electricity . . . . . . . . . . . . . . . . . . . . . C-241

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6FC5 397-0CP10-1BA0 vii
Table of Contents

D SINUMERIK 802D sl License Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-243


D.1 General Terms and Conditions for the Use of Software for Sinumerik and
Drive Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-243
D.2 General Terms and Conditions for the Use of Software for Sinumerik and
Drive Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-244
D.2.1 Delivery of the Software to licensees and granting of rights of use in the Software . . . . . . D-244
D.2.2 License type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-245
D.2.3 Software type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-246
D.2.4 Upgrade and PowerPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-246
D.2.5 Further rights and duties of the Licensee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-247
D.3 License Provisions for Free Software Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-248
D.4 Liability for Free Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-248
D.5 see gpl.txt on the Toolbox CD under /licenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-249
D.6 see bsd.txt on the Toolbox CD under /licenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-249
D.7 see zlip.txt on the Toolbox CD under /licenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-249
D.8 see lgpl.txt on the Toolbox CD under /licenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-249
E Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-251

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viii 6FC5 397-0CP10-1BA0
System Overview 1
Overview
The operator panel of the SINUMERIK 802D sl control systems combines all CNC, PLC,
HMI and communication tasks in one component. The maintenance-free hardware integra-
tes the PROFIBUS interface for the drives and for the I/O modules with the slimline operator
panel into a ready-to-install unit (Panel Control Unit).
The SINUMERIK 802D sl can control up to 5 axes digitally. Up to 2 of these 5 axes can be
configured as a spindle.

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6FC5 397-0CP10-1BA0 1-9
System Overview

System overview: SINUMERIK 802D sl with SINAMICS S120

CNC operator panel (PCU) Machine control panel (MCP)


Electronic
handwheel (max. 2)

Digital inputs/
digital outputs

DRIVE-CLiQ

PROFIBUS DP

NC full keyboard
(upright format) (or,
alternatively, broad format)

I/O module PP72/48 1) I/O module PP72/48

PROFIBUS DP

DRIVE-CLiQ

1 Smart Line or Active Line Modules


(mains supply)

2 ... 6 Single motor module


SINAMICS S120 (power section)
1 2 3 4 5 6

Feed motor 1
Feed motor 2
Mains supply
conductor Feed motor 3
Feed motor 4
1) when using a
machine control panel Main spindle motor

Fig. 1-1 System overview: SINUMERIK 802D sl mit SINAMICS S120 (example)

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1-10 6FC5 397-0CP10-1BA0
System Overview

Components
The components of the SINUMERIK 802D sl control system are:
S CNC operator panel (PCU) with NC full keyboard (upright or broad format)
S Machine control panel (MCP)
Incorporates all keys and switches required for the operation of a machine (milling
machine).
S I/O module PP72/48
The PP72/48 I/O module is a straightforward and low-cost module (without a separate
housing) within the framework of an automation system based on PROFIBUS DP for
connecting digital inputs/outputs.
The module offers the following main features:
– PROFIBUS DP connection (max 12 Mbits/s)
– 72 digital inputs and 48 digital outputs
– On-board status display via 4 diagnostic LEDs
To supply the module and the digital outputs, an external voltage source (+24 V DC) is
required.
S Drive units
– SINAMICS S120
The communication between the SINUMERIK 802D sl control system and the
SINAMICS S 120 drive is provided via the DRIVECLiQ communication system
(Drive Component Link with IQ).

System software
The following system software is installed in the retentive internal memory of the PCU of
each SINUMERIK 802D sl by default:
S Boot software – starts the system
S Human Machine Interface (HMI) software – realizes all operator functions
S NCK software (NC Kernel) – realizes all NC functions. It controls up to 5 axes (2 axes
can be configured as spindles).
S Programmable Logic Control (PLC) software – executes the integrated PLC user
program cyclically.

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System Overview

Toolbox
A tool box is delivered on CD ROM together with the appropriate system software.
The toolbox contains software tools for configuring the control system. It must be installed
on your PC/PG.
The following software can be found in the Toolbox:
S Setup file for the technologies
S Cycle packages for the technologies
S Reloadable languages
S Reloadable system blocks (SDB)
S RCS802D Commissioning and Diagnostic tool
This program can be used to transfer texts, user data and programs from the PC to the
CNC operator panel (PCU) and vice versa.
S “PLC 802 Programming Tool” – tool for creating the PLC user program
S PLC user library
S “Starter” – parameterization and commissioning tool for the SINAMICS drive

Note
The table of contents and notes for setup can be found in the siemense.txt file.

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Description 2

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6FC5 397-0CP10-1BA0 2-13
Description

View
The illustration below shows the CNC operator panel (PCU) with its interfaces and the front
panel elements.

Front view of the CNC operator panel Front hatch, opened


(PCU)

Compact flash card slot

Graphical Error and status


display displays

Vertical softkeys

Horizontal softkeys

Rear view of the CNC operator panel (PCU)


Rating plate Power supply
connection X40
Ethernet interface X5

USB port X10

NC full keyboard
connection X9

RS232 COM port X8

PROFIBUS DP
interface X6
DRIVE CLiQ interfaceX1
and X2

Handwheel
connectionX30
Digital inputs/outputs
X20, X21
Optional interface

Grounding screw

Fig. 2-1 Position of the interfaces and front elements on the CNC operator panel

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Description

CNC operator panel (PCU) interfaces


The PCU and its functions are described in the table below.

Table 2-1 PCU interfaces

Interfaces Function
Compact flash card (CF card) 50-pin slot for CF cards, and 4 LEDs
slot see Chapter 4.1.1
Power supply connection 3-pin screw-type terminal connection for connecting the 24 V load
X40 power supply
For connecting SINUMERIK 802 D sl, please refer to Chapter 7.8
Ethernet interface 8-pin RJ45 socket connector for connection to an Industrial
X5 Ethernet
see Chapter 4.1.2

USB port 4-pin USB host for connecting USB accessories


X10 see Chapter 4.1.3
NC full keyboard connection 6-pin PS/2 socket for connecting the NC full keyboard
X9 see Chapter 7.9
RS232 COM port 9-pin DSub connector for connecting a PG/PC
X8 see Chapter 4.1.4
PROFIBUS-DP interface 9-pin DSub socket for connection to PROFIBUSDP
X6 see Chapter 4.1.5
DRIVE-CLiQ interface 8-pin RJ45 socket for connecting the SINAMICS S120 drive
X1 and X2 see Chapter 4.1.6
Handwheel connection 12-pin screw-type male connector for connecting max. 2 hand-
X30 wheels
see Chapter 4.1.7
Digital inputs/digital outputs 12-pin screw-type male connector for connecting the digital inputs
X20 and X21 and outputs
see Chapter 4.1.8
TB30 interface 48-pin female connector for connecting the MCPA module
see Chapter 4.2

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6FC5 397-0CP10-1BA0 2-15
Description

Notes

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2-16 6FC5 397-0CP10-1BA0
Operator Controls and Displays 3
3.1 Operator controls
Use the horizontal and vertical softkeys to select defined functions. For a description of the
individual softkeys, please refer to the SINUMERIK 802D sl Programming and Operator’s
Guide.
References: /BP/, Programming and Operator’s Guide

Vertical softkeys

Horizontal softkeys

Fig. 3-1 CNC operator panel

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6FC5 397-0CP10-1BA0 3-17
Operator Controls and Displays
3.2 Error and status displays

3.2 Error and status displays

LEDs on the operator panel CNC (PCU)


The following LEDs are installed on the operator panel CNC (see Fig. 2-1):

ERR RDY NC
ERR RDY NC DP
CF

The individual LEDs and their functions are described in the table below.

Table 3-1 Status and fault displays

LED Meaning
ERR (red) Fault condition
RDY (green) Readiness for operation
NC (yellow) Sign-of-life monitoring
CF (yellow) Reading from / writing to CF card

Note
For error descriptions, see SINUMERIK 802D sl Diagnostics Guide.
References: /DG/, Diagnostics Guide

LEDs on the PP 72/48 I/O module


The following LEDs are installed on the I/O module (see Fig. 4-3): The individual LEDs and
their functions are described in the table below.
Table 3-2 Status displays

LED Meaning
POWER (green) Power supply of the electronic equipment ready for operation
READY (red) I/O module ready for operation; however, no cyclic data exchange is
performed with DP Master
EXCHANGE (green) I/O module ready for operation; cyclic data exchange with DP Master is
performed
OVTEMP (red) Overtemperature display

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Interfaces 4
4.1 CNC operator panel (PCU) interfaces

4.1.1 Compact flash card (CF card) slot

Only type 1 compact flash cards can be used.


The compact flash card can be used, for example:
S for start-up data
S for NC programs
S to carry out software updates
S to store user data
S to save parameters which have been set by the user.

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6FC5 397-0CP10-1BA0 4-19
Interfaces
4.1 CNC operator panel (PCU) interfaces

4.1.2 Ethernet interface

A PG/PC can be connected to the Ethernet interface via a Fast Ethernet network. The
device connected must possess an Ethernet card and the appropriate software.
Industrial Ethernet is a communication network providing a transmission rate of
10/100 Mbps.

Female connector pin assignment


Designation: X7 (Ethernet)
Type: 8-pin RJ45 socket

Table 4-1 Pin assignment of female connector X5

Schematic view of the female connector, Pin Name Description


mounting position and labeling

1 TXP Transmitted data +


1 8

2 TXN Transmitted data –

A B 3 RXP Received data +


X5 IE 4 not assigned –
5 not assigned –
6 RXN Received data –
7 not assigned –
8 not assigned –
You can obtain additional information about the different cable systems for Ethernet from your
SIEMENS contact person.

4.1.3 USB port (available soon)

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Interfaces
4.1 CNC operator panel (PCU) interfaces

4.1.4 RS232 COM interface

A PC/programming device (PG) for data exchange with the CNC operator panel can be con-
nected to male connector X8.

Connector pin assignment


Designation: X8 (RS232)
Type: 9-pin D-Sub plug terminal strip
Table 4-2 Pin assignment of connector X8

Schematic view of the female Pin Name Description


connector, mounting position
and labeling

1 DCD Received Line Received signal level


RS232 Signal Detector
X8 Carrier Detector
1 2 RXD Received Data Received data
3 TXD Transmitted Data Transmitted data
9 4 DTR Data Terminal Terminal ready
Ready
5 M Ground Ground (GND)
6 DSR Data Set Ready Readiness for
operation
7 RTS Request To Send Transmission request
8 CTS Clear To Send Ready to send
9 not – –
assigned

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6FC5 397-0CP10-1BA0 4-21
Interfaces
4.1 CNC operator panel (PCU) interfaces

4.1.5 PROFIBUS DP interface

The CNC operator panel (PCU) communicates with the I/O modules via the PROFIBUS DP
interface.
The PROFIBUS DP protocol is used for the communication.
The baud rate of the PROFIBUS DP interface is 12 Mbit/s; the baud rate cannot be chan-
ged. Converters for optical fiber cable (OLMs, OLPs) or repeaters are not permitted.
The operator panel CNC provides master functionality.

Female connector pin assignment


Designation: X6 (DP)
Type: 9-pin D-Sub socket connector

Table 4-3 Pin assignment of female connector X6

Schematic view of the female Pin Name Description


connector, mounting position
and labeling

1 not –
DP assigned
X6
2 M24 24 V reference potential (teleservice)
1 3 B Data input/output (RS485)
4 RTS Transmission request
9 5 M5 5 V reference potential
6 P5 5 V power supply 90 mA, short-circuit-proof
7 P24 24 V power supply (teleservice) 150 mA, short-
circuit-proof, not isolated
8 A Data input/output (RS485)
9 not –
assigned

The CNC operator panel has a fixed PROFIBUS DP address.


The addresses of the PP 72/48 I/O modules must be set using the DIL switches S1
(see Section 7.12).

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Interfaces
4.1 CNC operator panel (PCU) interfaces

4.1.6 DRIVE CLiQ interface

The CNC operator panel (PCU) can communicate with the SINAMICS drive via the DRIVE
CLiQ interface.

Female connector pin assignment


Designation: X1, X2
Type: 8-pin RJ45 socket

Table 4-4 Pin assignment of the female connectors X1 and X2

Schematic view of the female Pin Name Description


connector, mounting position
and labeling

1 TXP Transmitted data +

1 8 1 8 2 TXN Transmitted data –


3 RXP Received data +
4 not assigned –
A B A B 5 not assigned –
X1 X2
6 RXN Received data –
7 not assigned –
8 not assigned –
A not assigned –
B not assigned –
Blanking plate for DRIVE-CLiQ interface: Molex corp., order no. 85999-3255

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6FC5 397-0CP10-1BA0 4-23
Interfaces
4.1 CNC operator panel (PCU) interfaces

4.1.7 Handwheel connection

Max. 2 electronic handwheels can be connected to connector X30 on the CNC operator
panel (PCU).
The handwheel must meet the following requirements:
Transmission technique: 5 V square wave signals (TTL level or RS422)
Signals: Track A as a true and negated signal (Ua1, Ua1)
Track B as a true and negated signal (Ua2, Ua2)
Max. output frequency: 500 MHz
Phase shift of
tracks A to B: 90° "30°
Power supply: 5 V, max. 250 mA

Connector pin assignment


Designation: X30
Type: 12-pin connector

Table 4-5 Pin assignment of connector X30

Schematic view of the Pin Name Description


connector

1 3P5 5 V DC supply voltage


1 2 M Ground (GND)
3 1A Track A, channel 1
4 X1A Track A_N, channel 1
5 1B Track B, channel 1
6 X1B Track B_N, channel 1
7 3P5 5 V DC supply voltage
8 M Ground (GND)
12
X30 9 2A Track A, channel 2
10 X2A Track A_N, channel 2
11 2B Track B, channel 2
12 X2B Track B_N, channel 2

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Interfaces
4.1 CNC operator panel (PCU) interfaces

4.1.8 Digital inputs/digital outputs

Various sensors and actuators can be connected to the connectors X20 and X21 via digital
inputs/digital outputs.
Max. 16 or 8 digital inputs and 8 digital outputs can be used.

Wiring diagram and block diagram

24 V DC ext. power supply P24


M

DRIVE-CLiQ socket 0

DRIVE-CLiQ socket 1
P24 M

X40
P24 + 24 V
1
M M
2
PE 3 PE
X1 X2
X20
1 DI0
2 DI1 PROFIBUS
3 DI2 X6
4 DI3
5 M3
6 P24_1 CNC operator
7 DI/DO0 panel (PCU)
8 DI/DO1
9 M_1
10 DI/DO2
11 DI/DO3
12 M_1
X21
1 DI4
2 DI5
3 DI6
4 DI7
5 M_4
6 P24_2
7 DI/DO4
8 DI/DO5
9 M_2
10 DI/DO6
11 DI/DO7
12 M_2

Grounding

Fig. 4-1 Connection example

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6FC5 397-0CP10-1BA0 4-25
Interfaces
4.1 CNC operator panel (PCU) interfaces

Connector pin assignment


Designation: X30
Type: 12-pin connector

Table 4-6 Pin assignment of the connectors X20 and X21

Schematic Pin Name Description Technical details


view

1 DI0 Digital input 0 Input:


1 Voltage: DC 24 V (20
(20.44 ... 28.8
28 8 V)
2 DI1 Digital input 1 Level:
3 DI2 Digital input 2 0 signal: –3...5 V
1-signal: 11...30 V
4 DI3 Digital input 3 Input delay:
0 → 1 signal: 15 ms (typ.
(typ 6)
5 M_3 Ground for DI0...DI3 1 → 0 signal: 150 ms (typically 40)
6 P24_1 DC 24 V Supply voltage for For the output:
DI/DO0...DI/DO3 (required max. output current:
for digital outputs) 1 signal: 5 mA ... 0.5 A
12 Total current of all outputs:
X20 7 DI/DO0 Digital I/O max. 2 A (in case of simultaneous occur-
rence 50 %)
8 DI/DO1 Digital I/O Output delay:
0 → 1 signal: 500 ms
9 M_1 Ground for DI/DO0...DI/ (typ. 150 ms)
DO3 1 → 0 signal: 500 ms
(typ 150 ms)
(typ.
10 DI/DO2 Digital I/O each with RL = 60 ohms
Switching frequency:
11 DI/DO3 Digital I/O 100 Hz (ohmic load)
2 Hz (inductive load)
12 M_1 Ground for DI/DO0...DI/
For the input:
DO3
Data see connector X21

1 DI4 Digital input 4 Input:


1 f th
for the d
data,
t see connector
t X20
2 DI5 Digital input 5
3 DI6 Digital input 6
4 DI7 Digital input 7
5 M_4 Ground for DI4...DI7
6 P24_2 DC 24 V Supply voltage for Output:
DI/DO4...DI/DO7 (required for the data, see connector X20
for digital outputs) Input:
12 7 DI/DO4 Digital I/O Voltage: DC 24 V (20.4 ... 28.8 V)
X21 Level:
8 DI/DO5 Digital I/O 0 signal: –3...5
3...5 V
9 M_2 Ground for DI/DO4...DI/ 1 signal: 11...30 V
DO7 Input delay:
0 → 1 signal: 15 ms (typ.
(typ 6)
10 DI/DO6 Digital I/O 1 → 0 signal: 150 ms (typically 40)
11 DI/DO7 Digital I/O
12 M_2 Ground for DI/DO4...DI/
DO7

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4-26 6FC5 397-0CP10-1BA0
Interfaces
4.1 CNC operator panel (PCU) interfaces

Danger
! The 24 V power supply is to be designed as functional extra-low voltage with protective
separation in accordance with EN60204-1, Section 6.4, PELV (with M ground).

Digital inputs (PCU)


These fast inputs correspond to Standard IEC 1131-2/DIN EN 61131-2, characteristic curve
type 2 (24 V-P-switching). Switches or proximity encoders (2 or 3-wire encoders) can be
connected.

Digital outputs (PCU)


These fast outputs (onboard) correspond to Standard IEC 1131-2/DIN EN 61131-2
(24 V-P-switching).

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6FC5 397-0CP10-1BA0 4-27
Interfaces
4.2 MCPA module interfaces

4.2 MCPA module interfaces

Overview
The illustration below shows the MCPA module with its interfaces and the status display.

X1020

X1021

1
10
1
10

X2

X1
X701

LED status display

X110

Fig. 4-2 Position of the interfaces and of the status display on the MCPA module

Table 4-7 Interfaces

Interfaces Function
Interfaces to the MCP 40-pin plug connectors for connecting the machine control panel (MCP)
X1 and X2
I/O interface 10-pin plug connectors for connection of the power supply and of the
X1020 and X1021 digital inputs and ouptuts
Analog spindle connection 9-pin D-Sub connector for connecting an analog spindle with directly
X701 mounted spindle actual-value encoder (TTL)
Interface to the PCU 48-pin plug connectors for connecting the MCPA module to the PCU
X110

Assignment of the interface to the MCP


Designation: X1, X2
Type: 40-pin ribbon-cable connector

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4-28 6FC5 397-0CP10-1BA0
Interfaces
4.2 MCPA module interfaces

Table 4-8 Pin assignment of the female connectors X1 and X2

X1
Pin Name Description Pin Name Description
1 KEY1 Input bit 2 KEY2 Input bit
3 KEY3 Input bit 4 KEY4 Input bit
5 KEY5 Input bit 6 KEY6 Input bit
7 KEY7 Input bit 8 KEY8 Input bit
9 GND 10 KEY9 Input bit
11 KEY10 Input bit 12 KEY11 Input bit
13 KEY12 Input bit 14 KEY13 Input bit
15 KEY14 Input bit 16 KEY15 Input bit
17 KEY16 Input bit 18 GND
19 KEY17 Input bit 20 KEY18 Input bit
21 KEY19 Input bit 22 KEY20 Input bit
23 KEY21 Input bit 24 KEY22 Input bit
25 KEY23 Input bit 26 KEY24 Input bit
27 GND 28 LED1 Output bit
29 LED2 Output bit 30 LED3 Output bit
31 LED4 Output bit 32 LED5 Output bit
33 LED6 Output bit 34 not assigned –
35 not assigned – 36 GND
37 not assigned – 38 not assigned –
39 not assigned – 40 not assigned –
X2
1 KEY25 Input bit 2 KEY26 Input bit
3 KEY27 Input bit 4 not assigned –
5 not assigned – 6 not assigned –
7 not assigned – 8 not assigned –
9 GND 10 FEED_OV_A Input bit
11 FEED_OV_B Input bit 12 FEED_OV_C Input bit
13 FEED_OV_D Input bit 14 FEED_OV_E Input bit
15 not assigned – 16 not assigned –
17 not assigned – 18 GND
19 SPINDLE_OV_A Input bit 20 SPINDLE_OV_B Input bit
21 SPINDLE_OV_C Input bit 22 SPINDLE_OV_D Input bit
23 SPINDLE_OV_E Input bit 24 not assigned –
25 not assigned – 26 not assigned –
27 not assigned – 28 not assigned –
29 not assigned – 30 not assigned –
31 not assigned – 32 not assigned –
33 not assigned – 34 not assigned –
35 not assigned – 36 GND
37 not assigned – 38 not assigned –
39 not assigned – 40 not assigned –

SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition


6FC5 397-0CP10-1BA0 4-29
Interfaces
4.2 MCPA module interfaces

Assignment of the I/O interface connectors


Designation: X1020, X1021
Type: 10-pin connector

Table 4-9 Pin assignment of the connectors X1020 and X1021

Schematic view Pin Name Description

1
1
2 DI0 Digital input 0
3 DI1 Digital input 1
4 DI2 Digital input 2
5 DI3 Digital input 3
6 DI4 Digital input 4
10
7 DI5 Digital input 5
X1020
8 DI6 Digital input 6
9 DI7 Digital input 7
10

1 P24 24 V DC supply voltage


1
2 Q0 Digital output 0
3 Q1 Digital output 1
4 Q2 Digital output 2
5 Q3 Digital output 3
6 Q4 Digital output 4
10 7 Q5 Digital output 5

X1021 8 Q6 Digital output 6


9 Q7 Digital output 7
10 M Ground (GND)

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4-30 6FC5 397-0CP10-1BA0
Interfaces
4.2 MCPA module interfaces

Connector pin assignment (analog output to the drive)


Designation: X701
Type: 9-pin D-Sub terminal strip
Table 4-10 Pin assignment of connector X701

Schematic view of the female Pin Name Description


connector, mounting position
and labeling

1 Analog Analog output with signal level $10 V


RS232 OUT
X8
2 not –
1 assigned
3 Uni-Dir2 Digital output for unipolar spindle +24 V
9 4 Uni-Dir2 Digital output for unipolar spindle +24 V
5 Enable 1 Analog drive enable (contact: electrically isolated
n.o. contact)
6 Analog Analog output 0 V Reference signal
OUT
7 not –
assigned
8 not –
assigned
9 Enable 2 Analog drive enable (contact: electrically isolated
n.o. contact)

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6FC5 397-0CP10-1BA0 4-31
Interfaces
4.3 PP 72/48 I/O module interfaces

4.3 PP 72/48 I/O module interfaces


The diagrams below show the interfaces, the operator controls and displays, as well as the
possibilities of connection to the I/O interface of the I/O module.

PROFIBUS DP
interface (X2)
Status displays

Power supply OVERTEMP EXCHANGE

connection POWER READY

X41

DIL switch
S1

X111
Terminal strip
X333 X222
I/O module converter
interfaces X111,
X222 and X333

to the machine control panel

Fig. 4-3 Position of the interfaces and status displays on the I/O module with connection to the MCP
and a terminal strip converter

PROFIBUS DP
interface (X2) Status
displays

OVERTEMP EXCHANGE
Power supply POWER READY
connection
X41
Terminal strip
converter
DIL switch
S1
X333 X222 X111

I/O module
interfaces X111,
X222 and X333

Fig. 4-4 Position of the interfaces and status displays on the I/O module when connecting 3 terminal
strip converters

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Interfaces
4.3 PP 72/48 I/O module interfaces

PP 72/48 interfaces
The interfaces and the operator controls of the PP 72/48 I/O module and their functions are
described in the table below.
Table 4-11 Interfaces

Interfaces Function
PROFIBUS DP interface 9-pin Sub-D socket X2 for connection to the PROFIBUS DP
Power supply connection 3-pin screw-type terminal connection X1 for connecting the
24 V load power supply
For connecting SINUMERIK 802 D sl, please refer to Chapter 7.8
I/O interface 50-pin pin connectors X111, X222, X333 for connecting the machine
control panel or the terminal strip converters for the digital inputs/outputs
DIL switch DIL switch S1 for setting the PROFIBUS DP address
see Chapter 7.12

PROFIBUS DP interface (X2)


The PROFIBUS DP protocol is used for the communication.
The baud rate of the PROFIBUS DP interface is 12 Mbps.
The PP 72/48 I/O module provides slave functionality.

Female connector pin assignment


Designation: X6
Type: 9-pin D-Sub socket connector

Table 4-12 Pin assignment of female connector X6

Schematic view of the Pin Name Description


connector

1 not –
assigned
2 not –
1
assigned
9 3 B Data input/output (RS485)
4 RTS Transmission request
X2 5 M5 5 V reference potential
6 P5 5 V power supply 90 mA, short-circuit-proof
7 not –
assigned
8 A Data input/output (RS485)
9 not –
assigned

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6FC5 397-0CP10-1BA0 4-33
Interfaces
4.3 PP 72/48 I/O module interfaces

I/O interface
The following devices can be connected to the connectors X111, X222 and X333 (50-pin rib-
bon-cable plug):
S either one machine control panel (MCP) and one terminal strip converter for digital inputs/
digital outputs (see Fig. 4-3)
or
S three terminal strip converters for digital inputs/digital outputs (see Fig. 4-4)
The terminal strip converters are connected to the PP 72/48 I/O module via ribbon cable.
The individual wiring can be performed at the terminal strips according to your particular
application.

Connector pin assignment


Designation: X111, X222, X333
Type: 50-pin ribbon-cable connector

Table 4-13 Pin assignment of the connectors X111, X222, X333

Pin Name Description Pin Name Description


1 M Ground (GND) 2 P24OUTINT DC 24 V, internal supply
voltage for the inputs
3 DI m+0.0 Input bit 4 DI m+0.1 Input bit
5 DI m+0.2 Input bit 6 DI m+0.3 Input bit
7 DI m+0.4 Input bit 8 DI m+0.5 Input bit
9 DI m+0.6 Input bit 10 DI m+0.7 Input bit
11 DI m+1.0 Input bit 12 DI m+1.1 Input bit
13 DI m+1.2 Input bit 14 DI m+1.3 Input bit
15 DI m+1.4 Input bit 16 DI m+1.5 Input bit
17 DI m+1.6 Input bit 18 DI m+1.7 Input bit
19 DI m+2.0 Input bit 20 DI m+2.1 Input bit
21 DI m+2.2 Input bit 22 DI m+2.3 Input bit
23 DI m+2.4 Input bit 24 DI m+2.5 Input bit
25 DI m+2.6 Input bit 26 DI m+2.7 Input bit
27 not – 28 not –
assigned assigned
29 not – 30 not –
assigned assigned
31 DO n+0.0 Output bit 32 DO n+0.1 Output bit
33 DO n+0.2 Output bit 34 DO n+0.3 Output bit
35 DO n+0.4 Output bit 36 DO n+0.5 Output bit
37 DO n+0.6 Output bit 38 DO n+0.7 Output bit
39 DO n+1.0 Output bit 40 DO n+1.1 Output bit
1) x = 1 for connector X111; x = 2 for connector X222; x = 3 for connector X333
m = 0 for connector X111; m = 3 for connector X222; m = 6 for connector X333
n = 0 for connector X111; n = 2 for connector X222; n = 4 for connector X333

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Interfaces
4.3 PP 72/48 I/O module interfaces

Table 4-13 Pin assignment of the connectors X111, X222, X333, continued

Pin Name Description Pin Name Description


41 DO n+1.2 Output bit 42 DO n+1.3 Output bit
43 DO n+1.4 Output bit 44 DO n+1.5 Output bit
45 DO n+1.6 Output bit 46 DO n+1.7 Output bit
47 DOCOMx1) DC 24 V Supply
pp y voltage
g for 48 DOCOMx1) DC 24 V Supply
pp y voltage
g for
49 DOCOMx1) the outputs 50 DOCOMx1) the outputs
1) x = 1 for connector X111; x = 2 for connector X222; x = 3 for connector X333
m = 0 for connector X111; m = 3 for connector X222; m = 6 for connector X333
n = 0 for connector X111; n = 2 for connector X222; n = 4 for connector X333

Danger
! The 24 V power supply is to be designed as functional extra-low voltage with protective
separation in accordance with EN60204-1, Section 6.4, PELV (with M ground).

Note
The connection cable between the voltage source and the load current supply connector
and the associated reference potential M should not exceed a maximum length of 10 m.

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6FC5 397-0CP10-1BA0 4-35
Interfaces
4.3 PP 72/48 I/O module interfaces

Digital inputs
The diagram below shows the connector pin assignment for the digital inputs at connection
X111 (example). The connector pin assignment of X222 and X333 should be performed
analogously.

X111
P24OUTINT Pin number:
PP72/48 (+24 V DC) 2 1

3
Receiver

4
Receiver :
: :
: :
: 26
Receiver

+24 V

2 24 V DC ext. power
supply
1
0V

M
1 when using the internal P24OUTINT power supply
2 when using an external power supply

Fig. 4-5 Connector pin assignment for the digital inputs

Internal power supply (P24OUTINT)


The internal power supply for the digital inputs (X111, X222, X333: pin 2) is taken from the
general power supply of module X1, pin 2 (P24).

Caution
Make sure that a max. current of Iout = 0.25 A at X111, X222, X333 on pin 2 is not exceeded.
Exceeding of the maximum current may destroy the module.

External power supply


If an external power supply is used for the digital inputs, their reference ground must be con-
nected to X111, X222, X333: pin 1 (M).
In this case, X111, X222, X333: Pin 1 (P24OUTINT) remains open.

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4-36 6FC5 397-0CP10-1BA0
Interfaces
4.3 PP 72/48 I/O module interfaces

Digital outputs
The diagram below shows the connector pin assignment for the digital outputs at connection
X111 (example). The connector pin assignment of X222 and X333 should be performed
analogously.

24 V DC ext. power
supply
PP72/48 X111
+24 V 0V
Pin number:
47, 48, 49, 50
(DOCOM1)

31
Relay

Driver

Driver 32
: :
: :
Driver 46

1 (M)

Fig. 4-6 Connector pin assignment for the digital outputs

To supply the digital outputs, an external 24 V DC power supply must be connected to


DOCOMx (X111, X222, X333: pins 47, 48, 49, 50).
The reference ground of the external power supply must be connected to X111, X222, X333:
pin 1 (M).

Caution
It is the user’s responsibility to ensure that the max. current consumption per DOCOMx pin
(X111, X222, X333: pins 47 through 50) does not exceed 1 A.
It is imperative to connect the 24 V power supply for the digital outputs for DOCOMx to all
four pins (X111, X222, X333: pins 47 through 50).

Danger
! The 24 V power supply is to be designed as functional extra-low voltage with protective
separation in accordance with EN60204-1, Section 6.4, PELV (with M ground).

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6FC5 397-0CP10-1BA0 4-37
Interfaces
4.3 PP 72/48 I/O module interfaces

Use of two PP 72/48 I/O modules


If two PP 72/48 I/O modules are installed, the assignment of the input/output bytes will be as
follows:

Table 4-14 Assignment of the input/output bytes

1st PP 72/48 I/O module, PROFIBUS DP address 9


Connector X111 X222 X333
Input byte 0...2 3...5 6...8
Output byte 0...1 2...3 4...5

2nd PP 72/48 I/O module, PROFIBUS DP address 8


Connector X111 X222 X333
Input byte 9...11 12...14 15...17
Output byte 6...7 8...9 10...11

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4-38 6FC5 397-0CP10-1BA0
Dimension Drawings 5

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6FC5 397-0CP10-1BA0 5-39
Dimension Drawings
5.1 Dimension drawing and drilling pattern for the CNC operator panel (PCU)

5.1 Dimension drawing and drilling pattern for the CNC operator panel
(PCU)

Dimension drawing CNC operator panel (PCU)

295.6
309.4
302.9
154.7
13.8
7.2
0

70
8.2

15

35
7
330
321

Required clearance

50
161.2

A
5

9
0
15

Required clearance A-A


13 13
90°
50

20 20
∅ 4.5 (8x)

Fig. 5-1 Dimension drawing for the CNC operator panel

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5-40 6FC5 397-0CP10-1BA0
Dimension Drawings
5.1 Dimension drawing and drilling pattern for the CNC operator panel (PCU)

Drilling pattern for the CNC operator panel (PCU)

Panel cutout
M4 1)
0.5

Z
2)3

302$0.3

Z
2)

281.8$0.15
281.8$0.15

285$0.3
295$0.15

1) M4 rivet-down, insert nut or M4 extruded hole (8x)


140.9$0.1

2) Drill holes for fixing the position ∅ 5.2 mm (2x)


2)

1.6
5

5
0
286.6$0.15

152$0.1
312$0.15

Fig. 5-2 Drilling pattern for the CNC operator panel

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6FC5 397-0CP10-1BA0 5-41
Dimension Drawings
5.2 Dimension drawing and drilling pattern for the machine control panel (MCP)

5.2 Dimension drawing and drilling pattern for the machine control
panel (MCP)

Dimension drawing of the machine control panel (MCP)

A
A 90°
128

33 34
68.7

∅ 4.5 (6x)

263

330 17.2
170
154

19

159.8 152.2
8

Fig. 5-3 Dimension drawing of the machine control panel

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5-42 6FC5 397-0CP10-1BA0
Dimension Drawings
5.2 Dimension drawing and drilling pattern for the machine control panel (MCP)

Drilling pattern for the machine control panel (MCP)


w2

147

140

M4 (6x) 1)
0
7

0
141.2

11
301
290

1) M4 rivet-down, insert nut or M4 extruded hole

Fig. 5-4 Drilling pattern for the machine control panel

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6FC5 397-0CP10-1BA0 5-43
Dimension Drawings
5.3 Dimension drawings and drilling patterns for the NC full keyboard

5.3 Dimension drawings and drilling patterns for the NC full keyboard

Dimension drawing for the NC full keyboard (installed beneath the PCU)

2)
320
330

10

0
0

2)

86.1

172.2

Connection socket Grounding screw M5


7.7
1)
24

Note:
1) Add the height of the connector
(15 mm) to this dimension
20 290 20 (24 + 15) = 39 mm
2) Pin for fixing the position (2∅4.7)

172.2
165
15

158.8
142.2

13.4
15

7.2
0
0
9
330

321

161.2

Fig. 5-5 Dimension drawing for the NC full keyboard (installed next to the PCU)

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5-44 6FC5 397-0CP10-1BA0
Dimension Drawings
5.3 Dimension drawings and drilling patterns for the NC full keyboard

Drilling pattern for the NC full keyboard (installed beneath the PCU)

303.5
302.5

143.7
2+3

295

7.5
8.5
0
0
0.3

73

5 (2x) 2)

0.5
145.7
146
M4 (6x) 1) 151.9
Up 3)

1) M4 rivet-down, insert nut or extruded hole


2) Drill holes for fixing the position ∅ 5 mm (2x)
3) Please observe the cutting direction.

Fig. 5-6 Drilling pattern for the NC full keyboard (installed next to the PCU)

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6FC5 397-0CP10-1BA0 5-45
Dimension Drawings
5.3 Dimension drawings and drilling patterns for the NC full keyboard

Dimension drawing for the NC full keyboard (installed beneath the PCU)

2)

87.5
175

0
0
7.2

Connection socket

Grounding screw M5

302.2
309.4
2)
7.7

Note:
1)

1) Add the height of the connector (15 mm) to this dimension


24

(24 + 15) = 39 mm
2) Pin for fixing the position (2∅4.7)
15 145 15

309.4
15

295.6
279.4

154.7

13.8
15

0
175
169

6
0

Fig. 5-7 Dimension drawing for the NC full keyboard (installed beneath the PCU)

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5-46 6FC5 397-0CP10-1BA0
Dimension Drawings
5.3 Dimension drawings and drilling patterns for the NC full keyboard

Drilling pattern for the NC full keyboard (installed beneath the PCU)

0.5
2 +3

5 (2x) 2)

290

285

283.4
M4 (6x) 1)

142.5

1.6

5
76.5

0
158

153

1) M4 rivet-down, insert nut or M4 extruded hole (8x)


2) Drill holes for fixing the position ∅ 5 mm (2x)

Fig. 5-8 Drilling pattern for the NC full keyboard (installed beneath the PCU)

SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition


6FC5 397-0CP10-1BA0 5-47
Dimension Drawings
5.4 Dimension drawing for the PP72/48 I/O module

5.4 Dimension drawing for the PP72/48 I/O module

Dimension drawing for the PP72/48 I/O module

194
10.5

6.5
325

306

10 10 170

35
35

Fig. 5-9 Dimension drawing for the PP 72/48 I/O module

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5-48 6FC5 397-0CP10-1BA0
Installation 6
Overview
To install SINUMERIK 802D sl, first secure the individual components on the site of installa-
tion and then connect them with each other. When doing so, observe the Section “Configu-
ring the electrical design” (see Chapter 7, “Connecting”).

Open-type equipment
The modules of SINUMERIK 802D sl are open-type equipment. This means that you are
only allowed to install SINUMERIK 802D sl in housings, cubicles or electrical service rooms.
Access to these housings, cubicles or electrical service rooms must only be possible using a
key or a tool and must be restricted to instructed or authorized personnel.

General procedure when installing SINUMERIK 802D sl

Warning
! Before installing or removing the components of the SINUMERIK 802D sl control system,
make sure that the system is disconnected from the mains.

Note
When installing the control components, observe the dimensions given in Chapter 5. These
drilling patterns constitute the basis for preparing the mounting holes.

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6FC5 397-0CP10-1BA0 6-49
Installation

Mounting the CNC operator panel (PCU)


Install the CNC operator panel as shown on the relevant illustrations and diagrams 5-1
and 5-2.

Caution
! If you do not have access from the rear during installation, you must connect the CNC
operator panel prior to its installation. When doing so, note that connector X40 (powersupply
connection) and the lines connected to it protrude beyond the mounting edge.
When installing the CNC operator panel, do not pull off the connector; otherwise, the
cables could be damaged!

Installing the machine control panel


Install the CNC operator panel as shown on the relevant illustrations and diagrams 5-3
and 5-4.

Installing the CNC full keyboard


You can install the CNC full keyboard either next to the operator panel or beneath the CNC
operator panel. Observe the specifications in Figs. 5-5 through 5-8.

Installing the PP72/48 I/O module


This module must be installed according to EN 60204. For the dimension drawing of the
module, see Fig. 5-9.

Installing the SINAMICS S120 drive


For information regarding the SINAMICS S120 drive system (design, connection, planning,
dimensioning, configuring, etc.), see:
References: /GH1/, /GH2/, Equipment Manuals

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6-50 6FC5 397-0CP10-1BA0
Connecting 7
General rules
The present chapter describes various general rules for electrical design. You must observe
these rules to ensure trouble-free operation.

Safety rules
To ensure safe operation of your plant, realize the following measures and adapt them to
your particular conditions:
S An EMERGENCY STOP strategy in accordance with generally accepted rules of current
engineering practice
(e.g., European Standards EN 60204, EN 418, and the like).
S additional measures for the limiting of limit positions of axes
(e.g. hardware limit switches).
S devices and measures for protection of motors and power electronics according to the
design guidelines for SIMODRIVE or SINAMICS.
To identify hazard sources for the entire plant, we additionally recommend a risk analysis in
accordance with the general safety requirements/Annex 1 of the EC Machinery Directive
89/392/EEC.
In this context, observe also Chapter D, “Guideline for handling electrostatically sensitive
devices (ESD)” in this Manual.

Further references
For further information on EMC guidelines, we recommend the publication: EMC Installation
Guideline, Planning Guide (HW)
References: /EMV/, Description

Standards and regulations


When connecting SINUMERIK 802D sl, please observe the relevant VDE guidelines, in
particular VDE 0100 or VDE 0113 for disconnecting devices, short-circuit and overload
protection.

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6FC5 397-0CP10-1BA0 7-51
Connecting
7.1 General rules for operation of a SINUMERIK 802D sl

7.1 General rules for operation of a SINUMERIK 802D sl


When integrating a SINUMERIK 802D sl into a plant, you must observe the following general
rules.

Starting the plant after certain events

In case of ... ...


Startup after voltage drop or power failure all hazardous operating conditions must be avoi-
ded. If necessary, force an EMERGENCY STOP.
A startup after unlocking the EMERGENCY-OFF no uncontrolled or undefined start must occur.
equipment

Mains voltage

With ... make sure that ...


stationary plants or systems without all-pole building installation must contain a mains
mains disconnector disconnect switch or a fuse.
load power supplies, power supply modules the set range of the rated voltage complies with
the local mains voltage.
all current circuits deviation of the line voltage from the rated value
must be within the permitted tolerance (refer to
“Technical specifications of the installed
components”).

24 V DC power supply

With ... ensure ...


24 V supply safe (electrical) isolation of the low voltage

Protection against external electrical phenomena

With ... make sure that ...


all plants, installations and systems in which the plant, installation or system is connected to
SINUMERIK is installed the protective conductor for diverting
electromagnetic interference.
power supply, signal, and bus cables the wiring arrangement and installation complies
with EMC regulations.
signal and bus cables a cable or wire break cannot lead to undefined
statuses in the plant or system.

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7-52 6FC5 397-0CP10-1BA0
Connecting
7.2 Rules regarding current consumption and power loss of a cubicle arrangement

7.2 Rules regarding current consumption and power loss of a cubicle


arrangement
The power loss of all components used in a cabinet must not exceed the maximum amount
that can be dissipated from the cabinet.

Note
When dimensioning the control cubicle, make sure that the permissible ambient temperature
is not exceeded for the components installed, even in case of high outside temperatures.

For the current consumption and the power loss of the individual modules, please refer to
Chapter 8, “Technical Specifications”.

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6FC5 397-0CP10-1BA0 7-53
Connecting
7.3 Overall design of the SINUMERIK 802D sl

7.3 Overall design of the SINUMERIK 802D sl


The following section provides information on the overall design of the SINUMERIK 802D sl connected to a
grounded power supply.

L1 Low voltage distribution


L2 e.g. TNS system (3 x 400 V)
L3
N
PE

Cubicle

CNC operator panel I/O module PP72/48

X111/222/333 1) 2)
M
X40 X1
DOCOMx
P24 P24
DOCOMx
M M
DOCOMx
PE PE
DOCOMx

Ext. power supply

24 V DC
P24

Grounding rail in the cubicle

Machine control Handwheel NC full keyboard


panel (MCP) (option)

1) For use of an external power supply for digital inputs, see Section 4.3 “Digital inputs”.
2) The load power supply is configured by the user.

Fig. 7-1 Possibility of supplying the modules

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7-54 6FC5 397-0CP10-1BA0
Connecting
7.4 Connecting the protective conductor for the individual components

7.4 Connecting the protective conductor for the individual


components

Caution
! The components shown in Fig. 7-1 require connection to a protective conductor. The
individual components must be connected to the central grounding point.
Make always sure that a low-resistance connection is provided to the protective conductor.

Minimum cross-section of the cable to the protective conductor: 10 mm2


Whereas all remaining components are grounded via a grounding screw, the PP72/48 I/O
module must be connected directly to the central grounding point via the mounting plate
(installation acc. to EN 60204). If no grounding can be provided via the mounting plate,
it must be connected to the central grounding point via an additional line (cross-section
> 10 mm2).

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Connecting
7.5 Connection overview for the SINUMERIK 802D sl

7.5 Connection overview for the SINUMERIK 802D sl

SINUMERIK 802D sl
CNC operator panel (PCU)

Ethernet Ethernet-bus cable


X5 X40 24 V DC
node power supply

RS232 COM 6FX80021BA01.... USB


X8 X10
interface port

DRIVE-CLiQ included in the scope of NC


X1 and X2 X9
supply of the keyboard full keyboard

Cable
6FX8008-1BD61-1FA0 1) Electronic hand-
X30
v3m wheel (max. 2)
Connector
6FC9348-7HX
X20
Digital inputs/
and
digital outputs
X6 X21

PP72/48 I/O module


(max. 2)
X2 2 x 50-pin 2)
X111 Machine control panel
24 V DC X222 (MCP)
X1
power supply
Terminal strip
X333
converter

X200

SINAMICS S120
(max. 5 axes)

1) Delivered length: 50 m Preassembled cable


2) standard yard ware Single wiring

Fig. 7-2 Connection overview without MCPA

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Connecting
7.5 Connection overview for the SINUMERIK 802D sl

SINUMERIK 802D sl
CNC operator panel (PCU)

Ethernet Ethernet-bus cable


X5 X40 24 V DC
bus nodes power supply

RS232 COM port 6FX8002-1BA01-.... USB


X8 X10
port

DRIVE-CLiQ included in the scope of NC


X1 and X2 X9
supply of the keyboard full keyboard

Cable
6FX8008-1BD61-1FA0 1) Electronic hand-
X30
X110 v3m wheel (max. 2)
Connector
MCPA module 6FC9348-7HX
X20
Digital inputs/
and
digital outputs
X6 X21

X1 X2

PP72/48 I/O module


(max. 2)
X2
X111 X1201 X1202
24 V DC X222
X1
power supply Machine control panel
X333 (MCP)

X200
Terminal strip
converter

SINAMICS S120
(max. 5 axes)

1) Delivery length: 50 m Preassembled cable


Single wiring

Fig. 7-3 Connection overview with MCPA

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Connecting
7.5 Connection overview for the SINUMERIK 802D sl

Note
Connect the lines as shown in Fig. 7-2 or 7-3.
The preassembled cable sets from Siemens provide optimum interference immunity.

For information regarding the cables (cable designations, connector types, etc.) shown in the
illustrations, see:
References: /BU/, Catalog or /Z/, Catalog
For information regarding PROFIBUS DP and Ethernet, see:
References: /IKPI/, Catalog

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Connecting
7.6 Connecting the MCPA module

7.6 Connecting the MCPA module


The MCPA module is connected to the PCU via X110. The new machine control panel
(MCP) is connected using the supplied ribbon cable. X1 is connected to X1201, and X2 to
X1202 (see Fig. 7-3).
The power supply to the MCPA module is provided via connector X1021
(PIN1 24 V; PIN10 0 V).

Note
The variable assignment of the machine control panel is described in the PLC user interface
(please refer to: Description of Functions 802Dsl).
See also: PLC subroutine library V01.07.00 of SINUMERIK 802D sl.

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Connecting
7.7 Connecting the analog spindle

7.7 Connecting the analog spindle


The analog spindle is connected via the X701 interface on the MCPA module.

Analog spindle with directly mounted spindle actual-value encoder (TTL)


The TTL encoder requires an SMC 30 module. For configuring the X520 interface (encoder
connection: TTL with open-circuit monitoring), please refer to the table below.

Table 7-1 Assignment of the X520 interface

Description of the female Pin Name Description


connector

1 Reserved, –
not assigned

15 2 Reserved, –
not assigned
3 Reserved, –
not assigned
1
4 P_Encoder 5 V / 24 V Sensor power supply

X520 5 P_Encoder 5 V / 24 V Sensor power supply


6 P_Sense Sense input sensor power supply
7 M_Encoder (M) Ground for sensor power supply
8 Reserved, –
not assigned
9 M_Sense Ground sense input
10 R Reference signal R
11 R* Inverted reference signal R
12 B* Inverted incremental signal B
13 B Incremental signal B
14 A* Inverted incremental signal A
15 A Incremental signal A

Caution
The sensor power supply can be parameterized to 5 V or 24 V. The sensor may be
destroyed if you enter the wrong parameters.

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Connecting
7.8 Connecting the power supply

7.8 Connecting the power supply


Connect the required 24 V DC load power supply to the following connectors:
S to screw-terminal block X40 of the CNC operator panel
S to screw-terminal block X1 of the PP72/48 I/O module

Features of the load power supply

Danger
! The 24 V DC protective extra-low voltage must be generated as a protective extra-low
voltage with safe electrical isolation (to IEC 204-1, Section 6.4, PELV) and grounded by the
user (provide a PELV M signal connection to the central grounding point of the system).

Table 7-2 Electrical parameters of the load power supply for the CNC operator panel (X40) and for
the PP72/48 I/O module (X1)

Parameter Values Conditions


Voltage range mean value 20.4...28.8 V
Ripple 3.6 Vss
500 ms duration
Non-periodic overvoltage 35 V
50 s recovery time
Rated current consumption
S CNC operator panel typically 1 A
S PP72/48 I/O module –

Starting current
S CNC operator panel 2.6A
S PP72/48 I/O module –
Power consumption
S CNC operator panel max. 50 W
S PP72/48 I/O module max. 11 W

Table 7-3 Pin assignment of the screw-terminal blocks X40 (on the PCU) and X1 (on the I/O module)

Terminal Signal Description


1 P24 24 V DC
2 M Ground (GND)
3 PE Protective earth

Note
Make sure that the interconnecting cable between the power supply and the load power
supply connection does not exceed a maximum length of 10 m (with PP72/48 I/O module
only).

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Connecting
7.8 Connecting the power supply

Connecting the mains lines

Warning
! Before connecting the modules, first disconnect the equipment from the mains!

For connecting the power supply, use flexible lines with a line cross-section of at least
1 mm2.
If you only connect one line per connection, end sleeves are not absolutely necessary.
If you connect several lines per connection, you should use end sleeves.
Remove the isolation from the cable end, fit an end sleeve if necessary, insert the cable end
(with end sleeve) into the screw-terminal connection and tighten the fastening screw.
Insert the screw terminal with the cables to connection X40 on the CNC operator panel.

Polarity reversal protection


With correct connection and the power supply turned on, the LEDs “RDY” (PCU) and
“POWER” (PP72/48) are lit in green.

Note
In case of polarity reversal, the control system will not work. However, a built-in reverse
polarity protection facility protects the electronics against damage.

Fuse
In case of a defect in the control system, an internally installed fuse protects the electronics
from collateral damage (e.g. fire). In this case, the entire control system must be replaced.

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7.9 Connecting the full keyboard to the CNC operator panel

7.9 Connecting the full keyboard to the CNC operator panel


The interconnecting cable for connecting the NC full keyboard to the CNC operator panel is
included in the scope of supply. Connect the female connector X9 on the CNC operator
panel to the PS/2 socket on the rear of the NC full keyboard.
For more information, please refer to:
References: /BU/, Catalog

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Connecting
7.10 Connecting the Ethernet interface

7.10 Connecting the Ethernet interface


Connect the Ethernet connection cable to the CNC operator panel, female connector X5.
Make sure that the connector locks into position when connecting.

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Connecting
7.11 Connecting the RS232 COM port

7.11 Connecting the RS232 COM port


Insert the D-Sub female connectors into connector X8 on the CNC operator panel and into
the connector on the PG/PC. Lock the connector into position using the knurled screws.

Note
Use only shielded lines twisted in pairs; the shield must be connected to the metal or
metalized connector casing on the side of the control system.
The cable set offered as accessories provides maximum interference immunity.

Connection diagram
The diagram below shows the pin assignment of the interconnecting cable between the CNC
operator panel and a PG/PC with 9-pin or 25-pin socket connector.

CNC operator panel (9-pin D-Sub) PG/PC (9-pin D-Sub)

DCD DCD
1 1
RXD RXD
2 2
TXD TXD
3 3
DTR DTR
4 4
M M
5 5
DSR DSR
6 6
RTS RTS
7 7
CTS CTS
8 8

Shield Shield

CNC operator panel (9-pin D-Sub) PG/PC (25-pin D-Sub)

DCD DCD
1 8
RXD TXD
2 2
TXD RXD
3 3
DTR DTR
4 20
M M
5 7
DSR DSR
6 6
RTS RTS
7 4
CTS CTS
8 5

Shield Shield

Fig. 7-4 Connection diagram for interconnecting the CNC operator panel and the PG/PC

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Connecting
7.12 Connecting the PP72/48 I/O module and the drive

7.12 Connecting the PP72/48 I/O module and the drive

PNO design guidelines


For electrical PROFIBUS networks, observe also the PROFIBUS DP/FMS design guidelines
of the PROFIBUS user organization. The contain important measures with reference to the
cable routing and for starting up PROFIBUS networks.
Issued by: PROFIBUS-Nutzerorganisation e.V.
Haid-und-Neu-Strasse 7
D-76131 Karlsruhe
Tel: +49 721 / 9658 590
Fax: +49 721 / 9658 589
Internet: http://www.profibus.com
Guideline, order no. 2.112

Bus stations
The following bus stations can be connected via the PROFIBUS DP interface:
S CNC operator panel (always master)
S PP72/48 I/O module (slave)

Bus connector and bus cable


The PROFIBUS cable is a two-core, stranded and shielded cable which must not be twisted,
stretched or squeezed.
For more information regarding the bus connector, the bus cable and the cable length,
please refer to:
References: /BU/, Catalog

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Connecting
7.12 Connecting the PP72/48 I/O module and the drive

Connecting a bus connector


To connect the bus connector, proceed as follows:
1. Connect the bus connector to the module.
2. Screw the bus connector tight.
3. If the bus connector is at the start or end of the PROFIBUS DP connection, you must
connect the terminator on the connector (switch position “ON”).

Terminator on Terminator not on

connected off
connected off

Fig. 7-5 Bus connector: Terminator connected and disconnected

Warning
! A bus segment must always be terminated on both ends; otherwise, the data traffic at the
bus could be disturbed.
Make sure that the stations at which the terminator is connected, is always powered, both
during booting and operation.
The terminator is without effect if the last station to which a bus connector is connected is
dead, since the bus connector is powered from the station.

Setting the PROFIBUS DP address


Each bus station must be assigned a PROFIBUS DP address at the PROFIBUS DP for un-
ambiguous identification. Each PROFIBUS DP address must be assigned at the bus only
once.
On the PP72/48 I/O module, the PROFIBUS DP address is set using the DIL switch S1 (see
Fig. 4-3). Use a screw driver to set the PROFIBUS DP address. It results from the addition
of the switches to be found on the right (ON position).

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Connecting
7.12 Connecting the PP72/48 I/O module and the drive

PROFIBUS-DP address Example: PROFIBUS DP address = 9

ÉÉ ÉÉ
1+8=9

ÉÉ
ON 1 20 (1) ON 1
ÉÉ
ÉÉ 1

ÉÉ
2

ÉÉ
3
21 (2)
22 (4)
2
ÉÉ
ÉÉ
ÉÉ ÉÉ
3
23 (8)

ÉÉ ÉÉ
4 4 8

ÉÉ ÉÉ
5 24 (16) 5

ÉÉ ÉÉ
6 25 (32) 6

ÉÉ ÉÉ
7 26 (64) 7

ÉÉ ÉÉ
8 not assigned 8

Fig. 7-6 Setting the PROFIBUS DP address on PP72/48

Changing the PROFIBUS DP address


You can change the PROFIBUS DP address once set at any time. However, the control
system will accept the newly set PROFIBUS DP address only after turning off/turning on the
24 V DC power supply.

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Connecting
7.12 Connecting the PP72/48 I/O module and the drive

Networking example
The diagram below shows a networking example for SINUMERIK 802D sl with two PP72/48
I/O modules.

SINUMERIK 802D sl

CNC operator
À panel (PCU)
Á
X6

12 MBaud
1. PP72/48 2. PP72/48
I/O module I/O module
 Â
X2 9 X2 8

Maximum cable length of 100 m


(from one terminator to another)

À Terminator activated
Á DP master
 DP slave
0 to x PROFIBUS DP addresses of the stations

Cable routing (bus connector):


Terminator

ON OF ON
F
A1 A1 A1 A2 A1 A2

B1 B1 B1 B2 B1 B2

1) 1)
PCU 1. PP 2. PP
72/48 72/48
1) Shield connected within the connector
A1, 2 = green; B1, 2 = red

Fig. 7-7 Networking example

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Connecting
7.13 Connecting the SINAMICS drive to the DRIVE-CLiQ interface

7.13 Connecting the SINAMICS drive to the DRIVE-CLiQ interface


Connect the female connector X1 on the CNC operator panel to the X200 female connector
on the drive using the DRIVE-CLiQ signal line.

SINAMICS

Fig. 7-8 Connection with ALM (Active Line Module)

SINAMICS

Fig. 7-9 Connection with SLM (Smart Line Module)

*) Input of the measuring system


With SMI motors (integrated measuring system interface), the connection is provided from
the motor directly to X202 via the DRIVE-CLiQ line. For direct measurnig systems, connect
the measuring system via a SMCxx module (xx depends on the type of the measuring
system you are using: e.g. SMC20 with incremental encoder or SMC30 with TTL encoder).

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Connecting
7.14 Connecting the digital inputs/outputs to the PCU

7.14 Connecting the digital inputs/outputs to the PCU

Connection cables
To connect the digital inputs and outputs, you should use flexible lines with a cross-section
of at least 0.5 mm2.
If you only connect one line per connection, end sleeves are not absolutely necessary.
If you connect two lines per connection, lines with a cross-section between 0.25 and
0.75 mm2 with end sleeve must be used.
Fasten the lines to the supplied screw terminals and insert the terminals to the connectors
X20 and X21 on the CNC operator panel.

Note
To ensure optimim interference immunity when connecting sensing probes or BEROs, it is
imperative to use shielded lines.

The max. line length is 30 m.

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Connecting
7.15 Connecting the digital inputs/digital outputs to the PP72/48 I/O module

7.15 Connecting the digital inputs/digital outputs to the PP72/48


I/O module
You can use the I/O interfaces X111, X222, X333 as digital inputs or digital outputs. To this
end, fasten the insulation displacement connector to the ribbon cable and route it from the
I/O module to the terminal strip converter. The individual wiring can be performed on the ter-
minal strip connectors.
Remove the insulation from the cable end, insert the cable end (with end sleeve) into the
screw terminal connection and tighten the fastening screw.

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Connecting
7.16 Connecting the machine control panel to the PP72/48 I/O module

7.16 Connecting the machine control panel to the PP72/48 I/O module
To connect the machine control panel (X1201 and X1202) to the PP72/48 I/O module (e.g. X222
and X333), use two ribbon cables.
For more information, please refer to:
References: /BU/, Catalog

Note
More information regarding the machine control panel and the pin assignment of the
connectors X1201 and X1202 is to be found on the installed toolbox at:
Start > Programs > Toolbox802sl > PLC802slLibrary > Description.

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Connecting
7.17 Connecting shielded lines via the shield connection (PCU)

7.17 Connecting shielded lines via the shield connection (PCU)


The shield of shielded signal lines must be connected to ground. The connection to ground
is achieved by connecting the shield connection directly to the housing.

Shield connection
The EMC shield clip EMVSK 12 is used as the shield connection. These EMC shield clips
(4 pcs.) are included in the scope of supply of the CNC operator panel.

Mounting the shield connection


1. Remove the isolation from the shield according to the EMC shield clip.
2. PLace the shield on the housing in the appropriate place (see Fig. 7-10).
3. Snap the EMC shield clip into the appropriate cutout on the housing.
Ensure firm fit of the cable on the housing.
4. For mechanical strain relief of the lines and cables, you can use the cable clamp or the
EMC shield clip (see Fig. 7-10).

Cable clamp (4x)

Cutouts for snapping in the


4 EMC shield clips

Fig. 7-10 Connecting the lines via the shield connection/fastening the lines mechanically

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Technical Data 8
User data memory
Compact flash card, type 1 (CF card)

Connected loads of the PCU

Table 8-1 Connected loads

Supply voltage 24 V DC (permissible range: 20.4...28.8 V)


Ripple 3.6 Vss
Current consumption from 24 V Basic configuration
typically 1.5 A (inputs/outputs open)
Power loss
S CNC operator panel (PCU) with NC full max. 50 W
keyboard
S Machine control panel v5W
S PP72/48 I/O module max. 11 W
Starting current, total 5A

Dimensions and weight

Table 8-2 Weights and dimensions

CNC operator panel (PCU)


Dimensions W H D [mm] 310 330 85
Weight [g] approx. 4,900

NC full keyboard (upright design)


Dimensions W H D [mm] 310 175 32
Weight [g] approx. 1,700

NC full keyboard (broad format)


Dimensions W H D [mm] 172 330 32
Weight [g] approx. 1,700

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Technical Data

Table 8-2 Weights and dimensions, continued

Machine control panel


Dimensions W H D [mm] 170 330 128
Weight [g] approx. 1,500

PP72/48 I/O module


Dimensions W H D [mm] 194 325 35
Weight [g]
S without mounting plate S approx. 300
S with mounting plate S approx. 1,200

Digital inputs of the PP72/48 I/O module (to IEC 1131-2/DIN EN 61131-2, type 2 characteristic)

Table 8-3 Digital inputs of the PP72/48 I/O module

Number of inputs 24 each per terminal strip converter

Parameter min. typical max. nominal


Voltage with high level (UH) 15 V 1) 30 V 24 V
Input current IIn at UH 2 mA – 15 mA –
Voltage with low level (UL) –30 V – 5V 0V
Signal delay time TPHL 2) 0.5 ms – 3 ms –

1) Supply voltage for the digital inputs


Typical output voltage: VCC – IOUT * RON
VCC: Current operating voltage (P24OUTINT) at X111, X222,
X333: Pin 2
2) In addition, take into account the PROFIBUS DP communication time and the application cycle time.
A polarity reversal does not cause a high signal level nor does it destroy the inputs.

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Technical Data

Digital outputs of the PP72/48 (as per IEC 1131-2 / DIN EN 61131-2)

Table 8-4 Digital outputs of the PP72/48 I/O module

Number of outputs 16 each per terminal strip converter

Parameter min. typical max. nominal


Voltage with high level (UH) VCC – 3 V 1) VCC 24 V
Iout – – 0.25 A –
Voltage with low level (UL) – – – Output
open
Leakage current at low signal level – 50 µA 400 µA –
Signal delay time TPHL 2) – – 0.5 ms –
max. switching frequency 2)
S ohmic load 100 Hz – – –
S inductive load 2 Hz – – –
S lamp 11 Hz – – –
1) Supply voltage for the digital outputs
Typical output voltage: VCC – IOUT * RON
VCC: Current operating voltage
Max. output currentIOUT: 0.25 A
Max. short-circuit current: 4 A (max. 100 µs, VCC = 24 V)
Internal resistanceRON: 0.4 Ω
2) In addition, take into account the PROFIBUS DP communication time and the application cycle time.
A polarity reversal does not cause a high signal level nor does it destroy the outputs.

General electric features:


S Galvanic isolation through opto-couplers
S Current limited to max. 0.25 A
S Protection from:
– short-circuit
– overtemperature
– loss of grounding
S automatic shutdown in case of undervoltage

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Technical Data

Notes

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Commissioning 9
9.1 General

Commissioning requirements
S You will need the following:
– SINUMERIK 802D sl User Documentation
– SINUMERIK 802D sl Description of Functions
– A PC for commissioning and data backup
– Tools installed from the Toolbox CD:
RCS802D Commissioning and Diagnostic Tool
PLC802 Programming Tool
802D sl Configuration Data
PLC Library
STARTER (for optimizing the drive)
Adobe Acrobat Reader
S The mechanical and electrical installation of the system must be completed.

Commissioning sequence
To commission the SINUMERIK 802D sl, proceed as follows:
1. Check that the PCU boots.
2. Set the language.
3. Setting the technology
4. Set the general machine data.
5. Start up the PLC.
6. Start up the drive.
7. Set the axis/spindle-specific machine data.
– Match the encoder to the axis/spindle.
– Match the setpoint to the axis/spindle.
8. Perform a dry run for the axes and for the spindle.
9. Optimize the drive.
10.Complete the commissioning; perform a data backup.

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Commissioning
9.1 General

9.1.1 Access levels

Protection levels
The SINUMERIK 802D sl provides a concept of protection levels for enabling data areas.
There are the protection levels 0 to 7 whereby 0 is the highest and 7 the lowest level.
The protection levels can be set for certain function areas (e.g. program editor) using the
display machine data (USER_CLASS...).
The control system is delivered with default passwords for the protection levels 1 to 3; if
necessary, these passwords can be changed by the person authorized to do so.

Table 9-1 Protection level concept

Protection Locked by Area


level
0 Siemens, reserved
1 Password: SUNRISE (default) Expert mode
2 Password: EVENING (default) Machine manufacturer
3 Password: CUSTOMER (default) Authorized operator, setter
4 to 7 No password and Authorized operator, setter or appro-
user interface from PLC NCK priate graduations as desired

Protection levels 1 ... 3


The protection levels 1 to 3 require a password. The passwords can be changed after acti-
vation. For example, if the passwords are no longer known, the control system must be reini-
tialized (booting with default machine data). This will reset all passwords to their defaults
according to the software release you have acquired.
The password remains set until it is reset by selecting the Delete password softkey.
POWER ON will notreset the password.

Protection levels 4 ... 7


Protection level 7 is set automatically if no password is set and no protection level interface
signal is set. The protection levels 4 to 7 can be set from the PLC user program even
without a password by setting the bits in the user interface.

Note to the reader


How to set the access levels is described in the User Manual: “Operation and
Programming”.

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Commissioning
9.1 General

9.1.2 Structure of machine data (MD) and setting data (SD)

Number and identifier


MD and SD are addressed via their numbers or their names (identifiers). The number and
the name, as well as the activation type and the unit are displayed on the screen of the
control system.

Activation
The activation stages are listed according to their priority. If any data is changed, it comes
into effect after:
S POWER ON (po) Turning off/turning on the SINUMERIK 802D sl
S NEW_CONF (cf) With RESET at the PLC interface (V3000 0000.7)
S RESET (re) With RESET at the PLC interface (V3000 0000.7) or at the end of the
program M2/M30
S IMMEDIATELY (im) After input of the value

Protection level
For start-up or machine data input, usually, protection level 2 is required.

Unit/system of units
Depending on MD 10240 SCALING_SYSTEM_IS_METRIC, the physical units of the
machine data (MD) differ as follows:

MD 10240 = 1 MD 10240 = 0
mm inch
mm/min inch/min
m/s2 inch/s2
m/s3 inch/s3
mm/rev. inch/rev.

If there are machine data with no physical unit assigned, the relevant field remains empty.

Note
The default setting is MD 10240 SCALING_SYSTEM IS METRIC = 1 (metric).

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Commissioning
9.1 General

9.1.3 RCS802D Commissioning and Diagnostic tool

For commissioning and diagnostic tasks, the RCS802D tool included on the supplied toolbox
CD can be used.
This tool provides the following functions:
S File management (deletion of files, creation of directories, etc.)
S Reading in/reading out setup files, text files, part programs, DDLs or pictures
S Remote diagnosis and remote control
Install the RCS802D tool on the PC/PG which you want to use to access the control system.
The starting window will be split into two halves. The drives of the control system and of the
PC are displayed in the left-hand half, and the contents of the selected directories are dis-
played in the right-hand half. Use the right mouse button to open the context menu dis-
playing the “Properties” window. It displays the file size, the creation date and the DLL
version.

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9.2 Turning on and booting the control system

9.2 Turning on and booting the control system

Procedure
S Check the system visually for:
– correct mechanical design and check that all electrical connections are performed
correctly.
– connected voltages
– connection of shielding and grounding.
S Connect the control system (booting in the normal mode)

Booting in the normal mode


When the control system is turned on, the boot sequence is displayed on the control system
with all its individual phases. Once the start screen of the user interface has appeared, the
booting sequence is completed.

Booting in the start-up mode


After POWER ON and once the operating system has been started, the word “SINUMERIK”
is displayed filling the whole screen. Once this word has disappeared, press the SELECT
key.
The START UP MENU is displayed. Use the arrow key to select an appropriate power-up/
start-up mode and press INPUT to confirm.
The modes specified in the START-UP MENU have the following meanings:
S normal startup
If this option is chosen, the control system will boot with the last machine data set and
the previously loaded programs.
S reload saved user data
If this option is chosen, the user data (machine data, programs, etc.) backed up to the
flash memory are accepted.
S start-up with default data (is only displayed if protection level 1 or 2 is set)
If this option is chosen, the control system will boot with default machine data.
S software update
In this case, the control system will not boot at all. The software can only be updated if a
CF card with a software update is inserted in the slot for the CF card.
S PLC stop
Select PLC Stop while the control system is booting if PLC Stop can not be triggered via
the user interface any more.

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9.3 Language setting and file management

9.3 Language setting and file management


English is set for both the foreground and background languages. You can change the lan-
guages by loading new language files from the toolbox using the RCS802D tool.

9.3.1 Creating a project

The RCS802D tool and the toolbox are installed on the PC/PG.

Sequence
S Start RCS802D on the PC.
S Select the Toolbox > Controller menu item from the Settings menu bar and select the
appropriate 802D control.
S Thereafter, select the Toolbox version Settings > Toolbox > Select Version.
S Use Settings > Toolbox > Select Project to select a project (1), insert front and back-
ground languages (2) and create the project (3) (see Fig. 9-1).

Fig. 9-1 Creating a project

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9.3 Language setting and file management

9.3.2 Help, language and alarm files

To create the help system, select the menu item Tools > Toolbox Manager > Generate
Help System (1) from the RCS802D menu bar. Here you can also create a new language or
new text files. You can either edit (2) or delete existing text files. After generating the text
files, click OK to finish (3) (see Fig. 9-2).

Fig. 9-2 Generating text files for the online help

Similarly, texts for PLC alarms (alcu.txt), user cycles (alsc.txt) and NC user alarms (alz.txt)
can be created using the Tools > Toolbox Manager > Select OEM menu. User stands
here for both end user and machine manufacturer.

9.3.3 Transmitting data to the 802D

Sequence
S Establish a V24 connection between the PC and the PCU (RS232).
S Turn on the control system and wait until the control system has completed its booting
sequence without errors.
S In the “System” operating area, set the password for protection level 2 or higher.
S In the “System” operating area, PLC > STEP7 connect. Check that the settings dis-
played on the screen are the same as the settings you have made (see Fig. 9-3); change
if necessary.
S Use Connection on to establish the connection.

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9.3 Language setting and file management

Fig. 9-3 Default communication parameters

S Start the RCS802D tool on the PC and establish a V24 connection between the PC

(default: COM1) and the PCU (RS232) using the appropriate icon . The 802D inter-
face parameters can be adapted using the Tools menu in the menu bar, Connect menu
item.
S In the menu bar, you can edit the functions Language (to select your 1st and 2nd lan-
guages), Help System (contains text files for the online help) and OEM (contains
text files for cycles and alarms) which have already been mentioned above under
Tools > Toolbox Manager, using Write Data to NC. See Fig. 9-4 and Fig. 9-5.
S Click OK to transfer your selection to the 802D sl.
S Restart the NC.
S The required language files are now active.

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9.3 Language setting and file management

Fig. 9-4 Transmitting user alarms to the control system

Fig. 9-5 Transmitting the language to the control system

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9.4 Setting the technology

9.4 Setting the technology

Note
The SINUMERIK 802D sl is delivered with default machine data. In the next step, the
appropriate setup file must be loaded from the toolbox into the control system.
The following setup files are offered to choose from:
S setup_M.arc Milling machine with complete cycle package
S trafo_Mx.ini Machine data for the Tracyl function – milling technology
(x ... corresponds to rotary axis A, B, or C)
S setup_T.arc Turning
S setupTra_T.arc Turning with transformation
The setup file must be loaded during the commissioning after booting of the control system,
but prior to the general configuration.

The trafo_Mx.ini describes memory-standardizing machine data. The data must be saved by
creating and rereading a series start-up file.

Note
Please always observe the readme file supplied with the “Toolbox”. It provides up-to-date
information.

Sequence
S Establish an RS232 connection between the PC and the PCU (RS232 – X8).
S Turn on the control system and wait until the control system has completed its booting
sequence without errors.
S In the “System” operating area, set the password for protection level 2 or higher.
S In the “System” operating area, select PLC > STEP7 connect. Check that the settings
displayed on the screen are the same as the settings you have made (cf. Fig. 9-3);
change if necessary.
S Use Connection on to establish the connection.
S Start the RCS802D tool on the PC and establish a V24 connection between the PC

(default: COM1) and the PCU (RS232) using the appropriate icon . The 802D sl
interface parameters can be adapted using the Tools menu in the menu bar, Connect
menu item.
S Use Copy/Paste to copy the icon of the setup file into the “Data” folder of drive A of your
802D sl (cf. Fig. 9-6).
If the toolbox has been installed in the default directory, the setup files are to be found,
e.g. at C:\Programs\Siemens\Toolbox 802Dsl\V030005\V01xxyyzz\ TECHNO\MIL-
LING\CONFIG_xx\.
S The control system boots automatically during the transmission several times.
S The SINUMERIK 802D sl is now preset to the required technology.

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9.4 Setting the technology

Fig. 9-6

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9.5 Entering the machine data

9.5 Entering the machine data

Overview
The most important machine data of the individual subareas are listed here to assist you.
For a detailed description of the machine data and interface signals, please refer to the
Descriptions of Functions (cf. cross-references in the tables of Chapter 7 “Machine Data and
Setting Data”).

Note
The default values of the machine data have been chosen such that usually no change is
required.

Entering the machine data (MD)


Before you can enter the machine data, the password for protection level 2 must be set.
Use the relevant softkey to select the following machine data areas and to change the ma-
chine data if necessary:
S General machine data MD 10000 ... 19999
S Channel machine data MD 20000 ... 29999
S Axis machine data MD 30000 ... 39999
S Display machine data MD 1 ... 999
S Drive machine data r0001 ... r9999 (read-only)
p0001 ... p9999 (read and write-enabled)
The data you have entered are written to the data memory immediately. An exception is the
drive machine data. To save the drive machine data permanently, set the parameter p971 for
each individual drive object separately or set p977 of the CU (SINAMICS_I) to “1” and wait
until it is reset automatically. If you forget to save the data, the old data is effective again
after the next drive reset.
The machine data is activated depending on the machine data property “Activated”,
Section 9.1.2.

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9.6 Setting the Profibus address

9.6 Setting the Profibus address


Certain bus configurations have already been prepared for SINUMERIK 802D sl. The
required configuration can be set via MD 11240[2]: PROFIBUS_SDB_NUMBER.
Depending on the physical plant configuration, set the relevant setting data bit (SDB) accor-
dingly to select the machine data 11240[2] Profibus_SDB_NUMBER. NCK Reset will accept
the changed machine data.

Table 9-2 SDB number

MD 11240[2] Number of axes


0 2 SINAMICS drive with Smart Line Module (SLM)
1 3 SINAMICS drive with Smart Line Module (SLM)
2 4 SINAMICS drive with Smart Line Module (SLM)
3 5 SINAMICS drive with Smart Line Module (SLM)
4 3 SINAMICS drive with Active Line Modules (ALM)
5 4 SINAMICS drive with Active Line Modules (ALM)
6 5 SINAMICS drive with Active Line Modules (ALM)

Set now the MD 11240[2]: PROFIBUS_SDB_NUMBER according to your particular bus


configuration.

Table 9-3

MD 11240[0] PB station (slave) PB address


0 PP module 1 9
PP module 2 8
PP module 3 7
Another preconfigured PB station: DP-DP coupler 6

PCU
Is master at PROFIBUS; address cannot be changed

PP 72/48
Is slave at PROFIBUS; max. three PP modules can be connected. The addresses are set
using DIL switch S1 on the PP module.

PB address DIL switch S1 (PP module)


9 (default setting) 1 + 4 = ON
(PP module 1) 2 + 3 + 5 + 6 + 7 + 8 = OFF
8 4 = ON
(PP module 2) 1 + 2 + 3 + 5 + 6 + 7 + 8 = OFF
7 1+2+3 = ON
(PP module 3) 4 + 5 + 6 + 7 + 8 = OFF

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9.7 Starting Up the PLC

Note
The newly set PB station address is only active after POWER ON.

9.7 Starting Up the PLC


After starting up the Profibus, the prepared PLC user program is ready to run and can be
used for further start-up. To load the PLC user program, use the Programming Tool.
For a description, please refer to Section 11.5.

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9.8 Configuring SINAMICS S120 with 802D sl

9.8 Configuring SINAMICS S120 with 802D sl

9.8.1 Commissioning using predefined macros without the STARTER


commissioning tool

Prerequisites
S SMI components (motors and encoder with DRIVE CLiQ interface)
S No direct measuring systems

Procedure
1. Firmware upgrade using macros
2. Reset to the default settings and loading the SINAMICS parameters with macros
3. Setting the Machine Data (Section 9.8.4)

Firmware upgrade using macros


The macro must only be started if necessary. If the start-up engineer, however, does not
know the firmware versions of all drive components, it is recommended to start the macro;
otherwise, the firmware version cannot be read out in this start-up phase without using the
STARTER tool. In any case, the macro must be started BEFORE commissioning the drives!

Procedure:
S Turn on the Sinumerik 802D sl and wait until the booting sequence is completed.
S Use the System > Set Password softkeys to set the manufacturer password or higher.
S Use the System > Machine data > Drive MD > Display parameters softkeys to select
the integrated CU003 as SINAMICS_I (cf. Fig. 9-7) and check that P0009=1; if not,
change.
S Set P0015=150399 to start the macro. The LEDs of the drive modules will flash in RED
and GREEN during the upgrade.
S The upgrade is completed successfully if 7829 changes to “0”. Runtime approx.
5 ... 10 minutes, depending on the number of modules
S Carry out POWER ON.

Reset to the default settings and loading the SINAMICS parameters with macros
To create the drive machine data automatically and load them with default data, macros are
provided which can be started by setting the drive parameter p15 (“p” for Parameter) of the
CU. To this end, select the “Display parameters” softkey (System > Machine data > Drive
machine data) to select the SINAMICS_I CU (cf. Fig. 9-7), and proceed as follows:

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9.8 Configuring SINAMICS S120 with 802D sl

Fig. 9-7 SINAMICS in 802D

S Disable all drive enables. The Line Module must be disconnected from the mains (mains
contactor). Otherwise, no data will be stored (p977 remains 0).
S p9 (device start-up, parameter filter) =30 (reset the CU to its default settings)
S p976 (reset parameter) =1 (reset all parameters to default)
S Wait until p9 is reset to 0 (checkback message “Resetting completed”).
S Assign p15 a macro number.

Note
With SINUMERIK 802D sl, version v 01.00, up to 5 axes can be initialized.

Macro 150111 – initialization of up to 6 axes + Active Line Module (ALM) + one/no BERO
as zero mark equivalent
Macro 150112 – initialization of up to 6 axes + Active Line Module (ALM) + two BEROs
as zero mark equivalent
Macro 150101 – initialization of up to 6 axes + Smart Line Module (SLM) + one/no BERO
as zero mark equivalent
Macro 150102 – initialization of up to 6 axes + Smart Line Module (ALM) + two BEROs
as zero mark equivalent
S Wait until p977 is set to 1 (start of nonvolatile saving of parameters) and is then reset to 0
again (checkback message “Nonvolatile saving of all parameters) (Attention: Resetting
of parameter p977 to “1” may take up to 5 minutes depending on your particular
machine. Do not turn off the machine; otherwise, you must restart from the
beginning.)
S The drive machine data are now saved to ROM. The drives will appear in the configura-
tion (see Fig. 9-8).

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9.8 Configuring SINAMICS S120 with 802D sl

Fig. 9-8 SINAMICS in 802D with configured drives

The macro will configure terminal X20/X21 as shown in Tables 9-4 and 9-5. With the Active
Line Module, the input PIN1 of the CU is linked with parameter p0840 of the Active Line
Modules; a leading contact must be connected from the main switch or from the mains
contactor.
Connect pin2 of the input to parameter p0849 for all drives. P0849 means AUS3 (rapid
stop). This function realizes braking with a configurable AUS3 ramp (p1135,1136,1137);
thereafter, pulse suppression and starting lockout. The drive stops controlled. The braking
behavior of each servo drive can be set separately, also via the main switch or mains con-
tactor, but should rather be connected via the PLC I/Os.

Table 9-4 Configuring terminal X20 using system macros

Pin no. Hardware Function Assignment Parameter Macro


features I/O no.
Active Line Moduleenabled
150111
Electrically isola- E Leading contact from main switch or ALM p840 = 47318016
150112
1 ted input, µ ,
p , 50µs, 0/1 edge
g mains contactor
smoothed required 150101
SLM hardware ready SERVO p864 = 47318016
150102
150111
Electrically isola- E Each SERVO
“OFF3 – rapid stop” 150112
2 ted input, 50µs, 0/1 edge 2nd OFF3, p849 =
smoothed required Behavior similar to terminal 64 150101
47318017
150102
5 Ground for pin 1 .. 4
6 24 P
150111
Bidir. I/O, 150112
8 I Bero 1 – zero mark substitute” p945 = 1
1µs, smoothed 150101
150102
9 Ground for pins 7, 8, 10, 11

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9.8 Configuring SINAMICS S120 with 802D sl

Table 9-4 Configuring terminal X20 using system macros, continued

Pin no. Hardware Function Assignment Parameter Macro


features I/O no.
150111
Bidir. I/O, 1µs, Sensing probe 2, encoders 1+2 Each SERVO p489 150112
10 I
smoothed (check that MD13210 = 1!) Index = encoder 1,2 = 2 150101
150102
150111
Bidir. I/O, 1µs, Sensing probe 1, encoders 1+2 Each SERVO p489 150112
11 I
smoothed (check that MD13210 = 1!) Index = encoder 1,2 = 3 150101
150102
12 Ground for pins 7, 8, 10, 11

Table 9-5 Configuring terminal X21 using system macros

Pin no. Hardware Function Assignment Parameter Macro


features I/O no.
6 24 P for 802
7 Bidir. I/O, 1µs, A Digital output $A_OUT[x] NCK 150111
smoothed Output set p728 150101
8 Bidir. I/O, A Digital output $A_OUT[x] NCK 150111
1µs, smoothed Output set p728 150101

150102
I Bero 2 – zero mark substitute” p945 = 4
150112
9 Ground for pins 7, 8, 10, 11
NCK
Bidir. I/O, 150111
10 A Digital output $A_OUT[x] Output set p728
1µs, smoothed 150101

NCK
Bidir. I/O, 150111
11 A Digital output $A_OUT[x] Output set p728
1µs, smoothed 150101

12 Ground for pins 7, 8, 10, 11

Creating the message frame type in the SERVOs


For communication with the 802 D sl and the SERVOs, the parameter P922 must be set
equal to the machine data MD13060.

P922 = ... Message frame dependent on the encoder system


999 with default setting
102 first measuring system
103 second measuring system (to this end, load additonal SDB from the toolbox into
the control system)
P977 = 1 Data backup of the selected SERVO components

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9.8 Configuring SINAMICS S120 with 802D sl

9.8.2 Starting up motors without SMI

When starting up motors, they are to be started up in SERVO for each axis individually, as
motor type, motor code and encoder code are not automatically detected. The measuring
system of the motor must be connected via an SMCxx.

P10 = 1 Check whether P10 = 1; if yes, perform the motor and encoder start-up.
P300 = ... Motor type
102 1PH2 induction motor
104 1PH4 induction motor
106 1PH6 induction motor
107 1PH7 asynchronous motor
206 1FT6 synchronous motor
236 1FK6 synchronous motor
237 1FK7 synchronous motor
P301 = ... Motor code number (to be taken from the STARTER tool)
P400= ... Encoder code number
2001 Incremental encoder: 2,048 A/B C/D R pulses (spindle)
2051 Absolute-value encoder: EncDat 2,048 pulses
2002 Incremental encoder: 2,048 A/B R pulses (spindle)
P922 = ... Message frame dependent on the encoder system
999 with default setting
102 first measuring system
103 second measuring system (to this end, load additonal SDB from the toolbox into
the control system)
P3900 = 3 Parameterizing the controller parameters and completing the quick start-up

For data backup, set P977 = 1 in SINAMICS_I.

9.8.3 Faults and warnings when starting up the SINAMICS S120 drive

To be able to diagnose in detail the alarms displayed in case of faults in the header and in
the alarm buffer, the warning buffer can be read out. It is thus also possible to diagnose
Profibus alarms in detail.
The most recent warnings/alarms (max. 8) are to be found in the parameters p2122 and
p2124 whereby the newer alarms have the higher indices (see Table 9-6).

Table 9-6 Meanings of the parameters for the warnings

Warning code Warning value Warning Warning


[meaning in alarm list] [meaning in alarm list] time time
coming going
Warning 1 r2122[0] r2124[0] r2123[0] r2125[0]
Warning 2 r2122[1] r2124[1] r2123[1] r2125[1]
[...] [...] [...] [...] [...]
Warning 8 r2122[7] r2124[7] r2123[7] r2125[7]

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9.8 Configuring SINAMICS S120 with 802D sl

Note
For the meanings of the contents of the individual warning codes and warning values,
please refer to the Manual /DG/ SINUMERIK 802D sl “Diagnostics Guide”, Chapter
“Sinamics Alarms”.

9.8.4 Setpoint/actual-value assignment

The axis machine data MD 30130: CTRLOUT_TYPE can be used to switch the setpoint out-
put, and MD 30240: ENC_TYPE can be used to switch the actual-value input between simu-
lation and PROFIBUS drive.

Table 9-7

Machine data Simulation Normal mode


MD 30130 Value = 0 Value = 1
Simulation In this case, the setpoint signals are output via
Profibus.
MD 30240 Value = 0 Value = 1 (INCR) or 4 (EnDat)
Simulation In this case, the actual values are read in via
Profibus.

Note
For simulation, MD 30130 and MD 30240 must be parameterized with “0”.

To enable the relevant NC axis to assign its setpoint to the appropriate SINAMICS drive, en-
suring that the actual values are returned from this SINAMICS drive, it is imperative to para-
meterize the machine data MD 30110: CTRLOUT_MODULE_NR and MD 30220: ENC_MO-
DULE_NR.
The following applies for the maximum configuration of 5 axes with Active Line Module:

Axis Drive number SINAMICS object no.


MD 30110
MD 30220
X1 2 3

Y1 3 4

Z1 4 5

SP 1 2

A1 5 6

If this setting does not match the order in the drive group (the order of the drive CliQ connec-
tions corresponds to the order of the SINAMICS object no., here: 1. ALM, 2. Spindle,
3. X1 axis, 4. Y1- axis, 5. Z1 axis, 6. A1 axis), the data must be adapted accordingly.

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9.8 Configuring SINAMICS S120 with 802D sl

Note
When performing the start-up with macros, the machine data MD 30110:
CTRLOUT_MODULE_NR and MD 30220: ENC_MODULE_NR must be set such that they
have the same drive number because there is a fixed assignment between measuring
system and motor.
The assignment topology can be modified using the STARTER tool.

Example:
The machine you want to start up is a milling machine. The milling machine possesses three
axes and one spindle.
S The default data record (setup_m) has been loaded.
S The bus configuration has been selected with MD 11240[2] = 5.
S Now, adapt the axis machine data MD 30110: CTRLOUT_MODULE_NR and MD 30220:
ENC_MODULE_NR as follows:

Axis Drive number SINAMICS object no.


MD 30110
MD 30220
X1 2 3

Y1 3 4

Z1 4 5

SP 1 2

S Set the PB addresses = object no. of the drives as specified in the table above. Due to
the fact that the 5th axis (A1) is not used, MD 20070: AXCONF_MACHAX_USED[4]=0
must be parameterized. This will remove the axis from the configuration of the NC.

9.8.5 Default settings of the axis machine data for feed axes

The following machine data list summarizes all default data or their recommended settings
with SINAMICS S120 drives connected.
Once they have been set, the axes are ready to traverse, and only a fine adjustment (refe-
rence point approach, software limit switches, position controller optimization, speed feedfor-
ward control, lead error compensation,...) must be performed.

Note to the reader


/FB/ SINUMERIK 802D sl “Description of Functions”

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9.8 Configuring SINAMICS S120 with 802D sl

Note
For feed axes, only parameter set 1 = index [0] is used. Index [1] ... [5] must only be
parameterized when using the “Switch set of parameters” function (see /FB/ Chapter 3),
G331 “Rigid tapping” or G33 (see /FB/ Chapter 11). In this section, the values must only be
entered in index [0].

MD Name Default Unit Remark


value
31030 LEADSCREW_PITCH 10 mm Leadscrew of the ballscrew

Load gear transmission ratio


31050 DRIVE_AX_RATIO_DENOM 1 Revolutions of the ballscrew
31060 DRIVE_AX_RATIO_NUMERA 1 Motor revolutions
32000 MAX_AX_VELO 10000 mm/min Maximum axis velocity

32300 MAX_AX_ACCEL 1 m/s2 Maximum axis acceleration

34200 ENC_REFP_MODE 1 1: Incremental encoder


Motor order no: 1Fx6xxx-xxxxx-xAxx
0: EnDat encoder
Motor order no: 1Fx6xxx-xxxxx-xExx

36200 AX_VELO_LIMIT 11500 mm/min Threshold value for velocity monitoring;


setting rule:
MD 36200 = 1.15 x MD 32000

Example:
Motor with incremental encoder
Gearbox transmission ratio: 1:2
Spindle lead 5 mm
Max. axis velocity 12 m/min
Max. axis acceleration 1.5 m/s2
Machine data settings:
MD 31030 = 5
MD 31050 = 1
MD 31060 = 2
MD 32000 = 12000
MD 32300 = 1.5
MD 36200 = 13800

The axis can now be traversed. The direction of movement can be reversed using
MD 32100: AX_MOTION_DIR = 1 or –1 (without influencing the control direction of the
position control).

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9.8 Configuring SINAMICS S120 with 802D sl

9.8.6 Default settings of the axis machine data for the spindle

With SINUMERIK 802D sl, the spindle is a subfunction of the entire axis functionality. The
machine data of the spindle are therefore to be found amongst the axis machine data
(MD 35xxx).
For this reason, data must also be entered for a spindle; this data has already been
described in conjunction with the start-up of feed axes.
The following variants are offered for the spindle drive:
S digital spindle drive (PROFIBUS) with spindle actual-value encoder integrated into the
motor
S analog spindle drive with directly mounted spindle actual-value encoder
S analog spindle drive with directly mounted spindle actual-value encoder

Note
For spindles without gearstage switching, only gear stage 1 = index [1] is taken into account;
index [2] ... [5] must only be parameterized when using the “Switch gearstage” function (see
/FB/ Chapter 5).

Table 9-8

MD Name Default Unit Remark


value
30200 NUM_ENCS 1 0: spindle without speed actual-va-
lue encoder (AM mode = operation
without encoder)

1: spindle with speed actual-value


encoder integrated into the motor
(1PH7 motor)

Load gear transmission ratio


31050 DRIVE_AX_RATIO_DENOM[1] 1 Load revolutions
DRIVE_AX_RATIO_NUMERA[1]
31060 1 Motor revolutions

35100 SPIND_VELO_LIMIT 10000 r.p.m. Maximum spindle speed

35130 GEAR_STEP_MAX_VELO_LIMIT[1] 500 r.p.m. Max. speed in gear stage 1

35200 GEAR_STEP_SPEEDCTRL_AC- 30 rev/s2 Acceleration in the speed controlled


CEL[1] mode

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9.8 Configuring SINAMICS S120 with 802D sl

Digital spindle drive with spindle actual-value encoder integrated into the motor
Parameterize the machine data listed in Table 9-8.
Example:

Motor with incremental encoder


Gearbox transmission ratio: 1:2
Max. spindle speed 9,000 r.p.m.
Max. spindle acceleration 60 rev./s2

Machine data settings:


MD 31030 = 5
MD 31050 = 1
MD 31060 = 2
MD 35130 = 9000
MD 35200 = 60
MD 36200 = 9900

For the spindle, it can be necessary to adapt the following additional machine data.

Table 9-9 Additional machine data

MD Name Default Unit Recommendation/remark


value
34000 REFP_CAM_IS_ACTIVE 1 0: without reference point cam

34060 REFP_MAX_MARKER_DIST 20 degrees 720_ = two spindle revolutions

34110 REFP_CYCLE_NR 1 ... 5 0: The spindle is not involved in chan-


nel-specific referencing.

35300 SPIND_POSCTRL_VELO 500 r.p.m.

36000 STOP_LIMIT_COARSE 0,04 degrees 0,4

36010 STOP_LIMIT_FINE 0,01 degrees 0,1

36030 STANDSTILL_POS_TOL 0,2 degrees 1

36060 STANDSTILL_VELO_TOL 0,0139 r.p.m. 1 (interface signal “Axis/spindle


stopped” V390x 0001.4)

36400 CONTOUR_TOL 1 degrees 3

Digital spindle drive with directly mounted spindle actual-value encoder


The operation of a second measuring system requires changes in the message frame type.
To this end, load a reloadable SDB from the toolbox, which allows message frame type 103
for the appropriate drives.
In SINAMICS_I, the message frame type must also be set in P922 = 103.
For the actual-value assignment, the following machine data must be set:

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9.8 Configuring SINAMICS S120 with 802D sl

Table 9-10 Machine data to be set

MD Name Value Recommendation/remark


13060 DRIVE_TELEGRAM_TYPE[0–5] 103

30220 ENC_MODULE_NR[0] 3 Here you must enter a module number to which the
measuring system is connected for the second
measuring system (e.g. “3”).

30230 ENC_INPUT_NR[0] 2 DRIVE-QLIQ_slot on the module to which the second


measuring system has been connected

32110 SENC_FEEDBACK_POL[0] –1 If necessary, swap the counting direction

Machine data example for 3 axes for milling with analog spindle
Output of an analog setpoint for a spindle drive for connecting a third-party converter (e. g.
MICROMASTER). With software release 01.01., connection is possible via the MCPA
module.
ALM; 1-axis module; 1-axis module; 1-axis module

Table 9-11 Machine data for the example

MD Name X Y Z SP Remark
30100 CTRLOUT_SEGMENT_NR 5 5 5 0 local bus segment for analog

30110 CTRLOUT_MODULE_NR 2 3 1 1 Module order

30120 CTRLOUT_NR 1 1 1 1 Setpoint output on drive module/module

30130 CTRLOUT_TYPE 1 1 1 1 Setpoint output type

30134 IS_UNIPOLAR_OUTPUT 0 0 0 0 Setpoint output is unipolar

30200 NUM_ENCS 1 1 1 1 Number of encoders

30220 ENC_MODULE_NR 2 3 1 3 Transport module (the SMC30 module is to be


connected to the axis module of the Y axis

30230 ENC_INPUT_NR 1 1 1 2 Input on the drive module (X202)

30240 ENC_TYPE 4 1 1 1 Encoder type

32250 RATED_OUTVAL (spindle) 80 Rated output voltage 8 V at Umax/min

32260 RATED_VELO (spindle) 3200 Rated motor speed at 8 V

To be able to transfer the encoder actual value, an SDB must be reloaded which reflects the
hardware configuration (see Toolbox 802D_SL\V0100xx00\Special\DMSforSpindle).
Thereafter, set the following machine data:

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9.8 Configuring SINAMICS S120 with 802D sl

Table 9-12 Additional machine data

MD Name Default Recommendation/remark


value
11240[2] PROFIBUS_SDB_NUMBER 0

13060[2] DRIVE_TELEGRAM_TYPE 103 Standard message frame type for


PROFIBUS DP

If the transport module is the 3rd axis (example: Y)

Connecting an analog spindle without spindle actual-value encoder


For an analog spindle without encoder, the same machine data apply as for an analog
spindle with directly mounted encoder, but MD 30240 must be set to zero.
If an analog spindle without measuring system is used, no reloadable SDB is required.

Unipolar spindle for SINUMERIK 802D sl


MD 30134 = 1 Unidirectional D/A value type “1”
MD 32100 = 1 Positive assignment, no inversion
MD 32100 = –1 Positive assignment, inversion

Machine data Direction of Voltage Setpoint VB38020004


spindle rotation display

30134 = 1 32100 = 1 Spindle CW >0 – Bit 6 = 1

Spindle CCW >0 + Bit 7 = 1

30134 = 1 32100 = –1 Spindle CW >0 – Bit 6 = 1

Spindle CCW >0 + Bit 7 = 1

MD 30134 = 2 Unidirectional D/A value type “2”


MD 32100 = 1 Positive assignment, no inversion
MD 32100 = –1 Positive assignment, inversion

Machine data Direction of Voltage Setpoint VB38020004


spindle rotation display

30134 = 2 32100 = 1 Spindle CW >0 – Bit 6 = 1

Spindle CCW >0 + Bit 7 = 1

30134 = 2 32100 = –1 Spindle CW >0 – Bit 6 = 1

Spindle CCW >0 + Bit 7 = 1

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9.9 STARTER start-up tool

9.9 STARTER start-up tool


To launch the STARTER program, click the STARTER icon or choose Start > Programs >
STARTER > STARTER from the Windows Start menu.

Note
The screenforms of the STARTER tool, version V3.2, are shown in the following. If your
particular version deviates from the version used here, your screenforms may deviate
slightly from those shown here.

9.9.1 Explanations regarding the STARTER user interface

To create the sample project, you can use STARTER (see Fig. 9-9). To perform the indivi-
dual configurations, use the user interface areas listed below:
S Project navigator: This area displays the elements and objects you will insert into the
project.
S Working area: Use this area to perform your task for creating the project:
– When configuring the drive, this area is assigned the wizard useful for configuring the
drive objects.
– If you configure, for example, the parameters for the speed setpoint filter.
– If you switch to the Expert list, a list of all parameters is displayed which you can view
or change.
S Detailed view: This area provides detailed information, for example, on faults and
warnings.

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9.9 STARTER start-up tool

Project navigator: displays the elements


and objects for the STARTER project.

Working area:
S Displays the wizard for configuring
the drive objects
S Displays, for example, the
parameters of the speed setpoint
filter

Detailed view: Displays specific information, for


example, faults

Fig. 9-9 The different areas of the STARTER user interface

9.9.2 Operating philosophy of the STARTER commissioning tool for


SINAMICS S120

When creating a drive unit for a SINAMICS S120 system, the following operating philosophy
is assumed:
The tool is used to configure objects (e.g. infeed). The name of the objects can be freely
selected.
A drive unit in the terms of the STARTER commissioning tool is always a control unit and the
appropriate drives.
With controlled incoming supply, the Active Line Module is configured in STARTER. A con-
trolled incoming supply is not configured in STARTER.
The appropriate drive consists, for example, of a motor (power section) and of a motor with
encoder.
Fig. 9-10 shows the STARTER project navigator. You can see that a project (Project_Philo-
sophy) and a drive unit (Drive_Unit_One_Motor) have been configured for a drive.

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9.9 STARTER start-up tool

Fig. 9-10 Drive unit with one motor

If you want to create a second drive unit, in this case, for two motors, the drive unit will also
consist of a control unit and an Active Line Module (incoming supply), but this time of two
drives.
Fig. 9-11 shows the STARTER project navigator. In the same project (Project_Philosophy),
a second drive unit (Device_Unit_Two_Motors), which is designed for two drives, has been
configured.

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9.9 STARTER start-up tool

Fig. 9-11 Drive unit with two motors

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9.10 Start-up sequence when working with STARTER

9.10 Start-up sequence when working with STARTER


STARTER provides two alternative procedures for creating a drive object:
S OFFLINE, where you can create and parameterize your drive unit configuration using a
wizard;
S ONLINE, where you load an existing configuration and parameterization of a drive unit
into STARTER using the wizard.
If you have created or loaded a project in STARTER, you can operate the drive using the
control panel of STARTER.

9.10.1 Creating a drive object OFFLINE

The following steps are required to create a drive object OFFLINE:

Table 9-13 OFFLINE

Step Procedure Section


1 Start the STARTER commissioning tool and use the STARTER project 10.1.1
Wizard to create a new project.
2 Set up the PPI interface. 10.1.1
3 Insert the drive unit. 10.1.1
4 Use the Wizard to configure the drive unit with, for example, the infeed, 10.1.2
drive properties, drive with power section, motor, encoder, and so on.
5 Save your project. 10.1.2
6 Continue with “Operating the STARTER control panel (motor rotating)”. 10.2

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9.10 Start-up sequence when working with STARTER

9.10.2 Operating the STARTER control panel (motor rotating)

The following steps are required to operate the control panel of STARTER so that the motor
rotates:

Table 9-14 Motor rotates

Step Procedure Section


1 Open the project. 10.2.1
2 Establish a connection to the target system. 10.2.1
Switch to ONLINE mode.
3 Load the project into the drive unit. When doing so, observe the LEDs on the 10.2.1
control unit; these indicate when the project has been loaded completely.
4 Save the parameters in the drive unit with RAM to ROM. 10.2.1
5 Operate the STARTER control panel; the motor will rotate. 10.2.2

9.10.3 Creating a drive project ONLINE (recommended)

The following steps are required to create a drive object ONLINE:

Table 9-15 ONLINE

Step Procedure Section


1 Start the STARTER commissioning tool. 10.3.1
2 Create a new project. 10.3.1
3 Set up the PROFIBUS interface. 10.3.1
4 Search ONLINE for the stations (drive units) which can be reached. 10.3.1
The drive project will be inserted into the project.
5 Configure and acquire the topology and configuration of the drive unit 10.3.2
automatically.
6 Configure the motor and check the acquired topology. 10.3.3
7 Save your project. 10.3.3
8 Continue with “Operating the STARTER control panel (motor rotating)”. 10.2

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9.11 Diagnosis via STARTER

9.11 Diagnosis via STARTER

Description
The diagnostic functions support commissioning and service personnel during commissio-
ning, troubleshooting, diagnostics and service activities.

General
Prerequisites: STARTER is in the online mode.
STARTER provides the following diagnostic functions:
S PROFIBUS diagnostic buffer
The message output window shows the states of the control/status words, parameters
and drive enable signals for the selected drive/device.
S Fault/alarm display in the alarms output window
Faults and warnings can be displayed either for one or for several drives/units. The fault/
alarm description is called up by selecting “Help –> Context” or by pressing the SHIFT
+ F1 keys.
S Diagnostic overview
An overview table of all drives existing in the project is displayed.
– Device: The existing devices and drives are displayed with their names; the device
status is displayed in the “Device diagnosis” window.
– Operating status: The operating status (e.g. OFFLINE, ONLINE, STARTUP, STOP,
STOP U, RUN) of the device or of the drive is displayed; it can be controlled via the
mode selector switch.
S Signals specified from the function generator (see Section 9.11.1)
S Signal recording using the Trace function (see Section 9.11.2)
S Analysis of the control behavior using the measuring function (see Section 9.11.3)
S Output of voltage signals for external measuring instruments via measuring sockets (see
Section 9.11.4)

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9.11 Diagnosis via STARTER

9.11.1 Function generator

Description
The function generator can be used, for example, to perform the following tasks:
S for measuring and optimizing closed-loop control circuits;
S for comparing the dynamic properties of coupled drives;
S for specifying a straightforward traversing profile without traversing program.
The function generator can be used to generate various signal forms.
The output signal can be supplied to the closed-loop control circuit via the BICO circuit in the
“Connector output” mode.
In the Servo mode, this setpoint can additionally be supplied into the control structure in
accordance with the currently selected mode, for example, as a current setpoint, disturbing
torque or speed setpoint. Any influence of overlaid closed-loop control circuits is suppressed
automatically.

Parameterizing and operating the function generator


The function generator is parameterized and operated via the STARTER parameterization
and commissioning tool.

Fig. 9-12 The “Function generator” start screen

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9.11 Diagnosis via STARTER

Note
Please refer to the online help for more information about parameterizing and using the
measuring sockets.

Features
S It is possible to switch to several drives simultaneously.
S The following signal forms can be freely parameterized:
– square wave
– staircase
– triangle
– PRBS (pseudo random binary signal, “white noise”)
– sinusoidal
S An offset is possible for each signal. The power-up to the offset can be parameterized.
The signal generation starts after the power-up for the offset.
S Restriction of the output signal to the minimum and maximum value settable.
S Operating modes of the function generator for servo and vector only
– Connector output
S Operating modes of the function generator for servo only
– Current setpoint downstream of the filter (current setpoint filter)
– Disturbing torque (downstream of the current setpoint filter)
– Speed setpoint downstream of the filter (speed setpoint filter)
– Current setpoint upstream of the filter (current setpoint filter)
– Speed setpoint upstream of the filter (speed setpoint filter)

Switching points of the function generator

Speed setpoint Speed setpoint Current setpoint Current setpoint


upstream of the filter downstream of the filter upstream of the filter downstream of the filter

Setpoint Speed Setpoint Current Controlled


filter controller filter controller system
from
– –
interpolator
Disturbing torque

funk_gen_ueber.vsd

Fig. 9-13 Switching points of the function generator

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9.11 Diagnosis via STARTER

Further signal forms


Further signal forms can be produced by parameterization.
Example:
The “triangular” signal shape can be parameterized with “upper limitation” to produce a
triangle with no peak.

Signal form Upper


“Triangular” limiting

Fig. 9-14 “Triangular” signal without peak

Starting/stopping the function generator

Caution
! With the corresponding ramp-function generator parameter settings (e.g. offset), the motor
can “drift” and travel to its end stop.
The motion of the drive is not monitored with the function generator activated.

To start the function generator, proceed as follows:


1. Provide for the prerequisites for starting the function generator.
– Activate the control panel.
Drives –> Drive_x –> Commissioning –> Control board
– Turn on the drive.
Control board –> Issue enable signals –> Switch on
2. Select the appropriate operating mode,
e.g. speed setpoint downstream of the filter.
3. Select the drive (as the control panel).
4. Set the signal form,
e.g. rectangle.
5. Load the settings to the target system (“Download parameters” pushbutton)
6. Start the ramp-function generator (“Start FctGen” pushbutton)
To stop the function generator, proceed as follows:
“Stop FctGen” pushbutton

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9.11 Diagnosis via STARTER

Parameterization
The “function generator” parameter screen is selected via the following icon in the toolbar of
the STARTER commissioning tool:

Fig. 9-15 STARTER icon for “trace function/ramp-function generator”

9.11.2 Trace function

Description
The trace function can be used to acquire measuring values over a specified period,
depending on the trigger conditions.

Parameterizing and operating the trace function


The trace function is parameterized and operated via the STARTER parameterization and
commissioning tool.

Fig. 9-16 The “Trace function” start screen

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9.11 Diagnosis via STARTER

Note
Please refer to the online help for more information about parameterizing and using the
measuring sockets.

Features
S Four recording channels per recorder
S Two independent trace recorders per control unit
S Triggering
– Without triggering (recording immediately after start)
– Triggering either to signal with edge or to level
– Trigger delay and pretrigger possible
S STARTER parameterization and commissioning tool
– Automatic or settable scaling of the display axes
– Signal measurement via cursor
S Settable trace cycle: integers of the base sample time

Parameterization
The “trace function” parameter screen is selected via the following icon in the toolbar of the
STARTER commissioning tool:

Fig. 9-17 STARTER icon for “trace function/ramp-function generator”

9.11.3 Measuring function (SERVO) (available soon)

Note
This functionality is available soon.

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9.11 Diagnosis via STARTER

Description
The measuring function serves to optimize the controller of the drive. The measuring func-
tion can also be used to eliminate specifically the influence of overlaid closed-loop control
circuits by simple parameterization and to analyze the dynamic properties of individual
drives. To this end, function generator and trace are coupled with each other. The control
loop is supplied with the ramp-function generator signal at a given point (e.g. speed setpoint)
and recorded by the trace function at another (e.g. speed actual value). The parameteriza-
tion of a measuring function automatically also parameterizes the trace. Certain operating
modes have already been predefined for the trace, which can be used here.

Parameterizing and operating the measuring function


The measuring function is parameterized and operated via the STARTER parameterization
and commissioning tool.

Fig. 9-18 “Measuring function” initial screen

Note
Please refer to the online help for more information about parameterizing and using the
measuring sockets.

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9.11 Diagnosis via STARTER

Features
S Measuring functions
– Current controller setpoint step change (downstream of the current setpoint filter)
– Speed controller reference frequency response (downstream of the current setpoint
filter)
– Speed controller setpoint step change (downstream of the speed setpoint filter)
– Speed controller disturbance variable step change (fault downstream of the current
setpoint filter)
– Speed controller reference frequency response (downstream of the speed setpoint
filter)
– Speed controller reference frequency response (upstream of the speed setpoint filter)
– Speed controller interference frequency response (fault downstream of the current
setpoint filter)
– Speed-controlled system (excitation downstream of the current setpoint filter)

Starting / stopping the measuring function

Caution
! With the corresponding measuring function parameter settings (e.g. offset), the motor can
“drift” and travel to its end stop.
The motion of the drive is not monitored with the measuring function activated.

To start the function generator, proceed as follows:


1. Provide for the prerequisites for starting the measuring function.
– Activate the control panel.
Drives –> Drive_x –> Commissioning –> Control board
– Turn on the drive.
Control board –> Issue enable signals –> Switch on
2. Select the drive (as the control panel).
3. Set the measuring function,
e.g. current controller setpoint step change.
4. Load the settings to the target system (“Download parameters” pushbutton)
5. Start the measuring function (“Start Measuring Function” pushbutton)
To stop the function generator, proceed as follows:
“Stop Measuring Function” pushbutton

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9.11 Diagnosis via STARTER

Parameterization
The “measuring function” parameter screen is selected via the following icon in the toolbar of
the STARTER commissioning tool:

Fig. 9-19 STARTER icon for “measuring function”

9.11.4 Measuring sockets (available soon)

Note
This functionality is available soon.

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9.12 Completing the start-up

9.12 Completing the start-up


After the start-up by the machine manufacturer has been completed, it is recommended to
carry out a data backup prior to delivery to the end customer:
1. Performing an internal data backup (at least protection level 3 required):
– Select the Save data softkey in the System operating area.
– To save the drive mmachine data, set parameter p977=1 in the CU (SINAMICS_I).
2. Resetting the access level:
– Select the Delete passw. softkey.

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9.13 Service display of the axis drive behavior

9.13 Service display of the axis drive behavior

Servo trace
For axis service, the SERVO trace function has been implemented in the “Diagnostic” menu
to represent axis signals graphically.
The trace function is selected in the System\Service display\SERVO Trace operating area.

Note to the reader


/BH/ SINUMERIK 802D sl “Operation and Programming”, Chapter 7

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9.13 Service display of the axis drive behavior

Notes

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Creating a Drive Project 10
10.1 Creating a drive project OFFLINE

10.1.1 Creating a project

Creating a project
The first step is to create a new project for your example:
1. Click the STARTER icon or choose Start > Program > STARTER > STARTER from the
Windows Start menu to run the STARTER commissioning tool.
When the software is started for the first time, the main screen (see Fig. 10-1) appears
with the following dialog boxes:
– “STARTER Project Wizard”
– “STARTER Getting Started Commissioning Drive”

You can call up the Project


Wizard by choosing
Project > New with wizard.
If you deactivate this field,
the Project Wizard will not
appear any more when the
STARTER is started next
time.

Fig. 10-1 Main screen of the STARTER parameterization and commissioning tool

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Creating a Drive Project
10.1 Creating a drive project OFFLINE

Note
If you deactivate the “Display wizard during start” field, the Project Wizard is not displayed
when you next start STARTER.
You can call up the Project Wizard by choosing Project > New with wizard.

Note
To deactivate the online help for “Getting started”, follow the instructions provided in Help.
You can call up the online help at any time by choosing “Help –> Getting started”.
STARTER features a detailed online help function.

2. Close the online help and follow the instructions provided by the Project Wizard
STARTER.
3. Select the Configure drive units offline button, as shown in Fig. 10-2.

Fig. 10-2 Project Wizard Starter

The wizard will guide you when creating a new project.


4. Enter the project name and, if required, a comment (see Fig. 10-3).

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10.1 Creating a drive project OFFLINE

Fig. 10-3 Creating a new project

5. Click Continue > to set up a PPI interface in the PC/PG.

Fig. 10-4 Setting up the interface

6. In this example, you need a PPI interface in the PC/PG. Choose Change and test....

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10.1 Creating a drive project OFFLINE

Fig. 10-5 Setting up the PG/PC interface: Properties

7. The system has determined all possible interfaces on your PC (e.g. Serial Cable (PPI)).
Select an interface via the Interface parameterization used list box; thereafter, click on
the Properties button and adapt the baud rate to the settings in the 802D sl
(default: 115.2 kbit/s).
Alternative: The connection can be established via the TCP/IP protocol. To this end,
connect the PC/PG to the CU directly using a X Crosslink patch cable or a standard
patch cable via the corporate LAN.
The following additional steps of operation are required here:
– Use the mouse to select the drive unit in the Project Navigator.
– Open the selection menu by clicking on the right mouse button.
– Use “Target device online access” to load data into the interactive dialog box which is
now displayed (see Fig. 10-6).
Slot 25 and the IP address do not comply with the default configuration.
In corporate networks, the IP address assigned by the administrator must be entered;
with direct connection, the SINAMICS is assigned the fixed IP address 169.254.11.22
in 802D.
When establishing a connection via Crosslink, the IP address of the PC/PG
(169.254.11.23) must be entered in the user-defined, alternative configuration
(see Fig. 10-8).
– For corporate networks with DHCP server, the password for protection level 1 must be
entered via HMI. Use System > Service display > Service control system >
Service network to change the DHCP entry to yes.

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10.1 Creating a drive project OFFLINE

169.254.11.22

Fig. 10-6 Features of SINAMICS

Fig. 10-7 Connection properties

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Creating a Drive Project
10.1 Creating a drive project OFFLINE

169.254. 11. 23
255.255. 0 . 0

Fig. 10-8 Alternative configuration

8. Add the following (see Fig. 10-9):


– a new drive unit with the name Machine Tool V1_2,
– a device: SINAMICS
– a type in 802D
– version V2.2 and
– bus address 5 with PPI (with TCP/IP, the bus address can be freely selected).
To add the components and data listed above, use the relevant list boxes for selection
and click on Insert button.

Note
Section 10.1.2 shows you how to configure the drive unit and its components.

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10.1 Creating a drive project OFFLINE

Fig. 10-9 Inserting the drive unit

Note
To insert other drives in the project, choose Insert.

The first time you choose Insert, the system displays a tutorial featuring an introduction
to the SINAMICS S120 drive unit (see Fig. 10-10).

Fig. 10-10 Introduction

9. Work your way through the introduction by choosing >, or exit by choosing X.

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Creating a Drive Project
10.1 Creating a drive project OFFLINE

Note
To call up this tutorial, choose Sinamics tutorial.

Once you have inserted the drive unit, the Preview window shows you how the comple-
ted project will appear in the STARTER project navigator (see Fig. 10-11).

Fig. 10-11 “Machine Tool V1_2” preview

10.Click Continue >.

Fig. 10-12 Summary

11. To complete the process of creating a new project for a drive unit, choose Complete.

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10.1 Creating a drive project OFFLINE

As shown in Fig. 10-13 below, the Project Wizard has created the Machine Tool V1_2
project and SINAMICS_In802D drive unit with a Control_Unit on board in the project
navigator.

Fig. 10-13 The STARTER “Machine Tool V1_2” project navigator

10.1.2 Configuring a drive unit

The following components are required in the example to configure a drive unit:
S Active Line Module
S Motor module
S Synchronous motor (e.g. 1FK6) with encoder for the servo control variant
S Asynchronous motor (e.g. 1PH7) with encoder for the servo control variant
To compile the components for the drive unit, proceed as follows:
1. In the project navigator, open the SINAMICS_In 802D directory and double-click the
Configure drive unit element (see Fig. 10-13).
As you can see in Fig. 10-14, the STARTER opens a wizard for configuring the drive unit
components.

Note
The graphical representation corresponds to the SINAMICS CU 320, there is no special
illustration for the CU 320 integrated into the 802D sl.

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Fig. 10-14 Configuration – SINAMICS CU320 option board

2. You will not use an option board in your example.


Confirm the default setting No option board by choosing Continue > to carry out the
next configuration step.

Fig. 10-15 Configuration – Introduction to SINAMICS CU320

3. In this example, you are using a controlled SINAMICS infeed with DRIVE-CLiQ
connection, an Active Line Module. Confirm the default setting Yes by choosing
Continue >.

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Note
If you are using an uncontrolled SINAMICS infeed, click No and then Continue >.

Fig. 10-16 SINAMICS_CU320 configuration for the Active Line Module

4. First choose the appropriate Active Line Module from the Selection listbox according to
type (order no.) (see rating plate), assign a name (Supply_1), and click the Line filter
available field.
5. Click Continue > to select further data for the Active Line Module (infeed)
(see Fig. 10-17).

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Fig. 10-17 Incoming supply: further data

6. Adapt the supply voltage and rated line frequency for the device accordingly. Click
Continue >.

Fig. 10-18 SINAMICS_CU320 configuration – PROFIBUS process data exchange (incoming supply)

7. For the supply in your example, you want to program a free message frame configuration
with BICO interconnection. Confirm the default setting Free telegram configuration
with BICO by choosing Continue >.

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Fig. 10-19 SINAMICS_CU320 configuration – Introduction to the drive

8. You now want to create a drive with a motor module (power section), motor, and encoder
for this example. Confirm the default setting Yes by choosing Continue >.

Select Servo.

Fig. 10-20 Drive properties

9. The “Drive properties” dialog box (see Fig. 10-20) provides general information about the
drive.
10.Choose Servo from the “Type of operation” listbox.
11. Assign a name for the first drive, Drive_1, and enter some general comments. Click
Continue >.

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Fig. 10-21 Control structure

12.Choose the “Control type” as shown in Fig. 10-21 (the default setting can be left as it is)
and click Continue >.

Fig. 10-22 Configuring the motor module

13.Select the appropriate motor module from the Motor module selection list box accor-
ding to type (order no.) (see rating plate) and assign a name (Power unit).

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14.Click Continue >.


15.Select the motor type, e.g.:
– 1FK6 synchronous motor
– 1PH7 asynchronous motor
16.Select the appropriate motor from the Motor selection list box according to type
(order no.) (see rating plate) and assign a name (Drive_1_Motor).
17.Click Continue > to select the motor holding brake (see Fig. 10-23).

Synchronous Asynchronous
motor motor

18. Choose “Without holding


brake”.

Fig. 10-23 Configuring the motor

18.Choose Without holding brake and click Continue > to select the encoder fitted to the
motor (see Fig. 10-24).

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Synchronous Asynchronous
motor motor

Fig. 10-24 Configuring the encoder

19.Select the appropriate encoder from the Motor encoder selection list box according to
type (order no.) (see rating plate on the motor).
20.Click Continue > to choose the control mode/setpoints (see Fig. 10-25).

Synchronous Asynchronous
motor motor

Select Siemens message frame 102.

Fig. 10-25 Control mode/setpoints

21.For your example with the drives, you want to select the Siemens message frame 102.
Select the message frame and click Continue >.
Alternatively, you can select the Siemens message frame 103 if the axis possesses a
direct measuring system. In the topology tree, this encoder must be assigned an axis.

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Fig. 10-26 Summary

22.Check the summary and confirm it by choosing Complete.


As you can see in Fig. 10-27, the configuration wizard has created the objects (including
Drive_1) for drive unit SINAMICS_In_802D in the project navigator.

Fig. 10-27 Project navigator with SINAMICS_In_802D

23.Save the project Machine Tool V1_2 using the Project > Save menu.
Once you have configured the drive unit with STARTER in OFFLINE mode, proceed with the
steps described in Chapter 10.2 “Starting the Drive Project (“Motor rotates)”. You will set the
parameters of the interface with the drive and rotate the motor.

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10.2 Operating the control panel in STARTER (with the motor rotating)

10.2 Operating the control panel in STARTER (with the motor rotating)
This chapter shows you how to start the motor using the control panel function in the
STARTER commissioning tool. These steps include:
S Load the project into the drive unit.
S Operate the control panel.

Prerequisites
The following prerequisites must be fulfilled to operate the control panel in STARTER:
S The components as described above are assembled.
S The drive unit is turned on as prescribed.
S You have established a connection from the serial PPI interface of the control unit to a
PC/PG with PPI interface.
S A project has been created using the STARTER commissioning tool.

10.2.1 Loading the project into the drive unit

Loading the project into the drive unit


To load the project into the drive unit, proceed as follows:
1. If you have not yet created the project “Machine Tool V1_2” (created in Section 10.1.1)
in STARTER, open the project using the Project > Open menu.
2. To use the “control panel” function, you have to switch to ONLINE mode. To switch to
the ONLINE mode, click the function key Connect to target system (as shown in
Fig. 10-28).

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10.2 Operating the control panel in STARTER (with the motor rotating)

2. Click on the function key


Connect to target system

Fig. 10-28 Project navigator with SINAMICS_In_802D

3. An ONLINE connection will be established, and an ONLINE/OFFLINE comparison will


take place. If any differences are found, these are displayed (see illustration below).

Fig. 10-29 ONLINE/OFFLINE comparison, loading into target system

4. You have changed the data OFFLINE; upload now these data into the target device. Click
the following menu items one after the other:
– Click <–– Load to target system in the “ONLINE/OFFLINE comparison” dialog box.
– When the system asks “Are you sure?”, click Yes. The system now starts loading the
data.
– When the system informs you that the data was successfully loaded to the target
system, click OK.
– Click OK for “Load from RAM to ROM”.

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10.2 Operating the control panel in STARTER (with the motor rotating)

5. Differences were detected during the ONLINE/OFFLINE comparison again. Click Load
to PG ––> (see screenshot below).

Fig. 10-30 ONLINE/OFFLINE comparison, loading into PG

6. You will load the newly created data from the drive unit into the PG. Click the following
menu items one after the other:
– When the system asks “Are you sure?”, click Yes. The system now starts loading the
data.
– When the system informs you that the data was successfully loaded into the PG, click
OK.
7. No further discrepancies are displayed in the ONLINE/OFFLINE comparison dialog box.
Click Close (see screenshot below).

Fig. 10-31 ONLINE/OFFLINE comparison, closing

Note
When loading, observe the LEDs on the control unit. The control unit is ready for operation
when the LED RDY is continuously lit (green).

The hardware configuration of the drive unit is completed. To operate the control panel in
STARTER, proceed as follows:

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10.2.2 Operating the control panel

After you have established the connection to the target system and uploaded the project, a
green connector symbol is displayed in the Project Navigator in front of the drive unit and the
other components configured. This indicates that the project data in STARTER and the tar-
get system is consistent (see Fig. 10-32).
The drive unit is now ready to operate.
The following steps are required to operate the control panel in the STARTER commissio-
ning tool such so that the motor rotates:

Green plug icon.

Double-click Control panel in the


project navigator.

Fig. 10-32 Control panel

1. Double-click Control panel in the project navigator under Drive_1 > Commissioning
(see Fig. 10-32).
The control panel is displayed in STARTER (see Fig. 10-33). You can use the control
panel to control the drive directly from the PC/PG.

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10.2 Operating the control panel in STARTER (with the motor rotating)

Click Assume control priority.

Fig. 10-33 Assuming control priority

2. Click Assume control priority to connect the control panel to the drive interface.
Note the message that is then displayed in the Control priority dialog screen. This note
is very important! (see also Fig. 10-34).

Danger
! Be cautious when using control priority!
This function is intended exclusively for start-up and diagnosis or within the framework of
maintenance work.
Make sure that the drive is in the “OFF” status and that no ON/OFF1 command has been
issued either by the control word for sequence control or another signal source (e.g. BICO
interconnection).
Once control priority has been transferred to the PC, the BICO interconnections on bit 1 to
bit 6 of the control word are no longer active.

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You can use the default monitoring time


(e.g. 3000 ms).

To continue with commissioning, choose


OK.

Fig. 10-34 Passing on the control priority to the PC

You can enter an application monitoring. This is the time that may pass between two set-
points until the sign-of-life monitoring of the drive responses (error 1910).
You can use the default monitoring time (e.g. 3000 ms).
3. Since our example concerns commissioning, confirm this dialog box for assuming control
priority by choosing OK.

Click
Display/hide diagnostics view.

Status “lamps” for the control word bits.

Fig. 10-35 Diagnostics view

4. To display, amongst other things, the status lamps for the control word bits, click Display/
hide diagnostics view.
Table 4-14 lists the most important digital input signals of the control word for sequence
control, which are required to set a motor to motion and which are issued via the control
panel for the control unit (CU320 in 802D).

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10.2 Operating the control panel in STARTER (with the motor rotating)

Table 10-1 Control word for the sequence control

Signal (control PROFIdrive Meaning


panel) bit no. in CTW
sequence control
ON/OFF1 Bit 0 0 = OFF (OFF1), stop via ramp-function generator, followed by pulse
block
1 = ON, service condition
ON/OFF2 Bit 1 0 = Coast down (OFF2), pulse block, motor coasts to standstill
1 = Do not coast down, operating condition
ON/OFF3 Bit 2 0 = Rapid stop (OFF3)
1 = No rapid stop, service condition
Pulse enable Bit 3 0 = Disable operation, pulse suppression
1 = Enable operation, enable pulses
Enable ramp- Bit 4 0 = Set ramp-function generator to 0
function gene- 1 = Enable ramp-function generator
rator
Start/stop Bit 5 0 = Freeze ramp-function generator, retain current output value
ramp-function 1 = Re-enable ramp-function generator; will follow the input value
generator
Setpoint Bit 6 1 = Enable setpoint
enable 0 = Inhibit setpoint and set to 0

Click the
Enables field.

Fig. 10-36 Enables

5. As shown in Fig. 10-36, click the Enables field to set the commands for enabling the
control words in the drive system.

Click
Infeed control priority.

Fig. 10-37 Incoming supply control priority

6. Click Infeed control priority. The supply (Active Line Module) is turned on.
7. Before starting the motor by choosing Motor on (see Fig. 10-38), you have to make the
following settings:

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– Enter a speed setpoint (e.g. 50 revolutions per minute).


– Use the cursor to highlight the slide controller for the setpoint in %. Position your cur-
sor on the slider, hold down the left mouse button, and set the speed to 0%.

Danger
! During the start-up, observe the traversing ranges of the machine, or take appropriate
external measures, such as a limit switch monitoring.

8. Drive ON button
Speed setpoint: 50
Percentage to 0%

Fig. 10-38 Control panel prior to “Drive on”

8. Click the Drive on button. The ON/OFF1 “enable” command is set and displayed on the
control panel (see Fig. 10-39).

9.Increase the speed slowly


from 0 to 100%.
ON/OFF1 “enable”
command set.

10. Drive OFF


button

Fig. 10-39 The motor starts to rotate

9. Move the slider for the speed slowly from 0 to 100% (see Fig. 10-39).
The motor is rotating.
10.When you click Stop, the motor stops. You can also trigger a fast stop by pressing the
space bar.
In the following steps, reset the master controls to disconnect the drive:
– Supply
– Control unit

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10.2 Operating the control panel in STARTER (with the motor rotating)

Click
Infeed control priority.

Fig. 10-40 Incoming supply control priority

11. Click Incoming supply control priority (see Fig. 10-40).

Click
Return....

Fig. 10-41 Incoming supply control priority

12.Click Return... to terminate the connection to the drive unit (see Fig. 10-41).

Fig. 10-42 Returning the control priority

13.Confirm the query Return control priority? with Yes (see Fig. 10-42)
Now you are in the STARTER commissioning tool project, as shown in Fig. 10-43 below.

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Fig. 10-43 Commissioning completed

Congratulations!
You have now successfully completed your first start-up of a drive with the
SINAMICS S120 drive system.

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10.3 Creating a drive project ONLINE

10.3 Creating a drive project ONLINE

Prerequisites
The following is required to create a drive project ONLINE using the STARTER commissio-
ning tool:
S The components as described above are assembled.
S The drive unit is turned on as prescribed.
S You have established a connection from the serial PPI interface of the control unit to a
PC/PG with PPI interface.
The SINAMICS firmware is able to recognize the actual topology automatically and store it in
the appropriate parameters.

10.3.1 Creating a project

To identify the drive configuration automatically using STARTER, use STARTER to open a
new project:
1. To start the STARTER commissioning tool, click the STARTER icon or choose the follo-
wing menu path in the Windows start menu: Start > SIMATIC > STEP 7 > STARTER.
The Project Wizard Starter is displayed.

Fig. 10-44 The STARTER project wizard

2. Click on the Find drive units online .... button (see Fig. 10-44).
The wizard will guide you when creating a new project.

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Fig. 10-45 Creating a new project

3. As shown in Fig. 10-45, enter the project name, e.g. “Machine Tool V1_2”, and if neces-
sary, the author and a comment.
4. Click Continue > to set up the PC/PG interface.

Fig. 10-46 Setting up the interface

5. In this example, you require a PROFIBUS interface on the PC/PG (e.g. Serial Cable
(PPI). Choose Change and test and confirm your selection with Continue >.
The Project Wizard will search for the drive unit ONLINE and will insert it into the project.
Once the search process is completed, the Project Wizard will display the drive unit with
its PPI address Drive_unit_Addr5 in the preview (see Fig. 10-47) (for alternative PC/PG
interface settings, see Figs. 10-6 to 10-8).

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Note
The system searches for drive units or, more precisely, control units; in other words, if more
than one control unit exists in the system, more than one drive unit is found.
The I/O components of the drive units (control unit, Active Line Module etc.) are not
displayed here; these are displayed when performing the step “Load drive configuration into
PG/PC”.

Fig. 10-47 Inserted drive unit

6. Click Continue >.


The Project Wizard will list a project summary (see Fig. 10-48)

Fig. 10-48 Summary

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7. Click on Finish. The new project with the drive unit will be displayed in STARTER (see
Fig. 10-49)

10.3.2 Acquiring the component topology and configuring the drive unit
automatically

After you have created the project and acquired the drive unit with its PROFIBUS address
ONLINE, you must now acquire the appropriate component topology and configuration of
the drive unit ONLINE.

2. Select
Connect to target system.

1. Select the drive unit


Drive_unit_Addr5.

Fig. 10-49 Project_1

1. Select the drive unit Drive_unit_Addr5 in the Project Navigator.


2. Select Connect to target system.
3. Select the drive unit Drive_unit_Addr5 in the Project Navigator.
4. Choose the Restore factory settings function key (see screenshot below).

4. Select
Restore default settings.

Fig. 10-50 Restoring the default settings

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10.3 Creating a drive project ONLINE

5. Confirm the following queries and messages by choosing OK:


– Interactive screenform “Reset to default settings?”
– Interactive screenform “Default settings have been restored”
– Interactive screenform “Data have been successfully copied from RAM to ROM”

Double-click on
Automatic configuration.

Fig. 10-51 Automatic configuration

6. In the Project Navigator, double-click on Automatic configuration under the drive unit.

Click on
Start automatic configuration.

Fig. 10-52 Automatic commissioning

7. Click on the Start automatic configuration button.


STARTER will automatically search for all drive unit components connected correctly and
will load them automatically into STARTER. In our case, it has detected a drive.

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Select the Servo type.

Fig. 10-53 Automatic commissioning

8. In the “Drive object type” dialog box, choose Servo and then click Complete.
“Loading from RAM to ROM” and “Loading into the PG” will take place.

Fig. 10-54 Message

9. A note is displayed. This note will list all drives for which the motors must be configured
in the OFFLINE mode. Click OK to confirm the message.

Note
The drives are listed with standard motors.
If a drive is equipped with a motor with a DRIVE-CLiQ interface, the motor does not need to
be configured in OFFLINE mode.

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Close

Fig. 10-55 Closing the automatic commissioning

10.Once the automatic commissioning is complete, click Close.


In the Project Navigator, all the drive unit components that have been found are displayed
with, for example, the Control Unit, Incoming supply, and Drive (see Fig. 10-56).

Select
Disconnect from target system.

Configuration with, for example, Control


Unit, incoming supply, and Drive.

Fig. 10-56 Automatic configuration

11. Choose Disconnect from target system.


The drive unit, all components and the drives are now integrated in the STARTER
project.
Now you must merely configure the motors of the drives and check the topology
(see Section 10.3.3).

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10.3.3 Configuring and checking the topology of the drives

Now that you have entered the component topology and configuration for the drive unit and
integrated these in the STARTER project automatically by carrying out the steps described
in Section 10.3.2.
Now, use the following operating sequence to configure the motor for the drive, and then
check the topology.

Double-click on
Drive navigator.

Fig. 10-57 Project_1 configuration

1. In the project navigator, choose the Drives folder and double-click Drive navigator under
the drive.
The Drive Navigator dialog box provides an overview in which you can configure the
main drive functions.

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Click on
Device configuration.

Fig. 10-58 Drive navigator

2. Click on Device configuration to configure the drive motor.

Click on
Carry out drive configuration.

Fig. 10-59 Device configuration

3. Click on Carry out drive configuration. The Project Wizard for configuring the drive is
displayed (see Fig. 10-60).

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Click on
Continue >to run the wizard.

Fig. 10-60 Project Wizard

4. Work through the wizard by choosing Continue> until you reach the point at which you
configure the motor (see Fig. 10-61).

Note
Change only the configuration of the motor. The supply etc. must not be changed!

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10.3 Creating a drive project ONLINE

15. Choose the motor type.

16. Choose the motor


according to type (order no.).

Fig. 10-61 Motor configuration

5. Select the motor type, e.g.:


– 1FK6 synchronous motor
– 1PH7 asynchronous motor
6. Select the appropriate motor from the Motor selection list box according to type
(order no.) (see rating plate) and assign a name (Drive_1_Motor).
7. Click on Continue > and Continue> again to proceed with the wizard until you have
come to the dialog with the summary (see Fig. 10-62 below).

Note
Change only the configuration of the motor. The supply etc. must not be changed!

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Fig. 10-62 Summary

8. Click on Finish.
Before you save the project, use STARTER to check the topology you have created.

Click on
Check topology.

Fig. 10-63 Device configuration

9. Click on Check topology.

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10.3 Creating a drive project ONLINE

Select
Project > Save.

Fig. 10-64 Topology tree

10.In this window, check the topology and DRIVE-CLiQ connection and compare this with
the actual topology (see Fig. 10-64).
11. Choose Project > Save and save the project under the name “Project_1”.
To start the motor, continue with the steps described in Section 10.2.

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Starting Up the PLC 11
General
The PLC is intended to control machine-related functional sequences. It is realized as a soft-
ware PLC.
The user program – a PLC cycle – is always executed in the same order of sequence.
S Refresh of the process image (inputs, user interface, timers)
S Processing of communication requests (operator panel, PLC 802 programming tool, ver-
sion 3.0 and higher)
S Editing of the user program
S Evaluation of alarms
S Output of the process image (outputs, user interface)
During the cycle, the PLC executes the user program from the first to the last operation.
The user program accesses the hardware inputs/outputs only via the process image and not
directly. The PLC refreshes the hardware I/Os at the beginning or end of program execution.
Thus, these signals are stable over a whole PLC cycle.
The user program can only be created using the PLC 802 Programming Tool, version 3.1
and higher, with the S7-200 programming language using ladder diagram. Ladder diagram is
a graphical programming language for representing electric circuit diagrams.

Important
PLC 802 Library with a description, which can be installed from the toolbox CD is offered
as the basis for the PLC user program. This provides a subroutine library and a sample pro-
gram for a milling machine.

Note
If the stop and reset buttons on the machine control panel are not realized as normally clo-
sed contacts, an open circuit cannot be detected.
Monitoring can be performed using software solutions, as shown in the example MCP_802D
(SBR 34) from the subroutine library.

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11.1 Commissioning the PLC

11.1 Commissioning the PLC


By default, the user program of the SINUMERIK 802D only consists of a NOP (“no opera-
tion”) instruction and is stored in the permanent memory. The user program addressing the
particular requirements of the machine is to be created by the user himself.

11.2 Start-up modes of the PLC

Table 11-1 Start-up modes

Selection Response
PCU PCU PT PLC 802 PLC Program Retentive MD for the
Switch-on menu Start-up menu (PC) program status data PLC in the
(802D) (802D) preselec- (battery bak- user interface
tion ked)
NCK start-up *
Normal booting Normal booting User pro- Run unchanged Acceptance of
gram *** the active
PLC MD
Booting Booting User pro- Run deleted Default
with default va- with default values gram *** PLC MD
lues
Booting Booting User pro- Run saved Saved PLC MD
with saved data with saved data gram *** data
PLC stop PLC stop unchanged Stop unchanged Acceptance of
after POWER ON possible ei- the active
ther in Run PLC MD
or in Stop

PLC start-up **
Cold restart Run (after User pro- Run unchanged Acceptance of
Stop) gram *** the active
PLC MD
Cold restart User pro- Stop unchanged Acceptance of
and debug mode gram *** the active
PLC MD

Overall reset User pro- Run deleted Acceptance of


gram *** the active
PLC MD

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11.2 Start-up modes of the PLC

Table 11-1 Start-up modes, continued

PCU PCU PT PLC 802 PLC Program Retentive MD for the


Switch-on menu Start-up menu (PC) program status data PLC in the
(802D) (802D) preselec- (battery bak- user interface
tion ked)
Overall reset User pro- Stop deleted Acceptance
and debug mode gram *** of the active
PLC MD
* “System” hardkey system/“Start-up” softkey/NC
** “System” hardkey system/“Start-up” softkey/PLC
*** is loaded from the permanent memory into the RAM

Thanks to the debug mode (see “Operation and Programming”, Chapter 7), the PLC remains
in PLC Stop after booting of the control system. All start-up modes set via softkey only come
into effect when the control system is booted the next time.
The “Run” mode activates the cyclic operation.
The following actions are triggered in the “Stop” mode:
S All hardware outputs are disabled.
S Profibus DP is inactive.
S No cyclic operation (the active user program is not executed).
S The process image is no longer refreshed (it is frozen).
S EMERGENCY STOP active.
Only in the “Stop” mode can the user load a corrected or new project into the control system.
The user program only becomes effective when the control system is booted the next time
or if the “Run” mode is selected.

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11.3 PLC alarms

11.3 PLC alarms


The control system displays max. 8 PLC alarms (system alarms or user alarms).
The PLC manages the alarm information per PLC cycle. It saves/cancels the alarms accor-
ding to their times of occurrence. The first alarm in the list is always the alarm last occurred.
If more than 8 alarms have occurred, the first seven alarms and the newest alarm with the
highest cancel priority are displayed.

Alarm response and cancel criteria


In addition, the alarm responses are managed by the PLC. The alarm responses always
come into effect, irrespective of the number of active alarms. Depending on the type of the
alarm response, the PLC will trigger the required action.
A cancel criterion must be defined for each alarm. The PLC uses the cancel criterion SELF-
CLEARING by default (see “Configuring user alarms”).
Cancel criteria are:
S POWERONCLEAR: The alarm is canceled by turning off/turning on the control system
(POWER ON).
S CANCELCLEAR: The alarm is canceled by pressing the Cancel key or the Reset key
(analogously to the NCK alarms).
S SELF-CLEARING: The alarm is canceled, since the alarm cause is no longer present.

The cancel conditions have the following priority:


S POWERON CLEAR – system alarms (highest priority)
S CANCEL CLEAR – system alarms
S SELF–CLEARING – system alarms
S POWERON CLEAR – user alarms
S CANCEL CLEAR – user alarms
S SELF-CLEARING – user alarm (lowest priority)
The responses to be triggered by the alarm in question in the PLC are defined for each
alarm. The PLC uses the alarm response SHOWALARM by default.
Alarm responses are:
S PLC stop: The user program is not executed any more, Profibus DP is inactive, and the
hardware outputs are disabled.
S EMERGENCY STOP: Once the user program is executed, the PLC transmits the EMER-
GENCY STOP signal to the NCK via the user interface.
S Feed disable: Once the user program is executed, the PLC transmits the feed disable
signal to the NCK via the user interface.
S Read-in disable: Once the user program is executed, the PLC transmits the read-in disa-
ble signal to the NCK via the user interface.

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S NC Start inhibited: Once the user program is executed, the PLC signals the “NC start
inhibited” signal to the NCK via the user interface.
S SHOWALARM: This alarm has no alarm response.

11.3.1 General PLC alarms

Note to the reader


SINUMERIK 802D sl Diagnostics Guide

11.3.2 User alarms

The user interface ‘’ 1600xxxx ‘’ provides the subareas (0, 1) for the user to define user
alarms.
S Subarea 0: 8 x 8 bits to set the user alarms (0 –>1 edge)
Byte 0 : Bit 0 => 1st user alarm “ 700000 ”
Byte 1 : Bit 0 => 9th user alarm “ 700008 ”
Byte 7 : Bit 7 => 64th user alarm “ 700063 ”
A new user alarm is activated with the relevant bit (subarea 0) via a 0/1 edge.
S Subarea 1: User alarm variables
Subarea 1 is intended for additional user information; it can only be read/written as a dou-
bleword.
S Subarea 2: Alarm response
Byte 0 : Bit 0 => NC start inhibited
Bit 1 => Read-in disable
Bit 2 => Feed disable for all axes
Bit 3 => EMERGENCY STOP
Bit 4 => PLC STOP
By using subarea 2, the user can evaluate the active alarm responses; this subarea is
read-only.
Self-clearing user alarms must be canceled by the user by resetting the appropriate bit in
subarea 0 (1 –> 0 edge).
Other user alarms are canceled by the PLC after detecting the relevant cancel condition for
the appropriate user alarms. If the bit of the user alarm, however, is still present, the alarm
recurs.

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11.3 PLC alarms

Type of action of a user alarm


User alarms have a higher priority than the appropriate signal in the user interface
(e.g. NC start inhibited, read-in disable, feed disable and EMERGENCY STOP).
Example:
MD 14516[0]: USER_DAT_PLC_ALARM = 8
If alarm 700000 is present, in addition, alarm 3000 EMERGENCY STOP is also present
even if the interface signal V26000000.1=0.

Configuring user alarms


A configuration byte is provided for each alarm. The user alarms can be configured by the
user in the machine data 14516: USER_DATA_PLC_ALARM.
Default setting of MD 14516[0...63]: 0 => SHOWALARM/SELF-CLEARING user alarm
Structure of a configuration byte:
S Bit0 – bit5 : Alarm responses
S Bit6 – bit7 : Cancel criteria
Alarm responses: Bit0 – bit 5 = 0: Showalarm (default)
Bit0 = 1: NC start inhibited
Bit1 = 1: Read–in disable
Bit2 = 1: Feed disable for all axes
Bit3 = 1: EMERGENCY STOP
Bit4 = 1: PLC stop
Bit5 = reserved
Cancel criteria: Bit6 + bit7 = 0: SELF-CLEARING alarm (default)
Bit6 = 1 : CANCELCLEAR alarm
Bit7 = 1 : POWERONCLEAR alarm
The alarm response to PLC Stop always has the cancel condition POWER ON.

Alarm texts
The user are offered two options of defining his own alarm texts:
S by using the System hardkey \ softkeys PLC \ Edit PLC alarm txt (see ”Operation and
Programming”, Chapter 7)
S by using the toolbox: Editing and loading the alarm text file using the text manager
If no alarm text is assigned by the user, only the alarm number is displayed.
The % character in the alarm text denotes an additional variable. The variable type is the
form of representation of the variable.
The following variable types are possible:
S %D integer decimal number
S %I integer decimal number
S %U decimal number without sign

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S %O integer octal number


S %X integer hexadecimal number
S %B binary representation of a 32-bit value
S %F 4-byte floating point number
Examples of user alarm texts (Note: The text after the ”//” is a comment and is not dis-
played.)
S 700000 ‘’ ‘’ // only the user alarm number
S 700001 ‘’ Hardware limit switch + of the X axis’’
S 700002 ‘’ %D ‘’ // only a variable as an integer decimal number
S 700003 ‘’ Alarm number with a fixed alarm text and the variable %X ‘’
S 700004 ‘’ %U Alarm number with variable and fixed alarm text ‘’
S 700005 ‘’Axis monitoring active : %U’’
Display: 700005 Axis monitoring active : 1
or 700005 Axis monitoring active : 3

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11.4 PLC programming

11.4 PLC programming


The PLC user program is created using the PLC 802 Programming Tool.
The handling of this tool for an S7-200 is described in the documentation “SIMATIC S7-200
Automation System Manual”. The PLC 802 Programming Tool constitutes a subset of this
documentation.
Compared to the S7-200 MicroWin base system, the following is to be observed:
S The user program can only be programmed in ladder diagram.
S Only a subset of the S7-200 programming language is supported.
S The compilation of the user program is performed offline on a PG/PC or automatically
when downloading into the control system.
S The project can be loaded into the control system (download).
S It is also possible to load the project from the control system (upload).
S Indirect data addressing is not possible. Thus, no programming errors will occur during
the runtime.
S The user must manage the data and process information type-specifically.
For all accesses to the data, it is imperative to use consistently the agreed data type.
Example:
Information 1 T value Memory size DInt (32-bit)
Information 2 Override Memory size Byte (8-bit)
User data
Memory double-word MD0 DInt (information 1)
Memory byte MB4 Byte (information 2)
S Furthermore, the alignment towards certain memory addresses is dependent on the data
type. This alignment is performed towards bus addresses which can be divided by the
byte length of the data type without remainder.
BOOL and BYTE can start at any byte address (0, 1, 2, 3, ...),
WORD and INT must start at an even byte address (0, 2, 4, 6, ...) and
DWORD, DINT, REAL must start at a byte address which can be divided by 4
(0, 4, 8, 12, ...).
Example:
Memory bits MB0.1,MB3.5
Memory bytes MB0,MB1,MB2
Memory word MW0,MW2,MW4
MW3, MW5 ... are not permissible
Memory double words MD0,MD4,MD8
MD1,MD2,MD3, MD5 ... are not permissible

Table 11-2 PLC data types permitted in the control system

Data type Size Address Range for logical operations Range for arithmetic operations
alignment
BOOL 1 Bit 1 0.1 –
BYTE 1 byte 1 00 ... FF 0 ... +255

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Table 11-2 PLC data types permitted in the control system, continued

Data type Size Address Range for logical operations Range for arithmetic operations
alignment
WORD 2 bytes 2 0000 ... FFFF –32 768 ... + 32 767
DWORD 4 bytes 4 0000 0000 ... FFFF FFFF –2 147 483 648 ...
(Double +2 147 483 647
Word)
REAL 4 bytes 4 – $10–37... $1038

PLC project
The PLC 802 Programming Tool always manages one project (combinational logic, symbols
and comments). All important information of a project can be stored in the control system via
a download. The information is transmitted from the control to the PC via upload.
The control system can save max. 6,000 instructions and 1,500 symbols. The PLC memory
required is influenced by the following components:
S number of instructions
S number and length of the symbol names
S number and length of the comments

S7-200 Ladder Diagram


The addresses and operations can be defined using the representation type “International”.
When using the ladder diagram, the user programs his program in networks. Each network
corresponds to a logic reflecting a certain sequence. The basic elements of a ladder diagram
are contacts, coils and boxes. The contacts, in turn, are divided into normally opened and
normally closed contacts. Each coil corresponds to a relay. Boxes are used to represent a
certain function. A box can be activated using an enable bit.

11.4.1 Command overview

Table 11-3 Operand identifier

Operand identifier Description Area


V Data V1000 0000.0 to V7999 9999.7
T Timers T0 to T15 (100 ms)
T16 to T39 (10 ms)
C Counter C0 to C31
I Image of digital inputs I0.0 to I17.7
Q Image of digital outputs Q0.0 to Q11.7
M Flags M0.0 to M383.7

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Table 11-3 Operand identifier, continued

Operand identifier Description Area


SM Special bit memory SM0.0 to SM 0.6
(see Table 11-6)
AC ACCU AC0 ... AC3
L Local data L0.0 to L51.7

Table 11-4 Forming the address in the V area (see “User interface”)

Type identifi- Area no. Subarea Offset Addressing


cation (mo- (channel/
dule no.) axis no.)
00 00 0 000 symbolic
(10–79) (00–99) (0–9) (000–999) (8-digit)

Table 11-5 802D Operand Ranges

Access Method Valid Operand Ranges for


Programming 802D
Bit Access (Byte.Bit) V(1000 0000.0–7900 9999.7)
I(0.0–17.7)
Q(0.0–11.7)
M(0.0–383.7)
SM(0.0–0.7)

T(0–39)
C(0–31)

Byte Access VB(1000 0000–7999 9999)


IB(0–17)
QB(0–11)
MB(0–383)
AC(0–3)
SMB(0)

KB (Constant)
Word Access VW(1000 0000–7999 9998)
T(0–39)
C(0–31)
IW(0–16)
QW(0–10)
MW(0–382)
AC(0–3)


KW (Constant)

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Table 11-5 802D Operand Ranges, continued

Access Method Valid Operand Ranges for


Programming 802D
Double Word Access VD(1000 0000–7999 9994)
ID(0–14)
QD(0–8)
MD(0–380)
AC(0–3)


AC(0–3)
KD (Constant)

Table 11-6 Special bit memory SM Bit Definition

SM bits Description
SM 0.0 Bit memory with defined ONE signal
SM 0.1 Initial position: first PLC cycle ‘1’, subsequent cycles ‘0’
SM 0.2 Buffered data lost – only valid in the first PLC cycle
(‘0’ – data o.k., ‘1’ – data lost)
SM 0.3 POWER ON: first PLC cycle ‘1’, subsequent cycles ‘0’
SM 0.4 60 s clock (alternating ‘0’ for 30 s, then ‘1’ for 30 s)
SM 0.5 1 s clock (alternating ‘0’ for 0.5 s, then ‘1’ for 0.5 s)
SM 0.6 PLC cycle clock (alternating one cycle ‘0’, then one cycle’)

The user can only view the statement list (STL) in PT802 under “View STL”. This type of
representation (see Table : Mnemonic) shows the sequential processing.

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11.4.2 Explanation of the stack operations

Table 11-7 INSTRUCTIONS Set

BASIC BOOLEAN INSTRUCTIONS


Instruction Ladder Symbol Valid Operands
Load normal open n: V, I, Q, M, SM, T, C, L
n
And n=1 close
Or n=0 open
Load Not normal close n: V, I, Q, M, SM, T, C, L
n
And Not n=0 close
Or Not n=1 open
Output prior 0, n=0 n n: V, I, Q, M,T, C, L
prior 1, n=1

Set prior 0, not set Bit S_Bit: V, I, Q, M,T, C, L


(1 Bit) prior 1 or ½ S n =1

Reset prior 0, no reset Bit


S_Bit: V, I, Q, M,T, C, L
(1 Bit) prior 1 or ½ n =1
R

OTHER BOOLEAN INSTRUCTIONS


Instruction Ladder Symbol Valid Operands
Edge Up prior ½ close
P
(1 PLC cycle)
Edge Down prior ¿ close
N
(1 PLC cycle)
Logical Not prior 0, later 1
NOT
prior 1, later 0
No operation n n = 0 ... 255
NOP

BYTE COMPARES (Unsigned)


Instruction Ladder Symbol Valid Operands
Load Byte = a = b close a a: VB, IB, QB, MB, SMB, AC, Constant,
And Byte = a  b open ==B LB
b b: VB, IB, QB, MB, SMB, AC, Constant,
Or Byte =
LB
Load Byte . a ≥ b close a
And Byte . a t b open > =B
b
Or Byte .
Load Byte 3 a ≤ b close a
And Byte 3 a u b open < =B
b
Or Byte 3

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WORD COMPARES (Signed)


Instruction Ladder Symbol Valid Operands
Load Word = a = b close a a: VW, T, C, IW, QW, MW, AC, Constant,
And Word = a  b open ==I LW
Or Word = b b: VW, T, C, IW, QW, MW, AC, Constant,
LW
Load Word . a ≥ b close a
And Word . a t b open > =I
b
Or Word .
Load Word 3 a ≤ b close a
And Word 3 a u b open < =I
b
Or Word 3

DOUBLE WORD COMPARES (Signed)


Instruction Ladder Symbol Valid Operands
Load DWord = a = b close a a: VD, ID, QD, MD, AC, Constant, LB
And DWord = a  b open ==D b: VD, ID, QD, MD, AC, Constant, LB
b
Or DWord =
Load DWord . a ≥ b close a
And DWord . a t b open > =D
b
Or DWord .
Load DWord 3 a ≤ b close a

And DWord 3 a u b open < =D


b
Or DWord 3

REAL WORD COMPARES (Signed)


Instruction Ladder Symbol Valid Operands
Load RWord = a = b close a a: VD, ID, QD, MD, AC, Constant, LD
And RWord = a  b open = =R b: VD, ID, QD, MD, AC, Constant, LD
b
Or RWord =
Load RWord . a ≥ b close a
And RWord . a t b open > =R
b
Or RWord .
Load RWord 3 a ≤ b close a
And RWord 3 a u b open < =R
b
Or RWord 3

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TIMER
Instruction Ladder Symbol Valid Operands
Timer Retentive On EN=1, Start Enable: (IN)
Delay EN=0, Stop Txxx S0
If TValue ≥ PT, TONR Txxx: T0 – T31
Tbit=1 IN
Preset: (PT)
VW, T, C, IW, QW, MW, AC,
Constant
PT
100 ms T0 – T15
10 ms T16 – T39
Timer On Delay EN=1, Start Enable: (IN)
EN=0, Stop Txxx S0
If TValue ≥ PT, TON Txxx: T0 – T31
Tbit=1 IN
Preset: (PT)
VW, T, C, IW, QW, MW, AC,
Constant
PT
100 ms T0 – T15
10 ms T16 – T39
Timer Of Delay If TValue < PT, Enable: (IN)
Tbit=1 Txxx S0
TOF Txxx: T0 – T31
IN
Preset: (PT)
VW, T, C, IW, QW, MW, AC,
Constant
PT
100 ms T0 – T15
10 ms T16 – T39

COUNTER
Instruction Ladder Symbol Valid Operands
Count Up CU ½, Value+1 Cnt Up: (CU)
R=1, Reset Cxxx S1
If CValue ≥ PV, Reset: (R)
CU CTU S0
Cbit=1
Cxxx: C0 – 31
R
PV
Preset: (PV)
VW, T, C, IW, QW, MW, AC,
Constant, LW
Count Up/Down CU ½, Value+1 Cnt Up: (CU)
CD ½, Value–1 S2
R=1, Reset Cxxx Cnt Dn: (CD)
If CValue ≥ PV, S1
CU CTUD
Cbit=1 Reset: (R)
CD S0
R
Cxxx: C0 – 31
PV
Preset: (PV)
VW, T, C, IW, QW, MW, AC,
Constant, LW

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Instruction Ladder Symbol Valid Operands


Count Down If CValue = 0, Cnt Down: (CD)
Cbit=1 Cxxx S2
Reset: (R)
CD CTD S0
LD
Cxxx: C0 – 31
PV
Preset: (PV)
VW, T, C, IW, QW, MW, AC,
Constant, LW

MATH OPERATIONS
Instruction Ladder Symbol Valid Operands
Word Add If EN = 1, ADD_I Enable: EN
Word Subtract b=a+b EN ENO In: VW, T, C, IW, QW, MW, AC,
b=b–a IN1 Constant, LW
IN2 OUT
Out: VW, T, C, IW, QW, MW, AC, LW

DWord Add If EN = 1, SUB_DI Enable: EN


DWord Subtract b=a+b EN ENO In: VD, ID, QD, MD, AC, Constant, LD
b=b–a IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT

Multiply If EN = 1, MUL Enable: EN


b=axb EN ENO In: VW, T, C, IW, QW, MW, AC,
IN1 Constant, LW
IN2 OUT
Out: VD, ID, QD, MD, AC, LD

Divide If EN = 1, Enable: EN
b=b÷a DIV
In: VW, T, C, IW, QW, MW, AC,
Out: EN ENO Constant, LW
16 bit remainder IN1
Out: VD, ID, QD, MD, LD
IN2 OUT
Out+2:
16 bit quotient
Add If EN = 1, ADD_R Enable: EN
Subtract b=a+b EN ENO In: VD, ID, QD, MD, AC, Constant, LD
Real Numbers b=b–a IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT

Multiply If EN = 1, MUL_R Enable: EN


Divide b=axb EN ENO In: VD, ID, QD, MD, AC, Constant, LD
Real Numbers b=b÷a IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT

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INCREMENT, DECREMENT
Instruction Ladder Symbol Valid Operands
Increment If EN = 1, Enable: EN
INC_B
Decrement a=a+1 In: VB, IB, QB, MB, AC, Constant LB
EN ENO
Byte a=a–1 Out: VB, IB, QB, MB, AC, LB
IN OUT

Increment If EN = 1, Enable: EN
Decrement a=a+1 INC_W In: VW, T, C, IW, QW, MW, AC,
Word a=a–1 EN ENO Constant, LW
a = /a Out: VW, T, C, IW, QW, MW, AC, LW
IN OUT

Increment If EN = 1, Enable: EN
INV_DW
Decrement a=a+1 In: VD, ID, QD, MD, AC, Constant, LD
EN ENO
a=a–1 Out: VD, ID, QD, MD, AC, LD
IN OUT

LOGIC OPERATIONS
Instruction Ladder Symbol Valid Operands
Byte AND If EN = 1, WAND_B Enable: EN
Byte OR b = a AND b EN ENO In: VB, IB, QB, MB, AC, Constant, LB
Byte XOR b = a OR b IN1 Out: VB, IB, QB, MB, AC, LB
IN2 OUT
b = a XOR b
Word AND If EN = 1, WAND_W Enable: EN
Word OR b = a AND b EN ENO In: VW, T, C, IW, QW, MW, AC,
Word XOR b = a OR b IN1 Constant, LW
IN2 OUT
b = a XOR b Out: VW, T, C, IW, QW, MW, AC, LW

DWord AND If EN = 1, WXOR_DW Enable: EN


DWord OR b = a AND b EN ENO In: VD, ID, QD, MD, AC, Constant, LD
DWord XOR b = a OR b IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT
b = a XOR b
Invert Byte If EN = 1, INC_B Enable: EN
a = /a EN ENO In: VB, IB, QB, MB, AC, Constant, LB
Out: VB, IB, QB, MB, AC, LB
IN OUT

Invert Word If EN = 1, INC_W Enable: EN


a = /a EN ENO In: VW, T, C, IW, QW, MW, AC,
Constant, LW
IN OUT
Out: VW, T, C, IW, QW, MW, AC, LW

Invert DWord If EN = 1, INV_DW Enable: EN


a = /a EN ENO In: VD, ID, QD, MD, AC, Constant, LD
Out: VD, ID, QD, MD, AC, LD
IN OUT

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SHIFT AND ROTATE OPERATIONS


Instruction Ladder Symbol Valid Operands
Shift Right If EN = 1, SHL_R Enable: EN
Shift Left a = a SR c bits EN ENO In: VB, IB, QB, MB, AC, Constant, LB
a = a SL c bits IN Out: VB, IB, QB, MB, AC
N OUT
Count: VB, IB, QB, MB, AC, Constant, LB
Shift Right If EN = 1, Enable: EN
SHL_W
Shift Left a = a SR c bits ENO
In: VW, T, C, IW, QW, MW, AC,
EN
a = a SL c bits Constant, LW
IN
OUT Out: VW, T, C, IW, QW, MW, AC, LW
N
Count: VB, IB, QB, MB, AC, Constant, LB
DWord Shift R If EN = 1, SHL_DW Enable: EN
DWord Shift L a = a SR c bits EN ENO In: VD, ID, QD, MD, AC, Constant, LD
a = a SL c bits IN Out: VD, ID, QD, MD, AC, LD
N OUT
Count: VB, IB, QB, MB, AC, Constant, LB

CONVERSION OPERATIONS
Instruction Ladder Symbol Valid Operands
Convert Double If EN = 1, convert the DI_REAL Enable: EN
Word Integer to a double word integer i EN ENO In: VD, ID, QD, MD, AC, Constant, LD
Real to a real number o.
IN OUT Out: VD, ID, QD, MD, AC, LD

Convert a Real to a If EN = 1, convert the TRUNC Enable: EN


Double Word Integer real number i to a EN ENO In: VD, ID, QD, MD, AC, Constant, LD
double word integer o.
IN OUT Out: VD, ID, QD, MD, AC, LD

PROGRAM CONTROL FUNCTIONS


Instruction Ladder Symbol Valid Operands
Jump to Label If EN = 1, go to label n. n Enable: EN
JMP Label: WORD: 0–127

Label Label marker for the n Label: WORD: 0–127


jump. LBL

Conditional Return If EN = 1, exit the sub- Enable: EN


from Subroutine routine. RET

Return from Subrou- Exit subroutine.


tine RET

Conditional End If EN = 1, END termi- Enable: EN


nates the main scan. END

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PROGRAM CONTROL FUNCTIONS


Instruction Ladder Symbol Valid Operands
Subroutine If EN ½, go to subrou- n Label: Constant : 0–63
tine n. SBR
EN
x1
x2 x3

(x... optional parameters

MOVE, FILL AND FIND OPERATIONS


Instruction Ladder Symbol Valid Operands
Move Byte If EN = 1, MOV_B Enable: EN
copy i to o. EN ENO In: VB, IB, QB, MB, AC, Constant, LB
Out: VB, IB, QB, MB, AC, LB
IN OUT

Move Word If EN = 1, MOV_W Enable: EN


copy i to o. EN ENO In: VW, T, C, IW, QW, MW, AC,
Constant, LW
IN OUT
Out: VW, T, C, IW, QW, MW, AC, LW

Move DWord If EN = 1, MOV_DW Enable: EN


copy i to o. EN ENO In: VD, ID, QD, MD, AC, Constant, LD
Out: VD, ID, QD, MD, AC, LD
IN OUT

Move Real If EN = 1, MOV_R Enable: EN


copy i to o. EN ENO In: VD, ID, QD, MD, AC, Constant, LD
Out: VD, ID, QD, MD, AC, LD
IN OUT

Swap Bytes If EN = 1, SWAP Enable: EN


exchange MSB and EN ENO In: VW, IW, QW, MW, T, C, AC, LW
LSB of w.
IN

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11.4 PLC programming

11.4.3 Program organization

A programmer should structure the user program into separate program sections (subrouti-
nes). The S7-200 programming language offers the user the possibility to create a structured
user program. There are two program types – main program and subroutine. Eight program
levels are possible.
A PLC cycle can be a multiple of the control-internal interpolation cycle (IPO cycle). The ma-
chine manufacturer must set the PLC cycle according to his particular conditions (see ma-
chine data “PLC_IPO_TIME_RATIO”). An IPO/ PLC ratio of 1:1 has been proven to provide
the fastest possible cyclic program execution.
Example: The programmer will write a sequence control in the main program using a cycle
defined by himself. This sequence control will organize all cyclic signals in the subroutine
(UP0); UP1/UP2 are called every two cycles, and UP3 controls all signals at an interval of
three cycles.

11.4.4 Data organization

The data can be divided into three areas:


S non-retentive data
S retentive data
S machine data for the PLC (all these machine data are active after POWER ON).
Most of the machine data, such as process image, timer and counter are non-retentive data
which are deleted each time when the control system is powered up.
The data area 1400 0000 –1400 0127 is reserved for the retentive data. The user can here
store all data which are to remain valid after POWER OFF/ON.
The user can either load the data in his program with default data using the PLC machine
data (see “User interface”) or parameterize various program sections.

11.4.5 Interface to the control system

This interface can be selected via SYSTEM, softkeys PLC > STEP7-connect.
This V24 interface continues to be active even after cold restart or normal booting. The con-
nection (STEP7 connect active) to the control system can be checked in the “PLC/informa-
tion” menu of the PLC 802 Programming Tool. If the interface is active, the active PLC
mode, for example (Run/Stop) is displayed in this window.

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Starting Up the PLC
11.4 PLC programming

11.4.6 Testing and monitoring your program

A check or error analysis of the user program is possible as follows:


S PLC status: Display and change of called operands
S Status list: Display and change of three freely selected variable fields
S PLC program: Display and monitoring (status) of the whole user program including sym-
bols and comments
S PT PLC 802: It is possible to connect a PG/PC and to activate the PT connection via mo-
dem

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Starting Up the PLC
11.5 PLC applications Download/Upload/Copy/Compare

11.5 PLC applications Download/Upload/Copy/Compare


The user can save, copy or overwrite the PLC project or the PLC applications in the control
system.
This is possible using
S PLC 802 Programming Tool
S RCS802 (binary file)
S CF card
The PLC project comprises the PLC user program including all important information (sym-
bols, comments, ...). It is loaded by the Programming Tool via upload/download or via File >
Import/Export.
The PLC application incorporates the PLC project and PLC user alarm texts. The PLC ap-
plication can only be generated by the control system.

PT PLC 802

Download/ 
Upload/
Compare
Permanent
802D 
memory
PLC
project 
  Export/Import
PLC PLC
user machine data

alarm texts Series machine
start-up

 PLC
Toolbox application

PLC
application
CF card

RCS802 Series machine start-up

Fig. 11-1 PLC applications in the control system

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Starting Up the PLC
11.5 PLC applications Download/Upload/Copy/Compare

Download
This function writes the transmitted data to the permanent memory (load memory) of the
control system.
S Download of a PLC project using the PLC 802 Programming Tool (Step 7 connect on)
S Series machine start-up (System > Start-up files > NC/PLC start-up archive) using the
RCS802 tool or CF card.
For example, CF card:
Copy the start-up archive from the customer CF card and paste it into the directory Start-
up files > Start-up archive (NC/PLC).
– NC data
– NC directories
– Display machine data
– Leadscrew error compensation (LEC)
– PLC user program
– Drive machine data
S Reading in PLC applications using the RCS802 tool or the CF card (PLC project and user
alarm texts) analogously to the series machine start-up

Upload
The PLC application can be saved from the permanent memory of the control system using
the either PLC 802 Programming Tool, RCS802 or the CF card.
S Upload from the PLC project using the PLC 802 Programming Tool (Step 7 connect on)
Reading out the project from the control system and thus reconstructing the current pro-
ject in the PLC 802 Programming Tool.
S Series machine start-up: System > Start-up file > Start-up archive (NC/PL) using
RCS802 (PLC MD, PLC project and user alarm texts) or the CF card
S Reading out the PLC application using RCS802 or copying to CF card (PLC project infor-
mation and user alarm texts)

Compare
This function compares the project contained in the PLC 802 Programming Tool with the pro-
ject loaded in the permanent memory (load memory) in the control system.

Version display
This function is called using the SYSTEM hardkey, softkeys Service Display > Version.
S PLC application
The transmitted project including the user program which is active in the user memory of
the PLC after booting of the control system.
The programmer can use the start of the first comment line in the comment of OB1 in the
PLC 802 Programming Tool for his own supplementary information in the version display
(see “View Properties”).

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11.6 User interface

11.6 User interface


This interface comprises all signals exchanged between NCK/PLC and HMI/PLC. In addi-
tion, the PLC decodes all auxiliary function commands for processing in the user program.

Note to the reader


/FB/ Sinumerik 802D sl Description of Functions, Chapter 20

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Starting Up the PLC
11.6 User interface

Notes

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Data Backup and Series Machine Start-Up 12
12.1 Data backup

12.1.1 Internal data backup

The data of the limited-buffered memory must be saved via a backup copy to the permanent
memory of the control system. This backup is performed internally and is always necessary
if the control system is switched off for longer than 50 hours.
Recommendation: After changing important data, it is recommended to carry out a data
backup immediately.

Note
During the data backup, an image of the limited-buffered memory is produced and stored
in the permanent memory. A backup of selected data (e.g. only machine data and no work-
piece programs) is not possible.

Performing an internal data backup


Select the Save data softkey in the System operating area (at least protection level 3 requi-
red). Press OK to confirm the notes which now appear.

Important
While the internal data backup is running, the control system must neither be operated, nor
be turned off.

Loading internally backed-up data


S Boot the control system in the start-up mode “Reload saved user data”.
S In case of data loss of the buffered memory, the data saved in the permanent memory
are automatically reloaded into the memory with POWER ON.

Note
Message “4062 Data backup copy has been loaded” is displayed on the screen.

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Data Backup and Series Machine Start-Up
12.1 Data backup

12.1.2 External data backup

In addition to an internal data backup, the user data of the control system can also be saved
externally. To do so, a PC with V24 interface and the RCS tool (included in the toolbox) or a
CF card are required.
An external data backup should be performed if major data changes have been made or al-
ways at the end of the start-up.
To create a complete data backup for a machine, it is sufficient to create the series machine
start-up file.

Variants of external data backup


1. Reading out the data completely: Series machine start-up
2. Files are read out/read in for each area individually. The following user data can be selec-
ted from the “System” operating area as individual files:
Data in the text format
– All machine data
– Setting data
– Tool data
– R parameters
– Work offset
– Compensation data (LEC)
– GUDs
Data in the start-up archive (NC/PLC)
– NC data
– NC directories
– Display machine data
– Compensation data (LEC)
– PLC user alarm texts
– PLC project (cannot be edited with PT 802)
– Drive machine data
Data in the start-up archive (HMI)
– User cycles
– User directories
– Language file SP1
– Language file SP2
– Start screen
– Online help
– HMI screens
3. Furthermore, the following data can be saved from the “Program Manager” operating
area:
– Manufacturer cycles
– Standard cycles

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12.1 Data backup

– User cycles
– Main programs
– Subroutines

12.1.3 Data backup via V24

Important
Never connect or disconnect the V24 cable when the PCU is connected to the mains.
Make sure that the settings of the RS232 interface of the 802D and of the COM port on the
PC are identical.

Creating a start-up archive in the PC (data transfer from the control system to the PC)
For the series machine start-up, please refer to Section 12.2.

Data backup in the 802D data area (text format)


On the PC, one single file will result which contains the data you have selected for backup.

Note to the reader


/BP/ SINUMERIK 802D sl “Operation and Programming”, Chapter 7

Data backup in the “Program Manager” operating area


The data from the Program Manager > NC directory operating area are output to the
RS232 in the text format.

12.1.4 External data backup via CF Card

On the CF card, the same data can be saved as those which are saved via the serial inter-
face. The selection of the data to be saved is performed in the same way (System > Start-
up files > 802D data > Copy)); saving to the card is performed via Customer CF card and
Paste.

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Data Backup and Series Machine Start-Up
12.2 Series machine start-up

12.2 Series machine start-up

Functionality
The objective of the series machine start-up is:
S to bring another control system at a machine of the same type to the same condition as
after a commissioning
or
S to bring a new control system to the initial state in case of servicing (after hardware repla-
cement) with lowest possible expenditure.

Start-up archive (NC/PLC)


The start-up archive (NC/PLC) incorporates the following data:
S Machine data
S R parameters
S Setting data
S PLC user alarm texts
S Display machine data
S PLC user project
S Part programs
S Cycles
S Work offsets
S Tool offsets
S Leadscrew error compensation data
S Drive machine data of SINAMICS

Start-up archive (HMI)


The start-up archive (HMI) incorporates the following data:
S User cycles
S User directories
S Language file SP1
S Language file SP2
S Start screen
S Online help
S HMI screens

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12.2 Series machine start-up

Prerequisites
The prerequisite for the series machine start-up is a PC with V24 interface for data transfer
from/to the control system, or a CF card.
In the PC, the RCStool must be used.

Sequence with PC
1. Creating a start-up archive (NC/PLC) in the PC (data transfer from the control system to
the PC):
– Establish a V24 cable connection between the PC (COM port) and the SINUMERIK
802D (RS232).
– Use the RCS tool to make the following settings in the RS232 Config menu in the
binary format (the settings not printed in bold correspond to the default setting when
starting WINPCIN):
COM port Number of the PC COM to SINUMERIK 802D
Baud rate 19,200 (default)
Parity none
Data bit 8
Stop bit 1
Software (XON/XOFF) OFF
Hardware (RTS/CTS) ON
Timeout 0s
STOP with EOF no tick
– Call the Receive Data menu in the PC, enter
a file name (any archive name) and start the data transfer.
The PC switches to “Receive” and is awaiting data from the control system.
– The control system requires the password for protection level 2.
– Configure the interface as above (default settings) using the System > Start-up
files > RS232 > Settings menu.
– Go back with Back and 802D Data and select the “Start-up archive (NC/PLC)” line;
use Copy to paste the contents to the clipboard.
– Back again in RS232,, select the “Binary mode transmission” direction key and then
Send. The series machine start-up is output to the serial interface.
2. Reading in the series start-up file from the PC into the SINUMERIK 802D
– Make the relevant settings for the V24 interface on the PC and on the 802D as speci-
fied under 1.
– In the System > Start-up files > RS232 “Binary mode transmission” menu, select
Receive. The control system will now wait for data.
– Use RCS802 on your PC to open the series machine start-up file from the Send Data
menu, starting the data transfer.
– Once reading-in has started, confirm the start of the series machine start-up in the
control system.
– A warm start of the NC/PLC is performed several times during the series machine
start-up. At the end of the series machine start-up, the whole control system will re-
boot (warm start). After an error-free series machine start-up, the control system will
be in a fully configured operating condition.

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Data Backup and Series Machine Start-Up
12.2 Series machine start-up

Sequence with CF card


1. Creating a series machine start-up file on the CF card:
– Make sure that the CF card is inserted in the slot on the device front panel.
– The control system requires the password for protection level 2.
– In the System > Start-up files > 802D data menu, select the Start-up archive (NC/
PLC) line and use the Copy command to paste the contents to the clipboard. Select
the Customer CF card softkey to display the contents of the inserted card. If you se-
lect the Paste softkey and subsequently enter the name for the archive file, the series
machine start-up is produced on the card.
2. Reading in the series start-up file from the CF card into the SINUMERIK 802D
– Make sure that the CF card is inserted.
– The control system requires the password for protection level 2.
– In the System > Start-up files > Customer CF card menu, select the line containing
the appropriate archive and use the Copy command to paste the data to the clipbo-
ard. Select the 802D data softkey and select the “Startup data (NC/PLC)” line. Selec-
ting the Paste softkey will transmit the series start-up to the control system.
– Once reading-in has started, confirm the start of the series machine start-up in the
control system.
– A warm start of the NC/PLC is performed several times during the series machine
start-up. At the end of the series machine start-up, the whole control system will re-
boot (warm start). After an error-free series machine start-up, the control system will
be in a fully configured operating condition.

Start-up archive (HMI)


This data backup is created analogously to the start-up archive (NC/PLC). For creation and
reading in, select System > 802D data > Start-up files > Start-up archive (HMI).

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12.3 Data backup in case of backlight failure

12.3 Data backup in case of backlight failure


In case of failure of the backlight of the control system, menu-assisted operation is no longer
possible. If a backlight failure occurs on the control system, an external data backup can be
carried out on a PC using a special command.
To do so, the CF card must be inserted.
After turning on the control system, wait until the boot sequence is completed and press
CTRL S. This will output the series machine start-up archives (NC/PLC and HMI) with the
latest current data.

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Data Backup and Series Machine Start-Up
12.3 Data backup in case of backlight failure

Notes

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12-194 6FC5 397-0CP10-1BA0
Machine and Setting Data 802D A
Data type
BOOLEAN Boolean value: 1 (TRUE) or 0 (FALSE)

BYTE 8-bit value,


as an integer value: –128 ... 127,
as a hexadecimal value: 00 ... FF
as a character as per ASCII character set, e.g. “a”

STRING Sequence of characters (max. 16)

WORD 16-bit value,


as an INTEGER value: –32768 ... 32767,
as a hexadecimal value: 0000 ... FFFF

UNSIGNED WORD 16-bit value,


as an integer value: 0 ... 65535,
as a hexadecimal value: 0000 ... FFFF

INTEGER 16-bit value (here defined locally),


integer value: –32768 ... 32767

DWORD 32-bit value,


as an integer value: –2147483648 ... 2147483647,
as a hexadecimal value: 0000 0000 ... FFFF FFFF

UNSIGNED DWORD 32-bit value,


as an integer value: 0 ... 4294967295,
as a hexadecimal value: 0000 0000 ... FFFF FFFF

DOUBLE 64-bit value,


floating point value: " 4.19  10–307 bis " 1.67  10308

Range of values (minimum/maximum value)


If no range of values is specified, the data type determines the input limits and the field is
marked with “***”.

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Machine and Setting Data 802D
A.1 List of machine data

A.1 List of machine data


A.1.1 Display machine data

Cross refe-
rence to the
relevant sec-
Number MD identifier tion/chapter
in the Des-
cription of
Functions
Read/write
Schematic view Name, miscellaneous Activation
protection level
Unit Default value Minimum value Maximum value Data type

202 FIRST_LANGUAGE 19
decimal Foreground language POWER ON 2/3
0 2 1 2 BYTE

203 DISPLAY_RESOLUTION 19
decimal Display resolution immediately 2/3
0 3 0 5 BYTE

204 DISPLAY_RESOLUTION_INCH 19
decimal Display resolution immediately 2/3
0 4 0 5 BYTE

205 DISPLAY_RESOLUTION_SPINDLE 19
decimal Display resolution immediately 2/3
0 1 0 5 BYTE

208 USER_CLASS_WRITE_TOA_GEO
decimal Protection level write tool geometry immediately 3/3
0 3 0 7 BYTE

209 USER_CLASS_WRITE_TOA_WEAR
decimal Protection level write tool wear data immediately 3/3
0 3 0 7 BYTE

210 USER_CLASS_WRITE_ZOA
decimal Protection level for “Write settable work offset” immediately 3/3
0 3 0 7 BYTE

212 USER_CLASS_WRITE_SEA
decimal Protection level for “Write setting data” immediately 3/3
0 7 0 7 BYTE

213 USER_CLASS_READ_PROGRAM
decimal Protection level for “Read part program” immediately 3/3
0 7 0 7 BYTE

214 USER_CLASS_WRITE_PROGRAM
decimal Protection level for “Enter part program” immediately 3/3
0 3 0 7 BYTE

215 USER_CLASS_SELECT_PROGRAM
decimal Protection level for program selection immediately 3/3
0 3 0 7 BYTE

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Machine and Setting Data 802D
A.1 List of machine data

217 USER_CLASS_WRITE_CYCLES
decimal Protection level for “Write cycles” immediately 3/3
0 3 0 7 BYTE

218 USER_CLASS_WRITE_RPA
decimal Protection level write R parameters immediately 3/3
0 3 0 7 BYTE

219 USER_CLASS_SET_V24
decimal Protection level for “Set V24” immediately 3/3
0 3 0 7 BYTE

221 USER_CLASS_DIR_ACCESS
decimal Protection level for directory access immediately 3/3
0 3 0 7 BYTE

222 USER_CLASS_PLC_ACCESS
decimal Protection level for PLC project immediately 2/2
0 3 0 7 BYTE

223 USER_CLASS_WRITE_PWA
decimal Protection level for protected working area immediately 2/3
0 7 0 7 BYTE

247 V24_PG_PC_BAUD
Bit pattern PG: Baud rate (300, 600, 1200, 2400, 4800, 9600, 19200, 38400) immediately 3/3
0 7 0 7 BYTE

280 V24_PPI_ADDR_PLC
PLCstation address POWER ON 3/3
2 0 126 BYTE

281 V24_PPI_ADDR_NCK
NCKstation address POWER ON 3/3
3 0 126 BYTE

289 CTM_SIMULATION_TIME_NEW_POS 10 (K1)


decimal Simulation of actual-value refresh rate immediately 3/4
0 100 0 4000 INTEGER

290 CTM_POS_COORDINATE_SYSTEM 10 (K1)


decimal Position of the coordinate system immediately 3/4
0 2 0 7 BYTE

291 CTM_CROSS_AX_DIAMETER_ON 10 (K1)


decimal Diameter for “Transverse axis active” immediately 3/4
0 1 0 1 BYTE

292 CTM_G91_DIAMETER_ON 10 (K1)


decimal Incremental feed immediately 3/7
0 1 0 1 BYTE

305 G_GROUP1
decimal User-oriented G group for position display immediately 3/7
0 1 1 1000 INTEGER

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Machine and Setting Data 802D
A.1 List of machine data

306 G_GROUP2
decimal User-oriented G group for position display immediately 3/7
0 2 1 1000 INTEGER

307 G_GROUP3
decimal User-oriented G group for position display immediately 3/7
0 8 1 1000 INTEGER

308 G_GROUP4
decimal User-oriented G group for position display immediately 3/7
0 9 1 1000 INTEGER

309 G_GROUP5
decimal User-oriented G group for position display immediately 3/7
0 10 1 1000 INTEGER

310 FG_GROUP1
decimal User-oriented G group for position display (external language) immediately 3/7
0 1 1 1000 INTEGER

311 FG_GROUP2
decimal User-oriented G group for position display (external language) immediately 3/7
0 2 1 1000 INTEGER

312 FG_GROUP3
decimal User-oriented G group for position display (external language) immediately 3/7
0 8 1 1000 INTEGER

313 FG_GROUP4
decimal User-oriented G group for position display (external language) immediately 3/7
0 9 1 1000 INTEGER

314 FG_GROUP5
decimal User-oriented G group for position display (external language) immediately 3/7
0 10 1 1000 INTEGER

330 CMM_POS_COORDINATE_SYSTEM
decimal Coordinate position of machine *) immediately 3/7
0 0 0 7 BYTE

*) Explanation:
Both the position and the size of the representation are handed over during initialization. The position of the coordinate system
can be influenced by the parameter “Axis direction” in the header of the file.
The following positions are possible: Position X+ Z+
0 up to the right
1 up to the left
2 down to the right
3 down to the left
4 to the right top
5 to the left up
6 to the right down
7 to the left down
The positions of the elements must be specified in position 4 (mathematic coordinate system). The simulation will then auto-
matically convert the representation to the relevant system.

331 CONTOUR_MASK
decimal Activating the 802 contour definition programming immediately 3/7
0 1 0 1 BYTE

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A.1 List of machine data

332 TOOL_LIST_PLACE_NO
decimal Activate location number in tool list immediately 3/3
0 0 0 1 INTEGER

343 V24_PPI_ADDR_MMC
decimal POWER ON 3/3
0 4 0 126

344 V24_PPI_MODEM_ACTIVE
decimal immediately 3/3
0 0 0 1 Byte

345 V24_PPI_MODEM_BAUD
decimal Baud rate for modem connection immediately 3/3
0 7 5 9 Byte

346 V24_PPI_MODEM_PARITY
decimal Parity for modem connection immediately 3/3
0 0 0 2 Byte

356 HMI_COL_TITLE_FOCUS_FORE
decimal Color settings title bar focus window foreground immediately 0/3
15 0 15 Byte

357 HMI_COL_TITLE_FOCUS_BACK
decimal Color settings title bar focus window background immediately 0/3
2 0 15 Byte

358 HMI_COL_SK_FORE
decimal Color settings softkey foreground POWER ON 3/3
0 0 15 Byte

359 HMI_COL_SK_BACK
decimal Color settings softkey background POWER ON 3/3
7 0 15 Byte

360 SPINDLE_LOAD_DISPL1
decimal Activate utilization display for spindle 1 immediately 3/3
0 0 1 Integer

361 USER_MEAS_TOOL_CHANGE
decimal Input enable for T/D no. in the “Tool gauging” window immediately 3/3
0 0 1 Byte

362 SPINDLE_LOAD_DISPL2
decimal Activate utilization display for spindle 2 immediately 3/3
1 0 1 Integer

363 SPINDLE_LOAD_BAR_LIM2
decimal Activate utilization display for the spindle, limit value 2 immediately 2/2
100 0 9999999 Integer

364 SPINDLE_LOAD_BAR_LIM3
decimal Activate utilization display for the spindle, limit value 3 immediately 2/2
100 0 9999999 Integer

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Machine and Setting Data 802D
A.1 List of machine data

365 SPINDLE_LOAD_BAR_MAX
decimal Utilization display for the spindle, maximum immediately 2/2
120 0 120 Integer

366 SPINDLE_LOAD_BAR_COL1
decimal Utilization display color for the spindle, range 1 immediately 3/3
10 0 15 Byte

367 SPINDLE_LOAD_BAR_COL2
decimal Utilization display color for the spindle, range 2 immediately 3/3
9 0 15 Byte

368 SPINDLE_LOAD_BAR_COL3
decimal Utilization display color for the spindle, range 3 immediately 3/3
9 0 15 Byte

369 PROBE_MODE
decimal Measuring system type: 1: Probe, 2: Opt. measuring technique immediately 3/3
1 0 2 Integer

370 TOOL_REF_PROBE_AXIS1
decimal Absolute position of probe X immediately 2/2
0 –999999.999 999999.999 Double

371 TOOL_REF_PROBE_AXIS2
decimal Absolute position of probe Y immediately 2/2
0 –999999.999 999999.999 Double

372 TOOL_REF_PROBE_AXIS3
decimal Absolute position of probe Z immediately 2/2
9 –999999.999 999999.999 Double

373 MEAS_SAVE_POS_LENGTH2
decimal Activate tool gauging; select “Save Pos” softkey for all values immediately 2/2
0 0 1 Byte

374 TOOL_WEAR_LIMIT_VALUE
decimal Limit value for wear control during input immediately 2/2
9.999 0 9.999 Double

375 USER_CLASS_READ_CUS_DIR
decimal Protection level for “Read user cycles” immediately 2/3
0 7 0 7 Byte

376 USER_CLASS_WRITE_CUS_DIR
decimal Protection level for “Write user cycles” immediately 2/2
0 2 0 7 Byte

377 USER_CLASS_WRITE_TO_MON_DAT
decimal Protection level for “Tool monitoring” immediately 2/3
0 3 0 7 Byte

378 USER_CLASS_LADDER_VIEW
decimal Protection level for “Select user ladder view” immediately 2/2
0 2 0 7 Byte

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Machine and Setting Data 802D
A.1 List of machine data

379 SPINDLE_DISP_MODE
0: Standard mode, display of spindle speed
decimal 1: Constant cutting rate, display with G96 set immediately 3/3
2: Mixed display
0 0 0 2 Byte

A.1.2 General machine data


MD MD identifier
number
Unit Brief description Activation
Display filter Attributes Data type
Default Dimension Default value Minimum value Maximum value Protection
System * Dimension Default value Minimum value Maximum value Protection
* Values other than those in the standard system
Note regarding the value definition:
TRUE corresponds to 1
FALSE corresponds to 0

10000 AXCONF_MACHAX_NAME_TAB
– Machine axis name POWER ON
N01, N11 – STRING
Default 6 “X1”, “Y1”, “Z1”, “SP”, – – 2/2
“A1”, “PLCX1”

10008 MAXNUM_PLC_CTRL_AXES
– Max. no. PLC-controlled axes POWER ON
N01, N09 – BYTE
Default – 0 0 1 2/2

10074 PLC_IPO_TIME_RATIO
– Factor of the PLC task for main run POWER ON
N01, N05 – DWORD
Default – 1 1 50 2/2

10088 REBOOT_DELAY_TIME
s Reboot delay IMMED.
EXP – DOUBLE
Default – 0.2 0.0 1.0 2/2

10200 INT_INCR_PER_MM
– Computational resolution for linear positions POWER ON
N01 – DOUBLE
Default – 1000.0 1.0 1.0e9 2/2

10210 INT_INCR_PER_DEG
– Computational resolution for angular positions POWER ON
N01 – DOUBLE
Default – 1000.0 1.0 1.0e9 2/2

10240 SCALING_SYSTEM_IS_METRIC
– Metric basic system POWER ON
N01 SCAL BOOLEAN
Default – TRUE – – 2/2

10710 PROG_SD_RESET_SAVE_TAB
– Setting data to be updated POWER ON
EXP, N01 – DWORD
Default 30 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, – – 2/2
0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,
0, 0, 0, 0, 0, 0, 0, 0

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Machine and Setting Data 802D
A.1 List of machine data

10713 M_NO_FCT_STOPRE
– M function with preprocessing stop POWER ON
EXP, N12, N07 – DWORD
Default 15 –1, –1, –1, –1, –1, –1, –1, – – 2/2
–1, –1, –1, –1, –1, –1, –1,
–1

10714 M_NO_FCT_EOP
– M function active for spindle after reset POWER ON
EXP, N07 – DWORD
Default – –1 – – 2/2

10715 M_NO_FCT_CYCLE
– M function to be replaced by a subroutine POWER ON
EXP, N12, N07 – DWORD
Default 10 –1, –1, –1, –1, –1, –1, –1, – – 2/2
–1, –1, –1

10716 M_NO_FCT_CYCLE_NAME
– Subroutine name for replacement of an M function POWER ON
EXP, N12, N07 – STRING
Default 10 – – 2/2

10717 T_NO_FCT_CYCLE_NAME
– Subroutine name for replacement of a T function POWER ON
EXP, N12, N07 – STRING
Default –1 – – 2/2

10718 M_NO_FCT_CYCLE_PAR
– M function replacement by parameters POWER ON
EXP, N12, N07 – DWORD
Default – –1 – – 2/2

10719 T_NO_FCT_CYCLE_MODE
– Parameterization of the T function replacement POWER ON
EXP, N12, N07 – DWORD
Default – 0 0 1 2/2

10735 JOG_MODE_MASK
– Enable jogging in the AUTOMATIC mode POWER ON
EXP, N01 – DWORD
Default – 0 0 0x1 2/2

10760 G53_TOOLCORR
– Effect with G53, G153 and SUPA POWER ON
N12 – BOOLEAN
Default – FALSE – – 2/2

10810 EXTERN_MEAS_G31_P_SIGNAL
– Assignment of the measuring inputs for G31 P.. POWER ON
EXP, N12 – BYTE
Default 4 1, 1, 1, 1 0 3 2/2

10812 EXTERN_DOUBLE_TURRET_ON
– Double–resolver head with G68 POWER ON
EXP, N12 – BOOLEAN
Default – FALSE – – 2/2

10820 EXTERN_INTERRUPT_NUM_RETRAC
– Interrupt number f. rapid retraction (G10.6) POWER ON
EXP, N12 – BYTE
Default – 2 1 8 2/2

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A.1 List of machine data

10880 MM_EXTERN_CNC_SYSTEM
– Def. of control system to be adapted POWER ON
N01, N12 – DWORD
Default – 1 1 3 2/2

10881 MM_EXTERN_GCODE_SYSTEM
– ISO_3 Mode: GCodeSystem POWER ON
N01, N12 – DWORD
Default – 0 0 2 2/2

10882 NC_USER_EXTERN_GCODES_TAB
– List of user–specific G commands, ext. language POWER ON
N12 – STRING
Default 60 – – 2/2

10884 EXTERN_FLOATINGPOINT_PROG
– Evaluation of progr. values without decimal point POWER ON
N12 – BOOLEAN
Default – TRUE – – 2/2

10886 EXTERN_INCREMENT_SYSTEM
– Increment system POWER ON
N12 – BOOLEAN
Default – FALSE – – 2/2

10888 EXTERN_DIGITS_TOOL_NO
– Number of digits for T number POWER ON
N12 – BYTE
Default – 2 0 8 2/2

10890 EXTERN_TOOLPROG_MODE
– Tool change program with ext. language POWER ON
N12 – DWORD
Default – 0 – – 2/2

11100 AUXFU_MAXNUM_GROUP_ASSIGN
– Number of auxiliary functions in AuxF groups POWER ON
N01, N07, N02 – DWORD
plus – 1 1 255 2/2

11160 ACCESS_EXEC_CST
– Right of execution for /_N_CST_DIR POWER ON
N01 – BYTE
Default – 7 – – 2/2

11161 ACCESS_EXEC_CMA
– Right of execution for /_N_CMA_DIR POWER ON
N01 – BYTE
Default – 7 – – 2/2

11162 ACCESS_EXEC_CUS
– Right of execution for /_N_CUS_DIR POWER ON
N01 – BYTE
Default – 7 – – 3/3

11165 ACCESS_WRITE_CST
– Right protection for /_N_CST_DIR POWER ON
N01 – DWORD
Default – –1 – – 2/2

11166 ACCESS_WRITE_CMA
– Right protection for directory /_N_CMA_DIR POWER ON
N01 – DWORD
Default – –1 – – 2/2

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Machine and Setting Data 802D
A.1 List of machine data

11167 ACCESS_WRITE_CUS
– Right protection for directory /_N_CUS_DIR POWER ON
N01 – DWORD
Default – –1 – – 3/3

11170 ACCESS_WRITE_SACCESS
– Write protection for _N_SACCESS_DEF POWER ON
N01 – BYTE
Default – 7 – – 2/2

11171 ACCESS_WRITE_MACCESS
– Write protection for _N_MACCESS_DEF POWER ON
N01 – BYTE
Default – 7 – – 2/2

11172 ACCESS_WRITE_UACCESS
– Write protection for _N_UACCESS_DEF POWER ON
N01 – BYTE
Default – 7 – – 3/3

11210 UPLOAD_MD_CHANGES_ONLY
– MD backup only for changed MD IMMEDIATEL
Y
N01, N05 – BYTE
Default – 0xFF – – 7/3
plus – 0x0F – – 2/2

11240 PROFIBUS_SDB_NUMBER
– SDB1000 number POWER ON
N01, N05 – DWORD
Default 4 –1, –1, –1, –1 –1 7 2/2
plus – 0, –1, 1, –1 – 1 2/2

11250 PROFIBUS_SHUTDOWN_TYPE
– Profibus Shutdown handling POWER ON
EXP, N01 – BYTE
Default – 0 0 2 2/2

11310 HANDWH_REVERSE
– Threshold for handwheel direction reversal POWER ON
N09 – BYTE
Default – 2 – – 2/2

11320 HANDWH_IMP_PER_LATCH
– Handwheel pulses per locking position POWER ON
N09 – DOUBLE
Default 6 1., 1., 1., 1., 1., 1. – – 2/2

11346 HANDWH_TRUE_DISTANCE
– Handwheel travel or speed specification POWER ON
N01 – BYTE
Default – 0 0 3 2/2

13060 DRIVE_TELEGRAM_TYPE
– Standard message frame type for Profibus DP POWER ON
N04, N10 – DWORD
Default 31 102, 102, 102, 102, 102, – – 2/2
102, 102, 102, 102, 102,
102, 102, 102, 102, 102,
102, 102, 102, 102, 102,
102, 102, 102, 102, 102,
102, 102, 102, 102, 102,
102

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A.1 List of machine data

13070 DRIVE_FUNCTION_MASK
– Used DP functions POWER ON
N04, N10 – DWORD
Default 31 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, – – 2/2
0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,
0, 0, 0, 0, 0, 0, 0, 0, 0

13080 DRIVE_TYPE_DP
– Drive type with Profibus POWER ON
EXP – BYTE
Default 31 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 4 2/2
0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,
0, 0, 0, 0, 0, 0, 0, 0, 0

13200 MEAS_PROBE_LOW_ACTIVE
– Polarity change of the probe POWER ON
N10, N09 – BOOLEAN
Default 2 FALSE, FALSE – – 3/3

13220 MEAS_PROBE_DELAY_TIME
s Detection of probe deflection delay time POWER ON
N10, N09 – DOUBLE
Default 2 0.0, 0.0 0 0.1 3/3

14510 USER_DATA_INT
– User data (INT) POWER ON
N03 – DWORD
Default 32 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, –32768 32767 7/3
0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,
0, 0, 0, 0, 0, 0, 0, 0, 0, 0

14512 USER_DATA_HEX
– User data (HEX) POWER ON
N03 – DWORD
Default 32 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 0x0FF 7/3
0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,
0, 0, 0, 0, 0, 0, 0, 0, 0, 0

14514 USER_DATA_FLOAT
– User data (FLOAT) POWER ON
N03 – DOUBLE
Default 8 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, –3.40e38 3.40e38 7/3
0.0, 0.0

14516 USER_DATA_PLC_ALARM
– User data (HEX) POWER ON
N03 – BYTE
Default 64 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, – – 7/3
0, 0, 0, 0, 0, 0, 0…

17530 TOOL_DATA_CHANGE_COUNTER
– Mark tool data change for HMI POWER ON
EXP, N01 – DWORD
Default – 0 0 0xF 2/2

18040 VERSION_INFO
– Version and (if necessary) date of PCMCIA card POWER ON
N05 READ STRING
Default 4 – – 7/2
plus – “802D–TM2” – – 2/2

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Machine and Setting Data 802D
A.1 List of machine data

18050 INFO_FREE_MEM_DYNAMIC
– Free unbuffered memory [bytes] POWER ON
N01, N02, N05 READ DWORD
Default – 430080 – – 7/2
plus – 1048576 – – 7/2

18060 INFO_FREE_MEM_STATIC
– Free buffered memory [bytes] POWER ON
N01, N02, N05 READ DWORD
Default – 262144 – – 7/2
plus – – – 7/2

18080 MM_TOOL_MANAGEMENT_MASK
– Reserved memory for the tool management (SRAM) POWER ON
N02, N09 – DWORD
Default – 0x0 0 0xFFFF 2/2

18102 MM_TYPE_OF_CUTTING_EDGE
– Type of D number programming (SRAM) POWER ON
N02, N09 – DWORD
Default – 0 0 1 2/2

18120 MM_NUM_GUD_NAMES_NCK
– Number of global GUD definitions (SRAM) POWER ON
N02 – DWORD
Default – 50 – – 2/2

18130 MM_NUM_GUD_NAMES_CHAN
– Number of channel GUD definitions (SRAM) POWER ON
N02 – DWORD
Default – 100 – – 2/2

18150 MM_GUD_VALUES_MEM
– Memory space for GUD values (SRAM) POWER ON
N02 – DWORD
Default – 32 – – 2/2

A.1.3 Channelspecific machine data


MD MD identifier
number
Unit Brief description Activation
Display filter Attributes Data type
Default Dimension Default value Minimum value Maximum value Protection
System * Dimension Default value Minimum value Maximum value Protection
* Values other than those in the standard system

Note regarding the value definition:


TRUE corresponds to 1
FALSE corresponds to 0

20050 AXCONF_GEOAX_ASSIGN_TAB
– Assignment ‘geometry/channel axis’ POWER ON
C01, C10 – BYTE
Default 3 1, 2, 3 0 6 2/2

20070 AXCONF_MACHAX_USED
– Machine axis number valid in channel POWER ON
C01, C10 – BYTE
Default 6 1, 2, 3, 4, 5, 0, 0 6 2/2

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Machine and Setting Data 802D
A.1 List of machine data

20080 AXCONF_CHANAX_NAME_TAB
– Name of channel axis in the channel POWER ON
C01, C11, C10 – STRING
Default 6 “X”, “Y”, “Z”, “SP”, “A”, – – 2/2
“PLCX”

20090 SPIND_DEF_MASTER_SPIND
– Number of master spindle POWER ON
C01, C03 – BYTE
Default – 1 1 2 2/2

20094 SPIND_RIGID_TAPPING_M_NR
– M function for axis mode (Siemens mode) POWER ON
C01, C03, C10 – DWORD
Default – 70 – – 2/2

20095 EXTERN_RIGID_TAPPING_M_NR
– M function for axis mode (external mode) POWER ON
C01, C11, C03, C10 – DWORD
Default – 29 – – 2/2

20106 PROG_EVENT_IGN_SINGLEBLOCK
– Prog events ignore single block POWER ON
N01 – DWORD
Default – 0x0 0 0x1F 2/2

20107 PROG_EVENT_IGN_INHIBIT
– Prog events ignore read–in disable POWER ON
N01 – DWORD
Default – 0x0 0 0x1F 2/2

20108 PROG_EVENT_MASK
– Event–controlled program calls POWER ON
N01 – DWORD
Default – 0x0 0 0xF 7/2
plus – – – – 2/2

20140 TRAFO_RESET_VALUE
– Active transformation in case of RESET RESET
C03 – BYTE
Default – 0 0 2 2/2

20204 WAB_CLEARANCE_TOLERANCE
mm Direction reversal with SAR POWER ON
C06 – DOUBLE
Default – 0.01 – – 2/2

20310 TOOL_MANAGEMENT_MASK
– Activate tool management functions POWER ON
C09 – DWORD
Default – 0x0 0 0xFFFFFFF 2/2

20320 TOOL_TIME_MONITOR_MASK
– Time monitoring for the tool in the toolholder POWER ON
C06, C09 – DWORD
Default – 0x1 – – 2/2

20360 TOOL_PARAMETER_DEF_MASK
– Definition of the tool parameters POWER ON
C09 – DWORD
Default – 0x0 0 0xFFFF 2/2

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Machine and Setting Data 802D
A.1 List of machine data

20380 TOOL_CORR_MODE_G43G44
– Handling of tool length compensation G43/44 RESET
C01, C08, C11 – BYTE
Default – 0 0 2 2/2

20450 LOOKAH_RELIEVE_BLOCK_CYCLE
– Block cycle time relief factor POWER ON
EXP, C05 – DOUBLE
Default – 0.0 – – 2/2

20460 LOOKAH_SMOOTH_FACTOR
% Smoothing factor for Look Ahead NEW CONF
EXP, C05 – DOUBLE
Default – 0.0 0. 500.0 2/2

20500 CONST_VELO_MIN_TIME
s Minimum time with constant velocity POWER ON
EXP, C05 – DOUBLE
Default – 0.0 0.0 0.1 2/2

20550 EXACT_POS_MODE
– Exact stop conditions with G00 and G01 NEW CONF
EXP – BYTE
Default – 0 0 33 2/2

20552 EXACT_POS_MODE_G0_TO_G1
– Exact stop conditions with the transition G00–>G01 NEW CONF
EXP – BYTE
Default – 0 0 5 2/2

20700 REFP_NC_START_LOCK
– NC start disable without reference point RESET
C01, C03 – BOOLEAN
Default – TRUE – – 2/2

20730 G0_LINEAR_MODE
– Interpolation behavior with G0 POWER ON
C09 – BOOLEAN
Default – TRUE – – 2/2

20732 EXTERN_G0_LINEAR_MODE
– Interpolation behavior with G00 POWER ON
N12 – BOOLEAN
Default – TRUE – – 2/2

20734 EXTERN_FUNCTION_MASK
– Function mask for external language RESET
N12 – DWORD
Default – 0 0 0xFFFF 2/2

21000 CIRCLE_ERROR_CONST
mm Circle end point monitoring constant POWER ON
C06 – DOUBLE
Default – 0.01 – – 2/2

21010 CIRCLE_ERROR_FACTOR
– Circle end point monitoring factor POWER ON
C06 – DOUBLE
Default – 0.001 – – 2/2

21020 WORKAREA_WITH_TOOL_RADIUS
– Tool radius with working area limitation RESET
C03, C06 – BOOLEAN
Default – FALSE – – 2/2

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A.1 List of machine data

22000 AUXFU_ASSIGN_GROUP
– Auxiliary function group POWER ON
C04 – BYTE
Default 255 1 1 64 7/2
plus 64 – – – 2/2

22010 AUXFU_ASSIGN_TYPE
– Auxiliary function type POWER ON
C04 – STRING
Default 255 ”” – – 7/2
plus 64 – – – 2/2

22020 AUXFU_ASSIGN_EXTENSION
– Auxiliary function extension POWER ON
C04 – BYTE
Default 255 0 0 99 7/2
plus 64 – – – 2/2

22030 AUXFU_ASSIGN_VALUE
– Auxiliary function value POWER ON
C04 – DWORD
Default 255 0 – – 7/2
plus 64 – – – 2/2

22035 AUXFU_ASSIGN_SPEC
– Output specification POWER ON
C04 – DWORD
Default 255 0 – – 7/2
plus 64 – – – 2/2

22040 AUXFU_PREDEF_GROUP
– Predefined auxiliary function groups POWER ON
C04 – BYTE
Default 33 1, 1, 1, 1, 1, 1, 2, 2, 2, 2, 2, 0 64 7/2
4, 4, 4, 4, 4, 4, 3, 1, 1, 1, ...
plus – – – – 2/2

22050 AUXFU_PREDEF_TYPE
– Predefined auxiliary function type POWER ON
C04 – STRING
Default 33 “M”, “M”, “M”, “M”, “M”, “M”, – – 7/2
“M”, “M”, “M”, “M”, “M”, “M”,
“M”...
plus – – – – 2/2

22060 AUXFU_PREDEF_EXTENSION
– Predefined auxiliary function extension POWER ON
C04 – BYTE
Default 33 0, 0, 0, 0, 0, 1, 1, 1, 1, 1, 0 99 7/2
1, 1, 1, 1, 1, 1, 1, 1, 0, 0,
0…
plus – – – – 2/2

22070 AUXFU_PREDEF_VALUE
– Predefined auxiliary function value POWER ON
C04 – DWORD
Default 33 0, 1, 2, 17, 30, 6, 3, 4, 5, – – 7/2
19, 70, 40, 41, 42, 43, 44,
45, –1...
plus – – – – 2/2

22254 AUXFU_ASSOC_M0_VALUE
– Additional M functions for program stop POWER ON
C01, C03, C10 – DWORD
Default – –1 – – 2/2

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Machine and Setting Data 802D
A.1 List of machine data

22256 AUXFU_ASSOC_M1_VALUE
– Additional M functions for conditional stop POWER ON
C01, C03, C10 – DWORD
Default – –1 – – 2/2

22400 S_VALUES_ACTIVE_AFTER_RESET
– S function active even after RESET POWER ON
C04, C03, C05 – BOOLEAN
Default – FALSE – – 2/2

22410 F_VALUES_ACTIVE_AFTER_RESET
– F function active even after RESET POWER ON
C04, C03, C05 – BOOLEAN
Default – FALSE – – 2/2

22534 TRAFO_CHANGE_M_CODE
– M code when switching the transformation type POWER ON
C04 – DWORD
Default – 0 0 99999999 2/2

22550 TOOL_CHANGE_MODE
– New tool offset with T or M function POWER ON
C01, C11, C04, C09 – BYTE
Default – 0 0 1 2/2

22910 WEIGHTING_FACTOR_FOR_SCALE
– Input resolution for scaling factor POWER ON
EXP, C01, C11 – BOOLEAN
Default – FALSE – – 2/2

22914 AXES_SCALE_ENABLE
– Activation for axial scaling factor G51 POWER ON
EXP, C01, C11 – BOOLEAN
Default – FALSE – – 2/2

22920 EXTERN_FIXED_FEEDRATE_F1_ON
– Activate fixed feedrate F1 – F9 POWER ON
EXP, C01, C11 – BOOLEAN
Default – FALSE – – 2/2

22930 EXTERN_PARALLEL_GEOAX
– Assignment of parallel channel geometry axis POWER ON
EXP, C01, C11 – BYTE
Default 3 0 0 6 2/2

24020 FRAME_SUPPRESS_MODE
– Positions with frame suppression POWER ON
C03 – DWORD
Default – 0x0 0 0x0000003 2/2

24100 TRAFO_TYPE_1
– Transformation 1 in the channel NEW CONF
C07 – DWORD
Default – 0 – – 2/2

24110 TRAFO_AXES_IN_1
– Axis assignment for transformation 1 NEW CONF
C07 – BYTE
Default 20 1, 2, 3, 4, 5, 0, 0, 0, 0, 0, 0, 0 6 7/7
0, 0, 0, 0, 0, 0, 0, 0, 0, 0...
plus 6 – – – 2/2

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A.1 List of machine data

24120 TRAFO_GEOAX_ASSIGN_TAB_1
– GEO/channel axis assignment for transformation 1 NEW CONF
C07 – BYTE
Default 3 0 0 6 2/2

24130 TRAFO_INCLUDES_TOOL_1
– Tool handling with active 1st transformation NEW CONF
C07 – BOOLEAN
Default – TRUE – – 2/2

24200 TRAFO_TYPE_2
– Transformation 2 in the channel NEW CONF
C07 – DWORD
Default – 0 – – 2/2

24210 TRAFO_AXES_IN_2
– Axis assignment for transformation 2 NEW CONF
C07 – BYTE
Default 20 1, 2, 3, 4, 5, 0 0 6 7/7
plus 6 – – – 2/2

24220 TRAFO_GEOAX_ASSIGN_TAB_2
– GEO/channel axis assignment for transformation 2 NEW CONF
C07 – BYTE
Default 3 0, 0, 0 0 6 2/2

24230 TRAFO_INCLUDES_TOOL_2
– Tool handling with active 2nd transformation NEW CONF
C07 – BOOLEAN
Default – TRUE – – 2/2

24573 TRAFO5_AXIS3_1
– Direction of 3rd rotary axis NEW CONF
C07 – DOUBLE
Default 3 0.0, 0.0, 0.0 – – 7/7

24800 TRACYL_ROT_AX_OFFSET_1
degrees Rotary axis offset TRACYL 1 NEW CONF
C07 – DOUBLE
Default – 0.0 – – 2/2

24805 TRACYL_ROT_AX_FRAME_1
– Rotary axis offset TRACYL 1 NEW CONF
C07 – BYTE
Default – 0 0 2 2/2

24808 TRACYL_DEFAULT_MODE_1
– Selection of the TRACYL mode NEW CONF
C07 – BYTE
Default – 0 0 1 2/2

24810 TRACYL_ROT_SIGN_IS_PLUS_1
– Sign of the rotary axis NEW CONF
C07 – BOOLEAN
Default – TRUE – – 2/2

24820 TRACYL_BASE_TOOL_1
mm Base tool vector NEW CONF
C07 – DOUBLE
Default 3 0.0, 0.0, 0.0 – – 2/2

24850 TRACYL_ROT_AX_OFFSET_2
degrees Rotary axis offset TRACYL 2 NEW CONF
C07 – DOUBLE
Default – 0.0 – – 2/2

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Machine and Setting Data 802D
A.1 List of machine data

24855 TRACYL_ROT_AX_FRAME_2
– Rotary axis offset TRACYL 2 NEW CONF
C07 – BYTE
Default – 0 0 2 2/2

24858 TRACYL_DEFAULT_MODE_2
– Selection of the TRACYL mode NEW CONF
C07 – BYTE
Default – 0 0 1 2/2

24860 TRACYL_ROT_SIGN_IS_PLUS_2
– Sign of the rotary axis NEW CONF
C07 – BOOLEAN
Default – TRUE – – 2/2

24870 TRACYL_BASE_TOOL_2
mm Base tool vector NEW CONF
C07 – DOUBLE
Default 3 0.0, 0.0, 0.0 – – 2/2

24900 TRANSMIT_ROT_AX_OFFSET_1
degrees Rotary axis offset TRANSMIT 1 NEW CONF
C07 – DOUBLE
Default – 0.0 – – 2/2

24905 TRANSMIT_ROT_AX_FRAME_1
– Rotary axis offset TRANSMIT 1 NEW CONF
C07 – BYTE
Default – 0 0 2 2/2

24910 TRANSMIT_ROT_SIGN_IS_PLUS_1
– Sign of the rotary axis NEW CONF
C07 – BOOLEAN
Default – TRUE – – 2/2

24911 TRANSMIT_POLE_SIDE_FIX_1
– Limiting of working area in front of / after the pole NEW CONF
C07 – BYTE
Default – 0 0 2 2/2

24920 TRANSMIT_BASE_TOOL_1
mm Base tool vector NEW CONF
C07 – DOUBLE
Default 3 0.0, 0.0, 0.0 – – 2/2

24950 TRANSMIT_ROT_AX_OFFSET_2
degrees Rotary axis offset TRANSMIT 2 NEW CONF
C07 – DOUBLE
Default – 0.0 – – 2/2

24955 TRANSMIT_ROT_AX_FRAME_2
– Rotary axis offset TRANSMIT 2 NEW CONF
C07 – BYTE
Default – 0 0 2 2/2

24960 TRANSMIT_ROT_SIGN_IS_PLUS_2
– Sign of the rotary axis NEW CONF
C07 – BOOLEAN
Default – TRUE – – 2/2

24961 TRANSMIT_POLE_SIDE_FIX_2
– Limitation of the working area in front of/after the pole NEW CONF
C07 – BYTE
Default – 0 0 2 2/2

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A.1 List of machine data

24970 TRANSMIT_BASE_TOOL_2
mm Base tool vector NEW CONF
C07 – DOUBLE
Default 3 0.0, 0.0, 0.0 – – 2/2

27100 ABSBLOCK_FUNCTION_MASK
– Block display parameterized with absolute values POWER ON
N01 – DWORD
Default – 0x0 0 0x1 2/2

27800 TECHNOLOGY_MODE
– Technology in the channel NEW CONF
C09 – BYTE
Default – 0 – – 7/2
plus – 0 – – 2/2

27860 PROCESSTIMER_MODE
– Activating the program runtime measurement RESET
C09 – DWORD
Default – 0x00 0 0x0FF 7/2
plus – 0x07 – – 2/2

27880 PART_COUNTER
– Activate workpiece counter RESET
C09 – DWORD
Default – 0x0 0 0x0FFFF 3/2

27882 PART_COUNTER_MCODE
– Workpiece counting using a user–defined M command POWER ON
C09 – BYTE
Default 3 2, 2, 2 0 99 3/2

28400 MM_ABSBLOCK
– Activate block display with absolute values POWER ON
EXP, C02 – DWORD
Default – 0 – – 2/2

28402 MM_ABSBLOCK_BUFFER_CONF
– Dimension size of upload buffer POWER ON
EXP, C02 – DWORD
Default 2 0, 0 – – 2/2

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Machine and Setting Data 802D
A.1 List of machine data

A.1.4 Axisspecific machine data


MD MD identifier
number
Unit Brief description Activation
Display filter Attributes Data type
Default Dimension Default value Minimum value Maximum value Protection
System * Dimension Default value Minimum value Maximum value Protection
* Values other than those in the standard system

Note regarding the value definition:


TRUE corresponds to 1
FALSE corresponds to 0

30110 CTRLOUT_MODULE_NR
– Setpoint: Drive no./module no. POWER ON
–, – – BYTE
Default 1 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 1 31 2/2
11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24,
25, 26, 27, 28, 29, 30, 31

30120 CTRLOUT_NR
– Setpoint: Output to module POWER ON
EXP, – – BYTE
Default 1 1 1 3 2/2

30130 CTRLOUT_TYPE
– Setpoint output type POWER ON
–, – – BYTE
Default 1 0 0 3 2/2

30134 IS_UNIPOLAR_OUTPUT
– Setpoint output is unipolar POWER ON
– – BYTE
Default 1 0 0 2 2/2

30200 NUM_ENCS
– Number of encoders POWER ON
–, – – BYTE
Default – 1 0 1 2/2

30220 ENC_MODULE_NR
– Actual value: Drive no./measuring circuit no. POWER ON
–, –, – – BYTE
Default 1 1 1 31 7/2

30230 ENC_INPUT_NR
– Actual value: Input number on module/measuring circuit board POWER ON
–, –, – – BYTE
Default 1 1 1 3 2/2

30240 ENC_TYPE
– Actual value: Encoder type POWER ON
–, –, – – BYTE
Default 1 0 0 5 2/2

30270 ENC_ABS_BUFFERING
– Absolute encoder: Traversing range extension POWER ON
EXP, –, – – BYTE
Default 1 0 0 1 2/2

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A.1 List of machine data

30300 IS_ROT_AX
– Rotary axis/spindle POWER ON
–, –, – SCAL, CTEQ BOOLEAN
Default – FALSE – – 2/2

30310 ROT_IS_MODULO
– Modulo conversion for rotary axis/spindle POWER ON
–, –, – CTEQ BOOLEAN
Default – FALSE – – 2/2

30320 DISPLAY_IS_MODULO
– Display modulo 360 degrees for rotary axis POWER ON
–, –, – CTEQ BOOLEAN
Default – FALSE – – 2/2

30350 SIMU_AX_VDI_OUTPUT
– Axis signals for simulation axis POWER ON
–, – CTEQ BOOLEAN
Default – FALSE – – 2/2

30465 AXIS_LANG_SUB_MASK
– Substitution of NC language commands POWER ON
N01 – DWORD
Default – 0 0 3 2/2

30600 FIX_POINT_POS
mm, Axis position with G75 POWER ON
degrees
–, – – DOUBLE
Default 2 0.0, 0.0 – – 2/2

31000 ENC_IS_LINEAR
– Linear scale POWER ON
–, – – BOOLEAN
Default 1 FALSE – – 2/2

31010 ENC_GRID_POINT_DIST
mm Scale division with linear scales POWER ON
–, – – DOUBLE
Default 1 0.01 – – 2/2

31020 ENC_RESOL
– Encoder lines per revolution POWER ON
–, – – DWORD
Default 1 2048 – – 2/2

31030 LEADSCREW_PITCH
mm Lead of the ballscrew POWER ON
–, – – DOUBLE
Default – 10.0 – – 2/2

31040 ENC_IS_DIRECT
– Encoder mounted directly on the machine POWER ON
–, – – BOOLEAN
Default 1 FALSE – – 2/2

31044 ENC_IS_DIRECT2
– Encoders installed at the attached gearbox NEW CONF
– – BOOLEAN
Default 1 FALSE – – 2/2

31050 DRIVE_AX_RATIO_DENOM
– Load gearbox denominator POWER ON
–, – – DWORD
Default 6 1, 1, 1, 1, 1, 1 1 2147000000 2/2

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A.1 List of machine data

31060 DRIVE_AX_RATIO_NUMERA
– Load gearbox numerator POWER ON
–, – – DWORD
Default 6 1, 1, 1, 1, 1, 1 –2147000000 2147000000 2/2

31064 DRIVE_AX_RATIO2_DENOM
– Denominator of attached gearbox NEW CONF
– – DWORD
Default – 1 1 2147000000 2/2

31066 DRIVE_AX_RATIO2_NUMERA
– Numerator of attached gearbox NEW CONF
– – DWORD
Default – 1 –2147000000 2147000000 2/2

31070 DRIVE_ENC_RATIO_DENOM
– Measuring gearbox denominator POWER ON
–, – – DWORD
Default 1 1 1 2147000000 2/2

31080 DRIVE_ENC_RATIO_NUMERA
– Measuring gearbox numerator POWER ON
–, – – DWORD
Default 1 1 1 2147000000 2/2

31122 BERO_DELAY_TIME_PLUS
s BERO delay time NEW CONF
–, – – DOUBLE
Default 1 0.000110 – – 2/2

31123 BERO_DELAY_TIME_MINUS
s BERO delay time NEW CONF
–, – – DOUBLE
Default 1 0.000078 – – 2/2

32000 MAX_AX_VELO
mm/min, Maximum axis velocity NEW CONF
rev/min
–, – CTEQ DOUBLE
Default – 10000. – – 7/2

32010 JOG_VELO_RAPID
mm/min, Rapid traverse in the JOG mode RESET
rev/min
–, – CTEQ DOUBLE
Default – 10000. – – 7/2

32020 JOG_VELO
mm/min, JOG axis velocity RESET
rev/min
–, – CTEQ DOUBLE
Default – 2000. – – 7/2

32100 AX_MOTION_DIR
– Traversing direction (not control direction) POWER ON
–, –, – – DWORD
Default – 1 –1 1 2/2

32110 ENC_FEEDBACK_POL
– Sign of actual value (control direction) POWER ON
–, –, – – DWORD
Default 1 1 –1 1 2/2

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32200 POSCTRL_GAIN
1,000 r.p.m. Servo gain factor NEW CONF
–, – CTEQ DOUBLE
Default 6 16.66666667, 0 2000. 7/2
16.66666667,
16.66666667,
16.66666667,
16.66666667,
16.66666667

32210 POSCTRL_INTEGR_TIME
s Integral action time of the position controller NEW CONF
– – DOUBLE
Default – 1.0 0 10000.0 2/2

32220 POSCTRL_INTEGR_ENABLE
– Activation of the integral portion of the position controller POWER ON
– – BOOLEAN
Default – FALSE – – 2/2

32230 POSCTRL_CONFIG
– Configuration of the position controller structure POWER ON
– – BYTE
Default – 0 0 17 7/2

32300 MAX_AX_ACCEL
m/s@, rev/s@ Axis acceleration NEW CONF
–, – CTEQ DOUBLE
Default 1.0 1.0e–3 – 7/2

32420 JOG_AND_POS_JERK_ENABLE
– Enable axial jerk limitation RESET
– CTEQ BOOLEAN
Default – FALSE – – 2/2

32430 JOG_AND_POS_MAX_JERK
m/s#, Axial jerk RESET
deg/s#
– CTEQ DOUBLE
Default – 1000.0 1.e–9 – 2/2

32431 MAX_AX_JERK
m/s#, Maximum axial jerk when traveling along the path NEW CONF
deg/s#
– – DOUBLE
Default 1.e6 1.e–9 – 3/3
plus – 1000 – – 3/3

32432 PATH_TRANS_JERK_LIM
m/s#, Max. axial jerk when traveling along the path with block transition NEW CONF
deg/s#
– CTEQ DOUBLE
Default 1.e6 – – 3/3
plus – 1.e3 – – /

32440 LOOKAH_FREQUENCY
– Smoothing frequency with LookAhead NEW CONF
EXP, – – DOUBLE
Default – 10. – – 2/2

32450 BACKLASH
mm, Backlash on reversal NEW CONF
degrees
– – DOUBLE
Default 1 0.0, 0.0 – – 2/2

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Machine and Setting Data 802D
A.1 List of machine data

32510 FRICT_COMP_ADAPT_ENABLE
– Friction compensation adaptation active NEW CONF
EXP, – – BOOLEAN
Default 1 FALSE – – 2/2

32520 FRICT_COMP_CONST_MAX
mm/min, Maximum friction compensation value NEW CONF
rev/min
EXP, – – DOUBLE
Default 1 0.0 – – 2/2

32530 FRICT_COMP_CONST_MIN
mm/min, Minimum friction compensation value NEW CONF
rev/min
EXP, – – DOUBLE
Default 1 0.0 – – 2/2

32540 FRICT_COMP_TIME
s Friction compensation time constant NEW CONF
EXP, – – DOUBLE
Default 1 0.015 – – 2/2

32630 FFW_ACTIVATION_MODE
– Feedforward control can be activated from the program RESET
–, – CTEQ BYTE
Default – 1 – – 2/2

32640 STIFFNESS_CONTROL_ENABLE
– Dynamic stiffness control NEW CONF
–, – CTEQ BOOLEAN
Default 1 FALSE – – 2/2

32642 STIFFNESS_CONTROL_CONFIG
– Configure dynamic stiffness control POWER ON
–, – CTEQ BYTE
Default 1 0 0 1 2/2

32644 STIFFNESS_DELAY_TIME
s Dyn. stiffness control: Delay POWER ON
–, – CTEQ DOUBLE
Default 1 0.0 –0.02 0.02 7/2
plus – –0.0015 – – 2/2

32700 ENC_COMP_ENABLE
– Encoder/lead error compensation NEW CONF
– – BOOLEAN
Default 1 FALSE – – 2/2

32810 EQUIV_SPEEDCTRL_TIME
s Equivalent time constant for the speed control loop NEW CONF
–, – – DOUBLE
Default 6 0.008, 0.008, 0.008, 0.008, – – 7/2
0.008, 0.008
plus – 0.003, 0.003, 0.003, 0.003, – – 2/2
0.003, 0.003

33050 LUBRICATION_DIST
mm, degr. Travel for the lubrication pulse PLC signal NEW CONF
–, – – DOUBLE
Default – 1.0e8 – – 3/3

34000 REFP_CAM_IS_ACTIVE
– Axis with reference point cam RESET
–, – – BOOLEAN
Default – TRUE – – 2/2

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A.1 List of machine data

34010 REFP_CAM_DIR_IS_MINUS
– Reference point approach in the negative direction RESET
–, – – BOOLEAN
Default – FALSE – – 2/2

34020 REFP_VELO_SEARCH_CAM
mm/min, Cam approach velocity RESET
rev/min
–, –, – – DOUBLE
Default – 5000.00 – – 2/2

34030 REFP_MAX_CAM_DIST
mm, Max. distance to reference cam RESET
degrees
–, – – DOUBLE
Default – 10000.0 – – 2/2

34040 REFP_VELO_SEARCH_MARKER
mm/min, Velocity when searching for the reference mark RESET
rev/min
–, –, – – DOUBLE
Default 1 300.00 – – 2/2

34050 REFP_SEARCH_MARKER_REVERSE
– Direction reversal on reference cam RESET
–, – – BOOLEAN
Default 1 FALSE – – 2/2

34060 REFP_MAX_MARKER_DIST
mm, Max. distance to reference mark RESET
degrees
–, – – DOUBLE
Default 1 20.0 – – 2/2

34070 REFP_VELO_POS
mm/min, Reference point approach velocity RESET
rev/min
–, –, – – DOUBLE
Default – 10000.00 – – 7/2
plus – 1000.00 – – 2/2

34080 REFP_MOVE_DIST
mm, Reference point distance NEW CONF
degrees
–, – – DOUBLE
Default 1 –2.0 – – 2/2

34090 REFP_MOVE_DIST_CORR
mm, Reference point offset NEW CONF
degrees
–, –, –, – – DOUBLE
Default 1 0.0 – – 2/2

34100 REFP_SET_POS
mm, Reference point position RESET
degrees
–, – – DOUBLE
Default 4 0.0, 0.0, 0.0, 0.0 –45000000 45000000 2/2

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Machine and Setting Data 802D
A.1 List of machine data

34110 REFP_CYCLE_NR
– Order of axes when referencing POWER ON
– – DWORD
Default – 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, –1 31 7/2
11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24,
25, 26, 27, 28, 29, 30, 31,
32, 33, 34, 35, 36, 37, 38,
39, 40, 41, 42, 43, 44, 45,
46, 47, 48, 49, 50, 51, 52,
53, 54, 55, 56, 57, 58, 59,
60, 61, 62, 63, 64
plus – 1 – – 2/2

34120 REFP_BERO_LOW_ACTIVE
– Polarity change of the BERO cam POWER ON
– – BOOLEAN
Default – FALSE – – 2/2

34200 ENC_REFP_MODE
– Referencing mode POWER ON
–, – – BYTE
Default 1 1 0 8 2/2

34210 ENC_REFP_STATE
– Absolute encoder adjusting status IMMED.
–, –, – – BYTE
Default 1 0 0 2 2/2

34220 ENC_ABS_TURNS_MODULO
– Modulo range of the rotary absolute encoder POWER ON
–, – – DWORD
Default 1 4096 1 100000 2/2

34990 ENC_ACTVAL_SMOOTH_TIME
s Smoothing time constant for actual values RESET
– – DOUBLE
Default 1 0.0 0.0 0.5 3/3

35000 SPIND_ASSIGN_TO_MACHAX
– Assignment ‘spindle – machine axis’ POWER ON
–, –, – – BYTE
Default – 0 0 2/2

35010 GEAR_STEP_CHANGE_ENABLE
– Gear stage change possible RESET
–, – CTEQ DWORD
Default – 0 0 12 2/2

35012 GEAR_STEP_CHANGE_POSITION
mm, Gear stage change position NEW CONF
degrees
–, – CTEQ DOUBLE
Default 6 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 – – 2/2

35014 GEAR_STEP_USED_IN_AXISMODE
– Gear stage for axis mode with M70 NEW CONF
–, –, – CTEQ DWORD
Default – 0 0 5 2/2

35020 SPIND_DEFAULT_MODE
– Spindle park position RESET
–, – CTEQ BYTE
Default – 0 0 3 2/2

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A.1 List of machine data

35030 SPIND_DEFAULT_ACT_MASK
– Activate spindle park position RESET
–, – CTEQ BYTE
Default – 0x00 0 0x03 2/2

35040 SPIND_ACTIVE_AFTER_RESET
– Own spindle RESET POWER ON
–, – CTEQ BYTE
Default – 0 0 2 2/2

35100 SPIND_VELO_LIMIT
rev/min Maximum spindle speed POWER ON
–, –, – CTEQ DOUBLE
Default – 10000.0 1.0e–3 – 7/2

35110 GEAR_STEP_MAX_VELO
rev/min Maximum speed for gear stage change NEW CONF
–, –, – CTEQ DOUBLE
Default 6 500.0, 500.0, 1000.0, – – 2/2
2000.0, 4000.0, 8000.0

35120 GEAR_STEP_MIN_VELO
rev/min Minimum speed for gear stage change NEW CONF
–, –, – CTEQ DOUBLE
Default 6 50.0, 50.0, 400.0, 800.0, – – 2/2
1500.0, 3000.0

35130 GEAR_STEP_MAX_VELO_LIMIT
rev/min Maximum speed of gear stage NEW CONF
–, –, – CTEQ DOUBLE
Default 6 500.0, 500.0, 1000.0, 1.0e–3 – 2/2
2000.0, 4000.0, 8000.0

35140 GEAR_STEP_MIN_VELO_LIMIT
rev/min Minimum speed of gear stage NEW CONF
–, –, – CTEQ DOUBLE
Default 6 5.0, 5.0, 10.0, 20.0, 40.0, – – 2/2
80.0

35150 SPIND_DES_VELO_TOL
– Spindle speed tolerance RESET
–, –, –, –, – – DOUBLE
Default – 0.1 0.0 1.0 2/2

35160 SPIND_EXTERN_VELO_LIMIT
rev/min Spindle speed limitation from PLC NEW CONF
–, – CTEQ DOUBLE
Default – 1000.0 1.0e–3 – 2/2

35200 GEAR_STEP_SPEEDCTRL_ACCEL
rev/s@ Acceleration in the control mode NEW CONF
–, –, – CTEQ DOUBLE
Default 6 30.0, 30.0, 25.0, 20.0, 1.0e–3 – 2/2
15.0, 10.0

35210 GEAR_STEP_POSCTRL_ACCEL
rev/s@ Acceleration in the position–controlled mode NEW CONF
–, –, – CTEQ DOUBLE
Default 6 30.0, 30.0, 25.0, 20.0, 1.0e–3 – 2/2
15.0, 10.0

35300 SPIND_POSCTRL_VELO
rev/min Position controller starting speed NEW CONF
–, – CTEQ DOUBLE
Default – 500.0 – – 2/2

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A.1 List of machine data

35310 SPIND_POSIT_DELAY_TIME
s Positioning delay time NEW CONF
–, – CTEQ DOUBLE
Default 6 0.0, 0.05, 0.1, 0.2, 0.4, 0.8 – – 2/2

35350 SPIND_POSITIONING_DIR
– Direction of rotation when positioning RESET
– CTEQ BYTE
Default – 3 3 4 2/2

35400 SPIND_OSCILL_DES_VELO
rev/min Reciprocating speed NEW CONF
–, – CTEQ DOUBLE
Default – 500.0 – – 2/2

35410 SPIND_OSCILL_ACCEL
rev/s@ Acceleration when reciprocating NEW CONF
–, – CTEQ DOUBLE
Default – 16.0 1.0e–3 – 2/2

35430 SPIND_OSCILL_START_DIR
– Starting direction when reciprocating RESET
– CTEQ BYTE
Default – 0 0 4 2/2

35440 SPIND_OSCILL_TIME_CW
s Reciprocation time for M3 direction NEW CONF
– CTEQ DOUBLE
Default – 1.0 – – 2/2

35450 SPIND_OSCILL_TIME_CCW
s Reciprocation time for M4 direction NEW CONF
– CTEQ DOUBLE
Default – 0.5 – – 2/2

35500 SPIND_ON_SPEED_AT_IPO_START
– Feed enable with spindle in setpoint range RESET
–, –, – CTEQ BYTE
Default – 1 0 2 2/2

35510 SPIND_STOPPED_AT_IPO_START
– Feed enable with the spindle stopped RESET
–, –, – CTEQ BOOLEAN
Default – FALSE – – 2/2

35550 DRILL_VELO_LIMIT
rev/min Maximum speeds for tapping NEW CONF
–, –, – CTEQ DOUBLE
Default 6 10000.0, 10000.0, 1 – 2/2
10000.0, 10000.0,
10000.0, 10000.0

36000 STOP_LIMIT_COARSE
mm, Exact stop coarse NEW CONF
degrees
– – DOUBLE
Default – 0.04 – – 2/2

36010 STOP_LIMIT_FINE
mm, Exact stop fine NEW CONF
degrees
– – DOUBLE
Default – 0.01 – – 2/2

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A.1 List of machine data

36020 POSITIONING_TIME
s Exact stop fine delay time NEW CONF
– – DOUBLE
Default – 1.0 – – 2/2

36030 STANDSTILL_POS_TOL
mm, Standstill tolerance NEW CONF
degrees
– – DOUBLE
Default – 0.2 – – 2/2

36040 STANDSTILL_DELAY_TIME
s Standstill monitoring delay time NEW CONF
– – DOUBLE
Default – 0.4 – – 2/2

36050 CLAMP_POS_TOL
mm, degr. Clamping tolerance NEW CONF
– – DOUBLE
Default – 0.5 – – 2/2

36060 STANDSTILL_VELO_TOL
mm/min, Threshold velocity for axis stopped NEW CONF
rev/min
–, – – DOUBLE
Default – 5.00 – – 2/2

36100 POS_LIMIT_MINUS
mm, degr. 1st software limit switch minus NEW CONF
–, –, – CTEQ DOUBLE
Default – –1.0e8 – – 2/2

36110 POS_LIMIT_PLUS
mm, degr. 1st software limit switch, plus NEW CONF
–, –, – CTEQ DOUBLE
Default – 1.0e8 – – 2/2

36120 POS_LIMIT_MINUS2
mm, degr. 2nd software limit switch minus NEW CONF
–, – CTEQ DOUBLE
Default – –1.0e8 – – 2/2

36130 POS_LIMIT_PLUS2
mm, degr. 2nd software limit switch, plus NEW CONF
–, – CTEQ DOUBLE
Default – 1.0e8 – – 2/2

36200 AX_VELO_LIMIT
mm/min, Velocity monitoring threshold value NEW CONF
rev/min
–, –, – CTEQ DOUBLE
Default 6 11500.0, 11500.0, – – 2/2
11500.0, 11500.0,
11500.0, 11500.0

36210 CTRLOUT_LIMIT
% Maximum speed setpoint NEW CONF
EXP, – CTEQ DOUBLE
Default 1 110.0 0 200 7/2

36300 ENC_FREQ_LIMIT
– Encoder limit frequency POWER ON
EXP, –, –, – – DOUBLE
Default 1 3.0e5, 3.0e5 – – 2/2

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A.1 List of machine data

36302 ENC_FREQ_LIMIT_LOW
% Encoder limit frequency resynchronization NEW CONF
EXP, –, –, – – DOUBLE
Default 1 99.9, 99.9 0 100 2/2

36310 ENC_ZERO_MONITORING
– Zero mark monitoring NEW CONF
EXP, –, – – DWORD
Default 1 0, 0 – – 2/2

36400 CONTOUR_TOL
mm, Contour monitoring tolerance band NEW CONF
degrees
–, – – DOUBLE
Default – 1.0 – – 2/2

36500 ENC_CHANGE_TOL
mm, Position actual–value switching tolerance NEW CONF
degrees
–, – – DOUBLE
Default – 0.1 – – 2/2

36600 BRAKE_MODE_CHOICE
– Brake behavior at hardware limit switch POWER ON
EXP, – CTEQ BYTE
Default – 1 0 1 7/2
plus – 0 – – 2/2

36610 AX_EMERGENCY_STOP_TIME
s Time of braking ramp in case of errors NEW CONF
– – DOUBLE
Default – 0.05 – – 2/2

36620 SERVO_DISABLE_DELAY_TIME
s Cutout delay controller enable NEW CONF
– – DOUBLE
Default – 0.1 – – 2/2

36710 DRIFT_LIMIT
% Limit value for automatic drift compensation NEW CONF
EXP, –, – – DOUBLE
Default 1 0.0 0 1.e9 1/1
plus – 1.0 – 5 3/3

36720 DRIFT_VALUE
% Drift base value NEW CONF
EXP, –, – – DOUBLE
Default 1 0.0 – – 2/2

37000 FIXED_STOP_MODE
– Mode “Traversing to fixed stop” POWER ON
– CTEQ BYTE
Default – 0 0 3 2/2

37002 FIXED_STOP_CONTROL
– Sequence control when traveling to fixed stop POWER ON
– – BYTE
Default – 0 0 3 2/2

37010 FIXED_STOP_TORQUE_DEF
% Fixed stop clamping torque default setting POWER ON
– CTEQ DOUBLE
Default – 5.0 0.0 100.0 2/2

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37012 FIXED_STOP_TORQUE_RAMP_TIME
s Time until the changed torque limit is reached NEW CONF
– – DOUBLE
Default – 0.0 – – 2/2

37014 FIXED_STOP_TORQUE_FACTOR
– Torque limit adaptation factor NEW CONF
– – DOUBLE
Default – 1.0 – – 2/2

37020 FIXED_STOP_WINDOW_DEF
mm, Fixed stop monitoring window default setting POWER ON
degrees
–, – CTEQ DOUBLE
Default – 1.0 – – 2/2

37030 FIXED_STOP_THRESHOLD
mm, Threshold for fixed stop detection NEW CONF
degrees
– – DOUBLE
Default – 2.0 – – 2/2

37040 FIXED_STOP_BY_SENSOR
– Fixed stop detection via sensor IMMED.
– CTEQ BYTE
Default – 0 0 3 2/2

37050 FIXED_STOP_ALARM_MASK
– Enabling of the fixed–stop alarms NEW CONF
–, – – BYTE
Default – 1 0 15 2/2

37060 FIXED_STOP_ACKN_MASK
– Masking of PLC acknowledgments POWER ON
– CTEQ BYTE
Default – 0 0 3 2/2

37610 PROFIBUS_CTRL_CONFIG
– Profibus control bit configuration POWER ON
EXP, – – BYTE
Default – 0 0 2 7/2
plus – – – – 2/2

37620 PROFIBUS_TORQUE_RED_RESOL
% Resolution of Profibus torque reduction NEW CONF
EXP, – – DOUBLE
Default – 1.0 0.01 10.0 2/2

38000 MM_ENC_COMP_MAX_POINTS
– Intermediate points for encoder/spindle compensation POWER ON
–, –, – – DWORD
Default 1 125 0 5000 7/0

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Machine and Setting Data 802D
A.2 Setting data

A.2 Setting data


MD SD identifier as of version
number
Unit Brief description Activation
Display filter Attributes Data type
Default Dimension Default value Minimum value Maximum value Protection
System * Dimension Default value Minimum value Maximum value Protection
* Values other than those in the standard system

Note regarding the value definition:


TRUE corresponds to 1
FALSE corresponds to 0

41010 JOG_VAR_INCR_SIZE
– JOG mode: Size of variable increment IMMED.
– – DOUBLE
Default – 0. – – 7/7

41110 JOG_SET_VELO
mm/min Axis velocity in the JOG mode IMMED.
– – DOUBLE
Default – 0.0 – – 7/7

41130 JOG_ROT_AX_SET_VELO
rev/min Axis velocity of the rotary axes in the JOG mode IMMED.
– – DOUBLE
Default – 0.0 – – 7/7

41200 JOG_SPIND_SET_VELO
rev/min Speed for spindle jog mode IMMED.
– – DOUBLE
Default – 0.0 – – 7/7

42000 THREAD_START_ANGLE
degrees Thread start angle [deg] IMMED.
– – DOUBLE
Default – 0 – – 3/3

42010 THREAD_RAMP_DISP
mm Acceleration pattern of the axis when thread cutting IMMED.
– – DOUBLE
Default 2 –1.0, –1.0 –1.0 999999. 3/3

42100 DRY_RUN_FEED
mm/min At least the programmed velocity with active dry run IMMED.
– – DOUBLE
Default – 5000 – – 7/7

42101 DRY_RUN_FEED_MODE
– Mode for dry run velocity IMMED.
– – BYTE
Default – 0 0 12 7/7

42110 DEFAULT_FEED
mm/min Default value for path feedrate IMMED.
– – DOUBLE
Default – 0 – – 7/7

42120 APPROACH_FEED
mm/min Path feed in approach blocks IMMED.
– – DOUBLE
Default – 0 – – 2/2

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Machine and Setting Data 802D
A.2 Setting data

42125 SERUPRO_SYNC_MASK
– Synchronization in approach blocks IMMED.
– – DWORD
Default – 0 – – 2/2

42140 DEFAULT_SCALE_FACTOR_P
– Default scaling factor for address P IMMED.
– – DWORD
Default – 1 – – 7/7

42150 DEFAULT_ROT_FACTOR_R
– Default rotation factor for address R IMMED.
– – DOUBLE
Default – 0. – – 7/7

42160 EXTERN_FIXED_FEEDRATE_F1_F9
– Fixed feedrates F1 – F9 IMMED.
– – DOUBLE
Default 10 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, – – 7/7
0.0, 0.0, 0.0, 0.0

42162 EXTERN_DOUBLE_TURRET_DIST
– Tool distance of dual resolver head IMMED.
– – DOUBLE
Default – 0. – – 7/7

42200 SINGLEBLOCK2_STOPRE
– Activate debug mode for SBL2 IMMED.
– – BOOLEAN
Default – FALSE – – 7/7

42440 FRAME_OFFSET_INCR_PROG
– Work offset in frames IMMED.
– – BOOLEAN
Default – TRUE – – 7/7

42442 TOOL_OFFSET_INCR_PROG
– Tool length compensations IMMED.
– – BOOLEAN
Default – TRUE – – 7/7

42444 TARGET_BLOCK_INCR_PROG
– Incremental programming with block search IMMED.
– – BOOLEAN
Default – TRUE – – 7/7

42480 STOP_CUTCOM_STOPRE
– Alarm response with TRC and preprocessing stop IMMED.
– – BOOLEAN
Default – TRUE – – 3/3

42490 CUTCOM_G40_STOPRE
– Retraction behavior of TRC with preprocessing stop IMMED.
– – BOOLEAN
Default – FALSE – – 3/3

42494 CUTCOM_ACT_DEACT_CTRL
– Approach/retraction behavior with 2–1/2D TRC IMMED.
– – DWORD
Default – 2222 – – 3/3

42496 CUTCOM_CLSD_CONT
– Behavior of the TRC with closed contour IMMED.
– – BOOLEAN
Default – FALSE – – 3/3

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Machine and Setting Data 802D
A.2 Setting data

42528 CUTCOM_DECEL_LIMIT
– Feedrate reduction at circles with TRC IMMED.
– – DOUBLE
Default – 0. 0. 1. 7/7

42940 TOOL_LENGTH_CONST 0
– Tool length component when changing the plane IMMED.
– – DWORD
Default – 0 – – 3/3

42950 TOOL_LENGTH_TYPE
– Tool length component not depending on tool type IMMED.
– – DWORD
Default – 0 – – 3/3

42990 MAX_BLOCKS_IN_IPOBUFFER
– Max. number of blocks in the IPO buffer IMMED.
– – DWORD
Default – –1 – – 2/2

43120 DEFAULT_SCALE_FACTOR_AXIS
– Default scaling factor with active G51 IMMED.
– – DWORD
Default – 1 – – 7/7

43200 SPIND_S
rev/min Speed for spindle start through virtual interface IMMED.
– – DOUBLE
Default – 0.0 – – 7/7

43202 SPIND_CONSTCUT_S
m/min Cutting rate for spindle start through virtual interface IMMED.
– – DOUBLE
Default – 0.0 – – 7/7

43210 SPIND_MIN_VELO_G25
rev/min Limits the spindle speed to the specified minimum value IMMED.
– – DOUBLE
Default – 0.0 – – 7/7

43220 SPIND_MAX_VELO_G26
rev/min Limits the spindle speed to the specified maximum value IMMED.
– – DOUBLE
Default – 1000.0 – – 7/7

43230 SPIND_MAX_VELO_LIMS
rev/min Limits the spindle speed to the specified maximum value with G96, G691, G97 IMMED.
– – DOUBLE
Default – 100.0 – – 7/7

43240 M19_SPOS
degrees Spindle position with M19 IMMED.
–, – – DOUBLE
Default – 0.0 –10000000.0 10000000.0 7/7

43250 M19_SPOSMODE
– Approach mode for spindle position with M19 IMMED.
–, – – DWORD
Default – 0 0 5 7/7

43340 EXTERN_REF_POSITION_G30_1
– Reference point position for G30.1 IMMED.
–, – – DOUBLE
Default – 0.0 – – 7/7

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Machine and Setting Data 802D
A.2 Setting data

43400 WORKAREA_PLUS_ENABLE
– Working area limitation active in the positive direction IMMED.
– CTEQ BOOLEAN
Default – FALSE – – 7/7

43410 WORKAREA_MINUS_ENABLE
– Working area limitation active in the negative direction IMMED.
– CTEQ BOOLEAN
Default – FALSE – – 7/7

43420 WORKAREA_LIMIT_PLUS
mm, Axial working area limitation active in the positive direction IMMED.
degrees
– – DOUBLE
Default – 1.0e+8 – – 7/7

43430 WORKAREA_LIMIT_MINUS
mm, Axial working area limitation active in the negative direction IMMED.
degrees
– – DOUBLE
Default – –1.0e+8 – – 7/7

43500 FIXED_STOP_SWITCH
– Selection “Travel to fixed stop” IMMED.
– – BYTE
Default – 0 0 1 2/2

43510 FIXED_STOP_TORQUE
% Fixed stop clamping torque IMMED.
– – DOUBLE
Default – 5.0 0.0 800.0 2/2

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6FC5 397-0CP10-1BA0 A-229
Machine and Setting Data 802D
A.3 SINAMICS parameters

A.3 SINAMICS parameters

Note to the reader


SINAMICS S parameter list

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A-230 6FC5 397-0CP10-1BA0
Standards and Approvals B
IEC 1131
The control system meets the requirements and criteria of the IEC 1131 Standard, Part 2.

CE designation
Our products meet the general and safety-related requirements of the following EC guide-
lines and conform to the uniform standards (EN) for programmable controllers published in
the official gazettes of the European Union:
89/336/EEC “Electromagnetic Compatibility” (EMC Directive)

EMC guideline
SINUMERIK products are designed for use in industry.

Range of application Requirements in respect of


interference emission interference immunity
Industry EN 50081-2: 1993 EN 61000-6-2: 1999

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6FC5 397-0CP10-1BA0 B-231
Standards and Approvals
B.1 Electromagnetic compatibility

B.1 Electromagnetic compatibility

Definition
Electromagnetic compatibility is the ability of equipment or systems to be used in their inten-
ded environment within designed efficiency levels without causing or receiving degradation
due to unintentional electromagnetic interference.
The D4xx also satisfies the requirements of the EMC regulations of the internal European
market.
Information on interference immunity and EMC conformance are provided in the following.

Pulse-shaped interference
The table below illustrates the electromagnetic compatibility of modules when exposed to
fast transients.

Fast transient Tested with Corresponds to the


degree of severity
Electrostatic discharge 8 kV 3 (air discharge)
tested in accordance with DIN EN 61000-4-2 4 kV 2 (contact discharge)
Burst pulses (fast transient interference) 2 kV (supply cable) 3
complying to DIN 61000-4-4 1 kV (signal cable)
Surge
complying to DIN EN 61000-4-5

S Asymmetric coupling 0.5 kV (supply line) 1


1 kV (signal line/data line) 2
S Symmetric coupling 0.5 kV (supply line) 1

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B-232 6FC5 397-0CP10-1BA0
Standards and Approvals
B.1 Electromagnetic compatibility

Sinusoidal interference
HF radiation on the device in accordance with EN 61000-6-2 requirements:
S Electromagnetic HF field, amplitude-modulated
– between 80 and 1,000 MHz
– 10 V/m
– 80 % AM (1 kHz)
S Electromagnetic HF field, pulse-modulated
– 900 "5 MHz
– 10 V/m
– 50 % duty cycle
– 200 Hz repetition frequency
S HF coupling on signal and data cables, etc., in accordance with EN 61000-6-2 require-
ments, high frequency, asymmetric, amplitude modulated
– between 0.15 and 80 MHz
– 10 V r.m.s. value, unmodulated
– 80 % AM (1 kHz)
– 150 W source impedance

Radio interference emission


Interference emission of electromagnetic fields to EN 55011: Limit value class A, group 1.

between 20 and 230 MHz < 30 dB (mV/m)Q


between 230 and 1,000 MHz < 37 dB (mV/m)Q
measured at a distance of 30 m

Interference emission via network alternating current supply in accordance with EN 55011:
Limit value class A, group 1.

between 0.15 and 0.5 MHz < 79 dB (mV)Q


< 66 dB (mV)M
between 0.5 and 5 MHz < 73 dB (mV)Q
< 60 dB (mV)M
between 5 and 30 MHz < 73 dB (mV)Q
< 60 dB (mV)M

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6FC5 397-0CP10-1BA0 B-233
Standards and Approvals
B.2 Transport and storage conditions

Extension of the range of application


If you intend to use the control system in residential areas, you must ensure that the control
system meets the requirements of limit value class B to EN 55011 in respect of interference
emission.
Recommendation: Install the control system in grounded metal cabinets, such as 8MC cabi-
nets (see NV 21 Catalog). Connect filters to the supply lines.

B.2 Transport and storage conditions


With regard to transportation and storage conditions, the D4xx surpasses the requirements
specified in IEC 60068-2. The following conditions apply to modules that are transported and
stored in the original packaging.

Type of condition Permissible range


Free fall v 1m
Temperature From – 20 _C to + 60_C
Air pressure 1,060 ... 700 hPa (corresponds to an altitude of 3,000)
Relative humidity from 5 to 95 %, without condensation

B.3 Mechanical and climatic ambient conditions for operation

Operating conditions
The control system is intended for use as a stationary equipment in a sheltered environment.
The conditions of use are compliant with requirements to DIN IEC 68-2-2:
The control system satisfies the operating conditions of the 3C3 class in accordance with
DIN EN 60721 3-3 (operating locations with high traffic densities and in the immediate vici-
nity of industrial plants with chemical emissions).
The control system must not be operated in the following locations without additional
measures being taken:
S at sites where a high volume of ionizing radiation occurs
S Locations with severe operating conditions, e.g., due to:
– the formation of dust
– caustic vapor or gases.
S in plants which require special supervision, e.g.
– lifts
– electrical equipment in especially hazardous rooms.
An additional measure for use of the control system may be, for example, the installation
incabinets.

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B-234 6FC5 397-0CP10-1BA0
Standards and Approvals
B.3 Mechanical and climatic ambient conditions for operation

Climatic ambient conditions


The control system can be used under the following climatic ambient conditions:

Ambient conditions Fields of application Remarks


Temperature From 0 to 50 _C With a simultaneity of 50 %
Relative humidity 5 to 95%, Without condensation, corres-
ponds to relative humidity (RH)
severity level 2 in accordance
with IEC 1131-2
Air pressure 1,080 ... 795 hPa –
Pollutant concentration Tested:
SO2: < 0.5 ppm; 10 ppm; 4 days
Relative humidity < 60%, without
condensation
H2S: < 0.1 ppm; 1 ppm; 4 days
Relative humidity < 60%, without
condensation

Mechanical ambient conditions


The mechanical ambient conditions for the control system are specified in the table below in
the form of sinusoidal waves.

Mechanical ambient conditions Operation Transport (in packaging)


Vibration tested in accordance 10 to 58 Hz: 0.35 mm 5...9 Hz: 3.5 mm
with DIN EN 60068-2-68 58 to 200 Hz: 50 m/s2 9 to 200 Hz: 10 m/s2
Shock resistance tested in accor- 10 g peak value, 6 ms duration 10 g peak value,
dance with DIN EN 60068-2-27 100 shocks in each of the 3 6 ms duration
axes vertical to one another 100 shocks in each of the
3 axes vertical to one another

Vibration reduction
If the control system is subjected to major impacts or vibration, appropriate measures must
be taken to reduce the acceleration or the amplitude of the vibration.
We recommend mounting the control system on shock-absorbing material (e.g. vibration-
absorbing metal).

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Standards and Approvals
B.4 Information on insulation tests, safety class, and degree of protection

B.4 Information on insulation tests, safety class, and degree of


protection

Test voltages
The insulation resistance is tested in a routine test using the following test voltage to
IEC 1131, Part 2:

Circuits with a rated voltage of Ue to other Test voltage


circuits or ground
0 V < Ue v 50 V 500 V DC

Class of protection
Class of protection I to IEC 536 (VDE 0106, Part 1), i.e. connection to protective conductor
required!

Protection against ingress of solid foreign bodies and water


Degree of protection to IEC 529:
S CNC operator panel (PCU) IP65 (front)
IP00 (rear)
S Machine control panel (MCP) IP54 (front)
IP00 (rear)
S PP 72/48 I/O module IP00

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Standards and Approvals
B.5 Safety of electronic control systems

B.5 Safety of electronic control systems

Introduction
The information provided here is mainly of general nature and applies irrespective of the
type of the electronic control system and its manufacturer.

Reliability
Comprehensive and cost-effective measures have been taken during development and pro-
duction to increase the reliability of the devices and components as far as possible.
These include
S the selection of high-quality components;
S worst-case design of all circuits;
S systematic and computer-controlled testing of all components delivered;
S burning in of all LSI circuits (e.g. processors, memories, etc.)
S measures preventing static charge when handling MOS ICs;
S visual checks and inspections at various stages of production;
S continuous heat testing at increased ambient temperature over several days;
S careful computer-controlled final testing;
S statistic evaluation of all returned goods for immediate introduction of corrective
measures;
S monitoring of the most important control parts by way of online tests (watch dog, etc.).
In terms of safety technology, these measures are called basic measures; they avoid or con-
trol most possible errors.

The risk
Special safety standards must be applied to any system – and therefore to the situation as
well – whenever, if a fault occurs, it may cause injury to persons or damage to property. For
these applications, special, plant-specific regulations exist which must be observed when
designing the control system (e.g. VDE 0116 for furnaces).
For electronic control systems with safety relevance, the measures to be taken to avoid or
control errors depend on the risk resulting from the plant. In this conjunction, the basic mea-
sures mentioned above are not sufficient any more for a certain hazard potential. Additional
measures (e.g. channel redundance, tests, checksums, etc.) must be implemented and cer-
tified for the control system (DIN VDE 0801).

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Standards and Approvals
B.5 Safety of electronic control systems

Division into safe and non-safe areas


Nearly all systems contain parts that perform safety-related tasks (e.g. emergency stop
switch, protective grating, two-hand controls). To avoid having to apply safety-related criteria
to the entire controller, it is customary to divide the controller into two areas – one that is
critical to safety and one that is not critical to safety. In the non-safe area of the control
system, no special demands are made, since a failure of the electronics will have no effect
on the safety of the plant. In the safe area, however, only controls and circuits which comply
with the relevant standards and regulations must be used.

Important note
If even a maximum degree of conceptional safety has been achieved when configuring an
electronic control system, e.g. through multichannel design, it is nevertheless imperative to
observe the instructions provided in the relevant instruction manuals exactly; otherwise, im-
proper or incorrect handling could put precautions intended to prevent hazardous errors out
of service or even create additional hazards.

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B-238 6FC5 397-0CP10-1BA0
Directive for handling electrostatically sensitive
devices (ESD) C
C.1 What does ESD mean?

Definition
All electronic modules are equipped with large-scale integrated chips or components. Due to
technological reasons, these electronic components can be damaged easily by overvoltage
and thus discharge from static electricity.
The acronym ESD has become the established designation for such Electrostatically
Sensitive Devices. The ESD designation is used internationally to refer to electrostatically
sensitive devices.
Electrostatically sensitive devices are marked with the following symbol:

Caution
! Electrostatically sensitive devices can be destroyed even by voltages which are far below
the human perceptive limit. These voltages already occur when you touch a component or
electrical connections of a module, without being electrostatically discharged. The damage
resulting at a module due to an overvoltage is in most cases not detected immediately, but
only noticed after a longer period of operation.

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Directive for handling electrostatically sensitive devices (ESD)
C.2 Electrostatic charging of persons

C.2 Electrostatic charging of persons

Charging
Any person connected to the electrical potential of the environment through a non-conduc-
tive connection can be charged electrostatically.
Figure C-1 indicates the maximum electrostatic voltages that can accumulate in a person
who is operating equipment when he/she comes into contact with the materials shown in the
figure. These values correspond with specifications to IEC 801-2.

Voltage in kV

(kV)
16 1 synthetic material
15
14 2 wool
13
3 antistatic material such as wood
12 or concrete
11 1
10
9
8
7
6
5
4 2
3
2
3
1
5 10 20 30 40 50 60 70 80 90 100 Relative humidity in %

Fig. C-1 Electrostatic voltages to which an operator can be charged

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Directive for handling electrostatically sensitive devices (ESD)
C.3 Basic protective measures against discharge of static electricity

C.3 Basic protective measures against discharge of static electricity

Ensure proper grounding


When handling electrostatically sensitive devices, ensure that human, workplace and packa-
ging are grounded properly to avoid static charging.

Avoid direct contact


Electrostatically sensitive devices should only be touched if this cannot be avoided (e.g.
when performing maintenance work). When you touch modules, make sure that you do not
touch either the pins on the modules or the printed conductors. In this way, the discharge
energy cannot reach and thus damage sensitive devices.
If you must perform measurements at a module, discharge your body first before performing
the work. To do so, touch a grounded metal object. To do so, touch grounded metal objects.
Use only grounded measuring and test equipment.

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6FC5 397-0CP10-1BA0 C-241
Directive for handling electrostatically sensitive devices (ESD)
C.3 Basic protective measures against discharge of static electricity

Notes

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C-242 6FC5 397-0CP10-1BA0
SINUMERIK 802D sl License Agreement D
License Agreement for the Sinumerik 802D sl Software – in the following referred to as
“Software”

D.1 General Terms and Conditions for the Use of Software for
Sinumerik and Drive Technology
This Software is protected by national and international copyright and treaties. Unauthorized
copying and illegal distribution of the Software or parts thereof is liable to prosecution both
under criminal and under civil law and will result in severe penalty and/or damage compen-
sation.
Prior to installation and use of the Software, please read the Terms and Conditions of this
License Agreement. An extract can be found in the Section D.2.
If you have received this software on a CD with the notice “Trial version” or together with
another software licensed for you, you are only permitted to use the software for test and
validation purposes according to the attached trial licensing regulations. To this end, it is
imperative to install certain programs, software libraries etc. on your computer.
We therefore strictly recommend you to install the Software either on a single-user
workstation or on a computer which is not integrated into the production process
and required for storing or managing vital data, since it cannot fully be ruled out that
existing files are modified or overwritten. We will therefore not assume any liability
for damage and/or data loss resulting from installing the program or not observing
this warning notice.
Any use of this Software other than that as prescribed by the present Terms and
Conditions is only permitted with a valid license from Siemens. If you do not possess
a valid license which can be proven by submitting an appropriate Certificate of
License/Software Product Form, please cancel the installation immediately and
contact a Siemens branch office immediately to avoid claims for damages.
If the Software contains Free Software, an appropriate note can be found in the readme file
for the Software under License. The Customer is entitled to use the Free Software according
to the relevant terms and conditions of licensing applying to the Free Software. These are
included on the data carrier on which the software is supplied to the Customer. If there are
any provisions in the terms and conditions of licensing for the Free Software which are in
contradiction to these General Terms and Conditions, the terms and conditions of licensing
for the Free Software shall prevail. The Customer shall be entitled to request the source
code of the Free Software against payment of the shipping costs at least for a time of three
years after acquiring the Software from Siemens.

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6FC5 397-0CP10-1BA0 D-243
SINUMERIK 802D sl License Agreement
D.2 General Terms and Conditions for the Use of Software for Sinumerik and Drive Technology

D.2 General Terms and Conditions for the Use of Software for
Sinumerik and Drive Technology

D.2.1 Delivery of the Software to licensees and granting of rights of use in the
Software

1. The delivery of the Software for automation and drive technology to the Licensee is sub-
ject to the applicable mutual written declarations. Any general terms and conditions of the
Licensee, however, shall only be valid if we have expressly agreed to them.
We grant the Licensee rights to use the Software mentioned either in the Order Confir-
mation or – if the Licensee has not received an Order Confirmation – in the Certificate of
License, or – if the Licensee has received a Software Product Form instead of the Certifi-
cate of License – in the Software Product Form. The Certificate of License and the Soft-
ware Product Form will be referred to in the following as “CoL”. The Licensee will receive
the CoL together with the delivery of the Software or the delivery note.
The form of delivery of the Software also results either directly from the Order Confirma-
tion or the Order Number of the Software specified in the Order Confirmation in conjunc-
tion with the relevant order data specified in the Catalog valid at the time of order confir-
mation (in the following referred to as “Order Data”), or from the CoL. If the Licensee has
not received a data carrier, he shall be entitled to make copies of the Software he has
already in his possession to the extent required to use the Software within the rights to
use granted to him. This shall apply analogously if the Software is delivered electronically
(via download).
If in these Terms and Conditions reference is made to the Order data or the CoL, the re-
ference to the CoL will only be relevant if the Licensee has not received an Order Confir-
mation. In any case, the data contained in the Order Data are also contained in the CoL.
2. The documentation that belongs to the software is to be acquired separately, unless it is
specified in the order data or the CoL that the documentation is included in the scope of
supply. If the Licensee is entitled to make copies of the software as it is mentioned in
Point D.2.1, Clause 1 above, this shall also pertain to the documentation so far as inclu-
ded in the scope of supply.
3. If the Licensee has received a license key for the software, this must also be installed.
4. The rights granted to the Licensee in the software result from the license type
(see Point D.2.2) and the software type (see Point D.2.3). License type and software type
result from the order data or the CoL.
If the Software is delivered electronically or by granting multi-user license rights, these
shall refer to the rights and duties in the legally created copies mentioned in these Gene-
ral Terms and Conditions.
5. If the Licensee is in the legal possession of a previous version/release of the Software
(in the following referred to as “Previous Version” ), the Licensee shall be granted the
right to exercise the right to use the Software either for the Software itself or – if this is
technically feasible – for the Previous Version (downgrading). If the Software is an
upgrade or a PowerPack as mentioned in Point D.2.4 below, Point D.2.4 shall apply in
addition.

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D-244 6FC5 397-0CP10-1BA0
SINUMERIK 802D sl License Agreement
D.2 General Terms and Conditions for the Use of Software for Sinumerik and Drive Technology

6. If the Licensee is to receive only the data carrier, and not a license according to the provi-
sions in the Order Data or resulting from the CoL, the Licensee shall only be entitled to
use the Software if he acquires a license as mentioned in Point D.2.2 below. The Licen-
see shall only be entitled to pass on the Software to third parties if he has acquired the
license.

D.2.2 License type

Depending on the license type, the Software Licensee is granted the following rights:
1. Single License (One-Off License, Copy License)
The term “One-Off License” or “Copy License” used in the Software Product Form cor-
responds to the Single License. The following regulation shall apply to the One-Off Li-
cense/Copy License to its full extent:
The Licensee is granted the non-exclusive right unlimited in time and assignable in accor-
dance with Point D.2.5, Clause 3 below to install the Software on one (1) device and to
use the installed Software as specified in the Order Data or the CoL (see “Type of use”).
2. Floating License
The Licensee is granted the non-exclusive right unlimited in time and assignable in accor-
dance with Point D.2.5, Clause 3, to install the Software on any number of devices of the
Licensee. The number of persons who are permitted to use the software simultaneously
(“users”) results from the order data or the CoL (see
3. Rental License
The Licensee is granted the non-exclusive right limited in time as specified in the Order
Data or the CoL (see “Type of Use”) to Point D.2.5, Clause 3, to install and use the Soft-
ware on one (1) device. If the time of use is specified in hours, the time used to calculate
the limitation in time shall commence at the time when the Software was started first and
end at the time when the use of the Software is finally completed. If the time of use is
specified in days, weeks or months, the specified period shall commence from the time
when the software was started first, irrespective of whether or not the software is in fact
used.
4. Trial License
The Licensee is granted the non-exclusive, nontransferable right to install the Software
on one (1) device and to use the installed Software for validation purposes in the manner
as specified in the Order Data or in the CoL (see The time of use shall be limited to
14 days, commencing at the time when the Software was started first, unless another
time of use is specified in the Order Data or in the CoL.

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SINUMERIK 802D sl License Agreement
D.2 General Terms and Conditions for the Use of Software for Sinumerik and Drive Technology

D.2.3 Software type

If the software type is specified neither in the Order Data, nor in the CoL, the Software shall
be subject to the rights specified in Point D.2.3, Clause 2 (Runtime Software).
1. Engineering Software
If the Licensee uses the Engineering Software to create his own programs or data which
contain parts of the Engineering Software, the Licensee shall have the license-free right
to make copies of these parts of the Engineering Software as a part of his own programs
or data, to use them or to deliver them third parties for their use. When delivering to third
parties, these must be bound in writing to the regulations of Point D.2.5, Clauses 1 and 2
in respect of the parts of the Engineering Software mentioned above.
2. Runtime Software
If the Licensee embeds the Runtime Software or parts thereof into his own programs or
data, the Licensee shall acquire a license in the Runtime Software according to the inten-
ded type of use in accordance with the Siemens Catalog valid at this time each time
when installing the Software or making copies, whichever is earlier. If the Licensee deli-
vers the programs or data mentioned above for use by third parties, these must be bound
in writing to the regulations of Point D.2.5 in respect of the embedded parts of the Run-
time Software. This does not affect the obligation for the Licensee to acquire a license in
the Runtime Software,if this software is to be copied in its original form.
If the Runtime Software contains tools for parameterization/configuration and if extended
rights are granted for these tools, this can be derived from the readme file of the Runtime
Software.

D.2.4 Upgrade and PowerPack

If it is to be understood from the Order Data or the CoL, for example through appending of
the suffix “PowerPack” or “Upgrade” to the name of the Software, that the Software serves
to upgrade another software (in the following referred to as “Original License”), the rights
granted to the Licensee in the Software are acquired also in respect of the original software
as soon as the original software is upgraded with the Upgrade/PowerPack. The rights of use
originally granted to the Licensee with the Original License are terminated with the upgrade.
The Licensee is however entitled to reverse the upgrade at any time (downgrading) – insofar
as this is technically feasible – and to exercise the rights of use in the software granted with
the Original License in accordance with Point D.2.1, Clause 5.

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SINUMERIK 802D sl License Agreement
D.2 General Terms and Conditions for the Use of Software for Sinumerik and Drive Technology

D.2.5 Further rights and duties of the Licensee

1. Unless a note to the contrary with specification of a certain number of copies is made on
the data carrier or in the readme file of the Software, the Licensee is permitted to make a
reasonable number of copies of each copy of the Software which he is entitled to use in
accordance with these Terms and Conditions exclusively for data backup purposes.
Furthermore, the Licensee is only permitted to duplicate the Software if and insofar as we
have granted rights of duplication in writing.
2. The Licensee is not permitted to modify, reverse engineer or recompile the Software, nor
is he permitted to segregate individual parts of the software, except where this is ex-
pressly permitted by the provisions of the laws on copyright. The Licensee is furthermore
not permitted to remove alphanumerical IDs, trademarks or copyright notes from the soft-
ware or data carrier and undertakes to duplicate such markings and notes unchanged
insofar as he is entitled to duplicate the Software. This provision applies analogously also
to the documentation provided in accordance with Section D.1.
3. The Licensee is entitled to transfer his rights of use in the Software to a third party, provi-
ded a written agreement is reached with this third party to the effect of all provisions of
this Section D.5 and provided he retains no copies of the Software.
If the Licensee has received a license key for the Software, this key must be passed on
to the third party together with the Software. Furthermore, the CoL is to be handed over
to the third party, together with these Terms and Conditions.
If requested by us, the Licensee is to be prepared to present the CoL received for the
Software at any time.
4. If the Software is a PowerPack or an Upgrade, the Licensee is to keep the Certificate of
License or the Software Product Form of the Original License and, if requested by us, is
to be prepared to present it together with the CoL received for the Software at any time. If
the Licensee transfers his rights of use in the PowerPack Software or the Upgrade Soft-
ware in accordance with Point D.2.5, Clause 3, the Certificate of License or the Software
Product Form of the Original License is also to be handed over to the third party.
5. If the Licensee receives a data carrier which contains further enabled software products
besides the Software, he is granted a right limited in time and without fees to use these
enabled software products exclusively for validation purposes. The time of use shall be
limited to 14 days, commencing at the time when the Software was started first, unless
another time of use is specified in the readme file of the software product concerned.
The provisions of these Terms and Conditions apply analogously to these software pro-
ducts provided exclusively for validation purposes. The Licensee is not entitled to transfer
these software products to a third party separately, i.e. without the Software.
Otherwise, the provisions of the purchase contract shall apply, unless contrary
provisions are specified expressly hereinafter for the Free Software.

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SINUMERIK 802D sl License Agreement
D.3 License Provisions for Free Software Components

D.3 License Provisions for Free Software Components


In the “Sinumerik 802D sl” software, the following free software components (in the following
referred to as “Free Software”) are used either in unmodified form or after modification by
us:
Name License
Linux-Kernel GPL (see gpl.txt)
Grub GPL (see gpl.txt)
devices GPL (see gpl.txt)
glibc LGPL (see lgpl.txt)
libstdc++ LGPL (see lgpl.txt)
libz Zlib license (see zlib.txt)
libgmp LGPL (see lgpl.txt)
liboop LGPL (see lgpl.txt)
busybox GPL (see gpl.txt)
lsh GPL (see gpl.txt)
tsort BSD (see bsd.txt)
udhcp-server GPL (see gpl.txt)
ipledd GPL (see gpl.txt)
betaftpd GPL (see gpl.txt)
tftpd BSD (see bsd.txt)
iptables GPL (see gpl.txt)
hotplug GPL (see gpl.txt)
ntpd BSD (see bsd.txt)
samba-mount GPL (see gpl.txt)
The Free Software is made available without fees. You are entitled to use the Free Software
in accordance with the corresponding license provisions. These provisions are to be found
under Point D.2.5 ff. above.BIn case of discrepancies between these license provisions and
the license provisions in accordance with Points D.2.1 and D.2.2, the license provisions in
accordance with Point D.2.5 shall prevail in respect of the Free Software. In case of violation
of these license provisions, the named licenser is entitled, alongside us, to assert resultant
claims and rights in his own name.
Where permitted by the relevant license provisions in accordance with Clause 5ff, you are
entitled to request the source code of the Free Software from your Siemens sales represen-
tative against payment of the shipping costs at least for a period of three years after acqui-
ring the Software.

D.4 Liability for Free Software


We assume liability for the Software, including the Free Software contained therein, in accor-
dance with the license provisions valid for the Software. All liability is excluded in respect of
use of the Free Software beyond the program sequences we have designated for the Soft-
ware, as well as in respect of defects attributable to modification of the Free Software.
No technical support is provided for the Software if it has been modified.

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SINUMERIK 802D sl License Agreement
D.5 see gpl.txt on the Toolbox CD under /licenses

D.5 see gpl.txt on the Toolbox CD under /licenses

D.6 see bsd.txt on the Toolbox CD under /licenses

D.7 see zlip.txt on the Toolbox CD under /licenses

D.8 see lgpl.txt on the Toolbox CD under /licenses

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SINUMERIK 802D sl License Agreement
D.8 see lgpl.txt on the Toolbox CD under /licenses

Notes

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D-250 6FC5 397-0CP10-1BA0
Abbreviations E
CF Compact Flash
CNC Computerized numerical control
COM Communication module
CU Control Unit
DC Direct current
DI Digital input
DIN Deutsche Industrienorm (German industrial standard)
DI/DO Digital input/output, bidirectional
DO Digital output
DP Distributed I/O
ESD Electrostatically sensitive devices
EMC Electromagnetic compatibility
EN Europäische Norm (European Standard)
HMI Human Machine Interface
IEC International Electrotechnical Commission
ISO International Standardization Organization
LED Light Emitting Diode
GND Ground
MCP Machine control panel
NC Numerical control
NCK Numerical Control Kernel
PC/PG Personal computer, programming device
PCU Panel Control Unit
PELV Protective extra-low voltage
PLC Programmable Logic Control
PNO PROFIBUS Nutzer-Organisation (PROFIBUS user organization)
RJ45 Interface standard; describes an 8-pin plug connection for twisted-pair Ethernet
RS232 Serial interface
RS485 Interface standard; describes the physical properties of a digital serial interface
SDB System data block

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Abbreviations

TB 30 Terminal Board 30
UL Underwriters Laboratories Inc.
USB Universal Serial Bus

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E-252 6FC5 397-0CP10-1BA0
Index

Index
Numbers Connecting the digital inputs/outputs, 7-71, 7-72
to the CNC operator panel, 7-71
802D machine data
to the I/O module, 7-72
802D machine data
Connecting the Ethernet interface, 7-64
Axis-specific, A-214
Connecting the I/O module, 7-66
Channel-specific, A-206
Connecting the machine control, 7-73
Display, A-196
Connecting the SINAMICS S drive, 7-70
General, A-201
Connection cables, 7-71
Connection for the CNC-full keyboard, 7-63
Connection overview, 7-56
A Connection to PROFIBUS DP, 7-66
Access levels, 9-80 Control panel, 10-140, 10-143
Ambient conditions, B-234 Control powerup, 9-83
Mechanical, B-235 Control word CTW1, 10-146
Analog output, Assignment, 4-31 Creating a drive project, 10-123
Analog spindle, Connecting, 7-60 OFFLINE, 10-123
Assuming control priority, 10-144 ONLINE, 10-150
Automatic configuration, 10-154

D
B Data backup, 12-187
BERO, 7-71 Data organization, 11-181
Bus connector, Setting the terminator, 7-67 Data types, L-195
Degree of protection, B-236
Description, 2-13
C Description of the PP 72/48 I/O module
Interfaces, 4-33
Cable clamp, 7-74
Operator controls, 4-33
CE, Identification, B-231
Design, Electrical, Configuring, 7-52
Check topology, 10-161
Detailed view, 9-105
Class of protection, B-236
Device configuration, 10-158
CNC full keyboard (installed beneath to the PCU), Dril-
Diagnosis via STARTER, 9-111
ling pattern, 5-47
Diagnostics function, 9-111
CNC full keyboard (installed next to the PCU)
Function generator, 9-112
Dimension drawing, 5-44, 5-46
Trace, 9-115
Drilling pattern, 5-45
Dielectric strength test, B-236
CNC full keyboard connection, 2-15
Digital inputs, 4-25
CNC operator panel (PCU)
Assignment, 4-26, 4-30, 4-34
Dimension drawing, 5-40
Description, 4-27, 4-34
Drilling pattern, 5-41
Technical Specifications, 8-76
COM port connection, 7-65
Digital inputs/outputs (CPU), 2-15
Commissioning using predefined macros, 9-93
Digital outputs, 4-25
Compact flash card (CF card) slot, 2-15, 4-19
Assignment, 4-26, 4-30, 4-34
Components, 1-11
Description, 4-27, 4-34
Configuring a drive unit, 10-131
Technical Specifications, 8-77
Configuring SINAMICS S120, 9-93
Dimension drawings, 5-39, 5-40, 5-42, 5-44, 5-46, 5-48
Connect to target system, 10-140
Dimensions, 8-75
Connected loads, 8-75
Drilling patterns, 5-39, 5-41, 5-43, 5-45, 5-47
Connecting, 7-51
DRIVE CLiQ interface, 2-15, 4-23
Bus connector, 7-67

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Index

Drive configuration, 10-158 L


Drive Navigator, 10-157
Language setting, 9-84
Drive on, 10-147
LEDs on the PP 72/48 I/O module, 3-18
Drive, 10-135

M
E
Machine control, 7-73
Electrical design, Configuring, 7-52
Machine control panel (MCP)
Electromagnetic compatibility, B-232
Dimension drawing, 5-42
EMC Directives, 7-51
Drilling pattern, 5-43
EMC Guidelines, B-231
Machine data, setting data
EMERGENCY STOP strategy, 7-51
Activation, 9-81
Entering the machine data, 9-90
Structure, 9-81
Error displays, 3-18
Macros, 9-95
ESD Guideline, C-239
MCPA module, 4-28
Ethernet interface, 2-15, 4-20
Connecting, 7-59
Assignment, 4-20
Measuring function, 9-116, 9-117
External electrical interference, Protection, 7-52
Measuring socket, 9-119
Modules, Transport and storage conditions, B-234
Motor rotates, 10-140
F Mounting the CNC operator panel (PCU), Interfaces,
Fast transients, B-232 2-15
Faults and Alarms, 9-97 Mounting the shield connection, 7-74
Feed axes, Initial setting, 9-99
File Management, 9-84
Find drive units online...., 10-150 O
Function generator, Features, 9-113
Operating conditions, B-234
Operating type, 10-135
Operator Controls and Display, 3-17
G Optional interface, 2-15
Generator for signals, 9-112
Guideline, ESD, C-239
P
PCU interfaces, 2-15
H Compact flash card (CF card) slot, 4-19
Handwheel, 1-10 Digital inputs/outputs, 4-25
Handwheel connection, 2-15, 4-24 Ethernet interface, 4-20
Assignment, 4-24 Handwheel connection, 4-24
PROFIBUS DP1 interface, 4-22
RS232 COM interface, 4-21
I USB interface, 4-20
PLC alarms, 11-166
I/O interface, 4-33, 4-34
PLC command overview, 11-171
IEC 1131, B-231
PLC programming, 11-170
Inserting a drive unit, 10-128
Power supply connection, 2-15, 4-33, 7-61
Installation, 6-49
PP 72/48 I/O module, 4-32
Interfaces, 4-19
PP 72/48 interfaces, 4-33
CNC operator panel (PCU), 4-19
I/O interface, 4-34
PP 72/48 I/O module, 4-32
PP72/48 I/O module, Dimension drawing, 5-48
Interference sizes
Probe, 7-71
Pulse-shaped, B-232
Product overview, 1-9
Sinusoidal, B-233

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Index

PROFIBUS address, 9-91 Start-up, 9-79


PROFIBUS DP interface, 4-33 Close, 9-120
PROFIBUS DP1 interface, 2-15, 4-22 PLC, 11-163
Programm organization, 11-181 Prerequisites, 9-79
Project navigator, 9-105 Sequence, 9-79
Protection against external electrical interference, 7-52 Series start-up, 12-190
Protection levels, 9-80 Start-up modes of the PLC, 11-164
Protective conductor, 7-55 STARTER start-up tool, 9-105
Status displays, 3-18
Stop, 10-147
R Supply, 10-133
Switch on, 9-83
Radio interferences, Emission of, B-233
System overview, 1-9
RCS802D Tool, 9-82
System software, 1-11
Recorder, 9-115
Returning the control priority, 10-148
RS232 COM interface, 2-15, 4-21
RS232 COM port, assignment, 4-21 T
Technical Specifications, 8-75
Digital inputs, 8-76
S Digital outputs, 8-77
Terminal strip converter, 4-34
Safety of electronic control systems, B-237
Test voltages, B-236
Safety rules, 7-51
Toolbox, 1-12
EMERGENCY STOP devices, 7-51
Trace, 9-115
Servo, 10-135
Trace function, Signal recording, 9-111
Servo Control, 10-135
Setpoint/actual-value assignment, 9-98
Setting data, L-226
Setting the technology, 9-88 U
Setting the terminator on the bus connector, 7-67 USB interface, 4-20
Shield connection, 7-74 USB port, 2-15
Shielded lines, 7-74 User alarms, 11-167
Signal recording with the trace function, 9-111 User interface, 9-105
Sinusoidal interference, B-233 Using the STARTER control panel, 10-140
Spindle
Analog, 9-103
Initial setting, 9-101 V
Unipolar, 9-104
Vibrations, B-235
Spindle actual-value encoder
integrated into the motor, 9-102
mounted directly, 9-102
Start automatic configuration, 10-154 W
Weight, 8-75
Working range, 9-105

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6FC5 397-0CP10-1BA0 Index-255
Index

Notes

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Index-256 6FC5 397-0CP10-1BA0
To Suggestions
SIEMENS AG Corrections
A&D MC BMS For publication/manual:
Postfach 3180
SINUMERIK 802D sl
D–91050 Erlangen
(Tel. +49 (0) 180 5050 – 222 [Hotline] Manufacturer Documentation
Fax +49 (0) 9131 98 – 63315 [Documentation]
E-mail: motioncontrol.docu@siemens.com
Instruction Manual
From:
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Siemens AG
Automation & Drives
Motion Control Systems
Postfach 3180, D–91050 Erlangen
Federal Republic of Germany  Siemens AG 2005
Subject to change without prior notice
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